Design Class Detail

PACO PROJECT Date

Expandability
Design Design Class
Item
Class 1 Class 2 Class 3
Spare DCS I/O No spare DCS I/O or No spare DCS I/O shall be provided. Space for future
space for expansion expansion shall be provided as defined by project.
shall be provided. TIC is 0.02% greater than Class 1.
Reducer Location Reducers shall be located outside globe valve Reducers shall be located
manifolds. outside globe valve
manifolds except on
applications where future
expansion is known.
TIC is 0.001% greater
than Class 1 per
application.
Capacity Utilization
Design Design Class
Item
Class 1 Class 2 Class 3
Pump Fin/Fan Pump/Fin Fan control Select the appropriate:
Control shall be local only.  Pumps/Fin Fans running continuously have local
Start/Stop and no Run indication
 Pumps/Fin Fans that require start/stop more than
once a day require remote operation. Provide
remote run indications only when no other input that
would indicate operation is provided.
 Pumps that require immediate action to start the
spare require auto-start
 Pumps, valves and other equipment that are
manipulated by a batch or sequence control require
remote operation
TIC is 0.1% greater than Class 1.
Redundant Only one transmitter per One year or less pay-out Two year or less pay-out
Control application. required for installation of required for installation of
a redundant transmitter. a redundant transmitter.
Transmitters
UPS/Back-Up No UPS or back-up UPS and back-up power supply shall be provided in
Power power supply shall be accordance with the EGGS.
provided. (Potential Loss TIC is 0.05% greater than Class 1.
of view once every 5
years)

DEP 00.00.07.87-Gen. Page 1 of 9

Design Class Detail
PACO PROJECT Date

Capacity Utilization (cont’d)

Design Design Class
Item
Class 1 Class 2 Class 3
Freeze Protection No freeze protection Heat tracing and insulation shall be provided as required
shall be provided. Unit by Location climate conditions.
will be shutdown and TIC is 0.35% greater than Class 1.
drained for cold weather.
Process Analyzers Only government Process analyzers will be Analyzers may be used
mandated process installed on streams that for closed loop control
analyzers (CEMS) will require a continuous with the DCS and/or
be installed. Laboratory analysis to monitor unit computer system for
analyzers will be used to operations. Analyzers with complex loops. Any
perform normal process continuous outputs may be process analyzer/control
analysis. used for control of simple loop requires justification
loops in the DCS. These to be installed on a
loops require adequate project.
justification (one year
payout).
Operability and Maintainability
Design Design Class
Item
Class 1 Class 2 Class 3
Vendor Selection Consideration shall be Vendors shall be on the SMFL.
given to vendors not on TIC is 0.05% greater than Class 1 per packaged unit.
the SMFL, especially for
package systems.

DEP 00.00.07.87-Gen. Page 2 of 9

Design Class Detail
PACO PROJECT Date

Operability and Maintainability (cont’d)

Design Design Class
Item
Class 1 Class 2 Class 3
Bypass Manifold No bypass valves Bypass manifolds shall be Most valves shall have
Around Control around control valves. used for the following bypass manifold or
Valves checked criteria. handwheel. Most control
 Primary feeds valves shall be able to be
maintained with unit
 High maintenance remaining operational.
valves (e.g. cavitating But, each control valve
services, erosion) application will be
 Loss of valve would determined during P&ID
require a shutdown of review.
the unit. TIC is 0.56% greater than
 Reliability and resulting Class 1 for carbon steel
cost/benefit shall be and 0.7% greater than
addressed during review Class 1 for stainless
of P&IDs. steel.
TIC is 0.28% greater than
Class 1 for carbon steel
and 0.35% greater than
Class 1 for stainless steel.
Isolation of Control No block valves or Block valves and drains will be provided for isolation of
Valves drains will be provided control valves.
for isolation of control TIC is 0.74% greater than Class 1 for carbon steel block
valves. valves and drains and 0.9% greater than Class 1 for
stainless steel block valves and drains.
Location of Control Control valves do not All control valves shall be at grade or a platform and
Valves have to be at grade or accessible for maintenance.
accessible via platform TIC is 0.82% greater than Class 1.
(i.e. may not be easily
accessible for
maintenance).
Transmitter Manifold Transmitters do not have All transmitters shall have manifolds.
to have manifolds (i.e. TIC is 0.04% greater than Class 1.
root valve only) (May
need to shutdown to
replace instrument)
Transmitter Support Transmitters may be Transmitters shall be supported by cable or U-bolt to the
directly connected process line.
(supported) on root TIC is 0.4% greater than Class 1.
valve piping.

DEP 00.00.07.87-Gen. Page 3 of 9

Design Class Detail
PACO PROJECT Date

Operability and Maintainability (cont’d)

Design Design Class
Item
Class 1 Class 2 Class 3
Spare Instruments No spare instruments Normal spare parts justification and procurement.
purchase. Rely on TIC is 0.2% greater than Class 1.
vendor stock and current
plant spares. Exception
is known long lead items
such as remote
diaphragm seals.)
Process Switch Direct connected Transmitter with receiver switch shall be used for most
Connection process switches shall applications.
be used in lieu of TIC is 0.02% greater than Class 1.
transmitters (level,
pressure, flow,
temperature) and
receiver switch.
Operational Use lowest cost Use the DCS if it is the Class 2 + Implementation
Interlocks operational interlock lowest cost option. of identified “vendor
systems (DCS may be Operational interlocks that package systems”
the lowest cost option). meet one of the following interlocks in the DCS.
criteria may be Justification based on
implemented in the DCS as reliability and
well: maintainability.
 Total loss greater than TIC is 0.1% greater than
$100M, less than Class 1.
$500M.
 Capital loss greater than
$50M, less than $100M.
 Demand rate greater
than one demand every
two years.
TIC is 0.06% greater than
Class 1.
Complex Loops Standard Complex Class 1 + Prototype complex loops installed to meet
Loops as defined by project requirements. Class 3 plants may require more
16 GS-102 (e.g. ratio, prototype complex loops.
overrides, fanout) Continuous Process: TIC is 0.05% greater than
Class 1.
Batch Process: TIC is 0.10% TIC greater than
Class 1.

DEP 00.00.07.87-Gen. Page 4 of 9

Design Class Detail
PACO PROJECT
Operability and Maintainability (cont’d)
Design Design Class
Item
Class 1 Class 2
Information System Points, NCF, groups, Class 1 + two to three page
Software trends, standard history, free format logs, operations
keyboard layout. calculations. Update
existing LIMS and ODS
systems for identified
points.
TIC is 0.05% greater than
Class 1.
Information System HM AM, HM, VAX
Hardware 2 GUS, single tier, 2-4 GUS total per operator.
native windows The higher number of GUS
may be required for BATCH
or more complex units.
Engineering Station.
TIC is 0.25% greater than
Class 1.
Batch No batch automation in DCS configured for single
DCS recipes, single mode of
operations.
TIC is 0.1% greater than
Class 1.
DEP 00.00.07.87-Gen.
Date
Class 3
Class 2 + custom history,
SPC, custom reports,
engineering calculations.
For each GUS: Non-
native graphics software.
TIC is 0.12% greater than
Class 1.
AM, HM, VAX
3-5 GUS total per
operator. The higher
number of GUS may be
required for BATCH or
more complex units.
Engineering Station,
Remote View Station,
Supervisor Station,
New LIMS and ODS
facilities.
TIC is 0.36% greater than
Class 1.
DCS customized:
recipes, lineups,
sequencers, abnormal
condition handlers, batch
logs, labelers, bar coders,
etc.
Special batch software
TIC is 0.3% greater than
Class 1.
Page 5 of 9
Design Class Detail
PACO PROJECT Date

Operability and Maintainability (cont’d)

Design Design Class
Item
Class 1 Class 2 Class 3
Custom Schematic Points that have outputs Identified process Full process overviews
Displays are displayed once. overviews; Points that have and custom interfaces.
Approximately 30 to 40 outputs may be shown on All information points
custom schematic multiple displays. shown.
displays Digital points (not all) are Approximately 75+
shown. custom schematic
Approximately 40 to 75 displays.
custom schematic displays. TIC is 0.1% greater than
TIC is 0.05% greater than Class 1.
Class 1.
Advanced Control None AM or VAX hardware. AM or VAX hardware.
Advanced control Advanced control
applications with six month applications with one year
payout (batch is typically payout (batch is typically
less). less).
TIC is 0.15% greater than TIC is 0.45% greater than
Class 1. Class 1.
Controller Location Direct connected or field Most controllers shall be inside the control room
mounted controllers and (individual controllers or DCS)
indicators shall be used. TIC is 0.18% greater than Class 1.
 Unless the loops are
very simple and
small in number
(e.g. stand alone
unit; less than 15
loops) distributed
control system
(DCS) will be less
expensive. Also if
using DCS for
control room, DCS
loops are less
expensive than field
loops.

DEP 00.00.07.87-Gen. Page 6 of 9

Design Class Detail
PACO PROJECT Date

Operability and Maintainability (cont’d)

Design Design Class
Item
Class 1 Class 2 Class 3
Pressure Regulators Pressure regulators shall Pressure regulators shall only be used in accordance
be used in the following with the DEPs.
applications: TIC is 0.25% greater than Class 1.
 Air
 Nitrogen
 Water
 Lube Oil
 Steam
 Tank Blanketing
 Process with no
decontamination or
corrosion concerns
Level Gauges/ If remote indication is All levels shall have gauge glasses with or without level
Transmitters required, number of transmitter.
level gauge glasses TIC is 0.093% greater than Class 1 for carbon steel.
shall be TIC is 0.107% greater than Class 1 for stainless steel.
eliminated/reduced. If
remote indication is not
required, only gauge
glasses shall be
provided.
PIs and TIs No local PIs or TIs shall Local PIs and TIs shall be Local PIs and TIs shall be
be provided. If justified, installed by the project installed by the project.
thermowells and root except for the following: TIC is 0.09% greater than
valves shall be provided  Local TIs for monitoring Class 1.
for devices to be exchanger
installed by Location as performance. Use TW
needed. More local only or hand held
indicators may be pyrometer.
needed since there is  Local TIs where a TT is
limited information in provided
control room.
 Local PIs where a PT is
provided
TIC is 0.045% greater than
Class 1.

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Design Class Detail
PACO PROJECT Date

Operability and Maintainability (cont’d)

Design Design Class
Item
Class 1 Class 2 Class 3
Controllers/ No indicators shall be Controllers shall be Indicators shall be
Indicators provided (i.e. controllers provided as required for provided to monitor most
only) in the control control. Indicators shall be process variables.
room. provided to monitor process TIC is 2.4% greater than
variables in a timely Class 1.
manner. Do not provide
indicators to monitor
variables (such as
exchanger fouling or filter
delta pressures) which
change gradually over
weeks or months.
TIC is 1.6% greater than
Class 1.
Compressor Surge Simple compressor Compressor surge control Use of a special surge
Control System surge control system system shall be more controller (e.g. CCC with
shall be provided complex . System may be measurements of suction
(consider fixed point). in DCS as required by & discharge T,P,F)
machine and process. should be justified basis
TIC is 0.025% greater than cost savings and risk of
Class 1 for each damaging the
compressor if control is in compressor.
the TDC using a simple TIC is 0.1% greater than
algorithm. Class 1 for each
compressor.
Vibration Monitoring Machinery shall have Machinery shall have probes and necessary hardware
probes and necessary for continuous vibration monitoring at the local panel or
hardware for periodic RIE/DCS.
“manual” vibration TIC is 0.075% greater than Class 1 per compressor.
monitoring

Operability and Maintainability (cont’d)

DEP 00.00.07.87-Gen. Page 8 of 9

Design Class Detail
PACO PROJECT Date

Design Design Class

Item Class 1 Class 2 Class 3
Pump Minimum No pump minimum flow Provide minimum flow Pumping system in which
Flow Bypass bypass or low flow bypass for critical charge the flow through the
alarms shall be pumps or other pumps pump may be less than
provided. Operator shall which would sustain minimum shall have
monitor the performance significant damage if flow minimum flow bypass
of the equipment to were stopped during normal This includes start-up,
keep the pumps running operation. normal, emergency, and
above their minimum TIC is 0.1% greater than shutdown conditions.
flow requirements. Class 1. TIC is 0.2% greater than
Class 1.
Redundant HVAC No redundant HVAC for Redundant HVAC shall be provided in control room and
control room or remote RIE.
instrument enclosure TIC is 0.08% greater than Class 1.
(RIE) shall be provided.
Protective First choice for First choice for PIS is TMR microprocessor (Triconex).
Instrument System protective instrument TIC is 0.075% greater than Class 1.
system (PIS) shall be
relay; unless complex or
large number of
systems.
Storage Tank Minimum or no Only local readout Instrumentation shall be
Instrumentation instrumentation shall be instrumentation shall be provided in accordance
provided. provided. with the EGGS.
Tank Gauging Local level gauges Honeywell smart Float-type transmitters
transmitters wired to wired to dedicated tank
Honeywell HPMs. gauging systems.
If tank gauging system TIC is 0.10% greater than
exists, new float type Class 1.
transmitters may be added
to it.
TIC is 0.05% greater than
Class 1.

DEP 00.00.07.87-Gen. Page 9 of 9