Sharing of instrumentation experience in petrochemical projects

Thread Content

At the early stage of the project, there are some common aspects related to automation control that I would like to share with everyone for reference. (Type it into Word first, then copy it to the post; the format may change, so please make do.) 1. Basis for instrument design 1.1 Rules to be followed 1.2 Content and level of detail in drawings 1.2.1 “Regulations on the content of detailed engineering design for petrochemical plants” SHSG-053-2011 1.3 Instrument selection 1.3.1 “Design specifications for the selection of automation instruments in petrochemical industries” SH3005-2016 1.4 Process diagrams 1.4.1 “Graphic symbols and textual codes for process monitoring and control diagrams” GB/T2625-1981 1.4.2 “Instrumentation Symbols and Identification” ISA-2.1 2009 1.5 Calculation of throttling devices 1.2.1 “Measurement of fluid flow in fully filled pipes using differential pressure devices installed in circular cross-section pipes – Part 1: General principles and requirements” GB/T2624.1-2006 / ISO5167-1:2003 1.2.2 “Measurement of fluid flow in fully filled pipes using differential pressure devices installed in circular cross-section pipes – Part 2: Orifice plates” GB/T2624.2-2006 / ISO5167-1:2003 1.2.3 “Measurement of fluid flow in fully filled pipes using differential pressure devices installed in circular cross-section pipes – Part 3: Nozzles and venturi nozzles” GB/T2624.3-2006 / ISO5167-1:2003 1.2.4 “Measurement of fluid flow in fully filled pipes using differential pressure devices installed in circular cross-section pipes – Part 4: Venturi tubes” GB/T2624.4-2006/ ISO 5167-1:2003 1.6 Calculation of control valves 1.6.1 “Industrial-Process Control Valves Part 1: Control valve terminology and general considerations” IEC 60534-1 1.6.2 “Industrial-Process Control Valves – Part 2-1: Flow capacity – Sizing equations for fluid flow under installed conditions” ISA 72.01.01 1.6.3 “Industrial process control valves – Part 2-1: Formulas for calculating flow capacity under installed conditions” GB/T17211.2-2005 1.6.4 “Pneumatic control valves” GB/T4213-2008 1.7 Protection rating of instrument enclosures 1.3.1 “Protection rating (IP code)” GB4208-2008 / IEC 60529:2001 1.8 Classification and design of hazardous areas 1.8.1 “Design specifications for electrical installations in explosive atmospheres” GB50058-2014 1.8.2 “Fire protection design specifications for petrochemical enterprises” GB50160-2008 1.8.3 “Explosive atmospheres – Part 1: General requirements for equipment” GB3836.1-2010 1.8.4 “Explosive atmospheres – Part 2: Equipment protected by flameproof enclosures ‘d’” GB3836.2-2010 1.8.5 “Explosive atmospheres – Part 3: Equipment protected by increased safety type ‘e’” GB3836.3-2010 1.8.6 “Explosive atmospheres – Part 4: Equipment protected by intrinsically safe type ‘i’” GB3836.4-2010 1.8.7 “Electrical equipment for explosive gas atmospheres – Part 5: Positive pressure enclosures ‘p″’” GB3836.5-2004 1.9 Instrument engineering design 1.9.1 “Design specifications for petrochemical control rooms” SH/T3006-2012 1.9.2 “Design specifications for gas supply systems in petrochemical industries” SH/T3020-2013 1.9.3 “Design specifications for isolation and purging of instruments and pipelines in petrochemical industries” SH/T3021-2013 1.9.4 “Design specifications for occupational safety and health in petrochemical enterprises” SH3047-1993 1.9.5 “Design specifications for heating and insulation of instruments and pipelines in petrochemical industries” SH3126-2013 1.9.6 “Design specifications for safety instrumented systems in petrochemical industries” GB/T50770-2013 1.9.7 “Design specifications for instrument pipelines in petrochemical industries” SH/T3019-2016 1.9.8 “Design specifications for grounding of instruments in petrochemical industries” SH/T3081-2003 1.9.9 “Design specifications for power supply of instruments in petrochemical industries” SH/T3082-2003 1.9.10 “Design specifications for distributed control systems in petrochemical industries” SH3092-2013 1.9.11 “Design specifications for installation of instruments in petrochemical industries” SH/T3104-2013 1.9.12 “Legend and textual codes for layout diagrams of automation instrument pipelines in refineries” SH/T3105-2000 1.9.13 “Design specifications for detection and alarm systems for flammable and toxic gases in petrochemical industries” GB50493-2009 1.9.14 “Radiological health protection requirements for instruments with sealed sources” GBZ125-2009 1.9.15 “Design specifications for lightning protection of instrument systems in petrochemical industries” SH/T3164-2012 1.9.16 “Method for measuring volume, density, and mass of liquids in vertical cylindrical tanks using hybrid (HIMS) tank measurement systems for oils and liquid petroleum products” GB/T25964-2010 1.9.17 “Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard” ASME B16.5-2013 1.10 Materials 1.10.1 “Steel pipe flanges, gaskets, and fasteners” HG/T20615~635-2009 1.10.2 “55° sealed pipe threads – Part 1: Circular male threads and tapered female threads” GB/T7306.1-2000 1.10.3 “55° sealed pipe threads – Part 2: Tapered male threads and tapered female threads” GB/T7306.2-2000 1.10.4 “60° sealed pipe threads” GB/T12716-2011 1.10.5 “Forged steel socket weld and threaded fittings for use in petrochemical industries” SH/T 3410-2012 1.10.6 “Guidelines for preparing materials for automation control design and installation” SHB-Z07-2001 1.11 Construction and acceptance specifications 1.11.1 “Construction and quality acceptance specifications for automation instrument projects” GB50093-2013 1.11.2 “Technical regulations for construction of instrument projects in petrochemical industries” SH/T3521-2013 1.11.3 “Construction and acceptance specifications for steel pipelines carrying toxic and flammable media in petrochemical industries” SH3501 2. Basic design data 2.1 Units of measurement The International System of Units (SI units) is used; common units are as follows (note the case of letters): Temperature unit: ℃ Pressure unit: MPa ； kPa ； Pa differential pressure unit: kPa Flow rate unit: liquid kg/h ； t/h ； m3/h gas Nm3/h (under standard conditions) steam kg/h ； t/h level measurement: mm ； %Density unit: kg/m3 ； g/cm3 ； kg/Nm3 (under standard conditions); unit for dynamic viscosity: mm2/s; unit for static viscosity: mPa·s. Note: Standard conditions refer to 0°C and 101.325 kPa. (a) 2.2 Instrument signals: Pneumatic signal: 20–100 kPa; Electric signal: 4–20 mADC ； 4–20Madc+HART3 Instrument Numbering Rules 3.1 Definitions and Abbreviations Table 3.1-1: Definitions and Abbreviations Table AI: Analog Input; AO: Analog Output; APC: Advanced Process Control; BPCS: Basic Process Control System; CCR: Central Control Room; CCS: Compressor Control System; CCTV: Closed-Circuit Television; DCS: Distributed Control System; DI: Digital Input; DO: Digital Output; EPCS: Equipment Package Control System; ERP: Enterprise Resource Planning System; EJB: Electronic Junction Box; FAR: Field Auxiliary Room; FAT: Factory Acceptance Test; FCR: Field Control Room; FCS: Fieldbus Control System; FF: Foundation Fieldbus; FGS: Fire Alarm and Gas Detector System; FJB: FF Junction Box; GDS: Gas Detection System; HART: Highway Addressable Remote Transducer high-speed communication protocol; HMI: Human Machine Interface; IDM: Intelligent Device Management; IFAT: Integration Factory Acceptance Test; MAS: Management and Automation System for Transformation and Storage; MCC: Motor Control Centre; MES: Manufacturing Execution System; MMS: Machinery Monitoring System; mV: millivolt; NSS: Networks Security System; OPC: OLE (Object Linking and Embedding) for Process Control; OTS: Operator Training Simulation; PCS: Process Control System; PES: Programmable Electronic System; PI: Pulse Input; PLC: Programmable Logic Controller; RTD: Resistance Temperature Detector; SAT: Site Acceptance Test; SER: Sequence Event Recorder; SIS: Safety Instrumented System; TC: Thermocouple; TCU: Tank Communication Unit; TMU: Tank Management Unit; TMS: Tank Management System; UPS: Uninterruptible Power Supply; VLAN: Virtual Local Area Network 3.2 Letter Codes The common measured variables for instruments and their corresponding letter codes are determined in accordance with relevant standards such as GB2625-1981 “Graphic Symbols and Text Codes for Process Detection and Control Flowcharts” and ISA-2.1 “Instrumentation Symbols and Identification”. Code numbers that are not specified in the standard specifications are uniformly indicated in these regulations, as shown in Table 3.2-1. Table 3.2-1 Common Measured Variables for Instruments and Their Letter Codes
Letter First Letter Subsequent Letters (Note) Measured Variable or Initial Variable Modifier Function Modifier
A Analysis Alarm
B Nozzle flame Safety barrier or isolator
C Conductivity Control (regulation)
D Density or specific gravity Difference Deviation
E Voltage (electromotive force) Detection element
F Flow Ratio (fraction)
G Scale (dimension) Field thermometers, pressure gauges, level gauges, etc.
H Manual (human-triggered) High
I Current Indication
J Power Scanning
K Time or time program Operator
L Level Light Low
M Moisture or humidity Intermediate
N (Optional) Signal scaling calculation Surge protector
O (Optional) Throttle hole Open
P Pressure or vacuum Test point (connector)
Q Quantity or number Integration, accumulation
R Radioactivity Recording or printing
S Speed or frequency Safety Switch or interlock
T Temperature Transmission
U Multivariable Multifunctional or calculator
V Viscosity, vibration Valve, damper, louver
W Weight or force Sleeve
X Axial displacement Surface Unclassified
Y (Optional) Y-axis Calculator, converter, or locator
Z Position Position Actuator, driver, or unclassified actuator