Control Engineering Design Criteria
Control Engineering Design Criteria
Control Engineering Design Criteria
APPENDIX 10E
APPENDIX 10E
The purpose of this appendix is to summarize the codes, standards, and standard design criteria and practices that will be used during the project. The general control design criteria defined herein form the basis of the design for the control systems of the project. More specific design information is developed during detailed design to support equipment and erection specifications. It is not the intent of this appendix to present the detailed design information for each component and system, but rather to summarize the codes, standards, and general criteria that will be used. Section 2.0 summarizes the applicable codes and standards and Section 3.0 includes the general design criteria for general conditions, instruments, modulating type control systems, motor controls, and control equipment locations.
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-1
Other recognized standards will be utilized as required to serve as design, fabrication, and construction guidelines when not in conflict with the above listed standards. The codes and industry standards used for design, fabrication, and construction will be the codes and industry standards, including all addenda, in effect as stated in equipment and construction purchase or contract documents.
b. c.
d.
e.
10E-2
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
shipment. Owner approval of information displayed on control screens is required. See Section 4.4 for additional information on FAT. f. g. h. The failure of any transmitter or switch will not shutdown more than one engine. Each Reciprocating Engine has its own control system and a failure of the DCS/PLC system power supplies will not shutdown more than one unit. Mechanical equipment on standby status will automatically start upon a trip of the operating equipment.
Local control and key engine indication will be provided at each engine. All instrumentation and systems will be designed to provide safe and reliable operation of each Unit in accordance with all applicable codes and standards. Main and redundant process transmitter inputs will be provided for critical control loops. Inputs will be brought into different I/O modules for integrity. Current-to-pneumatic (I/P) converters will be used to provide the interface between the electronic control signals and pneumatically actuated control valves. The converters will be responsive to the basic control signals for the system and will have a 3-15 psi output. Feedback from I/P converters mounted on control valves will be sent to the DCS/PLC for control system tuning purposes. Actual Line valve position feedback will be from position transmitters provided for split range control valve applications only, to provide CRT indication for the operators. The control system will be designed to require a minimum of operator action. The control system will include all necessary logic to change the operating mode for selector stations safely under various operating conditions. The control system will be designed to ensure transfer from manual to automatic and vice versa with no operator balancing or upset in the individual control loops. All backup pumps should be able to auto-start from the DCS/PLC on primary pump trip, low suction pressure, and low discharge pressure, at a minimum. The Contractor will provide Owner with a master set of the Contractors and vendors wiring drawings; reciprocating engine and BOP DCS/PLC control system configuration, cabinet arrangement, and power distribution drawings; instrument index; instrument and control valve data sheets; and P&IDs marked with all as-started up changes. All as-started up changes will be incorporated into the final drawings, documents, etc., which are to be submitted to the Owner before Substantial Completion. Project control system will be capable of day-ahead programming of key events (i.e. turning over unit to California ISO remote dispatch). The Contractor will be fully responsible for the interface design with the California ISO remote dispatch system. The Project will be operable from the control room by a single operator under all normal conditions from minimum to full load. The Project will also be remote started, operated, and shutdown and will be under AGC control.
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-3
10E3.1.1Performance Requirements
The system will be properly protected from voltage surges that normally occur in a power plant. Inputs, outputs, and other connections will meet the surge withstand requirements of ANSI C37.90a. The devices will have input to output isolation, shielding, separation of circuits, surge suppression, and other measures to meet these provisions. The system will operate satisfactorily without air-conditioning and with ambient temperatures from 40F to 110F at a relative humidity of 20 percent to 95 percent, non-condensing.
10E-4
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
The operating staff at the Project will be kept to a minimum. Therefore, a high level of automation and reliability is required. Each system will be capable of operating on full automatic. Fail-in-place lock-up features upon loss of air or signal will be provided as appropriate for the application. The DCS/PLC will alarm all abnormal process and operating conditions, system component failures, loss of air on critical control valves, etc., to ensure safe and efficient operation of the Unit. Alarms will also be provided to meet the requirements of all Applicable Laws and Applicable Standards. The operator will have the ability to tag out equipment (fans, pumps, valves, dampers, etc.) from the CRTs for work performed by maintenance personnel. When a piece of equipment is tagged out by the operator, the operation of that device by the control system will be inhibited in the system logic. The graphics displays will indicate when a device is tagged out.
10E3.1.6 Power
The failure of a power feed will to the DCS/PLC control systems will not shutdown more than one engine. The primary feed will be 24-Vdc for the control system, and 120-Vac with UPS for the WOIS system. A failure of a power supply will not affect system operation. Failure of any power supply will be alarmed on the CRTs on the main control room and Project maintenance personnel will be capable of replacing power supplies with the system on-line. Modular power supplies may be provided as a substitute for 100 percent power supplies provided they are
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-5
supplied on an N+1 configuration per cabinet. In addition, loss of any battery backup power should be alarmed in the DCS/PLC.
10E3.1.9 Printers
The system will include color graphics-capable quiet printers. Three printers and stands are required. One printer will be dedicated to alarms. Alarms will be printed in red. Cleared alarms will be printed in black. The other printer will be for logs and graphic displays printing.
10E-6
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
Sufficient spare rack and cabinet space will be available at shipment to expand the logic capacity and I/O capacity of each subsystem by at least 10 percent by adding the appropriate modules and equipment.
All cabinet ground buses will be grounded to building steel. Wire markers on both ends of each wire that is longer than 12 inches will be provided with indelible designations in accordance with the DCS/PLC suppliers wiring diagrams.
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-7
10E3.2.1.2 Logging
The system will log pre-selected variables at one hour intervals beginning at 1:00 AM. Values will be printed at the end of each 24-hour period at midnight on the log printer. The variables will consist of calculated values, averaged values, integrated values, instantaneous values, weight-averaged values, or the maximum value for the time period.
10E-8
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
The variables and the exact format of the log will be agreed to by the Parties. Data will be logged on sheets in column form with data for any given variable tabulated in one vertical column. The data currently being accumulated for the log will be protected in case of system failure. The log program will automatically re-initiate the accumulation of data following a system fail over without loss of data.
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-9
the operation of the Reciprocating Engine cylinders, main gas admission valve duration and timing through the Reciprocating Engine control systems. The DCS/PLC will be fully interfaced with the Reciprocating Engine control system. Critical control and protection/trip functions will be hardwired between DCS/PLC and Reciprocating Engine control system. The communication interface to the Reciprocating Engine control system will be provided in accordance with Reciprocating Engine manufacturers requirements for DAS functions and non-critical control signals. The Contractor will be responsible for complete interface between the DCS/PLC and the Reciprocating Engine control systems. The DCS/PLC will interface to the Reciprocating Engine control system to manage the following analog and digital Reciprocating Engine control functions: Startup sequencing through synchronization. Speed and load control. Safety control including: Automatic safe shutdown (ramp down) Selected shutdown (ramp down). Emergency shutdown (fuel shutoff).
The Contractor will provide sufficient manual control capability for Reciprocating Engine speed, generator voltage, and excitation such that a single operator can control the Project from the main electrical panel. Inputs for fuel gas flow to each Reciprocating Engine will be provided.
10E3.3 Testing
A standard factory acceptance test (FAT) of the complete control package including all software, hardware, graphics, and alarming will be provided. The FAT will be performed in the factory by the Contractor and witnessed by the Owner or Owner representative before shipment. See Section 4.4 for additional information on FAT.
10E3.3.1 Tools
One complete set of all special tools, software, and appurtenances required for maintenance and operation will be furnished with each system. The Contractor will itemize the special tools and software that will be furnished. If no special tools and software are required, the Contractor will make a clear statement to this effect before Substantial Completion. Any such tools required will become the property of the Owner.
10E-10
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
furnished for the Project. Refer to section on Documentation for the detailed requirements for the Instruction Books and Operating Manuals.
The system will be sized and constructed to provide a transit time from the stack probe to the analyzer no greater than 6 minutes. This transit time will including the time the analyzer requires to achieve a stable reading after a 95 percent step change in sample value in both the upscale and downscale directions (re: 40 CFR Part 75, App. A 6.4 Cycle Time Test criteria).
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-11
All of the analyzers, data logger, and manual control switches for each unit will be housed in a single standard 19-inch rack. Rack space will not be shared between generating unit systems. The space for pumps, filters, chillers, and other items may be shared between unit systems, but each item must be clearly identified by unit. The CEMS will be complete with analyzers, data logging, calibration gases, etc. At Substantial Completion, the Contractor will furnish a 6-month supply of certified gases in rechargeable cylinders for each flue gas constituent to be monitored. This includes calibration gases for the daily zero and span calibrations, and the low, medium and high range linearity gasses. Each gas cylinder will be supplied with an appropriate two-stage regulator and will be connected to the sample transport system. All tubing on the exterior of the CEMS building will be 316 stainless steel tubing or tubing with a stainless steel jacket. These cylinders will become the property of the Owner and remain on the Project site. Spare parts for both CEMS and Data Acquisition System will be provided.
10E-12
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E3.4.6 Documentation
Installation, operating, and maintenance instructions will be provided by the Contractor for each item in the CEMS system and building. These instructions will be provided both in hardcopy and on a CD-ROM. Hardcopy manuals may be scanned into Adobe Acrobat 3.0 or later and then included on the CD-ROM. Classroom and hands-on training will be provided.
10E3.4.7 Shipping
The complete CEMS will be shipped to the site assembled with all the CEMS apparatus, analyzer subsystem, sample transport system, and interior shelter features mounted in place.
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-13
The workstation computer will include the following items at a minimum: A current Pentium 4 or equivalent processor, with a minimum 512 MB RAM, 32X CD ROM, 4 mm tape backup, 80-GB hard drive, CD RW drive, 8MB AGP video, Ethernet card, and 56K modem. 21-inch video display terminal, high-resolution color monitor (SVGA or superior - 1600 x 1200 at 75 Hz-26mm dot pitch). Report printer All interconnecting cables. Full duplex Ethernet connectivity/capability for Project LAN connection.
The workstation computer, CRT, printer and other equipment will be mounted on a workstation/desk with an accompanying printer stand. This workstation will be in its own space in the Project control room.
10E3.4.10.1 Software
The system program will provide the following features: Multi-task operation such that data can be collected in background mode allowing report generating or data editing in foreground mode. Printer backup such that a printer failure will not cause the program to stop. All printer output is to be stored, so that when the printer is ready, the system will print in sequence all reports generated during the time the printer was unavailable. Auto-restart such that should a system failure occur, it would automatically restart itself when the failure is cleared. This feature eliminates the need for any manual reloading of the system program. Editing of all data on reports such that the revised data will be included in any requested report, unless otherwise specified.
10E-14
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
Internal clock/calendar with automatic leap year and operator-controllable daylight savings time adjustments. Keylock feature to limit access to program parameters using multi-level passwords. One level for operators to call up reports One level for engineers to edit report One level for technicians for diagnostics, etc.
Ability to download data in ASCII format. Capability of expanding if other emission monitoring points or types is added. Program backup on a CDROM for reloading should the system fail. The actual source code should be supplied in hard copy format. Software with standard REASONS CODES Video display terminal, to provide Real-time view of all measured and calculated parameters Engine (each) monitor status Visual alarm indication of potential emission standard violations, excessive monitor calibration drift, or monitoring system failure Graphics & trending
Hourly data transfer to the non-volatile memory or C hard drive and then daily transfer to the D hard drive. Software to support remote interrogation by modem Users Manual based on Owner specific software Calculations, record keeping, reporting, bias adjustment, automatic data substitution procedures, and other requirements set forth in 40 CFR Part 75. CEMs Data Acquisition System software will be the Contractors standards and will, to the maximum possible extent, comply with the requirements of this specification.
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-15
10E-16
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
The following units of measurement will be used in process measurement and control. English units are preferred, but metric units may be used when in common practice:
Parameter Temperature Pressure Units of Measurement degrees Fahrenheit (o F) pounds per square inch gauge (psig) inches of water column (in wc) or (inH2O) pounds per square inch absolute (psia) inches of mercury absolute (HgA) Level General Tank Gauge Deviation from normal level Flow Liquids gallons per minute (gpm) pounds per hour (pph or #/hr) Gases and Vapors Standard cubic feet per minute at 60 OF (SCFM) Standard cubic feet per hour at 60 OF (SCFH) Percent Gallons
Solids
Water Sampling PH Specific conductivity Cation conductivity Degassed cation conductivity Dissolved oxygen Silica or sodium Oxygen scavenger Sulfate, phosphate, chloride pH (pH Units) S/cm S/cm S/cm parts per billion (ppb) parts per billion (ppb) parts per billion (ppb) parts per billion (ppb)
Permanently attached stainless steel tags will be purchased with all major instrument equipment. Each tag will carry the item tag number. This tag is in addition to the nameplate, which provides the manufacturers model number and other data. Thermocouple and test wells will have the material of construction stamped on the well. If tag numbers are assigned to these wells, the number will also be stamped on the well.
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-17
Instruments in vapor or gas service will generally be mounted above the sensing point. Instruments in liquid, steam, or condensable vapor service will generally be mounted below the sensing point. If accessibility, visibility, or clearance requirements preclude either of these situations, provisions will be made in the instrument piping configuration to ensure proper operation of the instrument. Close-coupled line-mounted pressure and temperature gauges are mounted above the sensing point and are excluded from the aforementioned. Instrument root valves at piping or equipment connections will be accessible from grade, platform, stairway, or permanent ladder. Indicating instruments that must be visible for automatic control adjustment or manual operation will be visible from the adjustment or operating point. If plot or piping arrangement precludes this, other provisions will be made for indication at the adjustment or operating point. Indicating instruments not in the above category will be visible from operating aisles or passageways. Instruments will be located so that required clearances are maintained for walkways, accessways, and operation and maintenance of valves and equipment. Blind transmitting instruments will generally be line-mounted as near the sensing point as practical. Instruments will not be line-mounted when temperature or vibration from hydraulics or operating equipment will affect the operation of the instruments or cause damage to instrument piping. Local recording and/or control instruments, except displacer-type level controllers and flange-mounted transmitters, will generally be remote mounted at grade or outside platform handrails. When practical, remote-mounted instruments will be grouped and have common supports. Instrument piping will generally be routed through pipeways and areas provided for the routing of plant piping, and the piping will be routed such as to protect it from damage during plant operation and maintenance. Routing of instrument piping will be controlled by the Field Control Systems Supervisor or Engineer. Instrument piping will be supported from pipe supports, pipe, and any other permanent structure, except as follows: Instrument piping will not be supported from uninsulated hot (125F and above) or cold (40F and below) pipes. Instrument piping supports will not be welded to stress-relieved equipment or internally lined equipment. Instrument piping supports will be sufficient to maintain the piping in a neat manner. Instrument process piping having horizontal runs greater than 5-0 or combined horizontal and vertical runs greater than 10-0 will be supported. The maximum length of unsupported tubing at a bend will be 4-0.
All instruments and instrument process lines subject to freezing will be heat traced, filled with seal fluid, and purged or otherwise protected from freezing. Preference will be given to heat-traced sensing lines and heated enclosures. The instruments and process lines will be identified on the P&IDs.
10E-18
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-19
Pressure gauges will be provided with either a blow-out disk or a blow-out back. Alternately, separate safety valves may be used. Pressure gauges will have acrylic or shatterproof glass faces. Differential pressure instruments will normally be of the manometer type, either liquid-filled, bellows, or force-balance type according to requirements. Pressure gauge elements in contact with process fluid will normally be 316 stainless steel, except where the process requires a special material. Elements above 1,000 psig will be bored instead of drawn with threaded and backwelded connection to the socket and tip. Bronze elements will normally be used for air service. Sockets and tips will be stainless steel for stainless steel bourdon tubes, and brass for bronze bourdon tubes, in accordance with manufacturers standards. Overpressure protection will be 1.3 times the maximum tube rating to prevent permanent set or loss of calibration from continuous overpressures. For services of 0 to 60 psi and below, wide bourdon tubes will be furnished with external gauge protectors. Gauges will be vacuum protected. Ranges will be so specified that the gauges normally operate in the middle third of their scales. Gauges on pump discharges will be specified for over-range protection beyond the pump shut-in pressure or relief valve setting. Gauges on vessels will be specified for overrange protection not less than 1.2 times the vessel design pressure. Cases for gauges in the process area and in process service will be solid front, phenolic with a screwed ring, or plastic turret type with a snap ring. Outdoor cases will be weatherproof, and metal cases will be protected with weather-resistant black paint. Indoor instruments (inside buildings) are not required to have weatherproof cases. Weep holes will be provided on the case bottom of all gauges located in humid areas unless the case already has sufficient ventilation. Diaphragm protectors will be used where necessary to protect gauges from corrosive fluids. They will have 0.5-inch NPT screwed or flanged connections in accordance with piping specifications.
10E-20
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
Thermocouples general application will normally be magnesium-oxide insulated sheathed type. Thermocouple will be constructed with a 316SS sheath of 0.25-inch diameter. Thermoelectric properties, temperature limits, and limits of error of thermocouples and thermocouple extension wires will conform to ANSI Standard MC 96.1. Identification of thermocouples will be by a wired-on metal tag indicating the code or tag number. Thermocouple heads will be the cast aluminum type with an internal grounding screw. Conduit connection will be 0.75-inch. Connection to the thermocouple assembly will be 0.5-inch NPT. In general, temperature instruments will have scales with temperature units in degrees Fahrenheit. Exceptions to this are electrical machinery resistance temperature detectors (RTDs) and transformer winding temperatures, which are in degrees Celsius. RTDs will be either 100-ohm platinum type or 10-ohm, copper, three-wire circuits (R100/R0-1.385), and ungrounded. The element will be spring-loaded, mounted in a thermowell, and connected to a cast aluminum head assembly. Thermal-filled system instruments will be gas or liquid filled stainless steel capillary type. Material will be a minimum of ANSI Type 304 stainless steel machined from bar stock in a tapered configuration. Other materials may be specified as required by the piping specifications. The alloy used will meet the process metallurgical requirements. The temperature process connections will be 1-inch NPT where screwed connections are allowed by the piping classification. Where flanged connections are required by the piping classification, they will be designed to mate against a 1.5-inch raised face or ring joint flange in accordance with the piping specifications. Weld in thermowells will be at least 1-inch diameter. Special protecting tubes for high temperature applications of chrome iron, incoloy, or other special materials will be used as required by the temperature and the process materials. Thermowells in combining streams will be a minimum of 10 pipe diameters downstream of the junction for liquid services and 30 pipe diameters for vapor services. Brass plug and chain will be provided with all test wells. Thermowells will be designed to avoid root stress failure due to vibrations induced by wake vortices. Where the standard thermowell is designed to withstand the maximum fluid velocity permitted in the piping design standards, individual wake frequency calculators are not required. Dials of 3-inch diameter may be used in mechanical equipment lube and seal oil service or other auxiliary service. Installation of thermocouples, thermowells, test wells, and thermometers will be in accordance with utility and good engineering practice unless otherwise specified.
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-21
Transmitter Output will be 4 to 20 ma dc. Direct operated type level controls (e.g. ball float, mechanically linked valve) will be used on utility service only. Special level problems will arise periodically and will require special level measuring devices such as internal displacers or floats, bubblers, and electronic types (capacitance, ultrasonic, nuclear, conductive, or electrical resistance).
10E-22
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-23
Flow transmitters will be the essentially zero volume displacement differential pressure type. Bodies will normally be carbon steel with stainless steel internal trim, unless other materials are required for the particular services. Overrange protection equal to the body rating will be provided. Wherever possible, the maximum differential range in inches of water will not exceed the static absolute pressure in psia in a compressible fluid application. Span will be continuously adjustable over at least a 5:1 ratio. Variable area flow meters may be used for small flow rates where local indication is required. They may also be used where rangeability, nonlinearity, viscosity, or the hazardous nature of the fluid makes the differential-pressure-type instrument unsatisfactory. They will normally be the armored type with magnetic pick-up, except for water and air below 200 psig and 1-inch-or-smaller lines where glass tubes may be used. All glass tube area meters will have front and rear plastic guard plates. Positive displacement meters will be used to measure those flows where a highly accurate integrated flowing quantity is desired.
10E-24
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
Averaging pitot tubes will be used where the pipe diameter is too large for acceptable orifice plate design in applications such as pump minimum flow bypass control, or where normal straight pipe requirements are not met. The element may have two pipe diameters of straight pipe upstream and downstream mounted in a plane parallel to the maximum disturbance. Other types of flow elements should be considered where their use is desirable and the above-mentioned elements are not applicable. Integral orifice meters (combination primary element-measuring device) will normally be used for meter runs of less than 1.5 inches with a suitable strainer upstream of the meter. Eccentric type orifice plates will be used for fluids containing two phases. The eccentric-type orifice plates will have the bottom of the orifice bore flush with the bottom ID of the pipe. Eccentric orifice plates will be used only in horizontal runs.
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-25
control room or on a local panel will normally be thermocouple actuated with cold-junction compensation and be completely adjustable. Flow switches for direct operation by process fluids may be of the sight flow, rotameter, or paddle type for low accuracy requirements. Orifice plate and differential-pressure type will be used for high accuracy requirements. Solenoid valves will normally be used as pilots to actuate other instruments directly connected to process fluids. Valve bodies for solenoid valves will follow the piping specifications when used in process lines. Manufacturers standard brass will normally be used on air service. When outdoor installations are required, they will meet the area classification and will be weatherproof. Preferred voltage rating is 120 Vac. Coils for solenoid valves will be hi-temp molded and encapsulated and specified for continuous duty at rated voltage and frequency. Coils for direct current will be supplied with internal spike suppressors.
All necessary calibration and operating gases will be provided including gas cylinders and regulators. CEMS equipment will be according to manufacturers recommendations. Analyzers requiring gases for continuous operation will be provided with dual facilities for uninterrupted service. Calibration standards and facilities will be supplied for zero and span check where specified. Protected outdoor storage racks adjacent to the analyzer houses will be provided for the carrier and calibration gas cylinders (including inventory) and their associated regulators. Process sample regulators will also be located on the outside of the analyzer houses.
The sample systems will be designed to deliver clean, representative samples to the analyzers at the proper temperatures, pressures, physical conditions, and flow rates.
10E-26
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
All wetted components will be 316 stainless steel, or equivalent, unless other materials are required to minimize contamination and corrosion. Main line class pipe may be used in high-temperature samples. Appropriate measures will be taken to prevent plugging of sample lines due to freezing, condensation, or solids. Where sample recovery systems are required, provision for drains will be made in the building design. Transportation time from sample point to analyzer will be less than 2 minutes for chromatographs and less than 1 minute for other analyzer types. Fast circulating loops and/or bypass lines will be used to achieve fast response times except where such a design would cause EPRI guidelines to be violated or sample composition to be changed. For fuel gas samples, the pressure will be reduced at the sampling point to increase the velocity through the sample system and reduce time lag (except in CEMS equipment where the manufacturers recommendation are to be followed). All sample and bypass lines will have flow indicators, such as rotameters. Bypass flows and discarded samples will be routed to chemical safe drains or vented safely to atmosphere. Adequate facilities will be provided to protect against unwanted backflow, overpressure, or other abnormal conditions. When sample conditioning components require heating, they will be located inside a heated and insulated cabinet or enclosure.
The analyzer and sample system will be vendor assembled and pretested in the vendors shop before shipment, unless otherwise specified. Electrical wiring of analyzers will conform to the National Electrical Code and applicable local codes. For large instruments such as analyzers that cannot be mounted in an explosion-proof box, air purging may be required. ISA RP-12.4 should be followed. If possible, the analyzer houses should be mounted in nonhazardous areas. Process control loops that include an analyzer will normally be cascaded. In some cases where the analyzer output is continuous and not delayed, direct control may be provided. Holding circuits will be provided when the analyzer output is intermittent. The output of this device may be used for trend recording in addition to providing a signal for a control loop. Converters to provide a current or pneumatic output will be provided if required.
Reciprocating non-control measurements will be available through the DCS/PLC, if possible. Such information will include the following: Bearing metal thermocouples Bearing drain thermocouples
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-27
10E-28
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
accessibility, repair, and calibration in place, for easy access to the rear of the instruments (if needed), and for disconnection without resorting to cutting, burning, or welding. Instrument supports will not be mounted on or connected to handrails, stairways, or machinery or to any equipment subject to movement under load. All pipe-mounted temperature and pressure indicators and bridle-mounted level gauges will be mounted so as to provide direct visual readings from operating decks and accessibility for maintenance. If pipe-mounted instruments are subject to freezing, they will be appropriately freeze protected. Electronic process transmitters will be two-wire. Temperature, pressure, and differential-pressure transmitters, switches, and transducers will be mounted on either stands or racks or in local instrument cabinets as long as instruments are properly protected, including environmental protection (heat traced). Instruments that can be logically grouped will be installed on racks or in local instrument cabinets. Instrumentation, accessories, and all other equipment will be located and mounted such that calibration, maintenance, and removal work can be performed on any one piece of equipment without disturbing another. Adequate clearance will be provided so that calibration, adjustments, and connections are easily accessible without need of instrument removal. All instrument covers will be provided with adequate clearance space for removal. Equipment will be arranged such that work can be performed easily, without need for special tools. Instruments and manifold valves will be easily accessible for calibration. All pressure and differential-pressure transmitters will be installed with instrument manifolds. All differential transmitters will be installed with three-valve or five-valve manifolds. Two valve manifolds will be used for all static pressure transmitters. Orifice flanges and flow nozzles or venturis will be oriented such that taps are horizontal, neither above nor below the centerline of the pipe. Flow orifice plates will be installed only after applicable piping has been flushed or blown down. Each pressure connection, except for relief valves, will have a root valve. Double block and bleed valves are required for relief valves that would require an entire plant outage to service. Each temperature connection will have a well that will withstand the maximum system pressure and whose velocity rating to withstand vibration exceeds the maximum fluid velocity to which the well may be subjected. Thermocouple material will be compatible with the main process pipe material. All external electrical connections of junction boxes and cabinets will be made to terminal blocks. The wiring and terminal blocks for different voltage classes will be physically separated in order to minimize electrical noise and hazard to personnel. Terminal blocks will be provided with marker strips. Instruments will be mounted in a manner that prevents vibration effects. Snubbers or other suitable damping devices will be provided for pulsating services.
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-29
10E3.7.2 Instrument Cabinets and Local Control Panels 10E3.7.2.1 Local Instrument Cabinet Installation
Instrument cabinets will be secured to structural steel or to concrete. Cabinets will be electrically grounded. Bolting to bare or galvanized metal will be used for attaching a ground strap. Instrument cabinets will have sufficient clearances for the required blowdown piping and headers, door swing radius, etc., and the cabinets will be completely accessible for maintenance. The cabinets will be installed and anchored in place so that they are level, plumb, and properly aligned in accordance with the above mounting requirements. Cabinets will not be supported by handrails. All instrument line penetrations into instrument cabinets will be through bulkhead fittings (couplings). Bulkhead couplings will be supplied on instrument cabinets for each instrument location. Top entry of instrument cabinets or instrument cabinet junction boxes is prohibited. Bottom entry is the preferred method for conduits.
10E-30
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
The Contractor will touch up all equipment finish paint coats damaged while under the control of the Contractor. The Contractor will use paint of the original specification color and finish.
10E3.7.2.6 Marking
The Project will include stamped stainless steel tags for process root valves, each instrument, and panel or cabinet.
All tubing will be ASTM 213 type 316 stainless steel (except in acid service), both seamless and annealed and properly rated for temperature and pressure applications. Copper tubing will be ASTM B-75 and will be permitted only for instrument air service inside instrument cabinets and (individual) branch applications. Tubing will be installed so that sags and low spots are avoided. All tubing cuts will be made with a roller-type tubing cutter and will be deburred. All tubing bends will be made with an approved mechanical bender to avoid flattening of the bends. All tubing fittings will be compression type, Parker Hannifin CPI or Swagelok. The use of flared-type fittings will not be accepted and is strictly prohibited. Pipe dope or Teflon tape will not be used on the tubing-side threads of compression fittings. Tubing runs requiring support will be run in Tube Track. Each instrument sensing line will terminate with a main line class blowdown valve mounted adjacent to or below the instrument cabinet. Instrument sensing lines for draft measurements and other very low-pressure and differential-pressure measurements will be 1-inch minimum O.D. Instrument sensing lines for other pressure and differential pressure measurements will be 0.5-inch minimum O.D. The length of the sensing lines will be kept as short as possible to minimize instrument sensing errors Tubing used to connect instruments to the process line will be 3/8 inch OD x 0.049 WT seamless soft annealed copper ASTM B-75 (Instrument air service) or 3/8 inch OD x 0.065 WT SS seamless ASTM A-213 or A-269 Type 316 RB 80 Hardness as necessary for the process conditions. Instrument tubing fittings will be the compression type. One manufacturer will be selected for use and be standardized as much as practical throughout the Project. Differential pressure (flow) instruments will be fitted with three-valve manifolds, while two-valve manifolds will be specified for other instruments as appropriate.
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-31
Instrument installation will be designed for correct sensing of process variable. Taps on process lines will be located in such a manner that sensing lines do not trap air in liquid service or liquid in gas service. Taps on process lines will be fitted with a shutoff (root or gauge valve) close to the process line. Root and gauge valves will be main-line class type valves. Instrument tubing, including freeze protection, will be supported in both horizontal and vertical runs as necessary. Expansion loops will be provided in tubing runs subject to high temperatures. The instrument tubing support design will allow for movement of the main process line.
10E-32
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
An air filter pressure regulator with outlet gauge will be supplied for each individual instrument air user. The air filter pressure regulators will be mounted on the instrument air piping near the end user using a flexible hose connection between the regulator and the end user. All instrument air piping and tubing will be purged of extraneous material by blowing clean, dry, oil-free air through the system before final connection. All pipe-threaded fittings will use either Loktite, pipe sealant with Teflon, or Teflon tape to seal the connection. The use of lead-base pipe dope is not acceptable.
PO062006001SAC/344005/062560001 (HBRP_APP10E.DOC)
10E-33