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    60a1 PDF

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    Mukesh Muraleedharan

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    © All Rights Reserved
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    STANDARD SPECIFICATION NO. 60A1 IBSTRUMENTATION KUWAIT NATIONAL PETROLEUM COMPANY (K-S.C-) 1 4 Feb 10, 1986 KNPC ENG STD 60A1 Page Rev. Date: INSTRUMENTATION CONTENTS 1 GENERAL 2 CODES AND STANDARDS 2.21 RNNAN alaon Calculation Qualification Material Selection and Dimensions Explosion~Proof Construction Construction Method for Wiring Others 3. ENGINEERING DESIGN PHILOSOPHY 3.2 3.2 General Instrumentation Symbols and Identification and Units of Measurements 3.2.1 ° 3.2.2 Master Instrument List 3.2.3 Units of Measurement Component of Instrumentation Modes of Control Instrument Loops Board Loop Instrument Local Loop Instrument Requirement for Instruments Field-mounted Instruments Board-mounted Instruments Graduations of Charts and Indicating Scales Chart Sizes and Types Chart Drives Control Rooms, Boards and Nameplates 3.5.1 Control Room 3.5.2 Instrument Boards in Control Room 3.5.3 Instrument Panel in Field (Local Panel) Page He © wearaaa a 10 10 11 12 12 12 13 13 13 13 14 15 16 16 16 16 17 2 Page 2 4.3.4 Thermowells Rev. 4 Date: Feb 10, 1986 INSTRUMENTATION KNPC ENG STD 60A1 3.6 Electric Supervisory System 22 3.6.1 General 22 3.6.2 Indicating Lamp 24 3.6.3 Alarm System 24 3.6.4 Automatic Pump Starting System 25 3.6.5 Emergency System 25 316.6 Common Sequence 26 3.7 Transmission 26 3.7.1 Pneumatic Transmission 26 3.7.2 Electric Transmission 27 3.8 Instrument Air Supply System 27 3.8.1 General 27 318.2 System 28 3.8.3 Instrument Air Supply Piping 28 3.9 Instrument Power Supply System 29 3.9.1 General 29 3.9.2 Power ‘kup System for Instruments 30 3.10 Interlock and Control Descriptions 30 4 INSTRUMENTS AND CONTROL VALVES 31 4.1 Pressure Measurings 31 4.1.1 Pressure and Vacuum Gauges 31 4.1.2 Pressure Instruments 32 4.2 Flow Measurings 33 4.2.1 Primary Elements 33 4.22 Instruments 35 4,3 Temperature Measurings 36 4.3.1 Receiver Instruments of Temperature Measurement (Board) 36 4.3.2 Receiver Instruments of Temperature Measurement (Local) 37 4.3.3 Elements of Temperature Measurement 38 41 INSTRUMENTATION 4.5 Page 3 Rev. 4 Date Level Measurings General Displacement Type Level Instruments Differential Pressure Type Instruments Level Gauges Local Tank Gauges Remote Tank Gauging System valves ‘Type: Materials Actuators Accessories Assembly Safety and Relief Valves General Application Valve Sizing Bonnet Construction Connections Accessories Code Stamps Inspection and Testing Block Valve: 5 CONSTRUCTION MATERIALS FOR INSTRUMENTATION 5.1 Instrument Stanchions 5.1.1 Material 5.1.2 Type» Instrumentation Wiring Instrument Pressure Lead Piping Instrument Air Supply Piping and Pneumatic Signal Tubing Sealing, Purging and Winterizing Sal Sealing 5.2 Purging 5.3 Winterizing Feb 10, 1986 KNPC ENG STD 60A1 42 42 43 45 45 47 47 48 48 49 50 50 51 56 56 57 57 58 58 58 58 58 59 59 59 59 59 59 59 60 60 61 61 62 INSTRUMENTATION Page Rev. Date: 4 4a Feb 10, 1986 KNPC ENG STD 60AL 6 CONSTRUCTION WORKS FOR INSTRUMENTATION 6.1 6.5 6.6 Installation Work 6.1.1 General 6.1.2 Boards and Field Instrument Installation Instrumentation Wiring Instrument Pressure Lead Piping Instrument Air Supply Piping and Pneumatic Signal Tubing 6.4.1 General 6.4.2 Piping and Tubing Method ve els Instrument Connections Piping Instrument Connections 7 APPROVAL AND INSPECTION 8 IDENTIFICATION 9 SHIPPING TABLE I ‘TABLE IZ BOARD LOOP INSTRUMENT LOCAL LOOP INSTRUMENT 62 62 62 65 66 66 67 68 70 70 70 70 71 72 14 Page 5 Rev. 4 Dates Feb 10, 1986 INSTRUMENTATION KNPC ENG STD 60A1 1 GENERAL 1.1 ‘This standard describes the acceptable types of instruments and methods of instrumenting an industrial plant. Specific types of instruments and their application are recommended to provide instrumentation that will minimize costs and be consistent with good operating and maintenance practices. The intent of this standard is to provide general guidelines to design the instrumentation? and control systems. This standard describes an analog instrumentation system. A separate specification covers the total distributed control system with host computer. Standard API RP 550 Part I is applied as a general philosophy for instrumentation engineering. Section 1 - Flow 2 Level - Temperature - Pressure - Automatic Controller Control Valves and Accessories = Transmission systems ~ Seals, Purges, and Winterizing eoaunuveaew ' - Air supply System 10 - Hydraulic System 11 - Electrical Power supply 12 - Control Center 13 - Alarms and Protective Devices 14 - Proce: Computer systems Materials shall be in accordance with applicable commodity specifications for each project. INSTRUMENTATION 2 2.2 Page 6 Rev. 4 Date: Peb 10, 1986 KNPC ENG STD 60A1 This general standard is issued prior to the selection of vendors and their models. For increasing standardization and spare parts interchangeability, it is more convenient for Owner to adopt "Manufacturer's Standards" as much as possible. Therefore, this standard will be reviewed and revised (if necessary) when the manufacturers and models of equipment and/or materials are selected. The instrumentation for the plant must be able to withstand the climatic conditions described in "Site Condition and Utility Condition" section of the project specification, AND STANDARDS Calculation (1) Control valve sizing — ANSI/ISA-S75.01 Masoneilan valve sizing equations (2) Safety valve capacity API 526 43) Plow (Orifice) L K Spink Iso 5167 Same as JTS 70962 and ‘SIS 28763 Qualification (1) Thermocouple element ANSI MC 96.1* STs c 1602 (2), Resistance bulb DIN 43760 a) Extension wire ANSI MC 96.1* JIs c 1610 NOTE:* Same as ISA MC 96.1 Material Selection and Dimensions (1) Control valve body Per piping line class ISA 875,03 & 875.04 (2) Control valve internals Eng Std 65F11.2 (trim material) (3) Safety valve body Per piping line class INSTRUMENTATION 2.4 (4) Safety valve inner parts 5) Orifice flange (6) Accessories for orifice flange mm Orifice plate (8) Orifice holding ring (9) Flanges, fittings, etc (10) Other materials Explosion-Proof Construction (1) Instruments Page 7 Rev. 4 Date: Feb 10, 1986 KNPC ENG STD 60A1 API 526 Manufacturer's standard API 526 Manufacturer's standard Per piping line cl. ANSI B16. 36 Eng Std 50P1 (Appendix 8) Manufacturer's standard ISA RP 3.2 Manufacturer's standard ISA RP 3.2 Manufacturer's standard Dimensions to applicable ANSI standards Applicable ASTM standards Generally, intrinsically safe systems will be applied. However, the following instruments shall also be explosion-proof type if applicable. Explosion-proof instruments shall also be weatherproof. equivalent. They shall be NEMA 4 and 7 or - Pressure Switch, Level Switch, Flow switch - Solenoid Valve Codes and Standards Country Certifying Authority* ors Japan RIIS API RP 500A USA UL/FM Bs U.K, b BASEEFA VDE West Germany PTB NP France MIR cee canada csA Remark: API RP 500A shall be applied for this item, however, if manufacturer is located other than in USA, Page 8 Rev. 4 Date: Feb 10, 1986 INSTRUMENTATION KNPC ENG STD 60A1 such manufacturer shall state the explosion-proof construction is equivalent to NEC/API, then country of origin standard will be applied as listed on this table. ‘Note: RITS_—:_ Research Institute of Industrial Safety td 1 Underwriters Laboratories rH + Factory Mutual System BASEEFA : British Approval Service for Electrical Equipment in Flammable Atmosphere 9 3 & Physikalisch-Technische Bundesanstalt MIR : Ministere de 1'Industrie et de La Recherche CSA : Canadian Standards Association (2) Construction Materials for Same as Paragraph Electronic Inatrument Works 2.4(1) (such as junction boxes, conduit pipes and fittings, cable glands, etc.) 2.5 Construction Method for Wiring National Electrical Code The Contractor shall ensure that the construction methods conform to the applicable code(s). It is not necessary to be certified by authorized third party for wiring method but the Contractor shall have responsibility for safety in regard to the wiring method. Codes and standards described in ENG STD 70Al shall be applicable for the instrumentation where relevant. INSTRUMENTATION 2.6 3 : Page 9 a Rev. 4 Date: Feb 10, 1986 KNPC ENG STD 60A1 Others (2) Measurement of Petroleum Liquid Hydrocarbons by Positive Displacement Meter API 1101 (2) Mechanical Displacement Meter Provars API 2531 (3) Measurement of Liquid By@rocarbons by Turbine Meter Systems API 2534 a Flange Mounted Sharp-Edged Orifice Plates for Flow Measurement ISA RP 3,2 ENGINEERING DESIGN PHILOSOPHY 3.2 General 3.1.1 Instrumentation for the refinery shall be suitable for operating the plant from a central control room. Local pane: however, be used for packaged units . compressors, etc, to install local indicators and hand control units, permitting local start-up or shutdown of equipment. 3.1.2 No process fluid except air shall be piped to the main control room. Transmission of process variables shall be by means of electronic type instruments suitable for adaption to a computer system, The electronic control instrumentation shall be intrinsically safe type. All equipment, material, and installation procedures shall comply with the requirements of the particular vendor's approved design for IS loop, shall comply with the certifying authority in the country of origin. INSTRUMENTATION 3.1.3 3.1.4 3.1.7 Page 10 Rev. 4 Date: Feb. 10, 1986 RNPC ENG STD 60A1 Local loops shall be pneumatic. Field mounted electronic instruments shall be protected from direct sunlight and shall be suitable for operating under the climatic conditions listed in paragraph 1.4 herein. Sunshades shall be provided. totally enclosing the instrument with a 120° view, Sun- shades are to be fabricated from galvanized steel and angle iron and shall be of sufficient strength and rigidity. Molded polyurethane is acceptable. Process variable indication shall be provided at each transmitter, either direct reading or transmitter output, in terms of process variable. The import and use of instruments containing radioactive substances shall be licensed in accordance with local government statutory regulations. For standardization purposes, the same vendors shall be selected for each group of instruments. No prototype instruments or instruments of an experimental nature are to be provided. No instrument which requires special operation or maintenance facilities shall be supplied, as far as possible. Instrumentation Symbols and Identification and Units of Measurements 3.2.1 3.2.2 Instrumentation Symbol and Identification Refer to ENG STD 60A3. Master Instrument List INSTRUMENTATION 3.2.3 am (2) Q@ a) (5) Flow Liquid xc Feb. 10, 1986 RNPC ENG STD 60A1 A master instrument list shall be prepared as soon as the engineering flowsheets are completed. The list shall include the following information at the minimum: (1) Tag number with unit identification (2) Specification number (3) Engineering flowsheet numbax, (4) Location-field or control room (5) Service description (6) Loop drawing number (7) Blectkical drawing number Units of Measurement Units of measurement for instrument calibration shall be the following system. The details are as follows: Measurement Units Pressure + PST Pressure (draft or vacuum) : In H,0 or In Hg USGEM @ 60°R* BPD @ 60°F Wate: + OSGPH @ 60°F Gas : SCFH @ 60°F, 14.7 psia Steam 2 Lbs/Hr Air + SCFM @ 60°F, 14.7 psia Chemicals + USGPM @ 60°F Temperature oo - Level % Percent INSTRUMENTATION 3.3 (6) (7) (8) 0) (10) qu) *For control val Page 12 Rev. 4 - Date: Feb. 10, 1986 KNPC ENG STD 60AL Volume of Product Tank + API Barrel (this does not include (Petroleum) water tanks and intermediate tanks) Level for tanks + mm, cm and m Specific Gravity Liquid + Water Equals 1 @ 60°F Gas tir Equal 1 @ 14.7 peia @ 60°F Viscosity 1 cP Density + Lbs/Ft> Differential Pressure in Orifice Inches of H, 0 and shut-off valves use USGPM at operating temperature Component of Instrumentation 3.3.1 3.3.2 Modes of Control Modes of control shall be shown on each commodity specification and generally be lected as follows: Pressure + P+ I (slow) Flow : P+ (fast) Temperature : P+I+D, P +I for local control loop Level + P+ TI (slow), P for local control loop Wherever Integral (I) action is specified it shall have full range settings covering slow and fast actions, Further, ta standardize the controllers, the feasibility of adding derivative action facility shall be provided as and when required. - Instrument Loops INSTROMENTATION Page 13 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 The component of instrument loops shall be in accordance with the following: (See Tables I & qq) Board-Mounted Instrument Field-Mounted Instrument Electronic Type Instrument Pneumatic Type Instrument. Temperature Detecting Element Switch Type Instrument 3.3.3 Board Loop Instrument Refer to Table I, 3.3.4 Local Loop Instrument. Refer to Table II, General Requirement for Instruments 3.4.1 Field-mounted Instruments a) (2) ay uy (6) (6) a Electronic instruments shall follow WEC requirements according to the specific electrical area classification. Weatherproof construction is to be NEMA 4 (NEMA NO. 250) or equivalent. All instruments will be suitable for mounting on a 2-inch pipe except when installed on local panels. Finish of instruments shall be manufacturer's standard. Instruments, control valves and safety relief valves shall have nameplates showing tag number Indicators shall have dials with white facing, black figures and graduations. Material for nameplates shall be stainless steel as a minimum. . All electronic instruments shall be immune to RF interference. INSTRUMENTATION 3.4.2 (8) (9) Page 14 Rev, 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 Set point adjustments shall be made by a tamperproof screw or a knob that is internally installed or covared for Pressure switches, temperature switches, level switches, etc. Planges shall be in accordance with ENG STD 50A2, Gasket Dimensions and Surface Finish for Bolted Flanged Joints. Board-mounted Instruments a) (2) Q) 4) (6) m (8) (9) (Qo) Instruments shall be general purpos: miniature type and suitable for flush mounting on steel boards. Controllers shall either be integrated type or split architectural type. Pens for recorders will be of the capillary type with a reservoir for l-month ink supply. Automatic-manual or computer automatic/manual transfer switches for controllers will be provided and shall enable bumpless transfer. Continuous recorders shall be three (3) pens maximum and trend recorders shall be manufacturer's standards. Integrators shall be of the continuous type and shall be grouped together in logical sequence and by individual unit. All electronic instruments shall be immune to RF interference. Indicators shall have vertical type indication with white facing, black figures and graduations. Indicating controllers shall normally be of full scale indicatio: however, deviation controllers shall be applied where process operation requires. Temperature instruments shall have burn-out feature and the receiver or transmitter Page 15 Rev. 4 Date: Feb. 10, 1986 INSTRUMENTATION KNPC ENG STD 60AL (converter) shall have a function of linearization for EMF. 3.4.3 Graduations of Charts and Indicating Scales (1), For instruments measuring variables, the graduations on the charts and/or on the indicating scales shall be as follows variables Scales Chasts Pressure Direct reading © ~ 100 uniform * Flow (D/P) 0 - 10 sq Rt 0 - 10 Sq Rt Flow (linear) 0 - 100 uniform 0 - 100 uniform * Temperature Direct reading 0 - 100 uniform * Trend recorder 0 - 10 Sq Rt/ 0 - 10 Sq Rt/ 0 ~ 100 uniform 0 - 100 uniform (dual scale) (Two graduations) Other variables (Specified by (specified by package vendor) package vendor) * two graduation mixtured charts for (0 - 10 Sq Rt/ 0 - 100 Uniform) for items marked * may be used. (2) For instruments indicating or recording two or more variables the graduations of the charts and indicating scales shall be follows: (a) When all variables are of the same kind charts and/or indicating scales shall be graduated for that variable in accordance with the table described above. (b) When one of the variables is flow (D/P), a combined range chart 0 - 10 Sq Rt and 0 - 100 uniform shall be used. Indicating scale for recorder shall be” dual in accordance with the table described above INSTRUMENTATION 3.5 3.4.4 3.4.5 Control 3.5.2 Page 16 Rev. 4 Dat Feb. 10, 1986 KNPC ENG STD 60AL (e) For all other combinations of variables, a 0 - 100 uniform chart is used with indicating scales in accordance with the table described above. Chart Sizes and Types Chart sizes shall be in accordance with manufacturer's standards. Charts shall be rolled type. Chart Drives (1) Recording instruments shall have electric chart drive. (2) The spring-wound type chart drive shall not be applied. (3) 1 be manufacturers’ however, following approximate speed shall be applied: Miniature type recorder 3/4-inch per hour Multi-point recorder I-inch per hour Rooms, Boards and Nameplates Control Room (1) The control rooms will be located in a safe area and shall be air-conditioned and pressurized with static pressure of approximately 0.125 inch #,0, (2) Where split architectural type instruments will be used, rack spaces for such instruments will be provided near the control room, (3) The space for operator's desk will also be provided in the control room. (4) A clock shall be furnished in the control room. (5) In general, API RP 550 Part 1, Sections 12 and 14 shall be followed. INSTRUMENTATION Page 17 Rev. 4 Feb. 10, 1986 KNPC ENG STD 60A1 Date 3.5.2 Instrument Boards in Control Room a) (2) a) 4) (5) (6) a) (8) The instrument boards shall generally be semi~graphic type. Central control boards shall be free standing cubicle type with lockable door at the back (instead of backless type) , underground interconnections with ‘console. The instruments shall be accommodated in four (4) rows on the board. Installation of auxiliary instrumentation equipment shall be in the panel back of auxiliary rack. The layout of miniature instruments shall generally be as follow: (a) Top row will be indicator, alarm light, etc. {b) Second row will be fee, reflux, and top Products flow instruments. (c) Third row will be most ‘important instruments (temperature, pressure, etc). (a) Fourth row will be level of column bottoms, flow records of bottom products, etc. The board layout drawings shall be made for approval by Purchaser before construction can begin. At least 10% spare space will be provid No deviations from this standard or refe ice drawings will be permitted, unless such deviations are initiated or approved in writing by the Purchaser. Any conflict between this standard and the reference drawings shall be called to the attention of the Purchaser by the fabricator and resolved in writing by the Purchaser. 7 The height and layout of the control panel shall conform to the applicable drawings INSTRUMENTATION (9) q1oy (aay (12) Page 18 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 listed in the control panel specification. These drawings shall be considered as a basic requirement. The centerlines of the instrument cut-outs shall be as shown on th drawings listed in the control panel specification. A graphic panel may be divided into convenient sections to facilitate the graphic representation, packing, and shipping. The lengths of non-graphic sections, or of conventional control panel sections, shall be as shown on the drawings listed in the control panel specification, (a) Conventional panels shall be fabricated from 3/16" cold rolled steel. (b) Graphic panels shall be fabricated from 3/16" cold rolled steel base. The steel plate shall level within a tolerance of 1/8" in 8 feet of length. The control panel shall be reinforced to Prevent buckling due to excessive overhang or weight of the instruments and damage to the panel or instruments due to vibration. Painting and Graphic Representation (a) The steel portion of the control panel shall be primed and painted in accordance with good practice. The final finish color shall be advised by Purchaser. The fabricator shall be notified as to the procedure which will be used. (b) For those control panels which will have the final coat of paint applied at the jobsite, the panel fabricator shall first pickle the steel, grind smooth where necessary, seal, sand smooth, and the apply a minimum of two (2) coats of primer. (c) When plastic type facing is used, it - shall be attached to the steel panels in sections which can be individually removed. Thickness shall be TNSTRUMENTATTON Page 19 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 eeetoneers standard (preferably 1a"). (a) The graphic symbols and flow lines shall be in accordance withi the selected manufacturer practices. The thickness of the flow lines and symbols shall be fabricator's standard unless otherwise noted. They shall be attached to the base sheet by a means which WYll permit removal and replacement. (e) A Purchaser nameplate will be supplied by the Purchaser tothe fabricator for attachment to the panel, as shown on the drawing listed in the control panel specification. (£) The fabricator shall ship with the panel sufficient spare adhesive, solvent, screws, paint, spare flow lines, and spare symbols, so that the necessary touch-up work may be accomplished at the jobsite. (13) Wiring (a) ALL wiring shall comply with the National Electrical Code for the classification shown in the specification and with the electrical code of the locality in which the panel is to be installed. {b) A grounding bus shall be provided to permit the grounding of all instruments to one common system. System ground shall be unique and at one point only. Instruments shall not use the steel panel as _a ground. For details, see ENG STD 70A5. {c) Field wiring shall normally be installed by others. Any portions installed by the panel vendor shall conform to the following: Wiring shall be twistee (6 to 12 crossover i.e. 12 to 24 twists per INSTRUMENTATION (a) (f) (9) Page 20 Rev. 4 Date: Feb. 10, 1986 KNEC ENG STD 60A1 foot) pairs of stranded copper with PVC insulation over each conductor. Conductor size shall be 16 AWG for Separate individual pairs and for multi-conductor cables shall be overall shielded and separate pairs need not be delded. A copper drain wire shall be included within each shield. Where manufacturers standard is specified, the plug-in type multi-core system cable may be applied. Separate conduits, wireways, or troughs shall be provided for power supply, alarm, signal, and thermocouple aervic Space in each conduit, wireway or trough shall be provided for all spare receiver points or for 158 extra capacity, whichever is greater. Electrical connections to instruments shall be arranged in such a manner that they will not obstruct piping connections and access to instruments, including integrally mounted controllers. Entrance location for the electrical supply will be as shown on the control panel layout drawings. Switches shall be conveniently located near the devices they control and conpletely wired by the panel fabricator. Each panel section shall be wired to terminal blocks to conform with the number of circuits required above. Terminal blocks shall be so located that they will readily accessible, with all wiring in place. The Contractor will connect in the field the proper number of supply circuits and interconnect the panel sections. Instruments powered by common type DC power supplies with battery back-up - shall have separate power supplies for the instruments associated with each process unit, and shall be consistent INSTRUMENTATION 3.5.3 «ay (15) Page 21 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 with intrinsic safety requirements if applicable. (h) Power supply distribution shall maintain individual loop integrity, Approval and Inspection Refer to ENG STD 9341-60 Instrument List As soon as the necessary information is completed, a list of all instruments supplied by the Purchaser, complete with model number and manufacturer's name, will be forwarded to the panel fabricator. Instrument Panel in Field (Local Panel) am a a) a) (5) Instrument panels in field shall generally be non-graphic, cubicle type with doors at xear or side. They shall be fabricated from 3/16" minimum cold rolled steel sheets. Where the location of panels will be in safe area, weatherproof type panels will be used. Where the location of panels will be in. hazardous area, necessary protection will be considered for explosion such ast (a) General type panels with explosion proof equipment and wired in accordance with NEC requirement. (>) Water tight panels with general purpose electrical equipment and with preparation of fresh air purging in this case, NFPA-496/ISA RP 12.4 shall be applied. At least 20% spare space shall be provided. Local panels shall generally be furnished with the following: (a) Main equipment start/stop push buttons INSTRUMENTATION (6) Page 22 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60AL (b) Auxiliary equipment start/stop push buttons (c) Motor running Lamps (4) Ammeters for motors (e@) On-off switches for electric heaters (£) Auto/manual position switch (g) Locai/remote position switch (h) Main circuit breaker (4) Annunciators (3) Machinery monitoring systems (k) Receptacle and lighting No proceas fluid except instrument air shall be piped to the local panel. 3.6 Blectric Supervisory system 3.6.1 General This paragraph covers the requirements for equipment with the following servic a) (2) Indicating light To give information on the main board on position of process equipment, such as pump running or stopped, etc. When this equipment can only be operated manually, a visual indication is sufficient, however, audible alarn shall be provide if it is shown on the engineering flowsheets. When the status can be changed automatically, for example, starting of stand-by pumps, an audible alarm is also required. Switch contacts shall be specified single pole, double throw wherever possible. Only one function per switch shall be specified (.e., alarm only or interlock only). Contacts shall be AC 110V or DC 100V for INSTRUMENTATION (3) a) (5) (6) Page 23 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 instruments. Capacity of contacts shall be minimum 4A unless otherwise specified. Specifically, level, pressure, and temperature switches are mercury type (DC 110V 4A), valve limit awitches are dry contact (Dc 110V 0.4A). Use of snap-acting nicroswitches may be considered for applications susceptible to vibration and shock. Contacts of electrical actuating devices for signal and emergency systems will be closed under normal process conditions in order to obtain action if the actuating circuit ig broken accidentally. Wherever possible all actuating devices will be located in the instrument board or auxiliary rack. Only for those applications which require direct actuation, the actuating devices will be located in the field. All switches connected with shutdown sequence shall be direct acting type except for flow. Solenoid valves shall normally be used as pilots to actuate other instruments directly connected to process fluids. Coils for solenoid valves shall be specified for continuous duty at rate voltage and frequency ané shall be enpapsulated type. Valve bodies for solenoid valves shall follow specific line class requirements when used in process lines. Manufacturer's standard stainless steel or nickel plated brass shall be used for air service. Insulation grade shall be selected such that solenoid valve can operate continuously at temperature of 180°F (equivalent to class “H* from ASCO). Logic diagram shall be made in accordance with ISA §5.2*, However, relay sequence diagram shall be made by manufacturer in accordance with logic diagram. INSTRUMENTATION 3.6.2 3.6.3 Page 24 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 * "Binary Logic Diagrams for Process Operations". Indicating Lamp (1) The following color code will be used for indicating lights Alarm General White Emergency Red operative and safe (None) Pump runs Green’ Pump stopped Red* Valve status (full open) Green Valve status (full close) Red *Note: One lamp with dual lens (two colors) (2) Window type panel mounted annunciator units shall be used for alarms. (White/red base with black engraved letters.) (3) Lamps indicating pump status shall be one lap with dual lens (two colors) mounted on the semigraphic diagram. Alarm System (1) A signal system serves to announce abnormal operating conditions. It will consist of an actuating device, an alarm system and an wdible signalling device. When prt limits of operating conditions ai the actuating devices shall be operated whereupon the visual and audible signal announces these conditions. (2) The actuating devices of alarm systems will be operated: (a) By the output signals of transmitters and be located in the control board. (b) By the switches conneced to the procesa. variable directly (e.g. flow, pressure switches, etc) where transmission is not allowed. INSTRUMENTATION 3.6.4 Q (4) (5) (6) Page 25 Rev. 4 Dat Feb. 10, 1986 KNPC ENG STD 60A1 (c) Othér actuator, such as auxiliary contacts. These signals are usually not intrinsically safe and shall be connected to the signal system in such away that they do not invalidate the intrinsic safety of the signals coming from the field (e.g. by keeping non-intrinsic safe signals separate from the others). An audible signalling device common to the various signal systems, viz. a buzzer will be located per each specified process unit group in the control room. The buzzer connected ta first out sequence shall have a different tone for general alarm. Alarm service units will be grouped in the dnstrument panel or auxiliary rack. Lamp units will be grouped on the instruments panels. The common test, acknowledge and reset unit will be used for each process or each selected section. Acknowledge and reset unit (such as push buttons) shall be duplicated on the operators’ working station (console) . Automatic Pump Starting system These are intended to take action without need for plant shutdown, e.g. automatic starting of stand-by pump or sequence controls for batch processes. The engineering basis for these systems is the same as for emergency system. Emergency system (ly ‘An emergency shutdown system serves to protect personnel, process and process equipment when abnormal operating conditions occur. It will consist of an - actuating device and/or other devices which initiate protective actions when preset limits are reached. A "hold" device must INSTRUMENTATION 3.7 3.6.6 3.7.1 (2) @) Page 26 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60AL be incorporated to kee: until the emergency system is manually reset even when the process variable concerned has already returned to normal. A prealarm shall sound prior to shutdown. the alarm actuated Components of emergency system will, as far as feasible, be installed in the control room or auxiliary room. Logic diagram will only be made to the engineering drawings. However, relay sequence diagram will be made by manufacturer in accordance with logic diagram. Common Sequence @ (2 ion Alarm Sequence Solia state relays shall be used. Operating nce of the alarm is in accordance with ISA S 18.1 Type Al. Contact of actuating devices shall be normally closed under the plant normal operation. Shutdown sequence. Solid state relays shall be used. Operating sequence of the alarm ia in accordance with ISA F3M-1 with First Out. Contact of actuaing device shall be normally closed. Solenoid valves shall be normally energized (de-energized to trip). Pneumatic Transmission a) @ a) Pneumatic transmission shall only be used for local loops. Multi-tubes may not generally be used. Output signal from all transmitters shall normally he 3-15 psig. Instrument connections shall be 1/4" NPT. INSTRUMENTATION 3.7.2 Page 27 Rev. & Date: Feb. 10, 1986 KNPC ENG STD 60A1 All pneumatic receiver instruments and gauges shall normally have receiver elements designed for 3-15 psig input air signal. (4) Individual pneumatic transmission tubing hall be 1/4" 0.D, x 0.035" wall etainless steel, (5) Small groups of tubes shall be supported either from air supply piping with messenger clips, plastic or metal strip: or in tube race channels suitably braced’to structural supports Electric Transmission (1) Electronic panel instruments shall generally be compatible with each other, with field instruments and other devices used on the project, without the use of signal converters. (2) Transmission signal of an electronic control system shall generally be 4 ~ 20 mA De. All transmission signals shall be of the same type and within the same range, except level instruments (e.g. tank gauge), positive displacement meters and quality analyzers. Other type of transmission systems may be used in accordance with instrument manufacturer's recommendation. (3) In general, field-mounted instruments shall employ a true two wire transmission system. (4) Even where electronic transmission and control is used, the actuation of all control valves shall be pneumatic. 3.8 Instrument Air Supply System 3. 2 General. The instrument air shall be oil-free and dry The dew point of the instrument air shall be at" least 10°F below the minimum ambient temperature (i.e. 17°F) at the delivered pressure. Instrument air shall be available at 80 psig. £NSTRUMENTATION 3.8.3 Rev. 4 Date: Feb, 10, 1986 KNPC ENG STD 60AL Pneumatic instruments shall normally operate at 20 psig and 3-15 psig input and output signals. system The major components of instrument air sypply system, such as compressors, air receivers, air riers, etc, shall be specified separately. Instrument Air Supply Piping The instrument air supply for a plant area shall be taken from the main instrument air supply system via isolating valve, Drain valves shall be installed at all low points, of main header and on dead-end. For of mechanical strength, the air supply in pipe tracs shall have a minimum of 1 1/2", The size of the air piping will depend on the number of air pilots as follows: Number of Pilots Size_ 1-5 a2" 6 - 20 1" 21-50 212" Individual branches (size 1/2") to instruments will be taken from the top of the header. For ease of maintenance a ball valve will be installed adjacent to the instrument, At least 15¢ spare 1/2" branches shall be provided, evenly distributed through the process area. Main branch header valves shall be in accordance with piping line class AS. Individual isolating valves near instruments are of bronze. Each field~mounted instrument requiring air supply is provided with an air supply set, consisting of an air filter, a pressure reducer and an output gauge. In case the instrument (or valve 2 Positioner) has an integral air supply gauge, the reducer output gauge will be omitted. INSTRUMENTATION 3.9 Page 29 Rev. 4 Dat Feb. 10, 1986 KNPC ENG STD 60AL Instrument Power Supply System 3.9.1 General am 2) (3) The following considerations will be taken into account when designing the electrical. supply system. Voltage required (a) Analyzer : AC 110V (b) Chart drives, multi-point temperature recorders, other instruments (not part of process control loop) ac 110v (c) safety and shut-down system De 110v (a) Receptacles Ac 110v (e) Alarm system multi-temperature indicators, electronic instruments (forming part of proce: contrel loops), and instruments for personal protection 2 AC 1200 Reliability of Supply When the normal outside electricity supply fails, stand-by electricity sources would be available to: (a) Perform a safe shutdown of the processes. (b) Continue plant operation with the essential instruments (e.g. compressor, boiler, etc) when shutting down is not desired or possible in a short period of time. INSTRUMENTATION 3.9.2 3.10 3) Page 30 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 For cases (a) and (b), no special provisions shall be necessary for the voltages paragraph 3.9.1 (2) ~ (a), (b), and (4), but the supply of voltage paragraph 3.9.1 (2) - (c) and (e) shall be taken over by other sources, usually inverter and betteries installed in the battery room and having a capacity sufficient for at least a one hour period. Emergency supply voltage for 3.9.1 (2) = {c) and (e) shall be uninterrupted. Refer to ENG STD 70Al for further details. Power Backup System for Instruments mM The voltage regulating static system shall be of the isolating type to supply uninterruptible power for the shutdown systems and instruments. The system shall consist of an AC rectifier input section, static inverter, static transfer switch, manual bypass switch, isolating-regulating transformer and required batteries and chargers. For further details refer to ENG STD 70A1 for back-up and UPS services. Interlock and Control Descriptions @ (2) Process interlock and control logic @iagrans shall be prepared to define operations that cannot be completely defined on the engineering flowsheets. They should convey to electrical engineering sufficient information for them to prepare the schematic diagrams, These @iagrams shall be prepared in accordance with ISA 85.2. The first issue of the interlock and control logic diagram shall be made when the engineering flowsheets are issued for design. After obtaining comments from the electrical engineering group, the final issure of the interlock and control diagrams shall be made at the time the engineering flowsheets are issued for construction. INSTRUMENTATION a) Date: Feb. 10, 1986 KNPC ENG STD 60Al Separate safety flowsheets shall be prepared for interlock and control systems that are too extensive to be clearly defined on the engineering flowsheets. 4 INSTRUMENTS“ AND CONTROL VALVES 4.1 Pressure Measurings 4.1.1 Pressure and Vacuum Gaug am @) @) “) (5) (6) ring elements (a) Receiver gauges and diaphragm sealed gauges where bronze elements may be substituted, (>) On very low pressure ranges, such as for draft gauges or barometrically compensated elements for absolute prassure where alloy steel elements are not available. Pressure gauge movements shall be stainless for alloy steel and stainless stell bourdon tubes and stainless steel or bronze for brass or bronze bourdon tube: Sockets and tips of pressure gauges shall be the same materials as the bourdon tubes. Cases for pressure gauges shall be aluminum alloy with a screwed ring unless process conditions require other material. Cases shall be weatherproofed and shall be protected with weather-resistant black paint. Gauge size will be in accordance with manufacturer's standard; however, dial size 41/2 inch diameter is preferable. Pressure gauge dials shall be white, non-rusting metal or plastic, with black figur Blowout protection shall be provided on all pressure gauges in process service - connected directiy to the pressure source. Rupture discs or blowout plugs shall be located on the lower aide of locally -NSTRUMENTATION 4.1.2 m (8) (9) Page 32 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 mounted gauges and on the rear of board mounted gauges. Safety front guard guag shall be used on pressures of 1,000 psig and above, Remote seal type pressure gauge shall be used on discharge of reciprocatingpumps and on suction and discharge of reciprocating compressors. Instrument process connections shall be 1/2" NPT. * Diaphragm seals (filled type) may be used for congealing, slurry or highly corrosive service, Pressure Instruments @ 2) a) 4) (5) (6) m Pressure transmitters and instruments shall be furnished with backup pressure gauges. Pressure measuring elements shall be alloy or stainless steel. In general, pressure instruments shall be furnished with full scale pressure ranges having the lower limit of the range equal to zero gauge pressure. Suppressed range pressure instruments may be furnished where required for measurement sensitivity. Pressure instruments shall be located so that the head of liquid between the instrument and the point of measurement does not exceed the manufacturer's limit of impressed static head. Where this is not possible, zero suppression/elevation kits shall be used. Diaphragm seals may be used for congealing, slurry or highly corrosive service. For services requiring a range between -30" Hg and 30 psig, differential-pressure instrunents may be used as static pressure instruments Force-balance transmitters may be used for narrow-span instruments, for critical INSTRUMENTATION (8) Page 33 Rev. 4 7 Date: Feb. 10, 1986 KNPC ENG STD 60A1 + pulsating pressures and when line is vibrating, Local pressure controllers will have indications of measured value and set point. 4,2 Plow Measurings 4.2.1 Primary Elements a @ Q) “ (5) The standard primary element for flow instruments shall be a Type 304 or 316 stainless steel concentric orifice plates. Orifice flanges with flange taps shall be weld neck with minimum rating of 300% ANSI RF. Orifice flange taps shall be 1/2" NPT up to 600%. Dual taps with plugs diametrically opposite shall be provided. Dimensions of the orifice flanges shall be per ANSI B16.36. Ring joint gaskets and dimensions shall be per ANST 516.20. Line sizes up to and including ten inches shall use orifice flanges having flange taps. Refer to Section 2 CODES and STANDARDS. Line sizes twelve inches ard larger shall Use line flanges with radius taps in place of orifice flanges. However, for above 300% flanges, and for 300¢ flanges with line sizes of 12 inches and 14 inches, orifice flanges having flange taps will be used. Radius taps shall be 1 pipe diameter upstream and 1/2 pipe diameter downstream of inlet face. Refer to Section 2 Codes and Standards Metering orifices shall not normally be installed in lines less than 2". If the line is less than 2", one of the following devices shall be used: {a) Swaged 2" meter run (b) Certified meter run with corner taps INSTRUMENTATION (6) (7) (8) Page 34 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 (c) Rotameter (a) Integral orifice (e) 1 1/2" metering orifices in accordance with JIS Z 8762 (#) Swaged (1 1/2") meter run in accordance with JIS 2 8762 Metering orifices shall preterably be in horizontal lines only. The installation in a vertical line shall always be upward for liquids and preferably downward for steam and gases. When the line is horizontal, the tap: be horizontal for lic veritcal up for ga + When limited spacing dictates, taps shall be locate above horizontal for steam and gas, 45° below horizontal for liquids, shall wids and steam and 45° orifices (a) Orifice meter differential range shall be selected for a d/D ratio of 0.75 maximum and 0.25 minimum. With 2" pipe and 20 or 25 inches HO column differential range, 47D ratios smaller than 0.25 may be used. In any case, actual orifice diameter shail not be less than 0.25 inches. (b) Orifice shall be sized so that normal flow rate falls at approximately seven (7) and minimum flow rate not less than three (3) on a 0 ~ 10 square root chart. For compressible fluids differential range in inches H,0 shall not exceed the normal upstream@static Pressure in PSIA, except that for exhaust steam (approximately 15 psig) 50 inches H,0 range may he used. (c) Dimensions of the orifice plate shall be per ISA RP 3,2. (a) Differential pressure ranges shall be as follows: INSTRUMENTATION Page 35 Rev. 4 Dates Feb. 10, 1986 KNPC ENG STD 60A1 20 inches, 50 inches, 100 inches, 200 inches, 400 inches, and wherever practical will be 100 inches #,0. For special cases, other ranges shall be considered. {e) The length of orifice straight run shall be in accordance with API RP 550, Part 1, Section 1. 4.2.2 Instruments (1) @ Q@ 4) (5) Force-balance type differential pressure measuring instruments shall be selected for all pneumatic transmitters. Advanced low displacement type differential pressure instruments may be used for electric transmitter Rotameter type flow instruments may be used for the following: (a) In pipe sizes 1 1/2" and smaller. () For special applications, in larger lines where solids are present in the Process fluid. (c) Where an operating flow range exceeds the ratio of 3 to 1 (maximum to minimum), Normal rotameter rangeability is 10 to 1 and meter will be selected so that normal flow falls at 50 to 60% of maximum range, (a) Liquids which are very vicous. Rotameters and rotameter transmitters shall be installed in a manner which permits easy means of float removal for cleaning or repair purposes. Type and rating of end connections to be in accordance with piping line class. Rotameters (expect for purge meters, applications where process conditions : dictate otherwise, and in streams that can be temporarily interrupted for service) shall have meter size gate valves INSTRUMENTATION 43 (6) a) Page 36 Rev. 4 Date: Feb, 10, 1986 KNPC ENG STD 60A1 upstream and a meter size bypa: valve. with gate Special conditions may dictate the use of devices such as the following: (a) Turbine meters (b) Magnetic flow meters (c) Target meters (4) Positive displacement meters {e) Eccentric or segmental orifice plates shall be used to measure the flow of iguids which contain solids. (#) Venturi tubes or similar types of flow elements may be used to measure the flow of low presi jases or liquids where loss of pressure is an important condideration, {g) Pitot tubes or averaging pitot tubes such as Annubar, may be used to measure flow in certain applications and shall be so indicated on the engineering flowsheets, (h) Quadrant edge plates where low Reynolds nd segmental wedges for slurry service (j) Ultrasonic type flow meter (k) Non-contact nuclear flow meters {1) Diaphragm al differential pressure measuring element (m) Insertion type mass flowmeter for flare flow ‘Temperature Measurings Receiver Instrument of Temperature Measurement (Board) For multi-point temperature indicators and recorders, single loop temperature TRUMENTATION 4.3.2 @ a) (4) Page 37 Rev. 4 Date: Feb, 10, 1986 KNPC ENG STD 60A1 indicating controllers either iron-constanan or chromel-alumel (J or K type) thermocouples will normally be used. Temperature limitation between type J and K thall be in accordance with API RP 550 Part I, Section 3, Item 3.3.2.1. Multi-point temperature indicators will be panel-mounted, with digital read out. Thermocouple selection will be via toggle switches. For large numbers of points, a push button operated relay system will be considered. ; A check point shall be provided in a separate thermowell as close as possible to controllers thermowell or double thermocouple in the same well. 5 Multipoint strip chart recording potentiometers are made in accordance with manufacturer's standard, but time cycle shall not exceed 6 seconds per point. Receiver Instruments of Temperature Measurement (Local) a) (2) Q) Motion balance, thermal filled system instruments may be used for local temperature indication and for local control where high accuracy is not important, Self-contained temperature control valves employing thermal filled systems may be used for limited applications, where high accuracy or wide rangeability is not required. They shali also be restricted to systems using steam or hot water as heat medium, Filled-system instruments will be used for local control for simple applications, e.g. tank heating, etc. All other filled system instruments will be used between range limits of 32°F and 600°F (unless adquate calibrating facilities are available outside these limits). For applications outside these limits, a thermocouple will be used as the sensing element, together with an emf-to-pressure or electronic “STRUMENTATION Page 38 71 . Date: Feb. 10, 1986 KNPC ENG STD 60A1 converter when a pneumatic or electronic recorder or controller is used. 4.3.3 Elements of Temperature Measurement (1) Temperature Gauges ta) (b) (c) ta) le) Temperature gauges will be bi-metallic type with rigid stem, suitable for mounting in threaded or flanged thermowell, The dial size will be made in accordance with manufacturer's standard; however, dial size of 4 1/2 inch diameter is preferred. The case material will be cast aluminum, The stem will be every angle type. Normal operating condition is considered as the design basis and the scale range is selected from the following table in such a manner that its working range falls between 30 - 70% of the full scale: Scale ranges -100 to +100°P 0 to +200°F 0 to +300°F 0 to +500°R 0 to +750°r 0 to +1000°F (2) Filled system intruments fa) i) Ranges and their limits will be in accordance with the manufacturer's standard, Spans will be 100, 200, or 400°F, The capillary tubing will be stainless steel AISI Type 316 stainless steel or JIS SUS 316 and shielded by flexible stainless steel and PVC cover, according to manufacturer's standards. Length of capillary tubing will suit INSTRUMENTATION Page 39 Rev. 4 ate: Feb. 10, 1986 KNPC ENG STD 60A1 the application, but minimum length will be 5 feet. {c) For non-indicating transmitters or local controllers of the thermal system type one or more of the following devices will be provided close to the measuring point of the instrument for indication and/or checking of the measured value: ~ Local temperature gauge covering the range of the instrument - Thermocouple connected to a multipoint temperature indicator ~ Test well ‘Thermocouples (a) Thermocouple shall be furnished in accordance with ANSI MC96.1, ANSI equal to ISA MC96.1, or JIS C1602. For general service, single thermocouples hall be 16 AWG but within limit of Table VII of ANSI MC96.1. Duplex thermocouples shall be of AWG. (b) Standard materials for thermocouple shall be in accordance with API RP 550 rt 1, Section 3, item 3.3.2.1. In general, all thermocouples shall be of the magnesium oxide insulated type with protective stainless steel (or better) sheating. The outside diameter of the sheath will be no more than 3/8 inch in order to fit in the 3/8 inch bored thermowell. (c) Where abnormally long thermowells are applied such as in flue gas ducts, combustion chambers, etc, the thermocouple wires will be minimum AWG 8 (3.2 mm). . (4) Thermocouples for measuring skin temperature of furnace tubes will be in accordance with ENG STD 65B11.35. INSTRUMENTATION @) Page 40 Rev. 4 Date: Feb. 10, 1986 ENPC ENG STD 60A1 Generally, these couples will be connected permanently to the multi-point temperature indicator. (e) For high temperature services, where hydrogen diffusion to the thermocouple material may be expected , magnesium oxide insulated thermocouples with Inconel protective sheathing will be used. For these services a vent shall be provided to depressurize the thermowell, provided it is acceptable to the proc licensor. (f) Thermocouple heads shall be weatherproof for Class 1 Division 2 areas and explosion-proof and weatherproof for Class 1 Division 1 areas, as per NEC requirement, and shall’ have 1/2" NPT connections for conduit. (g) The temperature/emf characteristics of the thermocouples will be in accordance with ANSI MC96.1 or JIC C1602. (h) All thermocouples, in general, shall be ungrounded type. Resistance-element type instruments (a) Ranges will be selected from manufacture's standards and span will be small as can be reconciled with process requirenent: (b) The resistance bulb assembly will be made according to the following: ‘The element will be platinum, The characteristics will be in accordance with DIN 43760. Normal tance at 32°F to be 100 ohms. The ance element will closely fit the standard thermowelli (©) The resistance elements used for average temperature measurements in storage tanks may be made of nickel. ‘The characteristics will be in INSTRUMENTATION (2) a Date: Feb. 10, 1986 KNPC ENG STD 60A1 accordance with manufacturer's standard. (a) To compensate for change in the resistance of the extension cable a three wire system will be applied. (e) Elements shall be embedded in molded In general, threaded thermowells, 1" NPT, bar stock type without seal welding shali be used for piping and vessels up to 6008 ANSI pressure rating and 750°F maximum temperature. Flanged thermowells 1 1/2" pipe size shall be used for: {a} piping or vessels above 600# ANST pressure rating, (b) piping or vessels above 750°F, (c) refractory lined piping or vessels, (a) staini steel piping or ve: 1s, (e) "hard to hold" services such as hydrogen, {f) special services such as hydrogen sulfide (see ENG STD 50A10.2) Flanged thermowells, 4" pipe size, will be used for clad piping or vessels. Exception - connections for multi- thermowells, retractab! purged and skin temperature thermowells shall be selected to suit manufactuer's standard equipment. The length of flanged nozzles shall be in accordance with ENG STD 10Al. This paragraph is not applicable for measuring large duct flue gas, etc. - The type and length of thermowells shall be in accordance with ENG STDS 65511.51 and INSTRUMENTATION 4) (8) (6) am «@ Page 42 Rev. “4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 65811.52. Fluid velocity in pipelines shall not exceed maximum velocity indicated in these standards Pipe type thermocouple wells with welded ends shall be furnished for gas temperature measurement at fired heaters, boilers, furnaces, flues, stacks and large vessels. This also includes wells used for multiple element thermocouple assemblies in reactors, etc, Well material shall be suitable for process conditions. The type and length will be described in the commodity specifications. Standard material for thermowells will be AIST Type 316 stainless steel or JIS SUS 316. If dictated by the process conditions and above 900°F, other materials may be applied. Threaded thermowells in high temperature service shall hava 4" lagging extension to allow for insulation thickness. Consideration shall be given for thicker insulation in cold services. Thermowells for thermocouples, dial thermometers and filled system instruments shall be purchased with the instruments to assure proper fit. Wherever possible, thermowells will bi located downstream of.orifice assemblies so as not to disturb the flow pattern in the line upstream of the orifice plate. 4.4 Level Measurings 4.4.1 General a (2) For local indication of levels, level gauges and tank gauge will be applied. For remote transmission or local control, _ Aisplacement type or differentail pressure type instruments and others will be applied. [NSTRUMENTATION (3) a) Page 43 Rev. 4 Date: Feb. 10, 1996 KNPC ENG STD 60A1 ment type instruments will be selected for normal applications up to a range of 48 inches, unless the liquid is very viscous, highly corrosive or where flashing may occur. Displacement type level instruments used for local control shall be pneumatic, When remote signalling transmission will be required, P/I converter will be considered.’ For remote transmission only electronic transmitters will be used. Differential pressure type instruments will be selected where the use of displacement type instruments is not adequate. 4.4.2 Displacement Type Level Instruments ay (2) (3) (4) 5) Displacement type level instruments (transmitters and local controllers) shall generally be externally mounted type. Instrument case is to be rotatable with respect to vessel connections, Preferred ranges for these instruments are: Inches 14 32 48 For ranges over 48 inches, differential pressure instruments are preferred, however, where displacement type level instruments have to be applied, the following ranges may be used: Inches 60 72 84 96 108 120 Body material shall normally be cast carbon ateel with stainless steel displacer and Inconel torque tube, Air fins shall be mounted for applications above 450°F and below 32°F, Displacer chambers for external type displacer will have 1 1/2" ANSI 3008 (minimum) RF flange for making vessel connection unless a higher rating or different type of connection is required. If required, the mounting flange of a top mounted internal displacer type will be 4 inch ANSI 300¢ RF unless a higher rating INSTRUMENTATION (6) 7) (8) (9) Page 44 Rev. 4 : Feb. 10, 1986 KNPC ENG STD 60A1 or different type of connection is required. Connections will be given on engineering flowsheets according to the arrangement of vessel or column construction, But generally connections shall be determined as follows: (a) For general use, top and side connections are preferred, (b) For above 750°F side and bottom connections are preferred bu usable for ranges -30°F to 850°F. (c) For -20°F to 750°F top and bottom connections may be used. (a) Side and side connections shall only be used when space is limited. The mid-range of vessel instruments will be located at the normal level in vessel or column. To indicate the mid-range position of the displacer, a metal tag shall be permanently fixed on the cage. Level alarms shall normally be actuated by a receiver pressure switch or electronic monitor switch located in the control room where there is a receiver instrument on the panel board. Where the loop is local only with remote alarm, the switch shall be located in the field. Separate float switches shall normally be used for trip circuits. Indicating dials or scales for level instruments shall be graduated zero to one hundred percent of the level range, except in the case of API storage tanks where the graduations shall be meters, centimeters, and millimeters. Indicating pressure gauges shall be provided for both air supply and output. INSTRUMENTATION 4.4.3 Page 45 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1L (10) Where process conditions dictate and where shown on the engineering flowsheets, capacitance, radioactive, ultrasonic, magnetic float, etcetera-type of instruments may be used. Differential Pressure Type Instruments a (2) (3) 4) External differential pressure type level instruments shall be furnished for pressure vessels in level rau whieh ex: inches, unless process conditions make such type undesirable. ‘They may be furnished for shorter ranges where accessibility makes them preferable. Differential-pressure type level instruments will be mercury-less and of the force-balance type with continuously adjustable range The instruments will normally be of the externally mounted type. All level transmitters shall have zero suppression/elevation kits as a standard. The flange rating for flange mounted instruments will be ANSI 300% RF minimum. The flange size will be in accordance with rument manufacturer's standard. In jeneral normal sizes 3" and 4" are used for natruments with extended diaphragms, 6" is used for low range instruments. Flange mounted instruments shall be suitable for universal mounting. Level Gauges q@) Gauge glasses shall be sized to cover operating level ranges, not abnormal extremes in level. Where level range exceeds 11 feet the top and bottom 40 inches shall be covered. Where level is to be controlled between the top and bottom 40 inches a gauge glass of suitable length shall also be furnished to cover controllable range. When used in conjunction with a level instrument, their visible range will cover the entire range of this instrument. INSTRUMENTATION a) Q “) (5) (6) Page 46 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A2 When two or more level gauges are required to cover a longer range than 50 inches they will be arranged in such a way that the visible lengths overlap by at least 1 inch. I€ the required range has to be covered by more than one gauge, the gauges will be placed on a stand pipe. Where side and side connections are specified, a gauge shall haye two entries 180° apart at each end with one side plugged. Gauge glasses shall be of the transparent type except for clear services. In general clear services shall be of the reflex type. Transparent gauges shall also be used for interface between liquids: on liquids containing sediments which may coat the flutes of reflex glass; and liquids requiring protective shields such as steam and caustic service. Gauges on boiling service shall have large chamber transparent gauge: All transparent gauges shall be provided with illuminators. Gauge glasses for low pressure vessels containing low temperature non-flammable fluids such as water, or phosphate solutions may be tubular glass type in lengths not exceeding 30 inches. Center to center dimensions of process connections of level gauges will be manufacturer's standards. Frost shedids shall be used when the operating temperature is below 32°F, and mica shields shall be provided when the operating temperature is above 400°F and for all steam services All fittings and valves of level gauges - will be of steel unless the service requires a different material. Process connections of level gauges will be flanged LNSTROMENTATION 4.4.5 4.4.6 7) Page 47 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 11/2 inch ANSI 300# RF unless a higher rating or different type of connection is required. Gauge valves shall be furnished with all level glasses. They shall be offset type with ball check valves and armored glasses shall have spherical union at chamber connection. Rating and material shall meet piping and vessel specifications. In additionto gauge vaives, armorad type level glasses shall have primary shut-off valves. For separately installed level js these primary shut-off valves shall connections and for ations they shall be at the bridle connections. Rating and material of primary shut-off valves shall be in accordance with piping line classes. Local Tank Gauges Local level indicators for API type storage tanks shall normally be float type with internal guides. Refer to paragraph 4.4.6 (9). Remote Tank Gauging system @ (2) a 4 The tank gauging system will indicate on one display the tank levels and average temperatures of the numerous tanks. The system will be able to operate two (2) more receivers (in general on/off site panel) at the same time, and to c same tag numbers from two -(2) dif: receivers at the same time. The measuring value of tank level and average temperature will be indicated digitally. ‘The accuracy of measuring value for tank level and average temperature will be as follow: Accuracy Level #1.0 mm INSTRUMENTATION (5) (6) re) (8) ) Page 48 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 Average ‘Temp. 21°P If the tank gauging system is hooked up with a computer, continuous a scanning of the values will be performed by that computer. However, computer scanning of the measuring values will cease with regard to a tank selected by an operator by means of a conventional display keyboard. This tank gauging computer should be able to interface with the main computer located at the central control room.~ The number of indicating digits on the display panel will be as follows: Tank number 4 digits Level 5 digits Average Temp. 3 digits This value could be displayed on CRT instead of digital indicators. Additional informations such as volumes, low and high alarms could also be displayed. Selection of tank numbers will be done by means of a pushbutton type or turn-key board. It will be possible to incorporate two alarms for each tank level i.e. high and low. In addition to alarms given by the nicro-processor based system, low and high level switches are provided at each tank connected by hardwires to conventional alarm units. 4.5 Control Valves 4.5.2 ‘Type a) Globe type control valves shall usually be sized for a normal flow at no more than 70% of the capacity of the than 1/3 of the variable system frictio: Pressure drop excluding the pressure drop allotted to the valve. The allowable " ENSTROMENTATTON 4.5.2 Page 49 Rev. & Date: Feb. 10, 1986 KNPC ENG STD 60A1 pressure drop for the control valve is to be at least 15 psi in the case of pump discharges, except in special cases. Butterfly valves shall be sized for a maximum flow @60° angular opening except for a characterized vane valve (such as the “fishtail") which may be sized @90° angular opening. Three-way valves shall be sized to pasa maximum flow through either port with minimum available presgyre drop through the same port. (2) The manufacturer's "CV's" shall be used to select valve capacity. (3) The minimum size control valve shall be 1” except when the line size is smaller, in which case a line size control valve may be furnished. ‘The following body sizes will be used: i, 24/2", 2", 3", 4", at, 10", 12" and larger. (4) Normally all control valves shall be flanged. Special valves such as butterfly or ball may be wafer type designed to fit between companion flange: (5) The minimum flange rating for steel valves 4" size and smaller, shall be ANSI 300RF. Cast iron valves are an exception and may 125 FF. For larger sizes the pressure rating shall conform to the specific piping line class. The rating for butterfly valves shail conform to the specific piping line class regardless of size. (6) The flow direction shall be marked on the valve body. Materials (1) Control valves in process services shall have steel bodies unless piping line classes require alloy. (2) The following shall govern, unless otherwise recommended by process licensor or determined by other process conditions: INSTRUMENTATION 4.5.3 4.5.4 Page 50 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 Control valve trim shall be stainless steel 4s a minimum. Hardened stainless steel, or stellite facing, or solid stellite shali be furnished for valve plugs, seat rings, guide posts and bushings for pressure drops which exceed 150 psig, flashing lliquia services and for fluids which contain solid particles. More specifically, refer to ENG STD 65F11.2. Actuators Control valve actuators for general service shall be standard pneumatic spring and diaphragm type. Piston type operators may be used where high stem thrust requirements render diaphragm type operators impractical and for special vic h as pipeline control. Economic reasons are also determinin: factors where electro-hydraulic of electric motor operators may be used. Accessories a @ Q) 3) Guide bushings shall be of hardened corrosion resistant material. It is preferred that bushing material be minimum of 125 Brinell harder than the trim. Control valves shall be furnished with braided asbestos with solid Teflon cover packing for operating temperatures -320°F to 450°F and braided graphite asbestos packing with lubricator for operating temperatures above 450°F. Grafoil could be furnished for the temperature range above 480°F for all services exept strong oxidizing services. Cooling fins or radiation extension bonnets shall be provided for operating temperatures of 450°F or higher and for operating temperatures of 32°F or lower. — All positioners shall be pneumatic only. 1/P positioners shall be avoided. INSTRUMENTATION “) Page 51 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 Pneumatic valve positioners shall have 3 Pressure gaug Bypass valves shall be provided except on split range positioners or where operator is other than 3-15 psig. Valve positioners shall be furnished for throttling automatic control valves only under the following condition: {a} Slow response service such as temperature or averaging liquid level - Control (b) Venturi throat, three-way, butterfly valves (c) Unbalanced single seated valves larger than 1” pipe size ta) wes in split range services, coking, crystallizing, gumming or slurry service te) Operating temperature over 400°F and for 0°F or under (£) Valve sizes 6" and larger (g) Valves operating at pressure drop over 150 psig (h) Valves with more than 10% weight flashing Valve accessories such as I/P transducers, limit switches, solenoid valves, air set: positioners, relays, backup system fo: piston actuators, etc, shall be furnished with the control valve and assembled as a package. 4.5.5 Assembly a) 2) ALL control valve bodies 1 1/2" size and smaller shall be furnished with block and bypass valves. Control valves in corrosive, erosive or other services shall be furnished with block and bypass valves only where shown on engineering flowsheets. A corrosive service shall be defined as one in which INSTRUMENTATION q@) «@ Page 52 Rev. 4 Date: Feb. 10, 1986 KNPC ENG STD 60A1 the process fluid is more corrosive to the wetted parts of the valve than to the piping. Erosive service shall be defined as one where the line fluid contains solids or where the normal operating pressure drop across the control valve exceeds 150 psig. .Whenever the control valve size is 2” or larger and except when tl (2) applies, block and byp: be omitted. The control valve furnished with a handwheel operator. Size of manifold, block and bypass valve shall be determined by the size of the control valve body per the following tables: TABLE A necommancel inimm Block aod Bypass Valve sizing ‘ FLEXIBLE DESIGN ~ SIGHLFLCARE EXPANSION ANTICIPATED 34 1 Lan 2] 3a] 4 a | 1 | 12 3 B 2 a] 3s] 5] sf 3] a] 8 3 y|ayv]osy sp y¥ |{syjsyjsyri/syjsy|uy lay e|uef{uce | op ierl[ur{er[ur|ueiur {ue a}o a} oa] o a foaloafoajoaloatoa lou sje s}|cs]|c 8s |cs|cs|cs}cs|cs|cs |e s eee = S[RS/ESTES/ES/ESIE SR IES 2} seas) x. frweri2}--]--]--|--]--]- - ]- - ~ [33m] 12 fra2ia|22}--}--]--]|--]- - [- - - |= "= | 1a faaeiag{22}22}--]--]--]- - }- - - |- - | -- [rari |22}22}33}--|--[- - |- - -]J- -|--] - = [22]32/33]es]--]-- ]- - -]- -]--] - - [--f33]4aa fas foes ]- - ]- - -f- -]--] - - [--[--]ss}os]eeys a ]- - -|- -]--] - - J--]--[--]ee [tetas hor =]J- -]f--] - + [--}--]--]--] 88 fo 8 fro 20 -]f- -]f--] - - J--]--]--]--]-- fo fiz. -|- -f--] - - Je-f--]--]--|--]- - jee (2) At} sizes in inches (2) ALI block valves are to be pe (3) Bypa ‘up to 4-inch size co be globe type, 4-inch and over to be gate type. In slobe valves of same max Cy a control valve through 6-inch size. v ralves for plugging service. (4) Thin table fe based on the “flextble design”, which includes provision for future expansion. For flexible deaign, block valves are Line size, except vhere control valve ie two or wore sizes eualler than line aize, block valves may be one size sualler then Line size. Consideration should also be given to “minimus desiga”, vherein future jot anticipated. In this case a more economical approach may be caken. gn, make block valves one size larger chan the control valvé size (but no larger than line eize). The bypass line and valve shall normally have # capacity equal to the calculated or raquired Cy of the control valve,, but act greater than twice the selected Cy of the control valve. The minteum block an bypase valve aizing shall be ae per cable B. OTIvENGAMEISRT ‘W09 as ONS Dama ee 95 ova 9e6t ‘Ot aea TABLE B Recommended Minimum Block and Bypass Valve Sizing MINIMUM DESIGN - NO SIGNIFICANT FUTURE FXPANSION ANTICIPATED Control valve body size, Inch

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