RP30 1
RP30 1
RP30 1
Document Title
INSTRUMENTATION AND CONTROL
DESIGN AND PRACTICE
(Replaces BP Engineering CP 52 Sections 26-34)
APPLICABILITY
Regional Applicability: International
(a) guidance on the need and applicability of Instrumentation and Control Systems.
(b) a basis for designing, evaluating and selecting types of Instrumentation and Control
Systems for various duties.
(c) guidance on health and safety aspects associated with the design, installation and
operation of Instrumentation and Control Systems.
AMENDMENTS
Amd Date Page(s) Description
___________________________________________________________________
Section Page
FOREWORD ..................................................................................................................v
1. INTRODUCTION.......................................................................................................1
1.1 Scope...............................................................................................................1
1.2 Application ......................................................................................................1
1.3 Units................................................................................................................1
1.4 Quality Assurance............................................................................................1
2. CONTROL ENGINEERING PRINCIPLES .............................................................2
2.1 Basis for Design...............................................................................................2
2.2 Function of Instrumentation .............................................................................8
2.3 Selection and Installation of Instrumentation ....................................................10
2.4 Instrument Numbering System .........................................................................17
2.5 Units of Measurement and Display ...................................................................18
2.6 Instrumentation Supplied as Part of Packaged Units and Modular Plant............20
2.7 Documentation ................................................................................................21
2.8 Instrument/Electrical MCC Interface ................................................................24
3. SELECTION OF INSTRUMENTATION EQUIPMENT.........................................25
3.1 Selection of Electrical Instrumentation Equipment............................................25
3.2 Cables..............................................................................................................27
3.3 Earthing and Bonding Systems.........................................................................31
3.4 Marshalling and Junction Boxes .......................................................................31
3.5 Cable Tray and Racking ...................................................................................32
3.6 Selection of Pneumatic Instrumentation Equipment ..........................................33
4. INSTRUMENT INSTALLATION .............................................................................34
4.1 Location, Mounting and Accessibility...............................................................34
4.2 Instrument Piping.............................................................................................37
4.3 Pressure Instrument Installations ......................................................................38
4.4 Level Instrument Installations...........................................................................39
4.5 Temperature Instrument Installations ...............................................................40
4.6 Flow Instrument Installations ...........................................................................41
4.7 Analyser Installations .......................................................................................42
4.8 Control Valve Installations...............................................................................43
4.9 Instrument Air Systems ....................................................................................44
4.10 Hydraulic Systems..........................................................................................46
4.11 Control Panels................................................................................................47
4.12 Labelling ........................................................................................................47
4.13 Electrical Installations ....................................................................................48
4.14 Seals and Purges ............................................................................................52
4.15 Winterisation..................................................................................................52
4.16 Tropicalisation ...............................................................................................53
5. EARTHING AND BONDING SYSTEMS.................................................................53
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5.1 General Requirements ......................................................................................53
5.2 Equipment Rooms............................................................................................55
5.3 Field ................................................................................................................56
5.4 Instrumentation on Cathodically Protected Pipelines.........................................56
5.5 SCADA and Computer Type Equipment..........................................................57
5.6 Radio Frequency Cables...................................................................................57
5.7 Surge Diverters (Lightning Protection).............................................................57
6. INSTRUMENT POWER SUPPLIES.........................................................................59
6.1 General Requirements ......................................................................................60
6.2 Security of Supply............................................................................................60
6.3 Design Requirements .......................................................................................61
6.4 Distribution and Protection ..............................................................................62
6.5 Integral Power Supplies ...................................................................................62
6.6 Monitoring and Alarm Systems ........................................................................63
7. INSTRUMENT AIR SYSTEMS ................................................................................63
7.1 General Requirements ......................................................................................63
7.2 Capacity...........................................................................................................65
7.3 Oil Removal Equipment ...................................................................................67
7.4 Air Drying........................................................................................................67
7.5 Distribution......................................................................................................69
7.6 Piping and Tubing ............................................................................................70
7.7 Arrangement within Instrument Panels .............................................................72
7.8 Installation .......................................................................................................73
8. HYDRAULIC POWER SYSTEMS ...........................................................................73
8.1 General Requirements ......................................................................................73
8.2 Design Objectives ............................................................................................74
8.3 Design Considerations for System Components................................................76
8.4 Safety ..............................................................................................................81
8.5 Performance Tests ...........................................................................................82
8.6 Documentation Requirements ..........................................................................83
9. CONTROL PANELS..................................................................................................83
9.1 General Requirements ......................................................................................83
9.2 Selection of Control Panels ..............................................................................84
9.3 Panel Assembly ................................................................................................86
9.4 Drawings and Documentation ..........................................................................88
9.5 Inspection and Testing .....................................................................................88
9.6 Installation .......................................................................................................88
10. CONTROL BUILDINGS .........................................................................................88
10.1 General Requirements ....................................................................................88
10.2 Layout ...........................................................................................................90
10.3 Heating, Ventilation and Air Conditioning (HVAC)........................................90
10.4 Pressurisation.................................................................................................91
10.5 Analyser Houses ............................................................................................91
10.6 Lighting Levels ..............................................................................................91
10.7 Power Supplies for Test Equipment ...............................................................92
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10.8 Cabling ..........................................................................................................92
10.9 Fire and Gas Monitoring ................................................................................93
11. INSTRUMENT DATABASE SYSTEMS ................................................................93
11.1 Objectives ......................................................................................................93
11.2 Selection of System........................................................................................94
11.3 Functional Requirements ................................................................................95
11.4 Data Entry & Manipulation ............................................................................96
11.5 Data Transfer.................................................................................................98
11.6 Security .........................................................................................................99
11.7 System Maintenance.......................................................................................99
FIGURE 4-1 ....................................................................................................................101
TYPICAL AIR HEADER ARRANGEMENT .......................................................101
FIGURE 4-2 ....................................................................................................................102
TYPICAL INSTRUMENT PNEUMATIC MULTITUBE TERMINATION..........102
FIGURE 4-3 ....................................................................................................................103
FLOW INSTRUMENT HOOK-UP CONDENSABLE SERVICE
PREFERRED ARRANGEMENT..........................................................................103
FIGURE 4-4(PAGE 1 OF 2)...........................................................................................104
FLOW INSTRUMENT HOOK-UP LIQUID SERVICE PREFERRED
ARRANGEMENT.................................................................................................104
FIGURE 4-5(PAGE 1OF 2)............................................................................................106
FLOW INSTRUMENT HOOK-UP GAS SERVICE PREFERRED
ARRANGEMENT.................................................................................................106
FIGURE 5-1(PAGE 1 OF 2)...........................................................................................108
TYPICAL EARTHING DIAGRAM FOR INSTRUMENTATION
ONSHORE............................................................................................................108
FIGURE 5-2( PAGE 1 OF 2 ).........................................................................................110
TYPICAL EARTHING DIAGRAM FOR SCADA AND COMPUTER
TYPE EQUIPMENT.............................................................................................110
FIGURE 5-2(PAGE 2 OF 2)...........................................................................................111
TYPICAL EARTHING DIAGRAM FOR SCADA AND COMPUTER
TYPE EQUIPMENT.............................................................................................111
FIGURE 5-3 (PAGE 1 OF 2)..........................................................................................112
TYPICAL INSTALLATION DETAIL FOR CABLE TERMINATION AND
EARTH BONDING ..............................................................................................112
FIGURE 5-3 (PAGE 2 OF 2)..........................................................................................113
TYPICAL INSTALLATION DETAIL FOR CABLE TERMINATION AND
EARTH BONDING ..............................................................................................113
FIGURE 5-4(PAGE 1 OF 2)...........................................................................................114
TYPICAL EARTHING DIAGRAM FOR INSTRUMENTATION
OFFSHORE ..........................................................................................................114
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FIGURE 5-5(PAGE 1 OF 2)...........................................................................................116
TYPICAL EARTHING DIAGRAM FOR TELECOMMUNICATIONS
EQUIPMENT........................................................................................................116
APPENDIX A..................................................................................................................118
DEFINITIONS AND ABBREVIATIONS.............................................................118
APPENDIX B..................................................................................................................120
LIST OF REFERENCED DOCUMENTS .............................................................120
RP 30-1
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DESIGN AND PRACTICE
FOREWORD
The Introductory Volume contains a series of documents that provide an introduction to the
BP Group Recommended Practices and Specifications for Engineering (RPSEs). In
particular, the 'General Foreword' sets out the philosophy of the RPSEs. Other documents in
the Introductory Volume provide general guidance on using the RPSEs and background
information to Engineering Standards in BP. There are also recommendations for specific
definitions and requirements.
General
Section 1 Introduction
Section 2 Control Engineering Principles
Section 3 Selection of Instrumentation Equipment
Section 4 Instrument Installation
Section 5 Earthing and Bonding Systems
Section 6 Instrument Power Supplies
Section 7 Instrument Air Systems
Section 8 Hydraulic Power Systems
Section 9 Control Panels
Section 10 Control Buildings
Section 11 Instrument Database Systems
These Sections reflect the applicable previous sections generally retaining previous content
but in some cases additional sections and sub-sections have been added (see cross reference
list, page vi).
This document specifies all BP's general requirements for instrumentation and control systems
that are within its stated scope and is for use with a supplementary specification to adapt it for
each specific application.
This Recommended Practice gives the basis for the design of instrumentation, control and
associated information systems. It has been developed from cross-Business experience gained
during capital project developments, operations and maintenance; and from equipment
developments and evaluations carried out under BP's Business and Corporate R&D
programme.
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DESIGN AND PRACTICE
The document covers the rapidly developing field of digital technology, and gives guidance on
instrumentation and control system strategy, equipment selection and project development.
Where such codes exist for established elements of the technology, the document guides the
user as to their correct application.
It is intended to review and update this document at regular intervals, because it is essential to
maintain BP's commercial advantage from the effective deployment of the rapidly developing
technology covered by this Practice.
Application
This document may refer to certain local, national or international regulations but the
responsibility to ensure compliance with legislation and any other statutory requirements lies
with the user. The user should adapt or supplement this document to ensure compliance for
the specific application.
(a) The Practice has been revised to the new format to rationalise the sections, and
integrate the commentary into the main test.
(b) The sections have been updated to include references to new standards and reflect
changes in operating practices.
(c) Section numbering has been amended to suit the applicable part.
The cross-reference table at the end of this foreword shows relationships between new
documents and the old CP 18.
Users are invited to feed back any comments and to detail experiences in the application of BP
RPSE's, to assist in the process of their continuous improvement.
For feedback and further information, please contact Standards Group, BP International or
the Custodian. See Quarterly Status List for contacts.
RP 30-1
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LIST OF SECTIONS CROSS REFERENCED TO CP 18
Part 3 Measurement
RP 30-3 INSTRUMENTATION AND CONTROL SELECTION AND USE OF CONTROL AND SHUTOFF VALVES
Part 4 Valves and Actuators
RP 30-4 INSTRUMENTATION AND CONTROL SELECTION AND USE OF CONTROL AND DATA ACQUISITION SYSTEMS
Section I Introduction
Section 2 Digital Systems (new commentary added)
Section 3 Telecommunications
Section 4 Subsea Control Systems
Section 5 + Advanced Control Systems
RP 30-5 INSTRUMENTATION AND CONTROL SELECTION AND USE OF EQUIPMENT FOR INSTRUMENT PROTECTION SYSTEMS
RP 30-1
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1. INTRODUCTION
1.1 Scope
1.2 Application
1.2.2 Reference is made in the text to British Standards. These standards are
generally being harmonised with other European standards and will be
allocated ISO/EN reference numbers. In certain countries, national
Standards may apply. BP shall approve use of other standards.
1.3 Units
1.3.2 Nominal pipe sizes (NPS) are ANSI or API designations which have
not yet been metricated. However, metric DN numbers are given in
brackets.
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Further suggestions may be found in the BP Group RPSEs Introductory Volume.
2.1.1 BP will specify the overall requirements for instrumentation and control
applicable to a particular project. This will include the basis for design,
planned manning levels and the locations and functions of manned
control centres.
This design basis section is intended to give guidance to BP engineers on the areas
to be addressed and issues which may be relevant to the overall scheme. The
nature of plant and projects within the BP Group are many. Therefore, the user of
this document must use his own judgement as to the relevance of any requirement
to a particular job. Detailed guidance may be obtained from the custodian of this
document.
The control system designer must consult with the end user when formulating the
policy to be adopted for the control system for new, expanded or modified plant.
The end user in this context is most commonly the operating management for a
plant or complex. However, at the early design or concept stage of a grass roots
project there may be no operating management and it is necessary to consult with
the client's representative from the appropriate BP Business. It is essential to
establish the responsible organisation or person and work closely with the end user
when developing the outline control system philosophy since they will ultimately
have to approve the approach adopted.
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notably BP Group RP 22-1, 34-1, 42-1, 52-1, 44-1, 12, 4-4, 32-2, 32-3, 32-
4, 32-5, 50-2.
(b) The control strategy for the plant, including the degree of
information gathering and automatic operation necessary to
meet the planned manning levels and operating efficiency
targets specified by BP. This should include any
hardware/software provision for use by plant managers,
supervisors and maintenance staff.
The main control point for the plant must be defined at the pre-project
stage since it potentially has a major impact on cost and engineering
development. If it is unclear at the relevant contract stage, then the
contractor should be asked to address the options versus cost; for BP
approval of the ultimate design route.
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Generally, large and complex plant is operated from control rooms within
individual units from a control room for a group of units in the
geographical area or from a central control room for the whole site or
complex. Offshore, this may be one or more control rooms on one or more
platforms with communications to one control centre (possibly onshore)
for overall supervision.
(c) The location of operator and supervisor control stations and the
facilities thereon, including the methods of providing, displaying
and accessing plant measurements and controls, alarm handling,
and routine and on-demand reports.
The nature of the control facilities and information displayed at any point
will be related to the responsibilities of respective operations personnel
and their ability to control or otherwise influence any situation which
might arise.
The locations and basic layout of the operator and supervisor control
stations is an early decision for the project. It is preferable that the
requirements are specified by BP at the outset. This would entail a
decision on either:-
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The physical layout of the plant in relation to the operating policy will
influence the options open to the control engineer when developing
facilities. The ability to physically distribute modern control equipment
over a wide area can be exploited to save the installed cost (and space and
weight in the offshore scene). Offset against this may be the cost of
providing a suitable environment and services for electronic equipment on
or near the plant. (Refer also to 2.3.3).
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some projects these have to be submitted to authorities for approval. Such
documents should be developed under the authority of the safety or loss
prevention engineer appointed to the project.
(i) The interface with any external equipment (e.g. long distance
radio or telecommunications system, data processing
computers, management information system).
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The power supply and instrument design engineers must evolve a common
policy for the project. Refer also to BP Group RP 12.
* 2.1.4 When a centralised control room is specified, any designed use of local
control rooms as bases for field operators or for use during emergency,
trouble shooting or start-up conditions may impact on the site manning
levels. The contractor's proposals shall be subject to approval by BP.
(b) Existing earthing policy for signals and signal cable screens may
differ from the new equipment manufacturer's recommendation.
Advice should be sought from the control system supplier and, where
necessary, electrical safety consultants (such as ERA, SIRA).
Experience has shown that existing plant has been built (and perhaps previously
modified) to a variety of different standards. These can impact on the economic
options open when connecting existing equipment into new electronic systems.
Compromise is often necessary and well worth addressing before the design
progresses in detail.
* 2.1.6 BP will specify the basis of design for instrumentation to meet statutory
fiscal and accountancy measurements.
BP, as the operator is responsible for all negotiations with customers, commercial
partners, third parties and authorities. It is essential that those within BP
responsible for such agreements are consulted to ensure that all measurements are
identified and specified to the appropriate accuracy; and installed to ensure
RP 30-1
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DESIGN AND PRACTICE
adequate security of data, including data processing and readout. Reference
should be made to the BP Measurement Guidelines (which are regularly amended)
and to BP Group RP 30-2 Sections 5 and 6.
Additional measurements over and above those necessary for basic plant
operation will probably be required (e.g. for energy observation, advanced
control, plant optimisation, oil loss or stock control, or management
information schemes). Early specification of such measurement points
(even if only in outline) could minimise any risk of project cost escalation
and reduce the contractor's future scope for extras.
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(a) Means of recording plant variables for fault diagnosis and for
the prevention of unscheduled shutdown. This should include
real time information on sequence of events and plant trips.
(g) General evacuation alarms with policy for activation and sound
levels and frequencies in relation to surrounding plant.
The purchaser will specify any special regulation and applicable codes
necessary for the provision of:-
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automatic protective action incorporated, shall be subject to
approval by the purchaser.
2.3.3 When the installed cost of signal transmission cable is high or when a
control room or control centre is remote from the plant, the process
interface, control and protective equipment modules should be located
local to the plant with serial communication with operator facilities in
the control room. The ultimate choice of location shall be based upon
an overall economic assessment which shall include:-
RP 30-1
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(d) The provision of any additional facilities necessary for
maintenance.
Offshore there is, in addition, the potential to avoid masses of cabling and
consequent congestion, savings in space and weight, and the capability for
a higher degree of onshore completion and testing. BP Exploration have
commissioned a number of studies which will lead to the publication of a
series of design guidelines, including some for instrumentation.
The designer needs to look carefully at the relative benefits for the various
options applicable to a particular plant and plant configuration in order to
establish the overall optimum economic installed cost.
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(e) Space for control panels and equipment cabinets supplied with
packaged plant.
* 2.3.6 Equipment shall normally be selected on the basis of both field proven
ability for the application and manufacturer's support in the locality of
the plant. The sub-contractors and vendors included on the tender lists
for the supply of equipment and services shall be subject to approval by
BP.
(b) The proven long term spare part availability. Some manufacturers have
failed to support a product over a reasonable working life (say 15 years).
This is particularly true for specialised equipment (e.g. process analysers)
and for electronic systems. In some cases the local representative has
found it uneconomic to continue support where initial sales (and hence
spare part/service) demand was small. In other cases the manufacturer
has been unwilling (or unable due to his sub-suppliers policy) to maintain
support. Products have frequent updates and there have been instances of
versions of a particular model being difficult to maintain only a few years
after purchase.
The main criteria relating to equipment is proof that the equipment (i.e.
model numbers of the main elements on offer) is fully operational on a
similar sized facility. Alternatively, if an updated version is offered and is
advantageous, the designer should ensure that a proven fallback item is
available and compatible.
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The business unit should advise whether the overall installed cost should be on a
capital or whole life cost basis.
2.3.8 System components shall be selected such that the system will fail to a
designated state on component or utility failure.
Generally the more stringent the accuracy requirement, the more costly the
equipment and installation. Too high a specification may limit the choice of
measurement technology employed. Too low an accuracy requirement may result
in the measurement being ineffective for its purpose. It is important to consider the
overall system accuracy (including any manually input data/constants/assumptions)
and not just a single item being purchased.
RP 30-1
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2.3.12 Main plant instrumentation should be electronic and contain facilities to
serially communicate with a supervisory control system.
Any use of optical fibre transmission will inevitably lead to the laying,
jointing/repair and testing of optical fibre cables. The techniques for this are
evolving, but the end user company should be consulted in relation to the necessary
skills or specialist contractors being available locally.
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DESIGN AND PRACTICE
Optical systems may not automatically be considered to be inherently safe. To date
(1993), certified equipment is not available.
2.3.13 Analogue signal transmission shall conform to IEC 381 and IEC 382.
The following levels are preferred:-
(c) Pneumatic signals should be 0.2 - 1.0 bar (ga) (3-15 psig).
Serial transmission is commonly used in distributed control and SCADA systems for
data transmission, status information and operator commands to remote intelligent
devices such as controllers or controller files; and is now the accepted method for
major BP projects.
The use of a serial transmission link between the key elements in basic control or
protection of the plant should be avoided. The design should include automatically
initiated systems at the local level with commands (e.g. manual shutdown) only
transmitted. Where serial transmission within a critical system cannot be avoided,
a high overall system availability using redundant channels of communication is
normally essential. Typical applications may be protection of pipelines or remotely
operated satellite production platforms.
The use of serial transmission between 'Smart Transmitters and Valves' and process
controllers must be carefully applied. Problems may occur with interference to
other analogue loops in the same multicores, and there will be problems in
obtaining alternate supplies with the same protocols. There are potential
advantages in serial communications between 'Smart Transmitters' and flow
computers as the errors associated with the additional DAC/ADC units within the
transmitter and flow computer will be removed.
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* 2.3.15 The design of electronic equipment and its installation shall ensure that
plant operation is not impaired by electromagnetic (EMI) interference.
BP will specify the EMI frequencies and radiation levels to be
expected. Instrument system design should minimise the necessity of
hand-held portable radios for maintenance or operations in control
equipment areas. (See also Section 3 of this Recommended Practice
and BP Group RP 30-8).
* 2.4.1 The instrument numbering system used on any plant or plant expansion
or modification shall be subject to approval by BP at an early stage of
the contract. Each item of equipment shall be identified by a unique tag
number. The method used shall be based on ISA S5.1 but take into
account:-
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(b) Existing practice and site preferences at the BP operating centre
concerned.
Items of equipment not covered by ISA S5.1 such as fire and gas
systems, HVAC systems, power supply units, equipment racks and
marshalling cabinets shall be identified using a similar method.
2.4.2 P&I diagrams should show all items of instrumentation, each item being
identified by its unique tag number. For diagram clarity, complex
control systems should be identified on detail drawings, cross
referencing between the master and detail.
* 2.4.3 Documentation for batch and sequence systems shall include a logic
diagram and a flow chart or a ladder diagram. The methodology and
the symbols used shall be subject to approval by BP. Refer also to 2.7
of this Section.
* 2.5.1 BP will specify the units of measurement. These should follow ISO
1000, but may be modified to comply with local or national variations
or existing site practice.
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output and controller status shall be displayed as a minimum
requirement.
Symbols or VDU's should generally be to ISO 3511, and BS 1553 where applicable.
2.5.4 Refer to BP Group RP 30-5 Section 2 for the requirements for alarm
displays.
2.5.7 Rate of flow should be displayed directly in engineering units per unit
of time. Display of data on simple analogue display instruments
without a calculation or linearisation facility may be on scales of 0-10
square root or 0-100 linear with a multiplying factor.
RP 30-1
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2.5.10 Level in storage tanks shall be displayed in accordance with BP Group
RP 30- 2 Section 6.
2.5.12 Recording of data and events should be provided by the use of a digital
storage system which may stand alone or be integrated with a video
based digital control or computer system. This shall include facilities
for:-
(b) Display of real time and historical trend data at the operator's
station, with data and time discrimination adequate for the
dynamic changes anticipated on the plant concerned.
* 2.5.13 Paper chart analogue recording facilities should only be used for small
systems where a digital storage system is uneconomic and for
measurements displayed on pneumatic control panels.
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Circular chart recorders should be restricted to field service. Chart
rotation may be one revolution per day or per week as appropriate to
the duty.
Paper chart recording is of limited value for post fault analysis unless regularly
time checked. Maintenance and other attention may be high (mechanical parts,
inking, clearing blocked pens, chart changing, keeping chart running cleanly on
drive mechanisms).
In order to achieve these aims the bulk instrument item vendors should
be selected on a general basis during the FEED process such that when
the main module and package order are placed, the instrumentation
vendors have already been selected. BP requirements for specific items
of instrumentation equipment can be specified as part of the relevant
specifications.
Early project decision should be given to the policy for commonalty of equipment
between the main contractors design and packages, and also between packages
from different vendors.
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2.6.3 The design of modules shall minimise the degree of installation work,
inspection and testing offshore/at site. The project timetable,
component procurement programme and resources should ensure that
the degree of mechanical completion and testing is maximised before
despatch from the manufacturer's or fabricator's works.
Package units usually interface with the main plant instrumentation system and
with other packages. It is essential that one party (typically the main contractor)
has the clear responsibility to ensure compatibility between equipment supplied
under different contracts/sub-contracts. This responsibility must cover safety
aspects (e.g. loop certification requirement of intrinsically safe systems),
maintenance aspects (e.g. safe isolation of remote connected equipment) and the
provision of documentation (e.g. loop drawings) clearly defining the interface.
2.7 Documentation
2.7.1 Operating and maintenance manuals shall be provided for all plant and
equipment, including that supplied by vendors and sub-contractors.
Documents shall include a reference to the equipment tag number.
Vendor documentation should include a reference to the contractor's
and instrumentation supplier's order numbers. Manuals shall be
supplied to BP prior to mechanical completion of the respective plant,
plant section or module. They shall be updated to 'as built' status prior
to commissioning.
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(d) Logic diagrams, cause and effect charts, flow charts and ladder
diagrams, together with written description of the operation and
control functions.
(e) Maintenance manuals for equipment supplied as part of
packaged plant and for bought-in equipment.
(g) Schedule of all instrument calibrated ranges, and alarm, trip and
control settings.
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Some sites have computerised documentation (e.g. Teroman) and CAD
systems in service. The format of documentation received from
contractors/vendors for such systems should be carefully specified.
2.7.3 Software documentation, both text and hard copy, shall be produced in
triplicate. One reference copy of each issue shall be presented to (and
retained in a secure manner by) each of the following:-
The three reference copies of any issue shall at all times be transported
and stored separately, and clearly identified as to function, dates and
times of writing and updating.
2.7.5 The vendor shall supply a register of safety related devices which shall
include:-
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(a) Data pertinent to pressure let-down stations, including size,
type and fully open flow coefficients of the limiting valves or
orifices in every route between the high and low pressure
systems.
2.8.1 Many of the signals between the MCC and items of instrumentation
equipment are status signals only. Wherever possible these signals
should be sent via a serial link to the relevant instrument panel (e.g.
Process Control System or Shutdown System) in order to remove the
requirement for a large Interface Relay Panel. Where this is not
practical, a hardwired link should be considered, fused to protect the
instrument equipment input card.
The MCC cubicles should thus have no logic and could all be of the
same standard design.
Note that care should be taken to ensure that MCC initiated machine
trips are considered within logic design.
RP 30-1
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DESIGN AND PRACTICE
3. SELECTION OF INSTRUMENTATION EQUIPMENT
This Section specifies BP general requirements for the selection of electrical and
pneumatic instrumentation equipment.
In any hazardous zone, more than one type of protection may be used, provided all
types used are suitable for the hazard classification.
When using intrinsically safe equipment, special care should be taken with
segregation of the circuits, earthing and interfaces with other electrical equipment.
3.1.4 'Ex N' equipment should be selected for use in Zone 2 areas only. 'Ex
N' is only a National (UK) certification. Therefore for non UK projects
this type of protection should only be used if it has been approved by
the relevant national certifying authority.
It should also be noted that some manufacturers claim 'Ex N' classification for their
equipment without the certification to prove this. Due care should be taken in this
respect.
'Ex e' is the BP preferred method of protection for Zone 1 areas and is equally
preferred with 'Ex N' in Zone 2 areas. It is preferred on the grounds of being
generally lightweight, easy to maintain and of simple construction. Note that there
is no requirement to use 'Flameproof' cable glands or even glands labelled 'Ex e'.
The only requirement is to maintain the IP 54 rating of the enclosure and to
maintain the resistance to the 7 NM impact test.
Where 'Ex e' or 'Ex N' certified equipment is not suitable or available as methods of
protection in Zone 1 and Zone 2 areas, 'Ex d' certified equipment may be used.
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Note that the environmental protection for 'Ex d' may not be as good as 'Ex e', i.e.
there is no requirement for IP 54 rating. However, this rating may be achieved by
the use of suitable sealing gaskets, provided that these are approved as part of the
'Ex d' certification.
Note that the 'Ex d' protection is normally item certified only. Therefore a
modification to the 'system' inside the 'Ex d' enclosure may require re-certification.
'Ex de' is a hybrid protection method that is suitable for Zones 1 and 2. It is
generally used where the main equipment is enclosed in an 'Ex d' enclosure with an
'Ex e' terminal box attached. This method of protection is perfectly acceptable to
BP.
'Ex p' can be used in both Zone 1 and Zone 2 areas. In effect a localised non-
hazardous area is created by an 'Ex p' enclosure. However, for Type 'p' enclosures,
associated instrumentation is required to monitor the air purge and over-pressure.
Type 'p' equipment also tends to be purpose built, expensive and requiring of
significant maintenance. Therefore, type 'p' equipment should not be used where a
viable alternative exists.
Intrinsic Safety (I.S.) method 'Ex ia' is the only protection method suitable for use
in Zone 0 areas. Intrinsic Safety method 'Ex ib' can be used in Zone 1 areas and
below. Intrinsic Safety is the only protection method that does not rely on
mechanical integrity to ensure safety from causing ignition. Both Intrinsic Safety
methods are acceptable to BP.
Things to be considered when planning to use I.S. are that often additional
associated equipment is required, that there is general lack of understanding of I.S.
equipment and that the maintenance procedures and documentation necessary to
maintain the system integrity are demanding.
'Ex o', oil Filling and 'Ex q', Sand or Power Filling are not used commonly and in
the UK are currently only Certified for use in Zone 2 areas. If possible one of the
other methods of protection should be used in preference.
'Ex s', Special protection is a useful protection method to use for applications
where no other protection method is available or where the requirements cannot be
met in another way. This method of protection is normally acceptable for use in
Zones 1 and 2 and is perfectly acceptable to BP.
3.1.6 The use of equipment within the EC for applications where European
certified equipment is not available shall be subject to approval by BP.
Where necessary, such equipment shall be submitted for independent
assessment before approval. A document of conformity shall be
prepared which details the considerations made in assessing the safety
of the equipment.
This refers to the use of equipment with certification not of EC origin, such as UL
in the United Kingdom or special equipment which has not been certified. Where
this type of equipment is used, the engineer should satisfy himself that it is safe. It
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DESIGN AND PRACTICE
may be necessary to submit it to a suitable authority (e.g. BASEEFA or SIRA Safety
Services Ltd.) for certification to be obtained.
The certificate for a given item of equipment will have a certificate number. Where
CENELEC certifying bodies are concerned there may also be a letter at the end of
the certificate number. A 'U' indicates that the certificate is a component
certificate only, 'S' that special conditions apply to the use of the equipment. Due
care should be taken to ensure that the certification does not preclude the mode
and conditions of operation intended.
3.2 Cables
Generally, cables to BS 5308 : Part 1 are used where polyethylene insulated cables
are required. BS 5308 : Part 2 covers PVC insulated cables. In some cases,
special cables may be required (e.g. mineral insulated cables in hot areas). In such
cases the L/R ratio and voltage rating as defined in BS 5345 shall be met.
When the use of fire resistant or flame retardant cables has been
specified, reference shall be made to BP Group GS 112-12.
Fire resistant cables should be used in special fire risk areas, as determined by BP,
on those circuits whose continuous operation, for a period of time during a fire, is
essential for safe shutdown of the process plant or installation. Flame retardant
cables are used offshore and for some land based applications where some fire
resistance is required, but not so great as for fire resistant cables.
Traditionally, wire armouring has been used for all field installations. Section 4 of
this Recommended Practice requires that cable be installed in such a way that it is
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DESIGN AND PRACTICE
not subject to damage. The need for armoured cable throughout a project should
be carefully considered.
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Multi-circuit cables should have individually screened quad or
triple conductors.
(iv) Thermocouples
Twisted pair cables should be used for this service. Where volt
drop is excessive for the apparatus connected, and the
installation is not required to be intrinsically safe to BS 5345,
then non-twisted pair cable to BS 6346 (except as noted in this
Section) may be used.
Twisted pair cables should be used for this service. Where volt
drop is excessive for the apparatus connected, and the
installation is not required to be intrinsically safe to BS 5345,
then non-twisted pair cable to BS 6346 (except as noted in this
Section) may be used.
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Signal levels on adjacent cables in the same frequency band shall
be similar to minimise cross-talk.
Cables for telephone systems shall have cores identified with the
standard colour coding for telephone cable in the country of
use. For UK duty refer to British Telecom Specification
1308A, Telephone Cables 2000 series.
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(b) Glands and cable fittings shall be suitable for the cable type and
certified for hazardous areas where applicable.
For details of earthing and bonding systems see, Section, 5 of this RP.
3.4.1 Marshalling and junction boxes for both shutdown and intrinsically safe
circuits shall be separate from those on general instrument
measurement and control duty.
Separate marshalling and junction boxes are only necessary for intrinsically safe
and shutdown applications. Other circuits may use the same box, but the different
signal types should be segregated within the box by grouping and spacing or
physical barriers.
3.4.3 Clamp type terminals with slot headed screws should be used for all
connectors. The screws shall not be in direct contact with the
conductor.
While clamp type terminals are preferred, other types of terminal may be used
provided the form of clamping does not damage the conductor.
3.4.4 Cable entries should not be at the top of boxes unless installed in a fully
weather protected environment.
3.4.7 Marshalling and junction boxes used on intrinsically safe circuits shall
be and clearly labelled as containing intrinsically safe circuits.
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3.5 Cable Tray and Racking
3.5.1 Cable tray or racking should be constructed of heavy duty, hot dipped
galvanised steel. End cuts shall be sealed immediately after cutting.
Stainless steel and glass reinforced plastic cable tray should only be used for
corrosive atmospheres (e.g. platforms and areas of acid spillage) as both types are
expensive. Additionally, for glass reinforced plastics, the engineer should satisfy
himself that the surface resistivity is suitable for the installation (i.e. no static
charge build up). PVC coated tray has been found to be unsuitable for use on
external applications due to water ingress on cut ends.
3.6.2 For related air supply and tubing specifications, (e.g. supply pressure,
materials, bore and tube lengths etc.) refer to Sections 4 and Section 7
of this Recommended Practice).
Larger tubing may be required where actuator sizes are large, or two or more
actuators are connected in parallel. The speed of response of the equipment may
otherwise suffer.
3.6.4 Equipment should operate from a clean dry air main supply, reduced as
required via a suitable regulator to a pressure not less than 1.5 bar(ga)
20 psig).
Equipment can sometimes be operated from the process fluid and is especially
useful at remote locations with no electricity supply.
Vents from power cylinders, solenoids etc., should be piped to a safer location.
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DESIGN AND PRACTICE
* If instrument air is not available, the following may be used as the
pneumatic supply; subject to BP approval:-
(b) Bulk nitrogen provided that safe practice can be assumed, and
the service is clearly identified by labels at all maintenance
points.
4. INSTRUMENT INSTALLATION
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4.1.3 Instruments should be located away from potential fire risk and spillage
areas, hot or exposed environments, sources of vibration, and process
vents and drains. The location of instrumentation impulse pipe runs,
vents and cable trays shall not obstruct access, walkways or plant
which may require regular attention.
4.1.6 Indicators shall be readily visible from operating positions and under
the normal (natural or artificial) lighting levels at the location. Special
attention shall be given to the readability of liquid crystal displays
(LCD's).
4.1.7 Manufacturers' data plates, zero and span adjustments and manifold
valves (where fitted) shall be accessible. Data plates shall not be
painted over.
(a) They are not subject to vibration in excess of the manufacturers stated
maximum.
(b) The normal working temperature limits of the device will not be exceeded
due to conducted heat from hot lines, etc.
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(c) They are provided with adequate line isolation and vent facilities.
(d) They are located such that they are unlikely to be damaged due to
operations or maintenance staff standing or climbing upon them.
(e) Cabling to them is suitably supported and routed and/or a suitable local
junction box is provided to terminate those provided with 'flying leads'.
4.1.12 Where instruments are direct mounted on process lines that are heat
traced and lagged or lagged only, the mounting shall allow for removal
or maintenance of the instrument without removing the lagging or heat
tracing. The mounting arrangement must protect the instrument from
excessively high or low temperatures through conduction or radiation.
4.1.15 The cabinet should be provided with a clear window to allow indicators
to be read without exposing the equipment to temperature variations.
Care should be taken to ensure that too high a level of protection is not
unnecessarily specified, e.g. many suppliers may construct to IP 53 requirements,
but only one to IP 54 which could incur a cost penalty. IEC 529 defines the IP
levels of protection.
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DESIGN AND PRACTICE
Where a certain protection level is required, say IP 55, but only IP 44 is available,
the lower category enclosure may be used with an additional mounting box which
itself meets IP 55.
It should be noted, that grouping equipment into one large enclosure can be cost
effective and give operational and maintenance advantages. Typically, grouping of
analysers into a centralised house is beneficial in comparison to the use of
individual enclosures for each analyser.
4.2.1 Impulse pipework and fittings up to and beyond the first block valve
from the process line or vessel, shall be in accordance with BP Group
RP 42-1 and BP Group GS 142-6.
4.2.2 Impulse piping should be installed in accordance with BS 6739 and API
RP 550 Part 1.
4.2.5 The design shall include allowance for any differential movement
between the tapping point and the instrument due to thermal expansion
or vibration of the main plant pipework.
4.2.6 Where instruments are installed on immiscible fluid service the impulse
lines shall be installed horizontally. In all other applications impulse
piping shall be sloped to ensure self-venting or self-draining as
appropriate to the application.
4.2.7 Where instruments contain large inventories of process fluid (e.g. level
transmitters), or where frequent blowdown of impulse lines is
envisaged, vents and drains shall be in accordance with BP Group RP
42-1. For all other instrumentation, small volumes of non-toxic process
fluid (less than 2 litre) may be vented and drained to atmosphere
provided that safe disposal can be assured. Special care is necessary
where the installation is above grade and where hot, flammable or toxic
materials are involved.
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Generally, pressure gauges, pressure and differential pressure transmitters can be
considered as small volume devices, but in specifying vent and drain requirements,
the engineer should carefully consider the position of isolation valves, length of
impulse lines and potentially hazardous nature of the fluid and its process
condition, i.e. temperature and pressure. If in any doubt, the requirements of BP
Group RP 42-1 should be met.
The vent and drain requirements on non-hazardous duties can often be simplified
by installing integral valve manifold blocks, which allow maintenance checks to be
carried out with the minimum venting of process fluid.
Care should be taken to specify manifolds for the maximum pressure and
temperature they are likely to encounter. For example, on steam duty, the manifold
should meet the steam specification not just the condensate.
4.2.10 Impulse pipework shall be lagged, or heat traced and lagged, where the
process liquid would otherwise condense, solidify or be otherwise
adversely affected by low or high ambient temperatures. Lagging shall
also be provided to protect personnel from high or low temperature
impulse lines.
4.3.3 Gauges up to and including 150 mm (6 in) dial size may be close
coupled and supported by their own connections if the impulse piping is
flanged or welded (refer also to 4.1.1).
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4.3.5 Where a pressure instrument is located more than 2.5 m (8 ft) from the
primary block valve or where this valve is inaccessible an additional
block valve should be installed near the instrument.
4.3.6 Pressure gauges shall be installed so that their blow-out protectors are
not obstructed. Protectors shall face away from the operator.
4.3.7 Low range equipment shall be installed such that gravitational effects
on the sensing element do not cause calibration errors or induce noise
due to vibration. Impulse piping design should generally comply with
that for differential pressure flow instruments (see 4.6).
4.3.8 Where pulsation dampers are used, they shall be installed close to the
measuring element. The use of partially closed isolating valves is not
permitted.
4.4.3 Level gauges shall be installed such that the indicator is visible from
grade or platform.
4.4.4 General site lighting shall allow any level within the range of the gauge
to be seen at all times. Integral illuminators shall be provided for
through vision gauges.
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DESIGN AND PRACTICE
4.4.9 Displacer chambers connected to vessels containing slurries and highly
viscous liquids shall be provided with a liquid purge into the liquid
connection.
4.4.10 On applications where purged impulse lines or dip legs are provided,
non return valves should be fitted upstream of the purge controller.
4.5.3 Where capillary systems are used, they shall be continuously supported
and protected, and any excess length neatly coiled, clipped and
supported. The installation shall not introduce standing errors.
The most common application of sensors fitted without thermowells are skin
thermocouples on heater-tubes, bearing temperatures and fast response
measurements on gas turbines etc. Apart from such accepted applications,
temperature devices should be installed without thermowells only in exceptional
circumstances, usually for reasons relating to speed of response or severe space
limitations. The utmost care must be taken in the design to prevent accidental
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DESIGN AND PRACTICE
removal. Clear, permanently affixed labels must warn of the need to depressure the
line or vessel before removal.
4.5.6 Specific attention shall be given to ensure motor and generator winding
temperatures are segregated from other instrument sensing applications
via galvanic isolators. The integrity of the hazardous area shall be
protected against insulation failure or induced voltages.
4.5.7 When two thermocouples or RTD's are in the same pocket, their
terminals shall be clearly marked as to their function.
Where parallel runs are employed, elbows and isolation per BP Group
RP 42-1 shall be provided at each end of the meter runs to facilitate
removal of one run whilst the other is in service.
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DESIGN AND PRACTICE
The problem of removing meter runs, control valves, ball valves etc., while the
other streams are still in service, can be exasperated by using ring type joints. If
the meter runs are above the inlet and outlet headers and isolation valves, they
could be connected via elbows. The elbow can be removed, the valve blanked
allowing the meter run to be dismantled
* 4.7.1 Although the following items give BP's general requirements for
analyser installations, the detailed housing requirements specified in BP
Group RP 30-2 Section 7 shall be observed. Reference should also be
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DESIGN AND PRACTICE
made to EEMUA Publication No. 138 for additional general
information. All installations shall be subject to approval by BP.
4.7.3 Analysers fitted with sample systems and requiring gas bottles should
be installed at ground level in a designated analyser house.
Gas bottle racks are commonly picked out in safety reviews as being inadequate.
All bottles should be secured in an upright position.
4.7.9 Chemical stores shall be separated from the analyser house, and well
ventilated.
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* 4.8.2 Clearance shall be provided above and below the valve so that its
internals and actuator may be removed. Where this is not feasible and
the valve is flanged, it may be swung on a bolt axis to provide access.
This method shall be subject to approval by BP.
Swinging of valve bodies on a bolt axis to provide access to the valve trim,
although commonly carried out on site when no other method is available for valve
inspection, often requires the springing-apart' of the pipe flanges to allow gasket
renewal. Special care should be taken to minimise the need for swinging a valve,
especially where ring type joint flanges are used.
* 4.8.3 Control valves shall be installed such that they and their associated
equipment and valves are accessible for maintenance and manual
operation. Access may be from grade or a platform. Alternative safe
means of access may be permitted subject to approval by BP.
4.8.4 The valve should be capable of being maintained and operated from
these access areas, within comfortable arms reach set by the physical
constraints of the handrailing, etc.
4.8.6 Sufficient access shall also be provided for welding and heat treatment
of valves welded into the process line.
4.8.7 Control valves for volatile liquids shall not be installed adjacent to hot
equipment.
4.8.8 Diaphragm and piston actuated valves should be installed with their
stems vertical.
4.8.9 Butterfly valves shall be installed with their shafts horizontal unless a
different orientation is approved by the manufacturer.
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DESIGN AND PRACTICE
4.9 Instrument Air Systems
4.9.3 Where plastic sheathed tubing is used, the sheath shall continuously
cover the tube and be terminated at a seal incorporated within the
compression fitting.
4.9.4 PTFE tape shall not be used on screwed fittings downstream of the
filter regulator.
* 4.9.6 Provision shall be made for any differential movement between tubing
supports and connected equipment. Refer also to 4.2.
4.9.9 Tubing run together shall be installed vertically one above the other.
More than three runs shall be supported on a tray. Any joints which
may be necessary shall be staggered.
* 4.9.10 Transmission distance should not exceed 100 m (328 ft). Volume
boosters may be used to give the required response over greater
distances provided that other control characteristics are not down
graded.
On signal tubings, it is desirable to limit the volume of the tube to ensure that lags
in transmission are minimised. Volume boosters may be used to reduce lags,
alternatively smaller diameter tubing or preferably an electronic transmission
system should be considered.
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DESIGN AND PRACTICE
4.9.11 Tubing should not be run in hot environments or designated high fire
risk areas. Tubing should be located away from places where it may be
subjected to mechanical damage, spilt liquids or corrosive gases.
4.9.12 Tubing should be run such that it does not interfere with access to or
removal of plant equipment.
4.9.13 Multi-tube should be laid in sand filled trenches. When a trench also
contains electrical cables, multi-tubes shall be grouped together and
clearly identified.
* 4.10.2 The special requirements for subsea systems will be specified by BP.
4.10.5 Each individual user shall be provided with isolation valves in both the
hydraulic supply and return lines. These shall isolate the control
equipment and all accessories, including filters.
4.10.6 The supply and return pressure shall be indicated locally. Common
headers may be used when several users are at the same location; e.g.
control panel.
4.10.7 The supply to each individual user shall incorporate a filter and, where
necessary, a pressure reducing valve in accordance with the connected
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DESIGN AND PRACTICE
equipment manufacturer's specification. A pressure gauge shall be
fitted downstream of the reducing valve.
4.10.8 A non-return valve shall be installed in the return line from each user.
This shall be arranged to protect the control equipment from
contamination due to a reverse flow of hydraulic fluid under fault
conditions.
4.10.9 Tube and fittings used for control lines, for the hydraulic fluid supply
between the filter and the user, and for lines between the user and the
non-return valve shall be in accordance with Section 8 of this
Recommended Practice. The use of PTFE tape and jointing compound
is not permitted on screwed fittings within hydraulic systems.
4.10.11 Provision shall be made for any differential movement between piping
and tubing and connected equipment. Where there is insufficient
movement in standard tube or pipe, short lengths of flexible armoured
tube may be used. The final filter shall be downstream of the flexible
section.
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4.12 Labelling
4.12.1 All field instrumentation shall have a permanently affixed stainless steel
label which is stamped with the full instrument tag number.
4.12.2 All indicating and controlling instruments and control valves shall have
a clearly visible label adjacent to them giving the tag number and a brief
process description.
4.12.3 They should be made from white/black/white laminated plastic with the
exception of shutdown service which shall be made from red/white/red
laminated plastic.
4.12.4 All equipment that forms part of a shutdown system shall be clearly
labelled with a permanently affixed red plastic label marked 'TRIP'.
The English language shall be used but local or national alternatives may also be
required to clearly identify the 'TRIP' function.
4.12.5 Labels should be fixed with screws or bolts to a permanent part of the
plant structure that would not be removed when maintaining or
removing equipment. Labels shall not be fixed to cladding.
BS 5345
BS 6739
API RP 550 Part 1
BP Group RP 12
BP Group GS 112-1
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DESIGN AND PRACTICE
Only one core shall be used in each termination. Common connections
shall be made using the terminal manufacturers' standard bridging
arrangement.
All crimping wire wrap or other termination, shall be carried out using
a tool approved by the connector manufacturer.
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DESIGN AND PRACTICE
all or part of the run is not practical or economic, the routing shall be
subject to approval by BP.
Method of installation also needs to be considered early in the design, since long
lengths may be involved (1 km) and some manufacturers cable requirements create
difficulties in laying (e.g. minimising number of connections and non-flexible
coaxial cable). It is often easier to lay the cable in trenches or on cable trays than
to pull through conduits (e.g. under pipe tracks or roads).
4.13.4 The following minimum spacings between instrument and power cables
should apply:-
(a) Keeping parallel runs of power and instrument cables as short as possible.
(b) Ensuring all instrument cables are screened and earthed correctly.
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In cases where a spacing of only 50% or less of the recommended distance
is achievable, instrument and power cables should be separately routed.
All crossovers that bring power and signal cables into close proximity
shall be made at right angles. The cables should not touch at the cross-
over.
Where multicore cables pass from one area to another the transit should
be sealed. This is of particular importance where the dividing wall or
bulkhead separates a hazardous area from a non-hazardous area,
different hazardous area zone rating, or where the bulkhead is of a
specified fire rating. In these cases multi-cable transits of a suitable
accepted design shall be used.
Removable gland plates shall be furnished for cable access into panels
and equipment enclosures.
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4.14 Seals and Purges
4.14.1 Installation shall be in accordance with BS 6739 and API RP 550 Part
1.
4.14.2 Meter seals and fluid purges shall be used only where process fluid or
fluid conditions are not suitable for direct connection of an instrument.
4.14.3 Purge fluid shall be from a secure source and be compatible with the
process fluid. The purge fluid shall be available for start-up, and shall
assure adequate purging under all operating conditions. The purge
supply header pressure shall be indicated and annunciated if it falls to
an unacceptably low level.
4.14.4 Seal fluids in direct contact with the process shall be immiscible with
the process fluid.
4.14.5 Where diaphragm and capillary seals are used, the capillaries shall be
mechanically protected and supported. Errors shall not be introduced
due to temperature gradients along the capillary, or temperature effects
upon the diaphragm seal chamber.
4.15 Winterisation
4.15.2 The combination of heating and lagging shall not cause overheating of
instrumentation.
4.15.4 All valves and external adjustments associated with an instrument shall
be accessible without removal of lagging.
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4.16 Tropicalisation
Many so called sealed batteries can vent gas under certain circumstances (such as
high charging rates). This may be diffused into the room or contained in the
battery. Pressure relief valves are sometimes fitted to sealed batteries. It may be a
requirement to vent the top of the battery to atmosphere.
This Section specifies BP general requirements for earthing and bonding systems.
5.1.1 In the UK, minimum earthing requirements for electrical systems shall
comply with the IEE Wiring Regulations and IEE Regulations for the
Electrical and Electronic Equipment of Mobile and Fixed Offshore
Installations. Requirements for earthing of equipment in hazardous
areas shall comply with BS 5345.
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5.1.2 Elsewhere in the BP Group, the appropriate national standards shall
apply. Vendor recommendations shall also be taken into consideration.
5.1.4 Earthing and bonding for protection of personnel and plant shall be in
accordance with BP Group RP 12 Parts 5 and 16.
* 5.1.5 At an early stage in the project, the contractor shall submit his earthing
and bonding philosophy which shall be subject to approval by BP. The
philosophy shall include an earthing and bonding diagram based upon
the following Figures included at the end of this Recommended
Practice:-
Fig 5-3 Typical installation detail for cable termination and earth
bonding.
5.1.7 Earthing positions shall be selected to avoid earth loops which could
result in common or series mode signal interference.
5.1.9 At the tender stage, suppliers shall confirm that equipment and system
hazardous area certification is compatible with the project earthing
arrangements.
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5.1.10 Earthing conductors shall be stranded and insulated 600/1000 volt
grade to BS 6346 and be coloured green/yellow.
* 5.1.11 Plug-in metal cased devices (e.g. electro mechanical relays) shall have
the case earthed, and be arranged such that on removal continuity of
the earth contact shall be maintained until all other circuits have been
broken. This requirement may be relaxed for low voltage devices in
safe areas, with the approval of BP.
5.2.1 Panel earth bars shall be hard copper to BS 1433 or equivalent and a
minimum of 75 mm2 in cross sectional area. They shall be mounted on
insulators with a minimum spacing of 25 mm from the panel frame. All
earth bars shall be appropriately labelled according to their functions,
e.g. earth/reference earth.
5.2.2 Interconnections between earth bars, control centre earth and power
system earth shall be provided with insulated conductors of not less
than 35 mm2 in cross sectional area.
5.2.3 Where single conductors are used for interconnection between earth
bars, they shall be double bolted for security.
5.2.4 Flexible earth straps shall be fitted between panel doors and frame.
Screens shall be insulated from one another and earthed only at one
point. That is:-
5.2.7 Screen drain wires at the panel shall be provided with green/yellow
heatshrink sleeves and appropriate identification.
5.2.8 Field instrument cables between a junction box and the control cabinet
shall have the armour (and the lead sheath in onshore applications)
earthed at both ends of the cable via the gland.
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5.2.9 Earth leads between the control cabinet IS earth bar and the control
outstation earth bar, shall be provided with identification labels at both
ends indicating an intrinsically safe circuit.
5.2.10 The IS system earth shall be such that the impedance between any
barrier bus-bar and the control centre main earth point shall not exceed
1 ohm.
5.3 Field
5.3.1 All metallic instrument enclosures in the field shall be bonded to the
plant/platform steelwork at bolted connections. These shall be
provided with serrated spring washers to give earth continuity. Where
the earth bond cannot be assured, a 4 mm2 single core, insulated
conductor shall be provided between the enclosure and an effective
local earth point.
* 5.4.3 In the event of it not being practical to install a system as above the
method of installation shall be subject to approval by BP.
Special insulating kits for flanges exist, allowing impulse lines to be electrically
isolated from the pipeline and earthed.
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5.5 SCADA and Computer Type Equipment
5.5.1 Where system earth and frame earth are bonded together, SCADA and
computer type equipment shall be insulated from the structure.
5.5.3 Incoming and outgoing signals shall not be connected to frame earth.
5.5.4 The signal carrying conductors shall be galvanically isolated from the
transmitting and receiving equipment to ensure that earth loops are not
created via signal paths.
5.6.1 For co-axial cables carrying radio frequency signals, signal screens shall
be earthed locally at each end of the cable and may be connected to
frame earths as necessary when the cable passes through equipment
panels.
5.6.2 In the case of antenna feeder cables, added protection against lightning
strikes should be provided by earthing the screen to the antenna tower
earth at the antenna, at the foot of the antenna structure and to the local
earth at the transit into the equipment building.
Protection of every signal against the possibility of damage from static discharge
or lightning is neither practical nor economic. However, signal pairs at high risk
should be identified and added protection in the form of surge diverters included
where safety, environmental or the economic consequences of failure dictate.
Examples of signal circuits at risk are flare stack or tank instrumentation and
telecommunication lines.
5.7.2 The selection of surge diverter type shall depend on the level of
protection required, the assessed risk level of lightning strikes or other
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sources of induced high voltages, the criticality of the signal lines and
characteristics particular to the location.
It is important that any surge diverting device is returned to the best possible earth
via a substantial conductor. Currents in the order of hundreds of amps may be
encountered during a strike and any resultant voltage developed across the earth
lead will not be suppressed by the diverter.
5.7.3 Where large earth potential is known to exist at the ends of a cable
requiring protection, consideration should be given to fitting a surge
protection device at each end.
The Gas Discharge Tube is the simplest form of surge diverter. These are often
specified by telecommunications authorities.
They consist of a gas filled glass envelope containing three electrodes. One
electrode, usually the centre one, is connected to ground and the other two to the
incoming lines.
In the event of a high voltage surge between the lines and earth, the tube 'strikes',
conducting heavily and clamping both conductors to ground.
The tube takes approximately 0.2 microseconds to operate and limits the voltage
presented to the equipment to approximately 30 volts.
This type of device does not give sufficient protection for general electronic
instrumentation duties. A more complex device called a lightning protection unit
(LPU) is required.
Some LPU's contain resistors in series with the signal path and others contain
capacitors in parallel with the signal, therefore the effect of the LPU on the signal
and/or the signal line's transmission characteristics must be considered.
In these cases the manufacturers of the signal source and destination equipment
should be consulted.
(a) Disposable
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These resemble a Zener barrier of the type used in intrinsically safe
installations.
These units perform the same duty as the disposable LPU's, but are able to
survive more serious lightning strikes, while protecting the equipment by
blowing fuses to achieve isolation.
These are a development of the fuse link LPU's and have the advantage
that they disconnect the protected equipment for the duration of the strike
and then reconnect it.
These are expensive units and should only be considered for critical signal
lines and/or unattended locations.
This section describes BP general requirements for electrical power supplies for
Instrumentation and control systems. This includes power supplies for field
instrumentation, control panels, distributed control systems, telemetry systems,
supervisory computer systems, emergency shutdown systems and fire and gas
detection systems.
6.1.1 Instrument power supplies shall be designed such that the security of
power supply is consistent with the integrity required by the connected
loads, and does not exceed this requirement.
6.1.2 Power supplies shall be designed such that they meet the requirements
of the connected loads in terms of:-
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(a) Voltage
(b) Voltage stability
(c) Frequency
(d) Rate of change of frequency
(e) R.F. content
(f) Maximum interrupt time
(g) Harmonic content
(h) Power factor
* 6.1.5 The design philosophy for instrument power supplies shall be subject to
approval by BP.
(a) Class A
(b) Class B
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(c) Class C
(a) Class A
(b) Class B
(c) Class C
6.3.3 Alternating current power supplies shall comply with the requirements
of BP Group GS 112-10.
6.3.4 Direct current power supplies shall comply with the requirements of BP
Group GS 112-11.
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6.4 Distribution and Protection
6.4.2 Cartridge type fuses should be used throughout the power supply
system. Protective circuit breakers may be used only in final sub
circuits provided it can be demonstrated that discrimination will be
maintained with the other protective devices.
6.4.4 A separate switched and fused sub circuit shall be provided for each
functional loop. Redundant equipment shall be separately switched and
fused.
6.4.5 Each sub circuit shall be clearly labelled with a unique identifier.
6.4.6 Power supplies to ancillary equipment such as heating and lighting shall
be independent from the control system power supplies.
6.4.7 The distribution shall be designed such that failure of a single sub
circuit does not cause an unacceptable loss of control or loss of data
display to the plant operator.
6.5.1 Where power supply units are supplied integral to control systems
equipment adequate provision shall be made for ventilation and heat
dissipation.
6.5.3 Where dual power supplies are installed it shall be possible to replace a
single failed supply without reducing the availability of the equipment.
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6.6.2 Alarms shall be provided to indicate at a manned control point any fault
condition on a major unit in a power supply system. This may take the
form of a common alarm requiring examination of the local indication
to diagnose a fault condition.
Emergency Trip
Urgent Alarm
Information
Note: proposals for the use of fluids as an alternative to air are subject to approval by
BP. (Refer to para 3.6 of this Recommended Practice).
(c) System rating and reserve capacity, including any proposed use
of instrument air for services other than instrumentation (e.g.
for breathing air).
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Instrumentation is sensitive to the quality of its air supply. Contaminants such as
water, oil or particulate matter (e.g. corrosion products) can damage components,
result in blockage of protective filters or orifices, and lead to equipment
malfunction. Methods of avoiding contamination of the instrument air distributed
to control equipment must be addressed at an early stage of project development.
The benefits and disadvantages of totally oil free versus oil lubricated air
compressors should be addressed. The greater potential reliability of lubricated
compressors may prove a negative benefit because a high level of maintenance or
operator attention may be necessary on oil removal or drying equipment. Also,
once oil has contaminated an air distribution system, it proves difficult to remove;
particularly from any low points in the distribution pipework.
Note that oil lubricated compressors for instrument air supplies are specified for
some offshore applications.
7.1.2 Dried, filtered compressed air shall be made available at the dryer outlet
at a pressure which should not be less than 7 bar (ga) (100 psig) when
under rated load. This may be reduced, provided that an economic
benefit is shown and that other requirements of this Recommended
Practice (in particular paragraphs 4.1 and 4.2) are complied with.
The design of the system including pipe diameter and length should
ensure that the pressure drop between the air dryer outlet and the most
remote consumer does not exceed 5% of the system pressure.
Instrument air quality stated in specifications for the supply of instrumentation and
control equipment should include the design maximum oil content.
7.1.4 Drying plant, filters and coalescers shall be protected from the effect of
surge in the air supply system (e.g. on start-up of a stand-by
compressor following a sudden high demand).
7.1.5 The pressure in the main instrument supply line to a plant or complex
shall be indicated and low pressure alarmed at the appropriate control
centre(s).
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Any abnormal deviation of other key parameters within the air supply
generation, purification or distribution system shall be alarmed to the
appropriate operators. This shall include extra low pressure
downstream of the air dryers, and high differential pressure across
filters and coalescers.
7.2 Capacity
7.2.1 The system shall be rated for all the connected loads plus a minimum of
20%, unless otherwise specified by BP.
(c) For purge other than cat cracker catalyst duty - 1.0 (35)
For cases (a) and (b) these figures when used for a number of instruments,
some in steady state and some in dynamic motion, allow a reasonable
assessment of capacity to be made. Allowance is made for a supply
regulator of the bleed type. Cases (c) and (d) are continuous operations.
20% should normally be added to the calculated figure, to allow for a
limited expansion of the instrumentation. No allowance should be made
for leakages from poorly maintained instrument air systems.
Special care should be taken when assessing the demand for large
intermittent users such as large piston operators on ESD duty.
* 7.2.2 The system shall contain such storage capacities located downstream of
the air dryer that, for a period after system failure, all air-using
apparatus under rated load can continue to operate normally. The
reserve period will be specified by BP.
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Reserve capacity of the system should be agreed with the end user or plant
designer, as appropriate, at an early stage of design. Experience has shown 15
minutes reserve is usually adequate for general process plant. 5 minutes may be
adequate for less complex facilities such as a simple oil/gas separator.
(a) equipment (e.g. high pressure actuators) which may fail before
the majority of other users due to a reduction in the distribution
system pressure.
7.2.4 Local volume chambers shall be supplied via a non-return valve. They
shall be protected by a pressure relief valve in accordance with BP
Group RP 44-1. The design should permit removal of the relief valve
for testing without compromising the integrity of the supply.
The potential failure situations within the compressors and oil removal equipment
should be carefully assessed to ensure that oil breakthrough into the instrument air
distribution system is very unlikely to occur.
7.3.2 The equipment shall maintain the oil content of the air supply below the
maximum identified in 7.1.3. This shall apply to all expected
environmental conditions, including high humidity when extensive
water drop out may be expected. Equipment shall be protected from
corrosion products and other contaminants.
7.3.3 Oil and water disposal shall be automatic. A manual bypass of the
auto-dump facility shall be provided.
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7.3.4 Duplex equipment which can be cleaned or replaced without
interrupting the air supply or affecting its quality shall be provided.
Requirements for change-over normally indicated by pressure drop
shall be alarmed to the operator.
7.3.6 A sampling point for oil content shall be provided at the air outlet of
each oil removal train.
Methods to determine the oil content of instrument air at the ppm level are
available (e.g. infra-red spectrometry). Advice may be obtained from Analytical
Support, Group Research and Engineering Centre, Sunbury.
Heat regenerated air dryers are usually more economical for larger capacity
systems and consume less of the dried air during the regeneration cycle. Heatless
dryers however, are simple in their operation and lower in initial cost of
installation. Refrigeration type dryers may be more economic or more effective in
hot/humid environments.
Selection should also take into account the oil content of the air supply which could
ignite or otherwise damage the drier (e.g. during regeneration).
7.4.2 Where climatic conditions dictate, the air dryer should be installed
under cover.
7.4.3 The dew point of the air anywhere in the system (measured at the
distribution pressure and at the maximum air throughput) shall be at
least 10°C (18°F) below the minimum ambient temperature quoted in
the plant specification.
7.4.5 A duplex 3 micron filter, which can be cleaned without interrupting the
air supply, shall be installed downstream of the dryer. A differential
pressure gauge shall be fitted across the filter.
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A separate filter/coalescer unit should be provided upstream of an air
dryer to protect the absorbent material in the dryer from any
contaminants in the air supply.
7.4.6 Branches should be provided to allow for bypass of the drying system.
* 7.4.7 A sampling point for dew point measurement shall be provided in the
outlet pipe from each dryer. Any requirement for continuous dew point
measurement shall be subject to approval by BP.
7.4.9 Pilot operated valves shall be supplied with air from a cool location
such as downstream of the air receiver.
7.5 Distribution
7.5.1 Dry oil-free air for purposes other than instrumentation may be taken
from a point upstream of a non-return valve at the instrument air
receiver inlet.
Some older installations have a breathing air distribution system derived from the
instrument air supply. System modifications should not compromise the breathing
air capacity or quality.
The use of instrument air for purposes other than instrumentation should be
avoided because there is always the risk of contamination. There are however,
sometimes strong economic reasons to relax this requirement (e.g. for catalyst
activation) or for purging instrument impulse lines on air fluidised powder systems
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(e.g. FCCU's). Precautions must be taken to minimise the risk of instrument air
contamination due to reverse flow from the process (e.g. by the use of a suitable
check valve).
7.5.3 Air supply headers should be sized in accordance with the requirements
of 7.1.2 and should be a minimum size of NPS 1/2 (DN 15). Each sub-
header should have one spare distribution point.
7.5.4 The air supply to field mounted instruments and valve actuators shall be
through individual isolating valves, filters and regulator sets with
pressure gauges.
(a) The device(s), including local reserve air receiver being supplied
with air are not rated for the main air distribution pressure.
* Note that although instrument air supply regulators are normally of the
'bleed' type, the bleed port is not sized as a relief device should the supply
port fail fully open.
7.5.5 Refer to 7.7 for instrument air distribution within control panels.
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7.6 Piping and Tubing
7.6.1 The Main Distribution air supply piping and fittings in the distribution
system up to and including each instrument isolating valve shall be in
accordance with BP Group RP 42-1.
* 7.6.2 BP will specify the material required for low pressure air supplies and
signal lines downstream of the instrument air supply isolating valve.
Typical specifications for copper and stainless steel systems are as
follows:-
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(iii) Fittings, valves and accessories shall be of Type 316
stainless steel.
* 7.6.3 Multicore form tubing should be used when economic for long
transmission distances (e.g. from a control room to the field). The
multitube shall be sheathed overall in PVC or polyethylene (see 7.6.2).
Materials shall comply with 7.6.2. The use of plastic materials for the
cores shall be subject to approval by BP.
Copper is not suitable for offshore applications, either bare due to direct corrosion
or with a plastic jacket which is adversely affected by moisture and light. Type 316
stainless steel and 'Alloy 825' are available alternatives. At temperatures above
about 50°C, type 316 stainless steel may suffer stress corrosion cracking if exposed
to a marine environment; it may also suffer crevice corrosion. Monel 400 is a
suitable material in H2S environments providing temperatures are below about
150°C. However, if Monel is exposed to a mixture of H2S and air in damp
conditions, fairly rapid corrosion can occur. In such cases plastic coatings have
been used successfully to protect the Monel.
The use of nylon or plastic, both of which provide flexibility should be considered
when economic or where metals could become work hardened by continuous
movement. Care should be taken in the selection of tubing connections, both from
materials and joint integrity viewpoints. Advice on the correct selection of
materials can be obtained from Group Research and Engineering, Sunbury
Plastics generally should not be used in direct sunlight since they may become
brittle.
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* 7.6.6 Special materials for unusual applications shall be subject to approval
by BP.
7.7.1 Panels requiring instrument air shall obtain their supply from a header
or distribution block within or at the back of the panel. Normally, the
supply pressure is 1.5 bar (ga) (22 psig) and this shall be indicated on a
suitable gauge on the panel.
7.7.2 The header shall be fed from two sets of isolating valves, filters,
pressure reducing valves and pressure gauges installed in parallel and
arranged to permit on-stream maintenance. Each set shall be capable of
handling the rated load.
7.7.3 All supply points shall be taken from the top of the low pressure header
via isolating valves. A minimum of 20% spare supply points shall be
provided. The header, adequately sized to suit the duty, shall be sloped
at a minimum gradient of 1:12 and fitted with a drain valve at the lower
end.
* 7.7.4 The header should be of brass or stainless steel with air connections
downstream of the low pressure header as specified in 7.6.2. Materials
such as nylon or plastic may be used, subject to approval by BP.
The criteria of 7.6.4 generally apply with regard to the use of plastic or nylon
tubing and fittings within panels.
7.8 Installation
This Section specifies BP general requirements for hydraulic power systems to be used
for control systems, valve actuation, and similar equipment for wellheads and pipeline
valves. It should be read in conjunction with BP Group GS 134-1 Hydraulic Power
Supplies.
BP Group GS 134-1 specifies BP general requirements for the design, fabrication, testing and
installation of hydraulic power units and the associated piping systems.
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8.1 General Requirements
8.1.1 Each system shall be skid mounted and except for utilities and signal
sources the system shall be complete. It shall be suitable for the
atmosphere in which it is installed. For hazardous area installations, all
electrical devices shall comply with BS 5345 and BP Group RP 12-2.
8.1.2 Instrumentation within the hydraulic power system shall relate to the
monitoring and control of operating conditions, which shall be as
simple as possible and be the minimum consistent with the requirements
for reliability and safety.
8.1.3 When specified by BP, a Failure Modes and Effects Analysis of the
hydraulic system shall be carried out.
8.1.7 Proven equipment should be used, all of which shall be fully compatible
with the hydraulic fluid.
8.1.8 Provision shall be made for the safe lifting and handling of a hydraulic
skid module. Appropriate lifting lugs shall be provided on the skid and
equipment by the vendor.
8.2.1 The design of the hydraulic power system shall meet the requirements
of equipment to be controlled; it may have to be custom designed for a
specific application. A typical design should include a reservoir, filters,
pumps with drivers, accumulators, regulators, relief valves and a
distribution system. Liquid should be pumped from the reservoir into
the accumulators which feed a hydraulic distribution system or control
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equipment via pressure regulators. The pumps may be designed to cut-
in and cut-out within a defined operating pressure band.
8.2.2 The system shall be designed to maintain a supply pressure not greater
than 200 bar(ga) (2900 psig) unless otherwise approved by BP. If the
control equipment requires different pressure levels, duplicated
regulators in parallel configuration shall be considered, in preference to
separate sets of pumps to generate the required pressure.
It is usual for hydraulic systems pressures not to exceed 200 bar( ga) (2900 psig), as
in the past, problems have been experienced with umbilicals and connectors.
However, higher hydraulic pressures may be necessary to increase the speed of
system response, provide increased actuator torque, or to reduce actuator size
where space is limited. Wellhead down-hole safety valve actuators normally
require an operating pressure of at least 50 bar (72 5 psi) above the wellhead shut
in pressure. The hydraulic power system working pressure must take this into
account. Down-hole safety valve hydraulic operating pressure should be
adjustable to match the fall in wellhead shut-in-pressure as the reservoir declines
in order to minimise possible seal leakage. Special attention should be given to
component selection at higher hydraulic pressures.
* 8.2.3 Capacity requirements shall comply with BP Group GS 134-1 and shall
be subject to approval by BP.
8.2.4 A dynamic hydraulic analysis shall be carried out in all cases where
speed of valve operation to open or to close is critical. Typical
examples are: Wellhead valves, BOP valves, Diverter Valves or Shear
Rams.
The Analysis should include details of hydraulic fluid flow and control
line and component pressure drops.
8.2.5 Hydraulic circuits shall be kept free from air, water and dirt, to provide
reliable safe performance. Provisions shall be made to permit air
bleeding of the system. System filters shall be located to protect
components. Adequate drainage and sampling provision shall be made.
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Full system flushing, to a cleanliness level dependent on the dirt tolerance of the
system's components, should be carried out at the vendor's works for panels and
modules, and again on site when the system is installed. Off-line filtration facilities
should be considered in order to allow cleanliness levels to be maintained in
service. The cleanliness levels required should normally be specified, e.g. NAS
1638, Class 6 or BS 5540 : Part 4, Code 15/12.
For low and extra low level in a reservoir (alarm and subsequent pump cut-out), the
reservoir should be sized to allow time for operator intervention between the
reservoir low level alarm and trip points.
For low and extra low supply pressure (alarms), the extra low system supply
pressure sensor may be required to initiate plant shutdown before unprogrammed
shutdown occurs.
* 8.2.7 In general, the hydraulic system shall utilise an open vented type
stainless steel reservoir from which liquid is drawn. The vent shall
include a filter and a breather desiccator. The pumps shall be fed by
adequate gravity head. Closed type systems using inert gas for purging
and pressurisation or other air exclusion systems shall be subject to
approval by BP.
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The type of hydraulic fluid and any additives used (e.g. biocidal
additives, viscosity index improvers, oxidation inhibitors, corrosion and
rust inhibitors, metal deactivators, anti-wear and load carrying agents
and foam inhibitors) shall be subject to approval by BP.
The use of additives in the hydraulic fluid is a very specialised subject; professional
advice on this should be taken from the appropriate Department within BP.
Materials shall be suitable for use with the selected hydraulic fluid,
associated additives and where necessary, with sea water
contamination. The fluid may be mineral oil or water and glycol based
according to the application. O-rings, gaskets and seals in particular
shall be compatible with the hydraulic fluid employed.
The reservoir tank shall have adequate capacity for supply and
operation of the control equipment without frequent replenishment.
The precise requirement for each application will be specified by BP.
The capacity of the reservoir shall be sized such that the operating
volume between the normal maximum and normal minimum levels shall
hold the complete control system capacity plus 20%, or such additional
spare capacity as specified by BP.
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Return and suction connections on the reservoir shall be adequately
separated to maximise settling and cooling. The return line shall
terminate so that it is submerged at all times. No drains shall be
returned to the reservoir.
Foreign bodies (metals, plastics and rubber) due to mechanical wear and tear in
control equipment, actuators, hoses, piping and fittings may be expected in
returned fluid; particularly as a system ages. Sea water contamination can occur
following degradation of subsea umbilical hoses, connectors and seals. Crude oil
or gas contamination can occur due to failures at high pressure downhole valves.
Such contamination can seriously damage hydraulic systems.
For these reasons the relative merits of once through sea-water systems versus
closed oil based systems must be addressed. The practical difficulties in
maintaining the necessary fluid purity in closed systems should not be
underestimated.
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(c) Automatic cut-in and cut-out to maintain pressure within a
band, to be subject to approval by BP.
(d) Reservoir extra low level cut-out; restart shall require manual
reset.
8.3.4 Accumulators
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(d) Facilities shall be provided to safely check and re-charge the
accumulator(s) nitrogen precharge.
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8.3.5 Filtration Equipment
(c) Screen filters shall be used on the reservoir filler caps; mesh size
shall be a minimum of 200 microns.
8.3.6 Regulators
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8.3.8 Coolers
The panel shall provide local control and monitoring of the hydraulic
power supply operation. The functions controlled and monitored shall
include the following:-
A removable gland plate may be required for cable entries into the
panel, to enable cables to be directly connected to the junction box(es).
8.4 Safety
8.4.1 Safety design shall comply with all applicable national regulations and
BP Group Recommended Practices and Specifications for Engineering.
8.4.2 The design and installation shall ensure safe operation during normal
and abnormal circumstances and permit safe maintenance.
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8.4.3 Particular note shall be taken of the high pressures involved.
8.4.5 High pressure discharges and relief points shall be protected and piped
to a safe point.
8.4.6 The hydraulic fluids used may be potentially toxic or irritant. Provision
shall be made for safe storage, handling, mixing and drainage. Drip
trays and open grating flooring shall be provided where appropriate.
Hydraulic systems are usually custom built. The inspection engineer should ensure
that all components and functions are tested under normal operating conditions.
For pressure testing, the test pressure is normally 1.5 times the maximum working
pressure; this pressure should be held for at least one hour without loss. Some
equipment may need to be isolated during this test to prevent overpressurisation
damage.
The system should be thoroughly flushed and filtered to the required cleanliness
level before function tests are carried out. Fluid samples should be checked by
particle contamination measurement.
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8.6 Documentation Requirements
9. CONTROL PANELS
9.1.2 Control panels shall conform to EIC Specification CCI P/3, with the
additions and exceptions identified in this Section of the Recommended
Practice.
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The EIC (Energy Industries Council) Specification CCI P/3 is very specific in many
aspects of design, construction and inspection. It also contains statements of
significance to procurement, packing and shipping.
* 9.1.3 The type of control panel for each application and its size and layout
shall be subject to approval by BP.
9.1.4 The requirements for alarm systems are detailed in BP Group RP 30-5.
The level of necessary protection from the heating effects of direct sun should be
assessed.
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On-plant control panels shall be supplied as a free standing assembly
supporting the instrumentation and related equipment.
Panel design should take account of transportation and site handling, such as
structural strength, lifting arrangements, size and weight.
The affect to operations of purge failure should be taken into account. This is true
for automatic purge protection systems as well as advisory systems.
9.2.2 Layout
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9.3 Panel Assembly
* 9.3.1 Construction
The designer should consider the cost and technical merit of some form of shelter
to protect a field panel, as an alternative to a high category of protection for
individual instrument enclosures.
The exterior colour, the surface finish and the painting specification
shall be subject to approval by BP.
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9.3.3 Piping and Tubing
EIC Specification CCI P/3 calls for polyethylene tubing as standard. The designer
needs to specify copper, sheathed copper or stainless steel, if required.
Terminal blocks shall be of the slot headed screw clamp type. They
should incorporate a built-in disconnect facility. Stranded conductors
shall be terminated using an approved crimped connector.
* 9.3.5 Nameplates
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reading, colour contrast, lighting and ease of cleaning should be
addressed during the selection process.
For identification when removed from the panel, all equipment shall
have a removable nameplate attached giving the tag number.
9.6 Installation
10.1.2 The control building may accommodate one or more of the following
functional areas:-
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(a) Remotely located, continuously manned control centre (remote
control centre or process control centre).
* 10.1.3 The choice of control building type shall depend on the type and
complexity of the plant and its instrumentation. This shall be subject to
approval by BP.
10.1.5 The design of control buildings and rooms shall make provision for any
future requirements specified by BP.
10.1.7 Reference shall also be made to BS 6739 and API RP 550 Part I
Section 12.
10.2 Layout
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Early consideration should be given to the location of equipment not forming an
integral part of the main system, but closely associated with it. Examples are fiscal
measurement equipment, VDU's (Visual Display Units) for tank gauging,
maintenance systems (Teroman) and fire and gas monitoring equipment.
This spacing is based on normally manned control centres, where more than one
operator plus maintenance technicians may be present. It may be reduced in
unmanned, or infrequently manned control centres, or in relation to the manning
expected.
Facilities for instrument maintenance should be considered (e.g. space for hot
standby spares racks, test equipment storage, manuals/operating instructions,
magnetic program disk/tape storage)
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(e) Any chemical filtering that is necessary.
(f) Fire and gas monitoring and protective control actions. (See
10.9).
It should be noted that different parts of the building may have different
requirements in terms of acceptable variations in the environment, based on the
tolerance of individual installed equipment. To provide a high quality environment
for the whole building may not be cost effective.
It may be necessary to include automatic protective action (e.g. remove power for
uncertified equipment) should flammable or toxic gas be detected at the air inlet.
10.3.2 Special attention shall be given to the reliability and quality of the
environmental control to ensure that it is entirely suitable for the
installed equipment.
Particular measures should be taken to ensure that on HVAC failure, the heating
effect of installed equipment does not raise the ambient temperature above
manufacturers' specified limits, which may result in control system failure and
plant shutdown.
10.4 Pressurisation
10.6.2 Other areas shall have a lighting intensity and distribution consistent
with access and maintenance operations. (Minimum 300 lux
(average)).
It is not practical to define lighting levels universally. The designer should review
the requirements on an individual basis.
10.6.3 Where VDUs are installed, glare shields shall be fitted to reduce the
amount of light which can fall on the VDU screen.
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10.6.4 Emergency lighting supplied from its own batteries shall be provided.
10.7.1 Power outlet sockets, at a voltage of not more than 125 V, shall be
provided within 3000 mm (10 ft) of all installed instrumentation. This
shall apply to equipment racks, control panels and consoles.
10.8 Cabling
Generally, signal cabling is run below a computer floor. The height of this floor
and its support beams should be reviewed in relation to the quantity of cabling
below and the ease of cable pulling and stripping. The size and number of cable
entry points should be carefully addressed, particularly in relation to any
requirement for future plant expansion.
10.8.2 Cable installation should be consistent with the design and support
arrangement of the computer floor.
10.9.1 Fire and gas monitoring, protective control actions and locations of
control panels shall as a minimum requirement meet local and national
authority codes, standards and regulations. Any additional
requirements will be specified by BP.
Requirements for fire and gas monitoring and associated protective actions are
often included in local and national regulations applicable at the particular
location. Specialist advice should be obtained from a BP or external consultant
when specifying equipment.
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Consideration should be given to additional fire monitoring and protection at
unmanned buildings or rooms, particularly where expensive equipment is located
or where loss or damage could result in extended downtime. Fire detection in
cable voids may be desirable.
11.1 Objectives
11.1.3 The database system shall minimise the man-hours required for basic
design work by automatic data transfer and generation of
instrumentation documentation.
11.1.4 The database system shall interface effectively with other systems used
on a project in order to minimise any requirement for manually entering
duplicate data into different systems.
11.1.5 The database system shall improve the quality and consistency of
documentation by reducing the errors due to manual data transfer, and
automatically checking for discrepancies.
11.1.6 The database system shall maintain the data in a secure condition, and
provide a reliable record of updates and revision changes.
11.1.7 The database system shall function as a flexible design tool. The actual
design produced shall not be dictated by limitations of the database
system and associated design packages.
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In some cases the application of an integrated instrument database package, CAD
package and DCS configuration system has been found to hinder the design process
and restrict the final design produced. This has particular relevance to re-
instrumentation projects where the design packages may for example make
assumptions about field cabling and marshalling arrangements which are not
compatible with the existing plant installation.
11.2.1 Selection of the type of system required shall consider both the type of
project on which it is to be applied and the manner in which the project
is to be executed.
Projects in which an instrument database is required can range from a small re-
instrumentation project on a single plant executed by a BP on-site team, to a new
offshore development implemented by a major contractor. The data required, the
users of this data and the data flow within the project will differ significantly
between these two extremes. A significant consideration is the requirement for
transfer of data to the operator at the end of the project.
Most sites will have a maintenance system already in place (frequently 'TEROMAN'
or similar purpose built system), and it is important that information stored in the
instrument database can be easily transferred into this site facility rather than the
database itself offering a parallel maintenance utility.
Option 1 may prove to be expensive depending on the system selected and the size
of the project. A contractor may be reticent to have a proprietary system imposed
on him depending on the in-house system which is usually used in his offices.
RP 30-1
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some in depth knowledge of the database language should however be carefully
considered.
Preference within BP is for the use of DEC VAX equipment or IBM compatible
personal computers. The use of IBM PC based systems provides maximum system
flexibility. For medium sized multi-user systems the use of networked PCs should be
considered. A typical system could consist of a number of PCs on a 'Novell'
network with one or two PCs acting as file servers with hard disk and possibly
optical disk drive file storage.
11.3.2 The amount of data to be entered into the database. Where a large
number of tag numbers are to be entered into the system it may be
more efficient to divide the database into a number of sub-directories.
Where sub-directories are required, a coherent database structure shall
be maintained. The need to change the same fields in several sub-
directories shall be avoided.
Sub-division may be necessary if the amount of data produces too slow a response
on the hardware to be used or if the database is to be used in different physical
locations. Division may be by process module, physical location, or possibly into
divisions such as field, control room, DCS and supervisory system data.
11.3.3 The format of data to be entered into the system. The tag numbering
system to be used requires careful consideration. The use of separate
data fields for each part of the tag number i.e. plant number, instrument
identifier, loop number, suffix etc. will facilitate the manipulation and
sorting of data records.
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In some cases the standard ISA format may prove to be adequate. Alternatively the
tag numbering system may have to conform to existing plant or site standards.
Particular care must be taken when the project consists of a number of modular or
packaged units. The option in this case is for the package vendor to supply the tag
numbers and a package prefix to be added, or the design contractor to supply the
tag numbers to the vendor. Care should be taken where the instrument database is
merged with an overall equipment database that non instrumentation items such as
HVAC equipment are not given a numbering system that conflicts with the
instrument tag numbering system.
11.3.4 Data fields that will be required. This should include field name,
length, alphabet or numeric input, syntax or arithmetic checking and
source of the data.
11.3.5 Data output requirements. This should include the requirements for
standard or free format reports and the requirement for the generation
of documents such as instrument specification sheets, loop drawings,
hook-up drawings, and termination schedules.
11.3.7 Access and security requirements. This should consider the users of
the system, their physical location, and overall management of the
system to maintain the integrity of the data entered on the system.
11.4.1 The facilities available for manual data entry on a database system will
have a significant effect on the accuracy and speed of data input.
Typical features which should be available are:-
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The ability to copy blocks of database records is particularly applicable where a
plant consists of a number of identical process trains.
11.4.2 The database system shall provide error checking when data is entered.
Typically checks should include:-
11.4.3 The database system shall provide facilities for sorting data records into
sub-sets of the database by sorting on specified fields. The sorting
facility should allow the use of conditional functions such as AND, OR
and NOT. The system shall provide a count of the number of records
which have fulfilled the sort requirements. Typical fields on which the
database may be sorted could include:-
Tag Number
Instrument type
Requirements for database sorting may include several conditional sorts. e.g. sort
for a specified instrument type within a specified plant area.
11.4.4 To enable full use to be made of sorting facilities, data shall be entered
in a consistent manner. This requirement shall be particularly observed
when data is entered by a number of users, who may be in different
physical locations.
11.4.5 The database system shall provide the facility to order tag numbers
both numerically and alphabetically on the part of the tag number
specified by the user.
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For example the database may be ordered numerically on the plant prefix part of
the tag number, then alphabetically on the instrument identifier part of the tag,
then numerically on the loop number.
11.4.6 When the system takes a significant time period to manipulate data, the
user should be provided with indication that processing is in progress
and an indication of the progress in completing the task.
11.5.1 Requirements for data transfer shall be fully defined at the start of the
project. This should include requirements for data transfer between
DCS configuration systems, CAD systems, other design database
systems, systems used by vendors, contractors, and plant operators.
11.5.3 Where possible data transfers shall be carried out automatically when
required. This will ensure that systems do not become out of step due
to data transfers not being manually initiated at the correct time.
11.5.4 All data transfers shall be tested with dummy data at the time the
system is initially set up. This will prevent the possible need to re-enter
data in a different format should data transfer be found not to be
successful.
11.5.5 Any requirement for holding transferred data in a separate file for
checking prior to merging with the main database shall be considered.
11.6 Security
11.6.1 Security and control features shall be provided to protect the data
within the database. The extent of these features will depend on the
size and nature of the project.
11.6.3 Each user may have a unique identity and password which is recorded
against any changes that he makes.
11.6.4 A user should be granted access only to those facilities which he needs
to use, and only to those areas of the database which he is involved in.
'Write protection' may be required for specific database fields.
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11.6.5 A revision logging system for all data changes is essential. This may
include logging the identity of the user making the change and the
reason for the change.
11.6.6 The system shall provide reports detailing all changes made in a specific
period, all changes made by a specific user, and all changes relating to a
specified drawing or item of plant.
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DESIGN AND PRACTICE
100 USERS 100 USERS
50mm
50mm FALL 50mm
100mm
80mm 50mm
DRAIN
25mm
25mm 25mm 15mm
20 USERS 5 USERS
40mm
15mm
25mm 5 users
15mm
25mm 15mm
DRAIN 5 USERS
5 USERS
FILTER
REGULATOR
FALL FALL
COPPER
(6m or 10mm)
DRAIN INSTRUMENT,
CONTROL VALVE
POSITIONER, ETC
RP 30-1
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DESIGN AND PRACTICE
FIGURE 4-1
RP 30-1
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DESIGN AND PRACTICE
BULKHEADS
COUPLINGS INSTRUMENT
INSTRUMENT LOOP TAG LOOP TAG
6mm OR
10mm
O.D
SUFFICIENT SLACK COPPER
TO ALLOW TUBE
REMAKING
LOOPDOWN TO
PREVENT WATER
INGRESS
BLANK
MARKER
MULITITUBE
FIGURE 4-2
RP 30-1
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DESIGN AND PRACTICE
8
4
3
1
1
5
8
DIFFERENTIAL 4
6 PRESSURE
INSTRUMENT
2
7
5
1
NOTES:
1. HORIZONTAL OR VERTICAL LINE
2. INSTRUMENT MOUNTED BELOW ELEMENT
3. PIPWORK CONFIGURED WITH UPWARD SLOPE TO REFERENCE
DATUM POINT 1:10
4. RODDING OUT POINTS TO BE CAPPED OR BLANKED
5. DRAINS AND VENTS TO BE CAPPED OR BLANKED, OR PIPED TO SAFE
DISPOSAL (SEE TEXT)
6. INTEGRAL 3 OR 5 VALVE MANIFOLD PREFERRED (SEE TEXT)
7. COUPLING FOR INSTRUMENT REMOVAL
8. REFERENCE DATUM POINTS TO BE AT SAME LEVEL TO ENSURE
EQUAL CONDENSATE HEADS ON EACH SIDE OF INSTRUMENT.
CONDENSATE POTS TO BE USED FOR HIGH DISPLACEMENT
INSTRUMENTS.
FIGURE 4-3
RP 30-1
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DESIGN AND PRACTICE
1
RODDING OUT
POINTS
1
DIFFERENTIAL
PRESSURE
INSTRUMENT 3
6
2
5 5 1
FIGURE 4-4(PAGE 1 OF 2)
RP 30-1
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DESIGN AND PRACTICE
NOTES:
1. HORIZONTAL LINE
2. INSTRUMENT MOUNTED BELOW ELEMENT
3. PIPWORK CONFIGURED IN SELF - VENTING MODE WITH UPWARD
SLOPE THROUGHOUT OF 1:10 MINIMUM.
4. RODDING OUT POINTS TO BE CAPPED OR BLANKED
5. DRAINS AND VENTS TO BE CAPPED OR BLANKED, OR PIPED TO SAFE
DISPOSAL (SEE TEXT)
6. INTEGRAL 3 OR 5 VALVE MANIFOLD PREFERRED (SEE TEXT)
7. COUPLING FOR INSTRUMENT REMOVAL
FIGURE 4-4(PAGE 2 OF 2)
RP 30-1
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DESIGN AND PRACTICE
5
4
DIFFERENTIAL
PRESSURE 6
INSTRUMENT
2
1
6
7
4
1 4
1
1
RP 30-1
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DESIGN AND PRACTICE
NOTES:
1. HORIZONTAL LINE
2. INSTRUMENT MOUNTED BELOW ELEMENT
3. PIPWORK CONFIGURED IN SELF-VENTING MODE WITH UPWARD
SLOPE THROUGHOUT OF 1:10 MINIMUM.
4. RODDING OUT POINTS TO BE CAPPED OR BLANKED
5. DRAINS AND VENTS TO BE CAPPED OR BLANKED, OR PIPED TO SAFE
DISPOSAL (SEE TEXT)
6. INTEGRAL 3 OR 5 VALVE MANIFOLD PREFERRED (SEE TEXT)
7. COUPLING FOR INSTRUMENT REMOVAL
RP 30-1
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DESIGN AND PRACTICE
FIGURE 5-1(PAGE 1 OF 2)
TYPICAL EARTHING DIAGRAM FOR INSTRUMENTATION ONSHORE
RP 30-1
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DESIGN AND PRACTICE
NOTES:
3.0 FIELD
3.1 THE LEAD SHEATH (WHERE PROVIDED) AND ARMOUR TO BE BONDED
TOGETHER AND TO THE ENCLOSURE AT THIS POINT BY A BRASS CABLE
GLAND. IF A NON-METALLIC ENCLOSURE IS USED,MEASURES SHALL BE
TAKEN TO ENSURE ARMOURS AND LEAD SHEATHS (WHERE PROVIDED)
OF ALL CABLES ENTERING THE ENCLOSURE ARE BONDED TO ONE
ANOTHER AND TO THE PLANT POWER SYSTEM EARTH. EACH SCREEN
SHALL BE INSULATED WITH A SLEEVE.
3.2 DEPENDING ON SYSTEM REQUIREMENTS AND POWER SUPPLY
DISTRIBUTION THESE EARTHS MAY BE TAKEN TO A LOCAL EARTH
POINT.
3.3 THIS SHOWS THE PREFERRED EARTHING SYSTEM. IT MAY BE
NECESSARTY IN SOME CASES TO EARTH ON SIDE OF THE D.C SUPPLY
(SEE ALSO NOTE 2.1)
FIGURE 5-1(PAGE 2 OF 2)
RP 30-1
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DESIGN AND PRACTICE
FIGURE 5-2( PAGE 1 OF 2 )
TYPICAL EARTHING DIAGRAM FOR SCADA AND COMPUTER TYPE
EQUIPMENT
RP 30-1
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DESIGN AND PRACTICE
NOTES:
1. MORE THAN ONE CLASS ‘B’ AC POWER SUPPLY AND ISOLATING TRANSFORMER MAY BE
REQUIRED.
FIGURE 5-2(PAGE 2 OF 2)
RP 30-1
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FIGURE 5-3 (PAGE 1 OF 2)
RP 30-1
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DESIGN AND PRACTICE
NOTES:
1. FOR METAL CASE PROVIDE STAR WASHER BETWEEN BACKING NUT AND CASE. EARTH
TAG AND EXTERNAL WIRING ARE NOT REQUIRED.
2. THIS METHOD SHOULD BE RESTRICTED TO THE SITUATION WHERE MULTICORE
CABLES ARE RUN UNDERGROUND. WHERE MULTICORE CABLES TO BE RUN
UNSTRIPPED TO A GLANDPLATE.
3. PROVIDED THE ENCLOSURE IS METAL AND IS ADEQUATLY BONDED TO EARTH VIA THE
MOUNTING ARRANGEMENT. THE EARTH BOND MAY BE OMITTED.
4. WHERE BRAIDED ARMOUR ENTERS FIELD EQUIPMENT IT IS TO BE TEASED OUT,
TWISTED SLEEVED WITH GRN/YEL HAET SHRINK AND CONNECTED TO LOCAL EARTH
BAR/STUD. (FIG 3) WHERE STEEL WIRE ARMOUR ENTERS EQUIPMENT IT IS TO BE
CLAMPED AND THE INSULATED EARTH LINK TP BOE TAKEN TO LOCAL EARTH
BAR/STUD. (DETAIL A).
RP 30-1
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FIGURE 5-4(PAGE 1 OF 2)
TYPICAL EARTHING DIAGRAM FOR INSTRUMENTATION OFFSHORE
RP 30-1
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DESIGN AND PRACTICE
NOTES:
3.0 FIELD
3.1 THE LEAD SHEATH (WHERE PROVIDED) AND ARMOUR TO BE BONDED
TOGETHER AND TO THE ENCLOSURE AT THIS POINT BY A BRASS CABLE
GLAND. IF A NON-METALLIC ENCLOSURE IS USED,MEASURES SHALL BE
TAKEN TO ENSURE ARMOURS AND LEAD SHEATHS (WHERE PROVIDED)
OF ALL CABLES ENTERING THE ENCLOSURE ARE BONDED TO ONE
ANOTHER AND TO THE PLANT POWER SYSTEM EARTH. EACH SCREEN
SHALL BE INSULATED WITH A SLEEVE.
3.2 DEPENDING ON SYSTEM REQUIREMENTS AND POWER SUPPLY
DISTRIBUTION THESE EARTHS MAY BE TAKEN TO A LOCAL EARTH
POINT.
3.3 THIS SHOWS THE PREFERRED EARTHING SYSTEM. IT MAY BE
NECESSARTY IN SOME CASES TO EARTH ON SIDE OF THE D.C SUPPLY
(SEE ALSO NOTE 2.1)
3.4 THIS DETAIL ALSO GIVES THE PREFERRED EARTHING ARRANGEMENT
FOR SAFTEY BARRIERS FIELD MOUNTED IN EXPLOSION PROTECTED
ENCLOSURES.
FIGURE 5-4(PAGE 2 OF 2)
RP 30-1
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DESIGN AND PRACTICE
FIGURE 5-5(PAGE 1 OF 2)
TYPICAL EARTHING DIAGRAM FOR TELECOMMUNICATIONS EQUIPMENT
RP 30-1
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DESIGN AND PRACTICE
NOTES:
FIGURE 5-5(PAGE 2 OF 2)
RP 30-1
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DESIGN AND PRACTICE
APPENDIX A
Definitions
contract: the agreement or order between the purchaser and the vendor (however
made) for the execution of the works including the conditions,
specification and drawings (if any) annexed thereto and such schedules
as are referred to therein.
cost of ownership: the life cost of a system including initial supply contract value,
installation cost, ongoing support costs (e.g. spares, maintenance and
service charges).
works: all equipment to be provided and work to be carried out by the vendor
under the contract.
Abbreviations
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DESIGN AND PRACTICE
EMI Electro-Magnetic Interference
EMUG European Manufacturing and User Group
EN European Standards issued by CEN (European Committee for
Standardisation) and CENELEC (European Committee for
Electrotechnical Standardisation)
ERA Electrical Research Association
ESD Emergency Shutdown
FCCU Fluid Catalytic Cracking Unit
FEED Front End Engineering Design
GRP Glass Reinforced Plastic
HVAC Heating, Ventilation and Air Conditioning
IEC International Electrotechnical Commission
IEE Institutionk,,,,,, . of Electrical Engineers
IEEE Institute of Electrical and Electronic Engineers (USA)
IP Institute of Petroleum
IS Intrinsically Safe
ISA Instrument Society of America
ISO International Organisation for Standardisation
LCD Liquid Crystal Display
LNG Liquefied Natural Gas
LPG Liquefied Petroleum Gas
LPU Lighting Protection Unit
L/R Ratio of Inductance to Resistance
Lux Unit of light level measurement
MAP Manufacturing Automatic Protocol
MCC Motor Control Circuit
NAS National Aerospace Standard
NPS Nominal Pipe Size
PC Personal computer
P&I Process and Instrumentation Drawing
PLC Programmable Logic Controller
psig Pounds per square inch gauge
PTFE Polytetrafluorethylene
PVC Polyvinyl Chloride
RF Radio Frequency
RTD Resistance Temperature Detector
SCADA Supervisory Control and Data Acquisition
SI Systeme International d'Unites
SIRA Scientific Industries Research Association
UK United Kingdom
UL Underwriters Laboratory
UPS Uninterruptable Power Supply
VDU Visual Display Unit
RP 30-1
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DESIGN AND PRACTICE
APPENDIX B
A reference invokes the latest published issue or amendment unless stated otherwise.
ISO 1000 SI units and recommendations for the use of their multiples
(Identical to BS 5555) and of certain other units.
IEC 304 Standard colours for insulation for low-frequency cables and wires.
EIC Spec CCI P/4 Specification for colour coding of instrument signals cables.
EIC Spec CCI P/7 Specification for instrument cable numbering and junction box
identification.
ANSI/IEEE 802.4 Token passing bus access method and physical layer specifications.
RP 30-1
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DESIGN AND PRACTICE
ANSI/ISA S5.1 Graphic Symbols for process Displays
BS 6746C Colour chart for PCV insulation and sheath of electric cables.
RP 30-1
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EEMUA Publ. No. 138 Design and installation of on-line analyser systems.
RP 30-1
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DESIGN AND PRACTICE
BP Group RP 44-6 Area Classification
(replaces BP CP 39)
RP 30-1
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