2.1. 3503 Rev1 PDF

Functional Specifications Spec No : 3503
Design Division
For Rev. No : 1
Engg. Services
INSTRUMENTATION FOR Disc: Instrumentation
ISO – 9001:2000 PACKAGED EQPT Page : 1 of 22
FUNCTIONAL SPECIFICATION
FOR
INSTRUMENTATION FOR
EQUIPMENT PACKAGE
Rev 1 - Revised for updating ISO Format
TOTAL
PREPARED / REVIEWED
APPROVED BY No. OF DATE REV. No.
REVISED BY BY
PAGES
ET RS GRP 22 28.03.2007 1
MC MC AC 22 13.05.2003 0
FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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CONTENTS
Clause No. ITEM Page No.

1.0 Scope Of This Document 3
2.0 Codes And Standards 3
2.1 Reference Specifications 3
2.2 Other Specifications To Be Followed 3
3.0 Scope Of Supply 3
4.0 Instrumentation For Equipment package 4
4.1 Purpose / Application 4
4.2 General 4
4.3 Electrical Requirements 5
4.4 Unit Control Panels 6
4.5 Control Requirements 6
4.6 Selection Basis for Package Instrumentation 7
4.7 Material Requirements 16
5.0 Equipment Protection 17
6.0 Installation Requirement 18
7.0 Calibration, Inspection And Testing 20
8.0 Documentation 21
9.0 Tagging & Nameplates 22
10.0 Review And Approval 22
11.0 Vendor Pre-Qualification Requirements 22
12.0 Preparation For Shipment 22
13.0 Receipt And Storage 22
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1.0 SCOPE OF THIS DOCUMENT:
1.1 This specification describes the essential considerations in the selection, design,
procurement, testing, installation, calibration and commissioning requirements for
instrumentation forming part of equipment packages.
1.2 The Contractor shall be responsible for the selection of various type of instruments for
equipment packager suitable for their intended application, their procurement, packing,
calibration, testing at yard and offshore, shipment to yard and at offshore site,
installation and commissioning at site.
2.0 CODES & STANDARDS:
2.1 Reference Specifications:

a) Specification No. 3.6: Instrumentation Design Criteria
b) Basic Bid Work
c) Project P & IDs
d) Specifications of various equipment package (e.g. Functional Specification for
M.I.P., Fine Filter, Fuel Gas Compressor, etc.)
e) Functional Specification for Programmable Logic Controller specification no.
MR / OD / INST / FS / C101.
2.2 Other Specifications To Be Followed:
NIL
3.0 SCOPE OF SUPPLY:
3.1 The type of instruments to be used with the equipment package and their quantity shall
be as per the process requirements indicated in the Basic Bid Work, the P & IDs and the
functional specification of the respective equipment package.
3.2 The scope of supply shall also include commissioning spares and two years’ spares as
required by clause 3.6.4.8 of Instrumentation Design Criteria, and as suggested by the
Manufacturer.
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4.0 INSTRUMENTATION FOR EQUIPMENT PACKAGE:
4.1 Purpose / Application:
4.1.1 Instrumentation system for equipment package shall provide complete monitoring, local
and remote display, start-up, automatic control, interlock, alarm, normal shutdown and
emergency shutdown for the equipment package.
4.2 General:
4.2.1 The Instrumentation system for the equipment package shall include all items necessary
for the efficient, correct and safe operation of the complete equipment package.
4.2.2 Supply of all necessary items for the equipment package shall be regardless of whether
specifically referred to in the Company’s specifications or not, including the supply of
instrumentation required for control of the equipment installed in pipe work or other
equipment not in Contractors supply, unless specifically excluded in the particular
equipment specification.
4.2.3 The functional requirements of these instruments shall be as per the relevant functional
specification enclosed in the bid document. General requirements as covered in the
Instrumentation Design Criteria shall be applicable to all the instruments forming a part
of the equipment package.
4.2.4 The Contractor shall completely mount, pipe and cable all instrumentation items on the
packaged unit.
4.2.5 All wiring and tubing which requires interconnections with any other equipment
external to the package shall be terminated in appropriate junction boxes and bulkhead
plates, mounted adjacent to the package boundary be the Contractor. The locations and
details of all such junction boxes and plates shall be agreed by Company prior to
installation and clearly marked on the Contractor’s drawings.
4.2.6 Process fluids shall not be piped off the unit for measurement purposes. Measured
variables shall only be transmitted off the package by electronic signals.
4.2.7 Cable entries for outgoing cables shall be clearly marked on the layout drawings,
including the location, size and quantities, and shall be plugged until cable installation.
4.2.8 Equipment package, which requires pneumatic supply for instruments, shall incorporate
a 316SS Supply header of the proper size of the package. The on-package supply
piping shall terminate at the package boundary and the location and size of the supply
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connection shall be noted on the Contractor’s drawings. Each pneumatic instrument

shall be individually connected to a sub-header and provided with filter regulator and
isolation valve.
4.2.9 Control and shutdown functions shall be segregated by the provision of separate
dedicated instruments, process connections and logic solvers.
4.2.10 Electronic instrumentation transmission signals shall be provided by 2 wire transmitters

giving an isolated 4 – 20 mA DC linear output signal from a nominal 24 VDC supply,
and shall be compatible with having either pole grounded. All field transmitters shall be
microprocessor based; intrinsically safe (IS) “smart” type with HART protocol.
4.3 Electrical Requirements:
4.3.1 The electrical power supply for the instrumentation for equipment packages shall in
general be as per clause no. 3.6.4.2 of Instrumentation Design Criteria.
4.3.2 Power supplies and signal voltages shall be as listed below:

Digital I/O : 24 V DC
Analog Signals : 4 – 20 mA Smart signal with HART protocol
Power to control systems : 24 V DC or 110 V AC, 50 Hz single phase earthed neutral
supplies from UPS/Battery Bank
4.3.3 Signal interfaces to other systems shall be as follows:

• Process control system – via redundant serial links and /discrete digital and analog
I/O.
• ESD system – via volt – free contacts, 24 VDC circuit.
• Fire and Gas system – via volt- free contacts, 24 VDC circuit
• Critical Alarms – via. volt-free contacts, 24 VDC circuit.
4.3.4 All terminations shall be made on screw clamp type terminals, correctly certified (Exe)
where necessary. No flying leads shall be used.
4.3.5 Each cable core shall be labeled with a full circular cable ferrule, ‘C’ type are not
acceptable.
4.4 Unit Control Panels:
4.4.1 Where complex equipment packages such as turbo-generators, compressors and gas
chromatographs are supplied with integrated Unit Control Panels (UCP) as a part of the
package such system shall comply with the project specifications.
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4.4.2 Larger UCPs will communicate with the DCS via redundant serial data communication
links and with the ESD and Fire and Gas systems via hardwired signals. Such UCPs
shall be provided with suitable redundant communications ports to allow transmission
of monitoring, control and alarm information via serial interface (RS 232 C, RS 422 or
RS 485 etc.).
4.4.3 This function shall enable the unit to be monitored and controlled from the Central
Control Room (CCR), in addition to the local control and indication.
4.4.4 The Contractor shall ensure robust and secure integration of UCP communications into
the DCS using only standard software modules.
4.4.5 Shutdown and Safety Instrumented Systems (SIS), which are part of UCPs, shall
comply with the integrity requirements arising from the project risk assessment and
PISHAZOP, and IEC –61508.
4.5 Control Requirements:

4.5.1 Operational Requirements:
4.5.1.1 Local panels or field equipment will not normally be manned and therefore, automatic
control systems shall be provided to achieve optimum process operation under the
specified plant conditions. Local indication and manual controls shall be provided to
allow for local monitoring, control, start-up and shutdown of the equipment.
4.5.1.2 A local UCP shall be provided where the grouping of indicators, controls, alarms, etc. is
required for ease of operation or for safety reasons when carrying out manual start-up
and shut down procedures.
4.5.2 Shutdown and Auto Start Requirements:
4.5.2.1 The Control systems shall be designed to automatically ensure a safe shutdown
condition in the event of any malfunction, or when commanded by the platform ESD
system.
4.5.2.2 All shutdown signals, to and from a package, shall be cabled to a dedicated junction box
at the package limit for interfacing with the Platform ESD system.
4.5.3 Alarm Requirements:
4.5.3.1 In general, the alarm signal outputs from equipment package shall be transmitted from
the equipment package through potential free contacts. For larger system, non-critical
alarms may be transmitted to the DCS by serial link.
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4.5.3.2 Where an alarm annunciator is supplied as a part of the equipment package, the
annunciator shall have a “first –out” feature to indicate which of a group of alarm points
operated first.
4.5.3.3 Annunciation of shutdown and auto-start functions shall be provided by a contact

independent of that initiating the control function.
4.5.3.4 Every signal, which initiates a shutdown, shall also have a pre-alarm signal to warn of
an impending shutdown situation.
4.6 Selection Basis For Package Instrumentation:
4.6.1 General:
4.6.1.1 Proven commercial high quality instrumentation shall be utilized with particular
attention to reliability and materials of construction.
4.6.1.2 Instrument parts shall be resistant to the corrosive properties of the process fluid to
which they are exposed and to the external environment.
4.6.1.3 Seals and purges shall be used as necessary, to ensure reliable instrument performance.
4.6.1.4 Housing and exposed parts of field –mounted instruments shall be resistant to the
corrosive environment.
4.6.1.5 All instruments of one type shall be procured from the sane manufacturer.
4.6.2 Control Panels:
4.6.2.1 All enclosures shall be suitable for the environmental conditions specified in the data
sheet for the particular equipment package.
4.6.2.2 Control panels containing PLCs shall be located in non-hazardous areas.
4.6.2.3 Panels for outdoor use shall be fabricated from 316SS, with minimum sheet thickness of
1.5 mm, Panels shall be suitably reinforced to prevent warping or buckling.
4.6.2.4 Free standing Panels of width 1500 mm shall have a 100 mm channel base. Folding
around door opening shall be provided to prevent dust or water lodged on top of the
door from entering the panel when the door is opened. Panels shall have sloped roofs
and guttering to direct water away from doors.
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4.6.2.5 All hinged parts or doors shall be earthed to a fixed part of the frame connected by a
braided strap or fine stranded flexible wire connection.
4.6.2.6 Devices in separate compartments shall be capable of being replaced without shutting
down units in adjacent compartments and without exposing maintenance personnel to
live equipment. Door openings shall be large enough to permit removal of equipment.
4.6.2.7 All control and indicating devices mounted on penetrations shall maintain the IP rating
of the panel.
4.6.2.8 A minimum of 15% of clear mounting space shall be provided for large panels, and
25% for small panels to permit adding future control devices and panel instrumentation.
4.6.3 Flow Measurement:
4.6.3.1 General:
4.6.3.1.1 The Contractor shall select the flow meter best suited to the service whilst considering
maintenance periods and cost. The Company’s preference is to use vortex, Coriolis, or
magnetic flow meters over turbine and PD meters. Vortex meters may also be utilized,
provided they are not installed in areas where vibration will affect accuracy.
4.6.3.1.2 Meter transmitters shall be “Smart” with 24 V DC power supply and 4-20 mA output
and be equipped with a local LCD indicator.
4.6.3.2 Magnetic Flow Meter:
4.6.3.2.1 Magnetic flow meters may be considered where the turn down ratio is less than 1:10
where velocities are <10 m/s and fluid conductivity is >5microsiemens/cm.
4.6.3.3 Coriolis Flow Meter:
4.6.3.3.1 Coriolis meters may be considered where the turn down ratio is less than 1:30. These
may be used for the measurement of hydrocarbon liquid flow and / or density with
process pressure < 40 Kg. /Cm2. Maximum line size shall be DN 80. Consideration
shall be given to the meter pressure drop.
4.6.3.3.2 Where the meter is installed in a bypass line for density measurement, the contractor’s
design shall ensure that the flow rate through the meter provides the accuracy and
response times required by the process.
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4.6.3.4 Ultrasonic Flow Meter:
4.6.3.4.1 Multi path ultrasonic flow meters may be used for measurement of gases and liquids in
accordance with AGA 9. The piping design shall ensure that the meter measures a full
pipe. The Contractor shall ensure that all wetted parts are compatible with the process
conditions. Sensors shall be constructed from 316SS as a minimum.
4.6.3.5 Orifice Plates:
4.6.3.5.1 Flow measurement to AGA 3 and AGA 8 shall generally be carried out by different
pressure measurement across square edge orifice plates with flange tap orifice flanges
or special fittings. Orifice plates shall be concentric for gas flow and eccentric bore for
multiphase flow.
4.6.3.5.2 Other types of orifice plates and methods may be considered for approval where
necessary to satisfy special applications.
4.6.3.5.3 Meter Rangeability shall not exceed 3 to 1, and the design flow shall preferably be
within 0.65 to 0.80 of full range.
4.6.3.6 Flow Nozzles and Venturi Tubes:
4.6.3.6.1 These shall be considered where minimum head loss, and / or high capacity is required
and for use in non-homogeneous fluid with a low percentage of solids and shall be in
accordance with AGA3.
4.6.3.7 Differential Pressure Flow Transmitters:
4.6.3.7.1 Transmitters shall be fitted with 5 way isolation and equalizing manifolds (AISI 316
minimum grade). Mercury type elements shall not be used.
4.6.3.8 Variable Area Flow Meter:
4.6.3.8.1 Variable area flow meters shall be used only for local indication of non-hazardous
fluids. Glass tube meters shall not be used.
4.6.3.8.2 Meters shall be mounted in a vibration free location with pipe work anchored to prevent
stressing of the meter body. The meter shall be suitably protected against mechanical
damage.
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4.6.3.9 Turbine Meter:
4.6.3.9.1 Turbine meters shall be installed directly in the lines with minimum straight run
distances calculated according to API – 2534. Appendix C, but not less than 20 pipe
diameters upstream and 5 pipe diameters downstream. A strainer shall be installed
upstream of each turbine meter.
4.6.4 Level measurement:
4.6.4.1 General:
4.6.4.1.1 All components associated with level measurement shall conform to the vessel design
pressure and temperature, and the project specifications for piping design, materials and
fabrication.
4.6.4.1.2 Level transmitters and float switches shall generally be mounted in external chambers
piped to the vessel. To facilitate maintenance testing and calibration, drain points with
piped drain valves shall be provided. Chambers shall be provided with vent and drain
points.
4.6.4.2 Level Gauges:
4.6.4.2.1 Gauge glasses shall be either steel armoured transparent or reflex type. They shall be
provided with isolating valves, plugged drains and vent valves of size DN 15 minimum
except in certain specified applications.
4.6.4.2.2 Gauge glasses shall be selected on a basis of total visible length giving equal visible
coverage above and below the maximum and minimum anticipated operating levels.
4.6.4.2.3 The level gauge shall not exceed 1100 mm visible length.
4.6.4.2.4 Ranges in excess of 1100 mm visible length shall be covered by multiple gauge
assemblies. Visible length of multiple gauges shall overlap by a minimum of 50 mm.
4.6.4.3 Level Transmitters:
4.6.4.3.1 The primary type of level instrument for remote transmission shall be the displacer type.
Other types of instrument may be proposed for the Company’s consideration where
displacers are not suitable.
4.6.4.3.2 Differential pressure transmitters are only to be employed when specific gravity
changes are considered to be negligible.
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4.6.4.3.3 Meter transmitters shall generally be “SMART” with 24 V DC power supply and 4-20
mA output, and be equipped with a local indicator.
4.6.4.4 Level Switches:
4.6.4.4.1 Level switches shall generally be avoided, however where they are required, fixed
displacement or float type switches mounted in an external chamber shall be used.
4.6.4.4.2 Variable displacement type switches mounted in an external chamber shall be employed
where process requirements or operating conditions prevent the use of float type
switches.
4.6.4.4.3 Float switches shall generally have single pole double throw contacts, with contact
rating of 5A, 240 volt. Ac. The position of the float shall determine the set point. The
switch shall have a fixed differential.
4.6.5 Pressure measurement:
4.6.5.1 General:
4.6.5.1.1 All pressure instruments shall be specified with a range approximately twice the
operating pressure except where process conditions dictate otherwise. They shall be
capable of withstanding an over pressure of 25% above the relevant relief valve setting
without permanent set or loss of calibration.
4.6.5.1.2 All pressure instruments shall be provided with individual block and bleed valves as
well as the primary process isolation valve.
4.6.5.1.3 All instrument used for handling viscous or corrosive materials shall be sealed. Seals
may be the chemical type of suitable material and a silicone oil fill between the
diaphragm and the pressure element of the instrument. Capillary tubing shall be 316SS
3 mm OD with 316SS spiral wound armour. Diaphragm seals shall be flush out type.
4.6.5.1.4 Pressure transmitters shall be ‘SMART’ with 24 VDC power supply and 4-20 mA
output, and be equipped with a local indicator.
4.6.5.1.5 Pneumatic transmitters shall have an accuracy of better than 1% of span and wherever
applicable shall be of the indication type. Process connections shall be ½” NPT.
Transmitter output tubing shall be provided with a plugged tee for installation of a
calibrated pressure gauge.
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4.6.5.1.6 Pressure switches shall have single pole double throw contacts, with gold contacts rated
for low energy use 1A at 28 VDC. These switches shall have adjustable differential as
required.
4.6.5.2 Pressure Gauge:

4.6.5.2.1 Instrument range shall generally be selected so that the normal operating pressure
occurs at approximately two-thirds scale.
4.6.5.2.2 Standard ranges shall be used wherever possible. Gauges shall have an accuracy of ±1.0
% FSD and have 25% over range protection.
4.6.6 Temperature measurement:
4.6.6.1 General:
4.6.6.1.1 RTD transducer type Electronic transmitters shall be used for measurement less than
350oC.
4.6.6.1.2 The use of temperature switches shall be generally avoided. Where they must be used
they shall be single pole double throw contacts, rated for 1A at 28VDC.
4.6.6.1.3 Liquid or gas filled thermal systems are not preferred. However, if supplied they shall
be complete with stainless steel bulb, armoured capillary thermowell and union
connection. Alternatively the switch may be of bi-metallic type.
4.6.6.1.4 A thermowell shall be employed at all temperature measuring points except in

exceptional approved applications.
4.6.6.2 Thermowells:
4.6.6.2.1 Thermowells shall be a minimum of 316 SS, shall be flanged and be DN 40 for piping,
DN 50 for vessels. Screwed wells are not acceptable.
4.6.6.2.2 Thermowell extension shall be of sufficient length to ensure sensor head is clear of any
pipe or vessel insulation.
4.6.6.2.3 Sufficient clearance shall be provided to ensure the element can be withdrawn from the
sensor head without removal of any fittings, etc.
4.6.6.2.4 Test wells shall be equipped with a SS 316 plug. Plugs shall be attached to the well by
a SS 316 chain.
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4.6.6.3 Temperature Gauges:
4.6.6.3.1 Dial thermometers shall be adjustable, every angle bi-metallic type. Construction shall
be of SS 316 with external adjustment and accuracy / better than 1% of full scale.
4.6.6.3.2 The range shall be selected so that the normal operating temperature lies at
approximately two-thirds full scale.
4.6.6.4 Temperature Transmitters:
4.6.6.4.1 Electronic transmitters shall be used for all temperature measurements that are to be
displayed in the Control Room. Platinum RTDs shall be the preferred element. Other
sensor types may only be considered when it is demonstrated that an RTD is not
suitable. Transmitters shall generally be “Smart” with 24 V DC power supply and 4.20
mA output and LCD indicators.
4.6.7 Control valves:
4.6.7.1 General:
4.6.7.1.1 Control valves shall normally be located in horizontal lines and with the top work
mounted upright. Locations shall permit easy access for maintenance operations to the
valve body, actuator and any accessories.
4.6.7.1.2 Body and flange ratings shall be in accordance with the piping design and materials
specification. However, the minimum flange rating shall be ASME 300.
4.6.7.1.3 Valve trim shall be SS 316 minimum.

4.6.7.1.4 Control valve shall have tight shut off in accordance with ASME B 16.04 Class IV
unless otherwise specified.
4.6.7.1.5 All components shall be designed so that they fail-safe, i.e. in all failures the valve shall
move to the safe position.
4.6.7.2 Valve Type:

4.6.7.2.1 Globe valves shall be employed for process control purposes in higher DP, low capacity
service.
4.6.7.2.2 Alternative valves as allowed by the piping design and materials specification may be
used subject to Company approval.
4.6.7.2.3 Rotary globe valves (eccentric plug) with stellite facings with plug downstream may be
considered for flashing service.
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4.6.7.3 Valve Body:
4.6.7.3.1 Minimum Control Valve body size shall be DN 25 when the control valve manifold
piping is DN25 or larger.
4.6.7.3.2 Valves in flashing service shall have a body size at least one size larger than that
necessary to contain the calculated trim size.
4.6.7.4 Valve Packing:
4.6.7.4.1 The packing material shall depend upon the service condition. The recommended
packing material is PTFE for services from –200 to 200 deg. C. Flexible graphite
packing with external lubricator and isolation valve shall be used for service
temperatures above 200 deg. C.
4.6.7.5 Control Valve Sizing:
4.6.7.5.1 Valve flow coefficients shall be calculated for each operating condition in accordance
with the equations and methods in ISA 75.01.
4.6.7.5.2 Valve trim size for equal percentage characteristic valves shall normally be selected so
that:
Minimum flow valve travel is 20%.
Normal flow valve travel 60% to 80%.
Maximum flow valve travel 90%.
4.6.7.5.3 Valve trim size for linear characteristic valves shall normally be selected to be between
50 to 70% travel for normal flow. Maximum flow shall not exceed 90% of capacity.
4.6.7.5.4 Butterfly valves shall be sized so that the normal design flow rate does not exceed 60%
opening for throttling service.
4.6.7.5.5 In addition to the selection of valve and trim combination sized to suit the process
conditions, full consideration shall also be given to the inlet and outlet velocities and
possible occurrence of cavitation causing excessive noise, erosion and vibration. All
control valve sizing shall be verified by the valve vendor to ensure suitability to meet the
process requirements.
4.6.7.6 Valve Actuators:

4.6.7.6.1 Actuators shall be sized for operation under maximum shutoff pressure drop across the
valve, with minimum instrument air pressure or voltage to the actuator as specified in
this specification.
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4.6.7.6.2 A safety margin of 1.5 for regularly cycling valves shall be applied. For long standstill
service safety margin shall be a minimum of 2.
4.6.7.6.3 Each valve set shall be fitted with a 316 SS filter regulator air set combination.
4.6.7.7 Valve Positioners:

4.6.7.7.1 Intelligent valve positioners shall be provided for all modulating control valves.
4.6.7.7.2 Valve positioners shall be “smart type” with integral I/P, direct acting and have a spring
range for 4-20 mA signal.
4.6.7.7.3 Positioner by pass shall be fitted except where agreed with the Company.
4.6.8 Emergency and shut down valves:
4.6.8.1 General:
4.6.8.1.1 All shut down /sequence valves shall be of the ball valve type. They shall provide
bubble tight shut off (class VI) with the higher pressure from either direction.
4.6.8.1.2 All shut down valves shall be fail-safe and shall include a pressure accumulator where
necessary to achieve the required action or number of operations on loss of external
operating pressure.
4.6.8.1.3 All shut down valves shall be provided with a beacon type position indicator. Where
specified in the Datasheet, this shall house open and closed position proximity limit
switches. These shall be certified as Intrinsically Safe.
4.6.8.2 Valve Actuator:

4.6.8.2.1 Valve actuators shall be sized to operate the valve in both directions with zero pressure
downstream, and maximum pressure upstream and also with the maximum differential
pressure in the reverse direction. Sizing shall include a 30% safety margin above the
minimum operating torque requirements of the valve at the maximum DP. Actuator
torque shall not exceed the maximum stem shear torque of the valve at the maximum
supply pressure.
4.7 Material Requirements:

4.7.1 The material requirements for the equipment package instrumentation shall in general
be as per clause no. 3.6.4.5 of Instrumentation Design Criteria and as per the Material
Specifications listed in the Equipment/Instrument Specifications and Data Sheets.
4.7.2 Materials used for parts of the assembly not specifically detailed by the Company shall
be selected by the Contractor on the following basis:
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• Suitability for the specified process conditions.

• Consideration shall be given to the effects of stress corrosion cracking in 316 SS
when in contact with chloride at temperatures above 34deg.C
• Company approval is required prior to the use of aluminium for any instrument
component Aluminium may only be used if no other suitable material is
available from the manufacturer. Aluminum shall not be used for any
component in contact with the process fluid. If aluminium is used for any
housing or component it shall be certified as copper free i.e. less than 0.4%
copper by mass.
• Cast iron shall not be used for any item to which this specification applies.
Ductile iron shall not be used without the Company’s prior written approval of
each item.
• All proposed plastic component shall be non-toxic and fire resistant, UV
stabilized, and compatible with the environmental conditions.
• All spindles, bushing, bolting, screws etc, shall be manufactured from a suitable
grade of stainless steel.
• All molded polyester parts shall be in an anti-static version for hazardous area
locations, and in general be constructed from glass reinforced polyester ultra
violet stabilized. Surface resistance shall be less than 109 OHMS. Impact
resistance shall be –25% (EN 50.14).
• In-line instruments, including valves, shall be specified with suitable materials
in accordance with NACE MR 0175 where H2S is present in significant
concentration.
5.0 EQUIPMENT PROTECTION:
5.1 The protection requirements for the equipment package instrumentation shall in general
be as per clause no. 3.6.4.4 of Instrumentation Design Criteria.
5.2 Control Room Environment: The control rooms shall be normally pressurized and air-
conditioned environments and shall provide an environment in accordance with ISA
S71.01 and ISA S 71.04. These areas shall be subject to the following condition:
Ambient Air Temperature: 21-24oC
Relative Humidity : 45% to 55%
The equipment in control rooms shall continue to operate properly under conditions of
air conditioning failure, when the ambient conditions may rise to 50 o C and 95% RH
for periods up to 8 hours.
5.3 The majority of the field mounted instrumentation will be mounted in a Division 2
hazardous area although some will be located in a Division 1 classified area and some
in a safe area.
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5.4 For reasons of standardization, all field mounted electrical equipment shall utilize the
following methods of protection :-
• All electrical instrumentation equipment except junction boxes and solenoid
valves shall be certified intrinsically Safe Ex “ia” for Class 1, Div. 1, Group D,
Temperature Class T5 minimum.
• Junction boxes to be certified ‘increased safety” Ex “e” for IS circuits and
explosion proof/Ex”d” for non-IS circuits for Class 1 Div.1 Group D
Temperature Class T5 minimum, hazardous area.
• If instrumentation cannot be provided with the above methods of protection,
then alternative methods suitable for the classified area and certified by an
acceptable Authority shall be proposed for the Company’s consideration.
5.5 All certificates and documentation required to satisfy the conditions of the certification
shall be provided (including IS system entity and cable parameter calculations) in the
Hazardous Area Dossier.
5.6 Equipment shall be designed so that, under normal operating conditions, it shall be
unaffected by radio transmissions. A 5 watt RMS hand –held transmitter in the 50-200
and 400 – 460 MHz bands, positioned with the mid points of its aerial no more than 300
mm from the electronic module shall not impair or degrade the performance of that
module.
5.7 All equipment including entries and blanking plugs shall be dust tight and water proof
to IP 65/NEMA 4X. Instruments not classified IP 65 to be subject to Company’s
approval.
5.8 Weather shields shall be installed over Ex ‘d’ junction boxes, and instruments that do
not meet this standard.
6.0 INSTALLATION REQUIREMENT:
6.1 The installation requirements shall in general be according to clause 3.6.4.6 of

Instrumentation Design Criteria.
6.2 The principles and details of instrument mounting and location shall be selected so as to
have no adverse effect upon signal accuracy and repeatability. Any physical condition
such as mechanical stress, vibration, temperature etc. shall be limited to the maximum
figures specified by the instrument manufacturer by the use of appropriate mounting
methods.
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Design Division
For Rev. No : 1
Engg. Services
6.3 Special measures shall be taken to protect engine – mounted instrument from heat and
vibration, and ensure ready accessibility. Cable connecters for such items shall be
sufficiently robust to withstand the conditions and repeated disconnection/reconnection.
6.4 Instruments shall be positioned to provide sufficient space for ease of installation,
removal and maintenance.
6.5 Instrument Mounting:
6.5.1 Instruments shall not be mounted on handrails.
6.5.2 Instruments shall be mounted on DN50 pipe stands (except pressure gauges, dial
thermometers and other instruments which are screwed directly on the line).
6.5.3 Local instruments shall be mounted so that the centerline of the instrument is
approximately 1400 mm above grade or walkway.
6.6 Process and Instrument Connections:
6.6.1 Individual instrument connections shall be provided on process piping and equipment.
Each process connection shall have an isolating valve.
6.6.2 Process piping up to and including the first block valve shall confirm to the vessel or
line classification.
6.7 Tubing & Fitting Installation:
6.7.1 The installation requirements for tubing and fitting shall in general be as per clause no.
3.6.5.3 of Instrumentation Design Criteria.
6.7.2 Instrument installation shall be in accordance with API RP 550, the instrument
manufacturer’s instructions and the following:
6.7.3 All Process Impulse Tubing and Fittings shall be rated to suit the design conditions but
the following shall be considered minimum requirements.
• ½” X 0.065” W/T Fully annealed AISI 316 seamless stainless steel tubing to
ASTM A269 or equivalent with hardness less than RB 80.
• Fittings to be AISI 316 stainless steel twin ferrule compression type.
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Design Division
For Rev. No : 1
Engg. Services
6.7.4 All pneumatic tubing and fittings shall be in accordance with the following minimum
requirements.
• ¼” O.D. X 0.035” W/T.
• 3/8” O.D. X 0.035” WT.
• ½ “ O.D. X 0.035” W/T.
• Fully annealed AISI 316 Seamless Stainless Steel Tubing to ASTM A 269 or
equivalent. Hardness to be less than RB 80.
• Fittings to be Swagelok AISI 316 Stainless Steel Twin Ferrule Compression
type.
6.7.5 The tubing wall thickness of any larger size tubing shall be suitably rated to meet the
process design pressure to which it is subjected.
6.8 Instrument Electrical Installation:
6.8.1 Electrical Installation requirements shall be in accordance with the relevant sections of
Electrical Design Criteria.
6.8.2 Cable Segregation:
6.8.2.1 Intrinsically safe signal cables may be run on the same tray as the equivalent non LS
Signal cables but must be segregated by a metal barrier.
6.8.2.2 Cables carrying miscellaneous signals such as frequency/plus /analysis shall be

individually and overall screened and be run on separate tray unless individual approval
has been given to share a tray with other signal cables.
7.0 CALIBRATION, INSPECTION AND TESTING:
7.1 Calibration, inspection and testing requirements shall in general be as per clause 3.6.4.7
of Instrumentation Design Criteria. In addition, the following shall also be taken care
of:
7.2 All equipment shall be comprehensively tested before delivery. The testing shall
demonstrate the full functionality of the equipment.
7.3 In addition to the inspection and testing specified in the accompanying equipment
specifications, the Contractor shall also comply with the following minimum
requirements.
7.4 The Contractor shall provide to the Company, not less than six weeks prior to the date
of commencement of the control and instrumentation system test, a detailed schedule of
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For Rev. No : 1
Engg. Services
the tests and sample rest record forms for approval. The tests shall not be undertaken
until the test schedule and test forms are approved by the Company.
7.5 The test procedures shall include but not be limited to the following:
• All wiring shall be tested for insulation and the test voltage shall be compatible
with the wiring being tested.(Equipment likely to be damaged shall be
disconnected for these tests).
• Full stimulated function tests of the complete system with all equipment in
position and connected to suitable temporary supplies. The Contractor shall
provide the test stimulator consisting of dummy loads with indication of the
status of every output. The test simulator shall only be connected to the field
connection terminals and the input/output interface shall be individually labeled
to facilitate testing. The Contractor shall obtain Company’s approval of supply
unit characteristics and simulated input/output interface.
• All equipment failure modes e.g. fail-safe, self-diagnostic, power supply dip,
etc. shall be checked.
• Calibration of all instrument items shall be witnessed to ensure the required
accuracy is achieved.
7.6 All tests and corrective work shall be recorded for the Company’s approval.
7.7 The Contractor shall ensure that all inspections and tests are completed satisfactorily.
The Company reserves the right to back-charge any additional inspection work if
Contractor’s preparations are found to be unsatisfactory by the Company.
7.8 Tests shall be witnessed and results recorded on test sheets, which shall include test
reports and be forwarded to the Company for approval and acceptance prior to
shipment.
8.0 DOCUMENTATION:
8.1 The documentation requirements shall in general be according to clause 3.6.6.2 of

Instrumentation Design Criteria. In addition, the following shall also be taken care of:
8.2 Design Documentation:
8.2.1 The design documentation shall include the following:

• General arrangement drawings complete with parts list, materials of construction
and description. The drawings shall also include package dimensions,
instrument locations, interconnecting piping or tubing tie in points and tubing
termination bulkhead location, and junction boxes location at which all
instrument cables terminated. The instrument drawing symbols shall be in
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Design Division
For Rev. No : 1
Engg. Services
accordance with ISA S 5.1 Instrument tag No. on those drawings shall conform
to tag No.on P&ID drawings.
• A table of all instruments, including pressure gauges, relief valves, control
valves, thermometers, c. used throughout the package. This tabulation shall
show item number, model; number, manufacturer, service, size or range,
specification sheet No., set point and other data which would facilitate
identification and location of the instruments.
• Prices list of recommended commissioning spares.
• Prices list of spare parts for two years operation.
• Prices list of special tools.
• Itemized list of Contractor’s Deviations from Specification.
• Weights.
8.3 Final Documentation:
8.3.1 A manufacturing Record Book shall be compiled concurrently with fabrication such
that a full record of the fabrication, materials, inspection and testing is available.
8.3.2 All items in the manufacturing Record Book shall be numbered. Contents shall include,
but not be limited to the following:
• Front cover sheet detailing.
• Project Title.
• PO No.
9.0 TAGGING AND NAMEPLATES:
9.1 Tagging & Nameplate requirements shall in general be according to clause 3.6.6.1 of
10.0 REVIEW & APPROVAL:
10.1 Review and approval of purchase specifications and other related documents shall in
general be according to clause 3.6.6.3 of Instrumentation Design Criteria.
11.0 VENDOR PRE-QUALIFICATION REQUIREMENTS:
11.1 The Vendor pre-qualification requirements shall in general be according to clause

3.6.6.4 of Instrumentation Design Criteria.
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006
Design Division
For Rev. No : 1
Engg. Services
12.0 PREPARATION FOR SHIPMENT:
12.1 Preparation for shipment shall in general be as per clause 3.6.6.5 of Instrumentation
Design Criteria.
13.0 RECEIPT & STORAGE:
13.1 Receipt and storage requirements shall in general be as per clause 3.6.6.6 of
DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006

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Functional Specifications Spec No : 3503

Rev 1 - Revised for updating ISO Format

Clause No. ITEM Page No.

1.0 SCOPE OF THIS DOCUMENT:

2.0 CODES & STANDARDS:

2.1 Reference Specifications:

2.2 Other Specifications To Be Followed:

3.0 SCOPE OF SUPPLY:

4.0 INSTRUMENTATION FOR EQUIPMENT PACKAGE:

4.1 Purpose / Application:

connection shall be noted on the Contractor’s drawings. Each pneumatic instrument

4.2.10 Electronic instrumentation transmission signals shall be provided by 2 wire transmitters

4.3 Electrical Requirements:

4.3.2 Power supplies and signal voltages shall be as listed below:

4.3.3 Signal interfaces to other systems shall be as follows:

4.4 Unit Control Panels:

4.5 Control Requirements:

4.5.2 Shutdown and Auto Start Requirements:

4.5.3 Alarm Requirements:

4.5.3.3 Annunciation of shutdown and auto-start functions shall be provided by a contact

4.6 Selection Basis For Package Instrumentation:

4.6.2 Control Panels:

4.6.2.2 Control panels containing PLCs shall be located in non-hazardous areas.

4.6.3 Flow Measurement:

4.6.3.2 Magnetic Flow Meter:

4.6.3.3 Coriolis Flow Meter:

4.6.3.4 Ultrasonic Flow Meter:

4.6.3.5 Orifice Plates:

4.6.3.6 Flow Nozzles and Venturi Tubes:

4.6.3.7 Differential Pressure Flow Transmitters:

4.6.3.8 Variable Area Flow Meter:

4.6.3.9 Turbine Meter:

4.6.4 Level measurement:

4.6.4.2 Level Gauges:

4.6.4.3 Level Transmitters:

4.6.4.4 Level Switches:

4.6.5 Pressure measurement:

4.6.5.2 Pressure Gauge:

4.6.6 Temperature measurement:

4.6.6.1.4 A thermowell shall be employed at all temperature measuring points except in

4.6.6.3 Temperature Gauges:

4.6.6.4 Temperature Transmitters:

4.6.7 Control valves:

4.6.7.1.3 Valve trim shall be SS 316 minimum.

4.6.7.2 Valve Type:

4.6.7.3 Valve Body:

4.6.7.4 Valve Packing:

4.6.7.5 Control Valve Sizing:

4.6.7.6 Valve Actuators:

4.6.7.7 Valve Positioners:

4.6.8 Emergency and shut down valves:

4.6.8.2 Valve Actuator:

4.7 Material Requirements:

• Suitability for the specified process conditions.

5.0 EQUIPMENT PROTECTION:

6.0 INSTALLATION REQUIREMENT:

6.1 The installation requirements shall in general be according to clause 3.6.4.6 of

6.5 Instrument Mounting:

6.5.1 Instruments shall not be mounted on handrails.

6.6 Process and Instrument Connections:

6.7 Tubing & Fitting Installation:

6.8 Instrument Electrical Installation:

6.8.2 Cable Segregation: