October 2001

Process Industry Practices

Process Control

PIP PCCGN002
General Instrument Installation Criteria
 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application, and
engineering costs to both the purchaser and the manufacturer should be reduced. While
this Practice is expected to incorporate the majority of requirements of most users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering
situations should not be made solely on information contained in these materials. The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having the
same specifications are equally correct and may be substituted for those named. All
Practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these Practices or guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying or
acting on any material contained in or suggested by the Practice.

This Practice is subject to revision at any time by the responsible Function Team
and will be reviewed every 5 years. This Practice will be revised, reaffirmed, or
withdrawn. Information on whether this Practice has been revised may be found at
http://www.pip.org.

© Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3925 West Braker Lane (R4500), Austin,
Texas 78759. PIP member companies and subscribers may copy this Practice
for their internal use. Changes, overlays, addenda, or modifications of any
kind are not permitted within any PIP Practice without the express written
authorization of PIP.

Not printed with State funds

 October 2001

Process Industry Practices

Process Control

PIP PCCGN002
General Instrument Installation Criteria
Table of Contents

1. Introduction .................................. 2 7. Instrument Environmental

1.1 Purpose ............................................. 2
1.2 Scope................................................. 2
2. References ................................... 2
Process Industry Practices ........................ 2
Protection ................................... 6
7.1 Enclosures ......................................... 6
7.2 Heat Tracing ...................................... 6
7.3 Fire Protection ................................... 9

3. Instrument Identification ............. 2

3.1 General .............................................. 2
3.2 Safety Instruments Identification........ 2
3.3 Control and Rack Panel
Instruments and Accessories ............ 3

4. Instrument Mounting Location ... 3

5. Instrument and Tubing

Mounting Supports..................... 4

6. Instrument Process
Connections................................ 5
6.1 General .............................................. 5
6.2 Purging of Process Connections ....... 5

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PIP PCCGN002
General Instrument Installation Criteria October 2001

1. Introduction

1.1 Purpose
This Practice provides design criteria for the installation of an instrument system.

1.2 Scope
This Practice specifies requirements for instrument identification, mounting location,
instrument support, process connections, and environmental protection.

2. References
Applicable requirements in the latest edition (or the edition indicated) of the following
industry standards and Process Industry Practices (PIP) shall be considered an integral part of
this Practice. Short titles will be used herein when appropriate.

Process Industry Practices (PIP)

– PIP PCCGN001 - General Instrument Design Checklist
– PIP PCFGN000 - General Instrument Fabrication Details
– PIP PCIGN000 - General Instrument Installation Details
– PIP PCIGN001 - General Instrument Purge Details

3. Instrument Identification

3.1 General
3.1.1 All instruments, equipment, and enclosures shall be identified by the vendor
before shipment by using one of the following methods:
a. A permanently affixed nametag
b. An engraving on the instrument
c. A stainless steel tag affixed with a stainless steel wire
3.1.2 Nameplates shall have, as a minimum, the device tag number engraved.
3.1.3 The engineering contractor/designer shall include tagging requirements on
instrument data sheets.
3.1.4 All instrument tubing and wiring connections, including spares, shall be
identified with permanent nametags, nameplates, or wire markers at tubing
or wiring junctions. Paper nametags are not acceptable.

3.2 Safety Instruments Identification

In the field, safety instruments shall be clearly identified by using the owner’s
prescribed method.

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 PIP PCCGN002
October 2001 General Instrument Installation Criteria

3.3 Control and Rack Panel Instruments and Accessories

3.3.1 Instruments and accessories that require identification nametags or
nameplates shall include, as a minimum, the following:
a. Control panel front-mounted instruments (complete nameplate on the
front, nameplate or nametag with only the device number on the back)
b. Control panel rear-mounted instruments
c. Junction boxes, relay cabinets, and similar enclosures
d. Control panel sections and racks
e. Control system modular components (e.g., computers, programmable
logic controllers, printers, I/O enclosures, racks, modules)
f. Instrument electrical distribution equipment (e.g., fuses, breakers,
switches)
g. Control and indicating devices (e.g., hand switches, indication lights)
3.3.2 Nameplates for recorders shall include a color-coded legend to designate the
recorder pen color dedicated to the respective instrument tag number.

4. Instrument Mounting Location

4.1 Instrument mounting locations shall be selected with consideration of requirements

for functional operation and maintenance.

4.2 Field instruments shall be mounted to minimize the length of instrument impulse
lines connected to process pipelines or equipment.

4.3 Instruments that require frequent calibration or maintenance shall be accessible from
grade or from a permanent platform. These instruments shall be located between
2 and 5 feet above grade or platform. In heavy snow or flooding areas, these
instruments shall be located at least 4 feet aboveground.

4.4 Instruments requiring limited access shall be located as follows:

1. Less than 18 feet above grade and accessible by ladder or portable platform
2. Less than 7 feet above a permanent platform

4.5 Instruments mounted outside a platform handrail shall be located to allow

maintenance from the platform without reaching through or leaning over the
handrail. These instruments shall be located less than 5 feet above the platform and
less than 1 foot horizontally outside the platform edge.

4.6 Instruments shall be located no farther than 1.5 feet from fixed ladders to allow
maintenance from the ladder.

4.7 Instruments including pressure gauges, dial thermometers, and gauge glasses shall be
readable from grade, platforms, or permanent ladders.

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PIP PCCGN002
General Instrument Installation Criteria October 2001

4.8 Instruments shall not protrude into or obstruct access ways so as to inhibit area
personnel egress.
4.9 Instruments shall be located to allow performance of routine services with
unobstructed access.
Comment: Clearances shall be provided for the removal of covers and cases and
the opening of doors and enclosures. Access for appropriate lifting
equipment shall be provided when necessary for control valves.
Control valve bypass piping shall not interfere with mounting the
control valve operator vertically.

4.10 Local controllers and receiver instruments shall be located and readable in the
vicinity of the final control element. Actions resulting from operational changes of a
local instrument (e.g., control valve movement or vessel level changes) shall be
observable from the receiver instrument location.

5. Instrument and Tubing Mounting Supports

5.1 Direct-reading instruments shall be supported by piping or equipment. (e.g., pressure

gauges and dial thermometers).

5.2 Field instruments shall be mounted on instrument supports designed for that purpose.
These instruments may be supported on process pipe or on pipe stands.
Comment: Size and weight of instruments as well as heat or vibration in piping
systems affect the mounting location and support requirements.

5.3 A prefabricated, 2-inch, schedule 40 pipe stand support shall be used for field
instrument mounting. The pipe stand shall be hot-dipped galvanized as a minimum
requirement. The top of the pipe shall be plugged or sealed to prevent water entry.
For additional information, see PIP PCFGN000.

5.4 Welded areas, drilled holes, and pipe threads on galvanized steel shall be prepared
and sprayed with cold galvanized coating.

5.5 In general, single pipe stands dedicated to single instruments shall be used. When
necessary, a single pipe stand fabricated to support multiple support arms may be
used. For additional information, see PIP PCIGN000.

5.6 Pipe stands shall be securely anchored.

5.7 Instrument process piping and tubing shall be supported as necessary to maintain
structural integrity.

5.8 All instrument piping and tubing between the instrument and process equipment or
pipeline shall be properly supported to prevent strain on the instrument, equipment,
and piping connections. Care shall also be taken to accommodate thermal expansion
or relative motion of piping or equipment to which such instrument items are
connected. Supporting instrument piping from bare hot or cold pipe shall be avoided.

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 PIP PCCGN002
October 2001 General Instrument Installation Criteria

5.9 When fire protection is required for stainless steel tubing, it must be supported by a
stainless steel tray.
Comment: Galvanized supports for stainless tubing may present a problem
when exposed to a fire. Direct contact between stainless steel and
galvanized steel or inorganic zinc paint will cause liquid metal
embrittlement of the stainless and instantaneous “brittle” fracture
when the tubing is exposed in a fire.

6. Instrument Process Connections

6.1 General
6.1.1 A line class root or isolation valve shall be provided at each process
connection. This valve shall be specified and provided by the piping
discipline.
6.1.2 Instrument process connections shall be made to either the side, top, or upper
or lower 45-degree angle of process piping or equipment as directed by the
owner. When low-side connections are specified, these connections shall be
sufficiently high to prevent plugging by dirt or suspended solids.
Connections shall be short and without pockets.
6.1.3 Special attention shall be given to the location of process connections on
vessels. Temperature sensors shall be placed in flowing streams, not in
stagnant fluid. Where equipment has piped bypass, temperature sensors shall
be installed outside the bypass piping.
6.1.4 Pressure-sensing points (for pressure, differential, and level measurements)
shall be located such that error from fluid impact and velocity effects is
avoided.
6.1.5 Instrument process connections shall conform to the requirements in the
piping or equipment specifications.

6.2 Purging of Process Connections

6.2.1 Purging of process connections shall be used to prevent plugging, freezing,
and corroding. For additional information, see PIP PCIGN001.
6.2.2 The purge fluid shall be compatible with the process fluid.
6.2.3 When purging is required, the purging system shall not induce error into the
process measurement.
6.2.4 Gas purges shall not exceed 3 standard cubic feet per hour, and liquid purges
shall not exceed 3 gallons per hour, unless specifically required by design
conditions.
6.2.5 Water purge systems shall be protected from freezing.
6.2.6 Gas purges shall be traced and insulated if condensation is a problem.
6.2.7 Provision shall be made for draining condensed liquids from gas purge
systems at low points in the piping system.

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PIP PCCGN002
General Instrument Installation Criteria October 2001

6.2.8 For solids-bearing streams, the purge instrument connections to the process
equipment or piping shall be vertical or angled up.
6.2.9 The purge connection shall be near the instrument.
6.2.10 The temperature of the purge fluid shall not cause a change of state
(flashing, condensation, or solidification) of the process or purge fluid.
6.2.11 The supply source of the purge fluid shall be independent from the process
fluid so that it is available even when the process is not operating normally.
6.2.12 The purge fluid flow rate shall be the same to each tap on an orifice meter
installation.
6.2.13 Purging systems shall include a check valve and shutoff valve.

7. Instrument Environmental Protection

7.1 Enclosures
7.1.1 Instruments requiring protection from freezing shall be provided with an
insulating protective enclosure. Manifold valves, where required, shall be
included within the enclosure.
7.1.2 The temperature for instrument electronics shall be maintained within the
manufacturer’s recommended minimum and maximum values.
7.1.3 Use of “soft” type instrument enclosures is acceptable where space
requirements are not adequate for hard-pack enclosures.
7.1.4 Electrical heating elements used in the enclosure shall meet the electrical
area classification.
7.1.5 Space inside an enclosure and around the instrument shall be adequate for
routine maintenance and for removal of the instrument. Properly sized and
positioned access doors are required.
7.1.6 Process impulse lines shall enter through the side or bottom of the enclosure
(never through the top) and shall be located to minimize piping
requirements. All penetrations through the side or bottom shall be sealed.
7.1.7 Full hard-pack enclosures shall be wall-mounted or attached to an instrument
pipe stand.
7.1.8 Metal enclosures shall be corrosion resistant. The hardware, assembly bolts,
and screws shall be stainless steel. NEMA 4X enclosures shall be the
minimum rating for outdoor instrumentation.

7.2 Heat Tracing

7.2.1 General
7.2.1.1 Process impulse lines and instruments containing either vapors that
may condense at ambient temperatures or liquids that will freeze or
congeal shall be insulated and/or heat traced. Each potential
application shall be investigated to determine the degree and type of

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 PIP PCCGN002
October 2001 General Instrument Installation Criteria

heat tracing that is required. This section does not cover heat tracing
for process pipelines.
7.2.1.2 Self-limiting electric tracing shall not be used when temperatures
exceed 250°F.
7.2.1.3 Steam tracing can be used when required system temperatures are
above 200°F.
7.2.1.4 Constant-resistance electric tracing shall be used when temperature
control is required.
7.2.1.5 Insulation and heat tracing shall be applied to the process-wetted
parts of the instrument, never to electronics or to pneumatic parts.
7.2.2 Steam Tracing
7.2.2.1 The use of prefabricated heat-tracing bundles is preferred. When
short leads or configuration prevents reasonable use of this material,
individually designed systems shall be provided.
7.2.2.2 For maximum heat transfer, the tracer shall be held in direct contact
with the instrument line or equipment. Steam pressure shall be
selected for the desired heating; however, consideration must be
given to boiling or process degradation.
7.2.2.3 When the process fluid in the instrument line is temperature-
sensitive or has a boiling point lower than the steam temperature, the
tracer shall be separated from the line using a spacer or insulation to
prevent hot spots in the heated line. Asbestos-free insulation tape or
blocks shall be used to separate steam tracing tubing from meter
body, instrument enclosure, and impulse tubing and piping. Spacing
shall be a minimum of 1/2 inch.
7.2.2.4 All steam tracing connections shall be made outside the instrument
enclosure.
7.2.2.5 Low-pressure steam (less than 75 pounds per square inch gage
[psig]) shall be used for steam tracing of impulse lines.
7.2.2.6 Preinsulated tubing shall be used to carry steam tracing from a steam
tracing station to the instrument to be traced.
7.2.2.7 If a condensate return system is available, condensate from
individual steam traps shall be returned by preinsulated tubing.
7.2.2.8 Instrument tracing shall be 3/8-inch or 1/2-inch outside diameter
(OD) copper tubing.
7.2.2.9 The steam supply to the tracing leads shall enter at the high point of
the tracing system. The tracing leads shall be horizontal or
continuously sloped downward to a steam trap, low-point drain, or
condensate return header.
7.2.2.10 A separate trap shall be installed for each tracer circuit.
7.2.2.11 All bare steam tracers shall be insulated for protection of personnel.

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PIP PCCGN002
General Instrument Installation Criteria October 2001

7.2.2.12 Ends of tubing bundles and any other openings shall be sealed to
prevent entrance of moisture.
7.2.2.13 Tracing of individual instruments shall be done to allow removal of
the instrument for maintenance.
Comment: To prevent removal of the tracing line to an
instrument, a tubing block valve may be installed in
the tracer line at each instrument. This installation
avoids closing the header valve for maintenance. A
valve is also required on the condensate return line
if the condensate discharges to a header. Tubing
unions shall be supplied on both ends of tracing
wrap for the instrument. Unions installed in tracer
systems shall be left uninsulated for easy access,
unless protection is required.
7.2.2.14 Copper tubing tracer systems shall be limited to temperatures less
than 400°F.
7.2.2.15 Steam branches shall be taken from the top of the header to assure
that dry steam will be supplied. Each branch shall have an individual
shutoff valve to eliminate bypassing and recycling within the tracer
system. Each tracer shall be individually trapped.
7.2.2.16 Traps shall be accessible for inspection and maintenance.
7.2.2.17 Siphons, flanges, etc., are to be wrapped completely with fiberglass
tape to enclose tracer and instrument piping, even though the tracer
may not follow the siphon or full-flange surface.
7.2.2.18 Condensate pots shall not be insulated.
7.2.3 Electric Heat Tracing
7.2.3.1 Electric heat tracing system design shall be based on a minimum
ambient temperature of the region as specified in PIP PCCGN001.
Wind velocity of 25 miles per hour (mph) shall be used in
determining the required heat input. The system shall be designed to
maintain the temperature of all freeze-protected lines and/or
instruments at 50°F or greater, as required.
7.2.3.2 When designing an electric tracing system, abnormal situations such
as steam outs shall be considered. The heat tracing cable shall be
designed to withstand the maximum steam out temperature.
7.2.3.3 Electric heat tracing shall be designed to meet the electrical area
classification of the area in which the tracing will be installed.
Components used in the system shall be approved by a nationally
recognized laboratory for the area classification involved.
7.2.3.4 Self-limiting parallel resistance or constant-watt parallel resistance-
type heating cable shall be used for electric heat tracing. Heating
cables shall be selected with a watts per foot rating to prevent
overheating.

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 PIP PCCGN002
October 2001 General Instrument Installation Criteria

7.2.3.5 Only mineral-insulated or high-temperature-rated constant-watt-type

heating cable shall be used on applications that exceed 365°F.
7.2.3.6 Prefabricated tubing bundle systems (consisting of process
compatible instrument tubing, self-limiting or constant-watt heater
cables with insulation, and outer jacket) shall be the preferred
method of freeze protecting and heat tracing instrument impulse
lines.
7.2.3.7 Each heat tracing cable shall be permanently tagged with a stainless
steel identification tag attached at the power connection box end of
the circuit. The tag for each cable shall indicate the panel
identification (ID) and circuit number.
7.2.3.8 Heat trace cables shall be installed according to the manufacturer’s
recommended standards. Detail drawings shall give information
concerning specific application to instrumentation and impulse lines.
The manufacturer’s installation procedures shall be followed.
7.2.3.9 Tracing of individual instruments shall be done to allow removal of
the instrument for maintenance.
Comment: A breaker panel may be provided to de-energize
circuits, or physical disconnects may be provided in
tracers to permit the removal of instruments without
distorting or cutting the wire.
7.2.3.10 All electrically traced instruments shall be properly tagged with a
warning about the danger of cutting into an energized cable when
removing insulation.

7.3 Fire Protection

7.3.1 General
7.3.1.1 Instrumentation systems located in areas where potential fire hazards
exist shall be provided with protection from an external fire if loss of
these instruments could present danger to personnel or equipment.
Protection shall be provided for instrument components, tubing,
wiring, conduit, and control valves.
7.3.1.2 Fire protection shall be specific to the type of hazard and can be
achieved by using intumescent coating, insulation, jacketing, deluge,
or a combination of methods.

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