Icm-En-1600 - Field Instrument Installation

CAUTION: Based upon the publication date, this document may not contain the latest
guidance. The user is strongly advised to contact the Technology Manual Sponsor to
determine the appropriate subject matter expert for consultation on applicability to the
user’s specific case.
1600 Field Instrument Installation
Abstract
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This section covers recommended practices for the installation of field mounted
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instruments and provides information on the installation of pneumatic and electrical
signal transmission systems.
For details concerning the installation of specific process instruments (such as indi-
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vidual pressure, temperature, level, and flow devices) see the corresponding sections
of this manual.
Contents Page
1610
1611
Introduction
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Process Connections and Piping
1600-3
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1612 Pneumatic Installations
1613 Electrical Installations
1614 Suggested Checklist
1620 Instrument Installation and Mounting 1600-4
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1621 Field Instrument Installations

1622 Instrument Process Piping Material
1623 Instrument Field Supports and Mountings
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1624 Instrument Accessibility

1625 Nameplates and Tags
1630 Signal Transmission Systems 1600-13
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1631 Pneumatic Systems

1632 Pneumatic Raceways and Junction Boxes
1633 Electrical Instrument Installations
1634 Electrical Signal Transmission
1635 Electrical Cable Trays and Junction Boxes
July 1999  1999 Chevron USA Inc. All rights reserved. 1600-1
1600 Field Instrument Installation Instrumentation and Control Manual
1640 Model Specifications, Standard Drawings,

and Engineering Forms 1600-20
1641 Model Specifications
1642 Standard Drawings
1650 References 1600-22
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1600-2  1999 Chevron USA Inc. All rights reserved. July 1999
Instrumentation and Control Manual 1600 Field Instrument Installation
1610 Introduction
This section provides general guidance on designing and reviewing instrument
installations. To minimize design effort and manpower, a uniform approach to
installation design should be established and followed for each facility. Installation
design decisions and possible modifications must be made well before the construc-
tion stage. Otherwise, design omissions and modifications will cause scheduling
constraints, encourage installers to improvise, possibly violate Standards and Codes,
and compromise the quality of the installation.
Instrument installations fall into three distinct categories:
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• Process connections and piping
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• Pneumatic connections
• Electrical connections and wiring details
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1611 Process Connections and Piping
Process connections and piping cover the physical installation and piping up of field
instruments (sensors) that come in direct contact with process fluid. These instru-
ments may get connected to piping, pressure vessels, or mechanical equipment
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depending on their function. Their installation, to ensure that they provide mean-
ingful and reliable data is a primary concern. The designs must be economic, safe,
and maintainable.
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To provide the most accurate readout, instruments should be mounted as closely as
possible to their process connections. However, accessibility for maintenance and
adverse ambient conditions at the process, e.g., vibration or high temperature, may
require that the instruments be mounted remotely and connected by piping to their
process connections. Also, instruments that tie into safety monitoring and/or shut-
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down systems must be installed so that they are testable without shutting down the
process while they are being tested.
Process installation design and review by the responsible instrument engineer
include location and support of instruments, design of process piping and the test
connections (if necessary), and assuring that the connecting piping stays functional
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and does not plug.
1612 Pneumatic Installations

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With the development of microprocessor based controls there is a continuing trend

in the control industry to put less emphasis on pneumatic control systems. However,
although pneumatic systems are slower than electronics, they are rugged and reli-
able and have been in use for a very long time. Operators, maintenance personnel,
and many Company managers are very comfortable with pneumatic instruments.
Even if the main control system may be electronic, almost all control valves and all
field control loops will still be pneumatically actuated.
In production operations, where environmental regulations permit and especially on
offshore installations, natural gas is frequently used instead of instrument air to
operate pneumatic instruments. Natural gas is a reliable source of actuating power

and eliminates the capital expense to allocate space and to procure and install
mechanical compressors for pneumatic systems, environmentally conditioned
control rooms, signal distribution networks, emergency generators, and battery
backups for electronic systems. The lost revenue of nonrecovered gas is more than
offset by eliminating the expense to maintain such systems.
1613 Electrical Installations

There are extensive applications for electrical and electronic control systems. Elec-
trical instrument installations are very important to ensure signal isolation, system
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reliability, and conformance to codes.
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1614 Suggested Checklist
Review the following during the design phase:
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• Proper sizes and rating of process connections on piping, vessels, and major
equipment
• Instrument installation details and piping isometrics
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Heat tracings purges and winterizing of instruments, if applicable
Pneumatic installation details
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• Electrical installation details
• Equipment-vendor-supplied instrumentation
This review should be given particular emphasis. Vendors are inclined to omit root
valves and may try to substitute inferior instruments and installation material.
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1620 Instrument Installation and Mounting

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1621 Field Instrument Installations

Location of Instrument Process Connections
Locations of instrument process connections are determined either by the process
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equipment vendors or by the piping designers based on the applicable P&IDs.

Instrument engineers should review the instrument process connections to ensure
that piping for flow-meter runs and proper sized connections for relief and control
valves have been provided.
The exact locations of instrument process connections should appear on piping
isometrics and on equipment and piping layout drawings.
The size and type of material to be used for process connections are defined by the
piping and equipment specifications published for the particular process condition.
The instrument engineers and designers should review the location of the process
connections against the P&IDs to ensure the following are correct:
1. Orientation of instrument block and bleed valves is in compliance with piping
and instrument specifications.
2. Process connections of in-line mounted instruments match the connections
provided by piping designers (e.g., flange size and rating), block valves (where
required), and that adequate accessibility for servicing and for manual opera-
tion has been provided.
3. Shutdown switches cannot be inadvertently blocked off while isolating other
instruments for maintenance. Shutdown actuating devices should be installed
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on dedicated process connections, separately from other instruments.
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Once the exact locations of instrument process connections are established, the
instrument installation details and instrument location plan drawings should be
finalized.
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Instrument Installation Detail Drawings
Instrument installation details should provide the instrument connection arrange-
ment and tabulate the material required for the installation. When many instruments
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need to be installed, it is easier to separate the details by their function such as:
• Process connections
Pneumatic connections
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• Electrical connections
• Heat tracing and winterizing
• Miscellaneous (field supports, special fittings, etc.)
This approach is more efficient because the same process connection detail may
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apply to either pneumatic or electronic instruments, and heat tracing requirements

and needs for special fittings can also be applied interchangeably. When craft labor
is involved, this grouping also helps separate and define craft responsibilities.
Process Installation Review

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Process instrument installation drawings should be reviewed to ensure that the

following conditions have been met:
• All process pressure connections have been provided with 3/4-inch root valves.
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• Designs include provisions for testing instruments in alarm and shutdown

services.
• Pressure instruments have a safe means of depressuring the installation for
maintenance.
• Instruments are mounted above the line, and the process lead slopes down to
the process connection in condensing vapor services. If process temperature is
above 150F (except for steam flow meters), make sure that there is a siphon in
the process lead (either purchased or field fabricated).
• Instruments are mounted below the line, and the process lead slopes up to the
process connection in liquid services.
• Remotely mounted instruments are installed using stainless steel tubing beyond
the root valve. The tubing should be installed with a minimum slope of 1/2 inch
per foot (1 to 2 inches per foot is preferable if space permits) and should be
routed to avoid formation of pockets (high or low points where liquid or vapor
can get trapped and introduce an error into the instrument reading).
• Sufficiently long meter runs (upstream and downstream) have been provided
for flow instruments that require meter runs, e.g., orifice meters, vortex shed-
ding meters, or turbine meters.
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• Straightening vanes in lieu of long meter runs (to reduce turbulence in the flow)
have been considered where space is limited.
• Orifice meter runs in wet gas or vapor service should either be oriented verti-
cally with downward flow, or have a weep hole in the orifice plate in a hori-
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zontal run, to prevent accumulation of liquid on the upstream face of the plate.
• Differential pressure (d/p) flow instruments on orifice meters, both transmitters
and bellows-type readouts and switches, have been provided with bypass mani-
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folds at the instrument. (Three-valve manifolds are used in most manufacturing
and chemical applications. Five-valve manifolds are used in production appli-
cations.) These manifolds are used by maintenance to zero and calibrate the
meters.
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• On orifice meters in liquid service, the process taps are below the center of the
line (but not in the bottom), and the instrument is installed below the line.
• On orifice meters in steam service, process leads are extended above the line to
exactly the same elevation before they are routed back down to the instrument
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mounted below the line. In steam service, steam condenses in the process leads
and the condensate isolates the instrument from the high temperature of the
steam. Running the leads up to the same elevation keeps the height of the
condensate in the leads equal and balances out errors that would be introduced
if the leads were at different elevations.
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• Seal pots are provided on bellows-type orifice meters in steam service. Bellows
meters are high displacement instruments and if the flow changed, an error
equal to the displacement of condensate in the leads would be introduced until
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the steam recondensed. Seal pots provide a surge volume in this application.
• Seal pots are provided on all steam orifice meters in freezing climates. In
freezing climates, steam meter leads have to be filled with anti-freeze. Seal pots
identify the instruments that need to be winterized and state the type of anti-
freeze used.
• All blind (nonindicating) transmitters and switches have been provided with
pressure gages.
• For instrument in toxic (e.g., H2S), corrosive, and high-pressure service,

process connections include a restriction fitting in the instrument end of the
root valve to limit accidental spill of process liquids. Vent and drain valves are
piped to drains for personnel and environmental protection.
• Capillaries for instruments with diaphragm seals and capillary tubing are
supported in small channels to protect tubing from possible damage and to
provide protection from sunlight. Excess tubing is neatly coiled at instrument
end.
• Instruments connected to process fluids that may solidify or increase in
viscosity enough to impair measurement, have been heat traced or the process
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fluid isolated from the instrument by seal pots, diaphragm seals (gage protec-
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tors), purging, or other means. Refer to Section 1500, “Instrument Seals,
Purges, and Winterizing”,” of this manual and ICM-EF-409 “Seal, Purging, and
Winterizing of Instruments.”
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Standard Drawings GB-J1143 through GB-J1148 show typical installation details
for pressure instruments. Standard Drawings GB-J1158 through GBJ1173 show
typical installation details for level instruments. Standard Drawings GB-J1177
through GB-J1187 show typical installation details for flow meters. Standard Draw-
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ings GB-J1196 through GB-J1203 show methods for installing temperature sensing
elements in process lines and equipment.
1622 Instrument Process Piping Material

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Instrument process piping is defined as all piping or tubing between an instrument
and the root (block) valve nearest the process.
Stainless steel tubing is preferred over rigid piping because it is more resistant to
corrosion and is easier and more economical to install.
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With proper tools tubing can be bent to form slopes, pigtails and the required
configuration for the process installation of instruments.
Instrument process tubing should conform to ASTM A269. The tubing can be 304
or 316 stainless steel.
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Seamless, fully annealed and pickled tubing is usually preferred. Welded tubing is
available, but there have been problems with the quality of the welds. ASTM A269
requires that the allowable working pressure for welded tubing be derated.
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Figure 1600-1 shows allowable working pressures for seamless tubing and specifies
the ASTM derating requirements.
Allowable working pressure at -20F to 100F is calculated as specified by
ANSI B31.3 code.
Tube Fittings
Tube fittings for process tubing should be the flareless compression type of 316
stainless steel and should conform to ASTM A269.
Male threads should be rolled. Nuts should be pre-lubricated.
Fig. 1600-1 Pressure Rating of Seamless 304 and 316 SS Tubing

Wall Thickness (Inches)
0.028 0.035 0.049 0.065
Pressure Rating(1)
Tube O.D., In. psig psig psig psig
1/8 8500 10900 — —
3/16 5400 7000 10200 —
1/4 4000 5100 7500 10200
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5/16 — 4000 5800 8000
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3/8 — 3300 4800 6500
1/2 — 2400 3500 4700
(1) For welded tubing, multiply pressure rating by 0.80 for single welded tubing and 0.85 for double welded tubing.
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Tests performed by Chevron Research Corporation and by several fitting manufac-
turers show that unless a compression fitting is improperly installed (mismatched
fitting components, fitting not tightened properly, ferrule installed backwards, or the
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tube not inserted completely into the fitting before tightening), the tube will burst
before a compression fitting will fail. Therefore, the allowable working pressure of
the tubing is the limiting factor on tubing installations.
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Instrument Hand Valves
Instrument hand valves are defined as block, bypass, or bleed valves; remote or
close coupled with instruments; mounted between process root valves and
instruments.
The instrument hand valves can be single valves, single valves with multiports, and
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three- or five-valve manifolds.

The type of hand valves can be needle, ball, or globe design, with hard or soft seats
for various temperature and pressure ratings.
Needle valves are used for manual throttling of flow for purging, sampling, or just
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for straight shutoff.

Multi-port gage valves provide extra pressure connections for bleed or test of pres-
sure instruments.
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Three- or five-valve manifolds are used for differential pressure instruments where
the block, bypass, and bleed valving combinations are required for servicing and
calibration of instruments.
Three-valve manifolds are also used for pressure instruments where an additional
gage and bleed connection is required.
Valve bodies, stems, and trim should be 316 stainless steel.
Valves in services with pressures below 4,000 psig can have compression-type
tubing connectors.
Valves in services above 4,000 psig should have bar-stock bodies and threaded end
connections.
Teflon packing can be specified for services below 400F (204C).
Grafoil packing should be specified for services above 400F (204C).
Additional piping material like nipples and pipe fittings should be in accordance
with applicable piping specifications.
1623 Instrument Field Supports and Mountings

Most of the field transmitters, recorders, and controllers are supplied with 2-inch
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pipe mounting brackets. Surface mountings are available for mounting instruments
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remotely from the process. The required mounting must be specified by the instru-
ment engineer. The 2-inch pipe mounting brackets are specified for most field
mounted instruments.
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Types of Standard Instrument Supports
1. Free standing 2-inch pipe stanchions with flanged, concrete, or welded base
2. Two-inch pipe saddle type supports (with U-bolt clamps to process pipe)
3.
4.
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Two-inch pipe supports with welded or flanged wall mountings
Two-inch multiple pipe supports for two or three instruments
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5. Surface mounts supported by 2-inch pipe
6. Target supports for field gages
See Standard Drawing GB-J1233, Field Mountings for Instruments.
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Preferred Instrument Mountings:

Line-mounted flow measurement d/p cells are usually mounted on 2-inch pipe
saddles fastened by U-bolts or chain to the process line.
Remote mounted flow and level d/p cells are mounted on free standing 2-inch pipe
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stanchions or wall mountings.

Bellows type indicators, recorders, and switches are usually mounted on 2-inch pipe
stanchions.
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Field recorders and indicating controllers are usually mounted on free standing
2-inch pipe stanchions that are easily accessible for calibration and servicing.
However, it is sometimes desirable to rack mount these instruments with surface
mounts.
Most field gages, switches, and all of the temperature elements are line-mounted
(i.e., screwed directly into root valves or process connections). Temperature
elements can also be flanged to process connections.
If it is preferred that the readout be located mounted remotely from process connec-
tion, field gages can be ordered as surface-mounted.
Material for Supports

Pipe for instrument supports should be steel 2 inches and a minimum of
Schedule 40.
Pipestand baseplate should be a minimum of 8-inches square and manufactured of
3/8-inch steel plate.
Pipestands should be of all-welded construction, and the entire mounting assembly
should be hot-dip galvanized.
Mounting of Field Instrument Supports

Instrument supports should be welded (not bolted) to the steel floors, platforms, or
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structural steel. They can also be bolted to concrete floors and walls.
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Welding on process equipment or process piping is never allowed.
Instrument Location Plan Drawings
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Instrument location plan drawings furnish the following design and construction
information:
• The approximate locations and mounting elevations of remotely mounted
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instruments (relative to some fixed point such as a pipe line, process connec-
tions, or final control element)
The approximate location of instrument air subheaders (relative to main air
headers)
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• The exact locations and orientation of instrument junction and terminal boxes
• The approximate routing of tubing runs
Review of location drawings

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When remotely mounted instruments are used, the instrument engineer should
review the installation details and the instrument location plan drawings to ensure
that the following conditions are met:
• Easy access is provided for maintenance, repair, and calibration.
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• Sufficient front and rear clearance is allowed for access to and removal of the
instrument.
• There is a clearance of at least 2 feet per 100F (38C) between equipment with
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surface temperatures in excess of 200F (94C).

• Instruments are mounted so that the centerline of the instrument is either 4 feet
or 4 feet and 6 inches above grade (or platform elevation) depending on local
practices.
• Instruments are located as close to the primary connection as possible, consis-
tent with instrument accessibility and mounting requirements. Remote-mounted
instruments should be mounted no more than 25 feet from the point of measure-
ment. The shorter the lead the better the response.
• Instruments in gas, vapor service and services where plugging is likely to occur,
are installed above their process connections.
• Instruments in clear liquid and steam services are installed below their process
connections.
• Indicating controllers or receiver gages from non-indicating transmitters are
installed where their scales can be clearly visible from a point where manual
control may need to be performed, e.g., at the by-pass valve around a control
valve manifold.
• Instruments are not mounted on handrails or on removable structures.
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• Instruments are not mounted in locations subject to leaks, spills, or damage
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from process equipment. Where such locations are unavoidable, a suitable
shield or protective cover is provided.
• Instruments are not attached to vibrating structures. Where such locations are
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unavoidable, antivibration mounts should be provided.
• Instruments are not located in areas where the ambient temperature exceeds the
limits specified by the manufacturer.
1624 Instrument Accessibility

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Accessibility to instruments, safety and ease of maintenance, and servicing are
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important. Adherence to the Company “Safety in Designs” publication should help
ensure safe accessibility to instruments.
Instrument accessibility must include access to the associated process block valve
(i.e., root valve or the first shut-off valve remote from the root valve) and to the
instrument air supply block valve. Types of instrument access are described below.
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Instrument access requirements for specific instruments are given in Figure 1600-2.
• Grade or Permanent Platform Access: Platforms should have either permanent
ladders or permanent stairways.
• Permanent Ladder Access: Access while standing on a permanent ladder.
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• Portable Stepladder or Rolling Platform Access: Access limited to 10 feet

above grade or platform. Access from a portable stepladder or rolling platform
at grade is subject to the following conditions:
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– The location is easily accessible by one person carrying a stepladder or

moving a platform.
– The location is safe for placement of a stepladder or rolling platform.
– Access from a portable stepladder or rolling platform on an elevated plat-
form is not allowed.
When instruments must be installed in overhead pipeways they should be grouped
(if at all possible) to simplify access to the instruments.
Fig. 1600-2 Access for Instruments

Type of Platform Stepladder or Permanent
Instrument or Grade Rolling Platform Ladder
Transmitters (blind Yes Yes No
or indicating)
Field Controllers Yes No No
Field Recorders Yes No No
and Indicators
Field Switches (alarm Yes No No
and control)
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Routine Test Facilities Yes No No
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for Alarms and
Shutdowns
Control Valves and Yes No No
other Final Control
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Elements
Field Pressure Gages Yes Yes Yes
Dial Thermometers Yes Yes Yes
Thermocouples and Yes Yes Yes
Resistance Bulbs
Temperature Test
Points
Level Gage Glasses
Yes
Yes
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No
Yes
Yes
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Analytical and Other Yes No No
Special Instruments(1)
Hydrogen Sulfide, Combus- Yes Yes No
tible Sensors, etc.
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(1) This includes but is not limited to radioactive, chromatographic, capacitance, pH, boiling point, moisture, viscosity, oxygen,
and specific gravity analyzers.
Access from portable stepladders or rolling platforms is acceptable for transmitters

installed in the bottom level of overhead pipeways and mounted below the line
(e.g., liquid or steam service). Vertical distance should be reviewed to make sure
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that a maintenance person can work on the instrument at chest height if at all
possible.
Process connections for instruments mounted in overhead pipeways above the line
or in multilevel pipelines should be grouped and installed where they can be reached
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from a walkway across the pipeway.

Transmitters should not be mounted between pipeway levels.
Access to Flow Instruments in Pipe Trenches or Grade Level Pipeways: Where
the orifice plate is located in a pipe trench or grade-level pipeway, a permanent plat-
form or walkway should be provided for access to the instrument.
Access Requirements for Specific Instruments

The types of access acceptable for specific instruments are outlined in
Figure 1600-2.
1625 Nameplates and Tags

All instruments should be labelled for identification. Field instruments should have
316 stainless steel nameplates permanently attached to the instruments with 316
stainless steel screws, rivets, or wire by the manufacturer. Nameplates should be
stamped with the instrument tag number, purchase order number, model number,
and serial number.
Lettering size for nameplates should be a minimum of 3/16 of an inch.
Nameplates for intrinsically safe instruments should include the following informa-
tion.
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• Manufacturer
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• Model
• Serial number
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• Instrument tag number
• Hazardous area class and group suitability
• A statement indicating that the instrument is intrinsically safe
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A statement indicating that any substitution of components may impair intrinsic
safety
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• The agency certifying that the equipment is intrinsically safe
1630 Signal Transmission Systems

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1631 Pneumatic Systems

Although instrument air is the predominant medium used in pneumatic systems,
natural gas is occasionally used by production facilities. Design considerations
listed below for instrument air apply equally to gas.
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The main components of a pneumatic system are:

• Instrument air supply and distribution (instrument air header and its laterals)
• Pneumatic supply to individual instruments
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• Pneumatic signals between instruments

• Transmission of pneumatic signals to remote locations
Instrument Air Supply and Distribution

Clean dry instrument air is needed for pneumatic instruments to operate. Instrument
air is usually compressed to a pressure of 100 to 150 psig, dried to a dewpoint of at
least 20F lower than the lowest ambient temperature recorded at the facility, then
piped throughout the facility to provide pneumatic power to instruments and final
control elements.
The primary system for distributing air to instruments in a facility is usually routed
throughout the facility and is referred to as an instrument air header. Branch connec-
tions or laterals are piped from this header to provide air to instruments located in
the same operating area. The size of these laterals is determined by the number of
air users that the lateral has to supply.
Branch headers and laterals should be sized as follows:
Number of Instruments Supplied Branch or Lateral Size
1 to 5 ½ inch
6 to 10 ¾ inch
11 to 25 1 inch
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Full port ball valves are usually installed at each lateral and also at each end of the
air header (for blowdown). Standard Drawing GB-J1214, Instrument Air Supply
Header shows a typical air header layout.
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Supply to Individual Instruments
To minimize the air header size and to provide the needs of all final control
elements, instrument air is usually distributed at a high pressure. Individual instru-
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ments operate at much lower pressures and cannot withstand the pressure at which
air is available in the air header.
To ensure that instruments operate properly and are not over-pressured, instrument
air pressure is normally reduced at each instrument to match the rating of the instru-
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ment. Most transmitters and controllers require 18 to 22-psig instrument air, some
controllers and all diaphragm control valves positioners require a 40-psig air supply,
piston actuators and some other control elements require 60-psig and higher air
supplies. Pressure gages on the outlet of the regulators (integral with or separate
from the regulators) are used to set the air pressure.
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To satisfy individual instrument requirements, a ½ inch lateral is extended to the

proximity of the instrument, a ball valve and a pressure reducing regulator are
installed at the end of the lateral, and air is run through tubing to the instrument.
¼-inch OD tubing is usually sufficient, but special applications may require 3/8-inch
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or ½-inch OD tubing.
Standard Drawings GB-J1208 through GB-J1213 show typical instrument air supply
piping to instruments.
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Pneumatic Signals Between Instruments

Pneumatic signals are usually transmitted through ¼-inch OD tubing. Bare copper,
plastic coated copper, and stainless steel tubing can be used for pneumatic signals.
Within control cubicles (panels) individual plastic tubes are sometimes used.
When several pneumatic signals must be run in parallel, multitube bundles can be
utilized economically. Plastic sheeted cables consisting of multiple plastic tubes can
be run economically provided that they are protected from physical damage. Multi-
tube cables can be installed in cable trays or pulled in conduit in overhead installa-
tions. They can also be installed in underground conduit. Multitube cables are
available that are rated for direct burial — most Chevron Operating Companies
avoid burying multitube cables without protection for fear of unforeseen physical
damage, e.g., a backhoe cutting through a cable and shutting down a facility.
Pneumatic transmission systems should be designed to limit transit time to about
3 seconds. If transit time is greater than 3 seconds, volume boosters should be
provided to keep the transit time down.
Signal Tubing Installation

Signal tubing should be straight run, securely fastened, and arranged to facilitate
trouble shooting. Tubing should be installed with sufficient flexibility to allow for
normal equipment movement.
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Tubing Supports
Single and multiple tubing runs should be supported every 3 feet of running length,
both in and out of raceways.
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For support, single tubing runs should be placed in small steel channels or in galva-
nized thin wall steel conduits. Up to four tubes may be run in a single support
conduit.
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Exposed ends of tubing should be not less than 18 inches nor more than 24 inches in
length. Burrs and sharp edges should be removed from conduit ends to minimize
damage to plastic coating of tubes.
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Pneumatic Tube Routing
Instrument tubing should be installed in raceways, on pipe racks, or otherwise
supported to result in a plumb, level, vibration free and neat installation.
Tubing should be routed so to avoid removal of the tubing when maintenance or
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repair of equipment is required.

Tubing should not be routed through areas where a high risk of fire or mechanical
damage exists (such as over vessels, compressors, or pumps), unless required by the
application, e.g., emergency shutdown system, size loop, etc.
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Aboveground Installation of Multitube Cables

Cables should be installed in horizontal racks in the center of the pipeway as far
from pump rows as possible.
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Plastic cable tubing should be installed away from any heat source and should be
suitably protected in areas of likely mechanical damage.
Preferred cable sizes are 4, 12, and 19 tubes per cable. Spare tubes should be
provided in each cable; 2 in 4, 3 in 12, and 4 in 19.
Underground Installation of Multitube Cables

Multitube cables should be pulled in conduits, one cable per conduit. Multitube
conduits should be installed in the same manner as that specified for electrical
conduits.
Conduits should be sized for a maximum of 53% fill. The total degrees of bend
should not exceed 360 degrees between pull boxes. Permissible bend radius, pulling
length, pulling load, and handling method should comply with the manufacturer’s
recommendations.
Preferred multi-tube cable sizes for underground installation are 19 and 37. Spare
tubings should be provided in each cable; 4 in 19 and 6 in 37.
1632 Pneumatic Raceways and Junction Boxes

Pneumatic Tubing Trays, Channels, and Raceways
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Tubing lines should be supported with tubing trays or channels. The installed tubing
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trays should not present a hazard to personnel, block accessways, or prevent passage
of equipment. Tubing raceways of heavy-duty reinforced fiberglass or hot deep
galvanized steel (galvanized in accordance with ASTM A123, Specification for Zinc
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(Hot-Galvanized) Coatings on Products Fabricated from Rolled, Pressed, and
Forged Steel Shapes, Plates, Bars, and Strip) may be required for some applica-
tions.
Pneumatic Junction Boxes

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Multiple pneumatic lines should terminate in outdoor junction boxes that are
centrally located with respect to a group of field-mounted pneumatic instruments.
Tubing should enter outdoor junction box through the sides or bottom only and only
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through a bulkhead union connector. Bulkheads should be installed in accordance
with API RP 552, Transmission Systems.
A breather/drain fitting should be provided in the bottom of the box.
Junction boxes are available which are made of steel, stainless steel, aluminum, and
ed
fiberglass reinforced plastic materials.
1633 Electrical Instrument Installations

Electrical installations for instruments should be coordinated with electrical engi-
at
neers. Instrument engineers who are not electrical engineers should have a solid
understanding of electrical installation techniques and wiring and should be thor-
oughly familiar with the National Electric Code (NEC).
D
Electrical instruments must meet the following conditions:

• Installations must meet NEC requirements, particularly as related to hazardous
(classified) areas.
• Wire and cable construction and materials must be suitable for the environ-
ment, e.g., high temperature and contaminants.
• Flexible conduit connection must be provided between the instruments and the
rigid conduit.
• Drains should be provided at low points of conduits.
Standard Drawing GD-J1234 and GD-J1235, Instrument Conduit Connections show

typical conduit connection configurations for instruments.
Purging of Electrical Instrument Enclosures

Instrument enclosures can be purged to reduce the classification within the enclo-
sure:
Type X: From Division 1 to nonhazardous.
Type Y: From Division 1 to Division 2.
Type Z: From Division 2 to nonhazardous.
l
Power should be turned on in a purged instrument enclosure only after a four-
ia
volume purge (ten volume for enclosures exceeding 10 cubic feet) has been
completed and a minimum internal pressure of 0.1-inch water column has been
established.
er
Type X purging requires that all electrical power to the purged enclosure be de-ener-
gized in the event of purge failure. Purge failure should be monitored and an alarm
actuated by a pressure switch.
at
1634 Electrical Signal Transmission
This subsection provides an overview of wiring designs and installations for the
instrument engineer. The installation of the electrical signal transmission systems
M
should be coordinated with electrical engineers.
Two-Wire Transmitter System

Most two-wire transmitters are powered from the main or local control room panel.
The most common supply voltage is 24 volts DC. The standard operating signal
ed
level is 4 to 20 mA.
Four-Wire Transmitter System

Four-wire transmitters are powered from field power sources independent from
main or local control panel mounted instrument(s). The most common supply volt-
at
ages are 24 volts DC and 120 volts AC. The operating signal level is 4-20 MA.
Wiring and Cable Practices

The size of the signal wire should be in accordance with ELC-MS-3551, “Instru-
D
ment and Control Cable Signal and Multipair Construction.” The wire size
requirements depend on the classification of the signal as defined by the NEC.
Single-pair instrument signal lines are usually wired to field junction boxes with
screw-clamp type terminal blocks.
Multiconductor cables are run from field junction boxes to control panels. The size
of multiconductor cables should be in accordance with ELC-MS-3551. The most
commonly used cable for low voltage signal level is No.16 American Wire Gage
(AWG), twisted, shielded pair. NEC defines signal level classes and defines wire
sizes for each class.
Cable Routing
Parallel runs as well as crossovers of control signal wiring and cables and power
wiring and cables require separation to prevent induction of stray voltages into the
low level signal wiring. Specification ELC-MS-1675 in the Electrical Manual tabu-
lates separation requirements based on signal levels and power levels.
Control signal cables should not be routed through areas where a high risk of fire or
mechanical damage exists, e.g., pump rows.
l
Intrinsically Safe Systems
ia
Intrinsically safe systems are described in detail in Section 1400, “Intrinsic Safety”,
of this manual.
er
Basically, intrinsically safe equipment and wiring are incapable of releasing enough
thermal or electrical energy to cause ignition of a specific hazardous mixture in its
most easily ignited concentration. Intrinsically safe installations are much more cost
effective in hazardous (classified) locations when armored cables and cable trays are
used for signal routing instead of explosionproof fittings and conduit.
at
For a system to be intrinsically safe, power and current going to the field devices
must be limited, and all field components must be certified intrinsically safe.
M
Intrinsically safe field devices must be so identified. Instruments that have been
tested and approved for intrinsically safe applications are identified by a blue label
that states that the instrument is certified as intrinsically safe. Intrinsically safe
system wiring should be identified by either color coding all cables, wire and
conduits with a light blue color or by identifying them by other means such as signs
or tags.
ed
The Instrument Society of America (ISA) Recommended Practice ANSI/ISA

RP12.6 - “Installation of Intrinsically Safe Systems for Hazardous (Classified)
Locations” defines the installation requirements for intrinsically safe systems,
including installation methods, identification of wiring and components, and separa-
at
tion of intrinsically safe system wiring from nonintrinsically safe wiring.
System Grounds
Incorrect grounding of instrument components and systems can introduce stray volt-
D
ages and inaccurate reference ground potentials into the signals generated and
received by electronic instrumentation. Requirements for grounding and isolating
instruments and systems are explained in detail in Specification ICM-MS-3651,
“Installation of Digital Instruments and Computers.”
Standard Drawing GF-J1236, “Typical Ground System for Digital Instrumentation
and Process Computers,” which is referenced in ICM-MS-3651 and is also enclosed
in this manual shows recommended grounding connections for various combina-
tions of electrical and electronic instruments and systems. This drawing was
produced as a result of troubleshooting many grounding related problems in control
systems. This drawing has also been reviewed and is supported by most of the major
electronic instrumentation and control system vendors.
1635 Electrical Cable Trays and Junction Boxes

This section provides an overview of installing cable trays. For more specific details
refer to the section entitled “Electrical Installation,” in the Electrical Manual.
Signal Isolation and Routing

Cable trays should be installed in accordance with the following:
l
• Separate trays should be provided for instrument signal cables and power
ia
cables.
• Overhead routing of instrument cable trays usually provides the best possible
mechanical protection and isolation of cables from electrical interferences.
er
• Instrument cable trays should be routed away from pump rows and other high
fire hazard areas.
• Cable tray installations should not present a hazard to operating and mainte-
•
nance personnel.
at
Material for cable trays and accessories should be chosen in accordance with
the guidelines in the Electrical Manual.
M
Electrical Junction Boxes for Instruments
Electrical junction boxes for outdoor instrument signal wiring should be installed
complete with mounting hardware, nameplates, terminal blocks, and wiring. In
addition, the following conditions should be met:
ed
• NEMA 4X enclosures are normally preferred for outdoor electrical junction

boxes when they are not required to be explosionproof
• Explosionproof junction boxes should conform to the NEMA 7 specifications
• Entrances to junction boxes should be from the side or bottom. No holes are
at
allowed in the top of any junction box.

• High-density terminal strips should not be used in junction boxes
• Terminal boxes should be mounted at an accessible height and should be
D
provided with breather vents and drains

• Terminal boxes should be provided with low surface temperature heaters where
required
1640 Model Specifications, Standard Drawings, and Engineering Forms
1641 Model Specifications
ELC-MS-1675 Installation of Electrical Equipment

ELC-MS-3551 Instrument Wire and Cable
ELC-MS-3552 Thermocouple Extension Wire and Cable
ICM-MS-3651 Installation of Digital Instruments and Computer
l
ICM-MS-4815 Instrument Item List
ia
1642 Standard Drawings
er
ICM-EF-409 Seals, Purging and Winterizing of Instruments
GB-J1143 Pressure Gage installation - 3/4" Root Valve
GB-J1144
GB-J1145
GB-J1146
at
Pressure Gage with Diaph. Seal - 3/4" Root Valve
Remote Mounted Pressure Instrument
Remote Mounted Pressure Instrument — With Pressure Gage
M
GB-J1148 Draft Gage
GB-J1158 Level Gage With Screwed Process Connections
GB-J1159 Level Gage With 150# Flanged Process Connections
GB-J1160 Level Gage With 300# Flanged Process Connections
ed
GB-J1161 Level Switch, External Float Type With Screwed Process

Connections
GB-J1162 Level Switch, External Float Type With 150# Flanged Process
Connections
GB-J1163 Level Switch, External Float Type With 300# Flanged Process
at
Connections
GB-J1164 Level Instrument, External Displacer Type With Screwed
Process Connections
D
GB-J1165 Level Instrument, External Displacer Type With 150# Flanged

Process Connections
GB-J1166 Level Instrument, External Displacer Type With 300# Flanged
Process Connections
GB-J1167 Vessel Connections for Level Instruments and Gages With
Screwed Process Connections
150# Flanged Process Connections

300# Flanged Process Connections
GB-J1170 Vessel Connections and Level Instrument Bridle (Strongback)
Connections
GB-J1171 Differential Pressure Level Transmitter Mounted Below
Lower Tap
GB-J1172 Differential Pressure Level Transmitter Mounted at Lower Tap
GB-J1173 Differential Pressure Level Transmitter Mounted At or Above
Upper Tap
GB-J1177 Differential Pressure Flow Instrument, Gas Service - Instru-
l
ment Above Taps
ia
GB-J1178 Differential Pressure Flow Instrument, Liquid Service - Instru-
ment Below Taps
GB-J1179 Differential Pressure Flow Instrument, Dry Gas Service -
er
Instrument Below Taps
GB-J1180 Differential Pressure Flow Instrument, Wet Gas Service -
GB-J1181
GB-J1182
atDifferential Pressure Flow Instrument, Steam Service - Instru-
ment Below Taps
Differential Pressure Flow Transmitter, Gas Service - Instru-
ment Above Taps
M
GB-J1183 Differential Pressure Flow Transmitter, Liquid Service -
GB-J1184 Differential Pressure Flow Transmitter, Dry Gas Service -
ed
GB-J1185 Differential Pressure Flow Transmitter, Wet Gas Service -

GB-J1186 Differential Pressure Flow Transmitter, Steam Service - Instru-
ment Below Taps
GB-J1187 Differential Pressure Flow Throat Tap Connections
at
GB-J1196 Screwed Thermowell Installation in Piping

GB-J1198 Flanged Thermowell Installation in Piping
GB-J1200 Thermowell For Furnace Stack
D
GB-J1201 Furnace Tube Skin Point Thermocouple

GB-J1202 Reactor Skin Point Thermocouple
GB-J1208 Air Connections for Automatic Pump Start (Plastic Jacketed
Copper Tubing)
GB-J1209 Air Connections for Automatic Pump Start (Stainless Steel
Tubing)
GB-J1210 Air Connections for Instrument with Plastic Jacketed Copper
Tubing
GB-1211 Air Connections for Control Valve with Plastic Jacket

GB-1212 Air Connections for Instrument with Stainless Steel Tubing
GB-J1213 Air Connections for Control Valve with Stainless Steel tubing
GB-J1214 Typical Instrument Air Supply Header
GD-J1233 Field Mountings for Instruments
GD-J1234 Instrument Conduit Connections
GD-J1235 Instrument Conduit Connections
1650 References
l
ia
API RP 14F, Design and Installation of Electrical Systems for Offshore Production
Platforms
API RP-551, Process Measurement Instrumentation
er
API RP 552, Transmission Systems
ASTM A123, Specification For Zinc (Hot-Galvanized) Coatings on Products Fabri-
cated From Rolled, Pressed, and Forged Steel Plates, Bars and Ships
at
M
ed
at
D

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CAUTION: Based upon the publication date, this document may not contain the latest

1600 Field Instrument Installation

1621 Field Instrument Installations

1624 Instrument Accessibility

1631 Pneumatic Systems

1640 Model Specifications, Standard Drawings,

and does not plug.

1612 Pneumatic Installations

With the development of microprocessor based controls there is a continuing trend

operate pneumatic instruments. Natural gas is a reliable source of actuating power

1613 Electrical Installations

1620 Instrument Installation and Mounting

1621 Field Instrument Installations

equipment vendors or by the piping designers based on the applicable P&IDs.

apply to either pneumatic or electronic instruments, and heat tracing requirements

Process Installation Review

Process instrument installation drawings should be reviewed to ensure that the

• Designs include provisions for testing instruments in alarm and shutdown

• For instrument in toxic (e.g., H2S), corrosive, and high-pressure service,

1622 Instrument Process Piping Material

Fig. 1600-1 Pressure Rating of Seamless 304 and 316 SS Tubing

three- or five-valve manifolds.

for straight shutoff.

1623 Instrument Field Supports and Mountings

Preferred Instrument Mountings:

stanchions or wall mountings.

Material for Supports

Mounting of Field Instrument Supports

Instrument Location Plan Drawings

Review of location drawings

surface temperatures in excess of 200F (94C).

1624 Instrument Accessibility

• Portable Stepladder or Rolling Platform Access: Access limited to 10 feet

– The location is easily accessible by one person carrying a stepladder or

Fig. 1600-2 Access for Instruments

Access from portable stepladders or rolling platforms is acceptable for transmitters

from a walkway across the pipeway.

Access Requirements for Specific Instruments

1625 Nameplates and Tags

1630 Signal Transmission Systems

1631 Pneumatic Systems

The main components of a pneumatic system are:

• Pneumatic signals between instruments

Instrument Air Supply and Distribution

To satisfy individual instrument requirements, a ½ inch lateral is extended to the

Pneumatic Signals Between Instruments

Signal Tubing Installation

repair of equipment is required.

Aboveground Installation of Multitube Cables

Underground Installation of Multitube Cables

1632 Pneumatic Raceways and Junction Boxes

Pneumatic Junction Boxes

fiberglass reinforced plastic materials.

1633 Electrical Instrument Installations

Electrical instruments must meet the following conditions:

Standard Drawing GD-J1234 and GD-J1235, Instrument Conduit Connections show

Purging of Electrical Instrument Enclosures

Two-Wire Transmitter System

Four-Wire Transmitter System

Wiring and Cable Practices

The Instrument Society of America (ISA) Recommended Practice ANSI/ISA

tion of intrinsically safe system wiring from nonintrinsically safe wiring.

1635 Electrical Cable Trays and Junction Boxes

Signal Isolation and Routing