S10332300-3002 - 0 Instrument Installation
S10332300-3002 - 0 Instrument Installation
S10332300-3002 - 0 Instrument Installation
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 1
3
INSTRUMENT INSTALLATION
S10332300-3002
GFG-002
No.
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 2
3
TABLE OF CONTENT
SECTION DESCRIPTION PAGE
1.0 GENERAL 4
2.0 CODES AND STANDARDS 4
3.0 WORKMANSHIP AND SAFETY 4
4.0 INSTRUMENT MOUNTING AND FIXING 4
4.1 Field Instrument Installation 5
4.1.1 Orifice Fittings 5
4.1.2 Positive Displacement Meters 6
4.1.3 Turbine Meters 6
4.1.4 Rotameters (Variable Area Flow meter) 6
4.1.5 Level Switches, Gauges and Transmitters 6
4.1.6 Temperature Gauges and Transmitters 7
4.1.7 Pressure Instruments 7
4.1.8 Shutdown and Control Valves 8
5.0 PIPING 8
5.1 General 8
5.2 Thread Sealant 10
5.3 Instrument Air Lines 10
5.3.1 Air Headers And Branches 10
5.4 Process Impulse Lines 11
5.4.1 Pressure Instruments 11
5.4.2 Orifice Meter Tubing 11
6.0 INSTRUMENT CABLE INSTALLATION 12
7.0 GROUNDING 13
7.1 General 13
7.2 Instrument Earth 14
7.3 Intrinsicall y Saf e Earth 14
7.4 Shielding 15
8.0 HAZARDOUS AREA REQUIREMENTS 15
9.0 PAINTING 15
10.0 PROTECTION 16
GFG-002
TABLE OF CONTENT
SECTION DESCRIPTION PAGE
12.0 IDENTIFICATION OF CABLES, LINES AND INSTRUMENTS 166
13.0 STANDARDS OF MATERIALS 17
14.0 INSTRUMENT AIR/GAS SUPPLY 17
15.0 ISOLATION VALVES 17
16.0 INFORMATION REQUIRED FROM CONTRACTOR 18
17.0 INSPECTION AND TESTING 18
18.0 AUTHOR COMMITTEE 20
GFG-002
No.
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 4
3
1.0 GENERAL
The Contractor shall only use new material whose quality is of the standard prescribed and which
is in every way fit for its intended purpose.
The Contractor shall carry out the work in accordance with the standards listed herein and in
accordance with any local "Statutory Regulations."
• All instrument materials for tubing, fittings, stands and supports shall be in accordance with the
standard installation as described in hook-up or typical installation drawing.
No.
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 5
3
• No instrument with the exception of pressure gauges and temperature indicators shall be
installed in such a way that it depends for support on the process piping or electrical
connections to it.
• Pressure gauges or temperature indicators shall not be mounted directly on lines where
vibration is likely to be present.
• Wherever possible, local-mounted instruments shall be mounted at approximately 1.5 m above
the grade or floor in an accessible position. Instruments shall not impede process operation,
e.g., masking valves, etc.
• Local-mounted instruments shall be bracketed, mounted on sub-panels, or placed on a suitable
pedestal, in accordance with the drawings. These instruments shall be secured to the nearest
suitable firm steelwork in an acceptable manner.
• Differential-pressure instruments on gas or vapor service shall be mounted above process taps
and connecting piping (or tubing) shall slope downwards towards the process taps.
• Differential-pressure instruments on liquid service shall be mounted below process taps and
connecting piping (or tubing) shall slope upwards towards the process taps.
• Handrails shall not be used for supporting instruments.
• Process piping shall not used to support instrument.
• Instruments shall be mounted as close to the sensing points as possible.
• Sunshades shall be provided for all instruments that would otherwise be faced with direct
sunlight.
• Local mount stand or support for local instrument shall be galvanized or otherwise specification
as project specification.
• Vents not connected to utility water shall be fitted with a 316 stainless steel block
valve and 316 stainless steel -hexagonal plug.
No.
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 7
3
• Drain lines shall slope continuously towards the drain point. If this is not possible
then low point drains shall be provided as required. These low point drains shall be
fitted with a 316 stainless steel full bore ball valve with a 316 stainless steel
hexagonal plugged outlet.
• Prior to installation, all level switches, gauges and transmitters shall be checked
for conformance to specification requirements.
• Subsequent to level switches and transmitters shall be installed after total
completion of all related hydro-testing and flushing activities.
4.1.6 Temperature Gauges and Transmitters
• Prior to installation, all temperature instruments shall be checked for conformance
to specification requirements.
• Thermowell orientation shall ensure that the dial is visible and readable from grade
or appropriate access platform.
• Temperature gauges shall be installed at the latest possible instance during the
pre-commissioning activities in order to prevent damage from other construction
activities.
• Any temperature elements having extended lengths shall be handled with care
and suitably protected to prevent damage.
4.1.7 Pressur e Instrument s
• Tubing runs for remote mounted pressure instruments shall either be continuously
sloped towards the process tapping for gaseous service or towards the instrument
for liquids service. If these requirements cannot be achieved then either low point
drains or high point vents respectively shall be provided. At these drain or vent
points a 316 stainless steel instrument needle valve with 316 stainless steel
plugged outlet shall be provided.
• Prior to installation, all pressure instruments shall be checked for conformance to
specification requirements.
• Pressure gauges shall be installed at the latest possible instance during the pre-
commissioning activities in order to prevent damage from other construction
activities.
GFG-002
No.
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 8
3
5.0 PIPING/TUBING
5.1 General
• All instrument process lines shall be run with a slope downward from instrument (except
liquid flow measurements) of not less than 1:12 except where otherwise specified.
• Steel process piping downstream of the first block valve shall be as required in Project
Specifications except connections for instruments shall be flanged.
• Instrument air piping downstream of the header take-off block valve shall be schedule 80
ASTM A106, Grade B, galvanized per ASTM A120.
• Pipe fittings shall be galvanized 3000 lb ASTM A105. If stainless pipe shall be ASTM
A312 TP304 pipe fitting shall be ASTM A182-F 304.
• Multiple instrument lines shall be run in the vertical plane whenever possible and shall be
run with the minimum number of changes of direction consistent with good practice and
neat appearance.
• Tubing shall be bent with correct size tubing bender. Use of elbow fittings is to be kept to
minimum. A tubing cutter shall always be used to cut tubing. Cut tubing ends shall be
reamed prior to make-up.
• All tubing shall be run in such a manner as to give the maximum protection against
GFG-002
mechanical damage.
No.
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 9
3
• Tubing run in permanent enclosures shall not have joints, except in special junction boxes
provided for this purpose.
• Where tubing is run in permanent enclosures, the Contractor shall ensure that entry and
exit of such enclosures is clean and smooth.
• Pipes or tubes installed, but not connected, shall have the block valve and ends plugged
to prevent the entry of foreign material.
• All reasonable precautions shall be taken to prevent foreign material entering tubing and
instrument piping before and during erection.
• All lines shall be blown through with dry filtered air before connection to instruments.
• No pipe or tube shall be left with a mechanical strain on it.
• The size of instrument air/gas mains shall be established in accordance with the table
below unless otherwise specified.
• Where permanent enclosures are left with space for instrument tubing to be pulled-in at
some future date, a galvanized pull wire of adequate size shall be left in the tray.
• Galvanized piping shall not be formed, brazed, or welded.
• All venting instrument and pilot valves shall have bug screens fitted to the atmospheric
vents.
• On ends of fittings and in making up screwed pipe joints, Teflon tape shall be applied to
male thread in manner to insure tape is not over end of male fitting.
• Piping and tubing shall be adequately supported and fixed at distances not exceeding
those in the following table.
Max Distance
Single Tubing Between Supports
6 MM. OD 0.5m
GFG-002
8 MM. OD 1.0m
12-16 MM. OD 1.5m
No.
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 10
3
• Trays shall, wherever practicable, be run with the breadth of the tray in a vertical plane.
Where a short section must be run with breadth horizontal, the breadth shall revert to the
vertical plane at the earliest possible point.
• Tubing tray, where used, shall be of standard manufacture, designed for this application
and fabricated of galvanize steel. Tray shall be of slotted design, manufacturer's standard
tees, elbows, tubing clips, mounting and fixing hardware shall be used where required
and be galvanized steel.
• Stainless steel lines shall, in certain cases, be secured by appropriate clips or laid in
small-section angle bar.
• All tubing trays and racks shall have 20% spare capacity for future use.
• Tube racks shall not be used to support other services.
• Air sub-headers or branch lines that are not within easy reach of the air main
header isolation valve shall terminate at a local, 1/2" isolation valve. The local
isolation valve shall be fixed to a bracket or mounting surface at a distance no
greater than 900 mm from each instrument, manifold, filter or regulator.
• For multiple local air supply take-offs, termination at a multi valve distribution
manifold is preferred to simplify pipe-work and reduce potential leakage paths.
• The final connection to the instrument generally shall be 6 MM. OD tubing
minimum and installed with sufficient flexibility to allow normal equipment
movement and to protect against vibration.
• Screwed ports on valves should utilize tubing adapters to align the valve to the
desired tubing run.
• Where cables are run through conduit, the entry and exit shall be smooth and free from burrs.
• Cables shall be pulled into conduit in a way that ensures there is no damage to the cable.
No.
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 13
3
7.0 GROUNDING
7.1 General
• All metallic components, other than current carrying conductors, shall be connected to a
common earth system. This includes switchboards enclosures, control panels, cable
ladders, conduit, motors, transformers, enclosures, structural steelwork and any other
exposed metal.
• All instruments and equipment furnished by Contractor in a control panel shall be
grounded effectively to the panel frame. The panel frame shall be grounded to the
packaged equipment skid, where applicable, with a grounding conductor of minimum size
35 mm2.
• A suitable lug or terminal shall be bonded to the skid frame at two diagonally opposite
corners. These lugs shall be used in connecting the skid to the platform steel structure
upon installation. The lugs shall be sized for 70 mm2 bare copper wire.
• The frames or cases of all instrument panels and mounting supports, as well as vessels,
tanks, and structural parts shall be bonded to the grounding points on the skid if they are
not attached to the skid structure by means of fusion welding.
• All conduit, cable shields, and junction boxes are to be bonded to provide a continuous
ground connection between respective items. Normally the connection will be provided
by tightly engaged conduit threads. However a bare-copper bonded grounding conductor
is to be provided inside all flexible conduits.
• Unless specified otherwise, shields of cables for analogue instruments will be ungrounded
on package skids. Care shall be taken to avoid accidental contact with grounded parts.
Shields shall be terminated and linked, in separate terminals adjacent to the signal
terminals, at the instrument junction box. Shield grounding will be at one point only,
normally at the panel in the Control Room.
• Grounding conductors shall be soft-drawn, stranded copper wire with green colour
GFG-002
insulator. Conductors shall be protected from mechanical damage and rigidly supported
on skids. Grounding conductors shall be installed in conduit where they extend over 300
mm. above skid floor.
No.
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 14
3
• Gland plates shall be bonded to the panel structure by purpose built links.
• Where insulated glands are used in metal boxes the armour shall be through connected
to other cables and connected to plant earth in another junction box. Where insulated
boxes are used, the armour shall be through connected to a separate earth source. A
separate earth bar should be specified for this purpose in all junction boxes.
• The design shall require unused cores to be correctly terminated at both ends and
earthed at one end only.
• The cable armouring at each junction box or enclosure shall be connected to earth via
gland or cable clamp. Armour may not be connected to the screen earth at any point in
the system.
• To ensure a good earthing via the frame structure (plant earth), metal clad, instrument
enclosures or housings having electric connections shall be fixed by means of bolts
having a lock washer under the nut and under the bolt.
cubicles terminating cables from hazardous areas shall have a separate, isolated earth
bar labeled "IS Earth".
No.
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 15
3
• This earthing point shall facilitate the separate earthing of intrinsically safe circuits and
cables back to the plants main earth point via two cables of at least 25 mm2, and in any
case with a total resistance to earth of less than 1 ohm.
7.4 Shielding
• Electric signal cables from field electronic instruments to control room and back to final
control elements shall be continuously shielded.
• Cable shields shall be through connected to the earth bar in the control room. They shall
be connected to the eventual field destination via insulated terminals in field mounted
junction boxes.
• For termination of shield wires, junction boxes and control panels shall be equipped with
separate terminals that follow in numeric sequence below the respective signal-core
terminals.
• Shielding shall not be used as a signal return conductor in any case.
• The field end of cable shields shall not be connected to earth.
• To avoid accidental shorting or grounding of this shield within a terminal box, the shield
end and shield drain wire between the end of the cable jacket and the terminal strips shall
be insulated by green/yellow coloured PVC sleeving.
• The maximum length of individual unshielded cores at the terminal strips should be as
short as possible, and not greater than 50 mm.
• Signal cables between buildings shall have each screen -earthed only at one end.
9.0 PAINTING
• All materials supplied by the Contractor and not already protected shall have protective
coatings in accordance with Project standards. Type 316 stainless steel panels and parts
GFG-002
10.0 PROTECTION
• The Contractor shall cover all instruments with polyethylene bags, containing desiccant for
electric or electronic devices, and plywood (to protect glass) to ensure that the instruments are
adequately.
• Protected from the weather, sandblasting and weld slag. The covers shall be kept in place at
all times, except during work on the device they protect, until they are removed for start-up.
This label shall identify Instrument tag number and full description of service. The label
shall be black letters on white background.
No.
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 17
3
• All air headers and tubing lines shall be installed with wired on 316ss engraved tag giving
applicable associated instrument tag number and service.
• All junction boxes shall be supplied and installed with traffolyte labels fixed on the front
facing cover giving junction box tag number and service. This shall be in addition to
manufacturers nameplates.
• External labels shall be stainless steel fixed with two stainless bolts or screws. The means
of attaching the labels shall not affect the equipment NEMA or Ingress Protection (IP)
rating or certification.
• Control stations, panels and similar equipment shall also carry normal operating function
labels i.e. ‘stop’, ‘start’, ‘on’, ‘off’ etc.
otherwise specified, these valves shall be needle valves, ball valves, or gate valves as required
in appropriate Project Specification.
No.
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 18
3
• The Contractor shall insure by functional test, the proper operation of all instrumentation
including but not limited to the following:
• Controllers
• Recorders
• Control valves
• Shutdown valves
The Contractor shall provide written results of all the above tests and provide reasonable evidence
of the satisfactory condition of test equipment.
GFG-002
No.
S10332300-3002 Rev.0
INSTRUMENT INSTALLATION
Date Page
18 JAN 2013 20
3