PACKAGE UNIT INSTRUMENTS SPECIFICATION -...

1295-01-04-I-ET-001

IV TREN SAN JOAQUÍN JOSE 250 PROJECT

S060473103BI88800

ISSUED BY (Empresas Y&V): D.Aponte APPROVED BY (Empresas Y&V): H. Gomez APPROVED BY (PDVSA GAS): J. Leiva

SIGN ___________

SIGN __________

SIGN ___________

POSITION: DISCIPLINE LEADER POSITION: PROJECT MANAGER POSITION: ENGINEERING MANAGER N:\Realisation\2010\CF10-135 PROSERNAT\General\Client rules\INSTRUMENTATION S060473103BI88800 PACKAGE UNIT INSTRUMENTS SPECIFICATION 1 OF 1.doc

PACKAGE UNIT INSTRUMENTS SPECIFICATION

REFERENCES

ATTACHMENTS

• Instrumentation Information table

CLIENT: PDVSA GAS

REV. DATE Total Pag.

DESCRIPTION OF THE CHANGE ISSUED BY Y&V REVISED BY Y&V REVISED BY PDVSA GAS

A 08/14/06 56 Issued for comments T.I. L.O. A.G./ W.A

B 09/20/06 65 Issued with Comments Incorporated Z.I. D.A. A.G./ W.A

0 10/05/06 64 Final Issue C.C. D.A. A.G./ W.A

0 02/01/07 64 Final Issue – Emisión 1 C.C. D.A. A.G./ W.A

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REV: 0 DOCUMENT PDVSA Nº : S060573103BI88800

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N:\Realisation\2010\CF10-135 PROSERNAT\General\Client rules\INSTRUMENTATION S060473103BI88800 PACKAGE UNIT INSTRUMENTS SPECIFICATION 1 OF 1.doc

CONTENT

1. INTRODUCTION .........................................................................................................0

2. SCOPE ........................................................................................................................0

3. VENDOR RESPONSIBILITIES ....................................................................................0

4. STANDARDS AND CODES.........................................................................................0

5. TERMINOLOGY ..........................................................................................................0

6. ENVIRONMENTAL CONDITIONS...............................................................................0

7. AREA CLASSIFICATION AND INSTRUMENT ENCLOSURE .....................................0

8. SYSTEM DESIGN REQUIREMENTS ..........................................................................0

8.1. Units of Measurement........................................................................................0

8.2. General ..............................................................................................................0

9. TECHNICAL REQUIREMENTS ...................................................................................0

9.1. General ..............................................................................................................0

9.2. Transmitters, Receivers and Controllers............................................................0

9.3. Flow Measuring Instruments..............................................................................0

9.4. Level Measuring Instruments.............................................................................0

9.4.1.Type and Application of Level Measuring Instruments ....................................... 0

9.4.2.Installation of Level Measuring Instruments ....................................................... 0

9.5. Pressure Measuring Instruments .......................................................................0

9.5.1.Type and Application of Pressure Measuring..................................................... 0

9.5.2.Installation of Pressure Measuring Instruments.................................................. 0

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9.6. Temperature Measuring Instruments .................................................................0

9.6.1.Temperature Transmitters ................................................................................. 0

9.6.2.Thermocouple and RTD..................................................................................... 0

9.6.3.Temperature Gauges......................................................................................... 0

9.6.4.Thermowells ...................................................................................................... 0

9.6.5.Installation of Temperature Measuring Elements ............................................... 0

9.7. Final Control Elements.......................................................................................0

9.7.1.General.............................................................................................................. 0

9.7.2.Valve Action....................................................................................................... 0

9.7.3.Flow Characteristics of Control Valves............................................................... 0

9.7.4.Type and Application of Control Valve ............................................................... 0

9.7.5.Construction ...................................................................................................... 0

9.7.6.Actuators ........................................................................................................... 0

9.7.7.Handwheels....................................................................................................... 0

9.7.8.Valve Positioners, Transducer and Accessories ................................................ 0

9.7.9.Sizing................................................................................................................. 0

9.7.10.Noise Control ................................................................................................... 0

9.7.11.Safety and Relief Valves.................................................................................. 0

9.8. Local Control Panels..........................................................................................0

9.9. Control System ..................................................................................................0

10. MATERIALS FOR INSTALLATION ..............................................................................0

10.1. Pressure Leading Materials ...............................................................................0

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10.2. Electric Materials ...............................................................................................0

10.3. Junction Boxes ..................................................................................................0

11. INSTALLATION DESIGN.............................................................................................0

11.1. Process Installation............................................................................................0

11.2. Electrical Installation ..........................................................................................0

12. IDENTIFICATION ........................................................................................................0

13. DOCUMENTATION .....................................................................................................0

14. SPARE PARTS ............................................................................................................0

15. INSPECTION AND TESTS ..........................................................................................0

15.1. Inspection ..........................................................................................................0

15.2. Tests ..................................................................................................................0

15.2.1.Factory Acceptance Test (FAT) ....................................................................... 0

15.2.2.Field Tests and Site Installation ....................................................................... 0

16. PACKING AND SHIPPING...........................................................................................0

17. WARRANTY ................................................................................................................0

18. COMISSIONING AND START UP ...............................................................................0

19. TRAINNING .................................................................................................................0

20. INSTALLATION ...........................................................................................................0

21. ATTACHMENTS ..........................................................................................................0

21.1. Instrumentation Information table ......................................................................0

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1. INTRODUCTION

The objective of this project is the construction of a new NGL Extraction Plant (IV Tren in San Joaquin) with the capacity of processing 1000 MMSCFD of natural gas. This new plant is needed to extract the liquids of an additional production of Natural Gas required for internal market consumption in the East of the Country. On the first phase, the tren will have the capacity to recover 98% of C3+ liquids, and meet the methane sales gas specification. The C3+ liquids, will be fractionated in the Jose Cryogenic Complex located at 110 KM, and transported by an existing 16” pipeline. In the second phase of the project, the plant has to be retrofitted to produce ethane with 98% molar ethane recovery for the new Ethylene Plant that will be located in the Jose area.

2. SCOPE

This specification together with all applicable data sheets and any narrative shall indicate the minimum requirements to be met by the Vendor in the engineering, design, fabrication, inspection, testing and shipping requirements of all instrumentation and systems (including all cabinets and associated hardware) which are part of a packaged process equipment system, to be installed in the IV Tren Extraction Plant at San Joaquín, Anaco.

It is the responsibility of the Vendor to ensure that all instrumentation and systems outlined in this engineering design are correctly specified and installed per each application for reliability assurance.

3. VENDOR RESPONSIBILITIES

All deviations of the bid with regard to this specification shall be described and declared as deviations in the Vendor’s proposal, making reference specifically to the paragraph in this document.

Any conflict between these specifications, codes and standards, shall be indicated to PDVSA by the Vendor before starting the manufacture of the equipment. The conflict shall be presented in writing to PDVSA for him to take a resolution also in writing. In case there’s no response or any possible agreement, the stricter requirement of the codes or standards will prevail for the project execution.

Vendor shall submit a list of all appliances, special tools and accessories that are necessary or incidental to the proper installation, operation and maintenance of the equipment, even though these items are not included on the drawings, specifications or data sheets.

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Vendor shall submit a list of all utility requirements and consumptions including electrical, plant and instrument air, cooling water, steam, etc.

Vendor shall verify all existing dimensions and conditions shown on Project’s drawings.

It is Vendor’s responsibility to ensure that all work is performed by qualified technical personnel in accordance with accepted industry practices.

4. STANDARDS AND CODES

Packaged Units instruments and control equipments shall be in accordance with relevant codes and standards referred to herein. The following codes and standards shall be used:

PDVSA Petróleos de Venezuela, S.A.

PDVSA-HF-201-1993 Diseño de Tuberías para Instrumentación e Instalación de Instrumentos

PDVSA-K-300-1999 PDVSA Instrumentation Introduction

PDVSA-K-301-1999 Pressure Instrumentation

PDVSA-K-302-2001 Flow Instrumentation

PDVSA-K-303-2001 Level Instrumentation

PDVSA-K-304-2002: Temperature Measurement Criteria

PDVSA-K-305-1994 Process Analyzers

PDVSA-K-306-1994 Sample Conditioning Systems

PDVSA-K-307-1994 Electronic and Pneumatic Instrumentation

PDVSA-K-308-1994 Distributed Control Systems

PDVSA-K-329-2002 Instrument Junction Boxes Specification

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PDVSA-K-330-1994 Control Panels and Consoles

PDVSA-K-331-1994 Instrument Power Supplies

PDVSA-K-332-1994 Control Valves

PDVSA-K-333-1994 Valve Actuators

PDVSA-K-334-2002: Instrumentation Electrical Requirements

PDVSA-K-335-2000 Packaged Unit Instrumentation

PDVSA-K-336-2002 Safety Instrumented Systems

PDVSA-K-337-1999 Furnace and Boiler Instrumentation

PDVSA-K-339-1994 Rotating Equipment Instrumentation

PDVSA-K-341-2001 Instrument Air System Criteria

PDVSA-K-344-2002 Selection Criteria for Pressure Control Regulators

PDVSA-K-360-1994 Programmable Logic Controllers

PDVSA-K-363-1994 Fire, Gas and Liquid Leak Detection

PDVSA-K-369-1994 Instrumentation QA/QC

PDVSA 90620.1.111-2001 Flow Measurement Guidelines

PDVSA 90620.1.112-2001 Level Measurement Guidelines

PDVSA 90620.1.113-2001 Temperature Measurement Guidelines

PDVSA 90620.1.114-2001 Instrument Air Systems Guidelines

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PDVSA 90620.1.116-2002 Selection Criteria for Pressure Control Regulators Guidelines

PDVSA 90620.1.201-2003 Instrumentation Electrical Fabrication Details

PDVSA 90620.1.202-2003 Temperature Measurement Electrical Fabrication Details

API American Petroleum Institute

API 500-2002 Recommended Practice for Classification of Locations for Electrical Installations at Petroleum Facilities Classified as Class I, Division 1 and Division 2

API RP 520-2000 Recommended Practice for the Design and Installation of Pressure Relieving Systems in Refineries. Part I – Design, Part II – Installation

API RP 551-1993 Process Measurement Instruments

API RP 552-1994 Transmission Systems

API RP 553-1998 Control Valves

API RP 554-1995 Process Instrumentation and Control

API RP 555-2001 Process Analyzers

API STD 598-2004 Valve Inspection and Testing

ANSI American National Standards Institute

ANSI/ASME B1.20.1-2001 Pipe Threads, General Purpose (Inch)

ANSI/ASME B16.5-2003 Pipe Flanges and Flanged Fittings

ANSI/ASME B31.3-2000 Process Piping

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ANSI B16.10-2000 Face to Face and End to End Dimensions of Valves

ANSI B46.1-2000 Surface Texture

ANSI C33.76-2000 Standard for Industrial Control Equipment

MSS Manufacturers Standardization Society of the Va lve and Fittings Industry Inc.

MSS-SP-25-1998 Standard Marking System for Valves, Fittings, Flanges and Unions

ISA The Instrumentation Systems And Automation Soci ety

ISA MC96.1-1982 Temperature Measurement Thermocouples

ISA RP3.2-1978 Flange Mounted Sharp Edged Orifice Plates for Flow Measurement

ISA S5.1-1992 Instrumentation Symbols and Identification

ISA S5.2-1992 Binary Logic Diagrams for Process Operations

ISA S18.1-2004 Annunciator Sequences and Specifications

ISA S50.1-1992 Compatibility of Analog Signals for Electronic Industrial Process Instruments

ISA 75 Series-1995 Control Valve Sizing

ISA 12 Series Electrical System Safety Standards

ISA RP60 Series Environmental Conditions, Instrument Air Quality and Control Center Standards

ISA RP16 Series / ISA RP37 Series

Measurement Devices and Transducers Standards

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ISA 84.01 Process System Safety Standards (Safety Instrumented Systems for the Process Industries)

NEMA National Electric Manufacturers Association

NEMA-250-1997 Enclosure for Electrical Equipment (1000 Volts Maximum)

NFPA National Fire Protection Association

NFPA-70-2005 National Electric Code (NEC) – All Requirements

NFPA-72-2003 National Fire Alarm Code

IEEE Institute of Electrical and Electronic Enginee rs

IEEE-472-1979 Electrical Surge Protection

IEC International Electrotechnical Commission

IEC-801-2-1991 Electromagnetic Compatibility for Industrial-Process Measurement and Control Equipment – Part 2: Electrostatic Discharge Requirements

ASME American Society of Mechanical Engineers

ASME-B16.5-2003 Steel Pipe Flanges and Flanged Fittings

ASME-B1.20.1-1983 Pipe Threads. General Purpose

ISO International Organization for Standardization

ISO-5167-1-1991 Measurement of Fluid Flow by Means of Pressure Differential Devices. Part 1, Orifice Plates, Nozzles and Venturi Tubes

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ISO-5167-7-1998: Measurement of Fluid Flow by Means of Pressure Differential Devices – Guidelines for Specification of Nozzles and Orifice Plates

COVENIN Comisión Venezolana de Normas Industriales

COVENIN-200-1999 National Electrical Code

COVENIN-758-1989 Manual Alarm Station

COVENIN-823-1988 Instructive Guide about Alarm and Fire Extinction Detection System

COVENIN-1176-1980 Detectors. Generalities

COVENIN-1377-1979 Automatic Fire Detection System Components

NACE National Association of Corrosion Engineers

MR-0175 -2001 Petroleum and Natural Gas Industries – Material for use in H2S – Containing Environments in Oil and Gas Production

All materials shall be specified and certified by ASTM.

Codes or standards not specifically referenced in the text may be used for general information as necessary.

In case of conflict within this specification or between it and its associated specifications, and the above listed codes and standards, the Vendor shall bring the matter to the PDVSA’s attention in writing for resolution. In the absence of any guidance or agreement to the contrary, the most demanding requirements shall apply.

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5. TERMINOLOGY

Client: Refers to Petróleos de Venezuela S.A, PDVSA GAS.

Equipment: Package equipment supplied for the project, consistent with the mechanical specifications of the Package.

FAT: Factory Acceptance Test.

SAT: Site Acceptance Test.

Purchase Order: Defined as the package delivered to the Vendor, which includes the purchase order, terms and commercial conditions, requisition, all included technical documents (specifications, standards, drawings or maps and data sheets) and all reference documents, such as codes and standards not included in the package.

Vendor: Refers to Package Unit instruments and control equipment suppliers.

6. ENVIRONMENTAL CONDITIONS

The following environmental conditions are according with the document: “Process Design Basis”, No. S050373101IP11601, given by PDVSA.

Table 1 . Environmental Temperature Specifications

Maximum Absolute 108 °F Average 81 °F

Minimum Absolute 60 °F Maximum Average 93 °F Minimum Average 68.54 °F

Weather Type Warm-Raining

Table 2 . Barometric Pressure Specifications

Dry Station Wet Station Maximum 14.70 psia 14.74 psia Average 14.64 psia 14.64 psia Minimum 14.50 psia 14.50 psia

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Table 3 . Rainfall Specifications

Average 1200 mm/year Maximum Intensity 606 lps/Ha (Time: 5 Minute) Maximum Intensity Frequency 10 years Rain Month May-November

Table 4 . Relative Humidity Specifications

Dry Station Wet Station Maximum 100% 100% Average 77% 77% Minimum 13% 13%

Table 5 . Wind Specifications

Basic Velocity in Anzoátegui State 95 Km/h

Predominant Direction NNE Average Velocity KPH 17

Table 6 . Seismic Zone Classification Specification

Seismic Zone 4 Acceleration (a) 50 Value of Local Seismic Threat (γ) 4.25 Horizontal Acceleration Coefficient 0.25 Vertical Acceleration Coefficient 0.175

7. AREA CLASSIFICATION AND INSTRUMENT ENCLOSURE

The installation of electrical and electronic instruments shall be done according to the National Electric Code requirements and the American Petroleum Institute standards (API 500), as well as, according to the areas electrical classification where they will be installed.

All electronic instruments located in hazardous areas shall be Explosion Proof NEMA 7, weatherproof and corrosive environment resistant NEMA 4X (marine, H2S, HF, HCL and

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others), approved and certified for specific electrical area classification according to drawings “Hazardous Area Classification Plan” No: S050473104BE22100.

All electronic instruments located in non hazardous areas shall be weatherproof and corrosive environment resistant NEMA 4X (marine atmosphere, H2S, HF, HCL and others).

8. SYSTEM DESIGN REQUIREMENTS

8.1. Units of Measurement

The pipe diameters shall be in inches. Units to be used for measurement of process variables shall be English System as follow:

Table 7. Units

Quantity Unit Abbreviation

Acceleration Foot per second square Ft/S2

Amount of substance Pound-mole Lbmole

Area Square foot Ft2

Baffle pitch Foot Ft (‘)

Capacity and volume Cubic foot / Barrels Ft3/BBL

Concentration Parts per million

Parts per billion

ppm

ppb

Corrosion allowance Inch In (“)

Density-liquid/vapor Pound per cubic foot Lb/Ft3

Enthalpy Million BTU per hour MMBTU/Hr

Standard conditions - 60ºF and 14.696 psia

Temperature Degree Fahrenheit ºF Differential head Foot liquid

Pound per square inch Ft liquid Lb/in2 (psi)

Dimensions and elevations Foot, Inch Ft (‘), In ( “)

Electrical tension Volt V

Length Foot Ft

Electrical current Ampere A

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Table 7. Units( continued)

Line size Inches In (“)

Flow-liquid Cubic foot per hour

Pound per hour

Barrel per day/ Gallons per minute

Ft2/hr (CFH)

Lb/hr

BPD/GPM

Flow- gas/vapor Actual cubic foot per hour

Pound per hour

Million Standard Cubic Feet per Day

AFt3/hr (ACFH)

Lb/hr

MMSCFD

Fouling factor Hour. Square foot. °F per British Thermal Unit

Hr.Ft2 .ºF/BTU

Mass Pound Lb

Heat transferred Million British Thermal Unit per hour

MMBTU/hr

Nozzle size Inches In (“)

Energy-electrical British Thermal Unit BTU

Molecular weight Pound per pound mole Mw, Lb/Lbmol

Net positive suction Head (NPSH)

Foot Ft

Orifice area Square inch In2

Specific heat British Thermal Unit per pound. Of

BTU/Lb ºF

Voltage Volt V

Foot per second Ft/s Speed linear Rotating

Revolution per minute rpm Viscosity dynamic Centipoise cP Viscosity kinematics Centistoke cSt Pressure Design Critical/operating Pressure drop

Pound per Square Inch Gauge Pound per Square Inch Absolute Pound per Square Inch

PSIG PSIA PSI

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8.2. General

All the instruments of the packaged systems must be in accordance with the standard PDVSA K-335 “Packaged Unit Instrumentation”. In all cases, all electric equipment, instruments and associated systems must be specified and installed in accordance with the requirements of the area classification, environmental conditions and the service they will provide.

All instrumentation must be accessible for reading and/or maintenance, and therefore the facilities required for such purposes must be provided.

The scope of the supply for the Vendor of the packaged systems shall be limited to the instrumentation within the limit of the package as indicated in the P&ID’s. The instruments that form part of a proprietary or standardized system shall be governed by the criteria established in this document.

All instruments, and control systems shall be as shown in the Pipe and Instrument Diagrams (P&ID´s).

Any instrument not specified and/or omitted in the piping and instrument diagrams which the Vendor considers necessary for a safe and reliable operation, will be included in the package.

The packaged systems must include in their design the needs for integration with the HONEYWELL EXPERION PKS, Safety Instrumented System, Fire and Gas Detection System, at the hardware as well as communications and data transfer level.

The communication between the package Control Equipment and the other Plant Systems must be through ControlNet protocol or galvanic isolated circuits for hardwiring connections. Devices, actions and systems related to Control and Supervision, SIS and FGDS within the package are total responsibility of the Vendor, who must guarantee their compatibility with the systems to be installed at the plant and their complete capacity to communicate with them without additional equipment be required. In case of Control and Supervision System, the Vendor must guarantee communication with C-200 Controllers (HONEYWELL). Additionally, package Control Equipment must have capacity to receive shutdown commands hardwired, as well as information from the Process Control, SIS, and Fire and Gas Systems, so hardwired as for communication protocol.

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The Local Panel design must include all the devices necessary for the proper operation and management of the package (HMI, push buttons, annunciator lights, etc.). The design must include the availability of the monitoring and control signals in the existent Control Room.

The Vendor shall provide connection boxes, electrical connections and air connections at the skid battery limit or package to be delivered, as well as the facilities required for connection to the main systems.

All instruments installed at field shall be weatherproof, and compatible with the service, area classification and environmental conditions.

If the instrument will be placed in a hydrogen sulfide environment capable of producing sulfide stress cracking, the use of NACE standard MR-01-75 (latest revision) as a guide for material selection is mandatory.

All the instruments must have a stainless steel or aluminum plate which contains the following information, as minimum:

- “TAG NAME”, manufacturer’s name, model, serial number.

- Voltage, current, frequency, operating ranges for pressure and temperature.

The instrumentation connections must be in accordance with the specifications of the vessels and piping, taking care of its location during the detail engineering phase in accordance with the fluid and service which it will provide. In all cases, that established in the standard PDVSA H-221 must be complied with.

The instrumentation connections must be made on the top or at the side of the equipment, never underneath (this applies to vessels and piping).

Depending on the SIL required for the package, the instrumentation associated with the SIS systems must be separate from that associated with Process Control.

If the package should require on-line analyzers, the temperature sensors and sampling points must be located at points that guarantee a rapid response of the instrument.

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The field instrumentation shall be electronic, SMART type, latest generation, except for those instruments that due to their individual characteristics are pneumatic or direct-reading (local level / pressure / flow / temperature indicators, electric stations, among others). The electronic equipment used must be immune to the interference caused by electromagnetic fields (EMI) and by radio frequency (RFI).

Electronic transmitters shall have, as it is possible, the capability of Fieldbus Foundation protocol management with 9-32 VDC Power Supply.

The control, indication and transmission of the signal will normally be done as follows:

a) Analog signals shall be Fieldbus Foundation protocol or in defect 4-20 mA, 24 VDC (Loop Power Supply) with HART protocol.

b) For thermocouples, milivolts shall be used.

c) Pneumatic signals: 3-15 psig.

For shutdown purposes, the signals shall be as follows:

a) Pneumatic: 35 or 100 psig.

b) Electric: 24 VDC to shutdown.

c) Analog signals shall be 4-20 mA, 24 VDC (Loop Power Supply) with HART protocol.

Electrical power for the Control Systems and field instruments will be supplied by the essential services Distribution System and/or by 120 VAC, 1 phase, 60 Hz supplied from an uninterrupted Unit Power Supply (UPS).

The Power System will be designed for 25% spare capacity.

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9. TECHNICAL REQUIREMENTS

9.1. General

Documents and drawings for instrumentation installation will be prepared, taking into consideration constructability, compatibility with existing installations, economy and lowest time of construction and start up.

All field instruments shall be installed close to the process connections and shall be suitable for mounting on a two inches (2’’) steel pipe except pressure gauges (located in services without vibration) and instruments directly mounted to the process connection, such as displacement level instruments, flow meters, thermoelements and others.

All instruments shall be installed, to guarantee the easy and safety access following the operation and maintenance criteria. Otherwise, accessibility must be created. (i.e.: platforms, fixed walk away or fixed ladders).

All level instruments in vessel shall be installed on stand pipe of four inches (4”) diameter as minimum.

Indicating instruments, except for those instruments which are connected directly to process connections such as displacement level instruments, shall be installed in such a way that the center of the instrument is five feet (5’) minimum above grade, platform or walkway level, and be oriented such that they can be seen and read from grade, platform or walkway, or from the location where the measured medium is controlled, meeting the demand.

Non-indicating instruments except for the instruments that are connected directly to process connections shall be installed in such a way that the center of the instrument is 5 feet above grade, platform or walkway level.

For field instruments, connections shall be provided on process piping and equipment. Each process connection shall have an isolating valve, except for the instruments which are installed in piping, such as turbine meter and control valve, or installed internally in vessels or columns, as may occasionally be the case with level instruments, or separated from the process fluid by means of a thermowell.

The isolating valve shall generally be gate valve or ball valve, according to piping specification document.

For Package Unit electrical routing will be through galvanized steel conduit from instrument to junction box.

For all instrument cables, flame retardant cable type will be used.

The instrumentation for measurement and control shall be designed such that optimum operation of the process and utilities can be achieved economically.

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They will have local LCD integral indicators on the transmitter, for their process variables. The air distribution system shall be 10% oversized and shall be designed to allow a pressure drop of 5 psi within the supplier and the farther instrument when all the instruments are at maximum air consumption. The instruments and devices connections shall be as follow: Pneumatic transmission and control signals: ¼” NPT as minimum. Electrical Connections: ½” NPTF as minimum. Instrument air transmission lines shall be 0’035” minimum wall thickness, 316 SS tubing and 316 SS compression tube fittings. Connection to Vessels, tank or the process piping shall be as follow:

Table 8. Instruments Specifications

INSTRUMENT TYPE PIPE/STANDPIPE VESSEL

PRESSURE

Pressure Gauge with Seal Diaphragm (viscous or corrosive service)

1-1/2” Flange 2” Flange, 300 # min

Pressure Gauge (non viscous or non corrosive service)

3/4” NPT 2” Flange, 300 # min

Pressure Transmitter with Seal Diaphragm (viscous or corrosive service)

1-1/2” Flange 2” Flange, 300 # min

Pressure Transmitter (non-viscous or non-corrosive service

3/4” NPT 2” Flange, 300 # min

TEMPERATURE

Thermowell 1-1/2” Flange 2” Flange, 300 # min

LEVEL

D/P cell with Seal Diaphragm (Viscous or corrosive service)

2” Flange,

300 # min 2” Flange, 300 # min

D/P cell (Non-viscous or non-corrosive service)

3/4" NPT 2” Flange, 300 # min

Displacer external chamber 2” Flange,


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Displacer internal type, top mounted N/A 2” Flange, 300 # min

Internal Float N/A 2” Flange, 300 # min

Level Gauges

(Crude service)

2” Flange,


Level Gauges

(Other than crude service) 3/4" NPT 1” Flange, 300 # min

Radar (type anthenna) N/A 6” Flange, 300# min*

Radar (Wave Guided) 2” Flange,

300 # min

2” Flange,

300 # min*

FLOW

D/P Flow Transmitter with Diaphragm seal (Viscous or corrosive service)

½” taps on Flange, 300 # min

N/A

D/P Flow Transmitter (Non-viscous or non-corrosive service)

½” taps on Flange, 300 # min N/A

Thermal Dispersión Mass Flow 1 ½” 150# RF min N/A

Coriolis Mass Flow 2” Flange, 300 # min N/A.

Process values will be measured directly where possible. Indirect or computed methods will only be used where direct measurement is not possible.

Instrument cases shall be weatherproof (NEMA 4 minimum) and if electrical shall also meet the applicable electrical area classification.

For hazardous areas enclosures shall be Explosion Proof, NEMA 7 in accordance with hazardous area classification.

Enclosures for indoor installation shall be NEMA 12.

Flanges type and rating shall conform to Pipe Specification document, ANSI 300# as minimum.

To minimize vibrations effects, the instruments should be mounted on a rigid support adjacent, but not connected to the vibration source. Flexible tubing or conduit connections are required, between the vibration source and the instruments.

For all the instruments connections & interconnecting piping, should be, so that no pockets or traps can occur, otherwise, drain valves should be installed at low point.

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9.2. Transmitters, Receivers and Controllers

Smart transmitters shall be used for all control, monitoring (indication and alarm) and shutdown applications.

These transmitters used for control, monitoring will operate in Foundation Fieldbus technology and for shutdown applications in 4-20 mA, 24 VDC loop powered, two wire system, and shall use a digital communication protocol (HART).

The smart transmitters shall have autodiagnostic capability and an accuracy of 0.1% or greater, with local pushbuttons for zero adjustment and a refreshment lesser than 100 miliseconds. Switches shall not be used.

Non-smart transmitters will not be used in this work.

All transmitters shall have transient surge protection.

All transmitters located in corrosive or high viscous services shall be provided with diaphragm seal.

As for transmitters, the material of its body shall be manufacturer standard, and diaphragm shall be 316 SS, unless process conditions require other materials, or manufacturer’s standard execution is greater.

Maximum measurement error shall not exceed + 0.5% of span.

Repeatability shall be 0.25% of span.

Hysteresis shall not exceed 0.5% of span.

Dead band shall not exceed 0.25% of span.

Output change caused by 38 ºC (100 ºF) ambient temperature change shall not exceed 1% of span.

Control mode of controllers shall generally be selected as follows, and each controller shall have suitable functions for each variable:

Table 9 . Control Mode VARIABLE CONTROL

Flow PI Level P or PI Pressure PI Temperature PI or PID

Note: P=Proportional, I=Integral, D=Derivative

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9.3. Flow Measuring Instruments

This section covers operational flow measurement for process control. Flow meter applications will be selected in accordance to ISO-5167. The standard ISO-5168 (“Measurement of Fluid Flow Evaluation of Uncertainties”) shall be considered for Flow-measuring Instruments Selection.

Differential Pressure Type Flow-measuring Instruments:

Differential pressure type flow instruments should be applied for flow rate measurement, unless special considerations such as required rangeability or avoidance of obstructions in the piping make it necessary to apply other instruments. Written permission from the Contractor is required for application of flow rate instruments other than differential pressure instruments.

Variable-area flow meters shall be restricted to simple local indication applications. Written permission from Contractor is required.

Suitable combination of Differential Pressure Transmitter with variable range and throttling device such as Orifice Plate, Venturi, Flow-nozzles, etc., shall be used for signal transmission.

The preferred instrument is a 316 stainless d/p cell transmitter complete with a 316 SS 3-valve manifold as a minimum.

Other suitable materials such as 304 SS, monel, hastelloy may be used to resist the fluid corrosion and erosion properties.

V-cone is the preferred flow measurement primary element.

The minimum flange rating will be 300 # ANSI, and will be according to ISO 5167. Plate thickness shall be one eighth inches (1/8”) .Nominal for pipe sizes eight inches (8”) in and smaller and one fourth inches (¼”). for lines ten inches (10’’) and larger. The flange thickness will not be less than one and half inches (1 ½”) (38 mm) and the flange above will match the internal diameter of the piping schedule.

For sour service, connections shall be in accordance with the NACE Standard MR 0175-90.

All calculations will be performed with a software program based on ISO-5167/ASME and/or AGA 3 to 8.

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Orifice plate beta ratio (orifice diameter/inside pipe diameter) shall be between 0.25 and 0.70.

The preferred range for orifice plate differential pressure for flow measurement is 100”H2O. Other acceptable ranges are 200, 250 or 400”H2O, based on operation conditions.

Paddle type Orifice Plate shall be used. Orifice Plates handles shall be permanently marked on the upstream side with:

o Instrument Tag Number

o Orifice diameter

o Line size and flange rating

o Plate material

o Beta ratio

o “Upstream”

Materials of flanges, holder-rings, and of other accessories shall be in accordance with Piping Material Specification.

Type of pressure taps shall be according to instruments connection detail (included in Piping Material Specification).

Senior orifices, when specified on data sheets, shall have the following characteristics:

o Carbon steel flanged body with flanges according to piping class specification.

o Plates shall be retractable while process is operating and fitted with:

▪ Mechanical lifting system allowing easy lifting operation even in the case of large pressure drops and large sized orifices.

▪ Suitable safe isolation from process.

o Venting and/or draining facilities if needed.

o Tapered flow tubes may be used where a high percentage pressure recovery is required and/or very low inlet pressure is available, or where slurries are presented.

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The flow element type “Annubar” may be considered where flanges present problems for large pipe sizes or low inlet pressure is available. The single insert type is preferred.

Orifice bore required dimension shall be calculated to the nearest 1/16 inch (1mm).

For special applications, other type of Flow orifice may be considered, such as quadrant, conical, segmental, etc.

Installation of Orifice Plates:

The location of any flow meter shall be determined so that the fluid to be measured remains in a single phase when passing through the meter, i.e. no vaporization in liquid, no condensation in gas or steam or vapor.

The primary elements shall be located at a place where tap valves are readily accessible as far as possible. Moreover, enough space for differential pressure instruments and for pressure leading piping shall also be provided near the location of the primary element.

Throttling devices shall be located in pipes having adequate length of straight pipes upstream and downstream of the devices, and the internal pipe wall shall be absolutely smooth, and in case of welding neck flanges extra care shall be taken to remove protruding welding material.

The throttling device may be located in either a horizontal or a vertical line. However, it shall be located where the line is completely filled with fluid, i.e. for liquid metering, location in a vertical line with downward flow and highest level horizontal line shall be avoided, for gas or steam metering, location in a vertical line with upward flow and the lowest level horizontal line shall be avoided, and for vapor metering, location of the throttling device in a highest level horizontal line is preferable.

Where this is impossible, due to requirements for straight length or accessibility, carefully attention shall be given to the correct position of the tapping and the drain/vent hole in the orifice plate.

As far as possible, the throttling device shall be located where the fluid is flowing steadily and with less pulsation.

In case of double instrument, independent taps and block valves shall be installed for each instrument.

For accurate flow measurement a sufficient length of straight and unobstructed pipe is required both upstream and downstream of the measuring element, as per manufacturer recommendation. If sufficient straight length of pipe is not available, straightening vanes may be considered.

Meters Tapping and location of differential pressure meters shall, in principle, be as follows, and when these are unpractical, countermeasures shall be made taking into

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consideration the accumulation of gas or condensed liquid of the fluids to get stable measuring:

For gas metering in horizontal line, the tapping angle shall be 45 degree or more with respect to horizontal plane upward. For wet gas metering, the differential pressure meter shall be located upstream the throttling device, and for dry gas metering; it may be located either upstream or downstream throttling device.

For steam metering in horizontal line, the tapping angle shall be 45 degree or less with respect to horizontal plane upward. The differential pressure meter shall be located downstream the throttling device.

For liquid metering in horizontal line, the tapping angle shall be 45 degree or less with respect to horizontal plant downward. The differential pressure meter shall be located downstream the throttling device.

For metering in vertical line, for gas metering, the meter shall be located upstream the throttling device. For steam metering, the meter shall be located downstream the throttling device. For liquid metering, the meter shall be located downstream the throttling device.

9.4. Level Measuring Instruments

9.4.1. Type and Application of Level Measuring Inst ruments

Differential Pressure Type Level Measuring Instruments: Shall generally be used, unless process conditions dictate other types more suitable. Moreover, shall be diaphragm type and have continuously adjustable range.

Span calculations shall be based on the anticipated operating specific gravity of the process, excepting when the intent is to prevent the overflow of the tank, because in this case the minimum anticipated specific gravity should be used. See PCELI001 PIP guideline for a discussion of when normal specific gravity verses minimum or maximum specific gravity should be used.

Transmitters are preferred to be mounted at or below the centerline of the high pressure nozzle (lower nozzle on vessel).

The instruments shall be weatherproof and suitable for operation in surrounding atmosphere and electrical area classification. Where plugging of the connections is expected, the instrument shall have the high pressure side of direct mounting to a suitable flanged nozzle on the vessel.

Where necessary to avoid plugging of the nozzle, the instrument shall have an extended diaphragm flush inside of vessel. The extended diaphragm shall, however, not be specified for the instruments on vessels requiring mechanical cleaning.

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Materials of body shall be manufacturer standard, diaphragm shall be 316 stainless steel, unless process conditions require other materials, or manufacturer's standard execution is in better materials.

Pressure ratings and dimensions of connections shall be in accordance with the Vessel Material Specification.

The instruments shall have range elevation/suppression facilities.

The diaphragm seal fluid, seal leg fluid, or purge fluid shall be compatible with the process and ambient temperature extremes.

Remote diaphragm seals: Transmitters with remote diaphragm seals shall be mounted at or below the high pressure nozzle (lower vessel nozzle).

Diaphragm Seal material shall be 316 SS as minimum, unless process conditions require other materials or manufacturer's standard execution is in better materials.

Provisions shall be made for relieving pressure between the block valve and the diaphragm seal. Clean out or purge connections may be required on the process side of diaphragm seals in applications where plugging is likely.

Capillary tubing seal legs shall be mechanically protected and adequately supported to prevent sagging.

The manufacturer shall specifically design remote diaphragm seals used in vacuum service applications.

Welded capillary connections shall be specified for vacuum applications.

Fill fluid shall be rated for the maximum temperature and maximum vacuum conditions.

Diaphragm seal capillary tubing lengths shall be designed to take into account routing requirements. Capillary tubing shall be manufacturer’s standard length. Capillary lengths that are too long are as undesirable as capillary lengths that are too short. They cannot be modified in the field.

Long capillary lines shall be protected from exposure to sunlight, which can cause errors in measurement even in compensated systems.

Capillary lines shall be routed away and/or insulated if they pass by steam or high temperature heat transfer media jackets on a vessel or other high temperature sources.

Capillary length of both seal legs shall be identical on a remote seal differential pressure transmitter.

Remote diaphragm seals without block valves shall not be installed until the flush and pressure test of the vessel is complete.

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Level Gauges: shall be used for local indication of levels, unless process conditions, physical dimensions or required accuracy make other instruments more suitable. Besides, shall generally be stainless steel; sight glass as well as magnetic couple can be used. When used in conjunction with a level instrument it shall cover the operating range of the associate level instruments.

The indicator shall be flags type, bi-color red/white.

The float material shall be stainless steel and titanium and must be selected according to the specific gravity of fluid.

Pressure ratings, dimensions and materials of flanges and chambers shall be in accordance with the Vessel Material Specification.

Flange sizes shall be 2 inch unless special vessels (such as lined vessels) require other size.

Accessories:

The level gauges shall be provided with drainage valve.

Vaporization or Freezing Non-frosting type level gauges shall be used for liquid below 32°F (0°C). Level gauges with jacket s hall be used for liquids liable to congeal or vaporize.

Level measurement error on all other applications shall be less than 2%

9.4.2. Installation of Level Measuring Instruments

Standpipe shall be used to level measurement instrument installation.

Internal level instruments shall be mounted to a suitable flange provided on the top or side of the vessel.

In general, instruments shall be located so that the midrange position of the instrument is at the normal liquid level for design condition and the maximum and minimum liquid levels in normal operating conditions are covered.

Differential pressure type level instruments: provided with a pressure balancing line of dry leg system shall be located below and as close to the zero level at which the zero point adjustment can be made without providing an elevation kit. Flange mounted differential pressure instrument shall be provided with a shut off valve between the instrument and the vessel except for the instrument of extension diaphragm type.

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When the extension diaphragm type level instrument is employed, the nozzles shall be internally free from burrs and their length shall be compatible with the diaphragm extension length to prevent the diaphragm from protruding into vessel.

When sealing or purging system in pressure leading piping is required, the instrument shall be mounted below the lowest connection, or above the highest connection, depending on the selected sealing or purging method, and shall be located where the sealing liquid can readily be filled.

Level gauges: Where block valves are provided on a vessel, the gauge valve for level gauge may not be provided, unless the level gauge with ball check mechanism is required. Where a level gauge is installed together with other type of level instrument, the location and orientation of these gauges shall be selected from the standpoint of convenience for checking the other level instrument.

9.5. Pressure Measuring Instruments

9.5.1. Type and Application of Pressure Measuring

Pressure transmitters: SMART transmitters shall be used for all control,

monitoring (indication and alarm) and shutdown applications.

These transmitters used for control, monitoring shall operate in Foundation Fieldbus technology and for shutdown applications in 4-20 mA, 24 VDC loop powered, two wire system, and shall use a digital communication protocol (HART) superposed.

Daisy Chained connections are not allowed.

Pressure detecting elements such as bellows, diaphragm, spiral or helical bourdon shall be of 316 SS.

In case that the instrument for liquid and vapor measuring, were error resulting, when the liquid head was expected and zero point adjustment cannot be made only by adjusting zero point, the instrument shall be furnished with an elevation kit.

Where capillaries are required, the capillary will be stainless steel complete with PVC covered stainless steel bendable armor.

Remote diaphragm seals: Provisions shall be made for relieving pressure between the block valve and the diaphragm seal.

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Diaphragm seal material shall be 316 SS as minimum, unless process conditions require other materials or manufacturer's standard execution is in better materials.

Clean out or purge connections may be required on the process side of diaphragm seals in applications where plugging is likely.

Capillary tubing seal legs shall be mechanically protected and adequately supported to prevent sagging.

The manufacturer shall specifically design remote diaphragm seals used in vacuum service applications.

Welded capillary connections shall be specified for vacuum applications.

Fill fluid shall be rated for the maximum temperature and maximum vacuum conditions.

Diaphragm seal capillary tubing lengths shall be designed to take into account routing requirements. Capillary tubing shall be manufacturer’s standard length. Capillary lengths that are too long are as undesirable as capillary lengths that are too short. They cannot be modified in the field.

Long capillary lines shall be protected from exposure to sunlight, which can cause errors in measurement even in compensated systems.

Capillary lines shall be routed away and/or insulated if they pass by steam or high temperature heat transfer media jackets on a vessel or other high temperature sources.

Remote diaphragm seals without block valves shall not be installed until the flush and pressure test of the vessel is complete.

Pressure gauges: shall be used for local indication, and shall normally be Bourdon tube type. The selected pressure range will be such that the maximum process operating pressure does not exceed 80% of the range of the instrument.

The instrument shall be capable of withstanding an overpressure 1.5 times the maximum operating pressure, without sustaining any damage.

Pressure gauges will be specified in accordance with ASME/ANSI B 40.1.

Pressure gauges will be installed to indicate the controlled upstream or downstream pressure of the regulator.

The case will be furnished with a blow out disc in the back.

Pressure gauges will have pointers with adjustable micrometer screw types and will not have suppressed ranges.

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Pressure gauges in vibration service shall be remote mounting type and liquid filled type.

Pressure gauges to be used for pulsating service shall be provided with a pulsation damper.

Pressure gauges shall be provided with diaphragm seal for the following services:

For fluids viscous.

For strong acids, alkalis, and strongly corrosive fluids.

For slurry liquid and liquid containing sediment.

Scale plate size shall generally be 4-1/2 in nominal diameter dial.

Scale, scale graduation and marking shall be made with black color on white-colored scale plate.

For mechanical strength the recommended connection size is ½ in NPT.

A gauge may be supported by its piping, if it’s a close coupled to the process connection. Where the vibration is anticipated, requires independent support. Materials: of cases and covers shall generally be phenolic, aluminum (or aluminum alloy). Bourdon tubes, bellows, etc., shall be made of 316 SS.

Material of sealing diaphragm shall be selected, according to each character of fluid, and those are 316 SS, monel, hastelloy-B, -C, teflon, tantalum and others.

The selected range shall be such that the normal operating condition is approximately at mid scale and that the maximum process operating pressure does not exceed 80% of the range of the indicating instrument or blind self acting regulator.

9.5.2. Installation of Pressure Measuring Instrumen ts

Pressure transmitter: he pressure taps shall be located on the top side of the piping and/or at the vapor space of the vessels. The instrument for liquid and vapor pressure measuring, where error resulting form the liquid head is expected, shall be located below and as close to the pressure detecting point at which the zero point adjustment can be made without an elevation kit. For vapor pressure measuring, the instrument shall be located below the detecting point, and a remote seal shall generally be provided in process connection.

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Impulse piping should be as short as possible.

The location of receiver instrument shall be determined taking manual operation valve position, patrol way layout, etc., into consideration.

Where a pressure gauge is located on the same pressure line or vessel, the relative position of the instrument shall be determined so that the reading of one instrument may be used as a criterion for the checking of another.

Differential pressure instrument, which is used for measuring pressure drop within a distilling tower, reactor, etc., shall be located above low-pressure side pressure detecting point, in order to avoid the error resulting from vapor condensation and clogging of pressure leading pipes with accumulated powdery matter.

The pressure detecting point shall be located where there is no fluid impact pressure and where the flow is uniform. Therefore, location in an elbow and tee section shall be avoided. Pressure gauges The position and orientation of the pressure gauge shall be determined so that the indication can be readily read by operators on floor, platform, patrol way, etc. In particular, where a pressure gauge is installed in pump delivery, it should be able to read the indication while operating the pump outlet valve.

A pressure gauge shall be installed with a block valve, including needle, ball valve if required.

Pressure gauges installed in vibration service shall be provided with flexible hose.

Pressure gauge shall be provided with Siphon or “pigtail” condensate seal for steam or other hot condensate vapors services, considering to locate the gauge when it is mounted above the process connections, allowing condensate drainage to the process.

For the following temperature services, a pressure gauge shall, in principle, be provided with a siphon:

- For liquid temperature: 200 °F or higher:

- For gas temperature: 400 °F or higher.

- For steam temperature: 200 °F or higher.

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9.6. Temperature Measuring Instruments

9.6.1. Temperature Transmitters

SMART transmitters shall be used for all control, monitoring (indication and alarm) and shutdown applications.

These transmitters used for control, monitoring will operate in Foundation Fieldbus technology and for shutdown applications in 4-20 mA, 24 VDC loop powered, two (2) wire system, and shall use a digital communication protocol (HART) superposed.

Daisy Chained connections are not allowed.

Equipment enclosure will be subject to the area classification.

9.6.2. Thermocouple and RTD

RTD type temperature sensing elements shall be used for all electronic temperature transmitters and measuring systems up to and including 500 °F. Thermocouple type temperature sensing elements shall be used for temperatures above 500 °F.

Temperature elements in shutdown service shall be separate from elements in monitoring services and installed in separate thermowells.

Thermocouples and RTD’s assemblies shall be installed in thermowells.

Thermocouples and RTD’s sheath shall be 316 SS as minimum with 0.25 in O.D. for temperatures above 1706 °F, material sheat h shall be INCONEL or other appropriated material.

Thermocouples and RTD’s shall be fabricated with 18 gauge wire minimum in hard ceramic insulation (usually magnesium oxide).

Thermocouples will be standard construction type. It has a grounded tip welded on silver soldered to the sheath for fast response. Thermocouples will be ungrounded for differential temperature applications

Thermocouples shall be 2-wires type with terminal block inside head.

Thermocouple wires and thermocouple extension wire shall be of the first quality. Thermocouple extension wire shall have the same electromotive-force temperature characteristic as the thermocouple to which they are connected. Extension wire shall be in accordance with ISA MC 96.1.

RTD’s shall have the three (3) lead wire design and wire insulation shall be color coded per ISA.

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RTD’s shall be platinum, 100 Ohm at 32°F (0°C). The temperature coefficient of RTD’s shall be 3,85x10-3 ohm/°C. Three (3) wire elements shall be used.

Thermocouples and RTD’s head shall the following characteristics:

▪ Cast aluminum.

▪ Compression type terminal block with brass terminals and an extra terminal for attaching the extension wire shield connection.

▪ The heads shall be weatherproof and shall be installed to prevent ingress of water into the conduit entry.

▪ Conduit entry in heads will be 3/4” NPT-F and the connection to thermowell shall be 1/2” NPT-M.

9.6.3. Temperature Gauges

The local temperature indicators (Thermometers) shall be of bimetallic type with a five inches (5”) diameter dial, white background with marks and numbers in black. The scales must be direct read and be in accordance with the normal ranges of the manufacturer.

Thermometers must be of pivoting head adjustable to all positions or planes. Ranges must be defined so that the normal operating temperature indication is approximately in the middle of the scale.

Thermometers must come with thermowell, selected in accordance with the characteristics of the process.

9.6.4. Thermowells

Thermowells shall be used for protecting all temperature sensing elements except for measuring skin temperature; and permit changing of the element without draining the process.

Immersion length of thermowells shall be as follows, unless otherwise specified:

- Measuring in tanks, vessels, towers, etc.:

Thermowells mounted in horizontal vessels shall have at least an eighteen inches (18“) insertion length; however, insertion length shall not exceed ½” the vessel diameter.

Special requirements such as agitated vessels may require shorted thermowell installations.

Length shall be as indicated in the specification data sheet.

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- Measuring in pipelines:

Table 10. Pipelines

PIPE DIAMETER THERMOWELL INSERTION LENGTH (PERP. TO PIPE)

6" 7”

8" 7”

10” or higher 10”

Note: 1.- Special consideration shall be taken for insulated lines. 2.- Pipes smaller or equal to 4” shall be increase to 6”.

Materials of thermowells:

All thermowells shall be machined from type 316 SS bar stocks.

Other materials shall be applied when it cannot be used due to the nature of fluid.

Connection of thermowells:

Thermowells shall be provided with flanges in accordance with the pressure rating of corresponding equipment or process pipe lines.

For service on very high pressure and/or high temperatures, different constructions may be required, i.e. to prevent danger of thermowell collapse.

Size of flanges to be connected with equipment or process pipe lines shall be as follows:

- For process pipe lines: 1 1/2 inches

- For storage tanks and vessels: 2 inches

All sensing elements shall be mounted to thermowells with screw threads 1/2 inch.

9.6.5. Installation of Temperature Measuring Elemen ts

For thermowells and their mounting nozzles for temperature sensing elements to be installed on piping or equipment, the following shall be considered:

- Thermowells shall be located in easily accessible positions and temperature gauges shall be easily readable.

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- Thermowells shall be installed for all temperature sensing elements to permit their removal during operation.

- In lines above running equipment, thermowells shall be located such that it doesn’t have to do with running equipment.

- Where a throttling device is located in the same line, the thermowell shall be located downstream of the throttling device.

9.7. Final Control Elements

9.7.1. General

Final control elements are the final elements in a process control loop such as valves, dampers and others.

For economics in purchasing and spare-parts stocking, the selection of control valves shall aim at a minimum variety.

Top guided, top and bottom guided or cage guided trim globe, eccentric rotary plug, characterized ball or butterfly valves may be used for general services.

Globe or eccentric rotary plug type valves shall be considered the first option.

Single port, cage trim globe or characterized ball valves shall be used for tight shut-off.

Ball valves with a pneumatic piston-spring return type actuator are preferred for ON-OFF shutdown and blow down applications. Ball valve shall be Trunnion type.

Butterfly valve can be considered in sizes six inches (6”) or larger for high capacity and low pressure drop services.

Control valves shall be flanged type. Flangeless eccentric rotary, flangeless butterfly valves shall be used depending on the particular application and subject to client approval.

The control valve shall be specified to avoid moving surfaces between where sand can be trapped or cavities where solids can be collected.

The control valve seat leakage shall depend of the process conditions, and ON/OFF shutdown and blow down valve shall be tight shutoff ANSI V class (minimum), for liquid flow and ANSI VI class for gases flow.

Body size dimensions of the valve shall comply with ANSI standards.

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Control valves will be sized in accordance with ISA standard S 75.01.for the minimum, normal and maximum operating conditions to ensure the valve will operate between 17 and 90 percent opening in accordance with ISA S75.11

All valves shall have bolted gland type stuffing boxes with teflon packing within the temperature limits of these materials. Grafoil packing shall be used when process temperature exceeds 450°F. Bellows sea led packing boxes shall be used for applications involving toxic or hazardous fluids.

Control valve body size shall equal to the pipe diameter for lines of 1” of diameter or less.

For two phase flow, the control valve (Cv) shall be calculated adding the Cv of the liquid phase plus the Cv of the vapor phase; the quantities of liquid and vapor shall be based on outlet conditions; the physical properties of the two phases such as specific gravity, etc., shall also be established on the outlet conditions of pressure and temperature.

When the turndown ratio required to cover the operating range exceeds 20:1, the valve application should be carefully examined for acceptable valve opening range. If the operation is considered to be unacceptable, two valves in parallel shall be used.

Stellite or harder trim material will be used on: Flashing fluids, Fluids with entrened solids or pressure drops over 203 psi.

Generally, control valves will be air operated.

All control valves will be fitted with positioners.

All valves should be supplied with a permanently attached stainless steel tag, stamped with the manufacturer’s standard data or item number.

Electro-pneumatic positioners will be used on all applications where the positioner operation is not affected by line vibration.

Positioners will be supplied with input, output and air supply gauges, integrally mounted air filter regulator and internal bypass valves except on split-range and reverse acting positioners

9.7.2. Valve Action

Direction of valve action shall be determined so that the plant will be maintained in safe condition on power failure of actuator or input signal failure.

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9.7.3. Flow Characteristics of Control Valves

Shall be determined taking process characteristics according to various operation modes into consideration.

Equal percentage characteristic shall be considered the first option.

Linear Characteristic: The valves shall have linear characteristics for the following services: - For small load fluctuation.

- When the pressure drop across the control valve under all operating conditions is more than 2/3 of the pressure drop across the control valve in closed position.

- For steady normal operating condition

- For on-off control.

Equal Percentage Characteristic: The valves shall have equal percentage characteristics for the following services:

- For largely changing flow rate and pressure-drop.

- For relatively small pressure-drop across the valve, compared with system dynamic pressure-drop.

- For large load fluctuation.

Quick Opening Characteristic: For on-off control, when it is required by process.

9.7.4. Type and Application of Control Valve

Generally, globe or eccentric rotary plug type valves shall be used in general services except where large pressure drop across the valve, high capacities or other adverse operating conditions make other types more suitable.

Double Seated Valves: shall generally be used for services in size of 2 inch and larger and tight-shut is not required.

Single Seated Valves: shall be used for services in size of 1 1/2 inch and smaller and/or in process conditions that require tight-shut.

Angle Valves: may be used for the following services:

- For erosive such services as slurries and others.

- On applications where solid contaminants might settle in the valve body.

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- On hydrocarbon services with tendency for cooking.

- For high viscous liquid.

- On applications where the pressure drop across the valve is larger.

Butterfly valves: It’s valves and characterized (throttling) ball valves shall be considered whenever their high capacity at low pressure drop offers a distinct advantage.

May be used in services in size six inches (6”) and larger, and where the pressure drop across the valve does not exceed the design limitations, and where full closure is not permitted in process condition.

Ball valves: may be used for on-off and throttling services under the following services:

- Slurry liquid.

- Fluid suspended gummy particles.

- Tight-shut and/or quick action.

Diaphragm valves: may be used in the following services of utility facilities:

- When the pressure is low and the pressure drop across the valve is small and body lining is required.

- When tight-shut is required for low pressure slurry liquid service.

Self-Actuating valves: may be used where relatively rough control is permitted or steady normal operating is expected, and where instrument air is not available.

Solenoid valves: shall be used where electric on-off, control or emergency relief systems require automatic closing of valves.

Shall be supplied with junction box for connection.

Shall always be in the pneumatic air line to the shut-off valve, and they shall never be directly in the process line. Solenoid valves may, however, be installed in the oil system for running equipment.

It’s valves will be of the continuous duty type and will meet the area electrical classification (class H High temperature/ encapsulated coils).

Shall operate at 24 VDC, low consumption, less 5 watts.

On-Off/Motor-Operated valves: If electrical motor actuator type is selected for control process, the speed of response of the valve shall be carefully examined to ensure compliance with the particular application requirements;

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in general, these valves will be used for actuation speed low process. Additionally, caution must be exercised in determining the fully open to fully closed position duration to ensure that there are no occurrences of surge pressures due to sudden valve closures.

These valves shall be of a low inertia type, squirrel cage induction motor, totally enclosed in a fan cooled enclosure rated for continuous duty in +104 °F ambient temperature. Explosion Proof motors in C lass 1 service shall have overheating protection and the assembly shall consist of electric motor drive, motor starter, hydraulic pump, hand-pump backup, discharge check valve; vented, non-pressurized reservoir, return line filter, suction strener, filler cap, level sight glass, drain plug and other components specified on the data sheet. This kind of actuator shall be Foundation Fieldbus compliance.

The on-off/motor-operated valve shall have transmitter for closed and open remote and local position indication.

Others: In services where application of the valves above mentioned are unpractical, other special type control valves shall be considered.

9.7.5. Construction

Control valve bodies shall not be smaller than one inch (1”) for a line size of one inch (1”) and larger. In lines smaller than one inch (1”), a line size valve with internal threaded ends shall be used. Reduced trim to be specified if required. 1-1/4", 2-1/2" and five inches (5") control valve bodies shall not be used.

All control valves shall be provided with flanges, as a standard.

Body and end connections shall be 300# as minimum. For line rating higher pressure rating of control valves shall be determined in accordance with Piping Material Specification.

Body material shall be equal to or better than that specified in the Piping Material Specification for each application, but it will be carbon steel as minimum. Trim material shall be 316 SS as minimum. In case very exotic materials are required, consideration may be given to internal lining of the control valve body, e.g. with teflon or metallic coating.

Stellite (Alloy 6 or 12) plug and seat shall be used for throttling control valve in liquid services which are subject to erosion damage from the pressure drop, in well streams with sand and other abrasives, or in flashing or cavitation services.

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The control valve trim (consisting of plug, seat rings and stem) shall be 304 SS or 316 SS, unless otherwise specified. The use of other materials or special treatments can be adopted due the process conditions.

Valves on hydrogen sulfide and other toxics ambient conditions shall conform to the appropriate NACE specification.

Radiation finned bonnets shall be used where process temperature exceeds 450°F.

Plain extension bonnets shall be used where process temperatures are below 30°F.

9.7.6. Actuators

Actuator for control valve shall be spring opposed pneumatic diaphragm type as first option but a spring opposed pneumatic piston can be used when diaphragm actuator is not suitable because of its differential pressure.

The actuator shall be supplied with the control valves and mounted on the valve. This actuator shall be sized in accordance with the maximum differential pressure of operation.

The valve action on failure of the operating medium shall be determined by process requirements with regard to safe operation and emergency shut-down requirements.

Electric motor actuators with gear tens are not acceptable except for open/closed service. They should be considered where ON/OFF valves must be remotely operated and pneumatic operators are not practical to use.

Actuator for emergency shutdown and blow down valves shall be spring opposed pneumatic piston type.

9.7.7. Handwheels

Application of handwheel shall carefully be decided, considering speedy maintenance, economical aspects and easy operation during the control valve failure.

Handwheels shall be supplied when specified. They shall be declutchable type with a clear indication of the neutral position.

The handwheel mechanism shall not increase frictional load of the actuator and operable even against the specified maximum differential pressure.

Clutch/linkage mechanisms on rotary valves shall be designed such that the control of the valve position is not lost when engaging the handwheel.

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Handwheel shall be specified only after a “HAZOP” study has been performed and should be permanently marked to indicate valve: open & close directions

9.7.8. Valve Positioners, Transducer and Accessorie s

Control valves for throttling applications shall be mounted with an electro-pneumatic positioner.

Electro-pneumatic positioners shall be used. They shall accept a 4-20 mA DC input signal and provide the appropriate output signal to the actuator. Positioners for non loop critical or for those applications that require low speed response shall be Foundation Fieldbus compliance.

Electro-pneumatic positioners shall be SMART type.

Filter/regulator with pressure gauge shall be supplied with control valves piped and mounted on the valve.

Inlet and outlet pressure gauges shall be supplied with the filter regulator.

Shutdown and blowdown valves shall be supplied with a quick-exhaust valve to assure the stroking time required for the application.

In applications where a solenoid valve is required, it shall be supplied with the valve, pre-piped and mounted on the valve, to load/vent from the valve actuator. Solenoid valve shall be 316 SS body type, 1/2” NPTF, 24 VDC low power consumption, less than 2 Watts. Solenoid valve shall be three way type, soft seat and continuous duty type, equipped with class B encapsulated coils as minimum and will meet the area electrical classification.

Limit switch shall be snap acting hermetically sealed micro switch, mounted on the valves, with contact rating 24 VDC @ 1 Amp or 120 VAC @ 4 Amp; that is applicable in those cases which transmitter with Foundation Fieldbus appliance not is possible.

To avoid cavitation or noise level above 85 dBA, the valve shall be provided with accessories anticavitation or noise abatement.

9.7.9. Sizing

Calculations shall be made using a computer program based on the vendor’s published method and equations; the method shall provide valve coefficient, calculated noise, and a flag for cavitation or flashing. Calculations shall be made for each process case (normal, maximum, and minimum flow).

Control valve body size normally shall not be less than half that of nominal line size.

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The control valve shall be sized taking into account the minimum, normal and maximum operating conditions. The finally selected item shall ensure that the valve operates in accordance with the following:

- For linear characteristic, valve opening must be:

� At minimum flow at least 17 % of control valve.

� At normal flow not shall exceed 75% of control valve.

- For equal percentage:

� At minimum flow at least 20%.

� At normal flow not shall exceed 65% of control valve.

- Maximum flow has to be 90% or less of valve opening.

- All butterfly valve shall be sized so that flow rate does not require a valve disc opening greater than 60° for all valves in thr ottling service. 90° opening is permissible for valves in ON/OFF service.

9.7.10. Noise Control

An expected sound pressure level will be calculated using the method recommended by the vendor.

The valve shall operate without any cavitation. Permissible sound pressure level shall not exceed 85 dBA at three feet distance from the control valve, measured at 45° downstream, as acceptable noise lev el. In case an expected sound pressure level may exceed 85 dBA, proper acoustic treatment will be taken i.e. by providing an acoustic insulation, noise reducing orifice plates or a specially designed control valve.

Permissible noise exposures shall be in accordance with standard and specifications.

9.7.11. Safety and Relief Valves

Safety and relief valves shall be sized and installed in accordance with ASME Pressure Vessel Code, API RP 520 or any other such codes that may apply.

Safety and relief valves shall be conventional type spring loaded. Balanced bellows seals will be specified where required for built-up back pressure in excess of 10% of the set pressure or where constant or variable back pressure are considerable. Process group will define this condition at process data sheet.

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The ends connections shall conform to respective piping material specification, unless otherwise specified.

Safety Relief Valves shall be provided with permanently installed, non-adhesive, stainless steel or aluminum nameplates containing engraved the following information as minimum:

o Valves Tag Number

o Manufacturer's name and serial number

o Model Number

o Cold spring set pressure.

o Body and orifice size

o Body and flange pressure rating.

o Applicable code stamps

9.8. Local Control Panels

Auxiliary instrument panels shall be of stainless steel or synthetic resins. Height and width shall be as necessary as but no higher than eighty six inches (86”) and not less than three inches (3’’) deep, unless agreed upon in writing with the Purchaser. Front of panel instruments shall be above thirty two inches (32”) elevation. Panels shall not exceed between two inches and seven inches (2”- 7”) high overall.

Panels shall be appropriate for environment and electrical area classification, totally enclosed, front and properly gasketed. Panel mounted instruments shall be designed for outdoor installation, in accordance with the environment and corrosion conditions.

All local panels shall comply with the following criteria:

- 25 % of spare space for future instrumentation.

- 25 % of spare for free terminal blocks.

- All local panels shall be supplied with all mounted and connected cables and wiring on the internal wall of the panel.

Panel must be supplied with fully lockable doors for protection.

Local Control Panels provided by Package Units suppliers shall contain Programmable Logic Controllers (PLC’s), local indicators and hand switches; allow independent local start-up or shutdown procedures, with capability to accept remote shutdown commands. Indications and alarm signals will be sent to the EXPERION PKS from HONEYWELL for monitoring.

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9.9. Control System

Equipment operation shall be fully automatic and autonomous; therefore Vendor Control System shall have following characteristics as a minimum:

• Vendor Control Systems shall be located in a battery limit of the equipment. Everything related to analog or sequential control shall be centralized in a suitable local control panel in accordance to the area classification to be installed.

• Vendor Control Systems shall perform all startup and unit shutdown sequences without affecting performance of the rest of the plant.

• Sequences & control shall be implemented by Programmable Logic Controllers (PLC), vendor will supply an electronic and hard copy of PLC program.

• Automation level to be applied to control systems of equipments shall be Vendor's responsibility. Additionally, Vendor shall guarantee optimal performance of the equipment.

Safety Instrumented Systems (SIS) devices shall be independent and wired in a separate package junction box to SIS of the plant.

Alarm and shutdown systems shall be fail-safe. This is normally energized, de-energized to alarm or trip. Exceptions are to be identified, and agreed upon in writing before implementing.

The control system shall have external communication by ControlNet protocol to be communicated with C-200 Controller from HONEYWELL.

Vendor shall provide with all motors the following manual switches as follow:

• Start / Stop push button.

• Auto / Manual / Off / On selector station.

10. MATERIALS FOR INSTALLATION

10.1. Pressure Leading Materials

In general, 316 SS tube (size and wall thickness in accordance with pressure and temperature ratings) shall be used for pressure leading piping from the first block valve to instruments. Valves and fittings required shall be 316 SS compression types.

When tubing cannot be used, pipe and piping fittings required for pressure lead piping shall be in accordance with the applicable Piping Material Specification.

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10.2. Electric Materials

Conduits and Accessories: the wiring between each field instrument to junction box shall be housed in steel hot dip galvanized heavy series conduit tubes and flexible liquid tight conduit.

The minimum conduits size will be 3/4". All conduit fitting shall be suitable for environmental conditions and hazardous area classification.

For instrument conduit connection the fitting size will be ½” or ¾” as required.

Wire and Cables: the jacket of all cables will be of humidity resistant material, such that the cable can be approved for its installation in dry or humid locations, as well as it shall be resistant to ozone and sun. This jacket will be resistant to other factors, such as acids, alkali (caustic soda, caustic potassium and others), aliphatic solvents (gasoline, oil, grease), aromatic solvents (benzene, toluene, xylene and others), chlorinated solvents (carbon tetrachloride, trichlorine benzene, abrasion and others), if it is specified. In all cases, the jacket will have a component to make it flame retardant.

Those cables which requires to be directly buried or for tray use, shall be armored type.

The conductor material will be tender copper without tinning.

The insulation and jacket will be fire and corrosion resistant PVC.

The insulated conductors shall be uniformly braided to form a pair. The braided layer shall be greater than 8 times the braided diameter and smaller than 16. The cables braiding will be done at least 20 times by meter so they can’t be unbraided manually.

The pair number required shall be assembled together and in concentric layers.

The cable will be supplied with its entire required length, without cuts or joints in each reel.

The final ending of each cable shall be provided with a seal to prevent the humidity entrance during shipping or bleakness storage.

The initial ending of each cable shall be projected outside the reel, so it can be tested at the installation location.

The end of each cable shall be secured firmly and appropriately to the reel to avoid damages during the handling and shipping. The supplier is responsible of taking all necessary precautions to protect the equipment against damages and corrosion during shipping, handling, discharge and storage, so he shall provide the appropriate packaging and shipping for the equipment.

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All cables must transmit only one type of signal and never combined.

There are different types of cables to be used, which are the following:

- Type 1: Single pair with shielded for analog signals (4-20 mA)

Conductor: 16 AWG, 7 concentric threads, class B braiding, max. 300 volts.

Primary Insulation: PVC, 90ºC, 0.38 mm.

Colors Code: Black and White.

Jacket: PVC, Black, 90ºC, minimum 1,14 mm.

Overall Shield: Pairs will be a 100% covered with an aluminized tape plate with a thickness of 1.27 mils, helically applied. The aluminum layer shall be inside oriented so it is in contact with the neutral conductor which will be 18 AWG caliber and alloy solid conductor type.

- Type 2: Single pair for discrete signals (24 VDC) (solenoids, alarms, switches, relays)

Conductor: 16 AWG (minimum) a large wire size shall be used required by the calculations, 7 concentric threads, class B braiding, max. 300 volts.



Jacket: PVC, Chrome, 90ºC, minimum 0.81 mm.

- Type 3: Multipair with individually shielded pairs and overall shield




Jacket: PVC, Black, 90ºC, minimum 1.14 mm.

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Individual Shield: Each pair will be a 100% covered with an aluminized tape plate, helically applied over a stranded pair. The aluminum layer shall be inside oriented so it is in contact with the neutral conductor, which will be 22 AWG caliber with 7 braided threads. This shield shall be applied in such manner that it doesn’t detach when the cable is peeled for its connection.

Overall Shield: Pairs will be covered with an aluminized tape plate, helically applied over the stranded pairs. The aluminum layer shall be inside oriented so it is in contact with the neutral conductor which will be 20 AWG caliber with 7 braided threads.

Signal Type: Analog.

Note: These cables shall be armored.

- Type 4: Overall shielded multipairs






Signal Type: Discrete.


- Type 5: Single pair Thermocouple Extension Cable

Conductor: 16 AWG, alloy solid conductor, 300 volts.

Primary Insulation: PVC, 90ºC, 15 mils.

Colors Code: “J ” type, White (+) / Red (-).

Jacket: PVC, “J ” type, Black, 90ºC, minimum 20 mils.

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Signal Type: mV.

- Type 6: Fieldbus Cable

Conductor: 18 AWG, type A, 300 volts, 24 ohm/km.

Nominal Diameter: 6.43 mm.

Nominal Impedance: 100 ohm @ 31.25 kHz.

Nominal Capacitance: 78.7 pF/m.

Nominal Attenuation: 0.039 MHz.

Primary Insulation: Polyolefin, 75ºC.

Colors Code: Blue, Orange.

Jacket: PVC, Orange or Blue, 75ºC.

Overall Shield: 100% Beldfoil shield, 24.6 ohm/km.

Signal Type: Software.

- Type 7: Modbus Cable

Conductor: 22 AWG, 2 concentric threads, twisted, max. 300 volts.

Primary Insulation: PVC, 105ºC, 27.5 mils.

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Colors Code: White and Blue.

Jacket: PVC flame retardant, 105ºC, minimum 35 mils.

Overall Shield: The pair will be a 100% covered with a Beldfoil type shield. The shield shall be in contact with the drain cable, which will be tinned copper type, 22 AWG caliber. This shield shall be applied in such manner that it doesn’t detach when the cable is peeled for its connection.

Signal Type: Software.

- Type 8: ControlNet Cable Coax

Conductor: 18 AWG, solid, bare cooper covered steel, 91.7 ohm/km.

Nominal Diameter: 7.57 mm.

Nominal Impedance: 75 ohm.

Nominal Capacitance:54.1 pF/m.

Nominal Attenuation: 1 MHz.

Primary Insulation: Polyethylene, 75ºC.

Colors Code: N/A.

Jacket: PVC, Gray, 75ºC.

Overall Shield: Quad shield foil 60% Aluminum braid/ foil 40% Aluminum braid, 23.6 ohm/km.

Signal Type: Communication.

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- Type 9: Triad with shielded for RTD signals

Conductor: 16 AWG, 7 concentric threads, class B braiding, maximum 300 volts.


Colors Code: Black, White and Red.



- Type 10: Multipair with individually shielded pairs and overall shield Thermocouple Extension Cable

Conductor: 20 AWG, alloy solid conductor, 300 volts.

Primary Insulation: PVC, 90ºC, 15 mils.

Colors Code: “J” type, White (+) / Red (-).

Jacket: PVC, “J” type, Black, 90ºC, minimum 20 mils.

Individual Shield: Each pair will be a 100% covered with an aluminized tape plate, helically applied over a stranded pair. The aluminum layer shall be inside oriented so it is in contact with the neutral conductor, which will be 22 AWG caliber with 7 braided threads. This shield shall be applied in such manner that it doesn’t detach when the cable is peeled for its connection.


Signal Type: mV.


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10.3. Junction Boxes

Junction Boxes provided by Package Unit suppliers will allow independent local start-up or shutdown procedures, with capability to accept remote shutdown signals from SIS. Indications and alarm signals will be sent to the EXPERION PKS from HONEYWELL for monitoring.

Wiring works between instruments and junction boxes will be part of Package Unit supplier’s scope.

Where the quantity of signals does not need a local panel or a control system independent and autonomous, the skid-edges of the unit package shall be field junction box.

In general, junction boxes shall comply with PDVSA standard K-334 (Instrumentation Electrical Requirements).

Construction material will be metallic aluminum alloy based (0.4% maximum of copper) or another material resistant to corrosion and environment, waterproof.

The boxes destined to be located at environmental conditions and at unclassified areas, shall be provided with seals and protections to avoid the entry of water or dust. The boxes for this type of area shall be NEMA 4X, IP 66, according to the National Electric Code. Two different dimensions (height x width x depth) will be used: junction box type A, 305 mm x 305 mm x 203 mm, with two strips of 24 terminals each, and junction box B, 600 mm x 410 mm (o 203 mm) x 108 mm (T’), with two strips of 50 terminals each.

The Junction Boxes to be installed in classified areas shall be NEMA 7 and NEMA12 for indoor; they must be sized and specified in accordance with the needs of each case.

Junction box Dimensions of signals shall be appropriated to guaranty maintenance or expansion facility.

The perforations to the boxes for wire entry shall be from the bottom of the box.

The junction boxes shall be double fund type, for the adequate location of the terminal strips.

The door of the boxes shall be joined to them with individual hinges and quick release latches stainless steel, resistant to corrosion, easy to dismount and with an opening of 180º. The door shall include data pocket fixed to the backside of the door. Seams are sealed, no holes or knockouts.

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Junction Boxes supplied shall be pre-assembled and shipped in one piece (with inside panel, rails, terminal blocks, ground connection points, wiring ducts. Any loose accessories or other items, which can not be mounted shall be carefully marked, tagged, packaged and shipped with the same shipment, complete with installation instructions and drawings as applicable. Shipment of loose items shall be subject to prior approval, in writing, by PDVSA GAS.

11. INSTALLATION DESIGN

11.1. Process Installation

Direct connected instruments shall be installed with valves and fittings. Process connections shall be as a minimum 1/2 inch NPT, 316 SS tubing and fittings shall be used to connect remote mounted instruments. 316 SS tubing and accessories shall be used for pneumatic instrument air signals.

All tube fittings for process connection, instrument air supply and pneumatic signal circuits shall be Swagelock, Parker or similar, double ferrule type.

Tubing for process connections shall be as a minimum 1/2" 0.D. x 0.049" wall 316 SS, with 316 SS tubing fittings. Pneumatic tubing shall be 3/8" O.D. 316 SS with 0.035" (min.) wall thickness with 316 SS fittings.

Where possible, all instruments shall be factory installed on the skid. All instruments shall be installed in accordance with the Manufacturer's instructions in addition to the other requirements herein.

All instruments shall be installed so that accuracy or reliability will not be reduced due to vibration, pulsation, temperature or contamination. Pressure gauges installed in vibration service shall be provided with flexible hose, dampers or other approved methods of damping.

All instruments shall be installed so that they are easily accessible for maintenance and inspection. They shall not be located under deck grating or in any place or manner that would make it difficult or dangerous for personnel to inspect or work on them during normal equipment operation or shutdown.

Instrument piping, tubing and conduit shall be properly protected and supported. All tubing shall be continuously supported in steel channels. Pipe and conduit shall be securely supported by channels and clamps.

All instruments shall have a bleed valve between instruments and their block valves for all services.

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11.2. Electrical Installation

Instruments and electrical installation shall be as minimum NEC Class I, Division 2, Group C & D, unless otherwise specified. Instrument housings and the local panel shall be weatherproof and shall comply with electrical classification area.

Wiring systems of different signal levels (SIS, PKS, F&G) and power levels shall be kept separated by providing separate conduit, raceway, junction boxes, control panels, etc. for each type. The following types of instrument wiring systems shall be separated from each other in accordance with the National Electric Code.

− 120 VAC power

− 24 VDC power, status signals and controls

− 4 - 20 mA signals

− Thermocouple, RTD and similar millivolt signals.

− Communication signals.

Shutdown and interlock circuits shall not be directly series wired from device to device. Each device shall be wired to terminals in a terminal box.

All instrument electrical connections to and from the equipment shall be terminated in weatherproof junction boxes, which are suitable for the electrical area classification. Each junction box shall allow adequate gland/conduit space for Purchaser’s incoming cables. All junction boxes shall be provided with 30 % (minimum) spare terminals.

Each wire and wire pair shall be permanently identified and each terminal strip and terminal shall also be permanently identified. Imprinted, with black pre-typed lettering, heat shrink wire markers are preferred. Terminal blocks and terminals shall be identified with engraved phenolic nameplates or commercial terminal strip markers. The identifications shall correspond to and be shown on the related drawings. There shall be no more than two wires per connection. Each cable will be terminated with approved crimped type terminals blade or forked for non critical signals and circular or ball eyes for shutdown signals.

For convenience of operation and maintenance, a machine baseplate mounted instrument board may be furnished by the Vendor to minimize locally pipe mounted instrumentation. Mutual agreement shall be reached on those instruments that must be pipe mounted. The machine baseplate mounted instrument panel, if furnished, must be

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securely supported to eliminate vibration, undue forces on piping and damage during shipment, storage, operation and maintenance.

All wiring shall be run in rigid galvanized conduit, where applicable. Liquid tight may be used in areas that require flexible connection, but shall not be longer than three feets (3’).

Conduit unions and junction boxes shall be provided as necessary to facilitate replacement of instrument devices.

Conduit or piping shall not apply stress loads to instrument cases or mountings. This includes situations where the conduit or piping could be used for hand holds or to stand on by installation or maintenance personnel, therefore the same must be properly braced and supported.

Electrical Routing: Electrical installation design shall be according with the following codes and standard: CEN (COVENIN 200), API RP-551 and PDVSA standards.

This installation includes: instrument connection, conduit installation, junction box, and wire installation from instrument to junction box.

Junction box shall be located and conduits shall be arranged so as to prevent intrusion of rainwater into junction boxes (bottom connection for multiconductors and lateral side for conduits carrying individual cables).

Electrical routing between junction boxes to instruments shall be arranged with rigid conduit tubes. Steel conduits shall be organized so as to prevent intrusion of rain water into instruments, steel conduit size shall be determined so that the cables occupy less that 40% of the tube cross sectional area. The steel conduit tubes shall be supported from structures as far as possible. Connection between rigid conduit and instruments shall be with flexible conduit "liquid-tight".

Cable inlet and outlet of field instruments and junction boxes shall be sealed using sealing fittings, according to hazardous area classification.

Junction boxes shall be located where maintenance is easily made (preferable five feet (5’) high from floor or maintenance deck or cable duct), and as close to related instruments as possible.

Junction boxes shall be able to connect two multiconductors. Analog signal and digital signal shall be install in separated junction boxes, additionally the signals shall be install in separated junction boxes according to system, SIS signals, F&G system signals and Process Control System signals.

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In general, junction boxes shall have a minimum 30 % of spare of terminal blocks.

Considerations on Wiring: The different type of circuits shall be segregate routing according to the following considerations:

- Analog signals shall be separated from digital signals, power supply, and solenoid valves.

- SIS signals shall be separated from Process Control System signals, except for instruments main routes drawings.

- In junction boxes shall be provided terminal blocks for interconnect simple pair shield with multiconductors general shield.

- When the instrument cables and the electrical cables run in parallel, they shall be kept as far apart from each other as possible, and when they cross, they shall cross at right angles and be kept as far apart from each other as possible. Minimum separations are given in API RP 550.

12. IDENTIFICATION

All instrumentation equipment shall be identified with plates located in easy access places, which shall indicate, at least, the following information:

- TAG number of the instrument (according to the P&ID where it applies).

- Service.

- Range.

- Brand.

- Model (Instruments, Control Valves, etc.).

- Serial Number.

The identification plate shall be stainless steel AISI 304. The welding of the identification plates is not allowed.

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13. DOCUMENTATION

For the development of the project, Vendor shall deliver the following documentation with the equipment:

- Drawings needed to mount, connect and troubleshoot the instrumentation, including instrument locations, vessel trim details, installation details, logic diagrams, schematics, loop diagrams, junction box drawings, vessel sketches, data sheets & calibration certification, for all instruments and valves (pressure relief valve, control, self regulators, etc.).

- Instrument drawings required to connect field power, locate the field signals and junction boxes, run conduit or tray and connect wiring or tubing.

- Table for all instruments requiring power, to identify power requirements including loads, breaker settings and type of power (UPS requirements, etc.).

- Documents for online, custom and unusual instruments to Buyer for approval and as final certified drawings.

The drawings shall identify conformance with the requirements, dimensions for connections, instrument type and manufacturer, proper application, location of equipment including instruments and junction boxes, and interconnection diagrams with terminal numbers assigned. Emphasize safety considerations such as protection of personnel, capital equipment and the environment.

Besides, the documents shall:

- Include all the "packaged" equipment dimensional information.

- Depict piping, valves and instruments for the operation of the package unit.

- Include item numbers assigned by the Client for equipment and instruments.

- Identify size, type and description of each item and process and utility connection to Client’s piping.

- Locate instruments, junction and terminal boxes, and connections to piping, vessels and machines.

- Show instrument air tubing and piping and valves.

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- Provide a complete instrument list with type, manufacturer, model number and description for each instrument and instrument valve to be supplied by Vendor.

- Include copies of control valve, safety relief valve and orifice plate calculations.

- Include completed ISA data sheets for each instrument.

- Include parts list and list of recommended spares for instruments as defined in the Purchase Documents.

- Include instrumentation utility requirement schedule for power, cooling water, instrument air, nitrogen, etc.

- Document instrument removal and reinstallation procedure where required for shipping.

- Provide factory testing procedure.

- Instrument Specifications.

- PSV’s (to be supplied loose).

- Vessel Sketches (for review and approval).

- Wiring Diagrams for junction boxes including terminal strip identification.

- Loop Diagrams.

- Signal List.

- Cable & Conduit List.

- Instrument Layout.

- Mechanical Data Sheets.

- Package Control Philosophy.

- List of items to be shipped loose.

- Mechanical Equipment Fabrication Drawings (for review and approval).

- General arrangement drawing (including skid dimensions, anchor bolt locations, etc.).

The following are specific requirements from the Vendor:

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- Schedule for Detailed Engineering, Procurement and Fabrication with the dates of delivery of all documentation.

- A detailed weekly progress report, with “S” curve for all activities after PO placement.

- Pressure vessels require ASME stamp.

- Include in the offer the cost of delivery to site

- If for transportation purpose some items on the skid need to be shipped loose then the offer must include the re-assembly of the total package on site by the vendor.

- Also, include a quote, as optional, the supervision of assembly by COMPANY.

- Include in the offer supplier on site start-up and commissioning rates.

14. SPARE PARTS

The Vendor shall include in the quotation package, spare parts and special tools required, for commissioning start up and two (2) year of normal operation.

The quantity of spare parts shall be related to the number of instruments supplied. After purchase order is placed, Vendor shall provide a final spare parts list for approval.

Every spare part shall be clearly marked, those of small dimensions shall be packed in plastic bags marked with their corresponding part numbers, and those of large dimensions shall be individually packed and identified.

15. INSPECTION AND TESTS

15.1. Inspection

The Client reserves its right for inspecting the plant areas used by the manufacturer to build and assembly the system’s components described in this specification, in any stage of the construction and testing period. The manufacturer shall inform the Client, in writing, the dates of the system’s construction and start-up stages.

The visual inspection shall include the following items:

- Dimensions.

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- Painting and final touches.

- Wiring.

- Alarms logic operation (if applies).

- Panel controlled components operation.

- Panel operation safety.

- Circuits connection and grounding.

15.2. Tests

The Factory Acceptance Tests (FAT) shall be carried out according to the standards and codes mentioned in this specification, or those indicated by the Client.

The manufacturer shall maintain an updated record of the results of all tests carried out, in which there will be indicated all relevant events during the running of the tests.

Interruption of the tests due to equipments failures shall be described by the manufacturer, after they are corrected, in a written report indicating clearly the reason of the failure and the corrective actions that were taken. The report shall be delivered to the Client for his approval. Any corrective action necessary shall be carried out and proved before shipping the equipment to the Client for its installation.

Any problem or discrepancy found during the tests shall be recorded and corrected before ending the tests.

15.2.1. Factory Acceptance Test (FAT)

The operation tests shall include as minimum the following aspects:

- Verification of the operation of each electronic component specified in the package unit.

- Verification of the operation of the control panel.

The tests report shall be a complete report of the performed tests and will be delivered to the Client.

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The permission for shipping the package unit to the Client will be issued only after the tests has been completed and after any discrepancy in the equipments operation has been corrected.

After each test is successfully performed, the manufacturer and the Client will sign the test certificate.

15.2.2. Field Tests and Site Installation

Once the Package Unit has been installed, the manufacturer shall perform an operation test of the whole equipment.

16. PACKING AND SHIPPING

Vendor shall consider the most adequate way of packing in order to guarantee that instrumentation will withstand the risks and rigors of transport and storage without any damage. When possible, instrumentation shall be packaged separately and comply with the following:

- Each instrument shall be packaged in an appropriate way for its transport to job site and storage in a tropical environment without any damage. Moving parts of instruments shall be temporarily fixed by means of supports to avoid damage during transport.

- Each box containing instruments shall contain a desiccant to prevent humidity from damaging equipment during storage.

In addition to commercial information required, each box shall show tag number of instruments contained in it. This information shall be protected with varnish to prevent the erasure of tag numbers.

Vendor shall inform purchaser if some special conditions are needed to store equipment.

Every spare part shall be clearly marked, those of small dimensions shall be packed in plastic bags marked with their corresponding part numbers, and those of large dimensions shall be individually packed and identified.

17. WARRANTY

SUPPLIER warrants that the GOODS and the WORK shall comply with the terms of the CONTRACT from the date of first delivery thereof until:

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- Twelve (12) months from the date when the GOODS are put into service for its specified use; or

- Eighteen (18) months from delivery at site of the GOODS to COMPANY; whichever is the later and shall at its own expense remedy any defects that may arise in the GOODS or the WORKS during that period and pay all costs and expenses arising there from or consequent thereto, including but not limited to the costs of recovery, carriage and reinstallation.

These warranty and COMPANY's remedies hereunder shall be in addition to any rights COMPANY is entitled to pursuant to applicable laws and regulations.

18. COMISSIONING AND START UP

Vendor shall be fully responsible for instruments and control systems commissioning and start-up. These include installation, mounting, connection, calibration loop tests and tuning.

Vendor will clearly indicate the method to be used for the installation, testing an start up of all instrumentation and control system furnished loose or separate from equipment or panel, so that vendor will maintain all warranties in effect.

These activities shall be performed by specialized vendor personnel. Technical assistances rates shall be clearly specified in the quotation package.

The Purchaser will assign inspectors who will witness, approve or reject every activity performed during commissioning and start-up.

19. TRAINNING

Vendor shall provide training to Owner operations and maintenance personnel assigned by purchaser, according to operation and maintenance needs of systems and instruments related to equipment.

Training shall be performed, preferably at site, hands on equipment and with reliable learning resources provided by the vendor.

Training rates shall be provided in the quotation package.

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20. INSTALLATION

Provide, calibrate, install and test all instrumentation that is on the packaged unit. Provide all material required to interconnect or install instrument devices located off skid. Where shipment requires dismantling equipment that affects the instrumentation installation, clearly tag all cables, piping, tubing, etc. required for connection at the job site. Identify all instruments, which must be installed by the Buyer, on drawings, documents and procedures showing all required details.

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21. ATTACHMENTS

21.1. Instrumentation Information table

INSTRUMENTATION INFORMATION

TAG NUMBER

(1)

INSTALLED

(2)

SHIPPED LOOSE

(3)

INSTR. MFR.

MODEL

NUMBER

RANGE

VOLT. LEVEL

(1) For quotation, use Seller's Tag Number; for Purchase Order, use Buyer's Tag Number. Use additional pages as required.

(2) Indicate by an "X" all those instruments that are furnished, installed, piped, and wired by Seller on Seller's equipment.

(3) Indicate by an "X" all those instruments that are furnished by Seller and shipped loose for installation in the field by Buyer. Seller must provide complete installation details.

PACKAGE UNIT INSTRUMENTS SPECIFICATION -...

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