STUBB CREEK DEBOTTLENECKING AND UPGRADE PROJECT (SC DU PROJECT)

DOCUMENT NUMBER : 2503001-ARSL-SPC-J-0003

Organization Doc Type Department / Discipline Numeric Sequence Number
Generic Code
Code Code Code

2503001 ARSL SPC J 0003

GENERAL INSTRUMENTATION SPECIFICATIONS

Controlled
For Company Use Only

1 23-Oct-2025 Afees Olajide Testimony Aina Yomi Obaoye Issued for Design
0 10-Oct-2025 Afees Olajide Testimony Aina Yomi Obaoye Issued for Design
B 06-Oct-2025 Afees Olajide Testimony Aina Yomi Obaoye Issued for Review
Rev Date Prepared By Checked By Approved By Description
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Approvals, control and Amendment

An approval signature on the front cover indicates approval of this procedure. Controlled copies are identified
by controlled status on front cover - only controlled copies will be automatically updated. Amendments to
sections of this procedure are detailed in the following table. Approval of the amendment is indicated by the
responsible Manager’s initials on master soft copy and original signature on hard controlled copies.
Document history and change record

Issue Issue date Description of change

B 06-Oct-2025 Issued for Review

0 10-Oct-2025 Issued for Design

1 23-Oct-2025 Issued for Design

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Table of Contents
1 INTRODUCTION .........................................................................................................................6
1.1 Project Background ........................................................................................................................6
1.2 General Description of Project and Existing Facilities......................................................................6
2 PURPOSE ...................................................................................................................................8
3 DEFINITIONS AND ABBREVIATIONS ...........................................................................................8
3.1 Definitions .....................................................................................................................................8
3.2 Abbreviations ................................................................................................................................8
4 REFERENCE DOCUMENTS ........................................................................................................ 10
4.1 Project Documents ....................................................................................................................... 10
4.2 Company Documents ................................................................................................................... 10
5 APPLICABLE CODES & STANDARDS .......................................................................................... 11
5.1 List of Applicable Codes & Standards............................................................................................ 11
5.2 Order of Precedence .................................................................................................................... 12
6 SITE ENVIRONMENTAL CONDITIONS ....................................................................................... 12
6.1 Ambient Temperatures & Humidity ............................................................................................. 12
6.2 Rainfall ........................................................................................................................................ 12
6.3 Wind Speed ................................................................................................................................. 12
6.4 Dust ............................................................................................................................................. 12
7 UNITS OF MEASUREMENT ....................................................................................................... 13
8 FIELD INSTRUMENTATION ....................................................................................................... 14
8.1 General Requirements ................................................................................................................. 14
8.2 Flow Instruments ......................................................................................................................... 14
8.3 Pressure Instruments ................................................................................................................... 14
8.4 Level Instruments ........................................................................................................................ 14
8.5 Temperature Instruments ............................................................................................................ 15
8.6 Pressure Safety Valve (PSVs) ........................................................................................................ 15
8.7 Control Valves .............................................................................................................................. 15
8.8 On-Off Valves ............................................................................................................................... 16
8.9 Vibration and Wake Frequency Requirements ............................................................................. 16
8.9.1 General ............................................................................................................................................................ 16
8.9.2 Thermowells (Temperature Instruments) ....................................................................................................... 16
8.9.3 Pressure Safety Valves (PSVs) ......................................................................................................................... 16
8.9.4 Control Valves ................................................................................................................................................. 16
8.9.5 Documentation ............................................................................................................................................... 17

9 JUNCTION BOXES (JBs) REQUIREMENTS .................................................................................. 17

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10 INSTRUMENTATION AND CONTROL CABLES REQUIREMENTS .............................................. 17

10.1 General ........................................................................................................................................ 17
10.2 Construction Requirements.......................................................................................................... 17
10.3 Indoor Cables ............................................................................................................................... 18
10.4 Outdoor Cables ............................................................................................................................ 18
10.5 Signal Identification ..................................................................................................................... 18
10.6 Routing and Installation Practices ................................................................................................ 18
10.7 Testing ......................................................................................................................................... 19
10.8 Certification ................................................................................................................................. 19
11 PACKAGE EQUIPMENT INSTRUMENTATION REQUIREMENTS ............................................... 19
11.1 General ........................................................................................................................................ 19
11.2 Documentation ............................................................................................................................ 19
11.3 Integration Philosophy ................................................................................................................. 19
11.4 Communication and Interface ...................................................................................................... 20
11.5 Safety and Certification ................................................................................................................ 20
12 PROCESS CONTROL SYSTEM (PCS) ........................................................................................ 20
12.1 Architecture ................................................................................................................................. 20
12.2 Logic Solvers ................................................................................................................................ 20
12.3 Inputs and Outputs ...................................................................................................................... 20
12.4 Human-Machine Interface (HMI) .................................................................................................. 20
12.5 Data Historian .............................................................................................................................. 20
12.6 Cybersecurity ............................................................................................................................... 21
13 EMERGENCY SHUTDOWN SYSTEM (ESD / SIS) ...................................................................... 21
13.1 Logic Solvers ................................................................................................................................ 21
13.2 Inputs and Outputs ...................................................................................................................... 21
13.3 Field Devices ................................................................................................................................ 21
13.4 Shutdown Philosophy .................................................................................................................. 22
13.5 Testing and Bypasses ................................................................................................................... 22
14 CONTROL SYSTEM CABINETS................................................................................................ 22
14.1 General Requirements ................................................................................................................. 22
14.2 Environmental Control ................................................................................................................. 22
14.3 Electrical & Functional Requirements ........................................................................................... 22
14.4 Labelling & Documentation .......................................................................................................... 22
15 HUMAN-MACHINE INTERFACE (HMI) FOR PCS AND SIS ........................................................ 23
16 SAFETY INTEGRITY LEVEL (SIL) REQUIREMENTS .................................................................... 23
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17 UTILITY ................................................................................................................................ 23
17.1 General ........................................................................................................................................ 23
17.2 Secure Power (UPS)...................................................................................................................... 23
17.3 Non-Secure Power ....................................................................................................................... 24
17.4 Instrument Air System ................................................................................................................. 24
18 PACKAGING, TRANSPORT, AND STORAGE ............................................................................ 25
19 SPARES AND MAINTENANCE ................................................................................................ 25
20 LIFESPAN AND OBSOLESCENCE ............................................................................................ 25
21 QUALITY ASSURANCE AND TESTING .................................................................................... 25
22 DOCUMENTATION AND DELIVERABLES ................................................................................ 25
23 CONCLUSION ....................................................................................................................... 26
APPENDIX A – TABLE OF ASSUMPTIONS ......................................................................................... 27

LIST OF TABLES
Table 1.0 Abbreviations & Descriptions ............................................................................................... 8
Table 2.0 Project Documents ............................................................................................................. 10
Table 3.0 Company Documents ......................................................................................................... 10
Table 4.0 Site Temperatures and Humidity ........................................................................................ 12
Table 5.0 Standard Unit of measurement .......................................................................................... 13

LIST OF FIGURES
Figure 1.0 – Stubb Creek Field Location and Infrastructure Map ......................................................... 6
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1 INTRODUCTION

1.1 Project Background

Stubb Creek is a marginal field development located in Akwa Ibom State, Nigeria. The field is
currently producing oil from three wells (SC-6, SC-7, and SC-8) and has been onstream since Q1
2015. Crude oil production is transported via pipeline to the Seplat Energy operated Qua Iboe
Terminal. Associated gas is routed via pipeline to the nearby Uquo Central Processing Facility (CPF)
for processing and onward sale through the Accugas export system.
In the near term, Savannah Energy plans to debottleneck the existing production facilities to
increase oil throughput capacity to approximately 4,000 bopd (average annual rate). The
expansion scope also includes the installation of produced water handling infrastructure (3,000
bwpd) and new gas compression facilities (5 MMscfd). In the longer term, the Contingent Non-
Associated Gas Resources at Stubb Creek are expected to be developed and sold to Accugas, once
the Uquo Field is no longer able to fully meet gas demand. The locations of the Uquo and Stubb
Creek Fields, along with the Accugas pipeline infrastructure, are illustrated in Figure 1.0.

Figure 1.0 – Stubb Creek Field Location and Infrastructure Map

1.2 General Description of Project and Existing Facilities

Stubb Creek production commenced in Q1 2015 through an Early Production Facility (EPF). The
original intent was for the EPF to operate for one to two years, while a Central Processing Facility
(CPF) with a 10,000 bopd and 10 MMscfd capacity was to be constructed on an adjacent site. Once
the CPF was commissioned, the EPF would have been retired. Petrofac International completed
the initial Front-End Engineering Design (FEED) for the proposed CPF; however, the Detailed
Engineering Design (DED) was never carried out, and production has continued via the EPF.
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The EPF was constructed using a combination of new equipment and piping, along with redeployed
process vessels and heaters originally used at the Amoji Field. The redeployed equipment was
designed and operated as an EPF at Amoji, with a design life of 20 years, and was manufactured in
2009/2010. The new equipment and piping installed at Stubb Creek have a design life of 25 years
and were manufactured between 2012 and 2014.
The current EPF has an oil processing capacity of approximately 3,000 to 3,500 bopd (peak daily
rate), limited primarily by the oil stabilizer column and the oil rundown system to the storage tanks.
There are currently no produced water handling facilities at the EPF. The water outlet from the
Production Separator (V-102) is currently blinded. Water production is expected to commence in
early 2026, and therefore, produced water treatment, storage, and injection facilities will be
required. An existing water injection well is available and will be used for disposal of produced
water.
Gas compression for up to 2 MMscfd is currently available via a compression package. However,
gas export capacity is temporarily reduced to 0.8 MMscfd while one of the gas export coolers is
being replaced. The existing compression package is a gas engine-driven, two-stage Ariel
reciprocating compressor (JGR-2), packaged by Exterran and supplied as a refurbished unit in 2013.
The reliability of the compression package has historically been poor, leading to downtime and
increased flaring of associated gas. Larger, new compression package(s) will be required to
improve gas export capacity and operational reliability.
Much of the Basic Process Control System (BPCS) at Stubb Creek relies on locally mounted
pneumatic controllers. The COMPANY wishes to replace these with electronic/pneumatic controls,
operated via the existing Allen-Bradley ControlLogix system. Further expansion or upgrade of the
control system will be required to support the planned debottlenecking and facilities expansion
scopes.
Site power is currently supplied by a 200 kVA gas engine generator. The normal operating load is
close to the generator’s rated capacity. Additional power generation will be required to support
future loads, along with the expansion and upgrade of the site’s switchgear and electrical
distribution systems.
The existing flare scrubber is undersized and will require replacement. A thorough review of the
existing flare system and horizontal ground flare is required to confirm its adequacy for increased
and future flaring loads.
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2 PURPOSE
This General Instrumentation Specification defines the minimum technical requirements for field
instrumentation, process control systems (PCS), emergency and safety shutdown systems
(ESD/SIS), and associated lifecycle requirements for a modern industrial process facility. The
specification covers selection, design, installation, testing, documentation, packaging, and
lifecycle support.
The intent is to ensure that all instrumentation and control systems meet the highest standards
of reliability, safety, and maintainability, while being compatible with international standards and
best practices. All assumptions stated herein shall be reviewed and updated with project-specific
data.

3 DEFINITIONS AND ABBREVIATIONS

3.1 Definitions

Contractor: The party that carries out all or part of the design, engineering, procurement,
construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.

Vendor: The party that manufactures and supplies equipment and services to perform the
duties specified by the Contractor.

Principal: The party that initiates the project and ultimately pays for its design and
construction, in this case Universal Energy Resources Ltd. (Savannah Energy)

Shall: This indicates a mandatory requirement.

Should: This indicates a preferred (but not mandatory) course of action.
May: This indicates a possible course of action

3.2 Abbreviations
Table 1.0 Abbreviations & Descriptions

ANSI American National Standards Institute

API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society of Testing and Material
ATEX ATmosphères EXplosibles
BPCS Basic Process Control System
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DED Detailed Engineering Design

EEMUA The Engineering Equipment and Materials Users Association
EMI Electromagnetic Interference
EPF Early Production Facility
FEED Front End Engineering Design
FMEDA Failure Modes, Effects and Diagnostic Analysis
HAZOP Hazard and Operability Analysis
HSE Health Safety and Environment
ISO International Organization for Standardization
ICSS Instrumentation, Control and Safety System
NEMA National Electrical Manufacturers Association
NFPA National Fire Protection Association
CCB Central Control Building
CPF Central Processing Facility
EDP Emergency Depressurizing System
ESD Emergency Shutdown System
FAT Factory Acceptance Testing
FGS Fire & Gas Systems
I&C Instrumentation & Control Systems
I,C&T Instrumentation, Control and Telecommunications
HART Highway Addressable Remote Transducer
HMI Human Machine Interface
IEC International Electrotechnical Commission
I/O Input /Output
IS Intrinsically Safe
ISA International Society for Automation
IP Ingress Protection
IR Infra-Red
LSZH Halogen-free, Low Smoke
OPC Object Linking & Embedding for Process Control
OSD Operational Shutdown
PAEAS Public Address and Emergency Alarm System
PCS Plant Control System
PFD Probability of Failure on Demand
PLC Programmable Logic Controller
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RFI Radio Frequency Interference

SAT Site Acceptance Testing
SIF Safety Instrumented Functions
SIL Safety Integrity Level
SIS Safety Instrumented System
SOE Sequence of Events
SWA Steel Wire Armored
TCP/IP Transmission Control Protocol/Internet Protocol
UV Ultra-Violent
VFD Variable Frequency Drive
VIM Vendor Interface Module

4 REFERENCE DOCUMENTS
The following documents are referenced herein and shall be considered a part of this philosophy:

4.1 Project Documents

Table 2.0 Project Documents
Sn. Document No Title
1 2503001-ARSL-PHS-J-0001 Instrumentation and Control Philosophy
2 2503001-ARSL-PHS-J--0002 Fire and Gas Philosophy
3 2503001-ARSL-SPC-J--0002 Sales Gas Metering Specifications
4 2503001-ARSL-SPC-J-0001 Specifications for Fire and Gas System (FGS)

4.2 Company Documents

Table 3.0 Company Documents
Sn. Document No Title
1 SCPF-PETW-SPC-J-01002 Specification for General Instrumentation
2
3
4
5
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5 APPLICABLE CODES & STANDARDS

5.1 List of Applicable Codes & Standards

Standard for the Development of an Electrostatic Discharge Control
ANSI/ESD S20.20 Program for Protection of Electrical and Electronic Parts, Assemblies and
Equipment
Tank Calibration: Calibration of Upright Cylindrical Tanks Using the Optical-
API MPMS 3.2
Tape Method
API RP 550 Process instrumentation (flow, level, pressure, temperature)
API RP 551 Process Measurement Instrumentation
API RP 552 Pressure-relieving & depressuring systems
API RP 553 Refinery valves & accessories for instrumentation
API RP 554 Process Instrumentation and Control
API RP 555 Process analyzers
API RP 556 Instrumentation and Control Systems
ASME PTC 19.3 American Society of Mechanical Engineers (ASME) standard for the
TW-2016 mechanical design and evaluation of thermowells
ATEX 100a Equipment and Protective Systems in Potentially Explosive Areas
EEMUA 201 Alarm Systems - A Guide to Design, Management and Procurement
IEC 60079 series Explosive Atmospheres
IEC 60297 Mechanical structures for electronic equipment – Dimensions of mechanical
structures of the 482.6 mm (19 in) series
IEC 60502 Power cables with extruded insulation and their accessories for rated
voltages from 1 kV (Um = 1.2 kV) up to 30 kV (Um = 36 kV)
IEC 61131-3 Programmable controllers – Part 3: Programming languages
International Standard for Functional Safety of
IEC 61508 Electrical/Electronic/Programmable Electronic (E/E/PE) Safety-Related
Systems
International Standard for Functional Safety – Safety Instrumented Systems
IEC 61511
(SIS) for the Process Industry Sector
IEC 61340-5-1 Electrostatics – Part 5-1: Protection of electronic devices from electrostatic
phenomena – General requirements
IEC 62443 series Industrial Communication Networks Security
ISA 5.1 Instrumentation Symbols and Identification
ISA 75 series Control Valve Sizing and Specifications
ISA 18.2 Alarm Management
Packaging – Complete, filled transport packages – General rules for the
ISO 4180
compilation of performance test schedules
ISO 9001 Quality Management
General requirements for the competence of testing and calibration
ISO/IEC 17025
laboratories
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5.2 Order of Precedence

In the event of conflicts between the above listed applicable regulations, codes and standards,
the following order of priority shall be applied:
• Nigerian National Standards (Government Legislation)
• International Standards
• Industry Standards
• Contractor codes and working standards
The latest editions of all codes and standards as at the date of issue of this philosophy shall
apply.

6 SITE ENVIRONMENTAL CONDITIONS

6.1 Ambient Temperatures & Humidity

Table 4.0 presents site temperature and humidity data; this data has been taken from the
Stubb Creek Debottlenecking and Upgrade Project FEED scope of work:
Table 4.0 Site Temperatures and Humidity
Parameter Unit Value
Swamp temperature °C 20
Ground temperature °C 25 - 27.5
Average Air Temperature °C 26.7
Max. dry bulb Temperature °C
Humidity % 100
Black body temperature °C 60

6.2 Rainfall
Average Annual Rainfall = 4500 mm
Mean max. hourly Rainfall = 100 mm

6.3 Wind Speed

Wind Speed = 35.6m/s

6.4 Dust
During November/December of every year, Harmattan season, the atmosphere is laden with
extremely fine dust (particle size of 5 microns or less) which can penetrate equipment, block
air filters, etc.
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7 UNITS OF MEASUREMENT
All Instrument design, engineering, data sheets, and documentation shall use metric (SI) units
in accordance with the International System of Units (SI).
Table 5.0 Standard Unit of measurement
Parameter Unit Symbol
Temperature degree Celsius °C
Pressure bar bar
Length millimeter mm
Viscosity millipascal-second mPa.s
Density kilogram per cubic meter Kg/mᶾ
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8 FIELD INSTRUMENTATION

8.1 General Requirements

All instruments shall:
a) Be suitable for outdoor installation (minimum IP65, preferred IP66/67, NEMA 4X).
b) Be designed for 25 years of operational life with routine maintenance.
c) Provide digital communication capability (HART Communication Protocol only).
d) Be calibrated and supplied with ISO/IEC 17025 traceable certificates.
e) Be certified for the appropriate hazardous area classification.
f) Include clear, permanent tagging per ISA 5.1.
g) All instruments shall be certified for hazardous areas in accordance with the project facility
Hazardous Area Classification and relevant international standards such as IEC 60079, IECEx,
and ATEX. Protection methods (Ex d, Ex i, Ex n) shall be selected as per application.
Certificates shall be supplied.

8.2 Flow Instruments

Flow measurement shall be selected based on process conditions, accuracy requirements, and
fluid properties.
a) Types: Orifice plates, vortex meters, Coriolis meters, ultrasonic meters, magnetic flowmeters,
and turbine meters.
b) Accuracy: ±0.5% of reading (Coriolis/ultrasonic), ±1.0% of reading (vortex/magmeter).
c) Standards: ISO 5167 for differential pressure flowmeters; API MPMS standards.
d) Installation: Adequate straight pipe runs and flow conditioners shall be applied as required.
e) Outputs: 4–20 mA with HART Communication Protocol only.

8.3 Pressure Instruments

Pressure instruments shall include transmitters, gauges, and switches.
a) Ranges: Sized to process conditions with 50% over-range capability.
b) Accuracy: ±0.25% of span (transmitters).
c) Protection: Overpressure protection shall be installed where necessary.
d) Remote Seals: Used where high temperature, corrosive fluids, or clogging risk exists.
e) Standards: ASME B40.100, API RP 551.

8.4 Level Instruments

Level measurement shall use radar, ultrasonic, differential pressure, displacers, or guided wave
radar depending on service.
a) Continuous Measurement: Radar or DP cells preferred.
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b) Point Measurement: Vibrating forks, capacitance, or float switches.

c) Accuracy: ±5 mm for radar, ±0.5% of span for DP transmitters.
d) Special Services: Custody transfer tanks shall use certified radar systems per API MPMS 3.2.

8.5 Temperature Instruments

Temperature instruments shall include RTDs, thermocouples, and thermowells.
a) RTDs: Pt100, Class A, IEC 60751.
b) Thermocouples: Type K or J, per IEC 60584.
c) Thermowells: Flanged or welded; designed per ASME PTC 19.3 TW-2016, including wake
frequency analysis.
d) Accuracy: ±0.15°C (RTDs), ±1.5°C (thermocouples).
e) Transmitters: 4–20 mA with HART Communication Protocol only.

8.6 Pressure Safety Valve (PSVs)

Pressure safety valves shall comply with ASME Section VIII and API 520/521/526.
a) Set Pressure: As defined by process design.
b) Certification: All PSVs shall be certified and supplied with test certificates.
c) Materials: Wetted parts in stainless steel unless otherwise specified.
d) Testing: 100% shop-tested with certificates.
e) Wake Frequency: PSV stems and discs shall undergo wake frequency analysis in high-velocity
or multiphase services to prevent vibration-induced failure.

8.7 Control Valves

Control valves shall be specified to meet process dynamic requirements while ensuring tight
shutoff and reliability.
a) Valve Body Types: Globe, ball, butterfly, or plug depending on service.
b) Sizing: ISA S75.01 methodology.
c) Trim: Equal percentage for pressure, linear for level control.
d) Positioners: Digital smart type, with HART Communication Protocol only.
e) Accessories: Volume boosters, quick exhaust valves, filters, and regulators where required.
f) Materials: Stainless steel trim; hardened for erosive service.
g) Testing: Factory testing for stroke, seat leakage, and performance.
Special Note: An I/P Converter shall be provided for any existing pneumatically-actuated control
valve that is to be retrofitted from pneumatic control to electronic control.
h) Wake Frequency: Control valve trims and stems shall undergo wake frequency analysis for
high-velocity, cavitating, or flashing services to mitigate resonance risks.
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i) SIS-related valves: Shall comply with SIL requirements and have proof-test procedures.

8.8 On-Off Valves

On-off valves (PCS and SIS service) shall provide reliable isolation with fast actuation when
required.
a) Types: Ball valves, butterfly valves, or gate valves with actuators.
b) Actuation: Electric or pneumatic; pneumatic preferred for SIS due to fail-safe operation.
c) Solenoids: Certified for SIL service; with manual reset where required.
d) Testing: Partial stroke testing provisions shall be included for SIS valves.

8.9 Vibration and Wake Frequency Requirements

8.9.1 General
Instrumentation and final elements shall be designed to withstand process-induced vibration,
acoustic excitation, and vortex shedding forces.
The governing methodology for wake frequency analysis shall be based on ASME PTC 19.3 TW-
2016 (Thermowells), with adaptation for valves and PSVs where applicable. The specification
shall clearly state the convention being applied to avoid ambiguity.
8.9.2 Thermowells (Temperature Instruments)

• Wake frequency ratio fs/fn ≤ 0.4 (where fs is the vortex shedding frequency and fn is the
natural frequency of the thermowell).
• Redesign required if criteria are not met (shorten length, increase diameter, tapered design).
• In-line resonance region 0.4–0.6 (fs/fn convention) shall be avoided in line with ASME
guidance.

8.9.3 Pressure Safety Valves (PSVs)

• PSV stems and discs exposed to high-velocity/multiphase relief shall undergo wake frequency
analysis.
• Wake frequency ratio fs/fn ≤ 0.8 shall apply, consistent with thermowell criteria.
• Redesign (geometry change, material selection, or damping) shall be required if criteria are
not met.
8.9.4 Control Valves
• Control valve trims and stems in high-velocity/cavitating service shall undergo wake
frequency analysis.
• Wake frequency ratio fs/fn ≤ 0.8 shall apply, consistent with thermowell and PSV criteria.
• Redesign (trim modification, stiffening, or damping) shall be required if criteria are not met.
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8.9.5 Documentation
• Wake frequency calculations shall be provided in vendor documents.
• Deviations only accepted with test data or project approval.

9 JUNCTION BOXES (JBS) REQUIREMENTS

a) All junction boxes shall be weatherproof, corrosion-resistant, and hazardous area certified.
b) Minimum protection: IP66/67 (NEMA 4X) for outdoor use.
c) Preferred material: 316 stainless steel; GRP acceptable for non-critical applications.
d) Cable entries shall use certified Ex-rated glands.
e) Internal terminals shall be screw or spring-clamp type with a minimum 20% spare capacity.
f) Earth bars shall be installed and bonded to the enclosure.
g) JB tags shall be engraved or stainless-steel nameplates; terminals numbered per wiring
diagrams.

10 INSTRUMENTATION AND CONTROL CABLES REQUIREMENTS

10.1 General
a) All instrumentation and control cables shall be designed, manufactured, tested, and installed
in accordance with IEC 60228, IEC 60502, IEC 60332, IEC 61034, IEC 60092, and relevant
project specifications.
b) Cables shall be suitable for a 25-year design life in the specified operating environment.
c) Cable selection shall consider mechanical, electrical, thermal, and environmental conditions
(indoor, outdoor, hazardous area).

10.2 Construction Requirements

a) Conductor: Annealed stranded copper conductors, Class 2 or Class 5 (IEC 60228).
b) Insulation: XLPE, PVC, or PE insulation. For indoor installations, halogen-free low smoke
(LSZH) insulation shall be used.
c) Shielding:
• Individually shielded pairs/triples for analog signals.
• Overall shield for digital and communication cables.
• Shielding shall provide 100% coverage with a tinned copper drain wire.
c) Armor: Galvanized steel wire armor (SWA) or corrugated aluminum armor for outdoor and
buried installations.
d) Outer Sheath: UV-resistant, flame-retardant, halogen-free sheathing for outdoor
applications.
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10.3 Indoor Cables

a) Indoor cables shall be halogen-free, low smoke (LSZH) type to minimize smoke and toxic
emissions in case of fire.
b) Shall comply with IEC 60332-1/3 for flame propagation and IEC 61034 for smoke density.
c) All analog signal cables shall be shielded to prevent electromagnetic interference (EMI).
d) Routing shall be carefully planned to minimize electrical interference from power circuits and
rotating equipment.

10.4 Outdoor Cables

a) Outer sheath shall be UV-resistant, moisture-resistant, and rodent-resistant.
b) For direct burial, cables shall be provided with SWA or equivalent mechanical protection.
c) Shall withstand ambient temperatures of –20 °C to +90 °C continuous service.
d) Terminations at outdoor junction boxes shall use weatherproof cable glands (IP66/67, Ex d/Ex
e where applicable).
e) Overhead cable runs shall use stainless steel cable trays or conduits with corrosion
protection.

10.5 Signal Identification

a) All instrumentation and control cables shall be clearly identified along their route, at both
ends, and at junction/intermediate points.
b) Intrinsically safe (IS) cables shall be distinctly marked and labeled in accordance with project
standards to ensure clear recognition during installation, inspection, testing, and
maintenance.
c) Cables shall have durable, weather-resistant tags that remain legible throughout the lifecycle.
d) Color coding, ferrules, and tagging shall comply with the project cable schedule and ISA 5.1
requirements.
e) Documentation (cable schedules, wiring diagrams, as-built layouts) shall provide one-to-one
traceability between cable IDs and connected instruments.

10.6 Routing and Installation Practices

a) Cables shall be installed in cable trays, conduits, or trenches with proper mechanical support
and protection.
b) Minimum bending radius shall be 10 × cable diameter (unless manufacturer specifies
otherwise).
c) Maximum cable tray fill factor shall not exceed 40% to allow for future expansion and heat
dissipation.
d) Cables shall be kept at least 300 mm from hot surfaces (e.g., steam lines, exhaust ducts) or
provided with thermal protection.
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e) Adequate spacing shall be maintained from sources of high EMI/RFI interference (motors,
VFDs, high-voltage equipment).
f) Cables shall be clamped at regular intervals to avoid sagging and mechanical stress.
g) Vertical cable runs shall be supported with cable cleats or riser clamps.
h) Spare cables shall be coiled neatly and terminated with protective end caps.
i) All unused cable entries in junction boxes and cabinets shall be sealed with certified stopping
plugs.

10.7 Testing
a) Factory Tests: Conductor resistance, insulation resistance, high-voltage withstand, and
shielding continuity.
b) Site Tests: Insulation resistance (Megger), loop resistance, and continuity.
c) Acceptance Tests: Shall follow IEC 60502 and project QA/QC standards.

10.8 Certification
All cables shall be certified for:
a) Fire performance.
b) Hazardous area suitability.
c) Compliance with IEC/ATEX/IECEx where applicable.

11 PACKAGE EQUIPMENT INSTRUMENTATION REQUIREMENTS

11.1 General
All packaged equipment shall be supplied complete with instrumentation, local control panels,
and protective devices required for safe and reliable operation. Package vendors shall ensure
compliance with this General Instrumentation Specification as well as all referenced international
standards.

11.2 Documentation
Vendors shall provide full instrumentation documentation, including:
• Datasheets, wiring diagrams, and loop diagrams.
• Control and shutdown philosophy of the package.
• Integration interface details (signal list, communication protocol).

11.3 Integration Philosophy

Package equipment shall operate on a standalone basis with its own local controls. It shall
transmit equipment status and alarms to the PCS for monitoring purposes, and shall be capable
of receiving trip signals from the SIS for safety shutdown functions.
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11.4 Communication and Interface

Where digital communication is available, Modbus TCP/IP, Modbus RTU, or OPC UA shall be
preferred for PCS interface. Otherwise, hardwired signals (4–20 mA, dry contacts) shall be
provided. Interfaces shall be tested during FAT/SAT.

11.5 Safety and Certification

All package instruments located in hazardous areas shall comply with IEC 60079, ATEX, or IECEx
as applicable. Package shutdown devices shall meet SIL requirements where integrated into the
facility SIS.

12 PROCESS CONTROL SYSTEM (PCS)

12.1 Architecture

a) PCS shall employ redundant controllers, power supplies, and communication networks.
b) Networks shall be Ethernet-based with segregation from business/IT networks.
c) Remote I/O shall be used to reduce field cabling.

12.2 Logic Solvers

The PCS shall employ programmable logic solvers to execute continuous control, sequencing, and
advanced control strategies. They shall:
a) Be redundant (hot standby).
b) Support IEC 61131-3 programming.
c) Support OPC UA, Modbus TCP/IP, Ethernet/IP.
d) Be certified for high availability.

12.3 Inputs and Outputs

a) PCS shall support 4–20 mA with HART Communication Protocol only.
b) Diagnostics shall detect open circuits, short circuits, and module failures.
c) Safety-related I/O shall be physically and logically segregated from non-safety I/O.

12.4 Human-Machine Interface (HMI)

a) HMI graphics, alarms, and trends shall follow ISA 18.2 and EEMUA 201.
b) Alarm management shall include rationalization, prioritization, shelving, and event recording.

12.5 Data Historian

a) PCS shall include a historian with at least one-year rolling storage.
b) Historian shall integrate with higher-level plant information systems.
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12.6 Cybersecurity
a) PCS networks shall comply with IEC 62443.
b) Security measures include: firewalls, access control, patch management, role-based access,
and restricted remote access.
13 EMERGENCY SHUTDOWN SYSTEM (ESD / SIS)

13.1 Logic Solvers

a) The existing SIS logic solver shall be retained as part of the system architecture.
b) Only the controller module (Rockwell Automation Logix5562) shall be upgraded to a newer SIL
rated, compatible module suitable for the Studio 5000 platform, ensuring continued vendor
support, cybersecurity compliance, and integration with future installations.
c) The retained logic solver shall continue to meet the SIL requirements defined by the project
and applicable standards (IEC 61511, IEC 61508).
d) Trip actions executed by the SIS shall be fully documented in the Cause & Effect (C&E) charts
and aligned with the project’s safety and control philosophies.

13.2 Inputs and Outputs

a) All SIS I/O shall be galvanically isolated and segregated from PCS I/O.
b) Redundant I/O modules shall be provided for critical functions.
c) Voting architectures (1oo2, 2oo3) shall be applied where required.
d) Line monitoring and diagnostics (open circuit, short circuit, stuck signal) shall be provided on
all SIS input and output channels.
e) If required, additional I/O modules shall be suitable for installation in hazardous areas or
connected via certified intrinsic safety barriers/isolators.
f) Field terminations shall be designed for maintainability, with clear labeling and test facilities.

13.3 Field Devices

a) All field devices in SIS loops shall have SIL suitability certification (TÜV, Exida) and vendor-
supplied FMEDA data.
b) Sensors (pressure, temperature, level, flow) shall use redundant architectures where required
and comply with IEC 61511.
c) Thermowells for temperature devices shall be designed to ASME PTC 19.3 TW-2016, with wake
frequency analysis.
d) Final elements (shutdown valves, actuators, solenoids) shall be SIL-certified, fast-acting, and
include partial stroke testing capability where applicable.
e) Control valves and PSVs in SIS service shall undergo wake frequency checks to prevent
vibration-induced fatigue.
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f) Devices shall meet minimum IP66/67 protection, hazardous area certification, and 20-year
design life with proof testing per vendor recommendation.
g) All SIS field devices shall communicate using 4–20 mA with HART Communication Protocol only.

13.4 Shutdown Philosophy

a) The existing shutdown philosophy shall be retained. The SIS shall continue to bring the plant
to a safe state during emergencies.
b) Trip actions shall remain as documented in the approved Cause & Effect (C&E) charts and
aligned with the project’s established safety and control philosophies.

13.5 Testing and Bypasses

Proof test facilities shall be included. Any bypass shall require approval and be time-limited.

14 CONTROL SYSTEM CABINETS

14.1 General Requirements

a) Control system cabinets (PCS, SIS, marshalling, and power distribution cabinets) shall be
fabricated from powder-coated steel or 316 stainless steel as per environmental
requirements.
b) Enclosures shall have a minimum protection of IP42 indoors and IP66 outdoors.
c) Cabinets shall be designed for 25-year service life, with space and thermal margin for future
expansion (minimum 20% spare capacity for modules and terminals).

14.2 Environmental Control

a) Cabinets shall include internal lighting, anti-condensation heaters, and cooling (forced
ventilation or air conditioning) as required by heat load calculations.
b) Internal wiring shall be neatly routed on DIN rails or cable ducts, with color coding as per
project standards.

14.3 Electrical & Functional Requirements

a) Separate cabinets shall be provided for PCS and SIS to ensure functional segregation.
b) Redundant power supplies and redundant communication modules shall be mounted within
the cabinets.
c) Cabinets shall be factory-assembled, wired, and tested (FAT) before delivery to site.
d) Earthing bars shall be installed for signal and safety grounding.

14.4 Labelling & Documentation

a) Each cabinet shall be clearly tagged, with internal equipment labelled consistently with wiring
diagrams and loop drawings.
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b) As-built drawings, terminal schedules, and cable routing diagrams shall be provided with
delivery.

15 HUMAN-MACHINE INTERFACE (HMI) FOR PCS AND SIS

The existing HMI shall be utilized for both the PCS and SIS, providing integrated displays of
system health, trips, alarms, and bypasses. Access shall be role-based, with appropriate
restrictions applied for engineering and administrative functions to maintain system security and
integrity.

16 SAFETY INTEGRITY LEVEL (SIL) REQUIREMENTS

SIL ratings shall be assigned via LOPA and documented in project records. SIS design shall meet
required PFDavg targets. Proof test intervals shall be established during SIL verification.

17 UTILITY

17.1 General
The utilities supporting the Instrumentation and Control Systems comprise the secure (UPS-
backed) power supply, non-secure power supply, and instrument air system. These utilities are
fundamental to ensuring reliable operation of the Process Control System (PCS), Safety
Instrumented System (SIS), and Fire & Gas System (FGS).
All utility systems shall be designed, installed, and tested in accordance with applicable
international standards, including IEC 60364 for electrical installations, IEC 61000 for
electromagnetic compatibility, IEC 62040 for UPS systems, and ISO 8573-1 for compressed air
quality.
The design intent is to achieve continuous, reliable, and safe operation under all process
conditions, ensuring that any failure of non-secure utilities does not impair the function of critical
safety or control systems.

17.2 Secure Power (UPS)

The secure power supply shall provide uninterrupted 24 V DC power to all critical instrumentation
and control equipment, including the PCS, SIS, and FGS.
The DC power distribution system shall utilize regulated power supplies that receive 220 V AC
input from both the existing and new Uninterruptible Power Supply (UPS) systems. The new UPS
system shall be added to enhance capacity and provide redundancy for secure power distribution.
The UPS systems shall be designed in accordance with IEC 62040 and shall include fully automatic
changeover, overload protection, and monitoring features. Each UPS shall provide a minimum of
24 hours autonomy at full critical load and be designed for a 25-year service life under normal
operating conditions.
Critical control panels, marshaling cabinets, and communication interfaces shall be powered from
the UPS-backed DC system through properly rated circuit protection devices. The UPS systems
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shall be configured with redundant inverters and chargers where feasible to ensure no single point
of failure can lead to a total loss of secure power.
UPS system health, battery voltage, and charger status shall be continuously monitored by the
PCS HMI, with alarm indications for power failure, battery fault, or inverter malfunction. The
control system shall also include provisions for periodic UPS maintenance and testing without loss
of supply to critical loads.

17.3 Non-Secure Power

Non-secure power shall be derived from the existing Motor Control Center (MCC) and distributed
at 230 V AC or 400 V AC, as appropriate for connected equipment.
This supply shall feed non-critical devices such as analyzers, local junction boxes, auxiliary panel
heaters, lighting, and miscellaneous equipment not essential to plant safety or continuous
operation.
The non-secure power distribution shall be designed in accordance with IEC 60364 and shall
include overcurrent protection, earthing, and appropriate segregation from the secure (UPS-
backed) circuits.
All AC/DC power supplies serving instrumentation panels shall be provided with noise filters to
minimize electrical interference with sensitive control and communication circuits.
Cabling and terminations shall comply with IEC 60529 for enclosure protection and IEC 60332 for
flame retardancy. All non-secure loads shall be clearly identified and separated in drawings,
terminal numbering, and labels to avoid inadvertent connection to secure circuits.

17.4 Instrument Air System

The instrument air system shall provide a continuous and clean air supply for all pneumatic
instruments, control valves, and actuators within the facility. The air shall be supplied primarily
from the existing plant air system, with a new instrument air package added to increase capacity
and ensure sufficient redundancy for future operation.
The design pressure of the instrument air system shall be 13 barg (nominal), with the air quality
conforming to ISO 8573-1 Class 1.2.1, ensuring the absence of oil, moisture, and particulate
contamination.
Each air compressor shall be provided with a dryer, filter, and automatic condensate drain. Dual
compressor and dryer configurations shall be adopted to provide 100% redundancy, such that one
unit remains operational while the other is undergoing maintenance.
Instrument air pressure shall be continuously monitored by the PCS. Alarms for low pressure,
dryer malfunction, and high dew point shall be displayed on the operator HMI. Air receiver tanks
shall include pressure transmitters, relief valves, and manual drain valves.
All pneumatic control valves shall be designed for fail-safe operation — typically fail-close on loss
of air supply unless otherwise specified in the control logic or safety analysis. Pneumatic tubing
and fittings shall be stainless steel for outdoor service and rated for the system pressure.
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The instrument air distribution system shall be designed in accordance with ISO 8573-1, ASME
B31.3, and IEC 60079 where applicable for hazardous areas, ensuring leak-tight connections and
proper segregation from process air systems.

18 PACKAGING, TRANSPORT, AND STORAGE

All instrumentation shall be packaged per ISO 4180 and IEC 60297, protected against shock,
vibration, and moisture. Hazard labels and handling instructions shall be applied. Sensitive
electronics shall include desiccants and humidity indicators.

19 SPARES AND MAINTENANCE

Vendors shall provide spare parts lists for:
a) Commissioning spares.
b) Operational spares (minimum 2 years).
Critical spares shall be stocked onsite. Spare lists shall include lead times and shelf life.

20 LIFESPAN AND OBSOLESCENCE

All instrumentation and systems shall be designed for a 25-year service life with normal
maintenance. Vendors shall provide obsolescence management plans, upgrade paths, and
firmware support timelines.

21 QUALITY ASSURANCE AND TESTING

All instruments and systems shall undergo Factory Acceptance Testing (FAT) and Site Acceptance
Testing (SAT). FAT shall verify function, configuration, and communication. SAT shall confirm field
loop integrity.
Calibration certificates traceable to ISO/IEC 17025 shall be provided. QA shall comply with ISO
9001.

22 DOCUMENTATION AND DELIVERABLES

The following shall be delivered:
a) Datasheets (ISA format).
b) Calibration and hazardous area certificates.
c) Hook-up and wiring diagrams.
d) Logic diagrams (PCS & SIS).
e) SIL verification calculations.
f) O&M manuals.
g) Spare parts lists.
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h) FAT/SAT reports.
All documentation shall be in hard copy and searchable PDF formats with project numbering.

23 CONCLUSION
This specification provides the framework for instrumentation and control design, supply, and
lifecycle management. By adhering to international standards, maintaining a 25-year design life,
and ensuring compatibility with PCS, SIS, and cybersecurity requirements, the facility will achieve
long-term safety, operability, and reliability.
For the Emergency and Safety Shutdown System (ESD/SIS), the existing logic solver shall be
retained, with only the controller module upgraded (from Logix5562 to a newer SIL rated, Studio
5000-compatible version). This ensures system continuity, vendor support, and compliance with
modern safety and cybersecurity practices while minimizing disruption to the existing installation.
Additionally, the existing shutdown philosophy shall be retained, ensuring consistency with
previously approved safety strategies while maintaining compliance with the updated project
Cause & Effect (C&E) charts and overall control philosophy.
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APPENDIX A – TABLE OF ASSUMPTIONS

Category Assumption Basis / Reference

Ambient temperature: –10 °C to +55 °C IEC 60068

Environmental Average Air Temperature: 26.7 °C

Conditions Site Environmental Conditions
Ground temperature: 25 to 27.5 °C
as per the Scope-Of-Work
Relative humidity: up to 100%

Power Supply Instrument power: 24 VDC ±10% Industry standard

Hazardous Area
Zone 1, Gas Group IIB IEC 60079
Classification

Custody transfer meters shall be

Flow Instruments API MPMS
Coriolis or ultrasonic
Typical range: –1 to 250 bar(g) (-14.5
Pressure Instruments API RP 551
to 3626 psi(g))

Level Instruments Radar accuracy: ±5 mm Vendor catalogues

Thermowells shall comply with ASME

Temperature
PTC 19.3 TW-2016, including wake IEC 60584, IEC 60751
Instruments
frequency analysis with fs/fn ≤ 0.4
PSV stems and discs shall undergo
wake frequency analysis for high- API 520/521, ASME PTC 19.3
PSVs
velocity/multiphase service with fs/fn TW-2016 (adapted)
≤ 0.4
Control valve trims/stems shall
undergo wake frequency analysis for ISA 75, IEC 60534, ASME PTC
Control Valves
high-velocity/cavitating service with 19.3 TW-2016 (adapted)
fs/fn ≤ 0.4
Controllers: redundant PAC/PLC with
PCS ISA / IEC 61131-3
logic solver capability
Existing SIS logic solver retained;
Rockwell Logix5562 controller
SIS/ESD IEC 61511
upgraded to Studio 5000-compatible
module

Project requirement as per the

Lifecycle Minimum design life: 25 years
Scope-Of-Work