Instrumentation Design Basis

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT)
DESIGN BASIS INSTRUMENTATION AND CONTROL
ADDAR Specialty Chemical Production Plant, Jubail

(Greenfield Project)
Project No.
Document No.
Date
: P002429-001
: 2429.1-00-IC-DAB-001
: 06-09-2013
L&T Integrated Engineering Services

LARSEN & TOUBRO LIMITED
L&T Knowledge City, SEZ (IT/ITES)
rd
3 Floor, West Block-II
N.H No. 8, Vadodara-390019
Gujarat, India
Fax: +91 265 670 5353
www.Lnties.com
Doc. No. 2429.1-00-IC-DAB-001
Page 1 of 49

SYNOPSIS
This document presents the Design Basis for Instrumentation & Control for the Specialty Chemical
Production Plant, Liquid Sulphur Dioxide (SO2) Plant, Centralised Utility Building and Offsite Storage
facilities. This Design Basis shall be used for detailed engineering design of this project.
PROJECT P002429-001 ADDAR SPECIALITY CHEMICAL PRODUCTION PLANT

REV
DESCRIPTION
ORIGIN
REVIEW
L&T-IES
DATE
APPROVAL
VS/RD
MM
SBA
15-02-2013
Issued for Design
KD
MM
SBA
25-03-2013
Re-issued for Design
KD
MM
SBA
30-03-2013
Re-issued for Design
KD
MM
SBA
06-09-2013
Issued for client comments
Doc. No. 2429.1-00-IC-DAB-001
CLIENT
DATE
APPROVAL
Page 2 of 49

DISCLAIMER
This report has been prepared on behalf of and for exclusive use of ADDAR and is subject to and
issued in accordance with the agreement between ADDAR and L&T-IES. L&T-IES accepts no liability
or responsibility whatsoever for it in respect of any use or reliance upon this report by any third party.
Copying this report without the permission of ADDAR or L&T-IES is not permitted.
Doc. No. 2429.1-00-IC-DAB-001
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Table of Contents
1
Introduction
Scope of Document
General Information
3.1
Abbreviations
3.2
Units of Measurement
3.3
Reference Documents
3.4
Legends
9
9
10
11
11
Codes, Standards, Specifications and Regulatory Requirement

4.1
General
4.2
Codes and Standards
4.3
Client Specifications and Standards
4.4
Regulatory Requirements
4.5
Statutory Requirements
12
12
12
15
15
15
Environmental and Geotechnical Data

5.1
Site Conditions
5.1.1 Wind
5.1.2 Earthquake (Based on local regulation)
5.1.3 Temperature
5.1.5 Barometric Pressure
5.1.6 Rainfall
5.1.7 Altitude
5.2
Site Information
16
16
16
16
16
17
17
18
18
General Basis of Design
19
Hazardous Area
7.1
Certifications
7.2
Classification
7.3
Protection Type
7.4
Accessories
7.4.1 Intrinsic Safety Barriers
20
20
20
20
20
20
Instrument Air & Power Supply

8.1
Instrument Air Supply
8.2
Power Supply
22
22
22
Operation and Control Philosophy
23
10
Field Instrumentation
24
11
Electronic Transmitter
26
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12
Flow Measurement
12.1 Orifice Plate
12.2 Flowmeter Types
27
27
28
13
Level Measurement
13.1 Level Gauges
13.2 Level Switch
13.3 Level Transmitters
30
30
30
31
14
Pressure Measurement
14.1 General
14.2 Pressure Gauges
14.3 Pressure Switches
14.4 Pressure Transmitters
32
32
32
33
33
15
Temperature Measurement
15.1 Temperature Gauges
15.2 Resistance Temperature Detector (RTD)
15.3 Thermocouple
15.4 Thermowells
15.5 Temperature Transmitter
35
35
35
36
36
36
16
Analytical Instruments
37
17
Weighing Instruments
38
18
Valves
18.1 General
18.2 On/Off Valves
18.3 Control Valve
18.4 Solenoid Valves
18.5 Limit Switches
39
39
39
39
40
40
19
Cables
19.1 Cable Type
19.2 Cable Specification
19.3 Cable Glands
19.4 Cabling Philosophy
41
41
41
42
42
20
Junction Box
43
21
Control and Automation System
44
22
Cabinet and Enclosures
46
23
Cable Trays
47
24
Installation
24.1 Instrument Installation
24.2 Cabinet Installation
48
48
48
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25
Spare Philosophy
49
List of Tables
Table 3-1 Commonly Used SI Units .................................................................................... 10

Table 4-1 Commonly Used Standards ................................................................................ 12
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Introduction
Arab House for Industrial Consultancy a business unit of ADDAR GROUP (hereinafter
referred to as ADDAR) plans to design and execute grass root project for Specialty
Chemical (SA) Production Plant with annual capacity of 6000 MT in Jubail Industry city,
Kingdom of Saudi Arabia (KSA). Along with this facility, ADDAR is also setting up 15000 MT
per year Sulphuric Acid Plant, 4000 MT per year Liquid Sulphur Dioxide (SO2) Plant and 450
Nm3/hr capacity Hydrogen Plant for own consumption. In addition to above mentioned four
Process Plant Buildings, The project will have Centralised Utilities, off-site Storage,
Administrative Buildings and Infra-structure facilities.
Larsen & Toubro Integrated Engineering Services (hereinafter referred as L&T-IES) shall
provide detail engineering services for two process plants namely, Speciality Chemical Plant
& Liquid Sulphur Dioxide (SO2) Plant, Centralised Utilities, Off-site Storage and Administrative
Buildings & Infra-structure.
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Scope of Document
The purpose of this document is to cover the design basis, standard engineering practices for
Instrumentation and Control shall be followed during engineering activities.
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General Information
3.1
Abbreviations
The list of abbreviations and their meanings that are used in this document are as mentioned
below:
ANSI
American National Standard Institute
API
American Petroleum Institute
AWG
American Wire Gauge
ASTM
American Society for Test and Materials
MPMS
Manual for Petroleum Measurement Standards
ASME
American Society of Mechanical Engineers
ATEX
Atmosphere Explosives
BS
British Standard Institute
ISA
Instrumentation, Systems and Automation Society
IEC
International Electro-Technical Commission
ISO
International Organization for Standardisation
BASEEFA
British Approval Service for Electrical Equipment in Flammable

Atmospheres
NACE
National Association of Corrosion Engineers
NEMA
National Electrical Manufacturers Association
NFPA
National Fire Protection Association
FCI
Fluid Control Institute
DCS
Distributed Control System
PLC
Programmable Logic Controller
EMC
Electromagnetic Compatibility
FM
Factory Mutual
UPS
Uninterrupted Power Supply
IP
Ingress Protection
HART
Highway Addressable Remote Transducer
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3.2
SASO
Saudi Arabian Standards Organisation
L&T IES shall confirm during detailing
**
ADDAR to confirm/specify
Units of Measurement
Units of measurement shall be in accordance with ISO requirements and refer to:
BS ISO 1000 SI Unit Recommandations,
BS 350 Conversion factors for units.
A list of commonly used SI units in process calculations is shown in the Table 3-1 below:
Table 3-1 Commonly Used SI Units
Unit Name
Kilogram per centimetre
square(gauge)
bar(gauge)
Millimetre bar (gauge)
Cubic metre
Litre
Normal Cubic metre
Degree Celsius
Hertz
Joule
Kilogram
Tonne
Inch
Milimeter
Meter
Metre per second
Milligram per litre
parts per million
Millisecond
Second
Minute
hour
Newton
Ohm
Square metre
Square cm
Square mm
Doc. No. 2429.1-00-IC-DAB-001
Quantity
Notation Standard
Pressure
Kg/cm2(g)
bar (g)
mmbar(g)
3
Volume
Temperature
Frequency
Energy
Mass
Length
Velocity
Concentration
Time
Force
Resistance
Area
m
litre
3
Nm
o
C
Hz
J
kg
t
Inch ()
mm
Mtr
m/s
mg/l
ppm
ms
s
min
hr
N
m2
2
cm
mm2
Page 10 of 49

Unit Name
Millivolt
Volt
Watt
Cubic Metre /Hour
Liter/minute
Kilogram / Hour
Kilogram /Cubic Meter
Millimetre water column
Micro Siemens/m
Percentage
Ampere
Percentage
Centipoise
3.3
Quantity
Electrical potential
Power
Volumetric Flow
Mass Flow
Density
Differential Pressure
Conductivity
Relative Humidity
Current
Level
Viscosity
Notation Standard
mV
V
W
m3/ hr
l/min
Kg/hr
Kg/ m3
mmWC
S/m
%
A
%
cP
Reference Documents
Section 13420
Royal Commission Guideline Specification For Instruments
Section 13430
Royal Commission Guideline Specification For Boxes, Panels
And Control Centers

Section 13440
Royal Commission Guideline Specification For Indicators,
Recorders And Controllers

Section 13450
3.4
Royal Commission Guideline Specification For Central Control
Legends
Following marks shall be checked in the relevant bracket:
[ ]
Applicable
[ M]
Mostly Applicable
[ P]
Partially Applicable
Not Applicable
[ D]
To be decided at the Detailed Engineering stage
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Codes, Standards, Specifications and Regulatory Requirement
4.1
General
The precedence applying for use of the Codes, Standards, Specification, Regulatory &
Statutory requirements for this project is as follows:
Statutory & Regulatory Requirements
International Standards
L&T-IES Specifications and Standards
Accepted Industry Practice / Good Engineering Practice
In the event of an inconsistency, conflict or discrepancy between any of the Standards,

Specifications and Regulatory, the most stringent and safest requirement applicable to the
project will prevail to the extent of the inconsistency, conflict or discrepancy. Any
inconsistencies critical to the design shall be brought to the attention of the Project Manager
for resolution with ADDAR.
4.2
Codes and Standards

The design, construction and installation shall comply with relevant recognised international
standards and recommended practices such as those from ASME or API. If no standard is
specified the default shall be the relevant L&T-IES / Royal Commission Standard.
The following codes and standards shall be used for process design.
Table 4-1 Commonly Used Standards
TITLE
Pipe Threads, General Purpose (Inch)
Metallic Gaskets for Pipe Flanges-Ring-Joint, Spiral-Wound, and
Jacketed
Flow Equations for Sizing Control Valves
Face-to-Face Dimensions for Flangeless Control Valves (ANSI
Classes 150, 300 and 600)
REF
ANSI B1.20.1
ANSI B16.20
ANSI/ISA 75.01.01
ANSI/ISA 75.04
Control Valve Terminology
ANSI/ISA 75.05.01
Face-to-Face Dimensions for Flanged Globe-Style Control Valve
ANSI/ISA 75.08.01
Bodies (ANSI Classes 125, 150, 250, 300 and 600)

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TITLE
REF
Inherent Flow Characteristic and Rangeability of Control Valves
ANSI/ISA 75.11.01
Face-to-Face Dimensions for Flanged Globe- Style Control

Valve Bodies (ANSI Classes 900, 1500 and 2500)
Hydrostatic Testing of Control Valves
Face-to-Centre line Dimensions for Flanged Globe- Style Angle
Control Valve Bodies (ANSI Classes 150, 300 and 600)
Considerations for Evaluating Control Valve Cavitations
ANSI/ISA 75.16
ANSI/ISA 75.19.01
ANSI/ISA 75.22
ANSI/ISA RP75.23
Graphic Symbols for Process Displays
ISA S5.5
Quality Standard For Instrument Air
ISA S7.3
Manual of Petroleum Measurement Standards - Chapter 3 Tank Gauging Section 1A: Standard Practice for the Manual
API MPMS 3.1A
Gauging of Petroleum and Petroleum Products.

Tank Gauging Section 1B: Standard Practice for Level
Measurement of Liquid Hydrocarbons in Stationary Tanks by
API MPMS 3.1B
Automatic Tank Gauging

Temperature Determination - Static Temperature Determination
Using Fixed Automatic Tank Thermometer.
API MPMS 7.4
Chapter 16 - Measurement of Hydrocarbons Fluids by Weight or

Mass - Section 2: Mass Measurement of Liquid Hydrocarbons in
API MPMS 16.2
Vertical Cylindrical Storage Tanks By Hydrostatic Tank Gauging

Installation of Refinery Instruments and Control Systems Part 1 Process Instrumentation and Control
API RP 550 P1
Process Measurement Instrumentation
API RP 551
Pipe Flanges and Flanged Fittings
ASME B16.5
Face-to-Face and End-to-End Dimensions of Valves
ASME B16.10
Surface Texture (Surface Roughness, Waviness and Lay
ASME B46.1
Temperature Measurements
Thermowell installations in power and process piping
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ASME PTC 19.3

ASME PTC 19.3 TW
Page 13 of 49

TITLE
Bourdon Tube Pressure & Vacuum Gauges
Recommendations for Design of Scales and Indexes on

Analogue Indicating Instruments
REF
BS 1780
BS 3693
Instrumentation Cable
BS 5308
Specification for Electromagnetic Flow Meters
BS 5792
Code of Practice for Instrumentation in Process Control

Systems: Design and Practice.
Electromagnetic Compatibility. Generic Immunity Standard Part
BS 6739
EN50082-2
2: Industrial Environment
Control Valve Seat Leakage
FCI 70-2
Test on bunched wires or cables
IEC 332
Degree of Protection Provided by Enclosure
IEC 60529
Electrical Apparatus for Explosive Gas Atmosphere

IEC 60079-14
Electrical Installation in Hazardous Area
Standards Control Valve Manifold Designs (Carbon Steel Valves
only) for Maximum Flexibility
Specification, Installation, and Calibration of Turbine Flow meter
Petroleum Liquids and Liquefied Petroleum Gases-
ISA RP4.2
ISA RP31.1
ISO 5024
Measurement-Standard Reference Conditions

Measurement of Fluid Flow by Means of Pressure Differential
Devices-Part 1:
ISO 5167-1
Orifice Plates, Nozzels and Venturi tubes Inserted in Circular
Cross-Section, Conduits Running full
Measurement of Fluid Flow-Estimation of Uncertainty of a FlowRate Measurement
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ISO 5168
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TITLE
Petroleum and Natural Gas Industries-Materials for Use in H2S-
REF
NACE MR 01 75
Containing Environments in Oil and Gas Production-ISO 15156Part 1, Part 2, and Part 3
Enclosures for Electrical Equipment (1000 Volts Maximum)
National Electrical Code
4.3
NEMA 250
NFPA 70
Client Specifications and Standards

It is understood that ADDAR have no specific requirements on their specifications and
standards. Therefore, applicable national (Royal Commission) / International standards shall
be used.
4.4
Regulatory Requirements
All aspects of the Project shall comply with the requirements of the latest versions of all
relevant regulatory requirements i.e. Royal Commission.
4.5
Statutory Requirements
ADDAR shall be responsible for obtaining all statutory approvals, as applicable for all
instruments and control systems.
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Environmental and Geotechnical Data
5.1
Site Conditions
5.1.1 Wind
PARAMETER
Jubail Value
Principal wind direction (for March-November)
N,NNW
(For December-February)
-, NW
Max wind speed (m/s)
42.7
5.1.2 Earthquake (Based on local regulation)

Design specifications for seismic
Seismic Zone - 0
5.1.3 Temperature
5.1.3.1 Ambient Temperature
PARAMETER
Jubail Value
Maximum Recorded shade temperature (C)
52C
Average daily maximum dry bulb temperature
42.1C
Design Dry Bulb Temperature in Summer
46.0C
Design Wet Bulb Temperature in Summer
30.0C
Average daily minimum temperature
11.1C
Maximum temperature on record
49.9C
Minimum temperature on record
2.9C
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5.1.3.2 Design Temperature
5.1.4
PARAMETER
Jubail Value
For Air Compressor / Blower (C)
60
For Air Coolers (C)
60
Minimum Design Temperature for all Equipments (C)
Relative Humidity Air

PARAMETER
Jubail Value
Summer season relative humidity (%)
10 - 50
Winter season relative humidity (%)
10- 100
Daily average relative humidity (%)
38 - 65
At maximum design temperature of 60C, the relative humidity to be considered for design is
50%. At normal design temperature of 34C, the relative humidity to be considered for design
is 75%.
5.1.5 Barometric Pressure

PARAMETER
Jubail Value
Maximum barometric pressure (mbar)
1011.0
Minimum barometric pressure (mbar)
1008.8
Annual Average barometric pressure (mbar)
1010.0
5.1.6 Rainfall
PARAMETER
Jubail Value
Monthly maximum rainfall in one hour (mm)
145
Annual maximum rainfall in 24 hours (mm)
225
Design rainfall in one hour (mm)
50
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5.1.7 Altitude
Altitude above Mean Sea Level (M.S.L): 2.58 Mtr
Lowest Low Water Level (L.L.W.L.) below mean sea level: 0.6 Mtr
Highest High Water Level (H.H.W.L.) above mean sea level: 0.6 Mtr
5.2
Site Information
STATE
Jubail Value
Nearest Important Town & Distance
Jubail, 25 km
Nearest Railway Station & Distance
Dammam, 110 km
Nearest Port & Distance
Jubail, 20 km
Nearest Airport & Distance
Dammam, 105 km
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General Basis of Design

Control System:
[ ]
DCS
Field Circuit Design:

[ ]
Non-Hazardous area
[ D ]
Hazardous area
Electric Rules for Control & Acquisition:

[ D]
IEC
Following points must be considered while designing basic instrumentation & control system:i)
Instrumentation shall be complete in every respect and liberal to the extent of

providing data on all operations and variables sufficient for the safe, efficient and
easy operation of the plant.
ii)
The design and installation of instruments shall be generally in accordance with

ISA/API
recommended
practices
and
other
applicable
standards.
Material
specifications and practices shall, in general, conform to appropriate ASTM or

equivalent standards.
iii)
All instruments and equipment shall be suitable for use in a hot, humid and tropical
industrial climate in which corrosive gases and/or chemicals may be present. As a
minimum, all instruments and enclosures in field shall be dust proof and weather
proof to IP-65 and secure against the ingress of fumes, dampness, insects and
vermin. All external surfaces shall be suitably treated to provide protection against
corrosive plant atmosphere.
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Hazardous Area
7.1
Certifications
7.2
[ ]
Certification
[ D ]
BASEEFA
[ D ]
ATEX
[ D ]
PTB
[ D ]
FM
Classification
[ M ]
7.3
Hazardous area, Refer hazardous area drawing
Protection Type
[ ]
Intrinsically Safe - Exia( to suit specified hazardous areas)
[ ]
Increased Safety - Exe( to suit specified hazardous areas)
[ ]
Weather Proof - IP 65 (minimum) for field instruments/ junction boxes
7.4
Accessories
7.4.1
Intrinsic Safety Barriers

[ ]
Analog Input
[ ]
Analog Output
[ ]
Digital Input
[ ]
Digital Output
Following points must be considered while designing an intrinsically safe system:i)
All intrinsic safety barriers shall be active isolating type only and shall have isolation
between input, output and power supply.
ii)
Barriers must be selected based on entity concept. Cable parameters shall also be
considered while matching entity parameters.
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iii)
The signal transfer accuracy of barrier shall be at least equal to or better than the
transmitter selected.
iv)
Each instrument in the hazardous area and the intrinsic barrier shall be certified for
intrinsic safety by a statutory authority.
v)
Each input and output in a loop shall have separate barrier. No barrier shall be
shared between two loops or input/outputs.
vi)
Any intrinsically safe loop requiring any device to be connected in the hazardous side
permanently or temporarily shall also be intrinsically safe.
vii)
Configuration tools whenever required for any intrinsically safe item which forms part
of the intrinsically safe item shall also be certified intrinsically safe.
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Instrument Air & Power Supply
8.1
Instrument Air Supply

i)
Moisture free Instrument air shall be distributed to various equipment of C&I system
like pneumatic control valves, on-off valves etc. Pneumatic instrument connections for
signal and air supply shall be 1/4" NPT.
ii)
Minimum design pressures of 5 bar (g) for instrument air to pneumatic actuator of the
valves shall be provided.
8.2
Power Supply
i)
Most of the field instruments shall be 2-wire, 24 V DC operated, loop powered.
ii)
Electrical power supply shall be standardized at 120 V AC+/- 5%, 60 Hz+/-1%, via
redundant Uninterrupted Power Supply (UPS).
iii)
Non-UPS power supply shall be used for other utilities such as panel lighting.
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Operation and Control Philosophy

i)
The complete operation, control and monitoring of Speciality Chemical Plant, Liquid
Sulphur Dioxide (SO2), Utilities and Offsites shall be performed from DCS located in
the DCS room. The DCS shall consist of operator work stations and engineering work
stations as required to be finalised during detailed engineering. The safety integrity
level (SIL) shall be SIL 1 as a minimum.
ii)
iii)
Redundancy in control system shall be considered at following levels:
Controller Level
I/O Card level (for critical signals)
Power supply level
Communication level
Client Server level
Sulphuric acid plant shall be operated from dedicated localised PLC located in the
respective area,. Signals from sulphuric acid plant PLC shall also be sent to DCS for
data acquisition purpose.
iv)
The Hydrogen Generation Plant shall be operated from a dedicated localised PLC
placed in the rack room. An engineering/operating workstation shall be supplied &
installed by Hydrogen Generation package vendor in the Control Room for controlling
and monitoring the plant.
v)
The interface of the above mentioned localised PLC with DCS shall be done with
Fieldbus protocol (type to be specifically defined during detailed engineering stage).
Fieldbus communication shall be from PLCs /Remote Terminal Unit (RTU) and shall
be directly connected to main DCS.
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10
Field Instrumentation
i)
Field mounted direct actuated flow and temperature switch shall not be used. Instead,
receiver switch/trip amplifier shall be used along with flow element and temperature
element. Whenever specified in job specification, flow and temperature transmitters
may be directly connected to control system to achieve switch action.
ii)
Field instruments shall be as per P&IDs approved by Client during detailed

engineering.
iii)
Ranges for instruments shall be selected in general, such that in normal process
operation the indication is between 40% - 60% of span for linear and 60% - 80% of
span for square root inputs.
iv)
All process switches shall be provided with sealed micro switch contacts rated for the
specified application. Contacts shall be Single Pole Double Throw (SPDT) type
unless otherwise specified. Contacts used shall be gold plated.
v)
Ranges for process switches shall be selected, in general, such that the set point falls
preferably in the middle 30% of full adjustable range i.e. the set point shall fall
between 35% - 65% of adjustable range.
vi)
For pressure switches, switch differential shall be selected as per operating

conditions, it shall be less than 60% of difference between set value and operating
value.
vii)
All field instruments, junction boxes and local panels located in hazardous area shall
be intrinsically safe protection, however if intrinsically safe equipment are not
available, then flameproof enclosure as per IEC shall be considered, if flameproof
enclosure is not available then purging must be provided as per NFPA.
viii)
The makes and models of all different types of field instruments shall be standardized
for better inventory control.
ix)
Material for sour service shall be certified in accordance with NACE MR 0175.
x)
All field instruments i.e. transmitters, switches, on-off valves, control valves and
junction boxes shall be provided with SS tag nameplates.
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xi)
For material selection, if any specific material of construction / wetted parts is not
available for the instruments, then superior or suitable alternative materials
compatible with the service fluid shall be used, also while selection it is to be ensured
that dissimilar galvanic corrosion does not cause a decrease in the service life of the
equipment.
xii)
For field instruments located in outdoor area, suitable mounting brackets and weather
canopies for protection from direct sunlight/rain shall be provided.
xiii)
All circuit grounds, shields and drain wires shall be connected to the 'system ground'
bus which is isolated from 'AC mains earth'.
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11
Electronic Transmitter
Type:
[ ]
Smart Type
Signal:
[ ]
4 to 20mA
Accuracy:
[ M ]
+/- 0.1% or better
Enclosure:
[ ]
Weather proof IP-65 or better
Power Supply:
[ ]
24 VDC, 2 wire-loop powered
Cable Entry:
[ ]
NPT
Programming Unit Calibrator:

[ ]
Yes, HART
Display:
[ ]
LCD (4-digit display)
Hand-Held HART communicator shall be provided for online maintenance and calibration of
the electronic transmitters.
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12
Flow Measurement
12.1
Orifice Plate
Sizing Calculation:
[ ]
As per ISO 5167
Plate Dimensions:
[ ]
As per ISO 5167
Plate Material:
[ ]
SS316 or better
Accuracy:
[ ]
As per ISO 5168
Tapping:
[ ]
Corner Tapping (less than 50 mm)
[ ]
Flange Tapping (50 to 400 mm)
[ ]
D, D/2 Tapping (400 to 1000 mm)
Orifice Flanges Material:

[ ]
SS 316 or better
Jack Bolts:
[ ]
Required
Tap Valves:
[ ]
Required
Typical Differential Pressure Ranges:

[ ]
2500 mmWC
[ M ]
500:1250:5000:10000 mmWC
i)
Differential Pressure Range for the orifice meter shall always be selected less than
allowable pressure drop across the orifice.
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ii)
Flow measurement shall normally be carried out using thin square edged concentric
orifice plate mounted between a pair of weld neck flanges for line size 2" and above;
however, for flow measurement in lines less than 2", integral flow assembly shall be
selected.
12.2
Flowmeter Types
Type:
[ M ]
Electromagnetic Type Flowmeter
[ ]
Differential Pressure Type Flowmeter
[ ]
Rotameter
[ ]
Turbine meter
[ ]
Mass flow meter (Coriolis)
[ M ]
Vortex type Flowmeter
Wetted Material:
[ ]
SS316 or better
Mounting:
[ M ]
i)
Remote/Head Mounted
For all conductive fluid (more than 5 S/m) (except gas/steam fluid), corrosive
services, electromagnetic type meter to be used.
ii)
For application where density, temperature and viscosity are required along with flow,
Coriolis mass flow meter shall be used.
iii)
For accurate flow integration for fiscal metering/custody transfer turbine meter/
Coriolis mass flowmeter shall be used.
iv)
For steam application and where high rangeability is required, Vortex type Flowmeter
shall be used.
Doc. No. 2429.1-00-IC-DAB-001
Page 28 of 49

v)
For services where both unidirectional and bidirectional flow measurement is

required, Coriolis type mass flow meter or Electromagnetic type flowmeter shall be
used.
Doc. No. 2429.1-00-IC-DAB-001
Page 29 of 49

13
Level Measurement
13.1
Level Gauges
Type:
[ M ]
Reflex Type
[ M ]
Float operated magnetic type
Wetted Material:
[ ]
SS316 or better
Process Connection:
[ M ]
2 Flange
i)
Reflex type level gauges shall be used for colourless and clean services.
ii)
Magnetic type of level gages shall be used for corrosive, flammable, sour, toxic,
viscous fluid, and in high pressure as well as high temperature applications.
13.2
Level Switch
Type:
[ M ]
Vibrating Fork
[ D ]
Float Type
Wetted Materials:
[ ]
SS316 or better
Process Connection:
[ D ]
1 NPT
Enclosure:
[ ]
Weather Proof IP-65 or better
Electric Signal Cable Entry:

[ ]
NPT
Contact Seal:
[ ]
Hermetical
Doc. No. 2429.1-00-IC-DAB-001
Page 30 of 49

13.3
Level Transmitters
Type:
[ M ]
Differential Pressure Type
[ M ]
Displacer Type
[ ]
Radar Type
[ ]
Ultrasonic Type
Wetted Material:
[ ]
SS316 or better
Process Connection:
[ M ]
NPT Differential Pressure Type LT
[ M ]
2 Flanged RF for Displacer Type LT
[ M ]
3 Flanged RF for Radar Type LT
[ M]
2 NPT for Ultrasonic type LT
Mounting:
[ D ]
i)
Direct (Side or Top mounted as per requirement)

For liquid-liquid interface level measurements, displacer type level transmitters shall
be used. For higher interface level measurement, displacer type shall not be
preferred.
ii)
For corrosive, fouling and services where purging is required, differential pressure
type level measurements shall be used.
iii)
For viscous fluid and solid services, radar type level measurement shall be used. Also
for solid services ultrasonic level measurement shall also be used.
iv)
For Ultrasonic and Radar type level measurement, the range of the transmitter shall
be such as to cover the complete level span of the vessel taking care of blocking
distance and frequency attenuation due to obstructions.
Doc. No. 2429.1-00-IC-DAB-001
Page 31 of 49

14
Pressure Measurement
14.1
General
i)
Pressure measurements installation items such as diaphragm seal, pulsation

dampener, siphon and manifolds shall be provided as applicable
ii)
All pressure gauges with maximum operating pressure exceeding 60 kg/cm(g) and
gauges in toxic service shall be solid front type.
14.2
Pressure Gauges
Sensing Element:
[ ]
Bourdon tube
[ ]
Diaphragm
Measurement Type:
[ ]
Gauge
[ ]
Compound
Sensor Material:
[ ]
Stainless Steel
Dial Size:
[ ]
Front Glass:
[ ]
Shatter Proof
Case Material:
[ ]
Stainless Steel
Process Connection:
[ ]
NPT
Accuracy:
[ ]
+/- 1% of full scale
Enclosure:
[ ]
Doc. No. 2429.1-00-IC-DAB-001
Page 32 of 49

14.3
Pressure Switches
Sensing Element:
[ ]
Diaphragm
[ ]
Bellows
Measurement Type:
[ ]
Gauge
Sensor Material :
[ ]
SS316 or better
Indication Type:
[ ]
Indicating/Non-Indicating (Blind)
Enclosure:
[ ]
Contact Seal:
[ ]
Hermetically sealed
Electric Signal Cable Entry:

[ ]
NPT
Process Connection:
[ ]
NPT
Contact Rating:
[ ]
14.4
2 SPDT rated 5A at 120 V AC, 60 Hz and 1 A (maximum) at 24 V DC
Pressure Transmitters
Sensing Element:
[ ]
Piezoresistive
Measurement Type:
[ ]
Gauge/Differential
Doc. No. 2429.1-00-IC-DAB-001
Page 33 of 49

Sensor Material:
[ ]
SS 316 or better
Enclosure:
[ ]
Process Connection:
[ ]
NPT
[ D ]
2 Flanged RF for Diaphragm Seal Type
Doc. No. 2429.1-00-IC-DAB-001
Page 34 of 49

15
Temperature Measurement
15.1
Temperature Gauges
Sensing Element:
[ ]
Bi-metallic
Dial Size:
[ ]
Case Material:
[ ]
SS316 or better
Accuracy:
[ ]
15.2
+/-1% of full scale
Resistance Temperature Detector (RTD)

Sensing Element:
[ ]
Platinum 100, 3 wire (Duplex)
Sheath Material:
[ ]
SS316 or better
Accuracy:
[ ]
+/- 0.25% or better
Thermowell Connection:
[ ]
NPT
Enclosure:
[ ]

0
RTD shall be used within a temperature range of -200 C to 650 C.
Doc. No. 2429.1-00-IC-DAB-001
Page 35 of 49

15.3
Thermocouple
Type:
[ D ]
Duplex J,K ,E,T (as applicable)
Enclosure:
[ ]
Thermowell connection:
[ D ]
NPT
For higher temperature measurement, Thermocouple shall be preferred.
15.4
Thermowells
Type:
[ ]
Tapered Bar stock (for immersion length up to 500mm)
[ ]
Built up Type (for immersion length more than 500mm)
Thermowell Material:
[ ]
SS 316 or better
Process Connection:
[ D ]
1 Flanged RF
Immersion length (for nozzle length of 200 mm):

[ ]
280 mm (for pipe line size upto 6)
[ ]
320 mm (for pipe line size above 8)
[ ]
400 mm (for all columns/vessels)
Any pipe line size less than 4" nominal bore shall be blown to 4" size to install thermowell.
15.5
Temperature Transmitter
Mounting:
[ ]
Remote Mounted
Temperature Transmitters shall have a built-in linearising function to produce an output linear
to temperature range.
Doc. No. 2429.1-00-IC-DAB-001
Page 36 of 49

16
Analytical Instruments
Analyser Type:
[ M]
pH
[ M]
Conductivity
[ M]
Gas
Accuracy:
[ M]
+/- 0.01 pH for pH analyser
[ M]
+/-1% of full scale for conductivity analyser
[ M]
+/-2% of measured value for Gas analysers
Enclosure:
[ ]
Sample Tubing Material:

[ ]
SS316 or better
Doc. No. 2429.1-00-IC-DAB-001
Page 37 of 49

17
Weighing Instruments
Load Cell Type:
[ ]
Bending
[ ]
Shear (Beam)
[ ]
Compression
Sensing Element:
[ ]
Strain Gauge
Sensor Material:
[ ]
Stainless Steel or better
Sensor Excitation Voltage:

[D ]
5-15 V DC (as applicable)
Accuracy:
[ M]
+/- 0.05%
Enclosure:
[ ]
Doc. No. 2429.1-00-IC-DAB-001
Page 38 of 49

18
Valves
18.1
General
The action of valves on failure (Fail open (FO), Fail Close (FC)) in operating medium shall be
determined by process requirement with regard to safe operation and emergency shutdown
requirements.
18.2
On/Off Valves
Type:
[ M ]
Ball/Plug/Globe (as applicable)
Body Material:
[ ]
According to piping specification and process conditions
Leakage Class:
[ M ]
Class V (as applicable)
Process Connection:
[ ]
Flanged/Wafer (as applicable)
Actuator Type:
[ M ]
18.3
Pneumatically operated
Control Valve
Type:
[ M ]
Globe (as applicable)
Body Material:
[ ]
According to piping specification and process conditions
Leakage Class:
[ M ]
Class V (as applicable)
Process Connection:
[ ]
Flanged
Actuator Type:
[ ]
Pneumatically operated
Air Filter Regulator:

[ ]
Required
Doc. No. 2429.1-00-IC-DAB-001
Page 39 of 49

18.4
Solenoid Valves
Type:
[D ]
Universal/NO/NC
[D ]
Direct/Pilot Acting
Body Material:
[ ]
SS316 or better
Enclosure:
[ ]
Insulation Class:
[ ]
Class H
Solenoid valve shall not be used for process service applications.
18.5
Limit Switches
Type:
[ ]
Proximity
Enclosure:
[ D ]
Contact Seal:
[ ]
Hermetically sealed
Doc. No. 2429.1-00-IC-DAB-001
Page 40 of 49

19
Cables
19.1
Cable Type
Signal and Power Cables:
[ ]
As per IEC/SASO
Separation:
[ ]
300 mm between Power & Instrument/Control cable

2
For Instrumentation Signals (1.5mm ) - Analog and Digital:

[ ]
Single Pair for individual signals
[ ]
Multi pair for multiple signals

2
For RTD Cables (1.5mm ):

[ ]
Single Triad for individual signal
For Thermocouple Cables (20 AWG):

[ ]
Thermocouple Extension cable
For Power Supply (2.5mm2):

[ ]
3 core
For Control Cables (1.5mm2):
19.2
[ ]
2 core for individual signal
[ ]
Multi-core for multiple signals
Cable Specification
Fire Protection:
[ ]
Flame Retardant Low Smoke Zero Halogen
Shielding (for single/multi pair cable):

[ ]
Overall shielding only for Digital Signals
[ ]
Individual as well as overall shielding for Analog Signals
Outer Sheath:
[ ]
PVC Insulated
Doc. No. 2429.1-00-IC-DAB-001
Page 41 of 49

Core Material:
[ ]
Copper
Conductor Insulation:
[ ]
UV-resistant Cross Linked Polyethylene (XLPE)
Screen:
[ ]
Aluminium Mylar tape
Inner Sheath:
[ ]
Polyethylene
Armour:
[ ]
19.3
Round Galvanized Steel
Cable Glands
Type:
[ M]
Stainless Steel
Threading:
[ ]
19.4
NPT
Cabling Philosophy
i)
For all analog and digital signals to/from DCS, instrumentation pair cable shall be used.
ii)
For local push button signals (Electrical Signals), control cable shall be used.
Doc. No. 2429.1-00-IC-DAB-001
Page 42 of 49

20
Junction Box
Material :
[ ]
Die-cast Aluminium alloys
[ ]
Stainless Steel
Mounting:
[ ]
Column
[ ]
Wall
Enclosure:
[ ]
i)
Weather proof IP 65 or better

Separate junction boxes shall be used for the following type of signals:
Intrinsically Safe Analog Inputs/Outputs (4-20 mA)
Non Intrinsically Safe Analog Inputs/Outputs (4-20 mA)
Intrinsically Safe Digital Inputs/Outputs
Non Intrinsically Safe Digital Inputs/Outputs
ii)
Terminal size in junction box shall be suitable for 0.5 mm2 to 2.5 mm2 cables.
iii)
Drain port shall be provided with nozzle & valve assembly for all junction boxes.
Doc. No. 2429.1-00-IC-DAB-001
Page 43 of 49

21
Control and Automation System

Type:
[ ]
DCS Based System
Operator Interface:
[ ]
Workstation based Console
Power Supply:
[ ]
Redundant UPS
Process Interlock Logic:

[ ]
Built in DCS
Redundancy:
[ ]
Controller level
[ ]
I/O Card level (for critical signals)
[ ]
Power Supply level
[ ]
Communication level
[ ]
Client-Server level
Interfacing with Field:

[ ]
Serial Communication / Hard wired
Functional Requirements:
[ ]
Control Algorithm (P, PI, PID, Adaptive, Ratio, Gain control, etc.)
[ ]
Arithmetic and Logic Function
[ ]
Linearisation (Square root Extraction, Flow Computation, Polynomial etc.)
[ ]
Data Acquisition
[ ]
Interlock Logics
[ ]
Alarm Management
[ ]
Historian trending
[ ]
Dynamic Graphics
Doc. No. 2429.1-00-IC-DAB-001
Page 44 of 49

[ ]
Logging & Report Generation
Controller Response Time:

[ D ]
100 ms (for critical signals)
[ D ]
250 ms
Control Processor Loading:

[ ]
Less than 60%
i)
Failure of any one redundant part shall not interrupt other system functions; A failure
can be a hardware failure, software failure, power supply failure or the loss of one AC
feeder in a dual feeder system.
ii)
The switch-over time from primary to back up controller and vice-versa shall be of the
order of one second in case of failure of primary controller.
iii)
All controllers shall have facility for bumpless auto-manual and manual-auto transfer
and set point adjustment.
iv)
Flow, pressure and level controller shall be provided with proportional plus integral
action, while temperature controller with proportional plus integral plus derivative
action.
Doc. No. 2429.1-00-IC-DAB-001
Page 45 of 49

22
Cabinet and Enclosures

i)
The control system cabinets located inside air-conditioned control rooms shall have
appropriate IP rating, totally enclosed, free standing type with a 3mm (minimum), LM5/LM-6 material and dimensions measuring 2200mm (H) x 1200mm (W) x 800mm
(D). Dimension indicated are subjected to change during detailed engineering.
ii)
The cabinets shall have full height front and rear double leaf doors with louvers and
filters, suitable gland plates for top/bottom cable entry, isolated system and electronic
shield earthing buses, eye bolts and lifting hooks, etc.
iii)
The panel surfaces shall be painted with appropriate colour and adequate paint film
thickness.
Doc. No. 2429.1-00-IC-DAB-001
Page 46 of 49

23
Cable Trays
[ D ]
SS 316/ Mild Steel Ladder Cable Tray
[ D ]
Cable trays may be Hot Dipped Galvanised
[ D ]
Galvanized pipe Conduit if required for underground cabling
i)
Cable shall be run through cable tray, duct and trench as applicable during detailed
engineering.
ii)
Instrument and control cables shall not be grouped with power cables particularly
where there is already a possibility of induced pick-up affecting the signal.
iii)
All cable routes shall be fully co-ordinated with the relevant disciplines to preclude
interference of services and structures and ensure that routes do not obstruct correct
and safe access to mechanical equipment for maintenance and repair purposes.
iv)
Cable in hot areas shall have proper heat protection. Flexible conduits shall be
provided wherever necessary.
v)
Cable tray shall run in a two-tier arrangement and the top tier shall be covered.
vi)
Ladder Cable tray shall be most commonly used, perforated cable tray shall only be
considered for branch trays.
vii)
For intrinsically and non-intrinsically safe instrument cable separate cable tray shall
be envisaged. Blue colour tape shall be provided with intrinsically safe cable tray.
Doc. No. 2429.1-00-IC-DAB-001
Page 47 of 49

24
Installation
24.1
Instrument Installation
i)
The flow meter pipe shall be fully supported in both in the vertical and horizontal
orientations and not cause any strain on the flowmeter.
ii)
For electromagnetic type flowmeter, the pipelines must be completely filled.
iii)
Installation of electromagnetic type flow meters shall be avoided close to large

conducting surfaces such as metal supports. The metal objects may interface with the
magnetic field of the flow meter and hence influence its accuracy and its behaviour.
iv)
For pressure instruments installations, siphons shall be used for steam high
temperature applications.
v)
All gauges and switches for pipelines and vessels shall be installed in separate wells.
vi)
Control valve actuating systems and cabling shall not be located in close proximity to
high temperature sources.
vii)
24.2
The control valves shall be installed after the orifice plate in the direction of flow.
Cabinet Installation
i)
All controls, instruments and devices mounted on the front of the control cabinets
shall be flush mounted.
ii)
All panels, cabinets shall be welded or bolted to floor channels, also before
installation of cabinets and desks, the necessary openings and inserts required shall
made on the floor as applicable.
Doc. No. 2429.1-00-IC-DAB-001
Page 48 of 49

25
Spare Philosophy
DCS:
[ D ]
30% of electronic modules (signal conditioning modules, signal distribution

modules, input / output modules etc.) relays, isolators etc. mounted in each
cabinet.
[ D ]
30% of space in the control cabinet for future expansion.
Spare instrument as Engineering Spares:

[ D ]
10% or minimum one of each (range, type) (To be finalised during detailed
engineering)
Doc. No. 2429.1-00-IC-DAB-001
Page 49 of 49

Instrumentation Design Basis

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ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT)

DESIGN BASIS INSTRUMENTATION AND CONTROL

ADDAR Specialty Chemical Production Plant, Jubail

L&T Integrated Engineering Services

Doc. No. 2429.1-00-IC-DAB-001

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT)

PROJECT P002429-001 ADDAR SPECIALITY CHEMICAL PRODUCTION PLANT

Issued for Design

Re-issued for Design

Re-issued for Design

Issued for client comments

Doc. No. 2429.1-00-IC-DAB-001

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT)

Doc. No. 2429.1-00-IC-DAB-001

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT)

Codes, Standards, Specifications and Regulatory Requirement

Environmental and Geotechnical Data

General Basis of Design

Instrument Air & Power Supply

Operation and Control Philosophy

Doc. No. 2429.1-00-IC-DAB-001

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT)

Control and Automation System

Cabinet and Enclosures

Doc. No. 2429.1-00-IC-DAB-001

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT)

Table 3-1 Commonly Used SI Units .................................................................................... 10

Doc. No. 2429.1-00-IC-DAB-001

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT)

Doc. No. 2429.1-00-IC-DAB-001

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT)

Doc. No. 2429.1-00-IC-DAB-001

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT)

American National Standard Institute

American Petroleum Institute

American Wire Gauge

American Society for Test and Materials

Manual for Petroleum Measurement Standards

American Society of Mechanical Engineers

British Standard Institute

Instrumentation, Systems and Automation Society

International Electro-Technical Commission

International Organization for Standardisation

British Approval Service for Electrical Equipment in Flammable

National Association of Corrosion Engineers

National Electrical Manufacturers Association

National Fire Protection Association

Fluid Control Institute

Distributed Control System

Programmable Logic Controller

Uninterrupted Power Supply

Highway Addressable Remote Transducer

Doc. No. 2429.1-00-IC-DAB-001

ADDAR SPECIALTY CHEMICAL PRODUCTION PLANT, JUBAIL (GREENFIELD PROJECT)