STANDARD SPECIFICATION NO. 60A2 INSTRUMENTATION FOR PACKAGED UNIT KUWAIT NATIONAL PETROLEUM COMPANY (K.S.C.)Page 2 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 CONTENTS Page 1° GENERAL 2 REFERENCES 5 5 7 Qualifications 7 a a 9 2.1 Performance Criteria 202 2.3 Material Selection and Dimensions 2.4 Explosion-Proof Construction 2.5 Special Instruments 2.6 Environmental Conditions 10 3 ENGINEERING DESIGN PHILOSOPHY 10 3 General 10 Units of Measurement 11 3 Component of Instrumentation 12 3. General Requirements for Instruments 13 3.4.1 Graduations of Charts and 13 Indicating Scales 14 3.4.2 Chart Sizes and Types 146 3.4.3 Chart Drives 14 3.5 Local Panels 14 3.5.1 General 14 3.5.2 Functional Requirements 18 3,6 Alarm and Shutdown System 19 General 19 Indicating Lamp 20 Alarm System 21 Automatic Pump Starting 22 System Emergency System 22 Information to Main Control 23 Room 4 INSTRUMENTS AND CONTROL VALVES 23 4.1 Pressure Measurings 23 4.1.1 Pressure and Vacuum Gauges 23 4.1.2 Pressure Instruments 24Page 3 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 CONTENTS Page 4.2 Flow Measurings 25 4.2.1 Primary Elements 25 4.2.2 Instruments 27 4.3 Temperature Measurings 23 4.3.1 Receiver Instruments of 29 Temperature Measurement (Board) 4.3.2 Receiver Instruments of 29 Temperature Measurement (Local) 4.3.3 Elements of Temperature Measurement 30 4.304 Thermowells 33 4.4 Level Measurings 34 4.4.1 General 34 4.4.2 Displacement Type Level 35 Instruments 4.4.3 Differential Pressure Type 36 Instruments 4.4.4 Level Gauges 37 4.5 Special Instrumentation 39 4.6 Control Valves 40 Type 4l Materials 41 Actuators 42 Accessories 42 4.7 Safety and Relief Valves 43 4.7.1 General 43 4.7.2 Material of Construction 44 4.7.3 Thermal Expansion 44 4.704 Turbine Exhaust 44 4.7.8 Data Sheets 44 4.766 Bonnet Construction 44INSTRUMENTATION FOR PACKAGED UNIT Page Rev. Date: CONTENTS Connections Accessories Code Stamps 0 Block Valves mane Soh booed Flange Finish 5 INSTALLATION REQUIREMENTS FOR INSTRUMENTS S.1 5.2 5.3 5. General Instrument Air Supply Piping and Pneumatic Signal Tubing Instrument Pressure Lead Piping Instrumentation Wiring 6 INSPECTION 7 DOCUMENTS AND DRAWINGS 7.5 General Specifications Drawings Spare Parts 7.4.1 Spare Parts and Interchangeability List 7.4.2 Quotation Submittal Requirements Inspection Manual 8 IDENTIFICATION 9 SHIPPING 4 4 Mar 1, 1986 RNPC ENG STD 60A2 Page 44 44 45 45 45 4s 46 aT 48 4g 4g a9 49 49 49 49 50 50 51 51Page 5 Rev. 4 Date: Mar 1, 1986 ANSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 1° GENERAL This standard covers Instrumentation for Packaged Equipment. The vendor is expected to comply with all of the requirenents embodied in this standard. Prior to acceptance of the packaged equipment the Purchaser reserves the right to approve all furnished instruments and controls and substitute suppliers who conform to the approved vendor's list. The vendor shall submit all the specifications and drawings for the Purchaser approval as required in Section ¥-of this standard. The present standard is general, since it is being used to supplement basic specifications for a variety of packaged equipment. It is specifically intended that all its relevant requirements shall apply to the procurement of all types of packaged units or systems such as, but not limited to, blowers, compressors, furnaces, boilers, water-treaters, and their controls and instrumentation. The vendor shall be responsible for ensuring that the package instruments and controls properly interface with available utilities, process conditions, and related instruments including computers and programmable controllers external to the package. Vendor shall provide, where necessary any additional interfacing hardware required to make the system operational. 2 REFERENCES The following codes and standards supplement this standard and shall be applied as indicated. (1) American National Standards Institute ANSI B2.1 Pipe Threads ANSI 316.5 Steel Pipe Flanges and Flanged Fittings ANSI B16.10 Pace-to-Face and End-to~End Dimensions of Ferrous Valves ANSI B16.11 Forged Steel Fittings, Socketwelding and Threaded ANSI B16.20 Ring-Joint Gaskets and Grooves for Steel Pipe Flanges ANSI 816.36 Steel Orifice Flanges ANSI/ASME B31.3 Chemical Plant and Petroleum Refinery Piping ANSI MC 96.1 Temperature Measurement ThermocouplesINSTRUMENTATION FOR PACKAGED UNIT Page 6 Rev. 4 Date: Mar 1, 1986 KNPC ENG STD 60A2 (2) American Petroleum Institute API RP 500A Classification of Locations for Electrical Installations in Petroleum Refineries API_RP 520 Recommended Practice for the Design PART 1 and Installation of Pressure Relieving Systems API RP 526 Flanged Steel Safety-Relief Valves API RP 550 Process Instrumentatten and Control PART 1 (3) American Society of Mechanical Engineers ASHE Section I Boiler and Pressure Vessel Code (4) Deutsches Institut fur Normung DIN 43760 Electrical Temperature Sensors (5) Instrument Soceity of America ISA MC 96.1 American National Standard for Tenperature Measurement Thermocouples TSA $8.2 Binary Logic Diagrams for Process Operations ANSI/ISA 518.1 Annunciator Sequences and Speci fications ANSI/ISA $75.01 Control Valve Sizing Equations (6) Instrument Society Organization Iso 5167 (7) Japanese Industrial JIS C1602 SIS C1610 JIS 28762 STS 28763 (8) KNPC Engineering Sti Measurement of Fluid Flow by Means of Orifice Plates, Nozzles and Venturi Tubes’ Inserted in Circular Cross-Section Conduits Running Full Standard Thermocouples Indicating Resistance Thermometers Measurement of Fluid Flow by Means of Orifice Plates and Nozzles Measurement of Fluid Flow bv Means of Venturi Tubes andardsPage 7 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT RNPC ENG STC 60A2 50A2 Gasket and Surface Finish for (9) (oy qn Flanged Joints S50A11 thru 50A31 Piping Material Specification 60A3 Instrumentation Symbols and Identification §5F11.2 Trim Material Selection 70R2 Electrical Requirements for Packaged Equipment 92a1 Preparation of Material for Shipment National Association of Corrosion Engineers NACE Std MR-01-75 Sulfide Stress Cracking Resistant Metallic Material for Oil Field Equipment National Electrical Manufacturers Association NEMA 250 Enclosures for Electrical Equipment (1000 Volts Maximum) National Fire Protection Association NFPA 496 Purged Enclosures of Electrical Equipment in Hazardous Location National Electrical Code National Electrical Safety Code Performance Criteria (1) Control Valve Sizing ANSI/ISA-S75.01 Masoneilan valve sizing equations (2) Safety Valve Capacity API 526 (3) Flow (orifice) Iso 5167 L XK Spink Same as JIS 28762 and JIS 28763 (4) Annunciator Sequences ISA $18.1 Qualifications (1) Thermocouple Element ANSI MC 96.1 Same as ISA MC 96.1 or JIS C 1602Page & Rev. 4 Date: Mar i, 1986 INSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 (2) Resistance Bulb DIN 43760 (3) Extension Wire ANSI MC 96.1 2.4 Same as ISA MC 96,1 or JIS C 1610 Material Selection and Dimensions (1) Control Valve Body Per Piping Line Class (2) Control valve ENG STD 65E11.2 Internal (3) Safety Valve Boay Per Piping Line Class API 526 Manufacturer's Standard (4) Safety Valve Inner API 526 Parts Manufacturer's Standard (5) Orifice Flange Per Piping Line Class ANSI B16.36 (6) Accessories for Manufacturer's Standard Orifice Flange (7) orifice Plate ISA RP 3.2 Manufacturer's Standard (8) Orifice Holding Ring ISA RP 3.2 Manufacturer's Standard (9) Flanges, Fittings, Dimensions to Applicable etc ANSI Standards (10) other Materials Applicable ASTM Standards Explosion-Proof Construction qm Instruments Generally, an intrinsically safe system will be applied. ‘However, the following instruments shall also be explosion-proof type if applicable. Explosion-proof instruments shall also be weatherproof. They shall be NEMA 4 and 7 or equivalent. | . Pressure Switch, Level Switch, Flow switch ~Solenoid Valve2.5 Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 Codes and Certifying Stance ds Country Authority gis Japan RIIS API RP 500A U.S.A. UL/EM BS U.K. BASEEFA VDE West Germany PTB NF France MIR cEC Canada CSA Remarks: API RP 500A shall be applied for this item, however, if manufacturer is located other than in USA, such manufacturer shall state the explosion-proof construction is equivalent to NEC/API, then country of origin standard may be applied as listed on this table. *NOTE: RIIS + Research Institute of Industrial safety ub t Underwriters Laboratories FN 1 Factory Mutual system BASEEFA : British Approval Service for Electrical Equipment in Flammable Atmosphere PTB : Physikalisch-Technische Bundesanstalt MIR : Ministere de la Industrie et de la Recherche CSA Canadian Standards Association (2) Construction Materials for Electronic Instrument Works (such as junction boxes, conduit pipes and fittings, cable glands, etc.) Same as 2.4 (1) Instrument: Special Instruments For those instruments which are not certified because of their specialty, but whose operational safety has been- proven and which are in wide use throughout the world, like speed sensors around gas turbines, the Purchaser shall be informed in advance that certificates are notPage 10 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 obtainable, Written approval shall be obtained from Purchaser for use of these instruments. 2.6 Environmental Conditions The instrumentation on the packaged equipment must be able to withstand the climatic conditions described in "Site Condition and Utility Condition” section of the project specification. 3. ENGINEERING DESIGN PHILOSOPHY 3.1 General 3.1.1 The instruments in general shall be of the electronic type and/or pneumatic type whichever manufacturer recommends. However, transmission signal to main control room shall be of DC type. 3.1.2 Pneumatic signal shall be 3 - 15 psig. Electronic signal shall generally be 4 - 20 mA UC. Where special signal may be used, signal range shall be so specified by manufacturer and shall be compatible with overall 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, and shall comply with the certifying authority in the country of origin, 3.1.3 Local panels shall be used for packaged units such as boilers, compressors, etc., to install local indicators and hand control units, Permitting local start-up or shutdown of equipment. No process fluid shall be directly piped to the local panel. 3.1.4 Pield mounted electronic instruments shall be protected from direct sunlight and shall be suitable for operating under the climatic conditions described in “Site Condition and Utility Condition" section of the project specification. Weatherproof construction is to be NEMA 4 or equivalent. 3.1.5 Variable indication shall be provided either direct reading or transmitter output, in terns of measuring variable.Page 11 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT _ KNPC ENG STD 60A2 3.1.6 If the instruments containing radioactive 3.1.8 3.1.12 3.1.12 3.1.13 substance are used, their import and use shall be licensed in accordance with local government statutory regulations. Sunshades shall be provided totally enclosing the instrument with a 120° view. Sunshades shall be fabricated from galvanized steel and angle iron and shall be designed to provide sufficient strength and rigidity. Molded polyurethane is acceptable. Construction of electronic instruments and their accessories shall be suitable for applicable electrical area classification, 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. All field and board mounted electronic . instruments shall be immune to RF interference. Where manufacturer's standard deviates from this standard, manufacturer shall confirm and get approval in advance from the Purchaser. Symbols and identification shall be as per ENG STD 60A3. Numbering of instruments provided by package vendor shall be assigned from a block of numbers allocated by the Purchaser. Units of Measurement Units of measurements for instrument calibration shall be the following system. The details are as follows:ANSTRUMENTATION FOR PACKAGED UNIT a (2) @ a) (5) (6) 7) (8) (9) (10) (11) 3.3 Component of Instrumentation Measurement Pr ure Pressure (draft or vacuum) Plow Liquid HC Water Gas Steam Air Chemicals ‘Temperature Level Volume of product tank (Exception: : This does not include water tanks and intermediate tanks) Level for tanks Specific gravity, Liquid Gas Viscosity Density Differential pressure in orifice Page 12 Rev. 4 Date: Mar 1, 1986 KNPC ENG STD 60A2 Units PSI in H20 or in Eg USGPM @ 60°F* BPD at 60°F USGEM at 60°F SCFH at 60°F, 14.7 PSIA Lb/hr SCFM at 60°F, 14.7 PSIA USGEM at 60°F °F % (percent) API Barrel (Petroleum) mm, cm and m water equals 1 @ 60°F air equals 1 @ 14.7 psia @ 60°F) cP u/Fe? inches of Hy Modes of control shall actually be shown on each specification and generally be selected as follows: Pressure Flow Temperature Level P +I (slow) P +I (fast) P +I (slow) or P+I+D P or P +I (slow) *For control valves and shut off valves, USGPM at operating temperature.Page 13 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 Wherever Integral (I) action is specified it shall have full range settings covering slow and fast actions. Further, to standardize the controllers, the feasibility of adding derivative action facility shall be provided as and when required. General Requirement for Instruments 3.4,1 Graduations of Charts and Indicating Scales a (2) For instruments measuring variables, the graduation on the charts and/or on the indicating scales shall be as follows: Variables Scales Charts Pressure Direct reading 0-100 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 0-10 sq RT/ 0-10 sq RT/ recorder 0-100 uniform 0~100 uniform (dual scale) (Two graduations) Other (specified by (specified by package package vendor) vendor) For instruments indicating or reccrding two or more variables the graduations of the charts and indicating scales shall be as follows: (a) When all variables are of the same kind, the charts and/or indicating scales shall be graduated for that variable in accordance with the table described above. *Plow factor to be printed on circular or rectangular scale. Example: RDG X 100 =~ GPM. 100 is the flow factorPage 14 Rev. 4 Date: Mar 1, 1986 ANSTRUMENTATION POR PACKAGED UNIT RNPC ENG STD 60A2 a5 (>) When one of the variables is flow (D/P), a combined range chart 0-10 so RT and 0-100 uniform shall be used. Indicating scale for recorder shall be dual in accordance with the table described above. (c) For all other combinations of variables, a 0-100 uniform chart is used with indicating scales in accordance with the table described above. 3.4.2 Chart Sizes and Type Chart sizes shall be in accordance with manufacturers' standards. Charts shall be rolled type. 3.4.3 Chart Drives mM (2) (3) Local Panels Recording instruments shall have electric chart drive. The spring-wound type chart drive shall not be applied. Chart speed shall be manufacturers’ however, following approximate speed shail be applied: Miniature type 3/4-inch per hour recorder Malti-point i-inch per hour recorder 3.5.1 General a (2) Instrument panels in field shall generally be non-graphic, free-standing, totally enclosed cubicle type with hinged doors at rear or side. Local panels shall be fabricated from 3/16~inch minimum thickness cold rolled steel, with adequate stiffeners to prevent buckling during installation, shipping andPage 15 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION POR PACKAGED UNIT KNPC ENG STD 60A2 (3) (4) (5) (6) i) (8) handling. The plate shall fasten to the framing structure, with no exposed bolts or screws on face of panel, The doors, sides, and top of the panel shall be 1/8-inch steel plate. The docrs shall latch at 3 points and be fully gasketed with lockable door handles. Panel cutouts and holes may be cut or drilled by any standard method that will not cause deformation. Burrs shall be ground smooth. Panels shall be sandblasted, filled, primed, and finished with an adequate number of paint coats, Finish paint shall be semi-gloss weather resistant of a color to be specified later by the Purchaser. Front of panel instruments shall be flush mounted. They shall be arranged so as to permit easy access for calibration, maintenance, or replacement. All areas reserved for future use shail be kept clear of all wiring, piping, tubing, etc. Cutouts with cover plates shall be provided for future instruments. Where the location of panels will be in general purpose area, weatherproof panels will be used. Where the location of panels will be in hazardous area, necessary protection will be considered against explosion such as: (a) General type panels with explosion=proof instruments and wired in accordance with National Electrical Code requirements. (b) Weatherproof panels with general purpose instruments and with preparation of fresh air purging in this case, NFFA-496, Provide explosion-proof pressure switch to signal loss of air purge. At least 20% spare space shall beINSTRUMENTATION FOR PACKAGED UNIT Mar 1, 1986 KNPC ENG STD 6CA2 provided. (9) Piping (a) (b) tc) All pneumatic piping within the panel, except the air header, shall be 1/4-inch diameter stainless steel tubing. Incoming and outgoing lines shall terminate at a bulkhead plate located near the top (or bottom when specified) rear of the panel and point straight back for connection to Purchasers tubing. Piping shall be arranged to provide for future instrument additions, Ten percent spare bulkhead tubing fittings shall be supplied in place. Each terminal connection shall have an engraved metal or plastic plate with service marking and/or instrument tag number. When air is consumed at the panel, provide a minimum 1-inch air header, which extends the full length of the panel, It shell be carbon steel pipe, and rigidly mounted behind the panel, near the bottom, The header shall slope from the inlet end and terminate with a 3/4-inch drain valve on the bottom at the far end. (10) Electrical ta) (b) The vendor shall supply all necessary electrical equipment such as conduit, fittings, wire, seals, raceways, power distribution panels, junction boxes, terndnal strips, etc. to make 4 complete operational’ package. All electrical equipment and wiring shall be suitable for the specified electrical area classification and conform to the requirements of the latest edition of the following standards and codes. a National Electrical CodeINSTRUMENTATION FOR PACKAGED UNIT (e) (a) fe) (f) {g) (hn) a Page 17 Rev. 4 Dat Mar 1, 1986 KNPC ENG STD 60A2 (ia) Naticnal Electrical Safety Code (iii) APT RP 500A, (iv) Applicable Local Laws and Regulations Wire for ali 110 volt circuits shall be 14 AWG solid conductor or stranded with lugs and type TH¥ or THWN insulation, Plexible conduit is not allowed except when specified in the project specification. Each terminal connection shall be identified by an engraved metal or Plastic plate with a terminal and instrument tag number. Power supply for the panel shall be received at the tie-in terminals and distribution shall be made by vendor after tie-in point. Fower supply of AC 110 volt and/or DC 110 volt shall only be supplied to local panel. Where other electricity is required, such electricity shall be converted with adequate equipment, for instance transformer, rectifier, etc. All power supply wiring shall be run in separate conduit from signal and alarm wiring. All panel wiring shall be complete so that the Purchaser can wire directly to the terminals. No direct interconnection of instruments or splicing of any leads in electrical raceways is permitted. If interconnections between instruments are required, they shall be made at terminal strips. Each electrical instrument shall have an individual disconnect switch. Disconnect switches shall have metalp Page 18 Rev. 4 Date: Mar 1, 1986 ANSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 or plastic tag numbers, (J) Signal wire shall be 16 AWG twisted pair cables in conduit or troughs. Refer to END STD 70A2 for further details. (x) A thermocouple lead wire trough shall be provided, with rear face removable, located along the top or bottom of panel, for distribution of the various incoming lead wires. Thermocouple wire shall be continuous from the field to the corresponding instrument. (1) Resistance thermometer lead wires shall be provided with a separate conduit and pull box system. Lead wires shall be continuous from the field to the corresponding instrument. (11) Each instrument shall be identified by laminated phenolic nameplates. The nameplates color and size will be specified in the purchase specification. The nameplates shall be engraved with the instrument loop number and service as shown in the purchase specificaticn. Functional Requirements Local panel shall generally be furnished with following: (1) Main equipment start/stop push buttons (2) Auxiliary equipment start/stop push buttons (3) Motor running lamps (4) Ammeters for motors (5) On-off switches for electric heaters (6) Auto/manual position switch (7) Local/remote position switchPage 19 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 (8) Main circuit breaker and relays (9) Annunciators (10) Other instruments (11) Receptacle and Lighting (12) Machinery monitoring systems 3.6 Alarm and Shutdown systen 3.6.1 General This paragraph covers the requirements for equipment with the following services: a (2) Indicating lamp To give information on the local panel 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. (b) When the status can ke changed automatically, e.g. starting of standby pumps, an audible alarm is also required. Switch contacts shall be specified single pole, double throw wherever possible. Only one function per switch shall ke specified where feasible (i.e., alarm only or interlock only). Contacts shall be AC 110V, or DC 110V for 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 switches are dry contact (DC 110V, 0.48). Use of snap-acting microswitches may be considered for applications susceptible to vibration and shock.Page 20 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 (3) Contacts of electrical actuating devices (4) (5) (6) 47) for signal and emergency systems will be closed under normal process conditions in order to obtain action if the actuating eircuit is broken accidentally. Wherever possible all actuating devices will be located in the main control room or local panel. Only for those applications which require direct actuation, the actuating devices will be 1déated in the field. All switches connected with shutdown sequence shall be direct acting type except for flow. Where operational requirements demand, vendor shall make provision for repeating all or few alarms in control room by providing auxiliary potential free contacts at local panel, Where such provision is xequired, it shall be indicated in the engineering flowsheets. 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 rated voltage and frequency and shall be encapsulated type. Valve bodies for solenoid valves shall follow piping line classes when used in process lines. Manufacturer's standard brass valves 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 85.2. Logic diagram and relay sequence diagram shall be made by packaged vendor. Hermetically sealed magnetic relays shall generally be used for alarm and shutdown Sequence. Solid state relays may be used where applicable. 3.6.2 Indicating LampPage 21 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION POR PACKAGED UNIT RNPC ENG STD 60A2 (1) The following color code will be used for (2) (3) 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 assembly Window type panel mounted annunciator units shall be used for alarms (white/red base with black engraved letters). Lamps indicating pump status shall be mounted on the panel facing to the relevant equipment such as push buttons, etc. 3.6.3 Alarm System am Q) A signal system serves to announce abnormal operating conditions. It will consist of an actuating device, an alarm system and an audible signalling device. When preset limits of operating conditions are reached the actuating devices shall be operated whereupon the visual and audible signal announces these conditions. The actuating devices will be operated: (a) By the output signals of transmitters and be located in the local panel. (b) By the switches connected to the process variable directly (e.g. Pressure switches, etc.) where transmission is not allowed. {c) By other actuators, such as auxiliary contacts.Page 22 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT ENPC ENG STD 60A2 3.6.4 3.6.5 43) a) (5) Alarms (a) General alarm Solid state alarms shall be used. Operating sequence of the alarm shall be in accordance with ISA § 18.1 Type Al. Contact of actuating devices shall be normally closed under normal plant operation, (b) Shutdown alann Solid state alarms shall be used. Operating sequence of the alarm is ISA $18.1 Type F3M-1 with first out. Contact of actuating devices shall be normally closed under normal plant operation. An audible signalling device common to the various signal systems, viz. a buzzer will be located per each specified process units group in the local panel. The buzzer connected to first out sequence shall have a different tone than tone for general alarm. ‘The common test, acknowledge and reset unit will be used. Automatic Pump Starting System These are intended to take actions without need for plant shutdown, e.g. automatic starting of standby pump or sequence controls for batch Processes. The engineering basis for these systems is the same as for emergency system. Emergency System a) 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.Page 23 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 3.6.6 (2) A "hold" device must be incorporated to keep the alarm actuated until the emergency system is manually reset even when the process variable concerned has already returned to normal. An alarm shall sound prior to shutdown. Components of emergency system will, as far as feasible, be installed in the main control room or local panel. Information to Main Control Room a (2) (3) Following auxiliary dry contacts shall be provided on local control panel. (a) For common general alarm of packaged unit (b) For common shutdown alarm of packaged unit Where process requires 2 sequential operation combined with packaged unit, manufacturer will be required to prepare specific auxiliary dry contacts. All contacts (or outputs) required to be wired to the main control room shall be terminated in junction boxes by the package vendor. 4 INSTRUMENTS AND CONTROL VALVES 4.1 Pressure Measurings 4.1.1 Pressure and Vacuum Gauges m Pressure measuring elements shal] be alloy or stainless steel except for: {a) Receiver gauges and diaphragm sealed gages where bronze elements may be substituted. (b) On very low pressure ranges, such as for draft gauges or barometrically compensated elements for absolute pressure where alloy steel elements are not available.Page 24 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 (2) Pressure gauge movements shall be stainless (3) «4 (5) (6) ) (8) (9) steel for alloy steel and stainless steel bourdon tubes and stainless steel or brass for brass or bronze bourdon tubes. 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 proces conditions require other material. Cases shall be weatherproof and shall be protected with weather-resistant black paint. Gauge size will be in accordance with manufacturer's standard; however, dial size of 4~1/2" diameter is preferabl Pressure gauge dials shall be white, non-rusting metal or plastic, with black figures. Blowout protection shall be provided on all pressure gauges in process service connected directly to the pressure source. Rupture discs or blowout plugs shall be located on the lower side of locally mounted gauges and on the case back of beard mounted gauges. Safety front guard gauges shall be used on pressures of 1000 psig and above. Remote seal type pressure gauge shall be used on discharge of reciprocating pumps and on suction and discharge of reciprocating compressors, Instrument process connections shall be 1/2" NPT, unless prohibited by local regulations. Diaphragm seals (filled type) may be used for congealing, slurry or highly corrosive service. Pressure Instruments am (2) Pressure transmitters and instruments shall be furnished with backup pressure gauge. Pressure measuring elements shall be alloyPage 25 Rev. 4 Date: Mar 1, 1986 .NSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 3) a4) (5) (6) 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 teasurement does not exceed the manufacturer's limit of impressed static head. Where this is not possible, zero suppression/elevation spring shall be used. For services requiring a range between ~30 inch Hg and 30 psig differential-pressure instruments may be used. Force balance transmitter may be used for narrow span instrument, for critical services, pulsating pressures and when process line is vibrating, Local pressure controllers will have indications of measured value and set point. For field pressure switches, set point adjustments shall be made by a tamperprcof screw or a knob, that is internally installed or covered. Diaphragm seals may be used for congealing, slurry or highly corrosive service. 4.2 Flow Measurings 4.2.1 Primary Elements qa) (2) The standard primary element for flow instruments shall be a Type 304 or 316 stainless steel concentric orifice plates. Orifice flanges with flanges taps shall be weld neck with minimum rating of 3004 ANSI RF. Orifice flange taps shall be 1/2" NPT up to 600%, and 3/4” NPT above 600¢. Dual taps with plugs, diametrically opposite shall be provided.Page 26 Rev. 4 Date: Mar 1, 1986 FNSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 (3) Line sizes up to and including ten inches. a) (5) (6) (er) Orifice flange unions having flange taps shall be used. Refer to Section 2 References. Line sizes twelve inches and larger. Line flanges with radius taps shall be used in place of orifice flanges. However, for above 300# flanges, and for-300# flanges with line sizes 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 References. Generally, taps for gas and vapor will be installed vertically, and for liquid and steam horizontally. But when limited spacing dictates, taps shall be located 45° above horizontal for steam and gas, 45° below horizontal for liquid: Metering orifices shall not normally be installed in line sizes 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 (c) Rotameter (a) Integral orifice (e) 1 1/2" metering orifices in accordance with JIs 28762 (£) Swaged 1 1/2" meter run in accordance with JIS 28762 Metering orifices shall preferably be in horizontal lines only. The installation in a vertical line shall always be upward for liquids and steam, and preferably downward for gases.INSTRUMENTATION FOR PACKAGED UNIT 4.2.2 (8) Page 27 Rev. 4 Date: Mar 1, 1986 KNPC ENG STD 6CA2 Orifices (a) (b) Orifice meter differential range shall be selected for a /D ratio of 0,75 maximum and 0.25 minimum. For 2" pipe size with 20 or 25 inches of water column differential range only, a/D ratios smaller than 0.25 may be used. In any case, actual orifice diameter shall not be less than 0.25 inches. 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,O shall not exceed the normal upstream static pressure in psia, except that for exhaust steam approximately 15 psig when 50 inches H,0 range may be used. Instruments a (2 Qa) Force~balance type differential pressure measuring instruments shall, where possible, be selected for all pneumatic transmitters. Advanced low displacement type differential Pressure instruments may be used for electric transmitters. Rotameter type flow instruments may be used for the following: fa) (b) {c) In pipe sizes 1 1/2" and smaller. For special applications, in larger lines where solids are present in the process fluid. 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.Page 28 Rev. 4 Date: Mar 1, 1986 ANSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 rc) (5) (6) (a) Liquids which are very viscous. Rotameters and rotameter transmitters shall be installed in a manner which permits easy Means of float removal for cleaning or xepair purposes. Type and rating of end connections to be in accordance with piping line classes. Rotameters (except 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 upstream and ameter size bypass with gate valve. Special conditions may dictate the use of devices such as the following: fa) Turbine meter (b} Magnetic flow meters (ce) Target meters (4) Positive displacement meters le) Eccentric or segmental orifice plates shall be used to measure the flow of liquids which contain solids, (é) Venturi tubes or similar types of flow elements may be used tc measure the flow of low pressure gases or liquids where loss of pressure is an important consideration. (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 engine, ing flowsheets (h) Quadrant edge plates where low Reynolds numbers dictate and segmental wedge for slurry service. (3) Ultrasonic and nuclear type flow meter. Refer to Section 3 Engineering Design Philosophy.Page 29 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 (kx) Diaphragm seal differential pressure measuring element. 4.3 Temperature Measurings 4.3.1 4.3.2 Receiver Instruments of Temperature Measurement (Board) qa (2) (3) (4) (5) For multi-point temperature indicators and recorders, single loop temperature indicating controllers either iron-constantan or chromel-alumel (J or K type) thermocouples will normally be used. Temperature limitation between type J and K shail be in accordance with API RP 550 Part 1, Section 3, Item 3.3.2.1. Multi-point temperature indicators will be panel mounted, with digital read out, A check point shall be provided in a separate thermowell as close as possible to controllers thermowell or double thermocouple in the same well, Multi-point temperature indicators or recorders shall have burnout feature where applicable. Multi-point 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) ay 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 shall also be restricted to systems using Steam or hot water as heat medium.Page 30 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 {3) Filled-system instrument will be used local control for simple applications, e.g. tank heating, etc. All other filled system instruments will be used between range limits of 30°F and 600°F (unless adequate calibrating facilities are available outside these limits). For application: outside these limits, a thermocouple will be used as the sensing element, together with an emf-to-pressure or electronic converter when a pneumatic or electric recorder or controller is used. 4.3.3 Elements of Temperature Measurement a) Temperature gauges (a) Temperature gauges will be bi-metallic type with rigid stem, suitable for mounting in threaded or flanged thermowell. (b) The dial size will be in accordance with manufacturer's standard; however, dial size of 4-1/2" diameter is preferred. {c) When vibrations will be expected, filled type remote mounted gauges with capillary will be recommended. (4) ‘The case material will be cast aluminum. (e) The stems 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 betweer 30 - 70% of the full scale: Scale ranges ~-100 to +100°F to +200°F to +300°F to +500°F to +750°F to +1000°F ecco]INSTRUMENTATION FOR PACKAGED UNIT Page 31 Rev. 4 Dati Mar 1, 1986 KNPC ENG STD 60A2 (2) Filled system instruments @) (b) ) (a) Ranges and their limits will be in accordance with the manufacturer's standard. Spans will be 100, 200, or 40°F, The capillary tubing will be of stainless steel 316 and shielded by flexible stainless steel, according to manufacturer's standards. Length of capillary tubing will suit the application, but minimum length will. be 6 feet. 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: w Local temperatures gauge covering the range of the instrument (41) Thermocouple connected to a multi-point temperature indicator or recorder (iii) Test well For field temperature switches, set point adjustments shall be mada by a tamperproof screw or a knob, that is internally installed or covered. (3) Thermocouple (a) (b) For general service, single thermocouples shall be 16 AWG while duplex thermocouples shall be of 20 AWG. These shall be within limit of Table VII of ANSI MC 96.1. Where abnormaily long thermowells are applied such as in flue gas ducts, combustion chambers, etc., the thermocouple wires will be min. 8LNSTRUMENTATION FOR PACKAGED UNIT (4) (o) (a) te) (f (g) Page 32 Rev. 4 Date: Mar 1, 1986 KNPC ENG STD 60A2 AWG. In general, all thermocouples shall be of the magnesium oxide insulated type with protective stainless steel (or better) sheathing. For high temperature services, where hydrogen diffusion to thermocouple material may be expected, magnesium oxide insulated thermseouples with inconel protective sheathing will be used. The outside diameter of the sheath will be no more than 3/8" in order to fit in the 3/8" bored thermowell. 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 wells and 1/2" NPT connections for conduit. Duplex thermocouples have two 1/2" NPT connections for conduits. The temperature/emf characteristics of the thermocouples will be in accordance with ANSI MC 96,1 or JIS C 1602. All thermocouples, in general, shall be ungrounded type. Resistance-element type instruments (if applicable) fa) (b) Ranges will be selected from mantfacturer's standards and span will be as small as can be reconciled with process requirenents. The resistance bulb assembly will be made as follows. The element will be platinum. The characteristics will - be in accordance with DIN 43760. Normal resistance at 32°F to be 100 ohms, The resistance element willPage 33 Rev. 4 Date: Mar 1, 1986 INSTRUMENTATION FOR PACKAGED UNIT KNPC ENG STD 60A2 closely fit into the standara thermowells. (c]_ To compensate for change in the xesistance of the extension cable a three-wire system will be applied. (4) Elements shall be embedded in molded glasses. 4.3.4 ‘Thermowells w (2) (3) 4) In general, threaded thermowells, 1" NPT, bar stock type without seal welding shali be used for piping and vessels up to 600# ANSI pressure rating and 750°F maximum temperature. In general, 1 1/2 pipe size flanged thermo- wells shall be used for: (a) Piping or vessels above 600¢ ANST pressure rating, (>) Piping or vessels above 800°F, (c) Refractory lined piping or vessels, (a) Stainless steel piping or vessels (e) "Hara to Hola" services such as hydrogen Flanged thermowells 4" pipe size will be used for clad piping or vessels. Exception - Connections for multi-point thermowells, retractable, purged and skin temperature thermowells shall be selected to suit manufacturers standard equipment. The length of flanged nozzles shail be by Package vendor subject to approval by Burchi The type and length of the thermowell are in accordance with manufacturer's standard. Pipe type thermocouple wells with welded ends shall be furnished for gas temperature