QDR-GCS-ESJ-SPC-1000 RevA

OWNER PMC OIL & GAS DEVELOPMENT COMPANY LTD CONTRACTOR
QADIRPUR COMPRESSION PROJECT

GENERAL SPECIFICATION FOR DESIGN,
Document Title: FABRICATION AND INSTALLATION OF
INSTRUMENTS
Date: 15-Jan-07 Document No: QDR-GCS-ESJ-SPC-1000 Rev: A Class: 2 Sheet 1 of 28
GENERAL SPECIFICATION FOR

DESIGN, FABRICATION AND INSTALLATION
OF INSTRUMENTS
A Issued For Review 15-Jan-07 LY QBP LSH
Rev Description Date Prepared Checked Approved Client


INSTRUMENTS
TABLE OF CONTENTS
1INTRODUCTION..................................................................................................... ...........................4
1.1 Scope................................................................................................................................. ........................4
1.2 Abbreviations and Definitions........................................................................................... ..........................4
2CODES AND STANDARDS.................................................................................. .............................5
3REFERENCED DOCUMENTS................................................................................... ........................5
4ENVIRONMENTAL CONDITIONS................................................................................................ ......6
5GENERAL.................................................................................................................... ......................6
5.1 Detailed Design Requirements.................................................................................................... ...............6
5.2 Contractor and Fabricators Inspection................................................................................................. .......8
6DESIGN AND MATERIALS................................................................................................ ................9
6.1 General............................................................................................................................................... ........9
6.2 Units of Measurement and Scales................................................................................................ ............12
6.3 Equipment Tagging and Marking...................................................................................... ........................12
6.4 Temperature Instruments................................................................................................................ ..........13
6.5 Pressure Instruments.............................................................................................................................. ..14
6.6 Flow Instruments............................................................................................................... .......................15
6.7 Level Instruments.............................................................................................................. .......................16
6.8 Control Valves.......................................................................................................................................... .17
6.9 Safety Valves................................................................................................................................ ............18
6.10 Rupture Discs........................................................................................................................ .................18
6.11 Motorised Valves................................................................................................................................ .....18
6.12 Utilities...................................................................................................................................... ..............19
6.13 Station Control Systems (SCS)............................................................................................................... 19
6.14 Programmable Logic Controller (PLC)............................................................................................ ........19
6.15 Earthing.............................................................................................................................. ....................19
6.16 Alarms, Switches, and Interlocks........................................................................................... .................20
7SYSTEM INSTALLATION................................................................................................................ .20
7.1 Panels..................................................................................................................................................... ..20
7.2 Local Control Panels............................................................................................................................... ..22
7.3 Control Centers............................................................................................................ ............................23
7.4 Electronic Transmission.................................................................................................................... ........23
7.5 Noise Conditioners............................................................................................................ .......................25
7.6 Uninterruptible Power Systems (UPS).............................................................................................. ........25

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8INSTRUMENT AIR SYSTEM................................................................................................... .........26

9DOCUMENTATION......................................................................................................................... ..27

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1 INTRODUCTION
The Oil & Gas Development Company Limited (OGDCL) is operator of Qadirpur Gas Field,
situated in Sindh Province in Central Indus Basin.
COMPANY plans to install a new Gas Turbine Driven Compressor Station at the existing Qadirpur
Gas Treatment Plant and to extend the gas gathering system to enhance the raw gas production
and maintain a high production plateau.
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This specification is part of the detailed design dossier describing the technical requirements.
1.1 Scope
The purpose of this document is to define the general requirements for instrumentation and control
system. Any deviation from this Specification must be approved by COMPANY. A revision bar
indicates all changes made to this Revision.
1.2 Abbreviations and Definitions
COMPANY Oil & Gas Development COMPANY Limited (OGDCL)

EPCC/LSTK Engineering, Procurement, Construction, Precommissioning,
Commissioning and 6 Month of Operation / Lump Sum Turn Key
CONTRACTOR China Petroleum Engineering Construction Co. (CPECC), Carrying Out
the EPCC/LSTK Works for the Project
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SUB-CONTRACTOR A party which manufactures and/or supplies equipment, technical

documents/drawings and services to perform the duties specified by the
COMPANY/CONTRACTOR
PROJECT Qadirpur Compression Project
The word shall is a verbal form used to indicate requirements to be strictly followed in order to
conform to this specification and from which no deviation is permitted, unless accepted by all
involved parties.
The word should is a verbal form used to indicate that among several possibilities one is
recommended as particularly suitable, without mentioning or excluding others, or that a certain
course of action is preferred but not necessarily required.
The word may is a verbal form used to indicate a course of action permissible within the limits of

INSTRUMENTS
this specification.
The word can is a verbal form used for statements of possibility and capability, whether material,
physical or casual.
SCS – Station Control System
HMI – Human Machine Interface
ESD – Emergency Shut Down
USD – Unit Shut Down
2 CODES AND STANDARDS
The following codes, regulation and standards of the latest editions SHALL be used where
applicable. Where any conflict exists between the referenced codes or standards, the most
stringent of the codes or standards SHALL prevail.
API American Petroleum Industry Standards
EN European Standard
CE Declaration of Conformity to European Standards
ISA Instrument Society of America
DIN Deutsche Industrie Normen (German Industrial Standard)
IEC International Electro-technical Commission
3 REFERENCED DOCUMENTS
QDR-GCS-ESJ-SPC-1001 Specification for Station Control System

QDR-GCS-ESJ-SPC-1006 Specification for Instrument Cable
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QDR-GCS-ESJ-SPC-1008 Specification for Fire & Gas Detection, Inert Gas Extinguishing
Specification
QDR-GCS-ESJ-SPC-1009 Specification for Machine Monitoring System
QDR-GCS-ESJ-REP-1000 Instrumentation and Control Philosophy
QDR-GCS-ESJ-SPC-1004 Specification for Programmable Logic Controller
QDR-GCS-ESJ-SPC-1005 Specification for Cabinets
QDR-GCS-ESJ-DRG-1001 Control System Block Drawing
QDR-GCS-ESC-DRG-1005 Trench System, Ditches and Crossing Typical Details

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QDR-GCS-ESE-DRG-7500 Area Classification Plan

QDR-GCS-ENG-REP-1003 Tag Numbering System
4 ENVIRONMENTAL CONDITIONS
- Temperature Max 50 °C (122 °F)

Min 3 °C (17 °F)
- Absolute max/min recorded Max/Min 53 / -1.1 C
- Average Monthly Relative Humidity Max 77%
Min 20%
- Max/Min Barometric Pressure 1010.5 / 985.7 mbar
5 GENERAL
Where deviations occur between the documents, the order of preference is as follows:
1) Data (or specification) Sheets
2) Instrument Design Basis
3) COMPANY Engineering Standard
COMPANY will provide an approved SUBCONTRACTOR’s list which SHALL be used exclusively.
The production places of the SUBCONTRACTOR’s SHALL be in the European Union (EU), other
production places SHALL be approved by COMPANY.
All "package equipment" is to have the same type and quality of instruments and documentation
as the rest of the facility. Frequent quality control inspections will be required by COMPANY.
Functional Acceptance Test will be witnessed by COMPANY before "approval to ship" is granted.
5.1 Detailed Design Requirements
The following items SHALL be furnished for approval by COMPANY, as a minimum:

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1) Individual loop diagrams showing all interconnecting wiring and tubing SHALL be provided.
Controller and control valve action SHALL be included. Loop drawings SHALL be provided by the
engineering CONTRACTOR for all instrument loops appearing on P&ID or control and
instruments diagrams. ISA standard S5, Instrument Loop Diagram, or approved substitutes
SHALL be used. In the case of "interlocking instrument" or a "shutdown sequence”, Functional
Logic Diagrams SHALL be provided.
2) Functional logic diagrams SHALL use Boolean logic. Alarm and shutdown logic diagrams SHALL

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note trip points.
3) Bid specifications are required for instruments, SCS, analyzers, cabinets, fire and gas systems,
package equipment control systems.
The following items SHALL be furnished for review by COMPANY:
1) Data sheets for all instrumentation and analyzers using the COMPANY numbering system. Data
sheets for each instrument furnished on "package equipment”. COMPANY SHALL approve the
form of the data sheet. Acceptable forms are only the COMPANY forms, or an approved equal.
Electronic data bases may be provided in approved database / software on an approved media.
2) Location plan views showing instruments, junction boxes, local panels, and analyzer houses.
3) Conduit and cable schedules and routing plans.
4) Termination and wiring diagrams of junction boxes and marshalling cabinets.
5) Control panel layout and design, including centralized and local.
6) Control house design and floor plan, showing location of all consoles, racks, and associated
equipment.
7) Rack design with input and output arrangement.
8) Composite drawings of any special systems such as gas turbine controls and compressor
controls.
9) Orifice calculations, control valve calculations.
10) Copies of all purchase requisitions issued for instrumentation.
11) Piping drawings showing all in-line mounted instruments unless a model is available for review
before the piping drawings are made.
12) All vessel drawings or models that show location of all nozzles, connections, ladders and
platforms related to instrument locations and connections.
13) SUBCONTRACTOR drawings including those for Station Control System, turbine compressor
unit control system and other packages.
Any detailed design involving a Unit Emergency Shut Down System (USD) SHALL be the
responsibility of the assigned SUBCONTRACTOR.
SUBCONTRACTOR's certified drawings, instruction manuals, and recommended spare parts lists for

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all instrumentation shall be provided. The spare parts lists are needed in time to get delivery before
startup. This item SHALL be included in the master schedule for distribution six months prior to
mechanical completion.
As-built drawings are generally required for the following:
1) Instrument Index,
2) Data Sheets,
3) Orifice Calculations,
4) Loop Diagrams,
5) Conduit and Cable Schedules,
6) Junction Box Termination Details,
7) Panel Layouts,
8) Alarm and Shutdown List,
9) Symbolic Logic Diagrams with narrative, and all special systems.
When specified by COMPANY, all the above documentation SHALL be compiled and issued in bound
volumes separate from other manuals and issued according to the time schedule. Unless otherwise
specified by COMPANY, all documentation/drawings written by the CONTRACTOR SHALL be
provided in approved electronic format on approved media. All documents as hardcopy SHALL be in a
reproducible quality.
It should be notified to COMPANY of alternative measurement and control devices that could result in
lower cost or improved reliability. When alternatives are proposed, COMPANY SHALL approve all
changes.
5.2 Contractor and Fabricators Inspection
All systems as well as instrumentation on package equipment SHALL be subject to inspection by

COMPANY. A quality assurance plan SHALL be developed, itemizing those systems or packages
to be inspected in the shop. Frequent quality control inspections may be required by COMPANY.
The SUB-CONTRACTOR SHALL advise COMPANY four weeks before functional test and
checkout.

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6 DESIGN AND MATERIALS
6.1 General
1) All instrument and construction materials SHALL be new and unused.
2) Separate process connections SHALL be used for all instruments. All instruments in the
field area have to be mounted in suitable protective shelters and fixed on mounting racks.
Mounting and connection has to be performed in accordance with the typical hook-ups and
the requirements of the instrument SUBCONTRACTOR and have to take care for safe and
disturbance free operation of the instruments.
3) Stainless steel SHALL be the standard material of construction for all pressure elements and
wetted surfaces unless otherwise specified or approved. All process connecting piping
SHALL be 12 mm stainless steel tubing unless otherwise specified or approved. Tubing and
fittings SHALL meet the requirements of “General Specification Instrument Installation”.
4) All instruments SHALL be permanently tagged by the SUBCONTRACTOR or

CONTRACTOR with a screwed metal tag bearing the tag number and service.
Thermocouple assemblies, pressure gauges, etc., SHALL be tagged also, however, their tag
may be attached with stainless steel wire. Instruments installed in individual housing SHALL
also have an engraved stainless steel nameplate on the outside of the housing showing both
tag number and descriptor of service.
5) Instruments SHALL not be mounted on handrails or vibrating equipment or vibrating lines.

This applies also to pressure gauges on pumps having high frequency vibration.
6) Cables in hazardous areas SHALL be sealed using flameproof barrier glands.
7) Cable glands for incoming cables SHALL be supplied complete with any necessary locknuts,
washers, shrouds and earth tags.
8) Shutdown devices SHALL be completely separated from other sensing devices. All shutdown
systems SHALL have a final checkout by mechanically actuating the primary sensing device.
9) Standardization of instrument SHALL be implemented, as it will result in a smaller variety of

items to be purchased, installed and maintained. The standardization SHALL cover, as a
minimum the instrument selection (e.g. sizes, materials, SUBCONTRACTORs etc),
instrument installation and hook-ups (e.g. sizes, connections, tubing and fittings etc.),

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instrument cables and junction box (e.g. types, sizes etc.).
10) Instruments shall be manufactured to survive the environmental conditions and meet the
hazardous area requirements. Equipment designed for use in the field area, should be
protected from direct sunlight and ambient temperature higher than manufacturer’s maximum
recommended temperature.
11) It is preferable for the use of instruments which are less susceptible to failures and have the
capability to carry out an automatic functional test.
12) It is preferable for the use of SMART/intelligent instruments, which have remote accessibility
and can provide, and document, useful information for maintenance and operation (e.g. zero
point calibration, range calibration, remote diagnostic, etc.).
13) Specialized instruments which may require a specialist to be flown in for servicing and
maintenance should allow quick and easy replacement.
14) Shutdown and interlock logic shall be provided according the General Specification Emer-
gency Shut Down System.
15) Generally all field instrumentation SHALL be certified “Exd” flameproof, or “Exe” increased
safety. Where the instrumentation cannot achieve the stated degrees of protection an “Exia”
or “Exib” SHALL be applied.
16) All outdoor instrumentation cabinets, housings, devises etc. are to be protected to IP65 as
minimum.
17) Package equipment is to have the same type and quality of instruments as the rest of the
facility.
18) All engineering details pertaining to control systems on package equipment SHALL be made
available for review by COMPANY before the design is finalized.
19) All recorders SHALL be mounted on the main control panel or console. Local controllers
SHALL be the indicating type, except displacement level controllers, and SHALL be limited to
simple applications requiring infrequent set point changes such as seasonal changes. Self-
contained regulators SHALL also be limited to simple applications and where operator
attention is not required.
20) All field instruments and control valves SHALL be within working reach of a man standing at

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grade or on a permanent platform. Preferred mounting height is 1.3 meters to the centerline
of instruments.
21) All gauge glasses and indicating dials SHALL be oriented to be readable by a man standing
at grade or on a permanent platform.
22) Individual filter regulators SHALL be furnished for the air supply to each pneumatic in-
strument, except those on panels.
23) Dedicated junction boxes shall be provided for electrical supply cables. Signal cables SHALL
be taken to separate boxes. Colour coding SHALL be used to differentiate all signal junction
boxes from power junction boxes.
24) Separate junction boxes shall be provided for each of the following groups of cables:
 Cables carrying non-intrinsically safe digital signals
 Cables carrying intrinsically safe digital signals
 Cables carrying non-intrinsically safe analog signals
 Cables carrying intrinsically safe analog signals
25) Cable carrying different characteristic signals SHALL be segregated in cable runs and
SHALL be connected to dedicated junction boxes, for example on/off switch signals and 4 to
20 mA DC signals. All junction boxes SHALL be labelled with JB numbers. All junction boxes
SHALL be installed to allow adequate room for the loops of bottom entry off-skid cables. All
junction boxes SHALL be provided with glands and shrouds for the off-skids cable.
26) Tubing and cableways to control valves and instruments SHALL be routed in the field so as
to avoid obstructing walkways or ladders and prevent damage from personnel traffic.
27) Electronic systems are preferred to pneumatic. Generally, only local field loops will be
pneumatic.
28) Provision SHALL be made to paint all steel instrument supports and mounting brackets for
corrosion protection. Aluminum supports and brackets or hot-dipped galvanized steel can be
used as a substitute for painting.
29) All instruments SHALL be RFI immune. Manufacturers SHALL test their equipment per
SAMA Standard, PMC 33.1. All instruments SHALL be affected by no more than 1% of span

INSTRUMENTS
when exposed to field strength of 10 volts per meter (Class 2) with a frequency range of 50-
500 MHz (band b and c).
6.2 Units of Measurement and Scales
The units and scales both in Imperial Unit System and IS System shall be applied for the project
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as listed below.
Vapour flow ft3/h, MMscfd Mass Flow lb/h
Pipe diameter in Volume Flow bpd/gpm
Heat Duty MMBtu/h Molar Flow kmol/s
Specific Heat kJ/kg Density lb/ft3
Heat Transfer Btu/hft°F Viscosity cP, cS
Temperature °F Voltage V
Length km, m, mm Current A
Mass lb Power kW, MW
Time s, h, d, a Rotation rpm
Pressure psig, psia Noise dB(A)
6.3 Equipment Tagging and Marking
Identification labels SHALL be provided for each motor, panel, power supply or control device,
cables and other components.
The information SHALL be stamped or engraved on a stainless steel plate permanently affixed to
the equipment. The nameplate SHALL provide at least the following information:
1) Tag number
2) Manufacturer's name, model and serial number of the instrument
3) Energy supply (electrical or pneumatic)
4) Measuring range
5) Material grade(s) used, in particular for bodies and plugs of control valves, transmitter

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bodies, etc.
6) Method of protection with certification number for certified equipment.
Further requirements are detailed in related “Specifications” for particular instruments.
All terminals and disconnect able terminations with wiring > 0,75 mm 2 SHALL be provided with
closed-type numbered designation sleeves on the wiring.
All permanently installed cables SHALL be identified by using permanent, durable labels including
unique and clear cable numbers. The cable SHALL be marked at both ends and at intervals of
50m.
The cable numbering shall be taking into consideration according with QPR-ESJ-SPC-5300.
6.4 Temperature Instruments
1) All thermometers, thermocouples, and temperature switches SHALL be installed in wells.

Wells with an insertion length of 300 mm or less SHALL be of drilled bar stock. Wells over
300 mm SHALL require approval by COMPANY. Wells SHALL be of 316 stainless steel
unless otherwise approved by COMPANY. Tapered wells are required in vibrating service.
Extension necks are not needed on flanged wells. In general flanged wells SHALL be used.
The flange SHALL be 1 ½ inch with minimum rating of 300# and facing according the piping
class. Well depth SHALL be engraved or stamped on a tag attached to the head of the well.
2) Bimetal dial thermometers of the adjustable angle type are acceptable for local indication.
Fully compensated filled systems with remote dials SHALL be used where required for
readability or protection from vibration.
3) Resistance thermometer SHALL be 3 wire and 4 wire Pt 100 type ANSI/ISA MC 96.1 Class
A. The maximum temperatures for which the Platinum resistance thermometers are allowed
to be used is 500°C.
4) Thermocouple extension wire material SHALL match the thermocouple.
5) All temperature instruments SHALL include a provision for thermocouple burn-out indication.
6) Temperature measurements SHALL have up scale at a burn out.
7) Thermo wells SHALL be assessed for vibration resonance effect (wake frequency
calculations using ASME PTC 16.3).

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8) Dial size SHALL be 100 mm (4") nominal and instruments will be ”every angle” head type.
6.5 Pressure Instruments
1) All process pressure connections SHALL be 12 mm OD x 1.5 mm NPT or instrument flange.
2) Two valve manifolds SHALL be provided for all pressure transmitters, switches and gauges.
3) Remote pressure measurements should be provided with pressure transducers with unified
analogue output signal 4 to 20 mA and/or digital. Basic transducer error should be less than
0.5% of set measuring range. Instability of static transducer characteristic should not exceed
0.25% of maximal measuring range.
4) Pressure elements measuring a steady normal operating pressure should not exceed 75% of
their maximum range. Pressure elements measuring a fluctuating pressure should not
normally be operated beyond 60% of their maximum range.
5) Pressure gauges SHALL comply with Instrument Specification Pressure.
6) All local pressure/temperature gauges used in pulsation and vibration conditions are to be
glycol filled and where necessay, pulsation damperners should be adopted. If visibility is not
possible at operator level then these instruments shall be provided with liquid filled capillaries
for remote mounting.
7) There SHALL be a pressure gauge on the discharge of all pumps, and it SHALL be visible
from the location of the discharge block valve.
8) Local pressure controllers SHALL have weatherproof cases with adjustable reset and
adjustable proportional band.
9) All compressed air regulators SHALL be installed with a pressure gauge. Air sets on the
pneumatic supply tubes to instruments SHALL have supply and output gauges.
10) A differential pressure transducer SHALL be connected to the process through a 5-way valve
block which allows to connect it to calibrating-pressure source by calibration and equalize the
pressure in +/- chambers.
11) Pressure gauges SHALL conform to ANSI B40.1 grade A, accuracy 1 % of full range.
12) For pressure instruments the standard ranges should be specified also approved attached
factory test certificates.

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6.6 Flow Instruments
1) Square-edged, concentric-type orifice plates and prefabricated meter runs with weld neck
orifice flanges SHALL normally be specified. These meter runs, including an orifice
calculation, SHALL be furnished by an approved SUB-CONTRACTOR. Minimum meter run
lengths SHALL be sized according to API 551 or AGA 351 at a d/D ratio of 0.7. Meter runs
SHALL normally be between 2 and 12 inches in diameter.
2) Orifice plates in horizontal meter runs on saturated steam and vapours near their dew point
SHALL have drain holes. Where this is upstream of steam turbines, a drain valve SHALL be
provided also just upstream of the plate.
3) Orifice plates SHALL not be in the line during pre-start-up flushing or hydraulic testing.
4) The ultrasonic flowmeter must be installed in accordance with the requirements defined in
the ultrasonic gas flowmeter reference, installation and operations manual. A typical system
comprises the following main assemblies:
 Flowcomputer
 Meter body
 Transducers
 Drive Unit (Main unit, and Base unit)
5) The ultrasonic gas flowmeter body is mounted in the gas pipeline. The transducers are fitted
directly onto the meter body. The drive unit is either mounted directly onto the meter body, or
in some instances remotely on a suitable stand. The drive unit houses eight (senior sonic) or
four (junior sonic) individual cables, with plugs to connect to the transducers. The drive unit is
used to operate the ultrasonic transducers and also to digitise and then process the received
signals from the transducers. The drive unit normally communicates to a flow computer using
a RS 485 (RS 232 optional) communication link. The flow computer can be used to send
setup parameters and system constants to the drive unit. The drive unit computes the flow
velocity of the gas through the ultrasonic meter body from which the actual volume flowrate
can be determined. This information is then passed to the flow computer through the
communication link. The ultrasonic gas flowmeter shall be assembled with data transfer
facilities in both digital and analog signals for the Station Control System.

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6) If a Turbine Flowmeter is used, it will be calibrated with natural gas of pressure and Reynolds
index close to the operational values.
A 7) Unless otherwise specified by COMPANY custody transfer meters of liquids for above 20 cSt
viscosity application can be positive displacement meters.
8) Turbine meters, positive displacement flowmeter, magnetic flowmeter SHALL comply with
Instrument Specification Flow.
9) Electromagnetic flow meters may be used for measuring the flow of conductive liquids.
10) For flow instruments the standard ranges should be specified also approved attached factory
test certificates.
6.7 Level Instruments
1) Each level instrument SHALL be mounted on a dedicated vessel connection. Displacers,

floats, gauge glasses, alarms, shutdowns, etc., SHALL have separate vessel connections.
Pipe size, connection, and material for bridles SHALL comply with General Specification
Instrument Installation.
2) Gauge glasses SHALL meet the requirements of Instrument Specification Level.
3) Gauge glasses SHALL be used in services only up to 75% of their manufacturer's rating and
not to exceed 16 barg. Above 16 barg, metal tube gauges SHALL be used.
4) Gauge glasses SHALL be visible from the associated level instrument (e.g. Level Trans-
mitter) and the visible length SHALL cover or exceed the span of the level instrument, the
visible portion will overlap at least 50 mm.
5) Differential pressure type level instruments SHALL be used where the level range is greater
than 2134 mm (84”). Differential type level transmitters SHALL be provided with a zero
elevation/suppression adjustment.
6) Removable stilling tubes SHALL be provided for all internal displacers to prevent damage to
the displacer and faulty operation of the instrument.
7) Level chambers and displacers SHALL have drain discharge piping and a vent hole on the
top.
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8) Level switches SHALL be vibration type or other suitable and reliable types and will be used

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for critical (high-high) alarm actuation and/or shut down system, whenever transmitters are
used to measure the level.
9) For pressure instruments the standard ranges should be specified also approved attached
factory test certificates.
6.8 Control Valves
1) Control Valves SHALL conforms to Instrument Specification Control Elements.
2) Split body and loose flange design valves SHALL not be used.
3) Valve body material SHALL be in accordance with the line piping classification or better.
4) Carbon steel and stainless steel flanged globe and ball valves SHALL have a minimum
pressure rating of 300 lbs.
5) Butterfly valves SHALL have ratings as per the pipe line specification.
6) The minimum size for control valves SHALL be 1 inch (25 mm). Where line size is less than
1 inch (25 mm) a line size valve may be considered provided materials and connections
comply with line specification requirements. Valve sizes 1.25, 2.5 and 5 inch (30, 60 and 125
mm) SHALL not be used. Control valves 1 inch (25 mm) and larger SHALL be flanged or
suitable for insertion between pipeline flanges.
7) Butterfly valves SHALL be heavy duty design with powerful (piston) operators to permit
precise positioning of vane. Butterfly valves will operate over 60° angular opening unless
valve design provides full 90° characteristic capability.
8) Actuators are to be sized to drive the valve to its closed position against the maximum
differential pressure, taking into account the design pressure of the line in which the valve is
installed.
9) By-pass and split range valves SHALL be included with each positioner.
10) On-off service control valves SHALL be line size, with quick opening trim.
11) Adequate space SHALL be allowed for maintenance, and the valve SHALL be located for
convenient access. Butterfly valves SHALL not be installed close to fans or blowers.
12) By-pass where used SHALL be indicated on P&I Diagrams. When by-passes are not pro-
vided control valves SHALL be fitted with side-mounted hand wheels. Control valves which

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operate under emergency plant conditions SHALL not be provided with either by-pass or
hand wheels unless specifically shown on the P&I Diagrams.
6.9 Safety Valves
1) Design of pressure relieving systems SHALL comply with the requirements of Instrument
Specification Safety Valves.
2) Safety relief valve orifice sizes SHALL be calculated on a pure ”area” requirement basis,
capacity adjustments required by code revisions or other applicable regulations SHALL be
covered within the valve selection procedure.
3) Safety valves for general process service SHALL be direct spring loaded with high lift
characteristics, flanged and composed of a with minimum carbon-steel body and stainless
trim.
4) Lifting levers SHALL be provided as required by the applicable code to allow the disc to be
lifted from the seat when the operating pressure is 75% of the seat pressure.
5) Safety valves SHALL be set to open at the pressure stated on the P&ID. Where variable
back pressure exceeds 10% of the set pressure balanced, bellows seal type valves will be
used.
6.10 Rupture Discs
1) Rupture discs SHALL be reverse buckling narrow face capsule type complete with holders to
fit inside the ID of the bolt circle of standard flanges. Jacking bolts SHALL be supplied for
disc sizes 2" (50 mm) and larger.
2) Where a rupture disc is installed upstream of a safety valve an excess flow valve must be
installed downstream of the disc to prevent any back pressure on the disc in the event of disc
seepage insufficient to burst the disc, and 50 mm (2") diameter pressure gauge provided to
detect leakage or rupture.
3) Inconel discs SHALL be used for temperatures above 100 °C, where possible.
6.11 Motorised Valves
Motorised valves SHALL be in two or three way design, complete with actuator, manual
handwheel and protected three-phase 230/400 V, 50 Hz.

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6.12 Utilities
The following electrical power supply and instrument air supply SHALL be provided to the
appropriate instruments for design purposes.
The Voltage Levels for instruments SHALL be as follows:
1) 230 VAC, 50 Hz (single phase) (e.g. in system cabinets etc,)
2) 24 VDC (for solenoid valves)
3) 24 VDC (for transmitters etc.)
6.13 Station Control Systems (SCS)
1) Station Control Systems SHALL meets the requirements of the Specification for Station
Control System.
2) Electronic transmitters associated with the SCS SHALL derive their 24V DC supply from
within the SCS.
3) The instrument supply distribution SHALL be by fused distribution boards.
6.14 Programmable Logic Controller (PLC)
Programmable controller applications for shutdown and protective instrumentation SHALL comply
with Specification Emergency Shut Down System.
6.15 Earthing
The following earthing systems SHALL be provided when applicable:

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1) Instrument System Earth (Clean Earth) for signal earth’s, screens, etc.
2) Control Cabinet Earth (Dirty Earth) for mechanical continuity and personnel safety.
3) Barrier Device Earth for barrier system earth requirements (where intrinsically safe zener
barrier devices are included).
Cable screens SHALL be earthed at one location only, and this will generally be at the control
room terminal location area.
The Barrier Device earth SHALL be insulated from the Control Panel Earth and run separately to
the instrument system earth electrodes.

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For Instrument System and Barrier Device earthing the total earth loop impedance on any circuit
SHALL be 1 Ohm or less.
6.16 Alarms, Switches, and Interlocks
1) Protective instrumentation SHALL meet the requirements of Instrument Specification

Emergency Shut Down System.
2) Switches for alarms and interlock systems SHALL be used for on-off application only. The
design of the switches SHALL be suitable and approved to meet the electrical area
classification.
3) Flow switches for direct operation by process fluids SHALL be of paddle type. Flow
transmitters with external switch function may also be used.
4) Level switches for direct operation by process fluids SHALL preferably be of the pack less
type (i.e. torsion rod, diaphragm or magnetic coupled). Unless otherwise specified, internal
trim SHALL be 316 stainless steel.
5) First out sequence SHALL be used for solid state annunciators.
6) Power supply voltage SHALL be 230 V AC 50 Hz.
7 SYSTEM INSTALLATION
7.1 Panels
1) Control Room Panels SHALL be built by an approved control panel manufacturer. The panel
SHALL be built, tested and delivered to the site ready for operation. Field work SHALL
consist of loop checking of the external wiring, installation of separately packaged
instruments, and the connection of external utilities.
2) The following information, drawings and literature SHALL be furnished to the panel
manufacturer:
 Ambient temperature and relative humidity ranges.
 Hazardous area classification.
 Detailed panel cut-out information.
 Panel clearances to surrounding equipment.


INSTRUMENTS
 Any required physical layout for the panel front and the inside of the panel.
 Any required wiring details.
 Any required diagrams for pneumatic instrumentation and process connections.
 Any required ladder diagrams for relay logic systems.
3) The panel and all equipment within it SHALL be suitable for the area classification.
4) All materials not supplied by COMPANY shall be purchased and procided. All materials
SHALL comply with COMPANY requirements. A bill of material SHALL be submitted to
COMPANY for approval prior to construction.
5) Panels SHALL be self supporting, and have adequate stiffener bars to prevent distortion.
Removable lifting eye-bolts SHALL be provided on the top of the panel capable of supporting
the panel without distortion.
6) The panel SHALL have adequate mounting holes and provisions for anchoring to the
foundation.
7) All terminal strips SHALL have each terminal clearly identified. All wires SHALL be labelled
on each end.
8) Tubing SHALL be installed and connections made to instruments so that each instrument is
accessible for removal, maintenance, adjustment, or repair without removal or distortion of
tubing and/or equipment.
9) All instruments SHALL be installed so that they are easily accessible for maintenance and
inspection.
10) All panel instruments SHALL be permanently identified. All panel instrument locations SHALL
be identified on the face of the panel with a plastic name plate. Name plate colours SHALL
be approved by COMPANY. The name plate SHALL show the tag. The name plate SHALL
not be mounted on the removable cover of the instrument. Each instrument mounted in the
back of the panel and terminal strips SHALL be identified with similar nameplates showing
the tag numbers. The use of ‘masking tape’ for temporary identification is strictly Prohibited;
Only electrical insulation tape is acceptably for temporary panel identification.
11) The panel manufacturer SHALL perform the following tests prior to final inspection:

INSTRUMENTS
 Wiring point to point continuity check.
 Process and pneumatic leak checks.
 Operational action checks of all switches to ensure compliance with drawings.
12) Control panels SHALL include "as built" documentation with the following information:
 Detailed structural and panel cut-out drawings.
 Front and rear panel arrangement drawing showing equipment locations.
 Wiring details for power, auxiliary circuits, and instrument wiring.
 Piping diagrams for pneumatic instrumentation, and process connections.
 Dimensional details, connection diagrams, and instruction manuals for all

instrumentation.
 Function diagrams for any logic systems.
 Inter-connection wiring diagrams showing all terminal connections between the panel
and external instrumentation, equipment, and other panels.
13) The panel may be shop inspected by the COMPANY during and after final completion. The
SUB-CONTRACTOR SHALL notify COMPANY four weeks in advance of when the panel will
be available for final inspection. The panel fabricator SHALL make available as required,
power, analogue signal sources, pneumatic signal sources, jumpers, meters, and
measurement devices, and a technician to assist in the functional check out and inspection
of the panel.
14) All shelves mounted or delicate instruments SHALL be removed from the panel and packed
for separate shipment.
15) Unless otherwise specified by COMPANY, control panels SHALL not be used when a
Distributed Control System is available.
7.2 Local Control Panels
1) The design and fabrication of local control panels SHALL also conform to Section 7.1 of this
Specification. All instrumentation SHALL comply with all other sections of this specification.
2) All doors SHALL be gasketed, have a 3-point latching system with a key locking handle, and

INSTRUMENTS
have stainless steel hinges and hardware.
3) Sheet metal pockets for holding drawing and documents SHALL be provided on the inside of
the panel door.
4) Field tubing terminations and electrical conduits on local panels SHALL enter the side of the
panel. Low point drip legs and drains SHALL be added to all conduits just before entering the
panel. Connection between the field and panel tubing SHALL be made by means of a brass
bulkhead and tube fittings.
5) Sheet metal pockets SHALL be stainless steel. Panels for outdoor service SHALL meet IP 65
classification. Casketed hinged covers with safety glass or acrylic front, and key lock latch
SHALL be provided for all flush mounted instrumentation that would not meet IP 65 or that
would permit air leakage through the front of the panel.
7.3 Control Centers
1) The control room area within the Operation and Control Building is the area from where the
Compressor Station SHALL be monitored and controlled.
2) The cabinets SHALL be positioned within this area to provide front access.
3) All incoming cables SHALL enter the instrument room via cable transits below grade, the
floor SHALL be computer type with a void below.
4) The location and method of entry into the control building for field cables SHALL be
approved.
5) The Trunk Radio Communication system SHALL be located in the Control Room.
6) Control rooms SHALL comply with General Specification Distributed Control System.
7.4 Electronic Transmission
1) Instrument DC signal wire and thermocouple extension wire SHALL comply with General
Specification Instrument Installation.
2) Insulation suitable for high temperature SHALL be used where ambient temperatures exceed
60°C.
3) Where overhead cable runs are used, the junction box centerline SHALL be located 1400
A
mm above grade or platform with top of box not to exceed 2000 mm. Entry into junction

INSTRUMENTS
boxes SHALL be made in the bottom of the box.
4) Separate cable, conduit, and junction boxes SHALL be used for the different applications,
such as DC control wiring, DC alarm wiring, and thermocouple wiring.
5) All instrument cables SHALL be meggered both before and after pulling for shorts and/or
grounds with results recorded. Megger voltage SHALL be 1000V. Instruments SHALL not be
connected until after meggering.
6) Tubular clamp type sectional terminal blocks SHALL be used throughout the complete
system. The terminals SHALL be mounted on a raised base. Junction boxes SHALL be sized
to allow 150 mm spacing of terminal strips and a minimum of 150 mm clearance between
walls and terminal strips and a 150 mm box depth.
7) Junction box location SHALL be approved. All junction points SHALL be permanently
identified with loop number. Splices are not allowed. The boxes SHALL be numbered and
tagged with engraved stainless steel nameplates.
8) All wiring within junction boxes SHALL include 20% spares. Spares SHALL be labelled and
terminated at terminal blocks.
9) Incoming and outgoing thermocouple, control, and other instrument transmission wires
SHALL not be terminated at the same side of terminals in junction boxes.
10) Signal wires at all instruments SHALL be identified according to positive or negative lead.
Where black and white pairs are used, black is positive (+) and white is negative (-). In
addition, all wires SHALL be labelled as to loop number and wire number, using permanent
heat-shrink type labels or acceptable sleeve-type labels.
11) Two independent sources of power SHALL supply the instruments. The 230 VAC circuits to
the instrument panels SHALL be supplied from a separate distribution panel and SHALL
serve only instruments and alarm circuits. This distribution panel SHALL have 16 amp
protection devices. Approximately 20% spare circuits SHALL be provided. Each SCS rack,
console and operating station SHALL have a separate branch circuit. Each panel section or
multi-loop DC power supply SHALL have a separate circuit.
12) Instruments SHALL not be bracketed directly off process lines except where specified.
13) Transmitters SHALL be mounted on 2” pipe stands where practical.


INSTRUMENTS
14) Pressure transmitters may be line mounted supported from process lines, to keep impulse
line short.
15) Service conditions and licensers requirements SHALL also be considered for deciding close
or remote coupling. Instrument support brackets SHALL not be welded to process piping.
16) All electronic and electrical equipment SHALL be suitable for area classification in which it is
installed and SHALL be in accordance with current standards and must be certified by
national certifying authorities for operation in classified area and gas group.
17) Wherever possible instruments SHALL be located so that they are protected from damage by
passing or falling objects.
18) Local instruments with the exception of those on lines SHALL be mounted with the centre
line at approximately 1.4 m above the platform or floor in a position accessible for operation
and maintenance.
19) Handrails and removable flooring SHALL not be used for supporting instruments.
20) All electronic instrument enclosures, Marshalling cabinets and instrument housings with
electrical components SHALL be electrically grounded. Instrument enclosure ground and
cabinets frame ground SHALL be connected to the control centre ground bars.
21) If installation requires shutdown or partially depresurisation of any part of the pipeline or
pipeline station CONTRACTOR SHALL prepare detailed plan of works. The plan SHALL be
presented to Client and SHALL obtain Client’s approval. The plan SHALL be presented to
Client at least 2 months prior to the planned actions.
22) All transmitters exposed to direct sunshine SHALL be equipped with sunshine canopies.
7.5 Noise Conditioners
Power/noise conditioners SHALL be provided for all field (where powered from the instrument
rack) control and interlock instruments, all control room instruments, and all rack and computing
instruments. Power/noise conditioners may be omitted where their function is performed by an
acceptable Uninterruptible Power System (UPS).
7.6 Uninterruptible Power Systems (UPS)
1) Uninterruptible Power Supply (UPS) SHALL be provided for all safety and shutdown

INSTRUMENTS
interlocks, analogue, and microprocessor-based distributed instrumentation.
2) The UPS SHALL be designed to provide continuous power without interruption or under-
voltage or over-voltage for a time period of not less than 60 minutes (SHALL be confirm by
Turbine SUB-CONTRACTOR).
3) Where an AC mains and auto change over facility is provided the delay on change over
SHALL not exceed 10 milliseconds.
4) The PCS, ESD and Fire & Gas Detection System SHALL all be fed from UPS.
8 INSTRUMENT AIR SYSTEM
1) Stainless Steel tubing SHALL be used for pneumatic transmission. Minimum size is 6 mm
OD.
2) Tubing runs consisting of four or more tubes SHALL be made by using bundled tubing.
3) Tube, tube fittings, and installation SHALL comply with General Specification for Instrument
Installation.
4) All tubing bundles SHALL be supported in channels or trays. Individual tubes or groups of
individual tubes SHALL be supported in conduit or angle iron. Wiring or attaching to a pipe
SHALL not be done.
5) Angle iron SHALL not be attached to a control valve or instrument by the valve/instrument
bolts.
6) All tubing installations SHALL be leak-tested by using a bubbler systems and 2 bar in-
strument air. A leakage rate of more than 2 bubbles per minute is not acceptable and SHALL
be corrected.
7) Tube fittings SHALL be installed in strict accordance with the manufacturer's instructions.
8) Tubing SHALL be tested. Apply maximum signal input pressure to the process connection,
close the inlet valve and disconnect the pressure source. Observe the gauge on the signal
inlet and ensure that there is no fall off of pressure over a 3 minute period. Where leaks are
suspected, these SHALL be eliminated and the test repeated.
9) All tubing bends SHALL be made with benders.
10) Teflon tape SHALL not be used on pipe threads in instrument air or pneumatic signal service.

INSTRUMENTS
11) Any underground tubing for instrument service SHALL be in hot dip steel conduit and
protected with a minimum of three inches of red dyed concrete.
12) Each sub-header SHALL be fitted with a diameter pressure gauge.
13) Each air supply SHALL be marked at the sub-header with the tag number of the in-
strument/control valve it is feeding.
14) All field mounted, air consuming instruments SHALL have a combination of filter regulator
unit and an output pressure gauge. The output range of the filter regulator is to be chosen to
suit the item it is supplying.
15) All connections SHALL be made using stainless steel fittings.
16) Instruments SHALL be close coupled to the process to minimise mounting problems. Impulse
piping, etc. must be readily assessable for maintenance from grade or access platforms.
17) For instruments located remote from the process connection the impulse piping will slope at
least 10% between take-off and instrument.
18) All installations with process seals including those with condensate legs, pots etc., SHALL be
provided with fill connections.
9 DOCUMENTATION
System documents SHALL include PROJECT drawings, documents and SUB-CONTRACTOR

documentation (hardwire, software, user manuals) according with the Contract agreement, and
SHALL be supplied for final approval to the COMPANY before completion of Factory Acceptance
Test and Site Acceptance Test:
Document list:
1) Overall hardware and software descriptions,
2) Technical description of each hardware item,
3) Hardware maintenance manual of each component in the system,
4) Installation check-out documentation for all the system components,
5) Certified mechanical drawing of all units (including weights),
6) Certified electrical connection diagrams showing all plugs, cable termination blocks and

INSTRUMENTS
equipment,
7) System overall earthing arrangement,
8) Heat dissipation,
9) Power balance,
10) Software manual,
11) CONTRACTOR general and other specific documentation related to the system (including
reliability figures),
12) Safety certification dossier. This dossier must contain copies of all certificates and other
document pertaining to the safety of the system. This dossier SHALL be submitted to
COMPANY prior to the commencement of the FAT.
13) System hardware diagnostic programs with user instructions,
14) Description and user instructions for the operating system and all other programs and
subprograms provided by others,
15) A write-up covering system reloads, restarts and any other system user function, including
procedure to add new features such as new algorithms (sufficient examples SHALL be
included),
16) Test procedures,
17) Test Certificates and reports,
18) List of system and application software including the software back-up,
19) Purchasing records,
20) Preservation and storage procedure,
21) Installation procedure,
22) System black start procedure,

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OWNER PMC OIL & GAS DEVELOPMENT COMPANY LTD CONTRACTOR

QADIRPUR COMPRESSION PROJECT

GENERAL SPECIFICATION FOR

A Issued For Review 15-Jan-07 LY QBP LSH

Rev Description Date Prepared Checked Approved Client

QADIRPUR COMPRESSION PROJECT

QADIRPUR COMPRESSION PROJECT

8INSTRUMENT AIR SYSTEM................................................................................................... .........26

QADIRPUR COMPRESSION PROJECT

1.2 Abbreviations and Definitions

COMPANY Oil & Gas Development COMPANY Limited (OGDCL)

SUB-CONTRACTOR A party which manufactures and/or supplies equipment, technical

QADIRPUR COMPRESSION PROJECT

SCS – Station Control System

HMI – Human Machine Interface

ESD – Emergency Shut Down

USD – Unit Shut Down

2 CODES AND STANDARDS

API American Petroleum Industry Standards

CE Declaration of Conformity to European Standards

ISA Instrument Society of America

DIN Deutsche Industrie Normen (German Industrial Standard)

IEC International Electro-technical Commission

QDR-GCS-ESJ-SPC-1001 Specification for Station Control System

QADIRPUR COMPRESSION PROJECT

QDR-GCS-ESE-DRG-7500 Area Classification Plan

- Temperature Max 50 °C (122 °F)

1) Data (or specification) Sheets

2) Instrument Design Basis

3) COMPANY Engineering Standard

5.1 Detailed Design Requirements

The following items SHALL be furnished for approval by COMPANY, as a minimum:

QADIRPUR COMPRESSION PROJECT

note trip points.

The following items SHALL be furnished for review by COMPANY:

3) Conduit and cable schedules and routing plans.

4) Termination and wiring diagrams of junction boxes and marshalling cabinets.

5) Control panel layout and design, including centralized and local.

7) Rack design with input and output arrangement.

9) Orifice calculations, control valve calculations.

10) Copies of all purchase requisitions issued for instrumentation.

QADIRPUR COMPRESSION PROJECT

As-built drawings are generally required for the following:

5) Conduit and Cable Schedules,

6) Junction Box Termination Details,

8) Alarm and Shutdown List,

9) Symbolic Logic Diagrams with narrative, and all special systems.

5.2 Contractor and Fabricators Inspection

All systems as well as instrumentation on package equipment SHALL be subject to inspection by

QADIRPUR COMPRESSION PROJECT

6 DESIGN AND MATERIALS

1) All instrument and construction materials SHALL be new and unused.

4) All instruments SHALL be permanently tagged by the SUBCONTRACTOR or

5) Instruments SHALL not be mounted on handrails or vibrating equipment or vibrating lines.

6) Cables in hazardous areas SHALL be sealed using flameproof barrier glands.

9) Standardization of instrument SHALL be implemented, as it will result in a smaller variety of

QADIRPUR COMPRESSION PROJECT

instrument cables and junction box (e.g. types, sizes etc.).

QADIRPUR COMPRESSION PROJECT

 Cables carrying non-intrinsically safe digital signals

 Cables carrying intrinsically safe digital signals

 Cables carrying non-intrinsically safe analog signals

 Cables carrying intrinsically safe analog signals