Doc. No.

51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 1 of 33

Project Name: Vivergo Fuels Project

Project Number: 51203670
Client: Vivergo
Plant Location: Saltend, Hull, UK

Document Title: Instrument Design Basis

P.E. Cross SB
P1 26/07/07 S2 For Review/Comment
Rev Date PEM Description Original Checked QA Approved
Status By By Approval By

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 2 of 33

Revision Details of Revision

P1 For Review/Comment

Notes:
1. Revisions to document to be highlighted. Highlighting from previous revisions to be
deleted prior to next revision.
2. Any modifications to document to be Word Processed by Facilities Group in order to
maintain consistent formatting.

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 3 of 33

CONTENTS

1 GENERAL 6
2 SCOPE 6
3 APPLICABLE INSTITUTIONS FOR STANDARDS 6
4 LIST OF STANDARDS 6
4.1 Flow measurement 6
4.2 Level Measurement 7
4.3 Pressure Measurement 7
4.4 Temperature 7
4.5 Vibration 7
4.6 Computer system 7
4.7 Instrument services 8
4.8 Electrical equipment 8
4.9 Engineering & Design 8
4.10 Control Valves 9
4.11 Relief Valves 10
4.12 Control Room 10
5 BP Guidance on Practices 10
6 CONTROL PHILOSOPHY 11
6.1 Control Room Requirement 11
7 PACKAGE UNITS PHILOSOPHY 11
7.1 Operating Philosophy 11
7.2 Logic implementation 12
7.3 Configuration 12
8 GENERAL TECHNICAL REQUIREMENTS 12
8.1 Type of power Supply 12
8.2 Hazardous Area Protection 12
8.3 Intrinsic safety Barriers 12
8.4 Environmental Protection 13
8.5 Analyser Installation 13
8.6 Earthing System 13
8.7 Power Supply Requirement 13
8.8 Cable Entry 14
8.9 Transmitters 14
8.10 Control System 14
8.11 Minimum instrument types for Electrical Area Classifications 14
8.12 Protection 15
8.13 Instrument Electrical Construction 15
8.14 Spare Philosophy 15
9 CS REQUIREMENTS 15
9.1 Functional Requirements 15
© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 4 of 33

9.2 Operator Consoles 16

9.3 Engineering Console 16
9.4 Type of reports required 16
9.5 Type of Controller 17
9.6 Field Multiplexer 17
9.7 Foreign Device Interface 17
9.8 Redundancy Philosophy 17
9.9 Network loading philosophy 18
9.10 UPS Power Supply Loading + (20% spare + 20% future) 18
10 PLC REQUIREMENTS 18
10.1 PLC System Design 18
10.2 Logic Diagrams 18
10.3 Package System Software 19
10.4 Installation 19
11 OTHER CONTROL SYSTEMS 19
11.1 Wheat Storage 19
11.2 DDGS 19
11.3 Bio-Filter 19
11.4 Cooling Water 19
11.5 Packing units 19
11.6 SIS 20
12 PRESSURE INSTRUMENTS 20
12.1 Pressure Units 20
12.2 Equipment and Installation Considerations 20
12.3 Field Transmitter type 20
12.4 Field Transmitter Output Signal type 20
13 TEMPERATURE INSTRUMENTS 21
13.1 Temperature Units 21
13.2 Equipment and Installation Considerations 21
14 LEVEL INSTRUMENTS 23
14.1 Equipment and Installation Considerations-Continuous Level Measurement
Applications 23
14.2 Level Dip pipe philosophy 23
14.3 Magnetic level gauges 23
14.4 Tank Level Gauging 23
14.5 Unit for Level Instrumentation 24
14.6 Special Level Instrumentation (If required) 24
15 FLOW INSTRUMENTS 24
15.1 Flow Units 24
15.2 Equipment and Installation Considerations-Other Flow Instruments 25
16 INSTRUMENT PANELS 26
16.1 Instrument Local Control Panel Concept 26
16.2 Control Room Panel(s) 26
© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 5 of 33

16.3 Field Panel(s) 26

17 CONTROL VALVES 27
17.1 Body Connections 27
17.2 Seats 27
17.3 Bypass Manifolds 27
17.4 Packing 28
17.5 Actuator Sizing 28
17.6 Calculation Method 28
17.7 Fail-Safe Power 28
17.8 Valve Positioners 28
17.9 Solenoids 28
17.10 Others 29
18 ISOLATION/SHUTDOWN VALVES 29
18.1 Valve Body Type 29
18.2 Body Connection 29
18.3 Leakage Class 29
18.4 Seat Type 29
18.5 Fire Safe Design 30
18.6 Actuator Type 30
18.7 Manual Gear 30
19 INSTRUMENT PIPING AND TUBING 30
19.1 Installation/Tubing hook-ups 30
19.2 Material Requirements 31
19.3 Tube Fittings 31
19.4 Thread Lubricant 31
20 CONTROL BUILDINGS 32
20.1 Control Building 32
20.2 Rooms to be included in Control Building. HOLD 32
21 SITE AND ENVIRONMENTAL DATA 33
22 SUMMARY OF HOLDS 33

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 6 of 33

1 GENERAL

This document describes the basic requirements for the engineering and design of
instrumentation and control for the Vivergo Fuels Plant at Saltend, Hull, UK.

The basic design for the core plant will be provided by Praj, who will also provide the initial
Equipment List and P&IDs for the ISBL plot. The OSBL services will be provided and designed
by AKPG, Mumbai. AK Solent will be responsible for the co-ordination and incorporation of the
Praj design into the plot design, and liaison with the OSBL Team.

2 SCOPE

This document contains general requirements for instrumentation and control which when
completed, contains project specific data. This document shall be used by the detailed
engineering contractor as the technical baseline for all instrumentation and control system
work on the project. The technical requirements presented in this document primarily apply to
a new facility design and construction.

3 APPLICABLE INSTITUTIONS FOR STANDARDS

 British Standards (BS)

 Indian Standards (IS)
 American National Standards Institute (ANSI)
 American Society for Testing and Materials (ASTM)
 Instrument Society of America (ISA) Standards and Practices.
 National Electrical Manufactures Association (NEMA) Publications.
 American Society of Mechanical Engineers (ASME).
 National Fire Protection Association (NFPA)
 Scientific Apparatus Makers Association (SAMA)
 International Electro-Technical Commission (IEC).
 Open Software Foundation (OSF).
 American Petroleum Institute (API)
 Field Bus System Engineering Guidelines (AG-181) Revision - 2

4 LIST OF STANDARDS

4.1 Flow measurement

Measurement of fluid flow by means of orifice plates and ISO 5167 (2003),
venturi tubes

Measurement of fluid flow by means of Averaging pitot tube R.W.Miller

Measurement of Fluid flow evaluation of uncertainty ISO TR 5168 (1998)

Steel orifice flanges ANSI B16.36 (1996)

Pipe threads general purpose ANSI B 1.20.1 (1983)

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 7 of 33

4.2 Level Measurement

Nucleonic level installation shall be designed to meet the requirements of the UK Ionising
Radiation Regulations 1999. HOLD

4.3 Pressure Measurement

Pressure indicating dial type elastic element ASME B40.100 (2000)

Bourdon tube pressure and vacuum gauges BSEN 837 –1- 98 (1998)

4.4 Temperature

Temperature measurement thermocouples ANSI/ISA-MC96.1 (1982)

Industrial platinum resistance thermometer elements IEC 60751 (1983)

AMD. 2 (1995) / DIN 43760 (1987)

International thermocouple reference tables IEC 60584-1 (1995)

Thermocouples - extension and compensating cables IEC 60584-3 (1989)

Dial type expansion thermometers BS 5235 (1975)

Temperature measurement systems ISO 8310 (1991)

Thermowell Design ASME PTC 19.3 (1991)

4.5 Vibration

Vibration Axial-position, & Bearing temperature

monitoring system API 670 (2000)

4.6 Computer system

Binary logic diagrams for process operations ISA S5.2 (1976)

Graphic symbols for CS display information, logic ISA S5.3 (1983)

and computer systems

Instrument loop diagram ISA S5.4 (1991)

Annunciator Sequences and Specification ISA S18.1 (1979)

IEE Guidelines for Documentation of Computer Software for Real Time and Interactive
Systems

EIA Communication Standards for RS 485, and RS 232C

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 8 of 33

4.7 Instrument services

Quality standard for instrument air ISA S7.0.01 (1996)

Air pressure for pneumatic controllers, transmitters ISA S7.0.01 (1996)

and pneumatic systems

Recommended practice for producing quality ISA S7.0.01 (1996)

instrument air

Pneumatic control circuit pressure test ISA S7.0.01 (1996)

4.8 Electrical equipment

Electrical apparatus for potentially explosive EN 50014 (1998)

atmospheres EN 50018 (1995)
EN 50019 (1995)
EN 50020 (1995)

Electrical apparatus for Explosive atmospheres, part IEC 60079-10 (1995)

10 classification of hazardous area

Classification of locations for Electrical Installations API-500 (1998)

of Petroleum facilities

Definition and explanation pertaining to Electrical and ISA S 12.1, 1991

Instrumentation hazardous location

Specification for the colour of indicator lights, push IEC 60073 (2002)
buttons, annunciators and digital readouts

Instrumentation cables BS 5308 Part 2 (1986)

General standards for industrial controls and systems NEMA ICSI (1994)
(Amd. 1 1999)

Specification for degrees of protection provided by IEC 60529 (2001)

enclosures

4.9 Engineering & Design

Instrumentation symbols and identification ISA S5.1 (1992)

Symbolic representation for process measurement ISO 3461 (1976)

control functions and instrumentation ISO 3511 (1977)
BS 1646 (1646)

International system of units ISO 1000 (1992)

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 9 of 33

Process instrumentation terminology ISA 51.1 (1979)

Electromagnetic compatibility for industrial process IEC 60801-3 (1990)

measurement and control

Recommendation for design of scales and indexes BS 3693 (1992)

Steel compression couplings for tubes ISO 1179 (1981)

BS 4368 (1998)

Instrument signal ranges IEC 60381-1 (1982)

BS 5863-1 (1984)
BS5863-2 (1980)

Quality systems principals & applications ISO 9000 (2000)

Fire/smoke detection systems NFPA 72 (2002)

Instrumentation in Process Control Systems BS 6739 (1986)

Installation Design and Practice

Copper Tubes BS EN 1057 (Pt. 1) (1996)

Process Measurement Instrumentation-Manual on API 551 (1993)

Installation and Refinery Instrument & Control
Systems

4.10 Control Valves

Steel pipe flanges and flanged fittings ASME B16.5 (2003)

Flow equations for sizing control valves ISA S75.01 (1995)

Face to face dimensions for flanged globe style ISA S75.03 (1992)
control valves – till ANSI 600# rating.

Face to face dimensions for flanged globe style ISA S75.16 (1994)
control valves - ANSI 900# ~ 2500# rating.

Butterfly valves BS 5155

Steel ball valves BS 5351 (1986)

Control valve capacity test procedure ISA S75.02 (1988)

Valve inspection and testing API 598 (1996)

Testing of valves BS 6755 pt 1& 2 (1987)

Control Valve Manifolds ANSI/ISA S75.06 (1994)

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 10 of 33

Quality control standard for control valve seat leakage FCI 70.2 (2003)

Hydrostatic testing of control valves API 598 (1996)

4.11 Relief Valves

Sizing, selection and installation of pressure relieving API RP520 (2000)

systems in refineries Pt 1& 2 (2003)

Guide for pressure relieving and depressurising API RP 521 (1997)

systems

Flanged steel safety relief valves API 526 (2002)

Commercial seat tightness of safety relief valves with API 527 (1991)
metal to metal seat

Venting atmospheric and low pressure storage tanks API 2000 (1998)

4.12 Control Room

Process Plant Hazardous & Control Building Design

Emergency shut down system IEC 61508 (2000)

Hardwire testing of digital process computers ISA RP 55.1 (1975)

Environmental Conditions for Process Measurement ISA S71.04 (1985)

5 BP GUIDANCE ON PRACTICES

Relevant sections of:-

GP 30-80 Implementation of the Process Requirements Spec

GP 30-76-DRAFT-SIS-Development of the Process Requirements
GP 30-70 C+I Vendor Packaged Equipment
GP 30-85-Fire and Gads Detection
GP 30-81 SIS-Operations and Maintenance
GP 30-75 SIS Management of the Safety Lifecycle
GP 30-49 Control System Documentation
GP 30-45 HMI for Process Control
GP 30-40 Process Automation Systems

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 11 of 33

6 CONTROL PHILOSOPHY

a) Mode of Plant Operation Centralised Unit wise

All units Utilities & offsites

b) Type of Plant New Plant Expansion

6.1 Control Room Requirement

Location
Control
Process Units Hazardous Non-Hazardous Floor
Room
Area Area
Central For all process NO YES HOLD
Control Units ISBL/OSBL
Room

Type of Control and Monitoring

a) Centralised Control System (FF) for all process units

Remore I/O Panels. Large packages

Supervisory Computer for Supervisor

Others (SCADA) for____

b) Local Instruments Electronic Pneumatic

c) Final Control Element Pneumatic

7 PACKAGE UNITS PHILOSOPHY

7.1 Operating Philosophy

Control & Monitoring Interlock & Shutdown

Location
Control
Package Local Control Control Control
Local PL EM System
Location Room LCP System System
Panel C Relays SIS
Central Control (FF) (FF)
(SIL-3)
Room CCR
Package YES HOLD --- --- --- --- ---
within
units

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 12 of 33

7.2 Logic implementation

Package units through

Plant PLC

Package vendor’s PLC

Other

7.3 Configuration

Dual Processor, Single I/O

Dual Power supply

Vendor's standard for PLC Make

Communication Single

Other Redundant I/O’s (for close loop)

8 GENERAL TECHNICAL REQUIREMENTS

8.1 Type of power Supply

Type Tolerance Duration after mains Emergency power

failure supply requirement
110 V AC UPS 110 V + 1 % 30 Minutes Required
50 Hz + 3 %

8.2 Hazardous Area Protection

a) All field transmitters Intrinsically safe Flame proof

b) Field switches Intrinsically safe Flame proof

c) I/P & E/P converters Intrinsically safe Flame proof

d) Solenoid valves Intrinsically safe Flame proof

8.3 Intrinsic safety Barriers

Galvanic isolation

Single Channel Barriers Multi channel barriers

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 13 of 33

8.4 Environmental Protection

NEMA 4
Electronic card (G3 Quoting) IP 65 Minimum

IP 56 NEMA 4X
IP 54 IP 55
(Pneumatic)
All field instruments shall be suitable for the environment and winterized
where necessary.
Field panels to be air-conditioned (if required)

8.5 Analyser Installation

Analyser house
with Air conditioning
Type of HVAC Packaged
Separate Air conditioning & ventilation unit

8.6 Earthing System

a) Panels, racks, cabinets, consoles, Electrical earth grid

& all junction boxes with power of
110 V AC
b) Signal / screen earth Separate dedicated earth pit
c) System earth Separate dedicated earth pit

8.7 Power Supply Requirement

Sr. Item Description 110 V AC 24V 110 V AC

No. 50 Hz. UPS DC 50 Hz( Non UPS)
a) Control System
b) Supervisory Computer
c) Package Units
d) Alarm Annuciator (if applicable)
e) PLC packages
f) TMR solid state Interlock &
Shutdown System
g) Solenoid Valves
h) Input Interrogation
j) Analyser House
k) Nucleonic Instruments
l) Cabinets/Panel Lighting

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 14 of 33

Sr. Item Description 110 V AC 24V 110 V AC

No. 50 Hz. UPS DC 50 Hz( Non UPS)

8.8 Cable Entry

a) Control Rooms / rack MCT Blocks Pipe

room Sleeves

b) Field Control Rooms MCT Blocks Pipe

Sleeves
c) Analyser Houses MCT Blocks Pipe
Sleeves

8.9 Transmitters

Electronic transmitters 4 – 20 mA SMART with HART Protocol,/ Fieldbus (As

Applicable)

8.10 Control System

Distributed control system

Conventional pneumatic

Conventional electronic

8.11 Minimum instrument types for Electrical Area Classifications

Ex proof to Zone 2 Gas group IIA / IIB, T3 HOLD

U.L. (or equiv.) approved Class I, Div. 2

U.L. (or equiv.) approved Class I, Div. 1

Non-incendive

Intrinsically safe devices w/ barriers

Weather proof to IP 65 Field Junction Box Protection

8.11.1 Materials

Fibre glass (With SS316 nut, bolts, Plates and hinges)

Stainless Steel

Aluminium LM6 (for Ex-Proof boxes)

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 15 of 33

Sheet steel

8.12 Protection

Electric tracing

Self limiting (As per P&ID)

Constant resistance (As per P&ID)

Steam tracing By Low Pressure steam

Insulation Insulate Control valve body / line with Acoustic insulation.

8.13 Instrument Electrical Construction

8.13.1 Control Room

Cable tray (Hot Dipped Galvanised)

Cable Duct

8.14 Spare Philosophy

a) Spare instrument as Case to Case basis

Engineering Spares
b) Spare Parts For two years operation

For startup and commissioning

c) CS/SIS/F&G/Remote I/O/System Spare Philosophy

- Installed Spares I/O Level 20%
- Spare Space I/O Racks 20%
Marshalling Rack 15%
- Mandatory Spares 10 ~ 20% or minimum one of
each type of module

9 CS REQUIREMENTS

9.1 Functional Requirements

Control and Data Acquisition System

Data Logging and Report generation

Management Reports (Limited)

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 16 of 33

Plant Information Management System

Advanced Control (PC and IMS)

Data Storage and Archival

Colour Printer -

Laser Printer -.

9.2 Operator Consoles

a) No. of operator console in the Control Room

Location Hard wire Console No. of 20” TFT LCD Process Units
VDU
CENTRAL 3 nos ISBL
CONTROL
ROOM 3 nos. OSBL

9.3 Engineering Console

Required Not required

a) No. of consoles in Engineering Room

Location Description No. of 20” TFT LCD Name of Units

Display / Station
ENGINEERING Engineering One with Operation Common for
ROOM Station Capability ISBL/OSBL
AMS Config One - Do -
IMS Station One - Do -

9.4 Type of reports required

Hourly Alarm History

Shift wise Alarm Summary

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 17 of 33

Daily

MIS reports

Others

9.5 Type of Controller

Multi Loop

Single Loop

9.6 Field Multiplexer

Required Not required

i) 10 kV MV Motors

ii) 4-20mA open loop

iii) Thermocouple (open loop)

iv) RTD (Pt 100) open loop

v) Contact input (open loop)

9.7 Foreign Device Interface

Required for:
Wheat Storage
DDGS
Bo-Filter
Cooling Water
Scubber system

9.8 Redundancy Philosophy

a) Controller Sub-system 1:1 redundancy

b) Analog Input Redundancy

c) Analog output Redundancy

d) Communication sub system 1:1 redundancy

e) Power supplies 1:1 redundancy

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 18 of 33

f) Remote I/O HOLD

9.9 Network loading philosophy

Processor loading philosophy Control Processor <50 %

Communication network <50%

Serial Link Network <50%

9.10 UPS Power Supply Loading + (20% spare + 20% future)

For Total System hardware

10 PLC REQUIREMENTS

10.1 PLC System Design

10.1.1 Action on Power Failure

Outputs fail safe

Outputs hold last position

Sequence return to start

10.1.2 Energy Suppression Devices Required

Inductive DC outputs

Inductive AC outputs

10.1.3 Percent Spare Capacity

I/O modules 20 %

Redundant I/O modules 20 %

Module expansion space 20 %

Memory size 50 %

10.2 Logic Diagrams

Not required for

Required

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 19 of 33

Left-to-right format

Top-to-bottom format

Process figures required

Written description of logic required

10.3 Package System Software

By vendor

Custom design

Adequate vendor documentation

Documentation

10.4 Installation

Prefabricated enclosure

Field contractor to install

Integral environment control

11 OTHER CONTROL SYSTEMS

11.1 Wheat Storage

Required Not Required

11.2 DDGS

Required Not Required

11.3 Bio-Filter

Required Not Required

11.4 Cooling Water

Required Not Required

11.5 Packing units

Required Not Required

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 20 of 33

11.6 SIS

Required Not Required

12 PRESSURE INSTRUMENTS

12.1 Pressure Units

Bara

Barg

mm Hg

mm of H2O

kg/cm2g or kg/cm2

Vacuum (Inches H2 O)

12.2 Equipment and Installation Considerations

Use pressure transmitters only

Use pressure transmitter/pressure switch

Direct connected switches allowed

Pressure switches for packages allowed.

12.3 Field Transmitter type

a) For open & Conventional FF

closed loops
b) For anti-surge Conventional Smart
loops
c) For shut-down Conventional Smart with write
loops disabled

12.4 Field Transmitter Output Signal type

a) For transmitters FF digital

b) For Pneumatic transmitters 0.2 ~ 1.0 barg

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 21 of 33

13 TEMPERATURE INSTRUMENTS

13.1 Temperature Units

Degrees Fahrenheit (° F)

Degrees Celsius (°C)

Degrees Rankin (° R)

13.2 Equipment and Installation Considerations

13.2.1 Thermowells

Use flanged thermowell (Stainless steel 316L min. Bar stock)

Use threaded thermowell In low pressure & non-critical duties

(e.g. lube oil pressure)

Use welded thermowell

Use firebox thermowell

Thermowell flange rating As per piping specifications

Minimum 300# rating

13.2.2 Thermocouple

Thermocouple Types Used

Type E

Type K (0 ~ 1100 °C)

Type J (0 ~ 590 °C)

Thermocouple grounding

Ungrounded

Grounded

Transmitter to linearize

Locate in field (Head mounted)

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 22 of 33

Locate in control room

Digital equipment to linearize

Locate in field

Locate in control room

Shielding

Individual shielded twisted pair with shield grounded at T/C end

Multipair cable with overall shield un-grounded at CR

Other type shield & grounding

Sensor type

Simplex TC (18 AWG)

Twin TC (20 AWG)

13.2.3 RTDs

RTDs used for temperature below 400 °C.

RTD Type Used

100 ohm platinum

Other

3 wire RTD

4 wire RTD

Use of twin RTD elements minimum as a standard.

13.2.4 Electronic Temperature transmitter

Required Not-required

For all only for control and shut down

Location Field Head-mounted

Remote-mounted
© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 23 of 33

13.2.5 Temperature Gauges

Bimetallic Filled system every angle type

(For Vibrating eqpts.)

14 LEVEL INSTRUMENTS

14.1 Equipment and Installation Considerations-Continuous Level Measurement

Applications

Use Nucleonic devices As Specified on P&ID

Use DP transmitters As Specified on P&ID

Use Displacers As Specified on P&ID

Use Radar As specified in P&ID

Purged DP transmitters As Specified on P&ID

Use capacitance As Specified on P&ID

Level control throttling

Level control on/off

14.2 Level Dip pipe philosophy

As per P&ID

14.3 Magnetic level gauges

As per P&ID

14.4 Tank Level Gauging

Feed Tanks Servo Float Hydrostatic Radar

Intermediate Tanks Servo Float Hydrostatic Radar

Product Tanks Servo Float Hydrostatic Radar

Highly viscous service Servo Radar

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 24 of 33

14.5 Unit for Level Instrumentation

mm wg % mm

14.6 Special Level Instrumentation (If required)

RF Type for Silos

Ultrasonic Type

15 FLOW INSTRUMENTS

15.1 Flow Units

Gas Nm3/hr, lb/hr, Other kg / hr

Liquid kg/hr m3/hr, Other Te/ hr

Steam kg/hr lb/hr, Other Te / hr

Solid flow GPM, kg/hr, Other Te/ hr

Other Purge air used for level measurement SCCM.

Equipment and Installation Considerations-Orifice Type Flow Instruments

15.1.1 Transmitter Installation

Pipe nipples

Instrument manifold

Bracket and pipe support

Pipe spec valve at orifice

Double block for steam (if required due to very high pressure)

Steam service-welded root valves

15.1.2 General service

For > 50mm lines Orifice plate

Other

Variable area flowmeter

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 25 of 33

Vortex flowmeter

Magnetic flowmeter (for conductive fluids)

For < 40mm lines Variable Area meter

Meter Run

Integral Orifice / corner tap

Type of taps for orifice assembly

Flanged (General)

(For > 50mm lines)

(Also for conical entrance orifices)

D-D/2 2 1/2 D-8D

(For > 250mm lines)

15.1.3 Reliability/Maintainability Features

Rod out

Purge

Mount at grade

Output gauge required

15.2 Equipment and Installation Considerations-Other Flow Instruments

15.2.1 Special Flow Meters (As Specified on P&ID)

a) For viscous and fouling duty Mass flow (Coriolis type)

PD meter

Wedge

Orifice

Target

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 26 of 33

b) Other instruments Annubar, Ultrasonic flowmeter etc.

16 INSTRUMENT PANELS

16.1 Instrument Local Control Panel Concept

Provide free standing panel with plinth.

16.2 Control Room Panel(s)

16.2.1 Panel Type

Free standing with no graphics.

Semigraphic

16.2.2 Panel

Video wall for CS

16.2.3 Panel Structure

Free standing cabinet size to suit

Plinth of 150mm high

Sheet metal

Lifting eye bolts

Console

Match existing panels

Other

16.3 Field Panel(s)

a) Location Hazardous Area

Non-Hazardous Area

b) Type Weather-proof

Flame-proof

Other (Purge Panel)

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 27 of 33

c) Instruments Type Pneumatic Electronic

17 CONTROL VALVES

17.1 Body Connections

Screwed up to 50mm acceptable

Body rating (300# min.)

Flangeless style acceptable

Separable flanges acceptable

Split body

Globe

Angle

Ball

Eccentric Disc (Camflex)

SEG Ball (V-Ball)

Butterfly

17.2 Seats

Screwed allowed

Globe As Per Specification________

Shut-off required As Per Specification________ ______

17.3 Bypass Manifolds

On all valves

Selectively used As per P&ID by licensor

None

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 28 of 33

17.4 Packing

As Per Specification

Single

Double

Lubricated

17.5 Actuator Sizing

Minimum air pressure of 4.0 barg .

Max. size allowed by shaft

17.6 Calculation Method

Cv via Vendor's method

Cv via ISA method

Noise via other method shall not exceed 80 dB (A) @ 1 m.

Noise via Vendor's method shall not exceed 80 dB (A) @ 1 m.

Other

17.7 Fail-Safe Power

Actuator spring

Other

17.8 Valve Positioners

Pneumatic I/P

Electro-pneumatic with FF

17.9 Solenoids

Mechanical Latch/Reset As indicated in P&ID

Electrical Latch/Reset

Dual Coil As indicated in P&ID

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 29 of 33

Single Coil As indicated in P&ID

On line trip testing

17.10 Others

Valve colour- HOLD

Spares – interchangeability of valve spare schedule required.

18 ISOLATION/SHUTDOWN VALVES

18.1 Valve Body Type

Ball (For size < 80mm)

¼ turn Butterfly (For size > 100mm)

Gate for steam application

Globe

18.2 Body Connection

Flanged

Wafer

Screw

18.3 Leakage Class

As per Specification

ANSI Class IV

ANSI Class III

ANSI Class VI

18.4 Seat Type

As per Specification

Soft

Metal
© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 30 of 33

18.5 Fire Safe Design

Required as per API 607 (Only for Ball valves)

Not Required

18.6 Actuator Type

18.6.1 For Isolation Valves

Air operated (Pneumatic)

Motor operated (Electric)

Hydraulic

18.6.2 For Shutdown Valves

Air operated (Pneumatic)

Motor operated (Electric)

Hydraulic

18.6.3 Hand Wheel As specified in P&ID

18.7 Manual Gear

Required

Air operated valve

Motor operated valve

Not Required

Air operated valve

Motor operated valve

19 INSTRUMENT PIPING AND TUBING

19.1 Installation/Tubing hook-ups

19.1.1 Instrument Installation

Closed coupled Remote
19.1.2 Instrument Tubing Piping

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 31 of 33

impulse lines
(Up to 600# rating) (More than 600# rating)
Any other Tubing 316L St.stl as required
19.1.3 Instrument Impulse Line Valves (Up to first isolation valve provided by
piping)
Isolation Valves Gate Globe
Vent/Drain Valves Gate Globe

19.1.4 Impulse tubing SS 316L Tubing min.

Instrument Air Tubing PVC covered Copper
Tubing
19.1.5 Instrument Air Isolation
Valves
Gate Ball

19.2 Material Requirements

19.2.1 Tray

Stainless steel

FRP

Hot dip Galvanized Steel

19.2.2 Air Supply Header

Galvanized Steel Other Stainless Steel

19.2.3 Instrument support

Mild Steel 50mm Class A (black colour pipe)

Other Galvanised Uni strat and Galvanised pipes

19.3 Tube Fittings

Brass with copper tubing on air duty 316 St.Stl on impulse lines

19.4 Thread Lubricant

SWAK (Cajon P/N MSPTS-50)

Loctite (592)

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 32 of 33

OTHER Teflon tape

20 CONTROL BUILDINGS

20.1 Control Building

None

Revision of existing Control Room

New Control Building

One level

Two level Elevation Requirements (HOLD)

Building

Strengthened (Classification)

Blast proof Design

Limitations/Requirements on doors (equipment installation), windows, raised

floor

Electrical Area Classification General Purpose

20.2 Rooms to be included in Control Building. HOLD

Approximate Size

Control room

Cabinet room

Engineering Room

Document room

UPS/ Battery room

Plant manager rooms

Store room

Inst. Workshop area

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED
 Doc. No. 51203670-90-000-161-EPI-0001
Vivergo Fuels Project
Rev. P1
Date 26th July 2007
Instrument Design Basis
Page 33 of 33

HVAC room

Battery room

Conference/Meeting room

Computer office

Inst / CS spare part room

Training room

Manager room

Other

21 SITE AND ENVIRONMENTAL DATA

HOLD

22 SUMMARY OF HOLDS

HOLD SECTION DESCRIPTION

1 4.2 Use of Nucleonic lnstrumentation
2 6.1 Control Room Requirements
3 8.11 Hazardous area classification
4 17.10 Valve colour code
5 20.2 Control building room allocations
6 21 Site & Environmental Data

© 2007 Aker Kvaerner No part of this document or the information it contains may be reproduced or transmitted in any form or by any
means electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission
in writing from Aker Kvaerner. THIS DOCUMENT IS NO LONGER CONTROLLED ONCE DOWNLOADED