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This document outlines general requirements for instrumentation design, installation, and testing for industrial facilities. It discusses topics such as process control systems, design considerations, instrument terminology, procurement documentation, drawings, testing, and references other Mobil Engineering Guides and industry standards. The document provides a high-level overview of Mobil's instrumentation requirements and processes.
This document outlines general requirements for instrumentation design, installation, and testing for industrial facilities. It discusses topics such as process control systems, design considerations, instrument terminology, procurement documentation, drawings, testing, and references other Mobil Engineering Guides and industry standards. The document provides a high-level overview of Mobil's instrumentation requirements and processes.
This document outlines general requirements for instrumentation design, installation, and testing for industrial facilities. It discusses topics such as process control systems, design considerations, instrument terminology, procurement documentation, drawings, testing, and references other Mobil Engineering Guides and industry standards. The document provides a high-level overview of Mobil's instrumentation requirements and processes.
TABLE OF CONTENTS 1. Scope 2. References 3. General 4. Instrument Terminology, Symbols, and Data Sheets 5. Design Considerations 5.1 Process Control Systems 5.2 Design Basis 5.3 Failure Requirements 5.4 Instrument Locations 5.5 Instrument Air Compressors and Dryers 5.6 Electrical Area Classifications 5.7 Electrical Power Supply 5.8 Interlock and Shutdown Systems 5.9 Burner Management Systems 5.10 Tank Gaging Systems 5.11 Blending Systems 5.12 Custody Transfer Systems 5.13 Metering Facilities 5.14 Instrument Grounding 5.15 Seismic Testing 5.16 Control Room and Field Piping and Wiring 5.17 Control Room 5.18 Pressurization 5.19 Winterizing and Heat Tracing 5.20 Instrument Seals 5.21 Fire Protection of Instruments 6. Flow Diagrams and Instrument Numbering 7. Drawings 7.1 Instrument Location Drawings 7.2 Piping and Wiring Drawings 7.3 Control Room Drawings 8. Procurement Data 8.1 Instrument Index 8.2 Procurement Status Report 8.3 Point Index 8.4 Source of Component Supply 8.5 Suppliers Drawings and Data 9. Calculations 10. Field Testing and Calibration 10.1 General 10.2 Alarms and Interlocks 11. Tags and Nameplates 12. Painting Appendix Equipment Guides Instrumentation Series and System Design Guides Control Systems Series History of Change 1. SCOPE This Guide defines general requirements for the design, installation, and testing of instruments; control systems; and related equipment for petroleum refineries, petrochemical plants, and other industrial applications. 2. REFERENCES The following publications form a part of this Guide. The references cited with dates in this Guide were used in its development. For all references which have been superseded, revised, and/or corrected, the user of this Guide is obliged to determine if the latest versions of the cited references have any impact on the content of this Guide or its use. Mobil Technology Company (MTC) Guide Sponsor should be consulted if there are any concerns or questions. MOBIL ENGINEERING GUIDE EGE 32-B-1 1995 PAGE 2 OF 15 JULY 1995 Mobil Engineering Guides Equipment EGE 00-B-2 (1992) Flow Diagrams General Requirements EGE 00-B-4 (1989) Winterizing and Heat Tracing EGE 00-B-5 (1989) Equipment Sound Levels EGE 00-C-4 (1993) Equipment Purchases General Engineering Requirements EGE Series 14 Storage Tanks EGE 16-B-10 (1994) Piping Instruments EGE Series 32 Instrumentation (See Appendix for complete listing) EGE 33-B-13 (1990) Electrical Lighting and Receptacle Installations EGE 33-B-16 (1990) Electrical Pressurizing Systems for Building Housing Electrical Facilities EGE 33-B-22 (1993) Electrical AC Uninterruptable Power Supply (UPS) System EGE 34-B-15 (1989) Fireproofing General Requirements EGE 35-B-10 (1995) Painting Manufacturing Facilities EGE 41-B-10 (1991) Compressed Air Dryer Regenerative Type Design and Fabrication Mobil Engineering Guides Systems Design EGS 303 (1993) Recommended Spacing Within Operating Facilities EGS 541 (1991) Instrument Air and Plant Air Systems EGS 805 (1995) Instrumentation Fired Boiler Burner Management System EGS 807 (1994) Product Blending Systems EGS 809 (1989) Instrumentation Calibration and Acceptance EGS 821 (1995) Instrumentation Watertube Steam Boilers EGS 1253 (1994) Blast-Resistant Control Buildings API (American Petroleum Institute) Recommended Practice RP 550 (1986) Manual on Installation of Refinery Instruments and Control Systems, Parts I Through IV NOTE: Although API RP 550 is not a current publication, Mobil considers the referenced material to be valid for Mobils purposes, except as noted in this Guide. Requests for a copy of RP 550 should be directed to The Librarian, American Petroleum Institute, 1220 L Street, NW, Washington, DC 20005, USA. Phone: (202) 682-8040/Fax: (202) 682-8232. ISA (International Society of Measurement & Control) Publications S5.1 (1984) Instrumentation Symbols and Identification S5.4 (1991) Instrument Loop Diagrams S12.4 (1970) Instrument Purging for Reduction of Hazardous Area Classifications RP 7.1 (1956) Pneumatic Control Circuit Pressure Test S20 (1981) Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves NFPA (National Fire Protection Association) Standards 8501 (1992) Single Burner Boiler Operation 85C (1991) Prevention of Furnace Explosions/Implosions in Multiple Burner Boiler - Furnaces 496 (1993) Standard for Purged and Pressurized Enclosures for Electrical Equipment 3. GENERAL 3.1 Mobil uses proven, cost effective microprocessor technology in control systems for all projects. Distributed digital instrumentation/control systems shall be part of the overall systems design for new plants and major upgrades. MOBIL ENGINEERING GUIDE JULY 1995 PAGE 3 OF 15 EGE 32-B-1 1995 A distributed control system (DCS) is a process control system where many individual controllers are implemented in a digital processors software. There are a multiciplicity of these processors. They communicate to the display, history, and application processors via a data highway. In conceptual design, a DCS permits flexibility in the establishment of control systems philosophy, control strategies, reliability requirements, and process interface requirements. The overall system requirements shall be defined during the initial stages of a project, even though field implementation may be accomplished in discrete stages. Early decisions are essential in considering the techniques to be used for meeting hazardous area requirements, protective interlock systems, information retrieval methods, system capacity and expendability, and plant wide communication systems. 3.2 Instrumentation shall conform to the specific requirements of this Guide, as well as to the requirements of all other applicable Guides, unless otherwise defined by the project specifications or other project documents specifying exceptions or modifications approved by Mobil. Examples may include purchase specifications, loop drawings, and agreed-upon minutes of meetings. Any exceptions shall be tabulated during the course of the project and shall be incorporated in the control systems specifications. 3.3 The Guides on instrumentation, EGE Series 32 (see Appendix), are based on API RP 550; specific exceptions and modifications are noted in individual Guides. Where no modifications are made, those practices described in API RP 550 as "advisable," "most common," and so forth shall be considered Mobil requirements. Purchases of engineered equipment shall conform to EGE 00-C-4. The term "Mobil approval" means written approval. 4. INSTRUMENT TERMINOLOGY, SYMBOLS, AND DATA SHEETS 4.1 Instrumentation symbols shall conform to EGE 00-B-2; also see ISA S5.1. 4.2 Data sheets contained in ISA S20 shall be used except where Mobil approves the use of a contractor's data sheets. If used, the contractor's document shall include, as a minimum, all data required on the ISA data sheets. 5. DESIGN CONSIDERATIONS 5.1 Process Control Systems (Refer to EGE 32-B-22) 5.1.1 The control system shall be a distributed, digital microprocessor-based network. It shall be designed for flexible, reliable, high-speed process communications configured for centralized control but adaptable to sectionalized control centers within a clearly defined hierarchy. Operator interaction with the process shall be accomplished with a number of operator stations, each consisting of a color cathode ray tube (CRT) display; functional keyboard; and other similar devices such as touch screen, mouse, trackball, or light pen for operator requests and inputs. 5.1.2 A control and information system (CAIS) shall be provided. It shall consist of a distributed digital control system; one or more computers for advanced control and/or management information; and subsystems including tank gaging, analyzers, blending, laboratory data, custody transfer and package unit control systems. A dual data communication link shall connect all parts of the system and shall provide automatic switchover in the event of a link failure. The selected CAIS shall allow growth to a full plant management system (PMS). A PMS permits sharing of the plant database among the various departments by using standard networking techniques. In Mobil refineries, these systems are called Integrated refinery information systems (IRIS). A typical IRIS would tie the CAIS to a refinery-wide local area network (LAN). A number of common PC-based workstations are used by the various departments to gain controlled access to the refinery database. Individual processors MOBIL ENGINEERING GUIDE EGE 32-B-1 1995 PAGE 4 OF 15 JULY 1995 for specific functions may also be tied onto the network (for example, maintenance, laboratory information, and automated drafting). In addition, the network would have a telecommunication facility for exchanging information with remote computers. 5.1.3 Specialized control and information requirements shall be satisfied by microprocessor-based dedicated systems. These systems shall have the capability to: (a) Operate as stand-alone systems independent of the DCS or the computer system. (b) Be linked to the CAIS or the plant network. Examples of such dedicated systems include tank gaging, interlock and shutdown, analyzer loops, rotating equipment condition monitoring, blending, metering, and custody transfer. 5.2 Design Basis 5.2.1 Control loops and Controllers Controllers shall not be locally mounted unless economic or application requirements justify the use of local pneumatic instruments and shall require Mobil approval. All locally mounted controllers shall be of the indicating type with auto/manual facilities. Locally mounted Input/Output (I/O) electronics require Mobil approval. 5.2.2 Analyzers (Refer to EGE 32-B-10) Application of onstream analyzers shall maximize profitability of process unit design. Analyzer benefits shall be quantified. 5.2.3 Package Units (Refer to EGE 00-B-2 and EGE 00-C-4) Particular attention shall be given to package units to ensure that the control systems designs are consistent with the main process units and the quality of the instruments used is of an equal standard. Wherever possible, the same instruments used for main process units shall be used in packaged units. They shall fulfill the basic requirements of the project and be integrated into the central control room data communications network. The package unit supplier shall pay particular attention to compliance with Mobil requirements for accessibility and ease of maintenance. All appropriate package unit drawings shall be reviewed by the Mobil Facilities Group engineer. 5.2.4 Codes and Agency Standards Instrumentation shall meet the requirements of applicable national and local codes. The contractor shall certify in writing that he has met all of these requirements. Any instrument loop not meeting the certification requirements of the country and locale of installation requires Mobil approval prior to purchase and installation. 5.2.5 Electronic vs Pneumatic Instrumentation In case of expansions of existing control rooms and process unit additions, electronic instrumentation shall be installed, even though existing equipment may be pneumatic. For integration into a DCS, existing pneumatic transmitters shall be replaced by electronic transmitters. MOBIL ENGINEERING GUIDE JULY 1995 PAGE 5 OF 15 EGE 32-B-1 1995 5.2.6 Automatic Operation Process units, offsite units, steam generation facilities, and utilities requiring minimum operator interaction during normal plant operation shall be instrumented for automatic operation where practicable. Sufficient data shall be provided to allow the operator to act effectively during a major plant upset. Local control panels shall be furnished as necessary to enable operations personnel to safely start up process equipment. 5.3 Failure Requirements 5.3.1 All instruments, pneumatic or electronic, shall fail to the safest position or lock in place upon air or power failure as shown on the piping and instrument diagrams. Control valves that are required to fail safe on air failure shall be spring assisted. The use of accumulators to meet control valve fail-safe conditions shall be minimized. When accumulators are used, the supplier shall furnish the sizing calculations. Mobil shall have final approval of the failure position of all instruments and related components. Temperature controllers shall fail in the safest direction upon thermocouple or power circuit failure. 5.3.2 Suppliers of electronic instrumentation and microprocessor-based control systems shall supply the following information so that failure action analysis can be made: (a) Maximum time (seconds or minutes) the power source can be interrupted without disruption of control circuit operations. (b) Quality of power supply required (in terms of maximum and minimum voltage level) and maximum ripple that can be tolerated (in millivolts, peak-to-peak). (c) Action of the instruments upon reestablishment of power; for example, drive full-scale up, drive full-scale down, or lock in place. 5.3.3 Particular attention shall be made to verifying that failure requirements are met for solid-state devices such as programmable controllers. 5.4 Instrument Locations The location of instruments and instrument connections, including terminal and junction boxes, control equipment, and relief valves, shall permit easy access from 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. A permanent platform may not be required where a clear area allows access from a ladder or mobile platform to an instrument or element not more than 4.5 m (15 ft) abovegrade; however, all instruments so mounted shall be subject to Mobil approval. All appropriate construction drawings, and models shall be reviewed by the Mobil engineer. 5.5 Instrument Air Compressors and Dryers (Refer to EGE 41-B-10 and EGS 541) Instrument air supply and drying equipment shall be in accordance with applicable specifications. Systems design shall be based on supplying air that is clean, dry, and free of oil vapors and shall include a dryer outlet dew point at least 10C (18F) below the lowest ambient temperature. Normally, two oil-free instrument air compressors with different types of drives shall be provided. MOBIL ENGINEERING GUIDE EGE 32-B-1 1995 PAGE 6 OF 15 JULY 1995 5.6 Electrical Area Classifications 5.6.1 All electrical or electronic instrumentation equipment shall conform to the requirements for installation in accordance with the area classification. Enclosures or cabling and grounding systems for all field-mounted or local panel-mounted electrical or electronic instruments (or instruments having electrical connections) shall conform to the requirements of the electrical classification of the area of installation. Housings located in unclassified outdoor areas or in unprotected areas shall meet the specifications of NEMA 4X as a minimum. 5.6.2 Special attention shall be given to those instrument installations that meet all area classifications and code requirements but may serve as a path for flammable gases or liquids to unclassified areas, even under normal conditions. In addition to EGE 32-B-13 (for cables and raceways), these paths may be formed by: (a) Tubing runs. (b) Air lines to pressure balance valves without isolation relays or dual diaphragms with a vent. (c) Air and lines to explosionproof housings designed for internal leaks rather than external sources of hydrocarbons; for example, an analyzer housing. 5.7 Electrical Power Supply 5.7.1 Electrical power to the control room shall be limited to that voltage required for instruments and lighting. Use of higher voltage levels requires Mobil approval. Lighting systems shall have adequate filtering to eliminate electrical noise (refer to EGE 33-B-13). 5.7.2 Instruments shall be supplied by uninterruptable power supplies (UPS) unless otherwise specified (refer to EGE 33-B-22). Redundant UPS systems shall be considered to eliminate single point of failure in instrument power systems. For analyzer power requirements refer to EGE 32-B-10. 5.8 Interlock and Shutdown Systems 5.8.1 Interlock and shutdown systems shall be installed as shown on the piping and instrument diagrams (P&ID) or as outlined in the cause and effect drawings or as per project specifications. 5.8.2 All interlock and logic systems shall be in accordance with EGE 32-B-11. 5.8.3 Interlock and shutdown systems shall be designed to avoid trips caused by process transients or power dips of short duration. The exact duration of these transients and power dips shall be specified by Mobil; for example, a 10-second delay for low-flow trip to heaters and a one-second delay on power dips. 5.8.4 The contractor shall be responsible for the compatibility of all elements of an interlock and shutdown system and for conformance of the total system to the requirements of the project. 5.8.5 The contractor shall be responsible for application of the requirements of Paragraphs 5.7.2 and 5.8.2 to interlock systems supplied with packaged units. 5.9 Burner Management Systems Microprocessor-based burner management systems shall be used with boilers (refer to EGS 805 and EGS 821). For process heater requirements refer to EGE 32-B-15. MOBIL ENGINEERING GUIDE JULY 1995 PAGE 7 OF 15 EGE 32-B-1 1995 5.10 Tank Gaging Systems Tank gaging display systems shall be of the microprocessor-based type and shall be capable of communication with a process computer or with the plant information network. All tanks shall be furnished with tank gaging and temperature equipment in accordance with EGE Series 14. They shall also be furnished with a ground reading level instrument and local thermometers. 5.11 Blending Systems Product blending systems shall be of the microprocessor-based type and shall be capable of communication with a process computer or with the plant information network. These systems shall be designed in accordance with EGS 807. 5.12 Custody Transfer Systems In some countries servo-operated tank gages, coupled with a microprocessor-based control system, are recognized as being sufficiently accurate to meet custody transfer requirements. Configurations intended to fulfill these requirements shall be submitted to Mobil for approval prior to purchase and installation. 5.13 Metering Facilities Metering systems, complete with high-accuracy flowmeters, microprocessor-based prover systems, and panel-mounted equipment, shall be capable of communication with a process computer or with the plant information network. 5.14 Instrument Grounding All electronic instrumentation shall be grounded at a single, common point in the satellite instrument house/remote instrument enclosure (SIH/RIE) or control room separate from the plant ground grid. Where multiple grounds are required by local codes, these earthing points shall be separate from, and not be a part of, the plant grid. When multiple grounds are required in an instrument wiring loop, galvanically isolated devices shall be used for loop coupling. 5.15 Seismic Testing When required by project specifications, instrumentation shall be subject to seismic testing. The standards used for testing and the necessary certification shall be developed by the contractor and submitted to Mobil for approval. 5.16 Control Room and Field Piping and Wiring 5.16.1 No process fluids, process gas, chemical, or steam (except for heating purposes) shall be piped into the control room. 5.16.2 Field piping and tubing shall conform to EGE 16-B-10. 5.16.3 Where underground routing in the field is not practicable, overhead cable and tubing shall be routed in vertical cable racks. These cable racks shall be located in areas not vulnerable to fire exposure. Routing shall not be over pumps, compressors, or adjacent to fired heaters. If a cable rack is in a fire exposure area, it shall be fireproofed in accordance with EGE 34-B-15. Vertical cable racks minimize the exposure of cable runs to mechanical and fire damage. Where it can be demonstrated that vertical racks are mechanically impractical or uneconomical, horizontal racks may be installed, subject to Mobil approval. MOBIL ENGINEERING GUIDE EGE 32-B-1 1995 PAGE 8 OF 15 JULY 1995 5.16.4 Cable shall be routed to enter the control house in at least two (preferably four) separate locations so that fire or physical damage to a cable run and rack shall affect no more than 50 percent (preferably 25 percent) of the operation. As far as practicable, these cables shall be kept separated in the control room. All field measurements shall terminate in separate, cross-connect panels or marshaling racks. Wiring shall be routed from the cross-connect panels, or marshaling racks, to the data interface cabinets and operator control stations below the modular floor, while still maintaining separation. 5.16.5 Terminal strips in field junction boxes and control room distribution panels shall be of modular construction. Electrical terminals shall be of the pressure-plate type, with all "live" parts recessed into the insulated block. Terminal strips suitable for the environment (for example, tropic proofing) shall be used as applicable. The terminal strips shall have separate connections available for test leads or jumpers. All screws and parts in the terminal blocks shall be captive. Construction materials shall be stainless steel or nickel-plated brass for all electrical contacts. Aluminum is preferred for all other metal parts. Terminal screws shall have integral lock washers, as a minimum, or be of tension-designed construction equivalent to a lock washer. All instrumentation terminal strips shall have this type of screw unless otherwise approved by Mobil. 5.17 Control Room 5.17.1 Ideally, the control room and SIH/RIE shall be located 150 m (500 ft) away from a blast source (refer to EGS 303). For closer locations, blast-resistant construction shall be used in accordance with EGS 1253. 5.17.2 A control room, computer room, SIH/RIEs, office, and maintenance and storage space shall be provided to house the CAIS activity. The facilities and equipment shall be completed in time to permit adequate computer system testing prior to startup. 5.17.3 For systems that will be located in refineries, the system specification shall require bidders to define the acceptable levels of sulfur dioxide and hydrogen sulfide in locations where equipment is to be housed. Depending on the existing environment, it may be necessary to provide supplemental chemical filtration to reduce contamination to acceptable levels. 5.18 Pressurization (Refer to EGE 33-B-16) Pressurization of instrument enclosures, SIH/RIEs, and field control panels for environmental or electrical area classification shall be in accordance with NFPA 496 and ISA S12.4 practices. Local standards shall prevail where they exceed the requirements of the NFPA or ISA practices. 5.19 Winterizing and Heat Tracing Winterizing and heat tracing of instruments shall be in accordance with EGE 00-B-4 or local practices. 5.20 Instrument Seals There are three types of instrument sealing methods used to prevent process fluid from damaging the instrument or plugging the lines to the instrument. 5.20.1 Diaphragm Seals A method of sealing using a flexible membrane to hold the seal liquid in the instrument and mechanically separating the sealing liquid from the process fluid in accordance with API RP 550 Part I, Section 8. MOBIL ENGINEERING GUIDE JULY 1995 PAGE 9 OF 15 EGE 32-B-1 1995 5.20.2 Liquid Seals A method of sealing that uses a liquid of a density different from the measured process fluid and that is immiscible with it. Mobil shall review and approve installation drawings for liquid seals and also approve the type of sealing material. 5.20.3 Process Purge A method that seals the instrument and sweeps the lines clean of the measured process material. This type of purging system is commonly used on process streams subject to coking, sedimentation, or other contaminants that might damage or plug the instrument or its lines. 5.21 Fire Protection of Instruments Fireproofing of instruments shall be in accordance with EGE 32-B-8 and EGE 34-B-15. Fireproofing of main instrument runs shall include supports and junction boxes. 6. FLOW DIAGRAMS AND INSTRUMENT NUMBERING 6.1 Flow diagrams shall be prepared in accordance with the project specifications and EGE 00-B-2. Instruments shall be identified by letter and number, and numbering sequences shall be in accordance with the requirements of the facility. The system shall be defined by the project specifications or by a separate document on the subject. 6.2 If a piece of equipment with an assigned number is deleted, the number shall still be carried on the instrument index, be shown as deleted, and not be used again on that project. If two or more pieces of equipment are inadvertently assigned the same number, the number shall be deleted and each piece of equipment, with the corresponding records, shall be assigned a new number. 7. DRAWINGS 7.1 Instrument Location Drawings 7.1.1 The contractor shall furnish standard location drawings. These drawings shall show the locations (elevations and line or vessel number) of all instruments except pressure gages and local thermometers. Pneumatic instruments and air lines shall be shown on one drawing or a series of drawings. Electronic instruments and electrical wiring shall be shown on a separate drawing or a series of drawings. Instrument equipment involving both pneumatic and electronic systems (such as electronic-to-pneumatic units and control valves) shall be shown on both drawings. Routing of the thermocouple leads shall be shown in elevation. All drawings shall have an alpha-numeric grid to allow for instrument cross-referencing and location. When a series of drawings is used, all drawings shall have the same series number, with separate sheet numbers or letters. For multiple-page drawings, appropriate match marks shall be shown on the grids. 7.1.2 Location drawings shall indicate instruments and auxiliaries that require fire or weather protection. Instrument air drawings shall show routing of the instrument air header, air branch supply leads, block valves, and controlled and transmitted air lines. 7.2 Piping and Wiring Drawings Upon mechanical completion acceptance, all drawings and diagrams shall be corrected to as-built configuration and made available to Mobil operating personnel for unit checkout and startup. 7.2.1 The contractor shall prepare hookup sketches (see API RP 550, Parts I through IV) for instrument process piping, electrical wiring, and instrument air piping. All sketches shall be subject to Mobil approval prior to construction. MOBIL ENGINEERING GUIDE EGE 32-B-1 1995 PAGE 10 OF 15 JULY 1995 7.2.2 Wiring and Logic Diagrams Wiring diagrams shall be furnished for all instrument systems. Wiring diagrams shall show all termination and cable identifications. Interlock, shutdown, and safety system logic diagrams shall also be furnished. All logic diagrams for these systems shall include block flow diagrams and a written description of the proposed operation. Each sequence trip and alarm shall be described in detail. When unit control systems have direct or ancillary effects, these effects shall be described. Examples are boiler combustion control effects on flame lightoff, and fuel interlocks or process control effects on the compressor shutdown and interlock system. All wiring and logic diagrams shall be submitted for Mobil approval prior to construction. 7.2.3 Loop Drawings Loop drawings and proposed formats shall be in accordance with ISA S5.4. The contractors standard may be used as a base, provided all data shown in ISA S5.4 are noted on sheets that have a similar format. A loop diagram showing all terminations and cable identifications shall be prepared for each complete instrument loop. Each loop drawing shall show and identify all items interconnected in an instrument signal circuit, including power supply terminals and computer terminals. Loop diagrams shall be large enough so that the dense wiring interconnections are clearly shown. Interconnections between power supplies shall be shown on a separate schematic. These schematics are required for both pneumatic and electronic loops. Related wiring shall be referenced on the loop diagram. 7.3 Control Room Drawings 7.3.1 The contractor shall prepare and submit, for Mobil approval, drawings of control room layouts showing locations of operator consoles, interface cabinetry, peripheral equipment, doors, and other items required by the project specifications. Provisions for future changes, if required by the project specifications, shall be clearly indicated on the drawings. 7.3.2 The contractor shall prepare detailed drawings of interconnecting wiring that conform to the approved control room layout. 7.3.3 The contractor shall provide specifications for power, floor loading, floor area, heating, ventilation, and air conditioning, as well as heat dissipation and sound level data for the system and its peripherals. Fire protection/safety systems should be zoned in accordance with local codes and system hardware configurations. 8. PROCUREMENT DATA 8.1 Instrument Index 8.1.1 The contractor shall furnish a master instrument index. MTC has developed a computer-generated instrument index that may be used as a model from which individual project requirements may be adapted. 8.1.2 For basic project data, as a minimum, each index sheet shall display a title line showing the revision number, date, area number (unit number), unit title, and sheet number. For detailed instrumentation data, horizontal line entries are made for each unit (instrument, module, cabinet, etc.) and include tag number, service, and remarks. 8.1.3 Computer programs and printouts shall be used for the instrument index. On occasion, when a licensor or packaged unit supplier provides data sheets describing the furnished equipment, the contractor may use different instrument numbers. In such cases, the instrument index shall show a cross-reference MOBIL ENGINEERING GUIDE JULY 1995 PAGE 11 OF 15 EGE 32-B-1 1995 between the contractors index sheet and instrument numbers. The index shall be updated and submitted to Mobil according to the document schedule defined in the project specifications. 8.1.4 An alarm and trip schedule shall be provided by the contractor. 8.2 Procurement Status Report The contractor shall furnish a procurement status report. As a minimum, the status report shall display a title line showing the revision number, date, area number (unit number), unit title, and page number. For the instruments, there shall be separate columns for: (a) Instrument type and code. (b) Total number of items. (c) Number of requisition. (d) Number on inquiry. (e) Number of supplier inquiries approved. (f) Number of purchase orders issued. (g) Number of supplier-certified prints received. (h) Number of spare-parts lists received. A consolidated summary shall be included for the entire project. Computer programs and printouts shall be used. The status report shall be updated and submitted to Mobil according to the document schedule defined in the project specifications. 8.3 Point Index A computer-generated point index shall be used to assist in computer input point selection and control. All documentation, user manuals, and tapes of computer programs, required by this Guide, shall be furnished to Mobil and shall be upgraded to an as-built configuration by the contractor. Sufficient portions of the point index shall be furnished during the engineering phase to permit verification of the programs. These programs allow Mobil to continually upgrade the documents during the life of the unit. 8.4 Source of Component Supply The supplier shall provide, on request, the name and source of the components used in the manufacture of his equipment. The supplier shall not deviate from these stated names and sources of component supply without Mobil approval. 8.5 Supplier's Drawings and Data The contractor shall furnish the required number of copies (as specified in the project specifications) of the suppliers certified drawings; electric circuit details; complete installation startup and service instructions; complete and detailed field adjustment instructions; maintenance instructions; complete parts list with illustrations; and price list of recommended spare parts, including flow sheet item number, catalog number, and a serial or model number of each instrument that a part will fit. The contractor shall also furnish a MOBIL ENGINEERING GUIDE EGE 32-B-1 1995 PAGE 12 OF 15 JULY 1995 cross-reference of the suppliers instructions and spare-parts lists. This may be included on the master instrument index. 9. CALCULATIONS 9.1 The contractor shall provide Mobil with calculations for orifice plates, control valves, traps, drainers, and relief valves as they are completed. The equipment shall not be purchased until these calculations are approved by Mobil. Final plant data books shall have consolidated sections including all of these calculations. 9.2 All symbols used in the calculations shall be identified. References shall be quoted for the equations and methods of calibration used. 9.3 Sizing and sound level prediction of control valves shall be based on the control valve suppliers computer program. The contractors base program may be used to confirm the suppliers data. Where sizing data appear to be incompatible, the ISA method may be used as a secondary reference. 9.4 The flow elements shall be sized based on the suppliers standard computer program. Contractors who do not have a computer program shall submit their calculations and calculation sheet format to Mobil for confirmation. Where a discrepancy occurs, a recognized standard applicable to the location of installation shall be used to resolve it. 9.5 Sound level calculations are required for all instrumentation devices that generate noise or contribute to the plant sound level. These limits shall be in conformance with EGE 00-B-5 and shall be incorporated in the project specifications. 10. FIELD TESTING AND CALIBRATION 10.1 General 10.1.1 The contractor shall demonstrate to Mobil that all instruments and control equipment are properly installed and connected, pressure tested, and fully operable. 10.1.2 Test procedures shall require Mobil approval. EGS 809 shall be the basis for instrument calibration and acceptance. 10.1.3 Pneumatic tubing shall be leak checked as required by ISA RP 7.1. 10.1.4 All tests and calibrations shall be subject to witness and approval by Mobil. 10.2 Alarms and Interlocks Alarm settings and interlock action shall be checked for proper operation in the presence of a Mobil representative. All interconnecting wiring on electronic instruments shall be checked for continuity, grounding, and shielding (if required) as shown on the approved wiring diagrams. 11. TAGS AND NAMEPLATES An identification tag shall be attached to each piece of instrumentation equipment. Tags for field-mounted instruments shall be of 1.3 mm (16 US gage) stainless steel (or equivalent) unless approval is given for the use of laminated plastic. All field tags shall be attached by 1.3 mm (16 US gage) wire or stainless steel drive screws. Rectangular tags, a minimum of 25 mm by 50 mm (1 in. by 2 in.), shall be used for each piece of MOBIL ENGINEERING GUIDE JULY 1995 PAGE 13 OF 15 EGE 32-B-1 1995 instrumentation unless otherwise specified in the project specifications. Plastic tag strips shall be used in all junction boxes and behind control boards and shall be secured by metal fasteners, alpha-cyanoacrylate adhesive, or other means approved by Mobil. All lettering shall be at least 5 mm (3/16 in.) high. Nameplate color and nomenclature shall be submitted for Mobil approval. 12. PAINTING Control room panels and visible portions of instruments mounted on the panel shall conform to the painting schedule in EGE 35-B-10. The manufacturers standard colors shall be used for all other instrumentation, unless otherwise specified by Mobil. MOBIL ENGINEERING GUIDE EGE 32-B-1 1995 PAGE 14 OF 15 JULY 1995 APPENDIX
EQUIPMENT GUIDES INSTRUMENTATION SERIES EGE 32-B-1 (1995) Instrumentation General Requirements EGE 32-B-2 (1993) Instrumentation Flow EGE 32-B-3 (1994) Instrumentation Liquid Level EGE 32-B-4 (1993) Instrumentation Temperature EGE 32-B-5 (1991) Instrumentation Pressure EGE 32-B-6 (1994) Instrumentation Transmitters and Receivers EGE 32-B-7 (1994) Instrumentation Controllers EGE 32-B-8 (1994) Instrumentation Control Valves EGE 32-B-9 (1994) Video Display Consoles and Control Panels EGE 32-B-10 (1993) Process Analyzers EGE 32-B-11 (1991) Instrumentation Alarms and Protective Systems EGE 32-B-13 (1994) Instrumentation Wiring for Instruments and Digital Systems EGE 32-B-15 (1995) Instrumentation Process Heater Controls EGE 32-B-17 (1992) Instrumentation Pressure Relief Devices EGE 32-B-18 (1990) Instrumentation Electric Motor Operated Valves EGE 32-B-19 (1992) Instrumentation Storage Tank Level Gaging EGE 32-B-20 (1992) Instrumentation Storage Tank Level Alarms EGE 32-B-22 (1995) Instrumentation Distributed Control Systems (DCS) SYSTEMS DESIGN GUIDES CONTROL SYSTEMS EGS 801 (1990) Control of Simple Distillation Towers EGS 804 (1991) Compressor Control Systems EGS 805 (1995) Fired Boiler Burner Management System EGS 806 (1995) Safety Instrumented Systems Design Methodology EGS 807 (1994) Product Blending Systems EGS 808 (1991) Control Centers EGS 809 (1989) Instrumentation Calibration and Acceptance EGS 821 (1995) Instrumentation Watertube Steam Boilers MOBIL ENGINEERING GUIDE JULY 1995 PAGE 15 OF 15 EGE 32-B-1 1995 HISTORY OF CHANGE The history of change contained herein does not constitute a complete listing of revisions and changes made to this document. Only revisions and changes of significant technical content (per sponsor and Steering Committee) are listed. EGE 32-B-1 1995 EGE 32-B-1 1995 supersedes the 1989 version with the following significant technical changes: 1. Revised to reflect current Mobil and industry practices. 2. Sections on distributed control systems (DCS) which will be covered by a new Guide (EGE 33-B-22) have been removed. 3. Information currently included in existing Guides has been deleted and the applicable Guides noted as references. 4. Added the System Design Guides (EGS 800 Series) to the Appendix.