INSTRUMENTATION PROJECT

SPECIFICATION AND DESIGN

CORE OF INSTRUMENTATION
Field Instruments

FGD system

Controller (DCS, PLC,

Facility Security Control

Safety PLC)
Final elements
Instrumentation cabling
Safety instruments

System &
Communication System
and CCTV

Field Instrument
Analog measurement :
Level, pressure, temperature, mass or volume flow,

analitycal, vibration, speed measurement.

Field electronic instruments & Field instrument
gauges
Digital measurement :
Pressure, flow, & level switch
Environment enclosure NEMA 4x ~ IP65 (For all field instruments)

Field Instrument
Explosion enclosure (for field electronic instrument)

Suitable for Flame proof Class I Zone I : Ex d, except for

vibration sensor, Ex nA (Non sparking Clas I Zone 2)

SIL requirement

Minimum SIL-2 certified for all field instruments in

process area of Ammonia plant, Urea plant, & Gas
metering station

Field Instrument

All process transmitter are electronic 4 20 mA

SMART Hart protocol

Field Instrument
EMI & RFI protection (source : HP, radio,etc)

Field strength of minimum 10V/cm over the band

frequency of 30MHz 1 GHz
Lightning protection

Completed with individually

built-in lightning surge
arrester

Field Instrument
Harsh environment protection

All field instruments covered with individual

protection box, solar radiation resistant, with glass
window

Process connected instrumentation

min. SS316

Controller (DCS, PLC, Safety PLC, Anti surge control,

Performance control, Machine monitoring, FGD control
Controller
DCS controller for Ammonia, Urea, and Service

unit
Safety PLC for Ammonia & Urea
PLC for Demin plant, Bagging, HVAC
Rotating machine monitoring, anti surge control, &
speed control for Air, Refrigerant, Natural Gas,
Synthesis Gas, & CO2 Compressors (ITCC if any)
FGD system for Process Area, SS, & Main control
building

Controller (DCS, PLC, Safety PLC, Anti surge control,

Performance control, Machine monitoring, FGD control
Corrosion atmosphere class

min G2 corrosion class

Power supply : 110 VAC floating from UPS

Final Elements
Valve (Control & Shutdown)
Actuator (Spring oppose diaphragm, Spring-return

piston actuator, & electric actuator)

IA maximum design 4 kg/cm2
IA supply pressure connection or NPTF
Positioner : SMART positioner and electro
pneumatic type
Enclosure : Ex d, NEMA 4x
Mounting : Yoke mounted, SS316 mounting
brackets
IA supply pressure connection NPTF

Final Elements
Limit switch for position indicator
Contact rating, SPDT

Enclosure : Ex d, NEMA 4x
Solenoid valves
Enclosure : Ex d, NEMA 4x
Bracket material SS316
IA supply pressure connection or
Power supply : 110 VAC from UPS
Power of solenoid between 10 20 Watts
Min. class H insulation for solenoid coil

Final Elements
Manual override facility (latching type)
Body material Stainless Steel

Final Elements
Valve
Minimum flange rating 300 for globe valves in

size NPS 6 and smaller

In 900 LB class valve size 1, 1 , 2, the flange
rating is 1500 LB
Control valve range ability 1:30
Control valve min. leakage class : Class IV (metal
to-metal)
Max. control valve noise 85 dB (A)
Single seat for globe valves

Final Elements
Surface hardness, RF : 125-250 AARH, FF : 250-

500 AARH
Material certificates : Mill Test & PMI certificates
Valve type :
- Globe valve for general use
- Angle valve for high press. drop (Common in
Urea)
- Cage for high DP and high noise
- Vee-ball for high viscosity and slurry service
- Ball for on-off valve

Instrumentation cabling
Cable (API 552)
Conductor : Tinned copper
Insulation : XLPE
Screering : Individual & Overall Almunium mylar
Armour : Aluminium interlocked tape
Jacket : PVC

Instrumentation cabling
Size : 1.5 mm2 for signal & control cable, 2.5 mm2

for power cable

Fire resistant cable (IEC 60331) for fire zone or
high temp. area
Stainless steel cable gland
Junction box
Enclosure : Ex e, NEMA 4X
Material : Stainless steel with 2 mm thickness

Instrumentation cabling
Cable tray
Aluminium heavy duty ladder type c/w cover and

additional grounding cable

Cable arrangement
1.5 MM2 conductor size in hot dip galvanized steel

open channel/tray from instrument to Junction

box
1.5 MM2 conductor size in aluminium heavy duty
ladder tray from Junction box to Control Room

Instrumentation cabling
3 (three) separate cable tray
a. Analog signal 4-20 mA and On-off signal 24

VDC
b. Thermocouple and vibration
c. Power supply 110 VAC

Safety Instruments
API 520 for MAWP 15 psig or greater
API 2000 for MAWP up to 15 psig

FGD System
Addressable FGD system
FGD Controller c/w system diagnostic
Detectors : Flammable/Hydrocarbon gas, Flame
Alarm
Annunciators
Operator interface

Facility Security Control System &

Communication System and CCTV
Telephon system
LAN sytem
Paging system (Speaker, mic)
CCTV system

Presure instrument
General
Wetted part material SS316L
For corrosive, crystalize, slurries, & high viscosity application shall be

diapraghm remote seal type

Pressure switch applied for trip system
Pressure gauge
Bourdon type, 100mm dial diameter
Stainless steel inner parts, and SS316 tube, NPT connection
Accuracy 1.5% FS
Pressure transmitter
Have overpressure protection of 2000 psig
Accuracy 0.25% FS

Presure instrument

Capacitive
sensor

Temperature measurement
General
Thermowell : ASME PTC 19.3 (Thermowell dimension, material,

etc)
Thermowell for general apllication : metalic shetated type

SS316, Drilled bar stock type

Thermowell connection :
1 inch NPT for utility pipe line 600#
1 inch RF flange for pipe lines of 600# except for utilities
Weld connection for pipe lines of 900# except for alloy pipe

lines
1 inch RF flange for vessel and alloy pipe lines

Temperature measurement
Temperature transmitter
Standard used

Thermocouple & RTD : ANSI MC 96.1 (element material, wire colour, etc)
RTD Pt 100: IEC60751 (accuracy class, vs Temp. Value, colour code, etc)
All temperature measurements incorporated with shutdown system shall

use temperature transmitter

RTD 3 wire connection (4 wire if required)
Double element for Primary reformer, secondary reformer, Ammonia

converter,...
Head mounted transmitter shall not be used

Temperature measurement
Preferred range
-200 C s.d. 350 C : RTD Pt 100 or Thermocouple type J
351 C s.d 900 C : Thermocouple K (Chromel-Alumel)
Over 900 C : Thermocouple R (Special request for Primary and

Secondary Reformer, Sensor conductor diameter min. 3,2 mm)

Temperature gauge
Use stainless steel bimetalic type thermometer
Dial diameter is 100 mm
Field thermal