ISP003 Rev 5 - Instrumentation Design & Documentation

PT.
VALE INDONESIA, TBK
ISP-003 Instrumentation Design & Documentation
ISP-003
Instrumentation Design & Documentation
5 19 Nov 2019 Add wire numbering standard LA YNR TP
4 13 Aug 2009 General Revision CRM JH MA
3 5 Dec 2008 General Revision CRM AS MA
2 18 Sept 2006 Allow for Utilities tag naming standards JH CRM MH
1 20 Oct 2004 General Revision of Project 105 ISP-2 CRM MM MH

Issued Date Description Prepared Reviewed Approved
ISP003 Rev 5.doc

PT. VALE INDONESIA, TBK
TABLE OF CONTENTS
1.0 ............................................................................................................................................ GENERAL 1

1.1 Standards ....................................................................................................................... 1
1.2 PT Vale Indonesia Standard Specifications..................................................................... 1
1.3 PT Vale Indonesia Standard Instrument Installation Details ............................................ 2
1.4 Hazardous Areas ............................................................................................................ 2
1.5 Engineering Units ........................................................................................................... 3
1.6 Power Supplies ............................................................................................................... 5
1.6.1 A.C. Powered Instruments .................................................................................. 5
1.6.2 D.C. Powered Instruments.................................................................................. 5
1.6.3 Instrument Signals ............................................................................................. 5
1.7 Air Lines ......................................................................................................................... 5
1.8 Colour Coding................................................................................................................. 6
1.8.1 Control Panel Wiring .......................................................................................... 6
1.8.2 Thermocouple Extension Wire ........................................................................... 6
1.8.3 Direct Current Signal Cable Pairs ....................................................................... 6
1.8.4 Power Wiring ..................................................................................................... 6
1.8.5 Control & Indication ............................................................................................ 6
2.0 ............................................................................................................... EQUIPMENT PARAMETERS 7

2.1 Enclosures ...................................................................................................................... 7
2.2 Terminations................................................................................................................... 7
2.3 Cables ............................................................................................................................ 8
2.3.1 Power Cable....................................................................................................... 8
2.3.2 Control Cable ..................................................................................................... 8
2.3.3 Analogue Single Pair or Single Triad Cables ...................................................... 8
2.3.4 Analogue Multipair of Multi-triad Cables ............................................................. 9
2.3.5 Digital Multiconductor Cable ............................................................................... 9
2.3.6 Thermocouple Extension Cable.......................................................................... 9
2.4 Cable Segregation .......................................................................................................... 9
2.5 Transmitters ................................................................................................................... 9
2.6 Control Valves .............................................................................................................. 10
2.7 Positioners and Actuators ............................................................................................. 10
2.8 Telemetry ..................................................................................................................... 10
2.9 Instrument Piping.......................................................................................................... 10
2.10 Instrument Manifolds .................................................................................................... 10
2.11 Instrument Process Tapping ......................................................................................... 10
3.0 ..................................................................................................................................MEASUREMENT 12
3.1 Flow Measurement ....................................................................................................... 12
3.2 Level Measurement ...................................................................................................... 12
3.3 Temperature Measurement ........................................................................................... 12
3.4 Pressure Measurement ................................................................................................. 13
3.5 Density Measurements ................................................................................................. 13
3.6 Analysers...................................................................................................................... 13
4.0 ...................................................................................................................CONTROL PARAMETERS 14

4.1 Communications ........................................................................................................... 14
4.2 Interlocking ................................................................................................................... 14
4.3 Diagnostics ................................................................................................................... 14
ISP003 Rev 5.doc

5.0 ........................................................................................................................ NUMBERING SYSTEM 15

5.1 Area Numbers .............................................................................................................. 15
5.2 Equipment Numbers ..................................................................................................... 15
5.3 Loop Numbers .............................................................................................................. 15
5.4 Tag Numbers ................................................................................................................ 16
5.5 Junction Box Numbers.................................................................................................. 16
5.6 Cable Numbers............................................................................................................. 19
5.6.1 Individual Loop Cable....................................................................................... 19
5.6.2 Multiple Loop Cable ......................................................................................... 19
5.6.3 Communication Cable ...................................................................................... 19
5.6.4 Control Networks Communication Cable .......................................................... 21
5.6.5 Electrical Cable ................................................................................................ 21
5.6.6 Power Supply Cable ......................................................................................... 21
5.7 Wire Numbers .............................................................................................................. 22
5.7.1 Digital Signal .................................................................................................... 22
5.7.2 Analog Signal ................................................................................................... 22
5.8 Instrument Panel Numbers ........................................................................................... 22
5.9 Marshalling Cabinet Numbers ....................................................................................... 23
5.10 Optical Termination Board Numbers ............................................................................. 23
5.11 PLC Address Numbers ................................................................................................. 24
6.0 ......................................................................................................................................... DRAWINGS 25

6.1 Drawing Title and Number Format ................................................................................ 25
6.1.1 Drawing Number .............................................................................................. 25
6.1.2 Keyword ........................................................................................................... 26
6.2 Piping & Instrumentation Diagram ................................................................................ 26
6.3 Block Diagrams ............................................................................................................ 26
6.4 Interconnection Diagrams ............................................................................................. 26
6.5 Instrument Loop Diagram ............................................................................................. 27
6.5.1 Content ............................................................................................................ 27
6.5.2 PT Vale Indonesia Format ................................................................................ 27
6.5.3 ISA Format....................................................................................................... 28
6.6 Conduit, Tray, & Cable Plans ........................................................................................ 28
6.7 Instrument Location Plans............................................................................................. 28
6.8 Instrument Installation Details ....................................................................................... 29
6.9 Drawing Revisions ........................................................................................................ 29
7.0 .............................................................................................................................. DOCUMENTATION 30

7.1 Bill of Material............................................................................................................... 30
7.2 Functional Description .................................................................................................. 30
7.3 Logic Diagrams............................................................................................................. 30
7.4 Instrument Index ........................................................................................................... 31
7.5 Instrument Data Sheets ................................................................................................ 32
7.6 Cable Schedule ............................................................................................................ 32
7.7 Operating, Maintenance and Installation and Commissioning Manuals ......................... 32
7.8 Spare Parts Listing ....................................................................................................... 32
7.9 Input/Output (I/O) Lists ................................................................................................. 32
8.0 ................................................................................................................... SAMPLE ATTACHMENTS 34
ISP003 Rev 5.doc

1.0 GENERAL
The purpose of this standard specification is to define the minimum requirements for all
instrumentation and controls design work carried out by or on behalf of PT Vale Indonesia.
The Instrumentation Design & Documentation Standard Specification ISP-003 shall take precedence
over other PT Vale Indonesia Standard Specifications.
1.1 Standards
Instrumentation design and installation shall be in accordance with the following standards, standard
specifications, and standard details:
Australian
AS 1000 The International System of Units (S.I.)
AS 1076 Pt 3 Apparatus with Type of Protection 'd' - Flameproof Enclosure
AS 1349 Bourdon Tube Pressure and Vacuum Gauges
AS 1828 Cable Glands for Explosive Gas Atmosphere
AS 2380.7 Electrical Equipment for Explosive Atmospheres, Intrinsically Safe Electrical
Apparatus
AS 2430 Classification of Hazardous Areas; Part 1
AS/NZS 3000:2000 Wiring Rules (Except for colour coding of conductors)
British
BS 1041 Temperature Measurement
BS 1042 Measurement of Fluid Flow in Pipes
North American
ANSI MC 96.1 Thermocouples and Thermocouple Extensions Wire
ISA Instrumentation, Systems & Automation Society
Recommended Practices and Standards
AGA American Gas Association
ASME American Society of Mechanical Engineers
NEC National Electric Code
NEMA The National Electrical Manufacturers Association
NFPA National Fire Protection Association
ANSI The American National Standard Institute
FM Factory Mutual Insurance Company
CSA Canadian Standards Association
International
IEC International Electrotechnical Commission
ISO International Standards Organisation
1.2 PT Vale Indonesia Standard Specifications

Only key documents in ESP / ISP series are listed here. Not all are well maintained at the time of
writing this specification but they do contain useful information.
ISP No. Rev Date Title

ESP-001 5 Oct 01 Electrical Requirements for Mechanical Equipment.
3 ESP-124 2 Sep 02 Specification for E, I, & Controls Construction Work
ESP-155 3 Sep 04 Cable Conduit & Tray
2
ISP-001 3 Oct 04 Instrument Requirements for Mechanical Equipment.
3 ISP003 Rev 5.doc Page 1 of 29

ISP-008 3 Dec 75 Differential Pressure Flow Elements
ISP-011 3 Feb 76 Load Cell Systems (Electronic)
3 ISP-016 2 Jan 76 Butterfly Control Valves
ISP-017 3 Mar 76 Control Valves (Globe, Ball, Diaphragm)
ISP-023 4 Jun 2002 Software Documentation Standards
ISP-024 2 Jun 2008 PLC Hardware
3 ISP-025 1 Aug 2008 PLC Programming
ISP-026 1 Aug 2008 HMI Configuration
ISP-133 Instrument Piping Materials & Workmanship
ISP-136 4 Nov 03 Instrument Control Panels
ISP-153 3 Mar 90 Differential Pressure Transmitters Electronic
1.3 PT Vale Indonesia Standard Instrument Installation Details

Refer to the following drawings for examples of customary practice:
Drawing No. Rev Title

000-0259-I 0 Installation Details Instrument Support Structures
000-0260-I 0 Installation Details Air Supply Systems
000-0261-I 0 Installation Details Level Instruments – Tanks/Bins
000-0262-I 0 Installation Details Flow Meters – Liquid/Gas
000-0263-I 0 Installation Details Pressure Taps – Liquid/Gas
000-0638-I 3 Instrument Installation Details – Sheet 1
1.4 Hazardous Areas

All equipment supplied and installed in hazardous areas shall comply with the latest editions of all
relevant codes and standards, particularly the following:
AS/NZS 3000 Wiring Rules

AS 1828 Cable Glands for Explosive Gas Atmospheres
AS 2380.7 Electrical Equipment for Explosive Atmospheres Intrinsically Safe Electrical
Apparatus
AS 2380.6 Increased Safety Apparatus Type of Protection E
AS 1939 Degrees of Protection of Electrical Equipment
3 Where appropriate, instrumentation equipment installed in hazardous areas shall be certified, by

Standards Australia, to be flameproof.
3 Where appropriate, junction boxes installed in hazardous areas shall be certified, by Standards
Australia, for use in such areas.
Design and installation considerations are wide ranging, the following points are to be noted:
Hazardous areas shall be defined on site layout drawings.

All class 1 zone 1 areas shall be protected by intrinsically safe components listed as Exit.
All class 1 zone 2 areas shall be protected by EX'e' listed components.
ISP003 Rev 5.doc Page 2 of 30


Special attention shall be paid to Intrinsically Safe Circuits and their grounding techniques.
Intrinsically safe cabling shall be blue and segregated from non I.S. Associated terminals shall be
blue.
A Dossier of intrinsically safe equipment shall be prepared to cover the site hazardous areas and will
contain certifications for the following:-
i) Cable
ii) Instruments
iii) Equipment
iv) Systems
The single pair cable screen at the field device shall not be connected, so as not to form non I.S.
grounding points or ground loops.
The screen shall be stripped back and a green coloured sleeve pulled over the screen wire.
The I.S. screen of all single pair cables terminating into the field junction boxes shall be terminated to
a common IS ground bar, as will be the screen from the multicore cable. At the marshalling end of
the multicore the screen wire will terminate into a IS ground bar within the cabinet.
1.5 Engineering Units

The engineering units, as listed in Table 1.1, shall be used for all plant instrumentation other than the
following exceptions:
Pipe size, tube size, and associated pipe thread / fitting sizes may be identified by inch
and/or fractional inch dimensions.
The conductor size of electrical cables may be described using the American Wire Gauge
system.
The base conditions shall be:
Temperature => 0°C

Pressure => 101.325 kPa
Table 1.1 SI Units for Common Instrumentation Parameters

Parameter Unit of Measure Abbrev. Preferred Multiple
Length metre m mm
Mass kilogram kg kg
Time second s
o o
Temperature degree celcius C C
Force and Weight newton N kN
2 2
Area square metre m m
Volume cubic metre m3 m3
Pressure pascal Pa kPa unless agreed
otherwise
4 Pressure (draft) metres water column mWC mmWC
3 3
Density kilogram per cubic kg/m kg/m
metre
3 Energy, Work joule J J
Power watt W kW
Conductance (elect) siemens ( = Ohm –1 ) S


Conductivity (elect) siemens per metre S/m uS/cm
Flow (liquid) litres per minute l/m
Flow (steam) tonnes per hour t/h
3
Flow (gas) normal cubic metres per Nm /h
hour
4 Vibration (proximitor) metre m µm (micrometre)
Vibration (accelerometer) metre per second m/s mm/s

SYSTEM PARAMETERS
All instrumentation shall be electronic unless otherwise specified. Pneumatic instrumentation may be
used in conjunction with the electronic systems in such applications as pneumatic control valves fitted
with positioner converters.
Instruments shall withstand over-range inputs equivalent to 300% of maximum span.
1.6 Power Supplies

A power circuit shall be defined to mean a circuit that is used exclusively for power distribution wiring.
A control circuit shall mean those circuits used for intermittent power such as interlock circuits, contact
closures to annunciators, etc. Control circuits shall be 220V AC.
A signal circuit shall be defined to mean a circuit that is used exclusively for signal transmission, or to
supply extra low voltage (normally 32 V.D.C. or less) to a signal transmission or receiving device.
1.6.1 A.C. Powered Instruments

The instrument power supply shall be 220 Volts ±10%, 50 Hertz ±5%.
Each item of equipment shall be protected by a separate fuse or circuit breaker.
1.6.2 D.C. Powered Instruments

The normal instrument power supply shall be 24 volts ±5%.
1.6.3 Instrument Signals

All analogue electric/electronic transmission signals shall operate in the 4-20mA range and
shall be linear. Smart transmitters shall use HART protocol superimposed on the 4-20mA
signals.
Pneumatic transmission signals shall operate in the 20-100 kPa range, unless otherwise
specified.
Thermocouple, strain gauge and high-speed counter DC voltage signals, shall be used where
required.
Signal wiring shall originate in the control panel and be run continuously without splicing to
the instrument junction boxes or direct to field instruments.
Instrument signals shall be as follows;
(i) Discrete Inputs: 24 VDC/1A or 220 VAC/1A, Loop power from the controller.
(ii) Discrete Outputs: 24 VDC/1A or 220 VAC/1A, individually fused.
(iii) Analogue Inputs: 24 VDC, 4-20 mA DC, loop power from the controller. 1
(iv) Analogue Outputs: 24 VDC, 4-20mA DC, loop powered, individually isolated.
1
Except for 220VAC powered field transmitters such as magnetic flow transmitters, etc.
1.7 Air Lines

Design and installation of air lines shall be in accordance with PT Vale Indonesia standard
instrumentation installation details and ISP-133 except that 316SS tube and Swagelok compression


fittings should be substituted for copper tube and brass fittings. The following points are to be noted:-
A ½ inch NPT take off point complete with isolating valve will be provided within 5 metres of any
point requiring instrument air. This valve shall be a quarter turn ball valve. Where there are 4 or
more valves in close proximity a manifold will be used to distribute air supply.
- Air supply lines and associated pipe fittings supplying groups of 5 or less instruments
shall be of ½” nominal bore galvanised steel, schedule 80 pipe.
- Air supply lines to individual instruments shall be either nominal 3/8-inch OD, or ¼
inch OD 316 Stainless Steel as appropriate to the maximum airflow requirement.
- Instrument signal lines shall be a nominal ¼ inch OD tube. 316 Stainless Steel.
- Process impulse lines shall be a minimal ½ inch OD tube. 316 Stainless Steel
- Instrument air shall be reticulated at a nominal 550 kPa pressure. A filter regulator
and output gauge shall be required for each application.
1.8 Colour Coding

Colour coding of wiring and cables at PT Vale Indonesia is heavily influenced by North American
customary practices. While there has been some recent progress in adopting aspects of the Australian
AS/NZS 3000: 2000 Wiring Rules, the colour coding of wiring will continue to generally follow North
American practices. Importantly in this respect, the colour black will continue to be used for the Hot (or
Live) conductor.
1.8.1 Control Panel Wiring

All 220 V AC wiring shall be at least 1.5 mm2 (or 16 AWG) flexible with white PVC for all
direct neutral connections, black PVC for all active connections and intermediates supplied
from within the panel, and yellow PVC for active connections supplied externally.
All 24 V DC wiring shall be at least 0.5 mm2 (or 20 AWG) flexible with grey PVC for all direct
negative connections, blue PVC for all positive connections and intermediates.
All ground wiring shall use at least 1.5 mm2 flexible with green, or green/yellow PVC.
1.8.2 Thermocouple Extension Wire

Thermocouple extension wire shall be colour coded per ANSI Standard C96.1.
1.8.3 Direct Current Signal Cable Pairs

Cable pairs for use with low-level DC signals such as 4-20 mA shall be colour coded as
follows:
Black - Negative
White - Positive
Bare Tinned Copper - Screen Drain (Ground)
1.8.4 Power Wiring

Power wiring shall be colour coded in accordance with ESP-001
1.8.5 Control & Indication

Colour coding of indicator lamps shall be such that:-
Red represents drive stopped or valve closed;
Green represents drive running or valve open;


Amber or yellow represents alarm conditions.
2.0 EQUIPMENT PARAMETERS

Each instrument shall be identified by stamping the relevant tag number onto the instrument data plate
and onto a stainless steel tag to be securely fixed to the body of the instrument by rivets or wire of
stainless steel.
All materials shall be new and of the best quality and the class most suitable for the purpose specified.
All devices shall have corrosion resistant, weatherproof cases and be suitable for outdoor mounting.
Solenoid valve vent ports shall be fitted with stainless steel bug screens to prevent ingress of water and
insects.
Instruments shall have ½ inch NPT cable entry. Alternatively M20x1.5 cable entry may be acceptable
where specifically approved by PT Vale Indonesia. Where an instrument does not comply a thread
adaptor shall be supplied.
All instruments not mounted directly on process connections shall be suitable for 50 mm diameter pipe
stand mounting.
All instruments shall be weather rated to IP65, or better.
2.1 Enclosures
Control panels for indoor locations shall be of rigid construction from zinc coated steel and shall be
suitably painted. Control panels for outdoor locations shall be of rigid construction from 304 or 316
grade stainless steel and shall not be painted.
Control panels for indoor use shall be of weatherproof construction to IP52. Panels for outdoor use
shall be of weatherproof construction to IP65 and shall be supplied complete with a canopy. All
components on external panel surfaces shall maintain the applicable protection rating.
A removable aluminium gland plate shall be provided at the bottom of the panel to allow glanding of all
incoming and outgoing cables plus 20% spare capacity. There shall be a minimum of 150mm space
between the gland plate and terminals. Top entry cabling may be used only in special circumstances.
Junction boxes for use outdoors or in indoor process areas shall comply with the requirements of the
AS 1939 Standard for an IP65 enclosure. Junction boxes for use in areas where flammable vapours
may exist shall conform to the applicable electric code requirements of AS 2380.6.
Material used for junction boxes shall be either stainless steel, polycarbonate or glass filled polyester
and shall conform to the protection rating of AS 1939 for protection against mechanical impact to a
category 9.
Sufficient terminals shall be installed to terminate all cables with a further allowance of 25% spares.
Terminals shall be mounted on 35mm DIN terminal rail. Weidmuller WDU-4 terminals and ASK1/35
fuse terminals are preferred
2.2 Terminations
Each end of each wire shall be tagged with Grafoplast® or similar interlocked marker ferrules. Clip on
"C" type or adhesive fixed ferrules are not acceptable. Each terminal block shall be marked. Owner
shall approve contractor’s wire numbering system; numbering system may be altered to match plant


numbering system by Owner after review of the Contractor's first submission of drawings for approval.
All cables shall be terminated with approved, weatherproof, metallic cable glands.
Where specified, a plastic weatherproof shroud shall be fitted to each gland
Terminals for all wiring of solenoids, limit switches, etc shall be available as screw terminals. If
necessary terminated in an EX-e terminal box attached to the valve. Flying leads shall be avoided
where possible.
Sufficient terminals shall be installed to give a 25% spare capacity. Wiring ducts shall be provided
with covers and shall not be more than 75% full.
2.3 Cables
Cabling installations shall comply with AS/NZS 3000 wiring rules.
Cables carrying 4-20 mA or other analogue signals shall be sheathed electronic cable with twisted
pairs, overall screened and either steel wire armoured, or spiral wrap armoured cable.
Cable runs of one or two cables may be securely fixed to equipment structural members by saddling
with two-hole saddles at a distance of 300mm. Cable runs with more than three cables shall be
supported by stainless steel cable ladder in accordance with ESP-155 Section 6.0 Tray Design
Requirements. Galvanised steel cable ladder may be acceptable only in special circumstances.
Cables requiring additional support or protection shall be enclosed in Uni-strut or galvanised steel
screwed conduit. PVC conduit shall not be used.
To prevent ingress of water, cable entries at each device or junction box shall be arranged bottom
entry; glands shall be either nickel plated metal compression glands with close fitting PVC shrouds
applied, or purpose designed spiral wrap armoured cable glands (connectors). Cable cores shall be
terminated using electro tinned crimp type lugs.
Cables shall be identified at each end with cable markers and control cable cores shall be identified
using numbered interlocked marker ferrules.
Design of cable ladders shall ensure a minimum of 20% spare capacity. Control and instrument cables
shall be installed separately from power cables. If one cable tray is to be shared then a divider shall be
provided.
2.3.1 Power Cable

Power cables shall be 2 core and ground, 2.5 mm2 or 12 AWG, PVCSWAPVC (or spiral wrap
armoured), stranded copper, 0.6/1 kV, V75 grade insulation, black outer sheath.
2.3.2 Control Cable

Control cables shall be multicore and ground, 1.5 mm2 or 14 AWG, PVCSWAPVC (or spiral
wrap armoured), stranded copper black outer sheath.
2.3.3 Analogue Single Pair or Single Triad Cables

Single pair and single triad cables shall be twisted, screened; 1.0mm2 or 18 AWG stranded
copper conductors Bk/W or Bk/W/R PVC covered. Armoured for outside use. e.g. 1 pair
3
PVC SCR PVC SWA PVC, (or similar spiral wrap armoured cable) with grey (preferred) or


black sheath. 300 Volt rating.
2.3.4 Analogue Multipair of Multi-triad Cables

Multipair and multi-triad cables shall be multiple twisted 1.0mm2 or 18 AWG stranded copper
3 conductors Bk/W or Bk/W/R PVC covered. Individual and overall screened, a bare copper
drain and communications wire, PVC inner sheath, armoured and served with a grey
(preferred) or black PVC sheath. 300 Volt rating.
2.3.5 Digital Multiconductor Cable

Digital multiconductor cables shall be multicore and ground, 1.5mm2 or 14 AWG PVC SWA
PVC or spiral wrap armoured, stranded copper, black outer PVC sheath. White and
numbered cores.
2.3.6 Thermocouple Extension Cable

Single pair thermocouple extension cable shall have conductors of 0.5mm, 110oC PVC
insulated, solid alloy wire matched, calibrated and colour coded as per ANSI Standard C96.1.
The pair shall be twisted with an aluminium-mylar shield, bare copper drain wire, PVC inner
sheath served steel wire armour and an 110oC PVC outer jacket.
The cable shall be Olex Cables "Olex Dekoron Type IKG" or equivalent.
Multiconductor cable shall be multiple twisted, 110oC PVC insulated pairs of 0.3mm solid
alloy wire matched, calibrated, and colour coded per ANSI Standard C96.1. Each pair shall
be numbered and have an overall aluminium-mylar screen, a bare copper drain wire, a
communication wire, PVC inner sheath, steel wire armouring and a 110oC PVC outer jacket.
The cable shall be Olex Cables "Olex Dekoron Type IKH", or equivalent.
2.4 Cable Segregation

Wherever practical, analogue and discrete signals shall terminate into separate field junction boxes. In
exceptional cases where analogue and discrete signals terminate into the same field junction box,
cables and terminals shall be appropriately identified and segregated.
Signal cables to be segregated by metal barrier in any cable tray that is shared by any power cables.
2.5 Transmitters
Unless otherwise specified, electrical enclosures of the Transmitters shall conform to IP65 as a
minimum and shall be corrosion resistant.
Transmitters shall have non-interacting span and zero adjustments.
Transmitters that are located in a non-hazardous area shall be of weatherproof, dust tight and
corrosion resistant construction. Transmitters which are located in a hazardous area shall be approved
for use in such areas and shall not require the use of intrinsic safety zener barriers.
Each transmitter shall be furnished with a universal mounting bracket for 50 mm NB pipe.
Transmitters which are flange mounted shall have the flange dimensions in accordance with ANSI
B16.5 (BS 1560), - Flanges for pipes, valves and fittings.


2.6 Control Valves
Control valve sizing calculations shall be based on the estimated variable range of flow rate and
pressure drop shall be 33% of the total system friction head at design flow.
Noise level shall not exceed 85 dBA at one metre from the source. Noise calculations shall be
provided.
For nominal line sizes above 25 mm the minimum control valve body size shall be equal to or larger
than half the line size.
For nominal line sizes of 25mm and below, the control valve body size shall be line size.
All control valves 50 mm and larger shall be provided with an electro-pneumatic positioner.
Each controller shall be supplied with a supply pressure gauge and an output pressure gauge. Gauges
shall be minimum 50mm diameter, black on white, and shall be graduated in kPa.
2.7 Positioners and Actuators

Air operated actuators shall be used in all applications and designed to "fail safe" on air failure.
Positioners shall be fitted with filter/regulator, air supply gauge, air output gauge, and control air gauge.
All on-valve tubing between positioners and actuators shall be 316 stainless steel.
All exhaust ports on both the actuator and any pneumatic accessories shall be fitted with an insect
proof plug. This device shall not impair the operation of the equipment.
Rotary pneumatic actuators shall operate on a nominal 500kPa pressure and shall withstand a
maximum pressure 1000 kPa.
2.8 Telemetry
Telemetry systems shall generally be radio modem type. Wireless LAN may also be acceptable.
Radiolinx industrial hotspot 2.4GHz high speed industrial wireless Ethernet from Procom Technology is
3 used for wireless communication to the kilns and calcine transfer systems. Direct I/O wireless links
may be used for small-scale telemetry installations.
2.9 Instrument Piping

Instrument piping shall be in accordance with ISP-133, except that 316SS tube and Swagelok
compression fittings shall be substituted for copper tube and brass tube fittings.
2.10 Instrument Manifolds

Three valve, stainless steel manifold systems shall be used on all differential pressure flow metering
systems.
Where appropriate, manifolds shall have a mounting bracket which enables the manifold to be
mounted to a 50mm diameter pipe support and then support instrument, enabling removal of
instrument without any disturbance to manifold and instrument tubing
2.11 Instrument Process Tapping

Impulse lines from the process take-off up to and including the process shut-off valves shall conform to


the specifications for the lines or equipment to which they are attached. The process line take-off shall
not be less than diameter 15mm pipe up to the process shut-off valve. Beyond the valve and up to the
instrument valve the connecting lines shall be diameter 15mm or larger pipe, or 1/2 inch O.D. stainless
steel tubing, and stainless steel compression fittings, grade 316.

3.0 MEASUREMENT
All flow measuring devices shall have the facility to incorporate a locally mounted analogue or digital
indicator, preferably integral with the transmitter.
All gauges shall be provided with protection against damage by over-pressure up to 1.3 times maximum
scale reading.
3.1 Flow Measurement

Orifice plate metering shall be designed in accordance with British Standard B.S.1042.
Orifice plates shall not be used on line sizes less than 50 mm.
Where orifice plate measurement is employed, the style of plate shall be square edge concentric
orifice assemblies with flange taps. Installation requirements for the assembly shall be in accordance
with ISO 5167.
All orifice plates shall be manufactured from high-grade stainless steel suitable for the process
environment. The tag of the plate shall be installed vertically in the line, unless the line itself is
vertical. Unless otherwise specified flanges shall comply with ANSI B16.5 (BS 1560), - Flanges for
pipes, valves and fittings.
Magnetic flow meters shall be the preferred methods of measuring flow in liquid slurries.
All magnetic flow meters shall be suitable for flange mounting into the process line.
Area, target, turbine and vortex flow measurement may be acceptable dependant on application.
3.2 Level Measurement

Ultrasonic level transmitters shall be the preferred method of measuring the level of liquids and solids
in open vessels.
Displacement transmitters shall not be used on systems where solids may settle out in the chamber.
3.3 Temperature Measurement

Temperature measurement shall either be thermocouple or RTD. Temperature elements may be
3 cabled directly to suitable controller input modules, or have field mounted transmitters which provide a
linear 4-20 mA output.
For measuring temperatures that are greater than 400oC, the primary elements shall generally be
thermocouples. Chromel-Alumel (Type K) thermocouples shall be used in preference to other types.
Thermowells shall be used for all temperature measurement installations.
Platinum Resistance Bulbs shall be used for temperatures below 400oC, for all differential
measurement and where high accuracies are required. A three lead platinum element of 100-Ohm
resistance at 0°C shall be standard.
Filled systems shall be limited to locally mounted controllers and pilots.
The preferred type of locally mounted indication for temperatures shall be bimetallic type thermometer.


All thermocouple assemblies shall be ungrounded.
3.4 Pressure Measurement
For corrosive or slurry applications diaphragm seals shall be provided.
For pulsating service adjustable dampener shall be provided.
Case material shall be of non-corrosive material.
Pressure ranges should be selected so that the normal operating pressure will be between 50% and
70% of full-scale range.
3.5 Density Measurements

The preferred method of density measurement shall be coriolis type density meters. Where pricing or
other factors preclude use of coriolis meters then nuclear type density meters may be used.
3.6 Analysers
Where analysis measurement equipment is supplied, design details and selection criteria must be
submitted for approval prior to final detail design.
Sample systems where applicable shall be designed to suit the application and details submitted for
approval prior to final design.
Field mounted analysers shall be of corrosion resistant material, weatherproof construction and
suitable for outdoor installation.

4.0 CONTROL PARAMETERS

The basis control philosophy shall be to design a plant system that can interface process controllers,
motor controllers, motor protection, supervisory and high level management systems, such that all
information can be gathered into a central system for control, monitoring, modelling, archiving and
management purposes.
The method of centralising information at control rooms shall be through a network of communication
highways and not hard wiring.
Hard wiring of control signals shall not be allowed in control rooms except for safety requirements.
Design, installation and commissioning of the Process Control System shall be in accordance with one
of the following PT Vale Indonesia Instrumentation and control system standard(s):
3 For additions to existing PLC5 platforms:

ISP-310 PLC Based Motor and Analogue Control System Design Guidelines
For new or existing ControlLogix platforms: 2
ISP-024 PT. Inco PLC Hardware
3 ISP-025 PT. Inco PLC Programming
ISP-026 PT. Inco HMI Configuration
4.1 Communications
Digital electronic communications between control system components where used shall be of the
following types unless otherwise specified:
HART
ODVA DeviceNet
Modbus 2
Rockwell ControlNet for communication between ControlLogix IO racks
3 Ethernet IP for HMI communications or data logging
Allen Bradley remote I/O (RIO) for communication between PLC5 IO racks
Allen Bradley data highway plus (DH+) for PLC5 and SLC5 peer-peer
communications
4.2 Interlocking
All interlocks shall be implemented on the controller except for safety interlocks and specifically
identified interlocks that require direct hard wiring into the motor control circuits, or circuit breaker trip
circuits etc.
The process controller based interlocks that need to be active for both local and remote modes of
operation need to be terminated in the control circuit, preferably upstream of the local start/stop switch.
4.3 Diagnostics
Process controllers shall have diagnostic capabilities to detect communication, hardware and software
failures and shall be able to report the failures via an operator station.
It shall be possible to repair or replace faulty controller hardware without affecting system operation.
Back up systems including communication shall be continuously tested for faults.

5.0 NUMBERING SYSTEM

All instrument equipment used in the project shall be allocated an instrument loop number from a master
loop number list administered by Central Engineering Department. Individual instruments are allocated a
unique instrument tag number that is used as identification in documentation including data sheets,
instrument index, for process and instrumentation drawings, and physically on the instrument itself.
An instrument index listing all instrumentation equipment within its associated plant area shall be
prepared with allocated instrument tag numbers and progressively updated during the design period.
Cable numbers for individual instrument cables are based on the instrument loop number of associated
loop(s). Field junction boxes are also numbered based on the loop number of one associated loop, even
where cables for more than one loop share the junction box.
5.1 Area Numbers

Plant areas are identified by two digits. Plant sub-areas are identified with three digits, the first two of
these digits identify the plant area, and the final digit identifies the particular process line (or unit)
within the plant area. When no sub-areas exist the third digit defaults to zero. Refer to Table 6.1
5.2 Equipment Numbers

The format for equipment numbers shall be as specified in PT Vale Indonesia Maintenance Planning
Manual Rev 01 dated Feb 01 1982, and any subsequent amendments. On receipt of a request
supported by adequate information, the equipment numbers are allocated by one of four designated
people each responsible for one of the following plant areas:
(i) MEM / Mining (ii) Utilities (iii) Process Plant (iv)Town
5.3 Loop Numbers

Loop numbers are allocated from the PT Vale Indonesia instrument loop list administered by Central
Engineering Department. A single loop number may be common to a group of closely related devices
(generally) associated with the same process variable and representing one ‘control loop’.
The format of all instrument loop numbers shall conform to the following standard:
AAPLL Example: 241J5
Sequential ‘number’
Process line (Numeric)
Area Identifier (Numeric)
Up to 359 sequential ‘numbers’ for each area/process line are allocated sequentially as needed:
3 01, 02, 03, …….. 98, 99, A1, A2, … A8, A9, B1 …. B9, C1 … C9, ………... Y1, … Y9.
Where the total number of allocated loops for any area/process line exceeds 350, one of two methods
3 may be used to assign additional loop numbers – see below. Method (i) is preferred, however method
(ii) is also used (e.g. Furnace 3) but is not preferred, and should not be newly adopted elsewhere. Use
of the letters: I , O , Q , S, and Z should be avoided to a prevent confusion with numbers 0,1,2 and 5.
3
3 (i) Subsequent to Y9, use 1A, 1B, 1C …. 1Y, 2A … 2Y, …………….. 9A ..9Y.
(ii) An additional 6th character (letter) may be added to the end of the loop number.

Generally a block of consecutive loop numbers is assigned to the project engineer or consultant for
allocation on a specific project. The project engineer or consultant is then free to allocate numbers
within the assigned block to project related loops within the specific area/process line. For wide-
ranging projects, blocks of loop numbers for a number of different area/process lines may need to be
assigned.
5.4 Tag Numbers

For the purpose of identification, all instrumentation devices (whether in hardware or software) shall be
assigned a unique instrument tag number. The instrument tag consists of functional identification
letters followed by the relevant loop number, and separated by a hyphen. Functional identification
letters are to be assigned as per the relevant sections of ISA-S5.1 1984 (R1992) “Instrument Symbols
and Identification”. Where two or more devices would otherwise have identical instrument tag
identifiers, a suffix letter (A, B, C, etc) shall be added to ensure the tag for each individual instrument
device is unique.
The format of all instrument tag numbers shall conform to the following standard:
FFF - AAPLLS Example: TIT-24164
Functional Identification (Letters)

(Minimum of two, maximum of four)
Process line (Numeric) Loop No.
Sequential number (01-Y9)
3
Suffix (letter) (Only when needed)
Once new instrument tag numbers have been selected, they are to be submitted to P.T. Inco for
approval registration, either in the form of an instrument index or detailed on the relevant Piping & 3
3 Instrumentation Diagram for approval. See section 10.1 for instrument index format.
Functional Identification: As shown on instrumentation legend drawing. 000-637-I
5.5 Junction Box Numbers

Junction box location numbers shall be formed by appending “– JBx “ to the associated loop number,
3 (or appending “ – OJB” in the case of simple optical fibre junction boxes), where x = Sequential 3
number (1, 2, 3 etc as required).

Table 6.1 Abridged List of Plant Areas and Process Lines
AREA (AA) PROCESS LINE (P) AAP

00 Standards 0 Standards 000
0 Screening Station No. 9 190
1 Screening Station No.10 191
19 Screening Stations
2 Screening Station No.11 192
3 Petea Service Centre 193
1 Dryer No. 1 221
22 Rotary Dryers 2 Dryer No. 2 222
3 Dryer No. 3 223
1 Dry Ore Storage No.1 231
23 Dry Ore Storage
2 Dry Ore Storage No.2 232
1 Reduction Kiln No.1 241
24 Reduction Kilns 3 Reduction Kiln No.3 243
25 Sulphur Handling 250
26 Stacks 260
27 0 Raw Coal Supply 270
3 Coal Handling 1 Coal Mill No. 1 271
2 Coal Mill No. 2 (Future) 272
1 Electric Furnace No. 1 311
31 Electric Furnaces 3 Electric Furnace No. 3 313
4 Furnace Common Systems 314
1 Converter No. 1 321
Converter, Hot Metal 2 Converter No. 2 322
32 Crane, Product Drying & 3 Converter No. 3 323
Handling 4 Product Handling 324
5 Converter No. 4 325
33 Flux and Scrap 330
45 Power Distribution 450
47 Fuel / Diesel Oil Storage 470
52 Fuel Oil Transfer HSFO System 520
53 Water Treatment 530
54 Cooling Tower 540
56 Diesel Generation Plant 560
57 Service / Instrument Air 570
62 Balantang 620
64 Matano Pump 640
65 Mangkasa Point 650
80 Hydro General 800
0 Common 810
2
81 Hydro Larona
1 Unit 1 811

2 Unit 2 812
3 Unit 3 813
4 Auxillary 814
5 Switchyard 815
6 Dam 816
7 Canal & Penstock 817
0 Common 820
1 Unit 1 821
2 Unit 2 822
2
82 Hydro Balambano 4 Auxillary 824
5 Switchyard 825
6 Dam 826
7 Penstock 827
0 Common 830
1 Unit 1 831
2 Unit 2 832
2
83 Hydro Karebbe 4 Auxillary 834
5 Switchyard 835
6 Dam 836
7 Penstock 837

5.6 Cable Numbers

Cable numbers are assigned in a manner dependent on whether the cable is deemed to be for
‘electrical’ or ‘instrumentation’ use, and also according to the cable service. Each cable number shall
be unique.
5.6.1 Individual Loop Cable

Cable tag numbering assignment for instrument wiring of loop diagrams is based on the loop
number and shall be as follows:
ZAAPLL - CXX Example: Z24401– C02
Z = Instrumentation Cable
Area Number
Process line No. Loop
Number
Sequential No.
C = Cable, R = Raceway or Conduit.
Sequential No.
5.6.2 Multiple Loop Cable

Cable tag numbering assignment for general instrument cabling between a marshalling
cubicle or junction box and an instrument panel (or PLC) shall be as follows:
ZNNNN – CXX Example: ZK205 – C05
Z = Instrumentation Cable
Instrument Panel No.
Sequential No.
In the example above, an abbreviation (K205) of the full panel number IC-K2-05 has been
used.
5.6.3 Communication Cable

Cable tag numbering assignment for special cables such as communication cables between
Instrument Panels and/or PLC cabinets shall be as follows:
ZAAP – CXXX Example: Z310– C300
Z = Instrumentation
Area Number
Process line No. (Default 0)
Sequential No.


5.6.4 Control Networks Communication Cable

Cable tag numbering assignment for control networks cables such as used for the
communication protocols Devicenet (DN), Controlnet (CN), Profibus (PB), Modbus (MB),
3 Ethernet (EN), Remote I/O (RIO) and Data Highway (DH) shall be as follows:
ZAAP-CCCC-TTN-CXX Example: Z310– F1FPC-CN1-C10
Z = Instrumentation
Area Number (The most relevant area)
PLC Name (Omit if not relevant)
Comm. Protocol Type (DN, CN, PB, etc)
Network sequential No. for PLC CCCC
C=Cable, R = Raceway or Conduit.
Sequential No. (2 or 3 digits)
Note that the cable media (copper or fibre) is not specifically identified by the cable tag
number
5.6.5 Electrical Cable

Cable tag numbering assignment for ‘Electrical’ hardwired motor power and control circuits
shall be as follows:
HXMXX – CXX Example: H1M05– C12
Motor Control Centre No.

Motor No. (Expand to 3 digits if necessary)
Sequential No.
5.6.6 Power Supply Cable

Cable tag numbering assignment for power supply circuits from distribution boards or power
panels shall be as follows:
HXPPX – CKTX – CXX Example 1: H1PP05 – C12

Example 2: H1PP05 – CKT5 – C12
Name of DB or Power Panel.

CKT = Circuit (Optional)
DB or PP Circuit No. (Optional)


Sequential No.
5.7 Wire Numbers

5 5
5.7.1 Digital Signal

For digital signals, wires are tagged by its instrument tag number at both ends of the cable
(including junction box if any), with suffix of the instrument’s / device’s contact position (C and NO/NC).
Example:
XV-24401(C)
XV-24401(NO)
XV-24401(NC)
5.7.2 Analog Signal

For analogue signals, wires are tagged by its instrument tag number at both ends of the cable
(including junction box if any), with suffix of the instrument’s polarity, i.e. (+/-) and/or (+P/-P).
Example:
a. Two-wires instrument:
PIT-24401(+)
PIT-24401(-)
b. Four-wires instrument:
FIT-24401(+P)
FIT-24401(-P)
FIT-24401(+)
FIT-24401(-)
For some instrument such as RTD that doesn’t have polarity, the suffix shall use its wire colour
abbreviation according to IEC 60757.
Example:
TI-24401(BK)
TI-24401(RE)
TI-24401(WH)
5.1 Wire colour abbreviation according to IEC 60757
Wire Colour Abbreviation according to

IEC 60757
Black BK
Brown BN
Red RE
Orange OG
Yellow YE
Green GN
Blue BU
Violet VT
Grey GY
White WH
Pink PK
Turquoise TQ
5.8 Instrument Panel Numbers


For the purpose of identification, all instrumentation panels shall be assigned a unique panel number.
For the purpose of this definition, ‘instrument panels’ includes instrument equipment cubicles, PLC
cabinets, control panels and control room operator desks. The instrument panel numbers are allocated
from the PT Vale Indonesia instrument panel register administered by Central Engineering
Department.
The format of all instrument panel numbers shall conform to either of the following standards:
IC-AAP-XXS Example: IC-310-11
IC = Instrument Cabinet
Sequential number (01-99)
Suffix (letter) (Optional - not preferred)
IC- MM-XXS Example: IC-K2-05
IC = Instrument Cabinet
PLC or Plant Identifier
Sequential number (01-99)
Suffix (letter) (Optional - not preferred)
5.9 Marshalling Cabinet Numbers
Marshalling cabinets shall be numbered as for instrument panels.
5.10 Optical Termination Board Numbers
Optical termination board cabinets or enclosures installed for termination and routing of fibre optic
3 cabling shall be numbered as for instrument panels except that the letters OTB should be substituted
for the letters IC in the number. Optical termination board sequential numbers shall be allocated from
the PT Vale Indonesia instrument panel register administered by Central Engineering Department.
For the procedure for numbering simple optical fibre junction boxes installed to serve individual loops
or individual minor devices see section 5.5 Junction Box Numbers.
Note that previously at PT Vale Indonesia fibre optic cable termination panels were numbered WIC-
AAP-X. This numbering system shall be discontinued.

5.11 PLC Address Numbers

The following physical connection point address identification is defined for PLC equipment at P.T.
Inco.
Allen Bradley PLC5 Series
Analogue Address Point AXRRBD

Special Input Address Point SSSRRBD
3
Digital Address Point XRRBCC
Where A signifies an analogue signal

X = I/O type (I for input, O for output)
RR = Rack
B = Slot
CC = Bit
D = Channel (1 through ?)
SSS signifies input type: TC = Thermocouple type K
TCR = Thermocouple type R
3 TCS = Thermocouple type S
RTD = PT100 RTD
Rockwell ControlLogix Series
Analogue Connection Point AXRRBBD

3 Special Input Address Point SSSRRBBD
Digital Connection Point XRRBBCC
Where A signifies an analogue signal

X = I/O type (I for input, O for output)
RR = Chassis
BB = Slot
CC = Bit
D = Channel (0 through ?)
SSS signifies input type: TC = Thermocouple type K
TCR = Thermocouple type R
3
TCS = Thermocouple type S
RTD = PT100 RTD
SI = Speed Input (Frequency)
See ISP-024 PT. INCO PLC Hardware standard procedure for cable marking formats

6.0 DRAWINGS
English language and SI units of measure shall be used on drawings. The instruments and
instrumentation systems shall be identified by a system of letters, numbers and basic pictorial symbols.
The standard symbols and identification accepted by PT Vale Indonesia as standard are ISA-S.5.1 -
1984 (R1992) and ISA-S5.3 – 1983 issued jointly by ISA and ANSI. An abridged chart of symbols and
identification is given in Drawing 000-637-I P&ID Instrument Legend.
Drawings are to be submitted as drawing files on compact disk.

3 Final drawings are to be A1 or A3 size with minimum 2.5mm high lettering.
6.1 Drawing Title and Number Format

PT Vale Indonesia drawing numbers are allocated by the Central Engineering Department and shall be
included in the title block of all drawings whether produced by PT Vale Indonesia or by a consultant.
The title block of each drawing should conform to the following format:
Title Block Description

Line #1 Plant Area Description
Line #2 Keyword (from list)
Line #3 Drawing description
DRAWING TITLE DRAWING NUMBER REV
<PLANT AREA DESCRIPTION> AA0-XXXX-D

<KEYWORD> R
<DRAWING DESCRIPTION> CAD FILE NO: AA0XXXXD
Notes:
1 For an abridged list of plant area descriptions see Table 6.1
2 Drawing numbers use the area digits AA followed by 0, unless specified otherwise
3 For approved keywords – see PT Vale Indonesia Engineering Drawing Control Procedures in
“Engineering System Manual”
4 D is a discipline identifier: M - Mechanical, E - Electrical, C - Civil, I - Instrumentation, V -
Vendor
6.1.1 Drawing Number

Drawing numbering shall comply with the protocol below.
XXX-XXXXX-X
Discipline Identifier
C = Civil
M = Mechanical
I = Instrumentation
E = Electrical
V = Vendor
Sequential number – assigned by Lead Designer

Plant area number (from list)


NOTE: The Area number and the sequential number form the unique drawing identifier. The discipline
identifier is only for classification.
6.1.2 Keyword
P.T. Inco requires the following instrument drawing classes to be submitted in CAD format using
AutoCAD 2000 - (or later version of the program).
Piping & Instrumentation Diagram

Block Cabling Diagram
Interconnection Diagram
Instrument Loop Diagram
Instrument Equipment Layout
Instrument Installation Detail
Conduit & Cable Tray Plan
6.2 Piping & Instrumentation Diagram

The purpose of the P&ID is to convey the overall process equipment arrangement and control
philosophy to all personnel concerned.
All instrumentation hardware devices whether monitored and/or controlled by the control system or not,
shall be identified on the P & ID with an appropriate symbol, containing the instrument tag number.
The interlock symbol shall be shown to identify critical equipment interlock requirements.
Each P & ID shall have a similar format with the extreme right hand portion of the drawing dedicated
to:
Legend
Notes
Reference drawings
Reference drawings shall include those that are pertinent to the P & ID such as:
Process Flow Diagrams
Continuation or associated Piping & Instrumentation Diagrams
P&ID Legend Diagram
When it is necessary to assign a non – standard symbol, the symbol shall be shown on the P & ID with
a verbal description shown in remarks column.
The unclassified instrumentation function identification symbol “X“ shall be used as shown in the
instrumentation legend diagram. 000-0637-I.
6.3 Block Diagrams

Block diagrams show details of all cabling between control system devices. Cable termination details
are not shown.
6.4 Interconnection Diagrams

Interconnection diagrams depict all cabling and termination for motors, disconnect switches,
pushbuttons, control panels, junction boxes, and any other field devices that require wiring


connections. Internal wiring that is show on a vendor’s drawing would not be duplicated on an
interconnection diagram.
Typically, a block outline would be used to indicate the device enclosures. Inside, all necessary wire
termination points such as: terminal block and switch contacts on motor terminals would be shown with
any related numbering or identification that would be present.
All cables entering the device enclosure are identified using the cable number as described previously,
and are referenced as required if both ends of the cable are not present on the same drawing. All of
the individual wires from each of the cables are then shown connected to their appropriate termination
point within the enclosure. When the wire and its corresponding connection point do not have the same
identification number, it will be duly noted and clarified.
6.5 Instrument Loop Diagram

The loop diagram is an extension of the Piping and Instrumentation Diagram (P & ID). The loop
diagram shall show all components that make up the loop. All cabling, terminations and
interconnection wiring shall be shown. Special requirements such as safety shall be highlighted.
Line symbols and device symbols used on instrument loop diagrams shall generally be in accordance
with ISA-S 5.1.
A loop diagram normally should show only one loop; however loops of a similar type, or loops on the
same piece of equipment, can be shown on the same drawing. The drawing must not be crowded, that
is, space must be provided for future additions and loop data.
3
3 NOTE: The PT Vale Indonesia standard loop diagram format (drawings 000-8444-I through 000-8449-I)
is not a true loop diagram since details of multiple loops are shown on a single drawing. Therefore for
PTI standard loop drawings the drawing title block often does not include the loop numbers or loop
descriptions.
6.5.1 Content
Each loop diagram shall:
Show all instruments, switches, lights, relays, terminals, junction boxes, etc.
associated with the loop.
Show process, field equipment, marshalling cabinet and control system wiring
arranged from left to right.
Identify all single wires and multi-conductor cables by numbers related to their
function.
Identify all energy sources, electric, pneumatic and hydraulic.
Show failsafe position of valves.
Show any units of measure in accordance with the SI system.
6.5.2 PT Vale Indonesia Format

Loop diagram format shall be detailed as shown on PT Vale Indonesia standard loop diagram
templates listed below.
000-8444-I PLC Analogue Input
000-8445-I PLC Analogue Output
3 000-8447-I PLC Temperature Input PT100 RTD
000-8448-I PLC Temperature Input Thermocouple type K
000-8449-I PLC Temperature Input Thermocouple type R or S


Note these standard loop drawings templates shall be copied, revised to reflect new
instrument installations, then saved with new titles and drawing numbers.
In several respects the standard PT Vale Indonesia loop diagram deviates from international
standards such as ISA-S5.1-1991 since the PI Inco drawing customarily shows more than one
loop, and the drawing title describes the location of the controller input/output hardware rather
than describing the loop(s) detailed.
6.5.3 ISA Format

Loop diagrams shall follow standard ISA-S5.4-1991 Instrument Loop Diagrams.
Customarily each drawing shall have one loop only.
For multiple loops, two loops per drawing shall be considered.
6.6 Conduit, Tray, & Cable Plans

These drawings represent the method of routing all conduit, tray and cable through the plant to the
proper destinations as described on the conduit and cable schedules.
In general, routings are shown diagrammatically and are not dimensioned unless clearances are critical
or exact installation procedures are critical. Field devices are located as accurately as possible on the
drawings, but final placement is to be determined by using the appropriate vendor or mechanical detail
drawings and any obvious field conditions. Cables to all pieces of equipment are shown and identified
using the same cable numbers as previously described, and are routed through the tray system via tray
fill sections which list all cables contained in the selected section of tray.
Tray sizes, try fittings, junctions boxes, pull boxes, and any other field device that requires installation
or cable connections are shown on the plan drawings along with any necessary vendor or catalogue
information.
Sections, elevations and details are used to clarify any area of plan drawing that could be confusing to
the installer.
6.7 Instrument Location Plans

In general, specific drawings for the location of instrument are not to be made. The electrical “conduit,
tray and cable plan“ drawings show the junction boxes, and cable connections to electrical and
electronic instruments.
The location of a specific instrument is determined by one of the following:
Piping or Ducting Drawings:

Instruments that are in-line such as a control valve, flow meter, etc. or local (such as a
pressure transmitter connected by tubing or piping to a pipe or vessel).
Vessel or Bin Drawings:

Provide information for that instrument that would not appear on piping drawings.
Vendor Equipment Drawings:

Instrument may be inline or local (such as skid mounted hardware).
Special Instructions:
Area safety monitors such as CO analysers for example, are located initially by the project
instrument personnel subject to approval by PT Vale Indonesia.


6.8 Instrument Installation Details
Standards installation details shall be selected when ever possible.
These generic drawings shall shown mounting and connecting requirements
The details shall identify if an instrument (i.e. pressure transmitter) must be mounted above or below
the process pressure tap.
When a standard detail is not applicable, a special detail shall be provided.
Process analysers for example, often require extra mounting details, other than those supplied by the
analyser manufacturer.
Sometimes, for reason of accessibility and ease of maintenance, details should show instruments in
locations distant from their connections and/or grouped on a platform.
The installation details are a guide for field construction personnel; therefore these details can be
altered if necessary by authorized supervision.
6.9 Drawing Revisions

When drawings are issued for P.T. Inco approval, the revision description will be identified as:
Rev. A For Approval
If subsequent revisions are made to a drawing that has not yet been approved, the next revision will be
identified as:
Rev. B For Approval
Rev. C Etc. Etc
After as-building all previous revision symbols shall be removed and the first will be identified as:
2
Rev. 0 Asbuilt
As future as-built revisions occur, the as-built revisions will be identified as Rev. 1, 2 etc. With each
revision, the actual change and/or addition made on the drawing shall be encircled, and marked with
1
the numbered revision symbol shown as

7.0 DOCUMENTATION
All documentation shall be in English language, and shall use SI units of measure.
7.1 Bill of Material
The bill of material form included in the Sample Attachments is presently prepared in Microsoft Word.
BOM prepared using other software applications are acceptable so long as all the required information
is presented clearly.
The Bill of Material format includes fields for the following information:
Drawing Number(s) of drawing(s) to which the Bill of Materials is associated

Item Number
Quantity
Unit of Quantity
Item Description
PT Vale Indonesia Warehouse Stock Code
Materials Requisition (MR) or Purchase Order (PO) Number
Bill of Materials number and sheet number
Engineering Work Request (EWR) number or project number.
The Bill of Material number is assigned as follows:
Alt 1: The Bill of Material number is equal to the drawing number to which the BOM is
associated, or the first drawing number if more than one drawing is associated.
Alt 2: The Bill of Material number is not equal to the drawing number, but is equal to the
engineering work package (EWP) number, or similar relevant number.
7.2 Functional Description

The P&ID‘s will not necessarily show all details of the complete closed loop control as implemented by
process controller. The functional description expands upon the details shown on the P&ID providing a
thorough and detailed description of the proposed control system configuration. All details necessary
for successful programming of the control system must be included in the functional description
document.
The functional description also serves as a means to both consult and inform operations personnel
about the proposed control system configuration. Samples of proposed MMI graphic displays should
be included with the functional description.
In some circumstances the nature of the control system configuration may be such that the control
strategy is more effectively communicated by means of logic diagrams. In such cases logic diagrams
may supplement, or substitute for the written functional description.
7.3 Logic Diagrams

If a complex hard-wired relay system, programmable controller or some other kind of digital system is
to be applied, flow charts and/or logic diagrams shall be prepared if there is involved interlocking and
sequencing.

If drawings are required for approval or construction, the first sheet of the flowcharts and/or logic
diagram shall contain a legend explaining the symbols used.
The above diagrams shall be in accordance with software documentation standard ISP-023. The
preferred basis for logic diagrams is: ANSI/ISA-S5.2-1976 (R1992), “ Binary Logic Diagrams for
Process Operations“.
7.4 Instrument Index

The instrument index shall list details and reference information for each instrument item whether a
physical device of software device. The preferred column headings and order of columns is set out
below. This information should be supplied as a Microsoft Excel electronic spreadsheet file (or
compatible electronic file type) to help facilitate the relevant final information being pasted into PT
Vale Indonesia plant-wide instrument list.
Column Heading Explanation

A Device * Functional identification (letters) of an item
B Loop Number * The loop number with which an item is associated
C Service Description of service (Loop Title)
D P&ID Drawing number of P&ID associated with an item
E Device Description Description of device (such as "Pressure Indicator")
F Manufacturer Name of equipment manufacturer
G Model / Element Type Manufacturer’s model number / device type
H Range / Unit Calibrated instrument range and units (SI)
I Output Signal The nature of the output signal from the device
(E.g. 4-20mA or 20-100kPa or NO contact)
J Loop Diagram Number of loop Diagram associated with an item
K Spec / EWR Number Specification number under which item was specified
L Remarks Space for any notes or remarks relating to an item
M Supply Type and magnitude of energy supply to the item
(E.g. 24VDC or 220VAC or 140kPa)
3
N Users Choice 1 Suggestion: MR / PO number

O Users Choice 2 Suggestion: Location
P Users Choice 3 Suggestion: Location Drawing No.
Q Users Choice 4
R Users Choice 5
* The instrument tag for each item is formed by concatenation of the device functional
identification, a hyphen, and the loop number.
As an alternative to preparing an instrument index, for smaller projects the same information may be


supplied on PT Vale Indonesia instrument data sheets, one instrument per page. A sample is included
in the Sample Attachments.
7.5 Instrument Data Sheets

Standard ISA type instrument data sheets shall be completed. The data sheets shall be used in
conjunction with instrument specifications and shall become part of the specification for the purpose of
procurement. An abridged list of existing PT Vale Indonesia instrument specifications is included in
Section 1. Where new specifications are required extra to those existing, a new specification number
will be assigned by PT Vale Indonesia Central Engineering Department.
7.6 Cable Schedule

The cable schedule form included in the Sample Attachments is presently prepared in Microsoft Excel.
Cable schedules prepared using other software applications are acceptable so long as all the required
information is presented clearly.
The Cable Schedule format includes columns for the following information:
Row Number
Cable Number
Cable Type
From Location
To Location
Loop Diagram Number - 1
Loop Diagram Number - 2
Interconnection Diagram Number
Work Package Number
Estimated Cable Length
Where the project interconnection diagrams do not identify cable core colours (or core numbers) then
the cable schedule shall have rows/columns additional to those listed above, to clearly identify the
termination point for each core at both ends of the cable
7.7 Operating, Maintenance and Installation and Commissioning Manuals

The operating manual shall include a functional description of the plant and equipment for all operating
modes.
The maintenance manual shall supply all information needed for servicing and repairing equipment.
This shall include all relevant vendor information.
The maintenance and commissioning manual shall give complete instruction and procedures so that
the plant can be started up in an orderly and safe fashion and be brought to design operating capacity
7.8 Spare Parts Listing

A list of the spare parts and consumables required for the commissioning of a plant at a remote site
and its subsequent operation for two years shall be supplied for all equipment and systems.
7.9 Input/Output (I/O) Lists


These shall list all instrumentation and electrical device signals connected to the control system input
and output hardware, both analogue and discrete. The information to be included on the I/O list for
each I/O point includes the controller identification, instrument tag number (or other device number if
not an instrument), and the physical location where the instrumentation is connected to the control
system.
I/O lists are to be prepared for each control system to show the required information. The lists will be
used to:
Summarize all signals, for the purpose of purchasing I/O hardware
Provide summary data to use in making termination drawings
Provide programmers with programme addressing information
A separate I/O list is to be prepared for each controller. Each list is to include one record for each
connected signal. Each record shall contain the following information.
Instrument tag number or other device number (Eg motor No.)

Processor I/O physical connection point address
Signal description
Signal type (usually AIN, AOUT, TCIN, DIN, DOUT, COMM, Pulse Count)
Signal range (220VAC, 24VDC, 4-20mA, TC type K, PT100)
For DIN and DOUT, description of the ON state
Model name or number of processor input or output module
Controller tag/data table address if different from the physical connection point address
MMI tag/point name if different from the physical connection point address
I/O lists are to be submitted to PT Vale Indonesia Central Engineering Department as a printed report,
and also as electronic files on compact disc. Standard application files are required, such as Microsoft
Excel or compatible files.

8.0 SAMPLE ATTACHMENTS

Bill of Material sample format
Controller I/O List
Cable Schedule
Instrument Index
Instrument Data Sheet
Instrument Calibration Sheet
3 Loop Diagram templates 000-8444-I, 000-8445-I, 000-8447-I, 000-8448-I and 000-8449-I..
P&ID Legend 000-0637-I

ISP003 Rev 5 - Instrumentation Design &amp; Documentation

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PT.

VALE INDONESIA, TBK

ISP-003 Instrumentation Design & Documentation

Instrumentation Design & Documentation

5 19 Nov 2019 Add wire numbering standard LA YNR TP

4 13 Aug 2009 General Revision CRM JH MA

3 5 Dec 2008 General Revision CRM AS MA

2 18 Sept 2006 Allow for Utilities tag naming standards JH CRM MH

1 20 Oct 2004 General Revision of Project 105 ISP-2 CRM MM MH

ISP003 Rev 5.doc

ISP-003 Instrumentation Design & Documentation

1.0 ............................................................................................................................................ GENERAL 1

2.0 ............................................................................................................... EQUIPMENT PARAMETERS 7

4.0 ...................................................................................................................CONTROL PARAMETERS 14

ISP003 Rev 5.doc

ISP-003 Instrumentation Design & Documentation

5.0 ........................................................................................................................ NUMBERING SYSTEM 15

6.0 ......................................................................................................................................... DRAWINGS 25

7.0 .............................................................................................................................. DOCUMENTATION 30

8.0 ................................................................................................................... SAMPLE ATTACHMENTS 34

ISP003 Rev 5.doc

ISP-003 Instrumentation Design & Documentation

1.2 PT Vale Indonesia Standard Specifications

ISP No. Rev Date Title

ISP-003 Instrumentation Design & Documentation

1.3 PT Vale Indonesia Standard Instrument Installation Details

Drawing No. Rev Title

1.4 Hazardous Areas

AS/NZS 3000 Wiring Rules

3 Where appropriate, instrumentation equipment installed in hazardous areas shall be certified, by

Hazardous areas shall be defined on site layout drawings.

ISP003 Rev 5.doc Page 2 of 30

ISP-003 Instrumentation Design & Documentation

1.5 Engineering Units

The base conditions shall be:

Temperature => 0°C

Table 1.1 SI Units for Common Instrumentation Parameters

ISP003 Rev 5.doc Page 3 of 30

ISP-003 Instrumentation Design & Documentation

ISP003 Rev 5.doc Page 4 of 30

ISP-003 Instrumentation Design & Documentation

Instruments shall withstand over-range inputs equivalent to 300% of maximum span.

1.6 Power Supplies

1.6.1 A.C. Powered Instruments

Each item of equipment shall be protected by a separate fuse or circuit breaker.

1.6.2 D.C. Powered Instruments

1.6.3 Instrument Signals

Instrument signals shall be as follows;

1.7 Air Lines

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ISP-003 Instrumentation Design & Documentation

1.8 Colour Coding

1.8.1 Control Panel Wiring

1.8.2 Thermocouple Extension Wire

1.8.3 Direct Current Signal Cable Pairs

1.8.4 Power Wiring

1.8.5 Control & Indication

ISP003 Rev 5.doc Page 6 of 30

ISP-003 Instrumentation Design & Documentation

ISP003 Rev 5 - Instrumentation Design & Documentation

ISP003 Rev 5 - Instrumentation Design & Documentation

ISP003 Rev 5 - Instrumentation Design & Documentation