REVISIONS. App Thom. App Sud. App PC IG 2014/09/19

Transcription

1 /0 REVISIONS Rev Description Rev n by Sud PC Thom VB LH Clyd Act Issue Date YYYY/MM/DD Gen. updates to content, format and spec number. Previously FF 204/09/9 IG 204/09/9 N/A N/A N/A N/A N/A N/A 204/09/23 Sud = Sudbury, Ontario, PC = Port Colborne, Thom = Thompson, Manitoba, VB = Voisey s Bay, LH = Long Harbour, Act = Acton, England, Clyd = Clydach, Wales, N/A = Not licable

2 2/0.0 PURPOSE This specification, in conjunction with project design criteria, describes the minimum requirements for instrumentation systems at Vale. Unless otherwise approved by Vale in writing, any new or modified instrumentation installation shall not deviate from this standard. 2.0 APPLICATION This specification, applies at any Vale locations indicated with approval on the cover page, with the following exceptions: 2. EXCEPTIONS None. 3.0 REFERENCE DOCUMENTATION The following documents were used in the development of this document or have instructions and procedures applicable to it. They shall be used in their most recent revision. SPEC-0800 SPEC SPEC SPEC-5600 SPEC SPEC SPEC SPEC SPEC SPEC Design and Layout General Requirements Instrumentation Drawings Construction Electrical and Instrumentation General Requirements Process Measurement - Flow Process Measurement - Pressure Process Measurement - Temperature Process Measurement Level Fluids and Solids Process Control Valves Power Supply and Grounding Power Supply and Grounding DCS & PLC Systems 4.0 APPLICABLE CODES AND STANDARDS Design shall comply with the latest editions of the Codes, Regulations, Standards and other references applicable in the Province of Ontario unless specifically stated otherwise in writing. In the event of conflicting requirements, the most stringent shall apply.

3 3/0 5.0 DRAWINGS AND DATA A complete set of detail engineering drawings and instrument data sheets shall be prepared for all instrumentation systems as outlined in specification SPEC Data sheets shall be supplied in electronic format for archiving purposes complete with make and model number and, if applicable, CRN number once such information is known. 6.0 UNITS AND MEASUREMENT Pressure: - kpa, mm.h2o Flow: - l/s, m3/hr, kg/hr, tonne/hr Temperature: - ºC Level: - % Angular Speed: - rpm Linear Velocity: - m/s Density: - SG, % solids Weight: - kg, tonne Motor Power: - kw, HP 7.0 ENVIRONMENTAL CONDITIONS Field mounted instruments shall be capable of withstanding the following conditions as a minimum unless site or project conditions warrant a wider range: - Indoor: +5 to +40 deg Celsius - Outdoor: 40 to 40 deg Celsius - 00% relative humidity 8.0 NUMBERING SYSTEMS 8. INSTRUMENT NUMBERING Each instrument shall be identified with an instrument tag. The instrument tag shall consist of function code letters followed by a loop number. The function code letters shall be in accordance with the latest edition of Instrumentation Systems and Automation Society, ISA S5. and as modified by Vale for project requirements.

4 4/0 Example: PIT-2345 Function Loop Number Vale shall assign instrument loop numbers as required upon request. 8.2 CONTROL LOOP NUMBERING A control loop is a combination of two or more interconnected instruments arranged to measure or control a process variable. The components of a control loop shall be identified by a group of code letters followed by a common loop number. Example: A pressure control loop with a pressure indicating transmitter PIT-2345 could have a pressure indicating controller PIC-2345 and a pressure control valve PV-2345 with associated positioner PY-2345 Where there are two or more instruments with the same code letters in a loop, sequential letter suffixes from A to Z shall be added to the loop number. 8.3 CABLE AND WIRE NUMBERING Cables serving loops or multiconductor/multipair cables serving a junction box or control panel shall be identified by a number consisting of the loop or panel number followed by a suffix according to the following: -S, -S2, etc. for all low level analog signal cables -C, -C2, etc. for discrete control cables -P, -P2, etc. for power supply cables -T, -T2, etc. for instrument tubing Examples: JB-2345-C for a control cable serving a junction box PIT-2345-S for a signal cable serving a pressure transmitter The identification of individual wires of a cable serving a loop shall consist of the loop number followed by sequential numbers -, -2, etc. The same wire number shall be used as far as the wire is electrically continuous.

5 5/0 8.4 CONTROL PANEL AND JUNCTION BOX NUMBERING Control panel and junction box numbering shall consist of the equipment number or loop number they are associated with followed prefixed according to the following: CP- for single control panels or CP-, CP2-, etc. for multiple control panels JB- for single junction boxes or JB-, JB2-, etc. for multiple junction boxes Examples: CP-2345 for a single control panel associated with a piece of equipment or loop number CP-2345, CP2-2345, etc. for multiple control panels associated with a piece of equipment or loop number For field junction boxes used as a marshalling point for multiple field instruments, the lowest instrument loop number present in the JB can be used as the JB number. 9.0 TAGS AND MARKERS All instruments shall be identified by their tag number inscribed on a metal tag and riveted, or otherwise securely attached, to the instrument. Attachment to removable instrument covers is not permitted. All cables are to be identified at both ends with permanent, weather, oil and solvent resistant markers. Eg. K-Type PVC Cable Markers and Carrier Strips ty-rapped to the cable. All wires are to be identified at both ends with permanent, weather, oil and solvent resistant markers. Eg. Z-Type PVC Wire Markers. Terminal blocks are to be identified with the wire tag number. Supply control panels and junctions boxes with lamacoid nameplates generally with black lettering (/4 minimum) cut into a white background. Refer to panel or junction box layout drawings for details. Labels shall be permanently and securely attached without compromising the enclosure rating. 0.0 POWER SUPPLIES AND GROUNDING Refer to requirements as outlined in specifications SPEC and SPEC

6 6/0.0 TRANSMISSION SIGNALS Preferred interface signals between field instruments and the control system shall be as follows: Analog: Analog: Analog: Discrete: Pneumatic: 4-20 ma DC c/w Hart Protocol RTD mv (thermocouple) 20 VAC, 60 Hz kpa (3-5 psig) 2.0 INSTRUMENT AIR AND INSTRUMENT TUBING 2. GENERAL Clean, dry and oil free air for pneumatic instruments and actuators shall be in accordance with ISA-S7.0.0 Quality Standard for Instrument Air. Each instrument or actuator requiring an air supply shall be provided with a combination filter/regulator with an output pressure gage. For instrument sizing, instrument air provided as part of the plant utility system can be assumed to be: Minimum: - 45kPa (60 psig) Normal: - 620kPa (90 psig) Maximum: - 825kPa (20 psig) Protect tubing in areas where the possibility of abuse exists. Provide a sleeve for tubing penetrations through floors and walls. Instrument purge lines are to be angled downward and fitted with mufflers. Instrument air isolation valves shall be lockable. 2.2 MATERIAL Tubing shall be seamless 36 stainless steel instrument air tubing. Fittings shall be 36 stainless steel compression type for ¼ to ½ stainless steel instrument air tubing.

7 7/0 2.3 TUBE SIZING (MINIMUM, VERIFY PLANT PREFERENCE) ¼ O.D. tubes - for pneumatic signals and air supplies to instruments. ⅜ O.D. tubes - for air supplies to final actuators such as control valves, cylinders, etc. ½ O.D. tubes - as required. 3.0 ENCLOSURES Provide Nema 4X rated enclosures for indoor, outdoor and all underground installations. Junction boxes for indoor use may be polycarbonate. Use stainless steel junction boxes for outdoor installations. Provide Nema 2 control panels for electrical room installations. Cable entry or conduit connection must be made with approved fittings. Cable entries shall be from the bottom. For indoor installation side entry is acceptable. Marshalling panels shall be provided for terminating DCS and PLC I/O field connections. The terminations in marshalling panels shall be wired to the corresponding I/O modules or termination units via pre-wired cables supplied with the equipment. All shield wires shall be grounded only at one end, preferably at the marshalling panel. Warning nameplates required by Provincial and other Inspection Authorities shall be provided in accordance with Codes and Regulations. Size panels with 20% spare. 4.0 CABLE AND WIRING Single pair, multi-pair and triad cables shall be galvanized steel armoured, twisted, with individual and overall shield as applicable, stranded wires with minimum 600 V, 90 deg C flame-retardant insulation, FT-4 rated. Use wire size #6 AWG for single pair and single triad cables and #8 for multi-pair and multi-triad cables. Multiconductor cables shall be galvanized steel armoured, #4 AWG stranded wires with minimum 600 V, 90 deg C flame retardant insulation, FT-4 rated. Outer jacket colour coding shall be as follows: Grey for DC power and signal cables Black for AC power and signal cables

8 8/0 Red is reserved for underground blasting cable Wire colour coding shall be as follows: Black and white for paired wires Black, white and red for triads Thermocouple extension cables shall be galvanized steel armoured, single pair, twisted, shielded, #8 AWG, stranded wires with 600 V, 90 deg C flame retardant insulation, FT-4 rated with ISA colour coded outer jacket. Special unarmoured cables, i.e. co-ax, etc. that must be run through the plant shall be run in liquid seal flexible conduit. AC and DC signals shall not be combined in the same cable. 5.0 CABLE TRAY (Ref Vale Eng Std SPEC-50002) Generally, the same cable trays shall be used for both instrumentation cables and instrument tubing. Electrical motor control and lighting cables shall be kept out of these trays wherever possible. In the event that electrical cables are installed in instrumentation cable trays, the voltage in the cables shall not exceed 600 volts. Cable trays shall be sized such that they are initially filled to 75% of capacity to allow for future expansion. 6.0 FIELD INSTRUMENTS (Ref Eng Stds SPEC-5600 to SPEC-56005) The action of controllers, alarm contacts, final control devices, etc., shall be such that the system is failsafe. (Upon failure of air supply or power, the final control device shall move in the direction that presents the least hazard.) Transmitters shall be used in place of discrete switches whenever practical. Transmitters shall be configured to fail low (below normal signal lower limit) as a default unless this conflicts with safety or operating requirements. Fail Status shall be noted on Instrument Data Sheets. Transmitters shall have an integral indicator displayed in engineering units as standard.

9 9/0 Accuracy of measurement shall be adequate for the specific application. In general, the normal accuracy of ± 0.5% of full-scale range shall apply. Scale ranges shall be selected such that the normal measurement signal indicates within 50-75% of scale calibration for linear scales, and 70-85% for square root scales. Scales and recorder charts shall be direct reading, i.e., calibrated in engineering units. Each field mounted pneumatic controller, transmitter and valve positioner shall be furnished with a lockable air isolation valve, adjustable air filter/regulator with output gauge All instruments, which are in contact with the process, shall be fabricated from a material that conforms to or exceeds the piping specification used for the process line. Pressure and temperature ratings of the instruments shall conform to the ratings of the process system of which they are a part. Field instruments shall be suitably protected from mechanical damage and mounted on building steel or on separate stand or supports with due consideration given to remoteness from heat or vibration sources as well as water and material spillage. Accessibility shall be adequate for both maintenance and operation. Items that require frequent access for maintenance shall have access from the floor or by platforms or catwalks. All field-mounted instruments shall be enclosed in gasketted, dust and moisture proof cases, suitable for continuous satisfactory operation under plant ambient conditions. Special enclosures or intrinsically safe instruments shall be provided for use in hazardous areas where applicable. Control valves shall be lockable. VFD s shall be used over throttling control valves in pump flow control applications. Refer to the plant or mine site for preferred instrument manufacturers. 7.0 APPENDICES endix A: Revision and Transition Notes endix B: Keywords

10 0/0 endix A: Revision and Transition Notes (Revisions are listed in reverse chronological order with most recent revision at the top. Revision notes describe: what was changed, why it was changed, and the plan to implement the change, including whether changes are retroactive) Revision General updates to content, format and spec number. Previously Rev 4. (was also temporarily numbered SPEC-4000-now obsolete) endix B: Keywords