Section : TGPS –J1

Date : August, 2010

Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 1 / 379
Revision : 2
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GENERAL SPECIFICATION FOR INSTRUMENTATION

(General Project Design, Material and Equipment Specifications)

CONTENTS PAGE

I. GENERAL COMMENTS ON INSTRUMENTATION .........................................................2

II. UNITS OF MEASUREMENT AND SCALES.....................................................................31
III. INSTRUMENT CONNECTIONS ON VESSELS AND PIPING.........................................33
IV. FLOWMETERS.................................................................................................................34
V. PRESSURE MEASUREMENT..........................................................................................42
VI. LEVEL MEASUREMENT..................................................................................................48
VII. TEMPERATURE MEASUREMENT..................................................................................55
VIII. ELECTRONIC TRANSMITTERS......................................................................................65
IX. CONTROL VALVES AND ACCESSORIES.....................................................................74
X. ANALYSERS....................................................................................................................99
XI. ACCESSIBILITY..............................................................................................................125
XII. INSTRUMENT PIPING DESIGN......................................................................................129
XIII. ALARM, SHUTDOWN AND INTERLOCK SYSTEM.......................................................132
XIV. FIELD MOUNTED PNEUMATIC INSTRUMENTS...........................................................166
XV. INSTRUMENT WIRING DESIGN.....................................................................................169
XVI. CONTROL BOARD, PANELS AND CABINETS.............................................................187
XVII. DIGITAL DISTRIBUTED CONTROL (DCS)....................................................................193
XVIII. STEAM TRACING OF INSTRUMENTS...........................................................................289
XIX. WINTERIZATION AND PROTECTION OF INSTRUMENTS...........................................305
XX. SAFETY VALVES AND RUPTURE DISC.......................................................................312
XXI. DOCUMENT REQUIREMENTS.......................................................................................318
XXII. MOTOR OPERATED VALVES AND SHUT-OFF VALVES............................................328
XXIII. STANDARDS AND SPECIFICATIONS...........................................................................340
XXIV. INSTRUMENT / ELECTRICAL INTERFACE PHILOSOPHY..........................................341
XXV. GENERAL INSTRUMENT ERECTION SPECIFICATION FOR CONTRACTORS...........348
XXVI. INSTRUMENT DELIVERABLES...............................................................................367
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I) GENERAL COMMENTS ON INSTRUMENTATION

1.0 SCOPE

1.1 This specification set outlines basic instrumentation requirements

governing the basic design, selection, application and installation of
instrumentation and control system. It will be generally used and shall
govern for all instrumentation design. This specification gives directives
for the basic design criteria for instrumentation in general. The specific
design requirements for each type of instrument or instrument system are
covered by the individual specification of that particular item/category.
Any conflict between the requirements of this specification and related
codes, standards, data sheets, drawings, requisition, etc., shall be
referred to the OWNER for clarification. Owner’s approved vendor list
shall be followed strictly for procurement of various instruments.

1.2 No variations from the project specifications and all TÜPRAŞ

specifications have been allowed unless approved in writing by TÜPRAŞ.

2.0 STANDARTS AND SPECIFICATIONS

2.1 The referenced standards, codes and specifications will be considered

but will only be used to amplify the data herein, or to supplement it where
not adequately covered, or inferior.The various applicable codes and
standards are as mentioned below. In case of any conflicts /
discrepancies in general instrument specifications and individual items’
specifications, the most stringent conditions shall apply based on the
following standards. However, in all such cases, before taking any
decision, CONTRACTOR shall get formal approved of data/specification
sheets from OWNER.

The following standards shall be followed as a minimum during basic and

detail engineering of plant by consultant/vendors.
1. ASME B1.20.1 Pipe Threads, General Purpose (inch)
2. ASME B46.1 Surface Texture (Surface Roughness, Waviness and
Lay)
3. ANSI/ASME B16.5 Pipe Flanges and Flanged Fittings
4. ANSI/ISA S18.1 Annunciator Sequences and Specifications
5. ANSI/ASME PTC 19.3 Pt 3: Power Test Code. Thermowell strength
Calculations
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6. ANSI/FCI-70.2 Control Valve Seat Leakage.

7. ANSI/ISA 75.01 Flow Equations for Sizing Control Valves.
8. API RP 520 Sizing, Selection and Installation of Pressure Relieving
Devices in Refineries: Part 1: Sizing and Selection Part 2:
Installation
9. API RP 551 Process Measurement Instrumentation
R2 10. DELETED.
11. API RP 556 Instrumentation and Control Systems for Fired Heaters
and Steam Generators.
12. API 607 Fire Test for Soft-seated Quarter-turn Valves
13. API 670 Vibration, axial position and bearing temperature
monitoring systems
14. BS 3643 ISO Metric Screw Threads: Part 1: Principles and Basic
Data. Part 2: Specification for Selected Limits of size.
15. CE “Conformite Europeenne”, Harmonized Codes directed by the
European Community.
16. 97/23/EC Pressure Equipment
17. DIN ISO 228, Pt. 1 Pipe Threads where Pressure-tight Joints are
not made on the Threads. Pt. 1: Designation, Dimensions and
Tolerances.
18. DIN 16128 Nominal Ranges, Scale Spacing and Scale Numbering
of Accuracy Classes 1.0, 1.6, 2.5 and 4.0 Pressure Gauges.
19. DIN 19234 (NAMUR) Electrical Distance Sensors; DC Interface for
Distance Sensor and Signal Converter.
20. DIN V19250 Measurement and Control Fundamental Safety
Aspects for Measuring and Control Protective Equipment.
21. DIN 43729 Electrical Temperature Sensors; Connection Heads for
Thermocouple Thermometers and Resistance Thermometers
22. EN Standards (CENELEC) Electrical Apparatus for Explosive Gas
Atmospheres
23. EN 10204: Inspection Documents for the Delivery of Metallic
Products.
24. EN 60947 : Electrical Distance Sensors; DC Interface for Distance
Sensor/converters
25. IEC 60079:Electrical Apparatus for Explosive Gas Atmospheres
26. IEC 60085 : Thermal Evaluation and Classification of Electrical
Insulation
27. IEC 60227 : Polyvinyl chloride insulated cables of rated voltages up
to and including 450/750V.
28. IEC 60228 : Conductors of insulated cables
29. IEC 60331 : Test for electric cables under fire conditions. (Fire
resistant)
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30. IEC 60332: Test for electric cables under fire conditions. (Flame
retardant)
31. IEC 60364: Electrical Installation of Buildings.
32. IEC 60391: Marking of Insulated Conductors
33. IEC 60423 : Conduits for Electrical Purposes: Outside Diameters of
Conduits for Electrical Installations and Threads for Conduits and
Fittings
34. IEC 60529 : Degrees of Protection Provided by Enclosures (IP
Code
35. EC 60534 Industrial Process Control Valves:
36. Part 1: Control Valve Terminology and General Considerations
37. Part 2: Flow Capacity: Section 1: Sizing Equations for
Incompressible Fluid Flow under Installed Conditions.
38. Part 2: Flow Capacity: Section 2: Sizing Equations for Compressible
Fluid Flow under Installed Conditions.
39. Part 8: Noise Considerations:
40. Section 1: Laboratory Measurement of Noise Generated by
Aerodynamic Flow through Control Valves.
41. IEC 60584 Thermocouples -Part 2: Tolerances. Thermocouples -
Part 3: Extension and Compensating Cables Tolerances and
Identification System.
42. IEC 60654 Operating Conditions for Industrial Process
Measurement and Control Equipment.
43. IEC 60751 Industrial Platinum Resistance Thermometer Sensors.
44. IEC 60757 Code for Designation of Colors
45. IEC 60902 Industrial Process Measurement and Control Terms and
Definitions.
46. IEC 61000 Electromagnetic Compatibility for Industrial Process
Measurement and Control Equipment.
47. IEC 61508 Functional safety of electrical/electronic/programmable
electronic safety related systems.
48. ISO 5167 Measurement of Fluid Flow by Means of Pressure
Differential Devices.
R2 49. NACE MR0103 (95) Standard Material Requirements -Sulfide
Stress Cracking-resistant Metallic Materials for Oil field Equipment.
50. IEC 62086-1 Electrical apparatus for explosive gas
atmospheres_Electrical resistance trace heating_Part 1: General
and Testing requirements
51. ANSI/API RP 552 (1994) “Transmission System”
R2 52. ANSI/API RP 553 “Refinery Control Valves”
53. ANSI/API RP 554 “Process Instrument and Control”
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2.2 Should any conflict arise among this specification set, licensor standard
specifications, project specifications and any other referenced standards they
will be resolved by TÜPRAŞ after obtaining CONTRACTOR comments.

3.0 GENERAL

3.1 Basic type instrumentation (e.g. pneumatic or electronic) shall be as given in

the PROJECT SPECIFICATIONS. Instrumentation shall be selected and
specified for the plant in line with good petroleum plant practices. Adequate
instruments shall be provided to result in safe and easily operable plant.
Sufficient temperature, pressure, and flow meter test points shall be provided to
allow complete test runs on all units. Meters shall be provided for principal utility
services and alarms for vital utilities and process variables.

3.2 Engineering flow diagrams will identify all instrumentation according to legend
on flow diagrams . The instrumentations symbols will be based on ISA standard
R2 RP 5.1. The installation of instruments and control shall generally be in
accordance with API-551/552/553/554 (latest edition), unless otherwise
required by these specifications, the PROJECT SPECIFICATIONS, or local
regulations.

3.3 Instrument schedule and drawings will prescribe the installation of instruments.

3.4 Units will be operated mainly from a digital distributed control system using
digital data storage and retrieval techniques and associated peripheral and
interconnecting equipment.

3.5 Transmission of measurement and control signals will be 3-15 psig for
pneumatic instruments and two wire 4-20 ma (HART) 24 V DC signal system
for electronic instruments.

Generally, pneumatic and electronic output signals from transmitters will

increase with an increasing process variable.

3.6 One manufacturer shall be selected for each type of instrument including
instrument supplied by Vendors in packaged units for standardization purposes
unless otherwise approved by OWNER.

3.7 Materials of construction for instrument equipment shall be consistent with

corrosion, temperature and pressure requirements to handle the process fluids
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involved.

3.8 Generally the parts in contact with the process fluid will be similar to that used
in the related process vessel and lines. Where the instrument design prohibits
the use of these materials or where suitable material cannot reasonably be
procured the instrument shall be isolated from the process by seals or purges.

3.9 Pressure and temperature rating of instruments components will conform to the
rating of the process system to which they are connected. Consideration being
given to the reduced temperature at the instrument.

3.10 Instruments shall be located in convenient positions to facilitate maintenance

and accessibility as per the conditions stated in "ACCESSIBILITY"
section.(Section XI).

3.11 Orientation of instrument cases, where possible, will permit operators to

observe scales while adjusting related equipment.

3.12 No hydrocarbon or other flammable substances shall be permitted in the control

room. For control room environment see TGPS-R1.

3.13 Instrument leads and outdoor instruments shall be protected from freezing. All
instrument handling high poor point or viscous oils shall be provided with
temperature controlled steam tracing system and easily installed/removed
instrument insulating enclosures with weather and corrosion resistance.

3.14 Electrically operated instruments, alarms and shutdown systems shall be

powered from an 100% redundant separate AC and DC UPS systems
approved by OWNER.

3.15 Intrinsically safe type protection for all electronic instruments in field shall be
provided with the barriers to be installed the cabinets in the technical
rooms.Irrespective of plant’s hazardous area classifications, all the electronic
instruments (transmitters etc.) shall be intrinsically safe EExia IIC T6 complying
to CENELEC 50020 codes and flame proof EEx d IIC T6 certification
R2 weatherproof to IP66 as per IEC529 (Both certification as EExi and EEx d).
All Signals associated to Motorized valve are Non Intrisically Safe. (TTAB-
02030-1041)
All I.S type instrumentation system documents related to I.S loops / circuits
shall be certified by official certification organization. Intrinsically safe wiring
shall terminate directly on barriers for incoming and outgoing to field.
Compliance with ATEX Directive:
The “Instruments” and the associated accessories shall be certified according
to the ATEX Directives.
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Compliance with European Directive 97/23/EC (PED)

Field mounted electrical equipment and wiring shall be suitable for Class I,
Group B, Division 1 and Control room equipment and wiring shall be suitable for
non hazardous area only if ;

a) the control room is located within an area in which the nearest process unit
battery limit is minimum 30 meters; or

b) the control room floor is 0.7 meter above the grade of surrounding area and
the nearest process unit battery limit is minimum 15 meters. Regardless of
classification, enclosures for field mounted equipment shall be of heavy duty
construction, wiring shall be fully protected against physical damage, and
non-self cleaning electrical contacts shall be hermetically sealed to insure
operation in refinery atmospheres. The control room will be pressurized as
per API RP 554 section 5, point 5.4, item 5.4.4. Air purification will be
provided as per API RP 554 section 5, point 5.4, Item 5.4.3 and 5.4.5

3.16 Where applicable the “Instruments” and the associated accessories shall meet
the PED Requirements.

3.17 Enclosures of field mounted instruments shall be suitable for specified

environmental conditions and the minimum degree of protection shall be IP 66
as per IEC 529 recommendations.

3.18 Piped and mounted filter regulator assemblies complete with a regulator output
pressure gage shall be provided for all instruments, control valves, etc.,
requiring individual air supplies and shall be designed for 6-8 kg/cm2 air supply
pressure.

3.19 All instruments shall be tagged for identification. The tags shall be substantial,
of stainless steel, stamped with the tag number, and permanently attached to
the instrument with stainless steel screws or drive pins.

3.20 Electrical Connections on instruments shall be 1/2" ANSI B2.1 NPT.F

Pneumatic Connections on instruments shall be 1/4" ANSI B2.1 NPT.F.

3.21 All process connection of instruments (including pressure gauges) shall have
block and drain/vent valves as a minimum located near instruments.

3.22 The installation of instruments and controls shall generally be in accordance

with API RP-551/552, unless otherwise required by these specifications, the
R2 project specification or local regulations.

3.23 Connection of field mounted instruments to piping and bulky equipment shall
have the following features:
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3.23.1 As far as possible, support large case and bulky instruments from
rigid vibration-free basis and not from piping or walkways.

3.23.2 Avoid mounting instruments near known sources of vibration. (e.g.

near reciprocating compressors.

3.23.3 Piping connections shall have enough flexibility to absorb

movement resulting from thermal expansion including steamout
operations.

3.23.4 All process connections of instruments shall have block and drain
vent valves located near instruments.

3.23.5 Instrument nameplates shall be engraved in the language specified

in the Basic Engineering Design Data Sheet for the project. Field
mounted instruments, transmitters and control valves shall have
nameplates giving instrument service and number.

3.23.6 Draft gauges shall be supplied for all fired heaters.

3.23.7 All instruments will be of the latest but proven design of the
manufacturer.

3.24. All alarms related to instruments connected to safety system (ESD) will also be
sent to DCS via redundant-serial link with time stamp.
A dedicated DCS critical alarm to be provided when the emergency shut-down
system is activated by push buttons (local/on board).

3.25 Unless otherwise is specified, the following measurement requirements shall be

provided for all critical machineries (pumps compressors, turbines , generators
etc.) as minimum.

Vibration monitoring system shall be Bently Nevada make 3500 series only.
Bently Nevada vibration and displacement monitoring systems shall be
integrated into DCS System via serial or ethernet communication interface to
observe and trend all displacement, velocity and vibration data. The latest
proven technology and models of Bently Nevada vibration and monitoring
systems (hardware/software) shall be used.
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The machinery protection system shall be capable of interfacing with various

display options, including touch screen displays, a dedicated server operator
display, plant control system display station or via remote access. Bently
Nevada vibration and monitoring systems will be included a dedicated system
display unit 3500/95. DELETED
R2
DELETED.

The type/model of probes/proximeters and all primary hardware, which is

installed in the field, shall be as per applicable hazardous classification and
suitable for the application. All the Monitors shall be with built in Barriers.

The vibration monitoring cabinets shall be accommodated in a technical

cabinet rooms in the close vicinity of control room in RITTAL panel as specified
in DCS/ESD specifications. The probes and proximeters shall be installed in the
field.

R2 The trip from vibration monitoring system shall be via Series 3500 system with
hardwired relay outputs connected to central ESD system.

All the monitored variables of each module shall be connected with DCS via
MODBUS signals for continuous monitoring/trending purposes.

The power supply module in the vibration monitoring cabinets shall be 100%
redundant. Power to redundant modules shall be fed from two diff. 220 V AC
UPS feeders.

The BN 3500 system shall be of modular design with plug-in components.

Removing or inserting of any main module shall not disrupt the operation of
other unrelated modules in the system.

The BN 3500 for each machine shall consist of a rack, redundant power
supplies, rack interface module, any combinations of monitor modules
necessary for the relevant I/Os (e.g. radial vibration, thrust position, keyphasor,
etc.) and redundant Communication gateway.

Redundant power supplies in the monitor rack shall convert the incoming power
supply into the voltage levels required by the system. Each power supply
module shall be powered from the external redundant UPS power source with a
dedicated circuit breaker. The removal or failure of one power supply in the rack
shall not cause any disruption or machine to trip. Each power supply shall have
the capacity to power the fully loaded rack.

R2
DELETED
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All signals coming from BN probes in field will be wired directly to the BN
system (through dedicated FJB and multicables).

R2 The trip logics in the Bently Nevada shall send hardwired signals from relay
output cards towards the ESD.

The monitoring system shall have the self-diagnostic capability and it shall be
required to provide the advance diagnostics in all machinery problems. The
system fault alarms shall be provided for:

· Field circuit failures.

· Monitor circuit failure.
· Signal transmission fault.
· Power supply failures.

A common system fault alarm contact output from each rack shall be hardwired
to DCS for annunciation.
The Bently Nevada system shall be maintained and configured via 3500 Rack
R2 Configuration software, installed on a PC with an interface to the programming
ports of the MMS.

An integrated Health Monitoring and Advisory System (Bently Nevada System

1) will be supplied and installed and interfaced with each BN Monitoring System
as part of the RUP Project scope.

The Bently Nevada System 1 shall continuously evaluate both mechanical and
process parameters (including performance) and provide timely advisories to
operators, in order to avoid or mitigate catastrophic failures. This results in
improved site profitability from higher unit on-stream factors, lower maintenance
costs and more effective preventative and predictive maintenance.

3.25.1 Radial Position and Vibration Measurements

For machinery with sleeve type radial bearings of any design, (tilting
pad, cylindrical, elliptical, lobed, etc.) the Contractor shall supply to
orthogonally mounted (90 degrees separation) proximity probes to
measure radial vibration using the Bently Nevada XY & Gap
Monitor or the 3500 equivalent Monitoring System. The probes
should be mounted directly to the bearing cap.
The thin fluid film that supports the shaft, in a fluid film bearing,
permits shaft movement relative to the bearing. Two orthogonally
mounted proximity transducers are required to observe this motion
directly.
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Protection parameters related directly to machinery internal

clearances can be enabled using simply the overall amplitude and
DC position measurement. A range of chronic problems and acute
fault conditions (ie: misalignment, unbalance, shaft rub) can be
diagnosed effectively using the dynamic signal from the proximity
probes.
· Two Bently Nevada non-contact proximity displacement
transducers in XY configuration shall be installed at each journal
bearing in accordance with API 670 4th edition and connected
to BN 3500 monitors. This requirement covers gearboxes and
integrally geared compressors (bull gear and pinions) classified
as Critical equipment.

3.25.2 Axial Displacement (Rotor Thrust) Measurements

The axial thrust or axial displacement measurement shall be made

with two dual voting Bently Nevada Proximity Probes at each thrust
bearing using the Bently Nevada Thrust Monitor or 3500 Series
equivalent monitor.
A thrust bearing failure can quickly lead to catastrophic machine
failure. Dual thrust transducers must be installed at each thrust
bearing in order to detect thrust bearing degradation and/or failure.
R2 For SIL applications, three probes shall be installed, connected to
triple modular redundant monitors.
The preferred mounting arrangement for the thrust probes is directly
through the thrust bearing, however the machine design does not
always permit this. Thrust probe installation may also be engineered
to observe the end of the shaft (within 300mm of the thrust collar),
or another collar on the shaft within a similar proximity to the thrust
bearing.
· Two Bently Nevada non-contact proximity displacement
transducers in a dual-voting configuration to be installed in
accordance with API 670 4th edition, at each hydrodynamic thrust
R2 bearing and connected to BN 3500 monitors. For SIL
applications, three probes must be installed.
· For Gearboxes and Integrally Geared Compressors, a
single axial proximity displacement transducer to be installed on
each pinion shaft without a thrust bearing. (Most API compliant
gearboxes are manufactured with pre-machined probe mounting
locations at the pinion shafts) Specialty sensor designs such as
“Button probes” may be employed for this purpose when the
geometry of the machine prohibits conventional sensors

3. 25.3 Bearing Metal Temperature Measurements

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Two bearing metal temperature sensors installed at each radial

journal bearing (1 in use and 1 spare). Hydrodynamic thrust
bearings shall be equipped with temperature sensors in alternate
pads of the active side and 2 on the inactive side. The detectors
shall be resistance temperature (RTD) type as specified in API 670
4th edition and be monitored by Bently Nevada Temperature
Monitors or 3500 Series equivalent.
Radial and thrust bearings shall have Resistance Temperature
Detectors (RTD) installed to measure bearing metal temperature.
Installation shall be strictly in accordance with the practice specified
in API 670 4th edition.
· Critical machinery shall typically have two sensors installed in
each on-load pad, or within the load zone, for radial bearings,
and two sensors in each of two pads for thrust bearing
protection. The actual arrangement is dependent upon bearing
geometry and API 670 4th edition must be consulted to verify
correct engineering practice. The sensors shall be connected
to BN 3500 Temperature Monitors.

3.25.4 Keyphasor Requirements

One non-contact Bently Nevada Proximity Probe type Keyphasor

should be installed on the driver of each machine train for once-per-
rev phase reference measurements (either notch (preferable) or
projection). If the machine train comprises of rotating elements
operating at differing speeds (e.g. driven element via a gearbox)
R2 then a further single non-contact proximity transducer must be
installed on each of the differing speed elements. Keyphasor should
be monitored by Bently Nevada Keyphasor Monitor or 3500 Series
equivalent monitor.
One non-contact Proximity Probe type Keyphasor® transducer is
necessary for accurate phase information and must, as a minimum,
be mounted on the shaft of the driver machine. The target notch or
protrusion should be suitable to generate the correct signal at all
machine states, however the machinery manufacturer shall be
responsible to confirm this.
· One Bently Nevada non-contact proximity transducer shall be
R2 installed for once-per-rev phase reference measurements and
connected to BN 3500 Keyphasor Monitor. DELETED.
· Gas Turbines with separate Power Turbine must have
keyphasor sensors fitted to the Power Turbine in addition to the
Gas Generator shaft.
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· For Gas Turbines with spooled shafts, the High Speed shaft
speed is typically only accessible via the Auxilliary Gearbox. In
this case, a keyphasor transducer shall be mounted to observe
the gear teeth on the high speed gear wheel. The TÜPRAŞ
Engineering Manager shall approve any deviation from this
requirement. If the gear profile is not suitable for a standard 8mm
sensor, a specialty “Narrow Side View” transducer may be
substituted. All other keyphasor locations must be designed to
observe a once-per-revolution target.
· For Gearboxes and Integrally Geared Compressors, one
Keyphasor® sensor must be installed on each shaft for once-per-
rev phase reference measurements (unless already installed on
the driver or driven machine on the same shaft).

· For the Pinion shaft on an Integrally Geared Compressor, axial

oriented Keyphasor® transducers may be used to observe a
single machined depression in the shaft end if no other location
is available. Specialized “Narrow Side View” transducers may be
required in some installations, however this should be considered
in consultation with the machinery OEM.
· DELETED.
R2
· DELETED.

R2 3.25.5 DELETED.

3.25.6 Reciprocating Compressor Measurement Requirements

Each connecting rod shall be observed by orthogonally

mounted Bently Nevada proximity probes located next to the
packing gland. One of the probes shall be in the true vertical
position either above or below the rod. These probes shall be used
to measure rod position and dynamic motion and to detect wear ring
deterioration.
A Keyphasor shall be mounted on the crank shaft to provide timing
information to measure "instantaneous rod drop" and vibration
phase.
An Accelerometer shall be mounted on each cylinder casing close
to the cross head to measure "impact" response type failure.
(Looseness or excessive clearance between reciprocating
components).
Valve temperature shall be monitored by one RTD attached to each
cover. (Detects temperature increase due to gases recycling
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around worn valve).

A Velomitor shall be attached horizontally at each end of the crank
case to detect excessive motion due to foundation deterioration.

· A Keyphasor® transducer is required for vibration impuls event

monitoring and piston rod position analysis.

· Low-frequency Bently Nevada Piezo-velocity transducers shall

be mounted mounted on the crankshaft frame in the horizontal
direction at each main bearing.

· One Bently Nevada Accelerometer transducer shall be mounted

on the crosshead guide directly above the crosshead in the
vertical plane at each cylinder. For Hyper Compressors, an
additional accelerometer will be mounted at the auxiliary
crosshead.

· Two Bently Nevada orthogonally mounted proximity transducers

are required to monitor the radial location of the piston rod to
monitor the progressive wear of the piston rider bands and
schedule maintenance prior to incurring damage to the cylinder
liner.

· At each valve (inlet and discharge) an RTD shall be installed as

close to the valve as possible. (On-line valve temperature
measurement is required on all Critical Reciprocating
Compressors to identify the specific location of the failure for
better targeted planned maintenance)

· An RTD shall be installed in both the bottom and top of the

crosshead guide to detect the shoe temperature.

· Each cylinder shall have one dynamic pressure transducer

mounted at the head end and one at the crank end of the
cylinder. Typically all API compressor cylinders will be supplied
with pressure ports (Per API 618, 4th Edition, Section 2.6.4.6).
(The sensor must be suitable for continuous operation in a
corrosive sour gas environment with a frequency response
exceeding 5kHz)

· Pressure packing temperature can indicate problems related to

the packing, including excessive wear, insufficient cooling or
insufficient lubrication. At each cylinder, an RTD should be
installed as close as possible to the packing

· At each cylinder, an RTD should be embedded or affixed on the

packing case vent line for "Pressure Packing Vent Line
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Temperature" (It is important that there is only one packing case

vent line at each monitoring point). The placement of the
temperature probe should be as close to the packing vent
discharge as practical

R2 · DELETED.

· All sensor shall be connected to BN 3500 Monitors.

3.25.7 All communication links between the systems such as DCS, ESD,
PLC, F&G, B/N monitoring systems, PHD, anti surge control
system. , control panels , etc. shall be provided as redundant.
Moreover , the connection of each system ( device ) to other system
will be provided with separate and redundant communication ports .
Each redundant communication bus port will be included only one
system.

3.25.8 All screens / monitors will be LCD type instead of CRT monitors .

3.26 The use of Foundation Field Bus/ PROFIBUS or any other cluster/Multiplexer
type I/O philosophy shall not be allowed in project and any part thereof.

3.27 Minimum contact rating for disconnecting inductive loads shall be:

-1.0A for 24-48 V DC

-0.4A for 110-125 V DC
-5.0A for 60-260 V AC

3.28 Transmitters shall be in general utilized for trip functions. In principle no

switches to be used in process related areas.

3.29 Instrument ranges for trip functions and control functions in the same service
shall be equal.

3.30 Ranges used for measurement and control instrumentation shall overlap alarm
and trip settings by minimum 5% of the span.

3.31 Mercury, Asbestos and asbestos compounds are not allowed.

3.32 All field instruments, junction boxes, cabinets, panels etc. shall be provided
screwed SS tag plate with tag no. engraved or embossed on it.

3.33 Weights and measured approved Mass Flow meter shall be provided for all
type for fluids/material (input/output ), raw materials, finished product or by-
product, which is considered as custody transfer.
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3.34 All interlock shall also be realized from 4-20 ma analog input transmitters in the
ESD. No field switches shall be used for interlock purpose, except NAMUR type
proximity sensors for valve positions switches.

3.35 All signal exchange between field and central cabinet room shall be via
individual hardwire pair of cable as specified in detailed cable specifications.
From the field, all field transmitters shall be routed to field mounted junction
R2
boxes, from where these shall be taken to central cabinet room via multi pair
cables. Use of 6 pair or 12 core cable shall be used in special cases. All analog
multi pair cable shall be up to 24 pair. All Digital input/output multi pair cables
shall be either 24 core or up to 24 pair. All T/C multi pair cable shall be 12 pair
and RTD multi pair cable shall be 6/8/12 Triad only.

Multicables shall be named with the same tag of the Junction Box adding a “M”
instead of a “JB”, and an “I” in the cases of intrinsically safety.
Example: Example: 147-JA(I)-M-0015-DCS

3.36 To the extent possible, direct run cable from field instrument to central cabinet
room shall not be employed. All the signals to the central cabinet room shall be
routed through multi pair cables via field mounted junction boxes only.

3.37 Usage of Foundation Field bus / Profibus type clustered I/O wiring philosophy is
not allowed at any locatıon in the whole plant.

3.38 Few dedicated, special type of cables from special control system may be
directly routed to cabinet room in place of multi pair cables.

3.39 All the fiber optic cables / system cables, special cables must be armoured type
laid preferably in overhead trays/duct only. All system cables outside control
room should be armoured.
3.40 All type of single and multi pair power, control and signal cables in the field shall
be with steel armoured only for mechanical protection.

3.41 In the whole plant area, where there are chances of fluid leakages/spillage in
normal operating conditions, all cable trays/cable ducts shall be provided with
closed covers made of 2 mm thick SS304 sheets.

3.42 The following types of reports/certificates should at least be considered:

- EC declaration of conformity;
- Calibration report;
- Functional test report;
- Welding procedure/report;
- NDE report;
- Material certificates
R2 - NACE MR 0103(Latest Edition)
- Low Emission Certificates (TA LUFT, etc.);
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- Electrical certificates;
R2 - DELETED.

3.44 All instruments/equipments to be supplied shall be manufacture's standard

type. The instruments / equipment shall be purchased only from manufacturers
with long-standing experience. The vendor list approved by OWNER shall be
followed for the purpose.

3.45 The material components, which come into contact with the fluids to be
measured, shall be resistant to corrosion caused by said fluids. It shall be
compatible with the piping material when being clamped, welded or connected
by other methods.

3.46 All instruments and equipments shall be suitable for use in specified site
climatic conditions and industrial environment in which corrosive gases and / or
chemicals may be present. All external surfaces shall be suitably treated to
provide protection against corrosive plant atmosphere with epoxy painting /
powder coating.

3.47 The design of electronic instruments shall be in compliance with the

electromagnetic compatibility requirements as per IEC 801 'Electromagnetic
Compatibility for Industrial Process Measurement and control Equipment.

3.48 All in-line instruments shall be with flanged connection. Sandwich type
connections shall not be used. Pressure rating for all instrument items shall be
R2 ANSI 300 # minimum. For pipe classes with higher pressure rating the same
shall be as per pipe class. For pressure class 600 # and above RTJ type
connections shall be used if it is required by piping specifications.

3.49 Flange ratings for instruments may differ when instrument flanges and the
mating flanges on piping / equipment are of different materials (e.g. SS-316
thermowell on CS pipes). The contractor shall in such cases, ensure that the
rating of flange is chosen for the instrument and the corresponding flange on
piping / equipment.

3.50 Material of process wetted parts shall be SS-316 minimum. Superior material
shall be considered, if required, as per the process medium. This is a common
requirement for all Instruments and hence applicable even if not explicitly
specified against each type of instrument in the succeeding pages of this
specification.

3.51 Piping/Instrument scope change for instrumentation shall always be after first
isolation/drain valve for all types of instruments, including local Pressure
gauges.
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3.52 Transmitters shall be mounted on nearest platform / grade level keeping in view
requirements of readability and accessibility.

3.53 All remote seal diaphragm type Flow, Pressure and Level transmitters shall be
designed with 2” flange size except for low range pressure (vacuum 0.5
R2 kg/cm2) shall be 3” flange size. Also, irrespective of the pressure rating, the
minimum pressure rating for all the flanged instruments shall be ANSI CL 300.

3.54 Irrespective of the pressure rating, the minimum pressure rating of all
instruments nozzles, flange size shall be ANSI 300# ratings only. This includes
orifice flange assembly, thermowell flanges, RADAR type level transmitters,
Ultrasonic type level transmitters, Diaphragm type remote seal
Pressure/Flow/Level transmitters, Magnetic and mass flow meters and any
other flanged connection type instruments. Control valves and ON-OFF valves
R2 shall be rated in accordance with the line spec. unless otherwise specified
except that carbon flanged valve up to and including 6” shall not be less than
300 L.b (TRM-TQ-INS-0039)

3.55 At few places, for improving reliability and safety of operation and control, “2
Out Of 3” philosophy for Interlock shall be followed. The general guide line for
selecting such loops may be a trip/interlock, which is causing complete plant
shutdown, either directly or indirectly. This necessitates installing and
connecting 3 transmitters for interlock purpose with PLC on the same
parameter. If there is a closed loop control in DCS on the same parameter,
there shall be fourth transmitter, dedicated for connecting with DCS.

3.56 All temperature measurement in the plant shall be carried out using only
Thermocouple or RTD elements. Local temperature gauges may be used only
R2 where essentially required. All temperature points shall be provided with either
direct thermocouple (generally “E” type or “K” type) or RTD (generally 3 wires,
PT100) sensors with flanged thermowell assemblies. 2 wire, 24 V DC, SMART
transmitter shall be used for all temperature measurement.

3.57 All thermocouple/RTD sensors shall be duplex type with Flanged thermowell
along with nipple-union-nipple assembly along with thermocouple head,
certified as per EExia, IIC/T6 and weatherproof to IP65 as a minimum.
R2
Thermowell shall be manufactured from drilled bar stock, tapered. The cable
entry shall be ½” NPT(F) and complete assembly shall be provided with SS
MOC, double compression cable glands certified as per EEx “e”/”d”, IIC/T6 and
weatherproof to IP65 with PVC hood. EExia will not be considered.

3.58 Custody transfer instruments shall be submitted to a National Inspectorate of

Weights and Measures for verification and certification (e.g. flow metering, tank
gauging, weighing).

3.59 Measurement error (accuracy) percent value of span, unless stated

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otherwise, not worse than:

• ± 0.075 % for pressure transmitters.

• ± 0.075 % for differential pressure transmitters and multiparameter
transmitters.
• ± 0.25% in case of special flow turn down requirements only.
• ± 1.0% of calibrated range (acc.class 1) for pressure gauges.
• ± 1.5% for (differential) pressure gauges.
• ± 1% for ultrasonic flow measurement.
• ± 0.5% for level and temperature transmitters.
• For mass flow meters: · ± 0.1% for liquid flow. · ± 0.3% on gas flow. · ± 0.1
kg/m³ on liquid density. ± 0.1 kg/m³ on gas density.
• For vortex flow meters: · ± 0.75% for liquid flow. · ± 1% on gas flow.
• Hysteresis shall be maximum 0.1% of the range.
• All transmitters shall have minimum static pressure rating of 100 kg/cm².
• Ambient temperature variation of 40 °C shall not change output signals by
more than 1% of the range.

3.61 Systems enclosures shall have a degree of protection in accordance with IEC
60529, protection code IP 65 as a minimum. Preference to IP-65 due to heavy
rains/storms. Cable glands to be IP-66 to avoid ingress of local present
electrical conductive dust.
All field instruments shall be damp-proof and dust-proof, minimum protection
class as per IEC 529 shall be as follows:
Electrical / Electronic instruments : IP 67 Sensors; RTD, T/C, etc. : IP 65
Solenoid valves : IP 67 etc.

3.62 The design of electronic instruments should be in compliance with the

European Community (EC) harmonized codes and standards, which includes
Radio Frequency Immunity (RFI) and EC 61000 electromagnetic Compatibility .

3.63 The quality of the instrument air and the air supply pressure range for
transmission devices shall be in accordance with IEC 60654.

3.64 Instrument air shall be used for the pneumatic operated actuators (e.g. control,
on/off valves).

3.65 All central cabinet room located instrument systems including DCS/ESD
systems, stations, printers, etc., Fire and Gas detector monitoring systems,
CCTV System and cameras, Bently Nevada Vibration Monitoring system and
MMS, Local Control Panels, Pilot Ignition and Panels, Flare Local Panels,
Woodward Digital governor system, PA System, Analyzers, critical instrument,
mass flowmeters, Tank gauging systems, nuclear level instruments,critical
loads etc. shall be feeded 220 V AC UPS Power only.The instrument earthing
system consists of one or more earthing electrodes close to the control building
at a safe distance from any plant-earthing electrode. The resistance to earth is
to be less than 1 ohms. To achieve this an array of parallel electrodes
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may be used. The instrument earthing shall terminate in a copper bus, mounted
centrally to all instrument equipment, but electrically isolated from any other
equipment or structure. The cable connections shall be easily accessible for
testing facilities. All connections between the copper bus bars and to the central
earth bar shall be individually connected via a separate, insulated, stranded
wire conductor of at least 6 mm². To avoid undesired ground loops due to
differences in earth potential or influence of surface currents, the shield of
signal wires shall be connected to the instrument earth system only at one side
(in the control room/satellite building). The shielding shall be kept isolated from
cable armoring and instrument enclosures.

3.66 Speed Monitoring Systems:

The model / type of probe/sensors and all primary devices, which are to be
installed in the field shall be suitable for plant hazardous area classifications
and suitable to the application.

The over-speed trip mechanism/interlock for all the machines shall be equipped
R2 with Woodward make Protech Trip systems only. The secondary hardware of
these system shall be installed in cabinet rooms in a standard RITTAL panel of
1200mm (W) x800mm (D) x 2100mm (H) or 600mm (W)x 800mm(D) x
2100mm(H) with RAL7035 color shed. CONTRACTOR to supply suitable
armoured, pair/overall shielded, cooper conductor PVC cables between field
sensors and control room.
The system shall provide additional 4-20 ma isolated dc output to be connected
with central DCS for real time trend/historical analysis of various measured
parameters. Also system shall provide dry contacts for additional trips/alarms to
connecting these to central DCS/ESD system.

Apart from these hardwired input/outputs from speed system, it shall be

R2 equipped with communication ports, MODBUS protocol to communicate
(redundant)all the real time data to central DCS.

Programming PC for the system shall be accommodated in the central

engineering room in the close vicinity of central cabinet room. PC shall be with
21” TFT/LCD monitor.

3.67 Digital governing system for Turbo Machinery:

Digital governing system for turbo/machineries shall be Woodward make, digital
governor only. The secondary hardware of these systems shall be installed in
R2 cabinet rooms in standard RITTAL make, 1200mm (W) x800mm (D) x 2100mm
(H) or 600mm (W)x 800mm(D) x 2100mm(H) panels with RAL7035 color shed.
CONTRACTOR to supply suitable cables between field sensors and control
room. The power supply to the secondary unit installed in central cabinet room
shall be 220 V AC only. This shall be fed from PDB located at central cabinet room.
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All field sensors, input/output cables shall be laid between final control element
in the field and secondary electronic unit panel at cabinet rooms
WOODWARD digital governor shall provide necessary speed, controller
inputs/outputs (isolated 4-20 ma dc) and trip/alarms’ signals (Isolated DI & Dry
DO contacts) in hardwired form for connecting it with central ESD/DCS.

Apart from these hardwire signal exchange between Woodward digital governor
R2 and central DCS / ESD; Woodward governor have a communication
(redundant) link with MODBUS protocol for information exchange to central
DCS.

CONTRACTOR to supply suitable armoured, pair/overall shielded, cooper

conductor PVC cables between field sensors and control room.

3.68 Anti-surge control system for turbo/machineries

Anti-surge control system for turbo/machineries shall be CCC make only. The
antisurge control shall be achieved using CCC Series 5 VANGUARD redundant
R2
controllers with process control handled via the plant DCS. CPU, Power
Supply, I/O boards, communications etc shall be redundant.

An adequate degree of de-coupling between the antisurge and performance

controllers shall be ensured, primarily by controller response time differences.
Anti surge control system to be integrated with speed control system.

The secondary hardware of these systems shall be installed in cabinet rooms in

standard RITTAL make, 1200mm (W) x800mm (D) x 2100mm (H) or 600mm
R2
(W)x 800mm(D) x 2100mm(H) panels with RAL7035 color shed.
CONTRACTOR to supply suitable cables between field sensors and control
room.

The power supply to the secondary unit installed in central cabinet room shall
be from UPS 220 V AC only. This shall be fed from PDB located at cabinet
rooms. All field sensors, input/output cables shall be laid between final control
element in the field and secondary electronic unit panel at cabinet rooms.
Anti-surge control system shall provide necessary process parameters
indication, controller inputs/outputs (isolated 4-20 ma dc) and trip/alarms’
signals (Isolated DI & Dry DO contacts) in hardwired form for connecting it with
ESD/DCS.
Apart from these hardwire signal exchange between anti-surge control system
for turbo machinery and DCS / ESD; Anti-surge control system shall have a
facility for 2 wire RS485 communication (redundant) link with MODBUS
protocol for information exchange to central DCS.

CONTRACTOR to supply suitable armoured, pair/overall shielded, cooper

conductor PVC cables between field sensors and control room.
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3.69 Broad Specifications for various Field Junction boxes:

The following basic design criteria is to be followed for all type of junction
boxes, through out the specifications, including those being supplied by
package unit vendors. Irrespective of plant’s hazardous classification, the
supplied junction boxes shall be
EEx-ia- IIC/T6. All the field junction box shall be made of die-cast aluminium
with min. 7mm thickness. For intrinsically safe instrumentation junction boxes
with safety increase protection Eex-e, die cast aluminium painted blue, with
R2 terminal blocks blue shall be considered. For solenoid valves, junction boxes
Eex-d, die cast aluminium, painted gray, shall be considered. Electrical
connection NPT shall be specified. For the systems where it is used fire
resistant cables, shall have fire resistant junction boxes with fire resistant
terminal strips.There shall be diff. junction box for diff. type of I/O signals as well
as dif. destination like DCS and ESD systems. As a minimum the following
segregation shall be maintained:

- Signal Category wise segregation

- Analog Input and Analog output
- 24 V DC Digital Input / NAMUR sensors
- 24 V DC Digital Output used for lamps, etc.
- Digital output signals for SOLENOID valves
- AC power cables for field instrument power
- RTD signals
- T/C signals

Only for motorized valves, DI/DO segregation is not required.

Junction Boxes shall be named as it is indicated bellow:

R2 XXX-JY(I)JB-YZZZ-SYSTEM

XXX = Unit number: 3 digits

J”Y”JB = Identification Letters:
o JAJB- For Digital Input Signals
o JAOJB- For Digital Out Signals
o JAMOVJB- For Motorized Signals
o JSJB- For Analogue Signals
o JPJB- For Solenoid Valves
o JRJB- For RTD Signals
o JVJB- For Vibration Signals
o JFJB- For Sounders & Beacons Signals
o JCJB- For Comunications Signals
o J”Y”IJB- For Intrinsically Safety
Y = Sub-Unit number: 1 digit
o ZZZ = Sequence Number: 3 digits (001 to 999) Vendor Package Junction Boxes:
ZZZ = Sequence Number: 3 digits (501 to 999)
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o TR Junction Boxes: ZZZ = Sequence Number: 3 digits (001 to 500)

SYSTEM = System where the Junction Box is wired to:
o DCS (Distributed Control System)
o ESD (Emergency Shut Down System)
o FGS (Fire & Gas System)
o MMS (Machine Monitoring System)
o PLC (Dedicated Programme Logic Controller)
o XXX-YYY (XXX. Cabinet . YYY: system. P.e IRC-DCS. This will be used for
interconnecting signals.

Example: 147-JAIJB-0015-DCS

The naming philosophy for junction box shall be adopted in such a way that
from the tag number of the particular junction box, it shall be evident to decide
type of signal and destination
All junction box shall be die-cast aluminium and it shall be epoxy painted
according to the type of hazardous area protectıon type (example; blue for IS
signals). Based on requirement, there shall be diff. insulated shield and earth
bus bars are to be provided in the junction box. The individual branch cable
shall be brought to central cabinet room panel instrument shield bus bar via
insulated shield bus bars and multi pair shields from junction boxes.
All junction boxes shall have branch from side entries and multi pair cable
entries from bottom only.
R2 All junction boxes shall be weather proof to IP65 as a minimum. Generally 12
branch entries and 1 no. of main multi pair cable entry type junction boxes shall
be used in the total project.
The color code shall be based on type of signals. The qty. shall be as required.
Each junction box shall have engraved/embossed SS tag plate with tag
number. This tag plate shall be screwed on the junction box.

3.70 Instruments shall be mounted on a vibration free place. Special care shall be
taken for heat expansion.

3.71 All pressure instruments, except for those fitted with diaphragm seals, shall
have a block valve and a drain/vent facility, to provide the capability of
depressurizing the impulse line.

3.72 Differential pressure instruments shall be located above the taps for gas and
non-condensable fluids, and below the taps for liquids and condensable liquids.
For steam service, pressure instruments shall be mounted with a steam siphon
or condence pot.

3.73 When instrument supports have to be fixed to fireproofed plant structures, these
supports shall be welded to the steel structure before the fireproofing is applied.

3.74 Instrument process impulse lines shall generally be ½” OD. seamless,

annealed, stainless steel Grade AISI-316, wall thickness of 0.035”. Care
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shall be taken that selected fittings are compatible with the tubing size and its
specifications.

3.75 Where the above tubing and fittings are not suitable for the process fluid or the
process conditions and/or specific project requirements, other materials
conforming to the piping specification shall be used.
Tubing shall be supported and protected from vibration and physical damage.

3.76 No mechanical stress shall be induced upon an instrument that will cause a
malfunction or error in the readout. Tubing shall not be secured directly to
machinery or pipes. Tubing clamps and miscellaneous hardware shall be 316
stainless steel.
3.77 Individual instrument air supply and pneumatic transmission lines to and from
instruments shall be SS 316 tubing. Tubing shall be 6 mm x 1 mm wall thickness
soft annealed, seamless. High-volume pneumatic actuators may require 12 mm
R2 OD x 1 mm tubing. Fittings shall be SS double compression, Swagelok or Parker
only. Care shall be taken that selected fittings are compatible with the tubing
size and its specifications. Individual tube runs shall be supported by existing
structures and steelwork.

3.78 Nameplates of a permanent type, firmly fastened, showing tag number (and
service) shall be used.

3.79 Local indicating instruments shall be readable from where the related
equipments are operated or from where the primary instruments are to be tested
or calibrated.

3.80 Wherever possible, the centerline of instruments shall be 4'-6" above grade or
platform, with the exception of d/p flow transmitters which shall (in most cases)
be line mounted, close to the flow element. The closed coupled mounted
instruments shall be installed on the process pipe through a pipe strap
installation only when it is required as mandatory by the licensor. (TRM-TQ-INS-
0101 Rev01)
3.81 All instrument supports, cable ladders/trays, conduits and other iron supporting
materials shall be hot dip galvanized.

3.82 Stepless Capacity Control System Description:

Contractor shall supply clearance pockets and/or suction valve unloaders to
unload each compression stage in nominal steps of design capacity. Capacity
controls are to be pneumatically actuated and shall be operable from the local
compressor control panel and from the control house. Selector switches
between the two control modes (local and remote) shall be provided on the
local control panel.

3.83 SmartPlant Instrumentation

All instrumentation Project documents, datasheets, calculation sheets, and
drawings etc. shall be prepared by using INTOOLS software tools with latest software.
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Smartplant Instrumentation tools of Intergraph company shall be used. SPI is a

set of tools for the Instrumentation Engineer. SPI has been used in Tüpraş Izmit
Refinery with one server+ 5 clients license. Tüpraş has the right to use this
software for an unlimited time. Tüpraş has the maintenance aggrement with
Intergraph company and also maintenance fee includes new versions, hot fixes,
service packs, hotline and knowledgebase.

SmartPlant Instrumentation is a software suite for the engineering, design,

and maintenance of instrumentation systems for the process plant lifecycle. The
SmartPlant Instrumentation design and engineering software suite includes
integrated modules for instrument indexing, specifications, process data,
calculation, wiring, loop drawings, and hook-ups. The software has a
straightforward, easy-to-use interface that reduces the need for training and
increases productivity, and features design and data consistency checks that
reduce errors and improve data accuracy. Using either Oracle or Microsoft SQL
Server database, the software features data links to external systems, including
the Intergraph SmartPlant Solutions, vendor calculation packages, and
distributed control systems (DCS). The following modules shall be included:
System Administration; Instrument Index; Instrument Specifications; Process
Data; Flow Element Calculations; Control Valve Calculations; Relief Valve
Calculations; Wiring; Instrument Drawing (Loops); Hook-Ups, Cable Routing; &
Cable Drum. Cable Routing allows users to create modular cable routing
sections. Cable Drum allows users to efficiently utilize cable drums and setup
an organized method of cable drum assignment.

Authorized persons (instrument engineers- minimum five engineers ) of Tüpraş

to check and follow as on line of the Intools applications of Contractor shall be
allowed for the monitoring purposes only not for modification during the detailed
engineering stage. Application INTOOLS database of Contractor for the RUP
Project shall be loaded to Tüpraş FTP server from internet and refreshed each
week on Monday morning to follow the database of Project with Tüpraş
Instrument engineers during detail engineering stage. Final (as built) application
of INTOOLS database shall also be handed over to Tüpraş and loaded Tüpraş
FTP server.

The INtools database will include all the Input / Output signals with a physical
connection with systems (AIs from transmitters, contacts from switches, AOs to
valves, alarms to local panels etc.) and all the local instruments (thermometers,
pressure gauges…).
INtools shall also include all instruments that are part of package Vendors
scope of supply.
INtools shall also include all new instruments specification sheets that will be
completed after purchase order.
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The INtools modules and database will include, as a minimum, the following
information:
. Instrument List and index modules
. Instrument Specifications modules
. Process data modules-process sheets
. Database
. Inst. Type
. Administration modules
. Process Function
. Gen. Pr. Function Subcategory
. Spec. Sheet Form No
. Wiring and connection modules-panels, cables, connections, automatic
cross wiring, auto-wiring, intrinsic safe calculations, cable routing etc.
. Panel
. Cable
. Connection type
. Control system
. Hook-ups- AutomaticHOOKUP generation
. Panel Layouts
. Locations
. System I/O Type
. Skip loop creation
· Loops modules- Automatic LOOP generation(multiple sheets supported),
Enhancedsmart loop, Customizedsymbols, Revisioncontrol and instrument
tag number (field tag and system tag),
· Reference P&Id number,
· Line number or equipment number,
· Measuring range and engineering unit,
· Service description,
. Junction Boxes
. Marshalling racks
. Installation details modules
. Cabinets
. DCS&SIS
. DCS&SIS interfaces
. Control valve
. Calculations modules-flowmeter, valve, orifice, control valves, flow
elements, thermowell (vibration) etc.
. Procurement modules-order lists,reports,manufacture product
. DCS&ESD loop drawings
· Wiring information (RIE no., cabinet no, terminal strip reference no, etc.).

All alarm settings will be documented in a separate Database (ACM).

More details about the information to be considered in the database will be
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discussed in the Project Execution Proposal.

The tag naming convention to be adopted shall reflect the requirements

indicated in the refinery standards and will be fully discussed with the refinery
personnel.

Specific procedures shall be issued covering the split of responsibilities for the
database maintenance and updating during the various phases of the project
All necessary Hookup drawings must be generated from smart plant
instrumentation in ESL format.

3.84 The instrumentation loads such as DCS/ESD Systems (CPU and I/O cards,
cabinets, operator consoles and stations, engineering consoles/PC’s,
printers/hard copies etc.), CCTV system and cameras, Bently Nevada
Monitoring Systems, local control panels, pilot ignition and flame panels, flare
local panels, Fire & Gas Detection Panels, analyzers, special instruments
nuclear level instruments, positive displacement meter, capacitance level
instruments, ultrasonic level transmitter, tank gauging system, selling system
critical loads etc. will be feeded from UPS.

3.85 Limit switches / Position Switches:

- All type of limit switches shall be 2 wire, proximity type, and NAMUR
sensors only.
- The make shall be P+F only. The sensor shall be generally cylindrical
NAMUR sensor type proximity switch. The diameter and sensing range
shall be selected based on application.
- The material of the sensor shall be SS316. Krastin type probes shall not be
used, unless surrounding atmosphere heat permits the use of the same
under worst condition.
- All limit switches sensor shall be adjustable with the threaded length and
check nut arrangement.
- Flying lead type loose connections for NAMUR sensors are not acceptable.
All these NAMUR sensors installed on any instruments to sense the
position shall be housed in a closed box certified for weatherproof to IP67.
The gland size shall be ½” NPT(F).
- All ON-OFF type application valves taking in part in interlock/shutdown
shall be provided with Open and Close type NAMUR sensor as limit
switches. The sensors along with enclosure shall be installed in control
valve in such a way that it can be removed with ease for maintenance.
R2
- Limit switches shall not be used for Control Valves unless it is indicated in
pids. All controls valves shall be equipped with SMART positioner, from
where the analog output for continuous position is available, which shall be
used for interlock/control purpose.
- Limit switches shall be certified as intrinsically safe to Eexia-IIC-T6.
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 28 / 379
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3.86 For process Hook-ups, tubing compression fitting and manifolds shall be used
up to class 600. For class 900 and above and Hydrogen service shall be used
pipe and individual valves. Installation shall also be done as close couple when
R2
licensors required as mandatory (FW and UOP). For the rest of the units API
551 standard can be applied. Contractor must follow and apply the
requirements and comments of Tüpraş for the process Hook-ups without
charging any change order.

3.87 Intrinsically safe wiring shall terminate directly on barriers for incoming and
outgoing to field for DCS and SIS I/O signals-all. Barriers shall be ATEX
certified.

3.88 Vendors for the electronic transmitters (flow, temperature, pressure, diff.
pressure and diff. pressure for level ) shall be EMERSON, YOKOGAWA or
HONEYWELL.If the vendor is EMERSON, 3051S and 3144P series
transmitters of EMERSON must be selected and installed. If the vendor are
YOKOGAWA or HONEYWELL , the equal series and models transmitters which
have the same and or equal characteristics, features, standards, hardware and
software properties, functional and performance specifications etc. of the these
vendors must be selected and installed with the approval of Tüpraş.If the
transmitters properties of YOKOGAWA or HONEYWELL does not have same
or more proper and advanced specifications , 3051S and 3144P series
transmitters of EMERSON must be selected
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 29 / 379
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(II) UNITS OF MEASUREMENT AND SCALES

1.0 UNITS OF MEASUREMENT

Units of measurement shall conform to the following:

Temperature(1) : Degrees C
Pressure (near atmospheric) : MM H2O
Pressure (above atmos) : KG/CM2 gage or absolute
Vacuum : MM H2O
Level (2) : % of range for process.
Flowrate-Liquids :( 1 M3/H) : M3/H at 15C Refer to 5.332 & 5.333 utilty and
process metering (TRM-TQ-INS-0020)
- Gas and vapors : NM3/H
- Steam : KG/H
Mass Flow : KG/H

R2 For SRU (Liquid), units flow shall be given in Am3/d.

Analysers : Viscosity = cP or cST according to process specs

Conductivity = µ s/m ,
Density = Kg/m³
Direct reading as PH, % Oxygen, boiling point
temperature, etc.
Velocity = m/s
(1) Display shall be linear with temperature. Where required, linearization shall be
provided by using a suitable microprocessor based transmitter, by range or
sensor selection, or by addition of a linearizing device or function.

(2) Level will be displayed in mm of actual height for storage tanks.

2.0 CONVENTIONAL INSTRUMENT SYSTEMS

2.1 Scales

Scales shall be direct reading for all variables except level, which will be
displayed as "0-100%”. The square root implementation shall be made on the
differential pressure flow transmitters and the 4-20mA output of the transmitters
will be linear to the DCS or ESD systems.
2.2 Charts

R2 In general, chart ranges shall be 0-100 uniform for all variables. Flow
transmitters shall include the square root.
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 30 / 379
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3.0 DIGITAL CONTROL SYSTEMS

Flow signals shall be linearized prior to display.

3.1 Scales

Scales shall be direct reading for all variables except level, which shall be
displayed as 0-100%. Units shall be as above.

3.2 Charts for Recorders. (Dedicated or multipoint)

Charts shall be direct reading for all variables except level, which shall be 0-
100%

3.3 Others to be specified by OWNER.

3.4 All recorders shall be supplied with one year of charts and ink sets. Chart types
and ranges shall be standardized as much as possible.
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 31 / 379
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(III) INSTRUMENT CONNECTIONS ON VESSELS AND PIPING

PIPING LINE STANDPIPE EQUIPMENT

INSTRUMENT
SIZE RATING SIZE RATING SIZE RATING

1½”RF --- As piping

2”RF Spec (1)
2”RF Note 5 ---
Thermowell
3”RF

Diff. Press.
Level: 1”SW As Piping spec.(1) 1”SW As Piping spec.(1) 1”SW As Piping
- General spec.(1)
2”(3)RF MNFR.STD 2”(3)RF
- Remote Seal MNFR.
STD
Displacer/Radar
Level:
- Ext. Cage --- --- 2”RF 2”RF 300# as a
- Internal --- --- 300# as a 4”RF minimum
R2 minimum and and
Level Switch:
according to according
- Ext. Cage --- --- 1”RF 1”RF
piping to piping
- Internal Float --- --- --- 4”RF
specification specificati
Level on
Gauge/Magnetic: 1”RF 1”RF

Pressure
Instrument:
- General 1” SW As Piping spec. 1” SW As Piping spec. 1” SW As Piping
- Remote Seal 2”(3)RF As Piping spec. (1) 2”(3)RF As Piping spec.(1) 2”(3)RF spec.
- Draught --- --- --- ¾”SCRW As Piping
Gauge spec.(1)
Flow element
(tapping):
- Below 900# ½”(2) As Piping spec.(1) --- --- --- ---
- 900# and ¾”(2) As Piping spec.
above

Note 1: 300# as a minimum

Note 2: Screwed, with seal wedding
Note 3: Only for low range pressl. (Vacuum 0,5 kg/cm2g) shall be 3”RF
Note 4: Face (RTJ, RF)
Note 5: Size to be defined according to piping corrosion allowance.
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 32 / 379
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(IV) FLOWMETERS

1.0 REFERENCES (Latest Edition)

1.1 API RP 551, 552, 553, 554

1.2 LICENSOR STANDARD DRAWINGS
1.3 LICENSOR STANDARD SPECIFICATIONS
1.4 ISO - 5167
1.5 BS-1042
1.6 ANSI B16-136

2.0 MEASURING ELEMENTS

Orifice plate shall be the standard flow measurement device except for following
conditions:

- where required accuracy is not obtained

- where flow rate varies in wide range
- where allowable pressure drop is limited
- where other type of more accurate devices are required. For instance mass flow
meters for custody transfers, etc.

2.1 Flow of fluids shall normally be measured by sharp-edge concentric plates with
differential pressure actuated meters. Quarter circle-edge concentric orifice
plates with differential pressure actuated meters will normally be used for
viscous fluids having a Reynolds number below 20,000.

2.2 Where there is a possibility of an accumulation of sludge at the orifice plate,

eccentric or segmental type plates shall be provided.

2.3 Eccentric type orifice plates shall be used for fluids containing two phases. The
eccentric orifice plates shall have the bottom of the orifice bore flush with the
bottom I.D. of the pipe. Eccentric orifice plates shall be used in horizontal runs
only.

2.4 Flow elements such as flow nozzle, venturi, rectractable multihole averaging
pitot tube (annubar type) will be used where high capacity and good pressure
recovery is required.

R2 2.5 All “V-cone” or balanced type flowmeter transmitters shall be multivariable and
flanged capillary type.

2.5 Multihole averaging pitot tube(Annubar type) shall be used for larger pipe sizes
and clean fluids. It shall be multiple averaging type, retractable type allowing it
to be removed for maintenance during operation and purging accessories are to
be taken into consideration during selection.
 Section : TGPS –J1
Date : August, 2010
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İzmit Refinery Page No : 33 / 379
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2.6 Flow measurement shall generally be made using differential pressure type
primary sensors of advanced capacitance type with digital information
processing unless otherwise specified by OWNER.

Other methods of measurements will be selected depending upon the fluid

characteristics, rangeability required, general suitability and greater accuracy
requirement which cannot be obtainable with orifice metering. These include
integral orifice meters, rotameters, target meters, turbine meters, positive
displacement meters, vortex flowmeters, mass flowmeters.

2.7 Rotameters of the metal tube type will be used where applicable in process
service. Where streams cannot be easily interrupted in line, in toxic services
R2 and critical lines, block valves and by passes shall be provided under client
approval.
For venturi meter, V-cone meter, orifice plate, annubars and ultrasonic meter
independently of the size bypass and block valves shall not be considered.

2.8 Orifice plate dimensions shall be in accordance with Licensor standards (latest
edition) and for non licensor units primary elements shall be calculated,
R2 manufactured and installed in accordance with ISO 5167. For quarter circle
and conical entrance BS-1042 shall be used.
Orifice plate material is stainless steel 316 SS minimum (higher grade material
as per Piping Spec.).

The minimum thickness for orifice plate based on shall be in accordance with
ISO-5167 shall be:

PIPE SIZE THICHNESS

1"‐ 6" 1/8" (3 mm)
8"‐16" 1/4" (6 mm)
18"‐24" 3/8" (9,5 mm)

The Thickness shown is for service under 650 oF (343 oC). For services above
this temperature the thickness shall be increase 1/8” (3 mm)
2.9 The minimum orifice run shall be 2 inch diameter. If the process lines are
smaller than 2 inch, the line size shall be increased to 2 inch for the meter run,
provided that the requirements of flow can be met. If a line size smaller than 2
R2 inch and it is not possible to increase the line to 2 inch diameter, it must be
used an integral orifice meter (½ and ¾ inch) or precalibrated orifice meter run
(1 and 1 ½ inch) with corner taps shall be used. In conjuction with integral
orifice meter, a suitable strainer and flow conditioner shall be installed
preceding the meter. If service is continuous block and by-pass valves shall be
considered for integral orifice and meter run up to1 ½ inch.
 Section : TGPS –J1
Date : August, 2010
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İzmit Refinery Page No : 34 / 379
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2.10 Drain and wheep holes shall be provided for orifice plates which have a bore 1
inch and larger. Drain or weep holes shall be included in the orifice bore
calculations.

2.11 Flowrate measurements of process charge, product and utility streams involved
in material, utilities balance, boiler efficiency and process calculations requiring
compensated flowrate computations(i.e. corrected with actual temperature,
pressure and specific gravity) and totalization shall be performed by corriolis
type mass flowmeters as far as mass flowmeters sizes and measuring
capacities are applicable.

For periodic calibration requirements of mass flow meters a computerised

prover considering calibration of all sizes of mass flow meters will be provided
R2 and installed. This will be applied for flow measurement in process when fiscal
metering for selling to a third party is involven.

For pipe sizes bellow 18” orifice plate with tap flanges shall be used. For sizes
18” and larger radius tap shall be used, and taps shall be located one pipe
diameter upstream and one half pipe downstream.

2.12 Venturi Meters and Flow Nozzles:

Venturi meter & flow nozzles may be considered for gas/air flow measurement
in large size pipes / ducts, where high accuracy is required with less permanent
pressure loss For high velocity steam or similar fluid, flow nozzles may be used
in place of orifice plates to avoid problems due to erosion.
Irrespective of pressure, the minimum flange rating shall be ANSI 300#.

R2 2.13 Averaging Pitot Tubes:

Averaging pilot tubes shall be considered for low pressure loss, high velocity,
large diameter lines and air ducts. This shall be installed on 1 ½” size nozzle for
small lines and 3” for large lines or lines with large velocity. Small lines are lines
up to 12”, large lines are lines above bigger and equal to 12”, vendor
recommendation shall be used. The averaging pitot tube shall be of SS316
MOC as a minimum. It shall be retractable with ball valve arrangement and
shall be provided with end supports. Irrespective of pressure, the minimum
flange rating shall be ANSI 300#. Vendor recommendation for isolation valve
type shall be followed with client approval. All wetted parts (pitot utbe, flanges,
isolation valves shall be 316 SS as minimum, higher material as per piping
specification.
Mounting flanged and accesories for the installation to the pipe shall be
supplied by vendor.

2.14 Variable Area Flow meters:

 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 35 / 379
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Variable Area Flow meters or Rota meters shall be as per ISA-RP 16.1. 16.2,
16.3 16.5 and 16.6 and shall be used for viscous or corrosive services or where
rangeability of required flow precludes the use of an orifice.

Metal tube rota meters shall be used for all fluids. The devices for indicating or
transmitting shall be magnetically coupled with float or extension. Magnetic
coupling shall be glandless type.

The tube and flange be SS316 as a minimum. Flange connections shall be as

per piping specifications. Irrespective of pressure, the minimum flange rating
shall be ANSI 300#.

Rota transmitter shall be 24 V DC, 2 wire, 4-20 ma, SMART with local display
type. Irrespective of plant’s hazardous area classifications, all the Rota
transmitter shall be EExiaIIC/T6 as per CENELEC and Weather proof to IP67.

R2 Glass tube rotameters shall not be used except in analysers or where it is

indicated in the P&ID.

Linearity should be better than 5% for indication-only rotameters and better

then 1% for rotameter transmitter. Accuracy shall be 2% (or better) of full scale
for general and metal tube rotameters.

Variable Area Flow meters (purge rotameters) fitted with a constant flow
regulators shall only be used for fixed rate flows such as flushing or purging.

2.15 Coriolis Mass Flow Meters:

Where high accuracy is required like for input/output fluids in the plant, where
mass balance is important, where custody transfer is involved, or where liquid
physical property is varying, the Coriolis principle based mass flow meters shall
be used.

Coriolis mass flow meter shall be used for high-rangeabilty, high-accuracy

application requiring mass flow measurement or where plant’s input/output fluid
quantity is used for mass balance or custody transfer purpose. No other type of
flow meters like Thermal mass flow, etc. shall be used in the complete plant.
The Coriolis mass flow meters shall be used at all those locations, where liquid
physical property will vary.

The Coriolis mass flow meters shall be used for all density measurement, fuel
oil consumption of heaters and boilers, unit feed and liquid and gas products.

As a standard, sensor tube material to be SS 316L (a minimum). Better

material shall be provided based on process fluid/service conditions.
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 36 / 379
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Mass flow meters end connections shall be flanged and the minimum flange
rating shall be ANSI 300#.

Mass flow meters shall be 4 wire transmitters and supply shall be 220V AC
only. Mass flow meters shall be supplied with SMART
(Hart) transmitter with 4-20 ma output and pulse output. All mass flow meters
shall be supplied with Local LCD type display. All mounting bracket shall be
SS304.

All mass flow meters shall have accuracy of +/- 0.1% for both analog and pulse
output. It shall be possible to freely configure density or flow output over any of
these two available output options.

Meter and transmitter shall be weather proof to IP66.

R2 DELETED.

Electrical certification for the meters shall be EExib IIB/IIC T1-T6 and for the
transmitters shall be EExde ia/ib IIC T5
While selecting mass flow meters, consideration shall be given to fluid velocity
max. limit ( 2 meter /second for liquids), permanent pressure loss, etc.
Accuracy compliance (+/- 0,1%) will be the criteria to be followed for the
selection, even if velocity is higher than 2meter/sec. When pressure loss is
higher than the process requierement it must be submitted to process
approval.Vendor shall confirm the longest meter life by selecting the design
with the thickness wall and the slowest velocity that can provide the required
accuracy and range.

2.16 Magnetic Flow Meters:

Magnetic type flow meters shall be used for electrically conductive slurry,
cooling water or corrosive services and shall be installed with line size bypass,
with block and cleaning valves, at the lowest point in piping to ensure that
meter run is always liquid filled.

Grounding ring or ground electrode shall be used in all the magnetic flow
meters.

R2 In battery limits block and bypass valves for big lines shall not be considered.

If the electrical conductivity is equal to or more than 20 micro Siemens/cm most

of the conventional magnetic flow meter can be used. Special types, which will
measure the flow of liquids with threshold conductivity of as low as 0.1 micro
siemens/cm may also be used.
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 37 / 379
Revision : 2
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While selecting meter, effect of temperature on conductivity shall be

considered.

Magnetic flow meter shall be used with a full pipe size so that the measurement
is accurate.

Magnetic flow meters shall be installed with required straight lengths.

All magnetic flow meters shall be 4 wire transmitters. The power supply shall be
220 V AC.

All Magnetic flow meters shall be supplied withSMART transmitter with 4-20 ma
output and pulse output with hart communication .All magnetic flow meters shall
be suitable for 2” pipe mounting and shall be supplied with Local LCD type
display.

All magnetic flow meters assembly shall be EExia IIC/T6 as per CENELEC,
irrespective of the plant’s hazardous area classifications.

All the magnetic flow meters assembly shall be weather proof to IP67.
All mounting bracket shall be SS304.

The end connections shall be flanged type and min. pressure rating for flanges
shall be 300#.

2.17 Vortex Flow Meters:

Vortex flow meters shall be considered for following applications:

- Where higher rangeability is required

- Where high accuracy is required
- Where no maintenance spare is expected
- Where process is a clean service
- Where mechanical vibrations are not existent in pipe and sufficient straight
length can be provided.

Size the meter so that its maximum permitted flow rate is as close as possible
application maximum flow rate.

Vortex flow meter shall be used for steam mass balance of units.

Vortex flow meter shall not be used for the following services:

- High viscous and slurry service

 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 38 / 379
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- Liquids having large concentration of solids and two phase flow service.

Vortex flow meters shall be installed with required straight lengths. Vortex flow
meters shall be supplied with (Hart) SMART transmitter with 4-20 ma output
and pulse output. All vortex flow meters shall be be supplied with Local LCD
type display.The end connections shall be flanged type and min. pressure
rating for flanges shall be 300#. All Vortex flow meters assembly shall be EExia
IIC/T6 as per CENELEC, irrespective of the plant’s hazardous area
classifications. All the Vortex flow meters assembly shall be weather proof to
IP66. All mounting bracket shall be SS304.

For gas and steam applications Multivariable flow transmitter with integral
R2
temperature sensor shall be used.
The sensors shall be isolated from the process and can be replaced without
shutting down the process, so bypass and block valves for maintenance are not
required.
Temperature compensation is done by vortex flow meter and pressure
compensation is done by DCS.

2.18 Restriction Orifice:

R2
Restriction orifice plates shall be used where there is a process requirement to
create a pressure drop or limiting the flow rate. Simple or multiple restriction
orifices should be used.

For simple restriction orifice, the orifice diameter shall be calculated in the same
manner as a square-edge concentric orifice plate in accordance with ISO 5167,
considering relationship between differential pressure an permanent pressure
loss.

Multiple restriction orifices consist on two or more steps of pressure loss joined
one common mechanical device. These devices shall be used the following
applications:

-Gas and vapours services with ∆P= ½ P upstream

-Liquid service with ∆P= Pupstream – Pv

The thickness for restriction orifice shall be in accordance with “Flow

Measurement Engineering Handbook”- R.W. Miller (2nd Edition).
Flanges for simple restricition orifices are under Piping Department scope of
supply.

For multiple restricition orificies flanges must be welded. The rating must follow
piping specification.
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 39 / 379
Revision : 2
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R2 2.19 Ultrasonic Flowmeters

Ultrasonic flowmeters may be used for all liquid and gas applications where
there is a requieremente for the meter to present a minimum obstruction to the
flow an a magnetic flow meter is unsuitable.

3.0 SIZING AND LOCATION

3.1 The ratio of orifice bore to inside pipe diameter (d/D) shall be between the limits
0.20 to 0.70. If d/D ratio exceeds 0.70 for 5000 mm WC differential range, the
process line shall be increased for the meter run.

3.2 Differential range of orifice meters shall be selected 2500 mm WC for purpose
of standardization. In addition 1250 and 5000 mm WC can be used to obtain
the ratio d/D within the limits of 0.2 to 0.7.

3.3 Normal flowrate shall be approximately 70% of maximum flow meter capacity,
provided anticipated minimum and maximum flow rates will be between 30%
and 95% of capacity.

3.4 Minimum straight pipe requirements upstream and downstream of metering

element shall be in accordance with Licensor Standards . Requirements are
based on a  ratio of 0.70 to permit future enlargement of the orifice without
also requiring alterations to the piping.

3.5 Where two or more disturbances exist, the distance between any disturbance
and primary element shall not be less than the limits given on Licensor
Standards. Therefore, it is required to consider also those disturbances more
upstream, and not only the one closest to the orifice.

3.6 Installing thermowells, instrument connections, etc., preferably be downstream

of the orifice. On upstream side thermowells shall precede the orifice by at least
20 pipe diameters.

3.7 Vertical orifice runs are often preferred for gas or steam flows which contain
appreciable amounts of condensates and for liquids which contain vapor. If
vertical runs are used, flow shall be downward for wet gases and steam an
upward for liquids. The potential error in vertical lines can be minimized by
R2
proper manifolding. DELETED.

3.8 DELETED.
R2
3.9 Orifice or venturi flowmeter calculations shall be supplied on OWNER approved
 Section : TGPS –J1
Date : August, 2010
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İzmit Refinery Page No : 40 / 379
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form of CONTRACTOR and computer printout.

3.10 Orifice flanges shall be of weld neck type having flange tappings conforming to

ANSI B16.36. Minimum flange rating shall be ANSI 300.

3.11 Orifice flange taps shall have at least 500 mm. clearance accros them for
reaming purposes.

3.12 For pulsating services the DP measuring instrument shall have an internal
damping adjustment. Individual pulsation dampeners installed in the high or low
impulse piping is not acceptable.

3.13 Orifice taps at angles other than horizontal or vertically upward are not
acceptable.

3.14 For calibration purposes of corriolis mass flowmeters a computerized mass

flowmeter prover, having appropriate technical requirements considering
calibration of all sizes of meters to be purchased, shall be provided and
R2 installed at site by CONTRACTOR. This will be applied for flow measurement in
process when fiscal metering for selling to a third party is involven.

R2 3.15 Eccentric orifices, quadrant/conical edge orifices and segmental orifices should
be used in horizontal runs.

4.0 INSPECTION AND TEST

4.1 All flow elements shall be checked concerning dimensions, marking and name
plate according to the individual specification. Hardness test as per NACE MR
R2
0103 shall be provided where required in individual specification. The following
certificates shall be produced.

- Chemical analysis and mechanical properties of construction material.

- Hardness test of materials, if requested in individual specification.
- Shop internal test.

5.0 INSTRUMENT NAMEPLATE IDENTIFICATION

5.1 Instruments, except for orifice plates shall have the following information on a
nameplate permanently fastened to the instrument.
5.1.1 Instrument identification number.
5.1.2 Pressure rating of pressure holding parts.
5.1.3 Manufacturer's name, model, serial number, operating range and
materials of parts exposed to process fluid.
As applicable, nameplates shall also carry information relating to voltage and
frequency.
 Section : TGPS –J1
Date : August, 2010
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İzmit Refinery Page No : 41 / 379
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5.2 Orifice plates shall have, in addition to the requirement of API RP 551 process
measurement instrumentation, API RP 554 process instrument and control. The
equipment identification number and material stamped on the upstream side of
the plate.

(V) PRESSURE MEASUREMENT

1.0 REFERENCES

1.1 LICENSOR STANDARD DRAWINGS

1.2 LICENSOR STANDARD SPECIFICATIONS
1.3 API RP 551, 552, 553, 554

2.0 GENERAL

2.1 The range of pressure instruments shall be selected so that the normal pressure
will be in the middle third of the span.

2.2 Pressure instruments shall have over-range protection to the 1.3 times the
maximum range of the instrument.

Instruments which can be exposed to vacuum shall have under-range

protection to full vacuum.

2.3 Pressure ranges shall be standardized so that only one reasonable number of
different ranges need to be supplied to cover all probable refinery service.

2.4 For electronic transmitter type refer to "ELECTRONIC TRANSMITTER"

section.(Section VIII).

2.5 All pressure measuring elements on reciprocating, proportioning pump and

reciprocating compressor discharge and suction lines shall be equipped with
pulsation dampeners. They shall be externally adjustable type.

2.6 Local pressure measurement shall normally be by bourdon tube or spring

bellows, except for draft and building pressurization measurement.

2.7 Wherever used, bourdon tubes and bellows shall be AISI type 316 as a
minimum unless special conditions require otherwise. An exception may be
made in case of small size instrument air gauges.

2.8 Pressure instruments on steam and other hot condensable services shall be
fitted with syphons as necessary.

2.9 Pressure instruments shall be sealed or fitted with chemical protectors where
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 42 / 379
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necessary.

2.10 Process connection of pressure instruments (including pressure gauges) shall

have block and drain/vent valves as minimum located near instruments.

3.0 INDICATING PRESSURE GAUGES

3.1 Pressure gage measuring element shall generally be bourdon tube type. For
measurement of viscous, corrosive fluids and slurries, diaphragm seals shall be
used.

3.2 Direct indicating process pressure gauges shall be bourdon tube actuated with
160 mm diameter dials, bezel with a back flange and white with black figures.
On local panels 100 mm dial size gauges may be used. Pressure gauges shall
conform to OCMA specification 1N-1 or OWNER approved equal. All process
pressure gauges will be of “solid front” safety type.

3.3 Bourdon tube material for all pressure gauges shall be type 316 stainless steel
as a minimum unless otherwise required by special process conditions.

3.4 Pressure gauges shall have no suppressed range.

3.5 Gage connections shall have cases with bottom connections ½ " NPT-M ANSI
B 2.1 (except for diaphragm seal where 2” flanged connection shall be used in
general. Irrespective of design pressure, the minimum pressure rating for the
flange shall be ANSI 300#.) and ¼" NPT-M ANSI B 2.1 for pressure receiver
gauges and provided with wrench flats. Connection shall normally be 316SS
unless otherwise the special material is required.

3.6 All process pressure gauges shall be with "solid front" cases and be provided
with blow-out backs or disc inserts for safety.

3.7 Receiver pressure gauges shall have phosphor bronze measuring elements.

3.8 Pressure gauges shall be capable of withstanding intermittent overranging to

1.3 times the maximum scale reading without shifting calibration more than 0.5
% of scale range.

3.9 Gauge accuracy shall be or better than 0.5 % of scale reading.

R2 3.10 DELETED.
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3.11 Excess flow check valve on inlet of any gauge operating above 70 kg/cm²(g)
shall be provided.

3.12 Compound gauge shall be provided with appropriate upper range value at any
ejector inlet or on discharge of any pump taking suction from a vessel operating
under a vacuum.

3.13 Where diaphragm seals are used they shall be of a type which permits
separation of the "bottom bowl" without loss of fill. This permits removal of the
gage/seal assembly from the bottom bowl for the purpose of cleaning,
calibration servicing of the seal, etc. The gauge and seal shall be furnished
(filled and calibrated) as a complete assembly, with the gauge directly mounted
on the seal.

3.14 Pressure indicators shall be provided upstream and downstream of the draft
control dampers.

3.15 A suitable draft gauge system including connections at the inlet of convection
section, in the stack before and after the damper and at above heater floor shall
be provided. If the convection section of the heater has two or more flue gas
outlet connections to the sack the above group of draft connections, except the
ones in the stack, shall be provided for each convection section flue gas outlet.

3.16 Dial cover shall be of shatterproof glass. The dial face shall be marked with
pressure element material. Pointers shall have micrometer adjustment.

3.17 For low pressure and vacuum services pressure gauges with capsule sensing
element to be used.

3.18 All pressure gauges and diff. pressure gauges’ Cases shall normally be of
304SS and weatherproof to IP-65 as per IEC-529 / IS-2147.

3.19 Ranges shall be so specified that the gauge normally operates in the middle
third of the scale.

3.20 Diaphragm seals, filled type shall be furnished where plugging or congealing of
the element may occur. When chemical seals are required, they shall be
R2 provided with fabricated vent and drain arrangement. Diaphragm seal device
shall be furnished completely assembled with the pressure gauge.

3.21 Remote seal Diaphragm type pressure gauges with capillary shall be used
wherever required for access and visibility. Use of Schaffer diaphragm type
gauges will be avoided as far as possible.
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3.22 The diaphragm seal devices shall be stainless steel SS316. The flange and
Diaphragm rings and top housings shall be of SS304, unless a special material
is required.

3.23 Liquid filled gauge shall be used where extreme vibration of the gauge is
expected. Glycerin or other suitable case filling liquid with non coloring property
shall be used.

3.26 Oxygen service pressure/diff. pressure gauges shall be supplied with special
inert fluids and shall be free from grease/oil. These shall be clearly marked with
“For use in Oxygen services”.

3.25 Over range protector and pulsation dampener, whenever used, shall be of SS
316 as a minimum. Pulsation dampener shall be used for all pulsating services.
It shall be floating pin type, externally mounted and externally adjustable.

3.26 Design materials, connections and accessories not specified herein shall be in
accordance with the standards, suitable for the specified service conditions.

4.0 PRESSURE AND DIFF. PRESSURE SWITCHES

4.1 Pressure switches connected to the process shall have stainless steel
measuring elements (helical bourdon or spiral or bellows, etc.) as a minimum,
except where other (higher) alloys are required for the application.

4.2 Pressure switches for pneumatic signals shall have bronze elements
(preferably bellows). Alternatively Buna N diaphragm elements shall be used.

4.3 Instrument process connection shall be ½" NPT-M B 2.1 for direct pressure
switches and ¼" NPT-M ANSI B 2.1 for receiver pressure switches used on air
transmission signals.

4.4 Electrical connection for cable entry shall be ½" NPT-F ANSI B 2.1.

4.5 All Switch function shall be snap acting, Single-pole Double Throw (SPDT),
hermetically sealed and potential-free contacts.

4.6 Electrical execution shall be EEia/IIC/T6.

4.7 All interlocks/logic and alarms shall be realized via 2 wire, 24 V DC,
SMART,HART pressure/diff. pressure transmitters connected to ESD for
pressure, diff. pressure and level application.
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4.8 However, in special case, when required by machine vendors for machine
safety, for few critical applications, use of pressure and diff. pressure switches
shall be allowed.

4.9 The switch mechanism shall be designed to prevent spurious operation by

vibration.

4.10 The primary element shall be designed to withstand an over-range pressure of

25% greater than the full scale.

4.11 Pressure switches shall be provided with a positive means of protection against
process fluids entering the electrical housing in the event of element failure.

4.12 Pressure switches shall be operative in full specified range. The switch
differential shall be selected as per operating conditions; it shall be less than
60% of difference between set value and operating value.

4.13 Diaphragm seal type pressure switches with flanged end connections shall be
specified for applications on plugging / congealing services. In all these case,
R2
the diaphragm flange size shall be min. 2” x 300 # ANSI ratings and Material
shall be SS316 for flange. Better material shall be opted based on process
requirement.

4.14 All diaphragm type pressure / diff. pressure switches with flushing connection.
Diaphragm seal device shall be furnished completely assembled with the
pressure switch.

4.15 Pressure switches shall have repeatability of ± 0.5% of full scale as a minimum.

4.16 The switching set point shall be adjustable over the whole range, with an
internally calibrated scale.

4.17 Switches shall be specified such that the on/off differential does not prevent the
switch resetting inside normal operating pressure ranges.

4.18 Over range protection and pulsation dampener requirements and design shall
be as per as specified above.

4.19 Design materials, connections and accessories not specified herein shall be in
accordance with the vendor's standards, suitable for the specified service
conditions.

5.0 INSPECTION, TESTS AND CERTIFICATES

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5.1 All pressure switches, gauges shall be checked concerning dimensions,

marking and nameplate according to the individual specification, certified
R2 drawings and codes. Hardness test as per NACE MR 0103 shall be provided
where required in individual specification.

5.2 The following certificates shall be provided:

- Chemical analysis and mechanical properties of construction material.

- Hardness test of materials, if requested in individual specification.
- Shop internal test.
- Specified electrical safety certifications issued by CENELEC recognized
institute.

6.0 INSTRUMENT NAMEPLATE IDENTIFICATION

6.1 Instruments shall have the following identifying information on a nameplate

permanently fastened to the instrument.

6.1.1 Equipment identification number.

6.1.2 Pressure rating of pressure holding parts.

6.1.3 Manufacturer's name, model, serial number, operating range, and

materials of parts exposed to process fluid.

(VI) LEVEL MEASUREMENT

1.0 REFERENCES (Latest edition)

1.1 LICENSOR STANDARD DRAWINGS

1.2 LICENSOR STANDARD SPECIFICATIONS
1.3 API RP 551, 552, 553, 554
1.4 IEC 529
1.5 ANSI B16.5

2.0 LEVEL TRANSMITTERS

2.1 Level transmitters and local controllers shall normally be of the external float
displacer type. For level control on hot columns where steam is present, the
vapor space of the displacer chamber shall be gas purged to prevent
condensation and flashing of accumulated water. However they will not be used
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where hydraulic resonance or agitation due to boiling occurs. Level transmitters

shall be of the latest but proven design of the manufacturer.
R2 DELETED.

2.2 GWR (Guided Wave Radar) type will be used for interface level measurement
instead of displacement type for a better accuracy in the measurement unless
Licensor specifies another type. Displacer types may be used unless radar is
R2 not suitable to the process.

2.3 Differential instruments with static or flowing seals shall be used for extra high
pressure or temperature applications or where the service makes their use
particularly appropriate (e.g. interface between liquids. For ranges greater than
48" differential type instruments shall be used, directly piped, with either a
condensing or a filled reference leg.

2.4 External displacer type instruments shall have rotatable heads. External
R2
displacer type instruments with side-side connections shall be normally used for
level measurement upto 1524 mm. The standard ranges of 356, 813, 1219 and
1524 mm. Internal displacer type of level transmitter shall not be used.

2.5 Internal displacers without float cages may be used on open tanks and sumps.
In special services, such as extreme temperatures, high viscosity, with liquids
which could boil in an external cage, or where corrosion or other process
conditions dictate their use, internal displacers may be used in closed process
vessels. The design selected shall permit removal of the instrument without
entering or draining the vessel. Stilling wells shall be provided where required
by liquid turbulence.

2.6 Where necessary, to exclude process fluid from either or both connections or
from the instrument itself, the installation may be purged with gas or liquid
compatible with the process fluid.

2.7 Level transmitters with capillary connected diaphragm seals shall be applied.

2.8 When the above instruments do not satisfy the job requirements and process
conditions dictate, capacitance, ultrasonic, radioactive and other type of level
instruments shall be considered, e.g. de-asphalting solvent extraction interface.
Use of such instruments shall be subject to OWNER's approval.

2.9 Three pyrometer type liquid level indicators (rams horn temperature points)
shall be provided as a secondary indication for high temperature residual oil
services.

R2 2.10 All level transmitters shall be equipped with digital built in output indicator in
addition to the separate local indicator mounted near the final control element if
if they are indicated in pids.
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2.11 Displacement type level instrument minimum connection shall be 2”

irrespective of design pressure of vessel, flanged 300 RF min. level pipe
columns shall be provided with valved vent and drain connections. TRM-TQ-
INS-0045

2.12 Displacer type level transmitter shall be 2-wire, 24 VDC, 4-20 mA output with
LCD type local display.(hart) Irrespective of plant’s hazardous area
classification, the displacer type level transmitter shall be intrinsically safe and
weatherproof to IP67. Transmitters shall have ½” NPT(F) electrical cable entry.

2.13 The standard materials for Displacer and displacer chamber shall be SS316
and Torque tube shall be Inconel, as a minimum. Based on process fluid better
options shall be selected.

2.14 Finned torque tube extensions shall be provided as necessary for temperature
service conditions.

2.15 Differential pressure transmitter shall be used for level measurement above
1500 mm for services requiring purge or where liquid might boil in external
portion.

R2 2.16 Differential pressure transmitters for use on corrosive or fouling service shall
be diaphragm wafer with extended filled capillary type. The length of capillary
shall be 5 mtr. with SS armoured. DELETED.

2.17 The process connection size shall be 2” Flanged for remote seal diaphragm
type Level Transmitters. Irrespective of design pressure, the min. pressure
rating shall be 300# .

2.18 Flush or extended diaphragm type differential pressure transmitter shall be

considered for special applications only. Transmitters for closed vessel shall
have correction for suppression or elevation.

2.19 Diaphragm material shall normally be SS316L or better to suite process

condition. Stainless steel.

2.20 Dip Tube type level transmitters may be used on corrosive, congealing, slurry
services, where suitable diaphragm seal type transmitter is difficult to obtain or
where accuracy is not of prime importance.

R2 2.21 For design temperatures equal or higher than 300°C, toxic products only
magnetic level gauges shall be used. For other cases, licensor design can be
followed.

3.0 LEVEL INDICATORS

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3.1 Gauge glasses shall be provided for all levels requiring automatic or manual
control or monitoring. Gauge glasses shall have at least the pressure and
temperature rating of the equipment to which they are attached.
The Level gauge shall provide visible coverage of complete level transmitter /
controller range and the alarm/ trip level switches

3.2 Armored transparent type gauge glasses with integral illuminators shall be
provided for:

a. Interface between liquids.

b. Distillates heavier than 25° API gravity and oil crudes and residuals.
c. Liquids containing gum, sediment, or other solid material which may coat the
flutes of reflex glasses.
d. Liquids requiring protecting shields, such as steam above 250 psig or caustic
solutions above 15%, hydrofluoric acids, amines.

3.3 Armored type reflex gauge shall generally be used for light clean liquid level
indication.

3.4 The visible portion of gauge glasses shall cover the range end points of the
associated level transmitters or controllers.

3.5 Gauge glasses shall be standardized for individual glass section length and
R2 overall length achieved by multiple sections in a single casing. Overall length
shall not be achieved by screwing together short casings. Gauge glasses shall
be properly supported and valves shall be gate valve. Gauge glass shall
conform to size 7 and 9.

3.6 Protective shields shall be used where process fluid will attack glass.

3.7 Frost shields shall be used for process temperature below 32° F.

R2
3.8 For ranges in excess of 1399 mm (visible length) multiple gauges shall be applied
When two or more level gauge columns are required to cover a longer range,
the visible portion of the gauges shall overlap at least 1 in. No more than four
gauge units shall be used in one column.

3.9 Off-set type gauge valves shall be forged steel with horizontal ball checks.

3.10 Gauge glass lighting shall be provided by the gauge glass manufacturer and be
suitable for the area classification.

3.11 Consideration shall be given to the use of steam jacketed gauge glasses for
viscous stocks and to magnetic type level gauges where stocks are liable to
boil, e.g. propane, propylene etc.
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3.12 Gauge glass connections on all vessels shall be so located and arranged that
the gauge glass piping will be self-draining and cannot form a pocket for
retention of water.

3.13 In case where several connections for level instruments are located on one
vessel, a 3 in pipe column may be installed to reduce the number of
connections on vessel. The standpipe will be separated from the vessel by
block valves. All connections from this standpipe to instruments will be fitted
with block valves.

3.14 For application of gauge glasses to boilers and waste heat steam generators
refer to TGPS-F2 and TGPS-F3.

3.15 Gauge glasses for low pressure vessels containing low temperature non-
flammable, non-toxic fluids, such as water, or phosphate solutions may be
tubular glass type in lengths not exceeding 30" , with specific OWNER
approval.

3.16 Level gauge connections shall be min. 1 inch flanged 300 RF.

3.17 Magnetic type level gauges shall be used for the measurement of all liquids,
including dangerous, toxic or flammable fluids where glass breakage would
R2 cause a hazard. Centre to centre nozzle distances shall be as 300, 500, 800,
1000, 1500, 2000 and 2500mm, except for magnetic level indicator with
transmitter that center to center nozzle shall cover the total leght to be
measured.
Thermal expansion forces should be checked.

Magnetic type level gauges shall consist of a no-magnetic liquid chamber

enclosing a float which is magnetically coupled to a rotary wafer type indicator.

Float material for magnetic level gauge should be 316SS as minimum.

Body material for magnetic level gauge shall be as minimum SS304L, and follow
the associated vessel material specification.

The instrument connection shall be 1” for stand pipe and 1” for direct vessel
connections. Vent and drain connection shall be ¾”RF connection.

Preferred instrument connection type is side to side.

Where NACE is specified the magnetic level gauge shall be in accordance with
NACE MR0103. Hardness test and test certificates shall be provided.
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4.0 LEVEL SWITCHES

Transmitters shall be in general utilized for trip functions. In principle no switches to be

R2 used in process related areas.

4.1 Level switches operating interlocks, shutdown or process alarms which are
related to personnel or equipment safety shall be directly "process actuated",
and shall utilize separate connections to the vessels.

4.2 External cage float switches (with flanged end) of the welded cage type shall be
used where separate switches are required. Materials of construction and
pressure/temperature ratings shall be in accordance with the requirements of
the process piping specification.

4.3 Other type of switches, using the principles noted in para. 2.8 (transmitters)
may be used where process conditions dictate.

4.4 For alarm application magnetically coupled level switches with switch mount rad
attached to the out side of the float chamber will be utilised.

4.5 All externally mounted float/displacer type level switches, the process
connection size shall be1”. Irrespective of design pressure, the minimum
pressure rating for this diaphragm flange shall be ANSI 300#.

4.6 The low-level switch shall be mounted directly on the column when the set point
is not less than 630mm. When level gauge and level switch are on the same
stand pipe, minimum allowable low level set point shall be 480mm on the
column.

4.7 External displacer type level switches can be considered for lighter fluids where
specific gravity is less than 0.5. Internal float / displacer type level switches shall
only be used if external type is not possible, like in viscous services and in
underground tanks / vessels.

4.8 For all type of level switches, the micro-switches shall be hermetically sealed,
snap acting, with 230 V AC/5 Amps contact ratings.

4.9 For all type of Level switches, there shall be a DPDT with 2 NO/NC contacts
with adjustable differential.

4.10 For all type of level switches as specified above, the process connection shall
be flanged type and the flange size shall be 1”and irrespective of design
pressure, the minimum pressure rating for flange shall be 300#.
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5.0 Tank Level Instruments:

Irrespective of pressure rating, the minimum pressure rating for RADAR flange
shall be 300#.
RADAR type transmitter shall be standard SMART with HART protocol type
with Local LCD display.
Flange and wetted part for RADAR shall be min. SS316.
Irrespective of plants hazardous area classification, the RADAR type level
transmitters shall be intrinsically safe and weatherproof to IP67.
RADAR shall be with various software features like empty tank spectrum,
dynamic error corrections, false echo filtering, Programmable range from 0-
100%, throughout out the tank height, SPAN/ZERO elevation/suppression,
programmable blocking window distance, etc.
Trip level switches should be directly mounted on vessel/column and not with
the standpipes.
Connection of standpipe from the bottom of vessel must be avoided.
On horizontal vessels with boot, a separate standpipe shall be used for boot
interface level measurement in addition to standpipe used for horizontal vessel.
Level co-ordination sketches shall be produced showing all pertinent details
including nozzle locations, alarm levels, controlled level zones, shutdown level,
etc.
The type of tank gauging used shall be certified by local authority. Reference is
R2 made on to the API MPMS, Chapter 3.

Tank gauges for custody and transfer shall have an approval certificate from an
institute for weight and measures,

Tank gauging shall be provided with local integral read out.

When there is a requirement to measure the temperature (average reading) the

temperature detection system (multiples RTD’s or TC’s) shall be part of the
tank gauge.

High level trip functions shall not be combined with tank gauge.
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5.0 INSPECTION AND TESTS

5.1 All level instruments, switches and level gauges shall be submitted by
manufacturer to internal test procedure which vendor will indicate during the bid
phase.

5.2 All level instruments, switches and level gauges shall be checked concerning
dimensions, marking and nameplate according to the individual specification;
certified drawings and codes.
R2 Hardness test as per NACE MR 0103 shall be provided where required in
individual specification.

5.3 The following certificates shall be produced.

- Chemical analysis and mechanical properties of construction material.

- Hardness test of materials, if requested in individual specification.
- Shop internal test.
- Electric safety specifications issued by CENELC recognized institute.

6.0 INSTRUMENT NAMEPLATE IDENTIFICATION

Instruments shall have the following identifying information on a nameplate

permanently fastened to the instrument.

6.1 Equipment identification number if applicable.

6.2 Pressure rating of pressure holding parts.

6.3 Manufacturer's name, model, serial number, operating range, set value (if
applicable) and materials of parts exposed to process fluids.

As applicable, nameplates shall also carry information relating to voltage and

frequency.

(VII) TEMPERATURE MEASUREMENT

1.0 REFERENCES

1.1 LICENSOR STANDARD DRAWINGS

1.2 LICENSOR STANDARD SPECIFICATIONS
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1.3 ANSI MC 96.1

1.4 DIN 43760
1.5 IEC 529
1.6 API RP 551, 552, 553, 554
1.7 ANSI B16.5
1.8 ANSI B1.20.1

2.0 THERMOWELLS

Temperature measuring devices which penetrate the wall of piping or vessels shall be
located in thermowells except for those used in skin point measurement.

R2 2.1 Thermowells (well and flanges) shall generally be of minimum AISI 316 material
unless otherwise required in project specification or special process conditions
require other special materials.
Test thermowells shall be provided with stainless steel plug and chain.

All temperature elements shall be provided with thermowells, machined out of

bar stock up to 600 mm length & of minimum 316 SS material for flange rating
up to ANSI 600#. For thermowells above 600# rating, manufacturer may use
their own design, which is proven and as per various recommended
standards/practices. This could be welded with high pressure weldolet joints.
The flange material shall be SS316 as a minimum. In case of corrosive and
erosive services stellited thermowell shall be provided. The thermowell design
shall ensure no air gap between the tip of the element and thermowell to
minimize measurement lag. The internal diameter of thermowell shall be
suitable for sensing element /bulk OD of mm or 8 mm.

2.2 Thermowells shall be designed in accordance with Licensor Drawings.

2.3 Minimum flanged rating specified for flanged thermowell shall be 300 lbs.
Minimum connection for all temperature measurements as 1 ½ “for rating up to
600#. For ratings 900#, 1500#, 2500# minimum connection size shall be 2”.
Irrespective of design pressure, the minimum pressure rating for this thermowell
flange shall be ANSI 300#. Thermowells shall be installed with proper “Long
R2 Welding Neck Nozzle.

2.4 Flange material shall be of the same material as the well. Thermowell material
shall be clearly stamped on the flange or on the body. When NACE is specified
R2 process wetted parts shall be in accordance with NACE MR0103. Hardness
test and test certificates are required for NACE Thermowells

2.5 In applications where fluid velocity, pressure and temperature indicate the
necessity, velocity (Von Karman) and pressure rating calculations shall be
performed, to determine thermal well dimensions and installation configuration.

2.6 All temperature sensing devices except for those used in skin point
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measurement shall be installed in protecting wells so that they may be removed

from service without disturbing the process. For protection of skin point
thermowells se.dwgs. TD-20230.

2.7 Installation of Thermowells.

2.7.1 First preference is to install on an elbow, with the thermowell tip

projecting into the flow for lines 6" and smaller. If this is not possible
thermowells are to be installed in the vertical, on the top of the pipe.

2.7.2 For lines smaller than 3" any elbow installation must be in vertical.

2.7.3 Lines 2" and smaller shall be increased to 3" at the bend or 6" in the
pipe section where the thermowell is installed. When installing reducers
in horizontal the eccentric type shall be used to avoid pockets.

2.8 Immersion Lengths.

2.8.1 For pipe lines the well shall be sized to reach the center line of the pipe
when the bore is 12" or less. On pipes larger than 12" the tip should
extend at least 6" into the pipe.

2.8.2 For column tray measurement the well tip shall extend approx. 3" into
the column.

2.8.3 For column bases and vessels the well shall project 12" into the vessel.
Care must be taken to ensure that there is no conflict with any internal
parts that may be installed.

2.8.4 For the tank a 12 to 18 inch extension into the tank is necessary to place
the thermowell tip into the well mixed portion of the tank.
R2 2.9 DELETED.

2.10 The inside diameter of the finished thermowell shall be concentric with all other
diameters with a tolerance of 0.2 mm.

2.11 In case the thermowell design fails vibration analysis, alternate design may be
used by the contractor. All such design along with calculations shall be
submitted for purchaser's review and approval.

3.0 THERMOCOUPLES

3.1 Thermocouples will normally be used for remote temperature measurement.

All temperature measurement in the plants shall be carried out using only
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Thermocouple or RTD elements depending on the requirements. Local

temperature gauges shall be used wherever required.

3.2 Thermocouple element shall be generally "E" type of the metallic sheated
mineral insulated style, ¼" diameter (chromel-costantan). For special uses and
high temperature measurement range "K" (Chromel-Alumel) element shall be
used. They shall be fabricated from # 14 AWG wire which is 1.63 mm in
diameter.

3.3 Thermocouples shall be designed in accordance with Licensor Standard

Drawings, Licensor Standard Specifications, ANSI MC 96.1 and IEC 584,
Eidtion-2, IS7358 and shall have external sheath of 316 stainless steel as
R2 minimum. They shall have wire size of 18 AWG for single and 19AWG for
duplex elements.

3.4 Mineral oxide insulation shall be of pure ( 99.4%) compacted magnesium

R2 oxide with resistivity 1012 /cm at 538C at least and grounded, unless
ungrounded is specified by process. Grounded junctions are to be used where
fast response is required, if secondary system allows the use of grounded T/C
elements. The insulation resistance shall be >100 Mega Ohm. The
thermocouple wires shall be joined together by welding to form a hot junction.
Bulb / Sheath diameter shall be 8 mm and the overall diameter of the sheathed
element shall not deviate by more than 2%.

3.5 Connection of thermowells to thermocouple head shall be made by using a

screwed union for:

a. Easy removal,
b. Heat dissipation.

If such combination is not enough for adequate cooling, length of the pipe
nipple shall be arranged accordingly.

3.6 RTD and Thermocouple heads shall be as follows.

a. Heads shall be certified as EExia IIC/T6 (min. IP 65 as per IEC 529)

irrespective of plant’s hazardous area classifications.
All head assembly shall have two ½” NPT(F) cable entry. All assemblies
shall be supplied with either 1 no. of two nos. of double compression type
SS cable glands certified for EExia IIC/T6 as per CENELEC and
weatherproof to IP65. Wherever second element is not in use, the spare
cable entry shall be provided with ½” NPT SS304 plug certified for EExia
IIC/T6.
R2
b. Body and cover shall be die cast aluminium.
c. Cover shall be female threaded and gasketed, with retaining chain to the
body.
d. Cable entry shall be ½" NPT.
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e. The terminals shall be color coded as per element’s color code.

3.7 T/C's shall be furnished with thermowells as complete assemblies to assure

proper matching fit, with the thermocouple spring loaded to bottom out in the
well.

3.8 Heater tube skin thermocouples installation shall be in accordance with

Licensor Standard Drawings. For tubular heaters in process services, tube
metal skin thermocouples shall be provided. These shall normally be located in
areas of maximum metal temperature with additional thermocouples in any
other areas where rapid coking or scaling may be anticipated. In general, one
skin thermocouple shall be provided for approximately each 400 sq. ft of
radiant section tubing, with not less than one thermocouple per radiant pass
and one thermocouple per pass on the convection/shield section of the heater.

3.9 Minimum of 24 inch clearance shall be allowed beyond well for thermocouple
head, to permit removal of thermocouple.

3.10 A single well and thermocouple shall be used for each point on the control room
multipoint temperature indicator.

3.11 When digital distributed control system are used, multipoint temperature
indicator points shall be function of the distributed control system and
incorporated into the data acquisition facilities of the control system. Minimum
overall accuracy at reference conditions shall be ±1 percent of full scale and
minimum resolution shall be one degree.

3.12 Points on the panel multipoint temperature recorder shall be operated from
duplex type temperature elements, the second element being connected
directly to the multipoint indicator or its equivalent incorporated into DCS.

3.13 Two independent thermocouples located in separate adjacent wells shall be

used when a thermocouple is used in conjunction with a temperature controller,
R2 one thermocouple being connected to the controller, the other to the multipoint
indicator except where licensors specify otherwise.

3.14 Thermocouple actuated instruments shall drive the output (or contact) to a safe
condition in the event of T/C failure (open circuit).

3.15 T/C's used as sensors for interlocks, important process alarms on solid state
annunciator and shutdown circuits shall be of duplex type and installed in wells
separate from control circuit T/C's.

3.16 The decision to use grounded or ungrounded junction thermocouples shall

depend upon the requirements of the instrument device or system to which they
are connected, or upon other application consideration (e.g. cathodic protection
system for piping and vessels would preclude the use of grounded
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thermocouples.)

3.17 Deleted.

3.18 Thermocouples connected to blind EMF to signal convertors located in back of

control room panel shall be used for panel mounted controller.

3.19 Deleted.

3.20 Multipoint strip chart recorders, where used, shall be directly wired to the field
sensor and shall be digital data recorder type.

a. Input impedance shall be suitably high for measuring circuit(>10).

b. Continuous cold junction compensation shall be available.
c. Input accuracy for E and K type shall be ± 1°C or better.
d. Recorder shall have two built-in ranges than can be changed by software.
e. High and low alarm setpoints to be adjustable by software (for each
channel)
f. Scan rate to be adjustable and to be equal or faster than 1.5 sec/point.
g. Low and high alarm contact outputs to be available per each channel.

3.21 Deleted.

3.22 Hysteresis and dead band in temperature transmitters shall be less than 0.01%.
Input resolution for digital systems shall be at least 10,000 steps for the
temperature range specified.

3.23 Temperature Measurement:

R2 3.23.1 All temperature measurements shall be carried out with the help of
Thermocouple / RTD elements along with remote field mounted ,2
wire, 24 V DC, 4-20 ma, SMART, HART temperature transmitters.
No head mounted transmitters shall be used throughout the project
or any part thereof, including package unit instruments. Multiplexers
are not used and all temperature transmitters shall be connected to
systems.

3.23.2 All temperature interlocks/logic related measurement shall also be

carried out with the help of Thermocouple / RTD elements along
with field mounted ,2 wire, 24 V DC, 4-20 ma, SMART, HART
temperature transmitters. No head mounted transmitters shall be
used throughout the project or any part thereof, including package
unit instruments.

3.24 All temperature elements shall be spring-loaded, DUPLEX, mineral insulated

R2
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and sheath material as SS316 as a minimum, unless otherwise specified.

The second element of thermocouple will be leave as spare or second
indication depends on project developing.

3.25 The type of thermocouple shall be selected based on the following

guidelines as minimum:
Copper-Constantan (ISA-Type-T) (-) 200 to 200°C Chromel-Constantan
(ISA-Type-E) 200 to 600°C Iron-Constantan (ISA-Type-J) 0 to 600°C
Chromel-Alumel (ISA-Type-K) 600 to 1200°C Platinum Rhodium-Platinum
(ISA-Type-S or B) 600 to 1600°C.

3.26 The design of thermocouple assemblies shall be such that replacement of

elements shall be possible on-line. It shall be equipped with SS304
Nipple-Union-Nipple Joints. Assembly shall include nipple-union-nipple
(1/2" NPT threaded) to allow approximately 150 mm between top of well and
bottom of head, when made up.

3.27 Thermocouple sheathing material shall be 316 stainless steel as a minimum

and are constructed from a seamless tube with a wall thickness of at least 1
mm. Inconel 600 sheath shall be used for all application, where the temperature
0
is above 600 C.

3.28 The special thermocouples such as reactor thermocouples, reformer

thermocouples etc. shall be designed by CONTRACTOR and needs
purchaser’s approval.

3.29 For Reformer / heater tube skin thermocouple, wherever applicable, assembly
shall meet the equipment design requirements and shall be provided with
expansion loops. The sheath material shall be selected based temperature and
sulphur shall be selected based on temperature and sulphur content.

3.30 Class 'A' / Class '1’ tolerance as per IEC 751 / 584-2 shall be specified for all
RTD and thermocouple sensors in complete temperature measurements for all
open/closed loops and interlocks.

3.31 Head mounted temperature transmitters are not allowed at any location,
through out the project or part thereof. Field mounted remote temperature
transmitters shall be used for all temperature transmitters.
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4.0 THERMORESISTANCES

4.1 Thermoresistances shall be designed in accordance with Licensor

specifications. shall have external sheath in AISI 304 minimum.

4.2 Mineral oxide insulation shall be of pure (> 99.4%) compacted oxide with
resistivity 1012 ohm/cm at 538°C. The insulation resistance shall be >100 Mega
Ohm.

4.3 (RTD -Resistance Temperature Detector) Pt 100 OHM °C, 3 wire

thermoresistance type according to DIN 43760 shall be used.RTD shall be
calibrated as per IEC 751 / DIN 43760.

4.4 Heads shall be as per item 3.6 above.

4.5 Thermoresistances shall be used only where thermocouples do not meet

accuracy and span requirements.

4.6 Thermoresistances shall be furnished fully assembled with the measuring

junction firmly bottomed in the well.

4.7 RTD shall be used for a temperature range of -200 to 650°C. Three-wire
system shall be the element.

4.8 RTD shall generally be selected for applications requiring low temp with
comparatively shorter temperature span requiring accuracies of better than
+/-0.25%.

4.9 All RTD elements shall be duplex by default.

4.10 The design of RTD assemblies shall be such that replacement of elements shall
be possible on-line. It shall be equipped with SS304 material Nipple-Union-
Nipple Joints. Assembly shall include nipple-union-nipple (1/2" NPT threaded)
to allow approximately 150 mm between top of well and bottom of head, when
made up.
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4.11 RTD bulb sheathing material shall be 316 stainless steel as a minimum and are
constructed from a seamless tube with a wall thickness of at least 1 mm. Bulb/
Sheath diameter shall be 8 mm and the overall diameter of the sheathed
element shall not deviate by more than 2%.

5.0 THERMOMETERS

5.1 Bi-metallic, stainless steel, dial 150 mm, "every-angle" type thermometer shall
generally be used unless otherwise required in individual specification for local
temperature indication.

5.2 Thermometers shall be designed in accordance with Licensor STD DWG. .

Tempeture indicators shall be provided as Per parag. 11.1.1 of API standard
560 with the following modification.One connection shall be provided for each
30 feet (9.1 meters) radiant box / convection tube length or one connection for
each flue gas outlet from the convection section, whichever requires higher
number of connections.

5.3 Thermometer connection to the well shall be sliding ½" NPT ANSI B2.1

5.4 Accuracy required shall be ± 1% or better.

5.5 Range shall be so selected that the normal operating temperature indication is
approximately midscale.

5.6 Adjustment for different immersion shall be made with an adjustable

compression fitting.
R2 5.7 Temperatures gauges are preferred to have the following ranges: -
30/+60ºC,0/100 ºC,0/150 ºC,0/250 ºC,0/400ºC.

6.0 OTHERS

6.1 Local temperature switches utilizing filled bulb or bimetallic sensing elements
may be used where appropriate. DPDT switch contacts shall be provided.

6.2 Filled system type instruments may be used for local control, within the
manufacturer's recommended temperature limits, provided that failure of the
capillary system does not result in a hazardous control situation.

7.0 INSPECTION, TEST AND CERTIFICATES

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7.1 All thermocouples, thermowells and thermoelements shall be checked

concerning dimensions, marking and nameplate according to the individual
specification, certified drawings and codes. Hardness test as per NACE MR
R2 0103 shall be provided where required in individual specification.

7.2 The following certificates shall be produced.

7.2.1 Chemical analysis and mechanical properties of construction materials.

7.2.2 Hardness test of materials, if requested in individual specification.
7.2.3 Shop internal test.

7.3 For special use thermocouples the Vendor shall carry out all inspection and
testing, and shall provide all the certifications indicated below.

7.3.1 Following checks certified by the manufacturer shall be carried out.

7.3.1.1 Compliance with specification check which shall be witnessed

by Contractor/Owner.
7.3.1.2 Visual and dimensional check witnessed one sample for each
type by Contractor/Owner.
7.3.1.3 Check of degree protection.
7.3.1.4 Check of safety execution.
7.3.1.5 Thermal shock control.
7.3.1.6 Pressure test.
7.3.1.7 Hydrostatic test
7.3.1.8 X-Ray inspection.
7.3.1.9 Dye penetrant test.
7.3.1.10 Check of calibration.
7.3.1.11 Response time test.
7.3.1.12 Summary certificates of employed materials.
7.3.1.13 Check calibration and gauging of necessary instrumentation
for the testing.

8.0 INSTRUMENT NAMEPLATES

Thermoelements shall have the following identifying information on a nameplate

fastened to the instrument.

8.1 Equipment identification number.

8.2 Manufacturer's name, model, and serial number.

As applicable nameplates shall also carry information relating to voltage and

frequency, operating range and materials of parts exposed to process fluids.
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(VIII) ELECTRONIC TRANSMITTERS

1.0 REFERENCES

1.1 LICENSOR STD SPC. and DRWS

1.2 CENELEC EN 50018 and 50020
1.3 IEC 529 Instrument Housing Protection
1.4 API RP 551, 552, 553, 554 Process Instrumentation and Control.

2.0 BASIC DESIGN

2.1 General Constructional Specifications for pressure, differential and temperature

transmitters shall be as follow:

2.1.1 Transmitters shall be advanced, microprocessor-based, smart

(intelligent) type having 4-20 mA DC analog and digital HART output
mode selectable with software configuration without any physical
modification, capacitance type sensing module with digitally executed
compensation and correction functions.Extensive intelligence shall be
embedded in transmitters including diagnostics and programmability
capabilities. All field transmitters shall be 2 wire type, 24 Volt DC,
SMART with HART protocol, and shall be equipped with LCD type
digital indicator configured in engineering unit.

The transmitters shall be incorporate a non-volatile memory, which

shall store complete configuration data of transmitter. All necessary
signal conversions, including conversion to produce output with the
required protocol shall be carried out in the transmitter electronics. The
design of electronic parts shall be in compliance with the
electromagnetic compatibility requirements as per IEC 801.

Digital information transmission capability of the transmitters shall

basically be used for troubleshooting, diagnosis, rearranging etc of the
transmitters.Fifteen intrinsically safe handheld terminals for the
transmitters shall also be provided.

Transmitter shall also run complete diagnostic routine. In the event of

detection of failure, the output shall be driven to predefined value,
which could be either minimum (4 mA) , maximum(20 mA) or last good
value. This feature shall be programmable. High and low alarm
configuration limits shall be NAMUR compliant. DCS supplier shall
generate the corresponding alarms in DCS.
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Transmitters shall be supplied with double certification EExd/Eexi.

R2
316L S.S. gold plated for transmitters diaphragms and for remote
seals, just in the case of Hydrogen Services shall be used.

2.1.2 Communications with transmitters, modulated (hart protocol) over 4-20

mA output signal with a field communicator shall be provided to
configure, calibrate, modify, troubleshoot or verify the transmitter,
locally or remotely, without disturbing 4-20 mA or digital output signal.

2.1.3 Transmitters power supply shall be 24V DC. The maximum allowable
loop resistance and minimum required supply voltage at 20 mA and
max. load value of the output module/card of the control system shall
be advised by Vendor. 4 - 20 mA - 24 V DC output will be used for
tranmission unless the world ındustry digital field to board
communıcation standards have been finalized.

2.1.4 Transmitters shall be connected to the correspondent control room via

two wire system.

2.1.5 Transmitters shall provide an increase in output signal (analog mode)

on process increasing.

2.1.6 Transmitters accuracy in analog mode shall be or better than 0.10% of

calibrated span. (temp. 0.10%). Total performance shall be stated in
the datasheet and be beter than or equal to 0.1% of span.

The accuracy shall include the combined effect of linearity, hysterisis

and repeatability. Effect of static pressure on the transmitter in either
direction shall be negligible.

2.1.7 Instruments body rating shall be 1500 lbs minimum. Electrıcal

connections for cable entry shall be 1/ 2” NPTF.

2.1.8 All transmitters shall be equipped with easily accessible external zero
and span adjustments. Transmitters shall have integral vent/drain.

2.1.9 All transmitters shall be equipped with integral, built in indicators

capable of indicating engineering unit display, LCD type digital, in the
same transmitter cases.

R2 Additionally, field mounted local output digital indicators shall be

installed where are shown on P&IDs.

2.1.10 All transmitters shall have built-in transmitter/ambient temperature

effects compensation feature.
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2.1.11 All transmitters for level measurement shall have suppressed and
elevated-zero features.

2.1.12 All transmitters for flow measurement shall have square rooting feature
of 4-20 mA DC signal.

2.1.13 For all transmitters minimum span rangebility (turn-down ratio) shall be
200:1. Total response time (Td+Tc) shall be or less than 100 msec
(dynamic performance). Stability of the electronic transmitters shall be
or better than +/- 0.2 % of URL for 10 years. Minimum 12 year
warranty. The pressure (p, dp, absolute) transmitters in the emergency
shut down system shall be SIL2 compliant.

2.1.14 Operating temperature upper limit for the transmitters measuring cell
(sensor) shall be or greater than 120°C .

2.1.15 RFI/EMI protection shall be provided for all transmitters.

2.1.16 Internal damping adjustment shall be available for P and DP

transmitters.

2.1.17 Differential pressure transmitters shall withstand full line pressure on

either side without zero shift or calibration change.

2.1.18 P and DP transmitters shall be capable of withstanding over-pressure

at least up to the design pressure of the line, vessel, or equipment, to
which it is applied.

2.1.19 Material of construction for wetted portion (body, capsule, oval flanges,
process connections, drain, vents flange adapters material etc.) of the
transmitters including sensing element shall be Hastelloy C-276 as a
minimum and shall be able to withstand over pressure of at least 1.5
times the maximum working pressure . Other special materials may be
used as required by process fluid conditions. Conforming to the
corrosion requirements of the application shall also be taken into
consideration during material selection.

2.1.20 All instruments shall be equipped with supporting materials suitable for
2" pipe support and mounting.The transmitters shall be supplied with
SS304 mounting brackets, hardware, nut/bolts, etc.

2.1.21 Hysteresis and dead band in temperature transmitters shall be less

than 0.01%. The temperature Transmitters in the control loops and/ or
connected to emergency shut down system shall have dual sensor
input. The dual sensor shall work redundandly as automatic back-up
for one another. The temperature transmitters in the emergency shut
down system shall be SIL2 compliant.
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2.1.22 Cold junction compensation shall be provided on temperature

transmitters.

2.1.23 Field mounted temperature transmitters will be utilized for temperature

control loops instead of using converters mounted at control room.

2.1.24 Irrespective of plant’s hazardous area classifications, all these

transmitters shall be intrinsically safe EExia IIC T4 and flame proof
R2 EEx d IIC T6 weatherproof to IP65 minimum as per IEC529.

All transmitters are supplied with ATEX certificates and with double
certification EExd/EExi.

2.1.25 The min. loop load shall be 600 ohm for 4-20 ma output circuit of
transmitters. Transmitters shall be able to work between 12 to 35 V DC
with 600 ohm loop impedance.

2.1.26 Transmitter lower housing shall be as indicated in 2.1.19. The upper

R2 housing of transmitter shall be of die cast aluminium with Epoxy paint
as a minimum.

2.1.27 Pressure/ Differential Pressure Transmitter shall have electronic

capacitance, silicon resonant wire or any other type of proven sensor
technology meeting all functional specifications. Inductive type
measuring principle is not acceptable.

2.1.28 All remote seal diaphragm type pressure/diff. pressure transmitters for
pressure, diff. pressure, and flow and level application shall have 2”
Flanged diaphragm as process connection. Irrespective of design
pressure, the minimum pressure rating for the flange shall be 300#.

However in case of measurement of vary low range pressure ( in the

range of vacuum to 0.5 Kg/Cm2g)with remote seal diaphragm type ,
the diaphragm flange size shall be 3”.

2.1.29 The transmitter shall be so constructed that in case of a pressure

sensing diaphragm /element failure, the process material will not enter
the electronic portion of transmitter or wiring conduits.

2.1.30 Built in temperature sensors shall be provided to compensate for

process temperature and ambient temperature variations.

2.1.31 Care shall be taken while selecting the transmitter models that there
shall be minimum type of diff. models of the same category of
transmitters to reduce spare/inventory.
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2.1.32 In case of differential pressure transmitter with remote seals, adequate

care shall be taken to consider head pressure effect of capillary fill fluid
while selecting the transmitter. The instrument supplier shall document
the remote seal+ transmitter system performance.

2.1.33 The response time of smart transmitters shall commensurate with

process. It shall be equal or better than the half of the total scan time of
any critical loops for process requirement like anti surge controllers. In
any case, this shall not be less than 30 updates per second.

2.1.34 HART protocol of latest version shall be used and shall be suitable for
HART maintenance system with corner stone or AMS like software
with the following features as minimum:

- It shall allow multi masters (two for example, primary and

secondary) for configuration, calibration, diagnosis and
maintenance.
- The primary could be control system or host computer and the
secondary could be the hand held communicator or a
maintenance computer.
- It shall be capable of implementing universal commands. It must
be possible to communicate all the commands of HART
maintenance system to field transmitter and smart transmitters
shall be selected accordingly.

2.1.35 Unless recommended otherwise by compressor manufacturer, field

transmitters used in anti-surge control loop shall be non-smart.

2.1.36 The model selected shall be the latest from the vendors product range
and proven in the field for minimum of 1 year of operation.

2.1.37 For hydrogen gas service transmitters, Hastelloy wetted parts shall not
used to avoid damage due to hydrogen ion permeability. It shall be
R2 SS316L gold plated.

2.1.38 Diaphragm seal element with capillary shall be used for congealing,
corrosive and highly viscous services (higher than 200 cSt) at high
R2 operating temperatures. Filled fluid shall be capable of withstanding
the process temperature/pressure/fluid.Capillary shall be SS armoured
DELETED.

2.1.39 Oxygen service pressure/diff. pressure transmitters shall be supplied

with special inert fluids (including diaphragm type with remote seal and
capillary) and shall be free from grease/oil.These shall be clearly
marked with “for use in oxygen services”.
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2.1.40 Field communicator:

- For all the various type of SMART transmitters in the complete
project, min. xx nos. of Hand Held Communicator or HHT shall be
provided. This shall be loaded with latest HART 375 software,
Foundation Field bus library and all Device Descriptor Library.
- As a minimum, HHT provided shall support the programming of all
parameters of all the diff. type of SMART instruments used in
complete project.
- It shall be possible to perform routine configuration, calibration,
display process variable, diagnostics etc. from a hand held
portable calibrator
- The HHT shall be intrinsically safe and have min. 64 MB Memory
module to store min. 1000 transmitters configuration, which can be
used at later date to download in any of the failed transmitters.
which can be connected at any location in the transmitter loop.
- It shall be possible to perform all the above functions on line. The
loop function shall remain unaffected while communication is
going on between transmitter and the field communicator. No
output interruption should occur.
- They shall be battery powered with replaceable and rechargeable
batteries. Re-charger power supply shall be 230 V AC +/-10%, 50
Hz +/-3Hz.
- Plug in type connections shall be provided with field
communicator. Necessary interconnection cables and any other
accessories required for connection shall be supplied by
CONTRACTOR along with HHT.
- Offered communicator shall be dust proof certified intrinsically
safe and suitable for outdoor location. Carrying case shall be
supplied with each communicator. Each communicator snail be
provided with recharging unit.
- Each HHT shall be provided with a minimum of 64 MB removable,
plug in type Memory bank, which can store a minimum of 1000
transmitters’ configuration data.
It shall be possible to connect the communicator at any of the
following places for purpose of digital communication
- Marshalling cabinet serving the transmitter in safe area, control
room.
- Junction box serving the transmitter, in hazardous area, field.
- Directly at the transmitter, in hazardous area field.
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2.1.41 Wherever the above requirement of 2 wire, 24 V DC transmitters can

not be fulfilled, the 4 wire transmitter (SMART with HART protocol)
option shall be used such as RADAR type level transmitters, Magnetic
Flow meters, Mass Flow meters, etc. All theses device shall be
powered with 220 V AC UPS supply only. The power shall be fed from
PDB located at central cabinet room.

2.1.42 While designing, a care shall be taken to choose transmitters ranges/

rangeability, etc. for various applications in such a way that there shall
be min. type of diff. models of the same category of transmitters are to
required to be maintained as spares.

R2 2.1.43 All remote seal diaphragm type PT/DPT shall be supplied with min. 5
mtr. of capillary with SS armoured. DELETED.

2.1.45 Head mounted temperature transmitters are not allowed at any

location, through out the project or part thereof. Field mounted remote
temperature transmitters shall be used for all temperature transmitters.

2.1.47 All the Temperature transmitters shall be 24 V DC, 2 Wire, 4-20 m amp
dc output with SMART HART with HART protocol.

2.1.48 Temperature transmitters shall be suitable for 2” pipe mounting and

shall be supplied with all SS304 mounting brackets/nut/bolts, etc.

2.1.49 All temperature transmitters shall be equipped with local, LCD type
digital indication which shall be configurable in engineering unit.

2.1.50 Temperature transmitters shall have a built-in linearising function.

2.1.51 All temperature transmitters shall be of universal input type, so that it

can accept all type of Thermocouples or all type of RTD inputs with
2/3/4 wire options. This feature is a must to reduce inventory and have
interchangeability of various transmitters.

2.1.52 Burn out protection shall be provided with temperature transmitters.

Upscale or downscale or holding last good value options shall be
programmable in the transmitters.

2.1.53 All the transmitters shall be provided with min. two cable entries with
½” NPT(F) size. One entry shall be used for sensor cable input and
other shall be for 24 V DC/2 wire output cable.
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2.1.54 Deleted.

2.1.55 Each temperature transmitters shall be supplied with min. of two nos.
of double compression type, brass with nickel cadmium plated cable
gland. Cable glands shall be intrinsically safe to Eexia-IIC-T6 and
Weatherproof to IP65 as per IEC529.
2.1.56 Differential pressure transmitter shall be fitted with 5 valve manifolds,
R2
consisting of two for isolation valves an one for bypass valves and two
for drain valves for flow applications.

Pressure transmitter shall be fitted with two valve manifolds one for
isolation and one for drain
For the pressure ranting of class 900 and above, manifolds and tubing
shall not be used; pipe and valves shall be installed.

3.0 INSPECTION AND TESTS

3.1 All electronic transmitters shall be checked concerning dimensions marking

name plate according to the individual specifications, certified drawings and
codes.
Hardness test shall be provided as per NACE 01.75 where required in
individual specification.

3.2 The following certificates shall be produced.

3.2.1 Chemical analysis and mechanical properties of construction material,

3.2.2 Hardness test of materials, if requested in individual specification,
3.2.3 Shop internal test,
3.2.4 Certificates for installation of electrical equipments in hazardous area.

4.0 INSTRUMENT NAMEPLATES

Transmitters tag details shall be clearly stamped on the external part of the housing by
means of stainless steel label and shall have minimum the following identifying
information.

4.1 Equipment identification number.

4.2 Manufacturer's name, full model and serial number.
4.3 Pressure rating of pressure holding parts, operating range, voltage and
materials of parts exposed to process fluids.
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(IX) CONTROL VALVES AND ACCESSORIES

1.0 REFERENCES

1.1 LICENSOR STD SPC.

1.2 ISA S 75.01 Flow equations for sizing control valves

1.3 ISA S 75.03 Face-to-Face dimensions for flanged globe-

style control valve bodies.

1.4 ANSI/FCI 70−2 and IEC 60534-4 Control Valve Seat Leakage Classifications

1.5 ASTM A 193 Alloy steel bolting for high temperature service.

1.6 ASTM A 194 Carbon and alloy steel nuts for bolts for high
pressure and high temperature service.

1.7 ANSI B 16.5 Steel pipe flanges, flanged valves and fittings.

1.8 ASTM A 320 Alloy steel bolting materials for low temperature
service.

1.9 ASME B16.10 Face-to-Face and End-to-End Dimensions of Valves

1.10 ISA S75.19 Hydrostatic Testing of Control Valves

1.11 IEC 60534-2-1 Fundamentals of Valve Sizing

1.12 ISA S75.11 Inherent Flow Characteristic and Rangeability of

Control Valves

1.13 ASME B16.34 Temperature/Pressure Ratings for Valves

1.14 ASME B16.11 Forged Fittings, Socket-Welding and Threaded

R2
1.15 ASME B16.25 Buttwelding Ends

1.16 ASME B16.42 Ductile Iron Pipe Flanges and Flanged Fittings,
Classes 150 and 300

1.17 ASME B16.47 Large Diameter Steel Flanges NPS 26 through NPS
60
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1.18 ISA S 75.02 Control Valve Capacity Test Procedure

1.19 ISA S 75.05 Control Valve Terminology

1.20 ISA S 75.19 Hydrostatic Testing of Control Valves

1.21 IEC 60534-8 Control Valve Aerodynamic Noise Prediction Method

1.22 ISO 15848-1 Measurement, Test and Qualification Procedures fir

Fugitive Emissions

1.23 API RP-540 Electrical Installations in Petroleum Processing

Plants

1.24 MSS SP-55 Quality Standard for Steel Castings for Valves,
Flanges, and fittings and Other Piping’s Components -
Visual Method

2.0 BASIC DESIGN

2.1 GENERAL:

2.1.1 Control valves shall normally be pneumatic diaphragm actuated type,

with flow characteristics to suit application. Valve materials shall be
choosen according to Lıcensor Control valve specification .

Control valve type / design selection shall be made with considering

the following conditions :

- Pressure drops, which exceed 10 bars.

- Flashing or cavitating liquids.
- Steam service where pressure drop exceeds 5 bar.
- Corrosive fluids
- Control valves on erosive services (slurries)
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Smart control valves shall be used. Smart control valves shall have a
microprocessor based (controlled), HART digital positioner accepting
2 wire, 4-20 m amp input signals from central DCS system and are
capable of bidirectional communication with external electronic
devices, such as computers or operator’s console within the control
room and hand held terminals. The microprocessor is capable of
receiving signals and implementing changes in both settings and
diagnostic test instructions, and transmitting test outputs and
diagnostic trends collected automatically by the microprocessor.
Microprocessor technology shall be used to improve valve response
time and positioning accuracy in order to reduce process variability.

2.1.2 Block valves, bleeders and by-pass valves are required for all control
valves unless otherwise specified except that a bypass valve shall not
be provided in safety shutoff or depressurizing service or in applications
where solids suspended in the stream may collect and block the bypass
valve. Control valve piping assemblies shall be designed accordingly.
Block valves, bleeders and by-pass valves shall be provided where are
R2
shown on P&ID’s.
Outside these limits control valves with handoperator may be used,
except that in cases where removal for maintenance will cause
extensive plant shut-down, e.g. in integrated refineries. Hand operations
shall be side mounted type capable of full valve operation regardless of
spring or diaphragm failure.

2.1.3 Valve action shall be specified to minimize upsets and hazards upon
air or other motivation failure and shall be indicated on the Piping and
Instrument Diagram, i.e. FO (fail open) or FC (fail closed). Piston
operated valves shall have an air buffer storage cylinder to stroke them
to a safe position on air failure. Lock-up valves for maintaining last
valve position shall be used as necessary for equipment protection. A
separate air reservoir only to be used if the required action is
unobtainable by any other means.

2.1.4 For each valve the manufacturer, on the base of the data given in the
individual specification and the Cf of his standard valves shall
calculate the proper Cv and shall give in the bid the relevant noise
level, velocity, cavitation or flashing (if any) and percentage of opening
for the operating conditions. Calculations shall be made using a
computer program, and shall be made for each process case (normal,
max. and min. flow) and in accordance with IEC 60534-2-1 Preliminary
R2 Calculations shall be done in INTOOLS following ISA S 75.01
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Satndard and after that, the final calculation shall be done by Vendor
with his software program.

2.1.5 Control valves shall be sized in accordance with ISA S 75.01 and
generally, valves shall be selected to have twice the Cv required for
the normal design flow at specified conditions. Butterfly valves shall be
sized for maximum flow at 60 degree opening; characterized vane
valves such us "fishtail disc" may be sized at 90 degree opening.
Three way valves shall be sized to pass max. flow at min. available
pressure drop through either part.

2.1.6 The manufacturer shall check and notify that the valve type and the
required materials are suitable to the operating conditions indicated in
the individual specification, with particular reference to the pressure,
temperature, flash, cavitation, possible suspended solids,
crystallization phenomena, speed, noise and type of fluid.

2.1.7 Fluids speed measured at the outlet flange of valves must be kept
within the manufacturer's safety limits, for the valve body material. If
the speed limits would not be respected a material proper to the body
shall be chosen or the valve diameter shall be increased using a
reduced passage.

2.1.8 Liquid volume flow rate at flowing temperature. Gas volume flow rate
base temperature is 0°C, and base pressure is 1.033 kg/cm² abs.

2.1.9 Block and by-pass valves shall be sized in accordance with piping
specification.

2.1.10 Where block and by-pass valves are required these will be indicated
on engineering flow sheet.

2.1.11 Regulators for flow, pressure and temperature with integral actuators
shall be used where loads remain reasonably constant and for
application where accuracy is less demanding.

2.1.12 A local indicator shall be provided at pressure and temperature

regulators when indicated on engineering flow sheets to facilitate
control point adjustment.

2.1.13 Regulators shall normally be installed without block an by-pass valves

except where they are necessary for emergency operation.

2.1.14 Regulators for nitrogen blanketing shall be ACE 95 series of Fisher

regulators and also two regulators will be installed for each tank.
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2.1.15 The available instrumentation air pressure will be: min. 4 max.
7,5kg/cm².

2.1.16 All valves except self operated types, shall have position indicators.
Indicators shall also be provided on self operated wherever design
permits. Indicators shall be reversable where valve action can be
changed.

2.1.17 Valve shall be complete with set of packing lubrıcators charged with
correct lubricant and bearings correctly lubrıcated.

2.1.18 The manufacturer shall paint the valves as per painting specification
R2
TPS-N1 and shall supply all the accessories installed on the valve,
suitable for indicated climate conditions. DELETED

2.2 TYPES

2.2.1 Control valves shall be of types as mentioned in below paragraphs.

Control valves shall normally be globe type, top guided (up to 10
Kg/Cm2 Delta P) or cage guided (more than 10 Kg/Cm2 Delta P),
single seated, non-pressure balanced type only. Other valves like
butterfly, ball, rotary, angle or 3 way valves shall be selected based on
application. All control valves shall be flanged end type only the control
valve Body material and Body rating shall be as per piping
specifications. Control valves shall be rated in accordance with the line
specification unless otherwise specified except that carbon steel
flanged valves up to and including 6 inch shall not be less than 300 lb
rating

2.2.2 Single seat globe valves shall be used in services requiring tight shut-
off and where effective control can be achieved using a standard size
actuator. Single seat globe valves shall be heavy duty top (stem, port
or post) guiding type. For special applications on high pressure drop
and flashing services with low pressure recovery , may offer his cage
design with appropriate guiding.

2.2.3 High lift top and bottom guided globe valve with removable seat rings
and interchangeable bolted bonnet and blind. Capable of action
reversal without extra parts.

2.2.4 Angle type valves shall be used where pressure drop exceeds 300 PSI
and in erosive and coking services and shall be of heavy duty full
venturi type angle, with full guiding and removable seat.

2.2.5 Butterfly valves shall be considered for large flows with low pressure
drops e.g. draw-off lines to side stream strippers and shall be sized for

R2
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full flow at 60 degrees open. Butterfly valves shall be heavy duty wafer
type.
The wafer or lug type butterfly valves shall not be used in hydrocarbon
service however they should be used in systems which non-flammable
products unless specified by licensors.

2.2.6 Three way globe valves for combining or splitting services, with linear
plugs. Generally to requirements for globe valves.

2.2.7 1" valves with top guided reduced trim. Plugs for these valves shall be
of fluted design where the equivalent contour plug would be a needle
of diameter less than ¼ inch.

2.2.8 Self operated valves. Generally to requirements for globe valves. Self
operated valves with top or skirt guiding will be acceptable on low
pressure clean gas or air service only.

2.2.9 The Minimum control valve body size shall be 1" in general. Body size
shall be limited to 1", 1-1/2". 2", 3", 4", 6", 8'”, and 12”. Higher size may
be used if required. The flanged connection dimensions and pressure
temperature ratings shall be as per ANSI B16.5.

2.2.10 The accessories like Air Filter Regulator, Solenoid Valve, Limit
switches, Positioners, etc. shall be pre-tubed with actuator so that they
can be removed easily for maintenance purpose.

2.2.11 The max. allowable noise shall not exceed 85 dBA SPL ( Sound
Pressure Level). Control valves, exceeding this limit will be provided
with special precautions.TRM-TQ-INS-0099

2.2.12 Leakage class VI shall be considered, where tight shutoff is specified.

If no leakage class is specified, min. leakage class V is to be
considered.

2.2.13 For all interlock/shutdown valves, the minimum leakage class shall be
Class VI as per ANSI/FCI 70−2 and IEC 60534-4.

2.2.14 Control valve sizing shall be carried out as per ISA S75.01. The
selected CV shall permit up to 150% of normal flow or 110 % of
maximum flow, whichever is higher. In general, control valves shall be
sized so that the valve opening is as mentioned below.
- At Max. Flow :-80% Open
- At Normal Flow :-70% open
- At Min. Flow :-20% open

2.2.15 Equal% control valve shall be sized for 60% to 80% opening for normal
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flow. For two phase flow, both phase CV is to be considered with

relevant process condition while sizing the valve.

2.2.16 Flanged bolted type gland packing boxes shall be used, unless other
specified. Gland packing shall normally be self-lubricating type.
Packing shall be PTFE type up to 200”C. For temperature above 200 “
C, grafoil is to be used. Usage of asbestos is not allowed in any part.

2.2.17 Bellows seals shall be used for lethal services. Low emission packing (
TA-Luft or ISO 15848) shall be used for toxic / hazardous product. Low
R2 emission packing ( TA-Luft or ISO 15848) shall also apply for all
services except air, steam, water and Nitrogen

2.2.18 As a minimum, trim material shall be SS316. By default, all Guide

material shall be hardened stainless steel like 440 C, 17.4 PH. For
erosion service, high pressure drop, cavitating service hard surfacing
of plug and seat material, satellite shall be used. Special cases valve
may require 17.4PH seat and 440C solid plugs or other material like
Hastelloy, Monel, Zirconia, etc.

2.2.19 Where tight shutoff is required, fire safe type soft seat trims shall be
used, provided pressure/temperature of service permits the use of this.
For temperature above 300°C stellited facing shall be used for guide
and guide bushing shall always be harder by a minimum of 125 Brinnel
than that of the guide.

2.2.20 Trim characteristics shall be equal percentage, unless otherwise

specified. For high erosion service or in steam service where, the
differential Pressure is higher than 5 Kg/Cm2, hardened trim with
stelliting shall be used. When this is not sufficient, in such cases,
special Anti-cavitating trim, attenuator trim or shall be selected.

2.2.21 The allowed stroking time shall be governed by process requirement.

Generally, for control valves, equipped with positioner, max. stroke
time shall be 10 seconds up to control valve size 4” or smaller. And
shall be max. 15 second for control valve with size 6” and above The
stroking time of shut-off valves and critical control valves should be in
the range of 1-3 seconds.

The below detailed philosophy for the stroking time of the shut-off
R2 valves shall be followed unless otherwise specified on the licensor
documents. Durign the fail position, the valve shall reach a fully closed
or fully open position within the time specified
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For the critical shut off valves: (note 7)

 For valve size up to 2 inch : 2 seconds or less.
 For valve size from 3 inch to 12 inch: 1 second per inch.
 For valve size above 12 inch : 12 seconds or less.

For the non critical shut off valves:

 For valve size up to 3 inch : 5 seconds or less (note 2).
 For valve size > inch : refer to note 1.

Notes:
1. Stroking time of non-critical shut off valves for each valve shall
be checked/confirmed by CONTRACTOR Process Department
and specified on data sheets. These valves shall be noted as
non-critical valves on data sheets.

2. 5 seconds stroking time for the valve size up to 3 inch (non-

critical) shall also be checked by CONTRACTOR Process
Department for the less stroking time (if required).

3. Vendor specifications shall be followed for PSA packages.

4. HAZOP/SIL study and verification reports for stroking times shall

be taken into consideration and checked by CONTRACTOR.

5. Stroking times of the heater valves (fuel gas, pilot gas, etc.) shall
be specified according to the requirements of heater vendor
and NFPA-85.

6. Vendor shall provide, if necessary, restriction devices to prevent

hammer effect due to high speed strokes.

7. The above given stroking/shut off times of critical valves shall

also be defined/checked by CONTRACTOR Process
Department for each valve.

2.2.22 PCV shall be used only when load is constant and precise control is
not required.

2.2.23 All shutdown valves shall be floating ball design with full bore design,
unless otherwise specified.

2.2.24 The control valve flow to open/close should be as per process/safety

requirement.

2.2.25 Oxygen service valves shall be de-greased completely and certified for oxygen

R2
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service use. Body shall be Monel and trim shall be Inconel 600 only.

2.2.26 DELETED

R2
2.2.27 For all shutdown valves when it is indicated in P&ID or in Process, air
volume tank shall be supplied for the storage of air volume for
minimum 3 stroke operation.

2.2.28 Each valve shall be provided with SS material tag plate indicating the
following details as a minimum:
- Instrument Tag Number
- Vendor's Name -Valve Model Number
- Order/Requisition Number
- Body & Trim Material
- Stem Packing
- Material Body Size and Rating -Design CV (For
- Trim Characteristic or Cam Code/type as necessary
- Air-Fail Action
- Hazardous Area Class
- Actuator size
- spring range -air supply pressure

2.3 CONSTRUCTION CHARACTERISTICS

2.3.1 Body

2.3.1.1 Features and descriptions according to Licensor standard

specification.

2.3.1.2 Control valves shall be rated in accordance with the line

specification unless otherwise specified except that carbon
steel flanged valves up to and including 6 inch shall not be
less than 300 lb rating. Minimum body size shall be 1".
Face-to-ace dimensions of flanged globe valves shall be in
accordance with ISA S 75.03. (Minimum body rating for
screwed valves:600 LB.)

2.3.1.3
Unless otherwise indicated on the individual specifications,
valve body materials shall be choosen according to ANSI B
16-5 table 1, and shall meet the pressure temperature
ratings of table 2 to 8 of that standard. Vendor is free to
use higher grade materials than are strictly necessary to
meet pressure and temperature ratings, but materials must
be according to specifications listed in table 1 and agreed
with Owner. Body material shall conform to piping class requirements.
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2.3.1.4 Globe valve bonnet and blind shall be of the same material
as body and shall have retained gaskets suitable for
maximum pressure temperature and corrosion rating of the
body.

2.3.1.5 Extension and cooling fins shall be the same material as

the valve body.

2.3.1.6 Globe bodied threeway valves shall be designed so that

flow direction is from under the seats.

2.3.1.7 Valve body shall have direction of flow stamped or cast on.
Threeway valve shall have "COMMON" stamped on the
periphery of the flange of the combined stream connection.

2.3.1.8 Globe valves shall be of flanged bonnet and bottom (if any)
design with a confined gasket; gasket material shall be of
"non asbestos" type and be Vendor's standard, unless
otherwise specified.

2.3.1.9 The quality of and repair of body castings must follow the
requirements of the reference ASTM material specification.
Wall thickness shall meet or exceed min. of applicable
codes.

Pressure castings shall be free from ınjurious blowholes,

porosıty, shrinkage faults, cracks, or other defects. They
shall not be plugged , welded , burned or impregnated.

2.3.1.10 Valve body and pressure parts shall have pressure and
temperature rating equal to, or greater than flange rating.

2.3.1.11 Angle valve bodies and internals shall be of self draining

design.

2.3.1.12 The globe control valve bodies with top and bottom spindle
entries and butterfly valves shall have an easily reversable
action.

2.3.1.13 Flangeless valves (butterfly, ball, eccentric rotating plug

etc.) shall be supplied complete with tie rods for coupling
and the relevant nuts for installation between piping
flanges.

2.3.1.14 Body sizes 1¼, 2½, and 5 in. shall not be used.
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2.3.1.15 Tie rods and nuts materials shall be in complience with

standard ASTM A 193, A 320 and A 194.

2.3.1.16 Castings can be replaced with forged pieces but not vice
versa without any previous Owner approval.

2.3.1.17 Butterfly valves shall be of the heavy duty wafer type ,

designed to suit the pipe schedules or bores shown on the
data sheets.

2.3.1.18 Tights shut off valves shall have seals as specified on the
data sheets. Where grease seals are specified, supply
grease fittings, gun and IO LBS of correct grade of grease.

2.3.2 Trim

2.3.2.1 Trim materials shall be choosen according to Licensor

control valve specification and shall meet or exceed the
requirements of the piping material specification. The use
of alternate materials suggested by the manufacturer's
standard construction shall be subject to OWNER
approval.

2.3.2.2 Control valves for most applications shall be globe type

with single or double seated plug type trim with top and
bottom guiding for double seated and heavy duty top
guiding for single seated plug. Where appropriate, butterfly
type, rotary plug type (conventional or eccentric such as
"camflex") ball type shall be considered. Cage trim valves
shall normally be not permitted, except where the licensor
R2 process data sheets specified.

2.3.2.3 Plugs with a low torque are required for butterfly valves.
For throttling service, butterfly valve travel shall be limited
to 60° providing positive stops or other devices to prevent
overtravel in either direction.

2.3.2.4 Seating must be fixed to the body of the valve by means of

threading, and must be fitted with fins to facilitate
replacements. Threaded must be protected with "molikote"
powder or equivalent. The use of sealing compound is not
acceptable.

2.3.2.5 Plug shall be securely pinned to a threaded valve stem.

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2.3.2.6 For standard valves, leakage shall not exceed 0.5% of

rated capacity for double seated and butterfly construction,
nor 0.01% for single seated valves. Where leak tight valves
are specified, plugs and seats shall be ground and lapped
to give bubble tight shut off at the operating differential
pressure and temperature specified.

For all valves specified for batch blending service, plugs

shall be fitted with a retained sealing ring, designed to give
leak tight closure under maximum upstream pressure and
differential. Insert shall be PTFE, Viton or similar material,
capable of at least 12 months troublefree service in the
process fluid and at conditions specified.
For Licensed units, Licenser requirements for leakage
R2 classes shall be followed.
For Unlicensed units, leakage classes willl be defined by
Contractor according to process requirements

2.3.2.7 Control valve stem packing shall be teflon or approved

"non asbestos" alternate for services up to 400°F. For
operating temperatures above 400°F, grafoil (or equal)
packing shall be used without lubrıcator and isolating valve,
with standard bonnet and gland. A radiation fin bonnet or
extension bonnet shall be used where fluid temperatures
above 450°F or below 32°F. Extensions and radiation fins
shall be the same material as the valve body. One extra set
of packing for each valve shall be provided.

2.3.2.8 Internal cavities, where a fluid stagnation can cause

corrosion and/or crystallization phenomena must absolutely
be avoided for use on corrosive fluids or on fluids which
may crystallize (ex. urea, carbamate, etc.)

2.3.2.9 There shall be a difference of at least 125 BHN between

valve posts and guide bushings.

2.3.2.10 For angle valves plug diameter shall not be reduced

between the characterized section and the guide.

2.3.2.11 Except where tight shut off is required, butterfly valves shall
be swing through type, arranged for simple reversal of
action without extra parts. Discs may be plane, or
contoured to give enhanced operation characteristics. Tight
shut off valve shall have seals as specified in individual
specification.
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2.3.2.12 Butterfly valves bearings shall be outboard type, designed

to permit repacking of the shaft glands without removing
bearings.

2.3.2.13 Butterfly valves shall be fully protected against damage

from overload. Release devices such as shear pins, shall
be accessible for replacement without removing valve from
line.

2.3.2.14 Butterfly valves shafts shall be designed to withstand

maximum thrust with normal upstream and zero
downstream pressure, unless otherwise permitted by
individual specification.

2.3.2.15 Control valves in lethal services shall be fitted with bellows

seal and packing box. Seal bellows must withstand a
pressure equivalent to 1.3 times the maximum pressure
that is reached by the process fluid.

2.3.2.16 Valves with screwed seat rings shall not be used on steam
service.

2.3.3 Actuators

2.3.3.1 The standard actuator shall be diaphragm type with fully

enclosed spring designed to stroke valve fully with zero
down stream and max. upstream pressure or design
R2 pressure, springs must be surface treated so that they are
resistant to corrosion due to ambient conditions. Sizing
shall be done according to Licensor STD SPC.

For shut off valves actuator shall be sized in such a way

that it should be able to open the valve when full static
upstream pressure is acting on upstream in valve full
closed condition and down stream pressure is atmospheric
pressure. Actuator shall be oversized to 125% of the thrust
required for DP Shut off, as specified above. In short,
actuator shall be able to with stand max. shut off static
pressure with down stream atmospheric pressure, when
available instrument air pressure to actuator diaphragm is
minimum specified. Spring shall be painted with corrosion
resistant paint. All actuator open/vent port shall be provided
with breathers. Paint shall be min. epoxy type.

The actuator shall be sized to ensure operation under the

worst possible condition, i.e. with maximum differential
R2 pressure (difference between maximum upstream pressure
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and downstream pressure assumed to be zero) and with

the minimum actuator air supply pressure unless otherwise
specified licensor. However, actuators shall be sized 25%
more force than required throughout the complete valve
travel and shall develop sufficient seating load to insure
seat tightness and integrity. Actuators shall be sized to
operate with the air pressure specified on the data sheet.

Piston type actuator may be used where standard actuator

would be inadequate. Both types must be designed and
equipped to drive valve in the air failure direction called for
by the individual specifications. Piston type actuators shall
be complete with valve stem positioner.

2.3.3.2 Standard diaphragm material shall be high quality cloth

reinforced Neoprene or Buna N sheeting, withstanding 100
psi bursting pressure on 2" diameter. Moulded design to
give linear operation over valve stroke shall be supplied.

2.3.3.3 Diaphragm and case for self operated valve shall be

designed to meet process conditions and fluid. Use
stainless steel or monel diaphragms on fluids over 66° or
where valve head is traced. Diaphragm shall withstand an
overpressure of 1.3 times the maximum differential
pressure. Where valve is in differential pressure control, or
pressure ratio control, maximum differential pressure
means with low pressure side of diaphragm at zero psig.

2.3.3.4 The required thrust to stroke the valve as defined in item

2.3.3.1 shall be accomplished by applying area a 3-15 PSI
air signal. When the Vendor's largest diaphragm area
available does not produce sufficient thrust with a 3-15 PSI
air signal, a multiple thereof may be used other "bench
sets" are not to be used in order to undersize actuator.

2.3.3.5 Unless otherwise specified in the individual specification,

the manual control handweel shall be permanently
engaged side mounting type. For butterfly valves,
handwheel shall be declutchable geared type, engaging
disc shaft.

2.3.3.6 Actuater spring shall be stamped with identifying data and

given aluminized finish. Spring shall be adjustable with
valve in service.

2.3.3.7 Valve stem shall be designed to withstand maximum

developed trust, and shall be connected to actuator by
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threaded adjustment with positive locking device. Stem

finish shall be 2 to 4 micro-inches RMS.

2.3.3.8 Stand diaphragm case shall be steel, chemically treated,

and painted with paint resistant to chemical atmospheres.
Yokes shall be high duty modular iron castings, or
fabricated steel as a minimum.

2.3.3.9 Actuators without positioners shall be provided with gauges

to indicate loading pressure.

2.3.3.10 A stop, adequate to withstand the actuator thrust shall be

engaged in the full open position before the valve plug
reaches travel limit. In the closing direction, plug shall seat
before actuator reaches travel limit.

In case of butterfly valves stops are required at both open

and shut positions, and shall prevent actuator linkage going
over center.

2.3.3.11 Actuator for three way valves shall be direct acting unless
otherwise indicated on the individual specifications.

2.3.3.12 Standard signal and spring ranges are to be supplied

wherever possible. Actuators up to two sizes larger than
standard shall be used in preference to nonstardard ranges
unavoidable, valve positioners shall be fitted to operators in
throttling service.

2.3.3.13 Hand jacks for globe valves shall be permanently engaged

side mounting type. For butterfly valves, jack shall be
declutchable geared type, engaging disc shaft.
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2.3.3.14 For hand control valves, handwheels shall be nonrising

type with fine threaded stems. Parts shall be a precision fit
to prevent backflash.

2.3.4 Accessories
2.3.4.1 The manufacturer shall install and connect on the valves all
the accessories requested in the individual specification.
Unless otherwise specified the filters regulator and the
positioners, shall have ¼" NPT female couplings; the
pneumatic connection shall be carried out, 316 SS tubing
with 6 mm outside diameter and 1 mm wall thickness, with
R2 exception for the connection between the valve and
positioner which will be 12 mm and have a 1 mm wall
thickness. Where expressly required in the individual
specification, stainless steel AISI 304/316 tubing and
compression fittings in AISI 316 shall be used.

2.3.4.2 Each positioner shall be fitted with two weatherproof

miniature pressure gauges to pressure values of air signal
indicate the, outlet signal.

Smart HART positioners with diagnostic capabilities shall

be used to test for correct valve set up and to test for the
dynamic performance requirements. Smart positioner input
shall be 4-20 mA with hart communication protocol.

Positioners shall have adjustable gain. The

microprocessors of smart positioners shall have efficient
control algorithms that can improve the valve’s speed of
response when the user changes the operating conditions
of a process (setpoint change etc.). The microprocessor
can increase positioning repeability by up to 50%. Off-line
performance tests shall also be possible with these
diagnostic.

Irrespective of plants hazardous area classifications, all the

R2 positioner shall be Intrinsically safe to EExia/EExd-IIC-T6
(Double Certification) only and weatherproof to IP67.
Steady state Air consumption of the SMART positioner
shall not be more than 1.3 NM3/Hr. Positioner shall be
mounted on control valve so that it can be removed with
ease during the maintenance.

Positioner feedback link with control valve shall be fixed

with 100% secure mechanism so that there is no backlash in motions, resulting
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hysteresis or chance of dis-engagement of the link while

the control valve is installed with severs pipe vibrations.
Effort should be made to provide Smart Valve Positioners
with Magnetic Coupling for Position Feedback

2.3.4.3 Force balance positioners are preferred for general use.

Motion balance cam type positioners shall be provided
where special cam characteristics are called for.
Positioners shall be equipped with by passes wherever the
output and input air signals are the same range, but not
otherwise. Direct/reversal action selection shall be possible
at field with simple method.

2.3.4.4 Transducers input impedances shall be suitable for

operation with the isolated / nonisolated output cards of
DCS systems operating on 24 V DC, 4 - 20 mA output.
Transducers ınput will be 4 - 20 mA, output will be 3 - 15
psig or as required by the actuator, up to 95% of supply
pressure.

2.3.4.5 The connecting links between the positioner and the valve
stem outside the positioner case shall be in austenitic
stainless steel.

2.3.4.6 Positioners and transducers shall be weatherproof (min.IP

65) and be suitable for the specified electrical classification
and shall be continuously rated for operation in ambient
temperature range - 20°C to 70°C.

2.3.4.7 Positioners and yoke mounted transducers shall change

output no more than ½ % when subjected to vibration
frequencies of 0 to 60 cycles per second at a maximum of
1 g or 0.1" amplitude whichever is limiting.

2.3.4.8 Positioners and transducers shall be capable of reversing

output with a simple method without additional parts.
Transducer air capacity shall not be less than 4 Nm3/Hr
(150 Scfm) at 20 psi.

2.3.4.9 Where one controller output adjust more than one actuator
- except split range application- (e.g. louvers and
variablepitch fans) positioners, boosters or transducers
shall be installed at each actuator. Isolation valves shall
be provided for each actuator.

2.3.4.10 Accuracy of positioners and transducers shall be or better

then 0.5% of full scale.
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2.3.4.11 All control valves shall be equipped with smart hart

positioners.
If necessary pressure or volume boosters may be used
instead of a valve positioned.

2.3.4.12 Valve positioners equipped with features for selection of

the proper range shall be used for sequencing control
valves.

2.3.4.13 Magnetically operated limit switches are preferred.

Mechanically operated switches are generally not
acceptable and shall not be used without written approval
from Owner. Switches shall be DPDT type and min. rating
of 2.5 A, 220 VAC.

2.3.4.14 I/P transducers operating a single valve shall be mounted

such that the length of tubing between the transducer and
valve does not exceed 3 meters. If a single I/P transducer
is used to operate two or more valves, such as in split
range service, the valves and transducer shall be mounted
such that the total length of tubing from the transducer to
the valve does not exceed 3 meters; otherwise a separate
transducer shall be supplied for each valve.

2.3.4.15 Spring loaded, non - lubrıcated teflon packing is not

normally acceptable.

2.3.4.16 Unless otherwise requested, all auxiliaries are to be

mounted on the valve yoke and fully piped up.

2.3.4.17 Auxiliary equipment shall be complete with air filter /

reducers, and shall have one air pressure gauge
downstream of reducer, one on auxiliary output, and one
for each incoming signal.

2.3.4.18 Smart positioners, using the hart communication protocol,

shall give easy access to informatican critical to process
operation. This can be done using a hand held
communicator at the valve or at a field junction box, or by
using a personal computer or a system consol within the
control room.

Smart (digital) positioners shall have the following features:

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- Mounting of instrument shall be indepent of calibration.

Installed linearity of instrument does not depend on
mounting technique.

- Pneumatics and electronics shall be completely isolated.

- Direct instrument air moisture drain.

- Housing material shall be (min.) aluminium.

- PWB protection.

- Predictive, instead of prevent.

- Serviceability in the field or on the bench shall be very

easy. Master module can be replaced in a few minutes.

- Valve customization.

- Manual stroke (stroke up or down manually)

- Supply and output gauge protection.

- Talk terminals.

- Seperate wiring compartment.

- Loop current test points terminas.

- Supply and output gauges.

- Local keypad/display.

- Predictive maintenance.

- Remote calibration possible.

- Monitoring and diagnostics.

- Local security.

- Single/double acting.

- Direct/Reverse action

- LCD display with the buttons for the configuration

without HHC at field
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- Actuator pressure sensor.

- Integral position transmitter.

- IP 65 enclosure rating.

- Local/seperate terminals for hand held communicator.

Firmware capable of :

Set point range, characteristic curve (linear,=%, Q.0.) travel

range, trave alerts, min open/close time, cycle rounter,
travel accumulator, travel cut off (hi/lo), travel deviation
alert, dynamic by-pass, input filter, self test shut-down, auto
calibration.

Communicator capable of : configuring all parameters,

remote calibration, set up wizard, detailed help system.

PS based software capable of :

Configuring all parameters, all data stored with time/date

stamp, all data exportable, user secrrity, step response
diagnostic analysis, dynamic error band diagnostic
analysis, valve signatse diagnostic analysis, drive signal
diagnostic analysis, signal monitor, manual operation
screen, alert monitor, audit log.

Smart positioners shall use two-wire, 4-20 mA loop power.

The high cost of running seperate power and signal wiring
shall be avoided with two wire design.
Three hand held communicator and a note book PC with
software package and flow scanner diagnostic software
shall be provided to diagnose at a field junction box and
marshalling panels etc.

2.3.5 Solenoid Valves:

2.3.5.1 Solenoid valves shall normally be of universal three way

type unless otherwise specified in the individual
specification.

2.3.5.2 Solenoid valves shall normally be energized at 24V DC,

sealed type, fungus and moisture proof.

2.3.5.3 Electrical execution shall be EExd IIC T6 as per CENELEC

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EN 50018 code. Enclosure class shall be IP 65.

2.3.5.4 Solenoid valves shall be heavy duty type suitable for

continuous operation under 24 V DC voltage.

2.3.5.5 Pneumatic connection shall be ¼" NPT-F or ½" NPTF as

defined in individual specification; electric connection shall
be ½" NPT-F.

2.3.5.6 Body material shall generally be brass and internal parts in

stainless steel unless otherwise specified. Minimum orifice
size shall be 6 mm. Seats shall be of resilient type.

2.3.5.7 Solenoid enclosures shall be provided with sufficient room

to allow coil lead and wires to be spliced inside the
enclosure.

2.3.5.8 Where manual reset is specified its material shall be

stainless steel.

2.3.6 Direction of flow indication shall be engraved or embossed on the

body.

2.3.6.1 Limit switches, if specified in datasheets, shall be 2 wire,

NAMUR sensor, proximity type and P+F make only. This
shall be installed in weatherproof IP67 box. No flying lead
type connections are acceptable.

R2 Limit switches shall be certified as intrinsically safe to

EExia/EExd IIC T6 (Double Certification).

3.0 INSPECTION, TEST, DOCUMENTS AND CERTIFICATES

3.1 The manufacturer shall carry out the guarantee on the requirements of Licensor
Control Valves STD SPC.

CONTRACTOR to ensure the delivery of the following documents as a

minimum along with the valves .
Material certificate for control valve, all accessories and other bought out items
- GA Drawings, including all accessories
- Dimensional Cross sectional drawings of complete control
valve/accessories -All type of tests certificate like Hydrotest / seal leakage
test certificates
- Radiography test -IGC test as per ASTM A262, Practice A, Fig. 1
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- DP Test -Stroke calibration and stroke time test certificates

- Operation and Maintenance manual of control valve and all accessories
- Product catalog of control valve and all accessories
- Functional test certificates for all accessories
- Control Valve Drawings with exploded view showing part numbers and
locations of various parts.

The following standards/documents shall be used as design/test criteria.

- ASME B16.10 Face-to-Face and End-to-End Dimensions of Valves
- ISA S75.C1 Flow equation for sizing of control valves
- ISA S75.02 Control valve capacity test procedure
- ISA S75.03 Face to Face dimension for flanged globe style type
control valve bodies (Classes 125, 150, 250, 300 and
600)
- ISA S75.04 Face to Face dimension for flange less control valve
(Classes 150, 300, and 600)
- ISA 575.05 Control Valve Terminology
- ISA S75.11 Inherent Flow Characteristic and rangeability of control
valves
- API Std. 598 ISA Test procedure.
- ISA S75.13 Method of Evaluating the Performance of Positioners with
Analog Input Signals
- ISA S75.17 Control Valve Aerodynamic Noise Prediction
- ISA S75.19 Hydrostatic Testing of Control Valves
- NACE MR0103 (Where Sulfide Stress Cracking in Corrosive resistant
material required)
- EN 10204 European Certification Form
- PED “Pressure Equipment Directive 97/23/EC
- Valve Signature Series Test Report

3.2 The manufacturer shall guarantee that the performance listed hereinunder must
come within the following limits.

3.2.1 Pneumatic operation

3.2.1.1 Hyteresis : 5% of the travel

1% of the travel with connected positioner.
3.2.1.2 Dead band : 2% of the signal range
0.5 % of the signal range with connected
positioner.
3.2.1.3 Linearity : 5% of the travel
1% of the travel with connected positioner.

3.2.2 Sealing between the plug and seat

3.2.2.1 Double seat (metal-metal seal): 0.5% of the rated design flow
rate.
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3.2.2.2 Single seat (metal-metal seal) : 0.01% of the rated design

flow rate.
3.2.2.3 Single seat with soft insert : Perfect sealing.

3.3 The manufacturer shall provide below inspecting, testing a and certificates for
each control valve.

3.3.1 For unfinished materials:

3.3.1.1 Chemical analysis on material and origin/mill certificate
3.3.1.2 Mechanical tests of materials and origin/mill certificate
3.3.1.3 Visual inspection for steel casting and certificate by the
manufacturer. Quality standard for steel casting according to
MSS-SP 55
3.3.1.4 Ultrasonic examination and check certificate by manufacturer.

3.3.2 During fabrication:

3.3.2.1 Welding procedure records check for repairs and

certificates by manufacturer.
3.3.2.2 Welder's qualification records check for repairs and
certificates by manufacturer.
3.3.2.3 Radiographic tests on repair and certificate by
manufacturer. Tests are according to code ASTM-E-94/E-
142/E-446 and acceptance std. according to ASTM-E-446
and MSS-SP 54.

3.3.2.4 Hardness tests (trim/base material/quide/stem) and

certificates by manufacturer. The test stated by
manufacturer is valid.
3.3.2.5 Hydrostatic body test and certificate by manufacturer. Test
is according to Code MSS-SP 61.
3.3.2.6 Magnetic particles test and certificate by manufacturer
(Note 1).
3.3.2.7 Dye penetrant test and certificate by manufacturer (Note1).

NOTE 1 All castings, regardless of casting quality factor, for valves,

which are rated ANSI class 900 or greater shall be subject
to a magnetic particle or liquid penetrant examination and
radiography in accordance with the ASME Pressure Vessel
Code, Section VIII, Division 1, Appendix 7, paragraph 7-2
through 7-5.

When radiography is impractical because of small casting

size (2 inch or smaller), a helium mass spectrometer test
(probe technique) in accordance with the ASME Pressure
Code, Section V, Subsection A, Article 10, Appendix V, is
acceptable. The acceptance criteria for the helium test
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shall be in accordance with Section V, Article 10, Appendix

V. All other acceptance criteria and all repair methods shall
be in accordance with Section VIII, Division 1, Appendix 7.

3.3.2.8 Heat treatments on valve trim and certificate by

manufacturer.

3.3.3 Final test and checks

3.3.3.1 Check calibration and gauging of necessary

instrumentation for testing and certificates by manufacturer.

3.3.3.2 Compliance with specification and purchase order check

and certificates by manufacturer.

3.3.3.3 Visual and dimensional check and certificates by

manufacturer.

3.3.3.4 Sealing test at plug/seat according to code ANSI B 16.104

only when class V and VI are required with certificate by
manufacturer.

3.3.3.5 Sealing test at stuffing box and certificate by manufacturer.

3.3.3.6 Linearity/hysteresis/dead band checks and certificates by

manufacturer.

3.3.3.7 Suitability actuator check and certificate by manufacturer.

3.3.3.8 Noise check and conformity certificate.

3.3.3.9 Marking and flow direction check and certificate by

manufacturer.

3.3.3.10 Accessories check and certificates by manufacturer.

3.3.3.11 Check of safety execution and/or mechanical protection of

electrical accessories and official certification.

3.3.3.12 Summary certificates of employed materials.

3.3.3.13 Painting test and certificate by manufacturer.

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4.0 NAMEPLATE

Each valve shall be fitted with a corrosion resisting nameplate including the following
information.

4.1 Manufacturer's name or trademark

4.2 Valve serial number and model no

4.3 Maximum valve body pressure rating

4.4 Valve body material nominal pipe size and body sıze

4.5 Trim material, size and characteristics

4.6 Stem travel in millimetres

4.7 Valve action and operating signal characteristics.

4.8 Operating sıgnal range

4.9 Spring range

4.10 Bench setting

4.12 Flange rating

4.13 Tag number

A metal tag shall be wired to each lubrıcator specifyıng lubrıcant grade.

Equipment supplied loose shall have securely wired on metal plates blates
bearing tag number.

Pilot controllers shall have permanently fixed plastic nameplates showing

ınstrument tag numbers.

5.0 PACKING

5.1 Exposed machıned parts shall be coated with easily removable rust
preventative.

5.2 Exposed stems shall be protected by tape.

5.3 Flanged faces shall be protected by securely fastened wood covers.

5.4 Screwed ends shall be plugged.

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(X) ANALYSERS

1.0 REFERENCES

1.1 API RP 551, 552, 553, 554

1.2 Licensor STD.DWGs and SPECIFICATIONS
1.3 Environmental Normative:
 2001/80/CE Directive Regulation on the Large Combustion Plant
 2000/76/CE Directive Regulation on the Incineration of Waste
 2003/87/CE Directive Regulation on Emission Trade
 2001/81/CE Directive Regulation on National Emission Ceilings
R2  166/2006/EC Regulation
 EN ISO 14956/2002 Air Quality – Evaluation of the suitability of a
measurement procedure by comparison with a required measurement
uncertainly.
 EN 15675/2007 Air Quality – Measurement of stationary source
emissions. Application of EN ISO/IEC 17025:2005 to periodic
measurements.
 EN 15259/2007 Air Quality – Measurement of stationary source
emissions – Requirements for measurement sections and sites and
for the measurement objective, plan and report.
 EN 14181/2004 Stationary source emissions – Quality assurance of
automated measuring systems.
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 ISO 10780/1994 Stationary source emissions – Measurement of velocity

and volume flowrate of gas streams in ducts.
 ISO 14164/1994 Stationary source emissions – Determination of the
volume flowrate of gas streams in ducts – Automated method.
 EN 14790/2005 Stationary source emissions – Determination of the
water vapour in ducts.
 EN 15267-2/2007 Air quality – Certification of automated measuring
systems – Part 2: Initial assessment of the AMS manufacturers quality
management system and post certification surveillance for the
manufacturing process.
 EN 15267-3/2007 Air quality – Certification of automated measuring
systems – Part 3: Performance criteria and test procedures for
automated measuring systems for monitoring emissions from stationary
sources.
 ISO/IEC/EN 17025 General Requirements for the Competence of
Calibration and Testing Laboratories.

PARTICULATES
 ISO 10155/1995 Stationary source emissions – Automated monitoring of
mass concentrations of particles – Performance characteristics, test
methods and specifications.
 ISO 9096/2003 Stationary source emissions – Manual determination of
the mass concentration of particulate matter.
 EN 13284-2/2004 Stationary source emissions – Determination of the
low range mass concentration of dust – Part 2: Automated measuring
systems.
 EN 13284-1/2001 Stationary source emissions – Determination of low
range mass concentration of dust – Part 1: Manual gravimetric method.
GAS
 ISO 10396/2007 Stationary source emissions – Sampling for the
automated determination of gas emission concentrations for
permanently – installed monitoring systems.
 ISO 7935/1992 Stationary source emissions – Determination of the
mass concentration of sulfur dioxide – Performance characteristics of
automated measuring methods.
 EN 14791/2005 Stationary source emissions – Determination of mass
concentration of sulphur dioxide – Reference method.
 ISO 10849/1996 Stationary source emissions – Determination of the
mass concentration of nitrogen oxides – Performance characteristics of
automated measuring systems.
 EN 14792/2005 Stationary source emissions – Determination of the
mass concentration of nitrogen oxides (NOx) – Reference method:
Chemiluminescence.
 ISO 12039/2001 Stationary source emissions – Determination of the
mass concentration of carbon monoxide, carbon dioxide and oxygen –
Performance characteristics and calibration of automated measuring
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systems.
 EN 15058/2006 Stationary source emissions – Determination of the
mass concentration of carbon monoxide (CO) – Reference method:
Non-dispersive infrared spectrometry.
 EN 14789/2005 Stationary source emissions – Determination of the
volume concentration of oxygen (O2) – Reference method –
Paramagnetism.
 Environment Agency Technical Guidance, Note 13 Monitoring hydrogen
sulphide and total reduced sulphur in atmospheric releases and ambient
air.

2.0 GENERAL

2.1 Where possible "Insitu" analysers will be used to avoid the necessity for an
extractive sampling system.

2.2 Where extractive sampling systems and/or sample conditioning systems are
necessary, they shall be designed and provided by the manufacturer of the
analyser or analyser system. ASTM type sample probes shall be used where
samples must be taken from flowing lines.

2.3 Analysers shall also be protecteds with shelters meeting the recommendations
of the analyser manufacturer.

2.4 Walk-in type enclosures or analysers rooms, as required by climatic conditions,

analyser complexity or physically grouping of several analysers in a single
location, are subject to the following restrictions.

2.4.1 Walk in type enclosures or rooms shall not be located in ZONE 1

areas.

2.4.2 Walk in type enclosures or rooms housing two or more analysers

located in ZONE 2 areas, and housing two or more analysers in
nonhazardous area which enclose sample lines containing toxic or
flammable materials, shall be force ventilated to eliminate the
possibility of toxic or flammable gases accumulating within the
enclosure (shelter). Air conditioning shall also be provided.

2.4.3 Walk-in type enclosures and rooms housing two or more analysers
located in ZONE 2 area, and enclosing two or more analysers located
in nonhazardous areas which enclose sample lines containing
flammable and toxic gases shall be provided with a continuous
explosivity and toxic gas detecting analyser which will provide visual
and audible alarm in case toxic and explosive gases exceed certain
level.
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2.4.4 The manufacturer shall design and furnish the analysers, sampling
systems, sample return pump (if required), etc., to provide a complete
operating system.

2.4.5 Redundant forced ventilation system with "clean" air intake, (physically
and chemically filtered to assure corrosive/acidic component free air)
shall be provided for shelters/houses to maintain 5 mm WC internal
R2
overpressure with at least 10 changes/hour of internal air changing
capacity. A "U" tube type pressure indicator shall be provided. An
audible and visual alarm shall be provided in case of internal pressure
drops down 2,5 mm WC, common gas detectors malfunction and when
standby fan automatically starts running. Each alarm shall be repeated
also in the main control room.

2.4.6 Gas cylinders for calibration or carrier gas shall be rigidly mounted
outside the walk-in enclosure. All regulators, gauges, cylinder gas
piping manifolds and driers (if required) shall be provided by the
manufacturer. All calibration gases shall be provided with contractor for
one year operation.

2.4.7 Sample pressure reduction, conditioning, fast loop piping or sample

return pumps shall be installed outside the walk-in enclosure to
minimize hazards within the enclosure.

2.5 Analysers shall be installed whether individually or in analyser houses, with

particular attention to accessibility for operation, calibration and maintenance.

2.6 Reproducibility shall be  1% of span or better.Repeatability is defined as thee

closeness with which an analyzer repeats indications when measuring identical
values of the variable under the same conditions.

2.7 Sensitivity shall be  0,5% of full span or better.Sensitivity is defined as the

smallest change in a variable capable of causing a measurable corresponding
change in signal output.

2.8 Analysers shall meet a CLASS I DIVISION I (Zone 1) classification

requirements unless the analyser is located in a nonhazardous atmosphere and
the composition or amount of the sample inside the analyser is insufficient to
produce an explosive or ignitable mixture in the event of component leakage or
failure.

Approved analyzers and equipment which are required for hazardous areas
shall be labelled, listed or certified by an internationally recognized testing
organization such as ATEX, Underwriters Laboratory (U.S.A.), BASEEFA (U.K.)
OR P.T.B. (Germany). Where such equipment is not available, its design shall
conform to standards of a nationally recognized testing organization. Purging of
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cabinets, analyzer systems etc shall be avoided as far as possible. Where there
is no other option but purging to meet area classification, purging shall be
carried out as per NFPA-496 " Purged Enclosures for Electrical equipment"

2.9 A completely fabricated sample conditioning system shall be provided by the

analyser manufacturer. Provisions for measuring flow to the analyser shall be
included.

2.10 For analysers requiring cooling water, closed loop cooling water system with
pressure and flow measuring provisions shall be provided.

2.11 All components in contact with the sample shall be 316 stainless steel (as a
minimum.)

2.12 The sample conditioning system and the analysis section shall be located at
grade as close as possible to the sample tap.

2.13 Analyser enclosures shall be heated if the ambient temperature can drop below
50F.

R2 2.15 Other auxiliary equipment shall be located in the control house. (Recorders are
not used due to discontinued for analyzers).

2.15 Sample taps shall be made on the top of pipes. For pipe sizes up to and
including 20 inch, sample taps shall extend into the midpoint of the pipe with a
R2 45 degree beveled edge on the down stream side. In lines above 20 inch, the
immersion shall be 10 inch, minimum. (See API RP 555, Section A Part 4).

2.16 Sample taps shall be located at least 12 pipe diameters from the junction of two
streams, or at least 12 pipe diameters downstream of a pressure reducer,
where two phase can exist.
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2.17 An additional connection shall be installed on sample line immediately

upstream of the analyser for laboratory check.

2.18 All connected piping to the instrument and its sample conditioning system shall
be identified by permanently attached labels, marked with the same
designations as used on the drawings for the analyser.

2.19 A suitable system shall be provided to return the spent liquid sample to the
process line.

2.20 Self cleaning filters with 100 mesh stainless steel, filtering flow to the sample
conditioning system shall be provided.

2.21 Rotameters shall be armored type and shall be provided with block and by-pass
valves permitting rotameters to be removed for maintenance.

2.22 Where reverse flow is possible, a check valve in return line shall be provided.

2.23 To verify proper operation and calibration, provisions shall be made for
introducing a standard sample of known composition into the analyser.
Introduction of the sample shall be by manually operated valves at the analyser
location. It shall not be necessary to disconnect any tubing or piping to
accomplish this operation.

2.24 Vent lines subject to condensation of moisture or hydrocarbons, or both, shall

be steam traced or electrically traced and shall have a low point liquid train.

2.25 A convenient access to the sample location shall be provided.

2.26 Multistream analysis using one analyser shall not be used unless approved by
the OWNER.

2.27 Analyser manufacturer shall provide on year supply of a certified calibration

sample and all equipment necessary for field installation, including valves, pipe
fittings, regulators, etc. Calibration injection shall be made by manually
operated valves at the analyser location. If the composition of the calibration
samples deteriorates with time are not acceptable for field calibration. The
manufacturer shall propose an alternate field calibration procedure to the
OWNER approval.

2.28 A calibration curve for each analyser shall be furnished by the manufacturer.
Demonstrated deviation from the calibration curve shall be maximum of  1% of
span.

2.29 The power for all devices associated with a given analyser system shall be
supplied from the same source and each system shall have a single disconnect
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switch for the entire system. In addition, disconnect switches shall be installed
to permit isolation of each device in the analyser system.

2.30 The manufacturer shall furnish a competent service engineer to review

installation and supervise calibration and initial start-up and site training
activities for each analyser.

Beyond this requirement OWNER shall have the right within the scope of
purchase order to call for inspection of each analyser once within the defect
liability period by Manufacturer service engineer. Site visits after the defect
liability period will be executed by Manufacturer service engineer on basis of
Owner request and at Owner charge. The number of visits shall be up to three
in five years.

2.31 Automatic periodic flushing facilities with cleaning agent shall be provided for
PH meters. Only in case of coating, slurry and highly polluting fluid applications
R2
like waste water shall be used.

2.32 Metallic type filter instead of ceramic for measuring probe of O2 analyser shall
be used.

2.33 Oxygen analyzer shall be provided below convection section, one for each flue
gas outlet from the convection section when convection section flue gas outlet
is more than one.

2.34 All parts exposed to the process shall be resistant to the specified process fluid.
All parts exposed to the atmosphere shall be resistant to the atmospherıc
conditions.

2.35 Where feasible, a local indicator showing measured value of sample shall be
provided for calibration purpose.

2.36 Vendor shall specify certified gases which are necessary for operation of
analyzers ( zero and span calibration gases, etc.)

2.37 Electronic instrument signals shall be 4 - 20mA.

2.38 Electrical connections for cable entry shall ½ inch NPT - F.

2.39 When used as components of analyzer itself, electronic transmitters shall be

smart type with high frequency alternatıng current communication method over
4 - 20mA signal.

2.40 Wetted and process connection materials shall generally be according to

Licensor. In hydrogen service loose materials shall be pipe following piping
R2 specification as minimum. Rigid pipe shall be considered for H2 service, from
process line to analyzer shelter, but the arrangement of the sample conditioning
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system and sample line to the analyzer inside shelter will be used tubing
321/347 Stainless steel.

2.41 During transportatıon, threaded end connections shall be protecded with plastic
plugs or caps.

2.42 Where applicable, all the electrical connections on the analyzers shall be
provided by means of terminal block.

2.43 Required special devices for calibration and maintenance purposes shall be
provided.

2.44 Chromatograph is a stand alone, unit architecture based microprocessor

controlled instrument consisting of chromatograph, proper sample conditioning
system and programmer which is capable of working and generating hardwired
and serial outputs without the aid of any external device.
Programmer is a microprocessor based device which is a part of
chromatograph and controls the overall functioning of the system and also
provides hardwired analogy and serial outputs.

Analyzers shall be of the latest but proven design of the supplier.

2.45 Analyzer is defined as a specialized instrument used for measuring or inferring

physical or chemical properties or chemical composition, of gases, liquids, or
solids in process streams.In general analyzer and sampling systems shall be
designed and constructed in accordance with API-MPMS (Relevant portions).
Analyzers shall be suitable for outdoor installation and the specified
environment. CONTRACTOR shall not offer any prototype instruments in his
bid. All instruments offered should 'have been proven in refinery or
petrochemical plants before bidding.

Sample conditioning equipment is defined as a combination of modules

installed in the upstream of an analyzer used to prepare process samples for
analysis.

2.46 As a rule, no single analyzer (detection system) shall be used for measurement
of more than one component except chromatographs which can be multi
stream multi component type based on requirement. Process Stream sampling
shall be continuous. As a minimum, all analyzers shall provide one isolated 4-
20ma signal along with 2 potential free contacts to the control system. In
addition to the above, Chromatographs and IR analyzers shall be provided with
2 wire RS485 serial link with MODBUS protocol for communication with central
DCS.
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2.47 In the case of Analyzer houses, the electrical power supply distribution shall be
as follows:
- 3 phase, 4 wire, 380 Volts, 50 Hz power supply from Emergency Panel will be
used to feed motors <150 kW, ventilation fans, HVAC compressor, pumps, etc.
R2 A distribution board shall be mounted outside the analyzer House.
- All 220 VAC power supply, except the Analyzers and Safeguarding Systems,
shall be derived from the 380 VAC 3 phase feed from Emergency Panel. 220
volt, 50 Hz power supply will be used to feed house single users and house
lighting. A distribution board shall be mounted inside the analyzer house.
- Analyzers and Safeguarding System shall be powered with 220 VAC from the
plant UPS.

2.48 Analyzer enclosures and accessories shall be suitable for the specified
electrical area classification. As a minimum, the electronic unit of all the
analyzers shall be to the following standards :
- Weather proof housing IP65 as per IEC-529 / IS-2147
- Flame proof housing Flameproof Ex (d) as per IEC-79 / IS-2148
(Flameproof equipment shall also be made weatherproof)

2.49 All interconnecting wiring shall be color coded / numbered and terminal blocks
clearly identified.

2.50 The design of analyzer system shall be in compliance with the electromagnetic
compatibility requirements as per IEC-801.

2.51 GENERAL SAMPLING SYSTEM

2.51.1 As a rule, separate sampling systems shall be provided for detection of

each component unless stated otherwise. The sampling system shall
be furnished with all the necessary equipment and accessories to
condition and regulate the sample so as to supply the analyzer with a
continuously representative and measurable sample.

2.51.2 The sampling system shall be engineered, designed, fabricated and

furnished completely assembled as an integral part of the analyzer or
as a separate package. The sampling system shall be designed on the
basis of the utilities available as indicated in the basis of design of this
enquiry specification. The analyzer Vendor shall provide a completely
fabricated sample conditioning system.

2.51.3 Each sampling system component shall be capable of being removed

without disassembling the entire system.

2.51.4 If a separate sampling system is furnished, it shall be designed for

easy integration with the analyzer in the field.
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2.51.5 Sampling system design shall be such that the sample drawn for
analysis is truly representative of the process stream. Extra care shall
be exercised in the selection of the various components forming the
sampling system. Minimum material of construction for the sample
system components shall be SS 316.

2.51.6 Sampling system shall be designed to move the sample from the
process to the analyzer proper in the shortest possible time.
Transportation time for the sample from the process tapping point up to
the sampling system shall not exceed 30% of the cycle time specified
for the chromatograph. Sample tube material shall be selected based
on process fluid requirements and tube size shall be recommended by
vendor to suit process condition and avoid possible plugging. Any heat
tracing requirement of sample tubing such as condensible process
vapour shall be fulfilled using appropriate tracing with temperature
control. No sample shall be vented to atmosphere unless specifically
indicated otherwise. Sample disposal scheme shall be as per P&ID or
agreed upon before implementation.

2.51.7 Sampling system shall consist of one or more of the following

components as required by the service conditions: filters (coarse and
fine) pressure regulators, relief valves, flow indicators, flow controllers,
temperature indicators, scrubbers, heaters, coolers, dryers, sample
pumps, aspirators, flame arrestors, solenoid valves, etc. Any additional
equipment required shall be included by CONTRACTOR.
CONTRACTOR shall provide the facility of Auto calibration using
solenoid valves unless stated otherwise.

2.51.8 Filters shall be always dual and it shall be possible to remove and
replace one of the filters without upsetting the operation of the
analyzer. Pressure reduction where required, shall be provided with a
safety valve downstream. Variable area flow meters shall be provided
for Fast Loops.

2.51.9 Process sample return point, if needed and utilities as required will be
made available near the analyzer at pressure and temperature
conditions specified in the data sheet for each analyzer as single point
supply and return. In general, all the offered items are to comply with
maximum pressure and temperature data specified. Multi-point
distribution of utilities and process sample as needed, is to be
arranged by CONTRACTOR following good engineering practices.

2.51.10 The sampling system, analyzer, etc. shall be supplied pre-mounted on

a self-standing panel in general. The panel shall have holes to anchor
it to the ground with anchor bolts. The panel shall be weatherproof to
IP 55, as a minimum. All components in contact with the sample shall
be stainless steel unless otherwise specified
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2.51.11 Consumables / accessories such as Calibration cylinders. Gas

blending cylinders, Fuel gas cylinders etc. shall be supplied along with
the analyzer system keeping in mind the requirement for Start-up,
commissioning and 2 year's normal operation. Calibration gases shall
be furnished with testing and validity certificates. Cylinders shall be
stored external to the analyzer room with suitable mounting
accessories for the same. Cylinders shall be supplied in 2 sets such
that at any point of time, 1 set is in use and the other is for storage /
refilling.

2.51.12 The sampling system shall contain at least one wire mesh strainer of
US standard sieve mesh size 100 or finer. Where purchaser's data
sheets indicate greater possibilities of plugging, vendor shall provide
more filters / separators as required. Where purchaser's data sheets
indicate possibilities of polymer formation of presence of excess
polymers, vendor shall offer suitable design features to minimize
plugging because of polymer residue.

2.51.13 Wherever the process stream pressure is low, CONTRACTOR shall

provide the sample pumps. CONTRACTOR shall also indicate the
utility requirements (e.g. Water or air) for such device. Sampling
system shall include provision for connection of calibration standard.

2.51.14 For multi stream chromatographs separate sample handling sub-

assembly for each Stream shall be provided with stream selecting
valves and it shall be located as close as possible to the analyzer room
to minimize connecting tubing length and possibility of cross-
contamination of samples. Stream selecting valves shall have bubble
tight shut off and shall be fail closed so as to block the samples from
analyzer. Multi stream sample system shall consider the use of double
block with atmospheric pressure configuration with scavenging to
prevent cross-contamination.

2.51.15 When fast loop is specified, CONTRACTOR shall be provide flow

meters for sample bypass flow. Sample return line to process shall be
provided with isolation valves and check valves. In case of multi
stream gas chromatographs, separate fast loop return lines shall be
provided for each stream. Return pressure shall be higher than the
pressure of the process destination point specified by purchaser.

2.51.6 Interconnecting wiring shall be color coded and numbered. All terminal
blocks shall be dearly identified, and all individual terminals shall be
clearly marked. Bigger size and fused type terminals with the same
specifications may be used based on the requirement. CONTRACTOR
shall take care for separation or shielding of power and signal lines, or
both.
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2.51.7 Sample probes shall be considered within 4” process line and bigger.
R2
2.51.8 Analyzer shelters and analyzer cabinets shall be built hot dipped
galvanized steel with the external walls in specific color code RAL
7035 and the internal shelters walls finished with white epoxy paint.

2.52 SPECIFIC ANALYZER GUIDELINES:

2.52.1 Infrared / Ultra Violet Analyzers

Type of analyzer selected shall based on process data. The analyzer

system shall consist of the following:
- Sampling system
- Detector, amplifier and transmitting electronics
- Integral indicator with 0-100% percent linear reading with LCD

Analyzers shall be of the non-dispersive type. Special filters shall be

provided to minimize the interference of background components,
which are of least interest in the process stream. Windows and cells
used in the unit shall be suitable for the specified service. The following
performance characteristics shall be met, as a minimum.
Accuracy : +/-2% of full scale Repeatability : +/-1% of full scale Noise :
Less than 1% of full scale Span and zero drift : +/-1% full scale per day
Speed of response : Less than 5 seconds for 90% of final reading

2.52.2 Density / Specific Gravity Analyzer

The analyzer system shall consist of the following :

- Sampling system
- Detector, amplifier, transmitter electronics
- Converter

However, CONTRACTOR may offer direct probe type detector without

a sampling system if the service conditions permit. In such a case,
design shall ensure on-line removal of detector without any process
upset and all system components shall be capable of withstanding
max. design pressure/temperature of process fluid.
The sensing portion shall not employ any mechanical moving parts.
The measurement of density of liquids shall not be affected by
variation in pressure, flow rate or viscosity of the process fluid. The
density / specific gravity sensor shall have built in temperature
compensation.

The converter shall be a microprocessor based programmable unit and

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shall provide isolated analog current output as specified in the data

sheet.

The analyzer must offer +/-0.1% of span accuracy and +/-0.01% of

span repeatability.

2.52.3 Moisture Analyzer

The analyzer system shall consist of the following :

• Probe assembly or cell

• Sampling system
• Transmitter electronics
• Analyzer control unit

Probe Assembly -The probe when mounted inline shall not be

damaged by severe shock and vibration conditions. Each probe shall
be supplied as calibrated and shall be provided with its own calibration
curve.

The control unit of analyzer shall be solid state programmable type.

The electronics shall be self calibrating.The control unit shall provide
the following:

- Isolated analog current output signal

- A built in dual high and low set point alarm with SPDT contacts
- Direct read-out of ambient temperature in LCD
- Automatic sequencer of sequential readings of same points in multi
stream analysis.

The following performance characteristics shall be met as a minimum.

Accuracy : ± 1% of full scale
Repeatability : +/-0.5% of full scale
Sensitivity : 0.5 parts per million by volume

2.52.4 Oxygen Analyzer

2.52.4.1 Paramagnetic Type

The analyzer shall consist of Sampling system Sensor,

microprocessor based analyzer electronics and transmitter
unit with local LCD readout
The analysis shall not be affected by changes in
background gas composition.
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It shall be possible to change the range of measurement

with the help of a selector switches or by programmatically
from the front LCD display unit.
The measurement shall not be affected by changes in
sample pressure, flow rate, sample vent pressure and
ambient temperature.
Analyzer failure alarm shall be provided, in addition to
isolated 4-20 am output for DCS indication.
Paramagnetic analyzer shall meet the following
performance characteristics as a minimum:
Accuracy : +/-1% of full scale
Repeatability : +/-0.005% of oxygen
Response time : 5 seconds for 90% Response

2.52.4.2 Electrochemical Type For oxygen measurement

Electrochemical analyzer shall not be used.

2.52.4.3 Zirconia Type Oxygen Analyzer

These shall be both, insitu probe ( For Flue gas
application) type as well as with sample handling system
with analyzer installed in the analyzer room. It shall consist
of the following:
Shield assembly and adapter plate
Probe assembly
Microprocessor based analyzer and Control unit
Reference gas
Controller

Shield Assembly:

The shield assembly shall be attached to the stack or duct

through the adapter plate and shall provide mechanical
support and thermal insulation for the probe. All the
accessories like adapter plate, gaskets, and bolts required
for mounting probe and shield assemblies shall be supplied
by CONTRACTOR

Probe Assembly:

The probe assembly shall contain the measuring cell,

heater, thermocouple, ceramic filter and provisions for
reference and calibration gas connections. The measuring
cell shall be zirconia type specific for oxygen.
The cell shall be calibrated over a range of 0.1 to 20.9% oxygen. A calibration curve
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shall be furnished with each cell. The probe assembly shall

be flanged to the shield assembly. Probe assembly shall be
suitable for operating over sample temperature upto 750°C.
For higher temperature the probe may be located outside
the furnace and eductor is to be provided for drawing
sample out of furnace.

Control Unit:

The control unit shall contain all required microprocessor

based controls, indications including temperature control
for normal system operation and shall also provide output
signal. A solid state temperature controller shall maintain
cell temperature. Temperature sensor shall be ISA type K
thermocouple.
Temp controller shall shutoff heater power incase of
thermocouple bum out.

Reference Gas Control:

Reference gas shall be flow and pressure controlled.
Pressure shall be controlled by self-actuated pressure
control valve provided with pressure gauge.

It shall be possible to change the range of measurement by

a selector switch located on the front panel of the control /
analyzer unit.
Analyser shall provide isolated 4-20 ma dc output for DCS
and analyzer failure alarm contacts for connecting them
with DCS.
Following performance characteristics shall be met. as a
minimum:
Accuracy : +/-2% of Full scale
Repeatability : +/-0.2% of full scale
Response Time : Less than 10 seconds for 63%
Response

2.52.4.4 FLUE GAS ANALYZERS

Flue gas-monitoring system, typically used for measuring

emissions of heaters, stacks etc. Typical components
measured shall be SOx, NOx, CO / CO2. O2, and Opacity.
Dilution type for SOx and NOx and extraction type for CO /
CO2 with principle to meet the required specification and
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performance unless otherwise specified. Flue gas

analyzers for emission monitoring shall meet all EPA, USA
etc. requirements.

Probes shall be provided with necessary filter and material

suitable for process and temperature condition. Dilution
shall take place near the probe where dilution is specified.
Sample tubes shall be SS for dilution systems and
electrically traced and armoured Teflon tubes may be used
for extraction systems. The sample conditioning system
shall provide a fast loop condensate knock off system.
In general. NDIR principle for CO / CO2, UV for SOx and
Chemiluminascence /FTIR for NOx/N2O detection shall be
used. However, any proven superior detection system is
also acceptable.

2.52.5 THERMAL CONDUCTIVITY ANALYZER

The analyzer shall be supplied for hydrogen analysis is synthesis gas

complete with sampling system. It shall be microprocessor based 4-20
mA DC signal output with communication capabilities.

2.53 CALIBRATION

- Analyzer Vendor shall provide a two-year supply of certified calibration

sample, and all equipment necessary for its field installation, including
valves, pipe fittings, etc. Calibration sample injection shall be by manually
operated valves at the analyzer location. This includes supply of various
calibration gas cylinders, SPAN/Zero Gas Cylinders, Carrier Gases for GC,
Fuels gases for GC, etc. with pressure regulators/gauges in all the cylinders,
including those supplied as stand-by or spares.

Gas or liquid samples that deteriorate with time are not acceptable for field
calibration. Examples of samples having a composition that deteriorates with
time if stored in a cylinder include: hydrogen or gas mixtures, hydrogen
sulphide in gas mixtures, moisture in gas mixtures, and samples with
components present in amounts less than 20 ppm.

- If calibration samples cannot be provided due to restrictions

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regarding stability, an alternate method of calibration with all required set of

instruments/ calibration cuvettes, etc. shall be provided by CONTRACTOR.

- During calibration, the deviations of actual calibration from the calibration

curve supplied by vendor shall be within +_10% of the specified value. If
deviations within +/-10% are not achieved at site, then necessary
modification to the analyzer system shall be done by vendor without any cost
implication to Owner.

- For each gas Chromatograph, a dual cylinder carrier gas system shall be
dedicated one to each chromatograph providing automatic switchover to
standby cylinder when the first cylinder is exhausted. Number of cylinders
supplied by vendor shall be adequate for 2 years continuous operation. In
case of dual range of measurement, separate calibration standard for each
range shall be provided. Calibration standard supplied by vendor shall be
adequate to last six months. Also, Fuel gas cylinders for FID/FPD detector
for three months continuous operation. Each of the calibration gas and fuel
gas cylinders shall be provided with two stage pressure regulator. For carrier
gas manifolds, pressure regulator shall be provided on the manifold for each
cylinder.

- All analyzers shall be calibrated using a test sample showing 50% of scale
reading for the component of interest. Deviation of actual calibration from the
calibration curve supplied by vendor shall be within +/-1% of span.

- Repeatability shall be demonstrated for a period of at least 8 hours

continuously using a standard sample, unless otherwise specified. For infra-
red & ultra-violet analyzers, the preparation of components in the test
sample shall be changed to confirm the absence of interference from
components other than components of interest.

2.54 ADDITIONAL REQUIREMENTS FOR CHROMATOGRAPHS

Chromatograph shall be microprocessor based and constructed in accordance

R2
with basic principles of APl-RP 554. The Gas Chromatograph system shall in
general, consist of the following:

- Sample conditioning system including sample probe

- Chromatograph analyzer
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- Programmer / Controller
- Gas Cylinders for calibration standards, carrier gas and fuel gas.
- Communication Interface

Process Stream sampling shall be continuous. Following performance

characteristics shall be met as a minimum:
Sensitivity shall be ± 0.5% of span. Reproducibility shall be 1 % of span.
Accuracy shall be ±2 % of span.
The analyzer performance shall be within the specifications when the supply
voltage changes by 10 % of the specified value and supply frequency change
by ±_3 Hz of specified value. Battery back-up shall be provided for the volatile
memory.

Pick detection mechanism shall be fully electronic and shall not use recorders.
It shall be available in front LCD display of analyzer in real time basis.

Components of any sub-assembly that requires removal / maintenance shall

be removable without having to disassemble any other components. Such
components include items like stream selector valve, sample inject valves,
filters, pressure regulators, plug-in circuit, cards and detector cells.

Sampling valves shall be of special design to minimize peak tailing and

baseline separation problems.

The chromatograph chamber shall be maintained at a constant temperature

level. When the detector is of the thermal conductivity type, the temperature
shall be maintained within +/-1° C. Where multiple temperature controlled zones
are involved in a single Chromatograph, each zone shall be well insulated so
that the temperature of one zone does not affect that of another. All the
temperature controlled zones shall be operated at a temperature well above the
maximum ambient temperature. Provision shall be made for manual
temperature control.

The carrier gas system shall be complete with the supply of carrier gas bottles
and instrumentation for flow control. The carrier gas system shall use minimum
of threaded connections and fittings. These shall not be lubricated. Whenever
hydrogen, gas is used as carrier gas, the associated fittings and enclosures
shall be made flameproof to IEC Zone 1 Group IIC requirements.

With each chromatograph, vendor shall provide a pressure switch to shut off power
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supply to the detector during loss of carrier gas flow, so as to prevent any
damage to the detector.

All electrical components of the chromatograph shall be suitable for the

electrical area classification specified and shall be by a way of Flameproof
design certified for Ex-d IIC/T6 by CENELEC.

Base line drift during one analysis cycle, without auto-zero, shall be less than
1% of auto-zero adjust span.

Column life shall be expected minimum of six months during normal operation.
One spare set of columns shall be provided with each chromatograph. For
calibration blends, stability will be 1 year from date of commissioning.

CONTRACTOR shall supply the following items with each chromatograph:

- Carrier gas specification, and a device for measuring all flows during an
analysis cycle. This may be a portable burette with soap solution, a
calibrated draft gauge or permanently mounted rota meters.
As a minimum, the following alarms shall be provided as a minimum in the
form of Dry contacts for connecting them with central DCS.
Low Sample Flow, Low Instrument air pressure, Low carrier gas pressure,
Low detector Flame, Low Fuel pressure, Low detector flame, Low air
pressure
The programmer shall be dedicated to each chromatograph and shall be an
integral part of each chromatograph in this field. Programmer shall do the
following as a minimum:
- Properly control the analysis cycle
- Provide chromatogram outputs on LCD Monitor attached with Program
- Provide hardwired analog outputs for each components to analysis,
- Provide digital output to communication interface device
- Automatic zero adjustment and calibration of the chromatograph system.
- Maintenance diagnostics to be included in the software to allow rapid
troubleshooting in the event of system malfunction.
- Audio-visual alarms shall be provided for detector temperature deviation
and zero off-set, as dry contacts

During power failure or on communication failure between chromatograph and

programmer, the chromatograph shall revert to safe condition (back flush).
The communication interface is a 2 wire RS485 serial communication link
working over MODBUS protocol for interface between the chromatograph and
Owner’s central DCS or host computer. Unless otherwise specified, the
communication interface shall have the following capabilities:
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- Communicate the values for all measured process variables in the DCS in
a form (scaled variable or engineering units) consistent with the DCS data
highway. Each process variable will be designated by a unique point
identification or address. For multi stream analyzers, the same component
will have unique point identification or address for each stream.

- Individual component output of the chromatograph shall be transmitted to

DCS in the form of isolated 4-20mA dc signal for each component of each
chromatograph. Till the next cycle, these analog output values shall be hold
by chromatograph to the last analyzer value.

- Communicate the sample point no./data being used currently to the DCS
for multi stream analyzers. This will facilitate multiplexing of various analog
inputs with a fixed set of analog input channels on DCS. Communicate
individual chromatograph diagnostic alarm to the DCS for display and use
in DCS control strategies. This alarm must include a maintenance
diagnostic i.e. technician working on a chromatograph. if not provided
separately.

- Communicate selection of measurement range, stream and calibration

sample selection from DCS tc chromatograph for chromatographs with
these features.

- Communicate a system alarm for the common chromatograph

communication.

- Communicate a system alarm for the DCS interface hardware and

software. The logic and control of multi stream chromatograph is in the
scope of the chromatograph vendor. The interface shall enable the console
operator to select, which sample points are addressed by the
chromatograph. The DCS operation shall be able to select any combination
such as remaining on one sample point or cycling through a selected
subset of the possible points.

2.55 ANALYZER INSTALLATION

In general, analyzers shall be located in analyzer houses. CONTRACTOR shall

check the required numbers of the analyzer houses to be installed analyzers for
the all plants. All standard installation practices provided by vendor shall be
followed as a minimum.
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CONTRACTOR to calculate the exact amount of space required for all

analysers and additional 25% spare space for future installation of analyzer is
to be considered. The main objectives of analyzer rooms is

- To create a space within, an otherwise Div. 1 area, in which under normal

operating conditions a non hazardous atmosphere exists so that testing or
calibration of analyzers and maintenance can be performed with opened
casings and electrical circuits alive.
- To create a good environment in which analysers and their associated
equipment are adequately protected against adverse weather conditions.

The analyzer room shall be located as close to the analyzer sample points as
possible to reduce sample tubing lengths. Analyser room shall be provided with
a main door and an opposite door for emergency exit. Both doors shall be
openable outward with safety glass windows and automatic door closer.
Extension roof of @ 1000 mm shall be provided on both the doors.

Analyser rooms shall be able to house all the analyzers designated to that area,
including all sample conditioning accessories, etc. The calibration gas, carrier
gas and fuel gas cylinders shall be kept outside the analyzer room with a
structure provided at outside of the wall. Proper platforms shall be provided with
chain support to keep the cylinders with due care and safety.

Analyzer rooms shall be provided with air conditioners in such a way that the
inside temperature shall be 24’ C +/-1’C. The air conditioners shall provide once
– through A/C only and there shall be min. 10 nos. of single room volume
scavenges per hour. Air conditioners and all components shall be suitable to
plants hazardous area classifications and temperature class.

Analyser may be installed on self standing rack inside the room along with
sample handling system components, etc. There shall be flameproof power
supply junction box for powering up various analysers. Only 1 feeder to each
analyzer shall be fed from this junction box. Further distribution shall be done
by CONTRACTOR inside the analyzer cabinet/panels. There shall be analog
R2 and digital signal exchange junction box outside the analyzer room, preferably
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mounted on the side walls, for various signal exchange between analysers and
central DCS. There shall be multi pair cable laid between central cabinet
room/DCS and individual analyzer room junction boxes.

Analyser room shall be provided with proper lighting supply and illuminations.
The analyzer house shall be provided with fluorescent lamps to provide an
R2 illumination of 500 lux inside the shelter and 400 lux outside the shelter at
working levels.
Fluorescent lamps shall also be provided outside of the analyzer room for
carrying out the repair / adjustments on the equipments mounted on outside of
the analyzer shelters e.g. sample conditioning systems etc.

It shall facilitate cable, sample tubing entry/exist through the various cutouts on
the side wall at a height inside the room. All the entries shall be sealed to
prevent the loss of air conditioners.

Analyser room shall be equipped with all safety measures like panic bar at the
doors. Emergency alarm push buttons, LEL gas (hydrocarbon) detectors, Fire
detection system, Fire extinguishers, wash basin etc.

All electrical equipments, fittings, fixtures shall be Flame proof suitable for
hazardous area classification.

All safety valve outlets from the analysers shall be terminated in a common
header of 2" NB schedule 808 SS 304 pipe and single outlet shall be provided
outside the shelter with one non-return valve and lock open type 2" ball
valve.Similarly all vents to atmosphere shall be terminated in a similar 2" NB
Sch 80 S SS 304 pipe and single outlet shall be provided with non-return valve
and Lock open type 2" ball valve.

All analyzer room shall also have utility tapings from main pipe headers form
the main plant with proper isolation valves outside the analyzer room. This shall
include instrument air, utility Nitrogen and service water as a minimum.

All type of cables /tubing entry in the analyzer rooms shall be through Multi
Cable Transit (MCT) blocks to ensure gas tightness of the analyzer rooms.

All tubing work shall be done by using ½” , ¼” or 1/8” OD, SS316, Swagelok,
R2 Parker or Hoke only, type of double compression fittings only.

All wiring / tubing and all other erection work shall be done in accordance to API
RP 552.
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All cable entries / outlets in the junction boxes / distribution boxes etc and to the
analyzer shall be provided with double compression type certified flame proof
SS cables glands.

2.55 GAS Detectors:

A PLC shall be installed in each shelter. Gas Detectors shall be hardwired to

F&G plant System and their configurable relay outputs shall be hardwired to
R2 shelter PLC. According NFPA Smoke Detectors, MAC, Horns and Beacons
shall be hardwired to the F&G plant. The F&G plant shall provide a Fire Alarm
to the shelter PLC. Apart from the junction boxes for analog and digital signals
to be hardwired to DCS. In Analyzer shelters shall be considered three
additional junction boxes for F&G signals, one for analogue outputs, one for
digital outputs and one for digital inputs. Alarms annunciators shall be installed
in each shelter, one inside

2.55.1 LEL detectors:

- LEL detectors shall be SMART infrared type having 4-20 mA 24

VDC analog and digital HART output mode selectable with
software configuration, without any physical modification including
R2 diagnostic capabilities. Detectors shall be weatherproof to IP65
and Flameproof to EX-d IIC/T6 irrespective of the plants
hazardous are classification, so that it can be re-used in any area
in case of emergency.
- Necessary splash guard and dust shield shall be provided.
- LEL detectors shall be provided with local LCD type indicators.
- Material of construction shall be SS 304 with an accuracy of ± 2%
URV. Calibration kit with gases for minimum 2 years operation
after warranty period shall be provided. Separate gases shall be
provided for warranty period.
- LEL detectors shall be connected via junction boxes to the PLC of
R2 Fire and Gas located in Technical Room. The required windows
such as alarms and graphics etc. of the fire and gas detection
system shall be displayed on DCS screens. Engineering work
stations of F&G systems shall be installed in the
computer/engineering room of the control building

- Cable distance limitation between the detectors and Technical

R2 room shall be confirmed by CONTRACTOR bases on plant lay out
and LEL detector locations. Flying leads from the detector head
are not acceptable. The installation points shall also include diff.
analyzer houses also

- Hand held communicators with recharging kit shall be provided

with Gas detectors.
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2.55.2 H2S/CO DETECTORS

- H2S/CO detectors shall be SMART electrochemical type having 4-

20 mA 24 VDC analog and digital HART output mode selectable
withsoftware configuration, without any physical modification
including diagnostic capabilities. Detectors shall be weatherproof
R2
to IP65 and Flameproof to EX-d IIC/T6 irrespective of the plants
hazardous are classification, so that it can be re-used in any area
in case of emergency.
R2 - DELETED.
- Necessary splash guard and dust shield shall be provided.
Detectors shall be SMART-HART type with local LCD indication
- Material of construction shall be SS 304 with an accuracy of ± 3%
URV.
- Calibration kit with gases for minimum 2 years operation after
warranty period shall be provided. Separate gases shall be
provided for warranty period.
R2
DELETED.

H2S/CO detector shall be connected via junction boxes to the PLC of

Fire and Gas located in Technical room. The required windows such
R2 as alarms and graphics etc. of the fire and gas detection system shall
be displayed on DCS screens. Engineering work station of F&G
systems shall be installed in the computer/engineering room of the
control building.

For all the H2S/CO detectors, 2 No's of portable purge calibrators each
consisting of a volume bottle containing a known gas/air mixture, a
pressure regulator, a flexible hose and adaptor cap (to fit the sensing
head) shall be supplied to enable calibration of the sensors in the field
without dismantling them.

Gas detection system shall be sourced preferably from one vendor as

a whole system. The system shall be designed based on fail safe
philosophy. Construction and performance of gas detection system
shall be in general as per following applicable standards:

- Hydrocarbon : BS EN -50054 and 50057

- Hydrogen Sulphide : API RP 55
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2.55.3 Fire and Gas devices in analyzer Shelters

In the case of analyzer shelters, following Gas Detectors and F&G
R2 devices shall be installed:

- HVAC air supply duct to shelters:

• Two flammable Gas Detectors.
• Two Toxic Gas Detectors.

- Inside shelters at lead following quantities of detectors shall be

considered:

• One Flammable Gas Detectors.

• One H2S/CO Toxic Gas Detectors.
• Two heat Detectors.
• One Oxygen Deficiency Gas Detector.

- Two Manual Alarm Call Points (MAC) shall be installed in each

shelter door, one inside and one outside.

- Two Audible Alarm horns, one for Fire Alarm detection and one for
Gas detection.

- Three Beacon Lights, yellow for toxic gas detection, red for fire
detection and blue for flammable gas detection.

A PLC shall be installed in each shelter. F&G devices shall be

hardwired to Plant F&G PLC through junction boxes. The effect signals
shall be hardwired from the plant F&G PLC to the shelter PLC in order
to develop the logic for the HVAC management.

Apart from the Junction Boxes for analogue and digital signals to be
hardwired to DCS, in analyzer shelters shall be considered three
additional junction boxes for F&G signals, one for analogue outputs,
one for digital outputs and one for digital inputs
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3.0 CHECKS AND TESTS

3.1 When the analyzer and associated sample conditioning equipment are
completely assembled, OWNER shall subject them to inspection a factory test .
For a factory test as follows:
The factory test shall be an operating test, and it is the manufacturer's
responsibility to provide all facilities required to demonstrate the analyser in
accordance with the individual specification and this standard. The Owner or his
representative shall witness and approve all factory tests and reserves the right
to approve the test procedure.

3.2 Reproducibility shall be demonstrated continuously for a period of 8 hours

minimum using a standard sample. For samples which deteriorate over an 8
hour period, reproducibility may be demonstrated by calibrating the instrument
before and after 8 hours of operation and comparing the results of the
calibration. Results should check within  1%.

3.3 Calibration shall be demonstrated with a test sample giving approximately one
half scale reading for the component of interest. The concentration of the
component of interest in this test sample should be at least 25% of span
different from the concentration of the sample component in the standard
sample used for reproducibility test.

3.4 Accuracy and stability checks (Base line drift check on data sheet) shall be
performed.

3.5 Functional check comprising all the peripheral units such as printer, recorder,
etc. shall be performed.

3.6 Visual and dimensional check along with rated data check and marking check
shall be done.

3.7 A functional test using a radio set about 160 MHZ with a power of 5 WATT shall
be performed to check radio frequency immunity.

3.8 Ancillaries (i.e, sampling system and all other auxiliaries fit) shall be checked in
regard to for process fluid rating physical and chemical conditions with special
attention to seals (gaskets, O-rings etc.)

3.9 Visual check regarding suitability to environmental conditions and mechanical

protection (IP...) shall be performed.
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3.10 For all items above check certifications by the manufacturer shall be provided.

3.11 Prototype certification for mechanical protection (IP...) test (as per IEC 529
code), suitability to environmental test (according to MNF STD) and for safety
execution shall be provided.

3.12 Correspondence checks to the prototype shall be provided with a conformity

certificate.

3.13 Program print-out check and paragraph chart check shall be performed and
certified by manufacturer for chromatographies.

3.14 OWNER or OWNER representative (third party agency) shall have the right to
witness to all above mentioned checks and tests.

3.15 For chromatographs, a chromatograph of a standard calibration sample is

required before auto-zero. This chromatogram shall show attenuator setting,
trend baseline time scan rate, sample injection period, auto-zero period and
switching points for all auxiliary valves such as 'back-flush' etc. Each peak on
this chromatogram shall be labeled and attenuator setting noted. The
composition of the standard sample shall appear on the chart with all elusion
times of all components listed.

3.16 For infrared analyzers, the proportion of the components in the test sample
shall be varied to demonstrate freedom of interference from components other
than those of interest.

3.17 A leakage test shall be conducted on the entire system. Maximum permissible
leakage rates are as follows:
- Gas systems, 5% change per hour of the specified design pressure
- Liquid systems, no visible leakage.

4.0 NAMEPLATE IDENTIFICATION

4.1 Equipment identification number.

4.2 Pressure rating of pressure holding parts.

4.3 Manufacturer's name, model, serial number, operating range, voltage

frequency, and materials of parts exposed to process fluids.
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5.0 DOCUMENTATION

Copies of all instruction manuals and drawings shall be supplied for all the analyzers.
These shall cover the following as a minimum:

- Internal wiring diagrams,

- Interconnecting diagram showing all connections and shielding requirements.
- Markings for wire color coding or numbering, and for terminal identification, shall be
identical to those actually in the analyzer
- Complete hook up diagram of all analyzer, a drawing of pipe connections for the
analyzer and sample conditioning system.
- Detailed installation instructions,
- Calibration procedure
- Complete parts list
- Recommended spare parts for two years operation & commissioning
- Troubleshooting procedure
- Bill of materials for the sample conditioning system showing manufacturer's
catalogue numbers for all major components,
- Copy of the factory inspection sheet and test/calibration reports
- Copy of the testing organizations certificates showing the analyzer's suitability for
use in hazardous atmospheres.
- System wiring diagram including analyzer / chromatograph, programme and
communication interface etc.
- Wiring detail of communicator link and MODBUS protocol software details
- Circuit diagram of all electronic PWA.
- Cabling details including shielding / grounding requirements.
 Section : TGPS –J1
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(XI) ACCESSIBILITY

1.0 REFERENCES

Licensor standard specification

2.0 GENERAL

Instrument installations shall be designed for safe and convenient access for the
purpose of operation, maintenance of seals, calibration, other routine maintenance, as
well as for ease of construction and instrument protection. Primary sketches and hook-
up drawings of ınstrument installations shall be prepared in accordance with their
accessibility.

3.0 General criteria for accessibility for instrument installations are as follows:

3.1 Wherever possible, the centerline of instruments shall be 1400 mm above

grade or platform, with the exception of d/p flow transmitters which will (in some
cases) be line mounted close to the flow element.

3.2 Instruments, their process connection, and piping configuration shall be

oriented so as not to obstruct operating and maintenance areas.

3.3 Control valves shall be located with sufficient clearance above the diaphragm to
allow for diaphragm case plug and stem removal (min. 300 mm between the top
of the diaphragm and the underside of the nearest obstruction above it). Valve
manufacturer's drawings are to be consulted to insure sufficient clearance and
sufficient access to valve positioners and handwheel operators.

3.4 500 mm clearance shall be provided at the instrument process connections to

allow for rodding-out.

3.5 Gauge glass and level instruments shall be located adjacent to each other and
the gauge glass shall be readable from any valve which controls the level in the
vessel.

3.6 Where access to an instrument is from a platform, the instrument shall be

mounted not more than 2100 mm above the platform, or a permanent ladder
shall be provided. The use of portable ladders for access from platforms is
prohibited.
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3.7 All flow transmitters shall be accessible from platforms or grade unless
specifically approved by OWNER. The closed coupled arrangement is preferred
and impulse lines can be detoured at minor cost to gain accessibility to
transmitters from permanent platforms or grade. It is not intended to build
platforms solely for access to transmitters and where access from existing
platforms can not be easily obtained, transmitters shall be grade mounted
remote from orifice.

3.8 All ınstrumets (thermocouples, switches, gauges, transmitter, control valves,

safety valves, orifices etc.) shall be accesible from platforms, ladder or grade
unless specifically approved by owner.

3.9 The location for the meter runh and meter installation shall be selected to
provide accessibility from platform or grade. ( Up to certain meters mobile
platform could be used unless specifially approved by owner.

3.10 Primary sketches and hook - up’ s will be prepared in accordance with
accesibility
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TYPE OF ACCESS

Portable
Ladder or
Portable
Max. 7'-0" Above Platform Max
Grade or Permanent Permanent 22 Feet
Platform (Note 2) Ladder Above Grade
A. Instrument Process Connections
Instrument Tap on line or equip. X X X
Orifice flange X X X

B. Instruments which are located

at their process connection
Thermocouple X X X
Dial Thermometer (Note 1) X X X
Test Well X X X
Level Gauge (Note 1) X X -
Displacement Level Trans. X X -
Level Float Switch X X -
Control Valve X - -
Relief Valve X -
-
C. Instruments which may be located
remote from their process con-
nection
Temperature Transmitter X - -
Flow Transmitter X X X
Flow Indicator (Note 1) X - -
D/P Level Transmitter X - -
Pressure Gauge (Note 1) X X X
Pressure Switch X - -
Pressure Transmitter X - -
Analyzers X - -

Note 1: Instrument must be readable from the operating position.

Note 2: Access to items located more than 7’-0" above a permanent platform shall be by
permanent ladder only. Portable ladders are not to be used for access above
platforms.
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(XII) INSTRUMENT PIPING DESIGN

1.0 REFERENCES

1.1 Licensor STD. SPC.

2.0 INSTRUMENT PROCESS PIPING

2.1 This specification gives directives for the design, selection criteria, methods,
instructions and examples of instrument design scope of work. This shall be
read in conjunction with the general specification specified and individual
instruments specifications given in other parts of this document.

Any conflict between the requirements of this specification and related codes,
standards, data sheets, drawings, requisition, etc., shall be referred to the
Tüpraş for clarification. The instrument design scope of work covered by this
specification shall be designed and constructed in accordance with the
requirements of this specification and the edition of the applicable National
and/or International Codes and Standards. In cases of conflict between
standards the most stringent requirements shall apply.( API : American
Petroleum Institute API 551 : Process Measurement Instrumentation etc. )

This instrument design specification provides the basis of design for instrument
drawings and documents, instrument subcontracts and instrument installation
material requisitions. Project requirements that differ from this specification will
be submitted as exceptions with requisitions and subcontracts.

All instruments shall be mounted as close as possible to the process

connection provided. Maintenance and accessibility requirements are to be
taken into account. The length of the impulse line shall be minimal. The location
of instruments shall be such that direct drainage of condensate, water or
process fluids from adjacent equipment has no adverse effect.

All instruments, which require calibration or frequent periodic maintenance,

shall be accessible in either from ground or from a permanent finished floor of a
building with maximum inside height of 4½ m, so that an instrument can be
reached by using a portable ladder of 4 m high or from a permanent platform.
Accesibility of instruments located higher than 4½ m shall be done by a
permanent platform.
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Instruments shall be mounted on a vibration free place. Special care shall be

taken for heat expansion.

The interface connection between piping and instruments is always after first
isolation valve provided by piping group. No instrument needle valves shall be
used as first isolation valve. The various piping / instrument connections details
are given in this document.

Instrument piping up to and including the first block valve and inline instrument
equipment shall conform to the line class or vessel rating concerned. The
specific requirements will be found in "Piping Specification". The first block
valves shall be minimum ¾" size (½" size at orifice flanges) and will be installed
as close as possible to the process tapping. Piping for instrument connections
to process shall meet the minimum requiredments of OWNER’ s piping
specifiications. ( TGPS - L )

2.2 Socket weld pipe, valves and fittings shall be used for dead ended instrument
installations, with pipe threads allowed at vent, drain, rod-out, and instrument
connections only.

2.3 Piping for level gauge glasses, float type level switches, and external displacer
type level instruments shall follow the applicable piping specification, threaded
connections in socket weld piping specifications allowed at vents, drains, and
instrument connections only.

2.4 All process connections of instruments (including pressure gauges) shall have
block and vent/drain valves located near instruments. Additional block valves
for remotely mounted instruments shall be installed near the instruments.

2.5 If vent/drain connection not available on displacer level transmitter, float type
level switches, flanged hold rings having vent/drain connections shall be used.

2.6 In case of use of 3" stand-pipe for multi connections of level instruments
separate vent and drain connections shall be provided for stand-pipe apart from
the level instruments.

2.7 All vent and drain connections shall be furnished with gate valves and threaded
end caps.

2.8 Materials of construction for piping, valve and fitting materials to be used for
instrument-process connection shall conform to the corrosion, temperature and
pressure requirements of the process systems to which they are connected.
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2.9 Screwed connections are used when piping specifications allow. Seal welding
shall be applied for all screw connections except end connections for
instrument, vent/drain, rod-out and manifold block (if any).

2.10 Generally breaking flanges shall be applied for instruments removal as close as
possible to instruments.

2.11 Drain piping to sewer for displacement/float type level instrument shall be
provided.

3.0 INSTRUMENT AIR PIPING

3.1 Instrument air piping material shall follow the piping specifications for main and
branch headers up to and including the block valve at the individual users.
Between the block valve and the instrument, 6mm and 12 mm ODx 1 mm
R2 thickness stainless steel tubing shall be used with stainless steel compression
type tube fittings. The same type tubing shall also used for instrument
pneumatic signal lines .Piping for instrument air shall meet the minimum
requirements of OWNER’ s piping specifications.

3.2 Air supplies to the block valves at individual air sets at local controllers, control
valves, etc.., shall be ½" galvanized carbon steel pipe. All air piping shall be
galvanized inside and outside.

3.3 Maximum number of air users for branch headers shall be as follow:
½ inch for 1 to 5 taps, ¾ inch for 6-10 taps, 1 inch for 11-15 taps, and 1½ inch
for 16 to 20 taps. Branch headers shall have shut-off valves at the main air
header.

3.4 All branch headers shall have minimum 1 valve spare of 1/2" size connected to
each branch header for future spare needs.

3.5 All main and branch headers shall have valves at the dead ends for blowdown.

For points related with instrument control philosophy and design of complete
R2 RUP Project refer to Technical Specification for Control Philosophy and
Instrumentation Design, Chapter 29000
 Section : TGPS –J1
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(XIII) ALARM, SHUTDOWN AND INTERLOCK SYSTEM

1.0 REFERENCES

1.1 IEC Relevant standards.

1.2 SAMA PMC 331 Electromagnetic susceptibility of
process control instrumentation.

2.0 ALARM/ANNUNCIATOR SYSTEM

2.1 Alarm/annunciator system shall be independent of the DCS providing audible

and visual alarms to selected abnormal conditions and shall utilize modular
microprocessor based ( each module shall have its own processor, 32 bit or
higher, with its own separate memory) integrated system of distributed
hardware and software with high speed event management feature.

R2 2.1.1 Push button for trips will be hardwired from ESD matrix console to
remote ESD in CCB.

2.1.2 With an IBM compatible PC, printer and user interface software, which
are all in the scope of supply, it shall be possible to configure and
calibrate system even during operation. The software shall operate in a
MS - WINDOWS environmental making use of DDE capabilities, thus
allowing other windows application would make use of data for
additional processing and / or analysis. Events and alarms shall be
saved to a text file as well as immediate printing feature.

2.1.3 It shall be able to drive annunciator lamps, push - button inputs and
horns. It shall be possible to select any sequences and first - out
grouping shall be possible through program.

2.1.4 Modules operation shall be independent of PC and each module shall

have its own processor ( 32 bit or higher ) with its own separate
memory having at least 1000 event recording capacity.

2.2 Alarm switches (trip-amp units) shall be dedicated hardware, operating directly
from remote ESD in CCB. When digital control systems are used, these alarms
R2 shall be repeated into the operator station alarm display and logging facilities in
DCS console graphics
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2.3 Each window shall be fitted with two lamps.

2.4 The operating sequence for normal process alarm shall be as per below item
2.6.

2.5 The operating sequence for alarm annunciators which monitor shutdown of
process equipment such as fired heaters, compressors, incinerators, etc. , shall
include "first failure" facilities. This system will be of the triple flash type and will
have the following operating sequence.

Process/Signal Initiating Annunciator Window Audible

Status Switch First Fault Subsequent Alarm
Fault

-Normal Closed Black Black Silent

-Fault Opens Intermittent Steady
fast flash fast flash Sounding
-Accept P/B Open Slow flash Steady on Silent
operated
-Reset first fault Open Steady on Steady on Silent
-Process cleared Close Black Black Silent
-System test Closed Intermittent Intermittent Sounding
P/B operated fast flash fast flash

2.6 Alarm switches shall be of the normally energized closed contacts which shall
open for alarm (fail-safe). They shall be supplied with 24 d.c. from alarm
system.

2.7 The annunciator shall incorporate connections permitting individual in puts to

operate with the initiating contact normally open.

2.8 Alarm switches shall have DPDT (double pole double throw) contacts having
appropriate contact rating for interfacing to alarm system.

2.9 Alarm systems for installation in hazardous area such as local compressor
panels, pump house panels etc. shall be self contained (e.g. GEC lite-alarm)
explosion proof assemblies.
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2.10 All major pieces of processing equipment requiring a local operating panel shall
have all alarm and shut-down annunciator points on the local panel duplicated
on the main panel. The local panel is to be considered unattended during
normal operations.

2.11 Adequate isolation facilities shall be provided on alarm and control systems to
enable maintenance to be carried out on individual units without affecting the
operation of the other units, and also without affecting the safety of personnel or
the plant.

2.12 Alarm system shall be sectioned such that each process unit or process section
(each DCS console if distributed control systems are used) shall have its own
complete individual annunciator system.

2.13 Field mounted annunciator panels shall be explosion-proof or intrinsically safe

type incorporating two lamps for each alarm point, horn and
R2
acknowledge/reset/test buttons.

2.14 Input/logic cards in the alarm logic system shall be grouped such that no card
shall include alarm point(s) from different process units. Even in the same
process unit, each major process equipment (i.e. compressors, heaters,
pumphouses, etc..) alarm points shall be grouped on a separate card(s).

2.15 A minimum of 20% spare capacity shall be provided in alarm annunciator

systems. All spare capacity shall be provided with logic cards and windows
equipped with lamps.

2.16 Single large window annunciators will be installed on the panel above each
individual process section to act as a group alarm. This window will flash every
time an alarm occurs on the individual process section and is designed to assist
the operators in quick location of alarm conditions in busy multi process section
control rooms.

2.17 When an alarm unit is connected to equipment having its own power supply the
connection shall be made via an interposing relay to ensure complete
segregation. The interposing relay shall be certified barrier relay.

2.18 Alarm/annunciator systems (local and control room) shall be powered by the
control room UPS.
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2.19 The logic cabinet shall be so sized to ensure sufficient space to allow minimum
20% for future installation.

3.0 SHUTDOWN (TRIP) SYSTEM (SIS/ESD)

3.1 The shutdown system-SIS shall be functionally independent from all other
control systems such as DCS (monitoring and controlling system). All
components shall be of the latest generation, reliable and in current production.
Shutdown system shall be based on use of fail safe -fully triplicated architecture
( TMR) or quadruple architecture QMR (redundant architecture) thoughout
(approved for Safety Class-6 (AK6) as per TUV and IEC 61508 SIL 3 certified),
from the input modules, through the main processors, to the output modules, in
order to maximize reliability and process availability with system diagnostic
capability. There shall be 3 logic solvers ( microprocessors) running in parallel.
The I/ O and the logic solvers shall be voted 2 out of 3 or 2 out of 4D, and the I/
O or a single logic solver can be replaced while the system is online shall check
continuously for faults in the system hardware. During each cycle a full memory
test should be carried out.
The logics will be shown in the NORMAL OPERATING CONDITIONS (i.e in
absence of trips). In this condition all flows, pressures, levels, temperatures and
electrical power are at the respective normal operating values.

The various logics will operate according to the “DE-ENERGIZE TO TRIP”

(FAIL SAFE) principle:
Input contacts · Closed on process operating conditions (1 = closed)
(Initiating device) · Open on trip or alarm condition (0 = open)
Output contact · Closed on process operating conditions
(Responses) · Open on trip conditions.
· Open on power loss.
Solenoid valves · Normally energized on process operating conditions
(1= energized)
· De-energized on trip conditions (0 = de-energized)

3.1.1 Functionalities:

The SIS system shall be such as to provide:

- A safe automatic shut-down of the plant, equipment or
machineries upon detection of a potentially dangerous abnormal
condition;
- An interlock system to protect valuable equipment during all
operation phases;
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Features to minimise spurious shutdowns;

- "fail safe" (failure to safe) behaviour in case of system failure; this
feature has to be certified by recognized certification bodies.
- Facilities for testing, that shall be automatic, or manual, and
on-line. Input and output by-passes (where necessary) shall be
with dedicated alarm to indicate the "by-pass on" condition.
- Physical and electrical separation between I/O of independent
process units, also with use of a common logic processor, or,
where specified, with dedicated CPU's for groups of units;
- A global field maintainable design with room for future expansion;
- Automatic documentation of the implemented application software;
- Self diagnostic capabilities with facilities for system performance
monitoring.

3.1.2 The SIS system will be based on a PLC, with a fault tolerant (TMR -
triple modular redundant), fail safe architecture.A TMR (or QMR
redundant) PLC system is intended to be an equipment that utilises 3
(2x2) processors with identical logic, and duplicated or triplicated
input/output circuits. Different solutions to meet the fault tolerant
requirement shall be proposed by the VENDOR for TÜPRAS review
and approval. The SIS system shall be TÜV certified, according to
DIN-19250 AK6 (IEC 61508 SIL 3, 2oo3 or 2oo4D).

3.1.3 SIS Structure

The SIS system shall have the following characteristics.

- Modular architecture, with separate I/O circuits, processor
modules and communication modules, with possibility of remote
installation of I/O cards (connected to the CPU's by means of
redundant fibre optic cables);
- The possibility to replace any module "on line" without disturbing
the operation of the process or requiring any part of the system to
be powered down;
- The "auto spare" feature to allow the replacement of a defective
I/O module (i.e., in case of a module failure, the system shall
automatically switch to the back-up one);
- System diagnostic to identify all possible cover faults through
testing. Testing shall be either within each scan by software (SIFT)
or by hardware (HIFT) or a combination of these;
- For TMR PLC system, the following is requested:
- Selectable degradation sequence of 3-2-0 or 3-2-1-0. For
example, the 3-2-0 requires the TMR protective system to fail to
safety if, after a failure in one channel, a failure in a second one
occurs.
- The system shall be fault tolerant. Any failure in one of the three
channels in input, output, or processor modules shall not cause
any process malfunction.
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- Each I/O shall be processed by each one of the three processors

(or processor set) through a 2 out of 3 voting logic.

3.1.4 Output Circuits

- Output signals shall be, as a principle, directly connected to field

devices to allow a loop integrity check (stuck-on/stuck-off
detection) and to minimize the number of components in the loop
itself; this minimizes the possibilities of malfunctions due to
component failures.
R2 - Output signals driving (DELETED) and electrical motors shall
require interposing relays with DPDT contact of 220V AC 2,5 A
rating minimum.
Relays shall be powered by the PLC. When relays are to be
installed on critical outputs with TMR PLCs, three relays shall be
wired to three output channels in a "voting configuration". This
configuration requires each relay to have two normally open
contacts on a single armature. A failure of any one contact or coil
will not cause a spurious shut-down and will not prevent the
opening of the output circuit for a desired shut-down. With this
arrangement, the fault tolerant structure is fully preserved.
- Output circuit shall be individually fused, on both legs if the output
is floating.

3.1.5 RAM memories shall be with battery backup; the system shall be
suitable to maintain the memories for two years.
The battery charge state shall be continuously monitored.
A special alarm shall be generated when the required maintenance
times cannot be ensured.
All batteries shall be replaced with no interruption of the functionality
of the
associated memories.

3.1.6 Scan Time

The system must process the analog I/O and loops within the
maximum times specified below:
- analog inputs 20 msec.
- thermocouple inputs 1 sec.
- control loops 250 msec.

Logic or sequential control functions performance times shall be as

follows:
- SOE digital inputs 1 msec.
- digital inputs 20 msec.
- digital loops 100 msec.
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The system shall have SEQUENCE OF EVENTS RECORDING facility

for all inputs with 1msec resolution. This software shall have facility like
history of SOE, report generation and data transfer on a separate,
dedicated PC.

3.1.7 Field Interface (System/Marshalling Cabinets)

3.1.7.1 Cabinets
Both the system and the marshalling cabinets of SIS shall
be VENDOR’s own production, Rittal or equivalent, of the
same model and dimensions and subject to approval. The
IP rating for the cabinets in the equipment room shall be
IP43. The cabinets shall have the following specifications.
R2 - free standing, enclosed type;
- RAL 7035
- designed for bottom cable entry;
- vent louvres backed by wire fly screen (with ventilation
fans if heat dissipating devices are enclosed);
- lamp with door switch;
- doors equipped with lockable handles and concealed
hinges with pull pins for easy door removal;
- clamping rails shall be provided for incoming cables;
- safety ground bar;
- isolated instrument (reference) ground;
- temperature and fan status;
- name plate of appropriate dimensions (white engrave
on black background).

All metal parts of the cabinets including doors shall be

electrically continuous and wired to the safety ground bar.
Cabinets shall have enough space for maintenance
operations, especially for connection/disconnection
operation of internal wiring for terminal blocks.
R2
DELETED.

There shall not be any components on the lowest 100 mm.

of the marshalling cabinet mounting plate. This space can
not be considered as spare space in calculations.

The DCS/ESD panels and all system hardware shall be

located at central cabinet rooms in the close vicinity of new
Central control room and remote cabinet rooms. This
cabinet room shall accommodate all marshalling panels,
PDB panels, DCS/ESD system hardware panels, Barrier
panels, relay panels, other control package unit hardware
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panels e.g. Bently Nevada vibration monitoring system

panels, WOODWARD Digital Governor Panels, Speed
system panels, etc. etc.

DELETED.

3.1.7.2 Wiring Requirements:

- I/O card modules shall have front connectors to

facilitate module change without rewiring.
- Terminal blocks (KLIPPON/Weidmüller/Phoenix
Contact/MTL/P&F or equal) shall be of clip-on
disconnect type with LED fuse blown indication for the
field terminals and disconnect test type for the
intermediate terminals, which are suitable for wires up
to cross-section of 2.5 sqmm. All the terminals used in
the cabinets shall be of the same width to facilitate
wiring. Terminals shall be either tinned or silver plated
and terminal number shall be clearly identified.
- PVC insulated stranded copper wires shall be used.
VENDOR shall size the internal cables.
- Wire ends at terminal blocks shall be provided with
suitable compression type wire pins (AMP or
equivalent).
- Removable cover plates shall be provided over all
terminals with voltage above 50 Volts.
- The spacing between terminal blocks for each type of
signals shall be provided.
- All electrical instrument shall be mounted in such a
way that positive earthing is provided by metal to metal
contact to cabinet.
- Each wire internal to marshalling shall have identifying
markers. Using sleeve or plastic ferrules at all terminal
points. Markings, at each wire end (terminal point)
shall include incoming and outgoing terminal/card or
instrument identification.
- Terminal strips shall have an identifying marker
indicating their number.
- Minimum separation between power and signal wiring
shall be at least 300 mm if they are running in parallel.
- Within one multiconductor cable only one type of
signal (voltage level) shall be contained.
- Wires in the same conduit or support shall be of the
same type of signal (voltage level).
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- The electrical wiring shall be subdivided into following

categories:
- 220 VAC 50 Hz
- AI/AO (4-20mA) & RTD
- DI/DO (24 VDC)
- Solenoids
- T/C, mV signals

3.1.8 FIELD SENSORS PHILOSOPHY

- The use of transmitters as shutdown initiators is preferred to

switches.
When this field devices are triplicated, a median select routine in the
application program shall be implemented. To monitor the
performance of the transmitters it an excess deviation occurs
against the calculated median this shall be highlighted through a
common alarm; at the system maintenance station, details of
transmitter status will be displayed.
- When switches are used as an input to the system they are to be
voltage and ground free and closed during normal operation (in
accordance with the "fail safe" principle). Instead, proximity switches
and limit switches will close to the status that is to be monitored
(closed when shut, closed when open and closed when running).
- Final shut down devices (trip devices) such as solenoid valves shall
be designed and installed to cause a shut-down of the equipment
when de-energised.
- Voltage level for solenoid will be the same for all the plant; therefore
it will be defined during project basic design.
- Each solenoid shall be driven from a single output of the SIS
system; each coil must be continuously monitored for open circuit
(stuck-off detection).

3.1.9 Engineering workstations of SIS shall be a high performance and

commercially available PC stations capable of engineering and
configuring SIS. Necessary programming systems shall be provided to
allow; off-line configuration, programming, documentation and testing
capabilities. It shall permit the user to develop and emulate functions,
function blocks, custom libraries and for testing applications off line.
IEC Standard Library shall also be provided. The user shall be able to
write and download control programs, monitor system status, program
execution and perform maintenance operations.
Sequence of events collection in the memory and transmission of this
data to external computer for archiving, analysis and reporting shall be
supplied.
Failure of equipment's associated with communication between SIS
and DCS shall not affect safety related functions; furthermore, it shall
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not prevent other devices on the communication circuit from operating.

The SIS shall be equipped with a printer in order to aid maintenance
and troubleshooting activities.
The printer shall log all state changes of I/O's and of system variables
(those states that indicate the health of the system components).
Print out shall log tag numbers, time of day, and a brief description of
the state that has changed.

3.2 Shutdown initiating contacts shall generally be closed when process conditions
are normal and open when abnormal conditions arise, the circuits being
designed to fail safe.

3.3 Solenoid valves shall be energized in normal operation, and de-energized to

trip.

3.4 Failure of air or electrical supply to a measuring instrument used in a trip

system shall cause the instrument output to move through the trip condition.
Where this cannot be achieved, an alarm shall be provided to indicate loss of
supply and function.

3.5 A process condition causing a shutdown shall where possible be preceded by

an alarm giving prior warning of the possibility of the shutdown.

3.6 Shutdown systems shall be initiated from independent (dedicated) primary

R2
instruments, except flow trips may use a common primary element (orifice plate,
venture, etc.) DELETED.

3.7 Trip systems in general are to be manually reset. Where local operator attention
is required (as on some burner light-off systems). the reset function shall be
local.

3.8 Each shutdown initiator shall be alarmed of "first-out" type (refer to item 2) and
shall be repeated into the operator station alarm display and logging facilities.

3.9 By-passing of an emergency device in a system shall give a continually flashing

light in the control room.

3.10 Circuits performing logic functions shall be organized such that, at power supply
failure, at module extraction, at module insertion, and at wiring cut-off shall
ensure that system will never generate active commands on the plants
(actuators); will leave the actuator in the previous state.
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3.11 Shutdown system shall be provided with facilities for start-up, test, or
maintenance of the system so that the initiating devices and the logic circuit
itself can be tested during operation and start-up accomplished. By pass
switches shall be provided for all input signals related to ESD and outputs for
actuating device. Process override switches ( POS ) with key and status lamp
(lamp will be powered by ESD once the relevant by pass is activated.) shall be
provided, in order to exclude some shutdown couses during process start up.
These pos will be installed on the DCS operator console. Emergency push
buttons shall be provided for installation DCS operator console. These shall be
secured against accidental activation. Vendor shall provide a test lamps push
button, in order to check lamps integrity.Reset push buttons shall be provided
for installation on DCS console.

3.12 Deleted

3.13 Output signals driving (DELETED explosion proof solenoid valves) electrical
motors shall require interposing relays with DPDT contact of 220V AC 2,5 A
R2
rating minimum. ( When shutdown unit is connected to equipment having its
own power supply the connection shall be made via an interpasing relay to
ensure complete segregation. The interpasing relay shall be certified barrier
relay.)

3.14 Hard trip amplifiers, located in dedicated cabinets, shall be replaced by

software thresholds, generated inside the ESD.

3.15 The power supply system including trip-amplifiers cabinet (if separate) shall be
redundant (each module can supply the related subsystem) and independent
for each main subsystem. The system shall operate on UPS at 220 V 50 Hz.

3.16 Explosion proof solenoid valves shall be driven by 24V DC supplied from
redundant DC uninterruptable power system.

3.17 The system shall be provided with 20% of installed and 20% space spare
capacity as a minimum.

3.18 All electronic circuits of the shutdown system shall be provided adequate radio
frequency filtering. 5W radio transmitter set about 160 MHZ shall be keyed
within close proximity with the door are open and a test report certified by the
manufacturer and showing that keying action does not affect the accuracy of
the electronic instrumentation shall be supplied.
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3.19 Galvanic isolation between field and the logic system shall be provided. For
basis of channel to channel and channel to field isolation, refer to RUP project
R2 Technical Specification for Control Philosophy and Instrumentation Design,
Chapter 29000, point 5.3.24
The PLC I/O modules will supply power to all loop powered 4÷20 mA devices.
The input modules shall be also suitable to accept input from externally
powered (4-20 mA on 1-5V active) transmitters. The modules will be
equipped with an electronic device for the short-circuit protection. External
labels shall be used to identify the tag signals belonging to each I/O card. All
the Analog I/O shall be continuously tested to verify that they are within the
fixed ranges and alarm signals are produced in case of malfunction (open loop
detection).

3.20 All the START output commands going to ELECTRICAL SUBSTATION shall be
performed with normally de-energized relays and output contacts open.

3.21 Most important input signals shall be performed in two out of three configuration
(i.e. recycle gas compressors) to avoid that any single fault generates a
shutdown condition. Instead of creating three strings constituted by one of the
three initiators related to one shutdown cause; each three initiators for one
shutdown cause shall constitute a string, in order to avoid two different initiators
of the same string to cause a shut-down when would exist together.

3.22 For TMR systems every Input and Output modules shall contain the circuitry for
three independent legs reading the process data and passing that information
R2 to its respective main processor. For each type I/O module, the system shall
support an additional hot - spare module which takes control if a fault is
detected on the primary module during operation. Additional hot - spare
modules shall be installed adjacent to primary modules and shall be included in
the scope of supply.

%20 hot spare module for each type existing I/O cards shall be provided on
ESD for TMR systems

3.23 Software applications packages together with their necessary hardware

modules, PCs, etc., shall be supplied for below purposes.

3.23.1 DDE server for allowing Windows DDE client applications like Excel to
exchange data.

3.23.2 Sequence of events collection in the memory and upon request

transmits these data to external computer ( in the scope of supply) for
archiving, analysis and reporting.
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3.23.3 Sequence of events recording functionality to permit users to retrieve

selected history and event data the system and store it in a history file
on a PC ( in the scope of supply) hard drive.

3.24 Necessary programming systems together with its relevant workstation shall be
provided to allow off - line configuration, programming, documentation and
R2 testing capabilities. It shall run under Windows7, Windows NT or Windows 98
operating system. It shall permit the user to develop and emulate functions,
function blocks, custom libraries and for testing applications off line. IEC
Standard Library shall also be provided. The user shall be able to write and
download control programs, monitor system status, program execution and
perform maintenance operations.

3.25. Codes and Standards

3.25.1 General
The codes, standards and specifications listed below form an integral
part of this requisition. Each publication shall be the latest revision or
R2 addendum in effect on the date of issue of the purchase order, unless
noted otherwise. PCS VENDOR under the responsibility of
CONTRACTOR shall confirm that he will comply with all applicable
requirements.

3.25.2 International Codes and Standards

a. IEC rules for general electric installation and standards concerning
radiofrequency interference;
b. ISA standards and recommended practices;
c. ISA-RP-55.1/B-588 : Hardware Testing Digital Process Computers
(Codes of Practice for Testing Computer Based Systems)
d. IEC codes including but not limited to the following;

i. IEC61508: Functional safety of

electrical/electronic/programmable electronic safety related
systems;
ii. IEC 61131 : Programmable Logic Controllers;
iii. IEC 68/2 : Basic environmental testing procedures for
electronic components and electronic equipment;
iv. IEC 79 : Electrical Equipment for use in hazardous locations;
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v. IEC _801 : Electromagnetic compatibility for Industrial

process Measurement and Control Equipment;
- Part 1 : General introduction;
- Part 2 : Electrostatic Discharge Requirements;
- Part 3 : Radiated Electromagnetic Field Requirements;
- Part 4 : Noise Immunity against Fast Transient
Disturbances;
- Part 5 : Surge Immunity Requirements;
- Part 6 : Immunity to Conducted Radio Frequency
Disturbances above 9 kHz;
e. ISO standards;
f. NEMA Std.250: Manufacturing Standards for Enclosures for
Industrial Controls and Systems;
g. DIN V 19250 Maintenance override, version 2.2, 8 Sept. 1994.

SIS equipment shall also bear the CE mark meeting the EN standards
relevant to EMC interferences and immunity. PCS VENDOR under the
R2
responsibility of CONTRACTOR shall confirm this system immunity
together with the specification for the equipment limitations, e.g.:
maximum wattage, minimum distance, and frequency band. All
components of the system shall be suitable for the refinery
environment. Immunity to radio frequency and electromagnetic
interference, such as generated by hand held walkie-talkie of 5 watt set
about 450-470 MHZ (UHF), within near proximity of system
components (doors of cabinets open and within 300 mm distance)
shall be provided.
Shock of 15G, 10 millisecond duration shall not result in any damage
or malfunction. Steady state vibration of 2.5G, 5-500 Hz shall not
cause any damage or malfunction.
QUALITY CONTROL
In case the PLC VENDOR owns a Quality Assurance Manual
according to ISO 9001/2/3 standards or, anyhow, has a well
established Quality Assurance System, he shall submit to TÜPRAS the
review of his standard working procedure to obtain the relevant
approval.
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3.25.3 Order of precedence

In case of conflicting requirements the following descending order of
precedence shall be observed:
a. Authority requirements;
b. International codes and standards;
c. This requisition and attachments;
If there is any conflict between this requisition and any of the listed
documents, or documents referred to therein, PCS VENDOR under the
R2 responsibility of CONTRACTOR shall obtain resolution from TÜPRAS
before proceeding with work affected by such.

3.26 Logic Implementation and Technology

3.26.1 General
The following requirements will be guaranteed and applied to the SIS
system:
a. The protective system will be based on a fail safe type PLC (or
TMR) architecture, safety level meeting SIL3 (certified) with 2oo4D
(QMR) voting logic.
b. The system will have a degradable mode of operation. Failure of
one channel will result in a single fail-safe mode of operation: a
failure of a second channel will result in a trip (3-2-0 mode).
Diagnostic will indicate each failure level.
c. There will be no common mode or single failure point that could
affect two or more channels.
d. Input and output signals will be voted independently.
e. Output signals will generally open to trip.
f. It will be possible to replace an I/O processor or CPU module on
line without degrading the safety of the system. Repair will not
require disruption of the scanning process or "freezing" of output
states.
g. The program is required to be resident in a RAM memory with
battery back up; therefore, in case of a power failure the program
has to restart without any "load" operation after power restore.
h. The system will be immune to electromagnetic interference and
surge currents .The SIS system shall not be susceptible to any sort
of damages resulting from electrical transients on power or signal
wiring generated by switching large electrical loads, power line
faults, lightning strikes and lightning induced surges on power or
signal cables, or other electrical noise radiated or conducted.
i. The system (including all relays) will be TUV certified, according to
DIN-19250 AK6 (IEC 61508 SIL 3, 2oo3)
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j. Safe automatic shutdown of the unit upon detection of a potentially

dangerous abnormal condition. The system will be functionally
independent from the all other control systems.
k. Features to minimize spurious shutdowns will be included;
l. A method to declare a fail-safe (failure to safety) mode in case of
system failure, including all module removal and cable faults will be
included;
m.Response to abnormal conditions as detected by field sensors will
be included;
n. Automatic, on line facilities for testing and for monitoring system
diagnostics and performance will be included;
o. Automatic documentation features will be included;
p. Field sensors performing 2oo3 logic shall be wired to 3 different
input modules.

3.27 Power Supply System

3.27.1 General

a. The SIS will be powered at 220 VAC from UPS. Two independent
redundant 220V AC feeders will be made available for SIS. For
each voltage level there shall be a redundant power supply system,
based on two DC supply units; each one shall be sized for the
125 % of the full load.
Failure of one power supply unit shall be alarmed. Each power
supply unit shall be removable for maintenance without disturbing
the system operation.
b. The supply shall include redundant power supply systems like 220
VAC/24 VDC or any other voltage level to power all the I/O modules
and other circuits. Such systems will have on-line replaceable parts
in case of failures and will have fault-alarm contacts available for
monitoring.
c. The power supply system of the whole SIS system will be
redundant.
d. The SIS system will have internal power supplies arranged for
maximizing reliability. Therefore, if one of the feeder fails the other
one shall have sufficient capacity to operate the whole system.
e. The main electrical protections will be arranged so that no single
fuse failure can affect the availability of the entire protective system.
f. Dimensioning, arrangement and fuses coordination (selectivity) is
R2 as well included in PCS VENDOR scope under the responsibility of
CONTRACTOR.
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g. The SIS system DC power supply shall be floating 24 VDC. The SIS
system shall be capable of providing means to detect ground fault in
individual input field circuit.
j. Power supply to not removable components shall be fused.
k. Each user shall be individually fused. Power supply distribution
structure shall be arranged so that no single fuse failure can affect
the availability of the entire protective system.

3.27.2. Power Distribution

Redundant 220 VAC to DC converters will be supplied and installed for

the DC loads.Each electrical feeder will be protected with automatic
thermo-magnetic breakers.

3.27.3. Earthing
SIS system safety ground shall be connected to grounding system with
min. 25 mm2 copper cable having green and yellow colored insulation.

3.28. All the spare channels of the I/O modules will be properly configured and
wired to dedicated terminal boards in the marshalling cabinet. The SIS cabinet
R2 shall have minimum 15% spare space.20% spare terminals(included in 20% of
wired spare) and 20% spare space on marshalling cabinets shall be provided.

3.29 CONTRACTOR will guarantee the maximum expandability of processors and

memories utilized for continuous alarm & shutdown supervision, interlocks and
activation of sequences, in order to allow the future expansion of the systems:
at the end ofthe project they will appear utilized at less than 50% of their
potentialities.

3.30 No system device shall be loaded more than 50% of its maximum capacity
under any normal/abnormal case, this shall include, networks, gateways,
resident memory and disk media etc. The system design shall be such that
system availability shall be 99.9%.

3.31 The communication system will have enough capacity for the load envisaged
from the start, plus the load deriving from expansion of functions. Such capacity
will exist at every condition of the plant: at start-up, when running, during shut
down, etc.

3.32 There will not be a dedicated operator workstation for SIS system. The DCS
operator workstations shall be used for this purpose.
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3.33 I/O Modules Characteristics

The I/O signals for the SIS application shall be based on a dual redundant
technology.In addition:
a. Each module will have a hardware keying. Keying will prevent physical
insertion and on-line activation of a module in a wrong location.
b. I/O modules will have two individual power circuits, wired to internal bus
bars.
c. For basis of channel to channel and channel to field isolation, refer to RUP
R2 project Technical Specification for Control Philosophy and Instrumentation
Design, Chapter 29000, point 5.3.4
d. Each individual output signal path on the output module will be
automatically tested for proper operation at regular intervals.
R2 e. Each digital output will be individually fused with blown fuse indication.
DELETED.
f. All interposing relays will be provided by CONTRACTOR installed in IRC
cabinets in substation MCC.
g. Digital input signals will be conditioned by a low-pass filter (5 msec. typical)
to reduce the effects of noise and bounce.

R2 3.34 All the AI and AO (DELETED “cards” )shall support SMART HART protocol.

3.35 Each module of the system (eg. CPU, I/O modules) is interconnected by means
of a system bus/network to the other modules to exchange data. The network
interface modules and the system network shall be both redundant.

3.36 Interface

3.36.1 Interface with the DCS

The interconnections between the SIS and the DCS will be through
redundant process control network. As a general principle, PCS
R2 VENDOR scope under the responsibility of CONTRACTOR will supply
all the components (e.g. cables, connectors, terminators) needed to
connect properly all the modules of the system to the network. This link
will be used for a bidirectional data transmission (i.e. monitoring /
reporting, data flow SIS DCS ,or MOS enabling, interlock consents,
data flow: DCS, SIS).

3.36.2 Operator interface and external communications

- An operator interface shall be provided to indicate the status of the
inputs and outputs (where necessary) and the general condition of
the system; this interface shall be mainly the operator workstation
of the DCS connected to the SIS via redundant ethernet link or
digital bus.
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- As a minimum, the following information will be available for

transmission to DCS:
- Shut-down alarms (with first-out display; first-out logic mplemented
in the Protective system)
- Field sensor abnormal condition alarm (in case of triplicate sensor;
the alarm is activated when only one sensor detect trip conditions)
- Trip alarm (generated by the logic)
- Operating by-pass on alarm
- Maintenance by-pass on alarm
- Shut down valve status
- Motor status
- Congruency check alarm (command versus feedback)
- System malfunction alarm
- Power supply unit malfunction alarm

3.37 Interface with Compressor Annunciators

CONTRACTOR shall supply 2 ea. redundant serial communication cards

(Modbus) to transfer data to each compressor local annunciators from SIS
system. Time delay of signals to annunciators installed in the local control panel
of compressor in compessor shelter shall not be more than 2 sec. If it is not
guaranteed, hardwired connections for each alarm will be supplied from SIS to
compressor local annunciators at site.

3.38 Process & Maintenance By-passes

The POS (process override switch) shall be utilised to override the shut-down
input during well defined operation conditions. Operating by-passes will be
activated by means of key operated switches with relevant lamps installed on
the push button bay.

The MOS (maintanence override switch) are needed to exclude the effects that
could be caused during the necessary maintanence operations on the field
instruments connected to the SIS system.
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Maintenance bypasses are provided for all the digital and analogue inputs that
may cause the shut-down of critical equipment. For each process unit a key
selector switch shall be provided on the DCS pushbutton bay and hardwired to
SIS for MOS enabling.When MOS enable is activated a white lamp on the bay
will be activated and an alarm shall be sent to the DCS operator station by SIS
system.Insertion and removal of maintanence override will be managed by
DCS operators through dedicated DCS custom graphics. Only when the MOS
enable is activated one bypass at a time will be accepted by SIS system. When
SIS accepts a MOS a flashing orange lamp on the bay will be activated and an
alarm shall be sent to the DCS operator station indicating that one by-pass is
inserted for the corresponding unit.

- By-passes shall be provided to allow:

- overriding of shut-down input and/or output during well defined operation
conditions (e.g. plant start-up);
- on line testing and maintenance.
- Maintenance by-pass and process by-pass shall be kept separated and
segregated and designed to satisfy the different needs.
- By-passes shall not be provided for manual shut-down.
- To avoid mis operation, dedicated software sub-routines shall be
implemented in order to check the appropriate reset of the by-pass.
- By-passes shall be a separate (hardware or software) input to the system
and shall not by-pass the alarm associated to the input.

Maintenance By-pass
Maintenance by-passes, where required, can be either a physical input to the
system (generated by a selector switch) or a software input generated by the
engineering workstation.

The hardware by-pass selectors switch shall be key operated and installed on
the push button bay on operator console. Software by-passes shall be
accessible only through keyword and shall be enable through cumulative
enable switches (one by process unit) hardwired to SIS.

The condition of "By-pass on" shall be alarmed at DCS (one common by pass
and alarm for three inputs in case of triplicate sensors).
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Operating By-pass
- Operating by-passes shall be activated by means of key operated switches
installed at operator console.
- If allowed by the application, the use of automatic by-pass reset shall be
considered in order to automatically insert the initiator once the plant has
reached as condition where the by-pass is not needed anymore.
Again, the by-pass will be automatically reset if the plant is not started in a
reasonable time. In case automatic by-pass is provided, key-switches are no
longer required.

3.39 All the cabinets (system and marshalling) supplied by the CONTRACTOR will
have the same height and colour. It is mandatory to have all the cabinets of a
unit mounted together in the factory.The system cabinets and marshalling
cabinets shall be designed and manufactured according to the requirements
and specifications.

3.40 APPLICATION SOFTWARE

- Recognised industry standard shall be used by the SIS VENDOR in

specifying, developing and testing system software. Generally industry
standards also apply to application software. Typical of these are the
following IEEE standards for software quality assurance and configuration
management: IEEE Std 730, Std 828, Std 1042.
- The requirements of the application software will be defined using cause
and effect diagrams or flow charts or logic diagrams.
- Cause effect and logic diagrams are recommended for interlocks and
shutdowns. Flow charts are recommended for sequencing. Whichever
method is chosen, the representation will be kept as simple as possible to
allow participation by non control system specialists such as operation and
process engineers.
The application software shall be structured and commented to provide
anyone with a good understanding of the protection logic implemented.
Changes to software after Factory Acceptance Test (FAT) shall not be
permitted unless the changes are submitted to rigorous design change
verification, thoroughly functionally tested, and fully documented.
- Unauthorised modification of software shall be restricted. The restriction
shall typically be in the form of a key lock and password. The key lock will
prevent modified software to be downloaded to the PLC; the password will
prevent unauthorised software code modification on the programming
terminal.
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- The application software shall not utilise more than 50% of the available
system memory. The central processing unit shall, under normal working
conditions, be less than 50% loaded. This loading shall be demonstrated
during the factory acceptance test.
- Worst case conditions shall also be simulated to determine if degradation
of loading is within acceptable limits. These include multiple alarms,
automatic shut-downs, and so forth.
- The system shall allow application software to be developed and tested
off-line by means of a SIS engineering workstation.
- It shall be possible to download at least minor changes in software from the
engineering workstation to the SIS while it is on-line without disturbing plant
operation. Adequate testing procedures shall be available to verify the new
logic prior to activating it in the on line program.
The method of storing the application program in the protective system
shall ensure that the program is not lost in the event of a power supply
failure.

The software for the system configuration and by-pass management is included
in the supply. The software will be, as minimum, relevant to:
a. sensor input voting logic
b. input / output error checking (out of range input limits, health of output
devices, etc.)
c. SIS self diagnostics and alarming
d. continuous alarm & shutdown supervision
e. interlocks and activation of sequences
f. management of maintenance by-passes
g. SOE software
h. communication with DCS: (alarms, graphics, diagnostics, indication of
analog and digital variables, management of operating by passes; consider
that all input to SIS will be repeated to DCS)
i. Any software package (Advanced version of Hart Device Manager, Field
Device Manager, etc.) allowing user to provide a communication
environment, diagnostic and configure, tune or monitor all smart HART field
equipments located at the field shall be provided.

The provision includes development of the software for:

a. off - line configuration;
b. programming (IEC Standard Library shall be provided);
c. emulation;
d. documentation;
e. testing;
f. diagnostic and maintenance operations.
g. calculation procedures
h. control of machinery, furnaces and plant units.
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R2 For this purpose, PCS VENDOR under the responsibility of CONTRACTOR

shall develop the configuration for:
a. alarming: the alarms will be sent to DCS operator console;
b. shut-down: the PLC will drive all the shut-down actions;
c. start-up: the PLC will give all the consents needed to start machinery or
open the valves.

All this will be accomplished on the basis of the following documents prepared
by others:
a. I/O list with: point tag, engineering units, alarm limits, point description;
b. interlock logic diagrams of shutdown sequences and alarms (ISA
directions) and/or cause & effect tables.

The database configuration will include smart HART field devices’ configuration
as well as the hardwired and software linked signals. The assignment of a
signal to an I/O module (tag assignment) is included in PCS VENDOR scope of
R2 work under the responsibility of CONTRACTOR.
The software programming tool will be:
a. designed in order to allow modifications of the various shut-down logics
and will be protected from unauthorized changes
b. in accordance with IEC-61131 norm (Sequential Function Chart (SFC),
Function Block Diagram (FBD) or the Ladder Diagram(LD) programming
languages, or a combination of the three
c. self documented
The maintenance bypass functionality shall be as per TÜV guideline for
actuation from the DCS operator station or from the SIS workstation.

3.41 DOCUMENTATION

3.41.1. General
The documentation has to satisfy in quality and quantity. The whole of
the documentation is comprehensive of the following:
a. hardware documentation
b. software documentation
c. instruction manuals
d. certificates

Note: All drawings shall be produced using CAD tools, AutoCAD or

Intergraph Microstation compatible.
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3.41.2. Hardware Documentation

Following drawings have to be provided (standard documentation
without specific reference to the project is not acceptable):

a. list of power consumption calculations;

b. power feeding system;
c. cable list;
d. dimensional drawings;
e. cabinet layouts;
f. nest layout (tag assignment);
g. terminal strip drawings;
h. grounding system;
i. double wire (control loop wiring) diagrams
j. etc.

- Listing of power consumption

A detailed list with all of the system power users and corresponding
thermal loads.The list shall include at least the following:
- type of electric load;
- load characteristic;
- type of internal distribution;
- type and manufacturer of protective devices;
- protection device data;
- grounding requirements;

The above mentioned values have to be specified, even if preliminary,

R2
in the proposal.The PCS VENDOR shall state in addition the minimum
UPS capacity considering the worst operating condition.

- Feeding System
A drawing detailing the whole electrical network from the distribution
board up to the users (included those supplied by others, if integral
part of the system).

- Cable List
A detailed list of system cables included in the supply, with the
following information:
- cable item;
- cable type (identification code) and length;
- starting and terminal points.
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- Dimensional Drawings
Drawings of every SIS device included into the provision.

- Cabinet Layouts
One drawing for each cabinet shall show all the positions of the
devices into the panels (plan and front views).

Nest Layout – Tag Assignment

Drawings showing:
- system modules layout;
- tag assignment (points layout).

- Terminal Strip Drawings

Drawings showing the terminals strips in the marshalling cabinets.

- Ground System
Drawing showing how and where the system has to be connected to
the ground system. In particular, ground conductors sections and
connection points will be indicated.

- Double Wire (Control Loop Wiring) Diagrams

A sheet will be prepared for each signal or loop connected with the
system. The drawings scope starts from the I/O card on the rack
and terminates at the field side of the marshalling panel terminals.
All the intermediate connections must be shown (terminal
assemblies, terminals, relays, etc.). The drawings shall be in
accordance with ISA - S5.4 directions.

- Installation and Maintenance Manuals

They have to cover both system hardware and software; they have
to give the necessary instructions for trouble-shooting, software
loading and management.
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3.41.3. Software Documentation

The following documents will be in accordance with Std. ISA-S5
directions and will be included in the supply:
a. database: documents produced on a magnetic and paper support,
listing all the information regarding each signal on arrival into the
system;
b. I/O map for serial communication, if needed;
c. functional specification;
d. control & sequence flow charts;
e. interlock logic diagrams; for package equipments like compressors,
R2 for the rest C&E or safety narratives will be provided)
f. program print out (with comments).
g. etc.

- Database
A document produced on a magnetic/paper support, holding all the
information on system entities.
- Functional Specifications
On the base of description of software (for sequences), the
VENDOR shall issue a proposal for a solution. After Tüpraş
comments and approval, the VENDOR can start with the actual
development of software.
- Detailed Functional Specifications
It shall be issued by the VENDOR at the end of software
development and shall cover in details all the software activities
done to comply with Tüpraş requirements.The Detailed Functional
Specification shall be issued at least one month before the
beginning of the FAT and shall be approved by Tüpraş.
- Operator Manuals
R2 Scope of these manuals, written in English and Turkish languages,
is to give operators a guide to use of the System. The Operator
Manual must have a "Quick Reference" Section, suitable for a
prompt consultation.
- Control and Sequence Flow Chart
- Interlock Logic Diagrams
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3.41.4. “AS BUILT” Drawings

PCS VENDOR, under the responsibility of CONTRACTOR, scope of
R2 supply includes the preparation of the “as built” drawings such as:
a. system drawings;
b. marshalling cabinets drawings (ie. terminal strips drawings);
c. control loop wiring diagrams
d. hard copy documentation depicting the configuration of logic
blocks in the SIS system (Functional Logic Diagram FLD).
e. etc.

3.42 FAT / SAT Procedures

Included in CONTRACTOR scope is the development of the procedures for:

a. Factory Acceptance Test (FAT);

b. Integrated Factory Acceptance test (I-FAT);
c. Site Acceptance Test (SAT).

On the basis of this specification, CONTRACTOR will submit their own testing,
installation, commissioning and acceptance procedures for approval.
For hardware, the procedure will include: purpose of test, test definition of input,
procedure, results expected and acceptance criteria) For software it will
include: details of the method, list of tests, sequence of execution, results
expected and acceptance criteria.

3.43 Instruction Manuals

Operator Manuals: The aim of these manuals, written in English and Turkish
languages, is to give the operator a guide for the use of the system. All of the
R2
necessary instructions to recall specific functions etc. will be given. The
operator manual must have a “Quick Reference” suitable for a prompt
consultation.Installation and Maintenance Manuals: They have to cover both
Hardware and Software. These manuals will give the necessary instructions for
trouble-shooting,
software loading, and what is needed for software management.

3.43 Certificates and manufacturers declaration of conformity relevant to the offered

system have to be provided (e.g ‘’Fail safe’’ TUV certification, etc.).

3.44 Any shutdown reset push buttons shall however be mounted on the control
panel together with any required indicating light or annunciation.

3.45 The main objective of the SIS system is to protect personnel, environment and
the installation. The SIS system shall perform safe automatic shut-down of the
plant, equipment or machineries upon detection of a potentially dangerous
abnormal process condition.
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4.0 INSPECTION AND TESTING

Below specified test and checks shall be performed as a minimum and all will be
certified by manufacturer. The owner reserves the right to witness each test and check
stated below and satisfy himself.

- Visual and dimensional check.

- Painting check.
- Mechanical operating check.
- Mechanical protection check.
- Steel thickness check.
- Check of wiring connection of internal and peripherical equipments.
- Verification of easy accessibility and removal of components.
- Earthing circuit check.
- Check of documentation.
- Check of certificates.
- Examination of hardware test documentation.
- Dimensional check.
- Accessories check.
- Quality workmanship check.
- Compliance with specification check.
- Check calibration and gauging necessary instrumentation for testing.
- Power supply system check.
- Digital input-output tests.
- RFI test.

4.1 Factory Acceptance Test & Integrated Test

The system shall not be shipped before the tests mentioned in this document
and its attachments are successfully completed.

Tests will be organised in two phases: first, tests during manufacturing of the
system;

Second and the final factory acceptance test PCS VENDOR, under the
R2 responsibility of CONTRACTOR shall test and demonstrate the functional
integrity of the system hardware and Software with Tüpraş engineers. No
material or equipment shall be transported until all required tests are
successfully completed and certified. TÜPRAS reserves the right to be involved
and satisfy himself at each and every stage of inspection. TÜPRAS shall be
free to request any specific test on any equipment considered necessary for
him although not listed in this specification.
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PCS VENDOR, under the responsibility of CONTRACTOR to note that

R2 acceptance of any equipment or the exception of inspection or testing shall in
no way absolve the responsibility for delivering the equipment meeting all the
requirements specified. It shall be PCS VENDOR responsibility, under control
of CONTRACTOR to modify and/or replace any hardware and modify the
software if the specified functions are not completely achieved satisfactorily
during testing and factory acceptance..

A log of all failed components/modules in a sub-system shall be maintained

which shall give description of the failed component/module, effect of failure on
the subsystem, cause of failure and number of hours of operation before it
failed. If malfunction of a component/module in a subsystem repeat, the test
shall terminate and PCS VENDOR under the responsibility of CONTRACTOR
shall replace the faulty component/module. Thereafter the test shall commence
all over again. PCS VENDOR under the responsibility of CONTRACTOR will
produce the Factory Acceptance Test Procedure for approval.

PCS VENDOR under the responsibility of CONTRACTOR shall notify the

TÜPRAS/Consultant at least three weeks prior to final system testing. In the
event that representatives arrive and the system is not ready for testing, the
PCS VENDOR under the responsibility of CONTRACTOR will be liable for back
charges for any extra time and expenses incurred.

Factory Acceptance Test (FAT):

Phase – 1

PCS VENDOR under the responsibility of CONTRACTOR shall perform test at

his works to insure that all components function in accordance with their
respective specifications for each type of test.
This test shall be carried out on the basis of mfr internal procedures, a
TESTcertificate shall be issued by the VENDOR at the end of the test activities;
issue of such certificate shall allow the starting of the witnessed acceptance
test.

Quality Control Tests

Quality control tests shall be carried out to assure quality of all components and
modules in accordance with VENDOR's own quality control and assurance
procedures.

System Pre-test:
VENDOR shall check physically the workmanship including the system
hardware prior to powering up the system of the consoles, racks and all other
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accessories.
These shall be inspected externally and internally.

System Power-up Test

VENDOR as a minimum shall check the functions of all the system hardware
and software including diagnostic software at sub-system level by simulating
the inputs.

Testing Record
The test log book with the following information shall be sent to the TÜPRAS for
approval before FAT Phase-2 starts:

- date/time;
- assembly designation/loop tag number;
- test input;
- test result and sign off with personnel name;
- action required (if deficiency is detected);
- action taken, date of completion and sign off;
- special test methods (including special equipment requirement, bypasses
used etc.).

Phase –2
This test shall systematically, fully and functionally test all the hardware and
software in the presence of TÜPRAS representatives. Its purpose is to prove
the correct operation and performance of both hardware and software.System
shall be shipped to site only after this testing and certified ready for shipment by
TÜPRAS.

For the most complex parts of the plant, PCS VENDOR under the responsibility
R2 of CONTRACTOR will prepare dedicated software routines to allow the
functional test of the application software. This will complement the normal
testing that will be done by use simulation panels of switches, potentiometers
and lamps wired to the system (ie. marshalling cabinets).

This test shall start after the approval of Phase-1 log books and test reports and
if all the involved contractual documentation is completed.

Documentation to be provided include:

- hardware test procedure (previously agreed);
- system layout;
- hardware system drawings;
- cabinet layouts and I/0 assignments;
- typical loop diagrams;
- configuration and programming documentation;
- complex control scheme diagrams;
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- flow charts;
- logic diagrams;

Prior the starting of the test activities the system shall be installed in an area of
adequate dimensions, connected and powered.

Visual and Mechanical Tests:

- general quantity and quality check for conformity with the specifications;
- check of correct installation of equipment and components;
- check of correct installation of processor racks;
- check of correct installation of I/0 racks;
- check of correct installation of I/0 modules and field termination panels;
- check of correct equipment and components tagging and identification;
- check of correct installation and of the specification conformity of auxiliary
components (push buttons, lamps, selectors, etc.).

Functional Tests
Once the visual checking activities have been completed with satisfactory result
the functional tests shall start.
- Hardware Functional Tests

Hardware test shall consist mainly of:

- power supply system test;
- power supply system redundancy test;
- general system test by means of system diagnostic routines;
- checking of correct change -over of the back-up units in case of main units
failure;
- system diagnostics shall be thoroughly checked for sub-systems on local
level as well as on operator/engineering console. These include failure of a
subsystem, module, power supply, interface unit; failure of transfer to
redundant module failure etc. and other detailed diagnostic displays.
Diagnostic alarms for any ventilation fan failure shall also be checked;
- checking of RFI immunity for all components of SIS;
- simulation of power failure restarts;
- main equipment failure simulation (video stations, processors, power supply
units, I/0 card, communication bus and relevant equipment) and check of
response of the system diagnostics.
- Software functional tests
Once the hardware test has been completed with satisfactory results the
software test shall start.
Scope of this test is to demonstrate the correct functionality of the application
software including:
- the correct implementation of the control strategy;
- the correct implementation of the data base;
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The software test shall be carried out on all the configured points.

Activities relevant the software test shall include but shall not limited to:

- check of correct implementation of the continuous control algorithms, of the

sequential controls and of the combinatory logic controls. Test shall be done
by simulating the input signal and verifying the output at the marshalling
cabinets. Measured variables and output values, alarm and status
indications shall be checked;
- check of correct implementation of the data base (engineering units, full
scale, service description, alarm set, controller action, etc.);
- complete system configuration loading;
- checking of scan time values for controllers and data acquisition sub-system;
- checking of loop configuration for correctness with respect to ranges, limits,
alarm points, engineering units etc;
- checking of correct functioning of key-board operation for engineering
console;
- testing of proper functioning of all printers and hard copy units, etc;
- proper system operation at power supply specifications;
- emulation and simulation of data digital subsystems like PLC, computer,
analyser system etc. as specified. (Database and data communications).

Integrated Factory Acceptance Test (I-FAT)

An integrated test with DCS shall be done. The test shall include:

a. shipping the SIS to DCS premises;

b. testing the interface with DCS.

The test of DCS application software relevant to signal coming from the SIS
shall be carried out (e.g. custom displays).

Scope of this test is to demonstrate the correct functionality of the

communication hardware and software communication protocols between the
DCS equipment and SIS equipment, and to allow the testing of the SIS
application software relevant to physical I/0 handled by the SIS but displayed at
the DCS video stations.

The test shall be performed in accordance with an agreed test procedure and
shall be carried out in parallel with the SIS software test (parallel test is
mandatory as the DCS need to be physically connected to the SIS equipment
to demonstrate the full hardware and software functionality).
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Testing Record
During testing of Phase II, each test carried out shall be recorded. Any
deficiency or problem shall be clearly brought out and shall be corrected. Any
change in the data or configuration etc. informed to the VENDOR shall be
recorded and carried out by the VENDOR.

4.2. Site Acceptance Test

After the field system installation and prior the starting of the commissioning
activities the system shall be tested. Test shall be repeated to demonstrate the
fullfunctionality after transportation and field installation, complete dynamic loop
check and alignment shall be performed, generating and verifying the signals
directly from field.

During the site acceptance test particular care shall be taken to check the
power supply system and the grounding network system and to verify the
system bus functionality in the final configuration and maximum extension
Before the system power up and prior the I/0 module field connections all the
field I/0 signals shall be checked for continuity and isolation, in addition it shall
be verified the presence of undesired electrical potential, due to wrong field
connection, that could damage the SIS input circuits.

The tests, as a minimum, shall include:

- visual and mechanical testing;
- complete checking of hard wired instruments;
- complete checking of all interface with external computerised systems;
- complete system configuration loading;
- checking of loop configuration;
- checking of all graphic displays;
- checking of correct functioning of all keyboards;
- demonstration of all system diagnostic;
- checking of correct change over of redundant devices;
- checking of bus-degradation;
- checking of proper functioning of all printers, sample printing of all type of log
reports;
- checking of all historical trending points, alarm summary and alarm history.

5.0 NAME PLATE

5.1 Each cabinet shall carry a nameplate indicating its functional identification.
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(XIV) FIELD MOUNTED PNEUMATIC INSTRUMENTS

1.0 REFERENCES

1.1 IEC 529 Classification of degrees of protection

provided by enclosures.

2.0 HOUSING AND CONNECTIONS

2.1 Pneumatic instruments shall have metal housing to protect them from
environmental and mechanical damage. They shall be of minimum IP 65 type as
per IEC 529.

2.2 Connections for air supply, pneumatic transmission and control signals shall be
threaded ¼" NPT. Connections for process measurement shall be threaded ½"
NPT.

3.0 MATERIAL

3.1 All parts exposed to the process fluid, such as diaphragms, burden tubes and
bellows shall be resistant to the corrosive properties of the specified fluid
providing hastelloy C 276 as a minimum. Carbon steel body shall be minimum
where not otherwise specified.

3.2 All moving parts, such as linkages, bellows, springs and coils of instruments
shall be stainless steel.

4.0 GENERAL FEATURES

4.1 Pneumatic instruments shall have a standard 3-15 psig signal. Signal pressure
shall increase on increasing of process variable.

4.2 All pneumatic controllers shall be easily reversible and shall have manufacturer's
standard range of control function nearest to those defined in the individual
specification.

4.3 All automatic-manual air transfer switches shall be integrally mounted for local
pneumatic controllers.

4.4 Filter regulator assemblies shall be provided for all instruments requiring an air
supply and shall be designed for 50-100 psig inlet air pressure.
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4.5 The graduation of indicating scales shall be as specified in the individual

specification.

4.6 Mounting accessories for pipe stanchions shall be supplied.

4.7 Field mounted pneumatic controllers shall be of the force balance type, having
bypass relays. In addition, all field mounted controllers shall be supplied with
0-30 psig output and supply air gauges.

4.8 A means for calibration of transmitter, receivers and transducers shall be

provided to permit adjustment of zero output and the span of the output.

4.9 Force balance type transmitters shall have zero adjustment provision which does
not require removal of the instrument cover.

4.10 Measuring cell body temperature limit shall be minimum 120°C.

5.0 INSTRUMENT PERFORMANCES

5.1 Instrument performance for all local pneumatic receivers, recorders, controllers
and transmitters shall meet or exceed the following requirements.

5.1.1 Accuracy : ± 0,5% of span.

5.1.2 Hysterisis : not more than 0,2% of span
: 0,01% for temperature transmitter
5.1.3 56°C ambient temperature change shall affect controller output less
than 1% of span.

5.1.4 Proportional controller shall not change more than 0.25% of span as
the band is varied from minimum to maximum for a fixed process input.

6.0 INSPECTION TEST AND CERTIFICATES

6.1 All pneumatic instruments shall be checked concerning dimensions marking and
R2 nameplate according to the individual specifications, certified drawings and
codes. Hardness test as per NACE MR 0103 shall be provided where required in
individual specification. The following certificates shall be produced:

6.1.1 Chemical analysis and mechanical properties of construction material.

6.1.2 Hardness test of materials, if requested in individual specification.

6.1.3 Shop internal test.

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7.0 NAMEPLATE IDENTIFICATION

Instruments shall have the following identifying information on a nameplate

permanently fastened to the instrument.

- Tag number
- Manufacturer's name, model and serial number
- Pressure rating
- Body and internal parts material
- Air supply
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(XV) INSTRUMENT WIRING DESIGN

1.0 REFERENCES

1.1 API RP 551, 552, 553, 554

1.2 IEC standards

1.3 Licensor STD. SPC. 7-11-0

1.4 NFPA 70

1.5 EN 50288-7 The First Europen Standard for Instrumentation Cables

– Multi-Element Metallic Cables used in Analogue and Digital Communication
and Control Systems
Part 7: Instrumentation Cables

1.6 IEC 60584-3 Thermocouple & Extension Cables

2.0 INSTRUMENT CABLES

2.1 General

- In general, field mounted electric instrumentation shall be wired and

connected to identified junction boxes by means of single cables. Each
junction box shall be of die-cast aluminium and with all type of entries from
R2 side and bottom only. All junction boxes shall have single cables from side
entries and multi pair entry from bottom only. The junction box loading shall
be done in such a way that after successful implementation of complete
project, there shall be 15% spare space shall be available for future use

- In general, Instrument wiring between the field junction boxes and control
room shall be by means of multi-pair cables. In case of special
requirements for field mounted instrumentation, direct run (single) cables
shall be used. (e.g. frequency signals, governor signal, etc.)
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Cable for single and main runs up to 24 pairs shall be stranded tinned
R2 copper wire with (Insulation materials) XLPE (cross-linked polyethylene)
insulated, colour coded pairs, twisted according to EN-50288-7. Pairs shall
be screened individually with one layer of aluminium-bonded polyester
tape, between two layer of polyester tape with a drain wire. The max. nos.
of strands shall be 7 only. In case of thermocouple cable the conductor will
be solid. -DELETED-. For overall screening one layer of aluminium bonded
polyester tape between two layers of polyester tape with a drain wire, an
armour consisting of one layer of galvanized steel wires between PE or
PVC inner and outer sheaths shall be provided. Multiple twisted pairs shall
be twisted at least 6 times per foot. Single runs shall also be armored and
screened.

2.1.2 The outer sheath of twin and multicore cables shall be colored light blue
for intrinsically safe signal cables. When intrinsically safe cables are
specified for thermocouple extension cables;
IEC-584-3 cable colour coding shall be followed for thermocouple
extension cables.
2.1.3 All multicore cables and terminals in junction boxes shall have a
minimum 15% spare pairs (4 spare pairs in multipair cables of 24 pairs)
at each multicore cables to be used for alarm, shutdown, signal and
temperature measurement. All spare pairs shall be connected to spare
terminals in the junction boxes and coiled in the control center with
sufficient length to reach the most distant termination point.

2.1.3 All cables for instrumentation shall be flame retardant according to IEC
60332 and shall conform to BS6346 ( PVC insulated) except for the
following applications:
R2 All cables connected to the SIS System , shall be fire resistant
according to IEC- 60331
If the cables are buried shall be flame retardant according to IEC- 60332

All cables shall also be hydrocarbon, water, oil and sunlight resistant,
gas and vapor tight according to IEC 60332.

Cables used for Telecommunication System shall also be Fire Resistant

according to IEC 60331.
R2 2.1.5 All cables used for intrinsically safe signals shall be identified as such.
These cables shall be light blue color.
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2.1.6 Thermocouple extension cable shall be used unless otherwise specified.

(TRM-TQ-INS-0043)

2.1.7 The instrument cables shall be grouped according to the signal types.
The main groups are:

Electronic signals (4-20mA)

Low Voltage switching (24V DC)
Proximity Switches (Ee xi)
Proximitors (Vibration, Keyphasor, etc.) (Ee xi)
Bearing Temp.(Ee xi)
Solenoid signals and 24Vdc power supply cables.
Intrinsically safe signals.
Telephone - intercom communication cable.
Fire and gas signals.
Fibre Optic Cables
DI and DO signals
Thermocouple and RTD cables
Communication cables (MODBUS, RS 485, ETC.)
Etc.

2.2 Instrument Power Cables

2.2.1 Cable for instrument power supplies external to the control house shall
be PVC insulated, 2,5 mm² (minimum) stranded tinned copper conductor
600/1000V grade, galvanized steel wires armored, PVC sheathed
overall. Power supplies cables included in Electrical Department Scope
R2 shall not be tinned copper.

2.2.2 Cables for instrument power supplies within the control house shall be
R2 PVC insulated 2,5 mm² (minimum) stranded tinned copper conductor,
600/1000V grade, PVC sheathed overall. Power supplies cables
included in Electrical Department Scope shall not be tinned copper.

2.2.3 AC power wiring shall be colour coded as follows.Fixed - Lıve Red,

Neutral Black, Earth Green.Flexıble - Lıve brown, Neutral Blue, Eath
Green/Yellow.

2.2.4 DC power wiring shall be color coded as : positive red, negative black.
 Section : TGPS –J1
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2.3 Alarms and shutdown cables

R2 2.3.1 Multipair (up to 24 pairs) and singlepair cables shall be manufactured as

per item 2.1.

2.3.2 Cross section of conductors for single pair shall be 1,5 mm² and for
multipair 0.75 mm² .

2.3.3 Cable conductors shall be colored as blue (positive) and white

(negative). Cable conductors shall be numbered for multipair cables.

2.4 Electronic Signal Cables (4-20 mA)

R2 2.4.1 Multipair (up to 24 pairs) and singlepair cables shall be manufactured

as per item 2.1.

2.4.2 Minimum Cross section of conductors for singlepair and multipair shall
R2
be 1,5 mm² and for multipair 0,75 mm².

2.4.3 Cable conductors shall be colored as red (positive) and black

(negative). Cable conductors shall be numbered for multipair cables.

2.5 Thermocouple and Thermoresistance Cables

2.5.1 Single pair thermocouple extension cables shall be used for initial
installation and shall be manufactured as per item 2.1.

2.5.2 Multipair thermocouple extension cables shall only be used for providing
15% spare requirement from control room to junction boxes located in
the field. Multipair thermocouple extension cables shall be manufactured
according to item 2.1. Pair no. shall be 12.

2.5.3 Both single and multipair thermocouple extension cable conductor size
shall be 1,5 mm² .

R2 2.5.4 Colors for thermocouple extension cables shall be according to IEC-

584-3

2.5.5 Thermoresistance cables shall be single or multi-triad (e.g. 8 triads) type

and continuous length from control room to resistance element head.
Manufacturing of thermoresistance cables shall be according to item
2.1.
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2.5.6 The conductor size for thermoresistance cables shall be 2.5 mm².

2.5.7 15% spare requirements shall be met through multitriples (6 triples)

cables between control room and junction boxes located at field.

2.6 Solenoid Valve Cables

2.6.1 Single and multiple cores (24 cores) cables shall be as per item 2.2.1.
R2
2.6.2 Conductors color shall be black and numbered.

2.6.3 Conductor size shall be 2,5 mm² for single and 1,5 mm² for multipair
cables.

2.7 The insulation of instrument cable shall be 450/750 V minimum.

3.0 WIRING

3.1 All multicore cables, between control room and field junction boxes shall run
under ground in cable trench. Single pair cables shall run in trays between
junction box and instruments. Separated tray/junction box system shall be used
for each of the following instrument wiring. As SWA ( steel wire armoured)
cables are used for any link between ınstrument/ thermo couples and junction
boxes and junction boxes and panel, no conduits are used.

1. Analog (continuos) instrument signals-typically 4-20 mA, Digital (on-off)

instrument signals-typically 24V or 48V DC, Resistance temperature
devices (RTD's).
2. Thermocouple signals-millivolt.
3. Intrinsically safe signals
4. Pulse signals.
5. Data transmission.

R2 3.2 Extension cables and RTD cables may be run in the same tray but no other
wiring shall be included.

3.3 Intermediate joints shall not be permitted unless specifically indicated on

installation drawings and joints must be made in custom designed boxes.
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3.4 Clearances between signal and power cables.

3.4.1 Signal wiring shall be adequately separated and installed with respect to
power wiring and electrical equipment to minimize electrical interference
by any of the following:

1. Electrostatic or capacitive coupling

2. Electromagnetic or inductive coupling

3. Leakage current or ground loops.

Power cables including power cables of instruments and signal cables

shall never be in the same trunking, trench, tray or conduit.

3.4.2 Following are the minimum required separation distances between

instrument wiring and power wiring for parallel runs.

Power wiring Power wiring

less than 20A greater than 20A

1. Tray to tray spacing 6" 26’’

2. Tray to conduit spacing 4" 18"
3. Conduit to conduit spacing 3" 12"

3.4.3 Tray to tray spacing in the above table indicates the minimum distance
in inches between the top of one tray and the bottom of the tray above
or between the sides of adjacent trays. This also applies to the distance
between trays and to power equipment of less than 100 KVA.

3.4.4 Tray to conduit spacing in the above table indicates the minimum
distance in inches between trays and conduits.

3.4.5 Conduit to conduit spacing in the above table indicates the minimum
distance in inches between the outside surfaces of steel conduit. This
also applies to the distance between conduits and power equipment of
less than 100 KVA.
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3.4.6 Spacing of trays and conduits containing instrument wiring routed

parallel to high-power equipment enclosures of 100 KVA and larger shall
not be less than 5 feet for trays and 2 ½ feet for conduits.

3.4.7 When instrument wiring and power wiring must cross either in trays or in
conduits, they shall cross at 90°C angles at maximum spacing. Where it
is not possible to maintain the spacing indicated in the above table, a
grounded steel barrier shall be placed between unlike wiring at the
crossover point.

3.4.8 Maximum filling of Cable ladders/trays or trenches shall be 70%.

4.0 TERMINATION OF CABLES

4.1 Connections to instruments shall be provided with crimp type connection end.
No crimping shall be used on solid conductors.

4.2 All cables, their cores and terminals shall be identified as per drawing.

4.3 Screw clamp type terminals, snap fastened to a mounting channel shall be
used (Weidmüller SAK 2,5 or approved equal). They shall be non-hygroscopie
type.

4.4 Terminals shall be provided for each conductor and shield drain (where
R2 applicable). Typically analog signals require groupings of 3 terminals each,
digital signals require groupings of 3 terminals each.

4.5 Terminal blocks for thermocouple signals shall be constructed utilizing a metal
bar of the same material as the thermocouple extension wire.

4.6 All multicore cables (except initial T/C and RTD cables) will terminate in the field
at suitably positioned weatherproof (min. IP 65), suitable to hazardous area
classification, custom designed junction boxes.

4.7 RTD and T/C cables will terminate in the control house at receiving instruments.

4.8 Signal, alarm and shutdown multicore cables will terminate in the control house
at junction boxes, or suitably shielded terminal boards mounted on the panel
structure.

4.9 The cable tag as indicated in the cable list shall be used for cable identification.
Cable ends shall be provided with marker strips.
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4.10 Buried cables shall be provided with PE cable markers with stamped numbers
at each curve / branch and at 10 m intervals.

4.11 Wire ends shall be identified as per IEC 60391, with closed ring shaped coding.
Color of the ring coding shall be yellow with black lettering.

4.12 Cable glands shall suit the selected instrument cable and shall be suitable for
the area classification concerned, standard Ex-e di IIC/T6 and weatherproof to
R2
IP65 as a minimum with PVC hood. The thread of cable gland shall be NPT
Cable glands shall be brass with nickel (DELETED “cadmium”) plated.

5.0 WIRING INSTALLATION

5.1 Junction Boxes

5.1.1 Junction boxes shall be mounted on existing structural supports. Where

existing supports are inconvenient or inaccessible, junction boxes shall
be mounted on a field fabricated steel support, rigidly mounted to grade,
platform or floor.

5.1.2 The mounting length of junction boxes shall be 1500 mm from grade,
platform or floor to the centerline of the box.

5.1.3 Cables shall not enter junction boxes from the top. Entry at the bottom is
preferred; however side entry can be used if unavoidable. Cable glands
shall be closed and protected with a rubber gland shroud.

5.1.4 Each junction box shall be identified with a nameplate with 1" high
engraved letters. The nameplate shall be attached centrally by screws.

5.1.5 Twisting of pairs shall be maintained to within 2" of the terminals.

R2 5.1.6 DELETED.

5.1.7 Each conductor, cable and terminal shall be adequately identified.

All field single cabling shall be coded with the applicable instrument tag
number at both ends close to the instrument and to the junction box.
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5.1.7.1 All wiring shall be labeled at each end through the use of pre-
printed sleeve type wire markers and shall be oriented in such
a manner to be viewed without moving any wires. Non
corrosive punched metal tags or sleeve type weather proof
cabel labels can be used at field. Selection shall be approved
by Owner.

a. Individual pairs/triads from the field instruments shall be

identified with the instrument tag number inside the
junction boxes. Wires of each pairs/triads shall also be
identified with terminal numbers to be connected. Single
pair cables shall be labeled also at the entry of junction
boxes with its tag no.

b. Individual pair/triads in multiconductor cables are

identified by instrument tag number. Wires of pair/triads
shall be identified with terminal numbers to which they are
connected inside junction boxes and control room.

c. Multiconductor cables shall be identified with the

designated "cable number" both at the junction box and
control center.

d. Identification of wires at the instrument shall be made with

terminal numbers or polarities of the dedicated instrument
terminals and cables shall be identified with the field
instrument tags.

5.1.7.2 Terminals inside junction boxes shall be identified with terminal

number and polarities. Terminal markers shall be
manufacturer's standard.

5.1.7.3 Cable identification shall be made at each 25 meters, corner,

entry to control room, instrument, field junction box and panel
entry in control room.
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5.1.8 Junction Boxes shall be preferably installed at ground level. Material

shall be Die cast aluminium. Junction box segregation philosophy shall
be used for various category of I/O as under

Analog Input/ Analog Output ( 4-20 ma)

Digital Input (0-24 V DC)
Digital Output ( 0-24 V DC)
Digital Output for Solenoid valves
Digital Output ( MCC, high voltage)
RTD -T/C
Etc.

5.1.9 Separate junction boxes shall be provided for control and interlock
category of signals, which are destined for ESD or DCS marshalling
cabinets.

5.1.10 Intrinsic safe signals shall be mounted in separate junction boxes.

Color of terminals shall be grey for non-Exi signals, color blue for Exi
signals.

5.2 Routing

5.2.1 Separation of signal wiring from power wiring and electrical equipment
shall be according to item 3.4.

5.2.2 Instrument wiring shall not normally be routed through areas where
ambient temperatures exceed 80°C. Thermocouple extension wire is the
exception. The cable ladders/trays shall be routed away from hot
environments and places with potential fire risks, such as hydrocarbon
process pumps, burner fronts of furnaces and boilers, etc.

5.2.3 Thermocouples, however, may be located in areas of higher ambient

temperature. In that case, the thermocouple extension cable shall be
teflon insulated with teflon jackets which shall be used in ambients from
80°C up to 204°C. Only single pairs of this material are to be used from
the thermocouple head to the junction box. Specified (in item 2.1.1)
thermocouple extension cable shall be run from the junction box to the
control center.

5.2.4 Where a strong magnetic field is known to exist such as electric motors,
RF equipment, arc or inductive welding equipment, etc., instrument
wiring shall be routed with respect to this field to minimize interference.
(routing is to be parallel to the magnetic flux lines).
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5.2.5 Cable run shall enter control center underground in conduit. Sealing at
the point of entry shall be provided with a seal.

5.2.6 Rooting of overhead cables shall be designed to minimize exposure to

fire hazard. A lower limit of 5 meters above exchangers and pumps, and
3.5 meters away from furnace walls, pumps an exchangers shall be
maintained.

5.2.7 Main cable runs shall be routed away from fire hazardous area
especially considering critical instrumentation cables.

5.2.8 Covered cable tray system will be used between junction boxes and
instruments.

5.2.9 A fire within a process unit shall not disable critical circuits for other
process units not directly involved in the fire.

5.2.10 The cable ladders/trays shall be safely and easily accessible for
maintenance purposes.

5.2.11 The cable ladders/trays shall be located away from where they are
subject to mechanical damage, spilt liquids, escaping vapors and
corrosive gases. Where cable trays are liable to damage by traffic, they
shall be protected by freestanding and sturdy mechanical structures.

5.3 Conduit

5.3.1 With the exception of instruments installed in Division 1 locations, liquid

tight flexible steel conduit shall be used to connect field instruments to
the rigid conduit system. Flexible conduit shall be approximately 900 mm
long and shall be installed with a drip loop.

5.3.2 Seal fittings shall be installed in all conduits between enclosures that are
required to be explosion-proof and enclosures or conduit systems that
are not; in all conduits leaving a Division 1 area; and in all conduits
running between Division 2 and non-classifiied (non-hazardous) areas.
Where seal fittings are required in instrument installation they shall be
installed so that the instrument can be removed for maintenance without
disturbing the conductors. An explosion-proof conduit union shall be
installed between the conduit seal fitting and the instrument.
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5.3.3 Conduit size shall be determined by the number of conductors required

and by the available distance between supports. size versus conductors
shall conform to NFPA 70.

5.3.4 Threaded conduit joints shall be coated with an electrically conductive,

approved sealant and corrosion inhibitor that is not harmful to the
conductor insulation. Aluminum conduit shall be coated with compounds
specifically made for use with aluminum.

5.3.5 Horizontal runs of rigid metal conduit shall be properly fastened and
supported at intervals not exceeding the following.

Conduit Size Support interval in mm

½", ¾", 1! 300

1 ¼", 1½" 420
2", 2 ½" 480
3" and larger 600

5.3.6 Conduit shall be supported within 900 mm of each instrument, junction

box or fitting.

5.3.7 Drain fittings shall be installed in the conduit near the instrument for
vertical conduit drops. The drain fitting shall be installed immediately
before the flexible conduit connectors.

5.3.8 Cable pulling lubricants shall be used when installing cables in conduit.
The type of lubricants shall be suitable for the cable insulation involved.
Pulling tensions applied to cables shall not exceed the cable
manufacturers limitations.

5.3.9 The insides of conduits shall be cleaned before installation of cable or

wire. Cleaning shall be done by pulling a rag, tied up to the approximate
inside diameters, through the conduit.

5.3.10 To prevent the introduction of foreign materials and the project threads
during construction, the open ends of conduit shall be capped with pipe
caps whereas openings in fittings, boxes and instruments are to be
plugged.
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5.3.11 In general, conduit shall be installed parallel to or at right angles to

walls, columns, or beams.

5.3.12 Conduits run parallel to pipe or vessels shall be separated from the pipe
or vessels by a minimum of 300 mm.

5.3.13 Conduit run perpendicular to pipe or vessels shall be separated in

accordance with the following table.

Size Clearance
¾"- 2" pipe 100 mm
3" - 6" pipe 150 mm
8" and larger pipe and 200 mm
vessels

5.3.14 Conduits shall be routed a minimum of 7.5 meters horizontally from

equipment designated with high fire potential.

5.3.15 The selection of conduit fittings shall be guided by the designated

electrical area classifications:

5.3.15.1 In Division 1 locations, conduit fittings shall be designated for

use in hazardous locations, in the applicable Class and Group.

5.3.15.2 In Division 2 locations, conduit fittings shall be standard

threaded fittings with covers and gaskets except for the seal
fittings and unions, whiah shall be designated for use in
hazardous locations, in the applicable Class and Group.

5.3.15.3 In outdoor unclassified (general purpose) locations, conduit

fittings shall be standard threaded fittings with covers and
gaskets to prevent to entrance of moisture an dirt.
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5.4 Cable trays (raceways)

5.4.1 The raceways shall be supplied in sections of a length not less than 2
meters, and shall have the bottom perforated or slotted to allow for a
better ventilation of the cables laid on them.

5.4.2 Prefabricated raceways with the following nominal widths shall be used.
R2 All raceways shall be with covers of 1.5 mm min. thickness, and of
10 mm sidefin minimum.

 50 mm (min. thickness 1.5 mm)

 100 mm (min. thickness 1.5 mm)
 200 mm (min. thickness 1.5 mm)
 300 mm (min. thickness 2.0 mm)
 500 mm (min. thickness 2.0 mm)

5.4.3 The width of the prefabricated raceways shall be defined according to

Table 1 (item 5.4.6) based on the quantity and diameters of the
connections to be laid on same.

5.4.4 Raceways, coupling joints, covers and any special elements to be used
shall be steel Fe 37A-hot dip galvanized.

5.4.5 Prefabricated raceway sections shall be joined by coupling joints,

fastened by wide round head screws with underhead square, M6,
washers and nuts.

5.4.6 Below table defines the crowding criteria for cables to be laid on
raceways. The number of cables, shown in the table, is calculated
considering the same arranged on one layer only.
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TABLE NO.1

Cable O.D. Number of cables contained in Raceways

mm
50 100 200 300 500
3 8 28 58 88 148
3.5 7 24 50 75 127
4 6 21 43 66 111
5 5 17 35 53 89
6 4 14 29 44 74
7 3 12 25 37 63
8 3 10 21 33 55
9 2 9 19 29 49
10÷12 2 7 15 22 37
13÷15 1 6 12 18 30
16÷18 1 5 10 15 25
19÷21 4 8 13 21
22÷24 3 7 11 19
25÷27 3 6 10 16
28÷30 3 6 9 15
31÷33 2 5 8 13
34÷36 2 5 7 12
27÷39 2 4 6 11
40÷45 2 4 6 10
46÷48 1 3 5 9
49÷54 1 3 5 8
55÷60 1 3 4 7
61÷63 1 2 4 7
64÷66 1 2 4 6
67÷70 1 2 3 6
Usefull dimension for cables, mm
25 85 175 265 445
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5.5 Grounding

5.5.1 For all shielded instrument signals except thermocouple the drain wire of
shielded pairs and shielded cables shall be grounded at one point only.
The grounding shall normally take place in the control center unless the
control system vendor requires the ground to be elsewhere. In that case
the grounding shall be done at the field junction box.Special attention
shall be paid to the interconnection of cable screens, such that the
screening is earthed at the intended location only so that multiple
earthing does not occur. Generally all shields shall be earthed at
DCS/ESD marshalling panel side only. Vendor guidelines to be followed,
if applicable.
Care must be taken during the wiring installation to avoid unintentional
ground point by doing the following:

5.5.1.1 At the field instrument the pair shield and drain wire are to be
cut off even with the jacket and a length of tape or shrink
protector placed around the jacket and to protect the shield and
drain wire from possible ground contact.

5.5.1.2 At the field junction box, the multiconductor cable and pair
shields and the multiconductor drain wire are to be cut off even
with the jacket and taped or otherwise protected. The drain
wires from the pairs (individual and their corresponding
multiconductor pairs) are to be interconnected on designated
terminals. The drain wires are to be taped or sleeved from the
jacket end to the terminal to avoid possible ground contact.

5.5.1.3 At the control center the multiconductor cable shields and pair
shields are to be cut off even with the jacket and taped or
otherwise protected. The multiconductor cable drain wire and
pair drain wires are to be terminated at the designated
connections. The drain wires are to be taped or sleeved to
avoid contact with conductors or possible improper ground
contact.

5.5.2 For thermocouple signals, the signal shield shall be grounded near the
point of the circuit ground. For grounded junction thermocouples, the
signal shield ground shall be at the thermocouple head. For ungrounded
junction thermocouples, the signal shield ground shall be in the control
center. The overall multiconductor cable shield shall be grounded at the
control center for grounded and ungrounded junction thermocouples.
 Section : TGPS –J1
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5.5.3 The control panel earth, barrier earth and supply transformer earth must
be taken separately to the instrument system earth.

5.6 Intrinsic safety

5.6.1 An alternative installation in electrically classified areas is intrinsically

safe electrical devices and wiring. Intrinsically safe systems are
incapable of releasing sufficient energy under normal or abnormal
conditions to cause ignition of specific explosive atmosphere.
Intrinsically safe systems can be installed in any hazardous location for
which it is approved using any wiring method suitable for unclassified
locations as though the hazardous location was not present except that
conduit seals are required per item 5.3.2.

5.6.2 Wire and cable used in intrinsically safe installations is generally the
same as at other installations except that the individual conductor and
jacket color code is special, for intrinsically safe wiring.

5.6.3 External to panels, intrinsically safe wiring shall be physically separated

from non-intrinsically safe wiring in enclosures, conduit or cable trays
which are identified as containing intrinsically safe wiring. A portion of
an enclosure, or cable tray compartmented by an adequate insulating or
grounded metal partition, may be considered as a separate enclosure or
cable tray.

6.0 TESTS AND CHECKS

Below stated check, tests and certificates shall be provided as a minimum and owner
shall reserve the right to witness for each one.

6.1 Conformity certificate for chemical analysis, tensile test of the thermoplastic
materials, tensile test of the conductors and armoring, galvanization test.

6.2 Check certified by the manufacturer for the calibration and gauging of
necessary instrumentation for the testing.

6.3 Check certified by the manufacturer for visual and dimensional control,
inductance-capacity measurement, test of traction thermoplastic material,
conductors and armoring tractions test, shock thermic test, cold bending test,
galvanization test, flame proof or flame retardant test.
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6.4 Check certified by manufacturer for resistance of conductors, resistance of

electrostatic shield, continuity, insulation resistance and applied voltage test
between each conductor and groups of conductors.

6.5 For all above test and checks related IEC/CEI standards shall be followed.
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(XVI) CONTROL BOARD, PANELS AND CABINETS

1.0 REFERENCES

1.1 IEC
1.2 LİCENSOR CENTRE SPECIFICATIONS

2.0 GENERAL CHARACTERISTICS:

2.1 Since microprocessor based DCS with LCDs shall be used, control panel needs
shall be kept to a minimum. Control panel ınstruments shall be grouped in a
logical pattern and arranged in a sequence related to the process flew spacing
of instruments shall be compact but shall not limit convenient access for
operations and maintenance, control room panel layout and design shall be
subject to OWNER’s approval control panel ınstruments shall be miniature case
type in a high density arrangement.Control panels will be provided with
adequate space for the installation of futures.Panel instruments ( controllers,
recorders, ındıcators, annunciator panels etc.) and back up ınstruments shall
be configurable, digitally processing equipment of latest design of
manufacturer. These configurator terminals must be supplied with these
equipment.

2.2 All the cabinets shall be of free standing, enclosed type and shall be designed
for bottom entry for cable connection.

2.3 Cabinet structure shall be sound and rigid which shall be classified according to
environmental condition and dust protected.

2.4 In order to effectively remove dissipated heat from the cabinets, vent louvers
backed by wire fly secreen shall be provided to cabinet doors. In case louvers
are insufficient, ventilation fans shall be provided.

2.5 Equipment within the cabinet, shall be laid out in an accessible and logically
segregated manner. Clamping rails shall be provided for incoming cables to
prevent excessive stress on the individual terminal.

2.6 All metal parts of the cabinet including doors shall be electrically continuous
and shall be provided with a common grounding lug.
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2.7 All interconnecting wiring and cables shall be provided and pre-wired by the
vendor. Cables shall be terminated in cable order.

2.7.1 Terminal blocks shall be of the clip-on disconnect type (Wield Müller,
KLIPPON or equal). Terminals shall be either tinned or silver plated and
terminal number shall be clearly identified.

2.7.2 PVC insulated stranded copper wires shall be used. Size of all internal
wiring shall be determined according to manufacturer standard ; power
supply wiring shall be 14 AWG minimum size.

2.7.3 When instruments are provided with screw type connecting terminals,
the wire ends shall be provided with crimped-on spade lugs (make: AMP
or equivalent)

2.7.4 Removable cover plates shall be provided over all terminals with
voltages above 50 Volts.

2.7.5 The spacing between terminal blocks for each type of signals shall be
provided.

2.7.6 All electrical instruments shall be mounted in such a way that positive
earthing is provided by metal to metal contact to cabinet.

2.7.7 Each wire shall have identifying markers, using sleeve or plastic ferrules
showing both the terminal number to which it is connected and the
number of terminal or instrument from which it is coming.

2.7.8 Each terminal shall have plastic marker showing sequential terminal no.

2.7.9 Connectors shall have a nameplate on the mounting plate identifying

their numbers.

2.7.10 Minimum separation between power and signal wiring shall be at least
300 mm if they are running in parallel.

2.7.11 Within one multiconductor cable or cable duct only one type signal shall
be contained.

2.7.12 Wiring shall be routed in such a way that it will not interfere with
maintenance operation i.e. card removal, or insertion, etc.
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2.8 Each panel, cabinet and other equipment in control room shall be provided with
an earthing lug. All these lugs shall be properly secured to the AC mains
earthing bus.

2.8.1 All circuit grounds of electronic instruments, shields and drain wires of
signal cables shall be connected to instrument ground bus which is
electrically isolated from the AC mains earthing bus.

2.8.2 In any case, if the Vendor's equipment requires dedicated grounds the
proposal shall include sufficient information to determine how these
grounds are to be arranged.

2.9 All interconnecting cables into the cabinets will be supplied by Vendor.

2.10 The electric wiring shall be subdivided into the following categories.

 feeding 220V 50 Hz
 feeding 24V DC
 4÷20 mA signals
 other DC circuits
 T/C, RTD, mV signals

2.11 All electrical wires shall be housed in plastic raceways of suitable dimensions
(max. crowding 60%). Sufficient raceways shall be provided to group together
the electric wires according to their voltage level and function as per above item
2.10. Terminal strips for wires shall be suitable for conductor sizes up to 2.5
sqmm.

2.12 Doors shall be equipped with handles with lock and concealed hinges with pull
pins for easy door removal.

2.13 All instruments on the "control board" shall be identified by black nameplates
having white engraving giving tag number and services.

2.14 Fuses, where used, will be of the easy replaceable type, having a neon failure
indication light.

2.15 All equipment on the control board, panel and cabinets shall be identified with
appropriate tags.
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2.16 Boards and panels shall be supplied already assembled, in sections, together
with all the necessary materials for final installation on site (nuts, bolts, etc.)

2.17 Cabinets shall be provided with minimum.

 20% spare of installed material (i.e. terminal strips, disconnecting

switches, protection devices, etc.)
 20% spare of panel space.

2.18 A 220V, 50 Hz electric power from reliable source (control center UPS) is
available to feed each section of control board.

Power supply shall be made available at one point. Further power distribution
network shall be designed such that a single power fault or overload in any
branch system shall not cause a trip of the entire system. Each branch shall be
provided with a separate switch and miniature thermal/magnetic switches (no
fuse) system. Cut-out selectivity shall be guaranteed by the supplier.

2.19 All the cables connected to panels shall be identified with a suitable cable
markers or tags.

2.20 Supply voltage to cabinets, panels and board shall be 220V, 50Hz. For all other
voltages needed to operate instruments, components or modules, etc., 2
separate (1 is redundant) power supply for each voltage level one being
capable of supplying rated power to the cabinet, shall be utilized in parallel
sharing load in normal operation but if one fails the other takes the fully load
automatically. Means of monitoring power supplies status shall be provided on
DCS. Two separate AC input shall be provided for redundant P.S. systems.

3.0 CONTROL BOARD

3.1 "Control Board" will include enough sections to include of multipoint recorders,
vibration and displacement measuring devices for pumps and compressors,
analysers control devices and power supply units. The control board will be
installed in control room to permit direct accessibility and operability to the
instruments.

3.2 Instruments will be mounted in front of panels; two rear access doors for each
section shall be provided.

3.3 Signals and power supply wiring from terminals of each instrument to the
terminal strip, which shall be located in the lower part of the rear of each
section, shall be provided according to the control board connection and power
distribution diagrams.
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3.4 A board clock, to be supplied by panel vendor, shall be digital type with 50 mm
minimum nominal height filamentary 7 segment display. It shall have crystal
controlled time base, shall display hours, minutes and seconds, and shall be
resettable and adjustable from front of panel.

3.5 Instruments supplied by others, to be mounted on control board, will be

delivered to panels manufacturer factory for installation.

3.6 All electronic instrumentation mounted on the control board shall be provided
with adequate radio frequency filtering to about 160 MHZ. 5W radio transmitter
of close proximity while the doors of the board are open a test report certified by
the manufacturer and showing that keying action doesn't affect the accuracies
of electronic instrumentation shall be supplied.

3.7 Control board shall be supplied with internal lighting and forced ventilation
system.

3.8 Due to very high sulphur and other corrosive vapours content in refinery
atraosphere all relay, switch, push button, etc. Contacts and all connectors in
the control room shall be gold plated except the ones hermatıcally sealed.

4.0 INSPECTION, CHECK AND TESTING

4.1 Below identified checks and tests shall be provided and a certification for each
one shall be supplied by manufacturer. Owner or his representative shall have
the right to witness of all the checks and test to be executed.

4.1.1 Visual inspection cabinet dimensions.

4.1.2 Check quality/colour of paint finish.

4.1.3 Check gross weight, availability and rating lifting eyes.

4.1.4 Check access to cabinet components.

4.1.5 Check if protection covers are fitted to high voltage parts (>50 V)

4.1.6 Check spare space in cabinet.

4.1.7 Check cable entry.

4.1.8 Check if provisions are fitted for field cable supporting.

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4.1.9 Check installation safety earth bar.

4.1.10 Check installation of isolated instrument earth bar.

4.1.11 Check earth strips on racks, doors and frames.

4.1.12 Check if nameplates are fitted (not on equipment)

4.1.13 Check disconnecting and protective devices rating.

4.1.14 Check availability of spare switches (disconnecting and protection).

4.1.15 Check separation of wirings (AC power, T/C, 4-20 mA, etc...)

4.1.16 Check termination spare.

4.1.17 Check type and marking of terminals.

4.1.18 Check cabinet wiring identification up to and at terminal strips.

4.1.19 Check redundant power supply operation and indication/alarm for

diagnostic.

4.1.20 Check RF immunity test with 5W radio when doors are open.

4.1.21 Check if all loose items are marked to enable easy assembly on site
without possibility for mistakes.

4.1.22 Inspection of control system (if applicable) including a full functional

check out, simulating operational inputs and outputs together with all
related peripheral elements.
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(XVII) DIGITAL DISTRIBUTED CONTROL (DCS)

For points related with instrument control philosophy and design of complete RUP
R2 Project refer to Technical Specification for Control Philosophy and Instrumentation
Design, Chapter 29000.

1.0 REFERENCES

1.1 ISA S 5.1 Instrumentation Symbols and Identification.

1.2 ISA S 5.4 Instrument Loop Diagrams.
1.3 ISA S 18.1 Annunciator Sequences and Specifications.
1.4 ISA RP 55.1 Hardware Testing of Digital Process Computers.
1.5 ISA S 51.1 Process Instrumentation Terminology.
1.6 ISA S 50.1 Compatibility, analogue signals
1.7 ISA RP 60.3 Human engineering control centre
1.8 ISA S 71.04 Environmental Limits
1.9 IEC 68 Basic environmental Testing Procedures.
1.10 IEC 79 Electrical Apparatus For Explosive Gas Atmospheres.
1.11 IEC 529 Classification Of Degree Of Protection Provided By enclosures.
1.12 EIA RS 232 Interface Between Data Terminal Equipment and Data
Communication Equipment Employing Serial Binary Data
Interchange.
1.13 CCITT Recommendation V-24 List of Definitions For
Interchange Circuits
Between Data-Terminal Equipment and Data-Circuit-Terminating
Equipment.
1.14 Licensor Project specification- Control Center Specifications
1.15 ISA S 5.3 Graphıc Symbols
1.16 ANSI/ ISA MC 96.1 Temperature measurement Standarts by mears of
thermocouples

2.0 GENERAL

The following Abbreviations/Definitions are used in this engineering standard:

APC : Advanced Process Controller

CPU : Central Processing Unit
CSMA/CD : Communication Sense Multiple Access / Carrier Detect
DCS : Distributed Control System
HMI : Human Machine Interface (Man Machine Interface)
Lev. 0 Level 0 : this is the lowest level of the hierarchically ordered System structure.
It regards all the field instruments like sensors, initiator and actuator.
(Not covered by this engineering standard).
Lev. 1 Level 1 : this is the intermediate level of the hierarchically ordered structure of
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the System. It regards all the System equipment dedicated to Control,

Automation, and Data Acquisition functions.

Lev. 2 Level 2 : this level regards the System equipment having the function of HMI.
Level 2 is the control and supervisory level of the Plant.
Lev. 3 Level 3 : this is the level dedicated to Advanced Control and Plant Optimisation
MPC : Multivariable Predictive Controller
MR : Material Requisition
MTTF : Mean Time to Failure
MTTR : Mean time to Repair
P&ID : Piping and Instrumentation Diagram
PID : Proportional, Integral, Derivative Controller
RISC : Reduced Instruction Set Controller
SIS : Safety Instrumented System
SOE : Sequence of Events
TCP/IP : Transmission Control Protocol / Internet Protocol

2.1 General Requirements

2.1.1 DCS shall be a digital process control and data acquisition system of
the latest field proven technology that includes a comprehensive set of
algorithms and auxiliaries and provides full control and monitoring
capabilities. It shall be a flexible system that can be tailored to a wide
range of process requirements at the loop or unit level. The system
shall allow dependable and effective process control and shall permit
control and data acquisition functions to be distributed to remote plant
location.

2.1.2 The operator interface shall be implemented through interactive

operator workstations equipped with monitors, keyboard, mouse,
printer, and capable of managing the supervision, control, graphic
presentation, alarm, message, diagnostic functions. Also an
engineering station dedicated to the configuration of the system and
the implementation and modification of the user software will be
provided.

2.1.3 The control modules and operator stations are connected with a data
communications bus, based on open architecture.

2.1.4 The system shall be capable of carrying on a dialog through

appropriate interface module with external electronic computers and/or
data communications standard networks.
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2.1.5 The offered system shall have feature the latest technology (the latest
state of the art hardware and software platform and
hardware/software/firmware revisions of complete system will be latest
at the time of supply) available on the market at the time of bidding
and shall have a good record of competibility with the previous version
or systems offered by the Vendor.
In addition to these ,All the hardware and software of the DCS shall be
the most advanced model of DCS of vendor at the time of FAT.

2.1.6 System shall have upward compatibility of application software for

newer versions. The original application/configuration software shall be
capable of working on the newer versions when the system software is
upgraded without needing any special programming. System vendor
shall clearly define a migration path for maintaining upward
compatibility.

Any deviation from the general terms and conditions attached herewith
and the technical specification shall be clearly indicated.

Plant policy is one continuous control system development to match

changing process requirements and to exploit new techniques as they
emerge. The DCS shall provide the necessary facilities to allow
control system development to take place in a secure and efficient
manner.

2.1.7 All plants shall be controlled by modern DCS .All the interlocks shall be
realized in a fail safe ESD (TMR/QMR).

2.1.8 There shall be dedicated marshalling panels for DCS or ESD.

2.1.9 Complete engineering activity of whole plants instrumentation and

control system, downloading, online monitoring, changes, etc. shall be
carried out from the engineering (computer) room.

2.1.10 All the system hardware of DCS shall be ISA G3 level corrosion
protection. All the hardware including control/communication
processors, networks, cables, all type of system cards, all type of I/O
cards shall be hot replaceable.
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2.1.11 The system shall be designed giving the most consideration to its
reliability, inparticular the selection of the electronic components and
the individual entities forming the system shall be particularly accurate,
considering a continuous operating time of 2 years.

2.1.12 The system shall be of modular construction and easily expandible; the
module typology shall take into consideration the need of
interchangeability and storage cost reduction.

2.1.13 Hereafter is listed a series of basic DCS functionality to be provided:

- Capacity. The DCS must be capable of supporting the entire plant

process units, which will have a large number of basic instruments
and controllers. Speed of response for both control functions and
man-machine interface should not be degraded under any
conditions (such as alarm overload) since this is a relatively fast-
responding process. Multiple local area networks are allowed
provided that the overall functionality is satisfied.

- Redundancy. High reliability is important since loss of critical

process units would result in major upsets and costly restart time.
The DCS should have some type of ability to continue operation,
without upsets, during single point failure of critical controllers.
Identification of controllers being critical will occur during detailed
engineering. Also, redundancy of the basic communications network
between DCS elements is vital.

- Security. A DCS, by nature, is relatively easy to reconfigure. The

system should provide various levels of password and/or key
protection to allow for different levels of authorisation when
maintenance is being performed.

- Communications. The DCS must support standard instrument

types for process inputs. Also, serial communications for special
instruments (eg., gas chromatograph or PLC) should be supported.
Specific read/write communication module with the Emergency Shut
down System is required. It shall be able to transfer from the ESD
system to the DCS the first out alarms and the sequence of event
generated in the ESD module. This is an essential requirement.
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- Computer interface. Communication between the control

processors and operator/engineering stations is required. It is
essential that the communications be bi-directional, allowing reading
and writing between the two machines.

- Basic control. Modern DCS offerings allow implementation of

standard control functions (PID, ratio, cascades, etc.).
Preconfigured function blocks for industrial applications (suitable for
refinery applications) are assumed to be available.

- Extended control. The DCS should provide ways to implement

user functions including modifying standard algorithms or defining
new ones. This functionality should be available by use of a
high-level programming language, preferably an industry standard
such as C. The ability to include logic functions (eg. interlocks) may
be necessary for implementing certain advanced control functions.
Also, logic functions that support sequencing during start-up or
shutdown are required. This can be implemented as some type of
batch control capability.

- Multivariable control. A highly desirable feature of the DCS is that

multivariable predictive control (MPC) can be performed directly,
rather than in process control computer interfaced as noted above.
This will allow high speed, high reliability, state-of-the-art advanced
control within the basic instrumentation system. It also provides a
mechanism for the operator interface to be consistent for all
advanced process control applications. Multivariable control should
be able to run as fast as every 15 seconds, although most
controllers would typically run once per minute.

- Loop processing. Analog control loop functions need to be

processed rapidly, at least four times per second. Digital loops shall
be processed at least 10 times per second. The DCS must provide
a mechanism to distribute the processing load so that this wide
range of loop execution frequency can be accommodated. The load
distribution shall not affect any functionality here before specified
which execution speed, if needed, shall be increased to meet the
fast control requirement.

R2 - DCS System shall be able to support Loop Scout software

(Honeywell) or similar software to identify loop problems.
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2.2 The DCS shall be progressively and easily expandable.

System shall support concurrent engineering at different locations for flexible
and effective system engineering.

System shall have both virtual and target testing & debugging tools to simulate
application.

Commercially available PC workstations shall be used for HMI. BIOS

customization is not accepted.

The signal exchange between electrical and instrumentation shall be via

electrical/insrumentation interface panels, located in the electrical substation
buidings.There shall be two categories of interface cabinet, analog and
R2 digital.Analog interface panel will be used for (DELETED) various VFD signals
like 4-20 Ma speed signals, DCS controller output to VFD located at electrical
substation, etc.Digital interface panel shall be used for various digital input and
digital output signals from/to electrical/instrument systems like various
pump/motor running indication, stop command to MCC, etc.The quantity of the
panels shall be as requıred.This panel shall be demarcation of the scope
between the electrical and instrument department.All the required signals from
(DELETED) /MCC panels and substation to this panel
Shall be brought by Electrical deparment shall lay various cables between
these panels and varios DCS and ESD panels for interconnecting these
signals to/from control systems.

CONTRACTOR shall specify method of redundant/fault tolerant modules and

any hardware switching devices are not acceptable.CONTRACTOR to conform
the same.

The DCS shall be made of I/O modules for data acquisition and of processing
modules equipped with resident software to carry out control algorithms and
sequential control functions.Operator interface shall be implemented through
interactive workstations equipped with data display console, keyboard and
printer; plant will be controlled through graphic pages.Engineering workstations
for resident software configuration and management shall also be provided.The
DCS must have an "open" architecture, to interface with various electronic
devices and/or data communications standard networks.

2.3 Any part of the DCS system shall be capable of operation in the environment
conditions anywhere in between -10°C/+50°C for temperature and ±10% for
relative humidity deviation of environment design limits for the building in which
that part of the system operates.
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2.4 The system shall be able to operate and power the explosion proof field
instruments.

2.5 The DCS mentioned shall be suitable to operate with minicomputers and
computers on LAN, the data highway. They must be able to be interfaced to
LAN to operate with DCS for advanced control and optimization purposes.
Hardware and software requirements for APC shall not be provided. Hardware
and software requirements are for a microprocessor based digital data
acquisition and control system; Contractor shall design a whole system
according to his technology but within the limits of the characteristics of the
requirements of this section. In case of necessity of a minicomputer, Contractor
shall distinctly indicate it.

The microprocessor based digital data acquisition and control system

requested shall be suitable for the refinery applications. It shall be enable the
Owner to implement advanced control and optimization algorithms to monitor
and control his operations. Logic and sequence control and switching functions
shall be an integral capability of the system controllers as well as complete
diagnostic capability accessible from standard display allowing the operators to
monitor the status of all stations and components of the system. Each operator
station shall be of a master type shall have its own processor. In case a station
fails during normal operation, the other stations shall continue to operate
without distrupting the normal, stable and safe operation of the respecitve
process units. The system shall comprise basically I/O subsystem, power
R2
subsystem (for its operation and for field instruments), multiloop, multifunction
controllers subsystem, data communication subsystem, LCD or LED display
and operating center subsystem, Disk-Memory subsystem. The intelligent LCD-
Keyboard subsystem which is 100% (1 to 1) redundant shall be expanded with
enough number of restricted capacity LCD-Keyboards just for process
monitoring and control purposes.

2.6 System should be manageable by operators without a long-term training.

2.7 The operating center shall provide a common interface for all the following:

- Start-up and shut-down operations,

- Normal operation,
- During process up set,
- During equipment malfunction.

with all the capabilities of conventional control board with dedicated instruments
as a minimum.
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2.8 Operating system shall be Windows XP, Vista Professional (the latest version)
or Windows 7. This operating system shall be native (without modification) and
R2 single to guarantee fast response. Additional proprietary operating system is
not accepted. The operator station and the engineering work station of DCS
system shall have the capability to display simultaneously the DCS standard
graphic and application windows.

2.9 For digital systems, a crystal-controlled system clock, independent of line

frequency shall be used.

2.10 Operation status indication of all electric motors and turbine drivers shall be
included in DCS system. Color changing method shall be used for this purpose.

R2 2.11 DELETED.

2.12 Duplex type thermoelement will be used for temparature points to be connected
R2 one to DCS/ESD (by means of temeperature transmitter) and the other as
spare
2.13 For split range applications of two or more valves, dedicated controller output
range for each valve will be configured through the use of DCS software
techniques and then separate outputs will be assigned to each valve to be
operated in split range mode.

2.14 Each electrıcal/ steam drıven equipment will be indicated on DCS about their
R2 run/standby conditions. Speed from Governor for steam driven and auxılıary
contact of power supply contactor will be utılısed for this purpose.

2.15 The capacity of function modules, history modules, processor modules,

application modules or cards of the DCS system shall be maximized for
advanced control applications.

2.16 DCS and all its auxiliary equipments shall be supplied as a turn key system.

2.17 Hardware and software composing the system shall be field proven and the
latest model withe respect to Bid submission date.

2.18 It is empnasized that this specification provides the minimum requirements and
does not relieve the vendor from his responsibilities concerning proper design,
reliability and safe operation of the supplied equipment.

2.19 Contractor shall include in the supply all what is required to deliver a fully
working system.

2.20 The offered system shall be composed by the most updated hardware and
software release (i.e last version of controllers and I/O cards, configuration
tools, communication bus, operator stations etc.) available at the time of factory
acceptence test start.
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2.21 Graphic pages showing a single line diagram of the electrical system shall be
carried out in DCS, for low voltage level, medium and high voltage levels shall
be shown in Electric Scada. These pages shall have facilities to indicate the
R2 position of incoming and bus-tie circuit breakers and low voltage switchgear
systems. DCS shall also indicate alarm and trip events of incoming and bus-tie
feeders, including transformer protections. The power requirment of unit both
medium and low voltage level shall be visible from DCS as kW and ampere.

2.22 Signals listed in the I/O list for each group in the plant shall be distributed
equally among all control modules assigned for each plant.

2.23 Process control of the units through DCS system shall be based on
uncompensated raw process data only. Flow control loops in DCS shall be
based on the measurement from the flow transmitter output in the field without
any compensation for temperature, pressure, molecular weight, specific gravity,
composition, and/or and other parameter that may influence the controller
output. Contractor, however, shall configure separate computation blocks,
graphic pages and/or other relevant means to report the compensated flows
based on the respective pressures and temperatures directly measured from
the field. Additionally, a separate laboratory data input page shall be prepared
on operator stations where the corresponding laboratory data such as specific
gravity, molecular weight etc. can be entered into DCS system to be used in
compensation calculation blocks. Compensation calculation blocks shall directly
receive the entered process data through the designated data entry page and
perform the compensation calculations on line.

2.24 Network load shall not exceed 50% and Vendor shall prove it during F.A.T. and
S.A.T. Total memory, memory backup time and detailed sizing shall be as per
CHAPTER 29.000. This load shall be calculated based on the following system
R2 usage.

- No alarm status

- While standard operation displays shown on the operator workstations or

during calling up these displays.

- Simultaneous calling of historical events or trend displays.

2.25 The idle time of processor and the status of each I/O card and controller shall
be displayed on a dedicated controller diagnostic panel, easily accessible to
operator on the operator station.

2.26 DCS to achieve safe and effective control system shall be of the latest proven
design, model, the most advanced DCS on the market of DCS vendor’s

2.27 Compliance List

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The intent of this specification is to define the explicit and desirable

requirements of a microprocessor based DCS. The system proposed against
the specification shall conform to the requirements described here in and
CONTRACTOR shall high light the system features which fall in the “desirable”
category as well for proper evaluation. Exceptions and/or deviations are to be
R2 clarified in detail. VENDOR under the responsibility of CONTRACTOR shall
attach a compliance list which indicates one of the following for each item listed
in this inquiry document in a spread sheet format attached to this document.

C: Full complied. The capability meets the functional or design requirements.

E: The capability proposed does not meet the stated functional or design
requirement, therefore this feature is not offered.
V: The capability proposed meets the requirements but minor variations need to
be clarified.

2.28 VENDOR under the responsibility of CONTRACTOR shall describe in details

the integration of the DCS within the over all automation layers from field to
R2 information system CONTRACTOR shall provide with his proposal a detailed
configuration diagram with associated outline diagrams of the recommended
system depicting all interconnections.

2.29 All DCS equipment including operator station, printers, control modules and all
related nests for interfacing with field wiring shall be supplied with fans to
circulate sufficient amount of air to remove the heat dissipated by electronic
boards so that no excessive temperature rise occurs on any system
components. Also each piece of equipment and component in the system
(operator stations, printers, control modules, cabinets, etc.) shall be equipped
with proper filtration systems to eliminate the possibility of any dust
accumulation on electronic boards and in system components due to circulating
air through the system components. All pieces of equipment shall be assumed
that be kept in the controlled and safe environment in the control room.

2.30 System can be configured/programmed with an independent engineering work

station shall be procured with such a station and its related software. VENDOR
R2 under the responsibility of CONTRACTOR shall provide the latest version of all
relevant software of the engineering work station needed to perform any
configuration, diagnosis, graphic preparation etc works installed on the
computer with the proper manuals written English language to use these
programs and one set of back up copies of these programs.

2.31 Engineering work station and operator station shall be a high performance
commercially available PC work station capable of engineering and configuring
any DCS device linked on the network. BIOS customization for EWS is not
accepted. Stem shall support coexistence of 3rd party software such as virus
buster, PIMS, asset management or analyzing software to run on operator and
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engineering stations without needing separate PC’s.

2.32 VENDOR under the responsibility of CONTRACTOR shall specify the proper
start up and shut down procedures for all DCS modules, operator stations,
R2 computers, operating systems and any other relevant system components. All
component of DCS can be stopped or powered off at any time, without affecting
the others.

2.33 All parts included in any section of the system shall be easily accessible for
maintenance. Any part, card, cable, piece of equipment installed in any section
of the system shall be accessible without having to dismantle or remove
another part, card or a piece of equipment.

R2
2.34 VENDOR under the responsibility of CONTRACTOR shall, during bidding
stage, specify clearly the air quality required in the control room where the parts
of the DCS system are located, modifications required in the control room to
meet the air quality to minimise the corrosion on the parts of the system taking
into account that the DCS system shall be operating in a refinery environment.

2.35 All the necessary engineering for configuration, software applications, graphics
and logging shall be performed by CONTRACTOR. However, CONTRACTOR
shall ask for approval of OWNER for all activities in each phase of DCS
engineering.

2.36 The vendor shall have noticable systems installed base in Turkey and had to
continuous activity industry for the 10 last years. The vendor shall have
engineering and maintenance capability in Turkey (provide reference list).

2.37 The proposed system shall feature windows XP, Vista or Windows 7 operating
system for the operator interface.
R2
Operating system shall be native (without modification) and single to guarantee
fast response. Additional proprietary operating system on operator interface is
not accepted

2.38 The proposed system shall feature OPC server to enable exchange of data with
R2 computers, connected to ethernet. If required, Exaopc software shall be
implemented to DCS.

2.39 Deleted.

2.40 Functional Structure

A. Level 1 functions
The Level 1 equipment shall be suitable to carry out the following
functions:
- interface with field instrumentation such as transmitters and final
elements controlling the process parameters such as rate of flow,
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temperatures, levels, etc.;

- development of control or calculation algorithms for closed loops and
monitoring of complex variables;
- interface with the field instrumentation (analog or digital) and with the
final control devices involved by sequential logic;
- execution of logics (and, or etc.) and of arithmetic computations,
linearisation, selections, comparisons and timings;
- interface with various types of sensors in order to allow the monitoring
of the process variable measured by the same;
- handling of complex sequences and/or logics;
- handling of complex algorithms;
- transfer to Level 2 of all data, measurements, acquired events,
calculated or produced by Level 1 itself;
- handling the sequence of events whenever required and as specified
on the Material Requisition;
- receive from Level 2 commands and set points.

B. Level 2 functions
Level 2 represents the operator's interface towards the plant.
Each operator station will have its own real time and historical database.
R2 DELETED.
Each independent operator station shall handle/allow the following
functions
- indication of all analog or digital process variables, open or closed
loops and all related parameters;
- manipulation of control loops, including: set-point change, operating
mode, output, tuning, computation constants;
- alarm announcing;
- display of process graphics;
- logging and possibility of both historical and trend recording;
- SOE presentation
- display of self-diagnostics messages.
Still at Level 2, but through engineering station, the following functions
are handled in addition to the above mentioned ones:
- changes, additions, cancelling to the configuration of Level 2 (user
software) or of the lower levels.

C. Communication systems
The communication network in the system shall be a digital
communication bus providing a high speed (100Mb/1Gb) and reliable
data transfer. The operator stations and the process controllers are
preferred to be on the same physical redundant process network. If not,
the gateways to be used will be redundant, industrial type, reliable and
high performance models. System real-time control network shall be
deterministic (response time and network load guaranteed). Data link
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based on CSMA/CD shall not be accepted. The mesh control network

architecture shall be offered only if the inverted tree network topology is
implemented. Proprietary communication systems are acceptable; they
shall be submitted to TÜPRAS for review and approval. They shall be
able to communicate to open systems based on TCP/IP protocol or
equivalent.

2.41 SYSTEM PERFORMANCE/CAPABILITY

2.41.1 Characteristics common to all components Reliability

The system is implemented by holding reliability in the utmost
consideration and in particular the selection of the electronic
components and the individual entities forming the system is carried
out on the basis of a continuous operating time of 2 years.

Modularity
The system is of a modular construction and easily expandable; the
module typology holds in due consideration the requirements of
interchangeability and reduction of storage costs.

System requirements
- The system is installed in a non-classified area (control room,
equipment room). (ISA S71.04 & S71.01 G1AX).
- All the system components and panels shall be ATEX certified.
- The system can be supplied at 220 VAC at 50 Hz. from a UPS
with the following tolerances:
- Voltage 220 VAC +/-10%
- Frequency 50 Hz -4% / +3%

2.41.2 Vendor shall specify the proper start up and shut down procedures for
all DCS modules, operator stations, computers, operating systems and
any other relevant system components. All components of DCS can be
stopped or powered off at any time, without affecting the others. Any
card changes (I/O card, power supply card, bus communication card
and CPU card) shall be allowed on line.

2.41.3 All parts included in any section of the system shall be easily
accessible for maintenance. Any part, card, cable, piece of equipment
installed in any section of the system shall be accessible without
having to dismantle or remove another part, card or a piece of
equipment.

2.41.4 Equipment containing electronic devices shall have a minimum

maintainable life of 10 years with identical parts, and an additional life
of 10 years with equivalent parts as recommended by the
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manufacturer.

2.41.5 The mean time to failure (MTTF) of systems or equipment comprised

of electronic devices shall be no less than 5 years. The mean time to
repair (MTTR) shall be no greater than 4 hours under the following
conditions:
- Repairs performed at location.
- Repairs performed by plant technician.
- Stock of spare parts available on site.

2.41.6 Electric Supply

- The system is to supply all loops except those identified as
"externally supplied".
- DC voltage levels for I/O and other circuits shall be produced by
R2 equipment (redundant) placed inside the system or marshalling
cabinet.
- All supply units shall be redundant and implemented in such a way
that the malfunction of a unit may not propagate to the other units
as well.
- The transfer of supply from the unit under failure to the back up one
is instantaneous and without interruptions in the normal operation of
the system.
- The outputs of all supply units shall be monitored by the system -
and any malfunction shall be immediately identified and alarmed.
- In case of cycling the power to the system, the control processor
shall automatically run without manual data reloading from hard
disks, disks, tapes or else. The start or reset of any system
component shall not require the performance of complex
procedures.
- It shall be possible to isolate and replace each and every electrical
component in the system without affecting others.

2.41.7 Availability
The system shall be highly reliable and available. The availability shall
be not less than 99.5%.
The malfunction of a unit of the system, at any level, shall not
propagate to other devices of other levels.

2.41.8 Database
All I/O signals in the system shall be identified with the tagname of the
field instrument.
The system allows the I/O signals or in general the functions to be
identified with a name of 12 digits at least.

2.41.9 Memory
- Memory of non-volatile type shall be provided for the configuration
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data. It shall not be necessary to reload other "off-line" devices in

case of system restarting.
- In the event that RAM are used with buffer batteries, these shall be
suitable to maintain the memories for 30 days. The battery charge
state shall be continuously monitored. A special alarm signalling
shall be generated when the required maintenance times cannot be
ensured.
- All batteries shall be replaceable without needing to interrupt the
functionality of the associated memories.
- The system configuration shall be such as to leave at least 50% of
memory space available for future changes.
- It is preferred that all memory modules shall be expandable.

2.41.10 Synchronisation

2.41.10.1 The real time clock on each operator station shall be

crystal controlled, which shall be independent of line
frequency. All the real time clocks in the system shall be
synchronised with each other within 1 msec.

2.41.10.2 Any device (operator station, control processor,

communication card, etc.) shall generate a system alarm
when the time synchronisation is lost.

2.42 Characteristics/Performance of the Level 3 Device.

The system must have the following functionality to communicate (redundant)
with level 3 devices.

2.42.1 The DCS shall be able to interface level 3 computers in the following
ways:
- by means of dedicated gateways;
- on client/server basis in a open systems architecture.

2.42.2 The proposed system shall feature OPC server to enable exchange of
data with computers, connected to Ethernet.

2.42.3 The Vendor shall provide the related documentations of :

- Gateway configuration
- DCS - Advanced Process Control Integration.

2.42 Communication Bus

The digital communication bus handles the transfer of data among the devices
of Lev. 0, Lev. 1, Lev. 2 and Lev. 3.
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3.0 PROCESS CONTROL AND DATA ACQUISITION SUBSYSTEM

All input and output points to and from field or elsewhere except data bus(es) shall
terminate in proper, separate marshaling cabinets (following separation criteria as per
CHAPTER 29.000 ““TECHNICAL SPECIFICATION FOR CONTROL AND
R2
INSTRUMENTATION DESIGN”) located in the technical room area within the control
room.

3.1 Data Acquisition system

3.1.1 The system I/O shall be at enough capacity for:

 Only indication
 Only recording
 Controlling and/or indication, recording and controlling
 Only alarming
 Alarming prior or after processing of the signal

3.1.2 The system shall have input capabilities of accepting digital or 4-20 mA
DC signals from transmitters, on-off inputs (from switches, relays, etc.)
millivolt inputs from thermocouples of all types at various levels, resistive
inputs from RTDs, voltage inputs, pulse inputs (0-6 KHZ) ; 1-5V DC
analog and relays digital outputs.
System shall support I/O redundancy for all type of I/O cards available
in the system when necessary.

3.1.3 In case of transmitter, power shall be supplied by the system from I/O
units through two wire signal cables, except some analysers or field
R2 devices externally powered. Isolation shall be provided for externally
powered transmitters. Short circuit protection shall be provided.

3.1.4 The throughput should be sufficient to ensure fast updating of process

parameters and fast response command to field devices.

Control loop frequency response, defined as Bode Diagram corner

frequency, from the output connection at the transmitter to the input
connection at the actuator of the final control element (or positioner, if
furnished) shall be at least 1 Hertz, with the controller set for
proportional action only.

3.1.5 I/O hardware modules signal performances (electrical characteristics,

accuracy, resolution, noise immunity shall be suitable for the refinery
environment. These values shall be defined in the document.

Input resolution for I/O cards shall be at least 12 bits for all analog
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inputs. Output resolution shall be at least 1500 steps for the requested -
25% to +25% range to ensure additional force at the control valve
actuator to overcome plug unbalance forces and insure valve closure.

Accuracy for analog inputs shall be at least ± 0.1%.

3.1.6 I/O card replacement shall be possible without power shut-down and/or
disconnection/reconnection of wires (including any kind of input
conditioning card if available, functioning as termination unit or module).

Any card changes (I/O card, power supply card, bus communication
card and CPU card) will be allowed on line.

3.1.7 Temperature input data shall be characterized to compensate for non-

linearity of the primary device. Temperature inputs (other than the ones
involved in the control loop with transmitter) shall be directly connected
to dedicated T/C-T/R input cards (on DCS) without any linear
transducers (i.e. , mV to 4-20 mA or resistance to 4-20 mA). Cold
junction compensation and upscale drive on "T/C" burn-out shall be
provided.

3.1.8 Multipoint temperature indicator points shall be incorporated into the

data acquisition facilities of the control system. Minimum overall
accuracy at reference conditions shall be ±0,15 percent of full scale, and
minimum resolution shall be one degree.

3.1.9 All I/O cards shall follow Isolation Requirements described in RUP
R2 project Technical Specification for Control Philosophy and
Instrumentation Design, Chapter 29000, point 5.3.24.

3.1.10 Deleted.

3.1.11 Redundant power supplies (1 to 1 or n+2 if it is modular structure) shall

be available for I/O subsystem.

3.1.12 Contractor shall indicate the minimum scan time available for each kind
of signals. For data acquisition subsystem scan time shall be smaller
than below values:

Digital inputs: 100 msec. (except the ones involved in item 3.2.6, 2
msec)
 Analog inputs : 250 msec. max
 Temperature inputs : 1 sec. max
 Digital inputs: 100 msec. max (except the ones involved in
item 3.2.6, 2 msec)
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 control loops 250 msec.

Changing the input scan time on line while the plant is in operation shall
be possible.
Data update period of analog I/O cards shall not exceed 10 msec, for
digital I/O cards it shall not be more than 8 msec, for temperature cards
no more than 1 sec.
Logic or sequential control functions performance times shall be as
follows:
- SOE digital inputs 1 msec.;
- digital inputs 20 msec.;
- digital loops 100 msec.

3.1.13 Transmitter failure and thermocouple failure detection shall be possible

with alarm displaying on the system. The detection of the transmitter
failure shall cause the controller output to be held at the prior valid
output signal value until the operator takes action by transfering the
control to manual. Contractor shall specify at the bidding stage the
output value of the output cards when DCS starts up after a power
failure on DCS.
R2
3.1.14 DELETED.

3.1.15 Analog output cards shall have the capability to act immediately upon
loosing communication with controller part failure by the driving the
output to predefined level.

3.1.16 Characteristics/Performances of the Level 1 Devices

Characteristics of the I/O cards

3.1.16.1 General

3.1.16.1.1 I/O hardware modules signal performances

(electrical characteristics, accuracy, resolution,
noise immunity) shall be suitable for the refinery
environment.

3.1.16.1.2 The System shall be implemented in such a

way that all types of I/O cards may be installed
in all positions of the relevant nest. I/O card
replacement shall be possible without power
shut-down and/or disconnection/reconnection
of wires (including any kind of input
conditioning card if available, functioning as
termination unit or module).
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3.1.16.1.3 The System shall be equipped with diagnostics

tools to prevent errors in signal scanning while
the insertion or removal of I/O cards. The
System shall discriminate the card removed.

3.1.16.1.4 All fuses shall be equipped with optical

indicator; furthermore the fuses may be
replaced with no need to remove the card,
keeping in operation all channels not protected
by the fuse to be replaced. Each individual I/O
channel shall be protected by fuses. The
selection of fuses shall be such as to minimise
the possibility of loss of a whole card.

3.1.16.1.5 The minimum insulation between I/O channels

and between the channels and the common
shall be 75 Megaohms.

3.1.16.1.6 System shall support I/O redundancy for all

type of I/O cards available in the system when
necessary.

3.1.16.1.7 The field terminals of each I/O card shall be

separated from the I/O card itself. The field
terminals will be installed in dedicated
marshalling cabinets. Preformatted cables with
ELCO connectors or equivalent shall connect
the field terminals to the I/O cards.

3.1.16.1.8 All I/O cards shall be isolated from field as

described in RUP project Technical
Specification for Control Philosophy and
R2 Instrumentation Design, Chapter 29000, point
5.3.24

3.1.16.1.9 System shall have remote I/O capability when

necessary.

3.1.16.2 Analog Input Cards

3.1.16.2.1 The analog input cards shall be available for

the following types of signals:
- 1 - 5 VDC;
- 4 - 20 mA (24 VDC loop powered or external
powered);
- thermocouples (of all types with cold junction
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compensation and burnout detection);

- resistive inputs from RTD’s;
- pulse inputs (0-6 kHz);
- smart HART type analog I/O.

3.1.16.2.2 The analog input cards comply with the

following technical requirements:
- the resolution is 12 bits;
- the accuracy is +/- 0.1%;
- open loop–and short circuit detection;
- For isolation refer to RUP project Technical
R2 Specification for Control Philosophy and
Instrumentation Design, Chapter 29000, point
5.3.24
- separate A/D conversion unit for each
channel.

3.1.16.3 Analog Output Cards

3.1.16.3.1 The analog output cards comply with the

following technical requirements:
- they are suitable to control a load of 400 ohms
at least;
- the output range is 4-20 mA (extended range
is 0 to 24 mA);
- the resolution is 12 bits;
- the linearity is 0.1%;
- open loop and short circuit detection;
- For isolation refer to RUP project Technical
R2 Specification for Control Philosophy and
Instrumentation Design, Chapter 29000, point
5.3.24

3.1.16.3.2 Vendor shall clarify the output value of the

output cards when DCS starts up or
communication is lost with process controller.

3.1.16.3.3 The card circuitry shall be suitable to monitor the

state of the loop connected and in particular the
conditions of open loop or short circuit ones.

3.1.16.4 Digital Input Cards

3.1.16.4.1 The cards for digital or impulsive low frequency

inputs are complying with the following
requirements:
- For isolation refer to RUP project Technical
R2
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Specification for Control Philosophy and

Instrumentation Design, Chapter 29000,
point 5.3.24
- each loop is supplied from the system, which
recognises loop state changes with
impedances of 1000 ohms at least (including
the contact resistance);
R2 - In ESD system the state of each digital input
shall be visible on the card front through a
special LED;
- the digital input channels shall be equipped
with filter suitable to discard signals having a
duration of less than 2 msec.

3.1.16.5 Digital Output Cards

3.1.16.5.1 The digital output cards (with relay) comply with

the following technical requirements:
- 1 DPDT, 220VAC, 2,5A, 1500VDC insulated
for isolation;
- they are capable of switching 220 V 50 Hz
with 0.9 power f actor;
- they bear a continuous peak load of 2 Amp.
and 10 Amp;
- it is possible to select the state of each N.O.
or N.C. output;
- the relays used on the cards are suitable to
bear 1.000.000 operations at the provided
load;
- the relays shall be exempt from vibrations.

3.1.16.6 Scanning

The various I/O signals may possibly be assigned various

scanning times. The selection of the scanning time is
carried out by taking in due consideration the speed with
which each signal changes from its normal operating state
to the abnormal one. The scanning time of some I/O
signals may be automatically varied by the automation
logics to allow that points with normally slow dynamics are
sampled at greater frequencies during some particular
transients (starting).

3.1.16.7 Checking loop integrity

3.1.16.7.1 The system constantly checks all the analog I/O

to verify that they are within the fixed ranges
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and generates alarm signals in case of

malfunction. The displayed data relevant to the
points in malfunction state shall be the last valid
ones measured; in this event the datum on the
display shall be recognisable in its "frozen"
state.

3.1.16.7.2 As a rule the malfunction of an analog input

signal of a control loop shall cause an alarm to
be generated in order to call the attention of the
operator. Meanwhile the controller is switched
to the manual mode and the output is fixed to
the last processed value until the operator
changes it.

3.1.16.8 Congruence control

Where applicable the system carries out a congruence

control between
corresponding I/O signals (eg. valve open rather than
closed). Non congruent states shall generate alarm signals.

3.1.16.9 Following minimum functions shall be required for each

PID algorithm tag in the in the system. The contractor shall
consider the necessary number of points based on this
criteria and shall size the proposed system.

Analog input (with input conditioning like linearisation and

square root and
filtering) , input data compensation (dead time, flow, etc.); ,
alarm cheks, PID calculation (with feed forward function
and output limitation), BUMPLESS MODE changes
between manual, automatic and cascade, feed forward
function, analog output, output limit.
Standart software input processing shall be available to
provide square root and adjustable line segment, digital
filter and alarm checks.

3.1.16.10 Logic and sequential control function

The System performs the sequential functions relevant to
starting, stopping etc. (not for emergency) the
machine/device.

3.1.16.10.1 All the logic sequential control functions can

be implemented by means of the application
of suitable pre-configured control algorithm or
else by means of programming languages
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developed for the control in real time of

sequential industrial processes. Programming
is possible by means of the engineering
station at Lev. 2.

3.1.16.10.2 Among the sequential control functions, the

following ones are possible:
- forcing loop in manual;
- intervening on the output;
- signals changing set point (with possibility of
ramp);
- changing tuning parameters.

3.1.16.10.3 The sequential control uses all the

analog/digital signals resident in the
microprocessor data base heading to which
are the inputs/outputs from the field.

3.1.16.10.4 It is possible to have pulse outputs,

momentary or held without needing to resort
to specialised program blocks.

3.1.16.10.5 The states of the digital inputs and outputs are

available at operator station level; equally
available at the operator station are the states
of the pumps or motor driven valves.

3.1.16.10.6 The logic or sequential programs are to be

equipped with comments of such a quality as
to allow a quick interpretation.

3.1.16.11 Sequence of events (SOE)

3.1.16.11.1 Special Digital input Cards with a scanning

time of 1 ms. shall be available. The DI card
processor (SOE) shall provide the time stamp
to each event and will transmit to Level 2 the
buffer of the processed inputs. Level 2 will
provide to organise the sequence of events on
time basis.
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3.1.17 Response times

3.1.17.1 The response time is defined as the time between the

moment when a signal changes in value at the input
channel of a card and the moment when the controller
takes the consequent action and the output signal is sent
assuming that the following conditions occur:
- worse position from the varying point as compared with
scanning;
- maximum complication of the control algorithm;
- maximum traffic on the communication systems between
levels.

3.2 Process Control Subsystem

The control functions of the system shall be carried out by control processors.
The controller modules shall have equivalent, high level technology,
multifunction capability and be 32 (or more) bit high performance RISC
microprocessor-based with multiple inputs and multiple outputs for control and
data acquisition. The data acquisition system and the process control system
shall be fully integrated in order to guarantee a very high level of reliability,
availability and data integrity.

This controller equipped with resident software to carry out analog control
algorithms, interlocks and sequential control functions.
Controller shall be in dual-redundant configuration for processor, power
supplies, real-time control network and communication network with I/O sub-
system. Controller shall support I/O redundancy for all type of I/O cards
available in the system.

3.2.1 The module input and output in quantity (capacity) is to be at the

manufacturers standard.

3.2.2 The preprogrammed control algorithms and functions shall include

but not limited to:

 Input monitoring
 In addition to basic PID control algorithms, logic, sequence,
cascade and modulating control functions,
 Various type and quantity of algorithms which can be
implemented with each control type will at the minimum be
enough to realize algorithms, calculations necessary for refinery
operations.
 PID control with dead band
 Two position on-off control
 Three position on-off control
 Pulse duration on-off control (time proportioning)
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 Manual control
 Ability to bias a signal and sum it with controller output for feed
forward control
 Ratio setting
 Automatic signal selector
 Data exchange
 Signal switch
 Ramp functions
 Totalizing/Integration
 Mass flow computing (with compensation of temperature,
pressure and density)
 First order lead/lag unit.
 Rate limit
 Dead-time compensation control
 External feedback to prevent wind-up (for required loops)
 Moving/cumulative average
 Line segment function for non-linear signal
 Calculations (square-root, addition, subtraction, e-ponential
function, logarithmic function, multiplication/division, Sin/Cos
functions, ...etc.)
 Various advanced and control functions

3.2.3 Controllers shall be able to scan close loops in minimum 4 times per
second; and for digital loops 10 times/second. The control system
shall have sufficient memory to support twice as much as control
blocks that are necessary for application.

3.2.4 If system uses configurable function blocks, each controller shall

have 10,000 function block address range with sufficient additional
memory to support all 10,000 blocks.

3.2.5 Bumpless transfer between all control modes (e.g. manual,

automatic, cascade) shall be provided without manual adjustment of
balancing.

3.2.6 Digital inputs associated with shutdown, interlock, start/stop

sequence and critical process alarms shall be scanned on the
scanned SER with a minimum 1ms speed to get a proper sequence
of events log for analyzing shutdown and malfunctions causes.
Integrated SOER function on DCS shall be preferred.

3.2.7 Controllers shall also support ladder logic and high level
programming language to allow customized application programs to
be run. Necessary utility software packages which enable the user to
develop high level programming language (i.e. BASIC, C or other
special manufacturers programming utilities) shall be provided. All the
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control configuration and data acquisition such as regulatory,

sequence/logic, batch and protection/interlock control shall be
implemented in the same controller. Any other separate controller for
a specific application is not accepted.

Controller shall support implementing of advanced process control

algorithms without needing any special hardware or software
package.

3.2.8 VENDOR under the responsibility of CONTRACTOR shall guarantee

R2 a full redundancy (1/1) of the CPU, including automatic switch over,
error check function, no loss of data or tuning parameter and
replacement of the failed CPU on line with automatic down load of
the application software. Redundant processor switch-over shall be
instantaneous (0 ms) without controller output hold. This shall be
accomplished via fundamental hardware design requiring no special
software programming.

3.2.9 Signals listed in the I/O list for each group in the plant shall be
distributed equally among all control modules assigned for each
plant.

3.2.10 Interface to the process shall be through distributed microprocessor

based controllers. Each controller shall be a stand alone unit capable
of performing full data acquisition and control of the process via I/O
interface hardware. System shall have remote I/O capability when
necessary.

3.2.11 Dedicated software blocks shall be available for control of electrical

motors, actuators and pumps. The block shall be used to perform
LCD based operation to start up or shutdown motors, givign the
operator one faceplate to interface to the motor, if these are required
on piping and instrument diagrams.

3.2.12 Calculations shall be provided in the form of blocks, supporting

regulatory and sequence control functions as well as providing
general purpose calculation functions.

3.2.13 A general purpose calculation blocks shall support linking to various

inputs/outputs or other regulatory blocks. And allow for implementing
several program steps to achieve complex calculations combined
with logical decisions within the same block.

3.2.14 Easy function block whether regulatory control, sequencing or

calculation type have as a standard its own pre-configure faceplate.
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3.2.15 Following minimum functions shall be required for each P&ID

algorithm tag in the regulatory control. The CONTRACTOR shall
consider the necessary the number of points based on this criteria
and shall size the proposed system.

3.2.15.1 Analog input

3.2.15.2 Standard software input processing shall be available to

provide square root and adjustable line segment, digital
filter with time constant and alarm checks shall be
provided.

3.2.15.3 Input data compensation (dead time comp., press./temp.

comp., etc.)

3.2.15.4 Alarm checks

3.2.15.5 PID calculation

3.2.15.6 CAS/AUTO/MAN switching (with bumpless transfer)

3.2.15.7 Feed forward function

3.2.15.8 Output limit

3.2.15.9 Analog output

3.2.16 Also the followings are the minimum functions required for each
monitoring point in the regulatory control (including temperature
monitoring).

3.2.16.1 Input data conversion such as square root, line segment

3.2.16.2 Digital filter for analog inputs

3.2.16.2 Alarm check

3.2.17 Smart field instrument integration: The system input card shall be
capable to separate the two signals and transfer digital information to
R2
the system engineering work station for transmitter setting,
maintenance and diagnostics. For this purpose, hardware and
software shall be offered.
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3.2.18 The control modules power system shall be a back up battery

capable of providing regulated power in the event of the loss of input
power.

3.2.19 System shall have upward compatibility of application software for

newer versions. The original application/configuration software shall
be capable of working on the newer versions when the system
software is upgraded without needing any special programming.

3.2.20 System vendor shall clearly define a migration path for maintaining
upward compatibility.

3.2.21 The implementation of self-calibration algorithms is to be advised if

available. In any case, such self-regulation algorithms shall require
no upsets of the process conditions for detecting the responses from
the process itself and, furthermore, they must be overridable.

3.3 Field Interface (System/Marshalling Cabinets):

Cabinets for interfacing between the field and the acquisition
subsystem of the DCS shall be supplied. Both the system and the
marshalling cabinets of DCS shall be VENDOR’s own production or
Rittal or equivalent, of the same model and dimensions according to
R2 it specified in CHAPTER 29.000 “TECHNICAL SPECIFICATION FOR
CONTROL AND INSTRUMENTATION DESIGN.” The IP rating for
the cabinets in the equipment room shall be IP43 as minimum.
There shall be diff. marshalling cabinet for analog input/output
signals, digital inputs, digital output and relays, RTD inputs and T/C
inputs.

3.3.1 All the cabinets shall be of free standing, enclosed type and shall be
designed for bottom cable entry. Cabinets shall be equipped with rear
and front access doors, lamp with door switch, safety ground bar,
isolated instrument (reference) ground and name plate of appropriate
dimensions (white engrave on black background). Doors shall be
equipped with lockable handles and concealed hinges with pull pins for
easy door removal.

3.3.2 In order to effectively remove dissipated heat from the cabinets, vent
louvers backed by wire fly screen shall be provided to cabinet doors
together with ventilation fans. Cabinet fans and temperature status shall
be checked continuously by the system self diagnostics and shown on
the operator station.

3.3.3 Equipment within the cabinet shall be laid out in an accessible and
logically segregated manner. Clamping rails shall be provided for
incoming cables to prevent excessive stress on the individual terminal.
The field cables shall terminate on rail mounted, disconnect type
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marshalling racks.

3.3.4 All metal parts of the cabinets including doors shall be electrically
continuous and shall be provided with a common grounding lug.

3.3.5 The multicare cables with industrial type, multi-pin plugs and connectors
(ELCO connector or equal, so called system cables) shall be executed
in the Vendor's shop. The multicore cables shall be standardized on the
length, number of lead and lead connection. The plugs and socket
system shall have the following features as a minimum.

3.3.5.1 Industrial type with gold plated fork contacts.

R2 3.3.5.2 DELETED

3.3.5.3 All spare cables to terminate on the terminals after the socket,
and all cables and incoming panel no. shall be marked clearly.

3.3.6 Cabinets shall have enough space for maintenance operations,

especially for connection/disconnection operation of internal wiring for
terminal blocks.

R2 3.3.7 DELETED.

3.3.8 There shall not be any components on the lowest 100 mm. of the
marshalling cabinet mounting plate. This space can not be considered
as spare space in calculations.

3.3.9 Wiring Requirements:

Marshalling equipment will be provided including cabinets,

intrinsic safety barriers and wiring. All interconnecting wiring and
cables shall be provided and prewired by the Vendor. Field cables shall
be terminated in cable order.

3.3.9.1 Terminal blocks (Weid Müller/MTL/P+F or equal) shall be of

the clip-on disconnect type with LED fuse blown indication
for the field terminals and disconnect test type for the
intermediate terminals, which are suitable for wires up to
cross-section of 2.5 sqmm. All the terminals used in the
cabinets shall be of the same width to facilitate wiring.

Terminal shall be either tinned or silver plated and terminal

number shall be clearly identified.

3.3.9.2 Intrinsically safe wiring shall terminate terminals for incoming

R2
and outgoing to field and then wiring from terminal to
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barriers. For temporary attaching of Hand Held

Communicator leads into the safe or field side of barriers
appropriate termination utilities shall be applied.

3.3.9.3 PVC insulated stranded copper wires shall be used. Size

and color code of all internal wiring shall be determined by
Vendor.

3.3.9.4 When instruments are provided with screw type connecting

terminals, the wire ends shall be provided with crimped-on
spade lugs (Make: AMP or equivalent).

3.3.9.5 Wire ends at terminal blocks shall be provided with suitable

compression type wire pins (Make: AMP or equivalent).

3.3.9.6 Removable cover plates shall be provided over all terminals

with voltage above 50 Volts.

3.3.9.7 The spacing between terminal blocks for each type of

signals shall be provided.

3.3.9.8 All electrical instrument shall be mounted in such a way that

positive earthing is provided by metal to metal contact to
cabinet.

3.3.9.9 Each cabinet shall be provided with two different copper

earthing bars with sufficient earthing screws. One of them
shall be electrically isolated from the mechanical structure
which is to be used for instrument (reference) grounding.

3.3.9.10 Each wire internal to marshalling shall have identifying

markers. Using sleeve or plastic ferrules at all terminal
points. Markings, at each wire end (terminal point) shall
include incoming and outgoing terminal/card or instrument
identification.
Terminal strips shall have an identifying marker indicating
their number.

3.3.9.11 Connectors shall have an identifying marker on the mounting

plate indicating their number.
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3.3.9.12 Minimum separation between power and signal wiring shall

be at least 300 mm if they are running in parallel.

3.3.9.13 Within one multiconductor cable only one type of signal

(voltage level) shall be contained.

3.3.9.14 Wires in the same conduit or support shall be of the same

type of signal (voltage level).

3.3.9.15 Intrinsically safe wiring shall be separated from the others

and its conduit/tray shall be light blue in color. Wiring shall
be routed in such a way that it will not interfere maintenance
operation i.e. card removal or insertion etc. Certified
intrinsically safe circuits for all input and output points
coming from hazardous areas are required.

3.3.9.16 I/O signals shall be grouped based on the following:

 4.20 mA
 pulse
 mV/RTD
 Digitals
 1-5 V DC

3.3.9.17 Cabinets shall have enough space for maintenance

operations, especially for connection/disconnection
operation of internal wiring for terminal blocks.

3.3.9.18 Fused terminals shall have indicating led on them to indicate

whether fuses are blown or not.

3.3.9.19 Any kind of I/O card (including any kind of terminating or

input conditioning card) shall be removed without having to
disconnect all wires from it. Removable male-female socket
type input/output connections shall be allowed for all kind of
I/O cards/modules.I/O card modules shall have front
connectors to facilitate module change without rewiring.

3.3.9.20 The electrical wiring shall be subdivided into following

categories:
- 220 VAC 50 Hz.;
- AI/AO (4-20mA) & RTD;
- DI/DO (24 VDC);
- Solenoids;
- T/C, mV signals.
- etc.
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3.3.10 Temperature Scanner:

If any temperature scanner, as part of the system, to monitor heater

skinpoint and reactors temperatures is used, capable of meeting the
following requirements.

 Scan speed shall allow each point to be updated between 3-7 sec.
 Alarm points to be adjustable
 Alarm print-out to be digital and to include true point number (i.e. not
coded) temperature, date and time.
 All temperatures to be logged at a preset frequency (for example
every six hours) and alarm conditions to be printed.
 Printer to be normally inoperative unless either an alarm point is
exceeded or total record print-out is initiated on time cycle.

4.0 COMMUNICATION SUBSYSTEM

4.1 DCS communication networks:

4.1.1 Each communication network in the system shall be a digital

communication bus providing an high speed and reliable data transfer
between all system modules (Operator Console, I/O cards, and other
devices connected to it). Communication system (real-time LAN) shall
be based on industrial grade digital communication link. Extremly high
reliabiliy and quality network shall be used. System real-time control
R2 network shall be deterministic (response time and network load
guaranteed). Data link based on CSMA/CD is not accepted Real-time
control network speed shall be 1 Gigabit/sec or 100 Megabit/sec.

4.1.2 Control network shall be dual redundant with self-diagnostic function for
data integrity check and with on-line self recovery functions In case of
main bus failure or any communication device failure, the transfer to the
back-up bus or device shall be automatic without interrupting the system
operation and without any operator's action. Information about the failed
bus/device shall be displayed on the operator consoles. Bus switch over
time shall not exceed 50 msec and bus error recovery time shall not
exceed 20 msec

4.1.3 Communication speed on the communication bus shall be 1 Gbps and

sufficient to update the operator console data base in every one second.
The overall system performance shall not be degraded whether the
communication subsystem is loaded at 10% or 100%.

The redundant 1 GB deterministic communication system will have

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enough capacity for the load envisaged from the start, plus the load
deriving from expansion of functions. Such capacity should exist at
every condition of the plant:at start-up, when running, during shut down,
etc The network load must not exceed 50%.

4.1.4 It shall be possible to connect or disconnect any device to/from the

communication subsystem without disrupting normal operation.

4.1.5 The real time LAN shall be capable of accomotating a large number of
devices and be able to provide extended communication up to 3
kilometers minimum with proper active repeaters and fibre optic cables.

4.1.6 Both communication lines in a dual redundant network shall be

continuously diagnosed and checked for errors.

4.1.7 Each node on the network shall be notified of the status of all nodes for
any trouble or failure on diagnostic panel.

4.1.8 Process data accessed by the displays shall be continuous and in real
time.

4.1.9 The proposed system shall feature as a minimum interface to sub

systems via,

- Serial link (RS 432 or RS 485)

- Ethernet
- Foundation field bus
- Profibus
- Modbus etc.
R2 4.1.10 DELETED.

4.1.11 The vendor shall be able to propose a plant resource management

software functioning all functionality for maintenance of the field devices

5.0 DCS OPERATOR INTERFACE

5.1 Operator Interface Station

5.1.1 The operator stations shall be provided with their electronic system.
Each operator station shall have its own separate keyboard and
electronics and shall provide a means for centralizing the task of
monitoring and manipulating the process while using distributed devices
to perform actual process interface and control functions.
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Each operator station shall keep its own application database (all real-
time and historical process data, trends, alarms & events) to provide
multiple functional redundancy. Separate process servers or common
historical modules even in redundant configuration can be accepted
R2 under Tüpraş’s approval. System shall support remote operation,
maintenance and engineering from multiple remote client PC’s without
needing direct connection to system real-time control bus and special
software. System shall also support remote operation over internet.

Client server architecture is acceptable, but at least, two workstations

per each Group Area Console should be directly sitting on plant
communication loop as independent nodes. Operating station shall be
R2
connected to plant communication loop through a server. At least two
workstations per each Group Area should be directly connected to main
plant communication loop as independent nodes. However, “view only
remote monitoring stations “which are meant for monitoring only and no
plant operation is to be performed from these, can be connected to plant
communication loop through server.

DCS system operator stations shall be according to CHAPTER 29.000

R2 “TECHNICAL SPECIFICATION FOR CONTROL AND
INSTRUMENTATION DESIGN”
Each operator station shall be of a master type and shall have its own
processor. In case a station fails during normal operation, the other
stations shall continue to operate without disturbing the normal, stable
and safe operation of the respective process units.

Engineering work station and operator stations shall be a high

performance and commercially available PC stations capable of
engineering and configuring any DCS device linked on the network.

Operating system shall be native (without modification) and single to

guarantee fast response. Additional proprietary operating system is not
accepted.

5.1.2 Each operator station shall be identical in presentation, operation, data

base, performance and capabilities in order to ensure system reliability
and complete interchangeability for process operation. So, each station
can perform the task of any other station and all stations can serve as
mutual back-up for each other provided that they are connected through
the same data highway. In order to guarantee high performance and
data integrity a direct connection of the operator station to the DCS real
time data communication network is required. Connection through a
secondary network and computer gateway is not acceptable.

All operator station shall be independent of engineering stations, self

bootable and do not require engineering station for putting them into
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normal operation or restoring them after rebooting, once the developed

project is deployed .System should allow online modification,
addition/deletion or change in any control loop or part thereof.

Each operator station shall be accommodated in its own independent

console/furniture with the best befitting furniture with good system
ergonomics and aesthetic.

Failure of any operator workstation should not effect more than one
operator station.

The operator station and the engineering work station of DCS system
shall have the capability to display simultaneously the DCS standard
graphic and application windows.

5.1.3 Each operator station shall be able to provide the following functions, as
a minimum:

 Indication of control, non-control, analog, digital and on-off

variables.
 Window display of several applications running on the other
operator stations.
 Manipulation of control loops, including set point, mode, output
and tuning constants.
 Dedicated real-time trend, and historical trend recording.
 Alarm annunciation, display and management together with
events.
 Custom graphics pages.
 Process variable, tabular log display.

 Reports/ logs
 Custom keys
 x- Window
 Status indication.
 Operating displays
 Window from computer application
 Self diagnostic messages.
 Input high and low values
 Deviation from set point

The operator stations shall be able to supervise the data of regulatory

control, sequence functions and batch control.

5.1.4 The real time clock on each operator station shall be crystal controlled,
which shall be independent of line frequency. All the real time clocks in
the system shall be synchronized with each other.
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5.1.5 Each operator station shall be able to process 100,000 tags as a

minimum in its database, if tag database feature is adapted.

5.1.6 Each operator station shall be able to be equipped up to maximum 4

LCDs.

5.1.7 Each LCD shall have industrial high resolution min. 27" color screen
R2
capable of displaying alpha-numeric and graphic displays.
The upper LCD monitors shall have swivel, tilt, rotate and height
adjustment facilities.
Bulk storage devices: Hard disks drive of the operator stations shall be
of redundant RAID-5 type 500GB hard disk with hot swappable
configuration which is avaible in the open market for all station wherever
applicable.

5.1.8 Multiple colors shall be used to distinguish parameters such as control,

information, process and alarms etc.

5.1.9 The operator station shall be arranged so as to permit access to

different functional levels ( operator level, engineer level, maintenance
level) of the system.

5.1.10 Operator stations of DCS system shall be DCS vendor’s own

production.

5.1.11 Refresh time and screen call-up time of real time data on standard
operation display for all windows (not only predefined Windows) shall be
one second (max) and not exceed one sec. Call up time to bring full
display with all information of a standard operation display shall take no
more than 1 second. This shall be tested and proved during F.A.T. and
S.A.T.
CONTRACTOR shall note that failure to comply with this will result in
removal from TÜPRAS’s vendor list for DCS vendor.

Response Time: At Level 2, the response time is defined as the time

elapsing between the change of value or state of an input of a I/O card
at Lev. 1 and the moment when the game information is available to the
operator at Level 2 at the LCD or printer. The response time is
calculated in the worst possible conditions which are:

- unfavourable position of the input and card with respect to scanning;

- complication of the control loop;
- maximum traffic on the bus between levels;
- times of the display, the LCD buffers, etc.

Considering what above, the response times for operator and

engineering stations are contained within:
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- operator command and equipment 1 sec.;

- alarm on LCD further to change 1 sec.;
- change given on LCD 1 sec.

5.1.12 The operator stations shall be connected directly to the real time
network (gateways are not acceptable).

5.1.13 System shall support coexistence of 3rd party software such as virus
buster, asset management or analysing software to run on operator and
engineering stations without the need of a dedicated computer.

5.1.14 The system shall be secure against unauthorised use by means of key
locks, passwords or equivalent methods; The vendor shall detail the
system security provisions and the number of access levels.

5.1.15 Only in reading mode it will be possible to display from an operator

console, by means of the relevant tagname, a variable belonging to
another operator console.

5.1.16 Keyboard

5.1.16.1 The keyboard shall be of the "self explanatory type", easy to

operate, and will allow an easy performance of the
configuration and system control functions. Easy-tolearn
"Call routines" shall help the operator in performing the
control operations.

5.1.16.2 The operator keyboard shall preferably be of the "touch

sensitive" membrane type.All commands from the keyboard
shall be recognisable by means of a sound.Ample warranties
shall be supplied on the non susceptibility to dust and
humidity.

5.1.6.3 At least, through the keyboard, it will be possible to have

access to:

- selection of all displays including the direct access to the

loops in alarm, possibility of selecting the video pages
(overview, group, loop), etc.;
- silencing of alarms (when announced on the operator
console);
- possibility of inserting new parameters and, at the same
time, cancelling the existing wrong parameters. This type
of access shall have to be documented;
- possibility of easily positioning the cursor for the selection
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of all parameters;
- possibility of requesting the prints of the graphics, logging
and alarms, addressing signals and trend recorders;
- possibility of changing the operating mode
(automatic/man/cascade) of each controller with
"bumpless" action, the state of a user (placed in manual)
and the state of a group of users.

5.1.6.4 In addition to the above, the keyboard shall have the

possibility of assigning some functions to personnel of a
higher level. These functions will have to be protected by
means of "security keys", that should preferably be software
type. Among these functions there will be:

- inhibition of alarms (installation stopped or under

maintenance);
- change to the alarm set;
- access to the loop tuning parameters;
- adjustment of the clock (on an external clock if possible);
- assignment of parameters for the historical recordings.

5.1.6.5 The above mentioned functions shall be documented.

5.1.6.6 The system shall be suitable to be use also with additional
pointer devices (mouse, track ball or equivalent).

5.2 LCD Displays

The displays on the LCD screens, consisting of fixed format displays and
variable format displays or custom graphics shall include as a minimum the
following features.

 Screen Call-up times shall be within one second.

 Screen Refresh time of real time data on a LCD screen shall be one
second.
Screen call-up time and refresh period on operator stations for system default
and custom made windows shall not exceed one (1) second. Also, vendor shall
clarify the source of dynamic data values (history or real time database) on the
graphics when the page is first called-up and at the periodic refresh intervals.
This shall be tested and proved during F.A.T. and S.A.T. In case the
requirement is not met, DCS vendor will be removed from TÜPRAS’s vendor
list.

5.2.1 Operating Displays

Each operator station shall have the following displays and functions

 Overview display
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 Group display
 Point detail display
 Alarm display
 Trend display (real time and historical)
 Configuration display
 System status display

 System diagnostic display CPU, I/O Modules communication bus,

PS, etc.l)
 Communication system status
 Auto/man/cascade
 Custom graphic display
 Sequential control display;
 Operator instruction display
and other displays as per Vendor's standard.

5.2.1.1 Over view Display

An overview display shall enable the operator to determine

the overall operation of a large segment of the plant. The
alarm condition of the pre-assigned points and groups shall
be displayed in the overview display with colour change and
blinking. The number of points which can be displayed in
one screen (i.e. one page) shall be more than 700 when
configured. The operator must be able to call up directly any
group display or other predetermined displays covered by
overview screen.

Any conditions of deviation from the set point shall be shown

by means of variations in colour, the condition of operation of
each loop (auto/man/cascade) shall be clearly signalled. All
alarm inputs shall be identified by a flashing with ISA A
logics (lock-in).

5.2.1.2 Group Display

A group display shall show a limited number of tags, i.e.

analog-digital, inputs-outputs, controllers, trend graph etc.
Each tag shall be displayed as a faceplate with graphical as
well as numerical presentation of variables like the
measured process variable, set point and controller output.
Faceplate shall have scale in engineering unit and
appropriate divisions. High/Low limits of output and alarm
limits for process variables shall also be displayed.For
discrete elements such as timers, switches, digital I/O etc., a
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faceplate shall be available as standard for each type.Each

faceplate shall be accompanied with numeric and text
description of :

tag number, tag service comment, alarm status, controller

mode engineering units, and digital values for process
variable, set point, and output are also to be displayed.The
alarm condition of each point shall be displayed in the group
display with colour change and blinking. Alarm acknowledge
shall be possible.The number of points displayed in one
screen shall be six to eight. It shall be possible to call up any
individual point display swiftly with one operator action from
tags shown on the group display.

Any tag may be displayed in several pages of the group

displays according to the operator or system engineer
assignment.

The group display shall indicate individually the groups of

loops (up to eight) shown in the overview display. Each of
the loops of the group display shall be indicated in a stable
way, at least: initial, unit of measure, description of the
service.

The group display shall at least make visible the following

detail information:

- the range and the value of the analog variable both in the
form of "bar graph" and in engineering units by means of
alphanumeric display;
- the value of the set point both in the form of "bar graph"
and in engineering units by means of alphanumeric
display;
- the value of the analog output both in the form of "bar
graph" and in percentage by means of alphanumeric
display;
- mode of operation for controller (man/auto/cas);
- alarm limits and alarms of the variable, deviation alarms,
etc.;
- indication of the selected loop (inside the group);
- position of the valve in case of "failure";
- the inputs and outputs with contacts shall be represented
graphically and also by means of alphanumeric
descriptions of the state.
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- for discrete elements such as timers, switches, digital I/O

etc., a faceplate shall be available as standard for each
type.

It will be possible to insert the same loop on various group

pages with no restrictions.

5.2.1.3 Point Detail Display

An individual display for all tags configured in the system shall

be available and showing all relevant information. This
information shall include tuning and operational parameters,
along with the faceplate and information as in the group display.

The alarm condition of the point shall be displayed in the

display with colour change and blinking. Alarm
acknowledgement shall be possible. The individual point
display shall include a small size of real time trend display to
facilitate easy tuning of control loops.

The graphic representation shall be similar to that of the group

display, but the following additional information shall be supplied:

- values of the tuning constants;

- values of bottom and full scale of the variables;
- set points of the alarms on the various parameters;
- limits on set point, output, etc.;
- control action (direct or reverse);
- position of failure of the final control element;
- values of computation (reports, bias, etc.);
- value of output;
- engineering units employed;
- real time trend for PID tuning(including PV,SP and OP).

It will be possible to modify the following parameters through key

from the keyboard:

- tuning constants;
- zero and span;
- alarm set;
- control mode;
- output;
- for the digital points, it will be possible to execute start/stop or
open/close commands.
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5.2.2 Custom Graphic Pages

5.2.2.1 Custom graphic pages are intended to be the primary tool for
the operator to monitor and control the plant activity in an
interactive fashion. per display page.Each page shall be
capable to include at least 500 parameters (live data) per
display page without degrading performance,where each point
may have more than one parameter including PV, SP, OP,
mode, alarm condition, etc. (no more than 5 parameters per
point shall be accepted for performance evaluation purposes).
Graphic displays capacity shall be equal or more than 500
pages and shall graphically show process lines, equipment and
relevant instrumentation as per ISA-5.1 and 5.3. The call up
time for any of those graphics shall be within one second.

5.2.2.2 Graphic displays shall be interactive type through which it shall

be possible to control the process. It shall also be possible to
send motor start/stop and shutdown valve open/close
command from this display. Furthermore it will be possible to let
start or stop a system from the system display through an only
command from keyboard, which automatically actuates or
deactivates all users (pumps, valves, etc.) being part of the
system in question.
The operator shall be able to call any operation displays and
graphic display.
It will be possible to obtain dynamic displays of graphic relating
to the various units of the installation on the screens of the
operator consoles.

5.2.2.3 The following information shall be made available, as a

minimum, from the custom graphic pages:

 Measured values for each analog input manipulated value

and set point for controllers.

 Status of digital inputs (in particular for pumps, motors,

on-off valves, package units etc.)

 Alarms for both analog inputs and digital inputs.

 Window function to give related information to the

operator without exiting the page. For example following
information shall be displayed from window.
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- Process alarms
- Faceplate indication to allow manipulation of the control
made, set point output.
- Graphical trends
- Plant overview
- Detail display. The detail display shall be composed of a
graphic showing a part of a process and be completed with
detailed information, which is selected from the available
fixed format displays.
 Aricmatic expressions

5.2.2.4 Graphic pages shall be built by the Vendor on the basis of plant
P & IDs. Items or pieces of equipment more commonly
displayed in these graphic pages shall be available in a system
library for future use; moreover, display building facilities shall
be available to make easier and independent of programming
languages for the generation of new graphics. Each graphic
page shall represent on indenepdent part of the process units
arranged in a logical manner to show all interrelated process
variable. A given proces variable may accessible from more
than one graphic page if this process variable is common in
more than one independent graphic page. The operator shall
be able to call up any operation displays from graphic display.

5.2.2.5 The graphics shall be configurable in field (only with

engineering privileges) by applying standard symbols or
symbols defined by the user. Items or pieces of equipment
more commonly displayed in these graphic pages shall be
available in a system library for future use. Display building
program shall be user friendly, easy to learn and use, and shall
utilise ‘drag and drop’ and ‘fill in the blanks’ operations instead
of scripting or programming.

5.2.2.6 At graphic level, the information relating to the process and

alarm variables shall be available and it will also be possible to
see and/or change values of set point, to manipulate the
variables, controller operation mode, etc. still by means of key
and with documented access).
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5.2.2.7 Dedicated software blocks shall be available for control of

electrical motors, actuators and pumps. The block shall be used
to perform LCD/TFT based operation to start up or shutdown
motors, giving the operator one faceplate to interface to the
motor, if these are required on piping and instrument diagrams.
Colour changing method shall be used for this purpose.

5.2.2.8 In particular the red colour shall be used for the alarm
conditions. Symbols and colours shall meet the EN60073
requirements.

5.2.2.9 All flows shall have totalizer. All tag numbers should defined
minimum character. Examp : 47PIC1542A. All graphic pages
should have title. All tag description should be in Turkish.
Control function shall be developed without compensation. All
trend and control group pages should be adressed to soft
touch buttons. Those soft touch buttons should be on bottom
line of the releated graphic pages. All major equipments colour
should be grey and line weight : 3
(furnaces,exchangers,pumps,compressors,reactors,column,etc)
All analog Instruments should have real time and historical
trends. Historical trends should have minimum 32 days
historian. DCS should have process report.(Alarms, Status
changes, operator actions etc.). All digital enstruments should
have alarm voice when it's in alarm condition. Last 3 process
alarm with tag description allways should be appear top line of
the graphic panel. Sistem alarms should be separated from
process alarms. First page of the graphic panels should be
''graphic index''. All graphic pages should have ''next page'' and
''previus page'' soft buttons. Same specific calculations should
be implemented and dispay in graphic panels (
Ratio,conversion,yield, etc.). All analog İnstruments should
have HH, LL, L and H alarm set points. All cascade controllers
should have set point traking between master and slave
controller. All controllers should have manuel traking between
PV and SV. ESD, System and Process alarm voices should
have different alarm sound. All alarms should be stored in the
alarm page. Acces level should be defined occording to
costomer requirement
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5.2.2.10 Graphic panel description

As a reference the following typical schemes can be followed,
R2 final templates and graphic configuration criteria shall be
defined together with Vendor through “CONTROL SYSTEM
FUNCTIONAL DESIGN SPECIFICATION”

INDICATORS :

A - Flows : FI

0000 Green Process Variable, turn to red

(Size :14 Dot) m3 and
Blinking According to PH,PHH,PL,PLL

B- Temperatures : TI

Green Process Variable, turn to red

(Size :14 Dot) 0000 OC and
Blinking According to PH,PHH,PL,PLL

C- Pressures : PI

Green Process Variable, turn to red

(Size :14 Dot) 0000 Kg and
Blinking According to PH,PHH,PL,PLL

D- Levels : LI

C-101

0000 % Green Process Variable, turn to red

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and
Blinking Acc. to
PH,HH,PL,LL

CONTROLLERS :

A- Flows : FIC
If controler mod MAN : Red Line (Size :3 Dot)
If controler mod AUTO:Yellow Line
If controler mod CAS :Blue
Line

Red Box (Line Size :3 Dot)

Grey Tag Number , turn to red and
Blinking Acc. to
FIC-188 PH,HH,PL,LL
P0000m3 Green Process Variable
Red line S0000m3 Green Set Value
Green Valve
M00000% Pozition
Grey Tx Red line

MV=0 , Closed : Red

MV>0 , Open :Green

B- Temperatures : TIC

If controler mod MAN : Red

Line
If controler mod AUTO:Yellow Line
If controler mod CAS :Blue
Line

Red Box (Line Size :3 Dot)

Grey Tag Number , turn to red and
Blinking Acc. to
TIC-226 PH,HH,PL,LL
P0000OC Green Process Variable
Red line S0000OC Green Set Value
M00000% Green Valve
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Pozition
Red line

MV=0 , Closed : Red

MV>0 , Open :Green

C- Pressures : PIC

If controler mod MAN : Red

Line
If controler mod AUTO:Yellow Line
If controler mod CAS :Blue
Line

Red Box (Line Size :3 Dot)

Grey Tag Number , turn to red and
Blinking Acc. to
PIC-218 PH,HH,PL,LL
P0000Kg Green Process Variable
Red line S0000Kg Green Set Value
Green Valve
M00000% Pozition
Grey Tx Red line

MV=0 , Closed : Red

MV>0 , Open :Green

D- Levels: LIC

Columns:
If controler mod MAN : Red
Line
If controler mod AUTO:Yellow Line
If controler mod CAS :Blue
Red line Line
C - 201
Red Box (Line Size :3 Dot)
Grey Tag Number , turn to red
and
LIC-252 Blinking Acc. to PH,HH,PL,LL
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P0000
% Green Process Variable
S0000
% Green Set Value
M0000 Green Valve
% Pozition

MV=0 , Closed : Red

MV>0 , Open :Green

Drums:

If controler mod MAN : Red

Line
If controler mod AUTO:Yellow Line
If controler mod CAS :Blue
Red line Line

Red
Box
Grey Tag Number turn to red
D - 20 and
LIC-255 Blinking Acc. to PH,HH,PL,LL
P0000
% Green Process Variable
S0000
% Green Set Value
M0000 Green Valve
% Pozition

LI-246
0000 %

MV=0 , Closed : Red

MV>0 , Open :Green

E- Manuel loaders: HIC

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Red
Box
HIC-224 Grey Tag Number
M0000 Green Valve
% Position
Red line

MV=0 , Closed : Red

MV>0 , Open :Green

3-LEVELS:

HI Limit

Blue Bar : According to LICXXX.PV ( No Blinking

)
Red Bar : If LICXXX.PV > 80% And Blinking
Red Bar : If LICXXX.PV < 20% And Blinking
LO Limit

4-PUMPS:

If Pump A or B Run : Grey ( No Blinking )

If Pump A and B Stop : Red ( No Blinking )
G-
Green 20A/B

If Motor status Run : Green ( No

Blinking )
If Motor status Stop : Red ( Blinking vith alarm
voice)

5-AIR COOLERS:

Equip. Number
:Grey
E-21
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A B C D E F G H

HIC-226 If Motor status Run : Green ( No Blinking )

If Motor status Stop : Red ( Blinking vith alarm
M00000% voice)

6-DIGITAL ALARMS
(LAL,LAH,PAH,PAL,ZAL,ZAH,VAH,TAH,TAL etc.)

D - 21 LAH223

If Alarm Inactive :Disappear (Black)

If Alarm Active :Appear Red and
Blinking

LAH221 LAL222

LAL220

7-SHUT-OFF VALVES :

TYPE A
: TYPE B :

If valve open : Blue ( No Blinking )

If valve closed : Red and Blinking

8-SOFTWARE SWİTCHES :
A: Three-way Switches :
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Mod-1 : ( 1 connected to 2 )
Line-1 to Line-3 : Disappear ( Black )
2 Line-1 to Line-2 : Appear ( Red )
1

HS-256 3 Mod-2 : ( 1 connected to 3 )

Line-1 to Line-3 : Appear ( Red )
Line-1 to Line-2 : Disppear ( Black )

B: Four-way Switches

2 Mod-1 : ( 1 connected to 2 , 3 connected to 4 )

Line-1 to 4 and Line-2 to 3 : Disappear (
3 Black)
Line-1 to 2 and Line-3 to 4 : Appear ( Red
1 )

FS-214 Mod-2 : ( 1 connected to 4 , 2 connected to 3 )

Line-1 to 2 and Line-3 to 4 : Disappear (
4 Black)
Line-1 to 4 and Line-2 to 3 : Appear ( Red
)

9-MAJOR ALARMS
For major alarms please make special graphic pages.

10-PROCESS LINES:
Weight : 3
Colour
:
Steam
Liquid : Grey : Blue
Dark
H2 : Pink Water : Blu
Air
Gas : Yellow : White
Chemical: Green
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11- INSTRUMENT SIGNAL LINES :

Weight : 1
Colour : Blue
and Round dot

12- INTERLOCK SIGNAL LINES :

Weight : 1
Colour : Blue
and Round dot

13- TEXT :
All equipment names and other texts colour should be grey , size minimum 14
All process data size should be minimum 14

14- TARGET AREA :

A - IF TOUCH SCREEN :

a-) Controllers : FIC, LIC , PIC , TIC ,HIC , HS ..etc.

FIC-188
Touch Target
P0000m3 Area
S0000m3
M00000%

a-) Indicators : LI , PI , FI , TI , AI , SI ...etc.

No need to define touch target area

If need to call Faceplate use curser

Curser 0000 OC
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A - IF NO TOUCH SCREEN :

Controllers : FIC, LIC , PIC , TIC ,HIC , HS

a-) ..etc.

FIC-188
P0000m3 Active area for track ball or mouse
S0000m3
M00000%

Indicators : LI , PI , FI , TI , AI , SI
a-) ...etc.

0000 OC Active area for track ball or mouse

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COMPENSATION: Control function shall be developed without compensation

GRAVITY DT01
FROM LAB.

TI-
TI-315 315.PV
0000 OC

CO

COMPENSATION RV
CALCULATION

IF ANY
PI-
PI-286 286.PV
0000 Kg

FIC-188.PV

FIC-188
P0000m3
S0000m3
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M00000%

GR10:DEBUTANIZERSİSTEMİ

TI-1532 A B
PI-1710
VAH151

TIC-1535
TI-1533 P0000 C
8 S0000 C
M00000%

E-112 C-108

ŞARJ TI-1575 TI-1534 21

G-101
TI-1704
36

LAH1521 PI-1711 TI-1536

LIC-1511
P00000%
S00000%
M00000%
LAL1520 DİZEL E
TI-1518 113

TI-1537

FIC-1701
P00000M3
S00000M3
M00000%
TI-1576
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Note:TG (Trend group

pages)
TG-81 TG-82 TG-83 TG-84 CG :(Control group pages)

All trend and control group pages should be adressed to soft touch buttons.
Those soft touch buttons. should be on bottom line of the releated graphic
pages.

5.2.3 Trend Displays

5.2.3.1 The system shall be capable of displaying the following trends:

a) Real time trend (stored at least 2 hours with 1 sec interval)

b) Historical trend (stored at least 1 month with 15 sec interval)

Historical trend data shall be recorded at configurable periods

R2 of time. History and trending functionality shall be in the
operator station (DELETED) shall be identical for all operator
stations.
The vendor shall explain the archiving (backup and restore)
operations of the historical data.

5.2.3.2 The recording, either trend or historical recording, shall be

possible for each variable or parameter such as input, output,
set point, etc.
Each group must be able to be trend displayed. Following data
related to the trends shall appear on the screen.

- Process parameter dentification

- Engineering units
- Present value
- Alarm status
- tag number and service comment
- scale of trended value

Up to eight variables shall be displayed on the same trend with

different colours.
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5.2.3.3 Historical data shall be stored on the non-volatile memory

device like hard disk; in such a way historical data can be
utilized for archival storage and subsequent recall. Historical
trend recording capacity shall be minimum 1 month with 15
seconds sampling period. Points or tags to be recorded shall be
all analog inputs (for control and acquisition inputs), regardless
of they are recorded in common plotter, and calculated points.
All of the process variables ( both I/O’s from to the field, set
point and calculated values) shall be addressable without
limitation to the DCS bulk memory for histrocal data trending.
Hourly averages shall be provided.

5.2.3.4 It shall be possible to sample and store data of instantaneous

and average value at the intervals mentioned below. However it
shall be possible to display by scrolling or expanding the time
base for all the trends. Pan, zoom and magnify features shal
exist to allow the operators to achieve on accurate historical
perspective of the variable to be trended. Trend display shall
support switching any pen ON/OFF.
a. At intervals 2 seconds and above from the real time trend.
b. At 15 seconds, 1 minute interval for historical trends.

It shall be possible to use a hair cursor to read the old value

exactly in the trend screen (with indication of value, date and
time).

5.2.3.5 Trend display shall be single line type or bar graph type with
additional information like loop tag number, engineering units,
span, present value of the trended point, alarm status etc.

5.2.3.6 Selection of the tag number and displaying time basis for real
time and historical trending shall be possible from operator
keyboard. Saved trend data shal be of the same accuracy
engineering unit, scale and range of the actual process valve.

5.2.3.7 The system shall also have a multitrend capability in such a

way that it shall be able to display set point, measured variable
and output on the same trend.

5.2.3.8 The extent of metering to be provided for utility measurement

25 process unit totals will be 25 following.
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5.2.3.8.1 Steam ( High and Medium Pressure) :

- Flow/ Indication/ Trend Recording / Integration
- Temperature/ Indication/ Trend Recording
- Pressure/ Indication/ Trend Recording

5.2.3.8.2 Steam ( Low Pressure) :

- Tempature/ Indication/ Trend Recording
- Pressure/ Indication/ Trend Recording

5.2.3.8.3 Fuel Gas :

- Flow/ Indication/ Trend Recording
- Temperature/ Indication/ Trend Recording
- Pressure/ Indication/ Trend Recording

5.2.3.8.4 Cooling Water Supply/ Feed Water/ Process Water :

- Flow/ Indication/ Trend Recording/ Integration

- Temperature/ Indication/ Trend Recording

5.2.3.8.5 Instrument Air/ Plant Air :

- Pressure/ Indication/ Trend Recording

5.2.3.8.6 Condensate :

- Flow/ Indication/ Trend Recording/ Integration

- Temperature/ Indication/ Trend Recording

5.2.3.8.7 Electric Power :

- Power ( KW)/ Indication/ Trend Recording/

Integration

5.2.3.8.8 Fuel Oil ( Supply and Return Header ) :

- Flow/ Indication/ Trend Recording/ Integration

- Temperature/ Indication/ Trend Recording
- Pressure/ Indication/ Trend Recording

General Note : All above stated indication, trend

recording and integration will be
performed on DCS.
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5.2.3.8.9 If the invidual consumers consume more than 20% of

the total consumption, Flow/ Indication/ Trend
Recording/ Integration will be provided for each
consumer within process units.

5.2.3.8.10 Operator shall have the ability to input a back ground

trend pattern from reference on scheduled trends, as
well as the ability to compare two trends gathered at
different time for the same point. (scheduled trend :
with starting time and end time of the trend recording
such trends shall start/stop operator demand or
triggered by sequence program.)

5.2.3.8.11 It shall be possible to use a hair cursor to read the old

value exactly in the trend screen (with indication of
value, date and time).

5.2.3.8.12 Trends shall be snap shots of process data. Accuracy

of trended process value shall be exactly the same
as the process value being measured at the time of
the snap shot.

5.2.3.8.13 Side information on the trend display shall show the

following information, for each trend channel :

- Tag number and service comment

- Process value
- Scale of trended value

5.2.3.8.14 Operator shall be able to select any point on the

trend display to be individually displayed in detail.

5.2.3.8.15 The trend display shall have the capability to call up

the faceplate from the operator keyboard while trend
group is displayed.

5.2.3.8.16 Trend display shall allow for marking pens on the

display to enable black and white hardcopy of the
display.
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5.2.3 System Status Display and Self-Diagnostic Function

The display shall show an overview of different subsystems connected

over the communication subsystem showing status of each of them.
When a failure is detected by the system self diagnostics routine the
display shall indicate the location and nature of malfunction. Status
indication shall be provided at the module level (CPU, I/O modules,
communication lines, videostation, etc.) including redundant
components through detailed LCD displays and report printout.

At the local level, failure of a module in a subsystem shall be identified

by an individual LED display.

5.2.5 Alarm Monitoring and Display

5.2.5.1 Alarm Management:

a. It shall be possible to display process alarms as well as

system alarms on the operator console together with
logging on printer. Alarm display show all existing process
alarms with blinking and colour modification. Each alarm
shall have time stamp of month, days, hard, minute and
second.

b. It shall be possible to set process alarm limits from the

engineering keyboard/operator stations i.e., alarm limits
on absolute value of measured variable, high, low, hi-
high, lo-low for the process variable, rate of change of
measured variable, high and low deviation set points, and
high extra-high and low extra-low points on process
variable and output. In addition it shall be possible to
derive alarm conditions on the basis of calculations
performed by the system.

c. Alarm messages shall be displayed by flashing the page

and group number of the input under alarm irrespective of
type of display.

d. Alarm management is at the discretion of the Vendor, in

the frame that video-flashing, color changing techniques
will be used and automatic logging on printer will be done.
Return to normal condition shall also be automatically
logged.
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e. Displaying and printing of system alarms on the operator

console regardless of the display currently selected.

f. Input and output signal open alarms for each point due to
short circuit or open circuit signals. Thermocouple open
circuits for each point with MV input.

g. The alarm messages are shown with the flashing of the

variable according to ISA A standard (lock-in) and of the
group under alarm without considering the selected
display at the time of the alarm. The system shall have at
least 7 alarm priority levels.

h. The alarm is also shown at overview display level by

means of a change in colour of the involved group. It is
possible to have access to the variable under alarm (at
loop level) with two commands maximum from operator
keyboard.

ı. If provided by the configuration simultaneously to the

graphic alarm an audio signal is generated. Such signal
shall be silenced only in the event of the alarm being
acknowledged by the operator.

Robust, high speed, dot matrix printers as Alarm and

Event printers shall be supplied.
This printer shall be dedicated to:
- printing of the real time process and system alarms or of
the alarm history request by the operators;
- each print out shows at least the data relating to:
tagname, service, time stamp of the alarm, type of
alarm,
- acknowledgment and return to normal shall also be
printed as above;
- print out of the real time events (actions taken by the
operator through the keyboard & mouse).

j. Alarm Management System software (CAMS from

Yokogawa or Honeywell’s Alarm Scout/OMPro-Operation
Management Pro ) and Event Analysis Package software
shall be provided and installed. Alarm Magement System
tool is included in RUP Contractor scope for DCS, the
advanced tools for alarms are not included in RUP
R2
Contractor scope for DCS because it is part of Integrated
Manufacturing Execution System, MES, and MES is not
included in RUP Contractor Scope
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5.2.5.2 Alarm Summary Display:

a. An alarm summary display shall be available. The alarms

shall be listed in chronological order.
It shall be possible to display and print summary of all
alarms in the sequence of their occurrence and shall
disappear from display only when they are acknowledged
by operator, cleared and the alarm condition has been
returned to normal. The alarm display shall list the
following for each alarm as a minimum.

i. The date and time of alarms

ii. Point identification (i.e. Tag number)
iii. Point description
iv. Type of alarm (absolute value or deviation)
v. Initials

b. The system shall be able to display on alarm summary

1000 alarms as a minimum.

5.2.5.3 Alarm History:

a. The history of alarm conditions shall be maintained in the

DCS bulk memory for alarm history display and printed, if
required on shiftly basis. The alarm display and print out
shall list the following for each alarm as a minimum:

i. The date and time of occurrence

ii. Point identification (i.e. Tag number)
iii. Point description
iv. Type of alarm (absolute value or deviation)
v. Time and date of return to normal

b. The system shall be able to display and print out the

alarm history of minimum 1000 alarms.
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5.2.5.4 System Alarms:

a. System shall have capability of on-line self diagnostic.

b. Any abnormal conditions in any sub-system or any other

function device shall be displayed as system alarm
message on the operator console irrespective of the
display selected.

5.2.5.5 Displaying and printing of all events and operator actions shall
be provided (e.g. start/stop of motors, set point changes),
including as a minimum.

a. Time and date of Occurrence

b. Event description

5.2.6 Report Function:

a. It shall be possible to report all measured and computed

parameters, operator actions, changes of state, alarms etc, from
operator consoles.

b. Standard reports and custom free format reports shall be provided

on an hourly, shiftly, daily and, if required, weekly and monthly
basis; moreover reports shall be made available on demand. Min 5
standard reports and min 10 free format reports to be approved by
OWNER shall be built by VENDOR. It shall be possible to build
report using standard MS-Excel software.

c. Since it is important to report events in its proper sequence during

operation upset, shutdown and catastrophic events, related
hardware and software facilities shall be provided to get such
sequence of events report with minimum 2 m sec resolution time.

The system is capable of displaying, through the sequence display,

the progress state of sequential operations. In particular, the display
will show information regarding:
- sequence identification number;
- sequence descriptive identification;
- operating phase in which the sequence finds itself;
- any messages to the operator.
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Any alarm or operating malfunction situations of the sequence shall

be signalled to the operator by altering the colour of the information
on display.

d. System shall have capability of writing programs in high level

language. High level language compiler software, sufficient free
memory space and necessary hardware shall be provided to enable
the user to make free format reports according to the management
and operation needs.
Report printers shall be connected to all the operator stations and
engineering station. All reports are printed automatically at the end
of the predetermined times or on request by the operator.

5.2.7 Operation Instruction Display

Operation instruction display shall send meassages/instructions to the

operator regarding the plant operation. Messages shall be sent from the
request of the sequencing control function. The operator shall be able to
know the occurence of those messages by sound. Message
acknowledge shall be possible. The operator shall be able to call up
another pre-determined display corresponding to each message directly
from operation instruction display by a key stroke.

5.2.8 Logging Functions

5.2.8.1 It shall be possible to obtain the logging of variables

measured and/or calculated, actions by the operator, alarms,
trends, etc. from the operator console. The logging functions
may be carried out on an hourly, shift or daily basis or else on
request by the operator and if specifically required by
particular applications on weekly or monthly basis.

5.2.8.2 All parameters required for logging are stored in the memory
with the data base updating time. However. it is possible to
make arithmetical calculations (summation, efficiency
calculations, average values, etc.) before logging.
The logging format is, in general, defined by the user.

5.2.8.3 Historical trend data shall be recorded at configurable periods

of time. Hourly averages shall be provided. The selection both
of the loops to be recorded and of the sampling times shall be
possible from the operator keyboard.
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5.2.8.4 At least 1000 of the most recent events shall be saved on the
hard disk and then archived for long-term storage.

5.2.8.5 The system will ensure historical management of the alarms.

In particular the history of the alarm conditions is kept in the
database of the alarm display and printed on the basis of the
times defined at configuration level. The alarm display and the
print of the same include the following information at least:
- date of the event with the time in seconds;
- initial;
- description of the service;
- type of alarm (absolute or deviation);
- time of acknowledgment;
- time of clearance.

5.2.8.6 SOE alarms shall be recorded with 1 msec. time stamp.

5.2.8.7 Any software package combining system monitoring and data

analysis in one package allowing the user to view current
process data in a Microsoft Excel spreadsheet or compatible
graphic format. The program shall access all records in the
spreadsheet format and also in graphic format at a time.
Briefly it shall allow the user to manipulate the data once it is
in the database.

5.2.9 Self diagnostics

5.2.9.1 The self diagnostic messages relating to the malfunction of

each system component shall appear on the screens of the
operator console, independently from the display selected in
that moment.
5.2.9.2 The system shall have an extended set of self diagnostic
routines allowing the identification of malfunctions at module
level at least, through detailed display and prints.
5.2.9.3 At local level the malfunction of a system component is
identifiable by led or by a lamp on the cabinet.
5.2.9.4 In order to help both the maintenance and the actual position
of the non operating component, the following displays are
available:
- display of the system structure with identification of the
system component under failure and the type of
malfunction;
- display of the state of each system macrocomponent (ie.:
each cabinet).
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5.2.9.5 The idle time of processor and the status of each I/O card and
controller shall be displayed on a dedicated system status
display, easily accessible to operator on the operator station.

6.0 APPLICATIVE SOFTWARE

The software applications wich are part of Integrated Manufacturing Execution System,
R2 MES, are not included in RUP Contractor Scope.

In addition to the other application software tasks and Licensor computations (

Reference : Licensor project specifications control center Requirements) the system
shall perform the following calculation packages. Relavant calculation technıques and
formulatıons to be taken as a base for real time reports stated above will be approved
by lıcensor and OWNER after relating specification will be prepared by the contractor.

6.1 Heat and material Weight Balances for the feedstocks, products, utilities
flowrates of each process unit.

All the flowrates used will be compensated with actual temperature, pressure
and specific gravity according to the needs and totalized. Moreover the same
streams are used in the yield calculations (volume or weight flowrate ratio
between each output stream and the feed stream) and in the specific
consumption calculations.

These results, adequately scheduled (shift, daily, monthly, yearly) or on

demand, will be available for reports and display.

6.2 Efficiency and Heat Duty of Heaters:

These calculations are based on the so-called "MEKLER and UNGAR" method.
Calculated efficiency is a thermal balance made of fuel/flue gas system.

On the basis of the amount of fuel oil and fuel gas it is possible to determine the
released heat and consequently the absorbed heat for each heater. These
results, adequately scheduled or on demand, will be available for reports and
display.
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6.3 Heat Exchangers Duty:

The thermal balances are based on a series of heat duty calculations like:

Heat Duty= (HC flowrate) * (Heat capacity) * (HC differential temperature

across the exchanger)
The heat capacity of liquid hydrocarbon will be calculated according to the
following formula:

CP(S,K,T)=1.00067 * {0.6811-0.308*S+(0.000815-0.000306*S)*T}
* (0.055*K+0.35) Kcal/Kg°C.

where:
S= Stream specific gravity 60°/60°F
K= Stream characterization factor
T= Stream temperature in °F.

These results, adequately scheduled or on demand, will be

available for reports and display.

6.4 Deleted.

6.5 For DCS, the configuration programming and data base assembly shall be
determined by the Owner such that the complete configured system can be
inspected at the factory before delivery.

6.6 Any software package providing relational data base for console tag list,
function block configuration and display files, and allowing checking for
consistency and concordance while letting user to search for specific items in
data base through simple English-language like statements shall be provided.

6.7 Any software package allowing user to provide a communication environment

for smart transmitters to configure, tune or monitor all smart transmitters located
at the field, shall be provided.

6.8 Any software package combining system monitoring and data analysis in one
package allowing the user to view current process data in a Microsoft Excel
spreadsheet or compatible graphic format. The program shall access all
records in the spreadsheet format and also in graphic format at a time. Briefly it
shall allow the user to manipulate the data once it is in the database.
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6.9 The software package in DCS shall also be capable to enable APC computer
system to communicate with his DCS. but not supplied in this project. The DCS
system shall have the capability to interface with upper level computers and
networks using Ethernet with TCP/IP protocol. Future hierarchical integration of
DCS together with the other existing system in various plants in the refinery,
shall be taken into consideration during specification work of the system

7.0 SYSTEM REDUNDANCY

OWNER tends to have a 100 % redundancy, however contractor should feel free to
recommend another degree of redundancy provided that operation of processes will
not be effected by the failure of any part of the system. Key components of the DCS
system shall be fully redundant so that neither a hardware nor software failure shall
result in the loss of the features supplied by the components. The system shall be
%100 fault tolerant. These means, all central control processors, all communication
processors and all other central rack and individual node’s common cards, all the
communication cards, networks, power supply cards and cables etc. shall be %100
fault tolerant. All the hardware including control processors, all communication
processors, all type of system cards, all type of I/O cards, networks, power supply
cards and cables etc. shall be hot replaceable.

Vendors shall note that there shall be no difference between the primary and backup
units (including the busses) physically or operationally. Any backup or secondary unit
can become primary when the primary unit fails or it is manually forced to. It shall be
on duty without any restriction on time or operation till the above conditions apply
again.

In order to provide the maximum degree of reliability the system shall be configured in
such a way that the malfunction of each component, except for the I/O cards, cannot
cause malfunction or incorrect operations of the continuous control, Boolean logics
and sequence functions.

Redundancy is required to meet the following requirements:

a. Hard disks carrying: real time database, images of displays, historical events,
redundancy shall include disk drives and disk path to the real time LAN.RAID5
shall be applied with at least 5 number of hard disks.

b. Real time communication network and related communication hardware, circuit

couplers etc.

c. Control processor

R2 d. All Power supply modules for controller part (DELETED)

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e. Control module internal communication circuit cards

f. I/O cards used for control loops

g. critical analog input cards

7.1 For Hardware and Marshalling Cabinets:

7.1.1 Power Supply

Supply voltage to hardware and marshalling cabinets shall be redundant

220V, 50 Hz AC. For all other voltages needed (e.g. 24, 18, 12, 5V DC,
etc.) 2 separate power supply one being capable of supplying load in
normal operation but if one fails the other takes the fully load
automatically. Means of monitoring power supply status shall be within
the DCS feature. If Vendor's configuration deviates from above, (n:2)
redundancy shall be applied.

Redundant power supply shall be designed with no more than 80% load
one each unit when operating individually.

Power supply distribution panels shall be provided by the Contractor.

Each component and cabinet of DCS shall be individually fed by a
separate dual (redundant) power cables from distribution panel with dual
separate circuit breakers. The equipment shall be designed so that no
damage shall be caused by a burn out or loss of power. Operator
stations, field control stations and engineering work stations of DCS
system shall be dual AC power system type/model.

7.1.2 Main Processor Unit/or main CPU :

Shall be redundant / duplicated together with data base, peripheral

devices and memories. If one fails, the other takes the control
automatically without disturbing the process, and failure alarm shall be
as in diagnostic section.

Reload of the application software to the new CPU shall be done

automatically from the running CPU with no intervention from the
engineering or operator station. (Loading from engineering station is not
acceptable). The replacement of the failed CPU shall be done on line
with no effect on the control and monitoring.

The redundancy layouts shall be implemented in such a way that the

transfer from each element to its back-up in redundancy and return is
bumpless, automatic and such as not to affect the process, the operator
stations, the computation or other functions.
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The transfer from a unit to the back-up one shall be in any case
alarmed.

The process controllers shall have synchronisation watchdog. When the

synchronisation between the process controllers is lost the system shall
generate an alarm. After the synchronisation loss, it shall be possible to
synchronise the system while it is running. The system shall be
implemented in such a way that it shall be possible to replace any
backup unit without affecting the operation of the unit on duty.
When the backup CPU is replaced, the application software shall be
replicated to it from the primary CPU without any intervention from the
engineering or operator station.

7.1.3 If single point integrity (1 channel/module) can not be offered, control

input/output modules (or cards), control output/input isolation modules
(or cards) shall be duplicated (redundancy 1/1) and a mean of indication
(i.e. LED) on modules (or cards) shall be provided to see which module
(or card) is in operation and which is stand by and/or faulty. Indications
for failure alarm and for status shall be incorporated into LCD.
I/O modules will be redundant for control loops, critical indications and
critical digital loops.

7.1.4 If Vendor's configuration deviates from 7.0 (100% redundancy) above

philosophy, Vendor shall prepare his standard design manufacturing as
high redundancy as possible and shall clearly state and explain the
deviation.

7.2 System Bus:

The DCS shall be provided with a dual redundant communication bus. No loss
of data shall occur due to switch over. Standby redundancy is not acceptable.

7.3 Deleted

7.4 Additionally a portable maintenance manual unit, equipped with quick-connect

mating terminations, shall be provided if available.

7.5 Beyond the requirements for redundancy stated above any other component
failure shall not affect more than one loop (single loop criteria)

8.0 CONFIGURATION TOOLS

8.1 The engineering workstation is meant as the basic configuration tool for all
system nodes, including display pages and report generation. Engineering work
station shall run in window based operating system, allowing multiple pages
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displays simultaneously.
CAD based system engineering tools which do not require special
programming knowledge shall be provided. System shall support concurrent
engineering at different locations for flexible and effective system engineering.

8.2 All data shall be able to be stored on disks. Data must be able to be up/down
waded to/from disk. Back up must be possible on commercially available media.

8.3 The configuration / reconfiguration activity shall be bumpless and transparent to

operator. The system shall allow for the configuration program to be compiled in
sections without need to perform compilation on all the system configuration
database. This will allow for partial modifications.

8.4 Configuration and programming activities shall be possible while the system is
on-line. Human error shall be minimised with the use of confirmation dialog
windows before executing commends that may affect the system database.

8.5 System configuration shall be performed through predefined templates or fill-in-

the-blanks pages. Mouse or track ball shall be used as the main device for the
engineering with the keyboard being used for text entry.

8.6 Tuning of control parameters will not be considered as "reconfiguration activity"

and therefore changes of parameters such as gains, reset and derivative
constants or alarm sets shall be accessed only by proper consent (i.e. software
or hardware keys).

8.7 The system shall be suitable to carry out programs written in high level
languages such as C and visual BASIC. Furthermore there shall be utilities
suitable to connect programs prepared with such types of languages with the
pre-configured control blocks.

8.8 The configuration developed off-line shall be loaded partially in a random

manner without disturbing normal operation.

8.9 The system contains routines suitable to verify that the changes/additions are
R2 normally correct (DELETED)

8.10 The engineering workstation is equipped with password system to avoid that
unauthorised personnel may tamper with the software.

8.11 Equally the engineering workstation stores both the date and time of the
intervention and the originator of the change.

8.12 The engineering workstation shall be easily connectable to the communication

bus without causing any interference to the normal operation of the system.

8.13 The configuration database shall run on the newer versions of the application
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software without reconfiguration. System vendor shall clearly define a migration

path for maintaining upward compatibility.

8.14 Any software package providing relational data base for console tag list,
function block configuration and display files, and allowing checking for
consistency and concordance while letting user to search for specific items in
data base through simple English-language like statements shall be provided.

8.15 Software package allowing user to provide a hart communication environment

with DCS operator stations for smart HART devices such as control valve smart
positioners, transmitters, etc to configure, tune, diagnostic or monitor all hart
devices located at the field, shall be provided.The software of the device
manager to be installed in DCS shall be “Advanced Version” software of DCS
Vendor.

8.16 The system shall be secure against unauthorised use by means of key locks,
passwords or equivalent methods; The vendor shall detail the system security
provisions and the number of access levels.

8.17 The engineering workstation shall have an MS Excel licence and DDE software
to exchange data between process database and Excel spreadsheets.

8.18 System shall support concurrent engineering at different locations for flexible
and effective system engineering.

8.19 Partial database modifications shall be possible while the system is on-line.

8.20 Back up must be possible on commercially available media.

9.0 SYSTEM SECURITY

The system shall be secure against unauthorized use by means of keylocks,

passwords or equivalent methods; The vendor shall detail the system security
provisions and the number of access levels. Moreover, all operator requests shall be
checked for format and syntax to ensure that control parameters entered are
consistent with the limits admitted by the system.

10.0 SPARE REQUIREMENTS

System shall be sized according to the given basic I/O list. In the sizing, the system,
the contractor shall consider the expansion capability of process and the system
loading described in accordance with the response times described else where in this
document. The following spare requirements shall be respected by Vendor when sizing
the system.

10.1 Controller software load and memory occupation shall be smaller than 50% with
reference to the I/O list. The calculation shall be supplied by Vendor. Controller
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shall have powerfull calculation capacity.

10.2 A minimum of 20% fully equipped and wired ready to use spare capacity in I/O
cards for each process units in TR-1, TR-5, TR-6 and TR-9 and 10 % in TR-2,
R2 TR-3 and TR-4, no matter they are for control or acquisition.

Requested spare capacity is also included for marshalling cabinets.

10.3 A minimum of 20% free space in system cabinets (that is, these cabinets shall
be loaded at most, at 80% of their rated capability).

10.4 A minimum of 20% spare terminal strips.( included in 20% of wired spare)

10.5 A minimum of 20% free space for marshalling cabinets.

11.0 NOISE IMMUNITY

All components of the system shall be suitable for the refinery environment. Immunity
to radio frequency and electromagnetic interference, such as generated by hand held
walkie-talkie of 5 watt set about 450-470 MHZ (UHF), within near proximity of system
components (doors of cabinets open and within 300 mm distance) shall be provided.

The vendor shall confirm this system immunity together with the specification for the
equipment limitations, e.g.: maximum wattage, minimum distance, and frequency
band.

12.0 TRAINING

The Vendor shall provide training courses for ten of Owner's engineers at Vendor's
training facilities. This training shall cover the following subjects such that the
engineers can later operate, reconfigure, maintain the system and generate graphics,
logs and reports.

 DCS system fundamentals

 DCS system operation
 DCS system engineering
 DCS system programming
 Logging and reporting
 Graphic building
 DCS system's hardware interface to APC
 DCS system's software interface to APC
 Hardware maintenance
 Software maintenance
 Tuning
 Application of hardware and software configuration techniques
 Trouble shouting and malfunction diagnostic
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For each proposed course the Vendor shall submit a summary including subject,
prerequisites (if any), and course position in the training program.

For the attendees may have sufficient time to plan their participation, they shall be
given notice at least 8 weeks before the course scheduled date. The course outline
and training documents shall be submitted 10 weeks ahead for review.

13.0 VENDOR' s ASSISTANCE AND/OR SUPERVISION AT SITE

The Vendor shall provide supervision to installation, commissioning and start-up of the
systems.

The Vendor shall quote separately the cost of a single additional day of this personnel
at site.

Separate quotation for up to three service visits to site in three years time after start-up
of units is requested too.

The Vendor shall also quote any other optional service deemed useful in installing and
support the system; The Owner reserves the right to select between the offered
services.

14.0 TESTS, INSPECTIONS AND CERTIFICATIONS WITH DOCUMENTATION

Equipments shall be submitted to all necessary tests and checks to verify that the
supply is in accordance with this specification and referenced standards.

The Vendor shall submit for approval a test procedure based on the requirements
included in this specification and in "ISA RP 55.1-ANSI MC8.1, Hardware Testing of
Digital Process Computers".

14.1 Factory Testing and Acceptance

Tests will be organized in two phases: first, tests during manufacturing of the
system; second, the final factory acceptance test which will be carried out on
the system completely assembled as if it were installed at site.

Vendor shall test and demonstrate the functional integrity of the system
hardware and software. No material or equipment shall be transported until all
required tests are successfully completed and certified.

Owner reserves the right to be involved and satisfy himself at each and every
stage of inspection. Owner shall be free to request any specific test on any
equipment considered necessary for him although not listed in this
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specification. The cost of performing all tests shall be borne by Vendor.

Vendor to note that acceptance of any equipment or the exeption of inspection
or testing shall in no way absolve the Vendor of the responsibility for delivering
the equipment meeting all the requirements specified.

It shall be Vendor's responsibility to modify and/or replace any hardware and

modify the software if the specified functions are not completely achived
satisfactorily during testing and factory acceptance.

The schedule for the factory testing shall be included in the proposal by the
Vendor.Vendor shall not replace any system component/module/sub-system
unless it has failed. A log of all failed components/modules in a sub-system
shall be maintained which shall give description of the failed
component/module, effect of failure on the subsystem, cause of failure and
number of hours of operation before it failed. If malfunction of a
component/module in a subsystem repeat, the test shall terminate and Vendor
shall replace the faulty component/module. Thereafter the test shall commence
all over again. The minimum requirements for testing during each phase are as
follows.

14.1.1 Phase -I

Vendor shall perform test at his works to insure that all components
function in accordance with their respective specifications for each type
of test. A test report shall be submitted to the Owner/Consultant for
review within two weeks of completion of each type of test giving details.

The test log book shall contain the following information about the tests:

a. Date/time
b. Assembly designation/loop tag number
c. Test input
d. Test result and sign off with personnel name
e. Action required (if deficiency is detected)
f. Action taken, date of completion and sign off.
g. Special test methods (including special equipment requirement,
bypasses used etc.)

Test Details:

Following tests shall be performed by the Vendor and report shall be

forwarded.

14.1.1.1 Quality control tests shall be carried out to assure quality of all
components and modules in accordance with Vendor's own
quality control and assurance procedures.
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Vendor shall forward the details of these procedures.

14.1.1.2 System Pre-test

Vendor shall check physically the workmanship including the

system hardwares prior to powering up the system of the
consoles, racks and all other accessories. These shall be
inspected externally and internally.

14.1.1.3 System Power-up Test

Vendor as a minimum shall check the functions of all the

system hardware and software including diagnostic software
at sub-system level by simulating the inputs.

14.1.2 Phase -II

This test shall systematically, fully and functionally test all the
hardware and software in the presence of Owner representative. All
the sub-system shall be inter-connected to simulate, the total
integrated system.

System shall be shipped to site only after this testing and certified
ready for shipment by Owner.

Testing Record

a. The test report/log book forwarded by Vendor after Phase I

testing shall be reviewed. Owner has right to witness any test
performed in Phase I, if found necessary.

b. During testing of Phase II, each test carried out shall be

recorded. Any deficiency or problem shall be clearly broughtout
and shall be corrected.

c. Any change in the data or configuration etc. informed to the

Vendor shall be recorded and carried out by the Vendor.

14.1.2.1 Visual and Mechanical Testing

Visual and mechanical testing shall be carried out in principle to

assure correct, proper, good and neat workmanship by the Vendor.
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14.1.2.2 Functional Testing

Functional testing shall include the simulation of each input and

output to verify proper system response for both analog and discrete
signals. The testing, as a minimum, shall include:

a. Complete system configuration loading.

b. Demonstration of all controller functions from local as well as

from central level e.g. changing of tuning constants, loop tuning,
checking of algorithm functions, changing controller action etc.

c. Checking of scan time values for controllers and data acquisition

sub-system.

d. Checking of loop configuration for correctness with respect to

ranges, limits, alarm points, engineering units etc.

e. Checking of all types of LCD displays including process and

system displays on operator and engineering console.

f. Checking of correct functioning of key-board operation for

operators & engineering console.

g. Checking of LCD refresh rate, data base update and display call-
up time.

h. Checking of correct change -over of the back-up units in case of

main units failure.

i. System diagnostics shall be thoroughly checked for sub-systems

on local level as well as on operator/engineering console. These
include failure of a sub-system, module, power supply, interface
unit; failure of transfer to redundant module failure etc. and other
detailed diagnostic displays. Diagnostic alarms for any ventilation
fan failure shall also be checked.

j. Checking of RFI immunity for all components of DCS.

k. Testing of proper functioning of all printers and hard copy units,

etc.

l. Testing of system features like interchangeability between LCDs of

a console.
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m. Checking of various log formats.

n. Proper system operation at power supply specifications. Emulation

and simulation of data digital subsystems like PLC, computer,
analyser system etc. as specified. (Data base and data
communications).

o. Simulation of power failure restarts.

The Vendor shall notify the Owner/Consultant at least three weeks
prior to final system testing. In the event that representatives
arrive and the system is not ready for testing, the Vendor will be
liable for back charges for any extra time and expenses incurred.

14.2 Field Testing:

All the equipment shall be checked throughly after its receipt at site. The tests,
as a minimum, shall include:

a. Visual and mechanical testing

b. Complete system configuration loading
c. Demonstration of all system functions
d. Checking of loop configuration
e. Checking of all LCD displays
f. Checking of correct functioning of all keyboards
g. Demonstration of all system diagnostic
h. Checking of correct change over of redundant devices
i. Checking of bus-degradation
j. Checking of proper functioning of all printers, sample printing of all type of
log reports.
k. Checking of all disc drives, historical trending points, alarm summary and
alarm history
l. Complete checking of all interface with external computerized systems
m. Complete checking of hard wired instruments
n. Demonstration of proper operation of system at specified power supply
specifications.
o. Power Supply testing. UPS effects on DCS.
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14.3 Final Acceptance Test:

14.3.1 The Owner will take over the system from the Vendor after the final
acceptance test, which is defined as successful uninterrupted
operation of the integrated system for two weeks after the positive
conclusion of the field tests. Vendor's personnel shall be present
during the test.

Any malfunctioning of the system components shall be

replaced/repaired as required. Once the system failure is detected, the
acceptance test shall start all over again from the beginning.

14.3.2 Testing/Calibration Requirements:

Vendor shall make available all consumables, instruments and

equipment necessary for testing, calibration, maintenance etc., as
defined in scope of works. All instruments and equipment used for the
above purpose shall be of standard make with accuracy better than the
accuracy expected from the calibrated/tested instruments, and certified
by the proposed agencies. These instruments/ equipment are
necessary only during testing/calibration/ maintenance.

14.4 Integrated Test

The test is relevant to all those equipment that are not part of the DCS but are
interfaced to the system in order to allow the centralised operation from the
DCS operator workstation. Scope of this test is to demonstrate the correct
functionality of the communication hardware and software communication
protocols between the DCS equipment and external specialised dedicated
equipment, and to allow the testing of the DCS application software relevant to
physical I/0 not handled by the DCS but displayed at the DCS operator stations.

The test shall be performed in accordance with an agreed test procedure and
shall be carried out in parallel with the DCS software test (parallel test is
mandatory as the DCS need to be physically connected to the external
equipment to demonstrate the full hardware and software functionality).
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14.5 Site Acceptance Test

After the field system installation and prior the starting of the commissioning
activities the system shall be tested. Test shall be repeated to demonstrate the
full functionality after transportation and field installation, complete dynamic
loop check and alignment shall be performed, generating and verifying the
signals directly from field.

During the site acceptance test particular care shall be taken to check the
power supply system and the grounding network system and to verify the
system bus functionality in the final configuration and maximum
extension.Before the system power up and prior the I/0 module field
connections all the field I/0 signals shall be checked for continuity and isolation,
in addition it shall be verified the presence of undesired electrical potential, due
to wrong field connection, that could damage the DCS input circuits.

The tests, as a minimum, shall include:

- visual and mechanical testing;
- complete checking of hard wired instruments;
- complete checking of all interface with external computerised systems;
- complete system configuration loading;
- checking of loop configuration;
- checking of all graphic displays;
- checking of correct functioning of all keyboards;
- demonstration of all system diagnostic;
- checking of correct change over of redundant devices;
- checking of bus-degradation;
- checking of proper functioning of all printers, sample printing of all type of log
reports;
- checking of all historical trending points, alarm summary and alarm history;
- power Supply testing, UPS effects on DCS.

14.6 Documentation

The documentation is an integral part of the provision. It includes:

- hardware documentation
- software documentation
- instruction manuals.

Note: All drawings shall be produced using CAD tools, AutoCAD or Intergraph
Microstation compatible.

14.6.1 Hardware Documentation

14.6.1.1 Listing of power consumption

A detailed list with all of the system power users and

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corresponding thermal loads.

The list shall include at least the following:

- Type of electric load
- Load characteristic
- Type of internal distribution
- Type and manufacturer of protective devices
- Protection device data
- Grounding requirements

The above mentioned values have to be specified, even if

preliminary, in the proposal.

Note: (1) The Supplier shall state in addition the minimum

UPS capacity considering the worst operating
condition.

14.6.1.2 Feeding System

A drawing detailing the whole electrical network from the

distribution board up to the users (included those supplied by
others, if integral part of the system).

14.6.1.3 Cable List

A detailed list of system cables included in the supply, with

the following information:
- cable item;
- cable type (identification code) and length;
- starting and terminal points.

14.6.1.4 Dimensional Drawings

Drawings of every DCS device included into the provision.

14.6.1.5 Cabinet Layouts

One drawing for each cabinet shall show all the positions of
the devices into the panels (plan and front views).

14.6.1.6 Nest Layout – Tag Assignment

Drawings showing:
- system modules layout;
- tag assignment (points layout).

14.6.1.7 Terminal Strip Drawings

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Drawings showing the terminals strips in the marshalling

cabinets.

14.6.1.8 Ground System

Drawing showing how and where the System has to be

connected to the Ground System. In particular, ground
conductors sections and connection points will be indicated.

14.6.1.9 Double Wire (Control Loop- Wiring) Diagrams

A sheet will be prepared for each signal or loop connected

with the system. The drawings scope starts from the I/O card
on the rack and terminates at the field side of the
marshalling panel terminals. All the intermediate connections
must be shown (terminal assemblies, terminals, relays, etc.).
The drawings shall be in accordance with ISA - S5.4
directions.

14.6.1.10 Installation and Maintenance Manuals

They have to cover both system hardware and software;

they have to give the necessary instructions for
trouble-shooting, software loading and management.

14.6.2 Software Documentation

These following documents shall be in accordance with Std. ISA S5

directions.

14.6.2.1 Database

A document produced on a magnetic/paper support, holding

all the information on system entities.

14.6.2.2 Functional Specifications

On the base of CONTRACTOR description of software (for

sequences), the vendor shall issue a proposal for a solution.
After Tüpraş comments and approval, the Supplier can start
with the actual development of software.

14.6.2.3 Detailed Functional Specifications

It shall be issued by the vendor at the end of software

development and shall cover in details all the software
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activities done to comply with Tüpraş requirements. The

Detailed Functional Specification shall be issued at least one
month before the beginning of the FAT and shall be
approved by Tüpraş. The complex loops shall be covered by
dedicated control narrative as part of the Detailed Functional
Specification.

14.6.2.4 Operator Manuals

Scope of these manuals, written in English language, is to

give operators a guide to use of the System.

All of the necessary instructions to recall specific pages, or

to initialise a trend in real time, etc. will be given.The
Operator Manual must have a "Quick Reference" Section,
suitable for a prompt consultation.

(XVIIIA) ELECTRIC HEAT TRACING OF INSTRUMENTS

1.0 REFERENCES

1.1 Licensor specifications

2.0 GENERAL

2.1 This section states the requirements for the design of electrical heat tracing
systems to maintain minimum specified process temperature under very low-
flow or no-flow condition in order to prevent freezing or condensation in
instruments and relevant impulse piping.

2.2 All heating cables and the ancillary materials for installation in a classified area
ZONE 0, ZONE1, ZONE2, Shall be approved for the purpose by an authorised
laboratory .

2.1 Heater cables shall not be designed for spiral wrap installations on pipe

2.2 All heater cables shall have an overall grounded metal covering

2.3 Verification of maximum sheath temperature of heater cables in classified areas

shall comply with relevant temperature class . (T4,T6 etc.)

2.4 System shall be designed minimum 125 % excess capacity of the calculated
wattage.
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2.6 Heat tracing systems shall be supplied from their own distribution panelboards.
Compound filled insulation transformers with thermal overload type
primary protection shall be provided. A main breaker and individual circuit
breakers for each heater shall be provided with a minimum initial spare
capacity of 20 % for each panel board.

2.7 Electrical heat trace cables shall be self-regulating /self-limiting, constant

wattage parallel, power limiting, high temperature polymer insulated series and
mineral insulated heating type. The heat tracing contractor shall be responsible
for selecting the type of heating cable to be used for a given application.

3.0 HEATER CABLE

3.1 Self-Regulating Heating Cable

Self-regulating /self-limiting heaters shall be utilized where possible,within the
restrictions of heat output and operating temperatures. They can be used for all
winterizing and the majority of compensation heating requirements.

A. Low Temperature - Self-Regulating Heating Cable

1. Heating cables shall be self-regulating, capable of maintaining process

temperatures up to 150°F and a continuous exposure to pipeline
temperature of 185°F while de-energized.
2. Cable must be of parallel construction so that it can be cut to length
without changing its power output per unit length.
3. The heater cable assembly shall have a monolithic heating core
construction consisting of two parallel 16 AWG nickelplated copper bus
conductors with a semiconductive PTC polymer extruded over and
between these parallel conductors.A polyethylene dielectric insulating
jacket is extruded over the heating element core.
4. The semiconductive heating matrix and primary insulating jacket shall
be cross-linked by irradiation.
5. The basic cable will be covered by means of a metallic braid of tinned
copper. The braid will provide a nominal coverage of eighty percent
(80%) and will exhibit a resistance not exceeding 0.0.0045 ohm/ft.
6. The cable shall be covered with a corrosion resistant overjacket of
thermoplastic elastomer (for possible exposure to aqueous solutions,
mild acids or bases) or fluoropolymer (for possilbe exposure to organic
chemicals or corrosives).
7. For longer circuit lengths and higher heat loss requirements greater
than 10 W/ft @ 50°F, the heating cable shall have 14 AWG nickel-
plated copper bus conductors
8. Long term stability shall be established by the service life performance
test per IEEE 515 Std-2004. Specification for Electrical Heat Tracing
Cables Page 4
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B. Medium Temperature Self-Regulating Heating Cables

1. Heating cables shall be self-regulating, capable of maintaining

temperatures up to 250°F and withstanding an intermittent pipeline
exposure temperature of 420°F while energized and 482°F
de-energized.
2. Cable must be parallel construction so that it can be cut to length
without changing its power output per unit length.

3. The heater cable assembly shall be a monolithic construction

consisting of two parallel 16 AWG nickel-plated copper bus conductors
and a semiconductive PTC polymer heating element. The high
temperature fluoropolymer primary dielectric jacket shall be co-
extruded over the heating core and be integrally bonded to the heating
core.
4. The basic cable will be covered by means of a metallic braid of nickel-
plated copper or tinned copper. The braid will provide a nominal
coverage of eighty percent (80%) and will exhibit a resistance not
exceeding 0.0045 ohm/ft.
5. The cable shall be covered with a fluoropolymer overjacket.
6. Long term stability shall be established by the service life performance
test per IEEE 515 Std-2004.

C. High Temperature Self-Regulating Heating Cables

1. Heating cables shall be self-regulating, capable of maintaining

temperatures up to 300°F and withstanding an intermittent pipeline
exposure temperature of 420°F while energized and 482°F
de-energized.
2. Cable must be parallel construction so that it can be cut to length
without changing its power output per unit length.
3. The heater cable assembly shall be a monolithic construction
consisting of two parallel 14 AWG nickel-plated copper bus conductors
and a semiconductive PTC polymer heating element. The high
temperature fluoropolymer primary dielectric jacket shall be co-
extruded over the heating core and be integrally bonded to the heating
core.
4. The basic cable will be covered by means of a metallic braid of nickel-
plated copper. The braid will provide a nominal coverage of eighty
percent (80%) and will exhibit a resistance not exceeding 0.0028
ohm/ft.
5. The cable shall be covered with a high temperature fluoropolymer
overjacket.
6. Long term stability shall be established by the service life performance
test per IEEE 515 Std-2004.
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D. High Temperature Power Limiting Heating Cables

1. Power Limiting heating cables shall be used to maintain temperatures

to 300°F and a continuous exposure to pipeline temperature of 500°F
when the cable is de-energized.
2. Power limiting heating cables shall consist of two 12 AWG nickel-
plated copper bus conductors, individually insulated with a high
temperature fluoropolymer. The bus conductors will be alternately
exposed for connection to the heating element at regular intervals.
3. A PTC (Positive Temperature Coefficient) conductor shall be spirally
wrapped around a fiberglass carrier strand to form a coiled resistor
heating element. This coiled resistor element shall be helically
wrapped around the insulated voltage supply bus wires making
electrical contact with alternate bus wires at regular intervals to
complete the heating circuit.
4. There shall be a fiberglass composite between the heating element
and primary dielectric jacket.
5. The basic cable will be covered by means of a metallic braid of nickel-
plated copper. The braid will provide a nominal coverage of eighty
percent (80%) and will exhibit a resistance not exceeding 0.0018
ohm/ft.
6. For applications subject to corrosive atmospheres, cable shall be
covered with a high temperature fluoropolymer overjacket.
7. Long term stability shall be established by the service life performance
test per IEEE 515 Std-2004.

3.2 Flexible Series Resistance Heat Tracing

A. Flexible Series Resistance Heating Cables shall be in two or three

conductor configurations. Conductor type shall be nickel-plated copper and
available in various sizes, ranging from 16 AWG to 10 AWG to ensure
required circuit resistance can be designed.

B. Electrical insulation shall be fluoropolymer rated for 600 Vac, with a

capability of withstanding continuous exposure to temperatures up to 500°F
when the circuit is de-energized. For temperature exposures greater than
400°F the cable shall have a fiberglass composite between the conductor
and jacket. The insulated conductors shall then be connected to approved
cold lead and end termination assemblies.
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3.3 Mineral Insulated (MI) Heating Cable

A. MI cables shall be capable of continuous exposure to temperatures of
1100°F when the cable is de-energized.

C. MI heating cable shall be one or two heating conductors with magnesium

oxide insulation and an 825 sheath. Cable voltage rating shall be either 300
Vac or 600 Vac. The complete heater assembly shall be approved for the
area it will be installed.

D. The MI cable shall be of seamless construction.

E. Each MI heater shall be factory fabricated to required length with a cold lead
for connection to power or where splices are required. Cold leads shall be 4
ft. or 7 ft. long. Cold leads shall have a gland type fitting for termination in
threaded hub junction boxes. Cables shall be factory terminated and sealed.

F. Each MI cable shall have a metallic tag attached to the cold lead. The tag
shall show the heat tracing circuit number and heater characteristics such
as length, voltage, current, watts, cold lead length, and catalog number.

3.3 All heating cables, except M.I. type, shall have a metallic braid for use as a
ground path. An overjacket shall also be required for all heating cables. For low
temperature heating cables the overjacket material shall meet the requirements
in the application as defined below:

A. For low temperature heating cables polyolefin overjacket shall be used in

moderately corrosive areas and where exposure to aqueous inorganic
compounds are expected.

B. For medium to high temperature heating cables a fluoropolymer overjacket

shall be used over the metallic braid in severely corrosive areas where
exposure to hydrocarbon based chemical solutions or vapors is expected.
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4.0 TEMPERATURE CONTROL

4.1 GENERAL
Each process will impose a unique set of constraints on achieving proper
temperature control. Such constraints may include maintenance and operating
flexibility, energy efficiency, acceptable temperature span, time and manpower
available to correct deficiencies, and the cost assignable to lost production.The
installation and selection of temperature control depend on the following
criteria:
- process/product considerations;
- energy saving;
- temperature limitation for safety reasons;
- protection against overheating of the heating elements.
If self-regulating cable is used (e.g. for winterisation) on impulse lines, the
‘power off’ point shall be below the temperature at which the impulse line liquid
starts to strip/evaporate.

4.1.1 Type I
A process where the temperature should be maintained above a
minimum point. An ambient sensing thermostat is acceptable.
Equipment might consist of a mechanical thermostat and few, if any,
alarms. Large blocks of power might be controlled by means of a
single thermostat, a contactor, and a panel board. Since heat input will
be provided unnecessarily at times, wide temperature excursions
should be tolerable, and maximum energy efficiency is not essential.
Energy efficiency can be improved through the use of dead leg sensing
control.

4.1.2 Type II
A process where the temperature should be controlled within a
moderate band. Pipeline temperature sensing devices, along with
some facilities for monitoring and alarming, are typical. Redundant
equipment is not generally specified, and the tracing requirement
would be sufficiently seasonal to permit planned maintenance and
repairs.
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4.1.3 Type III

A process where the temperature should be controlled within a narrow
band. Pipe sensing controllers using thermocouple or resistance
temperature detector (RTD) inputs will facilitate field calibration and
provide maximum flexibility in the selection of alarm and monitoring
functions. Redundant equipment may be warranted where
maintenance and repairs need to be performed without a process
shutdown. Heat input capability may be provided to warm and/or melt
the fluid within a specified range and time interval.
Type III considerations require strict adherence to flow patterns and
thermal insulation systems with the highest integrity.

4.2 The type of temperature control shall be discussed with the Contracter and
Manufacturer in the detailed engineering design stage.

4.3 TEMPERATURE LIMITATION FOR SAFETY REASON

Controlled design applications, which require the use of a temperature control

device to limit the maximum pipe temperature, shall comply with a) for zone 1
and either a) or b) for zone 2:

a) For zone 1 or zone 2 applications: controlled design applications, which

require the use of a temperature control device to limit the maximum
surface temperature, shall utilize a protective device that will de-energize
the system after the maximum operating temperature has been exceeded,
and reset shall only be possible by hand after the defined process
conditions have returned. In case of an error by, or damage to the sensor,
the heating system shall be de-energised before the defective equipment is
replaced. The setting of the protective device shall be secured and sealed
to avoid tampering. The protective device shall operate independently from
the temperature monitoring system.

b) For zone 2 applications: a single temperature controller with failure

annunciation may be used. If so, adequate monitoring of such
annunciation, such as 24-hour surveillance, shall be provided.
Alternatively, automatic reset may be used if the temperature limiter gives
an alarm in a manned control room when the heater is switched off.
The decision as to which option is to be applied shall be made with the
agreement of the TÜPRAŞ.
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4.4 TEMPERATURE LIMITATION FOR PROTECTION AGAINST OVERHEATING

It is sometimes required to install thermostats that monitor the surface

temperature of the heaters and disconnect the system from the supply if the
temperature is too high.

This high temperature could be damaging to:

- the material used in the heater and in particular the self-regulating/self-
limiting semiconductive material. Examples of this are highly insulated
small bore tubing and piping in which a product could flow with a
temperature higher than the maximum exposure temperature of the heater
when energised;
- the material used in the process piping or equipment (e.g. plastic);
- personnel, e.g. supply piping of safety showers, which may contain water at
too high a temperature.

The maximum allowable temperature when the heater is de-energised, as

stated by the Manufacturer, shall not be exceeded.
The requirement of such temperature limiters shall be discussed with the
Manufacturer in the detailed design stage.
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(XVIIIB) STEAM TRACING OF INSTRUMENTS

1.0 REFERENCES

1.1 API RP 551, 552, 553, 554

1.2 Licensor specifications

2.0 SCOPE

2.1 This standard shall govern the design and installation of the steam tracer and
enclosure required to protect instruments. Condensate return and temperature
control shall be by means of temperature control thermostatic valves (make
GONTZ or equal).

2.2 The term "instruments" when used herein, shall mean all instrument items
which are mounted externally to the process line or equipment. In-line items
such as control valves, variable area meters, etc. which require steam tracing
shall be traced with the process line tracer and shall not be considered part of
this standard.

2.5 This standard shall govern steam tracing of instruments to prevent the
following:
2.6
2.3.1 The freezing of fluids in instruments and lead lines.
2.3.2 Interference with the proper operation of an instrument by a viscous
fluid.
2.3.3 Damage to the electronic portion of an instrument.
2.3.4 Condensation of process vapors where condensation would be
detrimental.

3.0 SUPPLEMENTARY INFORMATION

This standard shall be supplemented by design data which will give the following
information.

3.1 Indication on the P&I diagram of the instruments to be steam traced.

3.3 Pressure and temperature of steam to be used for tracing.

3.3 Ambient weather conditions:

3.3.1 Minimum design temperature
3.3.2 Maximum design temperature
3.3.3 Wind speed

3.4 Special tracing requirements

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4.0 MATERIALS

4.1 Tracer

4.1.1 Copper tubing shall normally be used for that portion of the steam tracer
that is fastened to and insulated with the instrument piping or instrument
being traced. However, carbon steel tubing or stainless steel tubing shall
be used in the following instances.

(a) Carbon Steel

(1) The normal operating temperature of the line is above 200°C.

(2) Temperature of the tracing steam is above 200°C.
(3) Copper would be attacked by leakage of the traced liquid or by a
corrosive atmosphere.
(4) If traced line is above 1 ½".

(b) Stainless Steel

(1) The instrument piping and instrument to be traced is stainless

steel and the normal operating temperature is above 200°C.
(2) The pre-insulated bundle specified does not offer carbon steel
as on alternative.
(3) If traced line is above 1 ½".

4.1.2 The materials shall be as follows:

(a) Copper Tubing-Seamless, soft annealed ASTM B 68 or B 75

number 122.
3/8" OD x 0.032" wall
1/2" OD x 0.049" wall

(b) Carbon Steel Tubing-annealed, maximum Rockwell hardness RB

72.

3/8" OD x 0.035" wall ASTM A 179

1/2" OD x 0.049" wall ASTM A 178 Gr.A or ASTM A 214

(c) Stainless Steel Tubing-annealed, maximum Rockwell hardness RB

80, ASTM A 269 TP 304 or ASTM A 213 TP 304.

3/8" OD x 0.035" wall

1/2" OD x 0.049" wall
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(d) Compression type tube fittings shall be used, brass for copper
tracers, carbon steel for carbon steel tracers and 316 SS for SS
tracers.

4.2 Pre-insulated tubing

Where possible, pre-insulated tubing bundles shall be used rather than traced
and insulated instrument lead lines. This does not apply to line mounted D/P
flow transmitters, etc., where the bending radius of the bundle would prohibit its
use. However, where longer lead lines are encountered, a considerable cost
saving can be realized by utilizing a pre-insulated bundle. The bundle shall
have a factory-applied insulation and a PVC jacket, as manufactured by the
Unitherm Division of the Eaton Corporation, or of equal manufacture. The
following specifications shall be to the pre-insulated bundle:

4.2.1 Tubing specifications shall be the same as stated above for bare tubing.

4.2.2 Jacket surface temperature with 200°C tube and 26°C ambient=60°C.

4.2.3 Installation Recommendations:

(a) Maximum Support Centers:

Vertical - 3-4.5 meters
Horizontal 1.5- 1.8 meters

(b) Minimum Bending Radius:

Process Tube O.D. Tracer Tube O.D. Min. Radius

1/4" 1/4" 7"
3/8" 3/8" 7"
1/2" 3/8" 8"

(c) Minimum recommended slope for condensate runoff = 1/4" per foot.

(d) End sealant of sealing patch (insulation, fiberglass tape and rubber
cover) shall be used to protect and cover the tubing where it has
been stripped of the original insulation and covering during
installation.
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4.3 Instrument Enclosures

4.3.1 The instrument enclosures shall be constructed of fire-retardant rigid,

high - density, closed cell, to protect against ultraviolet exposure, a
positive seal against rain, dust and contaminants, corrosion resistant
fastening hardware and mounting support systems, high temperature
polyurethane as follows:

(a) Pressure Gauges- The enclosure shall be constructed of two

parts, held together with a strap or clips. It shall require no
external mounting and be easily installed or removed while the
gauge remains in service. The enclosure shall fit any 160 mm
bottom connected pressure gage. It shall incorporate a blow-out
to relieve built-up pressure in the event of a gauge failure. It shall
provide a complete unobstructed view of the gauge face.

(b) Differential pressure transmitters (partial enclosure)- The

enclosure shall be constructed of two parts held together with a
strap and shall enclose the body of the transmitter only; the
topworks shall be outside the enclosure. The enclosure shall
require no external mounting and be easily installed or removed
while the transmitter remains in service. It shall be capable of
enclosing a manifold valve with the transmitter if this type of
installation is required. It shall be complete with vent valve
extensions and manifold valve handle extensions. It shall also
enclose the exposed end of a pre-insulated tubing bundle where
the tubes are fanned out the match the transmitter connection.
This shall be the preferred enclosure for "standard" D/P
transmitters. When no partial enclosure is available or the
minimum design temperature is lower than the minimum
operating temperature listed by the transmitter Vendor, a
complete enclosure shall be specified.
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(c) Transmitter, controllers, recorders, etc. (complete enclosure)-

The enclosure shall be constructed of two parts hinged together
and secured with quick-release latches. The cover or door shall
be easily removable to provide complete access to instrument.

The enclosure shall be of sufficient size to house the instrument,

valves, filter/regulator, integral junction boxes, etc., as required.
The enclosure shall be suitable for mounting on a 2" pipe
pedestal with separate mounting brackets for mounting the
instrument. The enclosure shall be complete with a window if
required. It shall be drip-tight, weather-proof, water-tight and
dust-tight.

4.4 Instrument Enclosure Heating Systems

Enclosure heating systems shall use steam as the heating source. The method
of heating shall be as follows:

(a) Pressure gauge enclosures- The heating system shall either utilize the
inherent heat present in the process line by insulating up to the
enclosure for heat conservation or shall continue the steam tracer
around a cast aluminum heat transfer block located at the gauge
connection which will transfer heat into the bourdon tube.

(b) Differential pressure transmitters (partial enclosure)- The preferred

heating system shall be a continuation of the steam tracer either using
clamps which force the tracer to maintain intimate contact with the
transmitter by or using a heat transfer block in which the tracer contacts
the block and conducts heat through to the transmitter body. The
selection depends on the transmitter body style. The alternate heating
system consists of replacing one, two, or four of the transmitter body
bolts with hollow studs and connecting the steam tracer to the stud(s). In
general the clamp and heat block methods are for freeze protection. The
hollow studs are for freeze protection at very low ambient temperatures
and for high pour point applications. The hollow stud approach must be
used with attention to the steam temperature versus the transmitter
body temperature limits. Recalibration in service will probably be
required.

(c) Transmitters, controllers, recorders, etc. (complete enclosure)- The

heating system is a separate, finned steam heater connected by tube
fittings to the steam tracer. Finned steam heaters are available in
various sizes to provide the required heating for the different size
enclosures.

4.5 Instrument piping insulation shall be in accordance with TUPRAS specification

TPS-N3.
 Section : TGPS –J1
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4.6 Miscellaneous

4.6.1 Wire for fastening the tracers shall be 14 ga.(0.083") galvanized copper
bearing iron wire, ASTM A 111 grade BB or A 112 grade B. For stainless
steel piping or tracers, use stainless wire 14 ga., ASTM A 580 annealed.
DO NOT use galvanized wire.

4.6.2 All enclosures shall be supplied with a stainless steel identification tag
and seal kit.

5.0 GENERAL REQUIREMENTS

5.1 Determination whether heavy or light tracing is required should be based on

temperature of steam being used, minimum design temperature and the fluid
being traced. Heavy tracing utilizes intimate contact between the tracer and the
item being traced. Light tracing separates the tracer from the item being traced
with a wood block or a light layer of insulation.

5.2 Instrument lead lines being traced shall be grouped, wherever practical, and
insulated with a common tracer.

5.3 Steam tracer sizes shall be as follows:

a) Gauge glass and external displacer level instruments. 1/2" OD tubing.

b) Meter leads. 3/8" OD tubing

5.4 Each tracer shall be provided with an individual thermostatic valve allowing the
steam/condensate temperature to be controlled at the required temperature.

5.5 Sufficient unions shall be placed in the steam tracer, outside the insulation, to
allow the instrument to be removed for repair.

5.6 Tracers for horizontal lines shall be parallel to the line and located near the
bottom.

5.7 Tracers for vertical lines shall be parallel to the line and located where they
offer the least interference. Wrap-around tracing shall not be used unless
otherwise specified.

5.8 Where tight bends are required, tube bending, tube bending tools such as those
made by Parker or Ridgid shall be used.

5.9 The maximum length of 3/8" OD steam tracers shall be 60 feet.

5.10 Close coupled pressure gauges connected to steam traced lines may be traced
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with a loop in the line tracer. All other instruments or groups of instruments shall
be traced with a separate steam tracer.

5.11 Each instrument to be traced shall have its own separate tracing block valve.

6.0 INSTALLATIONS

6.1 The inlet of this section is to show typical instrument steam tracing installations.
The actual installations may differ from those shown to meet the requirements
of the specific application.

6.2 Pressure Gauge

6.2.1 Steam line, -25°C ambient temperature, 25 MPH wind, utilizing AGCO
CT-7 siphon. See figure 1.
6.2.2 Steam traced line with 3/8" or 1/2" line tracer. See figure 2.
6.2.3 Separate steam tracer. See figure 3.
6.2.4 Diaphragm seal. See figure 4.

6.3 Differential Pressure Transmitter (Partial Enclosure)

6.3.1 Line mounted with a clamped tracer. See figure 5.

6.3.2 Remote mounted with a clamped tracer. See figure 6.
6.3.3 With hollow studs. See figure 7.
6.3.4 With heat transfer block. See figure 6.

6.4 Transmitter, controller, recorder, etc. (complete enclosure). See figure 9.

6.5 Level gauge. See figure 10.

6.6 External displacer type level instrument. See figure 11.

6.7 Multiple level instruments on a vessel standpipe. See figure 12.

 Section : TGPS –J1
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STEAM TRACING
OF INSTRUMENTS

SCREWED
PRESSURE GAUGE HEAT BLOCK COUPLING AT
ENCLOSURE GAUGE CONN.

TRACER

A A VIEW "A-A"

STEAM TRACER IS TO FIT

TIGHTLY IN TO GROOVE IN
HEAT BLOCK

3/8" OD OR 1/2" OD TUBING UNION

LINE TRACER
USE HEAT TRANSFER CEMENT
BETWEEN HEAT BLOCK AND
NOTE: COUPLING FOR COUPLINGS
INSULATE UP TO ENCLOSURE OTHER THAN 3000#
FOR HEAT CONSERVATION FIGURE 2
PRESSURE GAUGE IN STEAM TRACED
LINE WITH 3/8" OR 1/2" LINE TRACER
 Section : TGPS –J1
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STEAM TRACING
OF INSTRUMENTS

PRESSURE GAUGE ENCLOSURE

3/8" OD TUBING FROM

STEAM SUPPLY STEAM TRACER IS TO FIT
TIGHTLY IN TO GROOVE IN
HEAT BLOCK SEE FIGURE 2

NOTE: TO THERMOSTATIC VALVE

INSULATE UP TO ENCLOSURE
FOR HEAT CONSERVATION FIGURE 3
PRESSURE GAUGE WITH
SEPARATE STEAM TRACER
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STEAM TRACING
OF INSTRUMENTS

D/P TRANSMITTER
3/8" OD TRACER PARTIAL ENCLOSURE
FROM STEAM SUPPLY
A

A CLAMP TO HOLD
TRACER TO
TRANSMITTER BOD

GROUP & INSULATE TOGETHER

TO THERMOSTATIC VALVE
NOTE: TRACER
INSULATE PIPING UP TO FIGURE 5 VIEW "A-A"
ENCLOSURE FOR HEAT FLOW TRANSMITTER

3/8" OD TRACER
FROM STEAM SUPPLY

A
D/P TRANSMITTER
PREINSULATED PARTIAL ENCLOSURE
TUBING BUNDLE A

TO THERMOSTATIC VALVE REFER TO FIGURE 5

NOTE: FOR VIEW "A-A"
INSULATE PIPING BETWEEN LINE CONNECTION
AND PREINSULATED TUBING FOR HEAT FIGURE 6
CONSERVATION FLOW TRANSMITTER
REMOTE MOUNTED WITH CLAMPED TRACER
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STEAM TRACING
OF INSTRUMENTS
 Section : TGPS –J1
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D/P TRANSMITTER
3/8" OD TRACER PARTIAL ENCLOSURE

HOLLOW STEAM STUD

(REPLACES ONE OF THE
TRANSMITTER'S BODY BOLTS)

90o ELL CONNECTOR FROM 1/4"

TUBING TO YHE HOLLOW STUD
(FURNISHED WITH STEAM STUD)

3/8" T *1/4" T REDUCING UNION

GROUP & INSULATE TOGETHER

TO THERMOSTATIC VALVE
NOTE:
INSULATE PIPING UP TO FIGURE 7
ENCLOSURE FOR HEAT CONSERVATION FLOW TRANSMITTER
LINE MOUNTED WITH HOLLOW STUD

3/8" OD TRACER HEAT BLOCK

FROM STEAM SUPPLY
1/2" MNPT* 1/2"FNPT
NIPPLE/COUPLING
ADAPTER
VIEW "A-A"

STEAM TRACER IS TO FIT

A TIGHTLY INTO GROOVE
IN HEAT BLOCK SEE FIGURE 2
PREINSULATED
TUBING SHOULD
BE USED IF
INSTALLATION
IS REMOTE A D/P TRANSMITTER
PARTIAL ENCLOSURE
TO THERMOSTATIC VALVE

NOTE: FIGURE 8
INSULATE PIPING UP TO ENCLOSURE PRESSURE TRANSMITTER
FOR HEAT CONSERVATION WITH HEAT TRANSFER BLOCK

STEAM TRACING
OF INSTRUMENTS
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3/8" OD TRACER
FROM STEAM SUPPLY
COMPLETE ENCLOSURE

TRANSMITTER, CONTROLLER,
RECORDER, ETC.

FINNED HEATER

3/8" T * 3/8" MNPT CONN

TO STEAM TRAP
NOTE:
INSULATE PIPING UP TO ENCLOSURE
FOR HEAT CONSERVATION FIGURE 9
COMPLETE ENCLOSURE

1/2" OD TRACER FROM STEAM SUPPLY

1/2" TUBE UNION

GAUGE GLASS

TRACER TO BE ON THE BACK OF

REFLEX TYPE GLASSES AND ON
ONE SIDE OF TRANSPARENT TYPES

TO THERMOSTATIC VALVE

NOTE:
INSULATION FOR GAUGE GLASSES TO BE ONE FIGURE 10
HALF SECTION OF PIPE INSULATION CAULKED LEVEL GAUGE GLASS
WITH PLASTIC
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STEAM TRACING
OF INSTRUMENTS
 Section : TGPS –J1
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1/2" OD TRACER FROM STEAM SUPPLY

1/2" TUBE UNION

EXTERNAL DISPLACEMENT TYPE

LEVEL INSTRUMENT

TRACER SHALL RUN STRAIGHT

DO NOT WRAP AROUND

TO THERMOSTATIC VALVE

NOTE:
INSULATE INSTRUMENT FIGURE 11
AND PIPING FOR EXTERNAL DISPLACEMENT TYPE LEVEL INSTRUMENT
HEAT CONSERVATION

2 S EPARATE 1/2" O D TRAC ERS

FRO M S TEAM S UPPLY

S TANDPIPE

LEVEL INS TRUMENT

1/2" TUB E UNIO N (TYPIC AL)

TO INDIVIDUAL TH ERMO S TATIC VALVE

NO TE:
INS ULATE INS TRUMENTS AND PIPING FIGURE 12
H EAT C O NS ERVATIO N MULTIPLE LEVEL INS TRUMENTS O N A VES S EL S TANDPIPE
 Section : TGPS –J1
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(XIX) WINTERIZATION AND PROTECTION OF INSTRUMENTS

1.0 REFERENCES

1.1 API RP 551,552,553,554

1.2 Licensor Specifications
2.0 SCOPE
2.1 This standard shall provide the basis for determining the correct method of
winterization and protection of instruments.
4.13 The term "instruments" when used herein, shall mean all instrument items
which are mounted external to the process line or equipment. In-line items such us
control valves, variable area meters, etc. shall be reviewed for winterization and
protection as part of the process piping, rather than as instruments and therefore,
shall not be governed by this standard.
2.3 This standard shall govern winterization and protection of instruments to
prevent the following:
2.6.1 Undesirable condensation, separation or freezing of fluids which would
occur at the design ambient conditions.

2.6.2 Interference with the proper operation of an instrument by a viscous

fluid.

2.3.3 Damage to an instrument by corrosive or hot fluids.

2.4 On all units, all instrumentation (mounted externally to the process line or
equipment) will be electrically heat traced for winterising applications when it is
labelled as “WISI” on the P&IDs or for maintaining the temperauture indicated in
the P&ID independent of the temperature objective. This criteria shall be
followed unless another definition will be indicated as mandatory by licensor.
Electrical heat tracing will be the first choice for winterization, compensation
heating and protection of the instruments. Contractor shall design heat tracing
for instrumentation according to the licensor specifications, TGPS-P1 (Section-
25) and TGPS-J1 (Section XVIIIA-XVIIIB-XIX).

2.5 DELETED.
R2 2.6 DELETED.
2.7 DELETED.
2.8 DELETED.
2.9 DELETED.
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3.0 GENERAL

3.1 The general methods of winterization and protection of instruments are as

follows:

3.1.1 Insulation of the instrument and/or the instrument piping to prevent heat
loss or gain.

3.1.2 Tracing the instrument and/or the instrument piping.

In case of steam tracing, steam will be utilised with thermostatic valves

which will control the required steam condensate temperature for each
field instrument separately.

3.1.3 Purging the instrument and/or the instrument piping to keep undesirable
liquids, solids or gases from entering the instrument.

3.1.3.1 The purge supply to rotameters (integral with flow adjusting

valve) generally shall be taken from a common header. In
cases where the process pressure is greater than one half of
the purge header supply pressure, a differential pressure
regulator shall be furnished to maintain a constant flow across
the rotameter. This regulating valve shall be furnished with a
gauge to indicate the pressure at the upstream side of the
rotameter.

3.1.4 Isolating the instrument from the process fluid through the use of a
diaphragm seal.

3.1.5 Isolating the instrument and the instrument piping from the process fluid
through the use of a sealing liquid. This method shall be applied instead
of the one stated in item 3.1.4 above.

3.1.5.1 An instrument may be sealed with the same fluid as in the

process line. Depending on the characteristics of the fluid, this
method may be entirely satisfactory.

3.1.5.2 Water may be used as a sealing liquid where the only purpose
is to protect against the entry of the process fluid. However, if
freezing temperatures are encountered, water seals must be
protected by tracing.
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3.1.5.3 An instrument may be sealed with a liquid having a low freezing

point (e.g., dibutyl phthalate -35°C or 50% ethylene glycol in
water -36°C ) to avoid having to trace the installation. But, this
is not the preferred method where tracing steam is available.

3.1.5.4 Instruments with a low (negligible) displacement may be sealed

in the normal piping arrangement. Instruments with appreciable
displacement (e.g., bellows type flow meters) require seal pots
with special piping arrangements for control of the seal liquid
level in order to prevent hydrostatic errors.

3.2 The recommended method of winterization and protection for a particular type
of instrument in a specified ambient condition can be determined from the
following:

3.2.1 Fourteen (14) fluid types have been established and listed, covering
virtually all fluids normally encountered (Table I).

3.2.2 The various methods of winterization and protection have been listed
(Table II).

3.2.3 Two schedules cross-referencing fluid type and instrument type against
the recommended method of winterization and protection have been
devised. The recommended method is indicated by the upper case letter
or letters. The lower case letters represent alternate methods of
protection which will be selected, by TUPRAS, when the standard
method is not considered feasible. Schedule A is given for ambient
condition above 32°F (0°C ), Schedules B for 32°F (0°C ) and below.

TABLE I - FLUID TYPES

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Fluid Type Fluid Definition or Property

1 Water and Water solution having a
freezing point of approximately 32°F (0°C
).
2 Liquids from which gravity separation
could cause water to accumulate in lead
lines (not because of steam-out
operations).
3 Corrosive liquids (only those corrosive to
the wetted parts of instruments or
instrument leads).
4 Liquids whose pour points are above the
minimum design temperature.
5 Liquids which may change in chemical
composition due to a decrease in
temperature from operating to minimum
design temperature
6 Liquids which could vaporize at operating
pressure and at ambient temperature
conditions.
7 Liquids which contain solids.
8 Steam.
9 Corrosive vapors and gases.
10 Air, vapors and gases containing solids.
11 Wet gas.
12 Vaporous Dowtherm, Therminol, etc.
13 Liquid Dowtherm, Therminol, etc.
14 No protection required (for fluids such as
dry gas. hydrocarbon gas, etc. The term
dry shall mean non-condensable at
minimum design temperature).

TABLE II - PROTECTION METHODS

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Method Code Letter Description of Protection Methods

0 No special protection required.
A Fill lead lines with process liquid.
B Fill lead lines with water.
C Fill lead lines with a seal fluid other than
line fluid.
D Insulate lead lines.
E Trace and insulate lead lines.
F Use seal pots.
G Use condensate pots.
H Liquid purge of lead lines.
J Air or gas purge of lead lines.
K Provide heated housing for instrument.
L Diaphragm seal.
M Syphon or condensate seal.
N Locate instrument or knockout pots at an
elevation higher than process
connection (to permit gravity flow of
condensate to the process connection).
P Insulate instrument.
Q Trace & insulate instrument.
 Section : TGPS –J1
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SCHEDULE A - MINIMUM DESIGN TEMPERATURE ABOVE 32°F (0°C)

Fluid Type Force Bellows All Direct Pressure External

Balance Type Connected Gauges Displacer
Type Differential Pressure Type Level
Differential Pressure Instruments Instruments
Pressure Instruments (Except & Gauge
Instruments Gauges) Glasses
1 0 0 0 0 0
2 B B B 0 0
3 H,c H,c+F L,c,h L,c H
4 E+K E+K E+K E+K E+Q
5 H,c H,c+f L,c,h L,c H
6 E,c E,c=f E,c 0 D+P
7 H H L,h L,h H
8 B B+G M M -
9 C,j C+G,j C,l C,l -
10 J J J J -
11 N,a,e N,a+g,e N,a,e N -
12 M,e+k* G,g+e+k* M,l,e+k* M,l,e+k* -
13 0,e+k* 0,e+k* 0,e+k* 0,e+k* 0,e

* Apply tracer and insulation only when temperature can go below 60°F.
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SCHEDULE B - MINIMUM DESIGN TEMPERATURE 32°F (0°C) AND BELOW

Fluid Type Force Bellows All Direct Pressure External

Balance Type Connected Gauges Displacer
Type Differential Pressure Type Level
Differential Pressure Instruments Instruments
Pressure Instruments (Except & Gauge
Instruments Gauges) Glasses
1 E+K E+K E+K E+K E+Q,d+p
2 B+E+K B+E+K B+E+K E+K E+Q,d+p
3 H,c H,c+f L,c,h L,c H
4 E+K E+K E+K E+K E+K
5 H,c H,c+f L,c,h L,c H
6 E,c E,c+f E,c 0 D+P
7 H H L,h L,h H
8 B+E+K B+G+E+K B+E+K D+M+K,d+l -
9 C,j C+G,j C,l C,l -
10 J J J J -
11 N,a,e N,a+g,e N,a,e N -
12 E+K G+E+K L,e+k L,e+k -
13 E+K G+E+K L,e+k L,e+k -

(XX) SAFETY VALVES AND RUPTURE DISK

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1.0 GENERAL

1.1 Scope

1.1.1 Safety valves and rupture disks shall be designed in accordance with
the API ST 520 "Recommended Practice for the Design and Installation
R2 of Pressure-Relieving System in Refineries" and API STD 2000 Venting
Atmospheric and Low Pressure Storage Tanks" latest edition.

1.1.2 Installation of safety devices shall be in compliance with API RP 521

"Guide for Pressure-Relieving and Depresuring Systems", latest edition.

1.1.3 Safety relief valves shall be used to protect vessels or systems from
pressure above design or maximum allowable working pressure
( MAWP).

2.0 Basic Design

2.1 General

2.1.1 Safety valves body and rupture disks materials shall be in accordance
with line or vessel classification as defined in individual specifications.

2.1.2
Flanged connections and rating shall generally be as per line/vessel
specifications and according to API ST 526 “Flanged Steel Pressure
R2 Relief Valves” latest Edition. Not threaded connections shall be used,
neither for Thermal Expansion Valves. The connections must be in
accordance with ANSI Code.Where 125 Ra is specified for flange
surface finish, the range for acceptance shall be 63 Ra minimum to 250
Ra maximum. Finishes shall be judged by visual comparison with
surface finish roughness standards conforming to ANSI B46.1. It is the
Vendor's responsibility both to comply with the above finish
requirements and to assure that such flange finishes be protected from
damage during shipping, storage and installation. The preferred method
of protecting flange finishes is as follow:
R2 2.1.2 If NACE requirements apply, valve shall comply with NACE MR-0103
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Machined surfaces shall be coated with an easily removable rust

preventative grease or strippable protective coating, and the entire
gasket surface of the flanges shall then be covered over with heavy duty
plastic flange protectors, bolted or steel-strapped wood, wood fiber, or
metal covers. Where wood, wood fiber or metal covers are used, a
plastic sheet shall be placed between the coated flange and cover for
additional protection.

2.2 Pressure Relief Valves

2.2.1 The following criteria have been taken into account for the valve
type selection:

- Conventional valves shall be specified:

o When backpressure is constant and lower than 10%

of Set pressure.
R2 o For PSV discharging to Atmosphere

- Balanced bellows valves shall be specified:

o When backpressure is variable or constant higher
than 10% of Set pressure.
o When PSV discharging to Flare
o For two-phase liquid/vapor relief
o For lethal services

- Pilot Operated Valves shall be specified:

o When backpressure is higher than 50% of Set
pressure.
When Licensors have specified this type of valve

2.2.2 Lifting devices shall be provided for pressure relief valves weighing
more than 45 kg.

R2 2.2.3 Trim material shall be stainless steel min. Suitable Trim for liquid shall
have to be considered, when applicable.

2.2.4 All calibration screws must be protected by a cap and provided with
R2 sealing to prevent temperings. Cap will be bolted for all valves, except
for ASME I, that it will be screwed.

2.2.5 All valves must be provided with a test gag.

2.2.6 Packed lifting lever, when requested (for water T>60ºC, air or steam),,

R2
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must be provided on valves with closed bonnet for ASME VIII valves.
Lifting Lever will be Plain with Open Bonnet for ASME I valves. All Lifting
Levers shall be incast iron. Lever will not be considered for thermal
expansion valves.

R2 2.2.7 All valves with seal or balancing bellows must have a bonnet with
threaded vent holes 1/2" ANSI B2.1 NPT. with SS bug screen

2.2.8 All flanged valves shall be supplied with full capacity nozzle.

2.2.9 Valves with flanged connections must have the flanges integral with the
body. (not joined by welding or coupled with half threading). Only for the
R2 thermal relief valves (3/4”x1”), flanges will not be integral with the body
but they will be welded.

2.2.10 Heating connections for valves with jacketed body must be threaded
1/2" female ANSI B2.1 NPT.

2.2.11 Each valve shall have identification markings containing all data
required by the applicable ASME Code and/or API Standard 526 (ANSI
B146.1), latest edition.

2.2.12 Spring must be marked, by means of punching or a metallic nameplate,

within following data: name of manufacturer, type of spring, pressure
and temperature range, spring material and cross section.

2.2.13 Valve spring calibrated within 18 kg/cm² must be capable of being

calibrated with a range of ±10% of the rating-plate value. For valves
calibrated over 18 kg/cm² , springs must be capable of being calibrated
within a range of ±5% of the rating-plate.

2.2.14 Tolerances permitted in calibration are as follow:

- For valves calibrated up to 5 kg/cm² ±28% of the calibration value.

- For valves calibrated above 5 kg/cm² ±3% of the calibration value.

2.2.15 Admissible losses with a pressure at he inlet equal to 90% of the tripping
value, a back pressure of 1/2" of H2O, and a drainage duct with an
internal diameter of 6 mm, are as follows:

- For standard valves

orifice F and smaller : 40 bubbles per minute
orifice G and larger : 20 bubbles per minute

- For valves with bellows

orifice F and smaller : 50 bubbles per minute
orifice G and larger : 30 bubbles per minute
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2.2.16 Spring material shall be protected against corrosion by means of

phosfatizing treatment.

2.2.17 Material Selection:

R2 - Body material and bonnet has been selected according to:

 Piping Specification at the valve outlet

 API ST 526 recommendations for relieving conditions
 Operation Conditions
 Piping Specification at the valve inlet ,for seminozzle valves

- Nozzle and other internal materials according Piping Specification at

the valve inlet

- Spring material tobe selected according to the API STD recommendations for
the discharge temperature.
R2 2.2.18 Weather Hood and ½”NPT drain, will be included for all ASME I valves

2.7 Rupture Disks

2.3.1 The admissible tolerance of rupture disks is ±5% of the rupture value.

2.3.2 Each rupture disk must show in a suitable place the following data:

- working temperature and pressure

- rupture temperature and pressure
- the word "PROCESS" on the disk side in contact with the process
fluid.
- all data relating to connections between the disk holder and line
coupling flanges.
- disk tag number (obtainable from the individual instrument
specification).

2.3.3 Each disk must have protection against a vacuum.

2.3.4 Burstıng dıscs shall be used with OWNER approval to protect vessels or
systems from high pressure above which these vessels and system
have been designed. They will be used either in series with relief valves
where necessary, or where conditions preclude the use of relief valves.

2.3.5 Bursting discs shall be mounted in holders designed to fit inside the bolt
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circle of standard flanges.

2.4 Vacum Breakers

2.4.1 Shall be used to protect vessels or systems from low absolute

pressures, below which these vessels and systems have been
designed.

2.4.2 Vacuum breakers shall be sized in accondance with API RP. 520 and
RP 2000.

3.0 INSPECTION AND TESTS

3.1 General

3.1.1 Shop inspection is required. The Vendor shall carry out all inspection
and testing indicated below and provide all the certification there
indicated.

3.1.2 The Vendor shall provide origin/mill certificate for:

Chemical analysis on material report

Mechanical tests of materials

3.1.3 The Vendor shall provide check certification for:

- Visual inspection for steel casting (Quality STD. for steel casting
according to CODE MSS-SP 55.

- Welding procedure records for repair

- Welder's qualification records for repair

- Radiographic tests on repair (According to CODE ASTM-E-94/E-

142/E-446 and acceptance STD. according to ASTM-E-446 and
MSS-SP 54 when required.

- Hardness tests (trim/base material/guide/stem)

- Sealing test of bellow

- Hydrostatic inlet body test (on valves with short nozzles only)
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- Hydrostatic body test on outlet side (According to ANSI B16.5)

- Hydrostatic test for nozzle (According to ANSI B16.5)

R2 - DELETED

- Check calibration and gauging of necessary instrumentation for

testing.

- Compliance with specification and purchase order check.

- Visual and dimensional check

- Seat tightness test (According to API RP 527)

- Back pressure tightness test on valves fully assembled.

- Popping test

- Marking check

- Painting check

R2 - DELETED

- Check pilot device system (For safety pilot valves only)

R2 - DELETED

- Summary certificates employed materials

3.1.4 The Vendor shall provide official certification for:

- Coefficient of discharge, over pressure blowdown (official

certification for one sample of each type according to code of
statutory of original country).

(XXI) DOCUMENT REQUIREMENTS

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1.0 REFERENCES

1.1 ISA S-20

1.2 ISA S-5.1
1.3 ISA S-5.2
1.4 ISA S-5.4
1.5 ISA S-5.3
1.6 SAMA PMC-22.1

2.0 LOOP DRAWINGS

2.1 All instrument individual specifications/requisitions shall be prepared on the

relevant sheets of ISA S.20.

2.2 Instrument Loop Drawings

 The terminology shall conform to ISA-S5.4

 Instrument loop drawings shall be point-to-point wiring/tubing drawings.

 ILD's shall be used for checkout and/or commissioning of instrument loops

after completion of instrument/instrument electrical construction. ILD's shall
be used for trouble-shooting instrument loops after commissioning of those
loops.

 All ILD's shall be multi-loop drawings. Each type loop shall have a graphic
sheet and one or more data tabulation sheets. Sheet #1 of any multi-loop
drawing, the graphic sheet, shall contain the graphic portion of the type
loop with identifying symbols for the variable information required to make
the type loop drawing correct for any specific loop. Subsequent data
sheets of any multi-loop drawing (sheets # 2,3,etc.) shall be tabular listings
of the information required for a specific loop; cross referenced to the
identifying symbols appearing on the graphic sheet (sheet #1) of that
multi-loop drawing.

 ILD's shall not duplicate information found on Engineering Flow Diagrams

(EFD's)/Piping and Instrument Diagrams (P&ID's).

 Identification of instrument wire and terminal numbers shall be shown.

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Power wiring shall not normally be shown on ILD's. Power wiring is shown
on other contractor or Vendor-supplied drawings.

 A Complete loop diagram shall contain the following elements:

a. All devices within the loop and a clear identification of each component
(with set points if applicable);
b. The interconnection of the devices;
c. The location of each device;
d. The power sources and auxiliary systems required for the loop;
e. The control action of the major components.

2.3 Logic Diagrams

 Terminology shall conform to ISA-S5.2

 Logic Diagrams (LD's) shall be binary logic diagrams of interlock,

sequencing and trip systems defining the permissive, operating and/or
shutdown functions required by process and/or equipment.

 LD's shall define the interlock, sequence on trip system logic. LD's shall not
define hardware on software. Identification of hardware or software shall be
made in other contract documents, but no specification of hardware or
software shall be made or implied on LD's

 All the set-points values activating logic systems shall be determined on the
Logic Diagrams.

 LD's shall be single sheet drawings whenever possible. When the logic is
too extensive to be shown on the largest standard drawing ( # 1 size), LD's
shall be shown on two or more equal-sized sheets.

2.4 Instrument Control Drawings

Instrument Control Drawings, generally known as SAMA (Scientific Apparatus

Makers Association) Drawings, are to be furnished in accordance with this
specification. This standard is generally in accordance with SAMA standard
PMC 22.1-1981 as modified to allow maximum use of the CAD systems; and as
modified to take into account the requirements of Digital Control Systems(DCS).

Terminology shall conform to SAMA standard PMC 22.1-1981 and to ISA-S5.4.

2.4.1 Philosophy:
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With the general acceptance of DCS in general and of the various

Multifunction Controllers (MFC's) of greater and lesser ability in
particular, it become apparent that the "Classical" loop drawing of the
type defined in ISA standard S5.4 was becoming inadequate if not
irrelevant. S5.4 loop drawings presumed a physical linking of basically
single-function discrete instruments. Attempts to adopt this method to
software "function mapping" were frustrated by, among other things,
the total lack of conformity in this area between DCS manufacturers.

These problems will be overcome in the following manner:

2.4.1.1 The "Software Side" of "Loop Drawings" shall be defined on

SAMA drawings.

2.4.1.2 These SAMA Drawings may be used as"auxilliary flow

sheets" where control schemes may be too large or too
complex for "standard ISA S5.1 balloon" presentation on
P&ID's.

2.4.1.3 The "Field Side" of "Loop Drawings" shall be point-to-point

wiring drawings, graphic printouts or text printouts defining
all connections before entering/after leaving the DCS.

2.4.2 Scope Definition:

2.4.2.1 SAMA drawings shall be produced for all continuous

measurement control or monitoring "loops" on a project
which are wholly or partially resident in a DCS which uses
some form of MFC.

2.4.2.2 SAMA drawings shall be produced for all discontinuous

(contact closure, pulse, etc.) "loops" on a project which are
wholly or partially resident in a DCS which uses some form
of MFC.
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2.4.2.3 SAMA drawings may or may not be produced for continuous

or discontinuous control or monitoring "loops" resident in
"Single loop Controllers", "Single Strategy Controllers", etc.
Discrete Digital Devices of this type may require special
treatment, which varies on a project-to-project basis.

2.4.2.4 SAMA drawings shall not be made for continuous or

discontinuous "loops" solely resident in "Programmable
Logic Controller" (PLC's).

2.4.2.5 SAMA drawings shall not be made for continuous or

discontinuous "loops" which are not resident in any type
DCS.

2.4.3 Format

2.4.3.1 If a substantial number of functionally identical SAMA

drawings exist, those drawings shall be produced as MAT
(Master-and-Tabulation) format drawings, sheet #1 shall
contain the graphic portion of the type SAMA drawing.
Subsequent data sheets (Sheet #2, #3, etc.) shall be
tabular listings of the information required for any individual
SAMA drawing, cross referenced to the identifying symbols
appearing on the graphics sheet (Sheet #1).

2.4.3.2 Unique SAMA drawings or SAMA drawings that are too

complex for the MAT format shall be shown as single
drawings, one per sheet.

2.4.3.3 SAMA drawings shall not duplicate information found on

Engineering Flow Diagrams (EFD's) / Piping and
Instrument Diagrams (P&ID's) - "Balloons" and equipment
symbols shall be used only for functional clarity and are not
to be considered reproductions of the more precise data on
EFD's/P&ID's.

2.4.3.4 Identification of instrument wiring on SAMA drawings shall

be limited to the definition of input/output identification at
the DCS, such as: Cabinet, rack, slot and termination. Full
data concerning field wiring to/from the DCS is shown on
other documents.
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2.5 Control Room Plan, Section and Detail Drawings

They shall show the physical location of all equipment in the control room and,
if necessary, in the auxiliary equipment and computer rooms as well. The term
"equipment in this case refers to panels, racks, consoles, controllers, cable
trays and power panels.

Control room drawings for this purpose will include:

a. A plan view (floor plan) of the rooms walls, doorways, windows, and non
removable equipment and furniture;
b. A sectional view showing access to the control room for equipment
installation;
c. All cable trays; and
d. Special section views or details required for correct equipment installation.

2.6 Control Room One-line Diagrams

These one-line diagrams shall show the interconnection cables between major
devices within the control room and those between auxiliary equipment and
field devices. The control room one-line drawings are primarily used to show all
cable interconnections and their relationship to the equipment, as well as to
identify all of the equipment located in the control room and auxiliary equipment
rooms.

This type drawing will include:

a. All major devices in the control room, auxiliary equipment rooms, and
computer rooms;
b. Schematics of all interconnecting cables;
c. Schematics of all control room cable trays;
d. Tables of all wires and cables; and
e. Wire and cable symbols, including wire size, type, number of conductors,
and length of runs.

2.7 Field Electronic Location and Conduit/Tray Plans

These drawings provide an overall view of the location of field devices and
details about their installation.

The plan drawings shall include:

a. A scale layout of the area, including columns, building outlines, dimensions,

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floor elevations, and all other information pertinent to positioning the

devices in their correct locations;
b. Instrument symbols, including identification flags and mounting elevations;
c. Control panel field locations;
d. Routing and elevations of cable trays;
e. References to installation details;
f. Area safety classifications;
g. Table of mounting brackets; and
h. If the project complexity warrants it, a key to enable Owner to track the
important details.

2.8 Electronic One-line Diagrams

Filed electronic one-line diagrams are schematic representations of the

instrument and control conduit and wire from the cable tray through
intermediate junction boxes to the field device. An electronic one-line drawing
shall include:

a. Junction boxes;
b. Field devices;
c. Wire and conduit symbols, including wire size, type, number of conductors,
and length of runs;
d. Table of wires and cables, and
e. References to drawings and installation details.

2.9 Pneumatic Location and Tubing Plan

Field pneumatic location and tubing plans are similar in purpose and content to
those of electronic diagrams preceding. All references to air manifolds, tubing,
and pneumatic devices shall be shown on an Instrument Location and Air Plan
Diagram.

2.10 Instrument Air One-line Diagram

The field air supply and pneumatic one-line drawing shall show in schematic
form the field air supply tubing and the pneumatic signal tubing. A pneumatic
one-line drawing shall show:

a. Instrument air headers or manifolds;

b. Devices using instrument air;
c. Instruments with pneumatic inputs or outputs;
d. Length of tubing runs; and
e. References to installation details.
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2.11 Hardware Installation Details

These detail drawings shall provide the information for exact mounting,
orientation, and connection of each device in the project. The actual details will
vary depending upon the hardware the project requires. Installation details
should contain all pertinent notes, diagrams of the installation, and lists of
materials and labor required.

Installation details should be organized by their functions and as logical working

units. They shall be organized in three groups:

2.11.1 Primary Drawings, showing the typical sketches the process primary
piping between instruments and process take off points containing the
materials list to be used.

2.11.2 Electric Secondary Drawings, showing typical electrical connection

sketches for field mounted instruments containing bill of materials to be
used.

2.11.3 Pneumatic Secondary Drawings, showing typical pneumatic (supply

and signal air) connection sketches for field mounted pneumatic
related instruments containing bill of materials to be used.

2.12 Power Panel Schedules

Power Panel Schedules schematically show the power sources for all of the
different instrument systems. The information on this shall include:

a. Panel voltage and amperage rating, with frequency, phase and number of
supply wires;

b. Location of breakers feeding the panel;

c. Branch circuit breaker size and number of poles; and

d. Branch circuit loadings with descriptions.

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2.13 Terminal Arrangements

Terminal arrangements will show the layout of any wiring terminal strip and the
interconnecting wiring. They shall be applicable for computer rooms, control
rooms, auxiliary equipment rooms, field terminal strips, control panels, and any
place elsewhere that multiple wires are admitted to an area and must be
interconnected to other multiple services. A typical terminal arrangement shall
include:

a. Type of terminal;

b. Number of terminals;

c. All interconnecting wiring

d. Wire numbers; and

e. Spare wires.

2.14 Junction Box Interconnection Diagram

This diagram is a specific form of a terminal arrangement. It will show the layout
of the terminal blocks and any interconnecting wiring or tubing. A junction box
interconnecting diagram will contain:

a. Type of terminal;
b. Location of terminals;
c. Number of terminals;
d. Wire or tubing numbers; and
e. All interconnecting wiring or tubing.

2.15 Instrument Data Sheet

It shall contain all the parameters involved in the instrumentation scope. It shall
include:

a. Identification data (tag, service)

b. Process data (fluid state, corrosive components or solids if available,
temperature, viscosity, min/normal/max. pressures, the set values of
switches, direct/reverse loop).
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c. Instrument sensitive element type (i.e. buordon, bellow,...)

d. Loop components identification (i.e. transmitter, direct pressure switch,
indicator, recorder, controller, switch unit, electric/pneumatic transducer
and other components if available).
e. Installation information for each loop component (field, board, DCS, etc.)
f. Calibrated range/span values.
g. Related individual specification/material requisition numbers.
h. Remarks, if any.

2.16 Bulk Materials List

It will be evaluated in three sections:

a. Primary Material List

It will specify the materials to be used for instrument process
connections, such as: tubes/pipes, fittings, valves, manifolds,
compression fittings, supports,

b. Pneumatic Secondary Material List

It will specify the materials to be used for pneumatic connections, such
as: copper tubings, compressing fittings, galvanized carbon steel pipes,
threaded fittings.

c. Electrical Secondary Material List

It will specify the electrical bulk materials to be supplied, such as cable
glands, cable trays, joints, fixing materials, bolts/nuts, conduits,
instrument cables and junction boxes.

13.0 SPARE PARTS

13.1 Vendor/Contractor shall submit a complete parts data package and a

recommended supplementary spare parts list with prices , fixed for 2 years, and
associated drawings and instructions. These instructions apply to all equipment
(all material classification codes) which require spare parts. Spare parts
information shall be obtanied as soon as possible to permit early order
placements.

13.2 Vendor/Contractor shall acquire and provide all information and complete parts
data packages for subvendors/manufacturer/suppliers, that are needed for the
procurement of operating spare parts. It is the Vendor/Contractor responsibility
to expedite the subvendor/manufacturer/supplier to provide the follow-up for
any missing or incomplete data.
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14.0 INSTRUMENT LIST DATA BASE

A data base programming shall be provided for each unit instrument tag (indication,
alarm, shutdown, transmitter, control valve, switch, converters, contact inputs/outputs,
etc.) containing below information as a minimum.

a. Device tag/model
b. Service
c. P&ID no
d. Line spec.
e. Range (rated/calibrated)
f. Set point (in terms of process variable)
g. Calibrated electronic switch set value
h. Junction box no.
i. Terminal wire in J.B.
j. Rack-in name and terminals
k. Rack-out name and terminals

It shall be supported by Microsoft Excel

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(XXII) MOTOR OPERATED VALVES AND SHUT-OFF VALVES

A- MOTOR OPERATED VALVES

1. REFERENCES (Latest Edition)

1.1 Licensor SPC.’s

1.2 ANSI B 16-104 "Control Valve Seat Leakage"
1.3 IEC Standards
R2 1.4 API 607
1.5 API 598

2. CONSTRUCTIONAL SPECIFICATION

2.1 General

Motorised valves shall be supplied as a single assembly, valve body and

actuator with torque, limit and other required switches already workshop
calibrated and ready for on-line assembly and electrical connection.

2.2 Valve

2.2.1 Body valve design shall be in accordance with characteristics defined in

"Valve Standard and Specification" indicated in individual specification.

2.2.2 The valve, stem and yoke shall be able to withstand the actuator at
maximum delivery torque.

2.2.3 A corrosion resistant name plate shall be fitted to each valve including
requested identifications as per relevant valve specification.

R2 2.2.4 The wafer or lug type butterfly valves shall not be used in hydrocarbon
service however they should be used in systems which non-flammable
products unless specified by licensors.

R2 2.2.5 All CS Valve shall be rating min CLASS 300 up and including 6”.

2.3 Actuator

2.3.1 General

2.3.1.1 The actuator shall be suitable for use on a nominal 690 V 3

phase 50 Hz power supply and are to incorporate motor,
integral reversing starter, local control facilities and terminals for
remote control and indication connections. Refer to TGPS-P1
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The nominal 380 V 3 phase 50 Hz power supply only is

R2 available in Tankage Area B, so actuator shall be suitable for
use this voltage rating

2.3.1.2 The actuator shall be suitable for outdoor installation and

capable of operating in variable atmospheres, wind, sand,
salinity and refinery severe ambient conditions in general.

2.3.1.3 The valve supplier will be responsible for the correct operation
of the actuator and its sizing. The actuator shall develop a
torque which is sufficient to open and close the valve within the
limits set by the design of the mechanical parts of the valve
itself.

2.3.1.4 The actuator shall be capable of operating in any position.

2.3.1.5 The actuator shall include a device to ensure that the motor
runs with the correct rotation for the required direction of valve
travel with either phase sequence of the 3-phase power supply
connected to the actuator.

2.3.1.6 It shall be possible to carry out the setting of the torque and
turns and configuration of the indication contacts without the
necessity to remove any electrical compartment covers. .(Non-
intrusive)

2.3.1.7 Under such conditiones control unit will be remote mounted

where excessive vibration or high temperature damages
electronic unit and hardly reachable places.

R2 2.3.1.8 Electrical protection shall be EExd IIC T3 minimum unless

otherwise stated in hazardous areas classification

2.3.2 Actuator Sizing

2.3.2.1 The actuator shall be sized to guarantee valve closure at the

specified differential pressure. The safety margin of motor
power available for seating and unseating the valve shall be
sufficient to ensure torque switch trip at maximum valve torque
with the supply voltage 10% below nominal.

2.3.2.2 The operating speed shall be such as to give valve closing and
operating at approximately 10-12 inches per minute unless
otherwise stated in the individual specification. "Water hammer"
effect shall be avoided.
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2.3.2.3 Sizing calculation sheets for each actuator shall be given to

TÜPRAŞ.

2.3.2.4 The maximum actuator torque shall not overstress any

component of the actuator or valve.

2.3.3 Motor

2.3.3.1 The electric motor shall be Class F insulated, with a time rating
of at least 15 minutes at 104°C (40°C) or twice the valve
stroking time, whichever is the longer, at an average load of at
least 33% of maximum valve torque.

2.3.3.2 Electrical and mechanical disconnection of the motor shall be

possible without draining the lubricant from the actuator
gearcase.

2.3.4 Motor Protection

Protection shall be provided for the motor as follows:

2.3.4.1 The motor shall be de-energised in the event of a stall when

attempting to unseat a jammed valve.

2.3.4.2 Motor temperature shall be sensed by a thermostat inserted

into stator winding to protect against overheating.

2.3.4.3 Single phasing protection.

2.3.5 Gearing

2.3.5.1 The actuator gearing shall be totally enclosed in an oil-filled

gear case suitable for operation at any angle. All main drive
gearing must be of metal construction.

2.3.5.2 Where the actuator operates gate valves or large diameter ball
or plug valves, the drive shall incorporate a lost-motion
hammer-blow feature.

2.3.5.3 For rising spindle valves the output shaft shall be hollow to
accept a rising stem, and incorporate thrust bearings of the ball
or roller type at the base of the actuator and the design should
be such as to permit the gear case to be opened for inspection
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or disassembled without releasing the stem thrust or taking the

valve out of service.

2.3.6 Hand operation

2.3.6.1 A hand wheel shall be provided for emergency operation,

engaged when the motor is declutched by a lever or similar
means, the drive being restored to power automatically by
starting the motor.

2.3.6.2 A hand/auto selection lever should be pad lockable in both

hand and auto position. It should be possible to select hand
operation while the actuator is running or start the actuator
motor while the hand/auto selection lever is locked in hand
without damage to the drive train.

2.3.6.3 The handwheel drive must be mechanically independent of the

motor drive, and gearing should be such as to permit
emergency manual operation in a reasonable time. Clockwise
operation of the handwheel shall give closing movement of the
valve unless otherwise stated in the individual (job)
specification.

2.3.7 Drive Bushing

The actuator shall be furnished with a drive bushing easily detachable

for machining to suit the valve stem or gearbox input shaft. Normally the
drive bush shall be positioned in a detachable base of the actuator.
Thrust bearings, when housed in a separate thrust base, should be of
the sealed for life time.

2.3.8 Torque and Turns Limitation

2.3.8.1 Torque and turns limitation to be adjustable as follows:

Position setting range : 0.5 to 100,000 turns, with resolution to

15 deg. of the actuator output.

Torque setting : 40% to 100% rated torque

2.3.8.2 "Latching" to be provided for the torque sensing system to

inhibit torque off during unseating or during starting in mid travel
against high inertia loads.
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2.3.8.3 The electrical circuit diagram of the actuator should not vary
with valve type, remaining identical regardless of whether the
valve is to open or close on torque or position limit.

2.3.9 Local Position Indication

2.3.9.1 The actuator shall include a digital position indicator with a

display from fully open to fully closed in 1% increments. Red,
green and yellow lights corresponding to Open, Closed and
Intermediate positions shall be included on the actuator. The
digital display shall be maintained even when the power to the
actuator is isolated.

2.3.9.2 Provision shall be made in the design for the additions of a

contactless transmitter to give a 4-20 mA analog signal
corresponding to valve travel for remote indication when
required.

2.3.9.3 Provision shall be made in the design for the addition of a

contactless transmitter to give a 4-20 mA analog signal
corresponding to actuator output torque for remote indication
when required.

2.3.10 Remote Valve Position/Actuator Status Indication

2.3.10.1 Four contacts shall be provided which can be selected to

indicate any position of the valve, with each contact selectable
as normally-open or normally-closed. The contacts shall be
rated at 5A, 250V AC.

2.3.10.2 As an alternative to providing valve position any of the four

above contacts shall be selectable to signal one of the
following:

– Valve opening or closing

– Valve moving (continuous or pulsing)
– Motor tripped on torque in mid travel
– Motor stalled
– Actuator being operated by handwheel
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2.3.11 Integral Starter and Transformer

The reversing starter, control transformer and local controls shall be

integral with the valve actuator, suitably housed to prevent breathing
and condensation building. The starter shall be suitable for 60 starts per
hour, and of rating appropriate to motor size. The controls supply
transformer shall be fed from two of the incoming three phases.

It shall have the necessary tappings and be adequately rated to provide

power for the following functions.

– Energization of the contactor coils

– Output where required for remote controls
– Supply for all the internal electrical circuits

The primary and secondary winding shall be protected by easily

replaceable fuses.

2.3.12 Integral Pushbuttons and Selector

2.3.12.1 Integral to the actuator shall be local controls for Open,

Closed and Stop, and a Local/Remote selector switch pad
lockable in any one of the following three positions:

– Local Control only

– Off (No electrical operation)
– Remote control plus local stop only

2.3.12.2 The local controls shall be arranged so that the direction of

the valve travel can be reversed without the necessity of
stopping the actuator.

2.3.13 Control Facilities

The necessary wiring and terminals shall be provided in the actuator for
the following functions:

2.5.13.1 Removable links for substitution by external interlocks to

inhibit valve opening and/or closing.
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2.3.13.2 Connections for external remote control fed from an 24V DC

supply and/or from an external supply to be suitable for any
one or more of the following methods of control:

(A) Open, Close and Stop

(B) Open and Close
(C) Overriding Emergency Shut-down to Close (or Open)
valve, from a "make" contact.
(D) Two-wire control, energise to close (or open), de-
energise to open (or close)

Selection of maintained or push-to-run control for modes (A)

and (B) above shall be provided and it shall be possible to
reverse valve travel without the necessity of stopping the
actuator. The starter contactors shall be protected from
excessive current surges during travel reversal by an automatic
time delay on energization of approximately 300 msec.

2.3.13.3 The internal circuits associated with the remote control and
monitoring functions are to be designed to withstand simulated
lightning impulses of to to 1.1 kV.

2.3.14 Monitoring Facilities

Facilities shall be provided for monitoring actuator operation and

availability as follows:

2.3.14.1 Monitor (availability) relay, having one change over contact,

the relay being energised from the control transformer only
when the Local/Off/Remote selector is in the Remote position
to indicate that the actuator is available for remote operation.

2.3.14.2 Where required, it shall be possible to provide indication of

Thermostat trip and Remote selected as discreet signals.

2.3.14.3 Provision shall be made for the addition of a diagnostic

module which will store and enable download of historical
actuator data to permit analysis of changes in actuator or
valve performance.
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2.3.15 Wiring and Terminals

2.3.15.1 Internal wiring shall be of tropical grade PVC insulated

stranded cable of appropriate size for the control and 3-phase
power. Each wire shall be clearly identified at each end.

2.3.15.2 The terminals shall be embedded in a terminal block of high

tracking resistance compound.

2.3.15.3 The terminal compartment shall be separated from the inner

electrical components of the actuator by means of a watertight
seal.

2.3.15.4 The terminal compartment of the actuator shall be provided

with a minimum of 3 NPT threaded cable entries.

2.3.15.5 All wiring supplied as part of the actuator to be contained

within the main enclosure for physical and environmental
protection. External conduit connections between components
is not acceptable.

2.3.15.6 A durable terminal identification card showing plan of

terminals shall be provided attached to the inside of the
terminal box cover indicating:
– Serial number
– External voltage values
– Wiring diagram number
– Terminal layout

2.3.15.7 The terminal compartment of the actuator shall be Plug-in type.

2.3.16 Enclosure

2.3.16.1 Actuators shall be O-ring sealed, watertight to IP-68 and shall

at the same time have an inner watertight and dustproof O-
ring seal between the terminal compartment and the internal
electrical elements of the actuator, fully protecting the motor
and all other internal electrical elements of the actuator from
ingress of moisture and dust when the terminal cover is
removed on site for cabling.

2.3.16.2 All external fasteners should be of stainless steel.

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2.3.16.3 The enclosure shall have an external and internal terminal for
earthing purposes.

2.3.16.4 Actuators for explosion-proof applications shall in addition be

certified flameproof for Zones 1 and 2 (Divisions 1 and 2)
Class I gases.

3.0 INSPECTION/TESTING

3.1 Actuator

Each actuator must be performance tested, and individual test certificates shall
be supplied.
– Current at maximum torque setting
– Torque at maximum torque setting
– Flash test voltage
– Actuator output speed or operating time
– Checking of the stall torque
– Checking of the thermostat operating temperature
– Checking of the electrical circuit continuity and insulation
– Checking of the electrical and mechanical operation.

3.2 Valve

– Test and checks stated in relevant valve specification.

– Checking of the valve seal when the valve is closed by the actuator.
– Checking of on-load and off-load operation, also the operation of end of
travel limit switches and torque switches.
– Backseat test on cover for gate and globe valves.
– Checking of plug and ball valves to ensure that the axis of the passageway
is perpendicular to the pipework axis in the closed position.

3.3 Certificates

The manufacturer shall provide the following certificates in English Language.

– Internal test certificates as per item 3.1 and 3.2 above.

– Certificates proving the safety execution of electrical equipments issued by
a recognised authority.
– Other test certificates required according to the individual motorised valve
specifications.
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3.4 Identification Plate

Each actuator shall have a stainless steel plate showing the following:

– Motorised valve tag.

– Name of manufacturer, model and serial number.
– Motor specification.
– Actuator specification.
– Degree of electrical protection.
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(XXII) B- SHUT-OFF VALVES

1. REFERENCES (Latest Edition)

1.1 LICENSOR SPECIFICATION

1.2 ANSI B 16-34
1.3 IEC Standards
1.4 API 607
R2
1.5 API 598

2. CONSTRUCTIONAL SPECIFICATION

2.1 General

Shut-off valves shall be supplied as a single assembly, valve body and actuator
with torque, limit and other required switches,selonoid valves and other devices
already workshop calibrated and ready for on-line assembly and pneumatic
connection.

2.2 Valve

2.2.1 Body valve design shall be in accordance with characteristics defined

in "Valve Standard and Specification" indicated in individual
specification.

2.2.2 The valve, stem and yoke shall be able to withstand the actuator at
maximum delivery torque.

2.2.3 A corrosion resistant name plate shall be fitted to each valve including
requested identifications as per relevant valve specification.

2.3 Actuator

2.3.1 General

2.3.1.1 Scotch-Yoke or Rack-and-Pinion mechanisms are

acceptable.

2.3.1.2 The actuator shall be suitable for outdoor installation and

capable of operating in variable atmospheres, wind, sand,
salinity and refinery severe ambient conditions in general
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2.3.1.3 The valve supplier will be responsible for the correct

operation of the actuator and its sizing. The actuator shall
develop a torque which is sufficient to open and close the
valve within the limits set by the design of the mechanical
parts of the valve itself.

2.3.1.4 The torque requirements for the actuator at any point in the
stroke shall be 1.5 times the valve torque required to
operate at max differential pressure for general duty
application and 2 times for protective applications.

2.3.1.5 Actuator assembly and accessories shall be weatherproof to

IP65.

2.3.1.6 All Accessories such as pneumatic volume booster, quick

exhaust valves etc if required to meet the stroking time/
actuator thrust shall be supplied by the vendor in the
mounted condition on the actuator complete with the tubing

2.3.1.7 Air supply for actuator calculation shall be 4 Kg/cm2g,

R2 excepts for Coker Unit (177) actuators which shall be sized
to achieve required shut-off or full opening at 80% of
minimum air supply pressure available (3.2 Kg/cm2g).

2.3.1.8 When is required valve fireproofing protection, it shall be for

R2 30 minutes and 1100ºC according UL 1709 (P) and as
following type is acceptable.
- Fireproofing cover and thermal insulation like Bilcoflex or
equal.
The fire proofing protection shall be designed taking into
account easy maintenance.

3.0 INSPECTION/TESTING

3.1 Actuator
R2
Each actuator must be performance tested, and individual test certificates shall
be supplied.
– Maximum torque
– Actuator output speed or operating time

3.2 Valve

– Test and checks stated in relevant valve specification.

– Checking of the valve seal when the valve is closed by the actuator.
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– Checking of on-load and off-load operation, also the operation of end of

travel limit switches.
– Backseat test on cover for gate and globe valves.
– Checking of plug and ball valves to ensure that the axis of the passageway
is perpendicular to the pipework axis in the closed position.

3.3 Certificates

The manufacturer shall provide the following certificates in English Language.

– Internal test certificates as per item 3.1 and 3.2 above.

– Certificates proving the safety execution of electrical equipments issued by
a recognised authority.
– Other test certificates required according to the individual motorized valve
specifications.
– PMI test and certificates as per requisition.

– Leakeage test and certificates as per API 598.

3.4 Identification Plate

Each actuator shall have a stainless steel plate showing the following:

– Valve tag.
– Name of manufacturer, model and serial number.
– Actuator specification.
– Degree of electrical protection (Solenoids and switches).

(XXlll) STANDARDS AND SPECIFICATIONS

This specification will be generally used and shall govern for all instrumentation
design.

The following standards and drawings will be considered, but will only be used to
amplify the data herein, or to supplement it where not adequately covered, or inferior.

Should any conflicts arise between this specification, TÜPRAŞ standards and
LICENSOR specifications they will be resolved by TÜPRAŞ after obtaining
CONTRACTOR comments.

1. TÜPRAŞ Standard Drawings

1-J-TD 20230 - Furnace Tube Skin Points Using Protection Tube

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1-J-TD 20231 - Fabrication Details of Protection Tube

1-J-TD 20241 - Standard Draft Gauge Connections

1-J-TD 20258 - Standard Termination for Plactic Tubing Cable With

Local Junction Box

1-J-TD 20301 - Standard Well for Pyrometer Type Liquid Level

Indicator

1-J-TD 20309 - Standard Details of Nameplates

2. Licensor Standard Specifications

3. Licensor Standard Drawings

XXIV. INSTRUMENT / ELECTRICAL INTERFACE PHILOSOPHY

SR.
NO. TOPIC
1 INTRODUCTION
2 ABBREVIATIONS
3 POWER INTERFACES
3.1 INSTRUMENT POWER SUPPLIES
3.2 LIGHTING SUPPLY/ANALYSER HOUSE SUPPLY
3.3 PACKAGE UNIT SUPPLY
3.4 ELECTRICAL HEAT TRACING TO INSTRUMENT LINES
5 MANAGEMENT SYSTEMS
6 E&I PLANT DESIGN INTERFACES
7 FIRE, SMOKE AND GAS DETECTION / WARNING SYSTEMS
8 EARTHING
9 AREA CLASSIFICATION

1.0 INTRODUCTION :

This Electrical and Instrument interface specification defines the basic division of
responsibilities between the two disciplines and involves both specialists engineering
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as well as design functions.

In addition this specification indicates how to organize the different interfaces. The
definition of the split of work and division of responsibilities as outlined shall be followed
unless specific circumstances dictate otherwise. These deviations shall be properly
recorded and routed as job instructions within the discipline’s task forces for each
project. It is the responsibility of both the E&I lead engineers that the procedures as
described in this specification are followed.

Interface control documents shall be prepared by the agreed responsible discipline for
each interface activity (power supplies, process I/0’s, etc) at the start of the project.
These interface control documents shall be maintained, updated and communicated by
the agreed responsible discipline in pre-planned intervals during the development of the
project. This shall be approved by OWNER before finalization.

2.0 ABBREVIATIONS:

The following abbreviations are used in this specification:

AC = Alternating Current DC = Direct Current DCS = Distributed Control System

E = Electrical EMC = Electro Magnetic Compatibility ESD = Emergency Shutdown
System or Programmable Logic Controller FO = Fiber Optic HV = High Voltage
I&CS = Instruments & Control Systems IFC = Interface Cabinet ILD = Instrument Loop
Diagram IMCS = Integrated Motor Control System I/O = Input / Output IRC = Interposing
Relay Cabinet LV = Low Voltage MC = Marshalling Cabinet MCC = Motor Control
Centre MOV = Motor Operated Valve PA = Public Address System P&ID = Piping &
Instrumentation Diagram PMS = Power Management System SCADA = Supervisory
Control And Data Acquisition UPS = Uninterruptible Power Supply VSD = Variable
Speed Drive System

3.0 POWER INTERFACES

3.1 INSTRUMENT POWER SUPPLIES

Electrical shall provide the power supply systems dedicated for I&CS, including
emergency or standby equipment such as generators and UPS systems, power
distribution boards and safety switches.

3.2 The various feeders of 220 V AC UPS supply from Electrical to I&CS Central
Cabinet rooms at diff. PDB shall be laid and terminated by Electrical dept.

3.3 Power supply distribution panels shall be the responsibility of Instrument dept.

3.4 In case sizing of power supply cable > 2.5 mm2, engineering, design and
supply by Electrical. The information and requirements for all I&CS users for
which Electrical shall provide the electrical power, shall be communicated by I&CS to
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Electrical by means of the “I&CS power supply interfaces list”.

3.5 Electrical to take care about distribution of various feeders amongst various
PDB panels located at cabinet rooms in I&CS area and panel allocations, circuit
allocations, cable number and cable size (no of cores and cross section area; to
allow for terminal and gland ) based on the requirement on the “E / I&CS power
supply interface list”.

3.6 LIGHTING FOR INSTRUMENTS /PANELS/ANALYSER HOUSES:

3.6.1 220 V A.C. Lighting for Level Gauges and various local panel as well complete
lighting of central cabinet room, central control room and central engineering
room shall be included in the “E / I&CS power supply interfaces list” with a
reference to the level gauge tag number for which the lighting fixture is
required.

3.6.2 For level gauge, supporting bracket (part of level gauge assembly) and fixture
specification is the responsibility of Instrument dept.

3.6.3 Engineering, design and supply by Electrical .

3.6.4 Distribution boards, if applicable, shall be located on the outside of the analyzer
house and shall be suitable for hazardous area classification of the plant.

3.6.5 In case of installation inside the analyzer house, this requirement can be
relaxed to general purpose.

3.6.6 No UPS supply shall be provided to analyzer house, local panel for any of the
instruments by Electrical. These shall be laid from the various UPS PDB panels,
located at central cabinet room by Instrument dept, as per requirement.

3.6.7 For Electric motor operated valves, position switches or position transmitters
shall be the responsibility of Instrument dept including supply of cables, glands,
terminations, etc.

3.6.8 Power supply to these MOV’s is the responsibility of Electrical, while the power
requirement of instruments attached to MOV shall be by I & C from the
DCS/ESD system ( if low voltage power

3.7 Power supply to Package Units

3.7.1 This shall be provided by I &C from the central PDB panel located at cabinet
rooms at only one location. Further sub distribution shall be carried out inside
the package unit by package unit vendor.

3.7.2 220 V A.C. power supply required for non-instrument purpose shall be provided
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by Electrical to all package units, directly from MCC

3.8 Electric Heat Tracing Of Instruments

By electrical group, Electrical heat tracing power supply for critical instruments
according to process conditions (to be discussed during the detailed engineering
stage) shall be feeded by UPS .

4.0 CONTROL AND MONITORING INTERFACES

4.1 Deleted.

4.2 The IFC will also be used for analogue signals (e.g. VSDS), Pump/Motor
bearing & winding temperature RTD sensors, and Current to Current transducer
installation. From this panel, all 4-20 ma or low voltage RTD signals shall be
wired to relevant I&C DCS panels.

4.3 Engineering, procurement and laying of cables and all termination from
MCC/Field Motors to IFC shall be carried out by Electrical for all these signals.

4.4 Configuration, interlock and control shall be designed by I&C based on process
requirement.

4.5 All potential free/dry contacts for pump / motor running indications, etc. from
MCC/SWB or VSD panels from electrical shall be wired to IRC and by
Electrical, including design, procurement and installation/laying of various
cables between MCC/SWB/VSD panels to IRC.

4.6 All Digital output commands from I&C DCS/ESD systems for various purpose
like Motor Trip/Auto-Manual Command( if used), Emergency Stop, etc. shall be
wired from respective DSC/ESD panels to IRC via interposing relays by I & C.

4.7 All Digital output commands from interposing relays meant for Electrical
MCC/SWB/VSD panels, etc. from IRC shall be wired from IRC panel to
MCC/SWB/VSD panel by Electrical. All cables shall be designed, procured and
laid by Electrical.

4.8 All IRC/IFC panels shall be of standard RITTAL make panels with 1200mm (W)
R2
x 800mm (D) x 2100 mm(H) size, with RAL7035 color and shall be located at
switchgear rooms in substations. within the premises of I & C. It is the
responsibility of I & C .

4.9 All cabling between the IRC/IFC and MCC/SWB or other electrical control
panels (i.e. VSDS panels), field Motors, etc. is the responsibility of Electrical.
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4.10 The measurement of power factor, frequency, power consumption and other
typical electrical signals to be processed / handled in instrumentation systems
is the responsibility of the Electrical discipline. I&CS will be responsible for
incorporation of these measurements into their system(s) from the interface
point (IFC) to respective ESD/DCS panel. Measurements shall preferably be
presented by Electrical as isolated analogue signals of 4-20 mA DC.

4.11 The monitoring and alarms annunciating associated with motors, switchgear,
transformers and any other electrical equipment, which are to be, annunciated
on instrument panels and/or in I&CS are the responsibility of Electrical. I&CS
will be responsible for incorporation of these alarms into their system(s) from
the interface point (IRC).

4.12 I&CS will be responsible for the detailed control, alarm, safeguarding
requirements as shown on the P&ID's and passing all signals required for
electrical control to the interface point as detailed for each Project.

4.13 I&CS shall include the tag number on the interface document

4.14 Instrument Loop Diagram shall show the complete loop inclusive a reference
drawing number with respect to the electrical wiring up to the point of interface,
i.e. IRC/IFC.

5.0 MANAGEMENT SYSTEMS

Motor management and power management system ("intelligent" or “smart” switch

gear) are the responsibility of Electrical. Since these systems will be integrated with
Distributed and/or Other control systems close coordination and exchange of data and
protocol agreement shall be established between the E&I. The SCADA being
designed, procured and implemented by Electrical shall have the following minimum
hardware / functionality for its interconnectivity with central DCS.

An isolated 2 Wire RS485 Serial Communication (Redundant) Link as an Interface
( Modem , over RS232C or current loop interfaces are not acceptable)

A proper communication media like twisted pair, screened/shielded cable laid
between Electrical and Instrument cabinet room.

MODBUS (Redundant) RTU protocol with complete memory map, configuration
details, etc.

The scan time shall be better than 3 to 5 seconds for transferring all parameters of
SCADA to DCS.
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6.0 E&I PLANT DESIGN INTERFACES

6.1 CABLE TRAY/LADDER / TRENCH ROUTING

6.1.1 Each discipline is responsible to provide the required input of the cable
tray/ladder routing. The coordination with Piping, Civil, Structural and
Pipe-support with respect to main tray/ladder routing (e.g. space
management, road crossings etc.) will be done by Electrical for both
disciplines.

6.1.2 An overall tray/ladder drawing (study) shall be prepared by Electrical,

with input from I&CS and will clearly indicating the following:

- Tray/ladder routes, including termination points of runs, space and

segregation requirements including spare capacity
- Elevations (for trays), Road crossings where applicable
- Segregation required between I&CS and Electrical cable
tray/ladder.

In general

All high voltage cables carrying Electrical control voltage
signal/current shall be routed in separate ducts/tray

All low voltage instrument signals like Run indication ( carrying 24 or
5 V DC interrogation voltage from DCS), low voltage electrical
signals like VSD 4-20 ma input/outputs, etc. shall be laid in a
separate tray/duct

All high voltage cables carrying Electrical control voltage
signal/current shall be routed in separate ducts/tray

All low voltage instrument signals like Run indication ( carrying 24 or
5 V DC interrogation voltage from DCS), low voltage electrical
signals like VSD 4-20 ma input/outputs, etc. shall be laid in a
separate tray/duct

All low voltage instrument signals like Run indication ( carrying 24 or 5

V DC interrogation voltage from DCS), low voltage electrical signals
like VSD 4-20 ma input/outputs, etc. shall be laid in a separate
tray/duct

All communication cables, PA system audio cables, telephone voice

cables, Fiber optic cables shall be routed through separate
duct/trays
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6.1.3 All the trenches/cable trays between instrument cabinet rooms and
electrical substation/MCC room shall be sized in such a way to have
50% spare capacity for future use

7.0 EARTHING

7.1 The main earthing, involving static earthing, protective earthing, lightning
protection and instrument earthing systems are the responsibility of Electrical.

7.2 The provision of earthing facilities on and within instrument equipment,

instruments and any specific shielding requirements are the responsibility of
I&CS. However necessary earth pits shall be provided by Electrical as per the
requirement of I & C. For the purpose I&CS will provide an instrument earthing
philosophy and relevant typical earthing block diagram to Electrical.

8.0 AREA CLASSIFICATION

This is the responsibility of the Electrical discipline in close coordination with Process.
Area classification schedules, layouts and if required sections will be prepared, from
which both E and I&CS disciplines shall obtain the material selection requirements to
ensure suitability in the specific areas.

9.0 I/O INTERFACES CONTROL DOCUMENT

A common database will be filled with information from I&CS, Electrical and Process
Group, based on various process requirement, facilities and interlock/control necessity.
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XXV. GENERAL INSTRUMENT ERECTION SPECIFICATION FOR CONTRACTORS

1.0 INTRODUCATION

This specification and all additional documentation as listed under the appendices
covers the materials and methods to be followed by Contractor when installing and
testing instruments and associated cabling, tubing, tray work etc. in the entire project

2.0 INSTRUMENT INSTALLATION, COMMISSIONING SCHEDULE

Installation and Commissioning schedule shall be followed as agreed upon between

Owner and CONTRACTOR and it shall be strictly followed. Various type of weekly,
monthly progress and schedule review shall be submitted by CONTRACTOR as and
when required by OWNER.

3.0 OBLIGATIONS OF THE CONTRACTOR

3.1 The obligations of Contracator in fulfillment of the requirements of this

specification are briefly stated below .

3.2 Instrument Installation work as per OWNER’s specifications, drawings and good
engineering and construction practice.

3.3 Erection, checking, tests.

3.4 Preparation of testing/loop checking reports/records in specified formats.

3.5 Co-ordination (as and when required with OWNER/other contractors/ agencies
working in the same area)

3.6 Providing guarantees for the work carried out/ materials supplied.

3.7 Submitting the bar chart, progress report on weekly basis for the work done
during the period, Tag wise status for all tags of instruments list of all complete
section, manpower and construction equipments, deployment details and such
other activities as per requirements of OWNER. Submission of monthly material
appropriation statement for cables, tubing, piping materials fittings, indicating
the quantity issued and expended in standard performa.

3.8 providing proper tools, manpower (fully conversant with their job), consumables
required for carrying out and completing the job correctly and within the
scheduled time.
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4.0 STANDARDS

4.1 The instrumentation installation and calibrations works shall be carried out
generally in accordance with various international listed below but not limited to
the following.
R2
i. API-RP-551/552/553/554 Manual on installation of refinery instruments and
control system.
ii. ISA standards and practices for instrumentation.
. All engineering documents enclosed with this enquiry and those issued
subsequent to awarding of contract and during execution of contract.
. Manufacturers’ standards and practices.

4.2 The Contractor shall carry out the work in accordance with the
documents/standards /drawings listed herein, and in accordance with any local
‘Statutory Regulations’, client’s requirements and supplementary
documentation.

4.3 The Contractor shall instruct his staff. Skilled and semi-skilled, in the standards
required by the purchaser and shall ensure that only competent persons are
allowed to handle or work on instruments or instrument systems.

4.4 All tools including welding sets, gas-cutting sets required for carrying out the
work uninterrupted shall be provided by the Contractor. Contractor shall furnish
details of all calibration equipment, their makes, model, calibration certificate
etc. to OWNER before commencement of work. Any instrument without proper
and valid calibration certificate from a recognized certifying agency will not be
allowed to be used.

4.5 Deleted.

4.6 The working hours, holidays, weekly off etc., shall be followed as per OWNER’s
rules/ regulations. However, if required Contractor shall arrange their personnel
to work extra after office hours and / or in shifts and on holidays to meet project
completion schedule with the prior permission of OWNER site In charge.
 Section : TGPS –J1
Date : August, 2010
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İzmit Refinery Page No : 340 / 379
Revision : 2
RESID UPGRADING PROJECT

5.0 WORKMANSHIP AND SAFETY

5.1 The Contractor shall be responsible for protecting installed equipment from
damage .

5.3 Only the best construction and engineering practices are to be used, and all
work must be done to the satisfaction of OWNER engineer who should be
consulted on any point requiring clarification. The Contractor is free to suggest
to OWNER engineer alternative methods for the execution of the work where
this would result in improvement.

5.4 The Contractor shall take adequate precautions during use and storage of gas
cylinders

5.4 Deleted.

5.5 Upon completion of the work, the Contractor shall promptly remove his
equipment and return to the relevant places and shall return any unused
material supplied by the engineer-in-charge. Finally the Contractor must clear
the site of all rubbish and scrap deposited by him to the satisfaction of the
engineer-in-charge.

5.6 The engineer-in-charge will with due reference to the relevant section of the
conditions of the contract lay down the safety regulations for the site and
Contractor shall ensure all his personals understand and comply with this
regulations. For working at height Contractor shall provide safety belts, ladders,
proper approach, etc at its own cost.

5.7 The Contractor shall prepare a comprehensive schedule for carrying out the
installation before commencement of actual work.
 Section : TGPS –J1
Date : August, 2010
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İzmit Refinery Page No : 341 / 379
Revision : 2
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6.0 SCOPE OF WORK AND RESPONSIBILITY

6.1 The instrumentation erection work covers various jobs listed under the various
schedules. However to ensure proper execution and completeness of the
instrumentation work any or all of the following shall also form the part of the
scope and shall be covered in the quoted rates.

6.2 Fabrication of pipe nipples, including threading wherever required.

6.3 Fabrication of seal pot/siphon/drain pot as per standards. Filling of seal pots
with filling liquids as per instructions from engineer-in-charge.

6.4 Back/seal welding of screwed fittings as required.

6.5 Laying of cable underground wherever required including excavation, sand

filling, brick laying and back filling.

6.6 Connection of purging devices for instrument as per drawings.

6.7 Minor civil works like chipping of pavements & grouting on the pavements the
instrument panels/supports/stanchions, & chipping, refilling & finishing of the
pavement for conduits.

6.8 Sealing of cables/tube entries into the control room after laying and testing of all
tubes, cables etc.

6.9 Rotation of control valve bonnet wherever required.

6.10 Reversing the action of control valve either by replacement of springs,

accessories or in positioner wherever required.

6.11 Painting of all structural supports for trays, pipes, junction boxes, instruments,
ducts, etc. as per painting specifications.

6.12 Identification with approved color of paint the instrument/impulse line/manifolds

connected with alarm / trips circuits. Also, punching of tag no on items shall be
carried out as per instructions of engineer-in-charge.
 Section : TGPS –J1
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İzmit Refinery Page No : 342 / 379
Revision : 2
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6.13 Coordination with mechanical and other sub contractors for proper installation
of lines/vessels/ equipments mounted instruments like control valves, orifice
assemblies, mass flow meter, level transmitter, level gauges, level switches,
other type of flow meter, flame arresters, breather valves etc., which involves
removal of instruments, disconnection of tubes / cables, reconnection for
alignment and proper installation etc. These instruments will be required to be
uninstalled and reinstall before final installation for flushing.

6.14 Drilling holes and making cut outs as required on panels, shutdown cabinets,
power supply cabinets, control panel pneumatic enclosures, junction box etc,
for cables/ multi tubes/glands/ grommets.

6.15 Grounding of shield of all shielded cables to respective instrument earth bus
provided in the control room/ local panel/ thermocouple head/ junction boxes.

6.16 Laying and termination at both ends between instrument earth buses provided
in the control room/ local panel to instrument earth pit provided by others.

6.17 Progress Reports: Contractor will provide progress report on weekly basis for
the work done during the period. Tag wise status for all tags of instrument list of
complete PROJECT area shall be prepared. Submission of monthly material
appropriation statement for cables, tubing, piping materials fittings, indicating
the quantity issued and expended in standard Performa.

6.18 Deleted.
6.19 Deleted.
6.20 Deleted.
6.21 Deleted.
6.22 Deleted.
6.23 Deleted.
6.24 Deleted.
6.25 Deleted.

6.26 Installation and terminations of tubing, cables etc. For analyzers (from field to
analyzers house and within analyzer house) and its accessories like sample
cooler etc.

6.27 Deleted.

6.28 Deleted.

6.29 The Contractor shall be responsible for the supply of installation materials as
detailed elsewhere in this document.
 Section : TGPS –J1
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İzmit Refinery Page No : 343 / 379
Revision : 2
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6.30 The installation will be tested in accordance with the instrument installation
testing procedures given elsewhere in this specification. If, however, others
carry out the testing, the Contractor shall ensure that instruments are
adequately protected during flushing and pressure testing.

6.31 The Contractor shall be responsible for the supply and cost of all replacement
material and labor necessary to rectify faults which show up during instrument
installation/ testing / commissioning, provided such faults are due to faulty
workmanship of faulty materials in the Contractor’s scope of supply.

6.32 The Contractor shall be responsible for the expediting and inspection of all
materials in his scope of supply. However, Owner reserves the right to expedite
and inspect such materials. OWNER reserves the right to reject any material
supplied by the Contractor if not found technically acceptable or of specified/
required quality.

6.33 The Contractor is expected to hand over a fully operable system and any
defects of design omission or discrepancies found which would impede this
achievement must be brought to the attention of OWNER representative
without undue delay.

6.34 The main instrument air header will (unless otherwise specified) be installed by
others as a part of piping upto and including the take off point (including the
isolation valve) on air header. Generally the Contractor shall be responsible for
the tubing downstream of a given isolation valve and this valve together with all
upstream pipe work will have been previously installed and tested by others (as
a part of piping work).

6.35 The installation of orifice plate assemblies, safety valves, breather valve, flame
arrestor, rupture disc, control / switching valves, mass flow meter, Rota meters,
sample connection points up to and including the first isolation valve for flow,
pressure, analysis, provision of flanged connection for temperature and any
other in-line equipment will be carried out as a part of piping work by a
contractor or agency responsible for piping.

6.36 All welders deployed on the job by the Contractor shall be approved by
OWNER. Any expenses to be incurred for welders’ qualification as per
requirement of OWNER shall be borne by Contractor.
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 344 / 379
Revision : 2
RESID UPGRADING PROJECT

7.0 Basis / Detailed Scope for VARIOUS ACTIVITIES

7.1 Installation of the field instruments

Installation of the field instruments such as electronic Smart transmitters for

pressure, flow, level, D/P etc., Magnetic Level gauges, pressure gauges,
temperature gauges and temperature elements with flanged/ welded
thermowells shall include, but not limited to the
- transportation of these items from the place of storage to the place of
installation
- unpacking,
- physical verification,
- Installation (in accordance to the applicable Hook Up drgs.).
- All stud bolts, gaskets etc. as required for fixing the thermowells,
- All instruments shall have first isolation valve on the equipment installed
by piping contractor. Installation scope of the all instruments shall be from
the downstream of first isolation valves.
- External chamber type level instruments shall include the assembly of
loose items (such as floats, torque tube assembly etc if these are
dispatched separately to avoid transportation damages).
- The Contractor shall inspect the installation of all online instruments such
as orifice plates, venture, Rota meters, control valves, which will be
installed by mechanical contractor.
- The contractor’s scope shall include plugging of all the unused (spare)
cable entries in the junction boxes.

7.2 Installation of cable trays

The scope shall includes, but not limited to the

- Transportation of the trays from the place of storage to the place of work,
- Lifting to the place of work
- Proper alignment and fixing/ clamping (SS clamp).
- The cable trays shall be supplied in standard straight lengths of approx.
2500 mm.
- Any bends, elbows, risers, tees etc. as required for cable trays as per site
conditions shall be fabricated by the Contractor from the straight run only.
- The scope of work shall include fabrication, welding and installation of
trays including supports from structural and laying of various sizes sub
trays in position.
- Minor civil works like grouting, providing inserts, chipping the concrete,
bricks etc shall be included under the Contractor’s scope of work.
- All supports, clamps and other fixtures shall be painted with min. two
coats of Redoxice and two paint coats of expoxy paints as per OWNER’s
standard color codes.
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 345 / 379
Revision : 2
RESID UPGRADING PROJECT

7.3 Installation of Tubes:

The scope shall includes, but not limited to the

- Transportation of the tubes from the place of storage to the place of work,
- Lifting to the place of work,
- Cutting (using the cutters),
- Bending,
- Fixing/Clamping(SS clamping)
- The scope shall include the installation of tubes using compression
fittings, laying of separate trays for instrument tubes, clamping (SS
clamps), supporting, pressure testing, leak checking and leak arresting.

7.4 Laying of Cables

The scope includes but not limited to the

- Transportation of the cable drums from the place of storage to the place
of work
- Cutting the cable to required length as per cable and drum schedules
- Laying and termination at both the ends.
- The scope shall include the installation, glanding and termination of
cables using cable glands at both the ends for all single and multi pair
cables.
- Grounding of junction boxes & cable -glands
- Supply of bootlace lugs, continuous ferrule sleeves, insulation tapes,
Teflon tapes, etc.
- - Laying of cables on trays, dressing, clamping, supporting, continuity
checking, meager testing and all related activities.
- Contractor will supply all the consumable items & accessories for the
grounding of junction boxes & cable glands and other items shall also be
includes in the scope of supply of Contractor like insulation tape, Teflon
tape, Teflon paste, silicon rubber paste, bootlace ferrules, lugs,
earthing/shielding cable sleeves, of all types/size, etc.

7.5 Package Instruments

The instruments coming in the package items, apart from above all items
mentioned at … to …, additionally the Contractor scope shall include the
dismantling of all the instruments for the calibration & refixing of the instruments
at their respective location with proper electrical connections.

Eğer montajlı geliyorsa

kalibrasyon belgesi yeterli.
Monte edilmeden gelen
paket enstruumanlar kalibre
edilecek.
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 346 / 379
Revision : 2
RESID UPGRADING PROJECT

7.6 Panel/ Local Panel/ Installation

The scope shall include, but not limited to the

- Transportation of the panels/cabinets from the place of storage to the
place of installation.
- The scope shall include the removal of packing, taking the panel to place
of installation
- Install the panel on the base frame with proper alignment & firm supports.
- Contractor shall offer the panel alignment checking to Owner’s engineer.

9.0 INSTALLATION DRAWINGS AND DOCUMENTATION

9.1 The list of drawings and documentation to be provided to Contractor shall include

9.1.1 HOOK UP – DIAGRAMS

Schematic hook-up drawings, indicating the typical arrangement for air supply
and process impulse tubing for each instrument or group of instrument together
with tag numbers and installation materials. Related isometric numbers will be
shown on hook-up diaghrams.

9.1.2 INSTRUMENT PLOT PLANS

This drawing shows approximate location of relevant instruments, junction

boxes, cable tray layout and routing. As this will be only a schematic, the actual
routing of trays and location of instruments and junction boxes shall be decided
by Contractor as per existing site conditions in consultation with OWNER’s
Engineer.

9.1.3 CABLE SCHEDULE

These schedules list all the cables, approximate cable lengths, sizes
connection points and relevant technical information.

9.1.4 BILL OF MATERIALS

This summarizes the quantities of Transmitters, Junction Boxes, tubes, valves,
etc. and other erection hardware required for the installation.

9.1.5 TERMINATION DRAWINGS

This document shall show the details of termination in the instrument, junction
boxes, controls racks etc.

9.1.6 PIPING AND INSTRUMENTATION DIAGRAMS.

9.1.7 CENTRAL CONTROL ROOM LAYOUT DRAWINGS.

 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 347 / 379
Revision : 2
RESID UPGRADING PROJECT

9.1.8 INSTRUMENT JB SCHEDULE. AIR MANIFOLD SCHEDULE, LOOP WIRING

DIAGRAMS ETC.

10.0 SUPPLY OF MATERIALS

The responsibility of Contractor for the supply of all materials will unless otherwise
specified be as follows, but not limited to the

10.1 Materials to be supplied by the Contractor at his own cost, as part of these
specifications.

10.2 The supply of consumables like Teflon tape, insulation tape, welding rods, gas
cutting sets, piping compound, nitrogen in cylinders etc.

10.3 Bolts and nuts for supports, U bolts with nuts, clamps for tubes and pipes,
anchor bolts for panels, expansion bolts of various sizes for fixing to concert
structure.

10.4 All industrial gases like oxygen, acetylene or inert, and all types of electrodes,
brazing rods, flux etc for welding purposes, with necessary facilities for testing
the welded joints.

10.5 Paints in various colors as required

10.6 All structural supports for instruments (including 2” pipe with SCH40 as a min.),
JB’s, Trays etc. Including their supply and fabrication including painting shall be
in scope of Contractor.

10.7 All materials for minor civil work like grouting etc.

10.8 Deleted.

10.9 Accessories like tees, bents, crosses, bolts, supports etc as required for
instrument to JB, JB to main branch cable tray, for sampling tubing from field to
analyzer house and within the analyzer house, small branch cable within
analyzer house as required.

10.10 Spool pieces and blinds for testing wherever required.

10.11 Lubricating oil, silicon oil, grease, soap solution etc..

10.12 Silicon carbide paper, painting brushes, yellow cloth, waste cotton for cleaning,
wire brushes, paint brushes, etc.

10.13 Neoprene rubber sheets

10.14 Nozzle cleaning wires

 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 348 / 379
Revision : 2
RESID UPGRADING PROJECT

10.15 Araldite, M-seal, locktite, quick fix, rubber compound, silicon rubber tube.

10.16 Deleted.

10.17 Any other items not specified, but required for completion of the job.

10.18 Materials approved by OWNER‘s representative shall always be used.

10.19 The Contractor shall procure the various installation materials from reputed
vendors and such materials shall be of good quality. OWNER reserves the right
to inspect and approve such materials.

11.0 INSTRUMENT INSTALLATION

11.1 Each instrument, erection hardware, or accessory to be installed by the

Contractor shall be inspected visually for any damage.

11.2 The Contractor shall then take it from where it is stored, lift it into position and
ensure it is leveled, plumbed and firmly secured.

11.3 The Contractor shall be responsible for transporting equipment to be installed

by him from the store to the place of installation. Once the instrument is issued,
loss or damage shall be to Contractor’s account.

11.4 Throughout the construction period, instrument shall be adequately protected

wherever necessary, by covering with suitable plastic bags. The Contractor
shall supply and fit these bags as required.

11.5 Instruments shall not be bracketed directly off process lines except where
specified by engineer-in-charge.

11.6 Local mounted instruments shall be bracketed, mounted in sub-panels or

placed on a suitable pedestal. They shall, wherever necessary, be secured to
the nearest suitable firm steelwork in a manner prescribed by OWNER.
Wherever possible, instruments shall be located so that they are protected from
damage by passing or falling objects

11.7 Local instruments with the exception of those on lines and vessels shall be
mounted with the centerline at approximately 1.2 meters above the platform or
floor in a position accessible for operation and maintenance.

11.8 Handrails shall not be used for supporting instruments.

 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 349 / 379
Revision : 2
RESID UPGRADING PROJECT

11.9 All electronic instruments or instruments with electrical components shall be

electrically earthed in strict accordance with drawings. Steel panel board shall
not be used for earthling. Çıkartılacak.
11.10 Instrument shall be installed in accordance with the appropriate hook-up
diagrams or as per the manufacturer’s recommendations, wherever hook
diagrams are not available. The Contractor is not permitted to deviate from
these diagrams with prior written approval from engineer-incharge. Instruments,
JBs, analyzer panels shall be installed strictly as per the installation drawings
provided for the projects.

11.11 All cable entries to instruments shall be preferably from bottom. If bottom entry
is not possible due to any reason, the cable entry shall be from side.

11.12 The instrument already mounted on the equipment shall be removed by the
Contractor for the calibration check and re-fix back.

11.13 The case of the Instrument shall be earthed by earthling wire to the nearest
earth bus bar provided by others for the safety reasons.

12.0 Instrument Tubing:

12.1 Instrument tubing to be installed can be classified in the following categories :

A) Air supply tubing B) Transmission/ signal tubing C) Process impulse line
tubing

12.2 Pipes/ Tubes shall be bent using pipe / tube bender; any hot bending will be
totally rejected. These shall be cut using pipe / tube cutting devices. Hot cutting
will not be allowed. Cutting of the tubes/tubing by hacksaw shall not be
acceptable.

12.3 Pipes or tubes installed, but not connected, shall have the ends closed in an
approved fashion to, prevent the entry of foreign material. For a period of up to
one week, adhesive tape may be used, for a longer period caps or plugs shall
be used.

12.4 Where instrument tubing is run parallel to each other, joints should be
systematically staggered and neatly offset. There must be at least two pipes /
tubes between adjacent joints.

12.5 Threaded fittings will have their threads specified in the purchaser’s
documentation. All threaded joints shall have Teflon tap as sealing medium
 Section : TGPS –J1
Date : August, 2010
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İzmit Refinery Page No : 350 / 379
Revision : 2
RESID UPGRADING PROJECT

12.6 Where compression fittings are used, the fittings shall be installed in strict
accordance with the manufacturer’s recommendation. Due care shall be taken
while handling the compression fittings to avoid loss of ferrules.

12.7 Where stainless compression fittings are used, the Contractor must ensure that
stainless steel nuts and olives are fitted unless otherwise specified by engineer.

12.8 Any discrepancies between the materials / fitting specified, and the material /
fittings provided shall be brought to the notice of the engineer-in-charge without
delay.

12.9 The number of joints in the tubing shall be kept to a minimum consistent with
good practice and also to keep the wastage to the minimum.

12.10 Sufficient flexibility shall be provided in meter leads, air supply and tubing lines
to allow for movement (e.g. expansion, of the lines or the equipments to which
connected.)

AIR SUPPLY AND TRANSMISSION TUBING

12.11 Horizontal runs of pipes and tubes shall have pipes / tubes laid vertically one
above the other as far as possible and shall be run with the minimum number of
changes of direction consistent with good practice and neat appearance.
12.12 All pneumatic signal tubing shall be cleaned by blowing through with instrument
air prior to installation.
12.13 Single tubing shall be run in such a manner as to give the maximum protection
against mechanical damage.
12.14 Where permanent enclosure trunking or conduit, etc., are left, space for tubes
to be pulled at some future date, a galvanized draw wire of adequate size shall
be left in the enclosure.

PROCESS TUBING

12.15 Impulse lines shall be kept as short as possible consistent with good practices.
12.16 All impulse tubing shall, in general, be run with a slope of not less than 1 in 12
except where otherwise specified. The slope of the impulse tubing shall be up
from the tapping point for gas service unless special provisions are made for
venting and draining.
12.17 S.S. tubing shall be joined by compression fittings, or by screwed connections
as shown on the instrument hook – up drawing.
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 351 / 379
Revision : 2
RESID UPGRADING PROJECT

PIPING AND TUBING SUPPORTS

12.18 Instrument air and signal tubing shall be adequately supported wherever
possible to prevent any mechanical damage.
12.19 Angle iron or 50 mm perforated trays shall be used for continuously supporting
four or more SS tubes and the tubes shall be secured to the tray at 0.5 meter
intervals by suitable Uclamps.
12.20 The tray must be provided with suitable supports to prevent sagging.

13.0 INSTRUMENT CABLE INSTALLATION

13.1 The Contractor must ensure that whenever an electrical specification is issued
the appropriate sections shall be read in conjunction with these specifications
and any omission or ambiguities should be resolved with the engineer-in-
charge.

13.2 The cable installation drawings and documentations will normally specify or
incorporate regulations for the electrical noise pick up. However following
general rules apply,

13.3 Parallel runs of the instrument cables and power cables should be avoided
where parallel runs must be made cable spacing specified in the documentation
must be maintained.

13.4 Where instrument and power cable cross in close proximity the cross shall be
made at right angle.

13.5 Multi core / multi pair cables shall be cut after the exact site measurements are
taken between ends the cable drum schedule shall be followed before cutting
the length to avoid any wastage. Drum schedule shall be provided by Owner
during execution.

13.6 Joints shall only be made at terminals in instruments or approved equipment.

No intermediate joints shall be made on cable tray or in conduit. Cables must
be run in accordance with the purchaser’s documentation.

13.7 All cables shall be terminated at junction boxes and instruments by proper
glanding, using proper size crimping lugs of approved design and with
appropriate crimping tools.

13.8 Qualified electrician who is well experienced in this type of work shall do the
junction box or instrument wiring connections in an approved manner.
 Section : TGPS –J1
Date : August, 2010
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İzmit Refinery Page No : 352 / 379
Revision : 2
RESID UPGRADING PROJECT

13.9 Where conduit terminates at cabinets, terminal box, it shall be secured with a
lock nut, brushed and ferruled in an approved manner. Sharp edges shall be
removed and conduit not otherwise connected shall be terminated in smooth
brushes.

13.10 Cables shall properly be laid in perforated trays.

13.11 All cable shall be tagged with permanently punched strip of aluminium and
identified as given in cable schedule. The cable tag shall be on instrument side,
junction box side, & control room panel. The aluminium strips shall be securely
fastened to cables using SS wires. Cable identification tags shall be provided
as following :
at an interval of 10 mtrs for cable laid above ground. at an interval of 5 mtrs. For
cable laid under ground.

13.12 Shield, drain wire, terminated in junction boxes or earthling strips shall be
provided with PVC sleeve cover. This shall be supplied by Contractor.

13.13 Yellow color continuous Ferrules sleeve (with black font) of proper size shall be
provided for each terminated wire as per termination drawing. Double cross
ferruling philosophy shall be used at all locations, which indicates
sour/destination side detail at each end.

13.14 Spare wires shall also be ferruled / tagged and neatly dressed.

13.15 Cables shall not be bent to radius less than the manufacturer’s
recommendations (i.e 10 times the cable O.D).

13.16 All copper cables shall be terminated at junction boxes and instruments by
proper glanding with PVC hood covering.

13.17 Clips and saddles securing to steelwork or tray shall be of aluminium. These
clips shall be spaced at 0.5-meter intervals.

13.18 The cable laid on the cable tray shall be properly dressed in such a manner that
the crossing of cables shall be minimized. The cable on the cable tray shall be
clamped with strip at every 0.5 mtrs in vertical tray & 2 mtrs in the horizontal
cable tray.

13.19 Deleted.
 Section : TGPS –J1
Date : August, 2010
Turkish Petroleum Refineries Co.
İzmit Refinery Page No : 353 / 379
Revision : 2
RESID UPGRADING PROJECT

14.0 PAINTING

14.1 All ferrous materials for brackets and supports supplied by the contractor and
other material not already protected in an approved way shall be cleaned and
primed before erection with primer as per painting specification given by
OWNER.

14.2 Painting of instrument supports, cable tray supports, all structural, all structural
supports shall be as under

14.3 The surface to be painted shall be throughly cleaned with wire brush/ sand
paper to remove all scales.

14.4 After cleaning, one coat of red oxide zinc chromate primer shall be given and
allowed to dry.

14.5 One coat of final red oxide shall be applied prior to first coat of paint.

14.6 Final coat of color shall be given before handing over the plant / commissioning.

14.8 The primer & final paint shall be of first class quality. The paints shall be confirm
to the specifications given above & first class quality in their products range of
any of the following manufactures

15.0 IDENTIFICATION OF LINES AND INSTRUMENTS

15.1 All site mounted instruments, cables, junction boxes, air header isolation
valves, tubing’s and wiring termination, shall be labeled or tagged in a manner
approved by Owner.

15.2 All cable termination shall be identified by ferrules. The ferrules shall be
continuous sleeve type, white or yellow PVC with black lettering. Contractor
shall supply ferrules of different sizes based on the cable sizes.

16.0 TESTING

All the necessary test equipments for performing the following tests shall be provided
by the instrument installation contractor. The instrument installation contractor shall
furnish a list of test and calibration equipments with make / model no that will be
provided by him. other types of test equipment shall be provided by contractor, if
required in order to carry out work as per specifications. Owner shall check the
calibration of the test equipments of contractor
 Section : TGPS –J1
Date : August, 2010
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İzmit Refinery Page No : 354 / 379
Revision : 2
RESID UPGRADING PROJECT

16.1 All pneumatic signal lines shall be disconnected and blown through with
instrument air for 15 minutes to remove traces of oil, dust and moisture. Air
manifolds shall also be blown with instrument air after installation.

16.2 All instrument air mains shall be isolated from the instrument and pressurized
pneumatically, 1.5 times maximum working pressure and isolated from the
source of pressure. The pressure shall not fall by more than 0.1kg/cm2 in ten
minutes. Also leak test by soap solution shall be performed in presence of
OWNER on each joint, which are to be leak tested.

16.3 All impulse lines shall be isolated from the instrument and hydraulically tested
to 1.5 times the working pressure and isolated from the source of pressure. The
pressure shall not fall by more than 0.1 kg/ cm2 in ten minutes.

16.4 All thermocouple, electric, power, and electronics instrument wiring shall be
tested for resistance between conductor and earth and for insulation between
conductors with a potential of 500V /1.1KV DC. This test shall be carried out
with all conductors disconnected except from the test instruments. The
resistance shall not be less than 10 M ohm.

16.5 Transmitter connection to the correct receivers and polarity shall be checked.

16.6 Correct connection of pneumatic and electric switches shall be checked.

16.7 The written results of the test in duplicate for retention by owner/ Engineer in
charge shall be approved by the engineer in charge.

16.8 The instrument installations contractors are responsible for supplying the
necessary test equipment and reasonable evidence of the satisfactory condition
of this shall be provided, if required.

16.9 All errors all faulty workmanship discovered during this testing or during
subsequent testing and commissioning shall be corrected by the instrument
installation contractor at his cost.

16.10 All test results shall be recorded in the approved formats.

16.11 All cable connections at field instruments and control rack terminals shall be
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checked for:
• Correct polarity
• Correct Numbering
• Proper jointing / termination using copper lugs and PVC sleeves
• Cable continuity check: This check shall be done from junction box to
individual instrument under supervision and as per the instruction of
OWNER.

16.12 All cables shall be checked for proper clamping / support and shall be neatly
dressed.

16.13 Solenoid Valves shall be checked for operation by energizing them and
checking their operation. Suitable power source (as per the voltage value and
type of voltage specified on the nameplate of the solenoid valve.) and suitable
voltmeter shall be arranged by Contractor for this purpose.

16.14 All control valves prior to stroke checking shall be externally cleaned
thoroughly.

16.15 The stroke of the valve shall be checked for opening & closing with 25% steps

16.16 Any adjustments required for obtaining full stroke & reducing hysteresis shall be
carried out.

16.17 Each on / off valve shall be checked by closing/ opening the valve a few times
(through respective solenoid valves) and noting the time of travel.

16.18 The limit switch (if any) shall be adjusted if necessary.

16.19 Temperature Elements shall be checked for continuity and resistance value (at
0%, 25%, 50%, 75%, 100% of the range and vice versa) using a suitable
temperature bath. Temperature transmitters (if any) shall be checked for
operation.

16.20 The level switches (external cage type) shall be set by filling the cage with
water to the desired alarm / trip level, while setting the switch, it shall be
ensured that the micro switches do not reset for full rate travel of the float.

16.21 The Contractor shall be responsible to keep proper record of all the tests
performed and these shall be approved by Owner. These records shall be
finally submitted to Owner.
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17.0 LOOP CHECKING

17.1 Loop test shall be performed after calibration of all instruments and leak test of
signal lines. Loop test are conducted to check the functional performance of all
element comprising the loop, thereby ensuring proper conditions and
operations. Instrument installation contractor should bring all the field cable and
terminate in the termination cabinet in the rack room. The loop testing shall be
done by Contractor with complete co-ordination with DCS/SIS supplier and
OWNER in presence of OWNER Engineers / Technicians.

17.2 Loop testing for all control loop shall be generally by simulation of process
condition and shall fix points namely 0%, 25%, 50%, 75%, 100%,75%,50%,
25%, 0% of full scale inputs. Detailed procedure shall be submitted to Owner in
charge for approval before proceeding with the loop testing.

17.3 In case of shutdown system field / receiver pressure transmitters are simulated
for abnormality by disconnecting the wires at terminal and function of all
associated system are checked.

17.4 After the loop testing is completed, the contractor shall connect back any
terminations and connections removed for loop test./ marking shall be done on
“loop checked” instruments.

17.5 A loop shall be considered as handed over only after all the tests are over in
that particular loop are completed and certified by Engineer in charge, in
addition to loop sheets being duly filled in all respects and approved and
accepted by Engineer in charge.

17.6 Final certified loop sheet should be submitted in two copies to OWNER.
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XXVI. INSTRUMENT DELIVERABLES

SR
TOPIC
NO.
1 SCOPE
CLARIFICATIONS OF THE
2
INSTRUMENT DELIVERABLES
INSTRUMENTATION INTERFACES
3
WITH OTHER DESCIPLINES
INSTRUMENTS DELIVERABLES
4
OVERVIEW LIST

Abbreviations used in the document

BDP = Basic Design Package

BDEP = Basic Design and Engineering Package
DCS = Distributed Control System
EBDEP = Extended Basic Design and Engineering Package
EPC = Engineering , Procurement And Construction
FAR = Instrumentation Field Auxiliary Room
FAT = Factory Acceptance Test
FGS = Fire And Gas System
I /O = Input Output
ITB = Invitation To Bid
MDF = Main Distribution Frame
MOV = Motor Operated Valve
MTO = Material Take-Off
PCD = Process Control Diagram
P & I D. = Piping And Instrument Diagram
RATTS = Range Alarm Timer And Trip Setting
SAT = Site Acceptance Test
SIL = Safety Instrument Level
SIS = Safety Instrumented System
VESDA = Very Early Smoke Detection Apparatus
PNS = Plant Naming /Numbering Systems
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1.0 SCOPE

This specification contains in the minimum requirements, with respect to control, of

the instrument engineering and design deliverables. This specification. Contains the
defined scope of instrument deliverables for engineering and design to be generated
for this project.

2.0 CLARIFICATION OF THE INSTRUMENT DELIVERABLES

2.1 INSTRUMENT PROJECT EXECUTION PLAN
The instrument project execution plan describes for instrumentation the
objectives, goals, responsibility split, scope of work, engineering and design
basis, risk and opportunities, execution strategy, design control and resources
and tools.
At the start of the Detailed Design Phase the instrumentation lead engineer
will prepare a discipline execution plan.

2.2. ENGINEERING SPECIFICATIONS

Engineering specifications determine the basic engineering and design

procedures. These cover the criteria for the execution of the detailed
engineering and design. Specifications applicable for the project . the
instrumentation specification to be provided by the CONTRACTOR is as
minimum but not limited to :

- General specification for instrumentation

- General instrument specification for package units
- Plant automation systems specification
- Fire Protection Philosophy
- Analyzer and Analyzer systems specification
- Instrument design specification
- Instrument deliverables

2.3 The CONTRACTOR shall provide at the start of the project the
design/drafting specification applicable for the project . The OWNER or his
representative will review these specifications. The specifications are as a
minimum but not limited to :
- Instrument symbology and identification specification as per ISA
- Instrument indices and nomenclature specification as per ISA
- Instrument Tag naming philosophy
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- In tools application specification and formats

- Instrument installation requirements spoliations in line with guide line
provided by OWNER.
- Instrumentation-electrical design interface specification as per guide
lines provided by OWNER
- Instrumentation-piping design interface specification.
- Instrument cable specification with minimum guide lines provided by
OWNER.
- Instrument drafting specification
- 3-D. standard set-up
- CAD standard set-up

2.4 INSTRUMENT CALCULATIONS

CONTRACTOR shall provide the following calculations as a minimum using

process data for instruments, calculations provide the information for sizing,
selection or verification of instruments or materials.

Following calculations shall be documented :

- Control valve calculation for sizing noise.
- Safety/relief device calculation for sizing.
- d/p Type Flow Measurement Calculation For Sizing/Selection
Orifice/Range
- d/p Type Level Measurement Calculation For Selection Range
- Analyzer sample loop calculation for determination of lead-time between
sample take-off and analysis result.
- Ex i loop calculation for determination of the capacitance and
inductance of the loop Voltage drop calculation for determination of the
allowed voltage drop/conductor size
- Instrument air consumption of all instrumentation.

NOTES :
1. Preliminary calculations are by the Process department. Final calculations
for control valves and safety/relief device may be replaced by seller
calculations.
2. Instrumentation shall provided Process with the selected CV value of
control valves for final relief valve load calculations.
3. All sizing programs shall be provided to owner.
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2.5 INSTRUMENT INDEX

The instrument index list instruments and/or functions that are required for
control and safeguarding of a process plant. As such, it functions as
instrumentation ‘’ scope of plant ‘’ and is the basic document next to the
P&ID’s from which the instrumentation work is executed. No instrument tag
numbers shall exist that are not listed in the instrument index. It includes as a
minimum the following, but not limited to the following.
- Tag
- Description
- Service
- Line no
- P& I no
- Loop number
- Location
- Type of instrument
- Make and model of instrument
- Range of instrument
- JB schedule
- Cable schedule
- Alarm/trip setting
- Control valve acting
- Interlock number
- Loop sheet no
- Vendor Name
- POR No
etc…

2.6 INSTRUMENT CONFIGURATION INDEX

The configuration index contains the basic information required for

configuration of the monitoring, control and input/output functions of a control
system . This index is used the manage and transfer the configuration
information to the party responsible for the system configuration .

2.7 RANGE, ALARM, TIMER AND TRIP SETTING (RATTS) LIST

The range, alarm, timer and trip setting (RATTS) list is a listing of all loops
that interface with a control and indication system , an interlock system and/or
with an alarm system . This listing shall contain all setting that are required
for safe and reliable operation of the plant. Data is provided by the process
department or derived from instrument calculations based on data provided
by the process department(see instrument calculations.)
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Note : timer settings are either provided in the narratives by the process
department or default.

2.8 REQUISITION
The requisition covers the requirements for purchasing of equipment,
materials and related services. The requisition shall consist of the following
attachments, But not limited to the

- Purchase specification, containing a technical description and

specification including .
- Instrument data sheets
- Requirements for documents.
- Requirement for inspection.
- Related technical documents.
- Purchase specifications.
- Technical descriptions.
- Instrument data sheets.
- Inquiry requisitions.
- Technical bid evaluations and recommendation.
- Purchase requisitions.
- Seller documents review.

Requisition subjects are as minimum but not limited to :

- Plant automation system inclusive DCS, SIS, FGS, etc.
- Fire detectors
- Gas detectors
- Plant Telecommunication system
- Beacons and sirens
- Very Early Smoke Detection Apparatus.( VESDA )
- Analyzer Houses, Analyzer systems and Local Analyzers
- Field instruments( Flow/Level/Pressure/Temperature)
- Tank gauging system
- Custody transfer flow metering
- Machine monitoring system
- Telemetry system
- Control valves
- Self-regulating valves
- On/off valves
- Instrument cables ( Single/ Multi core )
- Junction Boxes
- Push Buttons (Field)
- MOV’s
- MTO’s
- Etc.

Notes :
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1. The data sheets will be prepared in Database. The format of the

instrument data sheets shall be approved by the Client or his
representative. The completed instrument data sheets will be reviewed by
client or his representative prior to inquiry issue and prior to purchase order
placement and/or call-off.

2.9 PROCESS ANALYZER SPECIFICATION

The specification for process analyzers detail scope split, technical

requirements and authority coordination. Specified are as minimum, if and
when applicable :

- Applicable standards, codes and regulations

- Environmental conditions
- Enclosure (house /shelter/shed/cabinet)
- Air handling
- Utilities (electrical power, instrument air, plant air, nitrogen, carrier gas,
potable water, effluent handling, lighting, earthing , etc. )
- Sampling( probe, sampling handling, tube routing, supporting, etcetra )
- Interface with civil, piping, electrical
- Fire and gas detection
- Installation details.
- Analyzer maintenance systems communication .
- Certification
- Inspection( FAT, SAT, test reports)
- Documentation

Instrumentation shall design the process analyzer systems. The OWNER or

his representative will review the documents prepared by instrumentation.
The CONTRACTOR shall provide overall coordination with the Analyzer
System Integrator.
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2.10 SYSTEM FUNCTIONAL DESIGN SPECIFICATION

The system functional design specification provides the basic design
specification for the plant automation systems and shall be approved by
OWNER. The specification covers requirements for as minimum but not
limited to :

- System hardware inclusive interfaces with other systems

- Console design
- Displays (manufacturer’s standard, graphics, navigation, etc.)
- Alarm management
- Software implementation conventions ( process control loop strategies,
equipment
- Control strategies, safeguarding , etc.
- It is assumed that the client or his representative develops the
system functional design specification. Instrumentation will review the
specification.

2.11 INSTRUMENT SYSTEM BLOCK DIAGRAM

The Instrument system block diagram provides the schematic

representation of the major hardware architecture of the control, safeguarding
and related systems like fire and gas detection, machine monitoring, etc. The
related systems shall include all other subsystems interfaced to the
instrumentation/automation system e.g. computer/MIS (Management
Information System ) ,etc.

This drawing will show the physical location and their interrelation on the
signal type/carrier level of above mentioned hardware . It is assumed that the
CONTRACTOR shall develop the instrument system block diagram.

2.12 TYPICAL PROCESS CONTROL DIAGRAMS (PCD’S)

The PCD elaborates the functionality as shown on the P&I D’s and gives a
graphical overview of the functions of a loop or a combination of related loops,
their physical location and their interrelation. It is assumed that for consistency
purposes the CONTRACTOR shall develop the loop type templates listing
that are used to populate the instrument data base ıntools.
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2.13 INSTRUMENTATION CAUSE AND EFFECT – AND LOGIC DIAGRAMS

Instrumentation cause and effect diagrams are elaborated cause and

effect diagrams prepared by process. The instrumentation is supplemented
with :
- Study and evaluation of plant RISK as per DIN19250/AK-1 to AK6 or SIL-
14 as per IEC61508
- Classifying interlock and safety shutdown interlock
- Operational functionality ( e.g start-up overrides, maintenance, overrides,
resets, Auto change-over of pumps )
- Sub-system interconnections (e.g. between safety instrumented systems
located in different buildings )
- Logic/interlock description in narrative form with the help of process
group
- Logic/interlock diagram in Function Block Diagram From as per IEC1131
The logic/sequence diagram elaborates the functionality even further than
the instrumentation cause in effect diagrams and/or sequence flow chart.
CONTRACTOR shall prepare generic examples of logic functionality.
Instrumentation shall prepare the instrument cause and effect diagrams. It
is assumed that the CONTRACTOR together with the Plant Automation
System Vendor shall prepare the Logic diagrams and sequential diagrams
and implement these into the selected systems.

2.14 DCS GRAPHIC DISPLAY INFORMATION

DCS Graphic display information shall be provide with highlighted P&I D’s
showing the main process equipment to be implemented in the DCS displays.
Implementation shall be based on the DCS configuration and man
machine interface convention by DCS supplier. It is assumed that the
CONTRACTOR together with the Plant Automation System Vendor shall
developed the graphics based on the graphic design philosophy developed
by the CONTRACTOR.

2.15 INSTRUMENT INSTALLATION SCHEDULE

The instrument installation schedule shall contain all tag numbers of field-
mounted instruments with relevant PI&D. number , location of instrument
,installation drawings and requisition number , which shall be extracted from
the instrument index (index data base ). Instrumentation shall prepare the
instrument installation index.
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2.16 INSTRUMENT FIELD LOCATION LAYOUT

The instrument field location layout drawing shall be based on the plot plan.
The plot plan shall be divided instrumentation logical parts with preferable a
scale of 1:50 and a drawing size of A1. The layouts shall show the location
of instruments, local panels, cabinets , junction boxes and air header systems.

Each instrument will be indicated by means of a dot, instrument tag number

with letter code for type of instrument and its elevation. A legend drawing
shall show all general notes, symbols and reference drawing numbers of
instrument field layouts and with a listing of all relevant installation drawings.
The instruments shall be placed in the 3-D. PDS model. All in-line
instruments will be modelled by piping using dimensional information
supplied by instrumentation .

Similary piping will also model displacer instruments, capacitive probes, tuning
forks, servo level instruments, level gauges, thermowells, analyzer probes and
orifice flanges. For all in-line instrumentation initially when the
seller/manufacturer and model are not yet selected instrumentation will
provide dimensionally data based on generic catalogue data and/or
preliminary sizing calculations. The quality of the dimensional data will be
improved by instrumentation once the seller/ manufacturer and model are
selected. Finally instrumentation will provide dimensional data based on the
approved seller data.

Instrumentation shall provide dimensional data based on approved seller

data for the other on-line instruments; Contractor shall model these
instruments in the 3-D. model. Instrumentation shall model local panels and
junction boxes using an equipment model.

Instrumentation shall prepare the instrument field location layout.

2.17 INSTRUMENT FIELD CABLING LAY OUT

The instrument field cabling layout shall be based on the plot plan. The plot
plan shall be divided in to logical parts, with a preferable scale of 1:100 . The
layout shall show the location of local panels, cabinets, junction boxes, cable
main trenches/trays, cables, etc. Local panels, cabinets and Junction boxes
shall be indicated by means of an identification number. Instrumentation
shall use ıntergraph’s raceway module to support PDS areas in modelling
all space trays >=300 mm . Instrumentation shall prepare the instrument
field cabling layout . Conduit/tray installation details and drawings are by the
instrument installation contractor. Trenches are not foreseen.
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2.18 INSTRUMENT PROCESS PIPING DETAILS

Instrument process piping details shall show a schematic installation of the

piping between the instrument and the related process take-off point and a
listing and specification of the materials required for this installation.
Instrumentation shall prepare the Instrument Process Piping Details Inclusive
MTO.

2.19 INSTRUMENT AIR PIPING DETAILS

Instrument air piping details shall show a schematic installation of all

pneumatic instruments concerning air supply and air signals and a listing and
specification of the materials required for this installation . instrumentation
shall prepare the Instrument Air Piping Detail Inclusive MTO.

2.20 INSTRUMENT STEAM TRACING DETAILS

Instrument steam tracing details shall show a schematic installation of the
steam tracing between the instrument and the related process take-off point
and a listing and specification of the materials required for this installation .
instrumentation shall prepare the Instrument Steam Tracing Details
Inclusive MTO. Instrument electrical tracing is by Electrical.

2.21 INSTRUMENT ELECTRİCAL TRACING DETAILS

2.22 INSTRUMENT INSTALLATION DETAILS

Instrument installation details shall show a typical mechanical supporting
and typical electrical installation of indoor and outdoor instruments, junction
boxes, panels, cabinets, cable tray/ladders , etc. Details shall be provided for
supports on the paved/unpaved ground, concrete floors, wall/concrete
beams, steel structures, etc. Instrumentation shall prepare the instrument
Installation Details Inclusive MTO.

2.23 INSTRUMENT NAMEPLATE SCHEDULE

The instrument nameplate schedule is a listing of identification numbers for
instrument , cabinets, local panels, junction boxes, marshalling racks, detection
equipment, etc . instrumentation shall prepare the Instrument Name Plate
Schedule Inclusive MTO.
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2.24 INSTRUMENT LOCAL PANEL LAYOUT

Instrument local panel layout shall show the arrangement of local panel
mounted equipment such as push buttons, alarms, indicating, lights, gauges,
including approximate sizes. Local panels are designed and supplied with
the equipment package unit. No additional local panels are foreseen. Design
documents of seller shall be reviewed by instrumentation .

2.25 INSTRUMENT ROOMS EQUIPMENT LAYOUT

The control room and instrument field auxiliary building equipment layout
shall show the location and main dimensions of control panels and/or
consoles, telecommunications equipment, and if applicable , computer room
equipment, fire alarm panel, semi graphics, etc. Consoles will show monitors,
keyboards, trend recorders, radio and communication systems, etc. In case
other rooms are shown on the layout the related equipment will be shown too.
The basis is the hardware , as shown on the instrument system block diagram,
and the sizing, based on the hard I/O count. The CONTRACTOR shall
prepare the Instrument Control Building And Instrumentation Field Auxiliary
Building Layouts. Instrumentation provides preliminary dimension information
for any instrumentation in the control building.

2.26 INSTRUMENT ROOM CABLE LAYOUT

The cable layout for control rooms, technical/auxiliary/rack rooms shall show
the route of the cables between cabinets, racks, panels, consoles, etc. Also
the route of the in coming field cables will be shown. The contractor shall
prepare the Instrument Control Building And Instrumentation Field Auxiliary
Building Cable Layout.

2.27 INSTRUMENT ROOMS EARTHING LAYOUT

On the earthing layout the several earthing systems shall be shown. For
safety earth, instrument earth, computer earth, etc. All earthing systems will
be connected to a bus bar; each system will have its own bar. The
connection between the bus bar and the earthing electrode will be the
responsibility of the electrical discipline. The CONTRACTOR shall prepare the
Instrument Control Building And Instrumentation Field Auxiliary Building
Earthing Layout.
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2.28 FIRE AND GAS DETECTION LAYOUT

Fire and gas detection layout is based on the plot plan. The plot plan shall
be divided in logical parts with preferably a scale of 1:50 and a drawing size
of A1. The layout shall show the location of detectors, manual call points
installation, status lamps, alarm siren, junction boxes, panels, etc. Each
instrument will be indicated by means of a symbol. Fire and gas panels,
cabinets and junction boxes will be indicated by means of a rectangle and an
identification number. A layout with general notes, symbols and reference
drawing numbers shall show all general notes and symbols of fire and gas
detection layouts and further a listing of all relevant installation drawings.
Instrumentation will prepare the fire and gas detection layouts.

2.29 FIRE AND GAS DETECTION INSTALLATION DETAILS

Fire and gas detection installation detailed drawings shall show typical
mounting and electrical installations, such us detector installations, horn
installations, manual call points installation. Instrumentation will prepare the
fire and gas detection installation details.

2.30 INSTRUMENT CABLE LIST

Instrument cable list shall show all instrument cables. Furthermore, the
cable list shall show the cable number, type, length and size of cable, type of
signal, color of outer sheathing, description of run(from-to) requisition and item
number, drum number and a remarks column. Instrumentation shall prepare
the instrument cable list.

2.31 CONNECTION LIST INSTRUMENT FIELD SIDE

Junction boxes connection listing shall show the determination of all

instruments connected with single wiring/cabling to a junction box and the
signal transmission via a multi core/pair cable to the marshalling rack/cabinet
in technical (auxiliary) room.
Instrumentation shall prepare the connection list instrument field side.

2.32 CONNECTION LIST INSTRUMENT ROOM SIDE

Marshalling rack/cabinet connection listings shall show the determination of

all field cables at one (1) side (field side ) and all control/rack room cables at
the other side (control building side ) and the interface connections of
electrical signals. Cross wiring shall be shown on the same list .
instrumentation shall prepare the connection list instrument control building
side.
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2.33 ELECTRICAL INSTRUMENTATION INTERFACE

The electrical-instrumentation interface describes the method of signal

transmission from control and safeguarding system to the motor control units,
low and high voltage switchgear and variable speed drive system . The
signals are directly hardwired, hardwired via interposing relays or
communicated via serial link. The signals concern control, trip and status
information. Contractor provides the electrical instrumentation interface
specification. Instrumentation shall incorporated in the instrumentation
database Intools external power requirements for field instruments.
Instrumentation shall prepare an Excel extract from Intools showing
instruments, which required electrical supplied, external power indicating tag
number, location, voltage type and voltage level. CONTRACTOR to follow
the minimum guide lines as provided in Electrical instrument interface
specification portion of this documents.

3.34 INSTRUMENT LOOP DIAGRAMS

Instrument loop diagrams shall be prepared for each electronic loop on the
project. On the basis of one (1) loop per drawing. A loop shall contain each
component from field device to DCS and/or other system cabinet, including
physical location, equipment number/location, terminal row/number and cable
pair number/polarity. DCS and/or other system functions of the loop shall be
shown in a simplified manner , without all configuration details. More than one
drawing may be necessary for more complex loops.

Intools smart loop will be used for conventional hardwired loops.

Instrumentation shall prepare the instrument loop diagram from field
instruments up to including the terminals of the field cables at the field side of
the marshalling rack/cabinet (main distribution frames MDF ). The field
instruments include package unit supplied instrumentation. The
CONTRACTOR shall complete the instrument loop diagrams with the
systems side.
The format of the loop diagrams shall be approved by OWNER.

2.35 INSTRUMENT SUBCONTRACTS

The objective of the instrument subcontract is to define the instrument

subcontractor’s scope of work, service and supply for the instrumentation
part of the installation work of a project. The instrument subcontract shall
contain necessary design and engineering documents, developed during the
detailed design phase of the project.
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The applicable specifications will be attached to the subcontract, e.g. :

- Instrument engineering and design specification
- Instrumentation scope split matrix multi office execution.
- Instrument installation specification
- Instrument cable pulling installation specification.
- Test and precommissioning specification.
- Instrumentation shall provide the scope descriptions for and technical
attachments to the instrument subcontracts. The client or his
representative shall review these documents.

3.0 INSTRUMENTATION INTERFACES WITH OTHER DISCIPLINES

3.1 PROCESS DESIGN
3.1.1 PROCESS DEFINITION
3.1.1.1 Technology selection (comparison of processes )
3.1.1.1.1 Dynamic simulation instrumentation of process
Selected size/capacity of control and relief valves
is provided by instrumentation to process as
confirmation of the assumptions by process.

3.1.1.2 Process Philosophies

3.1.1.2.1 Process control and operating philosophy,
instrumentation reviews the philosophy.
3.1.1.2.2 Emergency shutdown philosophy, instrumentation
reviews the philosophy.
3.1.1.2.3 De-pressurization philosophy instrumentation
reviews the philosophies on the de-pressurization
and de- compression.
3.1.1.2.4 Fire protection philosophy
Instrumentation reviews the philosophy .
3.1.1.2.5 Effluent philosophy
Instrumentation reviews the philosophies on
drainage, venting and flaring. Equipment sizing
philosophy
3.1.1.3 Process flow diagrams.
Instrumentation reviews the process flow diagrams.
3.1.1.4 Process description.
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3.1.2 SAFETY AND ENVIRONMENT

3.1.2.1 Plant effluent data

Instrumentation provides the data of the analyzer system
effluents to process during detailed engineering .
3.1.2.2 HAZOP & SIL study and report.
Instrumentation representative is available for questions
and answers during the HAZOP meetings.
3.1.2.3 Noise study
Instrumentation provides predicted noise data for control
valves and safety relief valves based on instrumentation
preliminary sizing (30 % probability ) or on selected seller
supplied data ( 70 % probability).

3.2 PROCESS ENGINEERING

3.2.1 PIPING AND INSTRUMENTATION DIAGRAMS
3.2.1.1 symbology for P&I D’s
Instrumentation review the symbolgy (legend) for P&I D’s
prepared by process.
3.2.1.2 Process P&I D’s instrumentation provides tag numbers
for instruments, instrument loops, safeguarding blocks,
safety valves, gauges and actuated valves. An
instrumentation representative is available for questions
and answers during the screening meetings.
Instrumentation shall review the P&I D’s. Instrumentation
shall advice process of the modifications due to the detailed
design.
3.2.1.3 Fire and gas P&I D’s
See Process P&I D’s .
3.2.1.4 Utility P&I D’s
See Process P&I D’s .
3.2.1.5 Utility distribution P&I D’s instrumentation provides tag
numbers for instruments, gauge and actuated valves.
3.2.1.6 Interposing-connection and tie-in diagrams.
No input from instrumentation .
3.2.1.7 Demolition P&I D’s
3.2.1.8 Auxiliary P&I D’s
3.2.1.9 Package unit P&I D’s
3.2.1.10 Process control and safety instrumented system functional
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specifications (narrative) the process control functional

specification
PC-FS (narrative) contains functional descriptions of
complex regulatory loops, automated sequence/ batch
controls. If required, sequential function charts or
structured text can be provided for the sequence/ batch
type controls. The safety instrumented system functional
specification SIS-FS involves all instrument actions for
unscheduled process conditions and these are designed
to set the process in a safe mode if it tends to move
outside its operating parameters to wards unsafe
conditions. The reliability levels of the safeguarding
functions will be classified into SIL levels.(see also SIL
definition ) For each SIS block cause and effect diagrams
and interlock diagrams will be attached, being a graphical
representation of the main instrumented safeguarding
functions.
The documents are generated by process.
Instrumentation will review these documents. The
implementation is by CONTRACTOR.
3.2.1.11 SIL Definition Instrumentation provides input to the Safety
Instrument Level as determined by Process
Instrumentation together with Process will adjust the P I
&D’s according the requirements set by the SIL
classification.
3.2.1.12 Sequential re-start sequence instrumentation reviews the
sequential re-start sequence as prepared by Process in
close cooperation with Electrical.
3.2.1.13 Value improving practices, instrumentation will participate in
the value cost engineering meeting.
3.1.2.14 In-line instrument process datasheets.
Process provides process data sheets for in-line
instruments, relief valves and actuated valves.
3.2.1.15 On-line and off-line instrument process datasheets.
Process provides process data sheets for instruments for
on-lines instruments and off-lines instruments.
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Date : August, 2010
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İzmit Refinery Page No : 373 / 379
Revision : 2
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3.3 MECHANICAL

3.3.1 GENERAL
3.3.1.1 Specification for package unit instrumentation
Instrumentation prepares a general specification for
package unit instrumentation based on the general
instrument specifications provided in this document. This
specification covers the minimum requirements for the
engineering , design, supply and installation of
nstrumentation equipment and commodities forming part
of package units. Electrical instrument installations shall
also follow the requirements set forth in the specification
‘’Electrical requirements for package units’’.
3.3.1.2 Complex Package
Instrumentation prepares for each inquiry requisition for
complex package units a specific. Technical description
and specification including instrument data sheets. The
instrument data sheets shall be completed by the selected
seller.
Note : scope split for filling-in the instrument datasheet
shall be agreed upon in co-operation with the
seller.

3.3.2 STATIC EQUIPMENT

Vessel sketches columns, reactors , vessels, tanks, shell & tube heat
exchangers, air coolers, filters, heaters, boilers, indicating level, level
trip/alarm points, interface level, etc.

3.3.3 ROTATING EQUIPMENT

Pumps, steam turbines, air compressors & fans & blowers, turbines,
process gas compressors, diesel & gas engines, extruder units,
refrigeration units, vacuum units, providing various speed/vibration
monitoring detail.

3.3.4 SPECIAL EQUIPMENT

Package units, fire fighting equipment, HVAC equipment , mechanical
handling equipment , solid handling equipment .
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İzmit Refinery Page No : 374 / 379
Revision : 2
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3.4 PLANT DESIGN

3.4.1 CIVIL AND STRUCTURAL

3.4.1.1 Control building and instrument field auxiliary room building

instrumentation provides to Civil the internal room
dimension of Control rooms, instrument rack rooms and
instrument field auxiliary buildings. Location of rain water
drains are indicated.

3.4.1.2 Foundations
In addition to the building information instrumentation provides
to civil/structural Location, size and weight of instrumentation
supplied, pre-fabricated structures like analyzer houses/sheds
and free-standing local panels.

3.4.1.3 Undergrounding systems

Instrumentation provides to civil the routing and sizing of
trenches. However, in this complete project, no underground
cable trenches, etc. are involved. No underground instrument
cables shall be acceptable.

3.4.2 PIPING DESIGN

3.4.2.1 Plot plan

The plot plan is prepared by piping. Instrumentation provides
the routing and dimensions of main cable trenches, main
cable trays, and the locations and dimensions of analyser
houses/shed, control rooms and instrument field auxiliary
buildings.

3.4.2.2 Critical isometrics

3.4.2.3 Plant model

3.4.2.4 Line schedule

No input from instrumentation . The line schedule is used
by instrumentation during detailed engineering as reference
document and for yellow checking.
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İzmit Refinery Page No : 375 / 379
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3.4.3 PIPING ENGINEERING

3.4.3.1 Valve selection
Actuated piping valves requisitioned by instrumentation.
Follow the valve selection as per piping valve criteria.
Instrumentation does not provide input to the valve selection
specification.

3.5 ELECTRICAL

3.5.1 ELECTRICAL ENGINEERING

3.5.1.1 Electrical load list
Instrumentation shall provide Electrical with the required
loads of instrument equipment .

3.5.1.2 Electrical interface

Instrumentation shall inform electrical of the required
interface signals.

3.6 SUBCONTRACTING

3.6.1 Subcontracting project execution plan

Review of instrumentation part of the subcontracting project
execution plan.

3.7 OPERATIONS

3.7.1 CONSTRUCTION

3.7.1.1 Construction project execution plan Review strategy for

seller representatives of instrumentation and packaged
instrumentation to support construction and (pre.-)
commissioning activities. Constructability review with
aspects like pre-assembly, vessel pre.-dressing, heavy lift
requirements of valves, maximum dimensions of cabinets
and analyser houses. Review of mechanical completion
procedure. Review of strategy and procedures for (pre.-)
commissioning, unit performance test, initial start-up and
operation.
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İzmit Refinery Page No : 376 / 379
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3.8 SCHEDULES

Instrumentation reviews the level two schedule as prepared by scheduling.

Special focus is on the interface data with other disciplines and required-on-
site dates.
Instrumentation level three schedule will be prepared based on the
milestones from the level 1 and 2 schedules prepared by project control
department. Instrumentation shall provide input to, review and maintain the
schedule during the course of the project. Instrumentation shall take
corrective action to meet the level 1 and 2 schedules for their own part of the
work, if and when required.

4.0 INSTRUMENT DELIVERABLE OVERVIEW LIST ( BY CONTRACTOR)

In general CONTRACTOR to submit the following deliverables as a minimum for
OWNER’s approval and in corporate OWNER’s comments on the same. Also
CONTRACTOR to prepare a schedule for progressive monitoring of the below
mentioned deliverables but not limited to:
Instrument project execution plan.
Work schedule level 3 preparation.
Status reports
Specification
Instrument calculations
Control valve calculation
Safety/relief device calculation
D/p type flow Measurement calculation, incl Restriction orifices
D/p type level Measurement calculation
Analyzer sample loop calculation
Ex i loop calculation
Voltage drop calculation.
Heat dissipation
Instrument air consumption
Instrument index
DCS and ESD Systems
Instrument Configuration Index
Range, alarm, timer and trip setting (ratts) list
Requisition
Plant automation system
Fire and Gas Detection/Alarm System
Fire detectors
Gas detectors
Beacons and sirens
Very early smoke detection apparatus ( VESDA, only for substation )
Tank gauging systems
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İzmit Refinery Page No : 377 / 379
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Analyzer houses, analyzer systems and local analyzers

Field electronic instruments ( flow/level/pressure/temperature such as flow-pressure-
temperature and level transmitters, vortex flowmeters, displacer type instruments,
mass flowmeters, electronic indicators etc.)
Field local instruments (flow/level/pressure/temperature; such as thermometers with
wells, test wells, temperature instruments, skin type thermocouples, flow elements,
restriction orifices, level gauges, pressure gauges, miscellaneous hand switches,
vibration switches, rotameters, sight glasses, flow indicators etc. )
Tank gauging system
Custody transfer flow metering system .
Machine monitoring system
Control valves –globe type / butterfly type / contoured ball type/rotary
Self-regulating valves
MOV’s
Relief valves
On/off valves – ball type / butterfly type
Instrument cable ( signal / multicore )
Junction boxes, glands and JB wiring diagrams
Power supply cabinets
Push buttons ( field )
Process analyzer specification
System functional design specification
Instrument system block diagram
Typical process control diagram (PCB’s)
Instrument logic diagrams
Instrument cause and effect diagrams
Isometric check for instrumertation comments
Instrument piping specifications
Process Hook-up’s (to be specific with location not be general)
Electrical Hook-up’s
Support Hook-up’s
Pneumatic Hook-up’s
Air piping Hook-up’s
Tracing Hook-up’s
Piping MTO (in line with process, support, pneumatic and tracing hook-up’s)
Electrical MTO (in line with electrical hook-up’s and cable trays)
Above ground routing layouts and sections
Instrument cable trench layout and details
Control and technical rooms layout
Control system architecture and design
Elect.-Inst. Marshalling cabinet wiring diagrams
Batch controllers
Loading arms
Tank heat detection systems
Data sheets and calculation sheets
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İzmit Refinery Page No : 378 / 379
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Cable lists
Instrument, thermocouple signal cables and instrument power cables
Instrument fittings, tubings, valves and manifolds
Logic diagrams
Terminal drawings and wiring diagrams
Terminal strip connections
One line loop diagrams
Analyzers
Sequential diagrams
DCS&ESD I/O List and database
DCS graphic display information.
DCS&ESD system architecture
DCS&ESD typical loops
DCS&ESD loop wiring diagrams
Instrument installation schedule
Instrument List
Instrument piping specifications
Comments to typical piping details
Instrument field location layout (electronic and pneumatic instrumentation )
Instrument location layout for field ESD-switches
Analyzer drawings
Material Requisitions
Material Requisitions for Order (MR for Order)
Technical evaluation of Bids
Vendor Drawings, datasheets, documentation, calculations, etc. checks, comments,
finalization with Vendor and approval.
Vendor quotations review, comments, checks, direct contact by e-mail and/or phone
correspondences and meeting with vendors, preparation of technical bid evaluations of
vendors, conditional letters to vendors, revision and finalization of the vendor
quotations.
Vendor fabrication and final documents, drawings approval.
Instrument field cabling layout
Instrument process piping details
Instrument air piping details
Site surveys and supervision during detail engineering stage, construction and
commissioning stage
Instrument steam tracing details
Instrument installation details
Instrument nameplate schedule
Instrument local panel layout
Instrument rooms equipment layout
Instrument rooms cable layout
Instrument rooms earthing layout
Instrument electric supply
Control room and technical room layouts
Electric-inst. Signal list
Instrument Layouts
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Date : August, 2010
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İzmit Refinery Page No : 379 / 379
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Comments to control systems/instrumentation in packages

Instrument comments on vessels
Instrument Job specifications
Fire and gas mimic layout
Fire and gas detection layout
Fire and gas detection installation details
Instrument cable list
Connection list instrument field side
Connection list instrument field auxiliary room (FAR) side
Electrical instrumentation interface
Instrument loop diagrams
Instrument subcontracts
SIL reports ( with HSE ) ..
POR’s
DCS&ESD FAT in Vendor factory and approval of the systems
Etc.