(K-101X) Eng'g Spec For Instrumentation For Package Equipment - Rev.4 PDF

S-OIL ONSAN REFINERY
EXPANSION PROJECT
ENGINEERING SPECIFICATION
FOR
INSTRUMENTATION
FOR PACKAGE EQUIPMENT
ES No.
K-101X
Revision
PAGE 1 -
31
*REVISION HISTORY SHEET*

REV.
NO.
DATE
DESCRIPTION
May 12, 08
Newly Issued For S-OILs Review
Aug.19, 08
Revised as per S-OILs Comments
Sep. 08, 08
Oct. 24, 08
Mar. 10. 09

(3.7) DC 24V : solenoid valve added
(5.8.8) 115V AC was changed to DC24V
ISSUED
BY
TOYO
TOYO
TOYO
TOYO
SECL

EXPANSION PROJECT
FOR
INSTRUMENTATION
ES No.
Revision
PAGE 2 -
CONTENTS
1.
General............................................................................................... 4
1.1. Scope................................................................................ 4
1.2 Terms and Definition ......................................................... 4
2.
References......................................................................................... 4
2.1 Related Engineering Specification .................................... 4

2.2 Codes and Standards ....................................................... 4
3.
General............................................................................................... 5
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
Symbols and Identification ................................................ 5

Units of Measurement ....................................................... 6
Scales and Charts............................................................. 6
Selection of Ranges .......................................................... 6
Electrical Area Classifications ........................................... 6
Environmental Conditions ................................................. 7
Instrument Electricity Supply ............................................. 8
Instrument Grounding ....................................................... 8
Instrument Air Supply........................................................ 9
Signal Transmission.......................................................... 9
Instrument Connections .................................................... 9
Fail Safe Requirement .................................................... 11
EMI Protection ................................................................ 11
Painting ........................................................................... 11
Marking ........................................................................... 11
Inspection and Test......................................................... 12
Documentation................................................................ 12
Spare Parts and Consumables ...................................... 12
K-101X
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FOR
INSTRUMENTATION

EXPANSION PROJECT
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CONTENTS
4.
Control System Design................................................................... 12
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
5.
Field Mounted Instruments ............................................................ 17
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
6.
Control system ................................................................ 12

Cabinets and panels ....................................................... 13
Programmable logic controllers (PLCs)........................... 15
Redundancy.................................................................... 16
Electromagnetic relays.................................................... 16
Alarm circuit .................................................................... 16
Shutdown circuit.............................................................. 17
Machine Monitoring System............................................ 17
Tie-in signals to the EPC Contractors control system .... 17
System Integration Test .................................................. 17
General ........................................................................... 18
Transmitters and Controllers........................................... 18
Flow Instruments............................................................. 18
Level Instruments............................................................ 20
Pressure Instruments ...................................................... 22
Temperature Instruments................................................ 22
Process Analyzers .......................................................... 24
Control Valves................................................................. 24
Installation ....................................................................................... 27
6.1
6.2
6.3
6.4
6.5
Instrument Locations....................................................... 27
Instrumentation Cables ................................................... 27
Instrument Impulse Lines ................................................ 30
Instrument Heating.......................................................... 30
Instrument Air Lines ........................................................ 30
Attachment-1
Attachment-2
Attachment-3
Attachment-4-1/2/3
Attachment-5-1/2
Attachment-6-1/2
Attachment-7
Attachment-8-1/2
:
:
:
:
Instrument Grounding Diagram (typical)

Document List for Equipment Package Instrumentation
Spare Parts List for Equipment Package instrumentation
Instrument Interface Diagram for Package Unit (Critical LLI)
Nozzle orientation and location of instruments
: Winterization and Protection of instrument
: General requirements for instrument pressure piping/tubing
: Local Panel and Local Gauge Board (Typical)
FOR
INSTRUMENTATION

EXPANSION PROJECT
1.
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General
1.1. Scope
1.2
(1)
This engineering specification describes general requirements such as selection,

design, installation, etc. of instruments furnished with packaged equipment for the
S-Oil Aromatics Complex of Refinery Expansion Project, Korea.
(2)
If there are any conflicts in requirements between this specification and the other
specifications or drawings, or any deviations to this specification, the Vendor
shall bring the matter to EPC Contractor for technical justification and get
approval of EPC Contractor.
Terms and Definition

For the PROJECT, unless otherwise specified, the following terms with their definition
are applied:
OWNER
TOYO
PROJECT
EPC CONTRACTOR
VENDOR
2.
: S-Oil Corporation
: Toyo Engineering Corporation
: Aromatics Complex of Refinery Expansion Project
: Party who performs the detail engineering, procurement and
construction for the PROJECT.
: Manufacturer and/or Supplier of a commodity, system, a
piece of equipment to perform the specified duty.
References
2.1
Related Engineering Specification

The related engineering specifications to supplement this specification are as follows ;
(1)
(2)
(3)
(4)
2.2
K-201
H-103
O-301
AA-001
Inspection & Tests of Instrument

Piping Materials
Painting
Basic Engineering Design Data
Codes and Standards

The following publications shall form a part of this Specification. Unless otherwise
specified herein, use the latest edition or revision.
ANSI (American National Standards Institute)

ANSI/ASME B1.20.1
ANSI/ASME B16.5
ANSI/ASME B16.36
Pipe Threads, General Purpose (Inch)

Pipe Flanges and Flanged Fittings
Orifice Flanges
API (American Petroleum Institute)

API 551
API 552
Process Measuring Instrumentation

Transmission System

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API 553
API 554
API 670
API 2218
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Refinery Control Valves

Process Instrumentation and Control
Vibration, Axial Position and Bearing Temperature Monitoring System
Fireproofing Practices in Petroleum and Petrochemical Processing
Plants
ASTM (American Society for Testing and Materials)

ASTM E230
Electromotive Force (EMF) Tables for Standardized Thermocouples
FCI (Flow Control Institute)

FCI 70-2
Control Valve Seat Leakage
IEC (International Electrotechnical Commission)

IEC 60079
IEC 60529
IEC 60751
Electrical Apparatus for Explosive Gas Atmospheres

Degrees of Protection Provided by Enclosures (IP Code)
Industrial Platinum Resistance Thermometer Sensors
ISA (International Society for Measurement and Control)

ISA S5.1
ISA S18.1
ISA S75.1
ISA S75.3
Instrumentation Symbols and Identification

Annunciator Sequences and Specifications
Flow Equations for Sizing Control Valves
Face to Face Dimension for Flanged Control Valve Body
ISO (International Organization for Standardization)

ISO 228-1
ISO 5167
Pipe Threads (G and Ga)

Measurement of Fluid Flow by Means of Pressure Differential Devices
Part 1: Orifice Plates, Nozzles and Venturi Tubes inserted in Circular
Cross-Section Conduits Running Full
NACE (National Association of Corrosion Engineering)

MR1013
Material Resistance to Sulfide Cracking in Corrosive Petroleum Refining

Environments
OSHA (Occupational Safety and Health Administration)

29 CFR 1910.95
3.
Occupational Noise Exposure
General
3.1
Symbols, Identification and Scope

Instrumentation symbols and identification on Piping and Instrumentation Diagrams
(P&IDs) and Utility Flow Diagrams (UFDs) shall be in accordance with process
licensors standard and/or ISA S5.1.

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Instrument tag numbers, consisting of functional identification (letter) and loop

identification (number) shall be in accordance with the project engineering document
Basic Engineering Design Data (Spec. no. AA -001), para. 3. Numbering System
Basic binary logic symbols shall comply with ISA S5.2.
Vendors scope of supply and work for H2 Rich Gas Compressors (K-47202-A/B/C)
and Recycle Compressors (K-47201, K-48201 and K-48501), which are categorized as
Critical LLI, shall be referred to Attachment -4.
3.2
Units of Measurement
The following units of measurement shall be applied :
3.3
Flow :
Level :
Pressure :
Temperature
Analysis
Density
Conductivity
gas
liquid
steam
in general
low pressure
vacuum
differential
Nm3/h (at 0 C and 1 atm)

Sm3/h (at 60 F and 1 atm)
kg/h, t/h
%, m, mm
Mpa(g), KPa(g)
KPa(g), mmH2O
KPa(a), -KPa(g), mmH2O
MPa, KPa, mmH2O
C
Direct Reading
kg/m3
s/cm
Scales and Charts

Scales for panel mounted indicators:
Flow, pressure and temperature indications shall be direct reading. Level indications
shall be 0 to 100 % uniform except for tank gauge indications of direct reading.
Scales for local indicators:
Pressure and temperature indicators shall be direct reading. Flow indicators shall be
direct reading or 0 to 10 square root depending on the application. Level indications
shall be direct reading or 0 to 100 % uniform depending on the application.
3.4
Selection of Ranges
Unless otherwise specified, the instrument ranges shall be selected such that the
normal operation value is generally in the center third of the range, i.e. between 35%
and 70% of the range (linear scale).
For flow measurement by means of pressure differential devices, the normal operation
value shall generally be between 65% and 80% of the range.
3.5
Electrical Area Classifications

All electrical or electronic instruments, control & on-off valves, control equipment (e.g.
panels) and their accessories to be installed in the explosion hazardous area shall
have suitable explosion construction to meet the area classification.

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Type of protection for electrical or electronic instruments or devices for use in

hazardous area shall be of flameproof enclosure (type-d), intrinsic safety (IS) (type-i),
non-sparking type (type-n), increased safety (type-e), or pressurized apparatus (type-p)
and selected with following criteria.
- Flame proof type : generally be applied to instruments such as transmitters, switches,
temperature elements, control & on-off valves, etc.
- Intrinsically safe type : where flame proof type is not available but subject to the
purchasers approval in advance. Isolation type safety barrier
shall preferably be selected.
- Non-sparking type:
where flame proof type is not available but subject to the

purchasers approval in advance.
- Pressurized type : where flame proof type and intrinsically safe type are not available
such as local panel, etc. but subject to the purchasers approval
in advance.
- Increased safety type : Junction box, etc.
All electrical or electronic instruments or devices for use in hazardous areas shall be
approved by following internationally recognized authorities according to hazardous
area classification and proven certificate by domestic authorities (KOSHA, KGS and
KTL) shall be submitted as mandatory.
-
3.6
CENELEC (EU)
CESI (Italy)
KEMA (Netherlands)
LCIE (France)
PTB (Germany)
KOSHA (Korea)
RIIS/TIIS(Japan)
BASEEFA (UK)
FM (USA)
UL (USA)
CSA (Canada)
Environmental Conditions
Field instruments shall be suitable for operation in the following environmental
conditions.
Weather feature:
Coastal (corrosive, sea wind) atmosphere
Ambient temperature:
Design base maximum
Absolute maximum
Design base minimum
Absolute minimum
38
38
-18
-17
C
C
C
C

EXPANSION PROJECT
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Relative humidity
Design base
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97 %
The minimum degree of protection for enclosures containing electronic components

shall be IP 65 or equivalent.
The lightning protection device shall be provided for field instruments and control
system supplied by package vendor.
3.7
Instrument Electricity Supply

Instrument power supply shall be as follows:
Power Supply
User
AC 115V 60 Hz 1ph (UPS)
DCS, PLC, Instrument, Analyzer.
AC 220V 60 Hz 1ph
Receptacles, Illuminators for level gauges, cabinets,

panels, local gauge board, etc.
AC 220V 60 Hz 1ph
Ventilation and air conditioner for analyzer house
DC 24V
Alarm unit, Electromagnetic relay, Two-wired field

transmitter and solenoid valve.
All the power lines for both incoming and each consumer shall be protected by suitably
rated circuit breakers (double-pole type) or isolation switched (double-pole type) with
fuses on both lines. The fuses shall be equipped with a blowout indicator.
DC 24V power shall be provided within the system such as DCS, PLC, Panel, etc from
the AC 115V UPS source as required. DC 24V power supply unit (voltage converter)
installed in the system shall be of dual redundant and shall be supplied by respective
Equipment Vendor.
3.8
Instrument Grounding
Grounding philosophy shall be referred to Instrument Grounding Diagram (typical),
Attachment-1.
The equipment energized with the voltage > 50 VAC or 120 VDC shall be provided with
earth grounding protection. Grounding resistance shall normally be of following:
Safety / Shield ground: one hundred (100) ohms or less
System ground:
five (5) ohms, but consult with DCS/PLC system supplier
Intrinsic safety ground: ten (10) ohms or less
Metallic frames of cabinets, panels, consoles and junction boxes shall be connected to
the safety / shield ground. System ground is provided for grounding of digital systems,
such as DCS/ESD and PLC based systems, for which each systems manufacturer
recommendation on the arrangement of grounding shall be followed. Shield (screen) of

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instrumentation cables shall be connected to safety / shield ground for Non-IS cables
and to intrinsic safety ground for IS cables.
A tinned copper ground bus bar for safety / shield ground shall be mounted inside
cabinet or panel and connected to the metallic frame. Conducting parts such as doors,
etc., which is not permanently connected to safety ground, shall be connected to the
frame of cabinets or panels with a flexible ground straps.
Separate tinned copper ground bus bars shall be provided with clear demarcation in
each cabinet or panel for system ground and IS ground. Each ground bus bar shall be
electrically isolated from other ground bus bar one another.
3.9
Instrument Air Supply

The conditions of instrument air supply source shall be as follows.
-
Pressure,
normal
maximum
design
0.686 MPa(g)
--1.040 MPa(g)
normal
design
38 C
66 C
-40 C @ 0.686 MPa(g)
free
Temperature,
Dew point
Oil
All instrument consumers, pneumatic instruments or devices, shall have an air filter
regulator set of metallic case with a small size output gauge at the air supply
connection.
3.10 Signal Transmission
3.10.1
Electric signal transmission:

Standard range of electric analog signal shall be smart 4 to 20 mA DC with HART
digital communication. The voltage level for electric signal transmission shall
normally be DC 24 V. The electric signal transmission shall normally be a two
(2)-wire system.
3.10.2
Pneumatic signal transmission:

Standard range for pneumatic signal transmission shall be 20 to 100 KPa(g).
3.11 Instrument Connections

3.11.1
Process connection:
Process connection of instruments except for in-line instruments shall generally be
in accordance with the following table.
The flanged connections shall conform to ANSI B16.5. and according to Piping
Materials Specifications (H-103).
Standard connection of instrument shall be 1/2 NPT female as per ANSI B1.20.1.
The connection for first isolation valves shall be provided with following table.

EXPANSION PROJECT
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Type of Instruments
Revision
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First Isolation Instrument

Valve
Connection
1/2 screwed
1/2 NPT
or welded
2 flanged
2 flanged
1/2 welded
External Displacement
2 flanged
Internal Displacement
Ultrasonic or Radar Type Level
Instruments
Servo Balance Type Level
Instruments
Level Switch (Ball Float Type)
4 flanged
4 flanged
(consult with
inst. vendor)
(consult with
inst. vendor)
(consult with
inst. vendor)
Magnetic type Level Gauges

D/P type level instruments on
stand pipes
D/P type level instruments on
vessels
D/P type level instruments with
diaphragm seals
D/P type level instruments with
Extended diaphragm seals
Pressure instruments on pipe
Pressure instruments on
vessels
Pressure instruments with
diaphragm seals
Pressure gauge with diaphragm
seals
Thermowell on pipe
Thermowell on vessels
Analysis
3.11.2
K-101X
Orifice Tap
Capacitance Type Level Switch

Standard type gauge glass
Larger chamber type gauge glass
Process
Connection
ES No.
6 flanged
2 flanged
2 flanged
3/4 flanged
2 flanged
3/4 flanged
2 flanged *
6 flanged
(If necessary)
2 flanged
6 flanged
2 flanged
3/4 flanged
2 flanged
2 flanged
3/4flanged
2 flanged
3/4 flanged
2 flanged *
3/4 flanged
2 flanged *
3/4 flanged
3/4 flanged
1/2 NPT
1-1/2flanged
3/4 flanged
1/2 NPT
3 flanged
3 flanged
(if necessary)
3 flanged
4 flanged
4 flanged
3/4 welded
3/4 welded x
3/4NPT
1/2 NPT
1-1/2 flanged
3/4 flanged
1/2 NPT
3 flanged
3 flanged
3 flanged
2 flanged
2 flanged
2 flanged
1-1/2 flanged
1-1/2 flanged
1-1/2 flanged
1-1/2 flanged
or 3/4 NPT
1-1/2 flanged
1/4 or 1/2
NPT
1-1/2 or 3/4
2 flanged connection shall be used in service where internal lining and high
pressure (900#) is required.
Air connection
Instrument air supply connections on instruments shall normally be 1/4 NPT.
Instrument air supply connections on control valves shall be 1/4 NPT, 3/8 NPT, 1/2
NPT, etc. (the size depends on application and valve vendors information).
Instrument pneumatic signal connections on instruments and control valves shall
normally be 1/4 NPT.

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Electric connection
Size of cable entry to instruments shall normally be 1/2 NPT or 3/4 NPT screwed
threads. Size of cable entry to junction boxes, field panels, etc. shall normally be
selected from the series; 1/2 NPT, 3/4 NPT, 1 NPT, 1-1/2 NPT, 2 NPT.
Cable entry of instruments, junction boxes, etc. located in hazardous area shall be
provided with union coupling with sealing fitting and drain tee, or packing type cable
gland.
3.12 Fail Safe Requirement

All instruments, pneumatic or electronic, shall fail to the safest position or lock in place
upon instrument air or electrical power failure.
Control valves which are required to fail safe on instrument air failure shall normally be
equipped with spring load actuator. Use of accumulator (volume tank) to meet control
valve fail safe positions shall be minimized.
Input contacts to alarm, interlock and emergency shutdown system shall be closed
during normal operation and open on alarm or trip.
Solenoids shall be energized during normal operation and de-energized on trip.
3.13 EMI Protection
The instrument and control system shall be immune from the effects of Radio
Frequency / Electromagnetic interference such that error caused by RFI shall not
exceed 0.1 percent of span for exposure to field strength of 30 volts/meter over the
frequency range of 20 to 1000MHz. In other word, when the instrument and control
system are exposed to radio field which strength is 30 volts/meter with frequency range
varied from 20 to 1000MHz, reading error or signal error of the instrument and control
system caused by the radio field shall not exceed 0.1 % of calibrated span.
Otherwise Vendor shall clearly state the susceptibility of EMI of the instruments and
control system along with the referred industrial standard name, version, immunity test
data, etc. at the time of quotation.
3.14 Painting
Painting procedure for instrumentation equipment and materials shall be in accordance
the Manufacturers standard. The color of final finish shall be in accordance with
Engineering Specification, O-301 Painting or the Manufacturers standard unless
specified in the O-301.
3.15 Marking
All instrumentation equipment shall be provided with permanent identification of the
instrument tag number. Nameplates for field mounted instruments shall be stainless
steel or laminated plastic.
Terminal strips shall be furnished with the terminal makers.
Wire markers shall be installed on the wires inside panels and junction boxes at their
termination point.
Cable markers shall be installed to identify field cables inside panels and junction
boxes.

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3.16 Inspection and Test

Inspection and test items for instruments and control system shall be in accordance
with Engineering Specification, K-201 Inspection and Tests of Instrument.
Inspection and test of instruments and control system at the Manufacturers factory
shall be conducted as per the procedures approved by the EPC Contractor. The
inspection and test records including calibration certificate of all instruments shall be
submitted to the EPC Contractor.
Package Vendors control system shall be subject to 100% factory acceptance test.
This test shall be conducted by the Vendor at the control system suppliers factory and
witnessed by the EPC Contractor.
In case Package Vendors control system is requested to have data communication
with EPC Contractors DCS system, the Package Vendor shall ship the control system
or representative instruments of the system to the DCS vendor shop with engineers to
assist the DCS vendor during the system integration test for check and confirmation of
communication function.
3.17 Documentation
Package Vendor shall furnish documents and drawings for instrument and control
system as specified in the Attachment-2 and submit to the EPC Contractor for
approval. A part of documents and drawings may be instrument sub-vendors
(manufacturer) document. The Package Vendor shall be fully responsible for checking
and approval of these sub-vendors documents/drawings.
3.18 Spare Parts and Consumables
Package Vendor shall supply spare parts / consumables for installation and
commissioning of instruments and control system, as specified in the Attachment-3, as
a minimum. The vendor shall recommend additional parts and consumables and/or
quantity, if any.
4.
Control System Design

4.1
Control system
Control and safety protection of Equipment Package Units shall be performed by a
dedicated control system installed in control room cabinets or local panel, which is
supplied as a part of equipment package by the Package Vendor, or performed by
plant DCS/ESD supplied and implemented by the EPC Contractor in accordance with
the Package Vendors design information, depending on the application of the package
unit.
In case a package unit requires special electronic devices (e.g. governor for steam
turbine, over speed trip device, anti-surge controller for compressor, etc.), the
electronic units shall be in the Package Vendors scope and shall be housed in a
suitable panel. In addition, shut down of the special electronic devices will lead to a
plant shut down, redundancy configuration shall be applied for the system.

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Package Vendor shall submit, at quotation stage, the package P&IDs that shall be
defined/ up-dated before order placement including detailed limit of supply.
Package Vendor shall also submit, at the quotation stage, the proposed instruments
vendors list that shall be agreed with EPC Contractor before order placement.
4.2
Cabinets and panels

Cabinets and panel shall be fully prefabricated at the factory. All system hardware,
instruments and components provided with the cabinet and panel shall be installed and
wired. No field work shall be done inside the cabinet or panel except for field tie-in
cable termination.
Control room cabinets may include the following:
Marshaling cabinets to connect field cables
System cabinets containing PLC, display unit, operator terminal etc.
Depending on number of I/O counts of a package unit, marshaling cabinets may not be
required and the marshaling function may be contained in the system cabinet with
agreement from the EPC Contractor.
4.2.1 Control room cabinets

Control room cabinets shall be freestanding in the form of box, provided with dual
access doors (front and rear), preferably be Rittal make. The size of cabinets shall be
800mm width, 800mm depth, 2100mm total height including 100mm height plinth as a
rule. 600mm or 1200mm width may also be considered depending on the application.
Cabinet color will be decided during detail engineering phase and specified in O-301,
Painting specification. The minimum degree of protection shall be IP42 (IEC60529) or
equivalent.
Cable entry shall be in the bottom. Bottom plates shall have removable sealing clamp
plates for cable entries. Sufficient freely space shall be available for accommodating
and terminating all cables. All spare cores (minimum 20% cores of multi-core cables)
shall be connected to the spare terminal blocks in the cabinets. Properly designed
cable clamps and cable support rails shall be provided in order not to exert any undue
force on termination.
The cabinet shall be lockable. Forced ventilation, if required due to the amount of heat
generated inside, by means of openings in the doors fitted with dust filters and with
extraction fans mounted in the top of cabinet fitted with finger guard and screen. Dust
filters shall be of the replaceable or cleanable type, and this action shall be possible
without disturbing the cabinet functions. However, as a minimum, the cabinets shall be
provided with natural ventilation by means of screened and louvered openings in the
doors and in the top.
Interior lighting shall be provided, if required due to maintenance. The cabinets shall be
fitted with removable eyebolts for lifting purpose. The blinds shall be provided to seal
the holes after removal of eyebolts. Anchor bolt holes shall be provided at bottom in the
cabinets. The anchor bolts, nuts and washers shall be furnished with the cabinets.

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4.2.2 Local panels

Local panels shall be designed to provide with adequate instrument display and to
protect instruments from the specified environmental conditions. The panels shall be a
free-standing and weather protected construction that is suitable for service in the
specified electrical area classification. The degree of protection shall be IP 65
(IEC60529) or equivalent. The panels located in hazardous area shall be of pressurized
apparatus (type p, giving alarm) or of flameproof enclosure ( type d).
The panels may have rear access door for maintenance. The door shall be gasketted
and furnished with latches. The panel shall be lockable.
The panel shall be provided with a canopy and lighting installed beneath the extended
canopy. The panel shall also have suitable interior lighting, if required. The framework
shall be made of structural shapes with lifting lugs for handling.
Air purging may be required for environmental reasons as well as electrical safety.
Provision of cooling system like vortex cooler to protect instruments from temperature
rise should also be considered.
Cable entry shall be in the bottom or side. Cable entry plates shall have removable
sealing clamp plates for cable entries. Sufficient freely space shall be available for
accommodating and terminating all cables. All spare cores (minimum 20% cores of
multi-core cables) shall be connected to the spare terminal blocks in the local panels.
Properly designed cable clamps and cable support rails shall be provided in order not to
exert any undue force on termination.
4.2.3 Wiring and termination
All wiring to/from panel/cabinet shall employ terminal blocks which are located inside
panel/cabinet frame for wiring termination and the wires inside panel/cabinet shall be
laid in PVC made close slotted duct. Proper segregation among AC power lines, IS
signal lines and non-IS signals lines shall be made. Duct color of IS signal lines shall
be light blue.
Wiring over short distances between the PVC ducts and the instrument termination
blocks shall be protected by
plastic trunking or
spiral round vinyl protective strips, as appropriate.
Conductor size of internal wiring inside panel/cabinet shall generally be minimum 0.75
mm2 stranded with PVC insulation except for vendor's special, if any, wiring
requirements and for power cables.
Wiring shall be appropriately identified by means of colored insulation as below except
for any VENDOR's special wiring requirements.
AC 115V
AC 220V
DC24V
(later)
(later)
(later)
(later)
Black (+)
FOR
INSTRUMENTATION

EXPANSION PROJECT
Grounding
RTD
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White (-)
Green or Green/Yellow
Black
White
Red
Black (+)
White (-)
as per ASTM E230
Home-run cabling shall be terminated at marshalling cabinet. Connecting terminals for

the cables shall be rail-mounted type. All spare cores (minimum 20% cores of
multi-core cables) shall be connected to the spare terminal blocks in the cabinets.
Powered output shall have protection and isolation for maintenance purpose. VENDOR
shall suggest its method to be applied.
4.3
Programmable logic controllers (PLCs)

Manufacturer and model of the PLC shall be subject to EPC Contractors approval.
Package Vendor shall be fully responsible to supply all necessary system hardware
and software, and to perform a complete program development for project
customization. The supply shall include a programming terminal with each system.
Programming terminals:
A programming terminal shall be provided and used for program development, program
storage, diagnostics, system monitoring and application documentation. The
programming terminal shall record the user-defined logic programming on a removal
disk media for security and backup. The programming terminal shall also allow manual
forcing of input and output states and provide the resulting status on logic displays
and/or print-out in on-line and/or off-line modes.
Software changes shall be done off-line, tested, and then downloaded into the running
application.
Diagnostics:
The system shall incorporate comprehensive self-diagnostics so that all permanent and
transient faults are identified, located, alarmed and reported. All diagnostics shall be
performed automatically on-line, without disturbing the process or reducing the
reliability of the PLC.
Processor:
The processor shall be modular and removable for maintenance and electrically
isolated from associated I/O components. In the event of power loss, the processor
shall retain its memory. The processor shall be capable of scanning and updating the
I/O and of executing user-defined discrete logic.
I/O modules:
The I/O components shall be self-contained independent modules so that a failure and
subsequent replacement of one does not affect other components. All output modules
shall be replaceable with the I/O system powered. Modules shall have mechanical
keying to prevent physical insertion and on-line activation of a module in an incorrect
slot in the chassis. Shorting or grounding the field wires connected to any I/O module
shall not damage the module itself.

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DCS system interface module:

The PLC shall be capable of performing signal interface with other control system, such
as Distributed Control System (DCS). Where serial data transmission with other control
system is required, the data communication shall be MODBUS RTU, RS-485, 4-wire
base.
Visual display unit (VDU):
Where VDU (visual display unit) as operator interface shall be supplied together with
PLC based control system by Package Vendor and the VDU will be located adjacent to
the plant DCS VDU, the Package Vendors VDU shall be the same make and model as
the plant DCS.
Spare and expansion capability:
At least 10 % installed spare capacity of I/O shall be available within each system. In
addition to installed spare capacity required, at least 10 % spare space shall be
available within each system.
4.4
Redundancy
Control and shutdown system for Equipment package shall be considered for
redundancy in its system depending on its criticality, whichever implementation of the
system (into the Plant DCS/ESD or into the dedicated PLC supplied by the package
vendor) the Equipment package will take.
Generally control and shutdown system shall have following redundancy as minimum.
- instrument power supply (feeder & conditioning module) of the system
- processor (CPU) of the system
If shutdown of the package unit will lead to a total plant shutdown, full redundant
configuration including followings shall be provided for the system of the packaged unit:
- instrument power supply (feeder & conditioning module) of the system
- processor (CPU) of the system
- I/O module of the system for control and shutdown related loop
- communication bus of the system (internal bus and external communication port)
4.5
Electromagnetic relays
Electromagnetic relays shall have an indication of their energized or de-energized state
by LED, surge protection devices and plug-and-socket type connectors with screw
electrical connections. The electromagnetic relays used in the field shall accommodate
in a hermetically sealed enclosure.
4.6
Alarm circuit
Alarm signal (contact) shall be closed during normal condition (i.e. contact open at
alarm condition).
Alarm unit shall be of solid-state electronic type and alarm lamp shall be of LED (light
emitting diode) type.
Alarm sequence shall generally be in accordance with ISA S18.1 sequence A and
sequence F3A where first-out sequence is required from operational view point.
Alarm system shall include audible alarm and acknowledge, reset and test push
buttons.

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Annunciator windows shall be color-filtered according to their function as follows :

- Status
white
- Alarm
orange
- shutdown
red
4.7
Shutdown circuit
4.8
Shutdown system shall be energized and pressurized during normal condition (i.e.
open and de-energized at trip condition).
Shutdown system shall preferably be implemented by PLC. Use of electromagnetic
relay logic should be minimized and subject to EPC Contractor/Owners approval.
Bypass switch for maintenance, if used, shall be of key-operated type switch or
access-managed software switch and shall be announced with a flashing lamp when in
bypass position. Output signal shall not be bypassed.
Bypass switch for operation (process override), if used, shall be of key-operated type
and announced with a flashing lamp when in bypass position.
Provision of bypass switches shall be subject to EPC Contractor/Owners approval.
Machine Monitoring System
Requirement on Machine vibration and temperature monitoring shall be referred to the
requisition specification of each Equipment Package unit.
Bentley Nevada (B/N) 3500 vibration monitoring system will be used.
Field probes, proximitors and temperature sensors suitable for use in classified
hazardous area, shall be supplied by each Package Vendor and pre-fabricated on the
machine skid base, interconnected up to the skid mounted junction boxes.
B/N 3500 monitor mounted and completed including internal wiring inside cabinet or
panel shall also be supplied by the Package Vendor.
4.9
Tie-in signals to the EPC Contractors control system

Where a unit is controlled by a Package Vendors PLC, the PLC shall be equipped with
a serial data communication facility which will be connected to the plant DCS as
specified in paragraph 4.3 Programmable Logic Controllers (PLC) except for safety
protection related signal, which shall be via hard-wired analog or discrete signal.
Hard-wired analog signal, 4 to 20 mA DC, which is sent to the EPC Contractors control
system or to other suppliers system, shall be of isolated signal.
Hard-wired discrete signal, which is sent to the EPC Contractors control system or to
other suppliers system, shall be interposed and be of potential free contact. Where
other types of signal are required for tie-in signals to other control systems, it shall be
subject to the EPC Contractors approval.
4.10 System Integration Test

Where Package Vendors control system is requested to have data communication with
EPC Contractors DCS system, the Package Vendor shall ship the control system or
representative instruments of the system to the DCS vendor shop with engineers to
assist the DCS vendor during the system integration test for check and confirmation of
communication function.
5.
Field Mounted Instruments

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General
Package equipment vendor shall supply according to his good engineering practice
and field proven suppliers in line with the requirement as described in the following
paragraphs.
Number of manufactures and types of instruments shall be minimized in accordance
with the EPC Contractors vendor list. The manufacturers shall be agreed with the EPC
Contractor.
Use of pneumatic instrument except for control valve shall be minimized. Use of such
pneumatic instrument shall also be agreed by EPC Contractor.
Followings are to be reviewed by EPC Contractor from inquiry bidding phase.
- Extent and location of field instruments
- Extent and location of control system
- Signal interface with other control system and safety system such as DCS, ESD
system.
- Start up and operational procedures
- Utilities requirements
5.2
5.2.1
Transmitters and Controllers

Transmitters
Electronic transmitters shall be of two-wire 4-20mA signal smart type with HART
protocol. The transmitters shall generally be provided with integral indicators.
Differential pressure transmitters except for transmitters furnished with diaphragm
seals shall be provided with close coupled 3-valve manifolds.
Square root extraction for d/p type flow measurements shall be performed in the
DCS or PLC.
All process wetted parts of pressure transmitters and differential pressure
transmitters including manifolds shall be of type 316 stainless steel or better. Other
materials shall be used as required by the process conditions.
Material for sour gas service shall be in accordance with NACE MR01-75.
5.2.2
Pneumatic indicating controllers

Where the controls are performed locally, pneumatic indicating controllers, which
receive pneumatic signal from the transmitters, shall normally be applied. The input
signal, set point and output signal shall be indicated on the controllers. The
controllers shall be furnished with an automatic-manual transfer system and the
control action, direct or reverse, shall be changeable. The measurement element
shall usually be bronze bellows.
5.3
5.3.1
Flow Instruments
Selection of flow measuring devices
The first choice of flow measuring devices shall be concentric orifice plates for the
pipe sizes 2 inch or larger. Where the piping sizes is 1-1/2 inch or smaller, other

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type such as variable area flowmeter or integral type orifice flowmeter shall be
selected.
Their variations and other flow measuring devices may be considered where
accuracy, rangeability, fluid properties, or mechanical restrains justify their use. Flow
measuring devices and their variations acceptable to use shall be listed below :
5.3.2
Orifice
Flow nozzle
Venturi tube
Pitot tube
Variable area flowmeter
Vortex flowmeter
Electromagnetic flowmeter
Turbine flowmeter
Positive displacement flowmeter
Coriolis mass flowmeter
Thermal mass flowmeter
Ultrasonic flowmeter
Orifice plates and orifice flanges

Flange taps shall normally be applied to line size 2 up to 24. For line size larger
than 24, orifice plate with 1D and D/2 taps shall normally be applied.
In general, orifice plates shall be concentric edge orifice, but other type can be used
as follows :
-
Eccentric orifices shall be used for horizontal piping in the following cases.
(a) In case where the liquid contains solids
(b) In case where the liquid contains gases
- Quadrant-edge orifices shall be used for the flow measurement of viscous
streams
- Segmental orifices shall be used for slurry services
- Integral orifices shall be used for the measurement of very small flows.
The design of orifice plate and bore calculation shall conform to ISO 5167. Ratio of
the orifice bore to pipe inside diameter (d/D) shall normally be between 0.2 and 0.7.
The design of orifice flanges shall conform to ANSI B16.36.
Orifice flange material, rating and facing shall conform to those of the piping.
Orifice plates shall be of type 316 stainless steel or better. Other materials shall be
used as required by the process conditions.
Orifice plates shall be provided with tab handle which is integral with the orifice plate
or welded on the orifice plate.
Drain / weep holes shall be provided for orifice plates which have a bore of 1 inch
and larger. The drain / weep holes may be excluded from the orifice bore
calculation.

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The measurement range of differential pressure shall normally be selected from

500, 1250, 2500 and 5000 mmH2O. A range of 2500 mmH20 shall be preferred.
For installation of orifice plates, the minimum required straight length at upstream
and downstream shall be the values of column B given in Table 3 of ISO 5167,
2003.
5.3.3
Flow nozzle and venturi

Where orifice type flow meter can not be used, Flow nozzle or Venturi tube
according to ISO 5167, 2003, may be used.
5.3.4
Variable area flowmeters

In general, flowmeters to be fitted to piping of nominal 1-1/2 and smaller may be of
variable area type.
In case where flow rate changes at more than 1 : 3 or the meter is used for purging,
variable area type may be used.
Variable area flowmeter shall generally be metal tube type. Use of glass tube type
shall be limited to purging / flushing application. Body material and connection shall
conform to those for piping.
5.4
Level Instruments
Except for internal float type, electrode type or level switches used as protective
devices, all level instruments activated by the same liquid level shall be connected to
a single 2(minimum) stand- pipe (column) with a full size blinded flange at the top
and a 1/2 (minimum) drain valve at the bottom. All stand pipe shall be equipped with
block valves at vessel nozzles. Each individual instrument shall have separate valve
connections from the stand pipe so that isolation of one will not affect the other.
Level instruments used as protective devices, however, shall have separate
connections to the vessel independent of other instruments.
5.4.1
Selection of level transmitters

Displacement type level instrument shall normally be used for level measurement of
liquid up to and including 1200 mm.
Differential pressure (D/P) type level instrument shall be used for liquid variation
more than 1200 mm. However, for interface measurement, displacer type may be
used up to 2000 mm.
Other level measuring devices, such as radar type, capacitance type, ultra sonic
type or nuclear type, etc. may be considered where fluid properties or mechanical
restrains justify their use.
5.4.2
Displacement type transmitters

External chamber (cage) displacement transmitters shall normally be used. The
connections to vessels shall be 2 inch flanged, located side-side. The external
chambers shall normally be provided with 3/4 drain valve and 3/4 NPT vent plug.

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The mid range of instruments shall be generally located at the normal operating
liquid level in vessel or column.
Plain extension or radiation fin shall be provided as per services requirement.
Rotatable head construction is required for external type displacer.
Body (external chamber, flange, etc.) material shall be in accordance with the
applicable piping specification or equivalent. Displacer material shall be 316
stainless steel or better and torque tube shall be selected to meet the process
conditions based on Vendors standard.
5.4.3
Selection of Level Gauges

Armoured gauge glasses shall generally be used, and use of magnetic type may be
considered as required by the process conditions. Tubular type gauge shall not be
used. Transparent type or Magnetic type gauge shall be used in installations
involving acid, caustic or dirty (dark colored) liquids, in steam applications (mica
shield), for liquid-liquid interface service. Reflex type gauge shall be used on clean
and colorless service. In services where internal lining and high pressure (900#)
is required, use of magnetic gauges may be considered.
5.4.4
Gauge Glasses
Gauge glasses shall normally be provided with standard angle gauge valves
containing ball checks, a 1/2 drain valve and a 1/2 vent plug. The gauge glasses
shall normally be hooked-up top-bottom. The connections to vessels shall normally
be 3/4 flanged and located side-side.
Visible length of one (1) gauge glass shall not exceed 1500 mm. Where two or more
gauge glasses are required to cover a monitoring range, they shall be arranged in
such a way that the visible area of each gauges shall overlap by 25mm minimum.
Frost shields shall be used if specified operating temperature is below 0.
Transparent type gauge shall be equipped with illuminator suitable for hazardous
area classification and provided together with the gauges by the VENDOR.
Electrical power supply to the illuminators shall be as follows.
- Distribution system
- Supply voltage
5.4.5
: 1 phase 2 wires
: 220V AC, 60 Hz
Tank Gauges
Tank gauges shall be of servo-balanced, or radar type. The gauges shall be
furnished with a tank side indicator for local reading at ground level.
5.4.6
Level Switches
Ball float type liquid level switched with external chamber should generally be used.
Process connection shall be 2 flanged, located side-side. External chamber shall
normally be provided with 3/4 drain valve and 3/4 NPT vent plug.

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Body (external chamber, flange, etc.) material shall be in accordance with the
applicable piping specification or equivalent and float shall generally be stainless
steel.
Other type level switches (e.g. vibration type switch, etc.) may be used when the
process condition require.
5.5
5.5.1
Pressure Instruments
Pressure Transmitter
Material of all process wetted parts shall be of stainless steel type 316 as a
minimum. Other materials shall be used as required by the process conditions.
Diaphragm seal type shall be considered where plugging in the impulse line may
occur or where suitable element material is not available in highly corrosive service,
crystallizing service, fluid including solid, high viscosity service, etc.
5.5.2
Pressure Gauges
Pressure Gauge shall normally be of bourdon tube type and 100 mm nominal dial
size, 25 mm blowout disc and safety glass. Dials shall be white with black numerals
and markings. The gauges shall be bottom connected with 1/2 NPT. Where the
gauges are furnished with diaphragm seals, the process connection shall normally
be 2 flanged.
All process wetted parts shall be type 316 stainless steel or better. Other materials
shall be used as required by the process conditions.
Case material shall be of aluminum-alloy.
Pressure elements shall be capable of withstanding intermittent over-ranging to 1.3
times the maximum scale reading without shifting calibration more than 1% of the
scale reading.
Pressure gauge shall be equipped with siphon tube, pulsation dampner or over
range protection for the following service :
- Siphon
- Pulsation Dampner
- Over range protection
5.5.3
: for steam, hot condensable vapor

: for discharge of reciprocating compressor/pump
: expected maximum pressure beyond the range
Receiver Gauges, as pneumatic signal indicators

The nominal dial size shall be 100 mm. The gauges shall be flush mounting and
back connected, 1/4 NPT. The element shall usually be stainless steel type 316.
5.6
5.6.1
Temperature Instruments
Selection of thermo element:
Metal-sheathed type thermocouple shall generally be used for remote temperature
measurement. Resistance temperature detector (RTD) shall be considered where
high accuracy (temperature compensation for flow measurement, etc.) or narrow
span are specified.

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Thermocouple and Resistance temperature detector applied to Control loop and/or

Emergency duty shall have integral head mounted Smart type transmitter (two-wired
4-20 mA DC signal with HART communication). Where the mounting location of the
sensor is not easily accessible from platform, etc., a separated transmitter shall be
installed as close to the sensor as possible.
5.6.2
Platinum resistance temperature detector (RTD)

RTD shall be of nominal resistance of Pt100 ohm at 0 C in accordance with IEC
60751. Connection wire configuration shall be 3-wire.
Stainless steel sheathed and mineral (usually magnesium oxide) insulated
thermometers shall normally be used.
RTD applied to Control loop and/or Emergency duty shall have double elements.
Outer diameter of the sheath shall normally be 6.4 mm.
5.6.3
Thermocouples
The thermocouples EMF characteristics, tolerances and its extension wires shall be
in accordance with ASTM E230.
Stainless steel sheathed and mineral (usually magnesium oxide) insulated
thermocouples shall normally be used. The measuring junction shall normally be
ungrounded (electrically isolated from the sheath).
Thermocouple applied to Control loop and/or Emergency duty shall have double
elements.
Outer diameter of the sheath shall normally be 6.4 mm.
Type-K thermocouple shall be used as a rule, where possible.
5.6.4
Thermo element assemblies

Thermo element shall normally be provided as an assembly consisting of a thermo
element, a connection head, a connection head extension and a thermowell. The
element entry to thermowell shall normally be 1/2 NPT. The connection head
extension length shall normally be 150 mm. The element shall firmly contact the
bottom of thermowell.
5.6.5
Dial thermometers
Dial thermometers shall be of the bimetallic type or filled thermal system type. The
thermometers shall be provided with a thermowell. The sensor entry to thermowell
shall be 1/2 NPT. The ranges shall normally be selected from the series; 0/50, 100,
150, 200, 300, 400 and 500 . The temperature measuring element shall be
installed such that the sensitive part is always fully immersed in the medium to be
measured.
Dial shall be of free angle type and 4 (100mm) diameter. Case material shall be of
aluminum alloy.
5.6.6
Thermowells

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Thermowells shall normally be drilled bar stock and tapered. The material shall be of
type 316 stainless steel. Other materials shall be used as required by the process
conditions. The process connection shall normally be 1-1/2 flanged. Other type of
connection such as screwed, welded should be subject to Owners approval.
A thermowell installed perpendicular shall have a minimum immersion length of
60mm into the pipe. The insertion length shall be normally as follows.
- For installation on piping up to 30 inch :
Tip of thermowell shall normally be located in the center third of the pipe,
however the maximum insertion length shall be 400 mm.
- For installation on piping over 30 inch and on vessel :
500 mm, in general
The constructions and insertion lengths shall be verified by means of stress analysis
resulting from stream velocity condition. The wake frequency shall not exceed 66 %
of the thermowells natural frequency. Where the given thermowell length fails the
wake frequency limit, the length or the diameter of thermowell should be adjusted to
bring in the limit.
Empty thermowells (test wells) shall be provided with a blind plug.
5.7
Process Analyzers
The VENDOR shall be fully responsible to design and supply not only analyzers but
also all necessary sample conditioning systems and calibration systems to maintain
their proper operation. Sample conditioning systems are comprised of all the
components necessary to extract a representative sample and to condition the sample
for measurement by the analyzer. The design of total sample conditioning system that
includes sample probes, sample tap primary conditionings, sample transportation lines,
etc. shall be engineered for each specific application. All material of sample
conditioning system components in contact with the process sample shall be of type
316 stainless steel unless special material is required for the process fluids handled.
The transmission signal shall be normally be 4 20 mA (DC24V) linearized, and 2-wire
transmission system for PH and electro-conductivity analyzer shall be used.
5.8
5.8.1
Control Valves
Selection of valve types
For throttling (control) application, Globe type valve shall generally be used and for
on-off application, Ball type valve shall be the first choice as the valve type,
however, butterfly type may also be considered for both throttling and on-off
application to large size piping service and / or low differential pressure service.
Where internal lining of control valves is required for protection against corrosion,
the valve types may be as follows.
- Diaphragm valve (often called sanders valve)
- Butterfly valve

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- Plug valve
- Ball valve
Their variations and other valve types may be considered where fluid properties,
pressure drop, pressure and temperature constrains, seat leakage requirements, or
mechanical restrains justify their use.
5.8.2
Sizing
Control valve shall be sized such that the valve rated Cv (valve flow coefficient)
shall normally be more than 1.75 times the normal flow Cv, or 1.2 times the
maximum flow Cv, whichever is greater. Where minimum flow condition is specified,
the valve opening shall not be smaller than 10% of the valve travel. The sizing shall
be carried out based on ISA S75.01 and the Manufacturers standard equations.
5.8.3
Noise
Noise generated by the control valves shall not exceed 90 dB(A) at 1m away from
the pipe of 1m downstream of the valve under their normal operating conditions. The
noise prediction shall be based on the Manufacturers standard method.
5.8.4
Body construction
Valve body size shall be considered based on the following guideline after valve
sizing stated in the above paragraph.
- For the lines 1 and larger
- For the lines smaller than 1
: minimum 1 and not more than 2 size

less than the line size
: same as the line size
The body size shall normally be selected from the series; 1/2, 3/4, 1, 1-1/2, 2, 3, 4,
6, 8, 10, 12, and larger.
Flanged end connections shall be used for all globe valves. Threaded end
connections shall not be used.
Rating and material shall conform to those of the piping.
5.8.5
Bonnet construction
Cooling fins or Extension bonnets shall usually be required on high temperature
applications, exceeding 230 and Extension bonnets shall be used for low
temperature applications, below -18 . The valve packing material shall normally
be PTFE based for the temperature up to 230 , and graphite based for the
temperature above 230 . The control valve packing glands shall be of the bolted
type.
5.8.6
Trim construction
Materials:
Valve trim shall be type 316 stainless steel unless process conditions require a
higher grade or special material. Hardened trim shall be used for the following
services.

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Flashing liquids
Fluid containing solids
Valve pressure drops exceeding 0.7 MPa for steam service
Valve pressure drops exceeding 1.0 MPa
Service temperature above 350
Flow characteristics:
An equal percentage characteristic shall normally be specified for all cases, with the
exceptions of valves on the following services, for which linear characteristics shall
normally be selected.
-
Depressurizing control
Minimum flow control of pumps or anti-surge control of compressors
Level control in gravity service
Level control in the process where change in the level is proportional to flow rate
through the control valve
- Split range control
- Where two (2) valves are applied in parallel for increasing the rangeability
- Control valves that are only operated via manual control station (HC)
Seat leakage:
The following leakage class conformed to ANSI/FCI 70-2 shall normally be applied
to each type of valve.
Class
Application
I : Manufacturer's recommendation
II : Double ported valves or cage guided valves
III : Valves as agreed by process
IV : Single ported valves
V : Shutoff valves or valves as agreed by process
VI : Soft seated valves
The seat leakage of emergency shutoff valves shall be class V for gas services and
class IV for liquid services, as a minimum.
5.8.7
Actuators
Actuator shall usually be of pneumatic operating type, preferably spring-operated
type to take air fail action, otherwise double acting cylinder type with volume tank.
Actuator shall be sized to operate in smooth and stable with supply pressure, no
more than 0.4 MPa(g), assuming differential pressure of upstream pressure
(maximum) and downstream pressure (atmospheric) across the valve.
Actuators shall be equipped with a direct coupled adjustable travel or position
indication for local status indication.
5.8.8
Accessories
Positioners:
Control valves for throttling applications shall normally be provided with an smart
electro-pneumatic (E/P) positioner with HART protocol for an input signal of 4 to 20
mA DC. For pneumatic control loops, a pneumatic-pneumatic (P/P) positioner
suitable for an input signal of 20 - 100 KPa(g) shall be provided with the control

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valves. For high vibration or high temperature location of valves, E/P converter with
P/P positioner should be considered.
The positioner shall furnish with an air filter regulator and small size pressure
gauges which indicate supply pressure, input signal pressure, and output pressure
to actuator.
Handwheel:
Handwheel shall be provided for tags as specified in the P&ID. Handwheel shall be
of side mounted type. The handwheels shall not be used travel limit stops.
Solenoid valves:
Three (3)-way, brass body valves shall normally be used. The valve shall have 1.0
MPa (g) rating body and shall be of direct acting type and universal type. The coil
shall be plastic molded, class F insulation class, as a minimum, and suitable for
DC 24V.
Solenoid valves used as protective device shall be of manual reset type.
Solenoid valve shall be equipped with terminal box.
Limit switches:
Limit switches shall be of hermetically sealed micro switch type. A terminal box shall
be equipped with the limit switch. No flying lead connections shall be permitted.
Depending on applications, miscellaneous accessories, such as booster relays,
quick exhaust valves, lock-up valves, accumulators (air volume tanks), travel limit
stops, etc. shall be considered to maintain proper operation of the control valves.
For safety shut-off valve with emergency duty, the actuator shall have fusible plug to
take the valve to safe position in fire case. The melting temperature of fusible plug
shall be 75 to 105
6.
Installation
6.1
Instrument Locations
The location of instruments, control valves, including junction boxes shall permit easy
access from grade, permanent platforms or stairways for operation, inspection and
maintenance. Locations shall also minimize the possibility of damage from passing or
falling objects. Where a clear area allows access from a ladder or mobile platform to an
instrument or element, a permanent platform may not be required.
6.2
6.2.1
Instrumentation Cables
Routing
Instrument main cable way (home run cable) shall be laid in overhead cable duct
with protection cover. Cable duct shall be made of hot-dip galvanized steel.
Instrument branched cable runs from junction box or local panel to each instrument
in the field shall also be routed aboveground and supported with galvanized conduit
pipes.

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Instrumentation cables that form part of IS circuits, if any, shall be segregated from
other instrument signal cables with separator installed between IS cables section
and non-IS cables section in same cable duct. The cable duct shall be provided for
instrument power cables separately from the signal cable duct.
6.2.2
Instrument signal cable

(1) Construction and Material
Instrument signal cables shall be polyvinyl chloride (PVC) insulated, polyvinyl
chloride (PVC) sheathed cables of rated voltage, 600/1000 V. The cables shall be
flame retardant type with requirement of IEEE 383 Sec.2.5.
Conductors shall be stranded annealed copper wire and the insulated conductors
shall be twisted together to form a pair or a triad, one pitch per 40mm or less.
Overall collective screen (electrostatic shield), comprising laminated aluminum tapes
and a tinned copper drain wire, shall be applied for the cables.
(2) Conductor size
Nominal cross-sectional area of the conductors shall be as follows ;
-
Branch cable (analog and contact) : 1.5 mm2 with shield
Main cable for analog

Main cable for contact
: 0.75 mm2 with individual and overall shield

: 1.5 mm2 with overall shield
(3) Color identification

Insulated conductors in a pair shall be identified by means of colored insulation in
black and white. The pairs shall be identified by numbering on the black insulation.
Insulated conductors in a triad shall be identified by means of colored insulation in
black, white and red. The triads shall be identified by numbering on the black
insulation.
Color of outer sheath shall be black. Cables that form part of IS circuits shall have a
light blue outer sheath.
6.2.3
Thermocouple extension cables

Thermocouple extension cables shall be polyvinyl chloride (PVC) insulated,
polyvinyl chloride (PVC) sheathed cables of rated voltage, 300/500 V. The cables
shall be flame retardant type with requirement of IEEE 383 Sec.2.5.
Conductors shall be stranded and the insulated conductor shall be twisted together
to form a pair. Material of conductor shall meet the requirements of ASTM E230.
Tolerance class for thermocouple extension wires shall be standard cited by ASTM
E230.
(2) Conductor size
Overall collective screen (electrostatic shield), comprising laminated aluminum tapes
and a tinned copper drain wire, shall be applied for the cables.
Nominal cross-sectional area of the conductors shall be as follows ;
-
Branch cable
Main cable
: 1.5 mm2 with shield

: 0.75 mm2 with individual and
shield
overall

EXPANSION PROJECT
FOR
INSTRUMENTATION
ES No.
Revision
PAGE 29
K-101X
4
- 31

Color coding of insulated conductors in a pair shall comply with ASTM E230. The
pairs shall be identified by numbering on the insulation of positive conductors. Color
of outer sheath shall be in compliance with ASTM E230. Cables that form part of IS
circuits shall have a light blue marking by means of taping at each cable end.
6.2 4
Instrument power supply (AC) cables

Instrument power supply (AC) cables shall be two (2)-core cross-linked polyethylene
(XLPE) insulated and PVC sheathed cables of rated voltage, 600/1000 V. The
cables shall be flame retardant type with requirement of IEEE 383 Sec.2.5.
(2) Conductor size
Conductor shall be stranded plain annealed copper wire. Nominal cross-sectional
area of conductors shall be 2.5 mm2 as a minimum.
The color of outer sheath shall be black. Core of the cable shall be identified by
means of colored insulation in black and white.
6.2.5
Instrument grounding cables

Instrument grounding cables shall be single-core polyvinyl chloride (PVC) insulated
and non-sheathed cables of rated voltage, 600/1000 V.
Conductors shall be stranded, plain annealed copper. The color of insulation shall
be green or green/yellow stripe.
6.2.6
Field junction boxes

Single-pair or single-triad cables shall generally terminate at junction boxes, from
which the signals are carried via multi-pair or multi-triad cables to the field mounted
panel or the control system in the control building.
The junction boxes shall be certified IP65 and be of stainless steel sheet or
aluminum casting, provided with increased safety type enclosure, Ex (e) type.
The junction boxes shall be sized to allow termination of all the cores of the field
multi core cables, and to include 20% spare terminals. All spare cores (minimum
20% cores of multi-core cables) shall be connected to the spare terminal blocks in
the junction box. Cable entry shall be in the bottom.
Terminal strips shall be modular construction, and the electrical contacts shall be of
the tubular screw pressure plate type with all live parts recessed into the insulation
block.
A junction box shall contain only signals of the same level & system when those
signals are connected to DCS, ESD system and physically separated as follows ;
1) DCS-analog
2) DCS-digital
3) DCS-thermocouple

EXPANSION PROJECT
FOR
INSTRUMENTATION
ES No.
Revision
PAGE 30
K-101X
4
- 31
4) DCS-solenoid valve
5) ESD-analog
6) ESD-digital
7) ESD-solenoid valve
6.2.7
6.3
Deleted
Instrument Impulse Lines

1/2 outer diameter x 0,049 thickness annealed seamless stainless steel tube (316
SS) and double ferrule type tube fitting (316 SS), Swagelok or equivalent shall normally
be used for following services ;
-
Piping class 600# and below

Operating temperature below 426 deg C
1/2 steel or alloy pipes, socket weld valves and fittings as per the applicable piping
specification shall be used for the following services :
- Piping class 900# and higher rating
- Operating temperature exceeds 426 deg C
- Hydrogen services
Other materials shall be used as required for the process conditions.
All instrument impulse lines shall have facilities for venting or draining the instrument.
6.4
Instrument Heating
Package vendor shall determine the extent of heat tracing and insulation required to
ensure the proper operation of the instrumentation and controls, considering process
property and plant site ambient condition.
The vendor shall identify, on the P&IDs, the lines, instruments and equipments that
require heat tracing. The vendor shall furnish and complete the required tracing work at
the vendors facility before shipment.
The heating medium shall be steam, unless other type such as electrical tracing is
considered more suitable.
Steam trace tube shall be of 3/8 inch copper tube and chrome plated brass
compression fittings.
6.5
6.5.1
Instrument Air Lines

Instrument air supply lines
Galvanized carbon steel piping and threaded fittings shall be used for the instrument
air supply lines from the header up to the block valve close to the air consumer.
The block valve shall normally be 1/4 NPT stainless steel ball valve. Instrument air
supply lines from the block valve to the air consumer shall normally consist of
1/4 OD stainless steel tubing and double ferrule compression fittings. However, size

EXPANSION PROJECT
FOR
INSTRUMENTATION
ES No.
Revision
PAGE 31
K-101X
4
- 31
of air supply line and block valve for control valves and emergency shutdown valves
shall follow the valve vendors information in consideration of the valve performance.
6.5.2
Pneumatic signal lines

1/4 OD stainless steel tubing and stainless steel compression fittings shall be used.
Accordingly, internal tubing with fitting on the valve actuator shall also be stainless
steel.
Attachment-2
Attachment-2
Document List for Equipment Package Instrumentation
- Piping and Instrument Diagram (P&ID)

- Instrument index
- Instrument data sheet, ISA forms or equivalent
- Sizing and calculation sheet, for flowmeters, control valves, safety valves, etc.
- Instrument loop diagram, as per ISA S5.4 or equivalent
- Interlock Logic / Sequence diagram, as per ISA S5.2
- Alarm and shutdown set point list
- Control system design document and drawing, including,
Overall system block diagram (system architecture),
Power supply diagram,
Grounding diagram,
Chassis and modules layouts and assignments,
I/O points assignment on I/O modules,
Programming details (point database, ladder logic diagrams, etc.),
Address mapping (MODBUS) data for DCS interface signals
Bill of materials
- Cabinet or panel design document and drawing, including:
Outline dimensional drawing, Fabrication details and weigh,
Instrument arrangement drawing on front-of-cabinet or panel,
Instrument arrangement drawing inside cabinet or panel,
Annunciator window arrangement drawing with engraving,
Internal wiring diagram (signals, power supplies and groundings),
Terminals assignment list,
Terminal arrangement drawing,
Bill of materials
- Technical information for implementation on the Purchasers control system,
where applied, including:
Input/output (I/O) point list
Point building configuration data,
Loop function (algorithm) description (narrative),
Interlock Logic / Sequence diagram and description (narrative),
1/2
Attachment-2
Schematic graphic display plan (if any),

Operator display plan, such as group, trend, etc. (if any).
- Junction box design document and drawing, including:
Outline dimensional drawing and Fabrication details
Terminal assignment list,
Terminal arrangement drawing
- Instrument layouts, including
Junction box location drawing (plot plan),
Field instrument location drawing (plot plan),
Instrument cabling layout,
Instrument air line layout,
Instrument heat tracing layout
- Instrument installation details, including
Hook-up drawing,
Connection details,
Supports details
- Instrument termination schedule (wiring connection list)
- Heat tracing and winterizing specification with hook-up details
- Bill of materials for instrument installation materials
- Instrument Sub-Vendor (Manufacturer) list
- Instrument Sub-Vendor (Manufacturer) documents, covering specification,
drawing and operation/instruction manuals
- Utility consumption list for electrical power and instrument air
- Inspection and test procedure for FAT
- Inspection and test procedure for SAT
- Inspection and test reports
- Certificates of Instruments for electrical hazardous area
- Spare parts list
- Consumable list
- Special Tool list
2/2
Attachment-3
Attachment-3
Spare Parts List for Equipment Package Instrumentation
Fuses
100%
Lamps
100%
Electromagnetic relays
10% (min. 2 sets) per each type
Terminals
5% (min. 10 sets) per each type and size
Printer papers
Min. 1000 sheets per each printer
Printer cartridges or ribbons, etc.
min. 5 sets per each printer
Sealing materials (gasket, O-ring, etc.) 100%
Gland packing of control valve
10% (min 1 set) per each type, material

and size
Solenoids of control valve
10% (min. 1 set) per each type
Air set of control valve
10% (min. 1 set) per each type
Pressure gauges of positioner
10% (min. 2 sets) per each type and range
Fittings (tube fittings, etc.)
10% (min. 2 sets.) per each type
Touch-up paints
Min. 1 can per each cabinet and panel
PLC cards
Min. 1 set per each type
1/1
Attachment-4-1
SCOPE OF DESIGN, SUPPLY & INSTALLATION WORK
DCS
Operator Station
OPERATOR ROOM
VENDOR
PDP
(UPS &
Commercial)
ESD
I/O
DCS
I/O
(Note 1)
ELEC./INST.
INTERFACE
CABINET
Monitor
Module
(BN3500)
SCOPE OF
DESIGN
EQUIPMENTS & MATERIALS
Running Status
Start Command
Stop Command
Emergency Trip
Start Permissive
HS Auto/Man Pos. Status
MCC
(D)
(D) I/O COUNTS (DCS, ESD)
VENDOR
* Requirement of Machine Protection

* Installation in aux. cabinet
SPECIFICATIONS
VA),
VA),
REMARK
VDC,
VDC,
0
0
0
AO =
DO =
Other =
(ESD)
(Other)
0
0
VA),
UPS
(DCS)
(ESD)
(Other)
(ESD)
(DCS)
(ESD)
Size (
), Conn. ( Scrd / FL )
By LEC [ (1)INST., (2)PIPING ]
Size (
DO =
UPS
VA),
0
0
(DCS)
DI =
[between DCS/ESD and MCC
REMARK
LEC
(DCS)
LEC
SCOPE OF
INSTALLATION
DCS HARDWAR (incl. System Cables) SOFTWARE

ESD System HARDWARE (incl. System Cables)
ESD System SOFTWARE (e.g. Interlock Logic Diag.)
*
Machine Monitoring System MODULE (installed in aux. cabinet
AUXILIARY CABINET (incl. internal wiring etc.)
Elec. Sub-Station
VENDOR
TIE-IN CONDITIONS BETWEEN PURCHASER AND VENDOR

TIE-IN ITEMS
(
115
VAC,
(A) POWER SUPPLY To Vendor's Auxliary Cabinet
(
115
VAC,
(B) POWER SUPPLY To Local Instrument
(C) I/O COUNTS (DCS, ESD)
AI =
0
[between DCS/ESD and FIELD]
DI =
0
TE =
0
(Note 3)
RACK ROOM
FIELD INSTRUMENT
Pressure PIPING / TUBING For Field Instrument
FIELD CABLING (incl. Conduit, Duct, Tray etc.)
JUCTION BOXes (incl. Installation MATERIALS)
LOCAL GAUGE BOARD
MAIN CABLE (between FIELD JB and RACK ROOM)
MMS Field SENSOR (Vibration, Piston Rod Drop)
POWER CABLE For Special Instrument, if any
PIPING / TUBING for Instrument Air and Steam Tracing
LEC
SCOPE OF
SUPPLY
Hardwired I/O Counts between

FIELD and Rack Room.
TE = ( T/C type___ or RTD )
Hardwired I/O Counts of MCC signal
(E)
FIELD
(F)
(G) INSTRUMENT AIR SUPPLY
(H) STEAM SUPPLY For Instrument TRACING
(I)
Fr/To DCS
To MMS
Fr/To ESD
AI
AI
AI
AO
TE
AO
DI
DI
Power Supply
DO
DO
TE
TE
(C)
(C)
NOTE
1 Power Supplies to all Cabinets / PCs / Local Gauge Board, if required, are to be completed by LEC.
2 Local Gauge Boad is typically installed with PG's (incl. impulse lines), TG's (incl. capillary tube), Switches, Lamps and installed on the Compressor Skid.
3 Interface Signals with MCC for Main Motor and Auxiliary Pumps.
(B)
: Vendor Scope
J.B.s
J.B.s
J.B.s
for Trip
Local
Gauge Board
(Note 2)
(G)
I.A.
Vibration
Field
Instrument
Piston
Rod Drop
Compressor (Recipro.)
(Motor Driven)
(H)
Field
Instrument
Special Inst.
w/External
Power Supply
Q'ty of Pilot=
LP Steam
Work No. / Proposal Name

Item No.
Package Unit Name
P&ID
Originator
Delivery Condition of Instrument & Material
Controller Type & Location
Operation for Start-up, normal S/D, Mainten.
HMI for normal Monitoring
Hazardous Area Class. & Type of Ex. Proof
Inst. Data Sheet - Scope & Format
Loop Drawing - Scope & Format
FAT at Package Unit Shop
Integrated FAT at DCS Vendor Shop
No. of Loop
No. of Local Loop
0
NA
BA-0844
K-47202-A/B/C
H2 Rich Gas Compressor
(1)Static, (2)Rotating, (3)Heater, (4)Mate.Handl., (5)Utility, (6)FF, (7)[
]
(1)On Single Skid, or (2)On Separated Skids, (3)Loose, (4)[
]
(1)Local Control Panel, (2)Control Panel in Rack Room, (3)Main DCS&ESD
(1)Manually From Field, (2)Remotely from Main DCS/ESD, (3)[
]
(1)DCS, (2)HMI by Vendor, (3)[
]
(1)Unclassified, (2)Classified[
]: (a)Ex"d", (b)Ex"i", (c)Ex"n", (d)Gen. P.
(1)LEC (2)Vendor: (a)Paper(ISA like), (b)INtools ("IEE" or Excel sprd sht, if BV)
(1)LEC (2)Vendor: (a)Paper(ISA like), (b)INtools
(1)With Witness by C&I Eng'er [
days], (2)Without Witness by C&I Eng'er
(1)Not Req'd, (2)Communication Test Only, (3)Integrated Functional Test
INSTRUMENT INTERFACE DIAGRAM

FOR
PACKAGED UNIT
May 9, '08
for inquiry
L TOYO ENGINEERING CORPORATION
REV.
DATE
STATUS
PRE.
CHK.
AUT.
Attachment-4-2
Operator Console
DCS
Operator Station
OPERATOR ROOM
21
Anti Surge
Controller
PDP
(UPS &
Commercial)
ESD
I/O
(Note 1)
24
25
Running Status
Start Command
Stop Command
Emergency Trip
Start Permissive
(C)
(D)
ELEC./INST.
INTERFACE
CABINET
MCC
(E)
26
(Note 4)
22
Monitor
Module
(BN3500)
Governor
23
Over
Speed
Protection
ACTUATOR / SENSOR / PROBE For Steam Turbine Control

LOCAL GAUGE BOARD
LOCAL SWITCH BOX For Steam Turbine
DCS HARDWARE (incl. Sys. Cables) & SOFTWARE
Anti-surge Control Valve (FV)
Sensors for Anti-Surge Control (PT's, FT)
JUCTION BOX for ACS Loop (incl. Installation MATERIALS)
Machine Monitoring MODULE (installed in aux. cabinet 26
21
ANTI-SURGE CONTROLLER
GOVERNER For Steam Turbine (installed in aux. cabinet 26)
OVERSPEED PROTECTION (installed in aux. cabinet 26)
CABLE INSIDE CONTROL ROOM
Data Communication Cable bet. DCS and Other SYS's
AUXILIARY CABINET (incl. internal wiring etc.)
25
Fr/To ASC
AI
J.B.s
Fr/To Governor
AI
AO
DI
Fr/To Governor
To MMS
To OSP
AI
AO
Pulse
AO
DI
DI
AI
DO
TE
DO
TE
TE
J.B.s
J.B.s
DO
DI
DO
To MMS
AO
DI
Fr/To ESD
AI
DO
FV
(ASC)
PT, FT
AI
J.B.s
J.B.s
J.B.s
Local
Gauge Board
Stm IN
HS Box
for ST
(Note 3)
Hydraulic Actuator
(F)
I.A.
T
VE
Steam Turbine
Compressor
ZE
Field
Instrument
(Note 2)
: Vendor Scope
Speed Sensor
VE
(G)
ZE
KE
Stm OUT
Speed Sensor
Field
Instrument
* Inatallation in aux. cabinet 26
REMARK
LEC

REMARK
VA),
UPS
(Other)

0
0
0
TE = T/C type
or RTD
Hardwired I/O Counts of Machine

associated devices and DCS/ESD.
Hard. I/O Counts of MCC Signals

Q'ty of Pilot=
NOTE
1 Power Supplies to all Cabinets / PCs / Local Gauge Board are tobe finalized by LEC.
3 Hand Swich Box for Steam Turbine is typically installed with multiple switches / buttons such as START, RESET, RAISE, LOWER, ESD.
No. of Loop
4 Interface Signals with MCC for Auxiliary Pumps.
No. of Local Loop
for Trip

TIE-IN ITEMS
SPECIFICATIONS
( 115 VAC,
VA),
(
VDC,
(A) POWER SUPPLY To Vendor's Auxiliary Cabinet
(B) I/O COUNTS (DCS, ESD, Other)
(DCS)
(ESD)
(Other)
(DCS)
(ESD)
[between DCS/ESD/Other and FIELD]
AO=
AI=
0
0
0
0
0
DI=
DO=
0
0
0
0
0
TE=
Pulse=
0
0
AI=
AO=
0
0
0
0
[INSIDE RACK ROOM]
DI=
DO=
0
0
0
0
[Package vendor to prepare I/O address mapping]
(D) DATA COMMUNICATION with DCS
DI =
DO =
(E) I/O COUNTS (DCS, ESD) [Sig. I/F with MCC]
0
0
0
0
Size (
(F) INSTRUMENT AIR SUPPLY
Size (
(G) STEAM SUPPLY For Instrument TRACING
FIELD
VENDOR
24
(B)
LEC
23
Elec. Sub-Station
VENDOR
SCOPE OF
INSTALLATION
FIELD INSTRUMENT
MMS Field SENSOR (Vibration, Thrust Pos., Keyphase)
THERMO ELEMENT For BEARING Temperature
22
RACK ROOM
LEC
SCOPE OF
SUPPLY
26
Fr/To DCS
SCOPE OF
DESIGN
VENDOR
DCS
I/O
LP Steam
Compressor (Centri.)
(Turbine Driven)

Item No.
Package Unit Name
P&ID
Originator

FOR
PACKAGED UNIT
0
NA
BA-0844
K-47201
Recycle Compressor
]
]
]
]
0
REV.
May 9 '08
DATE
for inquiry
STATUS
PRE.
CHK.
AUT.
Attachment-4-3
Operator Console
DCS
Operator Station
21
Anti Surge
Controller
OPERATOR ROOM
PDP
(UPS &
Commercial)
ESD
I/O
(Note 1)
Running Status
Start Command
Stop Command
Emergency Trip
Start Permissive
(C)
(D)
ELEC./INST.
INTERFACE
CABINET
MCC
(E)
26
(Note 3)
(Note 4)
Fault Alarm
Speed Feedback
Speed Control Command
Elec. Sub-Station
(B)
Fr/To ASC
AI
J.B.s
Fr/To DCS
AI
AO
AO
DI
Fr/To ESD
AI
DO
AO
DI
To MMS
DO
AI
AI
TE
TE
TE
J.B.s
J.B.s
J.B.s
DI
To MMS
DO
VE
Motor
Variable Speed
(Note 2)
I.A.
VE
KE
(G)
ZE
Field
Instrument
(F)
Compressor
TE
25
: Vendor Scope
TE
REMARK
LEC
REMARK
VA),
UPS
(Other)

0
0
-
TE = T/C type
or RTD
Hardwired I/O Counts of Machine

associated devices and DCS/ESD.
Hardwired I/O Counts of MCC and

VVVF signals
Q'ty of Pilot=
NOTE
1 Power Supplies to all Cabinets / PCs / Local Gauge Board are to be finalized by LEC.
No. of Loop
3 Interface Signals with MCC for Auxiliary Pumps.
No. of Local Loop
4 Package vendor to specify in his quotation the required number and kind of signals for cable interconnection.
for Trip
Local
Gauge Board
24
VENDOR
J.B.s
J.B.s
FV
(ASC)
PT, FT
LEC

TIE-IN ITEMS
SPECIFICATIONS
(
115 VAC,
VA),
(
VDC,
(A) POWER SUPPLT To Vendor's Auxiliary Cabinets
(B) I/O COUNTS (DCS, ESD, Other)
(DCS)
(ESD)
(Other)
(DCS)
(ESD)
[between DCS/ESD/Other and FIELD]
AO=
AI=
0
0
0
0
0
DI=
DO=
0
0
0
0
0
TE=
Pulse=
0
0
0
AI=
AO=
0
0
0
0
[INSIDE RACK ROOM]
DI=
DO=
0
0
0
0
[Package vendor to prepare I/O address mapping]
(D) DATA COMMUNICATION with DCS
(E) I/O COUNTS (DCS, ESD)
AI=
AO=
0
0
0
0
[Sig. I/F with MCC & VVVF]
DI=
DO=
0
0
0
0
Size (
(F) INSTRUMENT AIR SUPPLY
Size (
(G) STEAM SUPPLY For Instrument TRACING
FIELD
VENDOR
SCOPE OF
INSTALLATION
23
CABLE INSIDE CONTROL ROOM

Data Communication Cable bet. DCS and Other SYS's
26 AUXILIARY CABINET (incl. internal wiring etc.)
RACK ROOM
LEC
SCOPE OF
SUPPLY
22
VVVF
Monitor
Module
(BN3500)
FIELD INSTRUMENT
MMS Field SENSOR (Vibration, Thrust Pos., Keyphase)
THERMO ELEMENT For BEARING Temperature
ACTUATOR / SENSOR / PROBE For Steam Turbine Control

LOCAL GAUGE BOARD
LOCAL SWITCH BOX For Steam Turbine
DCS HARDWARE (incl. Sys. Cables) & SOFTWARE
Anti-surge Control Valve (FV)
Sensors for Anti-Surge Control (PT's, FT)
JUCTION BOX for ACS Loop (incl. Installation MATERIALS)
Machine Monitoring MODULE (installed in aux. cabinet 26
VVVF with Panel
21 ANTI-SURGE CONTROLLER
24
25
SCOPE OF
DESIGN
VENDOR
DCS
I/O
Field
Instrument
LP Steam
Compressor (Centri.)
(VVVF Motor Driven)

Item No.
Package Unit Name
P&ID
Originator

FOR
PACKAGED UNIT
0
NA
BA-0844
K-48201, K-48501
Recycle Compressor
]
]
]
]
0
REV.
May 9 '08
DATE
for inquiry
STATUS
PRE.
CHK.
AUT.
Attachment-5-1
Nozzle orientation and location of instruments (1/2)
Process Fluid
Diff. Press. Type
Press. Instr. (including
Flow meter
Diff. Press. Type)
Nozzle
Inst.
Nozzle
Inst.
Direction
Location
Direction
Location
C-2
Below
C-4
Below
C-1
Above
A-4
Above
Above
A-4
Above
Liquid (general)
Remarks
(Note 4)
2
Liquid (volatile)
(Note 1)
3
Gas (general)
A-2
(Note 2)
4
Gas
(easy
to
(Note 2)
A-2
Above
A-4
Above
B-1
Below
B-4
Below
condense)
5
Steam
(Note 3)
Location of differential pressure type level gauge :
Shall be at a level the same as or lower than (but, for volatile liquid, the same as) the lower
nozzle of towers/vessels
Note 1: Pressure piping shall be long enough so that the liquid shall vaporized at ambient temperature or by
use of heating.
Note 2: Instrument may be located below the taps, when there is no possibility of producing drain.
Note 3: Condensate pots shall be provided for bellows type diff. pressure transmitter, or for steam
temperature 200 or higher.
B-2 orientation may be applied when B-1 orientation can not be applied due to the piping
arrangement.
Note 4: In case the liquid is easy to form solid matter, nozzle shall be provided 45 deg. above the horizontal
line as per A-2 or A-4.
Instrument shall be located above the pressure tap(s).
In case the formation of solid matter is prevented by use of heating, etc, nozzle orientation shall be
C-2 or C-4. And instrument may be located below the tap(s).
Attachment-5-2
Nozzle orientation and location of instruments (2/2)

For Differencial Pressure Type
For Pressure
Flow meter
Instrument
Gas
90
90
45
Type
45
45
A
A-2
A-1
A-4
Steam
45
Type
45
45
B
B-2
B-1
B-3
B-4
Liquid
Type
C
45
C-1
45
45
C-2
C-3
C-4
Attachment-6-1
Design Base : Minimum Ambient
Level trans.
Flow meter
Temp -18
Fluid
Winterization and Protection of Instrument (1/2)
Smart type
Pressure
Transmitter
Smart type
Press. gauge
External Disp.
Gauge
type Tr.
Glass
Smart type
Bellows type
D/P Tr.
D/P Tr.
F+R
F+R
F+R
F+R
F+R
F+R
F+R
B+F+R
B+F+R
B+F+R
B+F+R
F+R
F+R
F+R
C or J
(C + G) or J
M or C or J
M or C or J
(F + L) or (F + R)
(F + L) or (F + R)
(F + L) or (F + R)
(F + L) or (F + R)
F+R
F+R
F+R
7. Liquids which contain solids
M or J
M or J
8. Others which require no special protection
9. Steam Temperature 200 and below
F+R
F+H+R
F+R
D+N+P
10. Steam Temperature 200 or above
F+H+R
F+H+R
F+R
D+N+P
C or K
(C + G) or K
C or (M or K)
M or C or K
S or F or
S or F or
S or F or
S or F
(A + F + R)
(A + G + F + R)
1. Water and water Solution having a freezing point of
D/P Tr.
Press. Tr.
approximately 0
2. Liquids from which gravity separation could cause
water to accumulate in lead lines.
3. Corrosive liquids
Liquid
4. Liquids whose pour points are above the minimum

ambient temperature
5. Liquids which vaporize at operating pressure and at
ambient temperature
6. Liquids which vaporize by heating a lead line at
steam
operating pressure
Gas or Vapor
11. Corrosive vapors and gases

12. Air, Vapors and gases contain solids
13. Wet gases
14. Dry gases
(A + F + R)
x
Attahment-6-2
Legend :
A:
B:
C:
Winterization and Protection of Instrument (2/2)
Fill lead lines with process liquid

Fill lead lines with water
Fill lead lines with a seal fluid other than line fluid
D:
E:
F:
Insulate (Hot) lead lines

Insulate (Cold) lead lines
Trace and Insulate lead lines
G:
H:
Use seal pot *1

Use condensate pot
J:
K:
Liquid purge of lead lines

Air or gas purge of lead line
L:
Provide heated boxes for instrument
M:
Remote seal diaphragm
N:
Provide Syphon tube
P:
Q:
R:
S:
X:
Insulate (Hot) instrument

Insulate (Cold) instrument
Trace and Insulate instrument body
Locate instrument at higher elevation than process connection
No special protection required
*1 Application of seal pot

to orifice taps
to orifice taps
to meter manifold
to meter manifold
Seal liquid heavier

than line fluid
Seal liquid lighter

than line fluid
Attachment-7
General requirements for instrument pressure piping/tubing
1. Application of piping / tubing

Piping class
600 # and
ope. temp426
Other than above
Non H2 service
Tubing system
H2 service
Piping system
Piping system
piping system
2. Block valve (Note*1) for instrument pressure piping

Piping class
Non H2 service
300 #
Single
600 #
Double (Note*2)
H2 service
Single
Double (Note*2)
(Note*1): All block valves shall be in accordance with engineering specification

H-103.
(Note*2): A 3-valve manifold for differential pressure transmitter may be
counted as one block valve.
3. Vent / drain valve
1) Piping system
Piping class
300 #
600 #
2) Tubing system
Piping class
300 #
=
600#
Non H2 service
Single block
+ screwed cap
Double block
+ screwed cap
H2 service
Single block
+ blind flange
Double block
+ blind flange
Non H2 service
Single block with
Plug (Note*3)
Double block with
Plug (Note*3).
H2 service
N.A.
N.A.
(Note*3): Drain / vent line / valve is not necessary for pressure and differential
pressure transmitters equipped with drain or vent plug as
manufactures standard.
4. Others
1) Pressure gauge
Piping system shall be used for pressure gauges. And a vent valve shall be
provided regardless of the pressure rating. For piping class 600#, a vent
valve shall be provided between block valves.
2) Steam condensate pot
For steam condensate pot, no vent valve is necessary. A vent plug shall be
provided.
(1/2)
Attachment-8
LODAL PANEL AND LOCAL GAUGE BOARD (TYPICAL)
1. General
A local panel or local gauge board shall include all fundamental instruments
necessary for the package unit operation, and shall be clearly visible to the operator
controlling the equipment.
2. Construction and materials
Type
Front view:
Dimensions
Height
Width
Depth
Construction
Front
Side
Top
Rear
Frame work
Door
Roof
Illumination
:Self-standing open type, weatherproof IP45 enclosure, or

explosion proof type to meet the hazardous classification
:Conventional (non-graphic)
: 2100 mm to 2400 mm (max.) (including 100 mm height channel
base)
:Depends on the number of gauges
:700 mm
<Local gauge board>
<Local panel>
t
:3.2mm steel plate
:2.3mmt steel plate

t
Wire net
:2.3mm steel plate
t
:2.3mm steel plate
none (open)
:50 x 50 x 5 mm angles
:
:
:
Required
Required
Required
Not required
3. Finish and color

Finish
Color
:Backed melamine resin (semi-dull)

:Final color shall be in accordance with Engineering Specification
O-301.
4. Piping and tubing

Process piping
Material
Air tubing
:1/2 schedule pipe

:suitable for service condition
:1/4 stainless steel
5. Gauge and instrument arrangement

Gauges or instruments shall be arranged systematically, and the pitch shall be as
shown on the sheet 2/2. The minimum height of gauges shall be 1150mm.
Arrangement on the panel or gauge board shall be subject be the Purchasers
approval.
(2/2)
Attachment-8
LODAL PANEL AND LOCAL GAUGE BOARD (TYPICAL)
GAUGE ARRANGEMENT AND DIMENSION (EXAMPLE)

EYE BOLTS
200
250
250
250
200
16
500
15
250
250
2400 (MAX)
10
11
12
NAME PLATE
13
14
1400
(MIN.1150)
700
100
1150
IN CASE OF GAUGE DIMETER 150mm

EYE BOLTS
150
200
200
200
150
16
500
15
250
250
2400 (MAX)
10
11
12
NAME PLATE
13
14
1400
(MIN.1150)
100
700
900
IN CASE OF GAUGE DIMETER 100mm

1 LUBE OIL SUPPLY
9 EXHAUST
2 CONTROL OIL SUPPLY
10 EXTRACTION, IF ANY
3 SEAL OIL SUPPLY
11 EJECTOR SUPPLY
4 SEAL DIFFERENTIAL PRESSURE
12 SHAFT SEAL
5 SEAL OIL OVERHEAD TANK LEVEL
13 SPEED CONTROLLER
6 INLET STEAM
14 SPEED INDICATOR
7 STEAM CHEST
15 FLUORESCENT TUBE (Ex. PROOF TYPE)
ST
81
STAGE
16 ROOF FOR FLUORESCENT TUBE

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S-OIL ONSAN REFINERY

*REVISION HISTORY SHEET*

Newly Issued For S-OILs Review

Revised as per S-OILs Comments

Revised as per S-OILs Comments

Revised as per S-OILs Comments

Revised as per S-OILs Comments

S-OIL ONSAN REFINERY

2.1 Related Engineering Specification .................................... 4

Symbols and Identification ................................................ 5

S-OIL ONSAN REFINERY

Control System Design................................................................... 12

Field Mounted Instruments ............................................................ 17

Control system ................................................................ 12

Instrument Grounding Diagram (typical)

S-OIL ONSAN REFINERY

This engineering specification describes general requirements such as selection,

Terms and Definition

Related Engineering Specification

Inspection & Tests of Instrument

Codes and Standards

ANSI (American National Standards Institute)

Pipe Threads, General Purpose (Inch)

API (American Petroleum Institute)

Process Measuring Instrumentation

S-OIL ONSAN REFINERY

Refinery Control Valves

ASTM (American Society for Testing and Materials)

Electromotive Force (EMF) Tables for Standardized Thermocouples

FCI (Flow Control Institute)

Control Valve Seat Leakage

IEC (International Electrotechnical Commission)

Electrical Apparatus for Explosive Gas Atmospheres

ISA (International Society for Measurement and Control)

Instrumentation Symbols and Identification

ISO (International Organization for Standardization)

Pipe Threads (G and Ga)

NACE (National Association of Corrosion Engineering)

Material Resistance to Sulfide Cracking in Corrosive Petroleum Refining

OSHA (Occupational Safety and Health Administration)

Occupational Noise Exposure

Symbols, Identification and Scope

S-OIL ONSAN REFINERY

Instrument tag numbers, consisting of functional identification (letter) and loop

Nm3/h (at 0 C and 1 atm)

Scales and Charts

Electrical Area Classifications

S-OIL ONSAN REFINERY

Type of protection for electrical or electronic instruments or devices for use in

where flame proof type is not available but subject to the

S-OIL ONSAN REFINERY

The minimum degree of protection for enclosures containing electronic components

Instrument Electricity Supply

AC 115V 60 Hz 1ph (UPS)

DCS, PLC, Instrument, Analyzer.

Receptacles, Illuminators for level gauges, cabinets,

Ventilation and air conditioner for analyzer house

Alarm unit, Electromagnetic relay, Two-wired field

S-OIL ONSAN REFINERY

Instrument Air Supply

Electric signal transmission:

Pneumatic signal transmission:

3.11 Instrument Connections

REVISION HISTORY SHEET