Anexo VII (Del Alcancel Del Servicio) Design Standart Automation Systems Rev2

DESIGN STANDARD : AUTOMATION
SYSTEMS
DRP-1-431-04-9-ES0002
PS025-MI-TS0002
Automation Systems Design Criteria

La Oroya Smelter Design Standards : Automation Systems
DRP-1-431-04-9-ES0000 PS025-MI-TS0000 Automation Standards Instructions
DRP-1-431-04-9-ES0001 PS025-MI-TS0001 General Systems Automation Philosophy
DRP-1-431-04-9-ES0002 PS025-MI-TS0002 Automation Design Criteria
DRP-1-431-04-9-ES0003 PS025-MI-TS0003 Preferred Instrument Equipment Specification
DRP-1-431-04-9-ES0004 PS025-MI-TS0004 Automation Equipment Room Standards
DRP-1-431-04-9-ES0005 PS025-MI-TS0005 Instrument and Controls Installation Specification
DRP-1-431-04-9-ES0010 PS025-MI-TS0010 Instrument Tag Numbering Guidelines
DRP-1-431-04-9-ES0011 PS025-MI-TS0011 Automation Control System Equipment
DRP-1-431-04-9-ES0013 PS025-MI-TS0013 Automation System Documentation

DRP-1-431-04-9-ES0014 PS025-MI-TS0014 Automation Cable Type List

DRP-1-431-04-9-ES0015 PS025-MI-TS0015 Automation System Process Measurement Units

DRP Design Standard Automation System

Document Prepared By:
Xstrata Technology / MIPAC Pty Ltd
Document Approved By:
Design Consultant Brian Forrester
Doe Run Automation Carlos Vivas L., Cesar Chung Ching, Ricardo Caycho
Doe Run Project Manager Godofredo Oporto B

Revisions:
Rev Date By Description Checked
A 28/07/06 ROC Issued for Internal Use GAW
B 21/08/06 WAC Issued for Internal Review BSF
C 23/08/06 BSF Issued for Doe Run Peru Review CCC for DRP
0 08/09/06 WAC Issued for Design CCC for DRP
1 25/09/06 BSF Revised piping standard
2 16/10/06 CC-CV Issued to be used by DRP RC

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PS027-MI-TS0002 Rev2.doc 16-October-2006 Page: i

TABLE OF CONTENTS
1. INTRODUCTION 1
1.1 Purpose and Scope of Document 1
1.2 References 1
2. DEFINITIONS AND ABBREVIATIONS 1
3. GENERAL DESIGN CRITERIA 2
3.1 Statutory Requirements 2
3.2 Codes and Standards 2
3.3 Safety and Environmental 2
3.4 Site Conditions 2
3.5 Hazardous Area Requirements 3
3.6 Automation System Equipment Selection 3
4. OPERATIONAL DESIGN CRITERIA 3
4.1 Design Life 3
4.2 Operational Ratings 3
4.3 Noise 4
4.4 RFI Immunity 4
4.5 Immunity from Magnetic Fields 4
5. GENERAL AUTOMATION DESIGN CRITERIA 5
5.1 Overview 5
5.2 Automation Control Systems 5
5.3 Automation Power Supplies 5
5.4 Instrument Earth Design 5
5.5 Electrical Control Design 5
5.6 Instrument Tag Numbering 6
5.7 Automation Documentation 6
5.8 Process Measurement Units 6
6. AUTOMATION CONTROL SYSTEMS 6
6.1 Scope 6
6.2 Automation Control Equipment Locations 8
6.3 Automation Control System Integrity 8
6.4 Individual Hard-wired Interface Signals 10
6.5 Multiplexed Interface Signals 11
6.6 Control Equipment Enclosures 11
6.7 Equipment Cable Connections 12
6.8 Spare Capacity 12
7. AUTOMATION SYSTEM CABLING 12
7.1 Automation Cabling Overview 12
7.2 Automation Cable Arrangements 12
7.3 Cable Termination Design 13

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7.4 Spare Cable Capacity 13
7.5 Cable Installation Design 13
8. INSTRUMENTATION REQUIREMENTS 14
8.1 General 14
8.2 Instrument Nameplates 14
8.3 Instrument Tag Labels 15
8.4 Calibration Certificates 15
8.5 Process Connections and Instrument Air Supply Connections 15
8.6 Electrical Connections 15
8.7 Equipment Enclosures 15
8.8 Reverse Polarity 16
8.9 Instrument Isolation 16
8.10 Calibrated Range 16
8.11 Instrument Mounting 16
8.12 Instrument Air Supply 17
8.13 Instrument Piping and Tubing 18
9. MEASUREMENT TECHNOLOGIES 19
9.1 Process Analyzers 19
9.2 Nucleonic Instruments 21
9.3 Flow 22
9.4 Level 25
9.5 Pressure 27
9.6 Temperature 30
9.7 Weight 32
9.8 Position Switches 32
9.9 Underspeed Detection 32
10. VALVE REQUIREMENTS 33
10.1 Control Valve Selection 33
10.2 Control Valves (Including Self-Regulating Valves) 33
10.3 On/Off Valves (Actuated Type) 34
10.4 Shutdown Valves (actuated type) 34
10.5 Valve Materials 34
10.6 Design and Manufacturing Requirements 35
10.7 Selection of Actuator Type 35
10.8 Pneumatic Actuators 36
10.9 Actuator Sizing 36
10.10 Electro-Pneumatic Positioners 37
10.11 Hand Wheels 37
10.12 Accessories 37
10.13 Solenoid Valves 37
10.14 Safety Relieving Devices 38

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11. SAFETY INSTRUMENTED SYSTEM INSTRUMENTS 40
APPENDIX A RELEVANT ABBREVIATIONS 41

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PS025-MI-TS0002 Rev2.doc 16-October-2006 Page: 1

1. INTRODUCTION
1.1 Purpose and Scope of Document
The purpose of this document is to provide the automation system design criteria to facilitate the
standardization of measurement and control designs for Doe Run Peru. Automation systems
are defined as the process measurement and control systems that are used to operate the
plants.
The objectives are to achieve a consistent approach to design and equipment selection for the
automation systems across all operational areas, and to ensure the safe and reliable operation
of all automation equipment for the life of the plant. Ongoing maintenance of the plant will also
be assisted by this common design approach and by the use of common types of automation
equipment.
This design criteria document is applicable to instrumentation in all process areas. It is intended
to be read in conjunction with other engineering discipline project specific technical
specifications produced by others.
This document addresses the following design aspects:
Uniformity of design and design documentation.
Uniformity of the Plant Wide Control System.
Uniformity of field instrumentation.
Reliable control and instrumentation systems capable of supporting profitable plant
operation.
A level of plant automation consistent with minimum effective design.
Definition of minimum effective design - A design which achieves the goals of safe,
profitable, and maintainable plant operation, while economizing on capital expenditure.
1.2 References
This document is part of a package of automation standards that shall be applied on Doe Run
Peru. The automation standards set out general requirements only and will be supported as
necessary by more detailed project specifications and standard drawings.
The automation standards are listed in an index document that identifies the standards and the
associated project specifications and standard drawings. The principal automation standards
are also listed on the front cover of this document.
2. DEFINITIONS AND ABBREVIATIONS
For relevant abbreviations, refer to Appendix A.

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3. GENERAL DESIGN CRITERIA
3.1 Statutory Requirements
All statutory requirements for designing, constructing and operating the plant in the La Oroya
Smelter shall be complied with. The applicable relevant statutory requirements shall be listed in
project specifications. Where relevant statutory requirements have not been identified in
automation standards and project specifications, it is the designers responsibility to determine
these requirements.
Particular attention is drawn to the requirements of the relevant Mining Regulations, Electricity
Acts, Environmental Protection Acts, the Workplace Health and Safety Act, and any relevant
local authority permits and regulations.
3.2 Codes and Standards
All equipment and installations shall comply with the codes and standards nominated in the
automation standards or project specifications. Where no existing automation standards or
project specifications address the specific requirements, work shall conform to the most current
IEC standard or internationally recognized standard that the supplier would normally comply
with.
If a conflict is identified between any of the statutory regulations, standards, reference
documents, and the requirements on drawings, datasheets and this standard, the information
shall be documented and forwarded to Doe Run Peru in accordance with relevant contract
procedures.
3.3 Safety and Environmental
The relevant workplace health and safety requirements and environmental considerations shall
be identified in project specifications. Where specific requirements have not been identified and
documented, the Peruvian safety and environmental considerations shall apply, and the plant
designer shall be responsible for determining these requirements.
3.4 Site Conditions
Refer to the Doe Run Peru, La Oroya Site General Information specification for the site
conditions and requirements.
In addition to these requirements, all electrical equipment shall be designed to operate
continuously at full load for 24 hours per day, 365 days per year. Equipment may be required to
be protected against an environment subject to abrasive and corrosive dusts and liquids and
vapors.
The design capacity shall allow for the manufacturers recommended maintenance activities
and minor breakdowns to take place.
It should be noted that the La Oroya site is located at an elevation of 3800m above sea level
and so all electrical equipment should be capable of operating as specified at this elevation.
Motors shall be nameplated for the altitude of operation on site. DRP will not accept de-rating
for electric motors.
The ambient temperature can range from -5C (minimum, winter) to 30C (maximum, summer).
Particular attention should be paid to the suitability of equipment to operate over this
temperature range, and in particular to pneumatic equipment that could be affected by the
presence of moisture at low temperatures.

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3.5 Hazardous Area Requirements
All electrical equipment that is to be installed in locations where flammable atmospheres may
exist shall comply with the relevant Peruvian hazardous area requirements.
Design work for hazardous area equipment shall not commence until an approved project
specification defining the following is available:
Relevant Peruvian legislative requirements and standards
Doe Run preferred explosion protection techniques and design standards
Explosion protection identification and labeling requirements
Documentation and certification requirements.
3.6 Automation System Equipment Selection
3.6.1 Instrumentation and Bulk Equipment
Equipment such as instruments, valves, junction boxes and other miscellaneous items shall be
selected by plant designers to best suit each specific application. The selection will be made in
accordance with the requirements set out in:
This design criteria document
The project automation standard titled Preferred Instrument Equipment List
The above project standards constrain the design processes in the interests of standardization,
but leave the final responsibility for selection of suitable technologies and devices with the plant
designers.
3.6.2 Control System Equipment
Doe Run Peru aim to have a consistent control system implementation across all plants as part
of the Doe Run Peru - Projects Management. This objective is expanded elsewhere in this
document, as well as in the project automation standard titled General Automation Philosophy.
To facilitate and progress this objective, early design decisions applicable to all plants have
already been made by Doe Run. (Central control room with common DCS and equipment)
Requirements for control equipment in accordance with the Doe Run decisions are detailed in
the project specification titled Nominated Automation Control System Equipment, and are
mandatory for all plants.
4. OPERATIONAL DESIGN CRITERIA
4.1 Design Life
Electrical equipment shall be designed to operate continuously for the design life of the plant in
the conditions typically experienced at the location in which equipment is installed. Plant design
life requirements are nominated in project specifications for each plant.
4.2 Operational Ratings
Equipment operational ratings (such as load current) as shown on drawings shall be worst case
ratings taking into account all factors such as process design limits and supply voltage
tolerances.

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All components shall be selected and installed such that areas of the plant can operate
simultaneously at the full load rating shown on the drawings under the worst climatic conditions.
The installation shall be arranged to facilitate ease of operation, inspection and maintenance
and shall incorporate all safety measures necessary to protect operating and maintenance
personnel.
Installation details provided in design documentation shall be strictly in accordance with the
manufacturers recommendations.
4.3 Noise
As a minimum, all plant and equipment shall comply with the Peruvian Workplace Health and
Safety (Noise) Advisory Standard.
Control valve noise shall be calculated according to the latest edition of the ISA S75.17 or
equivalent.
In addition, all continuously operating equipment under normal operating flow conditions shall
not exceed the limits as detailed in the Doe Run Peru Site General Information Specification.
This requirement does not apply during start-up, shutdown or process upsets. Normal
operating flow conditions refer to flows between the minimum and maximum flows stated on the
data sheet.
Noise that is generated as a pure tone (single frequency or narrow bandwidth noise) has an
aggravating effect that is significantly greater than an equivalent sound pressure level of
broadband (multiple frequency) noise, and the acceptable sound pressure level of pure tone
noise is therefore much lower.
Special noise control trim shall be used where necessary to reduce noise to meet the specified
levels. Equipment which operates during plant excursions only (such as relief valves or
blowdown vents) is not required to meet the design noise limit, however, designers shall use the
best available design practice to minimize noise levels having particular regard for personnel
safety.
4.4 RFI Immunity
Selected instruments shall be RFI immune, complying with SAMA PMC 33.1C (IEC 801-3) or
equivalent standard in the frequency range from 20 to 1000 MHz and field intensity up to 10
mV/m.
4.5 Immunity from Magnetic Fields
Consideration shall be given to the suitability of equipment selected for installation in areas with
extra-ordinarily high magnetic fields.
Equipment with CRT displays and instruments with magnets may not function correctly in this
environment. Of particular interest are positioning equipment, reed switches, inductive pick-
ups, and magnetic flowmeters. Also of note are weighing systems in which material attraction
between vessel and support may occur.

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5. GENERAL AUTOMATION DESIGN CRITERIA
5.1 Overview
Compliance with Doe Run Peru standards and specifications is mandatory. Before
commencement of any work or procurement that deviates from a standard or specification,
approval shall be obtained from Doe Run for that specific deviation.
5.2 Automation Control Systems
This document sets out design guidelines for the control systems, covering such items as
equipment housings, system integrity, interface technologies, power supplies, and spare
capacity. For information on equipment selection refer to clause 3.6.2 above.
5.3 Automation Power Supplies
All automation measurement and control system equipment shall be protected against mains
power system disturbances, spikes, voltage fluctuations or loss of supply. Dedicated
Uninterruptible Power Supply (UPS) equipment shall be used for this purpose.
UPS equipment shall be installed for every control room and automation equipment room, and
each UPS shall be sized to provide 30 minutes of operation for the equipment at that location in
order to allow the control system to shut the plant down in an orderly manner.
The standard power supply for automation equipment is 120VAC 60Hz. UPS power will be
distributed as a single phase supply with Active and earthed Neutral connections.
5.4 Instrument Earth Design
Earthing of automation systems has to be carefully designed to avoid introducing unacceptable
levels of electrical noise into measurement and control circuits.
A separate instrument earth circuit is required throughout the plant, segregated from the
electrical safety earth. It is essential to ensure that electrical supply earth fault currents can not
flow through the instrument earth.
The instrument earth connections in each equipment room shall be insulated from the normal
electrical earth in the room, and a single electrical connection shall be made from the instrument
earth to an appropriate earthing point.
Automation equipment cabinets and enclosures containing mains powered electrical equipment
shall be earthed to the electrical safety earth.
The instrument earth shall only be used as an instrument signal reference point and to connect
instrument cable screen drain wires.
Details of typical earthing arrangements for automation equipment are shown on project
standard drawings PS025-MI-0-000-9-0032 (DRP-1-300-27-0032) and PS025-MI-0-000-9-0033
(DRP-1-300-27-0033).
5.5 Electrical Control Design
The design of electrical control circuits shall adhere to the requirements detailed in the project
electrical specifications and associated typical schematic diagrams.

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5.6 Instrument Tag Numbering
Guidelines for the allocation of instrument tag numbers and electrical control signal tag numbers
are defined in the project specification titled Instrument Tag Numbering.
5.7 Automation Documentation
The design of automation systems shall follow best industry engineering practices, and shall be
well documented in accordance with project standards. Guidelines for documentation are set
out in the automation standard titled Automation System Documentation.
Emphasis shall also be placed on producing support documentation that Doe Run Peru will be
able to use to maintain the complex after the construction phase is complete.
5.8 Process Measurement Units
All process data measurement units shall be specified using the engineering units listed in the
automation standard titled Automation System Process Measurement Units, unless specific
exceptions are approved by Doe Run Peru. These units shall be used for local gauges,
transmitter indicators and for all definitions and displays throughout the automation control
systems.
6. AUTOMATION CONTROL SYSTEMS
6.1 Scope
6.1.1 General
The measurement and control equipment to be provided for Doe Run Peru serves the following
functions:
Control and monitoring of process plants, including process automation
Control and monitoring of equipment packages, including equipment automation
Execution of safety-related trip and permissive functions
Manual plant shutdowns.
The control systems that provide these functions are discussed in the following sections.
If required by design, standard or regulation, a Fire and Gas System shall be provided as a
separate, segregated system. Fire and Gas System design criteria are not addressed in this
document.
6.1.2 Process Control System (Plant Wide Control System)
The primary process control system to be used in all new plants will be a common integrated
Distributed Control System (DCS). A network of DCS controllers will effectively form a single
plant wide control system.
The DCS will provide control, monitoring and automation functions for all process plants
included in Doe Run Peru.
All plants will use the same DCS equipment, and programming standards will be enforced
across all plant areas to ensure that the entire DCS has a common look and feel.

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Where the DCS communicates to smart measuring or control equipment that is capable of
implementing its own control functions, those local control functions shall not be implemented
unless they can be programmed and monitored using the standard DCS programming tools.
For example, control algorithms may be programmed into Foundation Fieldbus devices directly
from the DeltaV DCS.
The use of independent single loop or multiple loop controllers is generally not permitted.
Clause 5.3 of the Doe Run Peru automation standard titled General Automation Philosophy
discusses allowed exceptions.
6.1.3 Equipment Package Control
Individual equipment packages with special requirements may be fitted with a dedicated PLC or
other controller to facilitate control. These special requirements are limited to the following.
Applications with high speed scan rate requirements
Motor or equipment protection that cant be safely achieved via the DCS
Specific proprietary control requirements relating to a particular piece of equipment
Each PLC or other local controller will communicate with the DCS to provide consistent
monitoring and supervisory control facilities.
PLC equipment shall be in accordance with the Doe Run Peru automation standard titled
Automation Control System Equipment.
6.1.4 Safety Related Functions
Local equipment safety interlocks and trips may use approved dedicated control equipment or
hard-wired circuits in accordance with relevant codes and standards. Examples could include
conveyor pull-wires and burner management systems. These functions shall not be
implemented within the DCS or standard PLC controllers, but they shall be monitored by the
DCS or PLC as appropriate so that operators will be aware of the status of the trips and
interlocks.
Where plant hazard identification and hazard analysis studies indicate that the level of risk
imposed on personnel and equipment by everyday plant operation is unacceptably high, and a
decision is taken to use instrumented functions to provide a calculated level of risk reduction,
those instrumented functions shall be implemented in a separate, segregated Safety
Instrumented System in accordance with IEC61508 / IEC61511.
Design criteria for implementation of a Safety Instrumented System are not addressed in this
document. If a Safety Instrumented System is required for any plant, a Safety Management
Plan and all associated documentation shall be prepared in accordance with IEC61508 /
IEC61511 before design work commences on any part of the Safety Instrumented System.
Process interlocks and trips provided for equipment protection and to ensure satisfactory
process operation shall be implemented in the DCS or PLCs as appropriate.
6.1.5 Manual Plant Shutdowns
Individual process plants will use manual shutdown functions to provide plant operators with an
assured means of stopping plant operation. These will be activated by dedicated electrical
circuits initiated from local emergency stop stations or from hard-wired switches in the plant
control rooms.

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6.2 Automation Control Equipment Locations
6.2.1 Centralized Control Rooms
Doe Run Peru will provide a centralized control room serving the copper production plant.
The centralized control room will contain the DCS operator workstations plus any associated
equipment required by the operators, and will serve as the normal operating points for the
plants.
Project design specifications will establish the minimum requirements for environmental
protection and controls within the control room.
6.2.2 Local Control Points
Local control points will be provided only where it is necessary to operate plant and equipment
from an adjacent location
Where a local control point is installed, a monitoring function shall still be provided in the
centralized control room for that plant.
6.2.3 Automation Equipment Rooms
Within each plant area, dedicated equipment rooms will be provided to house automation
equipment. DCS equipment and automation UPS equipment will be installed in each equipment
room.
Project design specifications will establish the minimum requirements for environmental
protection and controls within the equipment rooms.
PLC controllers and other local control equipment may be installed in the equipment rooms as
appropriate.
6.3 Automation Control System Integrity
6.3.1 General
Overall integrity of a control system has to be considered on a pipe to pipe basis including
measuring and control interfaces and cabling as well a the DCS or PLC itself, and it has to
include consideration of failures and maintenance work outside of the DCS and PLC.
6.3.2 Objectives
Design for control system integrity shall be based on engineering practices that are intended to:
Minimize the risk that protective control functions (functions that are intended to protect
personnel and equipment from harm in the event of hazardous conditions occurring) can
fail or be disabled in an unsafe way. Unsafe in this context means that the function is
disabled without activating the protection, and without generating an alarm.
Minimize the risk that a single fault anywhere on the control system is capable of stopping
production in any plant area.
Provide facilities for carrying out maintenance work and engineering work on the system
with minimal disruption to production.
Control system redundancy shall be utilized where appropriate to assist in achieving the above
objectives. Redundancy is typically applied to critical items where a single fault can affect a
large quantity of IO points and control functions, and more particularly where the time needed to
repair the fault could be substantial. Redundancy allows production to continue, and therefore

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allows the fault to be attended to in a reasonable time frame rather than as an emergency
measure.
6.3.3 Process Control System Redundancy
Within the process control system DCS, redundancy will be applied as follows:
DCS central processing units shall be made redundant.
All DC electrical supplies to DCS components shall be made redundant.
DCS communications links between plant areas shall be made redundant.
Redundant DCS I/O cards shall be used where required.
Redundancy requirements for instrument control loops should be assessed on a case by case
basis with the following as a guide to formulating the specific requirements:
Where an instrument is for indication and warning alarms only no redundancy is
required.
Where an instrument is part of a control loop, which can be put into manual control mode
for a short period without adversely affecting production no redundancy is required.
Where an instrument is critical for plant control and is likely to require frequent
maintenance consider the use of redundant instruments, applying the principle of
Minimum Effective Design.
Power supplies for instrumentation in critical areas shall be designed to a level of redundancy
that will allow for maintenance activities and/or breakdowns to take place without loss of
significant plant production capacity.
Redundant communications links shall use separate cables and diverse cable routes for each
side of the link so that major physical damage to a cable route is unlikely to affect both sides of
the communications link.
6.3.4 PLC Control System Redundancy
Redundancy requirements for PLC controllers shall be determined on a case by case basis,
using a risk management based approach.
6.3.5 Interface Circuit Integrity
Instrumentation and control interface circuits shall be designed to fail-to-safe conditions such
that the system and plant shall move to or remain in a safe state after failure of signal
connections, electrical power or instrument air. For example:-
Except for high voltage circuits, all motor stop circuits shall be designed so that the when
the stop button is pushed the control circuit is opened and the related control relay is de-
energized.
All circuits that monitor the health of an item of equipment shall provide a "1" signal
(circuit complete or closed contact) to the monitoring or control equipment.
Where there is an interposing relay in such a circuit, the relay shall be energized in the
healthy condition and de-energized in the fault condition.
Where a position limit switch is used to detect if a valve is in a certain position, the switch
shall be actuated when the valve is in that position and this shall cause the contact to
move to the closed state. The closed contact ("1") signal shall complete the circuit to the
control system input point.
Allowance shall be made for status signals to be transmitted to the DCS for diagnostic
and display purposes.

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6.3.6 Manual Shutdown Systems
Manual shutdown systems shall be designed for simplicity and high reliability.
Shutdown systems shall be energized during normal operation, opening a contact to cause
shutdown.
All pneumatic components in shutdown systems shall be pressurized during normal plant
operation and shall be vented to cause shutdown.
6.4 Individual Hard-wired Interface Signals
Where individual measurement and control devices have a dedicated and direct electrical signal
connection to the DCS, the signals shall be designed as follows:
Signal Type Connects To Signal Description and Ratings
AI Analogue Input Continuous measuring
and indicating devices
2 wire, 4-20 mA, with digital HART
communications.
Devices may be powered directly from the
4-20 mA loop connection (loop powered),
or may require a separate power supply
connection (field powered 120V AC).
Loop powered devices shall be used
where available.
AO Analogue Output Continuous control and
indicating devices
2 wire, 4-20 mA, with digital HART
communications.
Devices are usually powered directly from
the 4-20 mA loop connection (loop
powered)
DI Digital Input Switches, relay contacts,
electrical control
equipment
2 wire, 24VDC, 120 VAC
Devices may provide volt-free contacts
(loop powered) or may switch 24VDC
signals (field powered). Loop powered
connections shall be used wherever
possible, and shall always be used for
signals to the DCS from a PLC.
All signals to DCS digital inputs shall be
connected using two wires per input. The
use of a common positive or a common
negative wire for multiple input signals is
not permitted.
Digital pulse inputs to the DCS should not
exceed the 75Hz maximum frequency
limit imposed by the DCS input cards.
DO Digital Output Output devices requiring
a control voltage shall
use an interposing relay.
DCS outputs will be 24VDC. These
connect to relay boards. Each relay
contact rating will be at least 120VAC, 3A.

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Signal Type Connects To Signal Description and Ratings
Solenoids, indicators,
relay coils, electrical
control equipment
2 wire, 24V for instruments and
2 wire, 120VAC, 3A rating.
Are to be volt-free contact (field powered).
All signals from DCS digital outputs shall
be connected using two wires per output.
6.5 Multiplexed Interface Signals
6.5.1 Electrical Control Equipment
Electrical control equipment may be connected to the DCS using DeviceNet if it can be
demonstrated that there are cost benefits to the project.
DeviceNet connections to electrical control equipment can be implemented in the following
ways:
By direct connections to smart equipment which has a native DeviceNet interface and
DeviceNet device descriptor files provided by the manufacturer. This is the preferred
method for large or critical drives as it allows device parameters to be viewed by
maintenance personnel using DCS workstations. For example, a smart overload relay or
motor protection relay can provide access to all trip parameters and trip history data
without requiring any additional DCS programming.
By placing a DeviceNet IO block adjacent to the electrical control equipment in order to
provide discrete signal connections to that equipment. This method may reduce cabling
between the DCS and the electrical control equipment, but does not allow the electrical
control equipment parameters to be viewed from the DCS workstations. This approach
would be appropriate for smaller, non-critical drives.
DeviceNet design shall comply with relevant project specifications and standard drawings.
6.5.2 DCS Communications Links to PLC Controllers
Communications protocols and design criteria will be established for each individual PLC
controller once exact model and application details are known. Available physical layer
communications protocols are:
RS-232 (This protocol is least preferred and shall not be used unless there is no choice)
RS-485
Ethernet (TCP/IP Ethernet over optical fibre cables is preferred by Doe Run Peru and
shall be used where appropriate.)
6.6 Control Equipment Enclosures
DCS and PLC equipment that is to be housed in automation equipment rooms shall be installed
in freestanding fully enclosed cabinets. All equipment installed in the cabinets shall be fully
accessible and removable for maintenance purposes.
Control equipment that is mounted in the field adjacent to the equipment under control shall be
mounted in enclosures designed to protect the control equipment against the environmental
conditions prevailing at that location.

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Enclosure design shall comply with the enclosure requirements defined in the automation
standard titled Automation Control System Equipment.
6.7 Equipment Cable Connections
All equipment enclosures shall provide adequate cable entry space for the intended usage.
Cable entry shall be by removable metal cable gland plates or alternative cable clamping
arrangements that provide support for the cable outer sheath and seal the cable entry point
against ingress of dust, contaminants and vermin.
Terminals for connection of instrument and electrical cables shall be either a screw type or a
spring clamp type in accordance with the automation standard titled Preferred Equipment List.
Insulation displacement technology shall not be used.
Note: These requirements apply only to the termination points for field cabling, not to internal
equipment wiring which may use any appropriate technology. Individual cores of field cables
may be disconnected and reconnected many times over the life of the plant
6.8 Spare Capacity
The following spares guidelines shall be applied to each DCS controller and PLC controller:
Each controller shall have a spare capacity of 20% installed IO for discrete hardwired
interface signals. This shall be interpreted as having adequate spare channels on IO
modules installed at that location to allow the number of points of each type of IO (AI, AO,
DI or DO) to increase by 20%.
Each controller shall have at least 20% spare slots for IO modules, and shall have a
minimum of three (3) spare slots.
Controller capacity (memory, processor capability, power supplies, ventilation) shall be
adequate to cater for the additional IO points and modules should the above spare
capacity be used.
Marshalling cabinets shall have adequate capacity to allow termination of the additional
IO points should the above spare capacity be used.
7. AUTOMATION SYSTEM CABLING
7.1 Automation Cabling Overview
The selection of cables and the preferred cable size ranges for automation systems are defined
in the automation standard titled Automation Cable Type List.
This document sets out design guidelines for the installation, termination and protection of
cables.
7.2 Automation Cable Arrangements
Dedicated cabling shall be used for all automation services, including all optical fibre
communications network cabling, and the cabling shall generally run directly from control
systems to measuring and control equipment or electrical control equipment as required.
Automation signals of different voltage levels shall be segregated into separate cables. Under
no circumstances shall a cable carrying 120VAC on any core be used for 24VDC digital or
analogue signals.

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Where appropriate, instrument junction boxes shall be provided to marshal the field
instrumentation cabling to convenient locations on each installation package. Junction box
location shall be selected to minimize the length of the instrument cables. Note that junction
boxes used for marshalling are not mandatory, and it is acceptable to run instrument cables
directly to DCS cabinets in the automation equipment rooms, particularly for short cable runs.
However the use of a single multi-pair cable to replace multiple single pair cables may offer the
following advantages in most cases:
Lower capital and installation cost
Easier addition of new circuits in the future
Easier cable gland installation in DCS cabinets, which typically have limited cable
glanding space available.
Instrument junction boxes shall be segregated for 24VDC and120VAC signals, and no general
power supplies shall be connected to any instrument junction boxes. No process or services
fluids other than instrument air shall be reticulated within instrument junction boxes.
Plant designers may choose to segregate 4 to 20 mA analogue instrument signals and 24VDC
digital instrument signals into separate cables and junction boxes for practical reasons, but this
is not mandatory.
7.3 Cable Termination Design
All pairs (including spare or unused pairs) shall be identified using an approved wire marking
system.
All wires shall be terminated with insulated bootlace ferrules of the correct size crimped with a
ratchet crimping tool. Two conductors may be terminated in a single terminal provided that they
are crimped into a single double-wire bootlace ferrule of the correct size. Space of 70mm
minimum shall be left between the terminal strip and ducting to enable the wire identification
ferrules to be clearly visible.
The screen or drain wire for individual pairs and the overall cable screen shall be connected to
the instrument earth at the DCS marshalling cabinet end only. The continuity of the cable
screen, (drain wires) shall be made continuous through junction box terminals. The drain wire
shall be cut out and insulated with heat shrink tubing to protect against inadvertent earthing at
the field instrument end.
7.4 Spare Cable Capacity
A minimum of twenty percent spare capacity shall be allowed for in the main runs of multi-core
and multi-pair cables.
Termination design shall allow for every spare core / pair to be terminated at each end of the
cable.
7.5 Cable Installation Design
Design criteria for detailed cable installation requirements and cable protection requirements
are not included in the scope of this document, but a brief summary of requirements is
presented below. Project specifications and standard drawings shall be prepared as required to
detail the requirements for cable installation design. These documents and drawings shall be
used by Doe Run Peru to prepare the detailed installation documentation for the installation
contractor.
All cables associated with the field instrumentation and control system that are installed outside
of control rooms, auxiliary equipment rooms or electrical switch rooms require protection against

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possible physical damage. The cable protection may be implemented by either of the following
means:
By installing cables in flexible conduits, steel conduits or ducts in all areas where the
cables are not adequately protected by the cable support systems, for example by metal
cable trays.
Cables that are confined to control rooms, automation equipment rooms or electrical
switchrooms shall be installed in such a manner that the risk of physical damage is minimized.
Cables shall be installed away from sources of heat likely to raise the temperature of the cables
above 50C.
24 VDC instrument cables shall be segregated from power cables. In particular, all instrument
cabling shall be installed so that it is well isolated from any power cabling associated with
variable speed drives.
It is essential that during the cable termination process, that screen off-cuts are managed and
collected, and that all screens are sealed with heat shrink tubing at cable ends.
8. INSTRUMENTATION REQUIREMENTS
8.1 General
Field instrumentation shall comply with the relevant requirements of the Doe Run Peru
automation standards, as well as all relevant Peruvian regulations and standards. Refer clause
3.1 above.
In general, unless otherwise specified, all instrumentation regardless of location shall be
designed for the ambient temperature range specified for the site. Refer clause 3.4 above.
This requirement may be relaxed in special cases, for example in air-conditioned rooms.
All instruments shall be supplied fully assembled where possible, factory calibrated, set-up and
configured with all parameters so they are ready for operation. The tag number and service
description shall be included in the configured parameters.
The materials of construction of all instruments shall be suitable for the specific process
requirements, and shall be detailed on instrument data sheets during the design process.
Transmitters shall be considered for process alarm and trip applications, taking into account
minimum effective design.
It should be noted that all process controls will be implemented in the plant wide DCS, and that
the use of independent single loop or multiple loop controllers is generally not permitted.
Clause 5.3 of the automation standard titled General Automation Philosophy discusses
allowed exceptions.
8.2 Instrument Nameplates
All instrumentation including actuated valves shall be identified with the manufacturers
standard, permanently attached metal nameplate. Stainless steel nameplates are preferred.
The means of attaching the nameplate shall be by stainless steel screws or rivets.
Aluminum nameplates shall not be used anywhere within the copper refinery building, and this
requirement shall be stated on all instrument data sheets issued for the copper refinery.
Nameplates shall show the manufacturer, model number, serial number, size, rating, date of
manufacture and other necessary equipment details.

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Nameplates on control valves shall state the manufacturer, model, serial number, air supply
pressure range, valve design temperature and pressure, body size and material, trim size and
material, trim characteristic, Cv, actuator spring range and bench set.
All explosion-protected (Ex) items of equipment shall be fitted with permanently attached
stainless steel labels. Labeling shall be in accordance with Peruvian Standards as discussed in
clause 3.5 above.
8.3 Instrument Tag Labels
All instrumentation including actuated valves shall be fitted with an additional, permanently
attached 316SS label complete with the instrument tag number engraved or stamped thereon.
The label shall be attached by flexible stranded stainless steel wire, screws, rivets or bolts to the
instrument or control valve body. The label shall be removable to allow for instrument
replacement.
For stand-mounted instruments, a similar label shall be permanently fastened to the instrument
stand.
Typical label details are shown on the project standard drawing titled Instrument Tag Labels.
8.4 Calibration Certificates
Each instrument that can transmit an electronic signal to the DCS shall be supplied with its own
calibration certificate showing the serial number of the instrument, tag number, purchase order
data, equipment name, calibration details, description of the tests performed, date of calibration
test, place of calibration and signature of person conducting the tests. Calibration certificates
shall be in the English language.
8.5 Process Connections and Instrument Air Supply Connections
Doe Run Peru has specified ANSI flanges, piping and pipe fittings, with NPT connectors.
For each plant area, instrument connections shall comply with the specifications and ratings in
use by the plant designer process, mechanical and piping groups.
The instrument process connections shall match the piping/vessel process connections for each
type of instrument. Reducers may be required on some of the screwed connections. Standard
instrument hookup drawings shall be prepared for each type of instrument to detail the required
process connections and instrument air connections.
8.6 Electrical Connections
Cable gland entries for instrument signal and electrical connections shall have M20 1.5mm
female threads. Where this thread type is not available with instrumentation then suitable
thread adaptors shall be used to connect the cable gland to the instrument connection.
For instruments that are supplied with an integral flexible cable, an in-line junction box shall be
used to connect the flexible cable to the main cable.
8.7 Equipment Enclosures
The minimum ingress protection classification for field-mounted instrumentation is
IP65/NEMA4X to IEC 60529. Field instrumentation shall be rated to IP66/NEMA4X when
installed in areas that can be hosed down by plant operators.

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Junction boxes shall have external mounting tabs so that the enclosure IP/NEMA rating can not
be affected by mounting bolt penetrations in the sealed section of the enclosure.
Complex process stream analyzer systems shall as a minimum comply with the enclosure
requirements defined in the automation standard titled Automation Control System Equipment.
The following additional requirements shall also be applied:
Analyzers which are critical to facility operation or have an ambient temperature limit of
40C shall be installed in air conditioned houses o r cabinets. All other analyzers shall be
supplied with forced air ventilation. Cooling and ventilation shall be provided by dual
redundant units.
These enclosures shall be located as close to the process sample points as practical.
More than one analyzer measuring and sample system may be installed in a single
enclosure if the sample line length is within the analyzer manufacturer's specifications.
8.8 Reverse Polarity
Each instrument shall be immune to damage caused by reverse polarity connection and output
short/open circuit.
8.9 Instrument Isolation
All instruments connected via process impulse tubing shall be provided with a primary isolation
device, installed as close as possible to the process, and also with a secondary isolation device
installed as close as possible to the instrument.
The secondary isolation device shall be delivered to site with the instrument, and may be in the
form of a manufacturers standard valve manifold. This device shall incorporate a vent/drain
facility to enable the impulse tubing to be depressurized safely.
The primary isolation device shall form part of the process piping design.
For instruments connected directly to the process, the isolation and vent/drain valves shall be
provided to facilitate maintenance, but shall not affect the instrument performance.
8.10 Calibrated Range
The accuracy, resolution and repeatability of the instrument shall be taken into account when
deciding on the number of digits to be displayed on indicator panels and operator stations.
Indicators shall not needlessly display digits that are less than the measurable accuracy or
precision of the instrument.
Meter scales and instrument spans shall be a decimal multiple of 1, 1.2, 1.5, 2, 2.5, 3, 4, 5, 6, 8
and 10. In the instance of the meter not directly measuring the displayed parameter (eg,
differential pressure being measured to indicate flow), the scale of the displayed parameter shall
be selected from the meter scales listed above and the measuring instrument range shall be
scaled to suit.
8.11 Instrument Mounting
Local indicator instrumentation such as dial thermometers, pressure gauges shall be plainly
visible from grade or platform.
All instruments (including valves) shall be installed to facilitate maintenance, wherever
practicable, using the following criteria:

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For the purpose of this section, readily accessible shall mean accessible for operation,
maintenance or replacement from grade or permanently installed platforms, without
requiring the use of scaffolding, portable ladders or machinery such as extendable mobile
work platforms.
Where an instrument system comprises a primary element mounted in a process line or
vessel, and a detached amplifier, transmitter or control device connected by sealed
capillary tubing, impulse tubing or cable, then the detached device shall be mounted so
that it is readily accessible, even if the sensor element cannot be practically mounted in
an accessible location. If the primary isolation valves at the primary element are not
readily accessible, then additional readily accessible isolation valves shall be provided in
the impulse tubing. If the instrument is fitted with an instrument manifold, the valves in the
manifold may be used as isolation valves. However, additional valves may be required if
the process fluid requires double-block-and-bleed isolation.
Instruments which require operations or maintenance access weekly or more frequently,
and instruments which are critical to process operations or safety shall be located so that
they are readily accessible.
The preferred mounting arrangement for instruments and ancillary equipment where
appropriate shall be 50mm pipe stands as detailed in the project standard hook up
drawings.
Instruments which require operations or maintenance access daily or more frequently, or
which repair or scheduled maintenance is labour intensive or requires the use of heavy
hand-carried tools, shall be readily accessible via a stairway, (i.e. access via a fixed
ladder is not acceptable in such cases).
Instruments which do not meet the criteria above shall be located to give the best
possible access within project cost constraints.
Instrument mounting brackets and associated fasteners shall be 316 SS as standard, but
alternative materials may be specified to suit project requirements. Mounting brackets shall be
included in the supply of all instruments with exception of line/flange mounted instruments.
Care shall be taken with stainless steel coming in contact with galvanized metal. Galvanic
action between the two dissimilar metals causes corrosion.
Consideration shall be given to the protection of instruments in areas prone to spillage. The
instruments may be fitted with suitable enclosures or protective bag covers with drawstrings.
(This still allows the use of local indicators by temporarily removing the bag when required).
Sunshades shall be fitted to all instruments exposed to direct sunlight if the maximum operating
temperature of the instrument will be exceeded. Details of construction for the sunshades shall
be included on the project standard instrument hookup drawings.
Instrument stands shall be positioned such that the stands and instruments do not intrude into
walkways. Instruments and any ancillary equipment shall not be mounted on handrails.
In general, remote mounted instruments, junction boxes and local panels shall be mounted at
the outside edges of each plant envelope, where practicable. This requirement is particularly
applicable to corrosive areas.
All equipment shall be installed strictly in accordance with the manufacturers instructions.
8.12 Instrument Air Supply
All instrumentation and control valves requiring an air supply shall be supplied from an
instrument-quality air reticulation system.
The instrument air supply system shall include compressors, dryers and filters capable of
supplying air to the following specifications

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Maximum dew point of -5C at line pressure
Maximum particle size of 3 microns in the air stream
The maximum total oil or hydrocarbon content, exclusive of non-condensables, shall be
as close to zero as possible, and under no circumstances shall it exceed 1 part per
million (ppm) on either a weight or a volume basis.
The capacity of the instrument air supply system shall be such that in the event of compressor
failure, sufficient air is available in reserve to operate the instrumentation enabling the plant to
shutdown safely. The minimum acceptable hold-up time is 30 minutes. At the end of this time,
the air pressure shall not be lower than the specified minimum pressure.
Air receivers in each process area shall be individually sized to cater for the reserve capacity
required.
The instrument air supply system and piping shall be designed to meet the following
requirements, measured at any point in the system:
Nominal pressure 680 kPa(G)
Maximum pressure 800 kPa(G)
Minimum pressure 500 kPa(G)
All pneumatic instrumentation and actuated valves shall be designed for service with an
instrument air supply which may vary in service over the pressure range specified above.
All instrument air consumers shall be fitted with a dedicated air filter/regulator with manual drain.
The air/filter regulator shall remove water, oil and sediment to the specification required by the
air consumer. A nominal 5 micron filter element is generally acceptable. The sediment bowl
and cage shall be constructed from a non-metallic or corrosion resistant material. The regulator
setting shall be selected to suit each application in accordance with supply pressure
requirements as shown on instrument data sheets.
Each instrument air consumer shall be supplied via a dedicated lockable isolating ball valve.
Each ball valve shall be fitted with a stainless steel tag stamped with the instrument air
consumer tag number.
In general, where multiple air consumers exist on a control valve, a single air filter/regulator and
isolation ball valve shall service all components.
The instrument air distribution piping shall be such that the air take-off points are located on the
top of headers and manifolds. Drain valves shall be located at the lowest points.
8.13 Instrument Piping and Tubing
Process impulse tubing and instrument air supply tubing shall be bare 316-grade stainless steel
unless otherwise specified or the process fluid or the process ambient conditions dictate
otherwise.
Process impulse tubing shall be O.D.
All threads shall be NPT.
The maximum length of any impulse tubing shall be 15 metres. All impulse lines shall be
installed with a minimum gradient of one in one hundred (I in 100) to ensure that the entire line
is self-draining. Impulse tubing shall not be used to support or brace instruments.
Plastic tubing shall not be used for air supplies to actuated valves or instruments, even in
areas of high vibration. A short flexible braided 316-grade stainless steel, or project specific
material, hose shall be used.

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In extreme acid/corrosive environments, instrument air tubing shall be (black) flame retarding
polyethylene or PTFE unless the environmental conditions require the use of different materials.
Special consideration shall be given to areas with ammonia, chlorine, chlorides and hydrochloric
acid.
Pneumatic equipment that may require frequent disconnecting for maintenance purposes shall
be fitted with flexible braided 316 stainless steel hoses unless the process fluid or the process
ambient conditions dictate otherwise. Stainless steel fittings shall be 316-grade.
Stainless steel valves and compression fittings shall be used unless the process fluid or the
process ambient conditions dictate otherwise. Tubing connections shall utilize two ferrule
mechanical grip compression fittings.
Where local air distribution manifolds are used, a minimum spare outlet capacity of 25% and a
drain point with a valve shall be provided.
All personnel installing stainless steel fittings and tubing shall have appropriate competency
certificates from the manufacturer to carry out such work.
9. MEASUREMENT TECHNOLOGIES
9.1 Process Analyzers
9.1.1 General
Process analyzers cover a wide range of measurements. The specific requirements are
detailed on the instrument data sheet and project specific Standard Specifications. General
requirements include the following:
pH, ORP and Conductivity Probes shall be self-cleaning where practically achievable.
Non-extractive sampling methods of analysis shall be employed wherever possible.
Design shall allow simple, automated calibration procedures.
Process analyzers shall be supplied complete with any necessary sampling and sample
conditioning systems.
All analyzers are to be completely piped, interconnected, and checked out for proper
functional operating condition.
Process analyzers shall be selected which do not require reagents, calibration gases
and/or liquids, wherever possible.
Necessary reagents, calibration gases and/or liquids required for at least twelve months
operation shall be part of a purchased package.
Where possible, each analyzer shall be supplied with valves, fittings and other
components that are required to facilitate on-line calibration of the analyzer.
Field mounted analyzers shall be of corrosion resistant material, weatherproof
construction and suitable for outdoor installation.
The output signal shall be galvanically isolated 4-20 mA (linear) for single component
analysis. Alternatively, for multiple component analysis, a serial output may be
considered as the method of data transmission to the Plant Wide Control System. Where
a multi-component analyzer is used for the purpose of process control, serial
communications shall not be used unless redundant communications paths can be
implemented.
All analyzer transmitters shall incorporate an integral mounted indicator, scaled in
appropriate engineering units.

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9.1.2 Calibration Equipment for Analyzers
All necessary calibration and operating gases including gas cylinders and regulators shall be
provided.
Analyzers requiring gases for continuous operation shall be provided with dual facilities for
uninterrupted service.
Calibration standards and facilities shall be supplied for zero and span check where specified.
Protected outdoor storage racks adjacent to the analyzer houses shall be provided for the
carrier and calibration gas cylinders and their associated regulators. Process sample regulators
shall also be located on the outside of the analyzer houses.
9.1.3 Sample System for Analyzers
The sample systems shall be designed to deliver clean, representative samples to the analyzers
at the proper temperatures, pressures, physical conditions and flow rates.
Wetted component materials shall be selected to minimize contamination and corrosion.
Appropriate measures shall be taken to prevent plugging of sample lines due to freezing,
condensation or solids.
Where sample recovery systems are required, provision for items such as drains shall be made
in the building design.
Transportation time from sample point to analyzer shall be designed to be less than two minutes
for chromatographs and less than one minute for other analyzer types. Fast circulating loops
and/or bypass lines shall be used to achieve fast response times.
For gas samples, the pressure shall be reduced at the sampling point to increase the velocity
through the sample system and reduce time lag.
All sample and bypass lines shall have flow indicators, such as variable area flowmeters.
Adequate facilities shall be provided to protect against unwanted backflow, overpressure, or
other abnormal conditions.
When sample conditioning components require heating, they shall be located inside a heated
and insulated cabinet or enclosure.
The sampling and sample conditioning system shall be designed, supplied and commissioned
by the analyzer supplier to suit the specific analyzer application.
Sampling and sample conditioning systems shall be constructed from materials that shall suit
the process conditions.
The sample shall be metered, pressure regulated, cooled, cleaned or treated as required to
obtain a satisfactory sample for the analyzer under all process conditions.
The sampling system shall be designed for reliability, ready access for maintenance and
service.
9.1.4 Electrical Requirements for Analyzers
Normally, the control circuits of the analyzer should be powered from an automation equipment
room UPS (Uninterruptible Power System). Each analyzer shall have an over current protective
device (a magnetic type circuit switch or a fuse). Local disconnect switches shall also be

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provided so that the instruments can be safely serviced. Cabinet heaters, circulating pump
motors and other devices which draw relatively high currents may be powered locally.
9.2 Nucleonic Instruments
9.2.1 General
Nucleonic instruments shall be considered where no other type of instrument will perform
adequately.
Radiation source and source containers shall meet the safety requirements of ISO 2919
Radiation Protection, Sealed Radioactive Sources. In addition all equipment (including radiation
source capsule, container and label) offered must comply with the national and regional
radiation safety requirements, Statuary Authorities and Regulations.
Nucleonic instruments shall be selected and positioned taking into account that non-destructive
testing with X-rays can interfere with their operation.
Where necessary, external shielding shall be provided to avoid cross-interference of
instruments or disruption to operations and maintenance activities.
All necessary details and drawings required to support licence applications for site installation
shall be provided with each instrument. All necessary warning signs and notices shall be
included with each instrument.
Test certificates shall be supplied with each radiation source.
An approved wipe test method to verify source capsule integrity, as required by any national
and regional conditions of licence, shall be provided with the instrument.
On pipeline applications 50 NB and greater, clamp on type units shall be used. On pipelines
size DN50 or less, Z type mounting arrangement where the beam is concentric with the fluid
flow path shall be used. The source and detector shall be installed in such a way that the pipe
is always full of liquid (i.e., vertical or near-vertical pipe, with upward flow).
For density measurement, facilities shall be included in the process piping, near the gauge, to
the Suppliers specifications in order to take a reliable sample for periodic calibration checks.
Lead absorber plates shall be supplied, if required for calibration of the instrument.
Automatic source decay compensation shall be provided.
A suitable source half-life of at least 10 years shall be selected to make the installations
practical, however oversizing shall be avoided. This involves a low activity source with a high
sensitivity detector.
Nucleonic source canisters shall be provided with hand-operated shutters for safety isolation.
Isolation shutters shall incorporate provision for padlocking, instead of or in addition to any built-
in key locking mechanism. Isolation shutters shall be provided with limit switches, arranged so
that a limit switch is closed when the corresponding shutter is fully engaged in the "normal
service" position. The preferred type of limit switch is an inductive proximity switch. Shutter
position switches shall be wired to DCS inputs.
Source, detector and transmitter housing shall be constructed of corrosion resistant suitable for
plant conditions, weatherproof and suitable for outdoor mounting.
Detailed source sizing calculations stating the vessel wall thickness and lining shall be supplied.
All necessary calibration equipment shall be supplied with each instrument.

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Warning signs shall be provided in accordance with the local regulatory codes and standards.
Nucleonic sources shall be able to be returned to the Supplier for disposal when expired.
The instrument supply shall include delivery to site.
9.3 Flow
9.3.1 General
All instruments will be specified with local indicators wherever practical.
9.3.2 Liquid
Magnetic flowmeters shall be used for liquid, where practicable. For liquid applications with
suspended solids, the ideal velocity through the flow tube shall be in the range of 1.5 to 3 m per
second to prevent sedimentation of solids and minimize wear on the liner.
Clean or low conductivity liquids and steam may be measured by vortex shedding meter.
Vortex meters shall not be used where the piping may be subjected to vibration. It should be
noted that vortex meters require a minimum flow to produce a signal. This may not be
acceptable for some applications during start-up and shutdown.
Averaging pitot tubes or orifice plates may be used as the primary measuring element on large
diameter clean liquid pipelines.
Coriolis meters shall be used for fuel oil and distillate flow measurements,
Custody transfer metering shall be accomplished using coriolis flowmeters on process fluid.
In-line variable area flowmeters (rotameters) with needle valve controls shall only be used on
non-critical purging and injecting services, eg, pump seals.
Transit-time ultrasonic flow meters may be used in special situations where their unique
advantages are required (eg, very high temperatures, non-contact measurement).
9.3.3 Gas and Steam
Averaging pitot tubes or orifice plates may be used as the primary measuring element on large
diameter piping with clean gas or steam flows. For mass flow measurement on gas flows using
pressure differential techniques, multi-variable transmitters with automatic temperature and
pressure compensation may be used.
Clean gas or steam flow may be measured by the Vortex shedding meter. Vortex meters shall
not be used where the piping may be subjected to vibration. It should be noted that vortex
meters require a minimum flow to produce a signal. This may not be acceptable for some
applications during start-up and shutdown.
Doe Run Peru prefers the use of Vortex meters where possible.
The Thermal Dispersion mass flow measurement technique may be applied for flow
measurement of clean, homogeneous gases that are relatively constant in composition. These
instruments shall be mounted with marks to indicate correct orientation of the device. Multi-
point units should be used wherever possible to ensure improved measurement accuracy.
Flow elements such as flow nozzle or venturi may be used where high capacity or high-
pressure recovery is required. The venturi nozzle should be considered in high vacuum
applications where high pressure recovery and low pressure drop is required.

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In-line variable area flowmeters (rotameters) with needle valve controls may only be used on
non-critical purging and injecting services.
Magnetic flowmeters are not acceptable for gas and steam services.
9.3.4 Flow Meter Installation
Due consideration must be made for the effects of turbulence caused by the piping, including
VSD pumps and control valves.
When the flow is controlled by a variable speed pump, the flowmeter shall be installed after and
as close as practical to the pump.
When the flow is controlled by a control valve, the flowmeter shall be installed upstream of and
as close as practical to the valve.
For flow meters in vertical pipelines, flow direction is preferably downward for wet gas or
saturated steam, and upwards for liquids.
9.3.5 DP Transmitter Installation
Differential pressure transmitters used with orifice plates shall be remote mounted.
Differential pressure transmitters used with averaging pitot tubes can be mounted close
coupled, if the flow element allows direct connection of the transmitter, and it is practicable and
maintainable.
Remote mounted transmitters shall be located as close as practically possible to their
associated primary element.
Tapping points shall have rod-out facilities where solids could be present in the process stream
with consideration to provide continuous purge of the sensing element.
Seals and condensate pots shall be used where necessary.
9.3.6 Flow Meter Orifice Plates
The standard primary element shall be square edge concentric orifice plate in accordance with
ISO 5167-2, except that a quadrant edge orifice, in accordance with BS 1042, shall be used
when the Reynolds number is below 20,000.
Flange taps shall be used. D-D/2 taps may be used if the line size is 400 NB or larger.
Orifice flanges shall have a minimum rating of 300#.
Material of orifice plates shall be type 316 stainless steel, unless special materials are required
by the process fluid.
Orifice plates shall have the instrument tag number, plate material, flow direction identification,
bore size and line number clearly stamped on the upstream side of the plate handle.
Straight-run lengths of pipe upstream and downstream of orifice plate installations and orifice
plate installations shall conform to the requirements defined in ISO 5167-2 and as required to
meet the specified accuracy.
Reduced straight-run lengths shall only be considered for lower-accuracy applications or where
pipe work constraints prevent the required straight-run lengths.
The orifice plate shall be installed in a manner such that it will always measure a full pipe flow.

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Orifice meter differential range shall be selected so that the d/D ratio exceeds 0.2 and is less
than 0.7.
Orifice meters, other than integral orifice, shall not be used on pipelines smaller than DN50 mm.
Alternative flow meters shall be considered for line sizes greater than 200 mm for clean gas or
steam service.
All integral orifice transmitter assemblies shall have flanged end connections as indicated on the
data sheets. Where there is a requirement for minimum lengths of straight pipe upstream and
downstream of the integral orifice transmitter flanges, a complete assembly comprising
transmitter and straight pipe lengths shall be supplied.
9.3.7 Differential Pressure Flow Measurement
Square root extraction for flow applications shall be configured in the DCS.
All differential pressure transmitters shall be fitted with an instrument valve manifold as
applicable, except where diaphragm seals are used.
In general, a 3-valve manifold shall be used.
A 5-valve manifold shall be used where toxic or hazardous process gases or fluids need to be
drained to a safe location.
Where impulse lines need to be filled, small valves shall be fitted to the transmitter body in place
of the drain plugs. The valve materials shall suit the process fluids.
The meter range shall be selected in accordance with the following:
For differential pressure flowmeters, normal flow rate shall be between 70% and 80% of
instrument span, provided that anticipated minimum and maximum flowrates will be between
30% and 95% of capacity.
For range ability larger than 30% to 95%, an alternative method of flow measurement shall be
used.
For variable area meters, the normal flowrate shall be between 50% and 80% of capacity.
Variable area flowmeters shall be selected from the suppliers standard range.
For line sizes smaller than 50 NB, an integral orifice meter shall generally be used.
Averaging pitot tubes shall use screwed connections. Note: The process connection size is
determined by pipe size and process conditions. Consideration shall be given to the use of the
retractable style, which enables them to be removed for maintenance while the plant is on line.
Differential pressure ranges for orifice plate applications shall be selected from a set of standard
ranges in the order of precedence indicated:
25 kPa
50 kPa or 10 kPa
100 kPa or 5 kPa
9.3.8 Magnetic Flow Instruments
The following issues shall be considered when installing magnetic flow meters in non-vertical
pipes:
Accumulation of silt and scale in low-lying piping.
Accumulation of gas or vapor bubbles in the top of the pipe.

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Measurement of 2-phase fluid flows can be affected by material segregation.
Gravity could affect the distribution of flow velocities across the electrode axes.
Magnetic flowmeters are acceptable for pipe sizes 200 mm and larger, in applications where the
reduced instrument accuracy can be tolerated.
Magnetic flowmeters shall not be located in pipes that drain when the flow stops. Where this is
not possible, for example some slurry lines, meters with empty pipe detection or suppression
logic should be considered to prevent the flow indication becoming invalid.
Flowmeters shall be supplied with remote converters when either:
the local indicator can not be read from floor or grade level, or
the flowmeter cannot be accessed for maintenance from floor or grade level.
Elsewhere, the converter shall be integral to the flowmeter body.
The converters for all hazardous area installations shall be remote to the flowmeter body.
If appropriate, wafer body flowmeters shall be used for applications where the line size is 200
mm or less in diameter. Flanged flowmeters shall be used where the line size is 250 mm
diameter or greater.
9.3.9 Vortex Flowmeters
Vortex flowmeters have a large turn down and can be used on a wide range of clean fluids, i.e.
liquids, gases, steam. They shall not be used on scaling services, pulsating flow or where
vibration is present. With sizing, the upstream pressure should be relatively constant.
Vortex meters are not suitable for two-phase flow measurement, including wet gas or wet
steam.
All vortex meters shall have a local indicator.
Insertion vortex meters shall not be used.
Vortex meters used for SIS signals shall have sensors replaceable while in service. Meters with
dual sensors may be considered.
Wafer body flowmeters shall be used for applications where the line size is 200 mm or less in
diameter.
9.4 Level
9.4.1 General
9.4.2 Design and Selection of Level Instruments
The use of non-contact level measuring devices for liquids shall be used wherever possible.
To prevent ringing or degraded performance, non-contact level instruments shall be selected
and installed so the front face of the instrument protrudes beyond the lower rim of the nozzle in
which they are installed.

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9.4.3 Ultrasonic
Ultrasonic devices are not suitable for vacuum environments.
Ultrasonic level sensors may be used for measurement of level in material handling applications
and vented vessels, tanks and sumps containing slurries. The rate of change of level should be
considered when selecting ultrasonic instruments. Other methods may be necessary in
applications where foam/froth, condensation, dusts or steams are prevalent. Transducers shall
be selected for adequate acoustic power under the most arduous process conditions.
Only ultrasonic level instruments with built in temperature measurement and compensation shall
be used.
Wherever possible, the process connection for top-mounted ultrasonic level transmitters shall
be either 80 mm or 150mm flanged. Smaller loop-powered units used for non-critical
applications such as sump level may use alternative mounting arrangements.
9.4.4 Radar
Radar level devices may be used on bulk material handling, vented or pressurized vessels,
vacuum vessels, tanks and sumps. They shall be used for applications where steaming,
foaming/froth, dust, condensation and where the potential for gas or product vaporization may
occur. They may be used in extremely dusty applications and where dust bursts are present
during product filling. The sensor shall be fitted with a horn or antenna, manufactured from
material chemically compatible with the process environment. Loop powered devices shall be
used, where practicable.
The process connection for top-mounted radar level transmitters is 80 mm or 150mm flanged. In
special cases, a larger flange may be used as required.
9.4.5 Differential Pressure Level
The DP method of level measurement may be used where ultrasonic and radar is not suitable.
Where a sealing fluid (eg, glycerine) would be required for the wet leg, remote diaphragm seals
shall be considered.
Differential pressure transmitters without diaphragm seals, shall be fitted with 3-valve or 5-valve
manifolds.
A 5-valve manifold shall be used where toxic or hazardous process gases or fluids need to be
drained to a safe location. On tanks and vessels, differential pressure transmitters fitted with
integral or remote diaphragm seals shall be 80 mm flanged.
On tanks and vessels, differential pressure transmitters with 12mm tube connections shall have
a 50 mm isolation valve connection. Suitable adapters shall be used.
Bubble tube devices shall be avoided unless other methods are not practical. Depending on the
duty, water purging may be required.
9.4.6 Capacitance, Admittance and RF Types
Capacitance and related types of level detector are generally not acceptable. They may be
used only in applications where a special case can be made for their use and with the approval
of Doe Run Peru.
9.4.7 Magnetic Level Gauge
Magnetically-coupled float level gauges are acceptable where sight glasses are not appropriate,
for example where clouding of the sight tube would occur.

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The style of level indicator used shall be the sealed float-type, enclosed within a stainless steel
cage or material suitable for the process fluid.
The sealed float shall be magnetically coupled to the level indication assembly that is attached
to the side of the cage.
The indication assembly shall be field adjustable to enable the scale to be viewed from the most
convenient orientation. The indicator shall be a series of interlocked (to prevent over-rotation)
rotating flappers contained within a hermetically sealed case and shall range fully between
tapping points.
Process wetted materials shall be 316 stainless steel minimum unless the process fluid
properties require the use of alternative materials. Magnetic level gauge and sight glass level
gauges shall have 50 mm flanges.
Drain and vent valves shall be fitted to all level gauges.
When designed, the vent and drain valves on level gauges shall be accessible from the same
floor where the level gauge is located. Sufficient space shall be left between the top and bottom
of the gauge and the floor grating to allow for maintenance.
External level bridles shall have 80 mm flanges for the main process connections. Refer to the
bridle connected instruments for their process connections.
9.4.8 Level Switches
Switches shall be used only for low integrity and clean services. Transmitters are preferred for
general process service.
Level switch devices shall use one or more of the following methods of measurement:
Internal float
External cage float/displacer
Vibrating fork
Capacitance
Ultrasonic
Conductivity
Rotary type
Microwave
Nuclear
Electrical switches shall have a contact rating of 24 VDC 2A minimum with SPDT contacts.
Internal float switches (side or top entry) mounted on tanks or vessels shall be 80 mm flanged.
The preferred process connection for other level switches shall be 50 mm flanged.
9.5 Pressure
9.5.1 General
Unless otherwise specified the process wetted parts shall be 316 stainless steel.

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Pressure ranges shall be selected so that the normal operating pressure is between 50% and
70% of full scale or instrument span with due regard for maximum pressure expected.
Process connections for pressure tapping points on non-lined pipes shall be threaded.
Process connection for pressure instruments on glass-lined and PTFE-lined pipes shall be 50
mm flanged.
The use of pneumatically or hydraulically-operated pressure controllers is not acceptable.
Mercury filled pressure instruments are not acceptable.
9.5.2 Pressure Gauges
Unless otherwise specified pressure gauges shall have stainless steel type 316 cases with clear
shatter resistant window.
Pressure gauges not subject to pulsation used for process air, instrument air, nitrogen, argon
etc. do not require liquid fill. All other gauges shall have liquid (glycerine) fill.
Pressure gauges shall incorporate blowout protection devices on the rear of each gauge.
Case diameters shall be 100 mm for process indications and 25 mm for gauges monitoring
instrumentation, such as air filter/regulators and positioners.
Scaling shall be in kilopascals (kPa). Dial scales shall be marked in black on a white
background with a red zone mark to indicate the approaching of the upper pressure scale.
Diaphragm seals shall be used where necessary to protect pressure elements against corrosive
or plugging process conditions.
9.5.3 Pressure Switches
Pressure switch measuring element may be Bourdon tube, bellows, piston or diaphragm type
depending upon the service and pressure.
Pressure switches shall incorporate over-pressure protection to prevent pressurization of the
case in the event of failure of the measuring device.
Electrical switches shall have a contact rating of 24VDC, 2A minimum with SPDT contacts.
The operating point for pressure switches shall be field adjustable, but adjustment shall not be
possible without the use of tools.
9.5.4 Pressure Transmitters
Pressure transmitters shall use materials that are suitable for the process applications.
Pressure transmitters shall be constructed using corrosion-resistant materials throughout. In
the case of single-ended pressure transmitters (i.e., those for gauge pressure service), this
requirement includes the low-side instrument flange (that which is not connected to the process
and is vented to atmosphere). For some brands of pressure transmitter, this may mean that all
transmitters must be purchased as differential-pressure models, since gauge pressure
transmitters may otherwise be supplied with a carbon steel vent-side flange and hence be
unsuitable.
Where differential and some gauge pressure transmitters are vented to atmosphere on one
side, such vents shall be fitted with a filter with fine pores and a large surface area. The vent
must be resistant to corrosion and to fouling by process materials or biological action.

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Except where remote diaphragm seals are used, the process connection of all transmitters shall
be threaded.
All pressure switches, transmitters (for gauge and absolute) and gauges shall be installed with a
2-valve block and drain/vent manifold for secondary process isolation and calibration except for
diaphragm seal applications.
Where the process fluid is hazardous or toxic, the drain/vent shall be piped to a safe location.
9.5.5 Condensing Vapors
Siphons or pigtail condenser seals shall be provided for connections to close coupled gauges
or transmitters in steam and other high temperature (> 60
o
C) condensing vapor applications.
9.5.6 Pulsation Dampers
Where pulsation is expected and the process is non-clogging, suitable adjustable dampers shall
be used. Dampers shall not be used in slurry applications.
9.5.7 Integral and Remote Diaphragm Seals
For diaphragm seal applications, where it is considered necessary, a flushing connection ring
shall be supplied. The material shall be the same as the diaphragm seal wetted parts and a
roddable bleed valve and plugs shall be fitted to allow venting and flush out. Fill liquid shall be
selected having regard to process conditions; glycerine or glycol/water is preferred for most
applications. Differential pressure transmitters with remote diaphragm seals shall comply with
the following process connection requirements:
Differential Pressure Instrument Process Connections
Between two tanks/ vessels 80 mm (tank/vessel) and 80 mm (tank/vessel)
Between a tank/vessel and a pipe 80 mm (tank/vessel) and 50 mm (pipe)
Between two pipes 50 mm (pipe) and 50 mm (pipe)
Remote diaphragm seals shall be pancake style.
Integral and remote diaphragm seals on gauge pressure transmitters shall be 50mm flanged for
pipes and 80 mm flanged for tanks or vessels.
Diaphragm seals shall be supplied as an assembly, complete with capillaries and shall be filled
under vacuum by the manufacturer in the factory.
Diaphragm seals shall not be used on vacuum services.
All capillary tubing shall be stainless steel, with stainless steel flexible armour and PVC jacket.
For all differential pressure applications, the capillaries on either side of the differential pressure
transmitter shall be of equal length.
NB: This means that differential pressure transmitters with one integral diaphragm seal and one
remote diaphragm seal are not acceptable.
Capillary length shall be kept to a minimum.
Capillaries exposed to direct sunlight may create a signal drift problem if not correctly selected
and installed.
Capillaries shall be designed with minimum volume of fill to minimise the drift effects caused by
temperature.

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9.6 Temperature
9.6.1 Temperature Instruments
Resistance Temperature Detectors (RTDs) shall be used for applications where the
temperature to be measured is less than or equal to 300C.
Type N thermocouples shall be used for applications where the temperature to be measured is
normally above 300C and less than 1200C. Type N thermocouples may be used to measure
temperature excursions up to 1300C, but they may exhibit drift and reduced accuracy if they
are exposed to long term working temperatures above 1230C.
Type S thermocouples shall be used for applications where the normal working temperature is
above 1200C.
Except where special requirements apply, temperature sensors shall be un-grounded, mineral
insulated, with 6 mm diameter stainless-steel sheaths.
Non-hazardous and Hazardous Areas:
Process RTDs shall preferably be installed with head mounted transmitters. Where
the requirement for maintenance access inhibits this, remote mounted transmitters
shall be used.
Process thermocouples shall preferably be installed with head mounted transmitters.
Where the requirement for maintenance access inhibits this, remote mounted
transmitters shall be used.
Where local indication of temperature is required, thermocouples or RTDs may be cabled to a
locally mounted temperature transmitter with built-in local indicator.
Heat tracing temperature sensors shall be directly wired to the Heat Tracing Control Cubicles.
Thermocouple transmitters shall be configurable for upscale or downscale output on
thermocouple failure.
Thermocouple extension compensation leads shall not be used for direct connection to the
control room.
Certain high-speed process controls require the use of bare temperature sensors installed
direct into process vessels or ducts without thermowells.
Bare sensors shall be:
used only where control requirements preclude the use of thermowells.
constructed of materials compatible with the process fluids.
retained using compression fittings.
physically arranged and wired up to facilitate removal and replacement.
clearly marked for safety reasons.
Except for surface temperature measurements and as provided above, all temperature sensors
shall be installed with a matching thermowell having pressure ratings compatible with the line or
vessel rating, and using materials compatible with the process fluids. Temperature sensors for
service in thermowells shall be spring-loaded to maintain the thermal coupling between the
sensor tip and the thermowell. Each temperature sensor assembly shall be fully assembled and
consist of a terminal head, a spring-loaded fitting, threaded extension nipples and union.

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9.6.2 Temperature Gauges
Unless otherwise specified local temperature gauges (indicators) shall have stainless steel type
316 cases with clear shatter resistant safety glass.
Case diameters shall be 100 mm.
Dials shall be free to rotate around the thermowell axis. Dial tilt angle (normal to the thermowell
axis) shall be adjustable through at least 90 degrees.
Sensing elements shall be bimetallic helix type unless otherwise approved. All sensing
elements shall be installed in thermowells having pressure ratings compatible with the line or
vessel rating, and using materials compatible with the process fluids. The stem length shall be
a minimum of 50 mm above the compression or gland nut when the stem is fully seated in the
thermowell.
Scaling shall be in degrees Celsius. Dial scales shall be marked in black on a white
background with a red zone mark to indicate the approaching of the upper temperature scale.
The stem connection thread shall be male.
9.6.3 Thermowells
Where practical, thermowells (including test wells) shall be flanged.
Thermowells shall generally have a tapered stem.
Special thermowells, which require an over-sheath, shall have a parallel stem if it is dictated by
the manufacturing process.
Thermowells shall be machined from solid bar stock in a single piece, except for flanges.
The bore diameter of the thermowell shall match the element.
Test thermowells shall have a screwed cap and chain to prevent dirt ingress.
Thermowell material shall be 316 stainless steel unless process conditions dictate the use of
other materials.
Lagging extensions shall be provided on thermowells installed in insulated pipes and vessels.
Thermowells shall not be mounted on pipes or elbows smaller than 40NB. Smaller pipes shall
be enlarged using reducers where required to allow a thermowell to be used. Thermowells
mounted in pipe elbows shall face into the flow, except for fouling services where the
thermowell may be required to face downstream to aid clearing of fouling materials.
Process connections shall be:
For installation in piping, the flanges shall be DN 50 mm.
For installation in glass-lined or Teflon-lined piping, flanges shall be DN 50 mm.
For installation in vessels and tanks, the flanges shall be DN 50 mm.
For installation in glass-lined vessels, the flanges shall be DN 100 mm.
Special designs may be allowed in certain situations.
Thermowell immersion length is the depth by which the thermowell protrudes past the inside
wall of the pipe. The immersion length shall be between one third and one half of the internal
pipe diameter, with 300 mm being the maximum immersion depth. For vessels and tanks the
insertion length shall be nominally 450 mm maximum, but special immersion lengths may also
be appropriate.

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9.7 Weight
9.7.1 Belt Weighers
The weigher shall be continuous in operation. The system shall be robust and easily
serviceable. The design shall suit the accuracy requirements of the application.
Weigh frames shall preferably include no moving parts or pivot points.
An accurate means of calibration of the system shall be provided with the weigher.
The system shall incorporate means to correct for variations in the conveyor belt speed. The
method of mounting the belt speed measurement device is directly on a non-driven belt pulley.
The system shall have a continuous rate readout calibrated in tones per hour. The output shall
be scalable. The output signals from the transmitter shall be a signal proportional to rate and a
pulse for totalization of flow.
Please note that if digital pulse inputs the DCS should not exceed the 75Hz maximum
frequency limit imposed by the DCS input cards.
Weigh frames shall be designed to prevent material build-up on surfaces.
The maximum accumulated rate error between weekly checks shall be 0.5% of full scale.
9.7.2 Loadcells
Wherever possible, the use of compression load cells with bearing surfaces shall be avoided.
Load beams, load stands or tension load cells shall be used.
Load cells shall have an overprotection range of 100% of full load or better.
Load cells shall be of welded stainless steel construction.
9.8 Position Switches
Inductive Proximity Switches shall be used in preference to mechanical limit switches.
Unless otherwise specified, the devices shall be suitable for operation on 24 VDC power supply.
Proximity switches used in non-hazardous areas shall be the 2-wire type.
Proximity switches used in hazardous areas shall be the 2-wire NAMUR type.
Proximity limit switches shall generally be designed so that the detected metal piece moves
sideways across the face of the proximity sensor in a shear action, rather than approaching the
proximity sensor end-on. End-on type detector action is dependent on the tolerance in the
sensitivity range of the sensor, and is difficult to set up and maintain.
All devices shall be fully corrosion resistant.
9.9 Underspeed Detection
Underspeed detection for conveyors shall be use of proximity type sensor with in-built start-up
delay timer and adjustment for speed.

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10. VALVE REQUIREMENTS
Actuated on/off valves and control valve bodies shall generally comply with the requirements of
the piping and valve specifications in use by the process and mechanical design groups in each
plant.
Each actuated valve shall have the same rating as the process line it is installed in.
10.1 Control Valve Selection
Selection must be carried out in conjunction with the sizing to obtain optimum results. As a
general guide, the initial selection should be as follows:
Butterfly Valves where applicable.
Globe valves on clean service up to 100 NB.
Eccentric disk valves for sizes greater than 80 NB for clean service and slurries with
less than 5% solids, where pressure drop allows.
Pinch valves (weir style) in slurries with more than 5% solids.
Vee-ball where a wide range of CV is required.
For corrosive and erosive service, follow manufacturers recommendations.
Control valve trim and body style shall be determined by the application.
Control valves shall not be used in safety shut-off service.
10.2 Control Valves (Including Self-Regulating Valves)
Control valves shall be selected and sized to meet the duty, providing a turndown ratio of
approximately 10:1, and in accordance with the manufacturers recommendations. Some
control valves may not require the 10:1 turndown to obtain adequate control.
The following guidelines should be followed in selecting modulating control valves:
Globe, Eccentric Plug and V-Ball Valves -
During maximum flow conditions, percentage opening should not exceed 90% of
valve travel.
During normal flow conditions, percentage opening should not exceed 65% of valve
travel.
During minimum flow conditions, percentage opening should not be less than 10% of
valve travel.
Butterfly Valves
During maximum flow conditions, percentage opening should not exceed 75% of
valve travel.
During normal flow conditions, percentage opening should not exceed 55% of valve
travel.
During minimum flow conditions, percentage opening should not be less than 20% of
valve travel.
No valve shall be more than one line size smaller than the size of the line, where practicable.
Valve bodies shall have an arrow to indicate direction of process fluid flow.

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As determined during the process design, some control valves shall be installed with upstream
and downstream block and bypass valves to enable manual operation in the event of the control
valve being out of service.
10.3 On/Off Valves (Actuated Type)
All on/off valves shall have minimum class 4 tight shut-off, and shall have pre-determined
shutdown times to eliminate water-hammer.
Each on/off valve shall be fitted with prewired open and closed proximity limit switches.
Rotary actuated valves shall have a limit switch box, complete with the limit switches pre-wired
to a terminal strip, mounted on the valve actuator. The limit switch box shall have at least two
M20 cable entries.
Linear actuated valves shall have the limit switches pre-wired to a terminal strip in a junction
box mounted on the valve. The limit switch junction box shall have a minimum of two M20
cable entries.
Each rotary actuated on/off valve shall have visual status indication mounted on the limit switch
box in the form of a dual colored dome style indication.
Each linear actuated on/off valve shall have visual status indication mounted on the valve body.
For equipment isolation valves (in on/off service) in 25 NB line sizes or smaller where position
feedback (proximity switches) are not required, the use of direct acting, in-line solenoid valves
may be applied.
On/off valves (except for pinch and lined butterfly valves) used for flammable gases or liquids
shall have a Fire Safe design in accordance with API 607 or BS 6755.
10.4 Shutdown Valves (actuated type)
The requirements for shutdown valves are the same that apply for on/off actuated valves, but
with some additional features.
Critical shutdown valves shall be partially stroke tested by the SIS on a regular basis to ensure
availability. An optical valve position transmitter fitted to the valve shall facilitate such testing.
Shutdown valves shall have the ability to be locked off as part of the isolation procedures.
10.5 Valve Materials
Generally the valve body material shall be carbon steel with 316 SS valve trim, unless process
or environmental conditions require a more suitable material.
Hard faced trims or hardened trim materials shall be applied for the following applications:
Erosive service.
Wet gas or saturated steam, when the pressure drop exceeds 500 kPa.
Dry/Clean gas, when
- Pressure drop exceeds 2.5 MPa for valves > DN 100.
- Pressure drop exceeds 1.2 MPa for valves <=DN 100.
- Flow is choked.
- Cavitations occurs, but is not considered to be severe.

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Liquid applications, when -
- Pressure drop exceeds 10 MPa.
- Flashing liquids.
- Temperature exceeds 315
o
C
Ductile Iron or Cast Iron valve bodies may be acceptable for low pressure valves, e.g. certain
lined plug valves, ball valves and butterfly valves.
In general, packing for operating temperature up to 230
o
C shall be teflon composition (non-
asbestos base). Packing for operating temperatures above 230
o
C shall be as per the valve
manufacturers recommendation.
10.6 Design and Manufacturing Requirements
All valve body end connections shall be in accordance with the Valve Piping Specification.
The faceto-face dimensions of flanged globe valves shall conform to ISA S75.03. Flangeless
faceto-face valve body dimensions shall conform to ISA S75.04.
Control valves shall be selected with the correct valve characteristic, ideally so that the
controlled quantity (flow, level, pressure etc) will vary linearly with valve opening, taking into
account the effect of non-linear elements in the surrounding process.
Where practicable, the required valve flow characteristic shall be achieved by selection of the
correct valve trim. Where this is not practicable, the required flow characteristic shall be
achieved by selection of a linearising positioner characteristic. Linearization within the control
system shall only be used where no suitable alternative is available.
Control valve sizing and selection along with an appropriate means of control, such as the use
of special trim or relocation of the control valve, shall be used to eliminate cavitation and
flashing during normal operation, but minimize cavitation and flashing during plant start-up,
shutdown and upsets.
Where fail safe is required and mechanical (spring) motive force is not available then
accumulator backup ancillary devices shall be used.
10.7 Selection of Actuator Type
Pneumatic actuators are generally preferred for automated operation of modulating control
valves and on/off valves. However electric actuators may be used where they are better suited
to the process or ambient conditions.
In particular, plant designers shall ensure that any selected pneumatic actuators are suitable for
operation in the ambient temperatures expected in winter (refer clause 3.4 above). In each
case the design shall consider:
Whether additional insulation and heat tracing is required.
The required quality specification for the instrument air supply.
If there is a significant residual risk that a pneumatic actuator may not be reliable at the
minimum expected temperature, use of an alternative such as an electric actuator shall be
considered.

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10.8 Pneumatic Actuators
Actuator design and selection shall be based on providing a fail safe action as specified on the
data sheet. The selected actuator should also allow the valve fail action to be changed in the
field if required.
Pneumatic connections for actuators and accessories shall be designed such that no external
air from the atmosphere is drawn into the actuator during actuation.
The materials of manufacture for the actuator, electro-pneumatic positioner and all accessories
shall be selected to withstand process and/or ambient conditions. This may necessitate using
special corrosion and ultra-violet resistant materials for certain applications.
An actuator shaft extension arrangement shall be used, if necessary, to ensure that the
temperature limit of the actuator and accessories is not exceeded.
All valve actuators shall be fitted with a corrosion resistant air filter/regulator and a stainless
steel air supply gauge. Unless otherwise specified, tubing and fittings shall be 316 stainless
steel and shall be pre-assembled as far as is practicable.
Valve stem position shall be indicated on a graduated reversible scale with the words OPEN
and SHUT or CLOSED at the valve stem travel limits.
10.9 Actuator Sizing
The actuator shall be specifically sized to satisfy process conditions such as shut-off pressure,
operating time, water-hammer problems and solids build-up (in slurries).
Actuators shall be sized to fully stroke the valve (in either direction) under max differential
pressure nominated on the data sheets.
All on/off actuators shall be sized and selected on an individual basis to best satisfy the specific
process and operating conditions.
On/off valve actuator torque shall be at least 1.25 times the maximum breakaway (opening) and
re-seating (closing) torque.
Modulating valve actuator torque shall be at least 1.5 times the maximum breakaway (opening)
and re-seating (closing) torque.
SIS valve actuator torque shall be at least 1.5 times the maximum breakaway (opening) and re-
seating (closing) torque.
The maximum allowable valve travel time (in both directions) shall be as follows:
Body Size Maximum Travel Time
< DN100 3 seconds
> DN 100 1 second per 25 mm of body size
For pneumatic actuators, the above design criteria shall be met at the minimum specified air
supply pressure.
Pneumatic volume tanks may be required to achieve the specified valve stroking times or
where an air fail static design is prescribed. The design and construction of these vessels shall
be in accordance with the applicable codes and standards.
Instrument air relays, quick vent valves or volumes boosters shall be used as required with
pneumatic actuators.

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10.10 Electro-Pneumatic Positioners
Electro-pneumatic valve positioners shall be provided on all modulating control valves with
pneumatic actuators. Smart (digital) controllers are acceptable.
Direct or reverse action shall be attainable on all positioners by simple field adjustments.
Valve positioners shall be mounted on the valve and furnished with a set of miniature dial
pressure gauges (stainless steel casing) to indicate the following:
Supply to the top of cylinder.
Supply to bottom of cylinder.
Supply pressure.
Valve positioner cases shall be rated at IP65/NEMA4 minimum and be constructed of stainless
steel, fiberglass or other corrosion-resistant material.
10.11 Hand Wheels
Hand wheels shall not be fitted to actuated valves unless nominated on the data sheet. If they
are fitted, they shall be either top or side mounted, and shall include a clutch release
mechanism.
10.12 Accessories
Valve accessories such as proximity switches, positioners, transducers, solenoid valves and
relays, shall be mounted on the valve, providing that vibration and temperature, etc. does not
affect operability of such accessories.
Valves requiring lubricators shall not be used.
10.13 Solenoid Valves
The solenoid valve shall be selected to suit the application.
Solenoid valve coils shall operate at 120V AC unless otherwise specified.
Solenoid valves shall have a manual over-ride facility and where possible a LED for status
indication.
Solenoid valve bodies and coil cases shall be made from a corrosion resistant material.
Solenoid valves shall have NAMUR interface mounting, solenoid valves with DIN style plugs
shall not be used unless there is no suitable alternative.
All solenoid valve exhaust ports shall be fitted with adjustable restrictors or bug vents.
All solenoid valve spare ports shall be fitted with threaded plugs or bug vents.
Direct acting solenoid valves shall be used on all SIS valves.
Two-way direct acting solenoid valves may be used on clean non-corrosive gases. They should
be limited to sizes that still make them economically viable instead of using actuated valves.
The valve bodies shall be 316 stainless steel or a suitable corrosion resistant material.

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10.14 Safety Relieving Devices
All pressure relieving devices shall be sized in strict accordance with applicable local, state, and
national code requirements. Formulae shall be according to API RP 520.
Percent accumulation used in calculating sizes of relieving devices shall be as follows:
3 percent Steam service according to ASME Code, Section I.
10 percent Gas or vapor service and liquids except as noted below.
16 percent 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 percent Vapor and liquid service in areas governed by fire conditions according
to ASME Code, Section VIII.
25 percent Liquids - for thermal relief of pipelines and pump discharges, if code
stamped valves are not required in all services.

Nomenclature used shall be according to API RP-520.
Safety and relief valves shall normally be direct spring loaded type. Balanced bellows valves
shall be considered for relief into closed flare and blow down systems. If balanced bellows
valves are used, the set pressure of the valve should be reduced to compensate for possible
failure of the bellows. Pilot operated valves shall be considered where operating pressures are
close to set pressures. Other types of valves may be considered for special applications.
Full nozzle type valves shall normally be specified for sizes 25mm and larger.
Rupture discs may be used in lieu of safety and relief valves, where applicable. Rupture discs
may be used in conjunction with safety and relief valves if required by environmental protection
regulations for valves which discharge to the atmosphere.
Pressure and vacuum relief valves for storage tanks shall normally be of the weight loaded or
pilot operated type, and sized according to API Standard 620 and API Standard 2000 or local
codes if they govern.
Packed lifting levers shall be furnished for all safety and relief valves in air, hot water (above
60C), or steam service according to the ASME Code, Section VIII.
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.
Closed relief valve discharge systems shall be designed according to API RP 520.
Connection sizes and ratings shall normally be as follows:
Flanged connections shall normally be furnished on all safety and relief valves, 25mm
and larger. Valve flanges shall match rating and facing of mating flanges on vessels
or piping.
Screwed connections shall be furnished on valve sizes below 25mm, unless process
or operating conditions do not allow.

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Materials of construction shall be as follows:
Steel bodies with stainless steel trim shall normally be specified.
Bronze bodies shall normally be specified for thermal relief in cooling water service
and air service, provided piping specifications permit.
Aluminum bodies shall normally be specified for API storage tank pressure and
vacuum relief valves providing piping and vessel specifications permit.
Alloy bodies or special materials shall be specified where required by process,
atmospheric, or operating conditions.
Springs shall be carbon steel for normal process operating temperatures of minus
30C through 230C, tungsten alloy steel above 230 C, and 316 stainless steel below
minus 30C.
Bonnet construction shall be as follows:
Plain closed bonnets shall normally be specified, with a tapped and plugged vent for
easy conversion to balanced type valve.
Exposed spring bonnets shall be specified for steam service above 230C as
required by ASME Code, Section I.
Full area block valves shall normally not be installed on the inlet or outlet of pressure relieving
devices. When provided, they shall be for inspection and repair purposes only, and shall be
locked or sealed open during normal operation.
10.14.1 Rupture Disks:
Rupture disks may be installed beneath safety and relief valves under the following conditions:
Where corrosive or fouling materials would cause damage or interference with
successful valve performance.
To prevent a loss by leakage of valuable, toxic or undesirable materials.
When required by air quality regulations for valves which discharge to the
atmosphere.
Rupture disks inserted under safety and relief valves shall be equipped as follows:
Each holder outlet flange shall be equipped with a tell-tale tap.
For all services, a suitable tell-tale indicator shall be provided between the rupture
disc and the relief valve.
The maximum burst pressure for each disk shall not exceed the maximum allowable
working pressure of the equipment to be protected.
Proper selection of rupture disks shall avoid the following conditions:
Fragmentation of rupture disk interfering with the proper operation of downstream
equipment such as pressure relief valves, control valves, or exchangers.
Pressure pulsations causing possible premature failure of rupture disk.
Reverse buckling rupture disks may be used in vapor and partial vapor relief systems, but shall
not be used in liquid hydrostatic relief systems.
Generally, insertable flanged rupture disk holders shall be specified. The holder shall be of
adequate height to be fully insertable, and shall shield the disk from contact with the companion
flanges.

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The crown (cap) of a disk shall not exceed the top of the holder. The manufacturer shall submit
certified drawings showing all holder dimensions with the rupture disk installed. The actual or
maximum crown (cap) height of the specified disk must be shown.
Capacities to be used in the selection of all rupture disks shall be that established and
guaranteed by the manufacturer for the service conditions installed.
11. SAFETY INSTRUMENTED SYSTEM INSTRUMENTS
Transmitters shall be used instead of switches for shutdown purposes, where practicable.
All shutdown instruments shall be physically and electrically separate from the related
control/indication instruments in the same service.
Shutdown signals shall be derived only from primary actuating elements.
On vessels, control/indication instruments and shutdown instruments shall be mounted via
independent process connections.
All trip instruments and valves shall be fitted with an additional permanently attached 316SS
label that indicates that it is connected to the SIS. This label shall be attached in the same way
as the Instrument Tag Label described in this specification.

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APPENDIX A RELEVANT ABBREVIATIONS

A Amps/Ampere.
AC Alternating Current.
ANSI American National Standard Institute.
API American Petroleum Institute.
ARPANSA Australian Radiation Protection and Nuclear Safety Agency.
AS Australian Standards.
ASA American Standards Association.
ASME American Society of Mechanical Engineers.
ASTM American Society for Testing and Materials.
CB Circuit Breaker.
CFS Combination Fuse Switch.
CT Current Transformer.
CRT Cathode Ray Tube (traditional video display using electron beam with
magnetic deflection coils)
CVT Constant Voltage Transformer.
Capacitive Voltage Transformer.
DC Direct Current.
DCS Distributed Control System
DIN Deutsches Institut fur Normung e.V. (Germany).
DOL Direct-On-Line (Particular to Motor Starting).
ELCB Earth Leakage Circuit Breaker.
ELV Extra Low Voltage As defined in AS/NZS 3000.
ESAA Electricity Supply Association of Australia.
FGS Fire and Gas System.
FRP Fibre-Reinforced Plastic.
HAZOP Hazard and Operability Study
HCI Hydrochloric Acid.
HV High Voltage As defined in AS/NZS 3000.
IEC International Electrotechnical Commission.
IEE Institution of Electrical Engineers (United Kingdom).
IEEE Institute of Electrical and Electronics Engineers (America).
IES Illuminating Engineering Society of North America.
IGBT Insulated Gate Bipolar Transistor.
ISA Instrumentation, Systems, and Automation Society.
ISO International Organisation for Standardisation.
kA kilo-Amps {x10
3
A}.
kV kilo-Volts {x10
3
V}.

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kW kilo-Watts {x10
3
}.
LAN Local Area Network.
LCD Liquid Crystal Display.
LCS Local Control Station.
LED Light Emitting Diode.
LGESA Local Government Electricity Supply Association of Australia.
LV Low Voltage As defined in AS/NZS 3000.
MCC Motor Control Centre.
MEN Multiple Earthed Neutral system As defined in AS/NZS 3000.
MOV Metal Oxide Varistor.
MTBF Mean Time Between Failure.
MTTR Mean Time to Repair.
MW Mega Watts {x10
6
W}.
NAMUR Standardization Association For Measurement and Control in Chemical
and Pharmaceutical Industries
NBS National Bureau of Standards (USA).
NEC (Australian) National Electricity Codes.
NECA (Australian) National Electricity Codes Administrator.
NEMA (American) National Electrical Manufacturers Association.
NEMMCO (Australian) National Electricity Market Management Company.
NFPA (American) National Fire Protection Association.
NH&MRC (Australian) National Health and Medical Research Council.
NPT National Pipe Thread (US).
NZS New Zealand Standards.
ODAF Oil Directed Air Forced.
ODAN Oil Directed Air Natural.
OFAF Oil Forced Air Forced.
ONAF Oil Natural Air Forced.
ONAN Oil Natural Air Natural.
P&ID Piping and Instrument Diagram
PC Personal Computer.
PCB Poly Chlorinated Biphenyls or Printed Circuit Board.
PCS Process Control System.
PLC Programmable Logic Controller.
PVC Poly Vinyl Chloride.
PWCS Plant Wide Control System.
RCD Residual Current Device.
RPS Radiation Protection Series.
RTD Resistance Temperature Detector.
SAA Standards Association of Australia.
SAMA Scientific Apparatus Makers Association

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SCA Switchgear and Controlgear Assembly.
SCADA Supervisory Control and Data Acquisition.
SCR Silicon Controlled Rectifier.
SIF Safety Instrumented Function
SIL Safety Integrity Level
SIS Safety Instrumented System.
TOL Thermal Overload.
UPS Uninterruptible Power Supply.
UV Ultra Violet.
V Volts.
VSD Variable Speed Drive.
VT Voltage Transformer.
W Watts.
WAN Wide Area Network.
XLPE Cross Linked Poly Ethylene.

Anexo VII (Del Alcancel Del Servicio) Design Standart Automation Systems Rev2

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