1.
7 Instrument Installation
I. H. GIBSON (2003)
COST
• On the order of 40 to 50% of the capital cost of the
equipment—extremely variable.
• A full set of PIP Process Control Practices documents
cost U.S. $6500 in 2002.
For process measurements to achieve the targets of safety, accu-
racy, reliability, and economy, more than measuring equipment
is involved. The entire system—from the process fluid charac-
teristics, the ambient conditions, legal and regulatory require-
ments, and operations/maintenance requirements—must be
coordinated to ensure that the equipment can be installed, cal-
ibrated, operated, recalibrated, maintained, and, if necessary,
rebuilt or replaced while meeting the above primary criteria.
This section attempts to provide guidance to persons who
are unfamiliar with current industrial practice; it does not
attempt to cover all industries and all measurements. Specif-
ically, it cannot cover the multitude of legal and regulatory
requirements mandated by bodies such as the Occupational
Safety and Health Administration (OSHA).
INSTALLATION DOCUMENTATION
The primary installation document is commonly called the
instrument index (see Figure 1.7a). This tabulates all the
tagged physical devices and commonly also includes tagged
software devices. Each of the physical devices is then refer-
enced to the associated installation drawings, such as the
physical location plans, installation details (mechanical sup-
port, piping and wiring), cable ladder and conduit routing
diagrams, and the connection diagrams. The instrument index
is usually one of many documents from a large database,
which also keeps track of calculations, specifications, and
procurement documents and may also interface with a three-
dimensional CAD model of the plant.
In a plant being designed with three-dimensional model-
ing, many of the dimensional drawings that otherwise would
have been made previously are generated on demand by selec-
tion from the model. This enhances the quality of the design
by flagging and eliminating clashes between equipment, piping
and electrical/instrumentation space requirements and permits
virtual walk-through reviews for operations and maintenance
personnel.
100
© 2003 by Béla Lipták
Physical vs. Schematic Documents
The physical or scalar documents are the location plans (often
sectional plans), cable/conduit routing plans, and the room lay-
out drawings. These are based on the mechanical or piping
layouts, commonly with the instrument information available
as an overlay. The instrument tapping locations will be defined
on the vessels and piping, and the final location for the various
instruments becomes a matter for negotiation between the var-
ious groups to balance the requirements for operability with
accessibility for maintenance. Traditionally, the instrument
installation details have been essentially schematic, being used
largely for material take-off. But with the growing use of three-
dimensional CAD techniques, there is a tendency to produce
approximately scale models for the common details to ensure
that access requirements are addressed. Connection diagrams
(electronic, electrical, pneumatic, hydraulic, and process) are
purely schematic. These are now largely automated, with a
minimal amount of input data being fed to a database loaded
with connection rules for the various types of equipment.
SAFETY IN DESIGN
The instrument connections to the process are commonly the
least mechanically secure components in the system. Consider
the relative strength of a 1/2NS (DN15) Sch. 160 pipe as used
by the piping designer to the usual 0.5-inch (12.7-mm) OD
seamless 316L tube with 0.049-inch (1.24-mm) wall used for
equivalent duty by the instrument designer. Yet this material has
in fact an adequate strength for most applications within the
range of Class 600 piping, provided that it is adequately pro-
tected and supported. Supported not only when the equipment
is in service, but when any components are removed for main-
tenance. Many installations can be found with long runs of tube
run to an absent transmitter, with the tube supported at best by
a rope or wire. Not only are long tubing runs a significant source
of measurement error, the lack of support is inherently hazard-
ous. Modern installation details will anchor the tubing runs by
supporting the instrument manifold, which remains in place if
the transmitter is removed, and minimize any hazard from the
temptation to use tubing runs as a hand (or foot) support.
The first valve off the process (known as the “root valve”)
has traditionally been the province of the piping designer.
More recently, the selection of this valve has become a joint
 Tag Number Instrument Type I/O Type Status Service Location Equipment Manufacturer Model Price
101-FE -100 D/P TYPE FLOW ELEMENT N Feed from V-8 Field FISHER-PORTER $110
101-FT -100 D/P TYPE FLOW TRANSMITTER AI N Feed from V-8 Field ROSEMOUNT 1151DP4E22S2B1M2 $1095
101-FY -100 I/P TRANSDUCER AO N Feed from V-8 Field FISHER 461 $580
101-FV -100 CONTROL VALVE N Feed from V-8 Field FISHER ES $3250
101-PI -100 PRESSURE GAUGE N Heat exchanger inlet Field ASHCROFT MGS-136 $65
101-PI -102 PRESSURE GAUGE N Heat exchanger outlet Field ASHCROFT MGS-136 $65
101-HY -101 I/P TRANSDUCER AO N C-101 Bypass Field C-101 FISHER 461 $580
101-HV -101 CONTROL VALVE N C-101 Bypass Field FISHER ET $2100
101-FE -102 D/P TYPE FLOW ELEMENT N Feed from C-1 Field $120
101-FT -102 D/P TYPE FLOW TRANSMITTER AI N Feed from C-1 Field ROSEMOUNT 1151DP4E22S2B1M2 $1095
101-PI -101 PRESSURE GAUGE N F-102 Stripper inlet Field ASHCROFT MGS-136 $65
101-TW -203 THERMOWELL N F-102 Overhead Field
101-TI -203 BI-METAL THERMOMETER N F-102 Overhead Field ASHCROFT EVERY-ANGLE-13/02 $45
101-PSH -208 HIGH-PRESSURE SWITCH DI N F-102 Overhead Field ASCO 8351B23 $720
101-PT -201 PRESSURE TRANSMITTER AI N F-102 TOP Field F-102 ROSEMOUNT 3051S1256 $1095
101-LT -201 DISPLACER TYPE LEVEL AI N F-102 Middle section Field F-102 MASONEILAN 9600 $1095
101-LY -201 I/P TRANSDUCER AO N F-102 Middle section Field FISHER 461 $580
101-LV -201 CONTROL VALVE N F-102 Middle section Field FISHER ED $1340
101-TW -202 THERMOWELL N F-102 Top Field F-102 $45
101-TE -202 THERMOCOUPLE N F-102 Top Field F-102 ASHFORD TE-11-34/13 $22
101-TT -202 TEMPERATURE TRANSMITTER AI N F-102 Top Field F-102 ROSEMOUNT 3051S1256 $650
101-TY -202 I/P TRANSDUCER AO N F-102 Top Field FISHER 461 $580
101-TV -202 CONTROL VALVE N F-102 Top Field FISHER V500 $2300
101-TW -201 THERMOWELL N F-102 Top Field F-102 $51
101-TI -201 BI-METAL THERMOMETER N F-102 Top Field F-102 ASHCROFT EVERY-ANGLE-13/02 $45
101-FT -201 D/P TYPE FLOW TRANSMITTER AI N Stripping Steam to F-102 Field ROSEMOUNT 1151DP4E22S2B1M2 $1095

DEFAULT STYLE Report

Test 1 Test 2 Test 3 Test 4
Filter: None

1.7 Instrument Installation

Sort: None
Plant name: New Refinery
Area name: Crude Area
Unit name: Crude unit 1 Sheet 1 of 3
Horizontal Section 1 of 1
Domain:FDMELB Last Revision:
No. By Date Chk App Revision Client Dwg. Name:

FIG. 1.7a
Typical instrument index report (extracted from Intools database).

101
© 2003 by Béla Lipták
102 General Considerations
FIG. 1.7b
Current generation instrument isolation and process DBB valves. (Courtesy of Oliver Valve Ltd.)
FIG. 1.7c
Fiscal orifice metering installation using direct-mounting technique.
(Courtesy of Tyco/Anderson Greenwood.)
responsibility, with ‘process-rated’ instrument valves being
available which give ‘double-block and bleed’ (DBB) capa-
bility in the envelope of a 1NS (DN40) blind flange (Figures
1.7b and c). The ability to close couple a transmitter to the
line in this manner can reduce potential leak points and
weight significantly for offshore installations at similar cost
to older designs.
The point of DBB deserves comment. For a technician to
work on a transmitter or gauge, the process must be securely
isolated. If the process fluid is flammable or at high or low
© 2003 by Béla Lipták
temperature any chance of a leak should be obviated. DBB
provides this by providing two isolation valves between the
technician and the process, with the space between vented to
a safe place. The definition of where DBB is required is
normally part of the operating company’s standards, but Class
600 (and higher) piping should always be covered by it. Toxic
materials call for more stringent techniques, with tubed vents
and designed-in decontamination methods.
Pipe and Tube Material
Current minimum design practice is to use a stainless steel
meeting both 316 and 316L for tubing and fittings for both
pneumatic and process connections. The pneumatic tubing
may be 0.25 inch (6.35 mm) or 0.375 inch (9.53 mm) OD,
while process connections are usually 0.375 or 0.5 inch (9.53
or 12.7 mm). The wall thickness of pneumatic tube is com-
monly 0.035 inch, while process tubing is a minimum of
0.048 inch, with heavier (0.064 inch) used for pressures
above about 1000 psi (6800 kPa). This is the heaviest wall
tube that can conveniently be bent and fitted off without using
hydraulic benders and setters.
Plants using metric standards may use either metric or
inch series tube but mixing the two in the same plant should
be avoided, as accidents can be caused by mismatching.
12 mm OD tube will fit in a half-inch compression fitting but
will rapidly disassemble itself under test. Always use seam-
less drawn tube for compression fitting installations, as elec-
tric-resistance-welded (ERW) tube has a small flat on the
outside that makes for difficulty in achieving a leaktight
connection.
316 stainless is a good general-purpose material, but it is
prone to chloride attack at temperatures above 140°F (60°C).
 1.7 Instrument Installation 103

This can be significant both internally and externally—tropical
marine installations can easily achieve such temperature in

sunlight. Monel (cupronickel) and duplex stainless are both
widely used in such locations; duplex offers higher tensile
strength and pressure rating. Ensure that the tube wall thickness
chosen meets the most stringent pressure and temperature com-
bination likely to be found.
If possible, avoid using or having tube with identical diam-
eter but different wall thicknesses and materials in the same
plant, even at the expense of using more costly material,
because the probability of getting under-rated material installed
during maintenance or modification is severely increased. If it
is necessary, ensure that the installations with higher-grade
material are permanently flagged on drawings and in the field
(Table 1.7d).
Electrical Installations in Potentially Explosive Locations
While the practices for piping/tubing installations are similar
around the world, there is a split between North American
and European practices (commonly described as NEC v. IEC
practices) in wiring methods. Fortunately this divide is now
closing, as IEC design practices are becoming accepted in
parallel with NEC in North America, though there are still a
few standards where features mandated by IEC are prohibited
by NEC. The best advice is to determine the statutory and
regulatory rules for the site, and try to avoid any violation of
them. ‘Try’ may be the operative word in many cases, where
considerable negotiating might be required with the regula-
tory inspectors if ‘state-of-the-art’ equipment is required, and
the approval certification is not quite ready for your site.
Physical Support
The traditional support for field instruments is 2NS (DN50)
pipe. Most non-inline field instruments are provided with
mounting brackets designed to attach to vertical or horizontal
pipe, and also to flat plate. Traditionally, these supports have
been fabricated from carbon steel pipe and plate and been
hot-dip galvanized after fabrication. Some design details
endeavour to weld zinc plated material, but this practice is
difficult in achieving good welds and the ‘zinc fume’ from
the welding is toxic. Therefore, one should generally avoid
the use of zinc coatings. Also, there have been a number of

TABLE 1.7d
Instrument Tubing Properties
−198 °C < T < 37 °C −254 °C < T < 37 °C −29 °C < T < 37 °C
−325 °F < T < 100 °F −425 °F < T < 100 °F −20 °F < T < 100 °F
Outside Diameter Wall Thickness Bore Max. WP 316/316L Max. WP 304 Max. WP Alloy400
inch mm inch mm inch mm psi kPa psi kPa psi kPa

0.125 3.18 0.036 0.91 0.053 1.35 11416 78729 10651 73454 10651 73454
0.1875 4.76 0.036 0.91 0.1155 2.93 7039 48545 6567 45292 6567 45292
0.250 6.35 0.036 0.91 0.178 4.52 5088 35091 4747 32740 4747 32740
0.048 1.22 0.154 3.91 7039 48545 6567 45292 6567 45292
0.064 1.63 0.122 3.10 9880 68137 9218 63572 9218 63572
0.375 9.53 0.036 0.91 0.303 7.70 3274 22577 3054 21065 3054 21065
0.048 1.22 0.279 7.09 4469 30821 4170 28756 4170 28756
0.064 1.63 0.247 6.27 6154 42443 5742 39599 5742 39599
0.500 12.70 0.036 0.91 0.428 10.87 2413 16642 2251 15527 2251 15527
0.048 1.22 0.404 10.26 3274 22577 3054 21065 3054 21065
0.064 1.63 0.372 9.45 4469 30821 4170 28756 4170 28756

Notes:
Max. working pressure based on the ASME B31.3 formula P = 2tSE/(D − 2tY), allowing a factor of 4 safety factor
t taken as 0.85 of the nominal wall thickness, according to ASTM A-269 manufacturing tolerance.
316/316L is a dual-graded cold-drawn seamless tube to ASTM A269/A213, max hardness Rb80.
Ultimate tensile strength 75000 70000 70000 psi
Temperature Correction at other
temperatures at nominal temperature
(above) 1 1 1
200°F 93°C 1 1 0.88
400°F 204°C 0.96 0.93 0.79
600°F 316°C 0.85 0.82 0.79
800°F 427°C 0.79 0.76 0.76
1000°F 538°C 0.76 0.76 —

© 2003 by Béla Lipták

104 General Considerations

ITEM QTY UM DESCRIPTION

1 1 EA 3-Valve Manifold
(Note 4)
2 4 EA Male conn 1/2"T × 1/2"P
9 4 3 A/R FT Steam traced tube bundle w/two 1/2" O.D. tubes
and one 1/4" O.D. copper tracer
5 ) 4 1 EA See enclosure detail
10 ote
8 (N ply 5 2 EA End seal kit
sup 6 2 EA Male conn 1/4"T × 3/8"P
am
Ste 7 1 EA Steam heater coil w/brackets
8 2 EA 1/2" Pipe tee 3000# thrd
9 2 EA 1/2" Hex head pipe plug thrd
es 10 2 EA 1/2" Pipe nipple - sch 80 minimum
alv
ot v g 2
Ro pipin
by 5 H
L
1

2
5

6 7
6
3)
ote
(N (Note 2)
3
To trap
assembly

Notes:
1. All instrument piping and piping components to be per instrument material Process Industry Practices
specification PIP PCSIP001 unless otherwise noted. Installation Details
2. Mounting support, brackets, and electrical considerations to be as indicated
in the instrument index. Differential Pressure Transmitter Practice Ref. PCIDP000
3. Horizontal tube run slope to be 1" per foot (minimum) down toward the transmitter. Steam Service/Steam Traced Tube Bundle Page 1 of 1
4. All penetrations to be per enclosure manufacturer. Drawing date 4/99
1/2" Connections,
5. Pipe tees should be at the same elevation (+/− 1/8").
3/8" Impulse

FIG. 1.7e
Typical PIP transmitter installation detail.

significant failures of stainless and high alloy piping when
minor fires melted the zinc from galvanized walkways, etc.
If molten zinc comes in contact with an austenitic alloy, it
penetrates its grain structure within seconds and the strength
of the alloy vanishes. To protect from this effect and to avoid
corrosion, a number of sites are now using stainless steel
“strut” supports.
PROCESS INDUSTRIES PRACTICES
A consortium of the major petroleum, chemical, and related
manufacturers, together with major engineer-constructors have
joined to form the Process Industry Practices (PIP) division of
the Construction Industry Institute, an organization associ-
ated with The University of Texas at Austin. The PIP offices
are located to 3925 West Braker Lane (R4500), Austin, TX
78759.
PIP (website http://www.pip.org) has generated a wide-
ranging series of standard practices in a variety of engineer-
ing fields. Among the 20 Practices for Process Control are
some 9 sets covering instrument installation. These are avail-
able to members of the consortium and subscribers for their
direct use, and can be purchased by other organizations
Figures 1.7e, f, and g).
In an effort to minimize the cost of process industry facil-
ities, these Practices have been prepared from the technical
requirements in the existing standards of major industrial
users, contractors, or standards organisations. By harmonis-
ing these technical requirements into a single set of Practices,
administrative, application, and engineering costs to both the
purchaser and the manufacturer should be reduced. While
these Practices are expected to incorporate the majority of
requirements of most users, individual applications may
involve requirements that will be appended to and take pre-
cedence over individual Practices. Determinations concern-
ing fitness for purpose and particular matters or application
of the Practice to particular project or engineering situations
should not be made solely on information contained in these
materials.
The tabulation of PIP installation documents (Table 1.7h)
is not exhaustive, and they are frequently edited and extended.
Bibliography
Process Industry Practices (see Table 1.7h) issued by Process Industry Prac-
tices, 3925 West Braker Lane (R4500), Austin, TX 78759, USA.

© 2003 by Béla Lipták

 1.7 Instrument Installation 105

Tap orientation
End view
(Note 1) 4)
,&
s 2, 3
(N ote

Flo
w ing
pip L
By instr.
By H
To
t ran
sm
itte
r

Notes: Process Industry Practices

1. Tap orientation is shown for orifice flange taps. Orientation may be used with
other taps (e.g., pipe taps, radius taps) and venturimeters, flow nozzles, etc. Installation Details
2. Slope down (minimum 1 inch per foot) from process taps to equalizing manifold.
3. Refer to installation details in PIP PCIDPOOO for materials. Practice Ref. PCIFL000
4. If required, locate optional tee pressure transmitter connection in high pressure side
Head meter with remote transmitter Page 1 of 1
of flow measurement in close proximity to equalizing manifold. below for liquid and steam service Drawing date 5/99
5. Refer to piping connection details in PIP PNF0200. horizontal run - horizontal side taps

FIG. 1.7f
Typical PIP element installation detail.

ITEM QTY UM DESCRIPTION

1 FT 1/4" O.D. Tubing. See note 1
Instrument 2 4 EA 1/4"T × 1/4"P Male tube connector. See note 1
air supply
as required

Pneumatic
transmitter

Note 2 1

Instrument Instrument
air supply 1 air supply
as required as required

2 2
2
1 1

Pneumatic Final element

controller

Notes:
1. All instrument piping and tubing components to be as specified in the instrument Process Industry Practices
index per material specifications from PIP PCSIP001, instrument piping and tubing
Installation Detail
specifications, unless otherwise noted.
2. Routing, installation and support to be per PIP PCCIP001, instrument piping and Practice Ref. PCIIA000
tubing systems criteria. Instrument Signal Page 1 of 1
Pneumatic Loop Drawing date 4/99

FIG. 1.7g
Typical PIP pneumatic installation detail.

© 2003 by Béla Lipták

106 General Considerations

TABLE 1.7h
Listing of Process Industry Practices for Instrument Installation
Differential Pressure
PCIDP000 Differential Pressure Installation Details Date: 07-01 (revised)
Native DGN PCIDP000_dgn.exe 5265 KB Native DWG PCIDP000_dwg.exe 9651 KB Native Text PCIDP000.doc 89 KB
PDF PCIDP000.pdf 4415 KB File

Electrical
PCFEL000 Instrumentation Electrical Fabrication Details Date: 12-99
Native DGN PCFEL000.dgn 97 KB File Native DWG PCFEL000.dwg 96 KB File Native Text PCFEL000.doc 50 KB File
PDF PCFEL000.pdf 122 KB File
PCIEL000 Instrumentation Electrical Installation Details Date: 02-00
Native DGN PCIEL000_DNG.ZIP 2293 KB Native DWG PCIEL000_DWG.ZIP 3485 KB Native Text PCIEL000.doc 119 KB
PDF PCIEL000.pdf 3040 KB

Flow
PCFFL000 Flow Measurement Fabrication Details Date: 01-01
Native DGN PCFFL000_DGN.EXE 1294 KB Native DWG PCFFL000_DWG.ZIP 1334 KB Native Text PCFFL000.doc 74 KB
PDF PCFFL000.pdf 238 KB
PCIFL000 Flow Measurement Installation Details Date: 04-01
Native DGN PCIFL000_DGN.exe 2573 KB Native DWG PCIFL000_DWG.exe 3532 KB Native Text PCIFL000.doc 76 KB
PDF PCIFL000.pdf 594 KB

General
PCCGN001 General Instrumentation Design Checklist Date: 07-01
Native PCCGN001.doc 893 KB
PDF PCCGN001.pdf 157 KB
PCCGN002 General Instrument Installation Criteria Date: 10-01
Native PCCGN002.doc 104 KB
PDF PCCGN002.pdf 44 KB
PCFGN000 Instrument Pipe Support Fabrication Details Date: 06-00
Native DGN PCFGN000_DGN.EXE 204 KB Native DWG PCFGN000_DWG.ZIP 248 KB Native Text PCFGN000.doc 93 KB
PDF PCFGN000.pdf 314 KB
PCIGN000 Instrument Pipe Support Installation Date: 06-00
Native DGN PCIGN000_DGN.ZIP 329 KB Native DWG PCIGN000_DWG.ZIP 475 KB Native Text PCIGN000.doc 68 KB
PDF PCIGN000.pdf 341 KB
PCIGN001 General Instrument Purge Details Date: 09-01
Native DGN PCIGN001_DGN.ZIP 860 KB Native DWG PCIGN001_DWG.ZIP 697 KB Native Text PCIGN001.doc 68 KB
PDF PCIGN001.pdf 234 KB

Instrument Air
PCIIA000 Instrument Air Installation Details Date: 07-01
Native DGN PCIIA000_DGN.ZIP 274 KB Native DWG PCIIA000_DWG.ZIP 1175 KB Native Text PCIIA000.doc 62 KB
PDF PCIIA000.pdf 482 KB

Instrument Piping
PCCIP001 Instrument Piping and Tubing Systems Criteria Date: 07-98
Native Text PCCIP001.doc 88 KB
PDF PCCIP001.pdf 30 KB
PCSIP001 Instrument Piping and Tubing Systems Specifications Date: 07-98
Native Text PCSIP001.doc 121 KB
PDF PCSIP001.pdf 103 KB

Process Analyzers
PCIPA001 Process Analyzer System Field Installation Date: 10-01
Native Text PCIPA001.doc 110 KB
PDF PCIPA001.pdf 39 KB

© 2003 by Béla Lipták

 1.7 Instrument Installation 107

TABLE 1.7h Continued

Listing of Process Industry Practices for Instrument Installation
Pressure
PCIPR000 Pressure Installation Details Date: 04-99
Native DGN PCIPR000_dgn.exe 3912 KB Native DWG PCIPR000_dwg.exe 3137 KB Native Text PCIPR000.doc 154 KB
PDF PCIPR000.pdf 8314 KB

Temperature
PCFTE000 Temperature Measurement Fabrication Details Date: 04-00
Native DGN PCFTE000_DGN.ZIP 242 KB Native DWG PCFTE000_DWG.ZIP 393 KB Native Text PCFTE000.doc 73 KB
PDF PCFTE000.pdf 632 KB

© 2003 by Béla Lipták