5578 E2 SP IU 00001 R0 Instrumentation and Control

PROJECT TECHNICAL SPECIFICATION

ABU DHABI OIL REFINING COMPANY

RUWAIS REFINERY EXPANSION PROJECT

AGREEMENT NO.: 09-5578-E-2

INSTRUMENTATION AND CONTROL

DOC. NO. : 5578-E2-SP-IU-00001 Rev. 0 Page 1/94

GS ENGINEERING & CONSTRUCTION CORP. GS Tower, 537 Namdaemun-ro 5Ga, Joong-Gu, Seoul, Korea









This page is a record of all revisions of this document. All previous issues are hereby superseded and are to be destroyed.

REV DATE DESCRIPTION PRPD CHKD REVD APPRD COMPANY

0 14 Jun 10 For Construction H.M.J. S.J.K. Y.S.K. C.H.L.

B 02 Apr 10 For Approval H.M.J. S.J.K. Y.S.K. C.H.L.

A 23 Feb 10 For Review & Comment Y.S.H. S.J.K. Y.S.K. C.H.L.

SIGNED (Initials)

NOTES;

(a) Revision bar (vertical line) would be placed in the left or right hand margin to indicate where the change has been made.

(b) PRPD = Prepared by, CHKD = Checked by, REVD = Reviewed by

APPRD = Approved by

(c) In case of conflict between any requirements stipulated in this document with the contractual requirements, the contractual requirements shall prevail.








.

PARAGRAPHS REVISED THIS ISSUE

Para. No. Para. No. Para. No. Para. No.

1.3

3.0

3.5

10.2.3

10.2.6

11.1.7

12.1

15.21.4

15.21.5

19.2








TABLE OF CONTENTS

1.0 GENERAL ..........................................................................................................................................7 1.1 INTRODUCTION ....................................................................................................................7 1.2 PURPOSE.................................................................................................................................7 1.3 DEFINITIONS .........................................................................................................................7 1.4 EXCLUSIONS .......................................................................................................................11

2.0 CODES AND STANDARDS............................................................................................................11 3.0 REFERENCE DOCUMENTS ..........................................................................................................15

3.1 INSTRUMENTATION - GENERAL SPECIFICATIONS.....................................................15 3.2 INSTRUMENTATION - EQUIPMENT SPECIFICATIONS ................................................16 3.3 INSTRUMENTATION - SYSTEM SPECIFICATIONS........................................................16 3.4 INSTRUMENTATION - STANDARD DRAWINGS ............................................................17 3.5 ELECTRICAL - GENERAL SPECIFICATIONS ..................................................................19 3.6 ELECTRICAL - EQUIPMENT SPECIFICATIONS .............................................................19 3.7 ELECTRICAL - STANDARD DRAWINGS .........................................................................19 3.8 PIPING - GENERAL SPECIFICATIONS .............................................................................19 3.9 PIPING - STANDARD DRAWINGS ....................................................................................19 3.10 PIPING - STANDARD PRACTICES ....................................................................................20 3.11 ARCHITECTURAL - GENERAL SPECIFICATIONS .........................................................20 3.12 MECHANICAL - GENERAL SPECIFICATIONS................................................................20 3.13 STRUCTURAL - GENERAL SPECIFICATIONS ................................................................20

4.0 DOCUMENT PRECEDENCE .........................................................................................................21 5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL .........................................................21 6.0 QUALITY ASSURANCE/QUALITY CONTROL ..........................................................................21 7.0 DOCUMENTATION ........................................................................................................................22 8.0 SUBCONTRACTORS/VENDORS..................................................................................................23 9.0 HANDLING......................................................................................................................................23 10.0 DESIGN ............................................................................................................................................23

10.1 DRAWINGS AND SPECIFICATIONS .................................................................................23 10.2 INSTRUMENT SYMBOLS AND IDENTIFICATION.........................................................29

11.0 SYSTEM TECHNICAL REQUIREMENTS....................................................................................30 11.1 GENERAL CONTROL PHILOSOPHY ................................................................................30 11.2 CONTROL AND MONITORING SYSTEMS.......................................................................33

12.0 FEED INSTRUMENT GENERAL REQUIREMENTS...................................................................36 12.1 CLIMATE...............................................................................................................................36 12.2 INSTRUMENT ENCLOSURE ..............................................................................................37 12.3 PAINTING..............................................................................................................................37 12.4 TROPICALIZATION.............................................................................................................38

13.0 HAZARDOUS AREA ......................................................................................................................38 13.1 HAZARDOUS AREA CLASSIFICATION ...........................................................................38 13.2 INSTRUMENTS SAFETY CLASSIFICATION....................................................................38 13.3 TYPE TEST CERTIFICATE ..................................................................................................39 13.4 CERTIFIED AUTHORITIES.................................................................................................40

14.0 INSTRUMENT PASSIVE PROTECTION AGAINST FIRE...........................................................40








15.0 SELECTION OF INSTRUMENTS ..................................................................................................40 15.1 GENERAL..............................................................................................................................40 15.2 CHARTS AND SCALES .......................................................................................................41 15.3 RADIO FREQUENCY INTERFERENCE ............................................................................42 15.4 TRANSMITTERS AND LOCAL INDICATORS..................................................................42 15.5 TRANSMITTER TEST/CONNECTION BOXES.................................................................42 15.6 FLANGE SURFACE FINISH................................................................................................43 15.7 RATING OF PRESSURE-CONTAINING PARTS................................................................43 15.8 SELECTION OF MATERIALS .............................................................................................43 15.9 FLOW MEASUREMENT......................................................................................................47 15.10 LEVEL MEASUREMENT ....................................................................................................51 15.11 PRESSURE MEASUREMENT .............................................................................................54 15.12 TEMPERATURE MEASUREMENT ....................................................................................55 15.13 ELECTRICAL PARAMETERS .............................................................................................61 15.14 SPEED INSTRUMENTS .......................................................................................................61 15.15 MACHINE MONITORS........................................................................................................61 15.16 ON-LINE PROCESS STREAM ANALYZERS.....................................................................64 15.17 RECEIVER INSTRUMENTS................................................................................................64 15.18 CONTROL VALVES..............................................................................................................64 15.19 SAFETY AND RELIEF VALVES..........................................................................................70 15.20 MOVS.....................................................................................................................................73 15.21 ELECTRONIC AND ELECTRICAL CABLES ....................................................................73 15.22 CORROSION MONITORING...............................................................................................76

16.0 INSTRUMENT CONTROL BUILDINGS AND ROOMS AND SISS ............................................76 16.1 GENERAL..............................................................................................................................76 16.2 LIGHTING .............................................................................................................................77 16.3 FALSE FLOORS ....................................................................................................................77 16.4 FALSE CEILINGS .................................................................................................................77 16.5 NOISE ....................................................................................................................................77 16.6 FIRE AND GAS DETECTION AND PROTECTION...........................................................77 16.7 TELEPHONES, INTERCOMS, PUBLIC ADDRESS...........................................................78

17.0 CABINETS AND LOCAL CONTROL PANELS ............................................................................78 17.1 INSTRUMENT IN LOCAL PANELS....................................................................................79 17.2 MARSHALING CABINETS .................................................................................................79

18.0 INSTRUMENT AIR SUPPLY..........................................................................................................80 19.0 ELECTRICAL POWER SUPPLIES AND EARTHING ..................................................................80

19.1 GENERAL..............................................................................................................................80 19.2 EARTHING ............................................................................................................................81

20.0 INSTRUMENT INSTALLATION....................................................................................................82 20.1 GENERAL..............................................................................................................................82 20.2 INSTRUMENT INSTALLATION DETAILS ........................................................................83 20.3 PACKAGE EQUIPMENT INSTRUMENTATION ...............................................................83 20.4 INSTRUMENT MOUNTING................................................................................................84 20.5 INSTRUMENT PROTECTION.............................................................................................84 20.6 HAZARDOUS SERVICE ......................................................................................................85 20.7 INSTRUMENT PROCESS CONNECTIONS .......................................................................86








20.8 INSTRUMENT PROCESS PIPING ......................................................................................87 20.9 INSTRUMENT AIR PIPING .................................................................................................88 20.10 SUNSHADES.........................................................................................................................90 20.11 PASSIVE CONDITIONED SHELTERS................................................................................90

21.0 LABELING.......................................................................................................................................90 22.0 INSTRUMENT RECEIVING, STORAGE AND INSTALLATION ................................................91

22.1 GENERAL..............................................................................................................................91 23.0 PAINTING ........................................................................................................................................92 24.0 TRAINING .......................................................................................................................................92

APPENDIX 1 ..............................................................................................................................................94








1.0 GENERAL

1.1 INTRODUCTION

This design specification along with specifications, practices, and standards referenced herein, provides the basis for engineering and design of the instrumentation required for monitoring and control to be provided for the Project.

The Ruwais Refinery Expansion (RRE) project includes new refinery process and associated offsite and utility units.

1.2 PURPOSE

The purpose of this specification is to establish the minimum design requirements and standards for Process Instrumentation and Control Systems and will apply to the following tasks for the Project:

a. Basic Engineering or FEED

b. Detailed Engineering

c. Purchasing

d. Construction

e. Installation

f. Commissioning

g. Licensor Coordination

Deviations from the requirements of this specification shall not be allowed unless a specific and express waiver is given by the COMPANY in writing.

The objective of the COMPANY is to achieve a design strategy based on minimizing the Life Cycle Cost (cost of ownership) by utilizing the state-of-the-art in proven technology.

Standardization of Philosophy of Design, drawing format, material (instrumentation and installation material), shall be assured across-the-board for all units (main plant, licensed units, package units, etc.).

1.3 DEFINITIONS

For the purposes of this specification, the following definitions shall apply:

General Definitions:

COMPANY ABU DHABI OIL REFINING COMPANY

CONTRACTOR GS Engineering & Construction (GS E&C)








MANUFACTURER/VENDOR Shall be defined as the supplier of equipment and support services for a particular piece of equipment/package.

CONCESSION REQUEST A deviation requested by the SUBCONTRACTOR or VENDOR, usually after receiving the contract package or purchase order. Often, it refers to an authorization to use, repair, recondition, reclaim, or release materials, components or equipment already in progress or completely manufactured but which does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is subject to COMPANY approval.

SHALL Indicates a mandatory requirement.

SHOULD The use of the word should indicates a strong recommendation to comply with the requirements of this document.

Specific Definitions:

GUP The General Utilities Plant (an ongoing project at the Ruwais Facility).

ICS Integrated Control System.

CENTRAL CONTROL ROOM(CCR) The Central Control Room for the Ruwais Refinery Expansion Project.

SATELLITE INSTRUMENT SHELTERS(SIS) A normally un-manned air-conditioned building housing control systems cabinets for local process units with operator and engineering workstations for local control and monitoring in special situations.

AMADAS Analyzer Management and Data Acquisition System

AMS Asset Management System

APC Advanced Process Control

BEDD Basic Engineering Design Data

BMS Burner Management System

BPSD Barrels Per Stream Day

BRC Blend Ratio Control

CMS Corrosion Monitoring System

CMMMS Centralised Maintenance & Materials Management System

DC Direct Current








DCS Distributed Control System

EDP Emergency DePressurising

EDMS Electronic Document Management System

EMS Emission Monitoring System

EPC Engineering, Procurement and Construction

ESD Emergency Shutdown System

FF FOUNDATION FieldBus

FAS Fire Alarm System

FAT Factory Acceptance Test

F&G Fire & Gas System

GDS Gas Detection System

GUP General Utilities Plant

HART Highway Addressable Remote Transducer

HSSD High Sensitivity Smoke Detection

ICS Integrated Control System

I/O Inputs/Outputs

IPCS Integrated Protection Control System

IPS Instrumented Protection System

KBPCD Thousands of Barrels Per Calendar Day

KTPA Thousands of Tonnes per Annum

LIMS Laboratory Information Management System

LPG Liquid Petroleum Gas

MCC Motor Control Centre

MIS Management Information System








MCMS Machinery Condition Monitoring System

MTPA Millions of Tonnes per Annum

MVC Multi Variable Control

OD Office Domain

ODBC Open Database Connectivity

OPC OLE (Object Linking and Embedding) for Process Control

PC Personal Computer

PCD Process Control Domain

PCN Process Control Network

PIS Plant Information System

PLC Programmable Logic Controller

PSA Pressure Swing Absorption (commonly used for H2 purification)

QMI Quality Measuring Instruments

RFCC Residue Fluid Catalytic Cracker

RON Research Octane Number

RRD Ruwais Refinery Division

RRE Ruwais Refinery Expansion

RTDB Real Time Database

SAT Site Acceptance Test

SIL Safety Integrity Level

SMART Self-Monitoring Analysis and Reporting Technology

SOER Sequence of Event Recorder

TGS Tank Gauging System

TIC Total Installed Cost








TUV Technische Uberwachungs Verein

UCP Unit Control Panel

1.4 EXCLUSIONS

This section is not applicable to this Specification.

2.0 CODES AND STANDARDS

It shall be the VENDORS responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.

The following codes and standards shall, to the extent specified herein, form a part of this specification.

Vendor to state with bid, current revision of all applicable standards that are referenced.

American Petroleum Institute (API)

API RP 520 Part 1 Sizing, Selection and Installation of Pressure-Relieving Devices in Refineries Part 1 Sizing and Selection

API RP 520 Part 2 Sizing, Selection, and Installation of Pressure-Relieving Device in Refineries Part 2 Installation

API RP 521 Guide for Pressure Relief and Depressurizing Systems (for information purpose only)

API STD 526 Flanged Steel Pressure Relief Valves

API STD 527 Seat Tightness of Pressure Relief Valves

API RP 551 Process Measurement Instrumentation

API RP 552 Transmission Systems

API RP 554 Process Instrumentation and Control

API RP 555 Process Analyzers

API STD 670 Vibration, Axial Position and Bearing Temperature Monitoring Systems

API STD 2000 Venting Atmospheric and Low-Pressure Storage Tanks Non-Refrigerated and Refrigerated








API MPMS 14.3.2 Manual of Petroleum Measurement Standards

Chapter 14 Natural Gas Fluid Measurements

Section 3 Concentric, Square-edged Orifice meters

Part 2 Specification and Installation Requirements

American Society of Mechanical Engineers (ASME)

ASME Boiler and Pressure Vessel Code Section I

Power Boiler

ASME Boiler and Pressure Vessel Code Section VIII

Pressure Vessel

B16.5 Pipe Flanges and Flanged Fittings

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

B31.1 Power Piping

B31.3 Process Piping

B46.1 Surface Texture, Surface Roughness, Waviness and Lay

ASME PTC 19 Series

Performance Test Codes

American Society for Testing and Materials (ASTM)

G93-88 Standard Practice for Cleaning Methods for Material and Equipment Used in Oxygen Enriched Environments

Deutsches Institut Fur Normung e.V. (DIN)

DIN 43760 Standard for Resistance Temperature Detectors (RTDs)

Fluid Control Institute (FCI)

FCI 70-2 Control Valve Seat Leakage

Energy Institute (EI)








EI Model Code P15

Model code of safe practice in the petroleum industry Part 15: Area Classification code for installations handling flammable fluids.

International Electrotechnical Commission (IEC)

IEC 60079-1 Construction and Verification Test of Flameproof Enclosure of Electric Apparatus

IEC 60079-0 Electrical Apparatus for Explosive Gas Atmosphere - General Requirements

IEC 60079-11 Construction and Test Intrinsically-Safe and Associated Apparatus

IEC 60079-14 Electrical Installation in Explosive Gas Atmosphere

IEC 60189-1 to 7 Low Frequency Cables and Wires with Insulation and PVC Sheath

IEC 60227-1 to 5 Polyvinyl Chloride Insulated Cables, Rated Voltage Up to and Including 450/750 V

IEC 60245-1 to 4 Rubber Insulated Cables of Rated Voltage Up to and Including 450/750 V

IEC 60331 Fire Resisting Characteristics of Electric Cables

IEC 60332 Test on Electric Cables Under Fire Conditions

IEC 60529 Degrees for Protection Provided by Enclosures (IP Code)

IEC 60584-1 Reference Tables - Thermocouples

IEC 60584-2 Thermocouple - Tolerance

IEC 60751 Industrial Platinum Resistance Thermometer Sensors

IEC 61000-4-3 Electromagnetic Compatibility (EMC) Part 4-3.

Testing And Measurement Technique Radiated, Radio-Frequency, Electromagnetic Field Immunity

IEC 61131-3 Programmable Controllers Part 3 Programming Languages Second Edition

International Organization for Standardization (ISO)








ISO No. 5167-1 Measurement of fluid flow by means of pressure differential devices inserted in circular cross-section conduits running full - Part 1: General principles and requirements

ISO No. 5167-2 Measurement of fluid flow by means of pressure differential devices inserted in circular cross-section conduits running full - Part 2: Orifice plates

ISO No. 5167-3 Measurement of fluid flow by means of pressure differential devices inserted in circular cross-section conduits running full - Part 3: Nozzles and Venturi nozzles

ISO No. 5167-4 Measurement of fluid flow by means of pressure differential devices inserted in circular cross-section conduits running full - Part 4: Venturi tubes

ISO 5168 Measurement of fluid flow - Procedures for the evaluation of uncertainties

ISO 9001-2000 Quality Management System Requirements

ISO 9004-2000 Quality Management Guidelines for Performance Improvement System

ISO 19011 Guidelines for quality and/or environmental management systems auditing

Instrumentation Systems and Automation Society (ISA)

ISA 5.1 Instruments Symbols and Identification

ISA 5.2 Binary Logic Diagrams for Process Operation

ISA 5.3 Graphic Symbols for Distributed Control - Shared Display

Information, Logic and Computer Systems.

ISA 5.4 Instrument Loop Diagrams

ISA 5.5 Graphic Symbols for Process Displays

ISA 8.1 Annunciator Sequence and Specifications

ISA 20 Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves

ISA MC96. 1 Temperature Measurement Thermocouples








ISA RP60. 1 Control Center Facilities

ISA RP60.3 Human Engineering for Control Centers

ISA 75.01.01 Flow Equations for Sizing Control Valves

ISA 75.08.01 Face-to-Face Dimensions for Flanged Globe-Style Control Valve Bodies: ANSI Classes 125, 150, 250, 300 and 600

ISA 51.1 Process Instrumentation Terminology

Telecommunication

ETISALAT Requirements as per International Radio Consultative Committee (CCIR) N385-1 Line of Sight

CCITT International Consultative Committee for Telegrams and Telephone

IEEE International Electrical Electronic Engineers (USA)

National Association of Corrosion Engineers (NACE)

MR-01-03 Sulfide Stress Cracking Resistant Metallic Materials for Oilfield Equipment

3.0 REFERENCE DOCUMENTS

The following Project Specifications and Standards shall act as the guidelines for this Project.

During engineering, any conflicts with or exceptions to the Project Specifications and Standards shall be identified to the COMPANY in writing for clarification.

3.1 INSTRUMENTATION - GENERAL SPECIFICATIONS

5578-E2-SP-IU-00002 Instrument Installation Design

5578-E2-SP-IU-00003 Instrument Piping Systems Material Specification

5578-E2-SP-IU-00004 Instrument Storage and Calibration

5578-E2-SP-IU-00005 Instrument Piping - Field Pressure Testing

5578-E2-SP-IU-00007 Instruments Furnished with Packaged Units

5578-E2-SP-IU-00009 Instrumentation for Depressuring Systems








5578-E2-SP-IU-00010 Analyzer Shelters

5578-E2-SP-IU-00011 Packaged Analyzer Systems

5578-E2-SP-IU-00012 Pressure Relief Devices

5578-E2-SP-IU-00050 ESD & On/Off Valves

5578-E2-SP-IU-00051 Instrument Numbering Rules

3.2 INSTRUMENTATION - EQUIPMENT SPECIFICATIONS

5578-E2-SP-IE-00001 Flow Instruments

5578-E2-SP-IE-00002 dp Type Flow Elements and Meter Runs

5578-E2-SP-IE-00003 Control Valves

5578-E2-SP-IE-00907 Telecommunication Cable

5578-E2-SP-IE-00008 Instrument and Thermocouple Cable

5578-E2-SP-IE-00009 Motor Operated Valves

3.3 INSTRUMENTATION - SYSTEM SPECIFICATIONS

5578-E2-SP-IS-00001 Distributed Control System (DCS)

5578-AMD-IS-002 Integrated Control System Vendor (ICV)

5578-E2-SP-IS-00003 Fire and Gas Detection System

5578-E2-SP-IS-00004 Emergency Shutdown System (ESD)

5578-E2-SP-IS-00005 Programmable Logic Controllers (PLC)

5578-E2-SP-IS-00008 Closed Circuit Television System (CCTV)

5578-E2-SP-IS-00909 Telephone Sets

5578-E2-SP-IS-00910 PA and Intercom System

5578-E2-SP-IS-00011 Machinery Condition Monitoring (MCM)

5578-E2-SP-IS-00014 Marshaling Cabinets

5578-E2-SP-IS-00015 System Cables








5578-E2-SP-IS-00020 Custody Metering Systems

5578-AMD-IS-021 Trunked Radio Systems (TRS)

5578-E2-SP-IS-00022 Burner Management Systems

5578-E2-SP-IS-00024 Continuous Emission Monitoring System (CEMS)

5578-E2-SP-IS-00925 Structured Cabling System

5578-E2-SP-IS-00050 Analyzer Management System

5578-AMD-IS-051 Laboratory Information Management System (LIMS)

5578-E2-SP-IS-00052 Compressor Control System

5578-AMD-IS-054 Oil Movement

5578-E2-SP-IS-00055 Asset Management System

5578-AMD-IS-056 Management Information System (MIS)

5578-AMD-IS-057 Plant Information System (PIS)

5578-E2-SP-IS-00058 Corrosion Monitoring System (CMS)

5578-AMD-IS-059 Online Optimization

5578-AMD-IS-060 Product Blending

5578-E2-SP-IS-00061 APC Strategy

5578-AMD-IS-062 Tank Gauging System

5578-E2-SP-IS-00063 Operator Training Simulator

5578-E2-SP-IS-00064 Alarm Management

5578-E2-SP-IS-00066 Design Rules for DCS Graphics

5578-E3-SP-IS-00067 Fieldbus Implementation Guidelines

5578-AMD-IS-068 System Security

3.4 INSTRUMENTATION - STANDARD DRAWINGS








5578-STD-IU-00001 Typical Arrangement for Fire Detection Tubing-Floating Roof Tanks

5578-STD-IU-00002 Typical Arrangement for Fire Detection Tubing

5578-STD-IU-00004 Analyzer Sample System (150# Service) to Analyzer House

5578-STD-IU-00005 Analyzer Sample System with Steam Tracing (600# Service) to Analyzer House

5578-STD-IU-00006 Analyzer Sample Return (600# Service) Sample to Analyzer House

5578-STD-IU-00007 Analyzer Sample System (600# Service) Steam Traced to Analyzer House

5578-STD-IU-00008 Analyzer Sample System (150# Service) with Pre-Cond. Sys. Analyzer House

5578-STD-IU-00011 Instrument Nameplates

5578-STD-IU-00012 Instrument Nameplates

5578-STD-IU-00013 Purge Orifice Nipple

5578-STD-IU-00014 Parallel Threaded Connections

5578-STD-IU-00015 Mounting Plate (L-Shape)

5578-STD-IU-00016 Mounting Plate (Rectangular)

5578-STD-IU-00017 Cubicle Panel for Compressor or Boiler Instruments

5578-STD-IU-00018 Level Gauges (Reflex Type)

5578-STD-IU-00019 Level Gauges (Transparent Type)

5578-STD-IU-00020 Level Transmitters (Displacer Type)

5578-STD-IU-00021 Flanged Thermowell

5578-STD-IU-00022 Backup Flange for Flanged Thermowell

5578-STD-IU-00023 Threaded Thermowell

5578-STD-IU-00024 Thermocouple Assembly (Standard)

5578-STD-IU-00025 Thermocouple Assembly (Furnace Tube Skin)








5578-STD-IU-00026 Thermocouple Assembly (Reactor Skin)

5578-STD-IU-00027 Thermocouple Assembly (Reactor Multipoint)

5578-STD-IU-00028 Symbology for Instrument Loop Drawings

5578-STD-IU-00029 Symbology for Logic Diagrams

5578-STD-IU-00030 Orifice Plates

5578-STD-IU-00031 Instrument Installation Details

3.5 ELECTRICAL - GENERAL SPECIFICATIONS

5578-E2-SP-EU-00001 Electrical Design Guidelines

5578-E2-SP-EU-00002 Specification for Electrical Items on Packaged Equipment

5578-E2-SP-EU-00020 Field Commissioning of Electrical Installation and Equipment

3.6 ELECTRICAL - EQUIPMENT SPECIFICATIONS

3.7 ELECTRICAL - STANDARD DRAWINGS

5578-STD-EU-00001 through 00003 Electrical Diagram Symbols

5578-STD-EU-00004 Electric Standard Abbreviations

5578-STD-EU-00071 Electric Heat Tracing Assemblies

5578-STD-EU-00011 through 00013 Standard Earthing Installation Assemblies

3.8 PIPING - GENERAL SPECIFICATIONS

5578-E2-SP-PU-00001 General Piping - Process and Utility Design, Layout and Drawings

5578-E2-SP-PU-00003 Technical Specification for Piping Systems

5578-E2-SP-PU-00016 Piping Material Purchase Specification (SPE Specs)

3.9 PIPING - STANDARD DRAWINGS

5578-STD-PU-00003 Vessel Layout and Orientation - General








5578-STD-PU-00004 Flange Tap Orientation, Clearances and Meter Runs

5578-STD-PU-00010 Thermowell Detail Selection

5578-STD-PU-00012 Instrument Symbols and Tagging

5578-STD-PU-00014 Control Valve Manifold Arrangement and Layout Guide

5578-STD-PU-00015 Control Valve Clearances

5578-STD-PU-00016 Relief Valve Piping Location

5578-STD-PU-00017 Level Instruments

3.10 PIPING - STANDARD PRACTICES

5578-STD-PP-D-00001 through 00004 Symbology for P&IDs (Piping and Instrument Diagrams)

3.11 ARCHITECTURAL - GENERAL SPECIFICATIONS

5578-E2-SP-AU-00063 HVAC System

3.12 MECHANICAL - GENERAL SPECIFICATIONS

5578-E2-SP-PB-00001 Preservation and Export Packing

5578-E2-SP-MD-00001 Pressure Vessels - General

5578-E2-SP-MF-00002 Field Erected Welded Steel Storage Tanks

5578-E2-SP-MU-00009 Equipment Noise Control

5578-E2-SP-MU-00013 Criticality Rating System

5578-E2-SP-PB-00002 Minimum Shop Inspection and Certification Requirements

5578-E2-SP-MX-00001 Painting

5578-TEC-MU-003 Equipment Data Forms Procedure

5578-E2-SP-MU-00008 Plant Noise Control

3.13 STRUCTURAL - GENERAL SPECIFICATIONS

5578-E2-SP-CU-00002 Structural Engineering Design Criteria








4.0 DOCUMENT PRECEDENCE

It shall be the responsibility of all parties to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.

The CONTRACTOR shall notify the COMPANY of any apparent conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein. Resolution and/or interpretation precedence shall be obtained from the COMPANY in writing before proceeding with the design/ manufacture.

In case of conflict, the order of document precedence shall be:

A) Datasheets

B) Specifications

C) Codes and Standards

D) Standard Drawings

5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations including, but not limited to, the Data Sheets and Narrative Specifications shall be sought by the CONTRACTOR only through Concession Request format. Concession requests require review/approval prior to the proposed technical changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.

6.0 QUALITY ASSURANCE/QUALITY CONTROL

CONTRACTORS proposed quality system shall fully satisfy all the elements of ISO 9001 - 2000 and ISO 9004 - 2000. The quality system shall provide for the planned and systematic control of all quality-related activities performed during design. Implementation of the system shall be in accordance with the CONTRACTORS Quality Manual and Project Specific Quality Plan, which shall both together with all related/referenced procedures, be submitted to COMPANY for review, comment and approval.

The VENDOR shall have in effect at all times, a QA/QC program which clearly establishes the authority and responsibility of those responsible for the quality system. Persons performing quality functions shall have sufficient and well defined authority to enforce quality requirements that initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness of the corrective action.








VENDORS proposed quality system shall fully satisfy all the elements of ISO 9001 - 2000 and ISO 9004 - 2000. The quality system shall provide for the planned and systematic control of all quality-related activities performed during design.

A copy of the VENDORS QA/QC program shall be submitted to the CONTRACTOR with its quotation for CONTRACTORS review and concurrence prior to award. If VENDORS QA/QC program and facility, where the work is to be performed, is ISO 9001 certified, then only a copy of the VENDORS ISO 9001 certificate is required. In addition, if VENDORS facility is ISO certified, CONTRACTORS QA audit requirements will be waived in favor of ISO 9001 registrar audits, unless the CONTRACTORS trend analysis program indicates areas of concern.

The VENDOR shall identify in purchase documents to its SUBVENDORS all applicable QA/QC requirements imposed by the CONTRACTOR, and shall ensure compliance thereto. On request, VENDOR shall provide objective evidence of its QA/QC surveillance of its SUBVENDORS activities.

The VENDOR shall submit certified reports of production test as soon as the tests are completed satisfactorily.

The COMPANY/CONTRACTOR reserves the right to inspect materials and workmanship at all stages of manufacture and to witness any or all tests. The VENDOR, 30 days after award but prior to the pre-inspection meeting, shall provide the CONTRACTOR with a copy of its Manufacturing and Inspection Plan for review and inclusion of any mandatory COMPANY/CONTRACTOR witness points.

The Criticality Rating (CR) System outlined in Project Specification 5578-E2-SP-MU-00013, Criticality Rating System shall be used to develop the design checking levels and minimum requirements for shop inspection, testing and materials certification given in Project Specification 5578-E2-SP-PB-00002, Minimum Shop Inspection and Certification Requirements.

7.0 DOCUMENTATION

The CONTRACTOR shall define the requirements for MANUFACTURER/ VENDOR drawings and documentation for CONTRACTORS authorization or information as listed in the individual Material Requisitions and Purchase Orders.

Mutual agreement on scheduled submittal of drawings and engineering data shall be an integral part of any formal Purchase Order.

Comments made by CONTRACTOR on drawing submittal shall not relieve VENDOR or SUBVENDORS of any responsibility in meeting the requirements of the specifications. Such comments shall not be constructed as permissions to deviate from requirements of the Purchase Order unless specific and mutual agreement is reached and confirmed in writing.








Each drawing shall be provided with a title block in the bottom right-hand corner incorporating the following information:

a. Official trade name of the VENDOR

b. VENDORS drawing number

c. Drawing title giving the description of contents whereby the drawing can be identified

d. A symbol or letter indicating the latest issue or revision

e. PO number and item tag numbers

f. TAKREER Logo.

Revisions to drawing shall be identified with symbols adjacent to the alterations, a brief description in tabular form of each revision shall be given, and if applicable, the authority and date of the revision shall be listed. The term Latest Revision shall not be used.

8.0 SUBCONTRACTORS/VENDORS

This section is not applicable to this Specification.

9.0 HANDLING

CONTRACTOR shall ensure preparation for shipment shall be in accordance with the VENDORS standards and as noted herein. VENDOR shall be solely responsible for the adequacy of the preparation for shipment provisions with respect to materials and application, and to provide equipment at the destination in ex-works condition when handled by commercial carriers.

Adequate protection shall be provided to prevent mechanical damage and atmospheric corrosion in transit and at the jobsite.

Preparation for shipment and packing will be subject to inspection and rejection by COMPANYS/CONTRACTORS inspectors. All costs occasioned by such rejection shall be to the account of the VENDOR.

After inspection and test, equipment shall be completely free of water and dry before start of preparation for shipment.

All equipment and material shall be preserved and export packed in accordance with Project Preservation Specification, 5578-E2-SP-PB-00001, Preservation and Export Packing.

10.0 DESIGN

10.1 DRAWINGS AND SPECIFICATIONS








Requirement of Drawings and Documents for COMPANY review, comments and approval shall be as per Attachment 1.

10.1.1 Construction and Layout Drawings

Construction drawings will contain instrument locations for all tagged instruments that have signals to or from devices.

10.1.2 Plant Standard Details

Plant standard details will show installation details for electrical, pneumatics, process hook ups and mounting arrangement.

Each detail will contain a specific reference number and a material take-off listing for electrical, pneumatic, process, and mounting materials. The Instrument Index shall be used to generate tag listings for the details.

10.1.3 Loop Drawings

Loop drawings / Fieldbus segment drawings shall be produced in SPI Smart Plant module for :

All hardwired signals connected to systems (DCS, ESD, Fire and Gas, SCADA, Machinery Monitoring, etc.) including package units instruments.

Where instruments are wired to one system but transmitted to a second system via a serial link, the loop diagram shall indicate this.

Where loops involve multiple systems, transmission of signals or information between systems, this shall be clearly identified.

All above loop drawings to be produced or coordinated by CONTRACTOR.

Each loop shall contain the following information:

a. a standard presentation of the loop

b. I/O card locations (i.e. rack, file, slot)

c. wiring terminations (with terminal numbers) between field instrumentation, I/O cards, panel instruments and junction boxes, if applicable

d. instrument cable numbers

e. J. B. location and number

f. failure position for (a) Control Signal and (b) Air Signal








g. reference drawings

Complex loops (e.g. boiler control loops) should be supported by narrative description.

10.1.4 Logic Diagram Drawings

Logic diagram drawings shall include binary operation function sequences, interlocks, interaction and interrupts using ISA standard symbology. Diagrams will flow from left to right where possible. The diagram should be supported by a narrative description of the function. This is mandatory for complex logics.

10.1.5 Console and Panel Drawings

Console and panel drawings will include front, back and interior panel layouts. Details will be part of the specification. Any interconnection wiring/cables will be indicated complete with its terminals.

10.1.6 DCS, PLC, and Computer Block Diagrams

These overviews will show how the system hardware is tied together with hi-ways, serial links and major instrument cables. There shall be a plant level simplified overview and detailed overviews which show smaller section of plant with actual amount of hardware estimated. This shall be based on the system in the market that require maximum space, power, heat load to result in conservative sizing of Satellite Instrument Shelters (SIS) and Control Rooms.

Also grounding for each of these systems will be shown in a separate drawing.

10.1.7 Instrument Index

The instrument index will be a complete listing of all tagged instruments and shall include as a minimum, the following:

a. tag number

b. process description

c. vendor and model number

d. P.O. and requisition no.

e. construction drawing

f. P&ID

g. loop drawing








h. installation detail (impulse line, electrical hook-up, weather protection, pneumatic, air supply and mounting details)

i. location

j. calibration range

k. data sheet no.

l. line no. and specifications

m. calculation sheet

n. criticality

A sample Instrument Index shall be included in all EPC tenders to ensure homogeneity within the whole site complex.

10.1.8 Instrument Specifications

A specification sheet will be generated for each instrument. Items such as PGs, TGs, etc. will be combined on multi-tag datasheets. Specification sheets shall contain as a minimum, the relevant process data, mechanical design and specification data, metallurgy, vendor name, model no., requisition no., P.O. no., notes, etc. In addition, the CONTRACTOR shall ensure the successful completion of the Equipment Data Forms per the Equipment Data Forms Procedure, TEC-MU-003. Instrument data sheets shall be ENGINEERS standard and shall be in accordance with ISA standards, as specified by the COMPANY.

10.1.9 Instrument Calculation

A calculation will be made considering different cases/scenarios for each control valve, safety valve and flow device. These calculations will be included in the design books.

10.1.10 Integrated Control System I/O Schedule

An I/O schedule shall be made for the above system based on P&IDs, control and operating philosophy documents for main process plant, utilities, offsites and package units. This shall also reflect exchange of signals to MCC, HVAC and to any existing plant systems as applicable. The format shall be developed in consultation with the system vendor to convey the required data for database and display/logic configuration.

10.1.11 Instrument Location Plan Drawings (Layout Drawings)

A detailed scaled location plan drawing shall be made based on piping General Arrangement Drawing (GADs) and/or the 3D Plant Model to locate instrument tapping points, instrument mounting elevations, junction boxes, tray routings, etc. Separate drawings shall be made for each area for (a) air supply distribution and consumers (b) electrical instruments.








10.1.12 Smart Plant Instrumentation

One database based on Intergraph Smart Plant Instrumentation (SPI) shall be developed and maintained for the RRE project by each EPC CONTRACTOR. This shall include database for packages. SPI shall be utilized to generate the following deliverables:

Instrument Index

Instrument Datasheets

ICS and subsystem I/O counts

Instrument Interconnection Wiring Diagrams

Instrument Loop Diagrams

Instrument Segment Diagrams

Instrument Index population shall be based on CONTRACTOR detailed design P&IDs and on Bubble Loop representations as defined in Project Guide for Short Form Instrument P&ID Loop Representations 5578-TEC-IU-003. These shall be further developed and expanded as necessary during EPC execution phase. The Instrument Index shall include all instruments as defined on Process, Utility, Auxiliary and Licensor P&IDs, as well as requirements from Vendor Packages. Upon completion of RRE project the electronic SPI database shall be supplied to COMPANY as a Watcom file.

SPI Version to be used will be confirmed by COMPANY during the detail engineering phase. The O&Us EPC shall be responsible for the co-ordination of SPI throughout the project. Population of SPI shall be inline with INTools Implementation guide 5578-TEC-IU-002.

In addition to the fields populated during FEED phase of the RRE project, the following additional fields shall be populated as a minimum by CONTRACTORS during detailed design phase:

Signal Type (Voltage free, pulse, 120 VAC, 24 VDC)

Valve Control action (direct/reverse)

Parallel area (to avoid parallel equipment being allocated to same I/O card)

FF Segment no.

Valve Criticality for allocation to FF segments

Long/Short format Service Description

Alarm and Trip Setpoints








Alarm Priorities

Instrument Engineering Units and Range

Signals that shall be Redundant (e.g. DCS AO)

Instrument Manufacturer

Instrument Model no.

Transducer range (for calibration of transmitters by vendor, generally required for D/P level transmitters)

MR no.

ILD/ISD drawing no.

Instrument Location drawing no.

Instrument mounting detail drawing no.

Instrument Hook up drawing no.

The data transfer between CONTRACTOR and ICV shall be carried out in two major stages, the hardware freeze stage and the software freeze stage. During detailed design the O&Us CONTRACTOR shall finalize the required fields to be populated for hardware and software freeze. The O&Us CONTRACTOR shall also be responsible for definition of SPI data exchange process with ICV. The data exchange process shall provide the method of data transfer between CONTRACTORS and ICV to ensure consistency of data and configuration of control system. The preferred format for data exchange shall be pre-defined Microsoft Excel templates. The data transfer files shall include:

I/O data file containing instrument index information

Junction Box/Cabinet assignment containing all signal cable information

ICV shall submit the following data in Microsoft Excel format for CONTRACTORs to produce deliverables from SPI:

Hardware information as soon as equipment is selected to enable creation of default equipment in SPI.

I/O allocations upon completion of nest loading.

Details of marshalling cabinet cross-wiring, including assignments for system cables.

Signal cable assignments to marshalling cabinets.








Specification sheets shall be produced for each instrument in SPI. Multi-tag datasheets can be utilized for PIs and TIs with prior COMPANY approval. The fields to be populated for each type of instrument datasheets shall be agreed with COMPANY during detailed design phase; as a minimum all instrument datasheets shall contain relevant process data, mechanical design and specification data, metallurgy requirements, vendor data and requisition number.

10.2 INSTRUMENT SYMBOLS AND IDENTIFICATION

10.2.1 The symbology for instrumentation shall be on the P&ID legend sheets.

10.2.2 Each instrument loop will have its own alpha numeric number. Any duplicate item within a loop will have an alphabetic suffix following the number:

Process Area Offsites

Flow 001 - 999 001 - 999

Level 001 - 999 001 - 999

Pressure 001 - 999 001 - 999

Pressure Gauge 001 - 999 001 - 999

Temperature 001 - 999 001 - 999

Temperature Gauge 001 - 999 001 - 999

Relief & Safety Valves 001 - 999 001 - 999

Emergency Shutdown 001 - 999 001 - 999

Miscellaneous 001 - 999 001 - 999

Retrofit, expansion, or modifications in existing process units, utilities, or offsites shall use spare tag numbers available in those units. These tag numbers will be made available during the detailed engineer phase of the project.

10.2.3 Plant/area numbers, will be a three or four digit number preceding the loop number, e.g:

1200 FALL 177 A

Unit Number Functional Identifier

Three digit Sequential no.

Alphabetic Suffix (e.g. split range valves)

For further information refer to PROJECT specification 5578-E2-SP-IU-00051, Instrument Numbering Rules.








10.2.4 Consistency with Existing Plant Numbering System

Although numbering system shall be as defined in Sections 10.2.2 and 10.2.3, the numbering system shall be modified in consultation with end user/operator to provide numbering system consistent with existing plant and avoid duplications. Specific blocks will be defined by end user/operator.

10.2.5 Package Units

Major vendors will be given block of tag numbers by the CONTRACTOR. For example, flow tags for package units will be numbered from 500 to 999 (or 5000 to 9999 if applicable) and individual block of 100 or 50 numbers (typical) within this 500 to 999 (or 5000 to 9999) will be assigned to each Package unit by CONTRACTOR. All tag numbers whether by CONTRACTOR or VENDOR will be referenced in an index supplied by CONTRACTOR and shall be subject to the COMPANYS approval.

10.2.6 Numbering of Instruments

CONTRACTOR shall number all instruments, including those instruments in Licensors units, as per P&IDs.

For further clarification on the Numbering of Instruments refer to 5578-E2-SP-IU-00051, Instrument Numbering Rules.

11.0 SYSTEM TECHNICAL REQUIREMENTS

11.1 GENERAL CONTROL PHILOSOPHY

In general, centralized plant control utilizing Integrated Control System (ICS) from a Central Control Room (CCR) is required along with Satellite Instrument Shelters (SISs) located at convenient places in close proximity to the plant to house all instrument racks/panels, etc.

Only hiways and few dedicated hardwired cables shall be run to Central Control Room (CCR). Otherwise all instrument cables shall be terminated in SISs. CCR shall have all operational control consoles and enable full start-up, monitoring and control and shutdown of the plant. SISs shall be normally unmanned.

The main intent of the Integrated Control System (ICS) is to eliminate all foreign platforms (hardware and software) as far as practically possible. Plant safety and reliability shall not be compromised. Use of foreign platforms shall be very carefully scrutinized and COMPANY approval shall be obtained.

Foreign devices (other instrument systems, microprocessor based systems, PC based systems and computer based systems) use shall be limited. Whenever Foreign Devices are used, they shall provide peer-to-peer communication with DCS system. All the Control and Monitoring Functions of the foreign device shall be performed from DCS Operator Control including engineering functions.








For foreign devices, CONTRACTOR shall ensure the data and features as available in Foreign Device Systems (work stations, their locations, printers) conveyed by gateways or serial interface to the plant DCS. CONTRACTOR shall maximize true integration by implementing other instrument sub-systems in DCS hardware/ software.

The CONTRACTOR is responsible to ensure that after completion of commissioning, sufficient spare capacity is available in all junction boxes, marshalling cabinets and multi-pair cabling to SISs. This free space shall be distributed in such a way that additional terminals, equipment or modules may be added to any group of controls and cables. All spare conductors shall be terminated. Additionally, installed spares and spare space within all systems cabinets and buildings shall be allowed as per requirements defined in Project Specifications.

The CONTRACTOR shall provide sufficient instrumentation to ensure that the requirements of the RRE project are fulfilled and that the required operability, maintainability, safety, dependability and availability of the plant are achieved.

11.1.1 Unified Operator Interface

A single-window approach shall be implemented for the plant. For details, refer to DCS Project Specification, 5578-E2-SP-IS-00001, Distributed Control System (DCS).

11.1.2 Package Unit Equipment

Refer to Project Specification 5578-E2-SP-IU-00007, Instrumentation Furnished with Packaged Units. Control, monitoring, alarm, and shutdown information for all equipment packages shall be brought back to main control centers.

A new state of the art, computer based vibration monitoring system shall be used for all major rotating equipment. Refer to Project Specification 5578-E2-SP-IS-00011, Machine Condition Monitoring.

11.1.3 Satellite Instrument Shelters (SIS)

In general, buildings shall be installed to house ICS I/O and processors and other devices that can be protected in these buildings in order to minimize field cabling length. The SISs and CCR shall be sized to include 30% future use in floor space, power at all levels and HVAC.

11.1.4 Control Room and SISs

All these buildings shall be located in a safe (nonclassified) area. The buildings shall be constructed as per Structural Specification 5578-E2-SP-CU-00002, Structural Engineering Design Criteria.

11.1.5 Process and Utilities

Main operational control will be out of the Central Control Room (CCR). Required number of new SISs will be located in the main process and utility areas.








11.1.6 Tank Farm and Off-Site Facilities

In general, main operational control will be out of the Central Control Room using required number of SISs.

11.1.7 System and Measuring Units

If a conflict occurs between the units listed below and units in other project specifications, the units listed below shall be used for instrumentation purposes.

The following engineering units shall be used. They generally will be in accordance with the international system (ISO)

Verification/approval should be obtained from the COMPANY in writing for variances or additions to the following:

UNITS OF MEASUREMENT

PARAMETER UNIT ACCEPTABLE ALTERNATIVE

Acceleration m/s2

Amount of Substance kg-mol

Area m2

Concentration (mass) ppmw ppbw

Concentration (volume) ppmv

Conductivity S/cm Density kg/m3

Electrical Current A

Energy kcal Gcal(106 Kcal), kWh

Energy-Electrical kWh

Volume Flow - Liquid m3/h BPD (Barrels per Day)1

Volume Flow Gas and Vapor Nm3/h MMscfd1

Molar Flow Kg-mole/hr

Mass Flow Kg/hr TPD (Tonnes per Day)

Mass Flow Kg/hr KTPD (Thousand Tonnes per Day)

Force N

Energy (Heat) kcal GCal (106 kcal)

Heating Value kcal/kg BTU/scf

Frequency Hz








UNITS OF MEASUREMENT

PARAMETER UNIT ACCEPTABLE ALTERNATIVE

Length m mm, km

Level % mm

Mass Kg t (1000 kg)

Molecular weight Kg/kmol

Potential Difference V

Power kW MW

Pressure Kg/cm2g Kg/cm2a

Pressure Differential (high) Kg/cm2

Pressure Differential (low) mmH2O

Production Capacity t/y t/d

Speed - Linear m/s

Speed - Rotating rpm

Temperature Time H

Velocity mm/s

Viscosity - Dynamic cP mPa.s

Viscosity - Kinematic cSt

Volume m3

* Given at normal conditions (0C and 1.0332 kg/cm2a + Given at operating conditions

For display of analog variables, a maximum of five total digits shall be used with a maximum of three decimal places. For custody transfer and totalized values, a maximum of nine total digits shall be used, with a maximum of three decimal places. Number of digits displayed shall not exceed the number of significant places inherent in the measurement system.

11.1.8.1 Field instrument indicators shall be scaled in Engineering Units.

11.2 CONTROL AND MONITORING SYSTEMS

The following control and monitoring systems will be provided in the CCR and SISs :

Process Control System Fire and Gas Systems








Hardwired Push Buttons for Deluge/Halon/Inergen Release and Main/Zone ESD are for major system failures. Push buttons will be wired into the final channel output and to an ESD input. Each push button action, including those for manual actuation of deluge valves, shall be logged into the ESD/DCS sequence of events/alarm system.

Shutdown Systems (ESD) Manual initiators for trip systems shall be according to the provisions of TUV AK6.

11.2.1 Fire and Gas System

The Fire and Gas system shall be state-of-the-art Fire and Gas systems and be part of ICS as per Project Specification 5578-E2-SP-IS-00003, Fire and Gas Detection System and duly approved by the COMPANY.

11.2.2 Shutdown and Alarm Systems

Alarm Systems

Alarm systems shall warn operators of an abnormal condition. Alarms shall be located in the DCS systems.

These alarms if not addressed and/or if the process does not react positively will shutdown equipment, control valves, etc.

11.2.3 Shutdown Systems

Shutdown system shall be state-of-the-art ESD systems implemented as a part of ICS. However, in specific cases, Triple Modular Redundant (TMR) with a voting system may be required. Shutdown systems shall be stand-alone type located in SISs and have dedicated primary devices. Information (alarms, start/stop of motors, valve open/close) and manual activation (override, resets, test push buttons) will be available in the DCS control stations through data bus communications. Manual actuation of ESD will be through hard wired push buttons and located as a part of the DCS control. First out and sequence of event (SOE) ability for major critical equipment items and for integrated equipment items/units where related trip may occur in rapid succession. This requirement includes package units.

The ESD systems shall have the facility to test repair/calibrate primary elements without activating the executive shutdown action. ESD valves shall be generally be implemented in such a manner to allow for on line testing without shutting down the process. In some cases bypass capability may be provided. Software jogging may also be evaluated for certain application. The ESD systems shall be as per Specification 5578-E2-SP-IS-00004, Emergency Shutdown System.

11.2.4 Analyzers








All analyzers will be evaluated on application, installation, sampling system requirements, maintainability, and return on investment. See Project Specification 5578-E2-SP-IU-00011, Packaged Analyzer Systems for reference.

Analyzers shall be mounted in pressurized and air-conditioned shelters and shall be prepackaged with analyzers and accessories. See Project Specification 5578-E2-SP-IU-00010, Analyzer Shelters and 5578-E2-SP-IU-00011, Packaged Analyzer Systems. A study shall be made by CONTRACTOR on the number of shelters, location, etc., for COMPANY review and approval.

CONTRACTOR shall be aware that the COMPANY intends to use advanced analyzer applications in selected offsites areas. CONTRACTOR shall be informed as to what the applications are during detailed engineering. Typically, installation of these advanced analyzers will be simpler than the conventional analyzers they would replace.

11.2.5 Servers

All Engineering/Maintenance control system servers shall be RAID 5 with automatic back-up facility. This shall include backups of control configurations, alarms, events and application software. All PC based equipment and printers shall be standardized for all the systems by the EPC CONTRACTOR for his scope of supply. Exceptions shall require specific approval by COMPANY.

11.2.6 Integrated Protection and Control System (IPCS)

Control of electrical equipment shall be via serial interface to Integrated Protection & Control System (IPCS) or hardwired via Interposing Relay Panels (IRP). Typically IPCS serial link shall be utilized for status information of Breakers/Feeders and noncritical equipment. Run hours shall be calculated in PIS server for all critical motors. Only critical motors and any motors that are operated via logic shall be hardwired via IRP. All ESD trip signals shall be hardwired via IRP. The table below details the typical signal requirements for motor control and electrical alarm/status information:

SIGNAL DESCRIPTION I/O Type F I N FAN

FIN FAN

w/VFD

P U M P (Local)

P U M P ( L o ca l w/ESD)

P U M P (Remote)

P U M P (Remote w/AUTO START)

PUMP (Remote w/ESD &

AUTO START)

3.3kV & 11kV

FeedersUPS

DCS HARDWIRED VIA IRP START COMMAND DO X X

STOP COMMAND DO X X X RUNNING INDICATION DI X X X AVAILABLE TO RUN DI X X

COMMON FAULT DI X SPEED CONTROL TO VFD 4 - 2 0 m A

X

VFD STATUS DI X

UPS FAULT DI X








DCS SERIAL LINK TO IPCS START COMMAND DOS X

STOP COMMAND DOS X X X X

RUNNING INDICATION DIS X X X X

AVAILABLE TO RUN DIS X

COMMON FAULT DIS X X X X X X

MOTOR CURRENT AIS X X X X X X X

BREAKER STATUS DIS X

BREAKER FAULT DIS X COMMUNICATION FAILURE DIS X X X X X X X X

DIAG. WATCHDOG ALARM DIS X X X X X X X X

PRE-ALARM DIS X X X X X X X X

MAINTENANCE TIME AIS X X X X X X X X

BUS VOLTAGE AIS X

FEEDER CURRENT AIS X

POWER FACTOR AIS X

ESD HARDWIRED VIA IRP START COMMAND DO

STOP COMMAND DO

RUNNING INDICATION DI

AVAILABLE TO RUN DI

COMMON FAULT DI

SHUTDOWN DO X X

During detailed design CONTRACTOR shall develop motor co-ordination schedule based on typicals agreed during FEED.

12.0 FEED INSTRUMENT GENERAL REQUIREMENTS

12.1 CLIMATE

All equipment mounted externally shall be able to operate in extreme weather conditions of temperature, precipitation, humidity, and salt-laden atmosphere.

Maximum Temperature (Shade) 58C Maximum Temperature (Solar) 87C Minimum Temperature 5C Maximum 24 Hr. Solar Temperature Differential 40C Maximum Relative Humidity at 43C 95% Barometric Pressure 760 mm Hg.








Control and rack rooms will be air-conditioned to 24C and pressurized and with air locks. Refer to Project HVAC Specification 5578-E2-SP-AU-00063, HVAC System.

All instrumentation, whether inside or outside, will be designed for maximum shade conditions at 58C. Instruments located in direct sun areas shall be designed either for maximum solar conditions or shall be covered by a suitable sunshade.

For shade details of pressure and differential pressure transmitters, see Project Specification 5578-E2-SP-IU-00002, Instrument Installation Design.

Where instruments require shades which are not available as standard equipment or require specially made supports/brackets such as for displacer level instruments, tank gauges, etc., these shall be shown on detailed construction drawings, and a decision shall be taken whether these can form part of the installation activities or whether they should be requisitioned for prefabrication.

In the field, only gauges, transmitters, switches, positioners, transducers are permitted. All other instruments shall be in adjacent functionally related SISs. Local panels near package equipment shall have only gauges, push buttons, lamps, etc. and all other relevant information shall be located in adjacent functionally relevant SISs.

Discrepancy between above information and other project design documents should be highlighted by CONTRACTOR to COMPANY for decision.

12.2 INSTRUMENT ENCLOSURE

Instrument enclosures degree of protection shall be in accordance with IEC 60529. The minimum degree of protection for junction boxes, electronic instruments, coils (solenoid valves), pneumatic instruments shall be IP 65.

NOTE: Attachment of identification plates installed on instrument enclosures, etc. shall not adversely affect the degree of protection.

12.3 PAINTING

Finish of plant-mounted instruments shall follow Project Painting Specification 5578-E2-SP-MX-00001, Painting. Color codes for field instrument, cabinets, panels, junction boxes, etc. shall follow each plant specification.

Instruments and the following items shall be protected against paint used on equipment and process units:

a. Glass fronts

b. Moving parts, i.e. control valve stems and positioners

c. Vents and drains








d. Name plates

e. Tube fittings and cable glands

f. Isolation and vent valves

12.4 TROPICALIZATION

Instruments will be tropicalized for humidity and fungus.

Particular consideration shall be taken on all printed circuit boards, even those located in control rooms shall be varnished and electrostatically protected.

CONTRACTOR shall take into account when electronic equipment is unpacked, that it is stored, temporary or permanent, in air conditioned environment.

13.0 HAZARDOUS AREA

Hazardous areas shall be classified in accordance with Energy Institute (EI) Model code of safe practice in the petroleum industry Part 15: Area classification code for installations handling flammable fluids.

13.1 HAZARDOUS AREA CLASSIFICATION

Refer to the area classification drawings for details of hazardous and safe areas.

13.2 INSTRUMENTS SAFETY CLASSIFICATION

The following protection means the electrical apparatus shall be considered for installation within hazardous areas:

a. Intrinsic safety i

b. Flameproof enclosures d

c. Pressurized enclosures p

d. Increased safety e

Use of Pressurized enclosures shall be kept to an absolute minimum.

Inside Zone O, electrical instruments shall not be installed.

Inside Zone 1 and 2, the choices of protection within process and utility units shall be as follows:








INSTRUMENTS AND ACCESSORIES ZONE 1 ZONE 2

Switches i i

Transmitters i i

Positioners i i

Temperature sensors i i

Level gauge illuminators d e

Junction boxes e e

Cable glands d d

Solenoid valves d d

Local cabinets d or p d or p

Fire and gas detectors i or d* i or d*

RTU (if not in safe area) e or i e or i

*Type d may be used in case of Type i nonavailability. Type d is to be generally applied for all instrumentation within hazardous area at the oil movements offsites area.

Analyzer shelters shall preferably be installed in safe area. If installed in hazardous area, then shelters must be pressurized by taking air from safe area.

For offsite areas, analyzer shelters are not required where analyzer housings are rated for the environment. If analyzer systems can be procured that meet the electrical hazard rating of an area with no reduction in operability or maintainability as well as reducing capital costs, then such applications shall be recommended for COMPANY approval.

In certain areas defined by the COMPANY, i ratings are not allowed, d ratings only are acceptable.

13.3 TYPE TEST CERTIFICATE

Each electrical instrument or system to be installed in hazardous area shall be built according to IEC recommendations and corresponding national translations and publications.

The local regulations shall have precedence if they are more stringent than the international corresponding code. For each concerned type of instrument or instrument system, the CONTRACTOR shall obtain from the VENDORS (and before purchasing stage) a copy of the certificate of conformity to the standards delivered by a certified national authority.








13.4 CERTIFIED AUTHORITIES

LCIE and CERCHAR in France TUV (Technisher Uberwachungs-Verein) PTB in Germany CSA in Canada UL in USA BASEEFA in UK

14.0 INSTRUMENT PASSIVE PROTECTION AGAINST FIRE

The following cables shall be fire resistant and meet IEC 60331:

a. Cables to fire pumps

b. Cables to remote fire fighting equipment

c. Fire detection circuits

d. Cables for ESD systems

e. Cables for safety evacuation lighting

f. Public address systems

g. Critical Control loops/valves required for shutting down the unit. Cables for MOVs on critical application or with large inventory of hydrocarbon (e.g. tanks, etc.)

h. Critical signals to monitor important process parameters

All other signal and control cables will be flame retardant and meet IEC-60332.

Accessories for ESD valves and actuators, and remote operated on/off valves will be protected from fire by installation inside protective local boxes. The boxes shall be rated for 30 minute fire ring without increasing internal temperature above the max. allowable limit for the actuator and accessories. The box design shall be provided with suitable access for operation of integral push buttons or to view local readouts/ status.

15.0 SELECTION OF INSTRUMENTS

15.1 GENERAL








The makes and types of instruments shall be in accordance with the COMPANYS List of Selected Instrument Equipment.

In general, the process instrumentation, control system, safeguarding system, fire and gas system, ESD system etc. shall be based on distributed networked control instrumentation located in air conditioned pressurized rack and control rooms, and will be used in conjunction with electronic transmitters and I/P converters. Basic process control, start-up, monitoring and shutdown for main process, utility, off-site areas including the package units in these areas shall be done from DCS through the Unified Operator Interface concept. Critical loops should be defined carefully and redundancy up to field equipment shall be considered for high safety and reliability. For further details, refer to Project Specification 5578-E2-SP-IS-00001, Distributed Control System.

All instrument material and components coming in contact with sour gas (as decided by piping material class), shall be certified per NACE MR 01-03.

Unless otherwise specified, the instrument ranges shall be selected such that the normal value will be between 50 and 75% of scale range taking into account the specified minimum and maximum values. Additional instruments may become necessary for normal minimum and maximum values. In these cases, a single scale and auto-ranging facility shall be provided in the DCS. For trip functions, the instrument range shall be selected such that the process trip value will be between 25 and 75% of transmitter/switch output range.

Dedicated instruments shall be used for instruments in trip service and ESD service with individual sensor, tapping point, cabling and power supply systems.

15.1.1 In general, only transmitters shall be used for all types of logic. Switches shall only be used with COMPANY agreement.

15.2 CHARTS AND SCALES

Variable Chart Scale

Temperature 0-100 Linear Direct Reading

Pressure 0-100 Linear Direct Reading

Flow (Differential) Direct Reading Direct Reading

Flow (Linearized) Direct Reading Direct Reading

Level 0-100 Linear 0-100 Linear

Analyzer 0-100 Linear Direct Reading








Variable Chart Scale

Signal to Valves 0-100% 0-100%

15.3 RADIO FREQUENCY INTERFERENCE

Unless otherwise specified by the COMPANY, with reference IEC 61000-4-3, for portable radio transmitters/receivers which have an electromagnetic field strength of 10 mV in the frequency range between 20 to 1.000 MHz, the total effect of the radio frequency interference shall be equal to or less than +/-0.1% of the output span with the instrument enclosure (cover) in place, and equal to or less than +/-0.5% of the output span with the instrument enclosure (cover) removed.

15.4 TRANSMITTERS AND LOCAL INDICATORS

All transmitters shall be provided with permanent (built-in) local integral indicators having engineering unit or % display. All square routing calculations shall be performed at the transmitter for linear output. If a transmitter output indicator is required, then additional indicators shall be installed in such a way that it can be read from the relevant control valve(s). All transmitters shall be either Smart type or FOUNDATION Fieldbus. The device shall provide self diag