BCD4-000-47-SPC-4-006-00 - rev0-REC General Instrumentation

PetroChina International Jabung Ltd.
Specification
General Instrumentation
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BCD4-000-47-SPC-4-006-00 Rev.0 Page 2 Updated – 19-May-10

PetroChina International Jabung Ltd. Specification
Table of Contents
Section Title Page
1.0 PURPOSE ........................................................................................................5

2.0 CODES STANDARDS AND SPECIFICATIONS .............................................5
3.0 DESIGN ............................................................................................................8
3.1 Environmental Conditions .............................................................................8
3.2 Units of Measurement ....................................................................................8
3.3 Materials ..........................................................................................................9
3.4 Technical Requirements ................................................................................9
3.4.1 Instrument Accessibility ..............................................................................10
3.4.2 Instruments Process Connections .............................................................10
3.5 Shutdown Valves and Blowdown Valves ...................................................11
3.6 Control Valves...............................................................................................11
3.7 Pressure Regulating Valves ........................................................................11
3.8 Pressure Safety & Relief Valves..................................................................11
3.9 Rupture Disc .................................................................................................12
3.10 Pressure Instruments...................................................................................12
3.11 Temperature Instruments ............................................................................12
3.12 Flow Instruments ..........................................................................................12
3.13 Level Instruments .........................................................................................12
3.14 Vibration Monitoring Instruments ...............................................................12
3.15 Tropic Proofing For Instruments.................................................................12
3.16 Instrumentation and Fire / Gas Detection Cables......................................12
3.17 Local Instrument Control Panels for Outdoor Installation .......................12
3.18 Control Room Instrument Panels and Consoles .......................................12
3.19 Instrumentation for Packaged Equipment .................................................13
3.20 Pig Signal ......................................................................................................13
3.21 Electrical Safety ............................................................................................13
3.21.1 Listing ............................................................................................................13
3.21.2 Panel Ground Structure ...............................................................................13
3.21.3 Electrical Shock Hazard ...............................................................................13
3.22 Grounding System........................................................................................14
3.22.1 Protective Grounding System (PG).............................................................14
3.22.2 Reference Ground System (RG)..................................................................15
3.22.3 Intrinsic Safety Ground System (ISG).........................................................15
3.23 Lightning Surge Protection System............................................................15

3.24 Distributed Control System .........................................................................16

3.25 Emergency Shutdown System (ESS)..........................................................16
3.26 Fire Detection System (FDS) .......................................................................16
3.27 Gas Detection System..................................................................................17
3.28 Power Supply and Instrument Air/Gas System .........................................17
3.28.1 Electrical Supply Characteristics................................................................17
3.28.2 Instrument Air / Gas System........................................................................18
3.28.3 Distribution System......................................................................................18
3.29 Protection of Instrument against Environment .........................................19
3.29.1 General ..........................................................................................................19
3.29.2 Interference ...................................................................................................20
3.29.3 Instrument Passive Protection against Fire...............................................21
3.30 Nameplates....................................................................................................21
3.31 Installation.....................................................................................................21
3.32 Shipping Preservation and Storage of Instrumentation Equipment........21
3.33 Tropic Proofing Requirements ....................................................................22
4.0 INSPECTION AND TESTING ........................................................................22
4.1 Inspection and Testing.................................................................................22
4.2 QA/QC Certification ......................................................................................22
4.2.1 QA/QC certification for visual controls ......................................................22
4.2.2 QA/QC certification for Functional..............................................................23
4.2.3 QA/QC certification for Factory Acceptance Tests (FAT).........................23
4.2.4 The Site Acceptance Tests (SAT)................................................................23
4.2.5 Integrated System.........................................................................................23

1.0 PURPOSE
This specification covers the minimum requirements for the design, selection, application and
installation of Instrumentation and Process Control Systems and their components for Betara
Complex Development Phase 4 (BCD4) Project of the PetroChina International Jabung Ltd
(PCI).
Instrumentation shall be provided to satisfy the following minimum requirements:
• Measurements and indications of various plant parameters.
• Enable safe and convenient plant start-up, uninterrupted operation and controlled
shutdown.
• Provide automatic protective action where deviation of plant variables could result in a
hazard to personnel or equipment.
• Provide information and controls to enable plant and utilities to meet the specified
requirements of safety, product quality, throughput, efficiency and economic operation.
• Equipment shall be selected on the basis of both field proven ability for the application,
maximum reliability and manufacture's support for the product.
2.0 CODES STANDARDS AND SPECIFICATIONS

The current versions complete with the latest amendments, of the following laws, statutory
regulations, codes, standards and specifications shall form part of and shall be read in
conjunction with this specification.
Indonesian Law
Statutory Regulations
American Gas Association (AGA):
AGA - Report 3 Orifice metering of natural gas
AGA - Report 8 Super compressibility factor computation
AGA - Report 9 Ultra Sonic Flow Measurement
American National Standard Institute (ANSI):

ANSI B16-104 American national standard for control valve seat leakage
ANSI B16-5 Pipe flanges and flanged fittings
American Petroleum Institute (API):

API RP 14 C Recommended practice for analysis, design, installation and testing of
basic surface safety systems on offshore production platforms.
API Spec 14 D Specification for wellhead surface safety valves and under water safety
valves for offshore service.
API RP 520 Recommended practice for the design and installation of pressure
relieving systems.
API RP 521 Guide for pressure relief and depressuring system
API RP 526 Flanged steel safety relief valves (sections 1 to 4)
API RP 527 Commercial seat tightness of safety relief valves with metal to metal
seat.

API RP 551 Process measurement instrumentation.

API RP 552 Transmission systems.
API RP 554 Process instrument and control.
API RP 555 Process analyzers
API 2000 Tank breather valves
American Society for Testing and Materials (ASTM):

ASTM D 1085 Standard method of gauging petroleum and petroleum products
ASTM D 1086 Standard method of measuring temperature of petroleum and
petroleum products
A106 Gr. B Specification for Seamless Carbon Steel Pipe
A411 Specification for Seamless Stainless Steel Mechanical Tubing
American Society of Mechanical Engineers (ASME):

Section I Power Boiler Code.
Section VIII Unfired Pressure Vessels Code.
International Electro-technical Commission (IEC):

IEC 68/2 Basic Environmental Testing Procedure for Electric Components and
Electronic Equipment.
IEC 801 - 3 Radiated Electro-magnetic Field Requirements
IEC 61131 -1 Part 1: General Information
IEC 61131 -2 Part 2: Equipment Requirement and Test
IEC 61131 -3 Part 3: Programming Language
IEC 61131 -4 Part 4: User Guidelines
IEC 61508 Functional safety: Safety Related System
International Standards Organization (ISO):

ISO 31 Size, units, symbols, conversion factors and conversion tables.
ISO 5167 Fluid measurement with orifice plates, nozzle and venturi inserted in
filled piping of circular profile.
ISO 5168 Flow measurement: calculation of errors.
International Society of Automation (ISA):

ISA - S5.1 Instruments symbols and identification
ISA - S5.2 Binary logic diagrams for process operation
ISA - S5.3 Graphic symbols for Distributed Controls
ISA - S5.4 Instrument loop diagrams
ISA - S18.1 Annunciator sequences and specification

ISA - S20 Specification forms for process measurement and control instruments
primary elements and control valves
ISA - S 51.1 Process instrumentation terminology
ISA - S 75.1 Control valve sizing equations
ISA - SP 84 Programmable Logic Controller Systems used in Safety applications
National Electrical Code (NEC):

National Electrical Manufacturers Association (NEMA):
Industrial Control Standards
Enclosures for Industrial Control
Underwriters1 Laboratories, Inc. (UL), or Factory Mutual (FM)
Flowmeter Engineering Handbook; Author: R.W. Miller
PCI Specifications:
BCD3-000-40-LST-4-001-00, Approved Manufacturers List
Rev.1
BCD3-000-40-SPC-4-001-00 Specification for 3rd Party Inspection Services
BCD3-000-40-PCD-4-008-00 Procedure Tender, Purchase of Equipment & Materials
BCD4-000-44-SPC-4-007-00 Piping Material Class
BCD3-000-47-SPC-4-015-00, Specification Control Valves
Rev.2
BCD3-000-47-SPC-4-024-00, Specification for Shutdown and Blowdown Valves
Rev.2.
BCD3-000-47-SPC-4-029-00, Specification for Pressure Regulating Valves
Rev.2.
BCD3-000-47-SPC-4-014-00, specification for Pressure Safety & Relief Valves
Rev.2.
BCD3-000-47-SPC-4-018-00, Specification Pressure Instruments
Rev.2
BCD3-000-47-SPC-4-019-00, Specification Temperature Instruments
Rev.2.
BCD3-000-47-SPC-4-016-00, Specification Flow Instruments
Rev.2.
BCD3-000-47-SPC-4-605-00, Instrumentation for Packaged Equipment
Rev.0
BCD3-000-47-SPC-4-017-00, Specification for Level Instruments
Rev.2.
BCD3-000-47-SPC-4-605-00, Instrumentation for Packaged Equipment
Rev.0
BCD3-000-40-PCD-4-005-00, Numbering Conventions
Rev.0.
BCD4-000-47-SPC-4-005-00 Specification for Instrumentation cable
BCD4-000-47-SPC-4-027-00. Specification for Fire & Gas Detection cable

BCD4-000-47-SPC-4-009-00. Specification for Outdoor Control Panels and Consoles

BCD4-000-47-SPC-4-010-00. Specification for Control Room Panels & Consoles
BCD4-695-47-SPC-4-002-00. Specification for Distributed Control System
BCD4-695-47-SPC-4-001-00 Specification for ESS/FDS Expansion
BCD4-000-42-CRT-4-004-00 Process Design Criteria
PCI is to be advised of any conflict between this specification and the above documents. A
written resolution shall be obtained from PCI before proceeding with the effected work.
The order of precedence is:
a) Indonesian national laws.
b) Statutory and local authority regulations.
c) This specification
d) Referenced codes and standards
3.0 DESIGN
3.1 Environmental Conditions

Generally all instruments and control systems shall operate under the environmental
conditions stated in the "Process Design Criteria", document no.: BCD4-000-42-CRT-4-004-
00. The environmental conditions in general are as follows:
Atmosphere Tropical, with 121 days of the year considered wet or rainy.
Ambient Temperature Min. 73.4° F (23 ° C) and Max. 87.8° F (31 ° C)
Humidity Max 79% relative Min. 72% relative
Wind Speed (max) 62.5 miles/h (100 km/h)
Earthquake design Moderate seismic area, classified as UBC zone 2. Seismic
Criteria based on API RP2A and NFPA 59A to be used
The ambient conditions in for HVAC controlled rooms are as follows:
Ambient Temperature : Min. 73.4° F +/- 4 (23 ° C) and Max. 87.8° F (31 ° C)
Humidity : 50 % relative
3.2 Units of Measurement

Units of measurements shall be in accordance with the Process Design Criteria Document
No.: BCD4-000-42-CRT-4-004-00. Imperial unit shall, in general, be used.
Further to the above, the following units shall apply
• Flow : Liquid : Barrels per day (BPD)
Gas : Standard cubic feet per day
(SCFD) (60°F 14.696 Psia)
• Pressure : General : Psi gauge (Psig)
(Absolute) : Psi absolute (Psia)
• Differential pressure : Psid, or Inches of water for flow measurement

• Temperature : Degree Fahrenheit (°F)

• Level : inches (or % of range)
• Viscosity : Centipoise (cP)
• Length : Inches/Millimeter/ Feet/Meter
• Analyzer : Determined by individual application
3.3 Materials
Instrumentation materials and instrument mounting hardware shall be minimum SS 316 and
for Instrument housings, use of "Vendor Standard" materials, suitable for the specified
environmental conditions, such as aluminum w/ epoxy or polyurethane coating, is
acceptable, subject to Company approval. Mounting hardware shall include nuts, bolts and
other fasteners.
All material for instrumentation in contact with process fluid shall be in conformance to the
Piping Material Class Document No.:BCD4-000-44-SPC-4-007-00.
3.4 Technical Requirements

Deviation from criteria set forth in this specification will not be permitted except with written
approval from PCI.
All materials and equipment furnished shall be new, unused and free of defects. Materials
and equipment shall be protected from construction damage, particularly damage due to
sandblasting and painting.
All instruments and equipment shall be selected from PCI's "Approved Manufacturers List",
Document No.: BCD3-000-40-LST-4-001-00, Rev.-0.
Proposed exceptions shall require written approval by PCI on a case by case basis.
Each instrument furnished shall be provided with fully completed data sheets. Data Sheets
shall be numbered and indicate manufacturer and model numbers. PCI’s datasheet format
shall be used.
Multiple listing of instruments on one sheet is permitted; however, they must be arranged in
numerical sequence by tag number. Only identical instruments may be listed on each data
sheet i.e. the only difference allowed is tag numbers.
An assigned tag number which is cancelled due to instrument revisions shall not be re-used.
Contractor shall prepare the Instrument Index / Instrument List. The format of this index/list
shall be approved by PCI.
Instruments shall be numbered and identified in accordance with "Procedure for Equipment,
Numbering Conventions" Document No.:BCD3-000-40-PCD-4-005-00, Rev.-0.
Where possible, the instrument selection shall represent the manufacturer's standard.
Standardization of instruments types, manufacturer, and model shall be considered for the
purpose of simplifying design and reducing spare parts.
Selection of instruments and supporting hardware shall be made with consideration of the
process fluid, the operating environment, and the electrical area classification.
Process fluids, steam or water shall not be channeled into control rooms for direct
measurements.
Instrument pneumatic analog signals shall be 3 - 15 psig, unless otherwise specified or
required by the equipment such as valve operators. Instrument pneumatic on-off signals
shall generally be 30 psig.

Pneumatic instruments requiring a regulated air supply shall be furnished with a filter
regulator and output gauge made of SS 316.
The use of transmitters shall be maximized to improve overall reliability and availability. All
transmitters shall be "SMART" electronic type utilizing 'dual mode' output with 2 wire 4-20
mA signal with superimposed 'HART' protocol communication signal.
Local electric control switches shall be DPDT, unless otherwise specified. Discrete (On-off)
electric signals shall be 24 VDC unless otherwise specified. Use of local electronic control
switches in lieu of electronic type transmitters requires PCI approval.
Separate instruments along with separate piping and vessel tapping / connections shall be
used for shutdown initiating devices.
Where two (2) pressure or temperature transmitters monitor the same parameter then local
gauge need not be provided. The control transmitter installation is to include a plugged
connection where a gauge can be added at future time. Plugged connection is not provided
for the gauges on control transmitter impulse lines, in order to standardize the impulse lines.
Instrument stands shall be designed to accommodate future gauges.
Each field and control panel instrument shall have a permanent SS 316 nameplate bearing
its tag number. Tag numbers shall be stamped and not engraved.
3.4.1 Instrument Accessibility

Each instrument shall be considered as a normal working location and therefore shall be
properly located in order to satisfy workers safety conditions as well as efficiency.
Instrument accessibility being able to induce heavy consequence on piping or complex
layout, this problem shall be considered as soon as possible during the detailed
engineering stage.
It shall be important to distinguish two kinds of working location:
a. Permanent working location,
b. Non permanent working location.
A working location shall be considered as permanent when visit frequency is higher than
once a week.
Non permanent working location shall have visit frequency lower than once a week.
For permanent type, the access shall be easy. Access platforms are to be provided where
applicable and movable ladders not permitted.
For non-permanent type, movable ladders shall be allowed if height is less than 3 meters.
The following instruments and accessories shall be considered as permanent working
location:
Control valves, ON/OFF actuated valves, transmitters, local controllers, local converters,
in-line flowmeters, level gages, level switches, pressure switches, temperature elements
(indication and control) with transmitters, analyzer take off point, sampling loop.
The following instruments shall be considered as non -permanent working location: orifice
flanges, pressure taps, thermocouples or RTD's, and thermowell. Permanent access at
these locations is not required.
3.4.2 Instruments Process Connections

When an instrument is connected to the process by means of flanges, those flanges shall
be ANSI 150# RF rated as a minimum.
The following Table-1 gives the main requirements concerning instrument taps/nozzles.

TABLE - 1: REQUIREMENTS FOR INSTRUMENT TAPPINGS/CONNECTIONS
CONNECTION TO EQUIPMENT Connection to Vent. &

Instrument drain
Vessels Pipe Tank
1
Thermowells 2" flanged 1- /2 "-2" flanged 2" flanged - -
(note-1)
1 1 1
Local press. Ind. 2" flanged 2" flanged x /2 2" flanged /2 " /2 "
" THD. Mono 1
Press. Transmit. 2" flanged 2" flanged 1/2" /2 "
flanged valve
1 1
d/p cell (pressure) 2" flanged 2" flanged /2 " /2 "
3
Torque tube level 2" flanged - 2" flanged 2" flanged /4 "
Torque tube level 4" flanged - 4" flanged 4" flanged -
(top)
d/p cell (level) -
1
Level gage 2" flanged - 2" flanged 3" flanged /2 "
note-2)
3 1
Level switch 2" flanged - 2" flanged /4" NPT /2 "
3
Level switch (top) 2" flanged - 2” flanged 2” flanged /4 "
-
4” flanged 4" flanged 4" flanged
Inline flow ind. - Depending on - - -
Rotameters piping class &
diameter
1 1
Flow d/p cell (up - 1/2"SW or 1/2" NPT - /2 " /2 "
to 600#)
3 1 1
Flow d/p cell (up - /4" flanged - /2 " /2 "
to 900#)
Pitot tube (Anubar) - 11/2"-3" flanged - - -
Note:
1. To be confirmed with TW stress calculations. 2-1/2” flange is not allowed due to
piping class constraint.
Minimum insertion length of thermowells shall be that of 4" pipe expander/reducers
as indicated on the P&ID's.
2. A 2 X 3 " expander shall be provided
3.5 Shutdown Valves and Blowdown Valves

Description of Shutdown and Blowdown Valves are specified in "Specification for
Shutdown and Blowdown Valves" Document No: BCD3-000-47-SPC-4-024-00, Rev.-2.
3.6 Control Valves

For Control Valve details, refer to the individual specification for Control Valves No.:BCD3-
000-47-SPC-4-015-00, Rev.-2.
3.7 Pressure Regulating Valves

For Pressure Regulating Valves details, refer to the individual specification for Pressure
Regulating Valves No.: BCD3-000-47-SPC-4-029-00, Rev.-2.
3.8 Pressure Safety & Relief Valves

For Pressure Safety & Relief Valve detail, refer to the individual specification for Pressure
Safety & Relief Valves No.:BCD3-000-47-SPC-4-014-00, Rev.-2.

3.9 Rupture Disc

Rupture disc material shall be 316 SS unless another material is required by process
condition.
Rupture disc shall be assembled by the manufacturer as a single unit. Vacuum-supported
seal or disc liners and protective ring should be riveted or welded together as one unit.
Maximum back pressure in the vent header will be specified on data sheets.
The rupture disc unit shall have the ASME required data permanently attached to the tap.
3.10 Pressure Instruments

For Pressure Instrument details, refer to the individual specification for Pressure Instruments
No.:BCD3-000-47-SPC-4-018-00, Rev.-2.
3.11 Temperature Instruments

For Temperature Instruments details, refer to the individual specification for Temperature
Instruments No.:BCD3-000-47-SPC-4-019-00, Rev.-2.
3.12 Flow Instruments

For Flow Instruments details, refer to the individual specification for Flow Instruments
No.:BCD3-000-47-SPC-4-016-00, Rev.-2.
3.13 Level Instruments

For Level Instrument details, refer to the individual specification for Level Instruments
No.:BCD3-000-47-SPC-4-017-00, Rev.-2.
3.14 Vibration Monitoring Instruments

For Vibration Monitoring Instrument details, refer to the individual specification for Vibration
Monitoring System No.:BCD3-000-47-SPC-4-013-00, Rev.-0.
3.15 Tropic Proofing For Instruments

For Tropic Proofing for Instruments, refer to 3.32 below in this section.
3.16 Instrumentation and Fire / Gas Detection Cables

For Instrumentation cable details, refer to Specification No.:BCD4-000-47-SPC-4-005-00.
For Fire & Gas Detection cable details, refer to Specification No.:BCD4-000-47-SPC-4-027-
00.
All cables shall be stranded.
3.17 Local Instrument Control Panels for Outdoor Installation

For detailed requirements of local instrument control panels for outdoor installation, refer to
the individual specification for Outdoor Control Panels and Consoles Document No.: BCD4-
000-47-SPC-4-009-00.
3.18 Control Room Instrument Panels and Consoles

For detailed requirements of the control room instrument panels & consoles, refer to the
individual specification for Control Room Panels & Consoles Document No.:BCD4-000-47-
SPC-4-010-00.

3.19 Instrumentation for Packaged Equipment

For detailed requirements of the Instrumentation for Packaged Equipment, refer to the
individual specification for Instrumentation for Packaged Equipment Document No. BCD3-
000-47-SPC-4-605-00, Rev.-0
3.20 Pig Signal

Pig Signal shall be bidirectional type with visual flag indicator.
3.21 Electrical Safety
3.21.1 Listing
All electrical equipment is required to:
1. Be listed and inscribed with a recognized, international safety marking, for
example, CE, UL/FM, CSA etc. as proof that it is has been tested and conforms to
international safety standards. Otherwise it is a fire risk and shall not be used.
2. Have a reputable manufacturer's specification sheet.
3.21.2 Panel Ground Structure

Each of the three following ground structures is required to consist of a copper bar with
nickel plating to eliminate corrosion, dimensions 2-inch wide by l/2-inch thick. It is required
to be fitted to the bottom of the panel. The bar shall be tapped for the current requirement
and an additional 20% spare. Each hole shall be fitted with self tapping bolt and locking
washer. Other types of bolt are prohibited. Each connection to the ground bar shall be
independent and unique - parallel connections are prohibited. End-user's external
electrical safety bond wire shall consist of two 16mm2 conductors with one connected at
each end of the bar. Tapping for this shall be provided:
a. Protective Ground (PG)
The protective ground is required for centralizing the bonding of electrical safety
bonding wires inside the panel and the end-user's external safety ground bond.
b. Clean Ground (CG)
The clean ground is required for the central bonding point for cable screens and
the end-user's external clean ground bond wires. Inside the panel it shall be
electrically insulated from PG.
c. Intrinsic Safety Ground (ISG)
An Intrinsic Safety ground is required for the central bonding point for intrinsically
safe components only and the end-user's external intrinsic safety ground cables.
Inside the panel it shall be electrically insulated from PG.
3.21.3 Electrical Shock Hazard

A strong rigid plastic safety cover is required to be fitted over and adequately cover
electrical terminals where the voltage exceeds 50V to eliminate an electrical shock hazard.
There will not be any exposed terminals. The cover is required to have markings in red
which indicate that there is an electrical shock hazard, for example, DANGER -
ELECTRICAL SHOCK HAZARD.
All electrical components are required to be fitted with the manufacturer's intended cover
to eliminate exposure of electrical parts.
Electrical safety ground bonding wires are required to consist of electrical copper cable,
minimum 2.5mm2 cross sectional area x 7 stranded wires, with overall green / yellow

striped PVC sheath. Each ground bond is required to have a wire number at both ends to
uniquely identify the equipment which it is connected to, for example PS-1 is the panel
identification number for Power Supply #1. A ground bond is required to be fitted:
1. Between any metallic fixtures or fittings which are not welded to the panel, for
example gland plate, panel doors, shelves etc. such that the resistance to ground
shall be less than 1 ohm.
2. To all electrical equipment using the corresponding terminal or bonding point
provided by the manufacturer to the common PG panel ground bar. Electrical
equipment is required to be independent and individually grounded to eliminate
looping of ground bond wires, which is prohibited.
3.22 Grounding System

This specification describes the grounding principles to be used for the field instrumentation,
control and safety systems, the telemetry system, and the telecommunications to ensure
adequate protection to both personnel and equipment three (3) grounding systems shall be
used.
a. PG : Protective Ground system ("Dirty" Ground)
b. RG : Reference Grounding system (Clean Instrument Ground)
c. ISG : Intrinsic Safety Ground
3.22.1 Protective Grounding System (PG)

The PG is used to protect the electrical power system, electrical equipment and to protect
personnel from electric shock.
The PG is a protective earth used only for instrumentation equipment, telecommunication
equipment and control systems. All instrument and telecommunication metallic enclosures,
equipment, instrument and telecomm cables armour shall be connected to the PG
In the field, PG dispatchers / busbar shall be installed to collect the screen shields of the
instruments and telecommunication equipment. These bondings shall be performed by
using PVC insulated copper conductors, green and yellow coloured with a minimum of 6
mm2 cross section. They shall be mounted on insulators with a minimum distance of 1
inch from the structure.
The field PG dispatches shall be connected to the closest PG connection by using a PVC
insulated stranded copper conductor, green and yellow colored with a 35 mm2 minimum
cross section.
For typical field instruments, grounding continuity between braided armour and instrument
casing by using a metallic cable gland shall be provided. The field instrument casing
bonding to PG dispatches shall be done through the ground lug. For field instrument with
non-metallic enclosures, an earth tag will be fitted to the cable gland to ensure a proper
bonding to the PG.
Grounding shall generally be in accordance with the requirements of NEC Article 250.
For typical junction box, braided armours are connected to a brass plate via the cable
glands. This brass plate, bored and threaded for each gland is connected to an extension
earth stud bonded to the field PG.
If the junction box is metallic, no grounding plate is required and the cable armour shall be
grounded through the cable gland to the junction box wall which shall be bonded to the
field PG.
Every marshalling/equipment cabinet in the technical rooms shall be fitted with an PG bus
bar mounted on insulated blocks. The instrument cable armour of incoming and outgoing

cables, together with equipment cases, shall be connected to this bus bar. The cabinet
steel frame shall be grounded on the electrical PG bus bar.
Each cabinet PG bus bar shall be connected to the PG loop in the technical room by a 35
mm2 cable. This PG loop shall be 70 mm2 yellow / green cable connected to the main PG
bus bar.
The control cabinets and desks shall be connected to the PG in the same way as the
marshalling cabinets. Where enclosures have hinged doors, the doors shall be bonded to
the main enclosure with flexible earth straps.
3.22.2 Reference Ground System (RG)

The RG is the final reference point for all digital, telecomm and measurement signals.
All instruments and telecomm cable individual screens and overall screens are connected
to this point through multi-pair cables screens. This includes the external braid of the
Digital Communication Network cable in order to eliminate excess noise.
For field instruments, the screens are insulated from ground at the field end.
For junction boxes dedicated to measurement signals, screen wires shall be connected to
dedicated screen terminals. Screen continuity shall be maintained up to the technical
room.
For junction boxes dedicated to digital signals, screen wires shall be connected to an RG
bus bar mounted on insulated blocks .The overall screen of the multi-pair cables shall also
be connected to the PG bus bar. The overall screen of the multi-pair cable shall be
grounded in the local technical room.
Marshalling/Equipment Cabinets in the technical room shall be fitted with one RG bus bar
mounted on insulated blocks. All multi-pair cable individual screens for measurement
signals, the overall screens of digital multi-pair cables and the external braid of the Digital
Communication Network cable shall be connected to this RG bus bar. Total resistance of
this earth loop i.e. the RG bus bar (cabinet) to the actual earth electrode shall not exceed
1 ohm. Refer to the specification for Instrument, Installation Document No. BCD3-000-47-
SPC-4-008-00 Rev.1 for further details.
The RG bus bar is mounted on insulated blocks and connected to the RG loop by a 0.06
sq.in (or #2 AWG) cable. The RG loop shall be a 0.1 sq.in (or #2/0 AWG) green cable
connected to the main RG bus bar.
These main bus bars shall then be bonded to the main structure with a PVC insulated
cable, green colored with a # 2/0 AWG minimum cross section.
3.22.3 Intrinsic Safety Ground System (ISG)

The ISG is the final reference point for all shunt diode barriers which require a high
integrity ground.
Isolation and termination of IS field cable screens at field devices, junction boxes and
cabinets shall be done in same manner as for RG above ( sub section 13.9.2 ), except that
they shall be connected to an IS earth bar.
The maximum resistance from the connection in the cabinet to the earthing point shall not
exceed 1 (one) ohm.
3.23 Lightning Surge Protection System

Lightning surge protection for instrumentation system shall be provided on:
a. Electronic type transmitters / switches.

Lightning surge protection shall be furnished by every electric /electronic type field
instruments, such as transmitters, switches, transducers include I/P, detectors.
Instrument data sheets shall clearly specify this requirement.
Field instrument's pipe support shall be properly grounded, using galvanized steel
earth rod.
b. Analog & Digital Control Loops.
Lightning surge protection shall be furnished in DIN Rail mounted, on Marshalling
Rack Cabinet.
c. Serial Link Data Transmission (RS-232 / RS- 485/ RS-422), Ethernet, Modem, etc.
d. Telecommunication Cable Transmission.
e. Incoming Electric Power supply for instrumentation.
Lightning surge protection system shall withstand lightning surge current in excess of 10 kA.
3.24 Distributed Control System

For detailed requirements of the distributed control system, refer to the individual
specification for Distributed Control System Document No.: BCD4-695-47-SPC-4-002-00.
3.25 Emergency Shutdown System (ESS)

The following description is related to the ESS system for the new facilities. The principal
aims and objectives of the ESS system are:
a. The protection of personnel.
b. The protection of complex and equipment.
c. The protection against pollution of the environment.
The ESS logic shall act automatically and manually as required by the Complex ESS
diagrams and the cause and effect diagrams to:
a. Detect any abnormal operational or equipment condition.
b. Shutdown and/or isolating sections of the complex, or the entire plant.
c. Shutdown of plant utilities.
d. Isolate the electrical supplies.
e. Manual shutdown initiation of sections of the facility.
The ESS systems shall be integrated to the Fire Detection System for BGP and Fire and
Gas Detection System in SWB and WB respectively and shall take executive action to
safeguard BCD4 facilities as per Cause and Effect Diagrams in the event of fire detection.
All input / output signals connected to ESS shall be of the hardwired type.
For all hardwired interfaces between ESS or its sub-systems, special attention shall be paid
not to power such links from a system which may be subject to a shutdown.
For project specific technical specifications, refer to the specification for ESS/FDS
Expansion at BGP, Document No. BCD4-695-47-SPC-4-001-00; specification for ESS/FGD
System at SWB, Document No. BCD4-185-47-SPC-4-001-00; and specification for
ESS/FGD System at WB, Document No. BCD4-195-47-SPC-4-001-00.
3.26 Fire Detection System (FDS)

The fire detection system shall be designed to detect and to carry out automatic or manual
executive actions for protection against fire by Flame Detector (UV/IR), refer to ESS/FDS

Expansion at BGP, Document No. BCD4-695-47-SPC-4-001-00; ESS/FGD System at SWB,

Document No. BCD4-185-47-SPC-001-00; and ESS/FGD System at WB, Document No.
BCD4-195-47-SPC-001-00.
In the event of fire being detected, the system shall automatically activate Horn and Beacon
to initiate the appropriate alarm and shall trigger relevant actions through ESD system
according to the Cause and Effect matrix, to the following:
a. Shutdown and Blowdown Valves,
b. Compressor Package Control Systems,
c. Distributed Control Systems,
d. Motor Control Center.
3.27 Gas Detection System

The gas detection shall be part of the DCS/GDS/UOI Expansion at BGP and ESS/FGD
System at SWB and WB, and to be designed to detect and to carry out automatic or manual
executive actions for protection against flammable gas, by Combustible Gas Detector (IR).
In the event of gas being detected, the system shall automatically activate Horn and Beacon
to initiate the appropriate alarm and shall trigger relevant actions according to the Cause
and Effect matrix.
For project specific technical specification, refer to the specification for DCS/GDS/UOI
Expansion at BGP, Document No. BCD4-695-47-SPC-4-002-00; specification for ESS/FGD
System at SWB, Document No. BCD4-185-47-SPC-4-001-00; and specification for
ESS/FGD System at WB, Document No. BCD4-195-47-SPC-4-001-00.
3.28 Power Supply and Instrument Air/Gas System

3.28.1 Electrical Supply Characteristics
240 VAC ± 10%, at 60 HZ ± 5% 1 ph. Uninterruptible Power Supply (UPS) floating ground
shall be used for the supply of following main systems:
1. Specific control room instruments and systems,
2. Printers,
3. Distributed Control System / Gas Detection System (DCS/GDS),
4. Emergency Shutdown System / Fire Detection System (ESS/FDS).
5. Utility Control Panels
24 V DC uninterruptible power supply shall be used for the supply of the following
equipment:
1. Alarm, safety and shutdown systems
2. Electronic instrumentation
3. Solenoid Valves
Electronic loops are powered by a 24 V DC supply which shall be provided from the
related control systems.
Generally, the electrical distribution boards will allocate the feeders of each type (240
VAC, 24 V DC) to every main consumer (i.e. DCS/GDS, Emergency Shutdown
System/FDS, etc.).
These feeders shall be redundant for critical services (i.e. DCS/GDS, Emergency
Shutdown System/FDS, etc.).

Where a Vendor requires a different supply, then the Contractor / Vendor shall provide all
necessary equipment, power supplies, AC/DC distribution and protection, fuses, circuit-
breakers, earth leakage detection, terminals to interface his equipment with the above
project standards.
Power distribution within the control systems shall be provided by Contractor and shall be
floating earth and fused on both legs. Incoming primary supply shall be provided with
Earth Leakage Detection.
In the event of unavailability or failure of the 240 V AC UPS, the power supply shall be
from essential switchboard fed by emergency diesel generator.
All instrument power supply users shall be depicted as a single line diagram to be updated
by Contractor for the duration of the contract, giving a complete power supply usage at
any time. This diagram shall also include start up load (inrush) and normal load (running).
3.28.2 Instrument Air / Gas System

Air/gas distribution network shall take into account the following considerations:
1. Complex layout,
2. Number of items to feed,
3. Possibility to isolate one or more units or sub-units from each other.
Service air shall be totally segregated from the instrument air network.
All pneumatic instruments shall be able to operate with a minimum pressure of 80 psig.
Instrument air and gas shall be distributed to instruments with the following characteristics.
• Minimum Operating Pressure Normal : 80 Psig
• Operating Pressure Maximum : 110 Psig
• Operating Pressure : 140 Psig
• Design Pressure : 160 Psig
• Dew Point : 40°F
• Operating temperature : 120°F
• Design temperature : 180°F
Instrument air shall be dry and oil free.
Instrument gas shall be free from dust, oil, and trace of methanol, and not saturated at
ambient temperature.
If instrument air is available, gas shall not be tied into the same system.
3.28.3 Distribution System

Distribution system shall easily permit future modifications and distribution even if a part of
the plant is stopped.
Except for main feeder, the instrument air or gas sub headers should have the same
routing and supports as the instrument cables routing.
Instrument air or gas sub headers shall have the following sizes:
• 1/2" for up to 10 distributed
• 3/4" for 11 up to 30 distributed
• 1" for 31 up to 50 distributed

• 1 1/2" for 51 to 120 distributed

Materials used for instrument air distribution shall be in line with related piping class
specification (for all parts located upstream the instrument air or gas feeding manifolds).
Feeding manifolds shall be made of suitable materials as defined in the "Specification for
Piping Material Class" on Document No. BCD4-000-44-SPC-4-007-00 on all parts installed
downstream.
Special care shall be given to water or condensate trapping problems. A 1/2" drain valve
shall be installed systematically at each low point of the secondary networks.
Future take off points fitted with valves shall be installed on the main header. Branching on
mains feeders on racks shall be 1" minimum size. Branching on secondary headers shall
be 1/2" minimum size.
All branching shall be taken at the upper part of the header and shall be isolated by ball
valves.
Local panels containing pneumatic instrumentation shall be provided with a common dual
filter/pressure regulator/pressure gauge assembly.
Filter regulator, fitted with pressure gauge, shall be installed for each air/gas pneumatic
instrument supply. Air set shall be SS 316.
Individual instrument air tubing, fittings, and accessories installed downstream of the filter
pressure regulator shall have the following characteristics:
• Material : SS 316L for tubing, SS 316 for fittings,
• Size : 3/8" OD x 0.049" WT for air supply
1/4" OD x 0.035" WT for signals
For utility balance sizing purpose, a usage factor of 0.1 will be considered for intermittent
consumers, like on/off actuated valves.
3.29 Protection of Instrument against Environment
3.29.1 General
Field electrical instrument devices shall meet the hazardous area classification
requirements, but shall be as a minimum, Class 1, Division 2, Group D. The hazardous
area classification shall not be met by enclosure purging. Hermetically sealed electrical
switches shall be provided for all electrical switches used in classified areas. Electrical
devices connected to a process stream shall be equipped with a dual barrier capable of
preventing the transport of process media into conduits or junction boxes. Electrical
devices shall be listed by Under Writers Laboratory Inc. (UL), Factory Mutual Research
Corp. (FM), Canadian Standards Association (CSA), or other recognized testing
laboratories approved by PCI.
Enclosures of instruments located outdoor shall be NEMA-4X protection as a minimum.
Local instrument cubicles and housings shall also suit NEMA-4X protection, as a minimum
requirement.
All field instruments shall be painted with epoxy or polyurethane paints.
Where instruments and/or junction boxes are located in areas subject to deluge conditions,
their protection index shall be rated NEMA-4X.
Housings shall be made of flame retardant and shockproof synthetic material (Glass
reinforced polyester or similar).

All Metallic parts of housings may be made of VENDOR STANDARD material, suitable for
the specified environmental condition, such as aluminum w/ epoxy or polyurethane coating,
subject to Company approval. Painting of housings and enclosures shall be performed in
line with the project specification.
Housings shall provide sufficient clearance for maintenance operations and shall be fitted
with quick-opening device.
All printed circuit cards shall be protected against corrosion, humidity and fungus by means
of appropriate varnish coating and gold plated connectors (including those located within
control and equipment rooms).
All electronic or electric field instruments shall be tropicalized and marine corrosion proof.
The marine corrosion proof will not be considered for instruments at ON-SHORE service.
3.29.2 Interference
All instruments and micro-processor based system shall meet the following Radio
Frequency Immunity (RFI) requirements that shall be tested at the acceptance test and
performance check-out stage:
TEST 1 SYSTEM RESPONSE

5W, VHF/UHF hand held transmitter No effect
operated at 1 meter from each side
panel/door, with all doors and covers in
place.
Test 2
As above with all doors opened but No damage to equipment. Analogue values
internal covers and printed circuit cards in shall not change by more than 1 % Full
place Scale Deflection. No other effects on
operation.
Test 3
As above, with a randomly selected input As test 2.
or output module per cabinet on an
extender card, if appropriate and with all
CPU and memory cards and their covers
in place. Alternatively, with one
input/output module removed.
The transmitters employed for test purposes shall be of the following frequency range: 50
MHz to 500 MHz.
Basic reference standard is IEC 801 (Part 3) for design and manufacturing considerations.
The above RFI immunity requirements are to be considered as a minimum.

3.29.3 Instrument Passive Protection against Fire

When installed in outdoor location, the following cables shall be fire resistant according to
NEC Article 300:
1. Cables for all fire and gas system detection circuits,
2. Cables for energized to trip Safety systems (ESS, F&G) circuits,
All other cables shall be flame retardant according to NEC Article 200
3.30 Nameplates
An identification nameplate shall be provided on each instrument furnished. Nameplate shall
be permanently attached using SS 316 bolts and nuts. Adhesives shall not be used.
Nameplates for field mounted instruments shall be of 16 gauge SS 316 plate.
Panel mounted instruments shall be provided with phenolic or stainless steel nameplates on
the rear in addition to white background black letter phenolic nameplate in the front, which
has with tag number and service description.
Nameplate on control valves shall show the valve size, valve trim style and serial number
and year of manufacture as a minimum.
Nameplates shall be in English. Lettering shall be 3/16 inch minimum height.
Nameplates shall be of SS 316 and are to be fixed with SS 316 bolts and nuts.
3.31 Installation
Detail instrumentation installation requirement is specified in specification for Instrument
Installation Document No.:BCD3-000-47-SPC-4-008-00 Rev.1.
Inspection and test related to each kind of instrument shall be stated in the particular
specifications. Unless otherwise specified, instruments and/or instrument systems may be
inspected at all stages of the design and fabrication.
3.32 Shipping Preservation and Storage of Instrumentation Equipment

After delivery and identification on site, all instrumentation equipment and associated
installation equipment shall be stored in a dedicated instrumentation warehouse with
adequate environmental conditions including HVAC as necessary.
Instruments shall generally be stored in their original packing.
The instruments shall be stored and handled with the greatest care.
The flanges and other connections shall remain as long protected as possible.
Special care shall be taken to prevent foreign materials (sand, dust, water, etc.) from
entering the instruments during shipping/storage.
When the instruments are temporarily removed from the warehouse, they shall be returned
to the warehouse in their original packing.
The installation equipment shall be dedicated to instrumentation installation and shall not be
assigned to other use.
All instruments shall be adequately preserved once permanently installed on site.
In particular, any electronic equipment shall be protected against humidity, high temperature
and dust.
The instrument cables shall be delivered and stored on drums.

Drums shall be stored on a plain surface with one layer of drum only, without risk of
mechanical damage.
3.33 Tropic Proofing Requirements

Generally Vendor's standards method of Tropic Proofing shall be applied for individual
instruments with the following minimum requirements:
a. Proper design and construction
b. Selection of materials not susceptible materials to fungus growth or moisture.
c. Treatment of any susceptible materials with a protective coating to prevent the
Growth of fungus. To prevent corrosion and to prevent absorption of moisture.
In addition to above, data sheets for individual instruments shall be referred for further
details.
4.0 INSPECTION AND TESTING

For Third (3rd) Party inspection and testing, refer to "Specification for 3rd Party Inspection
Services", Document No.:BCD3-000-40-SPC-4-001-00.
In addition to the above, the following inspection, examination and testing will be required.
4.1 Inspection and Testing

Inspection will be required on all aspects of the Vendor's documentation in relation to any
"As Built" drawings, applicable certification and test material certificates.
Individual calibration testing of instruments shall be required as well as pressure testing,
NDT, leak testing as stated in the particular specifications, data sheets. The following test &
inspection shall be included to the instruments / package instruments, as the minimum:
a. Visual Check
b. Functional Test
c. Calibration
d. Factory Acceptance Test
4.2 QA/QC Certification

Test reports shall be established for the complete supply:
4.2.1 QA/QC certification for visual controls

QA/QC certification for visual controls shall be performed on:
I. Type and model
II. Material
III. Rating
IV. Scale
V. Operating range
VI. Labeling
VII. Painting
VIII. Dimensions (flanges, threading, piping)
IX. Accessibility

X. Certificate of conformity for equipment used in hazardous areas

XI. Calibration certificates
4.2.2 QA/QC certification for Functional

Instrument manufacturers shall test and calibrate each instrument at the factory against the
specification and data sheet requirements.
Each instrument shall have a calibration certificate which shall include:
I. Measure 5 points : 0%, 25%, 50%, 75%, 100% (increase and decrease),
II. Threshold set point and dead band (increase and decrease).
III. Statistical controls shall be performed using the following sampling quantities:
• 10% of the supply for local indicators (manometers, thermometers etc.)
standard Control valves, temperature element,
• 20% of the supply for transmitters, local controllers or panel controllers and
other non listed items,
• 100% of the supply for flow orifices and non-standard control valves.
If a defective item is found, a new sample shall be controlled and if a new defective item is
found, the whole set shall be rejected.
4.2.3 QA/QC certification for Factory Acceptance Tests (FAT)

QA/QC certification for Factory Acceptance Tests (FAT) shall include:
I. A general review of drawings documents at their latest issue (as built),
II. Instrument calibration tests,
III. Location and installation checking of all instruments according to instrument hook-
up standard,
IV. Installation supporting and access to equipment,
V. Instrument functional tests,
VI. Energy consumption checking,
VII. Wiring checking,
VIII. Noise level checking,
IX. Grounding checking,
X. Grounding networks segregation checking,
4.2.4 The Site Acceptance Tests (SAT)
The Site Acceptance Tests (SAT) shall be performed as per the requirements of the
relevant pre-commissioning and commissioning specifications.
4.2.5 Integrated System

For integrated system such as the Process Control System, ESS, FDS, metering system,
etc. the related acceptance tests and check-out are fully described in the relevant
specifications. Refer to these documents for further information.

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TABULATION OF REVISED PAGES

PAGE REVISIONS PAGE REVISIONS

BCD4-000-47-SPC-4-006-00 Rev.0 Page 2 Updated – 19-May-10

1.0 PURPOSE ........................................................................................................5

BCD4-000-47-SPC-4-006-00 Rev.0 Page 3 Updated – 19-May-10

3.24 Distributed Control System .........................................................................16

BCD4-000-47-SPC-4-006-00 Rev.0 Page 4 Updated – 19-May-10

2.0 CODES STANDARDS AND SPECIFICATIONS

American National Standard Institute (ANSI):

American Petroleum Institute (API):

BCD4-000-47-SPC-4-006-00 Rev.0 Page 5 Updated – 19-May-10

API RP 551 Process measurement instrumentation.

American Society for Testing and Materials (ASTM):

American Society of Mechanical Engineers (ASME):

International Electro-technical Commission (IEC):

International Standards Organization (ISO):

International Society of Automation (ISA):

BCD4-000-47-SPC-4-006-00 Rev.0 Page 6 Updated – 19-May-10

National Electrical Code (NEC):

BCD4-000-47-SPC-4-006-00 Rev.0 Page 7 Updated – 19-May-10

BCD4-000-47-SPC-4-009-00. Specification for Outdoor Control Panels and Consoles

3.1 Environmental Conditions

3.2 Units of Measurement

BCD4-000-47-SPC-4-006-00 Rev.0 Page 8 Updated – 19-May-10

• Temperature : Degree Fahrenheit (°F)

3.4 Technical Requirements

BCD4-000-47-SPC-4-006-00 Rev.0 Page 9 Updated – 19-May-10

3.4.1 Instrument Accessibility

3.4.2 Instruments Process Connections

BCD4-000-47-SPC-4-006-00 Rev.0 Page 10 Updated – 19-May-10

TABLE - 1: REQUIREMENTS FOR INSTRUMENT TAPPINGS/CONNECTIONS

CONNECTION TO EQUIPMENT Connection to Vent. &

3.5 Shutdown Valves and Blowdown Valves

3.6 Control Valves

3.7 Pressure Regulating Valves

3.8 Pressure Safety & Relief Valves

BCD4-000-47-SPC-4-006-00 Rev.0 Page 11 Updated – 19-May-10

3.9 Rupture Disc

3.10 Pressure Instruments

3.11 Temperature Instruments

3.12 Flow Instruments

3.13 Level Instruments

3.14 Vibration Monitoring Instruments

3.15 Tropic Proofing For Instruments

3.16 Instrumentation and Fire / Gas Detection Cables

3.17 Local Instrument Control Panels for Outdoor Installation

3.18 Control Room Instrument Panels and Consoles

BCD4-000-47-SPC-4-006-00 Rev.0 Page 12 Updated – 19-May-10

3.19 Instrumentation for Packaged Equipment

3.20 Pig Signal

3.21 Electrical Safety

3.21.2 Panel Ground Structure

3.21.3 Electrical Shock Hazard

BCD4-000-47-SPC-4-006-00 Rev.0 Page 13 Updated – 19-May-10

3.22 Grounding System

3.22.1 Protective Grounding System (PG)

BCD4-000-47-SPC-4-006-00 Rev.0 Page 14 Updated – 19-May-10

3.22.2 Reference Ground System (RG)

3.22.3 Intrinsic Safety Ground System (ISG)

3.23 Lightning Surge Protection System

BCD4-000-47-SPC-4-006-00 Rev.0 Page 15 Updated – 19-May-10

3.24 Distributed Control System