AREA:
GENERAL
COMPER/EE/EAI
TITLE:
DESIGN CRITERIA – INSTRUMENTATION AND AUTOMATION
REVISION INDEX
REV DESCRIPTION AND/OR AFFECTED SHEETS
0 A B C D E ORIGINAL.
INCLUDED REQUEREMENTS FOR BOILER, CEMS AND FILDBUS FUNDATION RISK MANAGEMENT.
REVISED WHERE INDICATED. REVISED WHERE INDICATED
REVISED THE CONCEPT FOR CABLE ENTRANCE IN CCL AND CIC AND CEMS ITEMS REVISED WHERE INDICATED
REV. 0 REV. A REV. B REV. C REV. D REV. E REV. F REV. G REV. H DATE 03-30-07 06-08-07 08-21-08 01-08-09 01-25-09 24-07-09
DESIGN AB-PQF/UPB/ES AB-PQF/UPB/ES AB-PQF/UPB/ES/AEIAB-PQF/UPB/ES/AEIAB-PQF/UPB/ES/AEIAB-PQF/UPB/EE/AEI
EXECUTION ORESTES RICARDO RICARDO ORESTES ORESTES MARCIO
CHECK RICARDO ORESTES ORESTES DILERMANDO DILERMANDO ORESTES
APPROVAL FERNANDO FERNANDO DILERMANDO FERNANDO FERNANDO DILERMANDO
THE INFORMATION CONTAINED IN THIS DOCUMENT IS PETROBRAS PROPERTY AND MAY NOT BE USED FOR PURPOSES OTHER THAN THOSE SPECIFICALLY INDICATED HEREIN. THIS FORM IS PART OF STANDARD PETROBRAS N-381-REV. G ENGLISH ANNEX A – PICTURE A-1.
CONTENTS
1. OBJECTIVE ...6
2. APPLICABLE STANDARDS ...6
2.1. PETROBRAS...6
2.2. ABNT (Associação Brasileira de Normas Técnicas)....9
2.3. API (American Petroleum Institute)....10
2.4. NFPA (National Fire Protection Association)....11
2.5. IEC (International Electrotechnical Commission)....11
2.6. ANSI ( American National Standards Institute )...12
2.7. ASME (The American Society of Mechanical Engineers)....12
2.8. ASTM (American Society for Testing and Materials)....13
2.9. ISA (Instrumentation, Systems and Automation Society)....13
2.10. IEEE (Institute of Electrical and Electronic Engineers)....16
2.11. MSS (Manufacturers Standardization Society of the Valve and Fittings Industry Manufacturers Association)....16
2.12. NAMUR...16
2.13. NR (Normas Regulamentadoras de Segurança e Saúde no Trabalho - Ministério do Trabalho e Emprego)....16
2.14. ISO (International Organization for Standardization)....17
2.15. EIA (Electronic Industries Association) ....17
2.16. EEMUA (The Engineering Equipment and Materials Users Association)....17
2.17. UL (Underwriters Laboratories) ....17
2.18. Open Connectivity Organization (OPC)....17
2.19. Fieldbus Foundation (FF)....17
2.20. INMETRO ( Instituto Nacional de Metrologia, Normalização e Qualidade Industrial)....18
2.21. AGA ( American Gas Association)...19
3. DEFINITIONS...19
4. ENGINEERING UNITS ...20
5. INSTRUMENTATION DESIGN CRITERIA ...21
5.1. GENERAL CONDITIONS...21
5.2. INSTRUMENTS IDENTIFICATION...24
5.3. DESIGN DOCUMENTATION...26
5.4. GENERAL REQUIREMENTS FOR DESIGN AND SPECIFICATION OF INSTRUMENTS....44
5.5. TEMPERATURE INSTRUMENTS SPECIFICATION...47
5.6. PRESSURE INSTRUMENTS SPECIFICATION...48
5.8. LEVEL INSTRUMENTS SPECIFICATION...50
5.9. CONTROL VALVES SPECIFICATION....51
5.10. SALFETY AND RELIEF VALVES SPECIFICATIONS...53
5.11. PROCESS ANALYZERS SPECIFICATIONS...53
5.12. MARSHALLING CABINET...73
5.13. FIRE AND GAS DETECTION...74
5.14. RESERVE CRITERIA...75
5.15. INTERLOCKING AND EMERGENCY SHUTDOWN SYSTEM...75
5.16. PROGRAMMABLE LOGIC CONTROLLER FOR GENERAL APPLICATIONS...77
5.17. PROGRAMMABLE LOGIC FOR SAFETY SYSTEM...79
5.18. INSTALLATION OF INSTRUMENTS...79
5.19. PACKAGE UNITS...83
5.20. MOTORIZED VALVES TELECOMAND SYSTEM...86
5.21. MEASUREMENT STATION FOR CUSTODY TRANSFER – LIQUID EMED...90
5.22. EMED for measurement of gas...94
5.23. CONTINUOUS EMISSION MONITORING SYSTEM - CEMS...96
5.24. EMERGENCY ISOLATION VALVE – EIV...110
6. GAS COMPRESSORS AUTOMATION...110
6.1. SCOPE...110
6.2. GENERAL REQUIREMENTS...110
6.3. RECIPROCATING COMPRESSORS....119
6.4. CENTRIFUGAL COMPRESSORS...122
7. FIRED HEATERS AUTOMATION ...122
7.1. SCOPE...122
7.2. GENERAL GUIDELINES...122
7.3. FUNCTIONAL REQUIREMENTS AND INTERFACES...123
7.4. LOGIC SEQUENCE DESCRIPTION...125
7.5. GENERAL REQUIREMENTS...131 7.6. GENERAL NOTES...132 8. PUMP AUTOMATION ...132 8.1. SCOPE...132 8.2. GENERAL GUIDELINES...132 8.3. FUNCTIONAL REQUIREMENTS...132
8.4. INTERFACES AND ADDITIONAL INSTRUMENTATION...134
8.5. BLOCK DIAGRAMS FOR PUMP AUTOMATION...135
8.6. LARGE SIZE PUMP CONTROL ARCHITECTURE...139
9.1. SCOPE...143
9.2. GENERAL GUIDELINES...143
9.3. FUNCTIONAL REQUIREMENTS AND INTERFACES...143
9.4. LOGIC SEQUENCE DESCRIPTION...145
9.5. BLOCK DIAGRAMS: AIR-COOLED HEAT EXCHANGERS AUTOMATION...146
10. BOILER CONTROL AND SAFETY REQUIREMENTS...147
10.1. SCOPE...147
10.2. GENERAL GUIDELINES...147
10.3. CONTROL STRATEGIES...148
10.3.1. Steam flow control...148
10.3.2. Water level control in the steam drum...148
10.3.3. Steam temperature control...149
10.4. REQUIREMENTS FOR PROCESS INSTRUMENTATION...149
10.5. PROCESS ALARMS REQUIREMENTS...151
10.6. FIELD INSTRUMENTATION...152
10.7. SAFETY REQUIREMENT - SIS...153
10.8. FUNCTIONAL REQUIREMENTS AND INTERFACES...155
11. LOCAL CONTROLLER ROOM (CCL) AND CONTROL INTEGRATED CENTER (CIC)...156
12. SUPERVISION AND CONTROL SYSTEMS ...158
12.1. SUPERVISION SYSTEMS...158
12.2. CONTROL SYSTEMS...158
13. FOUNDATION FIELDBUS SPECIFICATION...159
13.1. SCOPE...159 13.2. . DEFINITIONS...159 13.3. INSTALLATION CRITERIA...159 13.4. FIELD DEVICES...160 13.5. HOST SYSTEM...161 13.6. SEGMENT DESIGN...162 13.7. CONFIGURATION TOOL...166 13.8. MAINTENANCE TOOL...167 13.9. DOCUMENTATION...168 13.10.ACCEPTANCE TESTS...169 13.11.TRAINING...169 13.12.SPARE PARTS...170
13.13.FOUNDATION FIELDBUS SEGMENT RISK MANAGEMENT...170
15. MODERN CONTROL STRATEGIES...172
16. THE ENTERPRISE-CONTROL SYSTEM INTEGRATION ...172
17. DYNAMIC PROCESS SIMULATOR...172
18. TRADE AUTOMATED SYSTEM – TAS ...173
19. ELECTRIC POWER SYSTEM FOR INSTRUMENTATION ...175
1. OBJECTIVE
The objective of this Technical Specification is to present the Instrumentation and Automation Design Criteria additional to those mentioned in the PETROBRAS standards, for the Basic and Detailed Design, of the RIO DE JANEIRO PETROCHEMICAL COMPLEX in Itaboraí, Rio de Janeiro State, Brazil.
2. APPLICABLE STANDARDS
The following list of standards shall be applied for design and specification of equipment or materials that are to be used in the current project. In case of doubts, PETROBRAS shall be consulted.
This Technical Specification complements and is complemented by the Specification Technique I-ET-6000.67-0000-700-PDY-001 - Design Criteria - Electricity.
2.1. PETROBRAS
N-0058 Símbolos Gráficos para Fluxogramas de Processo e Engenharia NI-0058 Graphic Symbols for Process and Engineering Flow-sheets
NI-0298 Graphic Symbols and designations employed in detailing drawings of industrials electrical instalations
N-0381 Execução de Desenhos e Outros Documentos Técnicos em Geral NI-0381 Execution of Drawing and Other Technical Documents
N-0839 Pote para Instrumentação
N-0858 Construção, Montagem e Condicionamento de Instrumentação N-1600 Construção, Montagem e Condicionamento de Redes Elétricas N-1735 Pintura de Máquinas, Equipamentos elétricos e Instrumentos N-1882 Critérios para elaboração de Projetos de Instrumentação NI-1882 Criteria for Preparing Instrumentation Design
N-1883 Apresentação de Projeto de Instrumentação
NI-1883 Presentation of Instrumentation/Automation Design N-1931 Material de Tubulação para Instrumentação
N-1939 Formulários p/ Construção, Montagem e Condicionamento de Instrumentação
N-1996 Projeto de Redes Elétricas em Envelopes de Concreto e com Cabos Diretamente no Solo
N-1997 Redes Elétricas de Bandejamento para Cabos – Projeto, Instalação e Inspeção
NI-1997 Electrical Networks in Cable Tray Systems- Design, Installation and Inspection
N-2065 Elaboração de Informações Básicas de Empreendimentos do Abastecimento
NI-2065 Preparing Basic Information for Refining Projects N-2160 Atuador Elétrico para Válvula
NI- 2160 Electric Valve Actuator
N-2166 Classificação de Áreas para Instalações Elétricas em Refinarias de Petróleo
N-2194 Controlador Programável NI-2194 Programmable Controller
N-2236 Inspeção de construção e montagem em Instrumentação – Qualificação de Pessoal
N-2247 Válvula Esfera em aço para Uso geral e Fire-Safe N-2268 Verificação, Calibração e Teste de Instrumento de Nível N-2270 Fabricação e Montagem de Linhas de Impulso
N-2271 Teste Pneumático para Linha de Alimentação e Sinal N-2272 Montagem de Linha de Alimentação e Sinal Pneumático N-2276 Teste Hidrostático e Pneumático para Linha de Impulso
N-2277 Teste de Isolação e Continuidade Elétrica de Circuito de Instrumentação N-2279 Inspeção de Placa de Orifício
N-2316 Fornecimento de Instrumentação para Unidade em Pacote e “SKID”NI-2316 Supply of instrumentation for package and skid mounted units
N-2368 Inspeção, Manutenção, Calibração e Teste de Válvula de Segurança e /ou Alívio
E
E
N-2384 Cabo Elétrico de InstrumentaçãoNI-2384 Electric instrumentation cable N-2547 Conversor de Freqüência para Controle de Rotação de motor Elétrico até 660 VCA
NI-2547 Frenquency converter for speed control of electric motor up to 660 VAC N-2595 Critério de Projeto e Manutenção para Sistemas Instrumentados de Segurança em Unidades Industriais
NI-2595 Design and maintenance criteria for safety instrumented systems in industrial unitis
N-2669 Configuração de Rede de TelecomunicaçõesNI-2669 Telecomunications network configuration
N-2747 Uso de Cor em Instalações Industriais Terrestres e Marítimas NI-2747 Use of Color in Industrial Onshore e Offshore Facilities
N-2760 Sistemas Ininterruptos de Energia para Uso Industrial NI-2760 Uninterruptible Power System for Industrial Use
N-2761 Critério de Segurança para Projeto de Sistemas de Detecção e Alarme de Incêndio e Gás no Refino
NI-2761 Safety Criteria for Design of Fire and Gas Detection and Alarm System in Refining Units
N-2778 Sistemas Ininterruptos de Energia para Uso Industrial – Folha de Dados NI-2778 Uninterruptible Power System for Industrial Use – Data Sheet
N-2781 Diretrizes de Engenharia de Confiabilidade NI-2781 Reliability Engineering Guidelines
N-2784 Confiabilidade e Análise de Riscos NI-2784 Reliability and Risk Analysis
N-2802 Folha de Dados de Instrumentação Coletânea
N-2833 Formulários e Listas para Projetos de Instrumentação NI-2833 Forms and Lists for Instrumentation Design
Diretriz Técnica – AB-RE/ES/TEE – DT-AB-RE/ES/TEE-001 – Instalação de Dispositivos de Segurança em Vaso de Pressão
Technical Guideline - AB-RE/ES/TEE - DT-AB-RE/ES/TEE-006 - “Use of spaired PSVs”
E
E
E
E C
Technical Guideline – EB-RE/ES/TEE – DT-AB-RE/ES/TEE-013 – Requirements for Process and Storage of Aromatics Products
2.2. ABNT (Associação Brasileira de Normas Técnicas).
NB 284 Válvulas de Segurança e/ou Alívio de Pressão – Aquisição , Instalação e Utilização
NBR 1333 Controle de Acesso para Segurança de Instalações Físicas de Processamento de Dados
NBR 5363 Equipamentos elétricos para Atmosferas Explosivas – Tipo de proteção “d” – Especificação
NBR 5410 Instalações Elétricas de Baixa Tensão
IEC-NBR-60079-12 -Equipamentos elétricos para Atmosferas Explosivas – Invólucros com Pressurização ou Diluição Contínua - Tipo de proteção “p” IEC-NBR-60079-0 Marcação de Equipamentos Elétricos para Atmosferas Explosivas NBR 8447 Equipamentos elétricos para Atmosferas Explosivas de Segurança Intrínseca – Tipo de proteção “i”
NBR 9441 Execução de Sistemas de Detecção e Alarme de Incêndio
IEC-NBR-60079-7 Equipamentos elétricos para Atmosferas Explosivas – Segurança Aumentada Tipo de Proteção “e”
NBR 10861 Prensa cabos
NBR 11515 Critérios para Segurança Física de Armazenamento de Dados
NBR 12313 Sistema de combustão – Controle e Segurança para Utilização de Gases Combustíveis em Processos de Baixa e Alta Energia
NBR 13225 Medição de Vazão de Fluídos em condutos fechados, Utilizando Placa de Orifício e Bocais em Configurações Especiais
NBR 10300 Cabos de Instrumentação com Isolação Extrudada de PE ou PVC para tensões de até 300 Volts
NBR 10700 Planejamento de Amostragem em Dutos e Chaminés de Fontes Estacionárias
NBR 10701 Determinação de pontos de Amostragem em Dutos e Chaminés em Fontes Estacionárias
NBR 14565 Procedimento Básico para Elaboração de Projetos de Cabeamento de Telecomunicações para Rede Interna Estruturada
E C E
NBRIEC60529 Graus de Proteção para Invólucros de Equipamentos Elétricos (Código IP)
NBRIEC60079-14 Equipamentos Elétricos Para Atmosferas Explosivas – Parte 14 Instalação Elétrica em Área Classificada (Exceto minas)
NBRIEC60079-17 Equipamentos Elétricos Para Atmosferas Explosivas – Parte 17 Inspeção e Manutenção em Áreas Classificadas (Exceto Minas) NBRIEC60079-27 Conceito Fieldbus Intrinsecamente Seguro (FISCO) e Conceito Fieldbus Não Acendível (FNICO)
NBRNM-IEC60050-426 Equipamentos Elétricos para Atmosferas Explosivas - Terminologia
NBRISO5167-1 Medição de Vazão Fluídos por Meio de Instrumentos de Pressão (Parte 1 – Placas de Orifício, Bocais e Tubos Venturi)
NBRISO/IEC 27002 Tecnologia da Informação – Técnicas de Segurança – Código de Prática para a Gestão de Segurança da Informação
2.3. API (American Petroleum Institute).
API RP 520 parts 1 and 2 Sizing, Selection and Installation of Pressure Relieving Devices in Refineries
API STD 521 Guide for Pressure Relieving and Depressuring Systems API STD 526 Flanged Steel Pressure Relief Valves
API STD 527 Seat Tightness of Pressure Relief Valves
API RP 536 Post Combustion-NOX for Fired Heater Equipment in General Refinery Services
API RP 540 Electrical installations in Petroleum Processing Plants API RP 551 Process Measurement Instrumentation
API RP 552 Transmission Systems API RP 553 Refinery Control Valves
API RP 554 Process instrumentation and Control API RP 555 PART 1-2-3 Process Analyzers’
API RP 556 Instrumentation and Control Systems for fired Heaters and Steam Generators
API RP 557 Guide to Advanced Control Systems
E
E E E
API STD 598 Valve Inspection and Testing
API STD 670 Vibration, Axial Position and Bearing Temperature Monitoring System
API RP 2001 Fire Protection in Refineries
API STD 2000 Venting Atmospheric and Low-Pressure Storage Tanks Non- refrigerated and Refrigerated
API PUBL 2218 Fireproofing Practices in Petroleum and Petrochemical Processing Plants
API MPMS Chapter 1 Vocabulary
API MPMS CHAPTER 2 Tank Calibration
API MPMS Chapters 3.1B and 3.3 Automatic Tank Gauging API MPMS Chapters 4.1 to 4.8 Provers and Proving Systems API MPMS Chapters 5.1 to 5.8 Measurement by Meters API MPMS Chapter 6.1 Lease Automatic Custody Transfer API MPMS Chapter 6.6 Pipeline Metering System
API MPMS Chapter 7 Temperature Determination
API MPMS Chapter 14.1 and 14.3.1. to 14.3.4 - Natural Gas Fluids Measurement
2.4. NFPA (National Fire Protection Association).
75 Standard for the Protection of Information Technology Equipment.
85 Boiler and Combustion System Hazards Code
101 Code for Safety to Life from Fire in Buildings and Structures. 496 Purged and Pressurized Enclosure for Electrical Equipment.
2.5. IEC (International Electrotechnical Commission).
IEC 60300 Reliability and Maintainability Management IEC 60300-1 Dependability Program Management IEC 60300-2 Guidelines for Dependability Management
E
IEC 60300-3 parts 1 to 14 Dependability and Reliability Management Programs IEC 60751 Industrial Platinum Resistance Thermometers Sensors
IEC 60770 parts 1 to 3 Transmitters for Use in Industrial-Process Control Systems IEC 61000 parts 2 to 4 Electromagnetic Compatibility
IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic Safety- Related System
IEC TR61131-8 Guidelines for the Application and Implementation of Programming Language
IEC 61131-3 Programmable Controllers – Programming Languages
IEC 62453-1 Field-bus Device Toll (FDT) Interface Specification – Concepts and Description
IEC 62453-3 Field-bus Device Toll (FDT) Interface Specification – PROFIBUS IEC 62453-4 Field-bus Device Toll (FDT) Interface Specification – HART
IEC 62453-5 Field-bus Device Toll (FDT) Interface Specification – Foundation Field-bus
IEC TR61158-1 Digital Data Communications for Measurement and Control Field- bus for Use in Industrial Control System - Overview and Guidance over IEC 61158
IEC 61158 parts 2 to 6 Digital Data Communications for Measurement and Control IEC 61285 Industrial-Process Control – safety of Analyzers Houses
IEC 61784-1 Digital Data Communications for Measurement and Control
ISO/IEC 7498-1 Information Technology – Open Systems Interconnection - Basic Reference Model
IEC TR 61831 On-line Analyzer Systems – Guide to Design and Installation
2.6. ANSI ( American National Standards Institute )
ANSI/FCI 70.2 - Standard for Control Valve Leakage Classification
2.7. ASME (The American Society of Mechanical Engineers).
ASME B1.20 Pipe Threads, General Purpose.
ASME MFC-2M Measurement Uncertainty for Fluid Flow in Closed Conduits
E
E C
ASME MFC-3M Measurement of Fluid Flow in Pipes Using Orifice, Nozzle and Venturi
ASME MFC-4M Measurement of Fluid Flow by Turbine
ASME MFC-5M Measurement of Fluid Flow in Pipes Using Transient-Time Ultrasonic Flow-meters
ASME MFC-6M Measurement of Fluid Flow in Pipes Using Vortex Flow-meters ASME MFC-7M Measurement of Gas Flow by means of Critical Venturi Nozzle ASME MFC-9M Method for Estimating Installation Effects on Flow-meters ASME MFC-14M Measurement of Fluid Flow by Coriolis Mass Flow-meter ASME MFC-16M Measurement of Fluid Flow by Electromagnetic Flow-meter ASME MFC-16M Measurement of Fluid Flow by Variable Area Meter
ASME PTC 19.3 Instruments and Apparatus : Temperature Measurement ASME PTC 19.13 Determination of Rotary Speed
ASME PTC 19.16 Density determination of Solids and Liquids
ASME PTC 19.17 Determination of the Viscosity of Liquids Instruments and Apparatus
2.8. ASTM (American Society for Testing and Materials).
E-119 Standard Test Methods for Fire Tests of Building Construction and Materials. D 3764 Standard Practice for Validation of Process Stream Analyzers
2.9. ISA (Instrumentation, Systems and Automation Society).
ISA 5.1 Instrumentation Symbols and Identification ISA 5.2 Binary Logic Diagrams for Process Operations
ISA 5.3 Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and Computer Systems
ISA 7.0.01 Quality Standard for Instrument Air
ISA 18.1 Annunciator Sequences and Specifications
ISA 20 Specifications Forms for Process Measurement and Control Instruments
E
ISA 37.16.01 A Guide for the Dynamic Calibration of Pressure Transducer
ISA 50.00.01 Compatibility of Analog Signals for Electronic Industrial Process Instruments
ISA 50.02Parts 2,3,4,5 e 6 Fieldbus Standard for Use in Industrial Control Systems ISA 71.01 Environmental Conditions for Process Measurement and Control Systems : Temperature and Humidity
ISA 71.02 Environmental Conditions for Process Measurement and Control Systems : Power
ISA 71.03 Environmental Conditions for Process Measurement and Control Systems : Mechanical Influences
ISA 71.04 Environmental Conditions for Process Measurement and Control Systems : Airborne Contaminants
ISA 75.01.01 Flow equations for Sizing Control Valves ISA 75.02 Control Valve Capacity Test Procedure ISA 75.05.01 Control Valve Terminology
ISA 75.08 Installed Face-to-Face Dimensions for Flanged Clamp or Pinch Valves
ISA 75.08.01 Face-to-Face Dimensions for Integral Flanged Globe-Style Control Valve Bodies (Classes 125, 150, 250, 300 and 600)
ISA 75.08.02 Face-to-Face Dimensions for Flangeless Control Valves (Classes 150, 300 and 600)
ISA 75.08.03 Face-to-Face Dimensions for Socket Weld-End and Screwed-End Globe-Style Control Valves (Classes 150, 300, 600, 90, 1500 and 2500)
ISA 75.08.05 Face-to-Face Dimensions for Butweld-End Globe-Style Control Valves (Classes 150, 300, 600, 900, 1500 and 2500)
ISA 75.08.06 Face-to-Face Dimensions for Flanged Globe-Style Control Valve Bodies (Classes 900, 1500 and 2500)
ISA 75.08.07 Face-to-Face Dimensions for Separable Flanged Globe-Style Control Valves (Classes 150, 300 and 600)
ISA 75.08.09 Face-to-face Dimensions for Sliding Stem Flangeless Control Valves (Classes 150, 300 and 600)
ISA 75.08.13 Method of Evaluating the Performance of Positioners with Analog Input Signals and Pneumatic Output
ISA 75.17 Control Valve Aerodynamic Noise Prediction ISA 75.19.01 Hydrostatic Testing of Control Valves
ISA 75.22 Face-to-Centerline Dimensions for Flanged Globe-Style Angle Valve Bodies (ANSI Classes 150, 300 and 600)
ISA 75.23 Considerations for Evaluating Control Valve Cavitation ISA 75.25.01 Test Procedure for Control Valves
ISA 75.26.01 Control Valve Diagnostic Data Acquisition and Reporting ISA 77.20 Fossil Fuel Power Plant Simulator
ISA 84.00.01 Parts 1, 2 and 3 – Functional Safety : Safety Instrumented System for Process Industry Sector
ISA 88.00.02 Batch control part 2- Data Structures and Guidelines for Language ISA 88.00.03 Batch control part 3- General and Site Recipe Models and Representation
ISA 88.00.04 Batch control part 4- Batch Production Records ISA 88.01 Batch control Part 1 – Models and Terminology ISA 95.00.01 Enterprise-Control System Integration Parts 1, 2 and 3
ISA TR99.00.01 Security Technologies for Manufacturing and Control Systems
ISATR99.00.02 Integrating Electronic Security into the Manufacturing and Control Systems Environment
ISA 100.11a Wireless Industrial Automation Network
ISA 60079-0 Electrical Apparatus for Use in Class 1, Zones 0,1 and 2 Hazardous Locations : General Requirements
ISA 60079-1 Electrical Apparatus for Use in Class 1, Zone 1 Hazardous Locations : Type of Protection Flameproof “d”
ISA 60079-5 Electrical Apparatus for Use in Class 1, Zones 1 Hazardous Locations : Type of Protection Powder Filling “q”
ISA 60079-6 Electrical Apparatus for Use in Class 1, Zones 1 and 2 Hazardous Locations : Type of Protection Oil Immersion “o”
ISA 60079-7 Electrical Apparatus for Use in Class 1, Zones 1 and 2 Hazardous Locations : Type of Protection Increased Safety “e”
ISA 60079-11 Electrical Apparatus for Use in Class 1, Zones 0, 1 and 2 Hazardous Locations : Intrinsic Safety “i”
ISA 60079-15 Electrical Apparatus for Use in Class 1, Zone 2 Hazardous Locations : Type of Protection “n”
ISA 60079-7 Electrical Apparatus for Use in Class 1, Zones 1 Hazardous Locations : Type of Protection Encapsulation “m”
ISA MC96.1 Temperature Measurement Thermocouples
2.10. IEEE (Institute of Electrical and Electronic Engineers).
IEEE 802.3 Standard for Local and Metropolitan Area Networks – CSMA/CD
IEEE 802.11-A and B Standards for Local and Metropolitan Area Networks – Wireless LAN
2.11. MSS (Manufacturers Standardization Society of the Valve and Fittings Industry Manufacturers Association).
MSS SP-72 Ball Valves With Flanged or Butt-Welding Ends for general Service MSS SP-99 Instrument Valves
2.12. NAMUR
NE 107-“Self-monitoring and Diagnosis of Field Devices”.
2.13. NR (Normas Regulamentadoras de Segurança e Saúde no Trabalho - Ministério do Trabalho e Emprego).
NR 10 Instalações e Serviços em Eletricidade. NR-13 Caldeiras e Vasos de Pressão.
NR 15 Atividades e Operações Insalubres – Anexos 1 e 2. NR16 Atividades e Operações Perigosas.
NR 17 Ergonomia.
NR-18 Condições e meio ambiente de trabalho na indústria de construção. NR-23 Proteção contra incêndios.
2.14. ISO (International Organization for Standardization).
ISO 11064 Parts 1,2,3,4 and 6 Ergonomic Design of Control Centers
2.15. EIA (Electronic Industries Association) .
EIA/TIA RS-232 Interface Between Data Terminal Equipment and Data communication Equipment Employing Serial Binary Data Interchange
EIA/TIA RS-422 Electrical Characteristics of Balanced Voltage Digital Interface Circuits Balanced Digital Multipoint Systems
EIA/TIA RS-485 Electrical Characteristics of Generators and Receivers for use in Balanced Digital Multipoint Systems
2.16. EEMUA (The Engineering Equipment and Materials Users Association).
Publication 138 Design and Installation of On-Line Analyzers System
Publication 191 Alarms Systems – A Guide to Design, Management and Procurement
Publication 201 Process Plant Control Desks Utilizing Human-Computer Interfaces
2.17. UL (Underwriters Laboratories) .
UL 2196 Safety Tests for Fire Resistive Cables
UL 1709 Fire proofing Pratices in Petroleum and Petrochemical Processing Plants
2.18. Open Connectivity Organization (OPC).
OPC UA parts 1 to 11 Unified Architecture – Concepts, Services, Data Access, Profiles, Historical Data, Alarms and Security
2.19. Fieldbus Foundation (FF).
FF-103 Common File Format FF-131 Standard Tables
FF-569 Host Interoperability System Test Procedures
FF-593 High Speed Ethernet Redundancy FF-581 System Architecture
FF-586 Ethernet Presence
FF-588 Field Device Access (FDA) Agent FF-589 HSE System Management
FF-801 Network Management Specification FF-803 HSE Network Management
FF-806 Data Link Protocol Specification Bridge Operation Addendum FF-816 31.25 kbit/s Physical Layer Profile Specification
FF-821 Data Link Layer Services Subset Specification FF-822 Data Link Layer Protocol Specification
FF-880 System Management Specification FF-870 Fieldbus Message Specification
FF-875 Fieldbus Access Sublayer Specification FF-890 Function Block Application Process - Part 1 FF-891 Function Block Application Process - Part 2 FF-892 Function Block Application Process - Part 3 FF-893 Function Block Application Process - Part 4 FF-894 Function Block Application Process - Part 5 FF-900 Device Description Language Specification FF-940 31.25 kbit/s Communication Profile
FF-941 HSE Communication Profile36
2.20. INMETRO ( Instituto Nacional de Metrologia, Normalização e Qualidade Industrial).
Portaria número 83 do INMETRO Regulamento de Conformidade de Equipamentos Elétricos para Atmosferas Potencialmente Explosivas, nas Condições de Gases e Vapores Inflamáveis
2.21. AGA ( American Gas Association)
Report 3 P1 Orifice Metering of Natural Gas and Other Related Hydrocarbons Fluids – part 1 – General Equations and Uncertainty Guidelines
Report 3 P2 Specifications and Installation Requirements
3. DEFINITIONS
a) MCC –Acronym of Motor Control Center. The electrical equipment responsible for the electrical motors protection and control.
b) CEMS – Acronym of continuous emissions monitoring systems that is the complete systems for monitoring toxic gas emissions with origin in the furnaces, heaters and boilers.
c) CIC – Portuguese acronym of “Casa Integrada de Controle” that means Integrated Control Center. From that house the operators supervise and operate all refinery process and utility units. The main equipment located in it is the DCS human machine interface.
d) DCS – Acronym of Distributed Control System. System responsible for process data acquisition, control and disposal of process unit information to operator for supervision. e) EMED – Acronym for custody measurement station that is the set of equipment with controlled accuracy responsible for the measurement of liquid and products to be sold to third party.
f) FF – Acronym of Foundation Fieldbus.
g) HMI – Acronym of Human Machine Interface.
h) LCP – Acronym of Local Control Panel. Local Control Panel is any instrumentation control panel, other than Remote I/O, located at field with control, interlock and/or process data acquisition purpose for a specific process systems or equipment. That panel can contain a PLC and any other specific equipment as well as a human machine interface (HMI).
i) LP - Acronym of Local Panel. Local Panel is any instrumentation panel, located at field with the purpose to provide operator’s local supervision of a specific process systems or equipment through a Human Machine Interface (HMI). That panel has not any control or interlock function, but can contain an independent instrument or equipment with it purpose that was installed in it just making good use of the available enclosure.
j) MC – Acronym of Marshalling Cabinet. Marshalling Cabinet is located at CCL and is used to re-arrange the cables coming from the field to match the wiring terminations of DCS controllers, PES or RCP.
k) PASE – Acronym of “Protection and Automation of Electrical System”. The PASE is the equipment responsible for protection, load shedding and motor acceleration.
l) PES – Acronym of Programmable Electronic System. Certified equipment developed to be applied as logic solver of a SIS.
m) PLC – Acronym of Programmable Logic Controller. Equipment responsible for control and data acquisition of a specific system or equipment.
n) RCP - Acronym of Remote Control Panel. Remote Control Panel is any instrumentation control panel, other than DCS and PES, located at CCL with control, interlock and/or process data acquisition purpose for a specific process system or equipment. That panel can contain a PLC and any other specific equipment as well as a human machine interface (HMI).
o) RUPS – Acronym of Redundant Uninterruptible Power Supply. Is a full redundant uninterruptible power supply for 120Vac.
p) CCL – Portuguese acronym of “Casa de Controladores Local” that means Local Controllers Room. That room shelter the main instrumentation equipment that interfaces the field instrumentation, of one or more process unit, for control and data acquisition purpose.
q) SIL - Acronym of Safety Integrity Level.
r) SIS – Acronym of Safety Instrumented System. System composed of sensors, logic solver, and final control elements for the purpose of taking the process to a safe state when a predetermined condition is violated.
s) STVM – Portuguese acronym of “Sistema de Telecomando de Válvulas Motorizadas” that means Motor Operated Valve System. System composed of motor operated valves with smart actuators connected through a network for data acquisition and control purpose. That system is connected to DCS.
t) TGS – Acronym of Tank Gauging System. System composed of smart level and temperature measurement instruments connected through a network for process data acquisition purpose. That system is connected to DCS.
u) VCD – Portuguese acronym of Via de Comunicação de Dados – Data Communication Route that means the fiber optics routes for connecting parts of the digital networks DCS, SCMD , PLC Remote Maintenance Network, Monitoring Vibration of Machines and HART Asset Maintenance Network.
v) VSD – Acronym of Variable Speed Driver.
4. ENGINEERING UNITS
The units of the process variables to be adopted to principals measurements are the following ones:
E
Others variables to be measure shall follow the SI – Sistema Internacional de Unidades, published by INMETRO.
5. INSTRUMENTATION DESIGN CRITERIA 5.1. GENERAL CONDITIONS
5.1.1 This document is not intended to define the scope of work but only general criteria for detailing. In case of doubt, PETROBRAS shall be consulted at all times.
5.1.2 The development and presentation of the instrumentation and automation design shall comply with the standards listed beneath.
a) presentation of design as per NI-1883;
b) detailing of instrument and automation design as per NI-1882; c) detailing of underground networks as per N-1996;
d) detailing of cable tray systems as per NI-1997; e) detailing of SIS units design as per N-2595; f) instruments identification as per ISA SP 5.1;
g) codified numeration of the engineering technical documents as per N-1710;
Process Variable Unit
Temperature oC
Flow (volumetric liquid) m3/h (water) or m3/d @ 20o C
Flow (mass liquid) Kg/h
Flow (Steam) t/h
Flow (Gas) m3/h corrigido @ 1atm e 20C
Pressure Kgf/cm2
Vacuum and Low Pressure mmH2O
Vacuum and Low Pressure mm H2O (blowers’ discharge, vacuum in heaters and boilers) and mm Hg (in condensers) Level 0 – 100 (%) Density kg/m3 Viscosity Cp E E E E
5.1.3 For the purchase of instruments and automation equipments the data sheets standardized in the PETROBRAS standards shall be used, as well as the associated specifications.
5.1.4 For the purchase of materials, the data sheets standardized in the PETROBRAS standards shall be used, where applicable.
5.1.5 Equipment and materials shall be chosen bearing in mind the classification of areas and the conditions of aggressiveness of the surroundings, at the installation site. In places subject to intense humidity, provision shall be made for drains in the casings of panels for outdoor installation. The requirements of Standard ABNT NBR-5410 shall be considered. Electronics parts of the instruments and panels shall be protect against fungus due the possibility of the humidity or condensate happening.
5.1.6 The detail designer shall issue the whole of the documents stipulated in standard NI-1883, observing the minimum degree of detailing and the form of presentation of information called for therein. The fact that similar documents will be issued by equipment suppliers does not do away with the need for issuance of these items by the detailing designer.
5.1.7 Data Sheets, Technical Specifications and Materials Requisitions (RM) supplied by PETROBRAS as an integral part of the documentation issued for contracting purposes shall not be used directly for the purchase of instruments.
5.1.8 Except for the PETROBRAS standards and drawings referring to installations already in existence, no technical document on instrumentation and automation supplied by PETROBRAS shall be used over or directly revised by the detailing designer. All documents shall necessarily be issued by the detailing designer and shall include all contractual technical requirements.
5.1.9 When the design is developed for locations where there are PETROBRAS industrial facilities already constructed that have interfaces with this project, the following requirements shall be met:
a) existing documents shall be revised and the whole of the remaining correlated documents affected by the revision shall also be updated, even if this means merely the inclusion of a reference;
b) where there is lack of space or legibility in design documents already existing, or yet incompatibility of those with projects issued with the use of the computer, new documents shall be issued. These new documents, besides including the new information, shall consolidate the information existing in prior projects so as to avoid the need for consulting a number of documents to obtain a given piece of information;
c) the designer shall conduct a complete field survey to develop the project, checking, amongst other items, the following factors:
- actual situation of the installations and interferences that shall be avoided or overcome;
- availability of existing installations (for example : spaces for enlargements), including issuance of a notice to PETROBRAS in case some specification prepared by the latter needs to be modified as a result of a field survey and the execution of the detailed design;
- all existing drawings involved to be revised.
5.1.10 Where applicable, the criteria and solutions adopted in the detailed design and in the selection of materials shall be compatible with the usual solutions adopted in the existing facilities.
5.1.11 Basic guidelines related to safety and health established in the Regulatory Standard NR 10 of “Ministério do Trabalho e Emprego – MTE” (Labor and Employment Ministry), shall be applied to the instrumentation and automation power supply design. 5.1.12 CONTRACTOR shall issue and furnish to PETROBRAS a Technical Appraisal, elaborated by a qualified Electrical Engineer, attesting that all the materials, equipment, project services, assembly services and the instrumentation and automation power supply system installed are in accordance with the requirements of the Regulatory Standard NR 10 of MTE and the ABNT Standards, mainly the Standard NBR 5410 - Instalações Elétricas de Baixa Tensão .
5.1.13 The CONTRACTOR shall generate the documentation electronically using a integrated Computer Aided Design – CAE software
5.1.14 The use of programs Autodesk AutoCAD and Microsoft, ACCESS, EXCEL and WORD for WINDOWS, last versions can be used, since they are authorized by PETROBRAS, in writing.
5.1.15 The BID analysis of the following instruments shall be submitted to the approval of PETROBRAS:
- analyzers; (conductimeters, chromatograph, densimeters, viscometers, photometers, etc);
- pressure, differential pressure and temperature transmitters (applied to Level, Flow or Pressure measurement);
- control valves and valve positioners; - shut-off valves and solenoid valves; - EIV, Emergency Inventory control Valve; - safety valves;
- programmable logical controllers (PLC’s); - intelligent electric actuators - STVM;
E
E
E E
- radar or servo-operated level meters- TGS; - distributed control system - DCS;
- programmable electronic system - PES;
- server computers, switches, routers and firewalls;
- advanced control software, reconciliation production data software, historical
production data software, process alarm management software, control loop tunning and auditing software;
- combustion emissions monitoring system – CEMS; - custody and transfer measurement station – EMED; - Dynamic Process Simulator;
- Automated System for Selling Products.
5.2. INSTRUMENTS IDENTIFICATION
5.2.1 Each instrument or Loop function shall be identified by an alphanumeric code or TAG classifying it functionally and sequentially, in accordance with ISA 5.1 Standard and I-DE-6000.67-0000-941-PDY-001 Standards drawings and specifications piping service & special identification.
5.2.2 To facilitate the use of data banks the following pattern for identification of instruments shall be followed:
ID_FUNC ID_LOOP SUFIX v m f f f - a a a a n n n
ID_FUNC = Functional Identification (maximum 5 characters); v = Measured variable or starter (1 character) ; m = Modifier letter or variable (1 character); fff = Function of instrument;
ID_LOOP = Identification of the loop (7 numbers) – Based on a range established by PETROBRAS;
aaaa = area or unit – 4 digits;
nnn = sequential number of loop;
SUFFIX (optional) = letter used to differentiate instruments with the same functional
5.2.3. For each process variable beginning with letter of ISA 5.1 table, sequence shall have all the range from 001 to 999. Instruments for the same service shall use the same sequential and a letter sufix.
5.2.4 Exceptionally at 3200 area, the tag numbering shall be according to following rule: The main area - 3200 - will be break according to the next sub-areas:
3210 Feed Pre-heat and Furnaces
3220 Primary Fractionation and Quench
3230 Cracked Gas Compression (includes the Depropanizers, The Hydrogenation
reactors, the Dehydrators and the Caustic tower)
3240 Cold Fractionation (Demethanizer, Deethanizer and C2 Spliter)
3250 Hot Fractionation ( C3 Spliter and Debutanizer)
3260 Refrigeration Systems
3270 spent Caustic Treatment
3290 Utilities
3550 C4 Hydrogenation
3600 Butadiene Extraction
The construction of the instrument numbering criteria (tag number) shall be modified as:
General tag construction = XX-AABBCCCDE, where:
XX from 2 to 5 letters to identify instrument type,
AA 2 numbers to identify the unit main part of the unit number 32,
BB the subsystem identification, as showed on “a” sub item above,
CCC serial number, 3 digits is mandatory, from 001 to 999,
D suffix identification, 1 letter if necessary, it’s prohibited to a hyphen before suffix,
E suffix modifier, 1 number, only if necessary;
5.2.5. Control and safety loops using the same primary element, such as orifice
plate, the whole loop shall use the same sequential with letter suffix. In case of
distinct instruments for control and safety loops at the same point, those for
control shall have different tagging from those for safety.
5.2.6. Valve position transmitters, switches and indicators shall use the same
number of the valve, with the inclusion of a letter suffix when required. The
duplicity in other process variable shall be verified at the moment of use of ZS´s.
5.2.7. TAG number for motorized and electric-hydraulic valves shall be consistent with their respective loop.
5.2.8 if the identification cannot be held down to 14 characters due to the limitations imposed by the Digital System, reduce the number of characters used for functional identification.
The following fields shall appear in the structure of the data banks: Field Number of Characters How it is filled in TAG 14 normal TAG; UNIT 4 adapted TAG; ID FUNC / LOOP 9 adapted TAG; SUFFIX 2 adapted TAG. b) Examples of functional identifications:
• Transmitters and valves: FT, LT, PDT, TT, LV, PV; • Converters: TY, LY, PY;
• Indicators: FI, FFI, PDI, PI, TI, LI, AI, DI, CI;
• Controllers: FC, FFC, PDC, FQC, IDC, TC, PC, AC, FFC; • Alarms: PAH, PAHH, PDALL, PAL, ZAL, ZAH;
• Positioners: ZT, ZSL, ZSH, ZLL, ZLH;
Note : In undefined cases, modifying letters H and L shall not be used. Hand switches are HS or HMS (instantaneous).
5.3. DESIGN DOCUMENTATION
The technical documentation that shall constitute the instrumentation detailed design, is that defined in PETROBRAS Standard NI-1883, which shall be integrally followed. See the minimum of documents but not restricted at the table below.
ITEM DOCUMENT BASIC DESIGN
1 PROCESS FLOW DIAGRAM (DE) 2 PROCESS DATA SHEET (FD) 3 CAUSE AND EFFECT MATRIX (DE) 4 PRELIMINARY LIST OF INSTRUMENT (LI)
5 PRELIMINARY ENGINEERING FLOW SHEET (DE) 6 SAFETY LOOP CLASSIFICATION REPORT
7 INSTRUMENTATION DESIGN CRITERIA (ET) 8 LOGIC DIAGRAM (DE)
9 SYSTEM ARCHITECTURE (DE)
10 DATA SHEET FOR SPECIAL INSTRUMENTS (FD)
11 TECHNICAL SPECIFICATION FOR SPECIAL SYSTEMS (ET) 12 PROCESS CONTROL DIAGRAM (DE)
13 CONTROL LOOP DESCRIPTION (MD)
14 DESCRIPTIVE MEMORANDUM FOR INSTRUMENTATION SYSTEM (MD)
DETAILED DESIGN
1 PROJECT SCHEDULE (CR)
2 LIST OF DESIGN DOCUMENTS (LD) 3 LIST OF INSTRUMENTS (LI)
4 LIST OF CABLES (LI) E
5 LIST OF MATERIALS (LI) 6 LIST OF SETPOINTS (LI) 7 LIST OF ALARMS (LI)
8 LIST OF INPUTS AND OUTPUTS (LI) 9 COMMUNICATION LIST ( LI )
10 TECHNICAL SPECIFICATION FOR SUPERVISORY AND CONTROL SYSTEM (ET) 11 TECHNICAL SPECIFICATION OF SAFETY INSTRUMENTED SYSTEM (ET) 12 CALCULATION SHEET FOR SIZING PRIMARY FLOW ELEMENTS (MC) 13 CALCULATION SHEET FOR SIZING CONTROL VALVES (MC)
14 CALCULATION SHEET FOR SIZING RELIEF AND SAFETY VALVES (MC) 15 PIPING AND INSTRUMENTATION DIAGRAM (DE)
16 INSTRUMENT MATERIAL SPECIFICATION (ET) 17 ELECTRICAL INTERCONNECTION DIAGRAM (DE) 18 CONTROL ROOM LAYOUT PLAN (DE)
19 PNEUMATIC INSTRUMENTATION PLAN (DE) 20 ELECTRICAL INSTRUMENTATION PLAN (DE)
21 PLAN SHOWING ROUTING OF MULTI-CABLES IN CONTROL ROOM (DE) 22 LOOP DIAGRAM (DE)
23 LOGIC DIAGRAM (DE)
24 PROCESS INSTALLATION DETAIL (DE) 25 PNEUMATIC INSTALLATION DETAIL (DE) 26 ELECTRICAL INSTALLATION DETAIL (DE) 27 FUNCTIONAL DIAGRAM (DE)
28 LIST OF ELECTRICAL LOADS FOR INSTRUMENTATION (LI) 29 GENERAL ASSEMBLY DETAILS (DE)
30 SUPERVISORY SYSTEM ARCHITECTURE DRAWING (DE) 31 INSTRUMENT DATA SHEET (FD)
32 MATERIAL REQUISITION (RM) 33 TECHNICAL REPORT (PT)
34 DOCUMENTATION ISSUED BY MANUFACTURERS 35 MANUFACTURING SCHEDULE
36 EQUIPMENT, INSTRUMENT OR MATERIAL DRAWINGS 37 LIST OF DOCUMENTS
38 TEST REPORTS 39 CERTIFICATES
The following items contain the modifications, inclusions and observations that shall be applied to documents.
5.3.1. LIST OF INSTRUMENTS
Form : A3 - standard NI-2833; by engineering program output, spread sheet or data base;
Notes :
a) the instruments shall be grouped by variable in alphabetical order, for loop nº. in the ascending order and according to item 5.2.2;
b) it shall include all instruments of the Unit, including those of “Package Unit”, c) the documents shall only be included in the list after its issuance;
d) for instruments for which no documents will be issued (process/pneumatic/electrical details, loop diagram, etc.) the respective column shall be filled out with a line;
e) the instrument list shall show the current situation of the project, being revised whenever a listed document is revised.
5.3.2. CONTROL ROOM LAY-OUT PLAN
Form : A2 to A0 – standard N-381 Notes:
a) all equipment shall be represented including the future ones;
b) the equipment shall be represented in scale and with the indication of the maximum height;
c) space shall be allowed for circulation, equipment inlet and outlet, maintenance, view of the process unit, etc;
d) it shall be showed section views of the arrival of cables, of trenches, etc;
e) the auxiliary systems shall be indicated (battery, telecommunications, conditioned air, pressurization, etc.);
f) reference documents shall be listed.
5.3.3. ARRANGEMENT AND DETAILS OF PANEL AND / OR CONTROL DESK
Form: A2 to A0 - standard N-381 Notes:
a) the panel type shall be in accordance with the guidelines of the project;
b) the layout of the instruments, commands and signals shall follow the main flow of the process;
c) all instruments, commands, signals and tags shall be identified; d) the heights of the instruments, commands, etc., shall be identified; e) the tag inscriptions shall be identified;
f) a detail of the panel fixture shall be indicated; g) a list of reference documents shall be indicated.
5.3.4. LOGIC DIAGRAM
Notes:
a) the used symbols shall be defined in a “symbols sheet”, according to Code ISA 5.2; b) all indicated events in the cause and effect diagram and / or in the descriptive memorial shall be indicated in the diagram;
c) reference documents shall be listed.
5.3.5. FUNCTIONAL DIAGRAM
Form : A3 – standard N-381 Notes :
a) symbols shall be in accordance with standard N-898;
b) electrical supply for instruments shall be indicated along with their switches, fuses and terminals;
c) the physical connection of the logic shall be indicated whenever it is executed by relays, showing field switches, terminals, relays and final elements;
d) when a relay is indicated, the contacts of this relay shall be identified related to its position in the functional diagram , through table of addresses in the same vertical of its coil.
5.3.6. LOOP DIAGRAM
Form : A3 – standard N-381 Notes:
a) pneumatic local loops that does not passes through junction boxes shall not be
represented in this diagram , because it would be a repetition of the pneumatic installation detail;
b) it shall be represented in the document the symbols system and codification;
c) instruments and terminals shall be located in columns according to its location (field, junction box, rack, behind the panel, front of the panel, etc.);
d) the cables, multi-cables, junction boxes, terminals, strips of terminals, number of the section of the panel, etc, shall be identified;
e) the electrical supply of the instruments, with its switches, fuses and grounding bar shall be represented;
f) indicate cables and multi-cables shields insulated next to the instrument and to the cabinets of the DCS, respectively;
g) indicate general shields of the multi-cables originated in the field and of the cabinets of DCS connected in the grounding bars of the marshalling cabinets, for analog, thermocouple and digital signals;
h) for analog signals diagrams, the individual shields of the individually connected pairs / terns shall be indicated in the terminals (terminals A and B in the marshalling cabinets) or alternatively in the vertical grounding bars (also individually) in the marshalling cabinets, for both the pairs / terns originated in the field as for those originated in the DCS or PES;
i) the CONTRACTOR shall prepare the complete loop diagram, filling out the applicable information related to the DCS, such as: terminals, location, logical address based in the information generated by the configuration team;
j) it is in the scope of the CONTRACTOR responsible for the detail design , the interconnecting design FIELD/DCS in the terminals marshalling cabinet based on Loading Table defining the connections in the DCS;
l) it is in the scope of the CONTRACTOR responsible for the detail design , the interconnecting design FIELD/PES in the terminals marshalling cabinet based on Loading Table defining the connections in the PES;
m) it is within in the scope of the CONTRACTOR responsible for the activity of construction and assembly the interconnection FIELD/DCS in the terminals of marshalling cabinet;
n) it is within in the scope of the CONTRACTOR responsible for the activity of construction and assembly the interconnection FIELD/PES in the terminals of marshalling cabinet;
m) it shall contain TAG’S index sheet.
o) a loop diagram design with H1 Foundation Fieldbus segments shall be as the following examples:
- General notes and symbols.
- FIRST PART: Segments per gateway H1 to HSE with junction boxes and devices.
5.3.7. LOCATION PLAN FOR PNEUMATIC INSTRUMENTS AND AIR DISTRIBUTION
Form : A2 to A0 – Standard N-381
The location plan for pneumatic instruments and air distribution shall be extract by the 3D model – PDMS design. The ground of drawing shall have the equipments and principals pipes with the valves on their real positions.
The equipments and pipes shall be represented with a thin line in a light gray scale and the instruments, instrument air distribution pipes and accessories shall be represented with a strong line to intent a contrast among then.
Notes:
a) the scale of the drawing and its limits preferably shall be the same of the equipment layout plant. The scales 1:50, 1:331/3, 1:25 can be used depending on the largest or smaller complexity of the drawing;
b) the drawing shall include reference, axis, structure, equipments and principals points such as battery limits, grade, adjacent drawings, etc;
c) the symbols used in the identification of the instruments shall be identified; d) the design north arrow shall be indicated on the drawing;
E
E
e) in case there are more than two drawings, a key plan shall be represented on the title block of the drawing with the location of the respective drawing hatched;
f) it shall be identified the elevation of the instruments and air distribution pots ;
g) it shall be identified on the drawing data such as width of the pipes and trays, elevations, elevation changes, quantity and identification of the tubes and multi-tubes in the tray, size of the pipes, etc.;
h) individual tubes of signal transmission shall be directed through reinforced fiberglass channel (perforated);
i) a list of materials shall be referred on the reference documents also containing the materials for supports in addition to those used in the Mounting and air distribution system ;
j) represent the main air line and their extensions with their respective diameters, instrumentations tie-ins and elevations;
k) reference drawings shall be listed;
a) air distribution pots shall be design with a block and drain valves, listed their consumers, two types will be applied:
a. type 1 prepare for 6 consumers and their respective block valve and let
one spare outlets .
b. type 2 prepare for 12 consumers and their respective block valve and let
two spare outlets .
m) installation between air distribution pots and consumers shall be represented on the pneumatic hook ups;
n) specials consumers shall be detailed on the plan;
5.3.8. LOCATION PLAN FOR ELECTRIC INSTRUMENTS, LOCALS PANELS, SPECIALS SYSTEMS AND CABLES ROUTING
Form : A2 to A0 – standard N-381
The location plan for electric instruments, locals panels, specials systems and cable routing, shall be extract by the 3D model – PDMS design. The ground of drawing shall have the equipments and principals pipes with the valves on their real positions.
The equipments and pipes shall be represented with a thin line in a light gray scale and the instruments, panels, junction boxes, cable trays, conduits, specials instruments and accessories shall be represented with a strong line to intent a contrast among then.
Notes: E E E E E E E E E E
a) the scale of the drawing and its limit preferably shall be the same of the equipment layout plant. The scales 1:50, 1:33 1/3 and 1:25 can be used depending on the largest or smaller complexity of the plant;
b) the drawing shall include reference, axis, structure, equipments and principals points such as battery limits, grade, adjacent drawings etc;
c) the symbols used in the plant shall be identified;
d) the design north arrow shall be indicated on the drawing;
e) in case there are more than two drawings, a key plan shall be represented on the title block of the drawing with the location of the respective drawing hatched;
f) it shall be indicated the elevation of the instruments, junction boxes, local panels, specials instruments, electrical conduits, cable trays and specials items represented on this drawing;
g) it shall be identified on the drawing data as size and cables in the conduits, width and service of the cable trays, signal type, quantity and identification of cables and multi-cables, elevations and changes of elevations, junction boxes, locals panels, specials items, etc.;
h) electronic signal cables shall be separated from the electrical sources according to the indicated distance in API RP 552;
i) the electrical equipment installation shall be in accordance with the electric classification area;
j) the symbols and coding of the electrical instalation shall be made according to N-298; k) The cables and multi-cables routing, in the field, shall be made through according to follow rules:
1. Main cable routing – cable trays with 200mm minimum width, installed along to main pipe-rack, interconnecting areas and/or linking equipments inside the areas as:
I. from junction boxes to local control room, II. from Local control to CIC.
III. from Local panels to local control room, IV. networks
2. Secondary cable routing – cable trays, with 100mm minimum width, installed inside the areas, at auxiliary pipe racks and structure to interconnecting internals instruments and components :
I. from instruments to junction boxes II. from Local panels to junction boxes.
III. from Local power supply panels to local consumers,
E E E E E E E E
The maximum width allowed for the cable tray shall be 600mm, the height shall be 100mm, The bend radius shall be 300mm
3. Tertiary cable routing – Aluminum conduits, from ¾ to 2 inch size, to carry cables from cable trays to instrument or equipment, This kind of installation shall be applied to carry and distribute signals in the area.
l) The cables shall be connected to the instruments and to the junction box through cable-press, at the end of the conduit shall be applied a bush to protect the cable; m) at least 3 different signal levels, far between 400 mm of distance trays with the
following signal distribution shall be considered:
1ª tray: electronic signals (4-20 mA) and thermocouple
2ª tray: digital signal as Foundation Fieldbus, RS-485, RS-232
3ª tray: discrete signals – 24 Vdc and feed for instruments (24Vdc)
Duplicated level of cable trays can be considered when the great number of cables requires,
n) The fiber optics shall be mechanically protected, installed in aluminum conduits, running beside at the cable trays, the redundant route shall be installed in a alternative way, avoid to lost of the communication in case of accident.
o) Avoid installing cable tray systems in regions with high fire-potential equipments, as defined in API 2218. In those cases in which routing cannot be avoided (see sections 5.2.1 up to 5.2.5, sections 9 and 10 of this standard), additional protection shall be installed for the cable tray system using covers resistant to direct hydrocarbon fire such as protective blankets or paint systems with fire-retardant characteristics dependent on Petrobras approval, in accordance with this Standard and the cable shall be calculated for this kind of installation.;
p) as basic criteria cables trays near these great an medium fire risk area shall be avoided;
q) the junction boxes shall be identified in the following way:
CJ (A)-(B) (C) where: (A) signal type
A Analog signals 4-20mA, electronic instruments
D Digitals signals 24 VDC, discrete instruments
F Digitals signals Fieldbus Foundation instruments
T Low Level Temperature instruments (mV or ohm)
X Power supply 120 Vac Instruments feeds
(B) - number of the Unit (primary element)
(C) - sequential number of the junction box unit
E E E E E E E E
r) the junction boxes shall be located preferably in areas of little electrical noise and of good natural illumination, considering the load distribution and whenever possible out of the electrical classified area; mounted at a structural steel rack in a easy access area. s) the inlet to the CCL shall be made through aerial cable trays;
t) consider 30% of spare pairs / terns in the multi-cables from the junction boxes in the field to the marshalling cabinets. These spare pairs / terns shall be connected to the terminals in both, marshalling cabinets and junction boxes, In the marshalling cabinets and junction boxes there shall be plus 20% of spare terminals over the pairs / terns effectively connected;
u) as criterion for grouping the signals of the multi-cables originated in the junction boxes there shall be, segregation by signal type and function, analog and digital signals of the same voltage level, terminal for solenoid, etc.) facilitating, this way, the marshalling to be done at the control room; at CJD’s, connecting digitals inputs and outputs shall be segregated in different terminals blocks and different multi cables. v) the electric feed cables for instruments 120 Vca, shall always be segregated of the signals cables;
x) this document can be incorporated to the pneumatic routing plan , provided it will not be too congested;
y) each VCD of the digital networks DCS, PES and Asset Management shall be designed in different documents.
z) The cable color code below shall be followed to facilitate the identification during the construction, maintenance and future expansion.
Signal type Instrument Type Over jacket color
Explosion proof
instruments Black
Analog signals
Intrinsically safety
instruments Blue
Thernocouple signals According to ISA/ANSI MC-96.1 Temperature signals
RTDs signals Black
Digitals signals 24 VCC Black
Fieldbus Fundation signals FF instruments network Orange
Profibus signals Profibus network Violet or purple Hard wired cables By MAC Industrial Network
Fiber optics cables By MAC Power supply Instruments and panels Black Fire and Gas signals Fire & Gas Systems Black E
E
E
E
5.3.9. PLAN SHOWING PANELS AND CABINETS POSITION AND ROUTING OF MULTI-CABLES IN CONTROL ROOM
Form: A2 to A0 - standard N-381 Notes:
a) This draw could be extract from 3D-model or drawn in 3D-CAD with the same coordinates (reference point) of the CCL on the 3D-model, the routing of the cables inside the control room shall be done through cable trays, aerial, under false floor or areas being allowed according to the design guidelines. The electric conduits use is only allowed to network route;
b) The draw shall show the route of cable trays in plan, view and details, cabinets and panels lay-out, interconnection with others draw indicating the cables and multi-cables coming to CCL.
c) the cable trays and / or electric conduits shall be independent according to the level of signal. The separation of the cables shall be as described in API RP 552;
d) the grounding point for the instruments and cables shall be exclusive, and the connection of this point to the grounding bars shall be done by insulated and independent cables for each bar according to API-550 and NI-1882;
e) The cabinets, panels and cable tray shall be grounded at electrical ground at the CCL;
f) a summary of the material used for the assembly shall be included (trays, supports, etc.);
g) The cable tray inside CCL, shall be perforated type and fabricated in carbon steel hot dip galvanized,
h) The cabinets and panel shall be fixed in the carbon steel structural support;
5.3.10.CABLES / MULTICABLES LIST AND INTERCONNECTION DIAGRAM
Form : A3 – standard N-2833
The cable list and diagram interconnection could be done on the same document, but the principals information shall be follow:
Cable List information:
a) identify the origin and the destination of the each cable or multi cable, b) shall be grouped in separated sheet by junction box, signal type, cable type; E E E E E E E E E
c) Indicating the estimated length for each circuit;
d) The summarize the quantity of each type of used cable; e) Plan of cables reel;
Interconnection Diagram information:
a) This document shall be use to interconnecting all cables and multi cables from field to CCL; b) identify all interconnection from the field instruments to marshalling cabinet,
c) Only one multi cable shall be showed per sheet;
d) Junction box, multi cables and terminal block at marshalling cabinet, shall be mnemonic;
The cables, multi cables, junction boxes and terminal block shall be identified according to the follow criteria:
a) For Hardwired cables:
a. Cables from instrument to junction box use the instrument tag as cable tag; b. If the instrument has a power supply use prefix “X” to indicate electric feed to
instrument and use a suffix “24” or “120” to indicate the power level, for ex: X-AIT-2200001-120; it means: electric feed to AIT-2200001 with 120V
c. For junction boxes see item 5.3.8; in case of the junction box need to use two or more terminals block, these accessories shall be identify by letters “A”, “B”, ect; d. Multi cables from junction box to marshalling cabinets shall be identified with the
same number of the junction box, for ex: Junction box = JBA-3200-01
Multi cable = MCA-3200-01, if there are more than one multi cable from this junction box, the multi cable shall have the follow identification = MCA-3200-01A; MCA-3200-01B, etc according to the terminal block it is connected;
e. Terminal block at marshalling cabinet shall be identified according to the multi cable number, for ex: MCA-3200-01 Multi cable, RBA-3200-01 terminal block;
f. each multi cable shall be interconnected in only one terminal block, i.e., is forbidden to split the multi cable in many terminals block;
b) For fieldbus foundation cables:
a. Cables from instrument to junction box use instrument tag with a prefix “S” indicating the connection from instrument to spur.
b. Fieldbus junction boxes, in the same segment all junction box shall be identified with the same sequential number plus a suffix “A”, “B” or “C”, for ex: one segment on 3100 area has a three junction boxes, these identification shall be: JBF-3100-01A + JBF-3100-01B+JBF-3100-01C
E
E