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GES J.14


Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

Rev 0 1999




1.1 Introduction 4
1.2 Other NOC Specifications 4


2.1 Technical 5
2.2 Contractual 5

3.0 DESIGN 6

3.1 Codes and Standards 6

3.2 Scope of Supply 9
3.3 Basic Design Criteria 9
3.4 Hazardous (Classified) Area Requirements 10
3.5 Electrical Power Supplies 10
3.6 Air Supplies 11
3.7 Instrument Signals 11
3.8 P & IDs, Instrument Symbols and Tagging 11
3.9 Junction Boxes and Field Panels 12
3.10 Cables and Wiring 12
3.11 Units of Measurement 13


4.1 General Requirements 13

4.2 Instruments and Instrument Tubing 14


5.1 QA/QC 14
5.2 Instrument Selection 14
5.3 Control Valves 15
5.4 Safety Relief Valves 16
5.5 Flow Instruments 17
5.6 Temperature Instruments 18
5.7 Level Instruments 19
5.8 Pressure Instruments 20
5.9 Block/Vent Valves 21
5.10 Solenoid Operated Valves 22
5.11 Controllers, Recorders and Indicators 22
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5.12 Instrument Connections 22

5.13 Fire and Gas Instrumentation 22
5.14 Panels and Junction Boxes 23
5.15 Package Control System Design 23
5.16 Analytical Instruments and Systems 24
5.17 Rotating Equipment Monitoring Systems 26


6.1 Field Instruments 26

6.2 Control Valves 26
6.3 Safety Relief Valves 27
6.4 PD Meters and Turbine Meters 27
6.5 Temperature Elements 28
6.6 Level Instruments 28
6.7 Pressure Instruments 28
6.8 Instrument Tubing and Fittings 28
6.9 Instrument Hook-Ups 29
6.10 Instrument Cable Tray and Glands 29
6.11 Earthing (Grounding) 30


7.1 Conformity to Specification 30

7.2 Materials Certification 30
7.3 Labelling 31
7.4 Marking 31
7.5 Cable Identification 31

8.0 TESTING 32

8.1 Factory Acceptance Testing (FAT) 32

8.2 Control Valves Testing 32
8.3 Pressure Relief Valves Testing 33
8.4 Site Acceptance Testing (SAT) 33


9.1 Introduction 34
9.2 Schedules and Reports 35
9.3 Hazardous Areas Certificates 35


10.1 Painting and Coatings 35

10.2 Spares 35
10.3 Packing and Storage 35
10.4 Shipping 36
10.5 Warranty 36

Table 1 - Process and Instrument Connections 37

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1.1 Introduction

1.1.1 This specification defines the minimum requirements for the design, fabrication, inspection and testing for
instrumentation for packaged units.

1.1.2 This specification applies to equipment for refineries, onshore oil and gas installations and processing

1.1.3 The Vendor/Contractor shall comply fully with the provisions laid down in this specification. Any
exception must be authorised in writing by the Owner.

1.1.4 All items necessary for the fully functioning, efficient, safe, reliable and satisfactory operation of the
package unit system shall be included, not withstanding their omissions for this specification.

1.1.5 In the event of any conflict between this specification and the Data Sheets, or with any applicable Codes
and Standards, the Vendor/Contractor shall inform the Owner and obtain written clarification or
authorisation from the Owner before proceeding with the work.

1.1.6 This specification together with the Data Sheets shall form part of the Purchase Order/Contract.

1.2 Other NOC Specifications

The following NOC specifications are an integral part of this specification and any non-compliance will
have to be approved by the Owner.

GES A.02 Flow Diagrams

GES A.06 Site Data

GES H.01 Fire and Gas Alarm Systems

GES H.02 CO2 and Halon Substitute Systems

GES J.01 Standard Instrument Symbols and Tags

GES J.07 Solenoid Valves

GES J.08 Motor Operated Valve Actuators

GES J.09 Hydraulic Valve Actuators

GES J.12 Indoor Control Panels and Cabinets

GES J.13 Field Panels and Junction Boxes

GES J.15 Instrument Air Systems

GES J.16 Instrument Cable and Cabling

GES J.17 Earthing of Instrument Systems

GES J.18 Electronic Controllers, Recorders and Indicators

GES J.19 Annunciators

Rev 0 1999
GES J.21 Programmable Logic Controllers

GES J.24 Fire and Gas Instrumentation

GES J.28 Process Stream Analysers (inc. Sampling)

GES J.31 Pneumatic Controllers, Recorders and Indicators

GES J.32 Emergency Shutdown and Blowdown Valves

GES L.28 Electrical Requirements for Packaged Units

GES L.35 Electrical Equipment in Hazardous Areas

GES P.02 Plant Piping Systems

GES X.06 Factory Coatings for Electrical Equipment and Instruments


2.1 Technical

The technical terms used in this specification are defined as follows:

Package Unit

A self-contained fully functional process unit requiring only the provisions of external utility supplies such
as air, gas, water, electricity etc and making process piping connections to other units. The package may be
skid mounted or for large packages, be site assembled and erected.

2.2 Contractual

The commercial terms used in this specification are defined as follows:


The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.


The company supplying the equipment and material.


The main contractor for a defined piece of work.


A company awarded a contract by a contractor to do part of the work awarded to the contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and facilities
have been designed, constructed, inspected and tested in accordance with the requirements of this specification
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and the Purchase Order/Contract.


A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority, who
verifies that the equipment and facilities have been designed, constructed, inspected and tested in accordance
with the requirements of this specification and the Purchase Order/Contract.


3.1 Codes and Standards

3.1.1 The package unit instrumentation design shall comply with this specification and the following codes and

3.1.2 Unless otherwise specified in the Purchase Order/Contract, the current editions of the codes and standards at
the time of the order shall be used.

American Petroleum Institute (API)

API RP 520 Sizing Selection and Installation of Pressure Relieving Systems in Refineries

API RP 521 Guide for Pressure Relief and Depressurising Systems

API RP 526 Flanged Steel Pressure Relief Valves

API RP 527 Seat Tightness of Pressure Relief Valves

API RP 551 Process Measurement Instrumentation

API RP 552 Transmission Systems

API RP 554 Process Instrumentation and Control

API 555 Process Analyzers

API 620 Design and Construction of large, welded, low-pressure storage tanks

API 650 Welded Steel Tanks for Oil Storage

API 670 Vibration, Axial-Position and Bearing Temperature Monitoring systems

API 2000 Venting Atmospheric and Low Pressure Storage Tanks

API 2510 Design and Construction of LPG Installations

API MPMS Manual of Petroleum Measurement Standards

American National Standards Institute (ANSI)

ANSI/FCI 70-2 Control Valve Seat Leakage

American Society of Mechanical Engineers (ASME)

ASME B1.20.1 Screw Threads - Pipe Threads - General Purpose (inch)

Rev 0 1999

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B16.10 Face to Face and End to End Dimensions of Valves

ASME B16.36 Orifice Flanges

ASME B16.34 Valves - Flanged, Threaded and Welding Ends

ASME PTC 19.3 Performance Test Code - Temperature Measurement

ASME B46.1 Surface Textures (Surface Roughness, Waviness and Lay)

ASME PV Power Boilers

Code 1

ASME PV Pressure Vessels - Division 1

Code 8 Div I

American Society for Testing and Materials

ASTM A 269 Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General

British Standards Institution (BSI)

BS 800 Specification for Limits and Methods of Measurement of Radio Interference

(Supplemented by BS EN 55014)

BS 1655 Specification for Flanged Automatic Control Valves for the Process Control Industry (Face to Face

BS EN 837-1 Pressure Gauges - Burdon Tube {Pressure Gauges - Dimensions, , Metrology, Requirements
and Testing

BS 1794 Specification for Chart Range for Temperature Recording Instruments

BS 3463 Specifications for Observation and Gauge Glasses for Pressure Vessels

BS 3643 ISO Metric Screw Threads

BS 4066 Part 3 - Tests on Electrical Cables Under Fire Conditions - Tests on Bunched Wires or Cables

BS 4800 Schedule of Paint Colours for Building Purposes

BS 5070 Drawing Practice for Engineering Drawings

BS 5308 Part 1 - Instrumentation Cables - Specification for Polyethelene Insulated Cables

BS 5345 Code of Practice for the Selection Installation and Maintenance of Electrical Apparatus
(All Parts) for Use in Potentially Explosive Atmospheres

BS 5501 Electrical Apparatus for Potentially Explosive Atmospheres

(All Parts)

BS 5536 Recommendations and Preparation of Technical Drawings for Microfilming

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BS EN 60534 Industrial-process control valves

BS 6121 Mechanical cable glands for elastomers and plastics insulated cables

BS 6346 Specification for PVC Insulated Cables for Electricity Supply

BS 6667 Electromagnetic Compatibility for Industrial Process Measurement and Control Equipment

BS 6739 Instrumentation in Process Control Systems : Installation Design and Practice

BS 7671 Requirements for Electrical Installations (Identical to IEE Wiring Regulations)

BS EN 10095 Heat Resisting Steel and Nickel Alloys

International Electrotechnical Commission (IEC)

IEC 331 Fire Resist Characteristics of Electrical Cables

IEC 60332 Tests on Electric Cables under Fire Conditions

(Part 2)

IEC 60529 Degree of Protection Provided by Enclosures (IP Code)

IEC 60584 Thermocouples -

Part 1 - Reference Tables
Part 2 - Tolerances
Part 3 - Extension and Compensating Cables
- Tolerances and Identification System

IEC 60617 Graphic Symbols for Diagrams

IEC 60751 Industrial Platinum Resistance Thermometer Elements

IEC 79-1 Electrical Apparatus for Explosive Atmospheres

Instrument Society of America (ISA)

ISA S5.1 Instrumentation Symbols and Identification

ISA S5.2 Binary Logic Diagrams for Process Operations

ISA S5.3 Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and
Computer Symbols

ISA S7.0.01 Quality Standard for Instrument Air

ISA S18.1 Annunciator Sequences and Specifications

ISA S75.19 Hydrostatic Testing of Control Valves

International Standards Organisation (ISO)

ISO 5167/1 Measurement of Fluid Flow Means of Pressure Differential Devices-Orifice Plates, Nozzles
and Ventury Tubes Inserved in Circular Cross Section Conduits Running Full

ISO 5208 Industrial Valves - Pressure Testing for Valves

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ISO 9000/1 Quality Management and Quality Assurance Standards. Guidelines for Selection and Use

ISO 9003 Quality Systems - Model for Quality Assurance in Final Inspection and Test

National Association of Corrosion Engineers (NACE)

MR 0175 Sulphide Stress Cracking Resistant Metallic Materials for Oilfield Equipment.

3.2 Scope of Supply

3.2.1 For each package the following shall be defined by the Owner and issued with this specification:

Control philosophy
Start up and shutdown philosophy
Operator interface requirements
Local/control room panel requirements
Interfaces with other plant systems
Alarm and trip requirements.

3.2.2 A project specific Vendor/Contractor scope of supply shall be developed. The scope of supply shall define the
extent of Vendor/Contractor's supply, acceptability and extent of Vendor/Contractor's standard
instrumentation, the scope of Vendor/Contractor's supply for non-package mounted (e.g. control room)
instrumentation and the extent of any free-issue equipment supplied to the Vendor/Contractor by the Owner.

3.2.3 The package control system shall be centralised where possible, with centralised display in the control room
and integrated with the plant control system. The intent shall be to provide a seamless interface between the
package and plant control systems, to the extent that the package control system is transparent to the operator.

3.3 Basic Design Criteria

3.3.1 Equipment supplied shall meet the environmental requirements of GES A.06.

3.3.2 All instruments, associated parts and interconnections shall be new, fit for purpose and shall be suitable for the
specified service and environment conditions. Tropicalised circuit boards, if specified, shall be tested before
and after tropicalisation.

3.3.3 Instruments installation shall conform to API RP 551, 552 and 554 and the Owner's standard process and
pneumatic installation diagrams where applicable.

3.3.4 The Vendor/Contractor shall supply all the instrumentation mounted directly on the equipment or piping as
required by the equipment specification or Purchase Order/Contract. The Vendor/Contractor shall also supply
local or control room panels as required by the equipment specification or Purchase Order/Contract. The
Vendor/Contractor shall ensure that the instrumentation and panels shall be capable of being interfaced to
external equipment specified in the specification or Purchase Order/Contract.

3.3.5 All instruments shall be supplied, installed and pre-wired to segregated junction boxes on the skid edge. All
pneumatic tubing and air headers shall be installed and piped up to the instruments. The Vendor/Contractor
shall provide a flanged connection at the skid edge for the air supply connection. Unless otherwise specified,
no free issue or loose items shall be provided by the Vendor/Contractor other than instruments removed on
temporary basis for packing and transportation.

3.3.6 All instrumentation shall be designed so that under normal operating conditions will be unaffected by radio
interference. A one watt hand held transmitter in the range 14 to 470 MHz positioned no more than 12 inches
(300 mm) from the instrument or panel shall not impair or degrade the performance by more than 0.1% of the
calibrated span with covers, cases and doors open. Equipment shall comply with the requirements of the BS
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3.4 Hazardous (Classified) Area Requirements

3.4.1 The area classification for electrical apparatus shall be as specified by the Owner or shall be shown on the
hazardous area classification drawings. The composition of any gases or hazardous vapours shall also be

3.4.2 All instruments shall be suitable for installation and use in accordance with the area classification, gas group,
and temperature classification.

3.4.3 All enclosures and equipment shall meet the requirements of the area classification and gas group, and the
protection concept. When used in classified areas, all enclosures shall be certified by an internationally
recognised approved body Sections CSA, FM, UL, BASEEFA, PTB etc. and to an internationally recognised
approved standard such as CSA, NEC, IEC, CENELEC etc.

3.4.4 Codes and standards listed in Section 3.0 of this specification refer mainly to the British, IEC and international
standards, Codes etc. In all cases, the appropriate sections of the USA or Canadian Standards and Codes may
be substituted. In the event of conflict the Owner's decision shall be final. If there is any doubt concerning
their interpretation of use, written clarification shall be obtained from the Owner, prior to proceeding with the
work. Refer also to GES L.35.

3.4.5 Field mounted instruments shall have weather protection to IP54 or better. IP 65 is preferred.

3.4.6 If the intrinsically safe (IS) protection concept is used, galvanic isolators are preferred to zener barriers.

3.5 Electrical Power Supplies

3.5.1 The package unit electrical system shall meet the requirements of GES L.28.

3.5.2 The power supplies available to the package unit instrumentation shall be as specified by the Owner.
Normally these will be 120 V AC 50 or 60 Hz, but other voltages and frequencies may be used as specified in
the Purchase Order/Contract and associated specifications and Data Sheets. The Owner

shall specify in the Purchase Order/Contract whether the supplies are uninterruptible also the voltage tolerance
and harmonic distortion in the supply.

3.5.3 Where an uninterruptible supply is required for the package instrumentation and is not supplied by the Owner,
then the Vendor/Contractor shall provide the equipment.

3.5.4 The electrical loading of the package shall be advised by the Vendor/Contractor to the Owner at the earliest
opportunity to enable the Owner to size the power supply cable(s). The Owner after sizing the supply cable(s),
shall advise the Vendor/Contractor the cable entry (gland) size.

3.6 Air Supplies

3.6.1 The air supplies available at the package unit shall be as specified by the Owner. The air supply pressure may
vary between a maximum of 110 psig (760 kPag) and a minimum of 70 psig (480 kPag). The quality of
instrument air supply shall meet the requirements of ISA S7.0.01.

3.6.2 The air consumption (steady state and at start-up) of the unit shall be established by the Vendor/Contractor at
the earliest opportunity to enable the Owner to establish the adequacy of the air supply system.

3.6.3 Where the protection of equipment for Classified Area is based on the use of pressurised or purged (EEX'p')
enclosures, the Vendor/Contractor shall liaise with the Owner in ensuring the reliability and adequacy of the
clean air supply.
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3.7 Instrument Signals

3.7.1 Electrical analogue signals shall be 4-20 mA, other than direct thermocouple or RTD signals. Pulse signals for
turbine, PD meters and vortex meters are acceptable and in all cases where accuracy is important.

3.7.2 Pneumatic analogue signals shall be 3-15 psig (20-100 kPag).

3.7.3 Digital signal transmission shall be by de-facto industry standard interfaces/protocols such as RS232-422-
485/Modbus and these shall be agreed with the Owner. The transmission of data, control signal and
error/status signals shall be transparent to the end user. User friendly configuration facilities shall be provided
to configure the port and protocol. No programming shall be necessary.

3.7.4 Relays and contacts shall be hermetically sealed, tropicalised and shall have hard gold plated silver contacts.
Mercury bottle switches are not acceptable. All terminals shall be suitable for 2.5mm2 cross sectional area

3.8 P&IDs, Instrument Symbols and Tagging

3.8.1 The Vendor/Contractor shall submit the package P&IDs in accordance with GES A.02 for review and
approval by the Owner.

3.8.2 All instruments shall be assigned tag numbers in accordance with the requirements of the Owner. The tag
number shall be used on all relevant drawings and documents.

3.8.3 All instrumentation and control drawings shall use uniform symbols based on GES J.01. The symbols shall be
in accordance with ISA S5.1 amended to be project specific. Binary logic diagram and graphic symbols shall
be in accordance with ISA S5.2 and ISA S5.3 respectively.

3.8.4 Other symbols shall be in accordance with IEC 60617.

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3.9 Junction Boxes and Field Panels

3.9.1 The Vendor/Contractor shall determine the location and size of junction boxes and field panels where field
cables are to be terminated as soon as is practicably possible, to assist in the sizing and routing of the field

3.9.2 The junction boxes and field panels shall be in accessible locations and provide for the bend radius
requirements of the field cables. Facilities shall be provided by the Vendor/Contractor for supporting the field
cables at the junction boxes and field panels.

3.9.3 Separate junction boxes and termination areas within field panels, shall be provided by the Vendor/Contractor
for instrument power supplies, intrinsically safe (IS) circuits, non-IS circuits, alarm and shut down circuits and
F & G circuits. Analogue and digital control signals shall be segregated in separate junction boxes and
termination areas within field panels.

3.9.4 Junction boxes and field panels shall be supplied in accordance with the requirements of GES J.13.

3.10 Cables and Wiring

3.10.1 Cable Construction

(a) Instrument Cable and Cabling shall meet the requirements of GES J.16.

(b) The cables shall be constructed generally in accordance with BS 5308, Part 1, Type 2 (Polyethylene
insulation,bedding, steel wire armour and PVC sheathing) and shall comply with the reduced flame
propagation requirements of BS 4066, Part 3 Category NMV 1.5 and IEC 60332, Part 3 Category C
for bunched cables. Cables used in safety related applications such as Fire and Gas, alarm and
shutdown signals shall comply with the requirements of IEC 331.

(c) Where head mounted temperature transmitters cannot be used, individually screened twisted pair or
multi-pair compensating cable incorporating drain wire shall be used. Copper constantan for Type K
& T thermocouples and Copper/Copper for Type B thermocouples (where the cold junction
temperature does not exceed 100°F (38°C)).

(d) Cable design and installation shall ensure that the cables comply with the general requirements of BS
6739. Attention shall be given to ensure that electrical interference is eliminated. Signal wiring shall
be twisted into pairs with an overall screen.

(e) Cable pair and triple identification shall be by solid contrasting colours and shall be consistent
between single pairs or triples and pairs or triples in multiple cables. White shall indicate positive
polarity and black shall indicate negative polarity. Multipairs or multitriples shall have the pair
number clearly identified on polyester film tape.

(f) The cable sheath shall be colour blue to identify intrinsically safe (IS) circuits. For Non IS circuits,
the sheath colours shall be dark grey in any event clearly distinguishable from power cables which
normally has a black sheath. Thermocouple cable outer sheath shall be to IEC 60584 except that the
colour blue or black shall not be used.

(g) Multicore cables shall be sized for a minimum of 20% spares at the time of shipment.

3.10.2 Cable Selection

(a) Generally, all field cables shall have seven strands 0.53 mm (1.5 mm2) minimum annealed copper
conductors and shall be protected by a single layer of steel wire armour.

(b) Signal selection shall comply with the categories as defined in BS 6739. Only signal categories 2 and
3 shall apply.
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Category 2 : High Level Signal Wiring (5V to 50V DC)

This group includes digital signals, alarm signals, shutdown signals and high level analogue signals.
eg. 4 to 20 mA.

Category 3 : Low Level Signal Wiring (Below 5V DC)

This group includes temperature signals and low level analogue signals.

(c) Signal segregation shall comply with the requirements as defined in BS 6739. Only signals of the
same category shall be contained in the same cable. Skid wiring shall be routed to dedicated junction
boxes, e.g. IS digital, IS analogue and Non IS digital. In addition, signals shall be collated via the
junction box into multipair cables dedicated for each control system, e.g. package controls,
DCS,ESD and Fire and Gas systems. IS and non-IS signals shall not be mixed in the same multicore.

(d) It is preferred that instrument cables above ground are run on dedicated cable trays and separate from
power cabling. If instrument and power cables run on the same cable tray or trench they shall be
grouped on opposite sides with a minimum separation distance as detailed below.

Separation of instrument and power cable on skids, cable tray or in cable trench shall be as follows:

125 V or 10A : 12 in (300 mm)

250 V or 50A : 18 in (450 mm)
440 V or 200A : 24 in (600 mm)
3.3 kV or 800A : 55 in (1400 mm)
11 kV or 1500A : 71 in (1800 mm)

3.11 Units of Measurement

A standardised units of measurement document shall be developed on per project basis by the Owner and
supplied to the Vendor/Contractor.


4.1 General Requirements

4.1.1 The Vendor/Contractor shall have an effective system of part numbering for all replaceable parts. The part
number shall completely define the part, including the material of which it is made.

4.1.2 All process connected instruments shall be of cast or forged steel equal to or better than the relevant ASTM
specification for the process material. Cast iron shall not be used. Aluminium enclosures shall be coated with
2 coats of Vendor/Contractor's standard epoxy paint finish.

4.1.3 The body material of direct mounted measuring instruments and control valves shall be to a standard equal to
or better than the piping or vessel classification of the piping or vessels to which they are connected.
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4.1.4 Wetted parts materials of devices in contact with the process medium shall be a minimum of ANSI Type 316
SS. Copper or copper bearing alloys shall not be used without the approval of the Owner. In general copper or
copper alloys shall not be used for any application with the exception of pneumatic transmission lines.

4.1.5 All equipment (e.g. instruments, hook-up material etc.) used in sour services shall conform to the requirements
of NACE MR 0175.

4.1.6 Carbon steel springs on relief valves shall be coated to resist corrosion. Tungsten alloy springs shall be
provided for process temperature higher than 450°F (232°C).

4.1.7 Tubing/piping for instrument air distribution within the package shall meet the requirements of GES J.15.

4.1.8 Control valves material shall be suitable for the specified duty and shall be reviewed and approved by the

4.1.9 Cast iron shall not be used for pressure retaining parts of any metering installation except that S.G. iron may be
used with prior agreement with the Owner.


5.1 QA/QC

5.1.1 The Vendor/Contractor shall submit to the Owner, for approval, details of his proposed quality assurance and
quality control plan.

5.1.2 The Vendor/Contractor shall maintain an effective quality system that complies with Project requirements as
well as those of ISO 9001/1 and 9003.

5.1.3 The Vendor/Contractor shall supply a preliminary quality manual with the bid followed with a project specific
quality plan after order placement.

5.1.4 This quality plan shall include monitoring performance for sub-contractor's work. The approved quality plan
shall be the control document for the performance of the work. The quality plan shall include references to the
quality manual.

5.1.5 The Vendor/Contractor shall submit for Owner's approval inspection requirements summaries for each item.
The Owner shall have the right to witness the Vendor/Contractor's QA/QC system operating on all equipment
during design, fabrication, assembly and testing.

5.2 Instrument Selection

5.2.1 All instruments and installation materials shall be technically acceptable to the Owner. The Vendor/Contractor
shall select instrument manufacturers in accordance with the Owner's preferred manufacturer's list. The
Vendor/Contractor shall submit a list of all selected manufacturers and instrument model numbers for

5.2.2 Where Vendor/Contractor's instrumentation and package control panel(s) is considered to be an integral part of
the equipment, e.g. turbines compressor sets, generators etc. and adherence to Owner's preferred
manufacturer's list may result in additional engineering, extra costs, warrantee disclaimers etc., the
Vendor/Contractor's standard instrumentation and control panels may be used subject to Owner's written

5.2.3 The extent of Vendor/Contractor's supply of standard instrumentation shall be decided taking into
consideration such issues as:

- technical acceptability of Vendor/Contractor's standard instrumentation;

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- cost benefit to Owner using Vendor/Contractor's standard instrumentation;
- Vendor/Contractor's expertise in instrumentation;
- requirements for string testing with other systems by Vendor/Contractor.

5.2.4 Maximum standardisation of instrumentation equipment and material and minimum project cycle costs shall
be pursued by the Owner.

5.3 Control Valves

5.3.1 Selection

Generally, all control valves for process liquids, and high pressure steam and gases shall have globe bodies.
They may be double seated with top and bottom guides or single seated trim (preferred) with plug or stem
guiding or case trim. Large volume flows and high shut-off differential pressures shall be controlled by full
bore ball valves or characterised ball valves. Larger volume flows at lower differential pressures shall be
controlled by butterfly valves.

5.3.2 Design

(a) All valves shall be assessed for their noise level. Maximum noise level shall be 85 dBA measured 3
feet (1 m) away from the pipe and one metre downstream. Low noise valves shall be considered.
This requirement shall be reviewed on receipt of the Vendor/Contractor's noise calculations for the
proposed valves.

(b) Flanged control valves shall comply with ASME B16.34. The face to face dimensions shall comply
with ISA S75-03. The flange finish shall be in accordance with the piping class.

(c) Control valve bodies shall be 1" minimum. Body sizes of 1¼", 2½", 3½" and odd sizes above 4"
shall not be used.

(d) The pressure rating of globe valves with bodies up to and including 4" size shall be at least Class 300.

(e) All valves shall have bolted gland type stuffing boxes with packing suitable for the service
conditions. The valve stem shall be protected against sand by a mild steel bolted on protective

(f) Seat leakage shall be specified for each valve using the six classes as defined in ANSI/ FCI

(g) Hardened stainless steel or stellite facing shall be provided where pressure drops exceed 100psi (70
KPa) temperatures exceed 600°F (315°C) or where otherwise required by process, e.g.
flashing/cavitating liquid, fluids containing solids etc.

(h) Actuators shall be provided with positioners and shall be air operated spring return. The normal
operating range should be 3 to 15 psig (approx. 20 to 100 kPa), but shall not exceed 58 psig (400
kPa) and shall be sized based on atmospheric pressure downstream and inlet pressure upstream.
Diaphragm actuators are preferred. Actuator springs shall be permanently coated to reduce the risk of

(i) The action of each valve on failure of its control signal or acting medium shall be to a fail safe

(j) Modulating control valves used for level control, split range control and, where the pressure drop
across the valves requires, shall have a linear characteristics. All other valves shall have an equal
percentage characteristic.

(k) Control valves shall be sized in accordance with ISA S75.01 and for the rates of flow and pressure
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drops under design conditions. Size and noise calculations shall be subject to checking and review
by the Owner. Control valves shall not be required to work outside the limits of 10% to 90% of their
stroke. A control valve shall be selected such that its capacity is 120% to 140% of design for linear
trim and 130% to 160% for equal percentage trim.
All calculations shall be capable of being manually checked i.e. the printout shall contain the original
process data, assumed data, formulae used and the calculated results. See also 5.4.1 (c).

(l) Electropneumatic positioners are preferred, fitted with inlet and outlet pressure gauges. Positioner
by-passes shall be fitted except where reverse acting or split range positioners are required or where
the actuator spring range is not compatible with the control signal.

(m) All automatic control valves (except self-contained regulators) shall be equipped with position

(n) Air filter regulators, positioners, pilot and solenoid valves, if fitted, are preferred mounted on the
valve body as a stand alone unit.

(o) Extension bonnets shall be used for fluid temperatures from 32°F (0°C) down to -148°F
(-100°C) or above 446°F (230°C), where the operator or gland packing is less than 6 in (150 mm)
above the valve.

5.4 Safety Relief Valves

5.4.1 Standards

(a) The selection, sizing, design, fabrication and installation of relief valves shall be in accordance with
the codes and standards listed in Section 3.1 of this specification.

(b) It is the Vendor/Contractor's responsibility to determine the requirements, sizes and set pressures for
the safety relief valves. All calculations shall be capable of being manually checked, ie. the printout
shall contain the original process data, assumed data, formulae used and the calculated results as well
as the rated valve capacity under relieving conditions.

(c) Evidence shall be submitted by the Vendor/Contractor to show that the computer programmes have
been checked and validated. The evidence shall include the validation procedure.

(d) Unless otherwise stated, all valves shall carry an ASME code symbol certifying the capacity.

(e) Valves on liquid duty shall be sized in accordance with API 520, with a nameplate showing the
capacity for Natural Gas and a separate nameplate to show liquid capacity. Nameplates shall be
stamped in accordance with API 526.
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5.4.2 Selection and Design

(a) Balanced relief valves shall be considered when:

- The variable, built-up and superimposed back pressures exceed 10% of the set pressure.
Consideration should be given to secondary systems in this respect.

- Fluid is corrosive or toxic.

(b) Valves shall be selected to ensure that the actual orifice areas of the valves are sufficiently large for
the effective orifice areas, derived in accordance with the sizing formulae contained in API RP 520
and to comply with the 90% capacity limitation imposed by ASME PV code 8.

(c) Relief valves fitted purely for relief of thermal expansion of liquids in blocked-in lines shall be of the
proportional lift type. Relief valves serving any other purpose shall be of full-lift design.

(d) Bursting discs may only be used with the written approval of the Owner. If used, bursting discs shall
be installed upstream of relief valves. An alarmed pressure switch shall be located between the
bursting disc and the relief valve to indicate bursting disc failure.

(e) In some instances bursting discs may be used without relief valves. These cases shall be approved, in
writing, by the Owner. This type of installation shall require the bursting disc to be fitted with a
pressure fusible wire which is broken upon bursting disc operation. The wire shall be suitable for use
as a switch to indicate disc failure.

(f) A vessel may have a full bore isolation valve between itself and the pressure relieving device for
inspection and repair purposes. The isolation valve shall be arranged so that it can be locked or
sealed open. When such isolation valves are installed, a secondary method of automatically relieving
vessel overpressure shall be provided. A mechanical interlock shall be provided to ensure that both
relief routes are not closed simultaneously.

(g) There shall be no upstream or downstream isolation of any single relief valve. Dual interlocked
PSVs and thermal relief valves shall be used where necessary. This also applies to fully spared

(h) Normally, relief valve shall have flanged inlet and outlet connections in accordance with the piping

(i) All safety relief valves on steam duty and hot water 140°F (60°C) or above shall be provided with
lifting levers and exposed springs. Relief valves on air service shall also be supplied with lifting

(j) Test gags shall shall be removed from the valve after testing.

5.5 Flow Instruments

5.5.1 Selection

(a) A square edge, concentric orifice plate with flange tappings is the preferred method of flow
measurement. Other types of flow measuring devices may be used subject to approval in writing by
the Owner.
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(b) Differential pressure transmitter used for flow signal transmission shall where possible utilise
SMART electronics. The transmitter shall be used in the analogue mode.

5.5.2 Orifice Plates

(a) Orifice plates shall be supplied in accordance with ISO 5167.

(b) Bleed holes shall be used if suspected necessary. The use of additional flange tapping for drainage is
preferred in such instances. Flange taps shall be used for sizes 2" NPS and above and corner taps
shall be used for sizes below 2" NPS.

(c) Beta ratio (d/D) shall be defined as the ratio of orifice bore to pipe actual internal diameter. Beta ratio
shall be limited to between 0.3 and 0.7. However, in some cases, beta ratios between 0.2 and 0.8 may
be used in accordance with ISO 5167.

(d) Standard differential ranges shall be 20, 25, 50, 100 and 200 inches (500, 625, 1250 or 5000 mm) of
water. Transmitter minimum accuracy shall be ±0.5% of span; calibration stability ±0.25% of span
over 6 months.

(e) For flow turndown greater than 3:1 the use of multiple or variable range transmitters shall be
considered although the flow turndown on a single orifice shall be limited to 9:1.

(f) Straight run requirements shall be per ISO 5167: Part 1 for an orifice plate with beta variation of 0.7
unless the use of a larger beta ratio plate is allowed in which case the straight run provision shall be
for a plate of 0.8 beta ratio.

5.5.3 Positive Displacement Meters and Turbine Meters

(a) Metering shall be in accordance with API MPMS.

(b) Automatic temperature compensators shall be provided to meet the requirements for metering heated
products. In all cases the use of automatic temperature compensators shall be agreed with the Owner.

(c) For calibration purposes, meters with automatic temperature compensation shall also have a counter
for gross volume registration.

(d) Where fluid properties can have an adverse effect on meter mechanical performance, turbine meters
with tungsten carbide, or similar, bearings shall be used. Adverse fluid conditions may include poor
lubrication such as motor gasoline and liquified gases and sulphur compounds.

(e) Ranges of temperature elements for automatic temperature compensators for heated oil positive
displacement metering installations shall be such as to cater for all temperatures which can be
expected under operational and static conditions. The effects of line and tank heating variations shall
be taken into account.

5.6 Temperature Instruments

5.6.1 Selection

(a) Resistance temperature detectors shall be employed except when process requirements dictate the use
of thermometers i.e. temperature higher than 660°F (350°C).
Rev 0 1999
(b) Temperature switches shall not be used. An RTD or thermocouple shall be used with a head
mounted amplifier to generate a 4-20 mA DC signal. A trip amplifier shall be used to generate any
alarm or trip signals required.

(c) Filled thermal systems shall not be used unless approved by the Owner in writing.

5.6.2 Design

(a) RTDs shall comply with IEC 60751 and have a resistance of 100 ohms at 32°F (0°C) with a
fundamental internal resistance of 38.5 ohms.

(b) Thermocouples shall comply with the requirements of IEC 60584 Parts 1 and 2. Except for multi-
point temperature indicators, field mounted transmitters are the preferred method of signal
transmission although a suitable junction box mounted converter may also be utilised. Short runs of
compensating cables are acceptable.

Interconnections between thermocouples and transmitter shall be in accordance with IEC 60584 Part

(c) Burnout protection shall be incorporated as follows:

Action on burn out shall be to the unsafe conditions for monitoring and alarm services.

Action on burn out shall be to the condition which will allow the plant to continue running for
control, shutdown and trip services. In this case an alarm shall be generated.

(d) Bimetallic dial thermometers shall be rigid stem with built in zero adjustment, 5" (130 mm) dial size
and any angle type adjustable head. Stem length shall be such that the tip of the stem touches the end
of the thermowell base. It is preferred that there is standardisation of the temperature ranges as

-22 to 140°F (-30 to 60°C)

32 to 320°F (0 to 160°C)
32 to 482°F (0 to 250°C)
32 to 752°F (0 to 400°C)

(e) Thermowells shall be suitable for the stresses generated by the stream velocity. The Wake frequency
shall not exceed 80% of the thermowell lowest natural frequency. The calculation shall be carried
out by the Vendor/Contractor to ASME PTC 19.3 (if well geometry is suitable) or other approved
method e.g. the original Murdock method.

(f) The theromowell calculation submission shall include all equations, assumptions and shall be subject
to approval by the Owner. (See also 5.4.1 (c)).

(g) All thermowells shall be hydrostatically tested after being radiographed.

(h) Welded thermowells integral to a pressure vessel shall be pressure-tested with the vessel.

5.7 Level Imstruments

5.7.1 Level Gauges

(a) Level gauges shall cover the entire transmitter and switch range. Only the project standard ranges
shall be used.

(b) Level gauges shall be steel armoured reflex or transparent type. Reflex gauges shall be used for all
clean process and utility fluids. Transparent level gauges shall be used on interface service and on
Rev 0 1999
acid, caustic or dirty fluids. All transparent gauge glasses shall be equipped with illuminators suitable
for the electrical area classifications.

(c) All glass gauges shall be supplied with a shut-off valve on the top and bottom mountings. Shut-off
valves shall be of a quick acting, offset type and shall have bolted bonnets and fitted with safety shut-
off ball checks, except on vacuum service.

(d) Glass level gauges shall be fitted with flow restriction devices to minimise loss of medium in the
event of glass failure.

5.7.2 Level Transmitters

(a) External displacement type level transmitters with side top and bottom connection are preferred
unless the range exceeds 48 in (1200 mm) or agitation or sedimentation exists. Differential pressure
transmitters shall be used for ranges in excess of 48 in (1200 mm).

(b) Displacement instruments shall have externally mounted chambers, connection configuration and size
supplied to project standard. Displacement instruments shall have rotatable heads.

(c) If differential pressure transmitters are employed then dry leg compensation is preferred to the wet
leg method.

(d) Calibration facilities, allowing for adjustment for specific gravity, shall be included in the design of
the instrument without resorting to a filling technique.

5.7.3 Level Switches

(a) Level switches shall be float-operated, with magnetic coupling and two sets of high quality snap-
acting SPDT switch contacts and suitable for the electrical area classification.

(b) Displacer type level switches may be used on interface level alarm or trip.

(c) External mounted level switches shall not be used for high viscosity fluids. For this application either
internally mounted switches or differential-pressure level instruments shall be used.

5.8 Pressure Instruments

5.8.1 General

(a) Range and graduating of pressure instruments shall be in accordance with BS EN 837-1.

(b) Pressure instruments measuring a steady normal operating pressure shall not operate beyond 70% of
their maximum range. Pressure instruments measuring fluctuating pressure shall not normally
operate beyond 60% of their maximum range. Pressure instruments on pulsating service shall be
equipped with pulsation dampeners.

(c) For measured ranges less than the process design pressure, over-range protection shall be provided to
at least 130% of the line or vessel design pressure. All instruments shall have a body pressure rating
to the line or vessel design pressure.
Rev 0 1999
5.8.2 Pressure Gauges

(a) Pressure gauge body and element shall be 316 SS as a minimum and suitable for the specified service
required. Gauge accuracy shall be ± 1% f.s.d. minimum.

(b) Gauge savers shall be provided where the maximum pressure can exceed the gauge rating.
Overrange protection shall be provided. Gauges shall be supplied with diaphragm chemical seal units
to protect the element from the process when used with viscous or corrosive fluids.

(c) Pressure gauges nominal sizes shall be as follows: 6" (150 mm) for panel mounted gauges, 4½" (115
mm) for local process gauges and 2½" (64 mm) for air receiver gauges.

(d) Differential pressure gauges are not preferred except across filters. It is preferred that a local
pneumatic DP transmitter with a local receiver gauge is used.

(e) When measuring pulsating pressure, suitable dampening methods shall be used (glycerine filled
gauges, dampening devices etc.).

(f) Process gauges shall be of the solid form safety pattern type with blow out backs, shatterproof glass
and micro meter type of adjustment. Blow-out back shall not face the operator.

Gauges shall be supplied with a back flange, and distance spacer for cases with blow out backs.
5.8.3 Pressure and Differential Pressure Switches

(a) Direct mounted pressure or differential pressure switches shall be used only on equipment shutdown
service. For all other applications pressure or differential pressure transmitters in conjunction with
receiving switches or receiving amplifier shall be used.

(b) Setpoint accuracy shall be ± 1% f.s.d. of span. Setpoint adjustment and indication shall be internally

5.8.4 Pressure and DP Transmitters

(a) SMART type pressure and DP transmitters are preferred, used in the analogue mode (4-20 inA DC).
Minimum accuracy ± 0.5 % f.s.d.

(b) Differential pressure transmitters shall have the following features

Differential overload protection up to line design pressure.

Static pressure rating up to line design pressure.

Variation in static pressure shall not affect the transmitter reading.

Integral damping adjustment.

Vent and drain facilities for each chamber.

5.9 Block/Vent Valves

5.9.1 Block or vent valves for emergency shut down or blowdown duty shall not be included in the package unless
the location is unavoidable. In this case agreement shall be obtained with the Owner and the valves shall meet
the requirements of GES J.32.

5.9.2 In general, block and vent valves shall be of the ball type and shall comply with the relevant piping
specification requirements.

5.9.3 All ball valves intended for hydrocarbon isolation duty shall be proven fire safe and of antistatic design to the
requirements of the piping specification for ball valves.
Rev 0 1999
5.9.4 Valve closed and open limit switches, where used shall be directly operated. Proximity type of limit switches
are preferred. Switches shall be mounted such that adjustment can be made to ensure operation occurs when
the valve is at the limit of its travel.

5.9.5 Actuators shall be provided with a mechanical full stroke valve position indicator external to the cage or casing
and located in the optimum position for viewing when installed. Air operated, spring return valves are

5.9.6 Facility shall be provided to partially close the valve for testing by the use of a local manually actuated spring
return push button.

5.9.7 Manual resets shall be ineffective until the solenoid valve is energised.

5.9.8 Air filter regulators, pilot and solenoid valves shall be mounted on the valve as a stand alone unit. If this is not
possible, then separate stainless steel cabinets shall be provided.

5.9.9 Motor Operated Valves shall meet the requirements of GES J.08.

5.9.10 Hydraulic Operated Valves shall meet the requirements of GES J.09.

5.10 Solenoid Operated Valves

Solenoid Operated Valves shall meet the requirements of GES J.07.

5.11 Controllers, Recorders and Indicators

5.11.1 Electronic and pneumatic controllers, recorders and indicators shall meet the requirements of GES J.18 and
J.31 respectively.

5.12 Instrument Connections

5.12.1 All electrical connections shall be 20 mm ISO x 1.5 mm ISO R7 to BS 3643 Part 1 - ISO Metric Threads.

5.12.2 All flanged connections shall be pipework, vessel or equipment rated and in any event a minimum of 300#
rated to ANSI B16.5, unless approved in writing by the Owner.

5.12.3 Process and instrument connections shall be in accordance with the project piping specification, but generally
shall be as shown on Table 1 on page 38.

5.13 Fire and Gas Instrumentation

5.13.1 Fire and gas detection systems where they are included as part of the package, shall meet the requirements of
GES J.24, GES H.01 and GES H.08.

5.13.2 Vendor/Contractor shall state in his bid, any deviations from the above specifications including any standards
(current at the time) listed in the above specifications.

5.13.3 The type of detector(s) used, the location of detectors, the voting configuration and signals to and from the
Vendor/Contractors system shall be agreed with the Owner.

5.13.4 Any free issued fire and gas detectors shall be listed in the Purchase Order/Contract.

5.14 Panels and Junction Boxes

5.14.1 General

(a) Pilot lights, pushbuttons and switches shall be of the oil tight, heavy duty type only. Pushbuttons
Rev 0 1999
shall have protective guards or be recessed mounted. Lamps shall be derated.

(b) Pilot lights and pushbuttons shall have the following colour

Red Abnormal, trip, shutdown, off, closed, emergency

Yellow Pre Alarm
Green Normal, on, open, permissive start
White Status, running, position

(c) At least one common lamp test pushbutton shall be provided.

(d) Panel annunciators shall meet the requirements of GES J.19.

5.14.2 Gauge Board

A skid mounted totally enclosed, weatherproof and suitable for area classification gauge board may be
provided for monitoring of the package. Vendor/Contractors standard gauge panel may be considered

5.14.3 Local Panel

If it is necessary to have a significant number of indications and controls local to the package, then a separate
electronic panel may be provided. Such panels shall meet the requirements GES J.13. The local panel may be
fitted with start and stop pushbuttons, status lamps, alarm indicators and such instrumentation as it is necessary
for local start up, shut down and monitoring of the package.

5.14.4 Control Room Panel

For packages where control room panels are required, the panels shall be supplied in accordance with the
requirements of GES J.12.

5.15 Package Control System Design

(a) Shutdown functions relating to package units may be carried out in the package by a galvanically
isolated interface (relay) to and from the plant ESD system.

(b) The Vendor/Contractor shall provide Process and Emergency Cause and Effect Diagrams for the
package using the Owner's standard form, a blank master will be provided with the Purchase

(c) The Cause and Effect Charts shall be prepared in accordance with the approved P&IDs and approved
functional description of control, start-up and shutdown procedures.

(d) The design shall be based on fail safe (fail safe on loss of power) principles, with inputs and outputs
moving to an open circuit for a trip, alarm or abnormal condition.

(e) Each process trip condition shall have an independent pre-trip alarm. Pre-trip and trip alarms shall not
be derived from the same primary tapping or instrument.

(f) Key operated maintenance override switches shall be provided on all trip input signals when no other
facilities are readily available for the instrument to be maintained or checked.

Operation of override switches shall be indicated/alarmed in the control room.

(g) Alarm functions shall not be overridden. An "Override On" uncancellable flashing lamp and lamp
test pushbutton shall be provided on the package control panel. The override lamp shall remain on
until the override is removed.
Rev 0 1999

The override status of any input or output shall be repeated in the control room. Common override
indication may be acceptable.

(h) Package emergency shutdown reset pushbuttons/switches shall be field mounted.

(i) Local annunciator flashing lamp and audible alarm shall remain on until accepted locally.

(j) Programmable logic controllers (PLCs) may be used for sequencing. PLCs shall not be used for
safety related applications unless approved by the Owner. The make and type of PLC may be
standardised for the facility or plant and shall be approved by the Owner.

(k) Unless otherwise specified on the Purchase Order/Contract the requirements of the GES J.21 shall
apply for PLC based systems.

(l) A full wiring diagram in relay ladder logic (RLL) or similar format to an agreed standard shall be
provided by the Vendor/Contractor. This diagram shall follow the functional logic diagram in an
efficient and user friendly way.

(m) The relay diagram shall show:

Point-to-point connections.
Pin numbers (if a card system is used).
Input/output terminal numbers.
Input/output terminations outside the relay cabinet.

(n) The drawings shall show relay contacts in "shelf position".

5.16 Analytical Instruments and Systems

5.16.1 General

(a) Analytical instruments and systems are deemed to include, but not necessarily limited to, the

i) pH and 02 Meters
ii) Viscosity Meters
iii) Density and Specific Gravity Meters
iv) Conductivity Meters
v) BS & W Meters
vi) Boiling Point, Pour Point, Cloud Point, Flash Point, Freeze Point Analysers
vii) Moisture/Dew Point Analysers
viii) Vapour Pressure Analysers
ix) Combustion Gas Analysers
x) HC and H2S Monitoring Systems
xi) Gas and Liquid Chromatographs
xii) Octane Monitors

Where such instruments and systems are included as part of the package, the requirements of GES
J.28 shall apply.

(b) Analysers generally shall be single stream systems and preferably selected such that continuous
measuring of the process variable is ensured.

(c) Measurement shall be indicated and/or recorded on board or local panel mounted instruments.

(d) Sample tap and sample conditioning system fittings shall normally be of compression type.
Rev 0 1999

5.16.2 Analyser Units and Cabinets

(a) Construction of analyser units shall comply with the area classification requirements.

(b) Based on the type of analysis, sample characteristics and ambient temperature conditions, analyser
units maybe located in cabinets or in the plant close to the measuring point.

(c) Where ambient conditions dictate that the analyser should be installed in a cabinet, the cabinet shall
be pressurised with gas detection and shutdown facilities on the air intakes of the cabinet.

(d) The temperature inside the analyser cabinets shall be controlled as to ensure adequate ambient
temperature conditions both for the equipment and maintenance staff.

(e) Cabinets shall be provided with a safety device which will sound an alarm in the control room in case
explosive mixtures exist in the cabinet.

(f) Control units, if any, for the analyser shall be housed in the cabinet with repeat outputs sent to the
control room.

5.16.3 Analyser Dischargers

(a) Spent liquid samples shall be either discharged to the plant drains system or returned to the process.

(b) Negligible gaseous discharges shall be vented to atmosphere.

(c) Spent cooling water shall be discharged to the plant drains system.

5.16.4 Analyser Sampling System

(a) For each type of analysis particular care shall be given to the design of the analyser sampling system.

(b) Whenever necessary the "fast-loop" approach shall be adapted to reduce the analysis time delay.
Analyser response times shall be reviewed by the Vendor/Contractor to ensure they are adequate for
the application. Sample treatment and whenever possible, special probes shall be used in accordance
with API-RP-555.
Rev 0 1999
5.17 Rotating Equipment Monitoring Systems

5.17.1 Shaft Vibration and Position Monitoring

(a) Large pumps and compressors shall be provided with vibration and shaft position monitoring
probes/sensors on the equipment to continuously monitor both radial vibration and thrust position of
the shaft.

(b) Provision of rotating monitoring equipment shall be in accordance with the requirements of API-670
and as specified by the Owner in the Purchase Order/Contract.

5.17.2 Temperature Elements and Indicators

(a) Large pumps and compressors shall be provided with temperature elements and indicators on the
equipment to continuously monitor temperature on the bearings, seals, lube and seal oils, casings,
windings and as specified by the Owner in the Purchase Order/Contract.


6.1 Field Instruments

6.1.1 Instruments shall be located away from potential fire risk and spillage areas, hot environments, sources of
vibration and process vents and drains. The location of instrumentation impulse pipe runs, vents and drains
and cable trays shall not obstruct access, walkways or plant which may require regular attention.
6.1.2 All instruments shall be mounted as close as possible to the process connection with a minimum length of
impulse piping.

6.1.3 Instruments requiring frequent operator access shall be mounted at a height of between 55 in (1.4 m) and 1.6 m
from grade or platform. Other instrumentation should be mounted between 25 in (0.7 m) and 63 in (1.6 m)
from grade or platform.

6.1.4 All instruments shall be accessible from grade. Indicators shall be visible from operating position. Zero and
span adjustments and instrument manifold valves shall be easily accessible and manufacturer's data plates
easily readable.

6.1.5 Local indicating instruments shall be visible from where the related equipment is operated from, or where the
primary instrument may be tested or calibrated.

6.1.6 Instruments shall not be supported by process lines unless specifically designed for direct mounting, e.g
pressure gauges and local direct reading bi-metallic temperatures indicators. Instruments shall generally be
mounted on 2" steel pipe stands and shall not be mounted on handrails.

6.1.7 Where exposed to direct sunlight, all electronic instruments shall be provided with sunshades.

6.1.8 Junction boxes shall be mounted on stands.

6.2 Control Valves

6.2.1 Control Valves shall be installed so that they are not subject to forces resulting from the thermal expansion of
piping, or from the mass of an unsupported line.

6.2.2 Block and bypass valves shall be fitted to all control valves unless otherwise specified. Control valves without
a by-pass shall have a handwheel.

6.2.3 Control valves shall be located so that they are readily accessible for maintenance purposes.
Rev 0 1999
6.2.4 Bypass valves shall be installed so that they are readily accessible to the operator for manual control.

6.2.5 Consideration shall be given to providing block valves upstream and downstream of the control valve, together
with a bypass valve so that the control valve can be removed without the need to shut down the plant.

6.2.6 Bypass valves shall not be installed if the process can not be controlled by hand.

6.2.7 Control valves for process lines and fuel lines to engines shall be located a sufficient distance away from the
machinery so that the control valves can be removed without danger of flashback.

6.2.8 To avoid distortion during flange bolting, gate valves shall be installed in the closed position, ball valves in the
open condition, and butterfly valves in the closed position.

6.2.9 Where vibration is a problem I/P converters shall be installed on vibration free stands in combination with
separate positioners.

6.3 Safety Relief Valves

6.3.1 All safety relief valves shall be easily accessible for inspection and maintenance.

6.3.2 Where safety relief valves exceed 50 lbs (25 kg) in weight, and the location is inaccessible for cranes, davits
shall be installed.

6.3.3 Discharge piping shall be self draining towards the discharge end. The use of traps or any other device with
mechanical systems shall be avoided.

6.3.4 The discharge line shall be heat traced where viscous materials may be released by the safety relief valves, or
where the discharge may solidify on cooling.

6.4 PD Meters and Turbine Meters

6.4.1 Strainers shall be installed upstream of metering installations. The mesh of the strainer shall be as advised by
the meter manufacturer.

6.4.2 An indicating device shall be installed across each strainer of the metering system to measure the differential
pressure and shall be arranged to activate either a remote or local high differential pressure alarm.

6.4.3 Air/vapour separators shall be provided wherever there is a possibility of air or vapour entering the metering
system. For small volumes of air/vapour, combined eliminator/strainers shall be considered.

6.4.4 Automatic flow limiting devices shall be installed where process conditions could cause meters to operate
above the maximum flow rate specified by the manufacturer. Alternatively, a high flow alarm may be supplied
subject to approval by the Owner.

6.4.5 One isolating valve of the block and bleed type shall be provided in each meter path.

6.4.6 Whenever quantities are metered for fiscal purposes, proving facilities (either permanent or temporary) shall
be provided. These shall permit the meter to be proved without disrupting normal operation. A single prover
shall not be used for both black and white oils.

6.4.7 Where permanent proving systems are provided for banks of meters, they shall be mechanical displacement
loops in accordance with API MPMS Chapter 4.

6.4.8 In designing a metering or proving installation, appropriate allowance shall be made to include access and
hard-standing for vehicles, meter and strainer lifting facilities for maintenance, piped drainage, flushing
facilities and hose connections.
Rev 0 1999
6.5 Temperature Elements

6.5.1 All temperature elements shall be installed in thermowells other than bearing temperature detectors and
furnace skin thermocouples.

6.5.2 Skin/welded tube type thermocouple installations shall be approved before any fabrication/welding takes
place. Skin/welded type thermocouples shall be function tested before welding and after welding. The
Vendor/Contractor shall supply 40% extra tube skin resistance thermocouples as spares.

6.5.3 Temperature elements installed in thermowells shall be supplied with spring loaded heads and unions.
Dimensions and design of thermowells and elements shall be in accordance with the project thermowell design
or to ASME PTC 19.3.

6.6 Level Instruments

6.6.1 Level tapping shall not be made into the bottom of vessels or tanks but shall be made to standpipes or directly
to the sides of the vessel. Low point drain valves shall be installed.

6.6.2 Level switches initiating shutdowns shall be mounted on dedicated nozzles on the vessels and shall not be
standpipe mounted.

6.6.3 Instrument connections to standpipes or vessels shall be provided with block valves to enable on-line isolation
and maintenance of the instruments.

6.7 Pressure Instruments

6.7.1 Manifold blocks shall be provided for each pressure instrument. The arrangement of valves shall be such that
the instrument can be calibrated and tested in situ.

6.7.2 Where there is a possibility of high temperature vapour entering the measurement chamber of an instrument
then a syphon shall be provided.

6.7.3 Where vibrations are expected pressure gauges shall be mounted on instrument stands or supports.

6.7.4 Draft pressure gauges shall be mounted as a gauge bank at grade level. Each draft gauge installation shall be
provided with rodding connections and a drain pot mounted at the lowest point near the gauge.

6.8 Instrument Tubing and Fittings

6.8.1 Instrument tubing shall be adequately supported along its route and near the connections so that stresses are
not transferred to connecting fittings. Tray or plastic tube clamps with steel bolts shall be used at regular
intervals as point supports.

6.8.2 Instrument tubing shall not be supported on handrails. Instrument tubing shall not be supported on the process
pipework, except for close coupled/direct mounted gauges.

6.8.3 All instruments tubings shall be assembled strictly in accordance with the tubing/fitting manufacturer's

6.8.4 The use of PTFE tape as a thread jointing sealant is not acceptable and only proprietary anaerobic sealing
compounds shall be used on threaded components. The type of thread sealant to be used shall be agreed with
the Owner.

6.8.5 Instrument manifold valves shall have non-rotatable stems.

6.8.6 Tubing to and from non-indicating instruments shall have a plugged `tee' for testing purposes.
Rev 0 1999

6.8.7 Instrument process hook-up shall be such that it shall be possible to test all alarm and shutdown initiation
devices, without interfering with the process operation of the package unit.

6.9 Instrument Hook-Ups

6.9.1 Process hook-up materials shall comply with the requirements of the project instrument installation material
specification. All instruments, tubing, piping, etc shall be adequately supported and protected against physical
damage by tray or channel.

6.9.2 To prevent zinc penetration and embrittlement of stainless steel in case of fire, pressure retaining stainless
components (pipe, tube, fittings, valves, etc) shall not be mounted, supported or be in direct contact with any
galvanised material (i.e. cable tray, platform grating, air header piping, etc) or any material covered with zinc
based protective coatings.

6.9.3 Running stainless steel under galvanised components should be avoided. Where this is not possible, sufficient
space shall be left around impulse lines for installing suitable protective shielding or insulation.

6.10 Instrument Cable Tray and Glands

6.10.1 Cable Tray

(a) All above ground cable runs shall be adequately supported on 180 microns thick galvanised cable
tray manufactured from corrosion resistant steel to BS EN 10095 and installed in accordance with the
manufacturer's recommendation. The tray shall be perforated, heavy duty with return flanges and
shall be supported by steelwork using deep galvanised proprietary support materials to minimise the
effect from atmospheric corrosion. Additionally, supporting brackets which are welded, screwed or
bolted shall be thoroughly cleaned and protected using etching primer and two coats of epoxy paint

(b) Installation components of dissimilar metals, eg. stainless steel and galvanised steel surfaces, must
not come into contact. Where this is not possible, insulating spacers shall be used to minimise
electrolytic action at the point of contact.

(c) Burrs and sharp edges formed on cable tray when cut shall be removed and treated to protect against
personnel injury and corrosion. Proprietary bends, tees, crosspieces and reducers shall be used
complete with coupling plates and earth continuity connectors. Fabricated construction is not

(d) The cable tray shall be routed to avoid obstruction and in positions that will prevent the cables being
exposed to mechanical damage, corrosive solvents and to the effect of heat. Where possible all cable
tray runs within the skid shall be in the vertical plane and the cables shall be securely fastened using
plastic coated stainless steel cable ties. Plastic only cable ties shall not be used.

(e) Where it is undesirable to terminate cables in junction boxes, for example for motorised valves,
motors, etc. this shall be run direct to the equipment. In these cases, the Vendor/Contractor shall
provide cable tray from an agreed position at the skid edge.

(f) The installation shall comply fully with the requirements of BS 7671.

6.10.2 Glands

(a) All cable glands shall be suitable for PVC sheathed, extruded bedded, single wire armoured or steel
wire braid cables (BS 5308 part 1, Type 2), as applicable, certified for the hazardous areas where

(b) All cable glands shall comply with the requirements of BS 6121 Part 1, BS 5501 Parts 1, 5 and 6 and
Rev 0 1999
other standards where applicable.

(c) For standardisation, designated flameproof EEx"d" glands shall be used throughout hazardous and
non-hazardous field locations, and industrial glands shall be used inside buildings in safe locations.

(d) Flameproof EEx"d" barrier glands shall be used only where enclosures contain a source of release
and will require the approval of the Owner.

(e) Brass nickel plated glands suitable for an exposed outdoor environment are preferred. Glands shall be
fitted with shrouds. Glands in the sulphur recovery areas shall be stainless steel and without shrouds.

(f) Each gland shall adequately grip the inner and outer sheath to provide a watertight seal (IP 66
minimum). The gland thread shall be ISO metric 1.5mm constant pitch.

6.11 Earthing (Grounding)

Earthing of instruments and systems shall comply with the requirements of GES J.17.


7.1 Conformity to Specification

The package or sub-units of the package e.g. local panels shall be subject to visual inspection(s) to ensure
conformity to the requirements of the Purchase Order/Contract and the associated specifications and Data
Sheets. Such requirements shall include visual check of the general appearance and finish, mechanical
assembly and dimensions and arrangements to Vendor/Contractor's approved drawings specified in the
Purchase Order/Contract.

7.2 Materials Certification

7.2.1 Material certification shall be in accordance with or better than the requirements of the relevant piping
specification. Certificates shall be supplied with the equipment.

7.2.2 Material certification shall be provided for all in-line instrument pressure containing parts. Non-pressure
containing parts can be covered by certificate of conformity.
Rev 0 1999
7.3 Labelling

7.3.1 A stainless steel identification plate shall be fixed by means of rivets or screws to the individual instruments,
system cabinets and junction boxes. The plate shall, as a minimum, carry the following information:

the Vendor/Contractor's name or trade mark;

the instrument model/type number;
the Vendor/Contractor's serial number;
the body rating (where applicable);
the material of the parts exposed to the process fluid;

7.3.2 Junction boxes shall be fitted with white/black/white traffolyte identification labels, (6 in x 2.25 in (150 mm x
60 mm)) high characters with the junction box number and signal type. The labels shall be fixed to the front
of the junction box using rivets or stainless steel screws. Adhesive shall not be used.

7.3.3 Junction box identification and terminal/cable core identification shall be to the Owner supplied identification

7.3.4 Normal labels shall be white/black/white traffolyte. Safety related label colours shall be white/red/blue.
Intrinsically Safe (IS) label colours shall be white/blue/white.

7.3.5 Individual instruments shall have permanently attached stainless steel labels engraved or stamped with the tag
number. The position of all field instruments shall be identified by laminated plastic nameplate engraved with
the tag number and service, mounted on cable supports adjacent to the instrument.

7.4 Marking

7.4.1 The direction of flow, and where applicable, the tight shut-off direction, shall be cast or stamped on the valve

7.4.2 The body shall be marked with the relevant material standard.

7.5 Cable Identification

7.5.1 Cables shall be identified at both ends and every 75 feet (25m) throughout their length, at entry to junction
boxes and instruments and either side of cable transits strap on cable markers shall be used in accordance with
the Owner's supplied identification system.

7.5.2 Identification of cables inside enclosures shall be implemented by using a printed cable marker system from a
supplier approved by the Owner.

7.5.3 Internal cables and cores such as inside junction boxes and control cabinets will be identified using suitable
cable and core markers. Spare cores shall be labelled "spare". Hand written cable and core markers are not

7.5.4 Identification of cables between enclosures and field instruments shall be uniquely identified using a
Vendor/Contractor designated system e.g. Critchley or equal black or yellow "K" type markers and stainless
steel caller strips secured by a steel Betastrip type to project requirements.
Rev 0 1999

8.1 Factory Acceptance Testing (FAT)

8.1.1 The Vendor/Contractor shall submit the FAT test procedure for approval by the Owner at least 8 weeks prior
to testing. The FAT shall not commence before the FAT procedure is approved.

8.1.2 The Vendor/Contractor shall supply, during FAT, all necessary equipment, personnel, consumables and utility
requirements, e.g. electricity and compressed air. The Vendor/Contractor shall also provide office, telephone
and fax facilities for the use of the Owner's test team.

8.1.3 The Vendor/Contractor shall not present the package control system for FAT until the items details below have
been completed:

1. The system has been finished with all modules and circuit boards installed and all loads connected.

2. Power the system and operate continuously, at full load, without failure for one week

3. Heat soak the system with power on for a period of 72 hours continuously at 122°F (50°C).
Vendor/Contractor shall provide a hard copy record of the heat soak test e.g. by record chart of
temperature at selected points inside the panels during the heat soak.

4. Carry out full factory test and correct deficiencies.

5. Produce a log of all faults arising from testing and rectify all faults.

8.1.4 The bench calibration of instruments, where applicable, shall be carried out prior to FAT. The Owner may, at
his discretion, witness all or part of the bench tests. The calibration results shall in any case be made available
to the Owner.

8.1.5 Where a local panel(s) is included in the package, the testing of the local panel(s) may be carried out
independently and before the testing of the complete packaged unit. In such cases all inputs and outputs shall
be simulated. At least one of each type of field instrument shall be available for testing together with the local
panel(s). All pneumatic instrumentation shall pass:

Leakage test of all piping and tubing.

Functional test of all pneumatic instruments.
Functional test of all pneumatic control loops.

8.1.6 FAT shall include:

Continuity tests.
Insulations tests.
Full functional tests exercising all field devices, inputs, output and display panels.
Multiple alarm occurrence tests.
Link interfaces/communication tests.

8.1.7 All in-line devices shall be subject to a hydraulic test with test pressure at 1.5 times the maximum working
pressure at ambient temperature.

8.2 Control Valves Testing

8.2.1 Packing shall be tight as required under normal conditions. Valves shall be hydrostatically tested with water at
ambient temperature in accordance with ISA S75.19 and the Owner's piping specification.

8.2.2 The test shall be executed in such a way that once the valve has been brought under testing pressure, the valve
shall be blocked in, so that no further pressure supply will occur. Hydrostatic testing of flanged valves shall be
Rev 0 1999
performed with the valve free standing with no end restraint.

8.2.3 Duration of test will start after the valve has been blocked in.

8.2.4 During the test period the pressure drop shall not exceed 0.25% of the testing pressure.

8.2.5 The test shall be made with water (which may contain a corrosion inhibitor) or with other suitable fluid
provided its viscosity is not greater than that of water. The test pressure shall be no less than 1.5 times the
ANSI B16.5 flange rating at 100°F (38°C).

8.2.6 For stainless steel bodies the chloride content of the fresh water used shall not exceed 30 ppm. The chloride
content shall be measured to verify this.

8.3 Pressure Relief Valves Testing

8.3.1 General

Testing of relief valves shall be in accordance with an agreed test procedure. The Vendor/Contractor shall
perform the test which may be witnessed by the Owner.

8.3.2 Hydrostatic Testing

(a) Pressure relief valve bodies to be used on gas or liquid shall be hydrostatically pressure tested in the
Vendor/Contractor's shop before pressure and leakage tests are conducted.

(b) The valve body shall be tested as follows:

Inlet side shall be tested at 1.5 times the design pressure of the valve body.
Outlet side shall be tested 1.5 times the outlet flange rating.

(c) Valves shall be tested for seat tightness, in accordance with API RP 527, following seat pressure test.
Valve tightness shall be within limits given in API RP 527 (for gaseous duty) and ASME PV code 8
(for liquid and steam duties).

(d) Additionally, all tests listed in the project piping specification shall be carried out.

8.4 Site Acceptance Testing (SAT)

8.4.1 Site Tests

Where specified in the Purchase Order/Contract, a site acceptance test (SAT) shall be carried out by the
Vendor/Contractor following the installation of the package equipment to confirm the correct operation of the
equipment. These tests shall include all of the functional tests carried out at the factory.

8.4.2 Specialist Engineering Services

The Vendor/Contractor shall provide a price, based on daily rate, for their specialist engineer(s) to attend site
installation and other site activities. Vendor/Contractor shall advise in his offer the number of specialist
engineers required to be present at site for the following stages of site activities.

Installation checks.
Functional test.
Loop testing and commissioning.
Training of Site Maintenance/Operating Personnel.

8.4.3 Site Services

Rev 0 1999
Where specified in the Purchase Order/Contract, the Vendor/Contractor shall include a separate price for the
following services to be performed by a trained service technician at site:

Supervise control panel(s) unloading and uncrating.

Supervise placement of control panel(s).
Verify completeness of shipment.
Install all components shipped separately including field instruments.
Verify proper system cabling.
Control panel(s) power-up.
Perform diagnostic tests on all control panels.
Verify the proper operation of all back-up systems.
Submit a detailed report on all activities undertaken.


9.1 Introduction

9.1.1 This section covers the documentation required for the design, fabrication, inspection and testing of the
packaged unit instrumentation.

9.1.2 All documentation shall be in English language.

9.1.3 Documents provided on 3.5" floppy disc, in addition to the hard copy, shall be in a format to be agreed with
the Owner.

9.1.4 The detailed list of documents that are required is attached to the Purchase Order/Contract but shall as a
minimum include:

Package P&IDs.
An instrument schedule of all package instruments to project standard format.
Data sheets for each instrument included in the package using project standard Data Sheets.
Calculation sheets for flow elements, control valves, relieving elements and thermowells.
Instrument cables and tubing routing diagrams.
Termination drawings and schematic diagrams.
Process and Emergency Cause and Effect diagrams for the package.
Alarm/Trip Setpoint Schedule.
Hazardous Area Certificates.
Material Test Certificates.
All test certificates.
Operating and Maintenance Manuals for each type of instrument and control panel.
Package wiring and termination drawings.
Cable and gland schedule.
Utilities consumption (instrument air, electrical power).
Rev 0 1999
9.2 Schedules and Reports

The manufacturer shall supply a schedule showing the documents for review and approval, proposed sub-
contractors and material procurement and a production/fabrication programme. Vendor/Contractor shall
provide regular progress reports, a minimum one per month, unless otherwise agreed with the Owner.

9.3 Hazardous Areas Certificates

Certificates covering the use of electrical components and equipment in hazardous areas shall be provided by
the Vendor/Contractor.


10.1 Painting and Coatings

10.1.1 Painting and protective coatings shall take into account the methods of transport to be used.

10.1.2 Surface preparation, painting and painting materials shall be in accordance with GES X.06.

10.1.3 Surfaces to be painted shall be dry and free from burrs, weld spatters, flux, dust, grease, oil and any other
foreign matter before paint is applied.

10.1.4 All carbon or alloy steel parts not in contact with the medium shall be blast cleaned and primed in accordance
with the Vendor/Contractor's standards, unless otherwise specified (gasket facings shall not be painted but
protected against corrosion by suitable fluids).

10.1.5 Vendor/Contractor's standard painting and coating systems may be acceptable subject to the Owner's approval,
provided they are equal or better to the Owner's standards specified in GES X.06 and are equally suitable for
the site environmental conditions specified in GES A.06.

10.2 Spares

10.2.1 The Vendor/Contractor shall submit with his proposal a priced list of recommended spares for start-up and
two year's operation for review by Owner.

10.2.2 Where analysers are used, reference and calibration gases shall be provided for commissioning and
recommendations shall be made for gases for two years of operation.

10.3 Packing and Storage

10.3.1 This section describes the minimum requirements for the preservation and protection of the package unit
instrumentation and associated control panel(s) during the sea and land transportation and storage prior to
installation. Packing shall be suitable for sea freight.

10.3.2 The probable storage period will be specified in the order/enquiry and will extend from the time of despatch to
the time of unpacking at site. If the storage period is not stated, a minimum period of 24 months shall be

10.3.3 Valves shall be securely packaged so that they are protected against external damage.

10.3.4 Machined or threaded exterior surfaces shall be protected during shipment and subsequent storage with a rust
preventative which is easily removed with a petroleum solvent.

10.3.5 Threaded end or socket welding connections shall be fitted with metal, wood or plastic plugs or caps.

10.3.6 Flanges shall be protected over the entire flange surface by 0.5 in (12 mm) thick plywood covers, bolted and
Rev 0 1999
sealed to prevent the ingress of dirt, dust and water.

10.3.7 Electronic items shall be suitably protected so as to prevent the ingress of moisture. The protection shall
include the use of desiccants.

10.3.8 After final acceptance, valve bodies shall be thoroughly cleaned internally and externally of all foreign matter,
rust, etc., and dried out.

10.3.9 All loose cables, tubing etc., which are disconnected for ease of shipment shall be securely tied back and

10.3.10 Where multiple crates or packages are used, then each shall be individually numbered and the number clearly
marked on the outside of the crate or package. A packing list relating the crate or package number to the
contents shall accompany the consignment.

10.4 Shipping

10.4.1 Instrumentation installed on package units or in local panels associated with packaged units shall not leave the
packaged unit Vendor/Contractor's works for shipment until the release has been approved by the Owner's

10.4.2 All "loose" and spare instrumentation shall be made available for inspection before shipment.

10.5 Warranty

10.5.1 The Vendor/Contractor shall warrant all materials and services supplied, against any defect, for a minimum
period of 12 months after commissioning or 24 months from the date of delivery to the site, whichever is the
shorter period, or for the period stipulated in the Purchase Order/Contract.

10.5.2 Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated with
restoring the equipment to the standard specified in the Purchase Order/Contract.

10.5.3 The Vendor/Contractor shall undertake to carry out the repair or replacement in an expeditious manner.

10.5.4 The terms and conditions of this Warranty shall be additional to any other requirements specified in the
Purchase Order/Contract.
Rev 0 1999
Table 1 - Process and Instrument Connections

Instrument Primary Instrument

Connections Connections
Size/Type Size/Type
Vessel mounted 2" flanged ½" NPT
Diaphragm seal 2" flanged 2" flanged
Pipe mounted ¾" NPT ½" NPT
900# and above 2" flanged ½" NPT
Orifice taps
below 900# ½" NPT F ½" NPT F
900# and above ¾" NPT F ½" NPT F
TW Vessel mounted 2" flanged 2" flanged
TW Pipe mounted
up to 400°F (200°C) 1" NPT F 1" NPT F
above 400°F (200°C) 1½" flanged 1½" flanged
Air System
Pneumatic Fittings ¼", _", ½" NPT ¼", _", ½" NPT
Receiver Gauge ¼" NPT M
Filter/Regulator ¼" NPT F
Instrument Air Supply ¼" NPT F
Gauge on Vessel 2" flanged 2" flanged
Gauge on Standpipe 1" flanged 1" flanged
Gauge Cocks ¾" NPT

Switch on Vessel 2" flanged 2" flanged

Switch on Standpipe 1½" flanged 1½" flanged
Top of Vessel mounted
Switch or transmitter 4" or 6" flanged 4" or 6" flanged

Displacer on Vessel 2" flanged 2" flanged

Displacer on Standpipe 1½" flanged 1½" flanged

dP Transmitters 2" flanged ½" NPT F

with Diaphragm seal(s) 2" flanged 2" flanged
Flange mounted 2", 3" or 4" flanged 2", 3" or 4" flanged

Level instrument ½" NPT


3" minimum NPS 2" flanged 2" flanged
Vent ¾" NPT
Drain 1" NPT