GENERAL INSTRUMENT SPECIFICATION
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1. GENERAL
The purpose of this document is outlines requirements and recommendations to be used by
Contractor to perform works during engineering stage, construction, until start-up of project.
The following applicable section of the latest edition of the Code and Standards, including
addenda, referenced documents and project documents shall form an integral part of this
specification. Where the requirement of the subject is defined by two or more references, the
more stringent reference shall govern.
2. CODES, STANDARDS AND REFERENCES
The reference documents, which are applied as a part of the instrument engineering requirement,
and shall be selected from the list documents standard:
International Electrotechnical Commission (IEC)
IEC 60079 – parts 0 to 14 Electrical apparatus for explosive air atmospheres
IEC 60364 Electrical installations of buildings
IEC 60529 Degrees of protection provided by enclosures (IP code)
IEC 61508 – part 1 to 6 Functional safety of electrical/electronic/programmable
electronic safety-related systems
IEC 61511 Functional safety - Safety instrumented systems for the process
industry sector
IEC 60228 Conductors of insulated cables
IEC 60502-1 Power Cable with Extruded Insulation and Their Accessories
from 1 kv up to 30 kv - Part.1 Cables for Rated Voltage 1 kv and
3 kv
IEC 60332 Tests on electric and optical fibre cables under fire conditions
IEC 60331 Tests for electric cables under fire conditions – Circuit integrity
American Petroleum Institute (API)
API RP 520 Sizing, Selection and Installation of Pressure-relieving Device
in Refineries
API RP 521 Guide for Pressure-relieving and Depressurizing Systems
API Std 526 Flanged Steel Pressure Relief Valves
API Std 527 Seat Tightness of Pressure Relief Valves
API RP 551 Process Measurement Instrumentation
API RP 552 Transmission Systems
API RP 554 Process Instrumentation and Control
API 598 Valve Inspection and Testing
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API RP 505 Classified of Locations for Electrical Installations at Petroleum
Facilities Classified as Class I, Zone 0, Zone 1, and Zone 2
Instrument Society of American
ISA S 20 Specification forms for process measurement and control
instruments
ISA 5.1 Instrumentation symbols and identification
ISA S 5.4 Instrumentation loop diagrams
ISA S 75.01 Flow equation for sizing control valves
ISA S 75.19 Hydrostatic testing of control valves
ISA 84.01 Application of Safety Instrumented System for the Process
Industries
American Society of Mechanical Engineers (ASME)
ASME B 16.36 Steel orifice flanges
ASME B16.5 Pipe Flanges and Flanged Fittings
3. DESIGN CONSIDERATIONS
The instrumentation for measurement and control shall be designed such that optimum
operation of the process concerned can be realized at minimum operation and maintenance
cost. The instrumentation and the installation methods shall further be designed for ease of
operation, maximum simplicity, reliability and minimum maintenance. Direct connections
between process fluids and the control room are not carried out.
4. AREA CLASSIFICATION & PROTECTION
Area Classification is based on the probability that flammable air or vapor, possible sources of
release include vents, flanges, control valve, drain, pump & compressor seals, fittings and
floating in roof seals.
Area classification is a method of analyzing and classifying the environment where explosive air
atmospheres may occur to allow the proper selection of equipment, particularly electrical
equipment, to be installed in that environment.
The object of the classification procedure is to enable the equipment to be operated safely in
these environments.
4.1 Class I, Zone 1
Class I, Zone 1 location is the following locations: In which ignitable concentrations of
flammable airs or vapors are likely to exist under normal operating conditions. Ignitable
concentrations of flammable airs or vapors may exist frequently because of repair or
maintenance operations or of leakage. In which equipment is operated or processes are
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came on, of such a nature that equipment breakdown or faulty operations could result in the
release of ignitable concentrations of flammable airs or vapors and also cause simultaneous
failure of electrical equipment in a mode to cause the electrical equipment to become a
source of ignition. That is adjacent to a Class I, Zone 0 locations from which ignitable
concentrations of vapors could be communicated, unless communication is prevented by
adequate positive pressure ventilation from a source of clean air and effective safeguards
against ventilation failure are provided.
4.2 Class I, Zone 2
Class I, Zone 2 location is the following locations:
• In which ignitable concentrations of flammable airs or vapors are not likely to occur
in normal peration and if they do occur will exist only for a short period.
• In which volatile flammable liquids, flammable airs, or flammable vapors are handled.
• Processed, or used, but in which the liquids, airs, or vapors normally are confined
within closed containers of closed systems from which they can escape, only as a
result of accidental rupture or breakdown of the containers or system, or as the result
of the abnormal operation of the equipment with which the liquids or airs are handled,
processed, or used.
• In which ignitable concentrations of flammable airs or vapors normally are prevented
by positive mechanical ventilation, but which may become hazardous as a result of
failure or abnormal operation of the ventilation equipment.
• Adjacent to a Class I, Zone 1 location, from which ignitable concentrations of
flammable airs or vapors could be communicated, unless such communication is
prevented by adequate positive-pressure ventilation from a source of clean air, and
effective safeguards against ventilation failure are provided.
4.3 Unclassified Area
Areas which beyond the Class 1, Zone 1 or 2 boundaries which means no flammable air or
vapors appears. This also stated as non-hazardous area
4.4 Enclosure Protection
The protection of instrument shall as follow:
• Panel enclosure for outdoor min. IP55 or higher
• Electronic device housing for outdoor min. IP65 or higher
• Flameproof (Ex’d’) for electrical items with active components inside the enclosure
such as breaker, etc. which potentially ignite flame or explosion
• Increased Safety (Ex’e’) for electrical items with potentially spark such as terminal
block, etc. (without active components)
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5. FIELD INSTRUMENT DESIGN AND SELECTION REQUIREMENTS
5.1 Pressure Instruments
1. Unless otherwise specified, all pressure instruments shall have block and bleed
isolation valve arrangements between them and the process block valves. Shutoff
and bleed valves shall be provided for each instrument from the process connection.
Each pressure instrument shall have a 1/2 inch, two way valve manifold for the
instrument.
2. All pressure measuring devices shall have 316 SS wetted parts, unless special
materials are required by the process. All devices shall be capable of withstanding
the design pressure extremes of the process with no loss of calibration and shall
normally operate at 1/4 to 3/4 of full scale.
3. Indicating, pilot operated pressure controllers shall be used for applications where
transmission to remote receivers is not required. The pressure sensing element and
controller shall be mounted in a weatherproof case or housing suitable for valve or
remote mounting. Controllers shall have a minimum of proportional and integral band
adjustment. Direct connected pressure gages shall be piped in parallel for local
indication.
4. Accessories for pressure instruments shall normally comply with the following:
Diaphragm seals shall be specified in services containing toxic, corrosive, slurry,
viscous, or auto-ignitable materials; they are to be mounted on the instrument. The
bottom section will be removable for cleaning. The entire system above the
diaphragm, including the element, is to be evacuated and entirely filled with an inert
liquid. Pressure elements with diaphragm seal are to have capillary bleeders. A
flanged 2 inch for vessel connection and 3/4” flanged for process connection on piping
shall normally be provided on the seal. Siphons are to be ½” seamless, schedule 80,
pipe, material suitable for process conditions and piping specifications. They may be
either the pigtail or pipe coil type. Siphons shall be used on hot condensable vapor
services where the instrument is close coupled and/or mounted above the tapping
point. Pulsation dampeners shall be furnished for all instruments and gauges on the
discharge of reciprocating pumps, and on the suction and discharge of compressors
and other pulsating service. They shall be ½” NPT female connections and be
externally adjustable. Dampener material shall be 316 SS, as minimum. Where the
possibility exists for the operating pressure to rise above the maximum working
pressure of the instrument, gauge savers shall be used.
6. VALVE
6.1 Safety Valve
1. All pressure relieving devices shall be sized in strict accordance with applicable government
and code requirements. MIGAS Certification is required.
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2. Pressure safety valves for unfired equipment shall be sized in accordance with API RP 520
and the ASME Pressure Vessel Code, Section VIII.
3. Rupture Discs may be used instead of or in combination with safety and relief valves where
applicable or required. When rupture discs are used in combination with relief valves, they
shall be purchased as a system with the relief valve.
4. The relief pressure shall be no greater than 125% of the maximum operating pressure of
the vessel or pipe or less if required by any Codes.
5. Material selection shall according to API 526
6. Percent accumulation used in calculating sizes of relieving devices shall be as follows:
3% : Steam service according to ASME Code, Section 1.
10% : Gas or vapor service and liquids except as noted below.
: Liquids - for thermal relief of pipelines and pump discharges, if code
stamped valves are not required in all services
16% : Vessels protected by multiple valves according to ASME Code,
Section VIII. However, one valve must be set at or below the MAWP
(Maximum Allowable Working Pressure) and the additional devices
may be set to open at higher pressure, but not exceeding 105 percent
of MAWP.
21% : Vapor and liquid service in areas governed by fire conditions according
to ASME Code, Section VIII.
7. Safety and relief valves shall normally be direct spring loaded. Balanced bellows valves
shall be considered for closed flare and blow-down systems or elsewhere if back pressure
may be present. Pilot operated valves shall be considered if operating pressures are close
to set pressures. Other types of valves may be considered for special applications.
8. Back pressure percentage of set pressure is affect in PSV choice wheter spring loaded
(conventional and balance bellow), or pilot types. Back pressure less than 10% could
accommodated by conventional spring-loaded PSV. Back pressure not more than 50%
could be accommodated by bellow balance PSV. On other hand, back pressure cannot
affect pilot types PSV due to open or close of PSV’s outlet is by dome or pilot. The
advantage of pilot types allows the system to operate close to set pressure.
9. Connection sizes and ratings shall normally be as follows:
• Flanged connections shall normally be furnished on all safety and relief valves 1 inch
and larger. The minimum rating shall be ANSI 150 class. Valve flanges shall match the
rating and facing of mating flanges on vessels or piping. Body flanges shall be per ANSI
B16.5.
• Screwed connections may be furnished on valves NPS ¾-inch and smaller, unless
process or operating conditions do not allow. Threaded connections shall be per ANSI
B2.1.
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10. Steel bodies with stainless steel trim shall normally be specified. Alloy bodies or special
materials shall be specified where required because of process, atmospheric or operating
conditions. It shall refer to API 526
11. When ASME code stamp relief valves (relief valves to which the code symbol is applied)
are required, they shall be fabricated by a manufacturer who is in possession of a code
symbol stamp and a valid Certificate of Authorization from the ASME Boiler and Pressure
Vessel Committee.
12. Full nozzle valves shall normally be specified for NPS 1 inch and larger.
6.2 Deluge Valve
Deluge Valve shall be suitable to comply with IEC 61508 / 61511 standard related with Safety
Instrumented Level (SIL). SIL shall be determined according to design and plant requirement.
Deluge valve shall rapidly to open when the system detect fire. Deluge valve shall be electro-
hydraulic type. Solenoid valve is applied with 24 VDC system to switches deluge valve in
open position, therefore water flowing from the main chamber. When the deluge valve is
installed in hazardous area, the electric part of valve system shall be flameproof type Ex’d’.
Deluge valve shall consist of accessories such as pressure gauge and other trim material
that connected into system of the deluge valve. Unless mentioned as specific material, the
trim material shall be 316SS. Deluge valve shall provide manual reset.
7. CABLING SYSTEM
7.1 General
All cables shall comply with the relevant applicable IEC recommendations and with the
regulation of the country of installation. Cables installed within control room or technical
rooms shall be unarmoured. Cables used for external installation shall be armoured. Cables
routed between technical rooms, control room and field shall be armoured. In general, cable
outer sheath shall be low smoke zero halogen, flame retardant type in accordance with IEC
60332-3-22. Fire resistant cables according to IEC 60331 shall be used for:
• Cables for safety related system.
• Cables for all fire and gas system circuits.
• Cables for energised to trip safety system circuits (e.g. inergen,CO2, water mist
solenoid valves, audible and visual alarms, status panels, line monitored loops such
as ESD push buttons,etc).
All other cables shall be flame-retardant as per IEC 60332 as a minimum equirement.
7.2 Voltage Grade
The insulation grade shall be as follows.
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• 300/500 V for analogue signals, digital signals and low-level signals.
• 600/1000 V for other signals and alternative current circuits up to 230 VAC.
• 500 V for instrument & telecom earthing cables.
7.3 Conductor
Conductor shall be circular stranded annealed bare copper, stranded as per IEC 60228,
class 2. The conductor shall consist of minimum seven (7) strands of uniform in quality and
free from defects. The conductor sizes shall be used as minimum and subject to voltage
drop calculation ± 2%:
• Min 24 AWG for serial link.
• 1.5 mm2 for analogue signal cables, digital signal cables, fire and gas signals.
• 2.5 mm2 for solenoid valves if required (otherwise 1.5 mm2) and instrument power
supply signals.
7.3 Mica Glass Tape
Cable fire resistant shall have layer Mica Glass Tape (MGT) to protect the conductor
whenever fire occured on cable, therefore cable still can flow the current of electricity to the
safety devices without breakage of the circuit.
7.4 Insulation
The insulation material shall be XLPE. The insulated conductors shall be twisted together to
form a pair/triad/quad. Lay of twist per pair/triad/quad shall be approximately 13 to 20 times
per meter. Insulation thickness shall be accordance with IEC 60502-1
7.5 Screen
Screen for multipair analog cable shall be consist of Individual and Overall Screen. For
multipair digital cable shall be consist of Overall Screen. Screen shall be coverage of
polyester tape and 7- stranded tinned copper drain wire with minimum size 0.5 mm2
7.6 Metallic Armour
Metallic armour shall be made of Steel Wire Armour (SWA). It’s required due to installed in
the outdoor application to protect cable from mechanical stress.
7.7 Inner and Outer Sheath
The Inner and outer sheath material shall be of low smoke zero halogen with the following
characteristics:
• Flame retardant as per IEC 60332-3-22 (previously called Cat A).
• Oxygen index: better than 30 as per ISO 4589
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• Resistant to water, UV and aliphatic or aromatic hydrocarbon.
• Gas and vapor tight
8. CABLE TRAY
Cable tray shall of following types:
1. Onshore installation hot dip galvanized steel, for indoor and outdoor.
2. Alternative stainless steel 316 tray or ladder may used where environment is sever.
All cable tray shall be bounded and grounded.
a. Technical Requirement
Cable tray for electronic and signal wiring shall be adequately separated from powering and
electrical equipment to minimize electromagnetic interface. Cable tray shall be adequate to
accommodate 30% of spare capacity. Cable tray shall be as perforated type with base material
of mild steel. The standard length is 3000 mm.
b. Hot Dip Galvanized
The mild steel shall be hot dip galvanized after fabrication as per ASTM A123. The sheet steel
thickness shall be 1.8 mm for cable tray and 2.5 mm for ladders.
Support channel shall be mild steel hot dip galvanized 2.5 mm thickness. All bolts, nuts, washers,
screws shall be hot dip galvanized.
9. UTILITIES
9.1 Power Requirement
There shall be a distribution board for each type and level of electrical supply: AC and DC
from UPS. Transmitters and actuators will preferably be powered directly from the control
systems at 24 VDC.
Service voltage for instrument system shall be:
DC, Loop power/switching contact = 24 VDC
AC, switching contact = 230 VAC
Frequency = 50 Hz
10. ELECTRICAL INSTALLATION
10.1 Wiring / Ducting
No wire splicing or connector will be permitted.
All components in the local panel shall be installed, wired, and tested. The only field
connections necessary shall be cabling from field and power tie-ins.
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In order to connect with marshalling cabinet of PCS/SIS, all components in the
marshaling cabinet shall be completely wired to their respective terminals. Wiring shall
be fire resistance, non-melting type, with minimal toxic fumes and smoke characteristic.
Wires shall be identified using single plastic sleeve markers. All wire shall bear an
alphanumeric identification at each end. Signal wires shall be run in separated raceway
from power and control wiring with separation accordance to IEC 60364-5-52 standard
considering appropriate current derating factor.
Wiring color should be follows:
Input/output signals : Black for (+ VE) & White for (- VE)
Dirty Protective Ground : Green with Yellow Stripe
Clean/Signal Ground : Green
Each local panel wiring shall be routed in vented PVC ducting with covers. The ducting
loading shall not exceed 50% of the cross – sectional area. The cable duct shall have
sufficient capacity for installed wiring plus 30% spare.
10.2 Termination
Solder connections for wiring prohibited. All terminal shall be readily accessible. Cable
shall be supported with properly designed cable clamp and support system sufficient to
guarantee that undue force is not applied to termination.
10.3 Grounding System
Metallic enclosure, gland plates and cable glands shall have ground continuity by
physical connection to the local structure.
Equipment support, doors, panels or installed equipment than bonding wires shall be
used to neutralize the potential with respect to the panel structure protective grounding
ground bar for personnel protective and grounding integrity. Bounding wire shall be PVC
insulated color green and yellow striped (NYA type of cable).
Resistance value for the grounding system (Protective earth) shall not more than 5 ohms.
The Protective Earth (PE) shall not be connected together with Instrument Earthing (IE).
They have to grounded separately.
11. CABLE GLAND
Cable gland shall be choosed as per IEC 60079-10 and with the Company approval that
appropriate to install in hazardous area classification
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Cable gland for armor cable shall be completed with inner and outer seals and armour clamps.
For certified equipment cable gland shall be of the same mode of protection as the device being
cabled (i.e Ex‘d’ glands for Ex‘d’ equipment).
If any adaptation is needed, only one reducer shall be allowed. Cable gland shall be nickel plate
brass type. All Ex’d’ shall use barrier cable gland (using compound). Cable gland shall be
completed with shroud.
12. NAMEPLATE AND LABELING
Panel nameplate may be considered as engraved name plate. Nameplate shall be traffolyte
except where permission is given by Company for use of an alternative. Field Instrument Device
Tag Number shall using 316 SS for nameplate.
13. INSPECTION AND TESTING
The responsibility for inspection and compliance with this specification rests with the Contractor
and Vendor. Company reserves the right to inspect materials, manufacturing and fabrication and
to witness tests at any time. Vendor shall provide the required access for such inspections and
test witnessing. Vendor shall not deliver any materials or instruments until it is inspected by
Company. Company reserves the right to waive tests.
Contractor and Vendor shall supply Company with a schedule of proposed inspection dates.
Observing, witnessing and/or acceptance of any inspection or test by Company do not relieve
the Contractor or Vendor of any guarantees. Vendor must submit all inspection and testing
procedures for Company approval at least seven (7) days in advance of implementing the
procedure.
Vendor shall supply Company a complete set of detailed manufacturing document and certificate,
which will be used to assist in the inspection of the equipment. Vendor shall provide
Manufacturing Data Record (MDR) of the equipments such as certificates, drawings, datasheets,
and other document for dossier.