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guidance. The user is strongly advised to contact the Technology Manual Sponsor to
determine the appropriate subject matter expert for consultation on applicability to the
user’s specific case.
Abstract
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This section covers recommended practices for the installation of field mounted
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instruments and provides information on the installation of pneumatic and electrical
signal transmission systems.
For details concerning the installation of specific process instruments (such as indi-
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vidual pressure, temperature, level, and flow devices) see the corresponding sections
of this manual.
Contents Page
1610
1611
Introduction
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Process Connections and Piping
1600-3
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1612 Pneumatic Installations
1613 Electrical Installations
1614 Suggested Checklist
1620 Instrument Installation and Mounting 1600-4
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Instrumentation and Control Manual 1600 Field Instrument Installation
1610 Introduction
This section provides general guidance on designing and reviewing instrument
installations. To minimize design effort and manpower, a uniform approach to
installation design should be established and followed for each facility. Installation
design decisions and possible modifications must be made well before the construc-
tion stage. Otherwise, design omissions and modifications will cause scheduling
constraints, encourage installers to improvise, possibly violate Standards and Codes,
and compromise the quality of the installation.
Instrument installations fall into three distinct categories:
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• Process connections and piping
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• Pneumatic connections
• Electrical connections and wiring details
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1611 Process Connections and Piping
Process connections and piping cover the physical installation and piping up of field
instruments (sensors) that come in direct contact with process fluid. These instru-
ments may get connected to piping, pressure vessels, or mechanical equipment
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depending on their function. Their installation, to ensure that they provide mean-
ingful and reliable data is a primary concern. The designs must be economic, safe,
and maintainable.
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To provide the most accurate readout, instruments should be mounted as closely as
possible to their process connections. However, accessibility for maintenance and
adverse ambient conditions at the process, e.g., vibration or high temperature, may
require that the instruments be mounted remotely and connected by piping to their
process connections. Also, instruments that tie into safety monitoring and/or shut-
ed
down systems must be installed so that they are testable without shutting down the
process while they are being tested.
Process installation design and review by the responsible instrument engineer
include location and support of instruments, design of process piping and the test
connections (if necessary), and assuring that the connecting piping stays functional
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1600 Field Instrument Installation Instrumentation and Control Manual
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reliability, and conformance to codes.
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1614 Suggested Checklist
Review the following during the design phase:
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• Proper sizes and rating of process connections on piping, vessels, and major
equipment
• Instrument installation details and piping isometrics
•
•
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Heat tracings purges and winterizing of instruments, if applicable
Pneumatic installation details
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• Electrical installation details
• Equipment-vendor-supplied instrumentation
This review should be given particular emphasis. Vendors are inclined to omit root
valves and may try to substitute inferior instruments and installation material.
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Instrumentation and Control Manual 1600 Field Instrument Installation
The instrument engineers and designers should review the location of the process
connections against the P&IDs to ensure the following are correct:
1. Orientation of instrument block and bleed valves is in compliance with piping
and instrument specifications.
2. Process connections of in-line mounted instruments match the connections
provided by piping designers (e.g., flange size and rating), block valves (where
required), and that adequate accessibility for servicing and for manual opera-
tion has been provided.
3. Shutdown switches cannot be inadvertently blocked off while isolating other
instruments for maintenance. Shutdown actuating devices should be installed
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on dedicated process connections, separately from other instruments.
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Once the exact locations of instrument process connections are established, the
instrument installation details and instrument location plan drawings should be
finalized.
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Instrument Installation Detail Drawings
Instrument installation details should provide the instrument connection arrange-
ment and tabulate the material required for the installation. When many instruments
•
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need to be installed, it is easier to separate the details by their function such as:
• Process connections
Pneumatic connections
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• Electrical connections
• Heat tracing and winterizing
• Miscellaneous (field supports, special fittings, etc.)
This approach is more efficient because the same process connection detail may
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1600 Field Instrument Installation Instrumentation and Control Manual
• Instruments are mounted below the line, and the process lead slopes up to the
process connection in liquid services.
• Remotely mounted instruments are installed using stainless steel tubing beyond
the root valve. The tubing should be installed with a minimum slope of 1/2 inch
per foot (1 to 2 inches per foot is preferable if space permits) and should be
routed to avoid formation of pockets (high or low points where liquid or vapor
can get trapped and introduce an error into the instrument reading).
• Sufficiently long meter runs (upstream and downstream) have been provided
for flow instruments that require meter runs, e.g., orifice meters, vortex shed-
ding meters, or turbine meters.
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• Straightening vanes in lieu of long meter runs (to reduce turbulence in the flow)
have been considered where space is limited.
• Orifice meter runs in wet gas or vapor service should either be oriented verti-
cally with downward flow, or have a weep hole in the orifice plate in a hori-
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zontal run, to prevent accumulation of liquid on the upstream face of the plate.
• Differential pressure (d/p) flow instruments on orifice meters, both transmitters
and bellows-type readouts and switches, have been provided with bypass mani-
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folds at the instrument. (Three-valve manifolds are used in most manufacturing
and chemical applications. Five-valve manifolds are used in production appli-
cations.) These manifolds are used by maintenance to zero and calibrate the
meters.
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• On orifice meters in liquid service, the process taps are below the center of the
line (but not in the bottom), and the instrument is installed below the line.
• On orifice meters in steam service, process leads are extended above the line to
exactly the same elevation before they are routed back down to the instrument
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mounted below the line. In steam service, steam condenses in the process leads
and the condensate isolates the instrument from the high temperature of the
steam. Running the leads up to the same elevation keeps the height of the
condensate in the leads equal and balances out errors that would be introduced
if the leads were at different elevations.
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• Seal pots are provided on bellows-type orifice meters in steam service. Bellows
meters are high displacement instruments and if the flow changed, an error
equal to the displacement of condensate in the leads would be introduced until
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the steam recondensed. Seal pots provide a surge volume in this application.
• Seal pots are provided on all steam orifice meters in freezing climates. In
freezing climates, steam meter leads have to be filled with anti-freeze. Seal pots
identify the instruments that need to be winterized and state the type of anti-
freeze used.
• All blind (nonindicating) transmitters and switches have been provided with
pressure gages.
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Instrumentation and Control Manual 1600 Field Instrument Installation
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fluid isolated from the instrument by seal pots, diaphragm seals (gage protec-
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tors), purging, or other means. Refer to Section 1500, “Instrument Seals,
Purges, and Winterizing”,” of this manual and ICM-EF-409 “Seal, Purging, and
Winterizing of Instruments.”
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Standard Drawings GB-J1143 through GB-J1148 show typical installation details
for pressure instruments. Standard Drawings GB-J1158 through GBJ1173 show
typical installation details for level instruments. Standard Drawings GB-J1177
through GB-J1187 show typical installation details for flow meters. Standard Draw-
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ings GB-J1196 through GB-J1203 show methods for installing temperature sensing
elements in process lines and equipment.
With proper tools tubing can be bent to form slopes, pigtails and the required
configuration for the process installation of instruments.
Instrument process tubing should conform to ASTM A269. The tubing can be 304
or 316 stainless steel.
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Seamless, fully annealed and pickled tubing is usually preferred. Welded tubing is
available, but there have been problems with the quality of the welds. ASTM A269
requires that the allowable working pressure for welded tubing be derated.
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Figure 1600-1 shows allowable working pressures for seamless tubing and specifies
the ASTM derating requirements.
Allowable working pressure at -20F to 100F is calculated as specified by
ANSI B31.3 code.
Tube Fittings
Tube fittings for process tubing should be the flareless compression type of 316
stainless steel and should conform to ASTM A269.
Male threads should be rolled. Nuts should be pre-lubricated.
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5/16 — 4000 5800 8000
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3/8 — 3300 4800 6500
1/2 — 2400 3500 4700
(1) For welded tubing, multiply pressure rating by 0.80 for single welded tubing and 0.85 for double welded tubing.
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Tests performed by Chevron Research Corporation and by several fitting manufac-
turers show that unless a compression fitting is improperly installed (mismatched
fitting components, fitting not tightened properly, ferrule installed backwards, or the
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tube not inserted completely into the fitting before tightening), the tube will burst
before a compression fitting will fail. Therefore, the allowable working pressure of
the tubing is the limiting factor on tubing installations.
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Instrument Hand Valves
Instrument hand valves are defined as block, bypass, or bleed valves; remote or
close coupled with instruments; mounted between process root valves and
instruments.
The instrument hand valves can be single valves, single valves with multiports, and
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Three- or five-valve manifolds are used for differential pressure instruments where
the block, bypass, and bleed valving combinations are required for servicing and
calibration of instruments.
Three-valve manifolds are also used for pressure instruments where an additional
gage and bleed connection is required.
Valve bodies, stems, and trim should be 316 stainless steel.
Valves in services with pressures below 4,000 psig can have compression-type
tubing connectors.
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Valves in services above 4,000 psig should have bar-stock bodies and threaded end
connections.
Teflon packing can be specified for services below 400F (204C).
Grafoil packing should be specified for services above 400F (204C).
Additional piping material like nipples and pipe fittings should be in accordance
with applicable piping specifications.
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pipe mounting brackets. Surface mountings are available for mounting instruments
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remotely from the process. The required mounting must be specified by the instru-
ment engineer. The 2-inch pipe mounting brackets are specified for most field
mounted instruments.
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Types of Standard Instrument Supports
1. Free standing 2-inch pipe stanchions with flanged, concrete, or welded base
2. Two-inch pipe saddle type supports (with U-bolt clamps to process pipe)
3.
4.
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Two-inch pipe supports with welded or flanged wall mountings
Two-inch multiple pipe supports for two or three instruments
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5. Surface mounts supported by 2-inch pipe
6. Target supports for field gages
See Standard Drawing GB-J1233, Field Mountings for Instruments.
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Field recorders and indicating controllers are usually mounted on free standing
2-inch pipe stanchions that are easily accessible for calibration and servicing.
However, it is sometimes desirable to rack mount these instruments with surface
mounts.
Most field gages, switches, and all of the temperature elements are line-mounted
(i.e., screwed directly into root valves or process connections). Temperature
elements can also be flanged to process connections.
If it is preferred that the readout be located mounted remotely from process connec-
tion, field gages can be ordered as surface-mounted.
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structural steel. They can also be bolted to concrete floors and walls.
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Welding on process equipment or process piping is never allowed.
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Instrument location plan drawings furnish the following design and construction
information:
• The approximate locations and mounting elevations of remotely mounted
•
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instruments (relative to some fixed point such as a pipe line, process connec-
tions, or final control element)
The approximate location of instrument air subheaders (relative to main air
headers)
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• The exact locations and orientation of instrument junction and terminal boxes
• The approximate routing of tubing runs
When remotely mounted instruments are used, the instrument engineer should
review the installation details and the instrument location plan drawings to ensure
that the following conditions are met:
• Easy access is provided for maintenance, repair, and calibration.
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• Sufficient front and rear clearance is allowed for access to and removal of the
instrument.
• There is a clearance of at least 2 feet per 100F (38C) between equipment with
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Instrumentation and Control Manual 1600 Field Instrument Installation
• Instruments in gas, vapor service and services where plugging is likely to occur,
are installed above their process connections.
• Instruments in clear liquid and steam services are installed below their process
connections.
• Indicating controllers or receiver gages from non-indicating transmitters are
installed where their scales can be clearly visible from a point where manual
control may need to be performed, e.g., at the by-pass valve around a control
valve manifold.
• Instruments are not mounted on handrails or on removable structures.
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• Instruments are not mounted in locations subject to leaks, spills, or damage
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from process equipment. Where such locations are unavoidable, a suitable
shield or protective cover is provided.
• Instruments are not attached to vibrating structures. Where such locations are
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unavoidable, antivibration mounts should be provided.
• Instruments are not located in areas where the ambient temperature exceeds the
limits specified by the manufacturer.
Instrument access requirements for specific instruments are given in Figure 1600-2.
• Grade or Permanent Platform Access: Platforms should have either permanent
ladders or permanent stairways.
• Permanent Ladder Access: Access while standing on a permanent ladder.
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Routine Test Facilities Yes No No
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for Alarms and
Shutdowns
Control Valves and Yes No No
other Final Control
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Elements
Field Pressure Gages Yes Yes Yes
Dial Thermometers Yes Yes Yes
Thermocouples and Yes Yes Yes
Resistance Bulbs
Temperature Test
Points
Level Gage Glasses
Yes
Yes
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No
Yes
Yes
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Analytical and Other Yes No No
Special Instruments(1)
Hydrogen Sulfide, Combus- Yes Yes No
tible Sensors, etc.
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(1) This includes but is not limited to radioactive, chromatographic, capacitance, pH, boiling point, moisture, viscosity, oxygen,
and specific gravity analyzers.
that a maintenance person can work on the instrument at chest height if at all
possible.
Process connections for instruments mounted in overhead pipeways above the line
or in multilevel pipelines should be grouped and installed where they can be reached
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• Manufacturer
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• Model
• Serial number
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• Instrument tag number
• Hazardous area class and group suitability
• A statement indicating that the instrument is intrinsically safe
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A statement indicating that any substitution of components may impair intrinsic
safety
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• The agency certifying that the equipment is intrinsically safe
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1600 Field Instrument Installation Instrumentation and Control Manual
The primary system for distributing air to instruments in a facility is usually routed
throughout the facility and is referred to as an instrument air header. Branch connec-
tions or laterals are piped from this header to provide air to instruments located in
the same operating area. The size of these laterals is determined by the number of
air users that the lateral has to supply.
Branch headers and laterals should be sized as follows:
Number of Instruments Supplied Branch or Lateral Size
1 to 5 ½ inch
6 to 10 ¾ inch
11 to 25 1 inch
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Full port ball valves are usually installed at each lateral and also at each end of the
air header (for blowdown). Standard Drawing GB-J1214, Instrument Air Supply
Header shows a typical air header layout.
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Supply to Individual Instruments
To minimize the air header size and to provide the needs of all final control
elements, instrument air is usually distributed at a high pressure. Individual instru-
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ments operate at much lower pressures and cannot withstand the pressure at which
air is available in the air header.
To ensure that instruments operate properly and are not over-pressured, instrument
air pressure is normally reduced at each instrument to match the rating of the instru-
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ment. Most transmitters and controllers require 18 to 22-psig instrument air, some
controllers and all diaphragm control valves positioners require a 40-psig air supply,
piston actuators and some other control elements require 60-psig and higher air
supplies. Pressure gages on the outlet of the regulators (integral with or separate
from the regulators) are used to set the air pressure.
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or ½-inch OD tubing.
Standard Drawings GB-J1208 through GB-J1213 show typical instrument air supply
piping to instruments.
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Instrumentation and Control Manual 1600 Field Instrument Installation
available that are rated for direct burial — most Chevron Operating Companies
avoid burying multitube cables without protection for fear of unforeseen physical
damage, e.g., a backhoe cutting through a cable and shutting down a facility.
Pneumatic transmission systems should be designed to limit transit time to about
3 seconds. If transit time is greater than 3 seconds, volume boosters should be
provided to keep the transit time down.
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Tubing Supports
Single and multiple tubing runs should be supported every 3 feet of running length,
both in and out of raceways.
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For support, single tubing runs should be placed in small steel channels or in galva-
nized thin wall steel conduits. Up to four tubes may be run in a single support
conduit.
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Exposed ends of tubing should be not less than 18 inches nor more than 24 inches in
length. Burrs and sharp edges should be removed from conduit ends to minimize
damage to plastic coating of tubes.
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Pneumatic Tube Routing
Instrument tubing should be installed in raceways, on pipe racks, or otherwise
supported to result in a plumb, level, vibration free and neat installation.
Tubing should be routed so to avoid removal of the tubing when maintenance or
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Plastic cable tubing should be installed away from any heat source and should be
suitably protected in areas of likely mechanical damage.
Preferred cable sizes are 4, 12, and 19 tubes per cable. Spare tubes should be
provided in each cable; 2 in 4, 3 in 12, and 4 in 19.
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1600 Field Instrument Installation Instrumentation and Control Manual
Conduits should be sized for a maximum of 53% fill. The total degrees of bend
should not exceed 360 degrees between pull boxes. Permissible bend radius, pulling
length, pulling load, and handling method should comply with the manufacturer’s
recommendations.
Preferred multi-tube cable sizes for underground installation are 19 and 37. Spare
tubings should be provided in each cable; 4 in 19 and 6 in 37.
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Tubing lines should be supported with tubing trays or channels. The installed tubing
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trays should not present a hazard to personnel, block accessways, or prevent passage
of equipment. Tubing raceways of heavy-duty reinforced fiberglass or hot deep
galvanized steel (galvanized in accordance with ASTM A123, Specification for Zinc
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(Hot-Galvanized) Coatings on Products Fabricated from Rolled, Pressed, and
Forged Steel Shapes, Plates, Bars, and Strip) may be required for some applica-
tions.
neers. Instrument engineers who are not electrical engineers should have a solid
understanding of electrical installation techniques and wiring and should be thor-
oughly familiar with the National Electric Code (NEC).
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Power should be turned on in a purged instrument enclosure only after a four-
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volume purge (ten volume for enclosures exceeding 10 cubic feet) has been
completed and a minimum internal pressure of 0.1-inch water column has been
established.
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Type X purging requires that all electrical power to the purged enclosure be de-ener-
gized in the event of purge failure. Purge failure should be monitored and an alarm
actuated by a pressure switch.
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1634 Electrical Signal Transmission
This subsection provides an overview of wiring designs and installations for the
instrument engineer. The installation of the electrical signal transmission systems
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should be coordinated with electrical engineers.
level is 4 to 20 mA.
ages are 24 volts DC and 120 volts AC. The operating signal level is 4-20 MA.
ment and Control Cable Signal and Multipair Construction.” The wire size
requirements depend on the classification of the signal as defined by the NEC.
Single-pair instrument signal lines are usually wired to field junction boxes with
screw-clamp type terminal blocks.
Multiconductor cables are run from field junction boxes to control panels. The size
of multiconductor cables should be in accordance with ELC-MS-3551. The most
commonly used cable for low voltage signal level is No.16 American Wire Gage
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1600 Field Instrument Installation Instrumentation and Control Manual
(AWG), twisted, shielded pair. NEC defines signal level classes and defines wire
sizes for each class.
Cable Routing
Parallel runs as well as crossovers of control signal wiring and cables and power
wiring and cables require separation to prevent induction of stray voltages into the
low level signal wiring. Specification ELC-MS-1675 in the Electrical Manual tabu-
lates separation requirements based on signal levels and power levels.
Control signal cables should not be routed through areas where a high risk of fire or
mechanical damage exists, e.g., pump rows.
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Intrinsically Safe Systems
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Intrinsically safe systems are described in detail in Section 1400, “Intrinsic Safety”,
of this manual.
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Basically, intrinsically safe equipment and wiring are incapable of releasing enough
thermal or electrical energy to cause ignition of a specific hazardous mixture in its
most easily ignited concentration. Intrinsically safe installations are much more cost
effective in hazardous (classified) locations when armored cables and cable trays are
used for signal routing instead of explosionproof fittings and conduit.
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For a system to be intrinsically safe, power and current going to the field devices
must be limited, and all field components must be certified intrinsically safe.
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Intrinsically safe field devices must be so identified. Instruments that have been
tested and approved for intrinsically safe applications are identified by a blue label
that states that the instrument is certified as intrinsically safe. Intrinsically safe
system wiring should be identified by either color coding all cables, wire and
conduits with a light blue color or by identifying them by other means such as signs
or tags.
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System Grounds
Incorrect grounding of instrument components and systems can introduce stray volt-
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ages and inaccurate reference ground potentials into the signals generated and
received by electronic instrumentation. Requirements for grounding and isolating
instruments and systems are explained in detail in Specification ICM-MS-3651,
“Installation of Digital Instruments and Computers.”
Standard Drawing GF-J1236, “Typical Ground System for Digital Instrumentation
and Process Computers,” which is referenced in ICM-MS-3651 and is also enclosed
in this manual shows recommended grounding connections for various combina-
tions of electrical and electronic instruments and systems. This drawing was
produced as a result of troubleshooting many grounding related problems in control
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Instrumentation and Control Manual 1600 Field Instrument Installation
systems. This drawing has also been reviewed and is supported by most of the major
electronic instrumentation and control system vendors.
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• Separate trays should be provided for instrument signal cables and power
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cables.
• Overhead routing of instrument cable trays usually provides the best possible
mechanical protection and isolation of cables from electrical interferences.
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• Instrument cable trays should be routed away from pump rows and other high
fire hazard areas.
• Cable tray installations should not present a hazard to operating and mainte-
•
nance personnel.
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Material for cable trays and accessories should be chosen in accordance with
the guidelines in the Electrical Manual.
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Electrical Junction Boxes for Instruments
Electrical junction boxes for outdoor instrument signal wiring should be installed
complete with mounting hardware, nameplates, terminal blocks, and wiring. In
addition, the following conditions should be met:
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ICM-MS-4815 Instrument Item List
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1642 Standard Drawings
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ICM-EF-409 Seals, Purging and Winterizing of Instruments
GB-J1143 Pressure Gage installation - 3/4" Root Valve
GB-J1144
GB-J1145
GB-J1146
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Pressure Gage with Diaph. Seal - 3/4" Root Valve
Remote Mounted Pressure Instrument
Remote Mounted Pressure Instrument — With Pressure Gage
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GB-J1148 Draft Gage
GB-J1158 Level Gage With Screwed Process Connections
GB-J1159 Level Gage With 150# Flanged Process Connections
GB-J1160 Level Gage With 300# Flanged Process Connections
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Connections
GB-J1164 Level Instrument, External Displacer Type With Screwed
Process Connections
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ment Above Taps
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GB-J1178 Differential Pressure Flow Instrument, Liquid Service - Instru-
ment Below Taps
GB-J1179 Differential Pressure Flow Instrument, Dry Gas Service -
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Instrument Below Taps
GB-J1180 Differential Pressure Flow Instrument, Wet Gas Service -
Instrument Below Taps
GB-J1181
GB-J1182
atDifferential Pressure Flow Instrument, Steam Service - Instru-
ment Below Taps
Differential Pressure Flow Transmitter, Gas Service - Instru-
ment Above Taps
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GB-J1183 Differential Pressure Flow Transmitter, Liquid Service -
Instrument Below Taps
GB-J1184 Differential Pressure Flow Transmitter, Dry Gas Service -
Instrument Below Taps
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1600 Field Instrument Installation Instrumentation and Control Manual
1650 References
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API RP 14F, Design and Installation of Electrical Systems for Offshore Production
Platforms
API RP-551, Process Measurement Instrumentation
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API RP 552, Transmission Systems
ASTM A123, Specification For Zinc (Hot-Galvanized) Coatings on Products Fabri-
cated From Rolled, Pressed, and Forged Steel Plates, Bars and Ships
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