SNBP Epc 00 Ins SPC 008

CONTRACT NO.
:
INSTRUMENT AND
SP3MK-
TELECOMMUNICATION 005/PG3400/2022-S7
DOCUMENT NO.:
PAGEs 40
SNBP-EPC-00-INS-SPC-008
JASA PERANCANGAN, PENGADAAN, DAN KONSTRUKSI PEMBANGUNAN PIPA GAS
SENIPAH – RU V BALIKPAPAN
INSTRUMENT DESIGN AND INSTALLATION
A 18/05/2022 Issued For Review SW ASW EFC

PREP’D CHK’D APV’D CHK’D APV’D
REV. DATE DESCRIPTION PT KILANG PERTAMINA
PT PGAS SOLUTION
BALIKPAPAN
JASA PERANCANGAN, PENGADAAN, DAN
KONSTRUKSI PEMBANGUNAN PIPA GAS
Document No. Rev. INSTRUMENT DESIGN AND Date: 13/05/2022

SNBP-EPC-00-INS-SPC-008 A INSTALLATION Page : 1 of 40
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REVISION NOTES
Implementasion
Revision Section Page Comment Remarks
(Y/N)

TABLE OF CONTENTS
1. INTRODUCTION ............................................................................................................ 6
1.1 General .............................................................................................................. 6
1.2 Scope ................................................................................................................. 6
1.3 Definitions ......................................................................................................... 7
1.4 References, Codes and Standards .................................................................. 7
1.5 ABBREVIATION................................................................................................. 7
1.6 References Document ..................................................................................... 8

1.6.1 Indonesia laws and codes ................................................... 8
1.6.2 International Standard and Codes .................................. 8
2. GENERAL REQUIREMENTS ...................................................................................... 10
2.1 Layoutand Buildings ...................................................................................... 13
2.2 Instrument Symbols and Identification ......................................................... 13
2.3 Units and Scales ............................................................................................. 13
2.4 Environmental Protection .............................................................................. 14
2.5 Tropic Proofing Requirements....................................................................... 15
2.6 Certification of Electronic Equipment in Hazardous Area ........................... 15
2.7 Interference ..................................................................................................... 15
2.8 Instrument Passive Protection Against Fire ................................................. 16
2.9 Power Supply and Instrument Air System .................................................... 16

2.9.1 Electrical Supply Characteristics .................................. 16
2.9.2 Instrument Air I Gas System ............................................. 17
2.10 Instrument Accessibility................................................................................. 18
2.11 Loop Checking ............................................................................................... 19


2.12 Inspection, Calibration, and Test Reports .............................................. 20
3. FIELD INSTRUMENTATION........................................................................................ 20
3.1 Pressure Instrument ....................................................................................... 20

3.1.1 General ......................................................................... 20
3.1.2 Pressure Gauges and Differential Pressure Gauge ................ 21
3.1.3 Pressure and Differential Pressure Transmitters .................. 22
3.2 Level Instruments .......................................................................................... 22

3.2.1 General .......................................................................... 22
3.2.2 Gauge Glasses................................................................ 22
3.2.3 Level Transmitters ........................................................... 23
3.3 TemperatureInstruments ................................................................................ 23

3.3.1 Thermowell ..................................................................... 23
3.3.2 Temperature Sensors ....................................................... 24
3.3.3 Temperature Gauges ........................................................ 25
3.3.4 Temperature Transmitters ................................................ 25
3.4 Flow Instruments ............................................................................................ 26

3.4.1 General .......................................................................... 26
3.4.2 Gas Ultrasonic Flow Meter (USM) ....................................... 26
3.4.3 Liquid Turbine Meter ........................................................ 26
3.4.4 Coriolis Meter .................................................................. 26
3.5 Control Valves ................................................................................................. 27

3.5.1 General .......................................................................... 27
3.5.2 Actuators ........................................................................ 27
3.5.3 Control Valve Size ........................................................... 28
3.5.4 Valve Positioner .............................................................. 28
3.5.5 Pneumatic Amplifier (Boosters).......................................... 28
3.5.6 Self Actuated Control Valves ............................................ 28
3.5.7 Control Valve Arrangements .............................................. 29
3.5.8 Control Valve Noise .......................................................... 29
3.6 Shutdown I Slowdown Valves ........................................................................ 29
3.7 Time Switching Valves ................................................................................... 30
3.8 Pressure Relieving Devices ........................................................................... 31

3.8.1 General .......................................................................... 31
3.8.2 Thermal Relief System ..................................................... 31
3.8.3 Pressure Relief Valves ...................................................... 31

3.9 Instrument Switches ....................................................................................... 32

3.9.1 Electric Switches ............................................................. 32
3.9.2 Pneumatic Switches ....................................................... 32
3.10 Solenoid Valves ............................................................................................. 32
3.11 Metering System ............................................................................................. 33
3.12 Instrument Tubing and Piping ....................................................................... 33

3.12.1 General ........................................................................ 33
3.12.2 Size and Material ........................................................... 33
3.12.3 Air Supply Connections .................................................. 34
3.12.4 Pneumatic Control Connections ........................................ 35
3.12.5 Miscellaneous Connection Sizes and Types ........................ 35
4. GROUNDING SYSTEM ........................................................................................... 36
4.1 Protective Earth (PE) ...................................................................................... 36
4.2 Instrument Earth ............................................................................................. 37
4.3 Intrinsically Safe Earth ................................................................................... 38
5. SURGE PROTECTION SYSTEM ................................................................................. 38
6. EQUIPMENT AND MATERIAL IDENTIFICATION ...................................................... 38
7. PREPARATION FOR SHIPMENT ............................................................................... 39
8. PRESERVATION AND STORAGE OF INSTRUMENT EQUIPMENT ......................... 39
9. SPARE PARTS AND SERVICES ................................................................................ 40
10. GUARANTEE............................................................................................................... 40

1. INTRODUCTION
1.1 General
PT Pertamina, hereafter known as COMPANY, plans to deliver gas from Senipah KP 7.2
that is operated by Pertamina Hulu Mahakam to PT PERTAMINA (Persero) Refinery Unit
(RU V) Balikpapan, East Kalimantan, to fulfill the gas demand at Refinery Unit (RU V)
Balikpapan as part of the RDMP program.
The Onshore Pipeline Senipah – RU V Balikpapan scope will comprise of development of

mini facility in Senipah and RU V Balikpapan area consist of gas metering, pigging
facilities, utilities and an onshore gas pipeline.
Figure 1.1 - Pipeline from Senipah to Refinery Unit (RU) V Balikpapan
1.2 Scope
This document provides the requisition for Gas Metering Package for onshore applications
to use in Sales Gas Senipah to RU V Balikpapan Pipeline Station.

This document does not dictate detailed design of the equipment or assembly of
components. It is intended that those responsibilities be retained fully by the VENDOR so
that all equipment and process warranties remain unmitigated.
1.3 Definitions
The following definitions shall apply to this document and all other referenced documents.
Table 1.3 List of Difinitions
Definitions Descriptions
COMPANY PT Pertamina as the owner of the Senipah – RU V
Balikpapan Onshore Pipeline Project
CONTRACTOR PT PGAS Solution, the party that carries out all or part of
the detail engineering, procurement, construction,
installation and commissioning as per contract
VENDOR/MANUFACTURE The party which supply materials, equipment, technical
document/drawing, and service to perform the duties by
the CONTRACTOR.
DIRJEN MIGAS Representatives from the Indonesian Government
which is responsible for issuing licenses and permits oil
and gas facilities.
1.4 References, Codes and Standards

The latest editions of all applicable codes, specifications and references shall define the
minimum requirements applicable to the subject work and no statement contained in this
document shall be limiting the work to such requirements. Wherever conflicts or omissions
between codes, specifications and contract occur, the most onerous condition shall apply.
VENDOR/CONTRACTOR is responsible for reviewing the list below and informing the
COMPANY of any omissions. All conflicts shall be formally brought to the attention of the
COMPANY.
1.5 Abbreviation
CCR Central Control Room
ECN Ethernet Communication Network
ESD Emergency Shutdown System
FGS Fire and Gas System
HART Highway Addressable Remote Transducer
HMI Human Machine Interface
HVAC Heating, Ventilation and Air Conditioning
ICSS Integrated Control and Safety System

IER Instrument Equipment Room

LAN Local Area Network
PCS Programmable Logic Controller
RFI Radio Frequency Immunity
RTD Resistance Temperature Detector
SIS Safety Instrumented System
SCADA Supervisory Control and Data Acquisition
VDU Video Display Unit
1.6 References Document
1.6.1 Indonesia laws and codes

No. 11, 1979 LN of 1979 No. 18 TLN No. 3135 Government Regulation of Republic of
Indonesia concerning Work Safety in Oil
and Gas Refining and Processing
No. 36/KPTS/DJ/MIGAS/1977 Decision of Director General for Oil
and Natural Gas

No. 43P/382/DDJM/1992 Directorate General Oil and Natural Gas (MIGAS)
Regulation for Terms and Conditions for
Appointment of third party
1.6.2 International Standard and Codes

API - American Petroleum Institute
API MPMS Measurement of Liquid Hydrocarbons by Turbine Meter
5.3
API MPMS Natural Gas Fluids Measurement Section 1-Collecting and Handling of
14.1 Natural Gas Samples for Custody Transfer
API MPMS Flow Measurement Using Electronic Metering System Section 1 - Electronic
21.1 Gas Measurement
API6D Specification for Pipeline and Piping Valves
API6FA Specification for Fire Test for Valves
API RP 505 Recommended Practice for Classification of Locations for Electrical
Installation at Petroleum Facilities Classified as Class I, Zone 0, Zone 1,
and Zone 2
API RP 520 Sizing, Selection, and Installation of Pressure-Relieving Devices in
Refineries, Parts I and II
API RP 521 Guide for Pressure-Relieving and Depressuring System
API STD 526 Flanged Steel Pressure Relief Valves
API STD 527 Seat Tightness of Pressure Relief Valves
API RP 540 Electrical Installations in Petroleum Processing Plants
API RP 551 Process Measurement Instrumentation
API RP 552 Transmission System
API RP 553
Refinery Valve and Accessories for Control and Safety Instrumented
System

API RP 554 Process Instrumentation and Control

API 598 Valve Inspection and Testing
API STD 607 Fire Test for Quarter-Turn Valves and Valves Equipped with Nonmetallic
Seats
API RP 2534 Measurement Control Charts and Statistical. Methods for Petroleum
Metering System.
AGA - American Gas Association

AGA - Report Measurement of Fuel Gas by Turbine Meters
No.7
AGA - Report Compressibility and Super Compressibility for Natural Gas And Other
No.8 Hydrocarbon Gases
AGA - Report Measurement of Gas by Multi-path Ultrasonic Meters
No.9
ASME - American Society of Mechanical Engineers

ASME 816.4 Cast Iron Threaded Fittings
ASME 816.36 Orifice Flanges
ASME PTC Thermowells
19.3
ASTM - American Society for Testing and Materials

ASTM A269 Standard Specification for Seamless and Welded Austenitic Stainless Tubing
for General Service.
ASTM A450 Standard Specification for General Requirement for Carbon Ferritic Alloy
and Austenitic Alloy Steel Tubes.
ASTM 01085 Standards Method of Gauging Petroleum and Petroleum Products
ASTM 01086 Standard Method of Measuring Temperature of Petroleum and Petroleum
Products
IP - Ingress Protection
IP 54 Limited protection against dust ingress (no harmful deposit), Protected against
splash water from any direction
IP 65 Totally protected against dust ingress, Protected against low pressure water
jets from any direction. Limited ingress permitted
ISO - International Organization for Standardization (ISO)

ISO 5167 Measurement of Fluid Flow by Means of Pressure Differential
Devices Inserted in Circular Cross Section Conduits Running Full.
ISO 5168 Measurement of Fluid Flow - Procedures for Evaluation of Uncertainties
ISO 8310 Refrigerated Hydrocarbon and Non-Petroleum based Liquid Gaseous
Fuels - General Requirements for Automatic Tank Thermometers on
board Marine Carriers & Floating Storage.
ISA - International Society of Automation

ISA 7.0.01 Quality Standard for Instrument Air Standard Control

ISA RP 4.2 Valve Manifold Designs Recommended Practices for

ISA RP 12.1 Electrical Instruments in Hazardous Atmospheres.
ISA S20 Specification Forms for Process Measurement and Control Instruments.
ISA S50.1 Primary Elements and Control Valves
ISAS51.1 Compatibility of Analog Signals for Electronic Process Instrument.
ISA S72.1 Process Instrumentation Terminology Proway LAN Industrial Data Highway
ISA S75.01.01 Flow Equations for Sizing Control Valves
ISA S75.02 Control Valve Capacity Test Procedure
ISA S75.03 Uniform Face to Face Dimensions for Flange Globe Style Control Valve Bodies
ISA S75.11 Inherent Flow Characteristics and Rangeability of Control Valve Safety
Instrumented System
ISA S84.01 Application of SIS for the Process Industries
IEC - International Electrotechnical Commission

IEC 61000-4 Electromagnetic Compatibility - Testing and Measurement
IEC 61000-5 Electromagnetic Compatibility (EMC)
IEC 60068-1 to Basic Environment Testing Procedure
60068-4
IEC 60079 Electrical Apparatus for explosive gas atmospheres
IEC 60092-352 Choice and Laying Cables for Low Voltage Power Supply.
IEC 60189-1 Cables and Wires for Low Frequency PVC Insulated and in Protective Sleeve
IEC 60227 Polyvinyl Chloride Insulated Cables of Rated Voltages Up To &
Including 450/750 V
IEC 60228 Conductors of Insulated Cables
IEC 60304 Standard Colors for Insulation for Low Frequency Cables Wires
IEC 60331 Test for Electrical Cables under Fire Conditions
IEC 60348 Safety Requirements for Electronic Measuring Apparatus
IEC 60529 Classification of Degrees of protection provided by enclosures
IEC 60584 Thermocouples. Part 3: Extension and compensating cables - tolerances
and identification system
IEC 60751 Industrial Platinum Resistance Temperature Sensor
IEC 61131 Programmable Logic Controller
IEC 61508 Functional Safety of Electrical/Electronic/ProgrammableElectronic Safety-
related Systems.
IEC 62382 Electrical and Instrument Loop Check
NFPA - National Fire Protection Association

NFPA 70 National Electric Code
NFPA 72 National Fire Alarm and Signaling Code
The latest revision of the above Project Specifications shall apply at time of placement of
Contract.
2. GENERAL REQUIREMENTS
a. All material necessary for the instrumentation and safety systems described
herein, shall be furnished by the Contractor and shall be new, unused,
purchased from the authorized manufacturers representative, and, unless

otherwise specified herein or on drawings, shall meet the following

designated specifications. Materials and equipment shall be protected from
construction damage, particularly damage due to sand blasting and painting.
b. Materials requirements shall conform to Purchase Specification, Data sheets and
Piping Specification.
c. Instrumentation materials and instrument mounting hardware shall be minimum SS
d. 316. Mounting hardware shall include nuts, bolts and other fasteners.
e. Aluminium material shall not be used for instrument enclosures. If use of
Aluminium is acceptable to CLIENT, then it shall be Copper free and Magnesium
content shall be less than 6%. Use of aluminium shall require company approval on
a case by case basis.
f. All material for instrumentation in contact with process fluid shall be
in conformance to the Piping Material Specification.
g. Each instrument furnished shall be provided with fully completed data sheets. Data
h. Sheets shall be numbered and indicate manufacturer and model numbers.
Standard ISA instrument date sheets will be acceptable.
i. Multiple listing of instruments on one sheet is permitted; however, they must
be arranged in numerical sequence by tag number. Only identical instruments may
be listed on each data sheet i.e. the only difference allowed is lag numbers.
j. An assigned tag number which is cancelled due to instrument revisions shall not
be re-used.
k. CONTRACTOR shall keep an "As-Built" Instrument Index that reflects all revision
that occur during the design and construction of the equipment and shall include
the "As-Built" Instrument Index in the final documentation for the project.
l. Wherever possible, the instrument selection shall represent the manufacturer's
standard. Standardization of instruments types, manufacturer, and model shall
be considered for the purpose of simplifying design and reducing spare parts.
m. Selection of instruments and supporting hardware shall be made with
consideration of the process fluid, the operating environment, and the
electrical area classification.
n. Instrument pneumatic analogue signals shall be 3 - 15 psig. Unless otherwise
specified or required by the equipment such as valve operators. Instrument
pneumatic on-off signals shall generally be 30 psig.
o. Pneumatic instruments requiring a regulated air supply shall be furnished with a
SS 316 fitter regulator and output gauge of SS 316. The filter shall feature a
manual drain water removal facility.
p. Process fluids, steam or water shall not be routed into control room for
direct measurement.
q. The use of transmitters shall be maximized to improve overall reliability
and availability. All transmitters shall be "SMART" electronic type utilizing 'dual

mode' output with 2 wire 4 - 20 mA DC signal with superimposed 'HART' protocol

communication signal.
r. All electronic field switches shall have double pole double throw (DPDT) contacts
unless otherwise specified. Discrete (On-Off) electric signals shall be 24 VDC
unless otherwise specified. Use of local electronic control switches in lieu
of electronic type transmitters requires CLIENT's approval.
s. Separate process tapping points and instruments shall be provided for
all Emergency Shutdown System (ESD) and Process Control Instrumentation.
Field instrumentation for process control via the PCS and ESD shall be entirely
separate from one another, utilizing separate process connection points,
dedicated field junction boxes, multi-pair cables, marshalling cabinets and I/O
modules.
t. Process tapping points for field pressure sensors/transmitters on piping shall
be used minimum of 1/2 inch NPT.
u. The facility to isolate, check and calibrate individual for local instruments, gauges
& transmitters shall be provided.
v. Software configured time delays shall be provided (typically 0-10 seconds, set at
2 seconds), as necessary to prevent spurious trips. All field equipment shall be
certified according to the area classification, in which it is installed. Minimum
Certification of Instrument Equipment shall be Class-1, Div-2, and Group-D.
w. Material requirements shall conform to purchase specifications, datasheet
and piping specification.
x. For packaged equipment, Vendor shall as a minimum supply the following
documentation as applicable:
1. Wiring Diagrams
2. Junction Box Details
3. Bulkhead Connector Details
4. Interconnecting Tubing Drawings
5. Layout drawing detailing skid dimensions, instrument locations, panel
locations, junction box locations, and tubing bulkhead locations.
6. Panel Drawings
7. Piping and Instrument Diagrams
8. Instrument Index
9. Complete ISA data sheets for instrumentation
10. Operating, Installation, and Maintenance Manuals for all Instrument Items.
11. Certified dimensional drawings, operating, installation, and maintenance
manuals are required for all engineering instrument items.

2.1 Layoutand Buildings

a. CCR, whether existing or new, will house all operator interface equipment including
Human Machine Interface (HMI), Operator keyboards and VDU's. The CCR shall also
house the plant SIS, SCADA monitors and other plant facilities Control Panels,
as required.
b. The Process Control System (PCS) and other control equipment such as Marshalling
Cabinets, SCADA system cabinets, and other related VENDOR equipment, power
supplies and associated ancillary hardware shall be physically located in existing or
new Instrument Equipment Room (IER).
c. Field instruments will be connected to I/O assemblies located in IER via dedicated
multi-pair cables from marshalling cabinets in IER to field mounted junction boxes and
then routed to field instruments and control devices.
d. The Central Control Building is the main location where system processor cabinets,
main communication buses, marshalling cabinets. Ethernet Communication Network
(ECN) interfaces, complex communication systems and all other associated
electronics and hardware are located.
2.2 Instrument Symbols and Identification
a. Designation of instrumentation shall be in accordance with ISA S5.1 Standard of
b. Instrumentation Symbols and Identification.
c. Numbers assigned to instruments and related equipment on the P&ID's shall be used
throughout the job.
d. Designation of HMI shall be in accordance with ISA S5.3 Graphic Symbol for
e. Distributed Control/Shared Display Instrumentation, Logic and Computer System.
2.3 Units and Scales

The following units shall apply:
Flow :
Liquid Barrels per day (BPD), US Gallon per Minute (USGPM)
Gas Million Standard cubic feet per Day (MMSCFD) (60 of, 14.696
Psia), Actual cubic feet per Minute (ACFM)
Pressure :
General Psi gauge (Psig)
(Absolute) Psi absolute (Psia)
Differential Psi, or Inches of water (inH20) for flow measurement
pressure
Temperature Psi, or Inches of water (inH20) for flow measurement
Level Inches (or % of range)
Viscosity Centipoises (cP)

Length Inches/Millimeter/FeetiMeter
Analyzer Determined by individual application
Volume Barrels (BBL), Gallon, MMSCFD
Vibration mils
All HMI based numerical display and instrument charts and scales shall be calibrated
as follow:
Analysis Direct reading

Flow Direct reading
Level 0 -100 % uniform
Pressure Direct reading
Temperature Direct reading
Vibration Direct reading
2.4 Environmental Protection

a. All field instruments shall be capable of working continuously under the
environmental conditions specified.
b. The field electronic instruments enclosure and junction boxes shall be corrosion
resistant and certified to IP 65 or equivalent as minimum for use in Class 1, Div-
1 or Div 2 Group D areas.
c. Pneumatic instruments in the field shall be weatherproof to IP 54.
d. Hermetically sealed electrical switches shall be provided for all electrical
switches installed in classified areas.
e. The instruments and panels located indoor shall be weatherproof to IP 42.
f. The indoor equipment located in air-conditioned environment shall be designed
to operate continuously in the following conditions:
Ambient Temperature : 18 - 25° Celsius

Humidity : 35 - 65% Relative Humidity
g. All metallic parts of housings shall be made of mild-steel epoxy coated or copper free
aluminium as minimum requirement. Painting of housings and enclosures shall be
performed in line with the project specification.
h. Housings shall provide sufficient clearance for maintenance operations and shall
be fitted with quick-opening device.

i. All printed circuit cards shall be protected against corrosion, humidity and fungus by
means of appropriate varnish coating and gold plated connectors (including
those located within control and equipment rooms).
j. All electronic or electric field instruments shall be tropicalized and marine corrosion
proof.
2.5 Tropic Proofing Requirements

Generally VENDOR's standards method of Tropic Proofing shall be applied for
individual instruments with the following minimum requirements:
 Proper design and construction.

 Selection of materials not susceptible materials to fungus growth or moisture. Treatment of
any susceptible materials with a protective coating to prevent the growth of fungus, to
prevent corrosion and to prevent absorption of moisture
2.6 Certification of Electronic Equipment in Hazardous Area

a. Enclosures for electronic instruments including solenoid valves shall comply with
requirements of the electrical area classification in which they are installed; Flame
proof (Ex'd') protection shall be preferred.
b. The junction boxes shall be certified as increased safety (Ex'e'). Intrinsically Safe
c. (IS) protection shall only be used with prior approval from COMPANY.
d. Another protection type may be applied for related hazardous area. i.e. pressurized
Local Control Panel with inert, dry gas, according to the ISA RP12.4 shall be given
consideration.
e. Electrical devices shall be listed by Under Writers Laboratory Inc. (UL), Factory
Mutual Research Corp. (FM), Canadian Standards Association (CSA), or other
recognized testing laboratories.
2.7 Interference
a. All instruments and micro-processor based system shall meet the following Radio
Frequency Immunity (RFI) requirements that shall be tested at the acceptance test
and performance checkout stage:
Table 2.7. Radio Frequency Immunity (RFI) requirements
TEST SYSTEM RESPONSE

Test 1

5W, VHF/UHF hand held transmitter No effect

operated at 1 meter from each side
panel/door, with all doors and covers in
place.
Test 2
As Above with all doors opened but No damage to equipment. Analogue

internal covers and printed circuit value shall not change by more than
cards in place 1% Full Scale
Test 3
As above, with a randomly selected As test 2.

input or output module per cabinet on
an extender card, if appropriate and
with all CPU and memory cards and
their covers in place. Alternatively,
with one input/output module removed.
b. Basic reference standard shall be IEC 801 (Part 3) for design and
manufacturing considerations.
2.8 Instrument Passive Protection Against Fire
When installed in outdoor location, the following cables shall be fire resistant
according to IEC 60331:
Cables for all fire and gas system detection circuits.

Critical telecommunication system.
Cables for 'energized to trip' Safety system (ESD and FGS) circuits.
All other cables shall be flame retardant according to IEC 60332-3-24 Cat. C.
2.9 Power Supply and Instrument Air System
2.9.1 Electrical Supply Characteristics

Negative earth Uninterruptible Power Supply (UPS) will be powered using electrical
supply in the following areas : 24 VDC for DC System and (380)/(220) VAC or
(400)/(230) VAC ± 10%, 50 Hz ± 3% for AC System

UPS floating ground shall be used for the supply of following main systems:
 Process Control System (PCS), including stations, network devices and printers.
 Safety Instrumented System (SIS)
 Telecommunication System.
 Package PLC System.
 Emergency Shutdown System
Wherever a VENDOR requires a different electrical supply, then the CONTRACTOR I

VENDOR shall provide all necessary equipment power supplies, ACIDC distribution
and protection, fuses, circuit breakers, earth leakage detection, terminals to interface
his equipment with the abortive project standards.
Power distribution within the PCS/ESD (i.e. 24VDC inside cabinet/marshalling) shall be
provided by VENDOR and shall be floating earth and fused on both legs. Incoming 220
VAC primary supply shall be provided with Main Circuit Breaker, Surge Arrester and
Earth Leakage Monitoring.
All instrument power supply users shall be depicted as a single line diagram to be
updated by CONTRACTOR for the duration of the contract giving a complete power
supply usage at any time. This diagram shall also include start up load (inrush, if
available) and normal load (running).
The PCS Operator interface and historical data retention will remain operational and the
ESD PLC based controller shall remain on line to affect a plant shutdown on notification
of plant power failure.
2.9.2 Instrument Air I Gas System

Air I gas distribution network shall take into account the following considerations:
 Complex layout,
 Number of items to feed,
 Possibility to isolate one or more units or sub-units from each other.
Service air shall be totally segregated from the instrument air network. All pneumatic
instruments shall be able to operate with a minimum pressure of 80 psig.
Instrument air and gas shall be distributed to instruments with the following characteristics:
Design Pressure : 175 Psig


Supply Pressure : 110 Psig

Oil Content : < 0.01 ppm wt
Dew Point : at least 10°C (18°F) below the minimum ambient.
Temperature
Operating temperature
Design temperature
Instrument air shall be dry and oil free, as per ISA S7.0.01 "Quality Standard for
Instrument Air". Instrument gas shall be free from dust, oil, and trace of methanol, and
not saturated at ambient temperature.
If instrument air is available, gas shall not be tied into the same system.
2.10 Instrument Accessibility

Each instrument shall be considered as a normal working location and therefore shall
be properly located in order to satisfy workers safety conditions as well as efficiency.
Instrument accessibility being able to induce heavy consequence on piping or complex

layout, this problem shall be considered as soon as possible during the detailed
engineering stage.
It shall be important to distinguish two kinds of working location:
 Permanent working location

 Non permanent working location.
A working location shall be considered as permanent when visit frequency is higher

than once a week.
Non permanent working location shall have visit frequency lower than once a week.
For permanent type, the access shall be easy. Access platforms are to be provided
where applicable and movable ladders not permitted.
For non-permanent type, movable ladders shall be allowed if height is less than 3
meters.

The following instruments and accessories shall be considered as permanent working

location: Control valves, ON / OFF actuated valves, transmitters, local controllers, local
converters, in-line flow meters, level gages, level switches, pressure switches,
temperature elements (indication and control) with transmitters, analyser take off point,
sampling loop.
The following instruments shall be considered as non permanent working location:

pressure taps, thermocouples or RTD and thermowell. Permanent access at these
locations is not required.
2.11 Loop Checking
a. CONTRACTOR shall carry out the loop checking when all individual loop components
have been calibrated, tested and their installation checked. Purpose of this is to
ensure satisfactory performance of complete instrumentation system. This shall be
carried out in the presence of CLIENT'S representative.
b. The loop checking for the instruments connected to the PLC shall be carried out in
association with the PLC VENDOR. The CONTRACTOR will work at the field and
the PLC VENDOR will work in the control room.
c. CONTRACTOR shall submit for approval a format of the loop check sheet meeting
IEC 62382 which shall record all loop check data. The loop check sheet shall be
signed off by both CONTRACTOR and the CLIENT.
d. Procedure for measurement and control/loops:
 Input is to be applied to the transmitter of the loop by a source described under

calibration procedure. Each loop component including trend recorder, if any,
shall be checked at 0%, 25%, 50%, 75% and 100% of transmitter range in the
increasing / decreasing order.
 Any alarm / trip in the loop is to be set at the required value. Then adjust the
transmitter / switch input to actuate the alarm / trip switch and check the action
of alarm / interlock circuit.
 Controller action shall be set correctly and the output shall be checked in both
auto and manual mode. In case of pneumatic controller, seal position shall be
checked for leaks.
 Control valve stroking shall be checked for full travel, open and closed position
and for operation of any, overriding control.
 Interlock system shall be checked for correct sequence of operation and all
output devices shall be proven to work satisfactorily.
 Loops involving analyzers shall be checked as per VENDOR'S recommendation.

 A loop check dossier shall be prepared and submitted by the CONTRACTOR

which shall contain the original signed off loop check records and the supporting
documents for each loop.
2.12 Inspection, Calibration, and Test Reports
After completion of the installation, calibration and 'check-out', CONTRACTOR shall

submit report, which shall record the details of all inspection, testes and calibration, carried
out on all instruments. This report shall focus on the following checkpoints, as a minimum:
 All instruments received comply with the purchase specification requirements. Necessary
documentation and certificates specified in the purchase specification are available for all
instruments.
 All instruments are installed according to the hook-up drawings and manufacture's
recommendations.
 All instruments are piped / tubed or wired according to the drawings.
 All impulse piping, tubing and wiring, as applicable are tested in line with the specification
requirements.
 All instruments are calibrated according to the specification.
 All interface requirements such as the interface with packages and utilities such as power
supply pneumatic supply, etc. are correctly furnished.
 Verify correctness of range, size, pressure rating, material, pressure settings, flange
 ratings or other parameters as called for in the instrument data sheets and drawings.
 Location of meter runs, pressure taps, control valves, relief valves straight run requirements,
etc., has been verified.
 In line instruments such as flow meters and control valves have been installed with the correct
flow direction.
 Local indications such as level gauges, pressure gauges, temperature gauges, etc. cover the
entire range of control and shutdown settings.
3. FIELD INSTRUMENTATION
3.1 Pressure Instrument
3.1.1 General
a. Pressure instruments shall be direct reading with indicating scales in imperial units
(Psig/Psia).
b. Pressure measuring elements may be of the bourdon tube, bellows diaphragm or
piston type.
c. Process connections for all pressure instruments shall be Yz" NPT.

d. Pulsating service installations shall be provided with pulsation dampeners Isnubbers.

e. All pressure measuring devices shall have 316SS wetted parts material, unless
special materials are required by the process.
f. All pressure instruments shall have block and bleed isolation valve. When the
instrument is located at a distance from the pressure connection, additional block and
vent valves shall be fitted adjacent to the instrument.
g. Shut-off and bleed valves shall be provided for each instrument when multiple
pressure instruments are manifold from the same process connection, each pressure
instrument shall have a X" two-valve manifold.
3.1.2 Pressure Gauges and Differential Pressure Gauge

a. Normally, bourdon tubes shall be the measuring element for range greater than 15
psig. Bellows elements may be specified for low and differential ranges. Piston type
elements may be specified for differential pressure applications.
b. Unless the process media demands another material, the measuring element,
movement, and socket shall be 316 SS. Sockets and tips shall be of same materials
as the element material.
c. Guaranteed accuracy shall be 1 - 1.6 percent of span or better over the entire range.
d. Liquid Filled Glycerin shall be preferred in general application except for low pressure
service, vacuum, cryogenic service, and temperature above 180°F.
e. Process gauges shall normally have Yz" NPT bottom connections. Gauge range shall
be selected so that it is normally a manufacturer standard range, and the normal
operating pressure shall be between 30% - 70% scale range.
f. Dials shall be circular, dial size 4-Yz" with dial reading in Psig, stainless steel case,
with black numerals and white background marking. Dials or pointers shall be field
adjustable for zero alignment.
Process pressure gauges shall be solid front, with on blow- out backs designed to
pop out when failure occurs within the gauge.
g. Over pressure protection shall be 1.5 times the maximum tube rating to prevent
permanent set or loss of calibration from continuous over pressure. Elements in
vacuum service shall be capable of withstanding full vacuum, regardless of range
without taking a permanent set or gang off calibration. Pressure element shall have
a minimum thermo elastic coefficient and be properly flexed, heat treated and stress
relieved for minimum hysteresis.
h. Diaphragm protectors shall be used where necessary to protect gauges from
corrosive fluids or Plugging.
i. Siphon shall be provided on steam services to minimize the heat conducted to the
pressure element.
j. Window material shall be provided with safety laminated glass
k. Case material shall be 304 SS

3.1.3 Pressure and Differential Pressure Transmitters

a. Electronic pressure transmitters shall be 4-20 mA DC, smart "HART" type.
b. Electronic transmitters shall be furnished in an enclosure suitable for the electrical
area classification. Reference accuracy shall be ± 0.5% of span. Total performance
shall be ± 0.15 % of span for ± 50°F temperature changes at 1: 1 to 5: 1 range
down. Stability shall be ±0.125% of URL for 5 years at 50 OF
temperature changes.
c. Transmitter elements and process-wetted parts shall be compatible with the process
fluid and 316 SS as a minimum.
d. The range limits shall be as specified on the data sheets. All transmitters shall be
factory calibrated for the specified span and have externally adjustable span and zero.
e. The span shall be continuously adjustable over the range of the transmitter.
f. All Pressure Transmitters shall be provided with 2-way valve manifold.
g. All Pressure Differential Transmitters shall be provided with 5-way valve manifold.
h. Pressure element shall be able to withstand over range pressure equivalent to
150% maximum span.
i. The pressure transmitter shall be designed so that, under normal operating
conditions, it shall be unaffected by radio transmission.
3.2 Level Instruments
3.2.1 General
a. Liquid level instruments shall be accessible from grade level or an access platform
shall be provided.
b. Level instruments shall be installed a sufficient distance from outlet connections to
prevent the outlet stream from affecting the instrument operation.
c. Level bridle standpipe size shall be 3" diameter in general application. Level bridle
piping shall not have bends that shall trap dirt, acid or water.
d. Wherever possible, common vessel connections with a minimum of 2" ANSI
flanges shall be used for multiple level instrument installations.
e. Level transmitter shall generally have accuracy reading ± 0.5% of span or better.
3.2.2 Gauge Glasses

a. Level gauges shall be provided on all vessels to cover the complete operating
range of level including the spans of level transmitters, level alarm and level
shutdown switches. Level gauges shall be located adjacent to applicable level
controllers of switches. The level gauges shall be visible from grade, platform or the
related instruments.

b. Reflex type gauge glasses shall be used where a liquid - gas interface exists and the
liquid is clean, colorless and will not make deposits on the glass.
c. Reflex gauge glassshall have pressure rating minimum according to main equipment
class.
d. Transparent: Illuminated thru-vision type gauge glasses shall normally be used in all
cases where a liquid - liquid interface exists, on services involving acid, caustic or
dark colored materials, on heavy and viscous oil service, and on steam
generating equipment
e. Chamber material and cover material shall be carbon steel.
f. Magnetic level gauge maybe used to replace level gauge glass.
g. Magnetic level gauge shall cover High- high and Low- Low Liquid level as
minimum
3.2.3 Level Transmitters

a. Differential pressure level transmitters may be used for level measurement where
b. Specific Gravity of Liquid is constant. Electronic pressure and differential pressure
transmitter shall be 4 - 20 mA DC, smart "HART" type, configurable for 0-100
percent-calibrated range. Electronic transmitters shall be furnished in an enclosure
suitable for the electrical area classification. Externally adjustable span and zero
shall be provided. Differential pressure level transmitters shall have an integral local
indicator.
c. When used, displacement type level instruments with external chamber are
applicable for liquid measurement up to 48" only. Displacer level instruments shall
be mounted directly to the vessel or bridle with isolation block valves. Sufficient
valves shall be provided to permit the removal of a level switch, transmitter or
gauge from service without affecting the other instruments. Float chamber drain
ball valves shall be centered under the float to permit checking that the float is free
to move. External type displacer level transmitters shall be side-side connections
only. No bottom connections are permitted.
3.3 TemperatureInstruments
3.3.1 Thermowell
a. All process temperature instruments shall be furnished with 316 SS.
b. Thermowells for general application thermocouples, resistance elements,
bimetallic thermometers and temperature test services shall be constructed for
interchange ability for all standard applications.
c. In vessels having a liquid-vapour interface, thermowell shall be installed
in the liquid phase.

d. Thermowell process connections and ratings shall meet the specification of

the pipe or vessel in which they are installed. Thermowell material, flange
size, rating and tag number shall be clearly stamped on the flanges body.
e. Thermowell material shall be machined in a tapered configuration from a
single bar stock. Welded construction is not acceptable.
f. A thermowell of drilled bar stock, made from a minimum of 316 SS, shall
be installed for each temperature sensing device. Lagging shall be
specified for thermowell used in insulated piping. Flanged wells shall
have 2" flanged connections for installation on the vessel of 1Yz" connection
for installation on the pipeline with W' NPT female threads suitable for all
thermometers.
g. Screwed process connections for thermowell are generally not acceptable.
If these are required for any specific application, prior approval from
CLIENT is required.
h. Thermowell shall be installed in pipe size 4" and larger, whichever pipe
size is smaller than 4", than pipe enlargement is required.
i. The immersion length of thermowell shall be between X to % of the pipe
internal diameter. The immersion length shall be a maximum of 16 inch minimum
9 inches for vessels, unless otherwise limited by calculation requirement
due to fluid velocity.
j. Wake frequency and resonance calculations will be carried out for all
pipemounted thermowell to ensure the selected thermowell are suitable
for the service. Calculations shall be as per ASME PTC 19.3. The design
must verify that each thermowell will resist obstructive vibrations (initiated
by process flow) under the worst condition of process flow.
k. Test wells shall be provided in location where temperatures reading are
required for occasional checking of equipment provided other means
of temperature measurements such as thermocouples, dial thermometers, or
filled system type instrument are not needed for the points in question.
3.3.2 Temperature Sensors

a. Temperature sensors shall be furnished as complete assemblies, including the
measuring elements, terminal heads, and thermowells or protecting tubes.
Elements (bimetal, RTD, thermocouple etc.) shall be spring-loaded type to assure
firmly contact the bottom of the thermowell. Thermal filled system instruments
may be used for special application.
b. Temperature element heads shall be of the corrosion resistant metallic
weatherproof type with a ground lug and heat resistant terminal blocks enclosed.
Terminal blocks shall have proper identification for each element. Connection to the
element assembly shall be W' NPT.

c. Resistance temperature detectors (RTD's) are the standard element for process
temperature measurement. RTD elements shall be platinum with a standard
resistance of 100 ohm at 32 of and shall be in accordance with IEC 751, alpha =
0.00385. Accuracy shall be to IEC 751, Class A or better.
d. RTD elements shall be the 3-wire type and shall be connected to measuring
instruments by three-wire cables. For application where high accuracy is required, 4
wire types of RTD's shall be provided.
e. Thermocouples for general application shall be type "K" chromel-alumel. Other
thermocouple types may be used for extremely high or low temperatures of
special atmospheres. Thermocouples shall be magnesium oxide insulated
sheathed type. The hot junction shall be grounded to the sheath. Thermocouples shall
be constructed with a 316SS or Inconel sheath. The tip of the sensing element
and the thermowell shall have a good thermal contact.
3.3.3 Temperature Gauges
a. Thermometers shall normally be bimetallic hermetically sealed type, adjustable

heads, heavy duty, every- angle with zero calibration adjustment, with minimum 5
inch dial diameter. The steam shall have a Yz" NPT connection. Dials of 3 in
diameter may be used in mechanical equipment, lube and seal oil service or other
auxiliary service.
b. The range of the thermometer shall be selected such that the normal temperature
indication is between one third and two third of full scale.
c. All thermometers shall be tested and oriented such that they are easily visible
from aisles and areaways used in normal operation.
d. Element sheath material shall be 316 SS
e. Case material shall be 304 SS
f. Window material shall be provided with safety laminated glass
3.3.4 Temperature Transmitters

a. Electronic temperature transmitters shall be of the HART protocol digital "smart"
type. They shall be equipped with ambient temperature compensation. Output
shall be configurable as digital or as 4-20 mA DC for 0 -100 percent-calibrated
range. Spans for temperature control shall be as narrow as is consistent with
process requirements. Electronic transmitters shall be furnished in an enclosure
suitable for the electrical area classification. Externally adjustable span and zero
shall be provided.
b. Temperature transmitters shall be used for all temperature signals used for
control or interlocks. Temperature transmitters may be provided as an integral
assembly, complete with local indication, element and thermowell.

3.4 Flow Instruments
3.4.1 General
a. Flow instruments will be specified and selected based on the application with
COMPANY approval and shall be shown in the P&ID's and Datasheets.
b. Ultrasonic flow meter shall be applied to measure flow rate of gas and turbine meter
for liquid fluid.
c. Meter runs for gas measurement shall conform to the recommendations of AGA
Report 9, latest edition and revision.
d. Turbine meters shall meet the requirements of API RP 551, API RP 2534 and
the appropriate chapter(s) of the API MPMS 5 Section 3.
3.4.2 Gas Ultrasonic Flow Meter (USM)

Detailed USM requirement is specified in Gas Metering Specification (PTG-OO-INS-
SPC-009).
3.4.3 Liquid Turbine Meter

a. Mating flanges and internal bore shall be of the same size as the turbine
meter. Gaskets for raised face flanges must have an I.D. }.I inch larger
than normal to prevent extension into the inner periphery of the pipe.
b. Meters shall be flanged same rating per piping specifications.
c. Pipeline strainers (preferably the "grass catcher" type) shall be
installed immediately upstream of the turbine meter run.
d. Turbine meter shall be installed with upstream and downstream requirements
in accordance with the Manufacturer's recommendation.
e. Turbine meter shall meet the requirements of API RP 2534 and API
MPMS 5 Section 3.
f. The pressure drop through turbine meters shall not exceed the
Manufacturer's rating for continuous service.
3.4.4 Coriolis Meter

a. Coriolis meter shall meet the requirements of AGA 11
b. Meters shall be flanged same rating per piping specifications.
c. Coriolis flow meter shall be sized to optimize the meter performance over
the flow rate range with pressure drop that is acceptable for the application.
d. The pressure drop through coriolis meters shall not exceed the
Manufacturer's rating for continuous service.

3.5 Control Valves
3.5.1 General
a. Control valves shall conform to the specifications of the piping to which
they serve, valve trim shall tie 316 SS. Satellite trims shall be specified for
flashing services and for critical pressure drops or erosive conditions.
b. Control valves larger than 1%" shall use flanged connection. Screwed or
welded connection may be used for 1%" valves or smaller if permitted by
Specification for Piping Material Class.
c. Globe body, single port type control valves shall normally be used, other
types like butterfly, ball valves etc. shall be selected as per service and
application.
d. Double port valves may be considered for services where slurry or
hydrocarbon service containing solids in suspension.
e. Control valves shall be 'fail safe' on signal and air supply failure, as indicated on the
P&ID's i.e. Fail Open / Fail Closed. Actuator acting mode (direct or reverse) must
comply with the required fail valve position.
f. Control valve trim characteristic shall be chosen to suit the duty. Valves shall be
selected which achieve flow characteristics within the plug and seat machining, not
by means within the positioner (i.e. Characterized cam)
g. Final selection of valve size shall ensure valves operate between 15-90%
maximum opening, or 60 degree for rotary valves, without any cavitations.
h. Linear characteristics shall normally be used for most level control, slow pressure
control loops (large vapor volume) and loops where the measurement is linear
and the variation in the pressure drops across the valve is small.
i. Equal-percentage trim characteristic shall be used in most throttling applications,
loops that have large variations in valve pressure drops, fast pressure control
loops, and most flow control loops.
j. Cavitation shall be avoided. If it's not possible to avoid cavitation, use of anti-
cavitation trim shall be considered. Prior notice to CLIENT is required.
k. Whenever flashing condition might be occurred and cannot be avoided, in
selecting valves shall consider the usage of hardened-face material for seat, plug,
etc.
l. Valves leakage class shall generally meet the ANSI Class IV, unless otherwise
specified in particular datasheet. Control valves with gas compressor recycle
valves and vent gas services shall meet the ANSI Class V shut-off minimum.
3.5.2 Actuators
a. Air operated spring loaded diaphragm type actuators shall normally be used for all process
control application. Diaphragm housings shall be pressed steel, multiple bolted type.

b. Spring shall be made of steel and finished to resist corrosion from facility atmosphere.
Cadmium-plating is not acceptable.
c. Piston actuators, motor actuators and self-operated regulators may be used for special
applications where spring loaded diaphragm cannot be applied.
d. Actuators shall be adequate to stroke the valve and sized based on the shut-off differential
pressure plus a safety margin for all valves.
3.5.3 Control Valve Size

a. Control valves shall be capable to handle all of the specified process conditions. Valve shall
be sized based on capacity defined in respective datasheet.
b. Valve selection/calculation shall refer to ISA S75.01 or the selected valves' manufacturer
formula to determine the valve's capacity (Cv). The valve's Cv calculation shall be provided
for minimum, normal and maximum flowrate. Valve size shall meet the requirement that its
Cv is equal to or greater than 1.3 times normal/ 1.1 times maximum specified flow rate.
c. For two-phase flow the control valve Cv shall be the summation of the Cv in liquid and vapor
phase. The quantities and physical properties of liquid and vapor should be established
on the outlet conditions of pressure and temperatures.
d. Valve bodies should be the maximum size required for any anticipated operating condition.
Valve trim shall be selected so no more than 80-90% opens at maximum flow, and at
least 15 - 20% opens at minimum flow. In order to handle changes to production rate over the
file of facility, valve bodies shall be selected, in so far as is practically and technically possible,
to allow an increase in flow rate by 50% or a decrease in flow rate 50% by changing the valve
trim.
e. Minimum size shall be 1" ANSI 150# RF. 2%" and 5" sizes shall not be used.
3.5.4 Valve Positioner

Current pneumatic converters shall be integrated with positioner, output signal 4-20 mA
DC, smart "HART" Type Protocol.
3.5.5 Pneumatic Amplifier (Boosters)

Pneumatic amplifiers (boosters) shall be used when:
 The pneumatic transmission distance is 300 feet or more.
 The control valve requires a large diaphragm operator.
 The speed of response would otherwise be slow.
3.5.6 Self Actuated Control Valves

Self-actuated control valves shall be usually limited to a maximum valve size of 4
inches. For regulated pressure less than 10 psig, a packless valve shall be used if
applicable.

Self-actuated valves may be used for services where a variation of 10 percent above or
below the set point can tolerated.
3.5.7 Control Valve Arrangements

a. Control valves shall be installed in accordance with ISA RP 4.2.
b. Isolation valves shall be provided upstream and downstream of control valves
with %" drain valve.
c. Control Valve manual bypass shall be provided for each installation.
d. Bypass valves shall have the same capacity to control flow rate as the control valve,
unless a larger size is required for start up or other reasons.
e. Minimum stops, where required, shall be jackscrew type (without handwheel) on the
diaphragm assembly or the adjustable type mounted on the bottom flange.
Handwheel shall not be used as travel stops
f. All control valves shall have stem travel indicator. The stem or shaft shall be
designed so that if failure of the stem-to closure member (e.g. ball, disc) or shaft- to-
closure member connection or internal failure of the stem/shaft occurs, no
portion of stem or shaft can be ejected from the valve as a result of internal
pressure.
3.5.8 Control Valve Noise

The control valve noise level shall be limited to 85 dBA at the distance 1 m from the
valve or in acceptance with "Noise Level in residential and plant area" on a case by
case basis. If the noise level exceeds the 85 dBA limit, it shall be reduced by the use of
special trim on a standard valve or by the use of a special control valve designed for the
service and noise attenuation. In-line silencers may be considered.
The preferred method is with valve selection rather than flow path treatment.
3.6 Shutdown I Slowdown Valves

a. Shutdown / Blowdown valves shall generally be reduced-ball valve type and shall be
certified to be fire sale as per API Spec 6FA or API 607. Full-bore ball valve shall be
provided on pigable line and/or it defined in Piping & Instrumentation Diagram
(P&ID).
b. Shutdown valves shall operate in fail safe mode.
c. Actuators (Piston Operated) shall preferably be pneumatic spring return
CLIENT approval shall be obtained for use of hydraulic, electric or other type.
d. Actuators shall be sized such that they are capable of opening and closing
the valve at shut-off differential pressure across the valve, with minimum safety
factor of 1.25 at minimum supply pressure.
e. Valve operating time shall be 1 second per inch of valve nominal diameter
to achieve the fail sale position, and 2 seconds per inch of valve nominal
diameter to achieve nominal operating position or as required by process
condition. Maximum closing time shall not exceed 45 seconds. Maximum
opening time for BDV's shall be 10 seconds upon receiving commands.

f. Stroking speed of the valves shall tie adjustable with the help of a speed
controlfacility (quick exhaust vent / bleed devices).
g. Shutdown/blow-down valves shall be fitted with limit (position of travel)
switches to indicate the valve open/close status as indicated on the P&ID's.
Limit switches shall be of proximity contact/sensor type. Explosion proof or
hermetically sealed housing shall be provided in hazardous classified area.
Limit switches shall be equipped with beacon (Red Closed & Green Open).
Beacon shall be labelled to indicate the valve position.
h. Materials requirement shall conform to Purchase Specification, Data
sheets & Piping Specification.
i. All Shutdown / Blow-down valves shall be fitted with solenoid valves, which
vent the pressure upon de-energized.
j. In accordance with safety requirements as indicated on the P&ID's.
the Shutdown/Blow-down valves shall be designed to "Fail Open", "Fail
Closed" or "Fail in the last position"
k. Flow direction shall be permanently marked on the body.
l. There shall be an interface to HMI for monitoring transition status of
valves as indicated on the P&IDs.
m. ESD shall provide all the Shutdown commands and permissive with status
being displayed on the PCS console.
n. Shutdown/isolating valves installed in pipeline(s) shall be designed and
comply with pipeline specification document
o. Partial Stroke device shall be provided when indicated in datasheet.
3.7 Time Switching Valves

a. Timed switching valves shall be of On -Off valve type with Quarter-turn
operation. The control of valves operation will be from PCS.
b. Timed switching valves shall be fitted with 2 each of solenoid valves, each
for "Open" and "Close" command function.
c. Timed Switching Valves shall have following characteristic:
 Non- contact during the ball stroking

 Single seated design
 Split body and trunnion mounted design
 Tight Shut Off or Zero Leakage
 Testing conform to API 598 or API 60
 Fire safe design to API 607
 Material Selection shall meet High Temperature Design
d. Fail safe position of Timed Switching Valves shall be as indicated in the P&ID's.
e. The actuator shall be designed with adequate safety factor so it can allow
the valves strokes Open and Close to the required stroking time.
f. All control accessories shall refer to particular datasheet.

3.8 Pressure Relieving Devices
3.8.1 General
a. All pressure relieving devices shall be sized in strict accordance with applicable
local, state, and national code requirements. Safety relief valves shall be sized
by calculating ASME areas required for the most severe relieving case and
shall follow the ASME requirements. Nomenclature and formulas used shall be
according on API RP 520. Generally, valve selection and installation shall
be based on API RP 520, part I and part II. Closed relief valve discharge
systems shall be designed in accordance with API RP 521.
b. All relief valves shall have ample capacity for relief requirements due to
thermal expansion or fire exposure. If equipment is provided with two relief valves,
their combined capacity may be used to meet the requirements for fire
exposure.
c. Each PSV shall contain an ASME Section VIII code stamp for use on
pressure vessels.
3.8.2 Thermal Relief System

a. Thermal relief valves shall be installed on piping systems that may be "blocked
in" where ambient temperature rise may cause overpressure of the piping
system due to thermal expansion.
b. In general, thermal relief valves shall be 3/4" x 1", screwed or flanged bodies,
with the set pressure equal to the design pressure of the piping system.
c. Thermal relief valves on hydrocarbon liquid service shall have the
discharge piping connected to a drain system carrying the discharge to an oil sump,
storage tank, or to a suitable lower Pressure Compatible System.
3.8.3 Pressure Relief Valves

a. Relief valves shall be manufacturer's standard type. The valve material
shall conform to the manufacturer's material recommendations. Safety and
relief valve bodies shall be carbon steel unless process conditions dictate
otherwise. Material for internal parts shall be suitable for the temperature
and service. Nozzle and disc material shall be minimum 316 SS unless
otherwise required by the service condition.
b. Relief valve connection shall be flanged inlet and outlet connection for valve
size 1%" and larger. Screwed connection shall be furnished for valves 1
inch and smaller, unless process or operating condition does not allow it.
c. Safety and relief valves shall generally conform to API Standard 526,
"Flanged Steel Safety Relief Valves"
d. Plain lifting liner shall be furnished for safety relief valves in steam and air
service.

e. Pressure relief valves shall be leak tested at specified percent of set pressure
in accordance with API-RP-527.
f. The following guidelines shall be observed for Conventional, Bellows and
Pilot Operated PSV's.
Table 3.8.3. Conventional, Bellows, and Pilot Operated PSV
Built up Back Built up Back Built up Back

Pressure Of Pressure Of Pressure Of
Less than More than More than Two phases Liquid Flow
Type 10% of set 10% 50% Flow PSVs PSVs
pressure and less than and less than
50% of set 90% of set
pressure pressure
Conventional acceptable not not acceptable acceptable
acceptable acceptable
Balanced acceptable acceptable acceptable acceptable acceptable
Bellows
Pilot acceptable acceptable acceptable acceptable acceptable
operated
3.9 Instrument Switches
3.9.1 Electric Switches

a. Switches shall be dry type, two (2) Single Pole Double Throw (SPOT) or Double Pole
Double Throw (DPDT) as specified in the data sheet
b. Enclosures shall be suitable for the electrical area classification. Hermetically
sealed electrical switches shall be provided for all electrical switches used in
classified areas.
c. Switches shall not control the final control element directly; an interfacing
controller shall be used for this purpose.
d. Switches shall have adjustable ranges with the adjustment located externally.
3.9.2 Pneumatic Switches

a. Switches shall be block and bleed relay valve configuration. Continuous bleed type
shall not be used. Switch shall block supply and bleed signal on abnormal condition.
When actuated, the supply port shall close and the control port open to the vent port.
b. Enclosures shall be watertight and weatherproof.
c. Switches shall have adjustable ranges with the adjustment located externally.
3.10 Solenoid Valves

a. Solenoid valves shall be selected for individual applications, which are 2-way, 3-
way, or 4-way as required.
b. Valve bodies shall be constructed of 316 SS Ion all applications.

c. Solenoid internal parts in contact with controlled media shall be stainless

steel. Valve seats shall be Buna "N" or equivalent for light shut-off.
d. Solenoid enclosures shall meet the requirements of the electrical
area classification.
e. Solenoid coils shall be of the molded type, moisture and fungus proof Class
H.
f. Operating voltages shall be 24 VDC; power consumption shall be maximum
10 watt. Alternate voltage ratings may be employed only with the express
approval of the CLIENT.
3.11 Metering System

The scope of supply of Metering System shall be included but not be limited
to the design, supply, fabrication, testing, delivery, supervision of
installation, and commissioning, provision documentation and manuals and
training of operations and maintenance personnel on the metering systems.
3.12 Instrument Tubing and Piping
3.12.1 General
a. Tubing shall be purchased in standard 20- foot lengths (joints),
b. All pipes shall be run in either horizontal or vertical plane. Traps and pockets
shall be prevented on process lines or drain valves shall be provided in the
low point and venting valves in the high point.
c. Tubing runs shall be grouped together where possible.
d. Plugs shall be bar stock with hex heads.
e. Tubing installation shall be neat, plumb, parallel, properly supported and
exhibit a professional workmanship.
f. Tubing shall be routed so as to allow easy accessibility to instruments for
routine maintenance with minimum tubing removal.
g. All pipe fittings shall be SS 316 with NPT thread connection.
3.12.2 Size and Material

a. Tubing
Table 3.12.2 Tubing size and material
Service Size
Material
Pneumatic 3/8" x 0.035 W.T. 316 SS min. Seamless
ESD system
Air Supply 3/8" x 0.035 W.T. 316 SS min. Seamless
Pneumatic 1/4" x 0.035 W.T. 316 SS min. Seamless

Control
Sensing lines 1/2" x 0.049 W.T. 316 SS min. Seamless
1/4" x 0.049" W.T. (max. 5750 psi)
Hydraulic 3/8" x 0.065" W.T. (max. 5000 psi)
1/2" x 0.083" W.T. (max. 4800 psi) 316 SS min. Seamless
b. Valves connected to SIS tubing shall be SIS bar stock ball valves.
c. Tubing I fitting I connectors I valves material shall be 316 SS as minimum. Higher
grade shall be provided in accordance with process I piping requirements.
3.12.3 Air Supply Connections

Distribution system shall easily permit future modifications and distribution even if a
part of the plant is stopped.
Except for main feeder, the instrument air or gas sub headers should have the same
routing and supports as the instrument cables routing.
Future take off points fitted with valves shall be installed on 1he main header.
Branching on mains feeders on racks shall be 1" minimum size. Branching on

secondary headers shall be Yz" minimum size.
All branching shall be taken al the upper part of the header and shall be isolated by
gate or globe valves.
Low points shall have a W' isolation valve installed as a drain and blowdown point.
Valves shall be accessible from platforms or decks without use of ladders or other
equipment.
Size of piping for supply headers and branch lines shall conform to the following rule of
thumb:
 Yz" for up to 5 distributed points

 1" for up 6 to 20 distributed points
 1%" for 21 to 50 distributed points
 2" for 51 to 100 distributed points
 3" for 101 to 300 distributed points
Pipe branch lines shall terminate no more than 36 inches from each high volume
instrument with a y," valve. The remainder shall be % inch tubing installed with sufficient
flexibility to allow for normal equipment movement and to isolate against vibration.
Manufacturers or fabricators supplying "skid" equipment or vessels, which incorporate
instrumentation requiring pneumatic supply, shall install a supply header on the skid.
The skid supply header shall terminate at the skid boundary with isolating ball valves.

The location and sized supply connection shall be noted on submitted VENDOR
approval piping drawings.
Local panels containing pneumatic instrumentation shall be provided with a common
dual filter / pressure regulator / pressure gauge assembly.
Filter regulator, fitted with pressure gauge, shall be installed for each air/gas pneumatic
instrument supply. The filter shall feature a manual drain water removal facility. Oil mist
lubricators shall only be used if specified by the VENDOR. Air set shall be SS 316.
Individual instrument air tubing, fittings, and accessories installed downstream of the
filter pressure regulator shall have the following characteristics:
Material : SS 316 for tubing and fittings

Size : %" 00 x 0.0355" WT for air supply
X" 00 x 0.035" WT for Signals
3.12.4 Pneumatic Control Connections

Signal transmission and Instrument air supply shall be through X-inch O.D.and %-inch
0.0., respectively.
Tubing, fitting, connectors and valves material shall be 316 SS as a minimum.
3.12.5 Miscellaneous Connection Sizes and Types

All instrumentation connection sizes end types shall be designed and installed in
accordance with applicable project piping and vessel specification. Where
possible, vessel connections with a minimum of 2" ANSI flanges shall be used.
When an instrument is connected to the process by means of flanges, those
flanges shall be ANS150# RF rated as a minimum.
Following table shall be used as general instrument tapping connection size:
Table 3.12.5. Instrument tapping connection size

Instrument Type Connection Connection Vent. And
to
Equipment
Vessels Pipe Tank To Instrument drain
Thermowells 2"flanged 1 X" flanged 2" flanged X" NPT
Local pressure 2"flanged %"NPT 2" flanged y," NPT
indicator
Pressure transmitter 2"flanged %"NPT 2" flanged y," NPT
dIp cell (pressure) 2"flanged WNPT 2" flanged y," NPT
dIp cell level 2"flanged - 2" flanged
Level gauge glass 2"flanged - 2" flanged

Level switch/ 2"flanged - 2" flanged

transm itter (side)
Level switch/ 4"flanged - 4" flanged 4" flanged -
transm itter (top)
Turbine/Ultrasonic - Depending - - -
meter on piping
class and
diameter
Flow dIp cell (up to - y," NPT - X" NPT y," NPT
600#)
Flow dIp cell (up to - WNPT - y," NPT y,"NPT
900#)
4. GROUNDING SYSTEM
The grounding principles to be used for the field instrumentation, control and safety
systems, the telemetry system, and the telecommunications to ensure adequate
protection to both personnel and equipment. Two (2) grounding systems shall be used.
PE : Protective Earth System (Dirty)

IE : Instrument Earth System (Clean Instrument Ground)
4.1 Protective Earth (PE)

The PE is used to protect the electrical power system, electrical equipment and to
protect personnel from electric shock. The PE is used only for instrumentation
equipment, telecommunication equipment and control systems. All instrument and
telecommunication metallic enclosures, equipment, instrument and telecoms cable
armour shall be connected to the PE.
In the field, PE dispatchers / bus bar shall be installed to collect the screen shields of the
instruments and telecommunication equipment. These bonding shall be performed by
using PVC insulated copper conductors, green and yellow colored with a minimum of 6
rnrn" cross section. They shall be mounted on insulators with a minimum distance of 1
inch from the structure.
The field PE dispatches shall be connected to the closest PE connection by using PVC
insulated stranded copper conductor, green and yellow colored with a 35 rnrn"
minimum cross section.
For typical field instruments, grounding continuity between armour and instrument
casing by using a metallic cable gland shall be provided. The field instrument casing
bonding to PE dispatches shall be done through the ground lug. For field instrument

with non-metallic enclosures, an earth lag will be fitted to the cable gland to ensure a
proper bonding to the PE.
Grounding shall generally be in accordance with the equipments of NEC (National
Electric Code) Article 250 in NFPA (National Fire Protection Association) 70.
If the junction box is metallic, no PE grounding plate is required end the cable armour
shall be grounded through the cable gland to the junction box wall which shall be
bonded to the field PE.
Every marshalling / equipment cabinet in the technical rooms shall be fitted with a PE
bus bar mounted on insulated blocks. The instrument cable armour of incoming and
outgoing cables, together with equipment cases, shall be connected to this bus bar.
The cabinet steel frame shall be grounded on the electrical PE bus bar.
Each cabinet PE bus bar shall be connected to the PE loop in the technical room by a
35 mm2 cable. This PE loop shall be 70 mrn" yellow / green cable connected to the
main PG bus bar.
The control cabinets and desks shall be connected to the PE in the same way as the
marshalling cabinets. Where enclosures have hinged doors, the doors shall be bonded
to the main enclosure with flexible earth straps.
4.2 Instrument Earth

The IE is the final reference point for all digital, telecoms and measurement signals.
All instruments and telecoms cable individual screens and overall screens are
connected to this point through multi-pair cables screens. This includes the external
shield of the Digital Communication Network cable in order to eliminate excess noise.
For field instruments, the screens are insulated from ground at the field end. For junction
boxes dedicated to measurement signals, screen wires shall be connected to dedicated
screen terminals. Screen continuity shall be maintained UP to the technical room.
For junction boxes dedicated to digital signals, screen wires shall be connected to an
IE bus bar mounted on insulated blocks.
Marshalling I Equipment Cabinets in the technical room shall be fitted with one IE bus bar
mounted on insulated blocks. Total resistance of this earth loop i.e. the IE bus bar
(cabinet) to the actual earth electrode shall not exceed 1 ohm.
The IE bus bar is mounted on insulated blocks and connected to the IE loop by a 0.06

sq.in (or # 2 AWG) cable. The IE loop shall be a 0.1 sq.in (or # 2/0 AMG) green cable
connected to the main Galvanized Steel IE bus bar.
This main bus bar shall then be bonded to the main structure with a PVC insulated cable,
green coloured with a # 2/0 AWG minimum cross section.
4.3 Intrinsically Safe Earth

The ISE is the reference point for all shunt-diode safely barriers which require a high
integrity ground. Use of shunt diode safely barriers shall be allowed only if galvanic
isolators which do not require high integrity ground.
5. SURGE PROTECTION SYSTEM

Lightning surge protection for instrumentation system shall be provided on:
 Electronic type transmitters I switches.
 Lightning surge protection shall be furnished by every electric I electronic type field
instruments, such as transmitters, switches, transducers include liP, detectors.
 Instrument data sheets shall clearly specify this requirement.
 Field instrument's pipe support shall be properly grounded.
 Lightning surge protection system shall withstand lightning surge current in excess of 10 kA.
6. EQUIPMENT AND MATERIAL IDENTIFICATION

All equipment and accessories shall be clearly and permanently identified by phenolic
or stainless steel nameplates and traffolyte label.
Nameplates shall be permanently attached using stainless screws or rivets. Adhesives
shall not be used.
Nameplates for field mounted equipment shall be 316 stainless steel plates. The
instrument tags shall be a minimum of 25.4 mm (1 inch) by 50.8 mm (2 inch).
Panel mounded equipment shall be provided with phenolic or stainless steel
nameplates.
Instrument equipment shall be white background black lettered phenolic, stainless steel
nameplate, or traffolyte label.
Fire and gas equipment shall be Red lettering on white background phenolic or
Stainless steel with engraving or die stamps lettering at least 13 mm (1/2 in) high
mounted with SS screws or bolts.
Nameplates shall be in English. Engraving or die stamps lettering at least 6.35 mm (1/4
in) high capital minimum.
The following information, as applicable, shall be shown on the nameplate, as a
minimum:

 Tag Number
 Service
 Manufacturer
 Model and Type
 Serial Number
Spare parts and special tools shall be clearly identified; either stamped of tagged, with
the Manufacturer's part numbers as referenced on the parts and special tools lists.
7. PREPARATION FOR SHIPMENT

a. Equipment shall be prepared for export shipment and shall be packed in a
manner to provide maximum protection during shipment and extended outdoor
storage. All exposed machined surfaces shall be protected by means of easily
removable rust preventives.
b. None of the equipment specified herein shall be prepared for shipment or shipped
before CLIENT has either inspected the equipment or waived inspection in
writing.
c. All openings shall be provided with substantial wood, plastic or metal closures. All
tapped openings, not otherwise closed shall be plugged.
d. Major equipment components shall be securely bolted to substantial skids for
shipment. Small and easily damaged parts shall be removed, tagged with the
description of the major item to which it belongs, and adequately protected during
shipment.
e. Tools and spare parts shall be packed in metal boxes suitable for long term
storage. The boxes shall be galvanized or coated.
8. PRESERVATION AND STORAGE OF INSTRUMENT EQUIPMENT

After delivery and identification on site, all instrumentation equipment and associated
installation equipment shall be stored in dedicated instrumentation warehouse with
adequate environmental conditions including HVAC as necessary. In particular, any
electronic equipment shall be protected against humidity, high temperature and dust.
Instruments shall generally be stored in their original packing. The instruments shall be
stored and handled with the greatest care.
The flanges and other connections shall remain as long protected as possible.
Special care shall be taken to prevent foreign materials (sand, dust, water, etc.) from
entering the instruments during shipping/storage.
When the instruments are temporarily removed from the warehouse, they shall be

returned to the warehouse in their original ticking.
The installation equipment shall be dedicated to instrumentation installation and shall

not be assigned to other use.
All instruments shall be adequately preserved once permanently installed on site.
The instrument cables shall be delivered and stored on drums. Drums shall be stoned on
a plain surface with one layer of drum only, without risk of mechanical damage.
9. SPARE PARTS AND SERVICES

VENDOR shall submit the list and include the price of the Construction, Commissioning
and Start-up Spare Parts on their Quotation for CONTRACTOR review.
VENDOR shall submit a list of Two Years Spare Parts on their quotation for
CONTRACTOR review. Upon receipt of CLIENT'S instruction, CONTRACTOR will
issue a separate Purchase Order for the Two Years Spare Parts.
When requested, VENDOR shall provide its qualified personnel to support
CLIENT/CONTRACTOR during Commissioning phase estimate the required man-day
to conduct this service.
10. GUARANTEE
Material and equipment shall be guaranteed by VENDOR/MANUFACTURER to
perform in accordance with specification requirements and to be free of defects and
poor workmanship including, but not limited to, those caused by inadequate
preparation for shipment for a period of one (1) year after material and equipment is
placed in service, but not exceeding eighteen (18) months following delivery to the
contracted destination.

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CONTRACT NO.

A 18/05/2022 Issued For Review SW ASW EFC

Document No. Rev. INSTRUMENT DESIGN AND Date: 13/05/2022

TABULATION OF REVISION SHEET

Document No. Rev. INSTRUMENT DESIGN AND Date: 13/05/2022

Document No. Rev. INSTRUMENT DESIGN AND Date: 13/05/2022

1.1 General .............................................................................................................. 6

1.2 Scope ................................................................................................................. 6

1.3 Definitions ......................................................................................................... 7

1.4 References, Codes and Standards .................................................................. 7

1.6 References Document ..................................................................................... 8

2. GENERAL REQUIREMENTS ...................................................................................... 10

2.1 Layoutand Buildings ...................................................................................... 13

2.2 Instrument Symbols and Identification ......................................................... 13

2.3 Units and Scales ............................................................................................. 13

2.4 Environmental Protection .............................................................................. 14

2.5 Tropic Proofing Requirements....................................................................... 15

2.6 Certification of Electronic Equipment in Hazardous Area ........................... 15

2.7 Interference ..................................................................................................... 15

2.8 Instrument Passive Protection Against Fire ................................................. 16

2.9 Power Supply and Instrument Air System .................................................... 16

2.10 Instrument Accessibility................................................................................. 18

2.11 Loop Checking ............................................................................................... 19

Document No. Rev. INSTRUMENT DESIGN AND Date: 13/05/2022

2.12 Inspection, Calibration, and Test Reports .............................................. 20

3.1 Pressure Instrument ....................................................................................... 20

3.2 Level Instruments .......................................................................................... 22

3.3 TemperatureInstruments ................................................................................ 23

3.4 Flow Instruments ............................................................................................ 26

3.5 Control Valves ................................................................................................. 27

3.6 Shutdown I Slowdown Valves ........................................................................ 29

3.7 Time Switching Valves ................................................................................... 30

3.8 Pressure Relieving Devices ........................................................................... 31

Document No. Rev. INSTRUMENT DESIGN AND Date: 13/05/2022

3.9 Instrument Switches ....................................................................................... 32

3.10 Solenoid Valves ............................................................................................. 32

3.11 Metering System ............................................................................................. 33

3.12 Instrument Tubing and Piping ....................................................................... 33

4. GROUNDING SYSTEM ........................................................................................... 36

4.1 Protective Earth (PE) ...................................................................................... 36

4.2 Instrument Earth ............................................................................................. 37

4.3 Intrinsically Safe Earth ................................................................................... 38

5. SURGE PROTECTION SYSTEM ................................................................................. 38

6. EQUIPMENT AND MATERIAL IDENTIFICATION ...................................................... 38

7. PREPARATION FOR SHIPMENT ............................................................................... 39

8. PRESERVATION AND STORAGE OF INSTRUMENT EQUIPMENT ......................... 39

9. SPARE PARTS AND SERVICES ................................................................................ 40

Document No. Rev. INSTRUMENT DESIGN AND Date: 13/05/2022

The Onshore Pipeline Senipah – RU V Balikpapan scope will comprise of development of

Figure 1.1 - Pipeline from Senipah to Refinery Unit (RU) V Balikpapan

Document No. Rev. INSTRUMENT DESIGN AND Date: 13/05/2022

Table 1.3 List of Difinitions

1.4 References, Codes and Standards

Document No. Rev. INSTRUMENT DESIGN AND Date: 13/05/2022

IER Instrument Equipment Room

1.6 References Document

1.6.1 Indonesia laws and codes

and Natural Gas

1.6.2 International Standard and Codes