J-21 Rev1

DK-2800 Lyngby, Denmark
PetroVietnam
Phu My Fertilizer Project
1350 MTPD Ammonia Plant
No. J22226/J-21 Rev. 1

Job 22226
Page 1 of 28
Job 22226
WBS 61
General Specification
for
Instrumentation
Rev.
Description
Date
Made by
Chd.
Appd.
0
First issue
12-OCT-2001
MAY
TO
HUL
1
General
update
28-JAN-2002
MAY
Information contained herein is our property and must not be used by or conveyed to any person without our authority - Haldor Topse
A/S
Contents
PetroVietnam
No. J22226/J-21 Rev. 1

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Page
1.
Preface.........................................................................................................................................3
2.
General ........................................................................................................................................3
3.
Flow Instruments ........................................................................................................................4
4.
Primary Flow Differential Producers.......................................................................................5
5.
Level Instruments .......................................................................................................................6
6.
Level Gauges...............................................................................................................................7
7.
Pressure Instruments..................................................................................................................8
8.
Pressure Gauges .........................................................................................................................8
9.
Temperature Instruments ...........................................................................................................9
10. Control and On/Off Valves .....................................................................................................10

11. Pressure-Relieving Devices ....................................................................................................15
12. Analysers and Accessories ......................................................................................................17
13. Alarm Switches .........................................................................................................................20
14. Control System.........................................................................................................................20
15. Emergency Shutdown System..................................................................................................21
16. Installation and Process Connections .....................................................................................21
17. Electrical Supply, Classification and Instrument Wiring......................................................22
18. Noise Immunity of Electronic Instruments............................................................................25
19. Package Unit Control Equipment ............................................................................................25
20. Pneumatic Equipment...............................................................................................................28
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1.
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Preface
The purpose of this General Specification is to define the overall design philosophy of the instruments and controls for 1350 MTPD Ammonia Plant and associated utilities at PetroVietnam, Phy
My. It gives the basic guidelines for the selection of equipment and the method of installation, and
is based on recognised codes and standards, supplemented by HALDOR TOPSE A/S experience in engineering and construction.
This General Specification is intended to serve as a guide and to promote uniformity in matters of
design, manufacture and installation. If applicable, it shall be used together with the relevant information contained in the documents listed below (in order of priority):
1.
2.
3.
2.
The official Letter of Intent or the succeeding official and confirmed order.
The Particular Specifications or Data Sheets containing specific requirements for this
project.
The Codes and Standards referred to in the above-mentioned documents and in this
General Specification.
General
The plant shall be controlled and monitored through a Distributed Control System (DCS).
The operator interface to the process shall be colour screens presenting overview, group and
point displays, as well as process flow diagram graphics with live data. The operator shall manipulate all facilities through dedicated operator keyboards.
The DCS shall have facilities for alarm management, data logging, trend recording and printing of
production reports.
A dedicated emergency shutdown system (ESD) shuts down the plant or single plant units according to the shutdown strategy. ESD status shall be monitored through the DCS and through a
conventional matrix panel (hard-wired mimic panel).
Transmission signals shall be 4-20 mA, temperatures mainly shall be measured by thermocouples.
2.1
Design Conditions for climate, power, air, etc. as well as applicable Codes and Standards, are
stipulated in the Design Basis Specification, HTAS Doc. No. 4237317.
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2.2
Classification of Electrical Equipment shall be in accordance with the hazardous area classification as per para. 17.2.
2.3
Corrosion. Copper and copper alloys are not allowed for tubing, valves, fittings, cable glands,
etc. as ammonia vapours may occasionally be present.
2.4
Marking. All field-mounted instruments and junction boxes shall have a Tag Numberplate with a
punched or engraved Tag Number. Size of letters and figures shall be min. 4 mm. A circular plate,
20-25 mm in diameter, 1-2 mm thick can be used. This plate shall be securely attached to the instrument with a soft stainless steel wire if it is impossible to fasten the plate with screws to the instrument body. The plate material shall be stainless steel. Self-adhesive tapes or signs are not allowed for permanent marking of any instrument or associated equipment.
Panel-mounted instruments shall have permanent signs on the front as well as on the rear.
2.5
Tropicalisation. All equipment has to be suitable for use and storage in a tropical climate.
2.6
Codes and Standards referred to in this specification and other instrument documentation shall
be the valid edition on zero date for the contract.
2.7
Field-Mounted Electronic Instruments shall be provided with IP 65 weatherproof and dustproof enclosures in accordance with IEC 529.
Field-mounted instruments, which are exposed to direct sun radiation shall, if necessary, be provided with sunshades.
3.
Flow Instruments
Flow measurements shall preferably be done by means of orifice plates and differential pressure
instruments. The sizing flow shall be approximately 10% higher than normal flow. Minimum rate of
flow that can be measured is approximately 25% of sizing flow.
3.1
Flow Transmitters shall be of the 'SMART' type. Bodies shall normally be in stainless steel with
AISI 316 internals. A pressure element in austenitic stainless steel, such as AISI 316, is a requirement. When the partial pressure of hydrogen is above 80 bar g, gold-plated measuring diaphragms shall be used. Connection shall be " NPT.
The transmitter shall be furnished with a LCD output meter with 0-10 sqrt. The overall accuracy
shall be better than 0.2% of calibrated span.
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Orifice Meter Installation with operational flow below 30% of sizing flow shall have a flow transmitter for the low range.
3.2
Armoured Rotameter Types may be used in pipe sizes from 2" and smaller. The meter shall be
selected for normal flow at 85% of the span. Tubes must be in stainless steel.
3.3
Special Flow Applications may require measurement devices such as turbine meters, magnetic
flow meters, Vortex meters, massflow meters, averaging pitot tubes, weirs floats, etc. Such situations shall be considered individually and the most suitable type of meter shall be selected.
3.4
Flow Switches for direct operation by process fluids may be of rotameter, or paddle type for
low accuracy requirements. Orifice plate and differential pressure type transmitter shall be used
for high accuracy requirements.
4.
Primary Flow Differential Producers
4.1
Calculations shall be in accordance with ISO 5167.

Orifice plates of the square-edged (concentric type) shall be specified, except where unsuitable
for the application. Materials shall be AISI 316 unless special materials are required for the service.
For temperatures above 300C AISI 410 shall be used.
4.2
Flanges with Flange Taps shall be used unless otherwise specified and be in accordance with
ANSI B16.36. Orifice flanges shall have a minimum ASME/ANSI rating class 300. Higher ratings will be as required by piping specifications. Tap size shall be 1/2" NPT for all flange ratings.
For sizes not covered by ANSI B16.36, the general piping specification shall govern.
4.3
Small Precision Bore Orifices shall be manufactured and calculated in accordance with ASME
"Fluid Meters, Their Theory and Application", 6th edition 1971, part II, para. II-III-15 to 19, except pressure-tapping shall be 1/2" NPT (F).
The meter run shall be supplied with ends prepared for butt-welding.
The meter pipe shall be of AISI 304 and with the same dimensions as the process pipe.
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4.4
Venturi tubes, or a similar type of element, may be used to measure the flow of low-pressure
gases or fluids where loss of pressure is an important consideration.
4.5
Flow Nozzles (ISA 1932 profile) may be used where erosion prohibits the use of square-edged
orifices. Flow nozzles are calculated and manufactured in accordance with ISO 5167.
4.6
Pitot Elements of the averaging type may be used where high accuracy is not required or the
pipe diameter is too large for acceptable orifice plate design, but shall be limited to combustion air
and cooling water services unless specially approved.
4.7
Circularity of pipe upstream and downstream a primary device shall comply with ISO 5167.
Verification procedure to be followed is described in "Flow Measurement Engineering Handbook", 2nd edition, by Richard W. Miller.
5.
Level Instruments
5.1
Level Transmitters of the differential pressure type shall be specified, unless unsuitable for the
application. Instruments of this type shall be in accordance with para. 3.1 Flow Instruments and
with 0-100 lin. LCD output meter.
Differential pressure instruments with remote seal diaphragms shall be used when the liquid has a
tendency to crystallise or solidify.
Remote seal diaphragms shall also be considered where cross-ambient temperature conditions of
the impulse lines exist.
5.2
External Cage Displacement type instruments shall not be used above a range of 1.219 meters. Chamber material shall be carbon steel. Where vessels are of alloy steel construction, chamber material shall be of equivalent or better material. The displacer shall be in AISI 316 and the
Torque Tube in Inconel.
Connection shall be 1" flanged with side to side connections.
The chamber shall be equipped with vent plug and drain valve. Heads shall be rotatable.
5.3
Direct Operated Type Level Controls (ball float, mechanically-linked valves, etc.) may be
used for utility service.
5.4
Special Level Measuring Problems may dictate the use of internal displacers, ball floats with
direct action, bubble tubes, capacitance, radioactive, ultrasonic type, etc. Each problem shall be
considered individually and the most suitable type specified.
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5.5
Level Switches shall be the external float cage type with 1" connection flanges.
Chamber material shall be CS. Where vessels are of alloy steel construction, chamber material
shall be of equivalent or better material. Level switches shall be of the vertical chamber type with
side-bottom connections. Standard centreline distance is 440 mm. The chamber shall be
equipped with a plug and drain valve, which shall be OS & Y type.
6.
Level Gauges
6.1
Magnetic Type Level Gauges in IP 65 stainless steel enclosures shall be used wherever suitable.
6.2
Gauge Glasses shall normally be reflex type, except for boiler drums, in corrosive services and
for interface services, where transparent gauges with glass protection and illuminators shall be
used. Transparent type shall be equipped with illuminators of minimum 40W.
Large Chamber Glasses shall be used where the liquid is close to boiling point. They shall be
well insulated and preferably installed without gauge cocks.
Pressure Rating for body and glass shall meet the General Piping Specification.
Gauge connection flanges shall be 1" and meet the General Piping Specification.
Standard Section Length of the armoured gauge glass shall be the No. 7 glass, (10 1/4" visibility). Maximum unit length shall be four sections.
Frost Extension shall be provided if the operating temperature is below 0C.
Protective Mica or Kell-F shields shall be used if the liquid will attack the glass, particularly in
steam and condensate services.
Gauge Valves, ball check, plus drain and vent valves shall be included. All valves shall be OS &
Y type. A plugged vent connection may be used instead of the vent valve.
6.3
Tubular Type Gauge Glasses shall not be used.
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7.
Pressure Instruments
7.1
Pressure Transmitters and differential pressure transmitters shall be modern, inherent motion-free 'SMART' types. Bodies shall be in stainless steel with AISI 316 pressure elements.
Pressure elements in martensitic stainless steel (such as AISI 410 and AISI 440) must not be
used in services with the presence of high pressure hydrogen. When the partial pressure of hydrogen is above 80 bar g, gold-plated measuring diaphragms shall be used.
The overall accuracy shall be better than 0.2% of calibrated span.
7.2
Pressure Controllers for application where transmission is not required, shall be a local indicating controller. The pressure element shall be in AISI 316. The case shall be weather-proof (IP
55). Convenient set point setting, as well as auto/manual switching shall be provided.
7.3
Pressure Switches for direct-connected process and utility service shall normally be diaphragm
or bourdon tube type, with materials suitable for the specified service. Connections shall be 1/2"
NPT male. Pressure transmitters shall be used as primary elements for low pressure and high accuracy requirements.
8.
Pressure Gauges
Gauges for process and utility service shall be the industrial-gauge types with the case in stainless
steel. The gauge shall be a safety type with solid front where pointer and glass are partitioned off
from the bourdon tube by a solid disc, and it shall have blow-out protection. Pressure gauges on
vibrating equipment shall either be of an oil-filled type or a standard gauge with flexible connection
and mounted on anti-vibration pads. Pulsation dampeners shall be installed with the gauges where
pulsating pressure occurs. Protection shall minimum be IP54.
Pressure gauges for steam and hot vapour service shall be equipped with a siphon.
Gauge Size shall be 100 mm for process and utility services.
Pressure Elements shall be austenitic stainless steel. Special elements, such as diaphragms and
bellows, can be selected in other materials. For gases containing hydrogen, martensitic stainless
steel (such as AISI 410 and AISI 440) must not be used.
Sockets and Tips shall be in the same material as the element.
Connections shall be 1/2" NPT male.
Dials shall be white, non-corroding metal or plastic with black figures.
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Range shall be so specified that the gauge normally operates in the middle third of the scale.
Over-range protection shall be selected in accordance with manufacturers recommendations.
Accuracy of all direct-connected gauges shall be guaranteed for 1% of full-scale reading.
When pressure gauges and transmitter are located on the same pipe, the pressure gauge shall be
installed next to the transmitter tapping.
9.
Temperature Instruments
All temperature elements shall be double: one connected and second to be installed as spare.
A field mounted transmitters shall be supplied for control and shut-down purposes, while for
monitoring purpose the temperature sensor signal shall be transferred directly to DCS.
9.1
Thermocouples shall be of a high purity magnesium oxide insulated and sheathed type. The hot
junction shall be grounded. Sheath shall be 6 mm (1/4") O.D. in Inconel 600 material, depending
on the service. The wire diameter shall be 0.51 mm as minimum.
Chromel/Alumel (ANSI type K) shall be used up to 900C. Platinum-rhodium/Platinum (ANSI

type R) shall be used in services up to approx. 1100oC. Thermocouple extension wire must be in
accordance with ANSI MC 96.1. Insulation resistance shall be more than 500 V.
9.2
Thermowells shall be in AISI 316 stainless steel, for temperatures higher than 538C AISI
347H shall be used. They shall be machined from bar stock material. Other materials shall be furnished as required by the piping specification. In high velocity streams thermowells shall be tapered in order to avoid resonance.
The immersion length of thermowells in pipes shall be maximum 125 mm. Generally, the immersion length of thermowells in vessels shall be according to table below:
Vessel diameter
TW immersion length
Up to 800 mm
200 mm
Above 800 mm and up to 1200 mm
300 mm
400 mm
500 mm
Above 2000 mm
600 mm
The insertion length is decided, depending of the nozzle/pipe fitting length.
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9.3
Process Connections shall be 1" NPT male on screwed thermowells. Flanged thermowells shall
be 1".
9.4
Thermo-Electric Properties and limits of errors shall conform to ANSI MC 96.1.
9.5
Thermocouple Heads shall be a weatherproof (IP 65) type. A spring-loaded design is required.
9.6
Resistance Temperature Detectors shall be considered for applications where very narrow
spans and high accuracy are required, as well as low temperature service. They shall be 6 mm
OD, stainless steel sheathed. Pt 100 ohms (0oC) element according to DIN 43760.
They shall be of the vibration-proof element type.
9.7
Multi-point Temperature Indicators shall, if used, preferably be with digital read-out in oC.
Cold junction compensation shall be included as standard. Accuracy shall be 0.1% of reading
or 1oC. The instrument shall be able to accept grounded as well as non-grounded thermocouples.
9.8
Temperature Transmitters shall, if used, be installed in a junction box or panel easily accessible for maintenance (not head-mounted). The accuracy shall be 0.1% of calibrated span.
9.9
Local Thermometers shall be bi-metallic, heavy duty, back connected type with 100 mm dial as
minimum with adjustable and rotatable head and stem. Case and stem shall be in stainless steel.
Degree of protection shall minimum be IP 55.
10.
Control and On/Off Valves
10.1
Valve Types. Single-seated, cage-guided, globe valve with balanced trim is the standard valve
type. Balanced trim shall be also considered for globe valves in flashing service. Single-seated,
unbalanced, globe valves are used for the valve sizes below 8 and when pressure drop and shutoff pressure can be handled.
The classical reversible double-seated globe control valve with top- and bottom-guided trim, or
heavy-duty type plug guiding is used when tight shut-off is a non-essential requirement and when it
is more cost-effective.
1.
Globe valve bodies shall conform to ANSI B16.34.

Valves with rotating plug can be used if suitable.
A/S
10.2
10.3
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2.
Butterfly valves shall be used in services with low pressure drop. High-duty butterfly
valves, e.g. firesafe in fuel gas service, shall be used for tight shut-off when more costeffective than ball valves.
3.
Ball valves shall generally be used as block valves, characterized balls shall be used as
control valves when the fluid has a tendency to crystallize.
4.
Angle valves shall be considered when the pressure drop is very high or fluid velocity is
extreme.
5.
Globe valves with shut-off function shall generally be single-seated.
6.
Valve sizes. 1" is minimum body size and 1", 2" and 5" shall not be used.
Body Materials shall be selected in accordance with the materials required by Piping Specifications and the process fluid characteristics.
1.
Cast carbon steel, A216 Gr WCB or WCC, or forged carbon steel, A105, is used in
non-corrosive service from -29C to 427C. Low temperature carbon steel, A352 Gr
LCB, can be used to -46C.
2.
Alloy steel, A217 Gr WC1, WC6, WC9 or C5, is used in flashing service and for temperatures above 427C.
3.
Stainless steel is used in flashing service, corrosive service and for temperatures below 29C.
4.
Monel is used in oxygen service.
Connection and Pressure Ratings. Globe valves shall have flanged connections with flange
rating and finishing, as per line specifications. If welding is specified, butt-welding is foreseen.
Flanges shall conform to ANSI B16.5
Face to face dimensions shall conform to ANSI B16.10 (ISA S75.03, S75.04) or ANSI
B16.47.
Other types of valves, such as eccentric rotating plug valves and butterfly valves, shall be wafertype for installation between flanges. Flangeless valves shall not be used in services with design
temperatures above 500oC.
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The direction of flow shall be clearly and permanently marked on the valve body.
10.4
Valve Characteristic shall be Equal Percentage

Valves with linear characteristic are used when the differential pressure is constant, such as in
pressure-reducing service and venting service, and when two valves are used in pairs in a 3-way
valve function. Gas compressor recycle valves shall also be linear.
The inner valve of a three-way valve shall have a linear characteristic when its function is flowsplitting.
Standard Trim material is AISI 316 unless otherwise specified.
Hardened trims, seats and stems are required when the pressure drop across the valve exceeds
10 bar or when the temperature is above 316C, when the pressure drop across the valve exceeds 5 bar in steam service, or when there is a risk of flashing/cavitation.
High friction trim is selected for high pressure drop applications, to prevent the onset of cavitation
and to reduce the noise level. High friction trim has a high pressure recovery factor, FL/ISA.
10.5
Bonnet shall be bolted according to ASME B31.3, and material shall be the same as the body
material. An extended bonnet is normally used when fluid temperature is below 0C or above
200C.
10.6
Seat leakage classifications are per ANSI B16.104:

Class II
Class III
Class IV
Class V
Class VI
0.5% of rated capacity

0.03 ml water/min. per 100 mm port diameter per bar differential.
in accordance with ANSI B16.104
Seat leakages shall be selected carefully, as the selection of a valve tighter than required has an
impact on the cost. Vent valves, that are normally closed, shall be very tight to minimise the leak
losses, class IV is the minimum class. Process steam valves shall not be more than class III.
10.7
Packing. The packing design for linear motion valves shall be with a packing flange.
Packing material shall be Teflon for bonnet temperature below 200C and graphite or graphoil for
higher temperatures. Packing design and material shall be selected carefully for minimum stem
friction.
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Vacuum service and special services like oxygen, require special packing materials and should be
given special considerations.
10.8
Flow Tendencies. For valves in shut-off service, flow tendency shall comply with the action of
the valve as required to put the plant in a safe condition in the case of power failure. In some
cases it is the back flow tendency to close that shall be considered.
For control valves in general it is the flow to open tendency that often is the most stable type of
operation.
Angle Valves: Flow tending to close.
Other Valves (globe, ball, etc.): Flow tending to open.
Valves with eccentric rotating plug: Flow tendency to correspond with valve action in case of
power failure.
10.9
Actuators. Control valves shall be equipped with a pneumatic actuator with a spring range from
0.4 to 2 bar g to obtain a small and fast actuator, since positioners are normally needed.
Actuators shall be sized to obtain a stroke time of 10 sec.
Ball valves and plug valves used as shutdown valves shall have an actuator designed with a safety
factor of 2.5 with respect to start friction, as the friction increases if the valve has remained in one
position for a long time.
10.10
Sizing and available pressure drop. The minimum available pressure drop shall be 15% of the
total system pressure drop to achieve effective control, however it is desirable to have 25%. If the
valve is a bypass valve of a heat exchanger, then the available pressure drop is often only 25% of
the pressure drop over the heat exchanger when the bypass valve is closed.
Control valves shall be sized in accordance with the calculation method and formula shown in ISA
S.75.01.
The required Cv is normally selected 30% larger than the calculated Cv for normal flow conditions, or in few cases as the calculated Cv for a maximum flow condition.
Butterfly valves shall be sized for a maximum opening angle of 60o.
Exception is made for characterized disc valves, which may be sized for a maximum opening angle of 90o.
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Maximum permissible velocity at valve outlet is 5 to 6 m/sec for ordinary liquids, is maximum 4
m/sec for MDEA solution and is Mach 0.5 at the outlet of the downstream pipe reducer for
gases. If velocity is Mach 0.3 or below, no extra noise is generated. Sound pressure level shall be
in accordance with the Design Basis, see point 2.1, measured one meter downstream from the
valve at a distance of one meter from the pipe.
Valve sizing shall be checked for:
-
10.11
minimum flow-rate conditions

flow velocity
noise level
flashing and/or cavitation
maximum differential pressure across the valve.
On/off Valves are generally selected in line size.
Ball valves are considered for fuel systems, in the process gas stream, in the CO2 absorption unit
and in compressor units. Line size body and full bore trim shall be used.
Firesafe butterfly valves are considered for fuel systems.
Gate valves with electric motors are used as block valves around the shift converters and for the
steam systems.
Globe valves shall be single-seated, line-size and full-size trim.
On/off valves used for double block and bleed-in fuel service shall be firesafe.
The actuators shall generally be spring to close diaphragm or piston types, with a stroking time of
less than 10 sec. The valves shall be supplied with 3-way solenoid valves, IP 65, coil with class H
insulation, allowing continuous operation in 85C ambient temperature.
Limit switches, if any, shall be SPDT, IP 65, EEx e/d and with screw terminals for AWG 13 wire.
10.12
Positioners and Tubing. E/P positioners shall have a 4-20 mA input, and output shall match
bench-setting of the valve. It shall have an output gauge in stainless steel and a filter regulator.
Valves in split range shall also have 4-20 mA input, the split is done in the DCS.
Positioners shall have air capacity to stroke the valves in 10 sec .
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For valves in service with process temperatures above 200C, an I/P converter and a pneumatic
positioner shall be considered.
Shutdown valves and other on-off valves shall be without positioners.
Air tube and fittings shall be in stainless steel. Size shall be adequate for the required stroking time
and it shall not be less than thin-walled 6mm tube.
10.13
Handwheels are normally required when no bypass valve is specified. Handwheels must not be
specified for shutdown valves.
Copper or copper alloy materials in the control valves, or accessories exposed to atmosphere,
are not allowed.
11.
Pressure-Relieving Devices
All pressure-relieving devices shall be sized in accordance with ANSI/API RP 520 and ASME
Code, sections I and VIII.
Furthermore, local and national codes shall be respected if they govern.
11.1
Percentage Overpressure and Accumulation Figures used in the calculation of orifice size of
relieving devices, shall be as follows:
Overpressure
3% 10% 10% 21% 25% -
Steam service where ASME Power Boiler Code (section I) applies

Gas or vapour service
For liquids
Fire exposure on unfired pressure vessels
For liquids (non-certified)
Accumulation
6% Steam service where ASME Power Boiler Code (section I) applies
10% Gas, vapour and liquid where ASME Pressure Vessel Code (section VIII)
applies
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16% Gas, vapour and liquid where ASME Pressure Vessel Code (section VIII)
applies and the system is protected by means of multiple valves
21% Fire exposure on unfired pressure vessels
Nomenclatures used shall be in accordance with API RP-520.
11.2
Safety and Relief Valves shall generally be flanged, direct spring-loaded types with high lift
high capacity and top-guided disc. Balanced bellow valves shall be furnished for relief into closed
flare and blow-down systems if the superimposed back-pressure is variable or the built-up backpressure exceeds 10% of the set pressure, or for lethal and toxic substances.
Pilot-operated valves shall be considered where light gases at high set pressures are encountered
and/or where operating pressures are close to set pressures.
11.3
Full Nozzle Type Valves shall normally be specified for sizes 1" and larger. Only the nozzle and
part comprising the disc are the parts exposed to inlet pressure, or to corrosive action of the fluid
when the valve is closed.
11.4
Base or Modified Nozzle Type Valves shall be specified for thermal relief service.
11.5
Rupture Discs may be used in lieu of, or in combination with, safety and relief valves, where applicable or required.
11.6
Storage Relief Valves. Pressure and vacuum relief valves for storage tanks shall normally be of
the weight-loaded or pilot-operated type, and sized in accordance with minimum requirements of
API RP-2000 or local codes, if applicable.
11.7
Materials for Construction shall be as follows:

Cast-steel bodies with stainless steel trim shall normally be specified as per API 526.
Cast-alloy bodies or special materials shall be specified where required, due to process, atmospheric or operating conditions.
Springs shall be carbon steel for normal process operating temperatures of -25oC to 232oC and
tungsten alloy steel or high temperature alloy steel above 232oC. Below -25oC, stainless steel
may be used.
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11.8
Bonnet Construction shall be plain closed pressure tight. Bonnets for toxic or inflammable
gases, as well as vapours and liquids. Exposed spring bonnets shall be specified for steam and
boiler service above 200oC. Bonnet extension shall be used above 400oC.
11.9
End Connections shall normally be flanged with facing and rating in accordance with the piping
specification. However, API 526 sizes and ratings shall always govern, where applicable.
11.10
Lifting Levers shall be furnished for exposed spring bonnets on safety relief valves in steam and
hot water service, and on air valves with closed bonnets and on valves in hot water service.
11.11
Test Gags shall be furnished on all safety and relief valves installed to protect vessels. Test gags
shall be removed and transferred to Owner's possession after testing. All test gags shall be
stamped with the valve tag number.
11.12
Code Stamps shall be furnished with safety valves where applicable.
11.13
Centre-to-Face Dimensions shall be in accordance with API 526, where applicable.
12.
Analysers and Accessories

The analysers shall mainly be of the following types:
Infrared analysers for
Thermal conductivity for
Zirconium Oxide for
Chemiluminiscens for
IR (in-situ) for
UV pulsefluorescent for
NDIR for
CH4, NH3, CO, CO2

H2
O2 in flue gases, field-mounted
NOx in flue gases
NOx in flue gases
SO2 in flue gases
SO2 in flue gases
Other principles (for specific gravity, LEL, etc.)

Gas Chromatographs or Mass Spectrometer will be considered if nitrogen shall be measured in
the synthesis loop, or if total compositions are required for feed streams. Analysers shall be installed in shelters or analyser rooms.
A/S
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No. J22226/J-21 Rev. 1

Job 22226
Page 18 of 28
As most sample gases are combustible, the analyser section or the whole analyser shall be provided with nitrogen purge (Exp). Vent lines shall have moisture separation. In case of low nitrogen purge, the analyser shall immediately be de-energised. The analysers can optionally be in Exd
enclosure.
Emission analysers installed in a non-hazardous area can be of the general purpose type, located
in a weatherproof enclosure.
If required, the cabinets shall be electrically heated to prevent internal condensation when not in
operation.
Analysers and their accessories shall be pre-mounted, tubed, wired and complete with selfstanding racks accessible from both sides.
12.1
Sample Conditioning Systems are as important as the analyser. The sample system shall be
provided by the same vendor as the analyser and be carefully designed. Refrigerator cooler shall
be used for CO2 and CO sample systems.
12.2
Gas and Vapour Systems volume shall be kept to a minimum. The tubing shall be of stainless
steel with a diameter of 6 mm.
For gas samples, pressure shall be reduced at the sampling point to increase the velocity through
the sample system and to reduce the time lag between the sample point and the analyser.
Special low volume insert type sample probes shall be used for analysers, particularly for high
pressure applications.
Sample bypasses around the analysers shall be supplied. This ensures that the sample lines are
purged and it reduces the time lag of the sampling. The sample bypass is either vented to the atmosphere or returned to a part of the process with a lower pressure.
The sample must be clean and free of particles. A strainer of suitable size shall be installed immediately ahead of the primary pressure reducer, or the reducer shall have a built-in filter. Additional
filters, strainers and drains, which may be required, should be specified as part of the system. All
components shall be as small as practically possible to minimise the volume of the sampling system. Water-washing of the stream may be required when dirty samples, such as from stack gas,
shall be analysed. The water should be recycled with only a small make-up and drain stream to
minimise composition changes.
A/S
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No. J22226/J-21 Rev. 1

Job 22226
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Normally, desiccants should be avoided when drying a sample stream. Chilling and trapping the
moisture is preferred, because desiccants can be spent, fail to function or they may absorb other
constituents besides water.
Steam or electrical tracing and/or insulation of the sample line are required if condensation of the
sample can occur at ambient conditions. A heated cabinet shall be provided by the manufacturer
for the sample-conditioning system, if there is any danger of condensation.
Sample calibration span and zero gases shall be provided with double block and bleed valves to
ensure positive isolation.
12.3
Liquid System Streams must be taken to the analysers, the sampling problem being similar to a
gas or vapour system. Filtering, pressure reduction, cooling or heating may be required. The extent of sample conditioning required shall be determined by the medium in the process line.
Liquid bypasses around the analyser shall normally be provided to reduce time lag of sampling.
They shall be drained to a sewer or returned to a part of the process with a lower pressure.
pH, conductivity and similar probes shall be installed in a bypass line to make it unnecessary to
interrupt the process for service of the electrodes.
12.4
Installation of analysers shall normally be in accordance with API RP - 550 part II.
12.5
Analyser Houses and Shelters shall preferably be located in a non-hazardous area.

External and internal explosion hazards are to be considered when equipment is chosen for analyser houses.
No sample or calibrating gases must be vented in the analyser house. Calibrating gases (bottles
and regulators) shall be placed outside (open air).
No direct connection to a sewer is allowed, therefore an open drain, located outside, shall be
provided.
12.6
Utilities shall be available at the analyser houses or shelters, i.e.:

-
Cooling water for final sample cooling

Potable water
Instrument air
Nitrogen
Power supply according to design basis
A/S
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No. J22226/J-21 Rev. 1

Job 22226
Page 20 of 28
Fire-fighting equipment.
12.7
Sample coolers are not required for most flue gas applications. Process gas streams above
100C normally require cooling, and a calculation based upon the sample rate and the latent heat
will clarify whether an air cooler is sufficient or if a water cooler is required.
13.
Alarm Switches
13.1
Alarms are generated from switches in the field, in analog electronic switches in panels/racks and
in the DCS or ESD system.
13.2
Contact Type shall be specified as single pole, double throw, wherever possible. Only one
function per switch shall be specified (i.e. alarm only or shutdown only). Gold-plated contacts to
be used for voltages below 48 V.
13.3
Switch Actions shall be closed circuit for normal operation and open circuit for alarm condition
(fail-safe).
14.
Control System
A Distributed Control System (DCS) from a recognised supplier shall serve as control system for
the plant. If feasible, it shall include the compressors and the utilities.
Supervision and control will take place from the central control room via a number of modular
Operator Workstations which provide the Operator's interface to the DCS.
The system shall be designed with a high degree of reliability, achieved by the use of redundant
data busses and redundancy for critical modules.
The normal display on the Operators Workstations shall be a graphic "flow sheet" display with
real time indication of the process parameters, and it is normally from this level of the display hierarchy that the operator's interventions take place, i.e. set point changes, manual control, stop/start
of pumps, etc.
The DCS shall have an open architecture enabling easy exchange of data with other systems
through standard protocols.
Printers are used for alarm- and event-logging and for shift reports.
A/S
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No. J22226/J-21 Rev. 1

Job 22226
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Turbine and Steam System Instrumentation:

In very fast loops smart transmitters shall have a dead time of maximum 20 ms or analog transmitters shall be used. The controllers can be in the DCS if the execution time is under 50 ms, otherwise dedicated digital or analog controllers shall be used.
15.
Emergency Shutdown System

The central part of the Emergency Shutdown System (ESD) shall have a very high degree of reliability. It is required that the system has fail-safe actions, but it is also necessary that the reliability
is so high that the "Mean Time between Failure" (MTBF), for a system failure that initiates an unwanted shutdown, is approx. 5 years.
The system shall have facilities for testing input, output and CPU function, without affecting the
operation of the plant.
This will result in a short fault detection time, and as such in a low "Mean Down Time" (MDT).
Consequently the availability will be high, which is the key parameter for the ESD system.
A hard-wired Mimic panel, which clearly displays status of trip alarms, bypasses, trip-groups,
etc. with a first-up alarm, shall be incorporated near the DCS Operator Workstations. Alternatively, a dedicated operator console, with graphics and functions as those described above, but
with hardware manual bypass and manual trip switches, shall be provided.
The operator shall also be informed about trip conditions by means of a warning sound (to be
different from the audible signal from the DCS alarm system).
The operator can inactivate a trip alarm input, required for start-up and restart. A light on the
mimic panel or on the screen shall indicate that the trip alarm is inactivated. The operator shall be
warned by sound and fast flash if the inactivated trip input goes to alarm status.
Pre-warning alarms will be provided for most trip alarms in the DCS.
For further description of the ESD system, see HTAS Doc. No. J-181 "General Specification for
Emergency Shutdown System".
16.
Installation and Process Connections
A/S
16.1
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Job 22226
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Primary Instrument Process Connections shall have the following sizes:

-
3/4" NPT (M) for pressure and differential pressure
1" NPT (F) for threaded thermowells
1/2" NPT (M) for sample points with sample probe for process analysis.
16.2
Installation of flow and pressure instruments shall be as closely coupled to the process connections as possible, in order to minimise problems of lead errors and heat tracing. They shall be
accessible from ladders or platforms, if not accessible from grade.
16.3
Instruments in vapour or gas service shall be located above the sensing point. Instruments in
liquid and steam service shall be mounted below the sensing point. If accessibility, visibility or
clearance requirements preclude either of these situations, provision shall be made in the impulse
piping to ensure proper operation of the instrument. Special precautions are to be taken where
cross-ambient conditions exist. Close-coupled pressure gauges to be mounted above the sensing
point are excluded from the aforementioned. However, they shall be used only on piping free of
vibrations.
16.4
Local Recorders and/or Controllers shall be accessible from grade or platform.
16.5
Flow and Level Transmitters (except wafer type) shall be installed using separate manifolds
with integral block and bypass valves. Instrument lead lines shall be min. 12 mm (") OD tube
and fittings of the double ferrule type, all in AISI 316. For ratings up to and inclusive ANSI 900.
Above ANSI 900 1/2 pipes and socket welded fittings shall be used.
16.6
Pressure Transmitters shall be installed with block and bleed valves. Instrument lead lines shall
be min. 12 mm (") OD SS tube and fittings of the double ferrule type, all in AISI 316. For ratings up to and inclusive ANSI 900. Above ANSI 900 1/2 pipes and socket welded fittings shall
be used.
16.7
Lock Pin or other locking device shall be provided for all instrument valve bonnets.
17.
Electrical Supply, Classification and Instrument Wiring
17.1
Electrical Supply available for the instrumentation shall be as follows:

Distributed Control System
Emergency Shutdown System
:
:
230V AC, 50 Hz
230V AC, 50 Hz
A/S
PetroVietnam
Control Room Instruments

Solenoid Valves
Local Panels
Local Illumination, equipment for air
conditioning, space heaters, ventilation
of local panels and similar purposes
Field-mounted Transmitters and Switches
Safety Circuits with lamps and relays
:
:
:
230V AC, 50 Hz
230V AC, 50 Hz
230V AC, 50 Hz
:
:
:
230V AC, 50 Hz
24V DC
24V DC
No. J22226/J-21 Rev. 1

Job 22226
Page 23 of 28
The 230V AC shall be supplied from an uninterrupted power supply (UPS) with directly earthed
neutral.
Where 24V DC is required locally, it shall be generated by local rectifier units, which are part of
the instrumentation supply. The power supply to these units shall be taken from the UPS.
Where 24V DC is used for Safety Circuits, the rectifier units shall be duplicated, and have a high
reliability. A failure in any unit must activate an alarm.
A separate instrument earthing system, interconnected to the power supply protective earthing
system at one particular earthing pit, shall be applied.
17.2
Electrical Classification. All electrical instruments, equipment and installations shall meet the
requirements for protection against explosion danger, as specified in relevant Codes and Standards.
17.3
Cables, Wiring and Cable-Laying

1.
Galvanised Steel Wire Armouring with PVC outer sheathing shall be used for all cables.
2.
Electronic Instrument Signal Wiring shall be with twisted pair cables, 15 twists or more
per metre. Conductors shall be 1.5 mm2 for one and two pairs, and 0.5 mm2 minimum radial thickness of 0.25 mm. Insulation between cores shall withstand a r.m.s. AC test voltage of min. 2000V.
3.
Multi-Pair cables shall be shielded with a common aluminium mylar tape with tinned copper drain wire. The temperature rating shall be min. 90oC. Each core shall be numbered
according to the specified standard.
A/S
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No. J22226/J-21 Rev. 1

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4.
Power and Control Cables for Solenoids, flame detectors , etc. shall be three coreand
normally have a conductor size of 1.5 mm2. However, conductor sizes for power cables
shall be co-ordinated with the design for the electrical installations, in order to avoid too
many different cable types.
5.
Resistance Element Wiring shall be made with cables equivalent to electronic instrument signal cables, but with 3 wires.
6.
Thermocouple Extension Wiring shall be with twisted pair cables, 15 twists or more per
meter. Conductors shall be 1.5 mm2 for one and two pairs and 0.5 mm2 for multiconductor cables. Conductors shall be according to the specified standard. Individual pair
cables and the individual pairs in multi-core cables shall be shielded with aluminium-mylar
tape with tinned copper drain wire. Multi-core cables shall also have a similar common
shield.
Standard insulation is PVC with minimum temperature rating of 90oC and each core shall
be colour-coded and numbered.
Separate conduits and separate multi-conductor cables shall be supplied for thermocouple
wiring, 4-20mA wiring and alarm system and power circuits, which will also ensure the
necessary segregation between non-incendive/intrinsically safe and incendive circuits.
7.
Hot Area Service e.g. for steam drums, where the cable temperature is likely to ex- ceed
90C, requires the use of high temperature silicone cables. These cables shall
only be laid
within the hot area and be terminated in a junction box mounted outside
the hot area.
8.
Non-incendive Circuits shall be designed with separate cables. In cable ducts and trays,
non-incendive cables shall be separated from other cables by a mechanical barrier. Such a
barrier is not required if all cables are provided with additional protective sheathing or
sleeves which provide equivalent protection, or if cables are securely fastened to ensure
that physical separation is maintained.
Non-incendive circuits shall be marked clearly to distinguish them from other circuits. The
enclosures shall be marked with labels.
9.
Intrinsically Safe Circuits shall be clearly marked to distinguish them from other circuits.
Such markings shall be by colour-coding cables and terminals, with the colour of the outer
sheath and terminals being light blue. The enclosures shall be marked by means of labels.
10.
Outer Sheaths of cables shall be fireproof in accordance with IEC Recommendations 227 and 332.
A/S
11.
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No. J22226/J-21 Rev. 1

Job 22226
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Closed Conduit Wiring Design shall not be used.
18.
Noise Immunity of Electronic Instruments
18.1
Radio Frequency Interference - RFI. Most electronic equipment is in some manner affected
by electromagnetic radiation, which is frequently generated by hand-held radio transceivers used
by maintenance and security personnel.
RFI effect on instruments can be manifested by:
-
temporary, zero or span shift

random output fluctuations
accidental tripping of alarms
unintentional triggering of plant shutdown devices
permanent span and zero shifts after total cut-off of instrument operation during
presence of strong radio frequency field.
All electronic instruments shall therefore have a susceptibility of less than 0.2% of span for a frequency range of 20 to 1000 MHz in a field strength of 30 volt/metre.
18.2
Electromagnetic Interference - EMI. As thermocouple signals can be several orders of magnitude smaller than the common mode voltages, all receiving thermocouple instruments (indicators,
recorders, transmitters, alarm switches, etc.) shall have a Common Mode Rejection Ratio of 80
dB at 50 Hz.
Normal Mode Rejection Ratio shall be better than 60 dB at 50 Hz and above.
19.
Package Unit Control Equipment

Package unit suppliers shall supply control panels, which are similar to the panels for the main
process with regard to construction, panel front layout and internal build-up.
Power supply shall be as per design basis and pressurised panels shall be designed for IP 55 enclosures.
The panels shall have ready-made gland plates with cable glands for incoming cables, providing
for the fastening of cables near the terminals. Cable ducts shall be fitted to accept the incoming
cables.
A/S
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No. J22226/J-21 Rev. 1

Job 22226
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If 24V DC power supply is required for instrumentation, it shall be provided by local, duplicated
rectifier units of high reliability.
If a package unit supplier wants to use a PLC or other similar digital control equipment, he first
has to seek the approval from the client, as it is in the clients interest to limit the number of different types of equipment used in the plant in order to reduce the required number of spare parts
and the education of the service personnel.
19.1
Panel Design shall be totally enclosed, modular, free-standing cabinets, constructed in convenient sections to facilitate shipment and installation, and the panel construction shall comprise a
welded or bolted frame construction.
The panels shall be made from min. 1.6 mm mild sheet steel. The front shall be stiffened where
necessary with profiles tack-welded on the rear side.
The panels shall be well sealed against dust, i.e. minimum IP 50 enclosure as per IEC 529 for indoor locations, and IP 55 for outdoor locations, and in wet areas. The panels shall be fitted with
lockable access doors and a protective canopy if located outdoors. The location of the cable entries shall be approved by the engineer/client.
Instrument air consumption for purge of local panels shall be limited to 10 Nm3/h at 6.5 bar g per
panel.
Panel front, sides and doors shall be sandblasted and cleaned before two coats of primer are applied. The primer shall be followed by two coats of paint. The colour shall be RAL 7035, bright
grey, if not otherwise specified. The final surface shall be semi-matt, free from blemishes and paint
runs.
19.2
Electrical Classification for the area shall be followed, and the equipment certified as described
in para. 17.2.
19.3
Wiring shall preferably be contained in plastic ducts routed in an orderly manner to instrument
housings. Intrinsically safe wiring shall be separated from other wiring, as well as thermocouple
extension cables and power wiring. There shall be spare capacity in the ducts.
Conductors shall be marked at each end, and cables shall be identified by cable markers on terminal boards, and at the panel-mounted instruments.
A/S
PetroVietnam
19.4
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Terminals shall be of the Weidmller/Klippon type, or similar in thermoplast, mounted on DIN

standard rails or equivalent.
Each terminal strip/terminal box shall be provided with spare terminals equal to 20% of the total
number of terminals. In case of open power terminals, the terminals shall be covered by a transparent cover, in order to protect the maintenance personnel from accidental contact.
Intrinsically safe terminals shall be separated by minimum 50 mm from other terminals.
19.5
Miniature Circuit Breakers shall be provided in the power supply feeder for each instrument
consumer.
19.6
Electrical Relays installed in the panel as part of any control circuit or interlocks shall be carefully selected, high quality, hermetically-sealed relays, with contact materials that are suitable for
the contact rating. The relays shall be provided with a button so it is possible to simulate energised
conditions. The relays shall be installed so they are insensitive to vibrations and mechanical shock.
19.7
Illumination. The interior of the panels shall be well illuminated with fluorescent fixtures mounted
at the top or sides of the panels. A single phase socket outlet for portable lighting, etc. shall also
be provided.
19.8
Nameplates shall be provided for each panel-mounted instrument, below the case, and shall be
mechanically fastened and not glued to the panel. Duplicate nameplates shall be provided and
mechanically fastened to the instruments in the panel rear. Rear-mounted instruments that do not
project through the face of the panel, shall also be provided with nameplates, mechanically fastened to the instruments.
Nameplates shall be furnished in accordance with the following specifications:
19.9
Material
Size
Lettering
:
:
1.5 mm thick white/black/white laminated three-ply traffolyte

engraved so that white letters appear on black background
25 mm high x 60 mm wide
3 mm high
Inside the Panel Enclosure a strictly non-hazardous atmosphere shall be maintained.

Pipelines entering the enclosure shall carry no other substances besides instrument air. They shall
in no way be directly connected to lines or equipment carrying other substances. The entry of cables and pipes shall be gas tight in case the panel enclosure is located in a hazardous area.
A/S
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No. J22226/J-21 Rev. 1

Job 22226
Page 28 of 28
19.10
Spare Panel Space for subsequent mounting of additional instruments shall amount to approx.
20% of occupied panel space and be distributed equally over the panels.
20.
Pneumatic Equipment
20.1
Signal Inputs and Outputs shall be 0.2-1 bar g.
20.2
Signal Tubing and Fittings shall be in stainless steel with a minimum tube size of 6 mm OD.
20.3
Instrument Air supply will be available at 7.5 bar g and with air quality according to ANSI/ISA
S7.3. Design pressure 11 bar g.
20.4
Instrument Air Users. Field instruments shall have individual air reducing stations with filter and
block valve. The reducing station and the associate consumer shall be sized for a minimum air
header pressure of 4 bar g.
20.5
Pneumatic Connections to or from the field shall terminate at tagged bulkhead connections.
Each line teeing off from a transmitter line to a pressure switch, relay, etc. shall have a block valve
and a plugged tee for testing purposes.
A/S

J-21 Rev1

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DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

Flow Instruments ........................................................................................................................4

Primary Flow Differential Producers.......................................................................................5

Level Instruments .......................................................................................................................6

Pressure Gauges .........................................................................................................................8

Temperature Instruments ...........................................................................................................9

10. Control and On/Off Valves .....................................................................................................10

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

Primary Flow Differential Producers

Calculations shall be in accordance with ISO 5167.

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

Tubular Type Gauge Glasses shall not be used.

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

Chromel/Alumel (ANSI type K) shall be used up to 900C. Platinum-rhodium/Platinum (ANSI

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

Thermo-Electric Properties and limits of errors shall conform to ANSI MC 96.1.

Control and On/Off Valves

Globe valve bodies shall conform to ANSI B16.34.

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

Globe valves with shut-off function shall generally be single-seated.

Monel is used in oxygen service.

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

Valve Characteristic shall be Equal Percentage

Seat leakage classifications are per ANSI B16.104:

0.5% of rated capacity

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

minimum flow-rate conditions

Positioners shall have air capacity to stroke the valves in 10 sec .

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

Steam service where ASME Power Boiler Code (section I) applies

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

Materials for Construction shall be as follows:

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1

Code Stamps shall be furnished with safety valves where applicable.

Centre-to-Face Dimensions shall be in accordance with API 526, where applicable.

Analysers and Accessories

CH4, NH3, CO, CO2

Other principles (for specific gravity, LEL, etc.)

DK-2800 Lyngby, Denmark

No. J22226/J-21 Rev. 1