PETROVIETNAM DOMESTIC EXPLORATION OPERATING COMPANY LIMITED PROJECT DAI HUNG GAS GATHERING PROJ ECT PHASE DETAILED ENGINEERING DESIGN DESIGN BASIS for INSTRUMENTATION A 29 / 07 / 14 Issued for review.
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DHG-PVE-DD-1-IN-BOD-101 Design Basis for Instrumentation_A_290714.pdf
PETROVIETNAM DOMESTIC EXPLORATION OPERATING COMPANY LIMITED PROJECT DAI HUNG GAS GATHERING PROJ ECT PHASE DETAILED ENGINEERING DESIGN DESIGN BASIS for INSTRUMENTATION A 29 / 07 / 14 Issued for review.
PETROVIETNAM DOMESTIC EXPLORATION OPERATING COMPANY LIMITED PROJECT DAI HUNG GAS GATHERING PROJ ECT PHASE DETAILED ENGINEERING DESIGN DESIGN BASIS for INSTRUMENTATION A 29 / 07 / 14 Issued for review.
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 6/40 3.13 On/Off, Blowdown & Shutdown Valves ................................................... 30 3.13.1 General ................................................................................... 30 3.13.2 Shutdown Valve Actuator Power Source ..................................... 31 3.13.3 Actuator Types and Controls ..................................................... 31 3.13.4 Position Indication.................................................................... 33 3.13.5 Solenoid Valves ........................................................................ 33 3.14 Relief Valves ........................................................................................ 35 3.15 J unction Boxes ..................................................................................... 35 3.16 Tagging Systems .................................................................................. 36 3.17 Noise .................................................................................................. 36 3.18 Miscellaneous ...................................................................................... 36 3.18.1 Pig detectors ........................................................................... 36 3.18.2 Intruder alarm system. ............................................................. 36 4. INSTRUMENT CABLES ........................................................................... 38 5. INSTALLATION ..................................................................................... 39 6. INSTRUMENT INSPECTION, CALIBRATION AND FUNCTION TEST ............. 40 7. TRAINING ............................................................................................. 40 8. SPARE PARTS AND SPECIAL TOOLS ........................................................ 40
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 7/40 1. INTRODUCTION 1.1 Project Overview Dai Hung Field is located at Block 05-1a at North-West of Nam Con Son basin within South-East continental shelf, Viet Nam, 260km far from Vung Tau seashore. In 2011, WHP-DH2 with existing system is operated to increase the capacity of associated gas up to 1 MMSCMD. Besides the associated gas there is considerable volume of natural gas located in bottom and middle of Mioxen layer. The overall Dai Hung Gas Gathering Project as show in figure 1 below:
Figure 1: Block Diagram Dai Hung Gas Gathering System Modifying WHP-DH2 and installation pipeline between WHP-DH2 and BK-TNG is to gather and transport 1.9 BMSCM of associated gas at outlet of HHP Separator and Test Separator of WHP-DH2 to BK-TNG platform. Gas from WHP-DH2 shall be transported to Dehydration Unit on BK-TNG platform before being routed to NCS2 gas pipeline phase 1.
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 8/40 Preliminary configuration of Dai Hung Gas Gathering Project is as follows: On WHP-DH2: Gas Cooler, Gas Scrubber, Gas Engine Generator, Corrosion Inhibitor Injection Skid, Electrical System, Instrumentation System, Fuel Gas System, Fire Fighting System, Telecommunication System and other Utility Systems. The 16 subsea gas pipeline (approximately 20 km) from existing 10 riser at WHP-DH2 to BK-TNG Platform and 16 Y-Tee for future connection. On BK-TNG Platform: 16 Riser, Slug Catcher, DH Gas Custody Metering System, DH Gas Compressor Suction Scrubber, DH Gas Compressor Package, DH Gas Compressor After Cooler, Fuel Gas System, Piping System, Instrumentation System, Telecommunication System, Open/ Closed Drain System, and other Utility Systems. 1.2 Purpose of Document This design basis document describes COMPANYs Instrument Design Basis for the extisting Dai Hung Well head platform (DH2) and additional facilities on DH2. This document establishes the minimum COMPANY requirements. The CONTRACTOR may propose alternatives where technical and/or economical improvement can be demonstrated. In all such cases prior approval of the COMPANY is required. All equipment, devices and systems proposed by the CONTRACTOR shall be fit for purpose, meet proven offshore industry practice and shall fulfil the technical requirements of the COMPANY. It is the responsibility of the CONTRACTOR to ensure that any systems proposed on the basis of this document are entirely suitable for their intended purpose. For a more detailed description of Field Instrumentation, see DHF-00-I-S-0004 Field Instrument Philosophy. 1.3 Definitions and Abbreviations 1.3.1 Definitions PROJ ECT : Dai Hung Gas Gathering Project CLIENT : PetroVietnam Domestic Exploration Production Operating Company Limited (PVEP POC) EpCI CONTRACTOR : VIETSOVPETRO J OINT VENTURE (VSP)
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 9/40 ENGINEERING SUB-CONTRACTOR
: PetroVietnam Engineering Consultancy J oint Stock Company (PVE) 1.3.2 Abbreviations FPU-DH1 Dai Hung 1 Floating Production Unit Platform WHP-DH2 Dai Hung 2 Wellhead Platform BK-TNG Thien Ung Platform MMSCMD Million Metric Standard Cubic Meter Per Day BMSCM Billion Metric Standard Cubic Meter ATEX Equipment for use in potentially Explosive Atmospheres BASEEFA British Approvals Service for Electrical Equipment for Flammable Atmospheres CENELEC European Committee for Electrotechnical Standardization E/I Room Electrical / Instrument Room ESD Emergency Shutdown F&G Fire and Gas System FSO Floating Storage and Offloading Vessel FEED Front End Engineering and Design FF Foundation Fieldbus HART Highway Addressable Remote Transducer (protocol; HART Communication Foundation) MDB Mid Depth Buoy MMI Man Machine Interface MDB Mid Depth Buoy PCR Process Control Room (FPU-DH1) PCS Process Control System PLEM Pipeline End Manifold RRS Rest Room Shelter
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 10/40 SGR Switch Gear Room SIL Safety Integrity Level SIS Safety Instrumented System 1.4 Codes and Standards Statutory Requirements TVCN 6171 1996 Vietnamese Standard for Fixed Offshore Platforms Regulations for the Technical Supervision and Classification International Standards AGA 3 Orifice Metering of Natural Gas and other Hydrocarbons API STD 6D Pipeline Valves API 6FA Fire Test for Valves API 607 Fire Test for Soft-Seated Quarter-Turn Valves API 670 Machinery Protection System API RP 14C Analysis, Design, Installation and Testing of Basic Surface Safety Systems for Offshore Production Platforms API RP 14G Recommended Practice for Fire Prevention and Control on Open Type Offshore Production Platforms API RP 550 Manual on Installation of Refinery Instruments and Control Systems API RP 520 Design and Installation of Pressure Relieving Systems in Refineries API RP 521 Guide for Pressure Relieving and Depressurising System API Std 526 Flanged Steel Safety Relief Valves API Std 527 Commercial Seat Tightness of Safety Relief Valves with Metal-to-Metal Seats. API Std 598 Valve Inspection and Test ASME B 16.37 Hydrostatic Testing of Control Valves ASME B16.5 Steel Pipe Flanges and Flanged Pipe Fittings
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 11/40 ASME B1.20.1 Pipe Threads, General Purposes ASME VIII Pressure Vessels Division 1 and 2 ASME B31.3 Chemical Plant and Petroleum Refinery Piping ASME B46. 1 Surface Texture ASME PTC 19.3 Instruments and Apparatus. Part 3: Temperature Measurement ASTM-A 262 Detecting Susceptibility to Intergranular Attack in Stainless Steel ATEX Directive 94/9/EC Legal requirement concerning equipment and protective systems intended for use in potentially explosive atmospheres in all European Union Member States CCITT V.24 List of Definitions for Interchange Circuits Between Data Terminal Equipment (DTE) and Data Communications Equipment (DCE) EN 10204 Metallic Products Type of Inspection Documents EIA-232E Interface between Data Terminal Equipment and Data Communication Equipment Employing Serial Binary Data Interchange EIA-422 Electrical Characteristics of Balanced Voltage Digital Interface Cards ERA 75.3L Code of Practice for Avoidance of Electrical Interference in Electronic Instrumentation and Systems FCI-70-2 Quality Control of Standards for Control Valve Seat Leakage IEEE 472-1974 Surge Withstand Capability Test, Guide for (ANSI C37.90.1-1974) IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres IEC 60228 Conductors of Insulated Cables IEC 60331 Fire Resisting Characteristics of Electric Cables IEC 60332 Tests on Electrical Cables Under Fire Conditions IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 12/40 IEC 60534 Industrial-Process Control Valves IEC 60584-1 Thermocouples PT 1 Reference table IEC 60584-2 Thermocouples PT 1 Tolerances IEC 60584-3 Thermocouples. Part 3: Extension and Compensating Cables - Tolerances and identification System IEC 60751 Industrial Platinum Resistance Thermometer Sensors IEC 60801 Part 1 EMI and RFI Immunity. Electromagnetic compatibility for industrial process measurement and control equipment IEC 61158-2 Foundation Fieldbus Standard for use in Industrial Control Systems- Physical Layer Specification and Service Definition. IEC 61508 Functional Safety of Electrical / Electronic / Programmable Electronic Safety Related Systems IEC 61511 Functional Safety - Safety instrumented systems for the process industry sector IEC 610000-4-2 Electromagnetic Compatibility EMC Requirements IEC 60092.3 Cables - Construction, Testing & Installation IEC 60754-1,2 Measurement / test on gas evolved during combustion IEC 61034-1,2 Measurement / test of smoke emission ISA S5.1 Instrument Symbols & Identification ISA S18.1 Annunciator Sequences and Specifications ISA S50.1-82 Compatibility of Analogue Signals for Electronic and Industrial Process Instruments ISA S75.01 Control Valve Sizing ISA S75.02 Control Valve Capacity Test Procedure ISA S75.03 Valve Bodies Face to Face Dimensions for Flanged Globe Style Control Valves ISO 5167 Measurement of Fluid Flow by Means of Orifice Plates, Nozzles and Venturi Tubes Inserted in Circular Cross Section Conduits Running Full
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 13/40 ISO 10497 Testing of Valves Fire Type Testing Requirements MSS-SP-82 Valve Pressure Testing Methods NACE MR-01-75 Material Requirements - Sulphide Stress Cracking- Resistant Metallic Materials for Oil field Equipment 1.5 References The Instrument Design Basis forms an integral part of all mandatory documents including the following: As built Documents: DHF-00-E-S-0018 General Equipment Specification for Power and Instrument Cable WHP-DH2-I-S-0001 Specification Process Control System (PCS) WHP-DH2-I-S-0002 Specification Safety Instrumented System (SIS) DHF-00-E-S-0010 Specification for Electrical Requirements for Packaged Equipment DHF-00-M-S-0003 Paint and Protective Coatings WHP-DH2-R-T-0002 Process Control Philosophy WHP-DH2-P-S-0001 Specification Addendum for piping materials DHF-00-P-S-0002 General Specification Piping Materials DHF-00-R-S-0001 System Valving & Isolation Philosophy DHF-00-I-S-0005 General Specification for Actuated On/Off Valves DHF-00-I-S-0006 General Specification for Control Valves Project Documents: DHG-PVE-DD-1-PR-BOD-101 Process Basis of Design DHG-PVE-DD-1-PR-MAN-101 Operation & Maintenance Manual (OMM) DHG-PVE-DD-1-PR-PHI-101 Shutdown & Blowdown and Isolation Philosophy DHG-PVE-DD-1-PR-PHI-102 Operation & Control Philosophy DHG-PVE-DD-1-PR-PHI-103 Pre-Commissioning, Commissioning and Start-up Philosophy DHG-PVE-DD-1-IN-PHI-101 Instrument Control and Telecom Philosophy DHG-PVE-DD-1-IN-SPC-104 Control Narratives - Process Control System
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 14/40 DHG-PVE-DD-1-IN-CHA-101 SIS (ESD & FGS) Cause and Effect Charts DHG-PVE-DD-1-IN-DBD-101 Instrument PCS/SIS/Telecom System Block Diagram 1.6 Service Conditions Location: The Dai Hung Full Field Development is located offshore south east of Vung Tau, Southern Vietnam. Environmental Conditions External Conditions: Ambient Temperature: 15 deg C min. to 35 deg C max. Environment: Salt Laden: Salinity 35 Max. Relative Humidity 100% Wind: 26 m/s (1 minute), 29 m/s (3 sec gust) @ 10m above mean sea level. Indoor (E/I Room): Natural Ventilated Room Temperature: Max +35 C Nominal +28 C Min 19 C Humidity 90%R.H. non-condensing Area Classification Non hazardous 1.7 Hazardous Area Classification Instrumentation installed within a hazardous area shall be certified for use in the degree of hazard in which it is installed. For most instruments, a Zone 2, gas group IIA, and temperature rating T3 certification would be appropriate. However, in order to permit interchange of instruments and for standardization purposes, all electrical equipment (instrumentation and telecommunication) located on the WHP-DH2 hazardous area, shall be as a minimum, certified suitable for a Zone 1, Gas Group IIB, temperature class T3.
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 15/40 All electrical and electronic equipment located in hazardous areas, shall be certified to IEC / CENELEC / ATEX standards or equivalent BASEEFA standards. Devices connected to an Exi certified circuit must be of increased safety construction to Exe standards and deviations from this must be agreed in writing by the COMPANY. 1.8 Utilities The following power supplies and utilities will be available for use by the Vendors package from the Purchasers supply systems. Electrical Supplies 220 V AC (10%), 60 Hz ( 5%), 24 V DC (10%) with battery back up for instruments Pneumatic Supplies Clean, dry, substantially oil-free instrument gas. The clean and dry gas will be available for use by Vendor package from Purchasers supply system. Instrument Gas Minimum 550 kPag (80 psig) for sizing actuator Nominal 690 Kpag (100 psig) Maximum 830 kPag (120 psig) Maximum Design As indicated on the data sheet Quality Saturated 1.9 Units of measurement
Measured Value Unit Symbol Flow mass kilograms/hour kg/hr Flow - volumetric cubic metres/hour m 3 /hr Volume cubic metres m 3 Level metres / millimetres m or mm Pressure gauge kiloPascals (gauge) kPag
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 16/40 Pressure absolute kiloPascals (absolute) kPaa Flow mass kilograms/hour kg/hr Flow - volumetric cubic metres/hour m 3 /hr Volume cubic metres m 3 Level metres / millimetres m or mm Pressure gauge kiloPascals (gauge) kPag Pressure absolute kiloPascals (absolute) kPaa Differential Pressure millimetres Water Gauge mmwg Temperature degrees Celcius o C Length metres / millimetres mm, m Density kilograms/cubic metre
kg/m 3 Dynamic Viscosity centipoise cP Kinematic Viscosity centistokes cSt Sound Pressure decibels dBA 2. GENERAL REQUIREMENTS 2.1 Overall Concept The main data processing equipment will be housed in an E/I Room on the Wellhead Platform. Consideration should be given to space conservation when considering the layout of the terminal panels within the equipment room. The Wellhead Platform (WHP-DH2) shall be controlled remotely from the FPU via fiber optic based high speed network interface with the FPU-DH1 operator station. The amount of equipment located on the Wellhead platform should be kept to a minimum. All cabling on the WHP-DH2 for the PCS, SIS (ESD and F&G) will go through the junction boxes.
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 17/40 2.2 Environmental Protection The minimum ingress protection according to IEC 60529 applied for instrumentation equipment shall be: IP42: Equipment located inside enclosure hoods IP65: All equipment to outdoor weather conditions The instrumentation equipment selected especially the electronic parts and circuit boards shall be suitable for tropical, humid, salt laden, marine offshore environment. All field devices exposed to direct sunlight (e.g. instruments on main deck), shall be protected with weather protection enclosures or sunshades. 2.3 PCS Instrumentation PCS system shall be interfaced with 4-20mA analogue smart instrumentation using HART protocol. For the WHP-DH2 platform, the PCS system shall consist of the following 1 Operator Station (with Engineering facility) PCS System cabinet with Controller, I/O Module, Memory and Power supply. Fibre Optic converters c/w Ethernet switches, FO patch chords, connectors, patch panels etc. Marshalling cabinets Serial Interfaces The PCS shall provide a single reporting point for all alarms which shall be time stamped from the F&G and ESD systems. The PCS shall be serially interfaced to any other subsystems as applicable to the project for monitoring and control purposes. PCS, ESD and FGS system shall share a common network of communication to form an Integrated Control System network. Data from the ESD and Fire and Gas System shall be available in the PCS for monitoring purposes seamlessly. DH2 PCS system on FPU-DH1 The PCS system at the WHP-DH2 and the operator station at the FPU-DH1 will be on the same communication network connected by Fiber optic cable between WHP-DH2 and FPU-DH1. At the FPU-DH1, the following are proposed 2 Operator station (1 operator station will have Engineering facility)
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 18/40 Fiber optic converters c/w switches , patch panels , patch chords, connectors etc. 1 PCS system cabinet with controller and I/O The controller and I/O module will interface the signals that are part of the WHP-DH2 export pipeline tie in into the FPU-DH1 facility. Wellhead control panel signals and intruder alarm system will be hardwired to PCS system for monitoring. Sequence of Event recording function shall be provided in the PCS system and be located in the FPU-DH1 facility. This sequence of event shall be combined with the SIS system. The resolution of the time stamping shall be less than 10 ms. 2.4 SIS Instrumentation SIS system shall consist of the ESD and Fire and Gas System. The SIS system shall be SIL3 rated system in order to execute SIL 3 rated loop functions if required. The SIS system design shall comply with IEC 61508. Fire and Gas System can be combined with ESD system cabinet to save space, however dedicated I/O modules to be provided for ESD and Fire and Gas System. All field instrument dedicated for safety functions (e.g. PZLL, XZV) shall be hardwired to the SIS directly. These instruments shall as far as possible be HART type. The SIS must be of a type that is capable of interfacing with Instruments using HART protocol or use a separate HART interface. Wellhead control panel signals will be hardwired to SIS system for logics and ESD functions. SIS system shall be integrated with PCS system communication network for operation and monitoring through operator station. SIS system shall have engineering facility which can be combined with PCS engineering station. However if combined Engineering facility for the PCS and SIS system is not feasible, then dedicated engineering station shall be provided for the SIS system. SIS system shall be provided with maintenance override /start up override functions as required
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 19/40 2.5 PAGA System WHP-DH2 platform shall not have any PAGA system. However, General alarms and annunciations shall be provided in the Wellhead platform which will be interfaced with the Fire and Gas System. 2.6 Wellhead Control Panel The WHCP will be an electro hydraulic Wellhead Control Panel (WHCP) for the monitoring and control of the wellhead flowlines, topsides pneumatically hydraulically actuated on/off and control valves. While pneumatically (instrument gas) operated on/off valves will be controlled directly from PCS/SIS. In addition, the WHCP shall be suitable for interfacing with the PCS and SIS as defined in applicable specification for well status, control and shutdown. All equipment, devices and systems of the WHCP shall be fit for purpose and shall fulfil the requirements of this specification. Wellhead control panels shall be designed for the following valves SCSSV, SSV(MV/WV) of the 12 well slots Choke Valves Riser ESD valves The Wellhead control panels shall be designed to provide High, medium and Low Pressure as necessary for the valve actuators. Further details of the WHCP shall be as per the specification WHP-DH2-I-S- 0004 3. FIELD INSTRUMENTATION PROJ ECT REQUIREMENTS 3.1 General All local instruments, where possible, shall be close-coupled to provide a good representational measurement of the process conditions, otherwise they shall be mounted remotely utilising the shortest possible impulse line lengths. Impulse lines will also be heat-traced and insulated where required to prevent crude waxing or hydrate formation, as applicable to service. All instruments shall be located and mounted to minimise the effects of vibration and to provide each item with adequate access for maintenance. The orientation of housings shall, where possible, permit operators to observe scales whilst adjusting related instruments. Escape routes shall not be
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 20/40 obstructed by instrumentation supports and equipments. Wherever possible, instrument mounting heights from grade or skid-access platform levels shall be between 1.3 m and 1.6 m. Handrails shall not be used for supporting instruments, impulse piping or cabling. Transmitters will be provided with integral local digital indication in engineering units, in lieu of local gauges, provided they can tolerate the minimum and maximum operating and environmental temperatures. Where indication is required at a location remote from the transmitter, signals will be repeated via either an analogue output from the process control system or an inline loop-powered indicator - depending upon loop type. The use of multivariable transmitters for non-critical control and monitoring will be maximised. Where process applications exist that require both a process control and a SIS instrument, then the instruments shall be specified to have identical ranges (i.e. offset and span) for the purpose of comparison between the instruments and for discrepancy alarms to be generated in the PCS. 3.2 Instrument Materials & Rating The pressure, temperature and materials rating of all instrument wetted parts and casings and their associated fittings shall conform to, or exceed, the design pressure / temperature of the process system or service to which they are connected and the environment in which they are to be installed. In particular, all soft goods (e.g. elastomers) subjected to the process conditions shall be selected on the basis of resistance to explosive decompression, chemical compatibility and suitability for the design pressure and the design maximum to minimum temperature range. Sensing element chamber and housing design shall be such that element failure does not cause the housing to become pressurised. Where appropriate to meet this requirement, a blow-out disk shall be provided preferably in the bottom of the housing. Materials (including bolting) for in-line instruments shall be, as a minimum, in accordance with the piping specification. However, where suitable, an appropriate grade of stainless steel may be used for the internal trim and/or body. Direct connections between process fluids and control or equipment rooms will not be permitted.
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 21/40 The use of brass or copper bearing alloys shall not be permitted. The use of aluminium for instrumentation bodies/casings shall be only permitted if available as Marine Grade, low copper, and the combined magnesium and titanium content is less than 0.6% and the surface is coated to prevent corrosion from the environment and sparking by abrasion with iron objects. Precautions are required to be taken to isolate aluminium from other metals to prevent galvanic corrosion, e.g. by the use of nylon washers, neoprene gaskets, etc with given approval from Company. 3.3 Instrument Process Connections & Hook-ups The process connections on all non-flanged instruments shall be NPT, while flanged instrument connections shall be ASME Class 150 RF on piping and on vessels, as a minimum, or in accordance with the Specification for Piping and Materials. Where non-carbon steel flanges are to be provided (eg 316SS), these shall meet the design pressure of the process, or an increase in the ASME class rating be made to achieve this. The process hook-up for hazardous fluids shall utilise integral double block and bleed units for process isolation at the instrument process tie-in points in accordance with the System Valving and Isolation Philosophy, DHF-00-R-S- 0001. Excess flow valves (such as Swagelok XS Series) shall also be fitted on all non- flowing instrument process tie-in points, utilising impulse lines in clean hazardous gas services above 2 MPag normal operating or 5MPag design pressure. This is to limit the release of hydrocarbon gas should the impulse line or fittings fail. Excess flow valves shall not be installed on compressor protection and surge applications. The instrument, if mounted remote from the process line, shall be connected using impulse tubing and compression fittings. At the instrument, an instrument manifold (2 or 3 valve for pressure, 5 valve for dP) shall be fitted for calibration. Furthermore, it shall be possible to remove the instrument whilst leaving the instrument manifold, impulse tubing and compression fittings in-situ. The process hook-up for non-hazardous fluids shall utilise integral single block and bleed units at the instrument process tie-in points in accordance with the System Valving and Isolation Philosophy, DHF-00-R-S-0001.
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 22/40 3.4 Instrument Tubing & Fittings All tubing and fittings shall be of imperial size, not soft metric. As a minimum, tubing shall be 316L stainless steel to ASTM A269, cold-drawn, seamless, fully annealed, pickled, have a minimum Molybdenum (Mo) content of 2.5% with surface hardness between 70 and 74 (but no more than 80) on the Rockwell B scale (Rb80). Tubing services up to 60C may use 316L stainless steel. Tubing services above 60C are subject to chloride stress corrosion cracking (CSCC) and shall have materials selected to suit the service. Compression fittings shall be Swagelok manufacture and 316L stainless steel as a minimum, selected to service requirements. Tubing of sufficient wall thickness shall be installed to meet the design pressure of the system to which it is connected. Tube sizes as presented in the following table shall be used. Note that standard wall thickness shall be used to minimise the possibility of low pressure tubing inadvertently being used in high pressure service.
SERVICE SIZE COMMENT Process Sensing 3/8 x 0.049 WT x 0.065 WT
Wellhead Control and Hydraulic tubing x 0.049 WT 3/8 x 0.049 WT
Process Flow or Sensing for Differential Pressure Instruments x 0.065 WT Instrument Gas Supply - (Upstream of Regulators, Panels, etc.) 3/8 x 0.049 WT x 0.065 WT
Manual Deluge, Control Signals, Fusible Plug Loops, & Instrument Gas Downstream of Regulators 3/8 x 0.049 WT Vent and Drain Tubing x 0.065 WT Sea Water Service 3/8 x 0.049 WT x 0.065 WT Monel
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 23/40 Recommended Maximum Allowable Working Pressure (ASME B31.3)
0.049 WT 0.065 WT Tubing Size <=94 o C <=204 o C <=94 o C <=204 o C 316SS 48,610kPa 46,665kPa 3/8 316 SS 31,110kPa 29,866kPa 42,128kPa 40,443kPa 316 SS 23,981kPa 23,022kPa 33,055kPa 31,732kPa 3/8 Monel 30,338kPa 23,967kPa 42,404kPa 33,499kPa Monel 22,064kPa 23,967kPa 30,338kPa 33,499kPa
Fittings subject to high vibrations, e.g. large rotating machinery packages, or high pressures, such as hydraulic power units, may employ a special type of compression fitting. The manufacturer and model number of each type will be determined and subject to approval during Detailed Design. 3.5 Accuracy All field transmitters shall have accuracy, linearity, repeatability and turndown suitable for the application. Typically, for field instrumentation an accuracy of 0.1%fsd or better is achievable. 3.6 Reliability and SIL Level Requirements for Field Instruments Critical instrumentation loops shall have SIL (Safety Integrity Level) / AK (Auforderungs klasse) classifications assigned. SIL level evaluations, and calculations shall be made in compliance with IEC-61508 guidelines. The following aspects specific to field instrument(s) selected and installed for each loop shall be considered in these studies and calculations: Instrument failure rate data Diversity and redundancy Specific hookup requirements Isolation requirements
DAI HUNG GAS GATHERING PROJ ECT DETAI LED ENGI NEERI NG DESI GN PHASE DESIGN BASIS FOR INSTRUMENTATION
Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 24/40 3.7 Flow Instruments General process flow measurement will preferably be carried out using orifice plate meter runs. Calculation of orifice diameter ,straight lengths and manufacture of primary elements and meter tubes will be in accordance with AGA-3 Part 1 (1990), 2 (2000) and 3 (1992) Nozzles, venturis and other pressure differential devices shall be in accordance with ISO-5167 Part 1 (1991) complete with Amendment 1 (1998). Ultrasonic meters shall be in accordance with AGA9 and / or MFC 5M. Calculation of compressibility and/or super-compressibility shall be in accordance with AGA- 8. Calculation of hydrocarbon gas calorific value, density and/or wobbe index shall be in accordance with ISO 6976. Determination of measurement uncertainty shall be in accordance with IS-5168.Other flow metering methods such as coriolis, turbine, averaging pitot tubes, vortex, nozzles, venturis, mag- flow, or V Cone will be considered where appropriate. Such instruments may be used where the benefits of increased accuracy, simplicity of installation, turndown, multiphase or bi-directional flow justify the higher equipment cost. For custody or fiscal transfer applications, multi-path ultrasonic flow meters shall be preferred a flow computer will typically be used for performing the flow computation and totalisation. For other applications, preference should be given to using PCS to perform the flow computation and totalisation. Where flow computations are performed in proprietary flow computers, the computed flow signals will be connected to the PCS via a serial communications link utilising an industry standard protocol, e.g. Modbus RTU. The non-fiscal data sent to the PCS will be configured in the PCS for inclusion into production reports, display on graphics, and for hand off to the production reports. 3.8 Level Instruments Vents and drains shall be provided on all external cage / chamber level instruments. Valves shall be connected to the external cage by means of flanged connections. Vent and drain hookups shall conform to the details given in document DHF-00-R-S-0001 Design Standard: System Valving and Isolation Philosophy. For all applications, the difference between liquid density and gas / vapour density should be taken into account when specifying displacer instruments or calculating the range of differential-pressure instruments.
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 25/40
External cage mounted displacer or float instruments shall utilise standard Vendor ranges: mm 356 559 813 1219 1524 in 14 22 32 48 60 Flange rating for the level instruments shall follow the equipment /vessel rating. 3.8.1 Level Gauges For local level indication the following types shall be used, in decreasing order of preference: Magnetic follower-type level gauges complete with external shuttle indicators, where the fluid specific gravity and design pressure and temperature allows the use of floats. Armoured gauge glasses, complete with gauge cock isolation valves and integral ball check blow-out protection. Reflex type gauge glasses shall be used for clean and colourless liquids, except liquid-liquid interface. Transparent type gauges shall be used for liquid-liquid interface, for dirty liquids service and for fluids that change colour when contaminated. Transparent gauge glass illuminators shall be avoided wherever possible due to the inherent high maintenance involved with illuminators located in high saline environments and/or hazardous areas. Local area lighting shall be supplemented to permit transparent gauge glass level readings to be taken. Glass type level gauges may be utilised on utility systems at atmospheric pressure. These may be of the welded pad or of the protected tubular glass style. 3.8.2 Level Switches Level switches initiating trip or safety instrumented system shutdowns shall have the float or displacer type primary element mounted in external chambers direct onto vessels complete with double block and bleed isolation (refer System Valving and Isolation Philosophy DHF-00-R-S-0001), i.e. not bridle mounted. The use of level switches shall be minimised as far as practically possible in preference for level transmitters.
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 26/40 3.8.3 Level Transmitters For level transmitters the following types shall be used, in decreasing order of preference: Float with magnetostrictive pick-up (complete with magnetic level gauge pick-up), where the fluid specific gravity, design pressure and design temperature allows the use of floats Displacer torque tube for all other applications Radar The use of other forms of level measurement, such as ultrasonics, nucleonics or differential pressure will be considered if the above methods are evaluated as unsuitable. 3.9 Pressure Instruments Over-range protectors shall be fitted to pressure elements where abnormal maximum pressures exceed the normal maximum operating range. Pulsation dampening methods shall be used where gauges are installed on the pump discharge. 3.9.1 Pressure Gauges For local pressure indication, bourdon tube type pressure gauges shall be used. Gauges shall have stainless steel movements, 100mm dial size, liquid filled and SS or phenolic case. The over range protection shall be 130% of the design pressure. Gauge ranges shall be selected from the following series, such that the normal working pressure is between 50% and 75% scale, and provided the maximum working pressure is within the instrument range: -100, 0, 100, 200, 300, 400, 600 kPa 1, 1.6, 2.5, 4, 6, 10, 16, 25, 40, 60, 100, MPa Where the diaphragm seals are specified, it shall be provided with integral diaphragm. Pressure and temperature rating shall be in accordance with datasheet. 3.9.2 Pressure Switches The use of pressure switches shall be minimised as far as practically possible in preference for pressure transmitters. Pressure switch measuring elements may be bellows or diaphragm type.
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 27/40 The deadband shall be significantly less than the difference in pressure between the normal operating pressure and the setpoint. Setpoint shall be within the middle 80 percent of the adjustable range. Setpoint adjustment shall be internal. Electric switch contacts shall be snap-acting, single pole, double throw (SPDT) as a minimum. 3.9.3 Pressure Transmitters For pressure and differential pressure transmitters, the pressure sensing elements shall consist of a diaphragm or bellows, as appropriate, in combination with either a capacitance capsule or an electrical strain resonance frequency transducer unit. All transmitters will be provided with local digital indication integral with the unit. The scale on transmitters will be in engineering units. However 4-20mA transducer type transmitters without integral indication may be accepted for the instruments those are located inside control panel(s). 3.10 Temperature I nstruments 3.10.1 Thermowells All temperature elements shall be installed in flanged thermowells, except for those applications requiring the measurement of surface temperature. Screwed thermowells are not permitted. Thermowells are typically 1 flanged connection for ASME 600# and below and 2 flanged connection for ASME 900# and above. Thermowell material shall be machined in a tapered configuration from a single bar stock. Material shall be 316 stainless steel as a minimum, Welded construction is not acceptable. Thermowells shall be designed to withstand hydrostatic testing conditions. Thermowells shall have wake frequency and stress calculations provided in accordance with ASME PTC 19.3. The thermowell immersion length shall place the measuring element near the centre of the pipe. Wells for insulated vessels and lines shall have extension necks and penetrate a minimum of six inches inside the vessel. The number of fittings used to meet the extension length requirements shall be minimised. Insertion length U shall be preferably be selected from 225, 300 or 450 mm.
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 28/40 Test wells shall have a screwed plug and chain. 3.10.2 Temperature Gauges Seal material shall be compatible with the process fluid wherever capillary is used between the seal end and instrument , the capillary shall be supported through out the entire length of the capillary. Capillary sealing system shall be factory welded. For local temperature indication, bi-metallic all-angle gauges shall be used. Gauges shall have 100mm dial and be liquid filled. Standard ranges are: -30/160, 0/160, 0/250, 0/400 o C 3.10.3 Temperature Switches The use of temperature switches is not permitted for critical devices. Trip and safety instrumented system duties shall be achieved with temperature transmitters and a trip derived in the receiving control or shutdown equipment or panel. 3.10.4 Temperature Transmitters For temperature transmitters, the sensing element shall use RTD technology for temperatures from minus (-) 50C up to + 400C and K-type thermocouples for 400 to 800C, as appropriate. RTD sensing elements shall be manufactured from platinum, have a resistance of 100 ohms at 0C, be of the 3-wire type for general use, and of the 4-wire type for metering applications. Flare pilot monitoring shall use either K-type (chromel-alumel) thermocouples complete with compensated cables, or piezo-electric pick-ups, depending on the flare tip type and manufacturer. 3.11 Analysers The following analysers shall be implemented as necessary: Water Cut Analyser together with the Net Oil Computer for monitoring water and oil content of well testing and production purpose. 3.12 Control Valves The following valve types shall be considered for modulating service: Globe (single or double seat)
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 29/40 Rotary (eccentric plug or segmented ball) Axial Characterised ball Butterfly Generally, globe style control valves will be specified, except where large sizes, high pressure, large capacities, high pressure drops or other adverse operating conditions make other types more suitable. Hardened trim materials (eg stellited SS, tungsten carbide shall be considered for erosive, cavitating, flashing or high dP/temperature service). Control valves shall be sized in accordance with IEC 534-2-1 and 534-2-2, or Vendor-supplied sizing software. Valve noise predictions shall be calculated in accordance with IEC 534-8-3 and 534-8-4. The selected control valve vendor shall supply final sizing calculations and valve trim recommendations, including turndown. The predicted noise shall not exceed 80 dB(A) sound pressure level (SPL) at 1 metre from the valve in any direction under normal operating conditions. This SPL is to permit more than one noise source to be located in close proximity to each other without exceeding 85 dB(A) in the general area. Special low noise valve designs shall be considered to meet these noise SPL criteria. Control valve flange-to-flange dimensions shall be standard to ISA (eg ISA S75.03). Where pressure classes and/or sizes are greater than those covered by ISA, then manufacturers standard shall be used. The use of flangeless valves for flammable, toxic or hot fluids and in locations with high fire risk is not permitted. Flanges will conform to ASME B16.5 for size 24 NB and below valves. Control valves shall have shut-off classifications in accordance with FCI-70-2. The following shut-off class shall be implemented: Globe Class IV (or Class V, where required by process conditions) Rotary Class IV (or Class V, where required by process conditions) Axial Class IV (or Class VI, where required by process conditions) Ball Class IV (or Class VI, where required by process conditions) Butterfly Class II (or Class IV, where required by process conditions)
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 30/40 Control valve actuators shall generally be pneumatic diaphragm or piston type, with spring return to a fail position. They shall be selected and sized for the highest pressure differential to which the valve will be subjected. A positioner shall always be provided on piston-operated valves in throttling service regardless of the response speed of the process systems. Only valves used on on/off control applications may be operated without a positioner. Positioners fitted shall be a Smart HART digital electro-pneumatic type. For split range control, the split-ranging shall be performed in the process control system and each valve positioner shall receive a full 4-20mA signal. Positioners shall be direct or reverse acting as necessary to ensure that the valve fail state is ensured upon open circuit of the 4-20mA control signal. 3.13 On/ Off, Blowdown & Shutdown Valves 3.13.1 General The following valve types shall be acceptable for services indicated in the following table. Table 11.1 - Service Application for On/ Off, Blowdown & Shutdown versus Valve Styles
Valve Type On/ Off Shutdo wn Blowdown May be Used with Fluid Category (as per IP 15) Axial Yes Yes Yes Hazardous Fluids A, B, C&G Non-Hazardous Fluids Ball Yes Yes Yes,with Restriction Orifice Hazardous Fluids A, B, C&G Non-Hazardous Fluids Ball Rising Stem Yes Hot service Yes No Hazardous Fluids A, B, C&G Non-Hazardous Fluids Butterfly Yes Yes No Hazardous Fluids C & G (ASME Class 300 and below) Non- Hazardous Fluids
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 31/40 Through Conduit Gate Yes Yes No Hazardous Fluids A, B, C&G Non-Hazardous Fluids
The above valve types shall be standard to API 6D, or for axial flow and butterfly valves, meet the intent of API 6D with respect to leakage class and/or face-to-face dimensions. All above valve types installed in a hydrocarbon service shall be of antistatic design. Furthermore, all shutdown and blowdown valves in a hydrocarbon service shall be certified fire-safe to either BS 6755 Part 2, API 607 or ISO 1049. Note that on/off valves not in a hydrocarbon service are not required to be certified fire-safe or of antistatic design. Butterfly valves used with hazardous fluids shall be of either the flanged or lugged wafer type, while butterfly valves used with non-hazardous fluids may be of the wafer type. For blowdown valves, it is generally expected that they shall be of the ball type, complete with a restriction orifice on the downstream side. Where it is determined that the noise level for this combination will exceed 120 dB(A), or exceed 111 dB(A) for 2 minutes, then the use of an integral purpose-designed blowdown valve shall be considered. 3.13.2 Shutdown Valve Actuator Power Source The energy source to close a power-assisted emergency isolation valve shall be an independent, reliable source that is not subject to electrical power or common mechanical failures and that will remain operative during a fire for 20 minutes or more. The only power source that may be considered for failing safe shutdown valve applications isa mechanical spring sized for driving the emergency isolation valve to the appropriate, air or power gas or hydraulic failure-mode position. Manually operated emergency isolation valves will not be used. 3.13.3 Actuator Types and Controls Actuators shall generally be one of the following types, depending on valve size, type and ASME Class: Pneumatically-operated, spring return, single-acting scotch yoke Pneumatically-operated, spring return, single-acting linear
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 32/40 Pneumatic actuator shall use Instrument gas as the actuation medium All actuators for ESD valves shall have provision for manual operation in case the stored energy is exhausted. Manual hand-wheels or backup hydraulic operators shall be capable of being locked out or sealed in the non-actuated mode. Automatic operation of the actuator shall not overrule manual actuator operation, except where ESD signals interface with integral MOV, remote/off/local selector switches. ESD commands shall override integral MOV selector switch signals except when the integral MOV selector switch is located in the 'off' position. An MOV shall provide a signal to the ESD system when its local selector switch is switched to the 'off' position. Stroking speed shall be specified to meet plant operational requirements and process dynamics. Careful attention shall be given to the specification of closing speed for pipeline applications, to avoid potential surge and/or water hammer effects resulting from rapid valve closure. Partial stroke valve testing shall be achieved by using HART digital positioners fitted to the valve and interfaced to suitable software on the PCS System. Additionally the positioner shall perform valve performance / signature tests. The addition of the HART positioners shall not impair solenoid valve initiated valve operation in response to an SIS trip command. Actuators and associated components shall be fail-safe by design. Actuators shall be sized to operate the valve at full ASME Class differential pressure with a safety factor of 1.5 times used for differential pressures applied from either end of the valve at the minimum specified supply pressure for the actuating medium utilised.The 1.5x margin shall be applied to break, run and seat torques with the valve operating in both directions. Actuators shall be rated for the power medium design pressure. Actuator overpressure protection by relief valve within the pneumatic control circuit is NOT permitted. The use of electric actuators shall be considered on a case-by-case basis in the event that the above actuating techniques are evaluated to be unsuitable. In particular, the First Valve On (FVO) and Last Valve Off (LVO) ESDVs shall be provided with priority accumulation for 3 valve operations, regardless of actuator type. Furthermore, it may also be a requirement that these ESDVs be fire-protected with a suitable intumescent coating. In such cases, their associated local control panels shall also be protected by suitably fire-rated enclosures.
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 33/40 3.13.4 Position Indication Critical actuated valves shall be provided with open and closed position indication. The indication mechanism, in general, shall be discrete output devices, e.g. switches. The use of analogue position indicators shall be considered on a case-by-case basis as an alternative. Furthermore, all position indication devices shall be provided with visual beacons, i.e. mechanical travel indicators showing 0-100% travel. The position indication mechanism, visual beacon and termination enclosure shall be provided as a complete unit. Position indication switches shall be hermetically sealed and/or encapsulated, of the magnetic proximity simple device type with noble metal contacts with a minimum rating 0.5A at 24 Vdc. They shall be configured to present closed contacts at the ends of travel.
Tag Number Function Valve Open Valve Mid Travel Valve Closed ZSO-xxxx Open Limit Switch Closed Circuit Open Circuit Open Circuit ZSC-xxxx Closed Limit Switch Open Circuit Open Circuit Closed Circuit
3.13.5 Solenoid Valves Solenoid valves shall be manufactured from 316L stainless steel, as a minimum. They shall exhibit the following features: 3-port, 2-way changeover design, Direct acting (internally piloted solenoid valves shall not be used where two solenoid valves are required in series). Operate on a supply of 18 to 28 Vdc, with pull-in at 18 Vdc. Utilise a protection method against back EMF effects Solenoid coil insulation class H Solenoid valve power shall be less than 5 watts. Complete with a termination enclosure Solenoid valves shall either be automatic reset or local/remote manual reset as appropriate for the application. In general the following will apply:
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 34/40 Service Typical Action Reset ESD valve Valves always latch (SIS latch) when tripped. Electrical reset pushbutton local to the valve. PSD Valve Valves typically latch (SIS latch) when tripped. Some may auto-reset (no individual valve reset required) on reset of the applicable PSD trip. Software reset typically available to the Operator on the PCS MMI. Valves performing both PSD and specific ESD service. On a PSD trip, the SIS latch function operates as described above. In the event of a PSD trip, the valve can be reset from the PCS MMI. On an ESD trip, the SIS latch function operates as described above. In the event of an ESD trip, the valve will require manual reset on the MMI softkey to provide PSD reset. Blowdown Valves Typically valves auto-reset (closed) upon reset of the applicable blowdown trip. N/A Switching / Routing Valves <Application Specific> <Application Specific> Solenoid Valves in non-valve applications (eg. deluge, wellhead control panel, chem inj pumps etc) <Application Specific> <Application Specific>
Mechanically-latching solenoid valves shall not be used.
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 35/40 3.14 Relief Valves Pressure relief valves shall be designed, constructed, tested and installed in accordance with ASME and API RP 520. Relief valves will have, where possible, standard dimensions in accordance with API Standard 526. Balanced-bellows relief valves shall be considered in the following duties except where the operating conditions preclude their use, or where the size of the selected valve would be unacceptable: Where possibility of hydrate or wax formation may occur High backpressure (>10% of setpoint) Corrosive service (including sea water) Pilot-operated valves may be considered on certain process applications where clean (non-dirty, non-wax forming or non-hydrating services) liquids or gases are the process medium. The use of pilot-operated valves, on their own, in potential dirty, wax or hydrating services is not permitted. The effective flow area of the orifice selected shall exceed the calculated area by an amount limited by the standard effective sizes available. Pressure relieving valves shall be constructed such that in the event of a fire the operation of the valve is not compromised due to the partial or complete destruction of the internal components. Valves shall generally have metal-to-metal seats. Resilient seat seals shall be considered on services where maximum tightness is essential, where the operating pressure is greater than or equal to 93% of the set pressure, and to limit leakage which may be caused by the effects of corrosion or vibration. 3.15 J unction Boxes Instrument junction boxes shall generally be Ex e certified and located either on equipment skids or local to process/utility areas. Preferred junction box construction shall be AISI 316L stainless steel, however UV stabilised ABS may be considered provided durability and robustness are not compromised. Individual junction boxes will be provided to segregate differing system functionality, voltage levels and signals as detailed in section 3 of this specification. During design, an allowance for future use of 20% spare terminal blocks shall be provided in all multicore junction boxes. The junction box and associated
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 36/40 terminals shall be designed to permit the termination of all spare wires/cores. All drains and shields shall be terminated to a separate insulated earth bar in the junction box. 3.16 Tagging Systems For process field equipment, the instrument tagging system structure shall include a number prefix designating the platform, followed by the instrument alphabetic designation as per ISA S5.1 standard, followed by a 4 or 5-digit numerical code uniquely specifying the instrument number. If required, a further alphabetic suffix will distinguish between same types of devices connected to the same equipment. For packaged equipment, instruments within the vendors boundary package will use the vendors standard numbering system subject to Company approval. Equipment number prefixes will be used to make the numbers unique. The fire and gas tagging system structure shall begin with a number prefix designating the platform followed by the alphabetic designator identifying the field device functionality, followed by a numbered code giving the fire or gas zone number (2 digits) and a unique sequential number (2 digits). 3.17 Noise All predicted Noise levels over 85 dBA, whether during Normal Shutdown or Upset conditions, shall be advised in writing to the Company with proposed solutions, typically acoustic enclosure etc. This noise shall be based on bare pipe before considering thermal and acoustic protection. 3.18 Miscellaneous 3.18.1 Pig detectors Local Pig Detectors shall be insertion, paddle type, raised face flange connected. Local indicator for Pig Detection can be a mechanical flag. 3.18.2 Intruder alarm system. The intruder alarm system shall be infrared type, shall be compact, medium range and suitable for hazardous environments. The system shall be c/w transmitter, receiver, controller/power supply, connecting cable and enclosures. The mounting hardware of transmitter and receiver shall have adjustment screws for rotational adjustment. The system shall have operating range approximately 10 mtr and suitable for the cable length between
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 37/40 controller and transmitter 100mtrs. The transmitter and Receiver shall be provided with EExd enclosure.
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 38/40 4. INSTRUMENT CABLES Design and construction of all instrument cables shall be in accordance with: DHF-00-E-S-0018 General Equipment Specification for Power and Instrument Cable
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 39/40 5. INSTALLATION The location of instruments and instrument connections, including terminal and junction boxes, control equipment and relief valves, shall permit easy access from deck/grade, permanent platforms or stairways for operation, inspection and maintenance. Locations shall also minimize the possibility of damage from passing or falling objects and from fire. Handrails shall not be used for instrument mounting. A permanent platform may not be required where a clear area allows access from a ladder or portable platform to an instrument or element not more than 4.5 m above grade, however, all instruments so mounted shall be easily accessed for maintenance. All indicating instruments shall be installed to be readable from grade and/or the related operational area. Instruments shall not be subjected to excessive vibration, mechanical stress and exposed to high temperature, which can influence the measurement.
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Doc No: DHG-PVE-DD-1-IN-BOD-101 Rev. A Page 40/40 6. INSTRUMENT INSPECTION, CALIBRATION AND FUNCTION TEST COMPANY shall reserve the right to perform inspection of the equipment during manufacture at any time. COMPANY shall be notified of FAT (10) working days prior to testing. 7. TRAINING Training for engineers and technicians is required to ensure safe and correct operation, configuration and maintenance of the field devices. Training is required particularly on special devices such as analyzers, thermal dispersion flowmeter, magnetic flowmeters and sand / corrosion detectors. Quotation (c/w training outline, duration and day rate for the instructor) for training shall be provided for: Onshore training of COMPANYs Engineers and Technicians for system and components. Offshore training of COMPANYs Production Operations. 8. SPARE PARTS AND SPECIAL TOOLS Spare parts, special tools and test kits shall be provided for installation, commissioning, start-up, operation and maintenance of field instruments. In addition an itemized list of spare parts for the initial 2 years of operation shall be provided, for COMPANY purchase.