Parsons Doc. No.

: EGP3-00-SP-032-605-001

CHEVRON NIGERIA LIMITED

ESCRAVOS GAS PROJECT - PHASE 3 DEVELOPMENT - ONSHORE

SPECIFICATION NUMBER EGP3-03.02

INSTRUMENTATION, CONTROL VALVE STATIONS AND INSTRUMENT AIR

REV DATE REVISION BY CL/APPR

0 August 14, 2002 Issued for ITB RMK DAP

1 October 1, 2002 Reissued for ITB RMK

2 January 28, 2004 Revised for ITB3 RBM DAP

January, 2004 Specification No. EGP3-03.02 Page 1 of 20

 REVISION RECORD SHEET

Notes

i.) Revisions numbers shall be A, B, C, etc. up through the issue for Invitation to Bid.

ii.) The issue for Invitation to Bid shall be Revision 0.

iii.) Revisions after the issue for Invitation to Bid shall be 1, 2, 3, etc. Any revisions made after
Revision 0 shall be denoted by a vertical line in the left hand margin against the revised text.

iv.) A brief description of the key changes made in each revision shall be included on this page.

REVISION DESCRIPTION OF REVISION

A Based on Specification EGP1-03.02

Issued for Review

B Issued for Squad Check

● Added Definitions & References – Sections 1.3 & 2.0
● Added Standards Section 3.1
● Added stainless orifice fittings Section 3.4.1
● Updated standpipes 3.6.2
● Revised temperature instruments Section 3.8
● Revised supports Section 5.5
C Issued for Chevron Nigeria Review

D Issued for FEED RFQ

0 Issued for ITB

1 Reissued ITB, Paragraphs 4.1.h and 4.6

2 Revised for ITB3

 3.2 – added exception regarding straightening vanes

January, 2004 Specification No. EGP3-03.02 Page 2 of 20

 TABLE OF CONTENTS

PAGE

1.0 SCOPE & DEFINITIONS 5

1.1 Scope 5

1.2 Definitions 5

1.3 Item Definition 5

2.0 REFERENCES 6

2.1 Industry Codes 6

2.2 Project Specifications 6

2.3 Standard Drawings 6

3.0 INSTRUMENTATION DESIGN AND CONSTRUCTION 6

3.1 Flow Instruments 6

3.2 Meter Runs 7

3.3 Strainers 7

3.4 Orifice Fittings and Plates 7

3.5 Rotameters 8

3.6 Level Instruments 8

3.7 Pressure Instruments 10

3.8 Temperature Instruments 10

3.9 Piping Supports for Instrument Pressure Piping 10

4.0 CONTROL VALVES 10

4.1 Design and Construction 10

4.2 Piping 11

4.3 Piping Sizes 12

4.4 Pressure Drop 12

January, 2004 Specification No. EGP3-03.02 Page 3 of 20
 4.5 Block and Bypass Valves 12

4.6 Station Location 13

4.7 Valve Centerline Location 13

4.8 Prevention of Overpressurization 13

5.0 INSTRUMENT AIR 13

5.1 Design and Construction 13

5.2 Material 14

5.3 Piping Sizes 14

5.4 Arrangement 14

5.5 Supports 15

5.6 Branch Connections 15

5.7 Instrument Supply Lines 15

5.8 Pressure Gauges 15

5.9 Fabrication 15

6.0 IDENTIFICATION AND MARKING 16

FIGURE 1 - TYPICAL CONTROL VALVE STATION ARRANGEMENTS 17

FIGURE 2 - Backup Control Valve in Low-Liquid-Level Service 18

FIGURE 3 - Control Valve Station With RO or Fixed Choke 19

Table 1 - Minimum Block and Bypass Valve Sizing 20

January, 2004 Specification No. EGP3-03.02 Page 4 of 20

1.0 SCOPE & DEFINITIONS

1.1 Scope
This specification, in addition to the "Piping - Valves, Material and Service
Classification Specification 3.00," covers the minimum technical requirements
for the design, manufacture, and testing of instrument and control valve
stations.

CONTRACTOR shall notify COMPANY of any conflicts between this

specification and other project documents or referenced industry standards.

1.2 Definitions
Definitions used in this specification are as follows:

"COMPANY" is defined as CNL

"CONTRACTOR" is defined as EPC Contractor

"SUPPLIER or SUB-CONTRACTOR" is defined as companies supplying material,

equipment or services to the CONTRACTOR.

"FEED CONTRACTOR" is defined as Parsons

"PROJECT" is defined as the EGP3 Onshore Project

1.3 Item Definition

a. The instrument pressure piping systems include all supports, piping,
fittings, valves, and layout from the process up to and including the first
block valve. The systems also include any instrument connections
directly exposed to process pressure.

b. Instrument stations include any in-line instruments such as turbine

flowmeters, magnetic flowmeters, and rotameters, with associated
piping, block valves, bypass valves, drains, and necessary supports.

c. Control valve stations include the required piping, block valves, bypass
valves, drains, and necessary supports required for installation of the
following types of proportioning control valves.

● Diaphragm-operated

● Motor-operated

● Piston-operated

● Hand-operated

January, 2004 Specification No. EGP3-03.02 Page 5 of 20

2.0 REFERENCES

The following documents are hereby referenced and are considered part of this
specification:

2.1 Industry Codes

Not Applicable

2.2 Project Specifications

EGP3-03.04 “Layout, Support, Flexibility & Design”

EGP3-11.01 “General Instrument Installation”

EGP3-11.02 “Field Sensors – Flow, Level, Temperature, Pressure”

EGP3-11.20 “Liquid Automatic Custody Transfer Metering”

2.3 Standard Drawings

Not Applicable

3.0 INSTRUMENTATION DESIGN AND CONSTRUCTION

a. As a minimum, instrument connections and the first block valve of instrument

pressure piping shall conform to the same design and material specifications as
the line or the equipment to which the instrument or valve connects.

b. Connections and block valve inlets shall be at least 3/4-inch pipe size except
that connections to orifice flanges may be 1/2-inch pipe size.

c. Provisions for rodding out instrument connection to prevent plugging shall be

considered on an individual basis. The design details for rodding out individual
connections will be subject to approval by the Company.

d. Locally mounted instruments of all types, including primary temperature

elements, control valves, and regulators, shall be mounted in positions that are
readily accessible from grade or from an operating platform. Mounting positions
generally shall meet the following requirements.

● Mounted between (900mm) and (1700mm) above the level of the deck

● Within reach of operating personnel

e. Instruments shall be installed in accordance with the EGP3.11.01 General

instrument installation specification.

3.1 Flow Instruments

a. Positive displacement meters shall be installed according to the
January, 2004 Specification No. EGP3-03.02 Page 6 of 20
 following API standards and manufactures recommendations

API MPMS 5 Manual of Petroleum Measurement Standards,

Chapter 5, Section 2, Measurement of Petroleum
Liquid Hydrocarbons by Positive Displacement

API MPMS 5 Manual of Petroleum Measurement Standards

Chapter 5, section 3 Measurement of Petroleum
Liquid Hydrocarbons by Turbine Meters

b. V – cone flow measurement device are to be laid out & installed

according to manufacturer's specifications & recommendations.

c. Turbine meters shall be installed according to the following API

standards and manufactures recommendations.

3.2 Meter Runs

a. Piping layout shall be designed so that straightening vanes are not
required in meter runs, except as required by Specification EGP3-11.20.

b. Meter-run lengths shall be installed with as much straight pipe upstream

of the orifice as practicable, but no less than manufactures
recommendation

c. Meter piping shall be installed so that air in the line will be purged
automatically and so that any condensate will drain into the meter run.

3.3 Strainers
a. Y-type strainers shall be installed upstream of all positive displacement
meters.

b. Y-type strainers shall be installed a minimum of ten pipe diameters

upstream of turbine meters.

c. Strainers shall be installed to permit cleaning without the necessity of

draining long sections of pipe.

d. Strainers for turbine meters shall pass no particles larger than one half
the distance between the tip of the rotor and the bore of the meter.

3.4 Orifice Fittings and Plates

a. Orifice fittings on horizontal meter runs in gas measurement service shall
be installed so that the orifice plate can be removed horizontally. The
lower side of the fittings on the upstream pressure connections shall be
equipped with drain valves.

b. Orifice fittings on horizontal meter runs in liquid measurement service

shall be installed so that the orifice plate can be removed from the top.

c. Orifice plates shall be located upstream of associated control valves.

January, 2004 Specification No. EGP3-03.02 Page 7 of 20
 d. Mating flanges of orifice-plate holders shall be aligned so that jackscrews
will be diametrically opposed.

3.4.1 Valves

a. Carbon steel Orifice fittings shall be provided with 1/2-inch full

port valves and with 1/2-inch nipples, Schedule 160 or higher.
Stainless steel Orifice fittings shall be provided with 1/2-inch
full-opening valves and with 1/2-inch nipples, Schedule 80s or
higher

3.5 Rotameters
a. Rotameters shall be mounted in locations that are as free of vibration as
possible.

b. Rotameters shall be mounted vertically, with the inlet connection at the

bottom and the outlet connection at the top.

c. If possible, rotameters shall be located with sufficient clearance to permit

vertical connection of the inlet piping to the bottom of the meter.

3.5.1 Piping and Valves

a. Piping for rotameters shall be designed to allow sufficient

clearance for removal of the floats without disturbing the
rotameter.

b. Rotameter piping installations shall provide a drain valve and a

vent valve.

c. If necessary to prevent complete unit shutdown, rotameter piping

shall provide block valves and a bypass valve. The valve
installation shall have sufficient clearance for rotameter removal.

d. A check valve shall be provided downstream from rotameters in

the following applications.

● Gas service

● If backflow is possible

● If liquid hammer is possible

3.6 Level Instruments

a. Level instrument installations shall be in accordance with the
requirements of the EGP3.11.01 General instrument installation
specification.

January, 2004 Specification No. EGP3-03.02 Page 8 of 20

 b. If level control instruments are internally mounted, displacers shall be
protected from turbulence and abrasion from inlet streams by still wells
within the vessel. The still wells shall be in accordance with API RP551
Process measurement instrumentation and API 554, Process
instrumentation and Control

c. Level controllers shall be installed a sufficient distance from liquid outlet

valves to prevent the outlet stream from affecting controller operation.

d. Floats for internal level control instruments shall be mounted so that the
bottom of the float is at least 3 inches (76mm) off the bottom in horizontal
vessels and 18 inches (457mm) off the bottom in vertical vessels.

3.6.1 Connections

a. Level instrument connections shall be made as shown on P&ID’s.

The instruments shall not be connected to process lines.

b. If problems with sand are possible in a vessel, the control column

connection shall be positioned to take an accumulation of sand
into account. The low-point connection for the control column
shall be positioned in the side of the vessel and not in the bottom.

c. Drain valves shall be installed on low-point connections.

d. Displacer-type level instruments shall not have common

connections with other services such as water, drain, or pump-out
lines.

e. Vessel nozzles for external level instruments shall be horizontal

and the connecting piping shall not be pocketed. Exceptions for
small-diameter horizontal vessels require approval by the
Company.

3.6.2 Standpipes

a. Where standpipes have been approved by company for individual

level measurement applications, the installation shall conform to
vessel design conditions but shall not be less than 3-inch
Schedule 40 pipe Contractor to check nozzle loading to insure no
overstressing occurs.

b. Level instruments and gauge glasses may share a common

standpipe as described in. EGP3.11.02 field instruments – flow,
level, pressure, temperature.

c. Standpipes shall be equipped with a vent valve with plug at the

top and a drain valve with plug at the bottom.

d. Standpipes shall be equipped with process block valves at vessel

nozzles.

e. Each level instrument shall have an individual, valve connection

January, 2004 Specification No. EGP3-03.02 Page 9 of 20
 so that isolation of one instrument will not affect another
instrument.

3.6.3 Gauge Glasses

a. Gauge glasses normally shall not be mounted on level instrument

cages. Exceptions require approval by the Company.

b. If multiple gauge glasses are installed, the visual area covered by

the glasses shall overlap a minimum of 1 inch (25mm).

c. Gauge glass assemblies shall be installed so that removing the

gauges will not interfere with operating the vessel.

d. If vessels have internal baffles, gauge glasses shall be supplied

on each side of the baffle.

3.7 Pressure Instruments

Pressure instrument installations shall be in accordance with the Pressure
Instruments specification. EGP3.11.01 General instrument installation.

3.8 Temperature Instruments

a. Temperature instrument installations shall be in accordance with the
Temperature EGP3.11.01 General instrument installation specification.

b. Thermowell connections shall be 1 1/2-inch, flanged connections.

3.9 Piping Supports for Instrument Pressure Piping

a. Instrument pressure piping shall be suitably supported and shall be
protected from accidental damage. The methods and details are subject
to approval by the Company.

b. In areas where mechanical damage to the piping is possible, piping lines

shall be protected either by continuous supports such as structural steel
angle and channel or, where practical, by supports spaced a maximum
of 24 inches (610mm) apart and secured to existing steel structures, pipe
racks, and other structural supports.

4.0 CONTROL VALVES

4.1 Design and Construction

a. Instrument and control valve stations shall have a compact arrangement
with sufficient clearance for removal and operation of all control, block and
bypass valves, instruments, and associated controls without requiring
disassembly of any other components. Station clearance shall be in
accordance with ISA RP 4.2, Standard Control Valve Manifold Designs.

January, 2004 Specification No. EGP3-03.02 Page 10 of 20

 b. If piping is screwed or socket welded, break out flanges shall be installed
upstream and downstream of the control valve or instrument for ease of
removal and maintenance. Unions may only be used if shown in piping
class specification & approved by COMPANY.

c. If a control valve or instrument is smaller diameter than line size, an

eccentric reduction (flat side down) shall be made to allow for drainage.
The reducer shall be located as close as possible to the valve, allowing
only enough space to service equipment. Figure 1 illustrates examples
of typical arrangements.

d. Stations shall be supported on the operating platform with base ells and
other similar items.

e. If a bypass for manual control is provided for a control valve station, the
controlled-variable indicator shall be readable from the station.

f. A drain valve shall be located on the piping between each block valve
and the control valve or instrument in liquid or vapor service if the control
valve is failed closed. For failed open control valves a drain shall be
placed on the upstream side only.

g. Sufficient flexibility shall be built into the control valve station to permit
replacement of the valve without damage to gaskets. For this reason, an
elbow located in a removable spool installed between a block valve and
a control valve is required see Figure 1.

h. Control valve actuators shall be oriented in a vertical position. If

necessary to orient valves with top works down, the valve position shall
be noted on the specification. Company approval is required for “Top
Works Down” installation.

i. Control valve installations in instrument pressure piping shall meet the

following requirements.

● Control valves shall be located in a position that permits reading the

controlled-variable indicator.

● Control valves in services involving flashing liquids shall be located

as near as practical to the line termination in order to minimize the
downstream pressure drop.

● Control valves shall not be located in an overhead pipe rack.

4.2 Piping
a. Piping shall be self-supporting when the control valve or instrument is
removed for maintenance.

January, 2004 Specification No. EGP3-03.02 Page 11 of 20

 4.3 Piping Sizes
a. In some cases, pressure and/or flow conditions may change to a
sufficient extent to require a larger (or smaller) control valve or
instrument.

b. If a larger or smaller control valve or instrument is required, piping shall

be designed for the largest size. Provision shall be made to facilitate the
change without major piping modifications (e.g., removable spool), as
indicated on the P&ID’s.

4.4 Pressure Drop

a. Piping shall be designed to minimize pressure drop in the piping
upstream and downstream of control valves. A maximum of 5 percent of
the total pressure drop for the station is permissible in the piping (total
including block valves).

b. In order to ensure good control characteristics, the system shall be

designed so that a minimum of 35 percent of the total system pressure
drop is across the control valve for equal percentage trim, or 50 percent
for linear trim.

4.5 Block and Bypass Valves

a. Unless otherwise specified, control valves shall be provided with block
and bypass valves.

b. Equipment shall not have block and bypass valves if the following
conditions apply:

● It creates a potential hazard as identified & agreed to by company.

● Down stream Equipment is unprotected

● The control valve is out of service

A centrifugal compressor surge control/recycle valve is an example of a

location that shall not have block and bypass valves.

c. The capacity of bypass lines and bypass valves shall be at least equal to
the calculated or required liquid sizing coefficient (Cv) of the control
valve, but not greater than twice the Cv of the control valve.

d. The minimum size for block and bypass valves is presented in Table 1.

e. Unless otherwise specified, block valves shall be full-port ball valves.

f. Bypass valves shall be of the globe for bypass valves larger than 4 inch,
company may approve use of gate valves.

January, 2004 Specification No. EGP3-03.02 Page 12 of 20

 g. Bypass valves shall be located where the operator can reach the
handwheel either from grade or an easily accessible platform.

h. Chain operators are not permitted on block or bypass valves.

4.6 Station Location

If possible, instrument and control valve stations shall be located at grade or on
a platform adjacent to related process equipment. If instrument and control
valve stations cannot be located, an easily accessible service platform shall be
designed and installed as described around the station, with Company
approvals.

4.7 Valve Centerline Location

Valves shall be on same centerline as the pipe with the following exceptions:

● If the valve requires bottom access, the centerline of an instrument or control

valve, 3 inches or smaller in size, shall be located a minimum of (450mm)
above grade or the operating platform.

● If the valve requires bottom access, valves 4 inches or larger in size shall be
located a minimum of (600mm) above the deck or operating platform.

4.8 Prevention of Overpressurization

In services where overpressurization of the downstream system could result
from full-open failure of the control valve (regardless of whether the control valve
actuator is fail-close or fail-open), provision for a secondary means of protection
shall be incorporated in the system design. The following methods are
acceptable.

● In automatic level control service, a low-liquid-level shutdown can be used,

either to shut down the process or to close a backup control valve. Figure 2
illustrates a typical backup control valve in low-liquid-level service.

● A restriction orifice (RO) or fixed choke can be installed downstream from

the control valve. Figure 3 illustrates a typical arrangement. If pressure
drop exceeds 300 pounds per square inch (PSI), a choke shall be installed.

● If specifically approved in advance by the Company, a downstream

high-pressure switch may be utilized to shut down the process.

● The primary protection against over pressurization in the low-pressure

system shall not be a relief valve.

5.0 INSTRUMENT AIR

5.1 Design and Construction

a. Instrument air supply headers in process pipeways shall be of the loop
January, 2004 Specification No. EGP3-03.02 Page 13 of 20
 type if possible.

b. The piping/instrument specification break shall be located on the

downstream side of branch block valves on the main header and all
subheaders.

5.2 Material
Instrument air piping materials shall comply with the requirements of piping
material classification A15.

5.3 Piping Sizes

a. The minimum size of instrument air header pipe shall be 2 inches except
that the minimum size of headers in process pipeways shall be 1 1/2-
inch pipe.

b. Unless a larger branch size is specified, branch connection takeoffs from

the header shall be 3/4-inch pipe.

c. The minimum size for subheaders shall be 3/4-inch pipe.

d. The minimum sizes of branch and subheader connections shall comply

with the following table.

Nominal pipe size Maximum instrument

(inches) connections

3/4 10

1 25

1 1/2 80

2 150

e. The minimum size for supply lines to individual instruments shall be 1/2-
inch pipe.

f. Instrument piping from the shutoff valve to the instrument normally shall
be 3/8-inch outside diameter (OD) tubing. The tubing for large
pneumatic actuators shall be 1/2-inch OD.

5.4 Arrangement
a. Instrument tubing or piping shall be run overhead in raceways, on pipe
racks, or otherwise supported in order to provide a neat, plumb, level,
vibration-free installation. Routing of the instrument air piping shall be
approved in writing by the Company.

b. The header and subheaders shall be arranged so that groups of

instruments can be isolated without affecting the air supply to the rest of
the system.
January, 2004 Specification No. EGP3-03.02 Page 14 of 20
 c. Air supply headers and laterals shall be arranged to allow free flow
through a full-size opening to facilitate final cleaning of the air system.

d. The piping installation shall minimize pockets and low points.

e. Low points in the main header and the subheaders shall be supplied with
3/4-inch valves. Valve end connections shall be threaded and shall have
plugs.

5.5 Supports
See EGP3-03-04 (13.0) piping layout, support and flexibility for support criteria.
As a minimum, supports shall be provided at (6m) 20-foot intervals.

5.6 Branch Connections

a. Branch connection takeoffs shall be provided along the length of the
main header. The takeoffs shall be spaced at intervals no more than
(15m) 50 feet apart.

b. Twenty-percent spare connections shall be provided on the instrument

header.

c. If a single takeoff from the main supply header serves more than one
instrument, each line to the individual instruments shall have a separate
ball valve.

5.7 Instrument Supply Lines

a. Instrument air supply lines shall be taken from the top of the header.

b. Each air line takeoff on the header shall be isolated with ball valves.

c. Instrument supply lines shall terminate with shutoff valves located not
more than (900mm) 36 inches from the instrument.

d. Instrument supply line piping shall be installed with sufficient flexibility to

allow for normal equipment movement.

5.8 Pressure Gauges

a. Pressure gauges shall be installed in the piping system at the beginning
and end of the main header and at the end of all sub-headers.

b. Supply lines to each instrument, including transmitters and valve

positioners, shall have a filter regulator set equipped with a 2-inch dial
pressure gauge.

c. Pressure gauges shall be readable from grade.

5.9 Fabrication
a. Pipe shall be fabricated so that no butt welds are in direct contact with
January, 2004 Specification No. EGP3-03.02 Page 15 of 20
 structural steel pipe supports.

6.0 IDENTIFICATION AND MARKING

a. Block and bypass valves shall be tagged with the valve specification number
from the applicable piping class specification.

b. Each control valve shall be identified before installation with an engraved

stainless steel nameplate. As a minimum, the nameplate shall have the
manufacturer's model number, serial number and size for both valve and
actuator; trim style; diaphragm operating pressure; material; and Company
item/tag number.

c. Nameplates shall be securely attached with stainless steel screws or rivets.

Stainless steel wire may be used in cases where stainless steel screws or rivets
cannot be used. In addition a phenolic tag shall be installed on each instrument
per EGP3 11.01

d. The instrument air piping system shall be identified by a blue color-coded label
in accordance with ANSI A13.1, Scheme for the Identification of piping Systems.

January, 2004 Specification No. EGP3-03.02 Page 16 of 20

 FIGURE 1 - Typical Control Valve Station Arrangements

January, 2004 Specification No. EGP3-03.02 Page 17 of 20

 FIGURE 2 - Backup Control Valve in Low-Liquid-Level Service

January, 2004 Specification No. EGP3-03.02 Page 18 of 20

 FIGURE 3 - Control Valve Station With RO or Fixed Choke

January, 2004 Specification No. EGP3-03.02 Page 19 of 20

 Table 1 - Minimum Block and Bypass Valve Sizing

Line Size
1/2 3/4 1 1-1/2 2 3 4 6 8 10 12

Valve Blk Byp Blk Byp Blk Byp Blk Byp Blk Byp Blk Byp Blk Byp Blk Byp Blk Byp Blk Byp Blk Byp

C
o 1-1/2 1-1/2
n 1/2 1/2 1/2 3/4 3/4 1 1 -- -- -- -- -- -- -- -- -- -- -- -- -- --

t
r 1-1/2 1-1/2
o 3/4 -- -- 3/4 3/4 1 1 2 2 -- -- -- -- -- -- -- -- -- -- -- --

l
1-1/2 1-1/2
1 -- -- -- -- 1 1 2 2 2 2 -- -- -- -- -- -- -- -- -- --

V
a 1-1/2 1-1/2
l 1-1/2 -- -- -- -- -- -- 2 2 2 2 3 3 -- -- -- -- -- -- -- --

v
e
2 -- -- -- -- -- -- -- -- 2 2 3 2 3 3 4 4 -- -- -- -- -- --

S
I
z 3 -- -- -- -- -- -- -- -- -- -- 3 3 4 3 4 4 6 6 -- -- -- --

e
4 -- -- -- -- -- -- -- -- -- -- -- -- 4 4 6 4 6 6 8 8 -- --

6 -- -- -- -- -- -- -- -- -- -- -- -- -- -- 6 6 8 6 8 8 10 10

8 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- 8 8 10 8 10 10

10 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- 10 10 12 10

12 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- 12 12

NOTE: All sized in inches.

January, 2004 Specification No. EGP3-03.02 Page 20 of 20