PHILOSOPHY FOR

INSTRUMENTATION AND
INSTRUMENT AIR

August,
2 th Issued for Use
24 2009 R. G. Draghici F. M. Matei M. Doloszeski
July, 02
A1 Issued for Comment / Approval D.Gh. Tudor A. Petri M. Doloszeski
2007
Rev. Prepared Checked Approved
Date Description
No. Originator

Document Title: Philosophy for Instrumentation and Instrument Air

Document Number: EP FA IN 01 PH Rev: 2

Facility Engineering Page:

Department Project Title: Project No:
1 of 45
 Authors

Projects & Engineering Business Unit,

2 Florin Marian MATEI
Facility Engineering Department
Projects & Engineering Business Unit,
1 Razvan George DRAGHICI
Facility Engineering Department

DIVISION
No. Name Signature
Department

Document Title: Authors

Document Number: EP FA IN 01 PH Rev: 2

Facility Engineering Page:

Department Project Title: Project No:
2 of 45
PETROM EP Philosophy

TABLE OF CONTENTS

1 INTRODUCTION............................................................................................................ 6

1.1 PREFACE ....................................................................................................................... 6

1.2 PURPOSE ...................................................................................................................... 6

1.3 DEFINITIONS AND ABBREVIATIONS.......................................................................... 6

1.4 CODES AND STANDARDS ........................................................................................... 7

1.5 ORDER OF PRECEDENCE........................................................................................... 10

1.6 REFERENCES .............................................................................................................. 11

2 REQUIREMENTS FOR INSTRUMENTATION............................................................. 12

2.1 GENERAL REQUIREMENTS FOR FIELD INSTRUMENTS ......................................... 12

2.1.1 General .................................................................................................................... 12
2.1.2 Environmental Conditions ...................................................................................... 14
2.1.3 Electrical Terminal Strips........................................................................................ 14
2.1.4 Pneumatic and Hydraulic Connections .................................................................. 14
2.1.5 Markings and Tags.................................................................................................. 14

2.2 TECHNICAL REQUIREMENTS FOR INSTRUMENTATION........................................ 15

2.2.1 General .................................................................................................................... 15
2.2.2 Pressure and Differential Pressure Instruments .................................................... 16
2.2.3 Flow Instruments..................................................................................................... 18
2.2.4 Temperature Instruments ....................................................................................... 20
2.2.5 Level Instruments.................................................................................................... 23
2.2.6 Process Stream Analysers ...................................................................................... 25
2.2.7 Corrosion Monitoring.............................................................................................. 26
2.2.8 Control Valves ......................................................................................................... 26
2.2.9 Self-contained Regulators ...................................................................................... 27
2.2.10 ESD/PSD & BDV Valves .......................................................................................... 27
2.2.11 Motor Operated Valves ........................................................................................... 29
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2.2.12 Pressure Safety Devices ......................................................................................... 29

2.2.13 Instrumentation included in Major Process and Utilities Packages ..................... 30

2.3 TECHNICAL REQUIREMENTS FOR INSTRUMENTS UTILITY SUPPLIES, CABLING

SYSTEMS AND CABINETS......................................................................................... 31
2.3.1 Electrical Power....................................................................................................... 31
2.3.2 Air Supply ................................................................................................................ 31
2.3.3 Cable Routing .......................................................................................................... 31
2.3.4 Cables ...................................................................................................................... 32
2.3.5 Cabinets................................................................................................................... 33

2.4 TECHNICAL REQUIREMENTS FOR INSTRUMENTATION TESTING ....................... 34

2.4.1 Manufacturer’s Internal Terst ................................................................................. 34
2.4.2 Final Tests................................................................................................................ 34

3 REQUIREMENTS FOR INSTRUMENT AIR SYSTEM ................................................. 36

3.1 ARRANGEMENT ......................................................................................................... 36

3.2 INSTRUMENT AIR QUALITY ...................................................................................... 36

3.3 INSTRUMENT AIR QUANTITY ................................................................................... 36

3.4 INSTRUMENT AIR SUPPLY FOR INDUSTRIAL CONSUMERS................................. 37

3.5 AIR SUPPLY FOR SAFETY EQUIPMENT.................................................................... 37

3.6 INSTRUMENT AIR SUPPLY SYSTEMS...................................................................... 38

3.6.1 General .................................................................................................................... 38
3.6.2 Air compressors ...................................................................................................... 39
3.6.3 Air inlet filters .......................................................................................................... 39
3.6.4 Condensate separators ........................................................................................... 39
3.6.5 Wet air receiver ....................................................................................................... 39
3.6.6 Air dryer................................................................................................................... 40
3.6.7 Buffer air receiver vessel......................................................................................... 41

4 MAINTENACE IN DESIGN .......................................................................................... 42

5 DOCUMENTATION REQUIREMENTS........................................................................ 43

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6 CERTIFYING AUTHORITY REVIEW REQUIREMENTS............................................... 44

7 SPARE PARTS ............................................................................................................. 45

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1 INTRODUCTION

1.1 PREFACE

This Philosophy defines the Petrom Exploration & Production SA corporate policy on the
design of instrumentation and instrument air for onshore hydrocarbon production and
processing facilities. The document specifies basic requirements and criteria, defines the
appropriate codes and standards, and assists in the standardisation of facilities’ design
across all onshore operations.

The design process needs to consider project specific factors such as the location,
production composition, production rates and pressures, the process selected and the
size of the plant. This philosophy aims to address a wide range of the above variables,
however it is recognised that not all circumstances can be covered. In situations where
project specific considerations may justify deviation from this philosophy, a document
supporting the request for deviation shall be submitted to Petrom E&P for approval.

1.2 PURPOSE

This Philosophy together with specific Project Technical Specification and relevant Data
Sheets covers the minimum requirements for the design, manufacture, testing of work,
packing for shipment, delivery of field instruments.

This document shall be used as the guideline in the Front End Engineering Design and
Detailed Design whenever a new facility is to be built or an existing facility has to be
revamped.

1.3 DEFINITIONS AND ABBREVIATIONS

Into this document it shall be used the following terms and abbreviations:

TECHNICAL SPECIFICATION Document that describes general requirements and basic

data of certain product, assembly or plant

DATA SHEET Issued form specific to a certain product, assembly or

plant that involve also the required data for manufacturing
and testing

ESD Short term for Emergency Shut Down. It is a safety system

that ensure the automate shut down of some equipment
or plant in case of detection of an abnormal functioning
situation

PCS Short term for Process Control System. It is a system that

provide the Operator with a means to operate the plant
safely and efficiently and to alert the Operator to any
alarms or events that require attention / action

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SCADA Short form for Supervisory Control And Data Acquisition.

It is a computerized system for information collection and
processing in real time designated for monitoring and
control by distance of some equipment and plant

ISCIR State Inspection for Boiler, Under-pressure Recipients of

Lifting Units

INSEMEX National Institute for Mining Safety and Explosion Proof

ANSI American National Standards Institute

API American Petroleum Institute

ASME American Society of Mechanical Engineers

IEC International Electrotechnical Commission

IEEE Institute of Electrical and Electronics Engineers

ISA Instrument Society of America

BSI British Standard Institute

TEMA Tubular Exchange Manufacturers Association

CE European ID for conformity.

Short term of Conformite Europeene

Shall The word “shall" is used where a provision is mandatory

Should The word "should" is used where a solution is preferred

May The word “may” is used where alternatives are equally

acceptable

1.4 CODES AND STANDARDS

The applicable reference standards for design, manufacture, inspection and testing of the
field instrumentation shall be the latest edition, including the amendments.

Directive 98/392/EC, “Council Directive on the approximation of the

amended by laws of the Member States relating to machinery”
91/368/EEC
93/44/EEC
93/68/EEC

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Directive 94/9/EC “Council Directive on the approximation of the

laws of the Member States relating to equipment
and protective systems intended for use in
potentially explosive atmospheres” - ATEX

Directive 97/23/EC “Council Directive on the approximation of the

laws of the Member States relating to pressure
equipment” - PED

Directive 89/336/EEC, “Council Directive on the approximation of the

amended by laws of the Member States relating to
92/31/EEC electromagnetic compatibility” - EMC
93/68/EEC

API RP 500 “Classification of Locations for Electrical

Installation at Petroleum Facilities”

API RP 520 “Sizing, Selection, and Installation of Pressure

Relieving Devices in Refineries”, Part I “Sizing and
Selection”, and Part II “Installation”

API RP 521 „Guide for Pressure-Relieving and Depressurizing

Systems”

API Std. 526 „Flanged Steel Safety-Relief Valves”

API Std. 527 „Seat Tightness of Pressure Relief Valves”

API RP 551 „Process Measurement Instrumentation”

API RP 552 „Transmission Systems”

API RP 553 “Refinery Control Valves”

API RP 554 “Process Instrument and Control”

API RP 6F “Recommended practice for fire test for valves”

API 2000 “Venting Atmospheric and Low-Pressure Storage

Tanks”

ANSI B1.20.1 „Pipe Threads, general purpose (inch)”

ANSI B2.1 „Pipe Threads”

ANSI B16.5 „Steel pipe flanges and flanged fittings”

ANSI B16.36 “Orifice Flanges”

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ANSI B16.37 „Hydrostatic testing of control valve”

ANSI B16.104 „Control valve leakage classification”

ANSI B31.3 “Standards of Pressure Piping”

ANSI/FCI 70.2 “Standard for Control Valve Leakage Classification

(Fluid Control Institute)”

ANSI MC 96.1 „Temperature measurement, thermocouple”

ASME PTC 19.3 Part 3 “Temperature Measurement Instruments and

Apparatus”

ASTMĂ D2843 “Standard Test Method for Density of Smoke from

the Burning or Decomposition of Plastics”

ISA S5.1 „Instrument Symbols and Identification”

ISA S5.4 „Instrument Loop Diagrams”

ISA S75.1 „Control valve sizing equations”

IEC 60331 “Tests for Electric Cables under Fire Conditions -

Circuit Integrity”

IEC 60751 “Industrial Platinum Resistance Thermometers and

Platinum Temperature Sensors”

IEC 60754 “Test on Gases Evolved During Combustion of

Materials from Cables”

IEC 60811 “Common Test Methods for Insulating and

Sheathing Materials of Electric and Optical Cables”
IEC 60092 “Electrical installations in ships”

EN 837 “Pressure gauges. Bourdon tube pressure gauges”

EN ISO 5167 „Measurement of fluids by means of orifice plates

and venturi tubes inserted in circular cross section
conduits running full”

EN 13190 “Dial thermometers”

EN 60079 “Electrical Apparatus for Explosive Gas

Atmospheres”

EN 60332 “Tests on electric and optical fibre cables under

fire conditions”
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EN 60529 “Degrees of Protection Provided by Enclosures (IP

Code)”

EN 60584 “Thermocouples”

EN 60654 “Industrial-process measurement and control

equipment. Operating conditions. Climatic
conditions”

EN 61000 “Electromagnetic Compatibility (EMC)”

EN CP 1013 “Earthing”

BS 1042 „Measurement of fluid flow in pipe”

BS 1904 „Industrial platinum resistance thermometer

elements”

BS 1259 „Intrinsically safe electrical apparatus and circuits

in explosive atmosphere”

BS 4568 „Steel conduits and fittings for electrical

installation”

BS 4662 „Boxes for the enclosure of electrical accessories”

BS 5308 „Instrumentation cables”

BS 5490 „Specification for degree of protection provided by

enclosure”

ISO 1000 „SI units and recommendations for the use of their
multiples and certain other units”
ISO 9000 „Quality Systems”

SR ISO 13443 „Gaz natural. Condiţii de referinţă standard”

NACE MR-0175 “Petroleum and natural gas industries—Materials

for use in H2S-containing environments in oil and
gas production”

1.5 ORDER OF PRECEDENCE

The order of precedence from Codes and Standards is as follows:

1. Local Regulations

2. European Directive

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3. National Directive

4. National harmonized with European Standard

5. European Standard and Codes

6. International Standard and Codes

Design of the instrumentation systems shall comply with the standards listed within this
philosophy, however, for instances where local standards are more onerous local
standards shall apply.

1.6 REFERENCES

This document is complemented by the following PETROM philosophies:

EP FA IN 02 PH Philosophy for Valve Actuation

EP FA IN 03 PH Philosophy for Flow Metering

EP FA IN 04 PH Philosophy for Process Control Systems

EP FA IN 05 PH Philosophy for Automation, Telecommunication

and Security Systems

EP FA IN 06 PH Philosophy for Tank Instrumentation

EP FA IN 07 PH Philosophy for Facilities Emergency Shut Down /

Wellhead Protection Systems

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2 REQUIREMENTS FOR INSTRUMENTATION

2.1 GENERAL REQUIREMENTS FOR FIELD INSTRUMENTS

2.1.1 General

The document gives basic requirements for the application of field instruments and
identifies the major systems to be provided for the control, monitoring and safeguarding
and operations of the facilities. Systems are addressed in greater details in the following
documents: EP FA IN 04 PH - Philosophy for Process Control Systems, EP FA IN 05 PH -
Philosophy for Automation, Telecommunication and Security Systems and EP FA IN 07
PH - Philosophy for Facilities Emergency Shut Down / Wellhead Protection Systems.

Instrument systems will generally be based upon proven electronic technology. Digital
electronic systems will employ standard hardware and software. Customisation beyond the
user level will be minimised. Specialised equipment shall be selected based on the following
guidelines:

- only proven equipment which has been successfully used in similar applications shall be
short-listed;

- the more sophisticated devices shall be carefully reviewed to ensure that their
disadvantages have been identified and do not become apparent only after installation,
commissioning, operation and maintenance phases; e.g. limitations on cabling lengths,
specialised cabling, complex set-up and commissioning requirements which require
specialised equipment, and require intervention by vendor personnel for operation and
maintenance.

Use of any field instrument that requires deviation from or relaxation of any standard, or
requires specialised cabling or installation methods, will not be used, unless agreed by
the PETROM/Purchaser.

Instrument design will aim to offer a cost-effective solution that is fit-for-purpose for the
operational and safety needs of the project.

As far as practically possible, variations in the selection of instruments and systems for
the project shall be kept to a minimum. This is to reduce engineering, procurement,
commissioning, maintenance, training and operations costs.

All electrical instrumentation equipment to be installed in classified areas will be supplied

complete with relevant certification issued by a recognized institute and be in accordance
with the installation requirements, as defined by EN 60079 “Electrical Apparatus for
Explosive Gas Atmospheres” and in specific Project Drawing - Hazardous Area
Classification.

Intrinsic safety, Ex (i)a shall be used as the prime method of protection. Deviation from
this will require consent from the PETROM/Purchaser. Should consent be given, the
allowable alternative methods of hazardous area protection are listed below in order of
preference:

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- flameproof or explosion proof, type Ex (d);

- increased safety, type Ex (e);

- special protection, type Ex (s).

Galvanic isolator protection devices will be used for intrinsically safe installations, unless
specific field instruments require Zener diode barriers in order to function correctly.

Solenoid valves utilised in hazardous areas shall be the explosion proof Ex (d) type.

The instrumentation main data shall be shown on the individual instrument Data Sheets.
All the materials used shall have characteristics suitable for the operating data and
ambient, as specified on the individual Project Data Sheets. Field instruments utilised in
Sour Service require special attention to be paid to instrument diaphragms, to prevent
corrosion and hydrogen penetration. Material for impulse lines, manifolds, instrument
pressure bodies for sour service shall be in accordance with the project material selection
philosophy. In addition, process instrumentation and analysers shall have drain and vent
ports tubed to closed drain and vent/flare headers, to divert any released fluids to safe
disposal routes.

All holes cases and the attachment for instrument connection shall be protected with plug
and clearly marked for identification purposes.

The instruments and their accessories requiring electric power supply shall be suitable for
the feeding specified on the individual instrument Data Sheets.

The instrument and their accessories requiring pneumatic feeding shall be suitable for
feeding with instrumental compressed air at the pressure specified on the individual
instrument Data Sheets.

The design life of field instrumentation shall be 25 years minimum. The design life of
control systems shall be 25 years minimum. This will be based on the following
prerequisites:

- maintenance and support of the system will be available for this duration;

- the entire system, including all sub-components, shall facilitate upgrade and are
selected from recognised manufacturers with a proven track record of system
maintenance and essential upgrades.

All instrumentation connected to process lines and equipments shall be in compliance

with European Pressure Equipment Directive 97/23/EC (PED) and all instruments to be
installed in a hazardous area meet all the relevant requirements of the ATEX Directive
(94/9/EC) and have the symbol clearly fixed to indicate compliance. All the electronic
instrumentation shall comply with Electromagnetic Compatibility (EMC) and radio
frequency interference (RFI) requirements in standard EN 61000 or similar applicable
standard. Compliance must be demonstrated by way of testing and/or certification
performed/issued by recognised institutes.

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2.1.2 Environmental Conditions

The field instruments shall be erected and function in a temperate continental climate
specific to Romania. It shall be designed as to be able to function continuous indifferent
of the season or ambient temperatures.

Field devices will be selected to be particularly robust to suit the environment and the
hazardous area requirements.

Externally installed instrument enclosures and junction boxes will meet environmental
protection level IP65 as defined in EN 60529 - ”Degrees of Protection Provided by
Enclosures (IP Code)”.

Instrument painting shall withstand weather conditions.

2.1.3 Electrical Terminal Strips

All electric connections shall terminate at one or more terminal strips located inside of the
case of each instrument, or in an external container assembled to the case of the
instrument concerned and having the same characteristics.

Each individual conductor terminal and terminal strip shall be numbered in accordance
and perfect compliance with the electrical diagrams and drawings.

Terminals shall be a type suitable to ensure and guarantee the thorough contact.

2.1.4 Pneumatic and Hydraulic Connections

All outlets relating to connections shall be marked so as to be identified in accordance

and compliance with the technical documents to be supplied by manufacturer.

2.1.5 Markings and Tags

Each instrument shall be provided with corrosion - resistant nameplate, permanently

attached to the instrument body and including:

- manufacturer’s name or trademark;

- model and serial number;

- Ex protection and IP degree;

- inlet and outlet connections;

- material;

- working pressure;

- any other key details, for example: compliance to “NACE MR-0175 (latest edition)”.

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Each instrument has to be provided with a dedicated AISI 316L plate showing the
instrument tag number according to project.

2.2 TECHNICAL REQUIREMENTS FOR INSTRUMENTATION

2.2.1 General

The instrumentation shall be according to the P&I diagrams and shall be based on
pneumatic, electric and electronic technology.

“SMART” type transmitters are preferred with a 4÷20 mA output signal obtained through
a two-wire system. HART protocol shall be supported. Trip signals for ESD/PSD and Fire
& Gas applications shall be derived from analogue 4÷20mA DC signals with the threshold
comparator implemented in controller logic as far as possible.

Voltage signals for switches, solenoids and interlocks will be 24Vdc where 4÷20mA
signals cannot be used. Optical isolation will be used to interface to other control circuits
which utilise Low Voltages, and interposing relays will be used to interface to High
Voltages.

Unless otherwise indicated on the data sheet, all electronic transmitters shall have an
integral LCD indicator, capable to be configured to read in percentage or engineering units.
Where applicable, the indicator shall comply for the location and hazardous area
classification. Only where required by project P&ID, the electronic transmitter shall have
remote mounted indicator (e.g. where the transmitter is not visible from normal viewing
location).

Redundancy (dual control) shall be used for those controls which are critical to production
continuity and safety level.

All instruments shall have the minimum degree of protection for field mounted
instruments/panel enclosures, when containing electric components, of IP65 according to
EN 60529.

As a minimum, AISI 316L material shall be employed for the instrument internal wetted
parts and for pressure and d/p transmitter bodies. Monel, Hastelloy, duplex or equivalent
corrosion resistant material shall be employed for instrument and valve wetted parts if
Chlorides and/or CO2 / H2S / H2O / SO42 are present in the process. Physical and chemical
process fluid composition shall be analyzed.

Instruments shall normally be located as close as possible to process take-offs. All

instruments and process take-offs shall be accessible from grade, platforms, walkways or
fixed ladders. Instrument process connections shall be as short as possible, self-draining
if on gas, sloped to the instrument when on liquid. Where these arrangements are not
practicable, catch pots and vent/drain valves shall be provided.

Instrument process and pneumatic lines shall be made by using seamless tubing and
twin-ferrule compression fittings, throughout the whole project. Tubing material shall be
AISI 316L as a minimum unless process fluid conditions justify a higher specification.

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Tubing wall thickness shall be selected according to the maximum design pressure. A
minimum of 10mm tubing shall be used for process impulse lines.

Instrument pneumatic signal lines and supply lines from air headers shall be AISI316L
Stainless Steel.

Suitable support clamps shall be used to ensure that galvanic corrosion between mild
steel and stainless steel does not occur.

Instrument electrical connections shall use steel-wire armored cables and certified cable
glands. Cables shall be fire retarding type (IEC codes) with toxic gas low emission in
accordance with cable specifications. Wire cores shall not be less than 1 mm2.

Cables trays will be prefabricated type in AISI 316L. As far as practically possible, the
cables trays shall be segregated for cables type: power cables / signal cables / IS cables.

2.2.2 Pressure and Differential Pressure Instruments

2.2.2.1 General

Pressure and differential pressure instruments will fall into four groups: transmitters,
direct reading instruments (local gauges), switches and local controllers.

Pressure instruments measuring absolute pressure shall have compensation for

barometric pressure changes.

Pressure instruments used on vacuum service shall have under range protection of full
vacuum.

Generally, the following measuring shall be used:

- bourdon-type, for a wide-range of pressure services (they will normally be used for
pressure gauges, repeaters and local controllers);

- diaphragm and bellow elements used for low pressure local measurements;

- diaphragm and strain gauge, generally used for pressure transmitters;

- diaphragm seals will be generally used on liquid hydrocarbons pressure connections,

where the presence of paraffin may lead to solids formation.

Fluid filled manometers shall not be used for process measurement services.

Where seals are required on corrosive or solids type processes they shall be suitable for
the process fluid and be equipped with armoured capillaries; or be directly mounted on
the vessels via flanges.

2.2.2.2 Local indication

Local pressure measurement devices will be Bourdon tube type pressure gauges. The dial
shall be of minimum 150mm in diameter for process monitoring. Smaller sizes may be
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used on local panels, and instrument air regulators. Other sizes will be considered for
special services. The dials shall be engraved black on white background.

Gauges shall be safety pattern type armoured glass and blowout discs. All gauges
installed in applications of 10 barg and above shall be full safety pattern fitted with
shatterproof safety glass. Gauges below 25 barg range shall have a safety blowout disc in
the back. Gauges for 25 barg and higher service shall have a solid front and blowout rear.

Pressure gauges shall be suitable for pressures of 1.3 x maximum stated design pressure.
Over-range devices shall be fitted where necessary.

The gauges shall have a minimum accuracy of ±1% at full scale.

Pressure gauges are to be pulsation resistant (using pressure snubbers) and vibration
resistant (using glycerine/silicon oil as filling liquid), where necessary. Wetted parts shall
be AISI 316L stainless steel as a minimum.

Siphons shall be employed when required by process conditions (generally on steam and
high temperature services).

Gauges shall be mounted on a close-coupled 2-valve manifold or on a needle gauge valve

isolation and a bleeder plug for gauge venting purposes (block & bleed).

Pressure gauges will be line mounted on services as close as practical to all pressure
transmitters, switches and local controllers.

Pressure and DP gauges shall be installed at points that can be viewed by the operators.
Remotely mounted indicators may be used for pressure measurements in inaccessible
plant areas.

Pressure and DP gauges shall be ranged so that the normal operating pressure is read in
the middle third of the span. Ranges shall be selected from the standard list in EN 837.

Differential Pressure Gauges with integral switches (as required) shall be equipped with
differential pressure sensing bellows. Wetted materials shall be AISI 316L Stainless Steel
as a minimum.

Gauges shall be supplied with ½” NPT male process connection.

When a diaphragm seal is required the pressure gauge shall generally be of the direct
mounted integral / diaphragm type without capillaries.

2.2.2.3 Transmitters

Pressure transmitters will be “Smart” electronic type with AISI 316L stainless steel wetted
parts as a minimum or, if dictated by the process, an alternative material shall be agreed
with the purchaser. Carbon steel shall not be used.

Electronic Pressure & DP Transmitters shall provide a minimum accuracy of ± 0.5%.

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Pressure and Differential Pressure Transmitters shall be suitable for a process connection
of ½“NPT-M.

Differential Pressure Transmitters shall be mounted on a close-coupled 3-valve manifold

as a minimum (5-valve manifold preferred). Pressure transmitters shall be mounted on a
close-coupled 2-valve manifold. All manifolds shall be of AISI 316L stainless steel
construction as a minimum.

Remote mounted transmitters shall be suitable for 2” pipe mounting via the close coupled
valve manifold, unless otherwise specified on the data sheets.

Pneumatic transmitters will be force-balanced type. The output signal shall be from 0.2 to
1 barg, with 1.6 barg air supply.

2.2.2.4 Controllers

Local controllers, either direct and/or receiver type, are to be used generally for less
important controls.

The measuring ranges shall be selected in accordance with the Manufacturer’s standards;
the span shall be reduced as much as allowed by process requirements and by the use of
suppressed ranges, if required.

2.2.2.5 Switches

Pressure and DP switches shall be used by exception only where continuous

measurement from a transmitter is not practical or necessary or in simple on-off controls
services. They shall not be used in ESD/PSD and Fire & Gas applications.

Switches shall have a minimum of type AISI 316L stainless steel wetted parts with
hermetically sealed Single Pole Double Throw (SPDT) electrical contacts. The switch shall
be in the closed position when the process condition is in the Normal Operating Range.

Conventional-type electrical pressure switches may be used as interlocking functions

within “package” installations.

2.2.3 Flow Instruments

2.2.3.1 General

Generally, for flow rate measurements shall be carried out by means of differential
pressure method, generated via orifice plates, pitot, venturi, or v-cone where turndown
ratio is not more than 3 to 1. Reference shall be made to EN ISO 5167 “Measurement of
Fluid Flow by means of Differential Devices”.

Generally, square edge orifice plate with concentric entrances and flange taps and / or
carrier ring shall be used. For critical duties the orifice plates shall be removable under
pressure, as indicated on the specific project P&ID’s.

The allowable Beta ratio shall be 0.7 maximum and 0.2 minimum.

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Orifice plates shall dimensionally conform to and be installed to EN ISO 5167 (latest
edition).

For Orifice plates, vent and drain holes will only be considered if the process fluid is clean
and the orifice bore is greater than 25mm. For orifice plates, minimum bore size shall be
8mm.

Orifice plates in lines less than 2” nominal size shall either have the line adjacent to the
orifice increased to 2”, or a 1” or 1 1/2” meter run shall be used.

All wetted parts shall be AISI 316L stainless steel as a minimum, unless the process fluid
requires higher quality materials.

Orifice flanges materials shall match the relevant piping specification. Flange taps
connection shall be in accordance with ANSI B16.36.

Each orifice plate shall be provided with a tab handle that is clearly visible in the final
installed position. The tab will be stamped, or deep engraved, on the upstream face with
“UPSTREAM”, the tag number, orifice plate material, measured bore and the I.D. of the
pipe. The tab shall also be in line with the drain or vent hole, when provided.

The flow factors will be expressed in the following units:

a) Gas: Energy kWh/MJ; Nm3/h, referred to a 1.013 bar pressure and a 0°C temperature;
Sm3/h, referred to a 1.013 bar pressure and a 15°C temperature;

b) Liquids: m3/h, as referred to a 15°C temperature.

The preferred meter-range will be 2500 mm H2O; the alternative meter-ranges are: 125,
250, 500, 625, 1250, 5000, 6000, 10000 mm H2O.

Specific requirements may call for the usage of one of the following flow instruments:

- quick-replacement type calibrated orifice measuring elements; these shall be used for
measuring ranges exceeding the allowable rangeability for one single plate;

- either Pitot tube or multihole Pitot tubes measuring elements; their calculation and
application ranges shall comply with the Manufacturer’s standards;

- Coriolis meters, Turbine meters, Vortex meters or positive displacement meters will be
used on liquid service where a greater turndown and accuracy are required. Vapour
eliminators, where required, will be installed upstream of the measurement device;

- Vent / flare gas flow measurements shall utilise time of flight ultrasonic flowmeters for
high accuracy and reliability. Where lower accuracy may be acceptable variable area
meters may be used providing an interface to PCS system is available for the meter
concerned;

- Magnetic flow meters may be considered for conductive fluids, where a low-pressure
drop is required and/or where corrosive fluids are involved;

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- For low flows in small lines, variable area flow meters with magnetically coupled
indicators (where necessary) will be used.

2.2.3.2 Flow metering purposes

Metering is performed to varying purposes having the following degrees of uncertainty:

- Well Testing - testing normally refers to the assessment of the volumes of fluids
produced from wells. This assessment is performed by individual measurements of
the 3 phases from a test separator. The test results are used for long term reservoir
management, and also for short to medium term planning of the production from the
facilities. Accuracy requirements shall be in the order of 3 percent or better for net oil
and 5 percent or better for gas;

- Operational Standard – for optimisation of processes for long term economic benefit
and the protection of the environment. Typical uncertainty requirements for the overall
operational metered values shall be in the order of 10 percent or better;

- Allocation Standard - for allocation of production from facilities that produce into
common trunk line, so that the production will be properly attributed to a source. As
the measured values are not required for custody transfer from one party to another,
the accuracy and uncertainty requirements are not as stringent as those for custody
transfer metering standards. Typical uncertainty for the overall allocation metering
values shall be in the order of 5 percent or better;

- Fiscal/Custody Transfer Standard - for fiscal/ custody transfer from one party to
another, for the verification of quantities transferred from one party to another. The
final metered value may be expressed in terms of volume, mass or energy terms.
Typical uncertainty for the overall Custody metered values shall be in the order of 1
percent or better.

2.2.4 Temperature Instruments

2.2.4.1 General

Temperature measurements may be made by Resistance Temperature Devices (RTDs),

thermocouples, filled bulb systems, or bimetallic thermometers.

2.2.4.2 Local indication

Local thermometers shall be bimetallic with minimum 150 mm dials and stainless steel
cases. Other sizes will be considered for special services.

Thermometers will be mounted on services close to all temperature transmitters,

temperature switches and local controllers. Thermometers will be installed at points that
can be viewed by the operators.

Thermometers shall have a spring mounted “any angle” head to allow viewing access
from acute angles. Remotely mounted indicators will be used for temperature
measurements in inaccessible plant areas.

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Scale graduations, zero adjustment and over-range protection shall be manufactured

standard, with accuracy to within ±1% of span. Dials shall have black graduations on a
white background.

Filled systems may be used for local temperature indicators or where provided as part of
a mechanical package Vendor’s standard supply.

2.2.4.3 RTDs

The preferred method of temperature measurement shall be via RTDs unless the process
temperature dictates otherwise. Temperature transmitters will generally use three-wire
platinum RTD elements with a resistance of 100 ohms at 0°C and a temperature
coefficient of 0.385 ohms per degree Celsius (PT100), in accordance with IEC 60751.
Temperature compensation on custody transfer metering measurements will use four-
wire RTDs with direct input to flow computers.

RTDs will normally be connected to temperature transmitters. Machine monitoring

temperature sensors may however use direct RTD inputs to a multi-point temperature
reading device.

All connections between thermoresistances and receiving instruments will generally

carried out by means of a 4÷20 mA transmitter, so as to make the connections between
thermoresistances and Control Room by a 2-wire transmission system.

Duplex sensors may be employed where replacement of the failed unit may be difficult
due to access or prolonged shutdown of equipment is not acceptable.

Thermoresistances shall be used for narrow spans and whenever an accurate

measurement is required.

Temperature Transmitters for RTDs shall have upscale burnout. Electronic Temperature
Transmitters shall provide a minimum accuracy of ± 0.5%.

2.2.4.4 Thermocouples

Consideration shall be given to the use of thermocouple sensors only where the
temperature range falls outside that which can be achieved by using RTDs.

The thermocouple type shall be selected in function of the operating temperature range to
be measured. According to the EN 60584 and ANSI MC 96.1 codes as far as possible it
shall be “K” type.

The measuring junctions of the thermocouple shall be insulated.

Thermocouple shall be mineral insulation type and shall be provided with stainless steel
external sheathing.

Thermocouple construction features shall usually comply with:

- standard covering mineral oxide insulation type;

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- ANSI MC 96.1 Code for the remainder types.

All connection between thermocouples and receiving instruments will generally be

carried out by means of a 4÷20 mA transmitter, to make the connection to the control
room by a 2-wire transmission system. Temperature Transmitters for thermocouples shall
have upscale burnout. Electronic Temperature Transmitters shall provide a minimum
accuracy of ± 0.5%.

All short connection between thermocouples and PLC shall be provided with balance
rope.

With the exception of those particular cases called for by either mechanical and/or
process requirements, duplex thermocouples located within the same thermowell are not
to be used on the following applications:

- control system;

- safety system.

2.2.4.5 Switches

Temperature switches shall be used by exception only where continuous measurement

from a transmitter is not practical or necessary or in simple on-off controls services. They
shall not be used in ESD/PSD and Fire & Gas applications.

Switches shall have hermetically sealed Single Pole, Double Throw (SPDT) electrical
contacts. The switch shall be in the closed position when the process condition is in the
Normal Operating Range.

2.2.4.6 Controllers

Self-regulating valves shall carry out local temperature controls.

2.2.4.7 Thermowells

Thermowells shall be provided for temperature sensing in process systems for:

- RTD assemblies;

- thermometers

- test points

Thermowells shall be fabricated from bar stock tapered construction, with flanged
process connections and threaded sensor head connections. Thermowell connections to
process shall be 1 1/2” flanged.

Materials for thermowells shall be dictated by the piping specification at the respective
measurement location. Thermowells shall be in accordance with piping interface designs.
Installation will meet API RP551 and will meet vortex shedding requirements as given in
ASME PTC 19.3 Part 3 “Temperature Measurement”.
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Thermowells for local indicators and transmitters at the same location are to be identical,
both in length and bore size.

Thermowells shall be made from AISI 316L stainless steel as a minimum.

The internal diameter of thermowells shall match the sensor elements.

The surface of the thermowell shall be smooth and free from burrs and notches.

Thermowells shall be assessed for resonance effects. Where thermowells are installed in
lines subjected to high fluid velocities, combined stress and frequency calculations shall
be carried out to a proven method.

Thermowells shall be installed such that the element and head can be withdrawn without
bending the element, or removing other equipment.

Thermowells shall be directly installed in lines 4 inches or greater. For lines smaller than 4
inches the thermowell shall be mounted in an elbow, or in a suitably enlarged section of
line.

2.2.4.8 Filling Bulbs

Filling-type primary elements will be used for thermostats, local controllers and
temperature self-regulating valves used for less important temperature controls (i.e. liquid
in storage tanks).

Bulb to thermowell connection shall be made by sliding fitting with ¾” ANSI B1.20.1 NPT
threaded end.

Operating ranges and application limits of instruments mercury-filled bulb type and of
thermometers dial type shall be as per manufacturer's standards.

2.2.5 Level Instruments

2.2.5.1 General

Level measurement instruments employed shall include gauge glasses, magnetic gauges,
floats and displacers, differential pressure type, capacitance types, radar and
microwave/radioactive types. Tank gauging systems are addressed in the following
philosophy EP FA IN 06 PH – Philosophy for Tank Instrumentation.

Consideration shall be taken of fluid type in selecting a measurement type. Particular

attention will be paid to fluid composition, measurement interface and opacity.

All external level instruments mounted on the equipment shall be provided with isolation
valves, ¾” drain valve and ½” vent valve to allow drainage.

Level Transmitters shall provide a minimum accuracy of ± 0.5%.

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2.2.5.2 Local indication

Magnetically coupled level gauges shall be used for local indication on vessels rated ANSI
CLASS 900 and above, where the risk of failure of glass type level gauges is greater, or
when dirty liquid services are involved.

For applications with lower pressure ratings and clean liquids, reflex glass gauges shall be
used whereas transparent type level glasses will be adopted for two liquids interfacing;
corrosive properties of the process fluid shall be taken into consideration. The visibility
shall cover the maximum operative field of the level gauge. The glass level gauges shall
be provided with isolation valves and “safety ball check”.

These devices will be mounted on bridles attached to the exterior of vessels/tanks.

Maximum gauge range shall be 1600mm. After that, over-lapping gauges shall be used.
Gauges shall overlap the range of level transmitters.

Device mounting will be such that the level indicators are given good access for
readability and routine maintenance. Acceptable means of access will include walkways,
platforms and ladders depending upon the specific application. Backlighting shall be
installed where appropriate.

2.2.5.3 Displacer and Float Devices Transmitters

Type AISI 316L stainless steel displacers (as a minimum), with external gauges and
rotatable heads shall be used with a maximum length of 60” (1.524 metres). Finned
torque tube extension shall be provided as necessary for high (>200 degC), or low
temperature service (<-20 deg C). Torque tube materials shall be Inconel as a minimum.

Typical applications will include interface measurement.

Displacer chamber materials shall be Carbon steel as a minimum. The top of the chamber
shall be full size flanged to allow removal of the displacer for maintenance.

Displacer chambers with side-side process connections are preferred. All displacer
chambers shall have a rotatable head flange to enable correct orientation.

Float type gauges may be used for tank gauging on storage tanks. Stilling wells may be
provided as necessary. An integrated tank gauging system may be provided to take an
inventory of the contents of product/storage tanks.

2.2.5.4 Differential Pressure Type Instruments

Differential pressure transmitters will be used for level measurement above 1500 mm
range. This includes signal inputs to PCS and ESD/PSD systems. Where seals are required
on corrosive, waxy or solids type processes they will use type AISI 316L stainless steel
armoured capillaries.

For level measurement in atmospheric pressure tanks, a flanged differential pressure

transmitter may be used, directly connected to the tank through a 1 inch flange. A shut-off
valve shall be provided for transmitter removal.

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DP transmitters must be capable of withstanding maximum differential in both directions.

Transmitters shall be capable of withstanding over-range pressure on either side of the
capsule at least equal to the body rating, without damage or calibration shift.

2.2.5.5 Radar Transmitters

Radar type gauges will be used for measurements on tall tanks and vessels where
appropriate. Radar instruments used in custody transfer allocations shall be of the high
accuracy type, with resolution in millimetres. Stilling wells may be provided as necessary.

An integrated tank gauging system may be provided to take an inventory of the contents
of product/storage tanks.

2.2.5.6 Microwave / Capacitance Transmitters

Microwave / Capacitance type gauges will be used for level measurements where it is
difficult to determine actual levels or interface levels due to emulsions or foaming, using
conventional technologies described above.

2.2.5.7 Interface level

For interface level measurement in separator vessels and tanks should be used the
following principles:

- radar;

- ultrasonic;

- displacer (interface level or density: 0.08 minimum differential).

2.2.5.8 Switches

Usage of float type level switches shall be carefully assessed. It is rather preferred to use
vibrating fork as much as possible.

When used, external float chamber level switches, shall be used for simple controls only.
Switches shall be hermetically sealed single pole, double throw (SPDT) type.

2.2.6 Process Stream Analysers

Process Stream Analysers installed in facilities will be completely automatic and will be
purchased from suppliers as total systems including the sample conditioning. On-line
process stream analysers will include the following services:

- density and/or gas composition analysis (as required) on Export Gas pipeline meters;

- BS&W analysis on liquids within Parks and Tank Farms.

Process stream analysers will be equipped with manual sample points for both laboratory
testing and calibration sample injection and in general, be equipped with local indicators.

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2.2.7 Corrosion Monitoring

Corrosion monitoring will use both sacrificial coupons and electrical probes. Coupons will
be used where an occasional only measurement is required. Electrical probes will be used
where regular measurements are needed.

Consideration shall be given to both hand-held recording devices and to permanently

connected units. The latter will be used where a continuous measurement is required.

2.2.8 Control Valves

2.2.8.1 General

Modulating control valves shall generally be pneumatically actuated. Control valve signals
will be 0.2 to 1.0 barg. Electro-pneumatic positioners shall be installed to provide local
feedback control where necessary. Selected positioners will be the “Smart” type.

In areas where Instrument air is unavailable Control Valves will utilise electric actuators.

Conventional control valves shall generally be installed in a horizontal position with the
actuator above the valve body. Where solenoid valves are used for intercepting the
pneumatic signal to the control valve actuator, the tubing between the two devices shall
be as short as possible and the solenoid valve shall preferably be installed directly on the
control actuator.

All the pneumatic tubing and fittings shall be in AISI 316L stainless steel.

The noise level of the valves shall not exceed 85-dB (A).

Minimum flange rating shall be ANSI CLASS 150.

It is possible that a single control valve manufacturer will not have the correct valve for
every application. Severe service conditions may require customisation from a specialised
vendor.

2.2.8.2 Valve Leakage

Valve leakage specifications and classes will be in accordance with ANSI/FCI 70.2. Class IV
will be specified for general services. Class V or VI is to be specified for tight shutoff
applications.

2.2.8.3 Valve Sizing

Valves will normally be sized for 80% open at maximum flow and for 15% open at
minimum flow. Normal pressure drop will be 33% of the total process system frictional
drop.

Control valves shall be in accordance with Cv/Kv standards. ISA S75.1 calculation method
shall be applied.

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Clutched type solid hand wheel manual overrides will be provided where block and
bypass arrangements prove prohibitively expensive and where the line can be blocked
without shutting down major processes and jeopardising safety.

2.2.8.4 Valve accessories - pneumatic

Where utilised, valve accessories will use a 0.2 to 1.0 barg pneumatic signal format. Each
air-consuming valve will be provided with its own independent filter regulator. Current to
pneumatic (I/P) converters shall be used to convert electronic signals to pneumatic signals
for control valve and damper actuation.

2.2.9 Self-contained Regulators

Self-contained regulators will be used for simple processes (utilities) and where
approximate control only of the process parameter is required. Valve materials will equal
or better the relevant piping line specification.

2.2.10 ESD/PSD & BDV Valves

2.2.10.1 General

ESD/PSD valves shall be provided and designed according to the project philosophy.

SDV valves shall be provided and designed failed closed upon loss of air or hydraulic
pressure.

BDV valves shall be provided and designed failed open upon loss of air or hydraulic
pressure.

Full bore style shall be applied for piggable lines and blow down valves and when process
specifications require a low pressure drop. Valve style, material and technical
requirements shall be in conformance with the Std. Specification indicated in the
technical piping class Spec.

The valve style shall normally be trunnion type, double block and bleed. Valves with a size
equal or greater than 2” for hydrocarbons service shall be “FIRE SAFE”, in according to
API RP 6F.

Actuators for shutdown valves will be specified by the Instruments section, while the
valves shall be specified by the Piping section, in accordance with the relevant piping line
specification.

In some cases individual valves may be under the control of both the PCS and the
ESD/PSD systems. In such cases separate solenoid valves will be required for the
individual PCS and the ESD/PSD systems, connected in series along the valve actuator air
supply line. The solenoid valve under control from the ESD/PSD system will be installed
closest to the valve actuator. The solenoid valve or current to pneumatic transducer under
control from the PCS will be installed upstream of the ESD/PSD system solenoid.

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Partial stroke testing of valves in safeguarding applications shall be considered in order to

test the integrity of the system. These techniques shall be applied, based on the outcome
of the Safety Integrity Level classification.

2.2.10.2 Pneumatic actuators

Shutdown valves shall generally be pneumatically actuated. Generally, single acting,

spring return, piston type actuators shall be used. However, this will be reviewed after
valve size and torque requirements have been established.

Type orientable single acting piston shall be used for size valve <8”. Type orientable
double acting piston shall be used for size valve ≥8”. Control medium: instrument air 4.2
bar (min.) 8 bar (max.) des. 10 bar. Self-unclutchable handwhells shall be provided.

Valve manufacturer is responsible for the calculation of the applied force, of sizing of the
supporting structure and of the correct sizing of the actuator. Actuator shall be sized
including a 1.5 safety factor.

Pneumatic control system shall be supplied assembled in an AISI316L SS panel fitted on

the actuator for smaller valves or mounted on a separate stand. The valve complete with
the accessories and relevant connections necessary to carry out the functions required:
open/close valve position, solenoid valves, accumulator for emergency operator, electrical
junction box.

When the control medium is natural gas, dehydration filter with automatic condensate
drain shall be provided.

Valve actuators shall be sized to operate at a pressure equal to the lower operating limit
of the instrument air pressure and at maximum shutoff differential.

2.2.10.3 Hydraulic actuators

In areas where Instrument air is unavailable ESD/PSD Valves shall utilise hydraulic
actuators. The hydraulic power will be derived from a common hydraulic power unit
(HPU) which will be used to provide hydraulic power to all ESD/PSD valves on the facility
concerned. HPU will employ redundancy of components to ensure high availability.
Failures of any kind will be reported to operator via PCS system.

The actuators must be supplied with the equipments, accessories and relative
connections necessaries to implement the control circuit required in the Project Technical
Data Sheet.

All hydraulic circuits shall be implemented with AISI316L SS tubing and compression
fittings.

Valve manufacturer is responsible for the calculation of the applied force, of sizing of the
supporting structure and of the correct sizing of the actuator. Actuator shall be sized
including a 1.5 safety factor.

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2.2.11 Motor Operated Valves

Motor operated valves (MOVs) shall have the capability to be controlled locally or from
PCS system. These valves will be connected back to the PCS for monitoring of valve
status on operator station.

Normally, these valves shall not be used in safety services unless they are provided with
some means of safety elements that will make the valve to turn to a safe position, either
close or open.

Typically, MOVs shall be used as switching valves (for e.g. on manifolds), or where valves
are not normally accessible to Operators (are in remote locations) or for large valves
where manual operation is not practical.

2.2.12 Pressure Safety Devices

2.2.12.1 Pressure relief valves

There will be four basic types of pressure relief valves used. These are as follows:

- pilot operated relief valve;

- conventional spring type relief valves;

- balanced bellows spring type relief valves;

- pressure/vacuum devices for protection of low pressure storage tanks where no

atmospheric vents exist.

Safety and relief valves are to be in accordance with API RP520 and RP521.
Pressure/Vacuum devices for low-pressure storage tanks will be sized in accordance with
API 2000.

Pilot-operated relief valves are to be used for clean gas service or clean liquid service,
where the set point is less than 10 percent above the operating pressure or where the
total backpressure downstream of the valve exceeds 10 percent of the set pressure. Pilot
relief valves will be used only where the pilot valve is unlikely to be subject to freezing,
hydrates or accumulated foreign matter. “No flow” pilots will be preferred.

General conventional relief valves will be used for liquid, gas or thermal relief service
where limited backpressure exists downstream of the valve.

Balanced safety relief valves will be used in liquid service where the total backpressure
downstream of the valve exceeds 10 percent of the set pressure. Bellows balanced safety
relief valves may be used where it can be demonstrated that the bellows will not be
subject to rupture due to ambient temperature conditions or excessive use.

If dual pressure relief valves are installed in a redundant configuration, an interlock

system shall be provided to ensure that one valve is always on line.

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2.2.12.2 Rupture discs

Rupture discs will generally be the reverse buckling type. They will be applied to:

- accomplish a fast response time, which cannot be achieved with a relief valve. This
could be required to cope with a sudden gas breakthrough due to a heat exchanger
tube burst or malfunctioning of a level control valve into a liquid filled system;

- prevent relief valves in vacuum service from drawing gas or air back into the process;

- protect relief valves from being in continuous contact with a corrosive or solidifying
process fluid;

- prevent leakage of toxic substances through the relief valve.

If a rupture disk is installed upstream of a relief valve, pressure alarm (in pressure service)
or a pressure gauge shall be provided between the disk and the relief valve. This will give
an indication when the rupture disk has burst. The burst pressure tolerances shall be
evaluated and sufficient margin allowed between the burst pressure and the relief valve
set pressure.

Two bursting disks shall not be installed in series to provide protection against fatigue
and creep.

Safety valves, except for thermal expansion valves, shall be sized in accordance with API
RP 520. Dual PSV installation shall be mechanically interlocked.

The established engineering philosophy for the plant shall be followed in the engineering
of the instrument and control systems for package units. Special attention must be given
to the compatibility of equipment/materials obtained from various sources, particularly in
relationship to interfacing package unit instrumentation and systems within the plant.

2.2.13 Instrumentation included in Major Process and Utilities Packages

2.2.13.1 Instruments

The engineering and installation of the instrumentation included in packaged units shall
comply with the overall plant instrument and control design.

2.2.13.2 Unit Control Systems (UCS) for packaged units

Field mounted/ skid mounted unit control panels may be provided for packaged units.

Main equipment packages such as compressors, turbines, etc may require dedicated Unit
Control Systems that perform management and monitoring of the system to perform the
complete control as well as the associated logic.

The Unit Control Systems shall be interfaced to PCS system via dual redundant
configuration data interfaces for remote monitoring and control. Shut down signals or

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commands activation related with the Emergency Shut Down (ESD) system shall be
hardwired type.

Generally, there will be a local emergency stop button on all control panels.

Smaller packages may have their controls implemented in the PCS or ESD as appropriate.
The requirements will be further reviewed and defined in the Detailed Design stage.

2.3 TECHNICAL REQUIREMENTS FOR INSTRUMENTS UTILITY SUPPLIES, CABLING

SYSTEMS AND CABINETS

2.3.1 Electrical Power

Power supply and distribution will be in accordance with specific Project Electrical Design
Philosophy.

The power supply voltage for field instruments will be standardised at 24 Vdc. However,
other direct current or alternating current supplies will be provided as necessary for
specialised instruments.

Generally, field instruments shall be loop powered by the systems that they are connected
to, via the 2 wire loop.

However, certain instruments may require separate power supply connections, via an
additional core in the cable (e.g. IR gas detectors), or a separate power supply cable (e.g.
vortex, ultrasonic, magnetic flowmeters, analysers). The power from the system for the
loop will be disabled accordingly.

2.3.2 Air Supply

Instrument air supplies will be free of oil, moisture and dust.

The Instrument air pressure shall normally be 6barg, with maximum operating pressure of
8barg (design 10barg) and minimum of 4.2barg.

The instrument air supply pressure at the various facilities will be monitored by the ESD
system to initiate an orderly shutdown in the event the pressure drops below a minimum
limit. This is in order to prevent erratic operation of the spring actuated shutdown valves.
The instrument air buffer receivers will be sized for sufficient air to allow for a safe plant
shutdown.

Where there is no instrument air supply, hydraulically actuated valves shall be

considered.

2.3.3 Cable Routing

Cable routings for the facilities will be laid in cable trenches or overhead cable racks/trays.
The actual configuration and routings will be determined during detail design stages,
when information on local conditions and process package configurations are available.

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Intrinsically Safe and non-Intrinsically Safe cables shall be routed in separate cable trays.
Where this not practicable, and both types of cable need to share the same cable tray,
divider plates shall be installed to segregate the two types. Common routing of control
and power cables shall be avoided. Control cables and power cables shall be routed in
separate cable trays with a minimum distance of 150 mm between them.

2.3.4 Cables

2.3.4.1 General

Single pair copper cables will be utilised for connecting field instruments to field junction
boxes and multi-core copper cables from the field junction boxes to the marshalling
cabinets. Multi-core copper cables will be utilised for short haul data links between
control systems.

Cables for field instruments will be manufactured to IEC 60331 for fire resistant and EN
60332 for flame retardant properties. The cables will be composite multi-core
construction, with solid conductors for light current application, or multi-strand for
heavier current applications. The cables and cores will be sized and selected for the
appropriate duty.

Signals will be protected against RFI through the application of individual or collective
screens.

Field cables will be mechanically protected against physical damage through the use of
embedded steel wire armouring, braiding or tape.

Specialised cables such as thermocouple extension, and system cables for

interconnection between cabinets will be utilised as appropriate.

The field circuits in the marshalling cabinets shall be linked to the control equipment in
the system cabinets by multi-core system cables, which shall have plug and socket
connections.

2.3.4.2 Specific characteristic

The cables shall have at least the characteristics listed here below:

a) resistance to environmental conditions specified, in particular the test methods for

temperature resistance stated in IEC 60811.

b) resistance to hydrocarbons in accordance with the tests stated in IEC 60092.

c) resistance to mineral oil immersion and ozone in accordance with the tests stated in
EN 60811.

d) non propagation of flame (self-extinguish and flame retardant), in accordance with the
tests stated in EN 60332.

f) fire resistance, if required, in accordance with the tests stated in IEC 60331.

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g) low emission of corrosive and toxic gases, in accordance with the tests stated in
IEC 60754.

h) low emission of opaque fumes, in accordance with the tests stated in ASTM D 2843.

i) mechanical protection by metallic armour made in galvanised steel tape or

galvanised steel wire braid;

Any deviation from these requirements shall be agreed in writing by the

PETROM/Purchaser.

2.3.4.3 External sheathing

The cable shall be covered by an external sheathing having the same characteristics of the
internal one. The external sheathing shall be identified by a different colour:

- for IS plants: light blue RAL 5015

- for power supply systems: black

- for all others plants (except IS): grey

- for thermocouples: according to EN 60584-3

If required, different external sheath colours shall be provided for cables for fire & gas
detection systems.

2.3.4.4 Cable glands

Entry into instrument housings and junction boxes will be via cable glands. Where cable
glands are intended for use in a Hazardous Area or where specified, cable glands shall be
certified by a recognised ATEX Testing Authority. Cable glands for use in oil & gas
industry applications are usually of brass construction, with nickel plating.

Entry into buildings and rooms will be via certified transit frames.

2.3.5 Cabinets

Cabinets for housing instrumentation and control systems installed inside buildings will
be standard vendor supplied cabinets, suitable for mounting equipment in air-conditioned
environments.

Cabinets which are required for mounting in outside areas (if any), shall be equipped with
sunshades to protect against solar radiation. Equipment mounted inside the cabinets shall
be rated to withstand the ambient temperature, with consideration given to the
temperature rise due to the internal heat generated.

Air-conditioned cabinets shall be considered for long-term protection of electronic

equipment mounted inside these cabinets. Passive cooling systems will be provided
where air conditioning is not practical.

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2.4 TECHNICAL REQUIREMENTS FOR INSTRUMENTATION TESTING

Each instrumentation unit and accessory, which due to its nature requires it, shall be
subjected to manufacturer’s internal tests.

2.4.1 Manufacturer’s Internal Terst

Internal tests shall be done before the official delivery date agreed upon, irrespectively of
the official check tests.

The relevant internal test certificate shall cover each instrumentation unit.

Each internal test certificate shall contain as more details as possible particularly
concerning the operation checks.

2.4.2 Final Tests

The following final tests are usually provided:

- visual examination;

- dimensional check;

- material test;

- performance test.

2.4.2.1 Visual examination

It shall be re-checked that the instruments, equipment and their accessories are free from
visually ascertained defects such as:

- dents;

- assembly or welding defects;

- breakage of parts such as glasses, gaskets etc.;

- presence of deposits that can affect the metering procedure;

- insufficient finish of machined parts, poor clearness of indicating parts such as dials;

- assembly different from that agreed upon or illustrated on Manufacturer’s Catalogue;

- shortage of parts such as stud bolts and machine bolts or accessories required on
specification etc.

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2.4.2.2 Dimensional check

The position, type, size of all connections and accessories, shape and size of cases, dials,
containers, etc. flange and thread characteristics diameters or other dimensions shall be
checked.

2.4.2.3 Material test

This type of test is intended to establish the compliance of the purchased instruments,
equipment and materials with the requirements of the individual instrument Data Sheet
revised for order.

Painting shall be checked for uniformity and proper distribution and absence of chipped
spots or manifest roughness; after a slight hammering, it shall not flake or detach from
the instrument.

Painting shall anyway be of a type suitable to resist the type of atmosphere as gathered
from the ambient conditions.

2.4.2.4 Performance tests

The performance test will check the next features:

- accuracy;

- uncertainty of a measurement;

- sensitivity;

- repeatability;

- hysteresis;

- linearity;

- action times;

- pre-established sequences;

- overloads.

The allowances value and the parameter of such features shall be indicated on the official
check test certificates.

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3 REQUIREMENTS FOR INSTRUMENT AIR SYSTEM

3.1 ARRANGEMENT

The instrument air supply system shall provide the required quantity of:

- instrument air;

- industrial air;

- air for safety equipments.

3.2 INSTRUMENT AIR QUALITY

The instrument air shall be free from oil and other liquids, and from toxic, corrosive,
flammable and obnoxious gases or vapours.

The quantity of solids shall be less than 0.1 mg/m3 and the diameter of the particles shall
not be more than 3 µm.

To prevent condensation in the supply piping or in the instruments, the dew point of the
air at operating pressure shall always be at least 10 °C lower than the lowest expected
ambient temperature for the air system at any location.

Unless otherwise specified, the instrument air pressure in the air supply piping shall be 6-
8 barg under normal operation and never less than 4.2 barg for proper operation of the
instruments. Design pressure of the instrument air system shall be 10barg.

NOTE: The requirements given above are in accordance with EN 60654.

3.3 INSTRUMENT AIR QUANTITY

The quantity of instrument air shall be estimated as accurately as possible taking into
account the requirements for:

- pneumatically operated instrumentation, based on the data stated by the

manufacturers or suppliers of such equipment;

- pressurizing electrical instruments in order to prevent an explosive gas atmosphere

inside the enclosure, by maintaining an over-pressure above the surrounding
atmosphere and where necessary by continuous dilution;

- purging/cooling of essential instruments;

- industrial users.

The consumption thus obtained shall be multiplied by 1.3 to account for uncertainties in
the data used for the estimate and to allow the installation of additional instruments
during the first years of plant operation.

This quantity is referred to as the “Design Quantity of Instrument Air”.

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NOTE: Control valves are the main instrument air consumers in modern plants. The
consumption of this group shall be carefully calculated based on data related to the
specific make of positioner and/or actuator.

3.4 INSTRUMENT AIR SUPPLY FOR INDUSTRIAL CONSUMERS

Instrument air can be applied within strict limitations for industrial consumers. However
the following industrial air consumers are permitted without restrictions:

- oil mist lubrication systems;

- flare ignition equipment.

When instrument air is required for the above applications, a separate system shall be
installed branching off the instrument air supply system at the battery limit of each
processing unit.

The requirements when applying instrument air for industrial consumers are that:

- there is no possibility of backflow from piping for industrial consumers to the

instrument air supply under all circumstances;

- a non-return valve and a safeguarding device shall be installed ensuring priority for
instrument air;

- the required quantity of instrument air for industrial use has been incorporated in the
total consumption of instrument air;

- connections shall not be made between the industrial air system and the instrument
air system at any other position.

For all other applications not specified above, written agreement shall be obtained from
PETROM.

NOTE: Tool air shall not be taken from the instrument air system. When tool air is
required, a mobile compressor should be connected to an individual tool air system
provided for each processing unit and which is normally depressurized.

3.5 AIR SUPPLY FOR SAFETY EQUIPMENT

When air is required for safety equipment such as breathing masks, separate branch-off
points shall be provided on the instrument air header in the processing unit.

The branch-off points shall be of size DN15 and be located close to the required position.

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3.6 INSTRUMENT AIR SUPPLY SYSTEMS

3.6.1 General

To ensure the maximum reliability of the instrument air supply, two (2x100%) identical
Instrument air packages shall be provided. Each package capacity shall cover 100% of the
max compressed air consumption and operate under a duty/ stand by philosophy.

Each Instrument Air Package shall mainly consist of an oil free rotary compressor
complete with lubrication system, air coolers, filters, wet air receiver, one 100% air dryer;
one buffer air receiver vessel shall be provided common for the two (2x100%) packages.

The package shall be complete with all piping, valves and instrumentation necessary for
safe operation.

The equipment shall be preassembled at manufacturer’s workshop in order to minimize

any site installation works.

The package shall be supplied into basic skids provided whenever necessary with
acoustic panel enclosures or devices (e.g. silencers) to meet the noise control
requirements.

Instrument air supply plant shall be provided comprising:

- air compressors;

- air inlet filters;

- condensate separators;

- wet air receiver;

- air dryer;

- buffer air receiver vessel.

The design of the instrument air supply shall be such that in emergencies, a guaranteed
source for a defined period is available for the utility supply plants and/or essential
process instrumentation.

For complex and large facilities, the instrument air system shall comprise an automatically
starting emergency compressor with an associated water separator.

NOTE: This emergency compressor shall be driven by a diesel engine, a petrol engine or
an electric motor, the latter only if an independent emergency electric generator or
independent supply system is available;

Consideration may also be given to obtaining air for essential consumers from an outside
plant instrument air supply system (if available).

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The air supply plant shall be located in a non-hazardous area.

The piping between the compressor discharge and the inlet to drier and buffer vessels
shall have automatic condensate draining facilities at all low points. In freezing climates
this piping, the valves, as well as the bottom part of the buffer vessel, shall be heat traced
and insulated.

The main air supply line shall be provided with a flow measuring element, a low-pressure
alarm and a historic trend recording facility for pressure on the panel/console.

The humidity shall be measured with a water content analyser having local indication and
a high-humidity alarm on the main panel/console.

Safety/relief valves shall be provided when required by statutory regulations, and/or by

the relation between maximum compressor discharge pressure and the maximum
allowable working pressure of vessels and piping.

All equipment shall satisfy the noise level shall not exceed 85 dB (A).

3.6.2 Air compressors

The compressor shall be an oil free rotary type; the lubricant for the drive train shall be
confined to the bearing and gear area, and shall not be allowed into the compression
chamber.

The compressor shall be to manufacturer’s proven design and construction, coupled

either directly or via V-belts to an electric motor driver. Direct coupled motors are
preferred.

Each compressor package shall be fitted with a relief valve which can be isolated, sized
for the full compressor capacity. In addition an hour counter shall be provided.

3.6.3 Air inlet filters

Air inlet filters shall have Δp < 1,25 mbar in clean condition. Filters shall be capable of
removing 99% of particles 10 micron or larger.

3.6.4 Condensate separators

A condensate separator is required at discharge of each compressor stage. Separator

shall be designed to handle the instrumented air compressor design flow rate and provide
sufficient liquid knock-out.

An automatic drain trap and a level alarm to control panel shall be provided as a
minimum.

3.6.5 Wet air receiver

An austenitic stainless steel wet compressed air receiver shall be installed downstream of
the after air cooler.

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The receiver shall handle the instrument air compressors design flow and provide
sufficient liquid knock-out to prevent liquids from entering the drier units.

As a minimum the air receiver shall be fitted with a safety relief valve, a pressure gauge,
an automatic drain/blow facilities and a manual bypass drain.

In addition a level alarm to control panel shall be provided.

3.6.6 Air dryer

At least two identical sets of air drying equipment shall normally be installed, one on duty
and one on stand-by. The change-over between the sets shall be manual. The operational
switch-over should be on a two-weekly rotation basis.

The air drier shall reduce the dew point of the air, under operating pressure at a
maximum oversaturation of 5 %, to at least 10° C below the lowest ambient temperature.

The air drier shall normally be of the twin-vessel adsorption type, with regeneration at
elevated temperature (except for the heatless drier) at either atmospheric pressure or at
operating pressure. Switching of the valves in the dryer inlets and outlets shall be
automatic. The switching shall be integrated with the automatic controls of the
regeneration cycle and shall be on a fixed time schedule.

In case of heatless type dryer the desiccant shall be Activated Alumina (A1203) in small
spherical form to be regenerated giving the moisture back up to a flow of purge air which
is a portion of the dry air from the working tower outlet expanded to the atmospheric
pressure.

The dryer package shall be provided with the following filters:

- two (2 x 100%) general purpose filters (particle removal 1 micron) upstream of the air
dryer. The filters will operate under a duty / standby philosophy;

- two (2 x 100%) high efficiency filters (particle removal 0,01 micron) upstream of the air
dryer and after the general purpose filters. The filters will operate under a duty /
standby philosophy;

- two (2 x 100%) general purpose filters (particle removal 1 micron) downstream of the
air dryer. The filters will operate under a duty / standby philosophy.

Filters shall have the following features:

- Differential Pressure Gauge

- Automatic Drain

- Sight Glass

A dew point analyzer shall be provided in the package upstream the discharge flange.

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The analyzer shall have a local indication and an high–humidity alarm on the unit control
panel.

3.6.7 Buffer air receiver vessel

One buffer vessels of adequate size shall be installed to serve:

- as buffer volume in the event of compressor failure;

- as a fluctuation damper when compressors are on load/unload control.

The Buffer Air receiver shall be common for both the duty and stand-by instrument air
package units.

The buffer vessel shall be sized to maintain the air supply between the instant of
compressor failure and the instant that the stand-by compressor(s) start(s) to operate. The
period between these events should be taken as the time required for starting the stand-
by compressor(s) manually if automatic starting is unsuccessful. This period shall be
determined by plant operations in conjunction with mechanical and utility engineering
and be of at least five minutes duration.

During this period unless otherwise specified, the instrument air pressure shall not drop
below the minimum value of 4.2 barg, which is required for proper operation of the
instruments.

The sizing of the buffer vessel shall be based on the design quantity of instrument air, in
order to allow the safeguarding devices to close.

The wall thickness of the vessel shall have a 3 mm corrosion allowance and be provided
with an internal protective coating.

The vessel(s) shall be installed downstream of the air driers.

The design, fabrication, erection and testing of piping should be in accordance with ANSI
B31.3 and B16.5.

The decrease in pressure between the outlet of the air drier and the most remote
consumer shall not exceed 1 bar.

The instrument air supply piping shall be designed as a ring main header system for those
parts of the supply piping where an uninterrupted supply of instrument air is required.

As a minimum the air receiver shall be fitted with a safety relief valve, a pressure gauge,
an automatic drain and a manual bypass drain.

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4 MAINTENACE IN DESIGN

The instrumentation shall be designed taking maintainability into consideration by

simplifying maintenance and reducing maintenance costs where practical.

The SMART instruments shall have built-in test and diagnostic facilities with fault
indication.

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5 DOCUMENTATION REQUIREMENTS

Each module shall be tagged with detailed product information minimizing the potential
for incorrect installation, operation, or misapplication of a reconfigured instrument.

Front End Design:

- instrument list;

- instruments data-sheet;

- sizing calculation sheets;

- instruments specifications;

- instrumentation philosophies;

- instruments layouts;

- cable lists;

- cable routing;

Detail Design:

- as above;

- instrument detailed specifications;

- general arrangement drawings;

- layout drawings;

- termination diagrams;

- loop drawings;

- data sheets;

- process hook-ups diagrams ;

- pneumatic hook-ups diagrams;

- hydraulic hook-ups diagrams;

- electrical hook-ups diagrams.

The use of database design tools should be considered where they are deemed to provide
a clear advantage in project design, construction, and plant operation and maintenance.
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6 CERTIFYING AUTHORITY REVIEW REQUIREMENTS

Where required by the certifying authority the following documents shall be submitted as
a minimum for review:

- certificates/approvals;

- basis of design document;

- philosophy documentation;

- functional design specification;

- P&IDs.

These should be issued to the CA in a timely manner to obtain approval before

commencing construction.

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7 SPARE PARTS

Spare parts shall be considered for commissioning and 2 years of operation.

All spare parts shall comply with the same specifications and tests as the original
instrumentation and shall be fully interchangeable with original parts without any
modification at site.

They shall be correctly marked with reference number and the manufacturer’s part
numbers and shall be properly protected to prevent deterioration during shipment and
storage.

To all spares shall be attached metal plates giving full information for ready identification
including maker’s name, serial number and purpose. All spares will be inspected before
delivery. The protection shall be such as to afford avoidance of corrosion and spoilage for
a minimum 3 years after delivery.

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