Professional Documents
Culture Documents
K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 1 - 31
CONTENTS
1. General............................................................................................... 4
1.1. Scope................................................................................ 4
1.2 Terms and Definition ......................................................... 4
2. References......................................................................................... 4
3. General............................................................................................... 5
CONTENTS
6. Installation ....................................................................................... 27
1. General
1.1. Scope
(2) If there are any conflicts in requirements between this specification and the other
specifications or drawings, or any deviations to this specification, the Vendor
shall bring the matter to EPC Contractor for technical justification and get
approval of EPC Contractor.
For the PROJECT, unless otherwise specified, the following terms with their definition
are applied:
2. References
The following publications shall form a part of this Specification. Unless otherwise
specified herein, use the latest edition or revision.
3. General
Vendor’s scope of supply and work for H2 Rich Gas Compressors (K-47202-A/B/C)
and Recycle Compressors (K-47201, K-48201 and K-48501), which are categorized as
Critical LLI, shall be referred to Attachment -4.
Unless otherwise specified, the instrument ranges shall be selected such that the
normal operation value is generally in the center third of the range, i.e. between 35%
and 70% of the range (linear scale).
For flow measurement by means of pressure differential devices, the normal operation
value shall generally be between 65% and 80% of the range.
All electrical or electronic instruments, control & on-off valves, control equipment (e.g.
panels) and their accessories to be installed in the explosion hazardous area shall
have suitable explosion construction to meet the area classification.
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 7 - 31
- Intrinsically safe type : where flame proof type is not available but subject to the
purchaser’s approval in advance. Isolation type safety barrier
shall preferably be selected.
- Non-sparking type: where flame proof type is not available but subject to the
purchaser’s approval in advance.
- Pressurized type : where flame proof type and intrinsically safe type are not available
such as local panel, etc. but subject to the purchaser’s approval
in advance.
All electrical or electronic instruments or devices for use in hazardous areas shall be
approved by following internationally recognized authorities according to hazardous
area classification and proven certificate by domestic authorities (KOSHA, KGS and
KTL) shall be submitted as mandatory.
- CENELEC (EU)
- CESI (Italy)
- KEMA (Netherlands)
- LCIE (France)
- PTB (Germany)
- KOSHA (Korea)
- RIIS/TIIS(Japan)
- BASEEFA (UK)
- FM (USA)
- UL (USA)
- CSA (Canada)
Weather feature:
Coastal (corrosive, sea wind) atmosphere
Ambient temperature:
- Design base maximum 38 ゚C
- Absolute maximum 38 ゚C
- Design base minimum -18 ゚C
- Absolute minimum -17 ゚C
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 8 - 31
Relative humidity
- Design base 97 %
The lightning protection device shall be provided for field instruments and control
system supplied by package vendor.
All the power lines for both incoming and each consumer shall be protected by suitably
rated circuit breakers (double-pole type) or isolation switched (double-pole type) with
fuses on both lines. The fuses shall be equipped with a blowout indicator.
DC 24V power shall be provided within the system such as DCS, PLC, Panel, etc from
the AC 115V UPS source as required. DC 24V power supply unit (voltage converter)
installed in the system shall be of dual redundant and shall be supplied by respective
Equipment Vendor.
The equipment energized with the voltage > 50 VAC or 120 VDC shall be provided with
earth grounding protection. Grounding resistance shall normally be of following:
Metallic frames of cabinets, panels, consoles and junction boxes shall be connected to
the safety / shield ground. System ground is provided for grounding of digital systems,
such as DCS/ESD and PLC based systems, for which each system’s manufacturer
recommendation on the arrangement of grounding shall be followed. Shield (screen) of
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 9 - 31
instrumentation cables shall be connected to safety / shield ground for Non-IS cables
and to intrinsic safety ground for IS cables.
A tinned copper ground bus bar for safety / shield ground shall be mounted inside
cabinet or panel and connected to the metallic frame. Conducting parts such as doors,
etc., which is not permanently connected to safety ground, shall be connected to the
frame of cabinets or panels with a flexible ground straps.
Separate tinned copper ground bus bars shall be provided with clear demarcation in
each cabinet or panel for system ground and IS ground. Each ground bus bar shall be
electrically isolated from other ground bus bar one another.
- Pressure,
normal 0.686 MPa(g)
maximum ---
design 1.040 MPa(g)
- Temperature,
normal 38 ゚ C
design 66 ゚ C
- Dew point -40 ゚ C @ 0.686 MPa(g)
- Oil free
All instrument consumers, pneumatic instruments or devices, shall have an air filter
regulator set of metallic case with a small size output gauge at the air supply
connection.
The connection for first isolation valves shall be provided with following table.
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 10 - 31
* 2” flanged connection shall be used in service where internal lining and high
pressure (≧900#) is required.
Size of cable entry to instruments shall normally be 1/2 NPT or 3/4 NPT screwed
threads. Size of cable entry to junction boxes, field panels, etc. shall normally be
selected from the series; 1/2 NPT, 3/4 NPT, 1 NPT, 1-1/2 NPT, 2 NPT.
Cable entry of instruments, junction boxes, etc. located in hazardous area shall be
provided with union coupling with sealing fitting and drain tee, or packing type cable
gland.
All instruments, pneumatic or electronic, shall fail to the safest position or lock in place
upon instrument air or electrical power failure.
Control valves which are required to fail safe on instrument air failure shall normally be
equipped with spring load actuator. Use of accumulator (volume tank) to meet control
valve fail safe positions shall be minimized.
Input contacts to alarm, interlock and emergency shutdown system shall be closed
during normal operation and open on alarm or trip.
Solenoids shall be energized during normal operation and de-energized on trip.
The instrument and control system shall be immune from the effects of Radio
Frequency / Electromagnetic interference such that error caused by RFI shall not
exceed 0.1 percent of span for exposure to field strength of 30 volts/meter over the
frequency range of 20 to 1000MHz. In other word, when the instrument and control
system are exposed to radio field which strength is 30 volts/meter with frequency range
varied from 20 to 1000MHz, reading error or signal error of the instrument and control
system caused by the radio field shall not exceed 0.1 % of calibrated span.
Otherwise Vendor shall clearly state the susceptibility of EMI of the instruments and
control system along with the referred industrial standard name, version, immunity test
data, etc. at the time of quotation.
3.14 Painting
3.15 Marking
Inspection and test items for instruments and control system shall be in accordance
with Engineering Specification, K-201 “Inspection and Tests of Instrument”.
Inspection and test of instruments and control system at the Manufacturer’s factory
shall be conducted as per the procedures approved by the EPC Contractor. The
inspection and test records including calibration certificate of all instruments shall be
submitted to the EPC Contractor.
Package Vendor’s control system shall be subject to 100% factory acceptance test.
This test shall be conducted by the Vendor at the control system supplier’s factory and
witnessed by the EPC Contractor.
3.17 Documentation
Package Vendor shall furnish documents and drawings for instrument and control
system as specified in the Attachment-2 and submit to the EPC Contractor for
approval. A part of documents and drawings may be instrument sub-vendor’s
(manufacturer) document. The Package Vendor shall be fully responsible for checking
and approval of these sub-vendor’s documents/drawings.
Package Vendor shall supply spare parts / consumables for installation and
commissioning of instruments and control system, as specified in the Attachment-3, as
a minimum. The vendor shall recommend additional parts and consumables and/or
quantity, if any.
In case a package unit requires special electronic devices (e.g. governor for steam
turbine, over speed trip device, anti-surge controller for compressor, etc.), the
electronic units shall be in the Package Vendor’s scope and shall be housed in a
suitable panel. In addition, shut down of the special electronic devices will lead to a
plant shut down, redundancy configuration shall be applied for the system.
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 13 - 31
Package Vendor shall submit, at quotation stage, the package P&IDs that shall be
defined/ up-dated before order placement including detailed limit of supply.
Package Vendor shall also submit, at the quotation stage, the proposed instruments
vendors list that shall be agreed with EPC Contractor before order placement.
Cabinets and panel shall be fully prefabricated at the factory. All system hardware,
instruments and components provided with the cabinet and panel shall be installed and
wired. No field work shall be done inside the cabinet or panel except for field tie-in
cable termination.
Depending on number of I/O counts of a package unit, marshaling cabinets may not be
required and the marshaling function may be contained in the system cabinet with
agreement from the EPC Contractor.
Control room cabinets shall be freestanding in the form of box, provided with dual
access doors (front and rear), preferably be Rittal make. The size of cabinets shall be
800mm width, 800mm depth, 2100mm total height including 100mm height plinth as a
rule. 600mm or 1200mm width may also be considered depending on the application.
Cabinet color will be decided during detail engineering phase and specified in O-301,
“Painting” specification. The minimum degree of protection shall be IP42 (IEC60529) or
equivalent.
Cable entry shall be in the bottom. Bottom plates shall have removable sealing clamp
plates for cable entries. Sufficient freely space shall be available for accommodating
and terminating all cables. All spare cores (minimum 20% cores of multi-core cables)
shall be connected to the spare terminal blocks in the cabinets. Properly designed
cable clamps and cable support rails shall be provided in order not to exert any undue
force on termination.
The cabinet shall be lockable. Forced ventilation, if required due to the amount of heat
generated inside, by means of openings in the doors fitted with dust filters and with
extraction fans mounted in the top of cabinet fitted with finger guard and screen. Dust
filters shall be of the replaceable or cleanable type, and this action shall be possible
without disturbing the cabinet functions. However, as a minimum, the cabinets shall be
provided with natural ventilation by means of screened and louvered openings in the
doors and in the top.
Interior lighting shall be provided, if required due to maintenance. The cabinets shall be
fitted with removable eyebolts for lifting purpose. The blinds shall be provided to seal
the holes after removal of eyebolts. Anchor bolt holes shall be provided at bottom in the
cabinets. The anchor bolts, nuts and washers shall be furnished with the cabinets.
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 14 - 31
Local panels shall be designed to provide with adequate instrument display and to
protect instruments from the specified environmental conditions. The panels shall be a
free-standing and weather protected construction that is suitable for service in the
specified electrical area classification. The degree of protection shall be IP 65
(IEC60529) or equivalent. The panels located in hazardous area shall be of pressurized
apparatus (type ”p”, giving alarm) or of flameproof enclosure ( type ”d”).
The panels may have rear access door for maintenance. The door shall be gasketted
and furnished with latches. The panel shall be lockable.
The panel shall be provided with a canopy and lighting installed beneath the extended
canopy. The panel shall also have suitable interior lighting, if required. The framework
shall be made of structural shapes with lifting lugs for handling.
Air purging may be required for environmental reasons as well as electrical safety.
Provision of cooling system like vortex cooler to protect instruments from temperature
rise should also be considered.
Cable entry shall be in the bottom or side. Cable entry plates shall have removable
sealing clamp plates for cable entries. Sufficient freely space shall be available for
accommodating and terminating all cables. All spare cores (minimum 20% cores of
multi-core cables) shall be connected to the spare terminal blocks in the local panels.
Properly designed cable clamps and cable support rails shall be provided in order not to
exert any undue force on termination.
All wiring to/from panel/cabinet shall employ terminal blocks which are located inside
panel/cabinet frame for wiring termination and the wires inside panel/cabinet shall be
laid in PVC made close slotted duct. Proper segregation among AC power lines, IS
signal lines and non-IS signals lines shall be made. Duct color of IS signal lines shall
be light blue.
Wiring over short distances between the PVC ducts and the instrument termination
blocks shall be protected by
・plastic trunking or
・spiral round vinyl protective strips, as appropriate.
Conductor size of internal wiring inside panel/cabinet shall generally be minimum 0.75
mm2 stranded with PVC insulation except for vendor's special, if any, wiring
requirements and for power cables.
AC 115V (later)
(later)
AC 220V (later)
(later)
DC24V Black (+)
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 15 - 31
White (-)
Grounding Green or Green/Yellow
RTD Black
White
Red
4-20 mA, 1-5V Black (+)
White (-)
T/C as per ASTM E230
Programming terminals:
A programming terminal shall be provided and used for program development, program
storage, diagnostics, system monitoring and application documentation. The
programming terminal shall record the user-defined logic programming on a removal
disk media for security and backup. The programming terminal shall also allow manual
forcing of input and output states and provide the resulting status on logic displays
and/or print-out in on-line and/or off-line modes.
Software changes shall be done off-line, tested, and then downloaded into the running
application.
Diagnostics:
The system shall incorporate comprehensive self-diagnostics so that all permanent and
transient faults are identified, located, alarmed and reported. All diagnostics shall be
performed automatically on-line, without disturbing the process or reducing the
reliability of the PLC.
Processor:
The processor shall be modular and removable for maintenance and electrically
isolated from associated I/O components. In the event of power loss, the processor
shall retain its memory. The processor shall be capable of scanning and updating the
I/O and of executing user-defined discrete logic.
I/O modules:
The I/O components shall be self-contained independent modules so that a failure and
subsequent replacement of one does not affect other components. All output modules
shall be replaceable with the I/O system powered. Modules shall have mechanical
keying to prevent physical insertion and on-line activation of a module in an incorrect
slot in the chassis. Shorting or grounding the field wires connected to any I/O module
shall not damage the module itself.
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 16 - 31
4.4 Redundancy
Control and shutdown system for Equipment package shall be considered for
redundancy in its system depending on its criticality, whichever implementation of the
system (into the Plant DCS/ESD or into the dedicated PLC supplied by the package
vendor) the Equipment package will take.
Generally control and shutdown system shall have following redundancy as minimum.
- instrument power supply (feeder & conditioning module) of the system
- processor (CPU) of the system
If shutdown of the package unit will lead to a total plant shutdown, full redundant
configuration including followings shall be provided for the system of the packaged unit:
- instrument power supply (feeder & conditioning module) of the system
- processor (CPU) of the system
- I/O module of the system for control and shutdown related loop
- communication bus of the system (internal bus and external communication port)
Alarm signal (contact) shall be closed during normal condition (i.e. contact open at
alarm condition).
Alarm unit shall be of solid-state electronic type and alarm lamp shall be of LED (light
emitting diode) type.
Alarm sequence shall generally be in accordance with ISA S18.1 sequence A and
sequence F3A where first-out sequence is required from operational view point.
Alarm system shall include audible alarm and acknowledge, reset and test push
buttons.
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 17 - 31
Shutdown system shall be energized and pressurized during normal condition (i.e.
open and de-energized at trip condition).
Shutdown system shall preferably be implemented by PLC. Use of electromagnetic
relay logic should be minimized and subject to EPC Contractor/Owner’s approval.
Bypass switch for maintenance, if used, shall be of key-operated type switch or
access-managed software switch and shall be announced with a flashing lamp when in
bypass position. Output signal shall not be bypassed.
Bypass switch for operation (process override), if used, shall be of key-operated type
and announced with a flashing lamp when in bypass position.
Provision of bypass switches shall be subject to EPC Contractor/Owner’s approval.
4.8 Machine Monitoring System
Where a unit is controlled by a Package Vendor’s PLC, the PLC shall be equipped with
a serial data communication facility which will be connected to the plant DCS as
specified in paragraph “4.3 Programmable Logic Controllers (PLC)” except for safety
protection related signal, which shall be via hard-wired analog or discrete signal.
Hard-wired analog signal, 4 to 20 mA DC, which is sent to the EPC Contractor’s control
system or to other supplier’s system, shall be of isolated signal.
Hard-wired discrete signal, which is sent to the EPC Contractor’s control system or to
other supplier’s system, shall be interposed and be of potential free contact. Where
other types of signal are required for tie-in signals to other control systems, it shall be
subject to the EPC Contractor’s approval.
Where Package Vendor’s control system is requested to have data communication with
EPC Contractor’s DCS system, the Package Vendor shall ship the control system or
representative instruments of the system to the DCS vendor shop with engineers to
assist the DCS vendor during the system integration test for check and confirmation of
communication function.
5.1 General
Package equipment vendor shall supply according to his good engineering practice
and field proven suppliers in line with the requirement as described in the following
paragraphs.
Number of manufactures and types of instruments shall be minimized in accordance
with the EPC Contractor’s vendor list. The manufacturers shall be agreed with the EPC
Contractor.
Use of pneumatic instrument except for control valve shall be minimized. Use of such
pneumatic instrument shall also be agreed by EPC Contractor.
Followings are to be reviewed by EPC Contractor from inquiry bidding phase.
- Extent and location of field instruments
- Extent and location of control system
- Signal interface with other control system and safety system such as DCS, ESD
system.
- Start up and operational procedures
- Utilities requirements
5.2.1 Transmitters
Electronic transmitters shall be of two-wire 4-20mA signal smart type with HART
protocol. The transmitters shall generally be provided with integral indicators.
Square root extraction for d/p type flow measurements shall be performed in the
DCS or PLC.
Material for sour gas service shall be in accordance with NACE MR01-75.
Where the controls are performed locally, pneumatic indicating controllers, which
receive pneumatic signal from the transmitters, shall normally be applied. The input
signal, set point and output signal shall be indicated on the controllers. The
controllers shall be furnished with an automatic-manual transfer system and the
control action, direct or reverse, shall be changeable. The measurement element
shall usually be bronze bellows.
The first choice of flow measuring devices shall be concentric orifice plates for the
pipe sizes 2 inch or larger. Where the piping sizes is 1-1/2 inch or smaller, other
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 19 - 31
type such as variable area flowmeter or integral type orifice flowmeter shall be
selected.
Their variations and other flow measuring devices may be considered where
accuracy, rangeability, fluid properties, or mechanical restrains justify their use. Flow
measuring devices and their variations acceptable to use shall be listed below :
- Orifice
- Flow nozzle
- Venturi tube
- Pitot tube
- Variable area flowmeter
- Vortex flowmeter
- Electromagnetic flowmeter
- Turbine flowmeter
- Positive displacement flowmeter
- Coriolis mass flowmeter
- Thermal mass flowmeter
- Ultrasonic flowmeter
Flange taps shall normally be applied to line size 2” up to 24”. For line size larger
than 24”, orifice plate with 1D and D/2 taps shall normally be applied.
In general, orifice plates shall be concentric edge orifice, but other type can be used
as follows :
- Eccentric orifices shall be used for horizontal piping in the following cases.
(a) In case where the liquid contains solids
(b) In case where the liquid contains gases
- Quadrant-edge orifices shall be used for the flow measurement of viscous
streams
- Segmental orifices shall be used for slurry services
- Integral orifices shall be used for the measurement of very small flows.
The design of orifice plate and bore calculation shall conform to ISO 5167. Ratio of
the orifice bore to pipe inside diameter (d/D) shall normally be between 0.2 and 0.7.
Orifice plates shall be of type 316 stainless steel or better. Other materials shall be
used as required by the process conditions.
Orifice plates shall be provided with tab handle which is integral with the orifice plate
or welded on the orifice plate.
Drain / weep holes shall be provided for orifice plates which have a bore of 1 inch
and larger. The drain / weep holes may be excluded from the orifice bore
calculation.
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 20 - 31
For installation of orifice plates, the minimum required straight length at upstream
and downstream shall be the values of column B given in Table 3 of ISO 5167,
2003.
Where orifice type flow meter can not be used, Flow nozzle or Venturi tube
according to ISO 5167, 2003, may be used.
In case where flow rate changes at more than 1 : 3 or the meter is used for purging,
variable area type may be used.
Variable area flowmeter shall generally be metal tube type. Use of glass tube type
shall be limited to purging / flushing application. Body material and connection shall
conform to those for piping.
Except for internal float type, electrode type or level switches used as protective
devices, all level instruments activated by the same liquid level shall be connected to
a single 2”(minimum) stand- pipe (column) with a full size blinded flange at the top
and a 1/2” (minimum) drain valve at the bottom. All stand pipe shall be equipped with
block valves at vessel nozzles. Each individual instrument shall have separate valve
connections from the stand pipe so that isolation of one will not affect the other.
Level instruments used as protective devices, however, shall have separate
connections to the vessel independent of other instruments.
Displacement type level instrument shall normally be used for level measurement of
liquid up to and including 1200 mm.
Differential pressure (D/P) type level instrument shall be used for liquid variation
more than 1200 mm. However, for interface measurement, displacer type may be
used up to 2000 mm.
Other level measuring devices, such as radar type, capacitance type, ultra sonic
type or nuclear type, etc. may be considered where fluid properties or mechanical
restrains justify their use.
The mid range of instruments shall be generally located at the normal operating
liquid level in vessel or column.
Body (external chamber, flange, etc.) material shall be in accordance with the
applicable piping specification or equivalent. Displacer material shall be 316
stainless steel or better and torque tube shall be selected to meet the process
conditions based on Vendor’s standard.
Armoured gauge glasses shall generally be used, and use of magnetic type may be
considered as required by the process conditions. Tubular type gauge shall not be
used. Transparent type or Magnetic type gauge shall be used in installations
involving acid, caustic or dirty (dark colored) liquids, in steam applications (mica
shield), for liquid-liquid interface service. Reflex type gauge shall be used on clean
and colorless service. In services where internal lining and high pressure (≧900#)
is required, use of magnetic gauges may be considered.
Gauge glasses shall normally be provided with standard angle gauge valves
containing ball checks, a 1/2” drain valve and a 1/2” vent plug. The gauge glasses
shall normally be hooked-up top-bottom. The connections to vessels shall normally
be 3/4” flanged and located side-side.
Visible length of one (1) gauge glass shall not exceed 1500 mm. Where two or more
gauge glasses are required to cover a monitoring range, they shall be arranged in
such a way that the visible area of each gauges shall overlap by 25mm minimum.
Transparent type gauge shall be equipped with illuminator suitable for hazardous
area classification and provided together with the gauges by the VENDOR.
Electrical power supply to the illuminators shall be as follows.
Ball float type liquid level switched with external chamber should generally be used.
Process connection shall be 2” flanged, located side-side. External chamber shall
normally be provided with 3/4” drain valve and 3/4 NPT vent plug.
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
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EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 22 - 31
Body (external chamber, flange, etc.) material shall be in accordance with the
applicable piping specification or equivalent and float shall generally be stainless
steel.
Other type level switches (e.g. vibration type switch, etc.) may be used when the
process condition require.
Material of all process wetted parts shall be of stainless steel type 316 as a
minimum. Other materials shall be used as required by the process conditions.
Diaphragm seal type shall be considered where plugging in the impulse line may
occur or where suitable element material is not available in highly corrosive service,
crystallizing service, fluid including solid, high viscosity service, etc.
Pressure gauge shall be equipped with siphon tube, pulsation dampner or over
range protection for the following service :
The nominal dial size shall be 100 mm. The gauges shall be flush mounting and
back connected, 1/4 NPT. The element shall usually be stainless steel type 316.
5.6.3 Thermocouples
The thermocouples EMF characteristics, tolerances and its extension wires shall be
in accordance with ASTM E230.
Dial thermometers shall be of the bimetallic type or filled thermal system type. The
thermometers shall be provided with a thermowell. The sensor entry to thermowell
shall be 1/2” NPT. The ranges shall normally be selected from the series; 0/50, 100,
150, 200, 300, 400 and 500 ℃. The temperature measuring element shall be
installed such that the sensitive part is always fully immersed in the medium to be
measured.
Dial shall be of free angle type and 4” (100mm) diameter. Case material shall be of
aluminum alloy.
5.6.6 Thermowells
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
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EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 24 - 31
Thermowells shall normally be drilled bar stock and tapered. The material shall be of
type 316 stainless steel. Other materials shall be used as required by the process
conditions. The process connection shall normally be 1-1/2” flanged. Other type of
connection such as screwed, welded should be subject to Owner’s approval.
The constructions and insertion lengths shall be verified by means of stress analysis
resulting from stream velocity condition. The wake frequency shall not exceed 66 %
of the thermowell’s natural frequency. Where the given thermowell length fails the
wake frequency limit, the length or the diameter of thermowell should be adjusted to
bring in the limit.
The VENDOR shall be fully responsible to design and supply not only analyzers but
also all necessary sample conditioning systems and calibration systems to maintain
their proper operation. Sample conditioning systems are comprised of all the
components necessary to extract a representative sample and to condition the sample
for measurement by the analyzer. The design of total sample conditioning system that
includes sample probes, sample tap primary conditionings, sample transportation lines,
etc. shall be engineered for each specific application. All material of sample
conditioning system components in contact with the process sample shall be of type
316 stainless steel unless special material is required for the process fluids handled.
For throttling (control) application, Globe type valve shall generally be used and for
on-off application, Ball type valve shall be the first choice as the valve type,
however, butterfly type may also be considered for both throttling and on-off
application to large size piping service and / or low differential pressure service.
Where internal lining of control valves is required for protection against corrosion,
the valve types may be as follows.
- Plug valve
- Ball valve
Their variations and other valve types may be considered where fluid properties,
pressure drop, pressure and temperature constrains, seat leakage requirements, or
mechanical restrains justify their use.
5.8.2 Sizing
Control valve shall be sized such that the valve rated Cv (valve flow coefficient)
shall normally be more than 1.75 times the normal flow Cv, or 1.2 times the
maximum flow Cv, whichever is greater. Where minimum flow condition is specified,
the valve opening shall not be smaller than 10% of the valve travel. The sizing shall
be carried out based on ISA S75.01 and the Manufacturer’s standard equations.
5.8.3 Noise
Noise generated by the control valves shall not exceed 90 dB(A) at 1m away from
the pipe of 1m downstream of the valve under their normal operating conditions. The
noise prediction shall be based on the Manufacturer’s standard method.
Valve body size shall be considered based on the following guideline after valve
sizing stated in the above paragraph.
- For the lines 1” and larger : minimum 1” and not more than 2 size
less than the line size
- For the lines smaller than 1” : same as the line size
The body size shall normally be selected from the series; 1/2, 3/4, 1, 1-1/2, 2, 3, 4,
6, 8, 10, 12”, and larger.
Flanged end connections shall be used for all globe valves. Threaded end
connections shall not be used.
Rating and material shall conform to those of the piping.
Materials:
Valve trim shall be type 316 stainless steel unless process conditions require a
higher grade or special material. Hardened trim shall be used for the following
services.
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 26 - 31
- Flashing liquids
- Fluid containing solids
- Valve pressure drops exceeding 0.7 MPa for steam service
- Valve pressure drops exceeding 1.0 MPa
- Service temperature above 350 ℃
Flow characteristics:
An equal percentage characteristic shall normally be specified for all cases, with the
exceptions of valves on the following services, for which linear characteristics shall
normally be selected.
- Depressurizing control
- Minimum flow control of pumps or anti-surge control of compressors
- Level control in gravity service
- Level control in the process where change in the level is proportional to flow rate
through the control valve
- Split range control
- Where two (2) valves are applied in parallel for increasing the rangeability
- Control valves that are only operated via manual control station (HC)
Seat leakage:
The following leakage class conformed to ANSI/FCI 70-2 shall normally be applied
to each type of valve.
Class Application
■ I : Manufacturer's recommendation
■ II : Double ported valves or cage guided valves
■ III : Valves as agreed by process
■ IV : Single ported valves
■ V : Shutoff valves or valves as agreed by process
■ VI : Soft seated valves
The seat leakage of emergency shutoff valves shall be class V for gas services and
class IV for liquid services, as a minimum.
5.8.7 Actuators
5.8.8 Accessories
Positioners:
Control valves for throttling applications shall normally be provided with an smart
electro-pneumatic (E/P) positioner with HART protocol for an input signal of 4 to 20
mA DC. For pneumatic control loops, a pneumatic-pneumatic (P/P) positioner
suitable for an input signal of 20 - 100 KPa(g) shall be provided with the control
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 27 - 31
valves. For high vibration or high temperature location of valves, E/P converter with
P/P positioner should be considered.
The positioner shall furnish with an air filter regulator and small size pressure
gauges which indicate supply pressure, input signal pressure, and output pressure
to actuator.
Handwheel:
Handwheel shall be provided for tags as specified in the P&ID. Handwheel shall be
of side mounted type. The handwheels shall not be used travel limit stops.
Solenoid valves:
Three (3)-way, brass body valves shall normally be used. The valve shall have 1.0
MPa (g) rating body and shall be of direct acting type and universal type. The coil
4 shall be plastic molded, class F insulation class, as a minimum, and suitable for
DC 24V.
Solenoid valves used as protective device shall be of manual reset type.
Solenoid valve shall be equipped with terminal box.
Limit switches:
Limit switches shall be of hermetically sealed micro switch type. A terminal box shall
be equipped with the limit switch. No flying lead connections shall be permitted.
For safety shut-off valve with emergency duty, the actuator shall have fusible plug to
take the valve to safe position in fire case. The melting temperature of fusible plug
shall be 75 ℃ to 105 ℃
6. Installation
The location of instruments, control valves, including junction boxes shall permit easy
access from grade, permanent platforms or stairways for operation, inspection and
maintenance. Locations shall also minimize the possibility of damage from passing or
falling objects. Where a clear area allows access from a ladder or mobile platform to an
instrument or element, a permanent platform may not be required.
6.2.1 Routing
Instrument main cable way (home run cable) shall be laid in overhead cable duct
with protection cover. Cable duct shall be made of hot-dip galvanized steel.
Instrument branched cable runs from junction box or local panel to each instrument
in the field shall also be routed aboveground and supported with galvanized conduit
pipes.
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 28 - 31
Instrumentation cables that form part of IS circuits, if any, shall be segregated from
other instrument signal cables with separator installed between IS cables section
and non-IS cables section in same cable duct. The cable duct shall be provided for
instrument power cables separately from the signal cable duct.
- Main cable for analog : 0.75 mm2 with individual and overall shield
- Main cable for contact : 1.5 mm2 with overall shield
The junction boxes shall be certified IP65 and be of stainless steel sheet or
aluminum casting, provided with increased safety type enclosure, Ex (e) type.
The junction boxes shall be sized to allow termination of all the cores of the field
multi core cables, and to include 20% spare terminals. All spare cores (minimum
20% cores of multi-core cables) shall be connected to the spare terminal blocks in
the junction box. Cable entry shall be in the bottom.
Terminal strips shall be modular construction, and the electrical contacts shall be of
the tubular screw pressure plate type with all live parts recessed into the insulation
block.
A junction box shall contain only signals of the same level & system when those
signals are connected to DCS, ESD system and physically separated as follows ;
1) DCS-analog
2) DCS-digital
3) DCS-thermocouple
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 30 - 31
4) DCS-solenoid valve
5) ESD-analog
6) ESD-digital
7) ESD-solenoid valve
6.2.7 Deleted
1/2” outer diameter x 0,049” thickness annealed seamless stainless steel tube (316
SS) and double ferrule type tube fitting (316 SS), Swagelok or equivalent shall normally
be used for following services ;
1/2” steel or alloy pipes, socket weld valves and fittings as per the applicable piping
specification shall be used for the following services :
All instrument impulse lines shall have facilities for venting or draining the instrument.
Package vendor shall determine the extent of heat tracing and insulation required to
ensure the proper operation of the instrumentation and controls, considering process
property and plant site ambient condition.
The vendor shall identify, on the P&IDs, the lines, instruments and equipments that
require heat tracing. The vendor shall furnish and complete the required tracing work at
the vendor’s facility before shipment.
The heating medium shall be steam, unless other type such as electrical tracing is
considered more suitable.
Steam trace tube shall be of 3/8 inch copper tube and chrome plated brass
compression fittings.
Galvanized carbon steel piping and threaded fittings shall be used for the instrument
air supply lines from the header up to the block valve close to the air consumer.
The block valve shall normally be 1/4 NPT stainless steel ball valve. Instrument air
supply lines from the block valve to the air consumer shall normally consist of
1/4” OD stainless steel tubing and double ferrule compression fittings. However, size
ENGINEERING SPECIFICATION ES No. K-101X
FOR Revision 4
S-OIL ONSAN REFINERY INSTRUMENTATION
EXPANSION PROJECT FOR PACKAGE EQUIPMENT PAGE 31 - 31
of air supply line and block valve for control valves and emergency shutdown valves
shall follow the valve vendor’s information in consideration of the valve performance.
1/4” OD stainless steel tubing and stainless steel compression fittings shall be used.
Accordingly, internal tubing with fitting on the valve actuator shall also be stainless
steel.
Attachment-2
1/2
Attachment-2
2/2
Attachment-3
- Fuses 100%
- Lamps 100%
- Electromagnetic relays 10% (min. 2 sets) per each type
- Terminals 5% (min. 10 sets) per each type and size
- Printer papers Min. 1000 sheets per each printer
- Printer cartridges or ribbons, etc. min. 5 sets per each printer
- Sealing materials (gasket, O-ring, etc.) 100%
- Gland packing of control valve 10% (min 1 set) per each type, material
and size
- Solenoids of control valve 10% (min. 1 set) per each type
- Air set of control valve 10% (min. 1 set) per each type
- Pressure gauges of positioner 10% (min. 2 sets) per each type and range
- Fittings (tube fittings, etc.) 10% (min. 2 sets.) per each type
- Touch-up paints Min. 1 can per each cabinet and panel
- PLC cards Min. 1 set per each type
1/1
Attachment-4-1
J.B.s
④ ④ J.B.s
④ J.B.s ④
Local
Delivery Condition of Instrument & Material (1)On Single Skid, or (2)On Separated Skids, (3)Loose, (4)[ ]
for Trip Controller Type & Location (1)Local Control Panel, (2)Control Panel in Rack Room, (3)Main DCS&ESD
Gauge Board
(Note 2) Operation for Start-up, normal S/D, Mainten. (1)Manually From Field, (2)Remotely from Main DCS/ESD, (3)[ ]
③ ⑨ HMI for normal Monitoring (1)DCS, (2)HMI by Vendor, (3)[ ]
(G) Hazardous Area Class. & Type of Ex. Proof (1)Unclassified, (2)Classified[ ]: (a)Ex"d", (b)Ex"i", (c)Ex"n", (d)Gen. P.
I.A. Inst. Data Sheet - Scope & Format (1)LEC (2)Vendor: (a)Paper(ISA like), (b)INtools ("IEE" or Excel sprd sht, if BV)
Loop Drawing - Scope & Format (1)LEC (2)Vendor: (a)Paper(ISA like), (b)INtools
Compressor (Recipro.)
⑦ Vibration Piston ⑦ ⑨ FAT at Package Unit Shop (1)With Witness by C&I Eng'er [ days], (2)Without Witness by C&I Eng'er
Rod Drop (H) (Motor Driven) Integrated FAT at DCS Vendor Shop (1)Not Req'd, (2)Communication Test Only, (3)Integrated Functional Test
Field ①② Field ①② Special Inst. ①② LP Steam INSTRUMENT INTERFACE DIAGRAM
Instrument Instrument w/External FOR
Power Supply PACKAGED UNIT 0 May 9, '08 for inquiry
L TOYO ENGINEERING CORPORATION REV. DATE STATUS PRE. CHK. AUT.
Attachment-4-2
RACK ROOM Elec. Sub-Station TIE-IN CONDITIONS BETWEEN PURCHASER AND VENDOR
№ TIE-IN ITEMS SPECIFICATIONS REMARK
(A) POWER SUPPLY To Vendor's Auxiliary Cabinet ( 115 VAC, VA), ( VDC, VA), UPS
(B)
⑪ (B) I/O COUNTS (DCS, ESD, Other) (DCS) (ESD) (Other) (DCS) (ESD) (Other) Hardwired I/O Counts between
FIELD and Rack Room.
FIELD Fr/To ASC [between DCS/ESD/Other and FIELD] AI= 0 0 0 AO= 0 0 0
⑪ AI DI= 0 0 0 DO= 0 0 0 TE = T/C type or RTD
J.B.s ⑱ AO TE= 0 - 0 Pulse= - - 0
Fr/To DCS Fr/To Governor Fr/To ESD DI (C) I/O COUNTS (DCS, ESD) AI= 0 0 AO= 0 0 Hardwired I/O Counts of Machine
AI AI To OSP AI DO [INSIDE RACK ROOM] DI= 0 0 DO= 0 0 associated devices and DCS/ESD.
AO AO Pulse AO (D) DATA COMMUNICATION with DCS [Package vendor to prepare I/O address mapping]
DI Fr/To Governor To MMS DI DI ⑰ FV ⑯ (E) I/O COUNTS (DCS, ESD) [Sig. I/F with MCC] DI = 0 0 DO = 0 0 Hard. I/O Counts of MCC Signals
PT, FT
DO DI AI DO To MMS DO (ASC) (F) INSTRUMENT AIR SUPPLY Size ( ), Conn. ( Scrd / FL ) By LEC [ (1)INST., (2)PIPING ] Q'ty of Pilot=
TE DO TE TE AI (G) STEAM SUPPLY For Instrument TRACING Size ( ), Conn. ( Scrd / FL ) By LEC [ (1)INST., (2)PIPING ]
④ ④ ④ J.B.s ④ NOTE
J.B.s J.B.s J.B.s J.B.s 1 Power Supplies to all Cabinets / PCs / Local Gauge Board are tobe finalized by LEC.
④ for Trip
2 Local Gauge Boad is typically installed with PG's (incl. impulse lines), TG's (incl. capillary tube), Switches, Lamps and installed on the Compressor Skid.
3 Hand Swich Box for Steam Turbine is typically installed with multiple switches / buttons such as START, RESET, RAISE, LOWER, ESD.
4 Interface Signals with MCC for Auxiliary Pumps. No. of Loop 0
No. of Local Loop NA
⋮
Module
24 CABLE INSIDE CONTROL ROOM ○ ○ ○
(BN3500)
⑲ 25 Data Communication Cable bet. DCS and Other SYS's ○ ○ ○
26 AUXILIARY CABINET (incl. internal wiring etc.) ○ ○ ○
RACK ROOM Elec. Sub-Station TIE-IN CONDITIONS BETWEEN PURCHASER AND VENDOR
№ TIE-IN ITEMS SPECIFICATIONS REMARK
(A) POWER SUPPLT To Vendor's Auxiliary Cabinets ( 115 VAC, VA), ( VDC, VA), UPS
(B)
⑪ (B) I/O COUNTS (DCS, ESD, Other) (DCS) (ESD) (Other) (DCS) (ESD) (Other) Hardwired I/O Counts between
FIELD and Rack Room.
FIELD Fr/To ASC [between DCS/ESD/Other and FIELD] AI= 0 0 0 AO= 0 0 0
⑪ AI DI= 0 0 0 DO= 0 0 0 TE = T/C type or RTD
J.B.s ⑱ AO TE= 0 0 0 Pulse= - - -
Fr/To DCS Fr/To ESD DI (C) I/O COUNTS (DCS, ESD) AI= 0 0 AO= 0 0 Hardwired I/O Counts of Machine
AI AI DO [INSIDE RACK ROOM] DI= 0 0 DO= 0 0 associated devices and DCS/ESD.
AO AO (D) DATA COMMUNICATION with DCS [Package vendor to prepare I/O address mapping]
DI To MMS To MMS DI ⑰ FV ⑯ (E) I/O COUNTS (DCS, ESD) AI= 0 0 AO= 0 0 Hardwired I/O Counts of MCC and
PT, FT [Sig. I/F with MCC & VVVF]
DO AI AI DO (ASC) DI= 0 0 DO= 0 0 VVVF signals
TE TE TE (F) INSTRUMENT AIR SUPPLY Size ( ), Conn. ( Scrd / FL ) By LEC [ (1)INST., (2)PIPING ] Q'ty of Pilot=
(G) STEAM SUPPLY For Instrument TRACING Size ( ), Conn. ( Scrd / FL ) By LEC [ (1)INST., (2)PIPING ]
④ ④ ④ J.B.s ④
J.B.s J.B.s J.B.s J.B.s NOTE
④ for Trip
1 Power Supplies to all Cabinets / PCs / Local Gauge Board are to be finalized by LEC.
2 Local Gauge Boad is typically installed with PG's (incl. impulse lines), TG's (incl. capillary tube), Switches, Lamps and installed on the Compressor Skid.
3 Interface Signals with MCC for Auxiliary Pumps. No. of Loop 0
4 Package vendor to specify in his quotation the required number and kind of signals for cable interconnection. No. of Local Loop NA
Note 1: Pressure piping shall be long enough so that the liquid shall vaporized at ambient temperature or by
use of heating.
Note 2: Instrument may be located below the taps, when there is no possibility of producing drain.
Note 3: Condensate pots shall be provided for bellows type diff. pressure transmitter, or for steam
“B-2” orientation may be applied when “B-1” orientation can not be applied due to the piping
arrangement.
Note 4: In case the liquid is easy to form solid matter, nozzle shall be provided 45 deg. above the horizontal
In case the formation of solid matter is prevented by use of heating, etc, nozzle orientation shall be
90° 90°
Type 45° 45° 45°
“A”
Steam
Liquid
Type
“C”
45° 45° 45°
4. Liquids whose pour points are above the minimum (F + L) or (F + R) (F + L) or (F + R) (F + L) or (F + R) (F + L) or (F + R) F+R F+R F+R
ambient temperature
Liquid
Legend :
A: Fill lead lines with process liquid
B: Fill lead lines with water
C: Fill lead lines with a seal fluid other than line fluid
(Note*3): Drain / vent line / valve is not necessary for pressure and differential
pressure transmitters equipped with drain or vent plug as
manufacture’s standard.
4. Others
1) Pressure gauge
Piping system shall be used for pressure gauges. And a vent valve shall be
provided regardless of the pressure rating. For piping class ≧600#, a vent
valve shall be provided between block valves.
2) Steam condensate pot
For steam condensate pot, no vent valve is necessary. A vent plug shall be
provided.
(1/2)
Attachment-8 LODAL PANEL AND LOCAL GAUGE BOARD (TYPICAL)
1. General
A local panel or local gauge board shall include all fundamental instruments
necessary for the package unit operation, and shall be clearly visible to the operator
controlling the equipment.
15
1 2 3 4
250
5 6 7 8
250
9 10 11 12
2400 (MAX)
NAME PLATE
13
14
(MIN.1150)
1400
1150 700
100
EYE BOLTS
150 200 200 200 150
16
500
15
1 2 3 4
250
5 6 7 8
250
9 10 11 12
2400 (MAX)
NAME PLATE
13
14
(MIN.1150)
1400
900 700
100