NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES J.31

PNEUMATIC CONTROLLERS, RECORDERS

AND INDICATORS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES J.31
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AND INDICATORS Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 3

1.1 Introduction 3
1.2 Other NOC Specifications 3
1.3 Data Sheets 3

2.0 DEFINITIONS 4

2.1 Technical 4
2.2 Contractual 4

3.0 DESIGN 5

3.1 Codes and Standards 5

3.2 Controllers, Recorders and Indicators 5

4.0 MATERIALS 8

5.0 MANUFACTURE 8

5.1 Procedures 8

6.0 INSTALLATION 8

7.0 INSPECTION 9

7.1 Procedures 9
7.2 Scope 9
7.3 Nameplates 9

8.0 TESTING 10

9.0 DOCUMENTATION 10

9.1 Introduction 10
9.2 Schedules and Reports 10
9.3 Drawings 10
9.4 Final Records, Documents and Manuals 10

10.0 PRIOR TO SHIPMENT 11

10.1 Painting and Coatings 11

10.2 Spares 11
10.3 Packing and Storage 11
10.4 Shipping 11
10.5 Warranty 11

DATA SHEETS (2)

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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification covers the minimum requirements for the design, manufacture, inspection, testing,
documentation and preparation for shipment of pneumatic controllers, recorders and indicators.

1.1.2 This specification applies to equipment for refineries, on-shore oil and gas installations and processing
facilities
including items
purchased either
directly or as part
of a package.

1.1.3 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorized in writing by the Owner.

1.1.4 In the event of any conflict between this specification, the Data Sheets or with any of the applicable
codes and standards, the Vendor/Contractor shall inform the Owner in writing and receive written
clarification before proceeding with the work.

1.1.5 This general specification, attached Data Sheets together will form part of the Purchase
Order/Contract.

1.2 Other NOC Specifications

The following NOC General Engineering specifications are an integral part of this specification and
any non-compliance will have to be approved by the Owner.

GES A.06 Site Data

GES C.55 Field Installation, Calibration and Testing of Instruments

GES J.05 Temperature Instruments

GES J.12 Indoor Control Panels and Cabinets

GES J.13 Field Panels and Junction Boxes

GES J.15 Instrument Air Systems

GES L.35 Electrical Equipment in Hazardous Areas

GES X.06 Factory Coatings for Electrical Equipment and Instruments.

1.3 Data Sheets

The technical data supplied by the Owner for the equipment is given on the Data Sheets which are
included at the end of this specification. The Vendor/Contractor shall complete the Data Sheets with
the remaining information.
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2.0 DEFINITIONS

2.1 Technical

Accuracy

The limit within which the stated value of a process parameter might vary relative to its true value.

Drift

An undesired change in output over a period of time, which is unrelated to the input, operating
conditions or local conditions. Drift is usually expressed as the change in ouput over a specified time
with fixed input and operating conditions.

Hysteresis

The difference in measurement signal force given process propery value when approached first from
a zero load and then from full scale.

Repeatability

The capability of an instrument to generate a measurement signal, the magnitude of which will stay
within the stated limits of repeatability, under identical process conditions, occuring at different times.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil and gas company, an associate or subsidiary, who is the end user of the equipment and
facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of
this specification and the Purchase Order/Contract.

Inspector
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A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection

Authority, who verifies that the equipment and facilities have been designed, constructed, inspected
and tested in accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

The equipment manufactured to this specification shall conform to the following Codes and Standards:

American Petroleum Institute (API)

API RP 552 Transmission Systems

API RP 554 Process Instrumentation and Control

British Standards Institution (BSI)

BS 5558 Controllers with Analogue Signals for use in Industrial Process

(EN 60546) Control Systems

Part 1 - Methods for Evaluating Performance

Part 2 - Guide to Inspection and Routine Testing

BS 5750 Quality Systems

(ISO 9000)

International Electro Technical Committee (IEC)

IEC 529 Classification of Degrees of Protection Provided by Enclosures

IEC 382 Analogue Pneumatic Signals for Process Control Systems

Instrument Society of America (ISA)

ISA S 51.1 Process Instrumentation Terminology

National Electrical Manufacturer's Association (NEMA)

NEMA ICS 6 Enclosures for Industrial Controls and Systems

3.2 Controllers, Recorders and Indicators

3.2.1 Basis of Design

(a) The equipment shall be suitable for the environmental conditions specified in GES A.06 if
mounted in exposed locations. If located in a ventilated enclosure or a control room, an
allowance will be made to this effect.

(b) Where an internal heat source exists within the cabinets and panels then the maximum
temperature figure in GES A.06 shall be increased by 18°F (10°C).
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3.2.2 Selection

(a) When deciding to use pneumatic instrumentation consideration shall be given to transmission
distances and lags, initial costs and maintenance, and electrical circuits interfacing.

(b) Transmitter to controller or controller to control valve distance shall not exceed 250 feet (75m)
using 1/4 " OD tubing. In any event the total distance from the transmitter to the control valve
(via the controller) shall not exceed 400 feet (120m).

(c) The use of booster relays to improve loop response shall be subject to approval by the Owner.

3.2.3 Pneumatic Instruments - General

(a) Instruments shall meet the following performance criteria:

Indicator Accuracy 0.50% of full scale.

Accuracy (Others) 0.25% of calibrated span.
Hysteresis 0.1% of calibrated span.
Deadband 0.1% of calibrated span.
Drift 0.2% of calibrated span over 6 months period.

(b) Set point accuracy shall be ± 0.5% of the scale range.

(c) Unless otherwise stated instrument transmitted signal range shall be 3 to 15 psig (20 to 100 kpa)

(d) Maximum overload of 30 psig (200 kpa) to any port shall not cause any damage to the
instrument.

(e) Controllers and recorders may be combined in one instrument subject to approval by the
Owner.

(f) Pneumatic connections shall be 1/4" NPT.

3.2.4 Controllers

(a) Pneumatic controllers shall not be used for compressor anti-surge application as the fast
response time required for this application is better achievable with electronic transmitters and
controllers.

(b) Where close control of a fast acting process is required or control is required over relatively
long distances e.g. liquid level control, controller shall be locally mounted. Such controllers
shall contain an internal or external indication of the process variable.

(c) All controllers shall have Proportional and Integral action. Controllers on slow processes e.g.
temperature controllers shall be supplied additionally with Derivative action.

(d) All controllers shall be supplied with the following facilities:

Integral Auto/Manual transfer.

Remote/Local Switch (where specified).
Pilot relay.
Output air gauge.
Bumpless transfer on A/M, cascade and remote setpoint.
Anti reset wind up bellows.
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AND INDICATORS Rev 0 1999

(e) Blind controllers shall not be used.

(f) Facilities shall be provided for setting and adjusting Proportional Band, Integral action and
Derivative time over the following ranges:

Proportional Band 5% to 500% (i.e. gain of 20 to 0.2).

Integral Action 0.01 to 50 minutes per repeat.
Derivative Time 0.01 to 50 minutes.

The above are typical values and controllers with values approaching these may be acceptable
subject to Owner's approval.

(g) The set-points of the controllers used in cascade shall be continuously indicated unless
otherwise agreed with the Owner.

(h) Scales shall be as follows:

Level 0 - 100%
Others Engineering Units (Multipliers permitted)

(i) All controllers shall have a scale range approximately 30% greater than the expected operating
range.

(j) Alarms if provided, shall be tamperproof and easily interpreted.

3.2.5 Recorders

(a) Multispan recorder colour coding system shall be as follows:

Temperature Red
Flow Rate Green
Pressure Blue
Level Green

(b) Unless otherwise stated on the Data Sheets, strip chart speed shall be 3/4" (20mm) per hour.
Each recorder shall be supplied with 10 rolls of strip charts. The chart length shall be sufficient
for at least 30 continuous days. Recorders shall be supplied with a rewind motor and an on/off
switch.

(c) No more than 3 pens in a single recorder shall be used unless approved by the Owner.
Recorder pens shall be replaceable. The number of pens required shall be stated
on the Data Sheets.

(d) Continuous trace (conventional) recorders shall have the following features

Non-clogging inking system.

Sealed, replaceable ink cartridges.
Cartridge ink level shall be visible when the recorder door is open.
Cartridge ink start flow feature.
All pen circuits shall have completely independent operation.

(e) Scale ranges shall be as follows:

Flow 0 to 10 Square root

Level 0 to 100 Linear
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Pressure,
Temperature, Analysis Direct Reading

(f) Chart ranges shall be as follows:

Flow 0 to 10 Square root

Level, Pressure
Temperature, Analysis 0 to 100 Linear and shared 0 to 10 Sq root and 0 to 100 Linear

(g) Circular charts for recorders may be used within Owner's approval.

(h) Recorders used in hazardous areas shall be suitably certified for the location specified on the
Data Sheets. Electric motors for chart drives are preferred. Chart drive motor power
requirement shall be stated on the Data Sheets.

3.2.6 Indicators

(a) Field indicators shall be a minimum of 4" (100mm) diameter.

(b) Indicator dials shall have black lettering on a white background.

3.2.7 Temperature Indicators (Filled Thermal Systems)

Pneumatic temperature instruments shall be supplied in accordance with the requirements of GES J.05.
Filled thermal systems shall not be used on alarm or shutdown service.

4.0 MATERIALS

4.1 Instrument parts subjected to the atmosphere shall be resistant to the atmospheric conditions.
Cadmium plating is not acceptable for the parts exposed to atmosphere.

4.2 Wetted parts materials shall meet the requirements of the Project Piping Specification.

5.0 MANUFACTURE

5.1 Procedures

The Vendor/Contractor shall submit to the Owner, for approval, details of his proposed Quality Control
Plan.

6.0 INSTALLATION

Installation shall be in accordance with the Vendor/Contractor's recommendations and API 554.

7.0 INSPECTION

7.1 Procedures

7.1.1 The inspection requirements are covered by the document "General Conditions of Purchase" which
forms part of the Purchase Order/Contract. Additional requirements are given below.

7.1.2 All inspection activities to be performed including any special requirements shall be agreed with the
 GENERAL ENGINEERING SPECIFICATION GES J.31
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AND INDICATORS Rev 0 1999

Owner and shall be incorporated within the agreed Quality Control Plan provided by the
Vendor/Contractor.

7.1.3 The Vendor/Contractor shall allow the Inspector free access to all areas of manufacture, fabrication
assembly and testing.

7.1.4 The Vendor/Contractor always has the responsibility to provide adequate control and inspection of
equipment and materials. Any inspection by the Owner or his Inspector shall not relieve the
Vendor/Contractor of these responsibilities or those under his warranties.

7.1.5 The Vendor/Contractor shall demonstrate to the satisfaction of the Owner that his Quality Plan will be
such as to ensure close agreement between the performance of random production samples and those
submitted for certification.

7.1.6 The Vendor/Contractor shall supply the following documentation before the final inspection and
witnessed testing:

1. Installation and Maintenance Manuals.

2. Vendor/Contractor's standard test procedure.

7.2 Scope

7.2.1 Dimensions, including overall and cut-out dimensions and paint colour, shall be checked against the
Vendor/Contractor's approved drawings.

7.2.2 Scale range, chart range, model number connection sizes shall also be checked.

7.2.3 Certificates of conformity shall be available at the time of inspection.

7.3 Nameplates

7.3.1 All instruments shall have the following information permanently identified on a stainless steel tag
plate, permanently fastened to the instrument:

Instrument tag number.

Manufacturer's name, model and serial number.
Pressure rating (where applicable).
Material of wetted parts.

7.3.2 All tubing connections on the instrument shall be permanently identified.

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8.0 TESTING

Testing shall be in accordance with BS 5558 (EN 60546).

The Vendor/Contractor shall provide all facilities to test the performance of the equipment.

All equipment functions shall be factory tested prior to dispatch. Factory testing shall include
calibration and functional testing.

Any commissioning spares supplied with the order shall be checked at the factory acceptance testing
stage.

9.0 DOCUMENTATION

9.1 Introduction

9.1.1 This section covers the documentation required for the design, selection, fabrication, inspection and
testing for all pneumatic instruments to be supplied against this specification.

9.1.2 The detailed list of documents that are required is attached to the Purchase Order/Contract. However,
as a minimum the following listed documents shall be provided by the Vendor/Contractor.

- General Arrangement drawings for all instruments

- Installation, Operation and Maintenance manuals

9.2 Schedule and Reports

The Vendor/Contractor shall submit with his tender a preliminary Quality Control Plan. The
Vendor/Contractor shall supply a schedule showing the documents for review and approval, proposed
sub-contractors and material procurement and a production fabrication programme.

9.3 Drawings

The drawings listed with the Purchase Order/Contract shall be sent by the Vendor/Contractor to the
Owner and/or the Inspection Authority for review and approval.

9.4 Final Records, Documents and Manuals

9.4.1 Two copies of the data books shall be supplied and shall be a record of the manufacturing process.
Where stated in the Purchase Order/Contract, it shall contain the following:

- General Arrangement drawings.

- Quality Control Plan.
- Hazardous area certificates.
- Test Certificate.
- Certificates of Conformity
- Owner's Release Certificate

9.4.2 Six (6) sets of installation, operations and maintenance manuals shall be supplied.

9.4.3 The manuals shall be presented in A4 format and be securely bound in heavy duty 4 ring binders.

9.4.4 The Vendor shall supply one set of mylar original drawings.
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10.0 PRIOR TO SHIPMENT

10.1 Painting and Coatings

Metal cased field mounted equipment shall be painted in accordance with GES X.06.
Vendor/Contractor's standard two (2) coats of epoxy paint finish may be acceptable in lieu of above,
subject to Owner's approval.

10.2 Spares

The Vendor/Contractor shall submit with his proposal a priced list of recommended spares for start-up
and two years operation.

10.3 Packing and Storage

10.3.1 This section describes the minimum requirements for the preservation and protection of electronic
controllers, recorders and indicators during the sea and land transportation and storage, prior to
transportation.

10.3.2 The probable storage period will be specified in the order/enquiry and will extend from the time of
despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of 24
months shall be assumed. Packing shall be suitable for sea freight.

10.3.3 The equipment shall be securely packaged so that it is protected against external damage during transit.

10.3.4 Equipment shall be packaged in moisture proof sealed bags containing a desiccant.

10.3.5 Any part which can be damaged or can cause damage during transportation shall be separately packed.

10.3.6 Machined or threaded exterior surfaces shall be protected from corrosion during shipment by coating
with a rust preventative fluid which is easily removable using petroleum solvent.

10.3.7 Flanges shall be protected over their entire gasket surface with securely attached metal, hard board or
wood protectors.

10.3.8 Threaded end connections shall be fitted with metal, wood or plastic plugs or caps.

10.4 Shipping

The instruments shall not leave the Vendor/Contractor's works for shipment until the release has been
approved by the Owner's Inspector.

10.5 Warranty

The Vendor/Contractor shall warrant all materials and services supplied against any defect, for a
minimum period of 12 months after commissioning, or 24 months from the date of delivery to site,
whichever is the shorter period, or for the period stipulated in the Purchase Order/Contract.
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Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring the equipment to the standard specified in the Purchase Order/Contract.

The Vendor/Contractor shall undertake to carry out the repair or replacement in an expeditious manner.

The terms and conditions of the Warranty shall be additional to any other requirements specified in the
Purchase Order/Contract.
 DATA SHEET No.

PNEUMATIC CONTROLLERS RECORDERS

AND INDICATORS P.O. / CONTRACT No.
CLIENT
PLANT LOCATION SHEET 1 of 2
SERVICE ITEM No. No. of UNITS

1 Vendor / Contractor 46 Receiver Element

2 47 Element Type Bourdon/Bellow/
3 General 46 Diaphragm/Spiral
4 Type of Instrument See Sheet 2 47
5 Case Rectangular/Circ. 48 Material St. St./
6 Case Size 49 Range
7 Case Colour 50 Connection Back/bottom
8 Dial 51 Connection Position
9 Mounting Flush/Surface 52 Other
10 Yoke 53
11 Chart type Strip/Circular 54 Accessories
12 Chart size 55 Filter Regulator
13 Chart drive Spring/Elec./Pneu. 56 Air Supply Gauge
14 Chart Speed 57 Charts and Inkset
15 58 Mounting Yoke
16 Control 59 Pulsation Damper
17 Control Mode P/P+I/P+I+D/P+D 60 Manifolds
18 Control Action Direct/Reverse 61
19 Cascade 62 Others
20 Control Location Remote/Instrument 63 Hazardous Area Classification
21 Anti Reset Wind Up 64 Degree of Protection
22 65 Type of Protection
23 66 Alarm Relays
24 67 Contact Rating
25 68 Electrical Entries
26 69
27 Auto/Manual Switch Ex./Int/Integral 70
28 No. of Positions 71
29 No. of Pens 72
30 73
31 Set Point Adjustment Int./Ext. 74 Supply
32 75 Electrical
33 76 Pneumatic
34 77
35 78
36 79
37 82
38 Notes: 83 Notes:
39 84
40 85
41 86
42 87
43 88
44 89
45 90
Revision No./Date 0
Prepared by/Date
Authorised by/Date
Purpose
(C) 1999 NATIONAL OIL CORPORATION. The information on this sheet may be used only for the purpose for which it is supplied by NOC.
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 DATA SHEET No.
PNEUMATIC CONTROLLERS RECORDERS
AND INDICATORS P.O. / CONTRACT No.
CLIENT
PLANT LOCATION SHEET 2 of 2
SERVICE ITEM No. No. of UNITS
1 Type of No of Scale
2 Tag Number P & ID No Instrument Inputs Chart Range Range Manufacturer Model No Service
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(C) 1999 NATIONAL OIL CORPORATION. The information on this sheet may be used only for the purpose for which it is supplied by NOC.
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