Aogc 036 in DSC 001 (B1)

CLIENT: CONSULTANT:
National Iranian Oil Company

Arvandan Oil and Gas Company ENERCHIMI ENG. CO.
SOHRAB WELL HEAD NO.1 FLOW LINE TO

Project: SOUTH AZADEGAN NORTH CLUSTER
Client Project No.: 14-71-148 Page 1 OF 52
Consultant Project
Doc. No.: AOGC-036-IN-DSC-001 19381 Rev.: B1
No.:
Document Title: INSTRUMENT DESIGN CRITERIA
“INSTRUMENT DESIGN CRITERIA”
F:\d\PROJECT\ARVANDAN\SOHRAB\93-06-29‫\ﻣﺪارﮎ ﺟﺪﻳﺪﯼ ﮐﻪ ﻣﻴﺒﺎﺳﺖ ﺑﺮاﯼ ﮐﺎرﻓﺮﻣﺎ ارﺳﺎل ﺷﻮد‬INSTRUMENT\AOGC-036-IN-
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Revision Summary Index

Modified In Rev. Number Modified In Rev. Number Modified In Rev. Number
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B0 B1
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Revision B0 B1
Issued for Tender Tender
Date 92.11.27 93.06.10
Consultant
Prepared R.A R.A
Checked S.SH S.SH
Approved M.N M.N
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Table of Contents
1. INTRODUCTION 6
1.1 Terms and Definitions ........................................................................................................... 6
2. ABBREVIATION 7
3. REFERENCES 7
3.1 ANSI(AMERICAN NATIONAL STANDARDS INSTITUTE) ......................................... 8
3.2 API (AMERICAN PETROLEUM INSTITUTE) ................................................................. 8
3.3 ASME(AMERICAN SOCIETY OF MECHANICAL ENGINEERS) ................................. 8
3.4 IEC(INTERNATIONAL ELECTRO-TECHNICAL COMMISSION) ................................ 8
3.5 ISA(INSTRUMENTATION, SYSTEM, AUTOMATION SOCIETY OF AMERICA) ..... 9
3.6 ISO (INTERNATIONAL STANDARD ORGANISATION) .............................................. 9
3.7 NACE (NATIONAL ASSOCIATION OF CORROSION ENGINEERS)........................... 9
3.8 IPS(IRANIAN PETROCHEMICAL STANDARD) ............................................................ 9
4. UNITS 10
5. ENVIRONMENTAL CONDITIONS AND PROTECTION 10

5.1 ENVIRONMENTAL PROTECTION ................................................................................ 10
6. GENERAL 11
7. CONTROL SYSTEM DESIGN PHILOSOPHY 11

7.1 SYSTEM CONFIGURATION AND CONTROL SYSTEMS........................................... 11
7.1.1 DCS System ................................................................................................................. 12
7.1.2 ESD System ................................................................................................................. 12
7.1.3 Fire and Gas Systems ................................................................................................... 13
7.1.4 Unit Control Panels ...................................................................................................... 14
7.2 SYSTEM DESIGN REQUIREMENTS.............................................................................. 15
7.2.1 Operating Stations ........................................................................................................ 15
7.2.2 Controllers.................................................................................................................... 16
7.2.3 Data Acquisition Devices ............................................................................................ 17
7.2.4 Alarms .......................................................................................................................... 17
7.2.5 System Redundancy, Spare and Load .......................................................................... 17
7.3 CONTROL AND TECNICAL ROOMS ............................................................................ 18
7.3.1 Heat, Ventilation and Air Conditioning (HVAC) ........................................................ 18
7.3.2 Main Facilities Control and technical rooms ............................................................... 19
7.3.3 Cabinet / Panel ............................................................................................................. 19
7.3.4 CABINET EQUIPMENT ............................................................................................ 20
7.3.5 CABLING .................................................................................................................... 20
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7.3.6 MARKING .................................................................................................................. 21

7.3.7 GROUNDING ............................................................................................................. 21
8. INSTRUMENTATION DESIGN 21

8.1 GENERAL .......................................................................................................................... 21
8.1.1 Transmitters ................................................................................................................. 21
8.1.2 Switches ....................................................................................................................... 22
8.1.3 Power Supply ............................................................................................................... 22
8.1.4 Accuracy of Instruments .............................................................................................. 22
8.1.5 Instruments Cable Entry .............................................................................................. 22
8.1.6 Material ........................................................................................................................ 22
8.1.7 Pressure/Temperature Rating of Instruments and Valves ............................................ 23
8.1.8 Impulse Lines ............................................................................................................... 23
8.1.9 Manifold valves ........................................................................................................... 23
8.1.10 Instrument Nozzle Rating on Vessels .......................................................................... 23
8.1.11 Local Indicators ........................................................................................................... 24
8.1.12 Diaphragm Seals .......................................................................................................... 24
8.2 FLOW INSTRUMENTS..................................................................................................... 24
8.2.1 Orifice Plates ................................................................................................................ 24
8.2.2 Coriolis......................................................................................................................... 26
8.2.3 Turbine ......................................................................................................................... 26
8.2.4 Variable Area flow meters ........................................................................................... 27
8.2.5 Ultrasonic Flow Meters................................................................................................ 27
8.2.6 Positive Displacement Flow Meters ............................................................................ 27
8.2.7 Pitot Tube ..................................................................................................................... 28
8.2.8 Venturi Nozzles ........................................................................................................... 28
8.2.9 Magnetic Flow Meters ................................................................................................. 28
8.2.10 Flow Transmitters ........................................................................................................ 28
8.3 LEVEL INSTRUMENTS ................................................................................................... 29
8.3.1 Level Transmitters for Control or ESD Services ......................................................... 29
8.3.2 Guided Wave Radar Level Measurement .................................................................... 30
8.3.3 Differential Pressure Level Measurement ................................................................... 30
8.3.4 Displacement Type Level Measurement ..................................................................... 31
8.3.5 Level Gauges ............................................................................................................... 31
8.3.6 Level Switch ................................................................................................................ 33
8.4 Temperature Instruments..................................................................................................... 33
8.4.1 Temperature Elements ................................................................................................. 33
8.4.2 Thermowells ................................................................................................................ 33
8.4.3 Temperature Gauges .................................................................................................... 34
8.4.4 Temperature Switches .................................................................................................. 35
8.4.5 Temperature Transmitters ............................................................................................ 36
8.5 PRESSURE INSTRUMENTS ............................................................................................ 36
8.5.1 Electronic Pressure Transmitters ................................................................................. 36
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8.5.2 Pressure Gauges ........................................................................................................... 37

8.5.3 Pressure Switch ............................................................................................................ 37
8.5.4 Pressure Instrument Installation ................................................................................... 38
9. VALVE AND ACTUATORS DESIGN CRITERIA 39

9.1 CONTROL VALVE SELECTION CRITERIA ................................................................. 39
9.2 CONTROL VALVE INSTALLATION ............................................................................. 39
9.3 CONTROL VALVE MATERIALS OF CONSTRUCTION.............................................. 40
9.4 CONTROL VALVE SIZING CRITERIA .......................................................................... 41
9.5 ACTUATORS ..................................................................................................................... 41
9.6 POSITIONERS ................................................................................................................... 42
9.7 ON/OFF ESD (SHUTDOWN) VALVES ........................................................................... 42
9.8 CONTROL VALVE LIMIT STOPS .................................................................................. 43
9.9 PROCESS REGULATORS ................................................................................................ 43
9.10 LIMIT SWITCHES ......................................................................................................... 43
9.11 SOLENOID VALVES .................................................................................................... 44
9.12 HAND WHEEL/ LOCKUP VALVE .............................................................................. 44
9.13 LOCK-UP VALVES ....................................................................................................... 44
9.14 PRESSURE SAFETY VALVES (PSV).......................................................................... 45
9.14.1 Pressure Safety Valve Requirements ........................................................................... 45
9.14.2 Pressure Safety Valve - Materials of Construction ...................................................... 46
9.14.3 Breather Valve ............................................................................................................. 46
10. SIGNAL TRANSMISSION, WIRING, INSTRUMENT AIR AND HOOKUP 46

10.1 SIGNAL TRANSMISSION ............................................................................................ 46
10.2 FIELD AND CONTROL/EQUIPMENT ROOM WIRING SYSTEM .......................... 47
10.3 INSTRUMENT AIR SUPPLY DISTRIBUTION ........................................................... 47
10.4 HOOK-UP CONNECTIONS .......................................................................................... 48
10.5 INSTRUMENT POWER SUPPLY DISTRIBUTION: .................................................. 48
10.6 NAMEPLATES / TAGGING ......................................................................................... 49
10.7 MATERIAL SELECTION .............................................................................................. 49
10.8 INSTRUMENT CONNECTIONS .................................................................................. 49
10.9 INSTRUMENT SIGNALS.............................................................................................. 49
10.10 PAINTING ...................................................................................................................... 50
10.11 SPARE PARTS ............................................................................................................... 50
10.12 INSPECTION AND TESTING....................................................................................... 50
10.13 TEST ASSEMBLING ..................................................................................................... 50
10.14 Check and Test of the Integrated System (including consoles, printers,
communication networks, etc.) ...................................................................................................... 51
10.15 Hardware system ............................................................................................................. 51
10.16 Functional checks and tests of the configuration............................................................. 51
10.17 Application software test ................................................................................................. 51
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11. DOCUMENTATION 51

1. INTRODUCTION
Arvandan Oil and Gas company intends to construct an 8" N.B. buried flowline
from Sohrab WH1 to South Azadegan North Cluster.
Sohrab Field is located at North of Azadegan Field, and 115 Km North West of
Ahwaz right along the international border with Iraq.
The major sections of the project are:
- Wellhead facilities (at WH No.1).

- 8" N.B, 50 Km (Approx.) buried flow line.
- Receiving trap facility at South Azadegan North Cluster.
1.1 Terms and Definitions
Owner/ client: Arvandan Oil & Gas Company (AOGC)
EPC Contractor: Shall Mean The Contractor Responsible

For Engineering, Procurement &
Construction Of The Project.
Consultant: Enerchimi Engineering Company (EEC)
Vendor/ Supplier: Refers to firm or person who will supply

and/or fabricate the equipment or
material.
Will: is normally used in connection with the

action by the "company" rather than by a
contractor, supplier or vendor.
May: is used where a provision is completely

discretionary.
Should: is used where a provision is advisory

only.
Shall: is used where a provision is mandatory.
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2. ABBREVIATION
CCR Central Control Room

DCS Distributed Control System
ESD Emergency Shut-Down System
F&G Fire & Gas System
FAT Factory Acceptance Test
HART Highway Addressable Remote Transducer
HMI Human Machine Interface
CMMS Computerized Machine Monitoring System
HVAC Heating Ventilation and Air Conditioning
I/O Input / Output
IS Intrinsically Safe
ITR Instrument Technical Room
LAN Local Area Network
MCC Motor Control Center
MTBT Mean Time Between Failure
NIS Non Intrinsically Safe
PDCS Power Distribution Control System
PLC Programmable Logic Controller
PSU Power Supply Unit
RTU Remute Terminal Unit
SAT Site Acceptance Test
SCADA Supervisory Control and Data Acquisition
SIL Safety Integrity Level
UPS Uninterruptable Power Supply
UCP Unit Control Panel
VDU Visual Display Unit
3. REFERENCES
Throughout this specification the following dated and undated standards and
codes are referred to. These referenced documents shall, to the extent specified
herein, form a part of this specification.
For undated references, the latest edition of the referenced document
(including any supplements and amendments) applies. For dated references, the
edition cited applies.
The applicability of changes in the dated references that occur after the cited date
shall be mutually agreed upon by Owner/Client and the Vendor / Contractor.
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3.1 ANSI(AMERICAN NATIONAL STANDARDS INSTITUTE)

B16 – 34 “Valves - Flanged Threaded and Welding End”
B16 – 104 “Control Valve Seat Leakage”
MC96 - 1 “Temperature Measurement Thermocouples”
FCI 70-2 “Control Valve Seat Leakage”
3.2 API (AMERICAN PETROLEUM INSTITUTE)
MPMS Chapter 5.2 “Measurement of Liquid Hydrocarbons by Displacement Meters”

MPMS Chapter 5.3 “Measurement of Liquid Hydrocarbons by Turbine Meters”
MPMS Chapter 5.6 “Measurement of Liquid Hydrocarbons by Coriolis Meters”
“Measurement of Liquid Hydrocarbons by Ultrasonic Flow Meters
MPMS Chapter 5.8
Using Transit Time Technology”
API RP-500 “Recommended Practices for Classification of Locations for
Electrical Installations at Petroleum Facilities”
API RP-500 Pt 1 “Sizing, Selection, and Installation of Pressure Relieving Devices in
Refineries”
API RP 521 “Guide for Pressure Relieving and De-pressuring Systems”
API RP 526 “Flanged Steel Pressure Relief Valves”
API RP 527 “Seat Tightness of Pressure Relief Valves”
API RP 551 “Process Measurement Instrumentation”
API RP 552 “Transmission Systems”
API RP 553 “Refinery Control Valves”
API RP 554 “Process Instrumentation and Control”
API RP 555 Recommended Practices for Process Analyzers”
“Valve Inspection and Testing”
API RP 598
3.3 ASME(AMERICAN SOCIETY OF MECHANICAL ENGINEERS)

ASME, B1.20.1 “Pipe Threads, General Purpose”
ASME, B16-5 “Pipe Flanges & Flanged Fitting”
ASME, B 16.34 “Valves Flanged, Threads and Welding End”
ASME, B16.36 “Orifice Flanges”
3.4 IEC(INTERNATIONAL ELECTRO-TECHNICAL COMMISSION)
IEC 60073 Basic & Safety Principles for Man-Machine Interfaces Marking and
Identification - Coding Principles for Indicators
IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere
IEC 60446 Basic & Safety Principles for Man-Machine Interfaces Marking and
Identification - Identification of Conductors by Colors or Numerals
IEC 60331 Tests for Electric Cables Under Fire Conditions
IEC 60332 Tests on Electric Cables Under Fire Conditions
IEC 60529 Degree of Protection Provided by Enclosures (IP code)
IEC 60584 Thermocouples
IEC 60751 Industrial Platinum Resistance Thermometer Sensors
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IEC 60794 Optical Fiber Cable

Electromagnetic Compatibility for industrial process measurement
IEC 60801
and control equipment
IEC 61000 Electromagnetic Compatibility
IEC 61508 Functional Safety of Electrical/Electronic/Programmable-Electronic
Safety Related Systems
IEC 61511
3.5 ISA(INSTRUMENTATION, SYSTEM, AUTOMATION SOCIETY OF

AMERICA)
ISA 5.1 Instrumentation Symbols and Identification
Graphic Symbols for Distributed Control/Shared Display
ISA S5.3
Instrumentation, Logic and Computer system
ISA 75.05 "Control Valve Terminology"
ISA 75.01 "Flow Equations for Control Valve Sizing"
ISA 75.02 "Control Valve Capacity Test Procedure"
Face-to-Face Dimensions for Flanged Globe Style Control
ISA 75.03
Valve Bodies
ISA 75.05 "Control Valve Terminology"
ISA 75.11 "Inherent Flow Characteristics and Rangeability of Control Valves"
ISA 75.17 "Control Valve Aerodynamic Noise Prediction"
ISA 75.19 "Hydrostatic Testing Of Control Valves"
3.6 ISO (INTERNATIONAL STANDARD ORGANISATION)

Measurement of Fluid Flow by Means of Pressure
ISO 5167 Differential Devices Inserted in Circular Cross-Section Conduits
Running Full
"Measurement of Fluid Flow By Means Of Pressure
ISO TR 15377 Differential Devices, Orifice Plates, Nozzles and Venturi Tubes
Inserted In Circular Cross Section Conduits Running Full"
3.7 NACE (NATIONAL ASSOCIATION OF CORROSION ENGINEERS)

"Materials Resistant to Sulfide Stress Cracking in Corrosive
NACE MR-01-03
Petroleum Refining Environments"
“Metals for Sulphide Stress Cracking and Stress
NACE MR-01-75
Corrosion Cracking Resistance in Sour Oilfield Environments”
3.8 IPS(IRANIAN PETROCHEMICAL STANDARD)

IPS-E-GN-100 “Engineering standards for Units”
IPS-E-IN-100 General Instrumentation
IPS-E-IN-110 Pressure Instrument
IPS-E-IN-120 Temperature Instrument
IPS-E-IN-130 Flow Instrument
IPS-E-IN-140 Level Instrument
IPS-E-IN-160 Control Valve
IPS-E-IN-180 Instruments electrical power supply and Distribution System
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IPS-E-IN-240 Measurement of Liquid Hydrocarbons

IPS-G-IN-200 Instrument Air System
IPS-G-IN-210 Instrument Protection
IPS-G-IN-220 Control Centers
IPS-G-IN-250 Distributed Control System (DCS)
IPS-G-IN-260 Indicating Lights, Alarms and Protective Systems
IPS-G-IN-270 Instruments of Fire & Gas Detection Equipment
IPS-G-IN-290 Programmable Logic Controllers (PLC)
4. UNITS
International System of Units (SI) shall be used in accordance

with "IPS-E-IN-100", unless otherwise specified.
5. ENVIRONMENTAL CONDITIONS AND PROTECTION
5.1 ENVIRONMENTAL PROTECTION
All field equipment shall be suitable for the ambient temperature as

specified in the project documents and the material and construction shall
be resistant to sulfurous dust, insect attacks, and moisture and fungus
growth.
The instrumentation, junction boxes and local control panels shall be
designed to meet the area classification where they are located. As a
minimum all field instrumentation will be suitable for Zone 1 according to
IEC-60079 and intrinsically safe. All electrical instrumentation, panels,
junction boxes and enclosures, which will be installed in hazardous areas,
shall generally be of intrinsically safe type suitable for the hazardous area
classification.
For equipment that intrinsically safe type is not available or the
working supply voltage precludes the use of intrinsically safe circuits,
explosion proof or pressurized type may be specified. These items shall
be CENELEC or CSA certified to meet the electrical area classification, be
stamped accordingly and issued with a certificate of conformity issued by a
recognized laboratory.
Hazardous area classification shall be as per API- 500.
Outdoor equipment (instruments, panels and enclosures) shall be
watertight to IEC 60529, IP 65 as a minimum. Large size outdoor local
panels, for which IP 65 may not be applicable, shall be pressurized.
Minimum ingress protection for all indoor panels shall be IP42.
Minimum ingress protection for all outdoor panels, instruments & junction
boxes shall be IP56.
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All transmitters that will be located outdoors shall be installed with

sunshades. Temperature class T3 and Gas Group IIB shall be specified for
all field instruments.
6. GENERAL
The Instrumentation and control shall be provided with sufficient number

and approved quality of all elements, necessary for the safe and efficient
control of the entire system and measurement of all input, output and
intermediate streams related to the process and utilities to satisfactory
operate the PLANT. Instrumentation shall be provided for monitoring of
all expected modes of operation including start-up, normal operation,
normal and emergency shut down and abnormal process conditions taking
into account all possible discharge of toxic/flammable liquids and gases.
The transmitters and other field instruments shall be located at or near
the measurement point, in such manner that they shall be easily
accessible from grade or permanent platforms for observation,
operation and maintenance.
7. CONTROL SYSTEM DESIGN PHILOSOPHY
In general, instruments and devices shall be smart type with 4-20mA

conventional signal and super imposed data communication with HART
protocol. The vendors shall supply Hand-held communicator for pre-
installation configuration check.
For ESD and F&G system, transmitters should be conventional type or
smart type with Write Protect feature.
7.1 SYSTEM CONFIGURATION AND CONTROL SYSTEMS
The instruments and process control system shall be so designed to

have the highest possible reliability and minimize the system failure in
order to achieve safe and satisfactory start up, normal shut down,
emergency shut down and safe continuous, accurate, efficient and
satisfactory operation with minimum maintenance.
Highly descriptive trouble shooting instruction covered in vendor
standard maintenance including sufficient information and data shall be
furnished for easy fault location and isolation.
All instrument/system shall be repairable by replacing defective parts
without interference on the other parts of the system.
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7.1.1 DCS SYSTEM

Distributed Control System (DCS) should be installed in a Central
Control Room, if required local control panels may also be considered. ESD
and Fire and Gas systems, Package PLC and other facilities shall be
considered to fulfill the project requirements.
Plant operation and supervision shall be carried out from PC-based
console type operating stations. The reliable hardware and software shall
meet the requirement of the continuous and smooth operation.
Operational logic shall be carried out inside the DCS itself. Some
packaged equipment shall have their own individual control system and
monitoring signals should be linked to the DCS.
Serial data links are envisaged between the DCS and UCP of Packages.
All relevant monitoring, control, protection, communication and simulation
systems / instruments shall be provided complete with standard and
application software installed and loaded on corresponding hardware. All
auxiliary / utility software shall be included. But in some cases, OPC may be
applied to Data transfer between DCS and UCP.
All above mentioned software are subject to complete simulation and test
correction and debugging prior to FAT.
Complete simulation and test shall be conducted for all software during
FAT. After final corrections and debugging a complete set of software shall
be handed over to the owner representative participated in FAT.
Licensed software shall be original and provided with relevant
certificates. Protected software shall be delivered with their soft / hard keys
and passwords.
The DCS shall be microprocessor based, comprising of control
data acquisition, communication, operator interface and data processing
subsystems.
At least 20% I/O shall be considered for future expansion of the DCS
system, 50% of this spare capacity shall be hot spare I/Os and 50% of
spare I/Os shall be wired up at handover stage.
7.1.2 ESD SYSTEM

The ESD system shall continuously safeguard the plant against
conditions that could lead to an event affecting plant assets, personnel
safety and impact to the environment through dedicated sensors that
monitor the processes, and manually activated push buttons. These
sensors shall be wired to the inputs of the ESD Programmable Logic
Controllers. The ESD PLCs shall then generate actions, as determined by
the pre-programmed logic.
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The system modules shall provide the following safety functions as

applicable:
(a) Shutdown (Process safeguarding) (SD)
(b) Emergency Shutdown (ESD)
(c) Emergency Depressurizing or blow down (EDP)
For each shut down sequence an emergency push button shall be
installed on auxiliary console, Matrix panel or External gate for ESD Push
Buttons and protected against accidental operation.
The shut down system shall be reset manually by a reset push button
installed on its local panel.
At least 20% I/O shall be considered for future expansion of the ESD
system, 50% of this spare capacity shall be hot spare I/Os and 50% of
spare I/Os shall be wired up at handover stage.
PLC for ESD System shall support and be certified for SIL3 unless
otherwise lower SIL specified by SIL study during project progress.
7.1.3 FIRE AND GAS SYSTEMS

The F&G Systems are dedicated to:
 Detect presence of fire and gas and/or gas leak to protect personnel,
environment and field equipment.
 Perform the related logic to control fire equipment, automatic
deluge valves, HVAC shutdown.
 Control and monitor the overall firewater network including fire pumps
and firewater piping network.
 In case of plant on fire the F&G functions initiate ESD and electrical
isolation via safety system functions.
 Initiation of Manual Call Point (MCP) triggers alarms without automatic
action.
 CO2 release (if applicable).
A representation of areas based on fire detection zones shall be
provided on matrix panel. Each light indicator will be flashing when an alarm
is activated and will stay “on” after acknowledgment until the cause of alarm
is removed.
F&G system will generally follow the principle of “energize to activate” for
systems. All inputs or outputs, which are not configured to be fail safe shall
be line monitored.
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A Human Machine Interface for F&G system shall be provided in CCR

for all facilities for alarm and shutdown annunciation and to enable the
operator to take executive action under emergency condition. The same
type of software shall be used for HMI for both DCS and F&G systems.
The HMI shall provide a permanently visible display of the Plant’s F&G
status and permanently accessible pushbuttons, in the form of VDU and
keyboard or a hard-wired matrix. The interface shall provide an instant
overview of the F&G status of the facilities and provide control and status of
the fire fighting system in the form of an F&G device layout of facilities.
7.1.4 UNIT CONTROL PANELS

Most of the equipment on the facilities will be supplied by specialist
machinery or packaged plant vendors. This equipment shall be controlled
and shutdown through its own dedicated unit control panel (UCP).
UCPs for machinery shall contain the electronics for machinery
(vibration) monitoring and data acquisition, a programmable Logic system
for processing relevant signals, and human machine interface in the form of
a VDU and keyboard to display individual alarms and enable control,
normal operation and shutdown from the equipment room. The UCP will
contain all the functions of DCS, ESD and F&G.
UCP shall interface directly to Motor Control Centre (MCC) for control
and shutdown of relevant electrical drives.
The control and monitoring system utilizing the package supplier’s own
equipment shall be fully programmed and configured.
The package control system shall be preferably of the PLC type. The
packages that need to be started locally may have the provision to be
monitored and controlled from the central control room after start-up.
Compressor UCPs shall include the anti-surge controllers, condition
monitoring system and dedicated machinery protection logic. Anti surge
valves shall also be provided by the compressor vendor. Generally, F&G
detectors and extinguishing facilities shall also be supplied with the
package and the F&G logic performed in the UCP. But it will be decided
case by case at detail design engineering stage.
For ESD, DCS and F&G systems, Anti-Surge controllers should be
prepared dedicated and independent of systems.
Data transfer to the DCS shall be limited to essential information required
by the operator in the CCR and shall be provided by volt-free contacts from
UCP.
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7.2 SYSTEM DESIGN REQUIREMENTS
All instrument/system hardware and software shall be latest proven type

and version.
All control system and related equipment i.e. auxiliary consoles,
annunciator, barrier cabinets, power distribution cabinets and etc as well as
local panels and package unit control systems shall be shop fabricated and
wired up to the terminals, ready for installation and interconnection at site.
Failure of interface between DCS and UCP shall not effect normal
operation of UCP.
7.2.1 OPERATING STATIONS

The operating stations shall be a complete, self-contained PC, including
high resolution TFT monitors with interactive membrane operating
keyboards and mouse or trackball, and all electronics, power supply, mass
storage devices, all necessary accessories etc. taking into account safe,
efficient and satisfactory control of the operation specially during start-up
and emergency conditions.
Each monitor and keyboard shall have its own electronics.
On each display type, the incoming process and system alarms shall be
shown via a message. Each alarm shall be shown on all monitors in all
cases and all levels of display.
Simplified “interlock display” and “sequence displays” shall be built
according to interlock diagram on DCS graphic displaying showing status
of logic tracing and fault locating.
The major functions to be performed by the Operating station shall be:
 Manipulation of control loops including set point, mode, output, two or
multi-position switches and selectors.
 Indication of analogue and digital control and non-control variables and
controllers status.
 Overview displays
 Group displays
 Loop displays
 Detail displays
 Alarms displays
 Trending and calculation hourly averages
 Custom display (interactive schematics)
 Reports as required
 Archival history
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 Customized program generation

 System diagnostics and reporting
 Help Displays
The Operator stations shall communicate with other devices
(controllers, data acquisition devices and interfaces) via dual redundant
communication line.
The system shall normally operate on uninterruptible power supply with
15mesc switching time. The power supply of two feeder carrying 230 V AC
± 1%, 50Hz ±0.5%, 1Ф shall be provided at one point at CCR and
marshaling room. Further power distribution shall be designed such that a
single power fault in any instrument branch system shall not cause a trip of
the entire system. Each consumer shall be provided with a separate switch
and fuse for isolation and protection of the system.
One of 230V/50Hz UPS feeder shall be considered for non-essential
socket outlets, internal lighting, fan and anti-condensation heater within the
DCS panels.
The auxiliary console shall be provided with the pushbuttons, selectors,
and hardwired alarm lamps. The console shall be featured with all
applicable characteristics as requested for the panels e.g. Installation of
telephones, paging or CCTV keyboard, etc.
7.2.2 CONTROLLERS
Controllers shall provide extensive standard algorithms as follow:
 P, I, D, PI, PD, PID control, cascade, ratio/bias, integral bias, lead/lag,

stack totalizer, feed forward function, set point totalizer, signal selector,
velocity limiter, 7th order polynomial, manual block, motor control,
valve control, motorized valve control, AND, OR, XOR, FLIP-FLOP,
LINK, off delay, on delay and pulse.
 Provide data acquisition, multiplication/division,
addition/subcontract, square root extraction, lead/lag, override,
high/low signal selection, high/low process variable absolute and
deviation alarm, logic control, sequence control.
 Provide I/O monitoring with following functions:
 Update input (analogue, digital or counter) point
records in the controller database;
 Transfer any changes in output records to outputs;
 Check momentary input and latch on if found to be on;
 Checks for feedback on digital points;
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 Sets alarms.
 Be unaffected by failure of the devices connected to the
communication system.
 Retain all control configuration memory in the event of power failure.
7.2.3 DATA ACQUISITION DEVICES

These devices shall monitor digital and/or analogue process inputs and
provide digital and/or analogue output signals.
Data acquisition devices shall process analogue inputs, providing square
root of flow devices, and linearization for the thermocouples and RTD’s.
They shall also detect alarms and change of state and shall be able to
convey this information to higher level devices via communication system.
The data acquisition device shall also perform self-diagnostics and
provide error and alarms status at the operator station.
All input and outputs shall be provided with galvanic isolation. Active
isolating barriers shall be plug-in types with the terminal block on base
(socket) unit. Barriers integrated with I/O cards are not acceptable.
Relays shall be hermetically sealed, and provided with gold-plated
contacts and LED. Marshalling and barrier cabinets may be combined.
Connection to DCS I/O shall be by high quality multi-pin plug and socket
connector.
Preferably, I/O cards (4-20mA) should have HART capabilities.
7.2.4 ALARMS
All the alarms will be configured on DCS and shown on operator’s
monitor; any signal force shall be treated as alarm.
Important ESD alarms shall be hardwired to the auxiliary console as per
process requirements. The system shall be combined audio-visual (either
integral with logic or remote).
Acknowledge, reset, lamp test etc pushbuttons shall be provided in the
Aux. Console (Matrix Panel or External Gate for ESD).
The audio system shall comprise a dual variable pitch horn system with
combined sound power of about 85 dBA.
7.2.5 SYSTEM REDUNDANCY, SPARE AND LOAD

In general all redundancies shall be automatic and bump less. The
following shall be dual redundant (1:1) for DCS system:
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 Interface module
 DCS Data Highway, control system communication network including
cabling, modems (if required), fiber optic cabling and interfaces, and
related hardware devices
 Input/output Module (For trip & Control Application).
 Power supply
 CPUs
PLC Redundancy:
 ESD PLC shall be fully redundant as per QMR or TMR (CPU, bus,
communication modules, power supply, I/O cards, etc).
 F&G PLC shall be fully redundant as per QMR or TMR (CPU, bus,
communication modules, power supply, I/O cards, etc).
 PLC of ESD and also F&G system should be SIL 3 unless otherwise
specified by SIL Study or Client Request.
7.3 CONTROL AND TECNICAL ROOMS
Sohrab Wellhead Cluster will include one Central Control Building

(CCB) with the following specification:
7.3.1 HEAT, VENTILATION AND AIR CONDITIONING (HVAC)

Temperature and humidity controlled environments will be provided to
house electronic control, safety, electrical and telecom systems
equipment. Manned control rooms will have environments suitable for
continuous human habitation.
As a minimum all rooms will be environmentally controlled by two
dedicated 100% (fully redundant) HVAC systems and be pressurized in
order that it is maintained at the required environmental condition and
permit the area to be electrically unclassified. Cognizance shall be taken of
the possibility of gas entering a room, in the event of HVAC failure, which
would change the room’s hazardous area classification. Non-classified
equipment shall be isolated on any such condition. Any equipment to
provide essential services required to function during these conditions, such
as telecom and safety, shall be certified to the required hazardous area
classification.
All equipment must be capable of operating for limited periods where the
HVAC systems have failed to provide adequate temperature and humidity
control. The design of equipment rooms shall minimize any temperature
and humidity rises to the most practical extent. The equipment must be
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capable of operating in extreme conditions, for example during the peak

heat of the day.
The control of HVAC for the equipment rooms shall be executed directly
from the HVAC control panel.
The HVAC control panel shall perform functions such as:
 Differential pressure monitoring and control.
 Start/stop of heaters and fans.
 Temperature monitoring and control.
 Auto-changeover and duty select of fans.
 The F&G shall perform safety related functions such as:
 Closing fire dampers
 Tripping heaters and fans (via HVAC control system)
The HVAC shall be critical since loss of pressurization within these
rooms will result in all non- certified electrical equipment being electrically
isolated due to the possible ingress of gas.
7.3.2 MAIN FACILITIES CONTROL AND TECHNICAL ROOMS

A Central Control Room (CCR), an Engineering Room, a Marshaling
Room, a Telecommunication Equipment Room, will be provided on the
plant to house control, safety and telecom systems equipment.
All the units of the plant shall be monitored and controlled by one
integrated system. Operator interfaces shall be located in the CCR for
control and monitoring of the process and utilities.
The control room shall include only hardware directly required by
operation staff; other auxiliary items which normally are not of operation
major use shall be located in the marshaling or local equipment rooms.
The engineering stations shall be installed in an engineering room
adjacent to control room. Proper Cableway shall be provided either in form
of cable trench or false flooring. Cables shall run on cable trays under false
flooring in equipment rooms.
False ceiling shall also be provided for air conditioning duct. Room
lighting shall be of proper intensity from cold source with even distribution.
No process fluid or air shall be piped into control room.
7.3.3 CABINET / PANEL

The cabinets shall be:
 Standard size for cabinet shall be 800l x 800w x 2100h (mm).any
deviation should be approved by purchase order.
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 Key lock system with the same key for all cabinets.
 Internal door pocket for drawings.
 IP42 for indoor cabinets.
 Standard type with eyelet’s.
 Painted sheet steel, according to RAL-7035 shall be Grey.
 Modular structure accessible from two sides.
 System and marshaling cabinets shall be separated.
 General earth for metallic parts.
 Separated and isolated earth for electronic circuits.
 Fans as required (with failure detection), or natural draft and thermal
control.
 Florescent lights controlled by door limit switches.
 Cable entry from bottom, with supporting bar and sealing plate.
 All cabinets and wires installed in cable duct or on cable tray, Facilities
on top for lifting with crane.
 The Supplier/Vendor for approval shall submit general panel
organization and dimensions.
7.3.4 CABINET EQUIPMENT

 The cabinet design must allow full and easy access to all
components, connections, terminations and assemblies by
installation, maintenance and repair personnel. All cabinets provided
by Supplier/Vendor shall be fully equipped/wired (frames and racks,
terminal strips and rail, wire markers and ferrules…) and ready to be
installed on site.
 System cabinets shall be equipped with front visual door for access of
modules status and alarm lamps.
 Cabinets shall further contain anti condensation heater, exhaust fan,
filter and louver and lighting.
7.3.5 CABLING
This includes wiring of all links internal to the equipment and inter-
connections:
 From marshalling cabinets to safety system hardware.

 For power, from each breaker to general cut-out.
 Interconnection cable between vendors cabinets supplied and installed
by vendor.( shall be prepared by Vendor)
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 Interconnection cable between vendor’s cabinets and other

CONTRACTOR control systems supplied by vendor but installation by
CONTRACTOR.( shall be prepared by Vendor)
Segregation of cables and wiring shall be in accordance with voltage and
level of redundancy. Internal wiring shall be flame retardant.
Space shall be left inside the cabinets to allow access to the spare
modules. In addition to space for access to components, each cabinet shall
include a minimum of 20% spare space for future expansion.
All cables shall be adequately supported and secured to prevent
unseating of the connectors and cable entry shall be C-Rail type.
7.3.6 MARKING
Each cabinet, rack, terminal block, plug, socket etc., shall be clearly
identified with a label or cable marker bearing a unique number. All cable
shall be identified using slip on, heat shrink type ferrule markers.
7.3.7 GROUNDING
The control system 24V DC signal power supply shall be floating from
ground. The following subjects shall be considered:
 Noise immunity
 Isolated signal reference
 Galvanic Isolation
Separated grounding should be considered for IS signals, Non-IS signals
and also dirty earth as required.
8. INSTRUMENTATION DESIGN
8.1 GENERAL
8.1.1 TRANSMITTERS
 Transmitters shall be smart type (for ESD transmitters should be Write
protected or conventional type), with 4-20mA signal and HART
protocol. Integral digital indicators shall be supplied for each
transmitter.
 All transmitters (pressure, flow, temperature etc.) shall be provided
with burnt-out protection.
 Electrical and electronic instruments shall meet the hazardous area
requirements.
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8.1.2 SWITCHES
 Field mounted transmitters shall be used in alarming, interlock or
shutdown services instead of field mounted switches as far as
possible.
 Field mounted switches, if any, shall operate on 24 VDC, volt free
contacts.
8.1.3 POWER SUPPLY

The 24 VDC power to all field instruments shall always be supplied by
the plant DCS and/or ESD As such all transmitters shall be of "current
sinking" type.
8.1.4 ACCURACY OF INSTRUMENTS

The minimum requirement shall be as follows:
a. Electronic transmitters: ±0.5% of calibrated span
b. Displacement type electronic Level transmitters: ± 0.5% of
calibrated span
c. PT-100 elements: IEC 751 class "A" up to 450 °C
d. Thermocouples: IEC 584-2 class 1
e. Pressure gauges: ± 0.5 % of span.
f. Thermometers: ± 1 % of span.
8.1.5 INSTRUMENTS CABLE ENTRY

Instrument cable entry size shall be ISO M20x1.5 for single pair cable
connection with the appropriate cable gland. For instruments with other
than single pair cable connection, appropriate ISO size with the cable gland
shall be specified.
8.1.6 MATERIAL
 All instrument wetted parts in connection with the process shall
generally be AISI 316, unless higher grades are required by the
process conditions. Instruments wetted part material in sour services
shall comply with NACE standard MR-01-75.
 Unless otherwise specified in this document, material of Control valve
bodies, ESD valve bodies, Orifice flanges, and in-line flow
instruments flanges, displacer type level instrument flanges shall
conform to the piping flange/valve materials in accordance with the
related Piping Specification.
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8.1.7 PRESSURE/TEMPERATURE RATING OF INSTRUMENTS AND

VALVES
Minimum rating of inline instruments and control/safety valves shall be in

accordance with the piping specification. Control, actuated (ESDV,MOV)
and safety valves shall have flanged connections with ratings in accordance
with the relevant line specification; except valves with nominal diameter ≤
1½" which shall be rated ASME/ANSI 300lb as minimum.
8.1.8 IMPULSE LINES

In general, all instrument impulse lines downstream of the first process
isolating valve shall be ½ inch OD, 316 Stainless Steel seamless tubing
with wall thickness of 0.065 inch minimum, and 316 Stainless Steel, bar
stock double-ferrule compression type fittings.
8.1.9 MANIFOLD VALVES

In addition to the process (or piping) isolation valve at the measurement
take-off point, each pressure instrument shall be provided with a dedicated
manifold valve to enable maintenance, in-situ calibration, venting and
draining. The manifold valves shall be provided as follows:
 2-valve for pressure gauges, pressure transmitters and switches.
 5-valve for DP gauges and transmitters
 Process connection of the manifold valves shall be ½ inch NPTF.
The manifold valves on Pressure and differential transmitters shall be
bracket mounted type with the base bracket mounting holes such that the
instruments can be directly connected to the manifold valves, and the
assembly can be installed and supported on 2" stanchions by bracket
mounted manifolds.
 As a minimum, material of the manifold valves shall be AISI 316
stainless steel.
8.1.10 INSTRUMENT NOZZLE RATING ON VESSELS

Minimum flange rating for instrument nozzles on vessels shall be as
follows:
 Level instrumentation standpipes: ANSI 300 #.
 Pressure relief valve: ANSI 300 #.
 All nozzle sizes equal or lower than 2 inches: ANSI 300 #.
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8.1.11 LOCAL INDICATORS

If a transmitter or any of the above mentioned instruments, serving a
control valve, has an integral indicator or a local gauge not readable from
the location of the control valve, a supplementary readable indicator or
gauge shall be provided.
8.1.12 DIAPHRAGM SEALS

 All pressure elements with diaphragm seal shall have capillary
bleeder. The entire system above the diaphragm, including the
element shall be evacuated and entirely filled with an inert liquid. The
bottom section shall be removable for cleaning.
 Where remote diaphragm seals are used, the capillary tube shall be
stainless steel 316 with stainless steel 304 armored as a minimum.
Seal liquid shall be selected such that the adverse effect of ambient
temperature change is kept to the minimum possible.
 Where Head mounted diaphragm seals are used, Integral type
instruments (transmitter / gauge / switch integral with diaphragm) could
be used. Also threaded type diaphragm seals could be used based on
pipe specification and process conditions.
8.2 FLOW INSTRUMENTS
The following types of instruments may be selected for the

measurement of liquids, vapors and gasses, when their selection can be
justified:
8.2.1 ORIFICE PLATES

 In general flow measurement shall be based on square edge
concentric type orifice plates mounted between flange taps.
 Concentric orifice plates shall be used for clean liquids, gases, and
steam flows when Reynolds numbers range from 20,000 to 107 in
pipes under six inches. Concentric orifice plates should not be used
for multi-phase fluids in horizontal lines. Eccentric and segmental
orifice plates are better suited for such applications. Concentric orifices
are still preferred for multi-phase flows in vertical lines because
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accumulation of material is less likely and the sizing data for these
plates is more reliable.
 Because of the minimum Reynolds number consideration, square-
edged orifices should not be used on viscous fluids. Quadrant-edged
and conical orifice plates are recommended when the Reynolds
number is under 10,000.
 Flange taps can be used with quadrant-edged orifices, but only corner
taps should be used with a conical orifice.
 Concentric orifices are still preferred for multi-phase flows in
vertical lines because accumulation of material is less likely and the
sizing data for these plates is more reliable.
 Orifice flanges will normally house the orifice plates unless the process
requires a senior
 (retractable) type orifice changer.
 Senior (retractable) type orifice changers shall be used in custody
transfer applications or when the process flow rate is expected to vary
on a regular basis and a different orifice size would be required.
 Orifice plates shall be 316 stainless steel in material as a minimum,
with 1/8" thickness in sizes 6" and smaller, 1/4" thickness in sizes 8" to
16", and 3/8" inch thickness in sizes 18" and larger.
 Sizing and installation of orifice plates including minimum up and
downstream lengths shall be based on the latest AGA criteria and ISO
5167 and 5168 and shall conform to the latest ASME Flow
Measurement Supplement to the ASME Power test Codes. IPS-E-IN-
130 shall be considered.
 Orifice shall be sized so that the maximum flow rate falls at
approximately 75% of maximum meter range and the minimum flow
does not be less than 25% of maximum meter range.
 The preferred differential pressure range is 250 mbar (100" water
column).
 The d/D Ratio of the orifice plate shall normally be between 0.25 and
0.70, with orifice bores of less than 0.125 inches to be avoided.
 Wherever possible meter runs shall be provided on the basis of d/D
ration not less than 0.70.
 Each plate shall be provided with a tab with projects data beyond the
flange. The symbol number, plate material, the actual measured bore
and the I.D. of the pipe shall be stamped on this tab. The tab shall be
in line with the drain or weep hole.
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 Drain or Vent valves shall be 3/4". For gas line, drain valve should be
considered and for liquid line, vent valve should be considered. For
mixed medium, both should be considered.
 Minimum pipe size for orifice flow measurement shall be 2”. Where
required, integral orifices could be used for lines smaller than 2”.
 Orifice flanges shall be consistent with ASME B16.36 and shall be of
the welding neck type.
 In flammable gas service and steam, pressure taps shall be provided
with reinforced butt- welded nipples. For other services screwed
nipples may be used if permitted by the applicable piping specification.
8.2.2 CORIOLIS
Coriolis flow meter shall be used only when flow measurement
cannot be obtained by measuring differential pressure, for large
rangeability, in applications where accurate measurement of mass flow or
density is required or corrosive services.
Coriolis meters are not suitable on liquid services containing significant
gas content, or on gas services with low in-line pressure.
Coriolis flow meters should be installed on line size 1/4" up to 8".
Preferred installation of coriolis flow meters is vertical with the flow
upwards thru the meter. If horizontal installation is the only available
method, the manufacturers’ recommendations shall prevail.
Coriolis meters on high temperature services shall have remote mounted
transmitters. The temperature limit shall be checked with the meter
vendors.
8.2.3 TURBINE
Turbine meters may be used for process flow measurement where highly
accurate, wide range measurement of very small flow rates is required or
on clean low viscosity liquids with high range-ability requirements.
Turbine meters require bypass lines, to avoid filling of subsequent piping
systems and filters in upstream direction if the fluid may be polluted.
Strainers shall be installed upstream of all turbine meters to protect it
from debris.
The minimum up and downstream pipe lengths shall follow
the manufacturers’ recommendation.
Turbine meters shall not be installed on lines prone to vibration or close
to equipment that emits electromagnetic fields.
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8.2.4 VARIABLE AREA FLOW METERS

Variable Area flow meters may be used for small flow rates where local
indications and recording is required. They may also be used where
rangeability, non-linearity, viscosity or the hazardous nature of fluid makes
the differential pressure-type instrument unsuitable.
Variable Area flow meters shall normally be the armoured type with
magnetic pick-up. ANSI 316 stainless steel tube is preferred unless the
operating conditions require a more adequate material.
Rotameters shall be installed vertically with gate type block and bypass
valves of the same size as the meter and in such a way as to allow easy
access and reading of flow rate.
Glass type variable area meters may only be used in low
pressure/temperature services and if the fluid cannot cause a hazardous
situation in case of a broken glass.
8.2.5 ULTRASONIC FLOW METERS

Ultrasonic meters may be used for applications where the minimal
pressure loss is required due to the presence of flow meter, in pipelines
applications with pigging requirements, or in flare lines.
Ultrasonic flow meters can be used in clean or dirty low viscosity &
slurry, or abrasive liquids. (The presence of bubbles or impurities within the
process fluid causes erroneous meter reading and as such care has to be
taken in their application).
If Ultrasonic meters are to be implemented they shall be multi-path
transit time type.
In order to minimize the effects of air or sediment, the transducer shall
not be located on top or bottom of the pipe.
System accuracy (meter and all compartments) shall be less than 2% of
full scale. Error shall be reduced by careful determination of pipe ID and by
increasing number of paths.
A calibration and proving procedure shall be provided to ensure high
measurement accuracy.
8.2.6 POSITIVE DISPLACEMENT FLOW METERS

Positive Displacement Meters will be used to measure the flows where
integrated flowing quantity and high accuracy is required.
Inlet piping to the positive displacement meter shall be equipped with a
strainer.
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Meter bodies shall be constructed for minimum pressure drop and have
calibration controls and integrated automatic temperature compensation.
The accuracy of the meters shall be ±0.2% or better.
Positive Displacement Meters shall meet the requirements of API
Manual of Petroleum Measurement Standards-chapter 5.2 "Measurement
of Liquid Hydrocarbons by Displacement Meters".
The Supplier in accordance with API MPMS 21.2 shall calibrate liquid
positive displacement meters.
PD flow meters shall be used only in Custody Transfer service.
8.2.7 PITOT TUBE

Pitot tubes (annubars) shall be utilized in large pipe diameters and
where accuracy is not a critical factor. Same accuracies as orifice plates
can be achieved with careful installation.
Pitot tube length and active length shall be designed to suit the pipe
diameter, and in cases where deflection or oscillation may occur, it shall be
supported or secured at the opposite side.
8.2.8 VENTURI NOZZLES

Venturi nozzles shall be generally in accordance with ISO 5167
standard.
High beta nozzles are recommended for diameter ratios between 0.45
and 0.80. Low beta nozzles are recommended for diameter ratios between
0.20 and 0.50.
8.2.9 MAGNETIC FLOW METERS

Magnetic flow meters shall be used for volumetric flow of conductive
liquids, including slurries and corrosive or abrasive materials. The minimum
fluid conductivity required is between 1 to 5 microS/cm.
8.2.10 FLOW TRANSMITTERS

Flow transmitters shall have 4-20mA HART output or frequency pulse,
local LCD indication, and powered by 24VDC. (Refer to relevant data sheet
for detail accessories.). They shall be housed in an IP65 weatherproof
enclosure.
The Differential Pressure Transmitters shall be able to withstand
the application of the maximum service static pressure to the "low"
pressure side, with the "high" side at atmospheric pressure, without any
adverse effect or requiring recalibration.
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Accuracy for flow transmitters shall be 0.5% of span or better.

Transmitters zero and span shall be adjustable and the process variable
shall be 25% to 75% of transmitter span.
Transmitters shall come with integral indicators and installed such that
they are visible from the grade or platform.
8.3 LEVEL INSTRUMENTS
8.3.1 LEVEL TRANSMITTERS FOR CONTROL OR ESD SERVICES

Every level instrument shall have a gauge glass mounted adjacent to it
for cross reference, including displacers, ball float, differential pressure
types, and hydrostatic head types, except if prohibited by the vessel code.
Level gauges shall cover the complete operating range of any other level
instrument installed on the same vessel section.
Displacement level measurement shall be used for all normal
transmitting and controlling applications, up to and including 1200 mm.
Separate dedicated instruments, preferably of a different instrument type to
prevent the probability of common mode failure, shall activate shutdown
functions.
The Differential pressure transmitter should be considered for the
applications where the ranges are beyond the normally approved
(standard) displacer range or where the presence of process (viscous,
violent boiling at liquid surface and etc) condition precludes the use of
displacer.
On vertical or horizontal vessels, level instruments may share the same
standpipe with the level gauges, while level instruments on level shutdown
service shall have independent direct vessel connections.(Level
instruments providing critical service alarms and / or shutdown signals shall
be installed by using connections separate from those used by the level
control and process alarm devices).
Level transmitters shall have 4-20mA HART output, local LCD
indication, and powered by 24VDC (Refer to relevant data sheet for detail
accessories). They shall be housed in an IP65 weatherproof enclosure.
Accuracy for level transmitters shall be 0.5% of span or better.
All transmitters’ construction materials that are exposed to the process
shall be ANSI 316 stainless steel unless the operating conditions require a
more adequate material. Those transmitters and their associated
measurement sensors that are installed in cold / cryogenic service must
have materials and gaskets that are compatible with these conditions.
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If a transmitter is used in sour service, the construction materials of the

transmitter that are exposed to the processes shall meet NACE MR-01-75.
Drain valves shall be ¾ inch, and shall be installed on the bottom
connection to level instruments, level switches and gage glasses. Drains
should be piped away from the instruments to a safe area of disposal. Vent
valves shall be ¾ inch and shall generally be piped to safe location.
8.3.2 GUIDED WAVE RADAR LEVEL MEASUREMENT

Guided wave radar transmitter shall be considered where eliminating
echo interference is needed.
Guided wave radar transmitters shall be considered only if the liquid
dielectric constant is greater than 1.4 (Low dielectrics (good insulators,
poor conductors like hydrocarbons) can be problematic for radar)
The guided wave radar sensor should be installed in an external bridle.
If a bridle installation is not possible, the sensor shall be installed at the
furthest possible point from the tank inlet and outlets.
If the transmitter is installed directly on the vessel and in the presence of
turbulence, a stilling well shall be used.
Guided wave radar level measurement is suitable to use in process
vessels containing baffles and heating coils, turbulent liquids or vapors,
powders, granulates, pellets, volatile or pressurized contents and also for
interface level measurement.
Guided wave radar transmitters and sensors shall be installed so that
there is sufficient clearance for removal and cleaning.
8.3.3 DIFFERENTIAL PRESSURE LEVEL MEASUREMENT

The Differential pressure transmitter should be considered for the
applications where the ranges are beyond the normally approved
(standard) displacer range or where the presence of process (viscous,
violent boiling at liquid surface and etc) condition precludes the use of
displacer. Also for high pressure services from 40 Bar & above, Cryogenic
services and temperature between 60 – 180 could be used.
Where plugging may occur or no suitable sensor material is available in
highly corrosive service the use of differential pressure transmitter with
diaphragm seal shall be considered. In this case, Flushing or bleed rings
shall be installed in order to aid in maintenance and cleaning.
Transmitter zero and span shall be adjustable and the process variable
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Differential pressure level instruments shall be supplied with on line

zero elevation and zero suppression capabilities.
8.3.4 DISPLACEMENT TYPE LEVEL MEASUREMENT

Displacer level instruments shall be externally mounted and supplied
with purge chamber and vent.
Side mounted external displacer type level transmitters shall be provided
with a 2” flange.
Top mounted internal displacer type level transmitters or level switches
shall be provided with a 4“flanged connection. This type is avoided unless
otherwise with Client approval.
Side mounted external displacer type level switches shall be provided
with 1” flange. The following standard ranges shall be used:
356 813 1219 1524 1829 2134 2438 2743 3048 mm
14 32 48 60 72 84 96 108 120 inch
Above 1200 mm range a differential pressure transmitter shall be used.
Upper and lower connections shall be:
 Side/bottom in general
 Top/bottom are allowed for interface
Displacement type level transmitters are recommended for use in
liquid / liquid interface applications.
Each displacement type level instrument shall be installed in its own
dedicated external cage and have sufficient clearance for installation,
removal, and cleaning. Cage shall be minimum 3” pipe diameter and shall
include 3/4" NPT vent or drain valves.
Displacers shall be long enough to cover the required measurement
range of the transmitter. All level instruments shall have vent and drain
valves.
Accuracy for Displacement type electronic Level transmitters shall be ±
0.5% of calibrated span or better.
8.3.5 LEVEL GAUGES
Magnetic level gauges may be used in services where glass is subject

to becoming dirty from process fluids, thus making it easier to interpret
liquid level.
Level gauge glasses, transparent or reflex types shall be provided for
local indication and to cover the operating range of all level measuring
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instruments with the exception of tank gauges. Reflex gauge glasses shall
be used only for all clean, non-viscous liquids except the following where
transparent gauge glasses shall be used:
 Interface between two liquids
 When the liquid temperature is below 0 ºC gauge glass shall be
provided with frost extensions
 Liquids requiring protecting shields (mica or other)
 Mica shields shall be used on steam and corrosive services
 The following centre to centre of nozzles shall be selected:
Nb and N° glasses Visibility (mm) Distance between

centers (mm)
1×9 320 600
2×9 680 950
3×9 1040 1300
4×9 1400 1650
5×9 1760 2000
The actual range is formed by the total visible glass length of all sections
per gauge.
Each level gauge shall meet the design pressure and temperature of
the vessel on which it will be installed.
Gauge body and cover shall generally be constructed of carbon
steel unless the process requires a more suitable material.
If illuminators are required, they shall be a minimum of 40 watts
and suitable for use in hazardous areas.
Level gauges shall be installed so that the visible length covers the full
operating range of the vessel including transmitter spans and level alarm or
shutdown points.
Level gauges shall be limited to 5 sections maximum. If multiple gauges
are required, they shall be overlapped such that the entire range is visible.
Frost shields shall be provided on gauge glass columns in service
where the operating temperature is below 0°C.
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Gauge glasses are prohibited for storage tanks in LPG service

(neither glass nor magnetic type).
8.3.6 LEVEL SWITCH

Mechanical switches shall be avoided whenever possible but if
necessary shall be 24VDC, 2A. Selection of the float and body material
shall be based on the design pressure and temperature
of the vessel, as well as specific gravity, viscosity, and other properties of
the fluid.
External cages shall be the preferred method of installation for level
switches. Switch function shall be snap acting, SPDT gold plated contact.
Mercury bottle switches shall not be used.
8.4 Temperature Instruments
8.4.1 TEMPERATURE ELEMENTS
Head mounted RTD or T/C 4-20 mA ‘Smart’ transmitters shall generally

be applied. For ESD Transmitters, Write protect Smart type or Conventional
type transmitters should be considered. Platinum RTD as Temperature
Element is recommended.
Resistance temperature detectors (RTD’s) shall be the preferred
method of measuring temperature for control and ESD applications.
Thermocouples shall be used for any process temperature exceeding
400°C (750°F), or for any severe service whereby an RTD is not
recommended.
Thermocouples shall be ANSI 316 stainless steel sheath 6mm diameter
type K calibration with magnesium oxide insulation. In very cold services
where type K is not suitable, the preferred ISA calibration shall be type T.
Thermocouples shall have isolated cold junction.
RTD’s and thermocouples shall be provided in complete
assemblies including head with 1/2"NPT conduit, terminal block, and
thermowell.
RTD’s shall be of 3 wire design if the lead wire is less than 100m. 4
wire designs shall be used for distances exceeding 100m.
RTD's shaft diameter should be 6mm and shall be accuracy class A.
8.4.2 THERMOWELLS
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All temperature-sensing elements shall be installed in thermowells

except for sensors that are embedded in bearings or windings.
Thermowells shall be constructed of one-piece ANSI 316 stainless
steel bar stock, unless the operating conditions require a more adequate
material.
Natural frequency, wake frequency, and maximum pressure calculations
shall be supplied for all thermowells .
Wherever possible, thermowells shall be installed horizontally in order

to prevent water from entering the thermowell.
Each test thermowell shall be supplied with enclosure cap
permanently affixed to the thermowell via stainless steel chain.
In liquid measurement, thermowells shall be installed in an active
area giving a good representation of process temperature.
Process connection for thermowells shall be 1 1/2” flanged type (at
least 300# ANSI) as per ASME B16.5 for pipe and 2” flanged type (at least
300# ANSI) as per ASME B16.5 connection for vessels. Flange material
shall be the same as specified for the associated Thermowells.
Material and tag number shall be clearly stamped / etched onto the
flange or wrench flats for each thermowell.
Thermowells installed in insulated pipes shall be ANSI flanged
according to the pipe specifications.
Thermowells should only be installed in process lines of 4” or larger.
Smaller pipe should be swaged up to 4”. If necessary, thermowells may be
installed in 3” elbows.
Thermowell lengths shall be selected such that the tip is located within
the centre one third of the pipe with maximum length of 12" according to
API MPMS 7.
The preferred installation of thermowell is vertical 180 degree on line.
Thermowells used on HP Steam and on high velocity flow service should
be welded type.
8.4.3 TEMPERATURE GAUGES
Bi-metallic elements are the preferred method of obtaining local

temperature indication.
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Bi-metallic thermometers shall have 150mm adjustable angle dials with

reset. Dials shall be dual scale (°F / °C), dry case, and scale shall be
printed in black with white background.
Operating temperature shall fall between 30% and 70% of the scale
range. Thermometer accuracy shall be ± 1 % of scale or better.
Thermometers of the filled capillary type shall be used in services where
the stem length exceeds 610 mm, where service conditions are too severe
or if there is nearby vibration or in applications where remote reading is
required.
Capillary thermometers shall be remote panel mounted and free from

mercury construction. Thermometers shall be fully compensated for
ambient temperature.
Thermometer capillaries shall be encased in ANSI 316 stainless steel
armour. Excess armour shall be coiled and fastened to the instrument
stand or tubing support.
Standard thermometer stem diameter shall be 6mm and stem
lengths shall be 4” (100mm),
6”(150mm), 9”(230mm), 12”(300mm), or 18”(460mm).
All thermometer cases shall be hermetically sealed and constructed of
ANSI 304 stainless steel. All thermometers in contact with process fluids
shall be supplied complete with thermowells. Thermometer connection to
thermowell shall be 1/2" NPT threaded.
For flange type thermowells thermometer connection shall be ¾” NPTM.
8.4.4 TEMPERATURE SWITCHES

necessary shall be 24VDC, 2A. Temperature switches shall be direct
mounted liquid filled or gas filled type.
Switches shall be fully compensated against variations in the ambient
temperature. The accuracy of the temperature switch shall be + /- 1% of
span.
Deadband shall be less than 1% of span. The deadband shall be field
adjustable.
Micro-switch shall be snap action type, hermetically sealed with gold
plated contact and it shall be SPDT type.
The contact rating for micro switches shall be 2A, 24VDC.
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The instrument shall within the middle third of the adjustable range
cover the set point of the temperature switch.
8.4.5 TEMPERATURE TRANSMITTERS
Temperature transmitters shall have 4-20mA HART output, local LCD

indication, and powered by 24VDC. (Refer to relevant data sheet for
detail accessories.). They shall be suitable for Zone 1, intrinsically safe
and housed in an IP65 weatherproof enclosure.
Local LCD indicator shall be installed such that they can be read from
the grade or platform. Transmitters shall have an accuracy of +/- 0.5% of
span or better.
Temperature transmitters shall have selectable behavior on sensor / wire
break and short circuit (upscale, downscale).
8.5 PRESSURE INSTRUMENTS
8.5.1 ELECTRONIC PRESSURE TRANSMITTERS
Pressure and differential pressure transmitters shall be diaphragm type

but other types of elements like capacitive or bourdon tube shall be
considered.
Differential pressure transmitters shall have high side (H) and low side
(L) pressure ports clearly marked on the sensor body.
Transmitters shall have 4-20mA HART output, local LCD indication,
powered by 24VDC. (Refer to relevant data sheet for detail accessories.).
They shall be suitable for Zone 1, intrinsically safe and housed in an IP65
weatherproof enclosure.
Transmitters shall have an accuracy of +/- 0.5% of span or better.
shall be 25% to 75% of transmitter span. Transmitter span must also
include the set pressure of the pressure relief valve for the system.
Pressure and differential pressure transmitters’ sensors shall be able to
withstand a minimum of 1.3 times the system design static pressure.
Pressure and differential pressure transmitter sensors shall be made of
high corrosion resistant materials that are suitable for the process
conditions.
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Transmitter sensor process connection shall be 1/2"NPTF and made

of ANSI 316 stainless steel unless the process conditions require a more
suitable material.
Transmitter housing could be of steel construction.
8.5.2 PRESSURE GAUGES

Bourdon tube pressure gauges are the preferred method of obtaining
local pressure indication. For low pressure indication where a bourdon
tube is not applicable, diaphragm or bellows sensors shall be used.
Local gauges shall have dial size of 6” (150mm). Dials shall be dual
scale (Barg / Psig), dry case, and scale printed in black on white
background.
Operating pressure shall fall between 30% and 70% of the scale range.
Pressure gauge accuracy shall be +/- 1% of span or better.
Case material shall be stainless steel.
Pressure gauge window shall be made of acrylic or shatterproof glass
with a transparency of 75% or better.
Pressure sensing elements shall be made of ANSI 316 stainless
steel unless the process conditions require a more suitable material.
Connection for process gauges shall be bottom connected 1/2"NPT
and made of the same material as the sensing element.
Pressure gauges shall be solid front with blow out back or blow out top
configuration. Pressure gauges that will be subjected to vibration shall be
liquid filled.
Liquid filling must be suitable for ambient and process temperature
conditions. Pressure gauges with electrical outputs shall not be used.
Diaphragm or chemical seals shall have a capillary bleeder in order to
relieve pressure. Pressure gauges shall be able to withstand 1.3 times the
maximum process design rating.
Where plugging may occur or no suitable sensor material is available in
highly corrosive service the use of diaphragm seal or purging shall be
considered.
Pressure gauges should be designed with vacuum protection.
8.5.3 PRESSURE SWITCH

necessary shall be 24VDC, 2A. The set point of the pressure switch shall
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be within the middle third of the adjustable range covered by the

instrument.
The pressure switches shall have internally accessible adjusters for both
set point and dead band. Adjusters shall be provided with range indication.
Pressure switches shall have standard over-range protection of minimum
130% of range and be capable of withstanding at least 1.3 times the full
static design pressure of the system without loss of accuracy.
Switch shall be snap action type, hermetically sealed with gold plated
contact and it shall be SPDT type.
8.5.4 PRESSURE INSTRUMENT INSTALLATION

In process gas measurement, pressure instruments shall be installed
such that the impulse line will not trap liquid that will affect the pressure
reading.
In process liquid measurement, pressure instruments shall be installed
such that solids or sediments do not plug the impulse line.
All pressure indicators shall be installed such that they are readable from
the grade or platform. Diaphragm or chemical seals shall be used in the
following harsh process environments:
 Fluids that are corrosive to the wetted surfaces of sensors
 Fluids that carry solids that can collect and plug sensors
 Fluids that may solidify and plug sensors
Cooling elements, capillary lines, or siphons shall be used for steam and
other fluids where temperatures can exceed 100°C
Pulsation dampeners or snubbers shall be used if the process pressure
is prone to pulsation such as those of reciprocating pump discharge and
suction and discharge of reciprocating compressors.
Block and bleed valves shall be installed for each individual instrument.
Differential pressure gauges and transmitters shall be installed with
3-valve manifolds for viscous liquid service and 5-valve manifold for light
liquid and gas service.
Gauge protectors shall be installed wherever there is a possibility of
overpressure.
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9. VALVE AND ACTUATORS DESIGN CRITERIA
9.1 CONTROL VALVE SELECTION CRITERIA
Unless otherwise required in the instrument data sheets or

dictated by its application the selection of a type of valve should be done
under the following order of preference:
 Globe or angle valves type shall be considered as the preferred
standard. Butterfly valves shall be selected for large flow rate with low-
pressure drop.
 Characterized ball valves shall be considered as an alternative to
standard globe valves when the process fluid is containing suspended
solids or is tending to polymerize or crystallize.
Special body types such as angle, split body, ‘Y” etc., may be considered
when the process fluid may be erosive, viscous or carrying suspended
solids.
The leakage class for all control valves shall be in accordance with
ANSI-FCI-70-2.
The maximum allowed A-weighted sound pressure (noise) level
of control valve on continuous duty, measured at 1 meter downstream of
the control valve at a distance of 1 meter from the pipe, shall not exceed 85
dB (A) under any of the operating conditions (min./norm./max. flow).
The stroking time of a control valve is defined as the time required
stroking the valve from 2% opening to 98% opening and vice versa
while it is at operating (min. to max.) differential pressure.
9.2 CONTROL VALVE INSTALLATION
Installation of control valves shall be in accordance with ANSI/ISA.

All control valves shall be installed with block and bypass valves with
bleed.
Flanges shall be in accordance with ANSI B16.5 up to 24”
inclusive and face to face dimensions according to ISA S75.03. and
ASME B 16.10.
Minimum control valve body size shall be 1”
The bonnet shall be of standard design where the operating temperature
of the fluid is between 0°C and 200°C. Finned or extended if the operating
temperature of the process fluid is greater than 200°C and the packing is
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Teflon based. Extended bonnet shall be used for temperatures between

0°C and -40°C and extra long bonnet shall be used for operating
temperatures below -40°C.
Radiation fins or extension bonnets shall be used on all hot (over 200°C)
or cold (under 0°C) processes respectively. All bonnets shall be bolted to
the valve body with flanges completed with appropriate gaskets.
Control valve body size shall not be less than two lines sizes smaller
than the nominal inlet pipe size.
Only standard control valve sizes shall be used. (1”, 1.5”, 2”, 3”, 4”, 6”, 8”,
10”, etc.)
Control valves shall be installed with the stem in the vertical position with
the actuator above the valve body.
All control valves shall have a permanently affixed stainless steel tag
with the following inscribed information:
Manufacturers name, Valve model and serial number
 Tag Number
 Valve action on air failure
 Body size, flange rating, type, material and Cv
 Trim size , type and material
 Control Characteristics
 Actuator size, model and serial number
 Maximum actuator supply pressure and bench set
Valve body shall have an arrow indicating flow direction.
9.3 CONTROL VALVE MATERIALS OF CONSTRUCTION
Valve body shall be made of carbon steel unless the pipe specification
requires other materials,
Depending on the characteristics of the process medium .Minimum
material for trim is hardened stainless steel. Stellited or higher grade
Hastelloy shall be used depending on if they are more suitable for the
particular process conditions.
Teflon shall be the preferred packing material for fluids under 200°C. For
fluids over 230°C, special packing using grafoil or equivalent materials may
be used.
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Packing shall not contain asbestos or external lubrication or grease

nipples. If used in sour service, control valves shall comply with NACE MR-
01-75.
Bellows seal bonnet extensions with double packing shall be applied for
services with toxic fluids.
9.4 CONTROL VALVE SIZING CRITERIA
The selected Cv shall be at least equal to the maximum calculated Cv

multiplied by 1.25 if not otherwise indicated on individual data sheets.
Range ability of the valve shall be such that the opening of the valve is
never less than 15-25% of the controllable Cv value for the minimum flow
through the valve.
If in primary design stage maximum flow is not available, then valves
shall be selected to have twice 1.4 *Cv at normal flow.
Unless otherwise specified, butterfly valves shall be sized for a
maximum opening angle of 60°, with the exception of valves with
characterized disk which must be sized for a maximum angle of 90°.
Sizing calculation sheets are required for control valve sizing. The
calculations will be executed according to either ISA S75-1 Control valve
sizing equation.
Vendor shall advise where any fluid velocity for a specified
valve would exceed the recommended limit and where cavitation,
flashing, erosion or fouling may occur.
Unless otherwise specified, the velocity of the process medium at the
valve outlet flange shall be no greater than 6 m/s for liquids and, in standard
practice, less than or equal to 0.33 Mach, at operating conditions, for gas
and vapor.
9.5 ACTUATORS
The preferred type of actuator shall be spring return pneumatically

operated diaphragm type. If differential pressure prohibits diaphragm use,
pneumatic piston type shall be considered.
If process differential pressure is severe, hydraulic actuators with volume
cylinder shall be considered.
Diaphragms shall be manufactured in a material which withstands age
deterioration and the environmental conditions.
Pneumatic actuator cases shall be in carbon steel. All internal parts and
the actuator springs shall be treated and painted against corrosion attack.
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The actuator shall be sized by the Manufacturer to ensure operation

under the worst possible conditions, e.g. with maximum differential pressure
and valve closed (difference between maximum upstream pressure and
downstream pressure assumed to be zero) and with the minimum actuator
air supply pressure.
All actuators used on shutdown valves must be installed with dome
indicators that show open and closed positions. Dome indicators shall be
housed in a clear, acrylic chamber and shall have two distinct colours; one
showing open position and the other showing closed position.
The Blow Down Valves (BDV) shall be fire safe in accordance with API
6F.
9.6 POSITIONERS
Positioners shall be of Smart type.

All control valves used in PID or critical control loops shall
incorporate the use of electropnuematic positioners.
Electropnuematic positioners shall be suitable for Zone 1, intrinsically
safe and housed in an IP65 weatherproof enclosure and accept a 4-20mA
signal and an instrument air supply. All positioners shall come with
stainless steel 2 1/2” (64 mm) pressure gauges to show supply and output
pressures.
Positioners shall be supplied with input and output gauges and shall be
easily convertible from direct to reverse action.
Positioners shall be capable to communicate with HART protocol.
Air sets (regulator with filter) shall be installed on the valve using 1/4”
ANSI 316 stainless steel tubing with compression fittings.
Air sets, solenoid valves and pneumatic tubing sizes shall be 1/4” for
control valves and ½” for shutdown valves. For large shutdown valves ½”
tubing shall be used as required.
9.7 ON/OFF ESD (SHUTDOWN) VALVES
Shutdown and / or depressurizing valves shall not be combined with

control operation. Shutdown valve body shall be the same size as the inlet
pipe size.
Shutdown valves shall be operated using pneumatic or hydraulic spring
return or double acting actuators without positioner.
All hydraulically actuated shutdown valves shall be provided with
individual accumulators. Shutdown valves with associated actuators and
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accessories shall be leak tested API fire safe and certified by the
manufacturer.
Shutdown valves shall be installed with accessories that enable them to
be tested regularly. Shutdown valves shall be fail-closed unless ESD
conditions dictate otherwise.
Shutdown valve stroking time shall encourage stability and safety. The
following guides shall be adhered to:
 For tripping, one second per inch of nominal valve bore;
 For resetting, three seconds per inch of nominal valve bore.
Speed control and quick exhaust valves may be used to facilitate the
appropriate stroking time.
Also for better safety and performance, Tight Shut-off "V" and Partial
Stroking facility (for larger than 10") shall be considered. ESD valves should
have local reset.
9.8 CONTROL VALVE LIMIT STOPS
If used on rotary valves, limit stops shall be mounted directly on the

actuator, adjustable at both the 0° and 90° positions. They shall be field
adjustable without dismantling the actuator.
If used on sliding stem valves, adjustable, screwed bolt type limit stops
shall be mounted directly on the valve stem.
All limit stops shall be provided with a locking mechanism to prevent
tampering.
9.9 PROCESS REGULATORS
Self-Acting regulators shall only be considered in clean fluids for the

purpose of pressure and backpressure regulation.
9.10 LIMIT SWITCHES
All shutdown valves shall be supplied with two proximity type limit
switches (One for open position and one to show closed position).
Limit switches shall be explosion proof EEXD or intrinsically safe EEx-ia
IIB T3 suitable for Zone 1, and shall be housed in an IP65 weatherproofs
enclosure.
Limit switches shall be hermetically sealed “REED” type having 2 SPDT
contact with 1Amp, 24VDC rating.
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9.11 SOLENOID VALVES
Solenoid valves shall be the preferred method for actuation of shutdown

valves.
Solenoid valves shall not be used directly for on-off process control. i.e.
Only used for instrument air or hydraulic applications.
In normal operating conditions, the solenoid valve shall be normally
energized via 24 VDC coils. They shall be suitable for Zone 1, Eexd
and housed in an IP65 weatherproof enclosure.
Solenoid valves shall be sized such that they can provide sufficient Cv
for the actuation of control or shutdown valves within the appropriate time
frame.
Solenoid valve exhaust ports shall be fitted with a length of 1/2” ANSI
316 stainless steel tubing bent to point downwards with a cut off angle of
45 to prevent plugging.
Solenoid valves used for shutdown valve actuation shall be installed
directly to the actuator. Solenoid valves used for control valve actuation
shall be installed between the positioner output and the actuator input.
9.12 HAND WHEEL/ LOCKUP VALVE
Where a hand wheel is required, the shaft-mounted declutchable type

shall be furnished.
9.13 LOCK-UP VALVES
Air Lock-up valves shall be provided when the control valve shall remain
in the last position in case of failure of the instrument air supply.
The lock-up valve shall have a bolt adjustment provided with a locking
facility, for example a locking nut to prevent tampering.
A separate nameplate shall be provided to indicate the set values.
The lockup valves shall be set at 0.5 bar above the required control
valve air supply pressure, unless some other set value is required for a
particular actuator. The lock up valves shall be properly adjusted by the
Vendor.
For Control valves with a valve positioner, the lockup valve shall be
installed between the positioner output and the actuator.
Where lockup valves are applied on valves operated by a solenoid valve,
this solenoid valve shall be installed between the lockup valve and the
actuator.
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9.14 PRESSURE SAFETY VALVES (PSV)
9.14.1 PRESSURE SAFETY VALVE REQUIREMENTS
Safety relief valves shall be provided to protect all equipment subject to

overpressure and under certain other conditions as specified herein.
Unless otherwise specified in this Specification, the safety devices shall
be provided when the overpressure exceeds the design pressure of the
equipment.
ASME Code stamp is required for all pressure relieving devices
except for the cases not required in the relevant data sheet.
The design of pressure and vacuum relief devices for storage tanks
should be in accordance with API Standard 2000 "Venting Atmospheric
and Low pressure Storage Tanks (Non- Refrigerated and Refrigerated),
unless otherwise specified in this Standard.
The required orifice area shall be determined in accordance with API
Recommended Practice 520 Part I Appendix C.
All safety relief valves shall be provided with pressure tight bonnets
except balanced type valves and the valves in steam and hot water
services. The safety relief valves in steam and hot water services shall be
provided with open bonnets.
Springs are usually designed and fabricated to the manufacturers own
standards.
Snuffing steam shall be provided for safety valves discharging to
atmosphere in the following services:
 Material above its auto-ignition point.
 Light hydrocarbon service at locations listed in the job specification
where hazard of exposure to lightning is prevalent due to high rate of
electrical storms.
 When snuffing steam is required, provide a DN 25 (one inch) snuffing
steam connection approximately 300 mm from outlet end of the
discharge piping. The steam line to this connection shall be run to
grade, provided with a double valve and bleeder at grade and a steam
condensate trap upstream of the double valves.
All pressure relief valves (except thermal relief valves) with the inlet
nozzle size of DN 25 (1 in.) and larger should be flanged, spring loaded,
high lift, high capacity type with a top guided disc. Pressure relief valves
with the inlet nozzle size under DN 25 may be of the screwed type
connection.
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9.14.2 PRESSURE SAFETY VALVE - MATERIALS OF CONSTRUCTION
The following materials shall be used for PSV construction, unless

the operating conditions require a more adequate material:
 Body and bonnet – carbon steel

 Spring – carbon steel (sweet service) or inconel (NACE service)
 Trim (nozzle, disc, guide) – ANSI 316 stainless steel
9.14.3 BREATHER VALVE
If breather valves are specified, they shall prevent moisture from

entering containers as well as protect the container from excessive
pressure or vacuum differentials.
Breather valves shall meet the specified service and fluid.
The vendor shall supply calculation for breather pressure release
threshold.
10. SIGNAL TRANSMISSION, WIRING, INSTRUMENT AIR AND

HOOKUP
10.1 SIGNAL TRANSMISSION
Generally the electric signal shall be used for transmission to equipment.

Pneumatic signals shall be limited to I/P or smart positioner output.
Care shall be taken to employ standard signals all over the Plant.
Electronic and signal wiring shall be adequately separated from power
wiring and electrical equipment to minimize electromagnetic interferences.
Cables shall be segregated as follows:
 Low voltage level cables non-intrinsically safe (24 VDC, electronic and
temperature).
 Cables intrinsically safe (24 VDC, electronic).
 230 VAC power cables (as far as possible).
 Redundant communication cables shall be routed by two different
ways.
Separation of instrument and power cable on parallel routes shall be as
follows:
POWER CABLE SPACING
125 V or 10 A 300 mm
250 V or 50 A 450 mm
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440 V or 200 A 600 mm

3.3 kV or 800 A 1400 mm
11 kV or 1500 A 1800 mm
These distances shall be considered as a minimum.
10.2 FIELD AND CONTROL/EQUIPMENT ROOM WIRING SYSTEM
Enclosures of junction boxes shall be made of cast aluminum or

stainless steel and the accessories shall be of suitable material.
Junction boxes shall be EExd or EExe.
Single pair or triad shielded twisted cable shall be used to connect field-
mounted instrument to local junction boxes. Single cables shall be
armoured types laid in galvanized carbon steel conduits with open ends or
on closed cable trays. In order not to damage the cable, a plastic annular
cap shall cover the tube end.
Multi-pair cables shall be used to connect field mounted junction boxes
to the marshaling cabinets. Multi-pair cables shall be armoured type and
shall run in concrete trench or direct buried.
Following different type of cables shall run in separate cable trays:
 Intrinsically safe analogue signals
 Intrinsically safe discrete signals
 Signal cables not intrinsically
 Instrument power supply cables
 Coaxial cables or telephone cables used as serial data buses
20% installed spare cores/pairs/triples accordingly shall be considered
for cables and terminals. Cable specification shall be in accordance with
IEC standard.
10.3 INSTRUMENT AIR SUPPLY DISTRIBUTION
An Instrument air header shall execute the instrument air supply

distribution with take-off valves provided by piping in all unit areas.
The sub-distribution branch headers shall be made by means of
galvanized carbon steel pipes and threaded fitting. Sub-distribution branch
headers shall be sized as indicated below:
 ½ “ for up to 5 users
 ¾” for up to 10 users
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CLIENT: CONSULTANT:


Consultant Project
No.:
 1” for up to 15 users
 1 1/2” for up to 20 users
Each Pneumatic user shall be provided with ¼” stainless steel valve and
one air filter regulator with pressure gauge (pressure gauge in case of
control valves shall be installed on the positioner). On/off ball valves will
be equipped with filter only.
All tubing for field-mounted pneumatic equipment shall be ½ inch
OD, 316 Stainless Steel seamless tubing with wall thickness of 0.035
inch, and 316 Stainless Steel, bar stock double- ferrule compression type
fittings.
10.4 HOOK-UP CONNECTIONS
In general, stainless steel tubing with stainless steel compression

fittings shall be used for process impulse line from piping take-off valve to
the instruments. Instruments including the differential pressure transmitters
used for flow measurement shall be installed at ground level or on
platforms.
Impulse lines and bodies of instruments shall be heat traced in following
cases and indicated on P&IDs:
 When the fluid on the process line can frost in ambient conditions;
 To prevent plugging of impulse line or instruments bodies due to the
high fluid viscosity;
 To avoid a critical condensation on the impulse line due to the ambient
temperature.
10.5 INSTRUMENT POWER SUPPLY DISTRIBUTION:
An Uninterruptible Power Supply (UPS) shall be furnished to provide a

minimum of 120 minutes electrical supply in case of power failure.
The 230V 50Hz UPS shall be used to supply the following:
 Control systems
 Shutdown and alarm systems
 Fire and Gas detection systems
 Field electrical systems
 Analyzer systems
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Consultant Project
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Power supply inside DCS, F&G and ESD systems shall be designed with
backup redundancy i.e. in case of one power failure; the associated
consumers shall automatically be fed from another stand-by power supply.
Using self-regulated DC-power supplies fed at 230V 50Hz for
supply to field electronic transmitters and implement the logic of the alarm
and shut down system, shall generate 24VDC.
20% of installed spare breakers and fuses shall be provided for future
expansion.
10.6 NAMEPLATES / TAGGING
Each instrument, equipment, cabinet and panel included in vendor’s

scope of supply shall have its individual name and tag plate.
All instruments shall be supplied with a stainless steel tag either fixed
to the instrument using stainless steel rivets or wire .Each tag shall have
the instrument tag number stamped or etched onto it and also including of
manufacture name, and model number, adjust measuring range, span
limit, type of signal, power supply protection class and classification type
(for electrical instruments only) have to be shown at the instruments in
weatherproof form.
Plate size, characters and character format shall be submitted for
EMPLOYER/CONTRACTOR’s review and approval.
10.7 MATERIAL SELECTION
As a minimum, all piping and flange connections shall meet the design
requirements of the piping class or vessel design limits to which it is
connected.
10.8 INSTRUMENT CONNECTIONS
Instrument cable entry size shall be ISO M20 X1.5 for single pair cable
connection with the appropriate cable gland. For instruments with other
than single pair cable connection, appropriate ISO size with the cable gland
shall be specified.
Earthing connection for instrument case and panel shall be done based
on earthing philosophy.
10.9 INSTRUMENT SIGNALS
Instrument signal shall be conventional 4-20 mADC with super-imposed

Hart Protocol.
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Consultant Project
No.:
A reliable and fast communication protocol, conforming to internationally

well known and proven industry standards, such as MODBUS protocol
based on RS-485 physical layer with error checking and handling shall be
employed in the field and data buses to link the main control system, DCS,
to be supplied under this specification. Description of bus linking for data
transfer to DCS along with signals and signals level should be specified to
meet the project requirement such as distances and available DCS
communication module according to international standards.
10.10 PAINTING
The paint system that is supplied on all instrumentation must be able to

meet the harsh environmental conditions experienced at the plant site.
Manufacturers’ standard finish that meet or exceed these requirements may
be accepted upon customer approval.
Painting shall be based on IPS-M-IN-220 section 9.
10.11 SPARE PARTS
The manufacturers shall recommend spare parts list for start-up;

commissioning and two years operation.
Spare Parts shall be in accordance with IPS-M-IN-220 Section 4.5.
10.12 INSPECTION AND TESTING
The supplier shall prepare a Factory Acceptance Test (FAT) procedure

document covering all inspection and test requirements for the packaged
system. This document shall be presented to the CONTRACTOR for review
and approval before the commencement of any system tests.
FAT shall be conducted at the supplier’s works with representation
from the CONTRACTOR throughout the FAT procedure.
Inspection shall be in accordance with IPS-M-IN-220 Section 6.
10.13 TEST ASSEMBLING
 Check of easy accessibility and removal of individual components

 Check of terminal strips functional separation
 Check of wiring separation for intrinsically safe circuits
 Check of wiring separation for various voltage steps
 Check of cable (color, section, length)
 Check of available spare capacity (20% installed)
 Check of space for future expansion (20% future)
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Consultant Project
No.:
10.14 Check and Test of the Integrated System (including consoles,

printers, communication networks, etc.)
 Verification of all reference documents for the FAT

 Check of the correspondence of bill of materials and the integrated
equipment
 Visual check of the preservation status of each component
 Accessories check
 Visual check of labeling and marking
10.15 Hardware system
 Check of peripheral systems wiring

 External interfaced systems compatibility check
10.16 Functional checks and tests of the configuration
 Check of standard software package completeness and updating

 Integrated test of the correctness of database and tag assignment and
addressing of input/output signal up to external terminal strips.
 Test of the implementation of specified algorithms and controls
 Check of static part and test of dynamic part of graphic displays
 Trend, alarm groups test
 Reports and events test
 Diagnostic functions test
10.17 Application software test
 Communication with external systems functional test

 Display of transmitter data and report generation
11. DOCUMENTATION
All documents and drawings produced by the vendor to satisfy

the requirements of this specification shall be in English language.
Documentation shall be in accordance with IPS-M-IN-100 Section 4.
Required documents which should be prepared by Vendor shall be listed in
Material requisition document.
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CLIENT: CONSULTANT:

National Iranian Oil Company

SOHRAB WELL HEAD NO.1 FLOW LINE TO

“INSTRUMENT DESIGN CRITERIA”

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Revision Summary Index

Prepared R.A R.A

Checked S.SH S.SH

Approved M.N M.N

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4. UNITS 10

5. ENVIRONMENTAL CONDITIONS AND PROTECTION 10

6. GENERAL 11

7. CONTROL SYSTEM DESIGN PHILOSOPHY 11

National Iranian Oil Company

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7.3.6 MARKING .................................................................................................................. 21

8. INSTRUMENTATION DESIGN 21

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8.5.2 Pressure Gauges ........................................................................................................... 37

9. VALVE AND ACTUATORS DESIGN CRITERIA 39

10. SIGNAL TRANSMISSION, WIRING, INSTRUMENT AIR AND HOOKUP 46

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11. DOCUMENTATION 51

The major sections of the project are:

- Wellhead facilities (at WH No.1).

1.1 Terms and Definitions

Owner/ client: Arvandan Oil & Gas Company (AOGC)

EPC Contractor: Shall Mean The Contractor Responsible

Consultant: Enerchimi Engineering Company (EEC)

Vendor/ Supplier: Refers to firm or person who will supply

Will: is normally used in connection with the

May: is used where a provision is completely

Should: is used where a provision is advisory

Shall: is used where a provision is mandatory.

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CCR Central Control Room

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National Iranian Oil Company

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3.1 ANSI(AMERICAN NATIONAL STANDARDS INSTITUTE)

3.2 API (AMERICAN PETROLEUM INSTITUTE)

MPMS Chapter 5.2 “Measurement of Liquid Hydrocarbons by Displacement Meters”

3.3 ASME(AMERICAN SOCIETY OF MECHANICAL ENGINEERS)

3.4 IEC(INTERNATIONAL ELECTRO-TECHNICAL COMMISSION)

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National Iranian Oil Company

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IEC 60794 Optical Fiber Cable

3.5 ISA(INSTRUMENTATION, SYSTEM, AUTOMATION SOCIETY OF

3.6 ISO (INTERNATIONAL STANDARD ORGANISATION)

3.7 NACE (NATIONAL ASSOCIATION OF CORROSION ENGINEERS)

3.8 IPS(IRANIAN PETROCHEMICAL STANDARD)