Norsok Standared I-001 Field instrumentation

This NORSOK standard is developed with broad petroleum industry participation by interested parties in the Norwegian petroleum industry and is owned by the Norwegian petroleum industry represented by The Norwegian Oil Industry Association (OLF) and The Federation of Norwegian Industry. Please note that whilst every effort has been made to ensure the accuracy of this NORSOK standard, neither OLF nor The Federation of Norwegian Industry or any of their members will assume liability for any use thereof. Standards Norway is responsible for the administration and publication of this NORSOK standard. Standards Norway Telephone: + 47 67 83 86 00 Strandveien 18, P.O. Box 242 Fax: + 47 67 83 86 01 N-1326 Lysaker Email: petroleum@standard.no NORWAY Website: www.standard.no/petroleum Copyrights reserved NORSOK STANDARD I-001 Edition 4, January 2010 Field instrumentation NORSOK standard I-001 Edition 4, January 2010 NORSOK standard Page 3 of 29 Foreword 4 1 Scope 5 2 Normative and informative references 5 2.1 Normative references 5 2.2 Informative references 6 3 Terms, definitions, abbreviations and units 6 3.1 Terms and definitions 6 3.2 Abbreviations 6 3.3 Engineering units 7 4 Functional requirements 7 4.1 General 7 4.2 Instrument supplies 7 4.3 Signal types 8 4.4 Instrument design principles 8 4.5 Instrument installation design principles 9 4.6 Provision for future modifications 9 4.7 Degrees of protection by enclosures 10 4.8 Instrument materials 10 4.9 Air supply design 11 4.10 Instrument installation bulk materials 11 4.11 Temperature measurements 12 4.12 Flow measurements 13 4.13 Pressure measurement 13 4.14 Level measurement 14 4.15 Control valves 15 4.16 Solenoid valves 16 4.17 Pressure relief valves and bursting discs 16 4.18 Pilot operated relief valves 16 4.19 On/off valve actuators 16 4.20 Choke valves 17 4.21 HVAC actuators 17 4.22 Vibration field instruments 17 4.23 Fire and gas detectors 17 4.24 Diagnostics 19 5 Installation 19 5.1 General requirements 19 5.2 Equipment earthing and bonding (see NORSOK E-001, 9.1) 20 5.3 Cables and wiring (see IEC 61892-6, Clause 5, and NORSOK E-001, 9.2) 20 5.4 Marking and labelling (see NORSOK E-001, 9.12) 21 5.5 Bulk materials 22 5.6 Instruments 22 5.7 Tubing installation 23 5.8 Fire and gas 24 ANNEX A (informative) Typical installation drawings 25 ANNEX B (informative) Level measurement guidelines 26 ANNEX C (normative) Instrument data sheets 27 NORSOK standard I-001 Edition 4, January 2010 NORSOK standard Page 4 of 29 Foreword The NORSOK standards are developed by the Norwegian petroleum industry to ensure adequate safety, value adding and cost effectiveness for petroleum industry developments and operations. Furthermore, NORSOK standards are, as far as possible, intended to replace oil company specifications and serve as references in the authorities’ regulations. The NORSOK standards are normally based on recognised international standards, adding the provisions deemed necessary to fill the broad needs of the Norwegian petroleum industry. Where relevant, NORSOK standards will be used to provide the Norwegian industry input to the international standardisation process. Subject to development and publication of international standards, the relevant NORSOK standard will be withdrawn. The NORSOK standards are developed according to the consensus principle generally applicable for most standards work and according to established procedures defined in NORSOK A-001. The NORSOK standards are prepared and published with support by The Norwegian Oil Industry Association (OLF), The Federation of Norwegian Industry, Norwegian Shipowners’ Association and The Petroleum Safety Authority Norway. NORSOK standards are administered and published by Standards Norway. Annexes A and B are informative and Annex C is normative. NORSOK standard I-001 Edition 4, January 2010 NORSOK standard Page 5 of 29 1 Scope This NORSOK standard identifies the requirements to field instrumentation design. 2 Normative and informative references The following standards include provisions which, through references in this text, constitute provisions of this NORSOK standard. Latest issue of the references shall be used unless otherwise agreed. Other recognised standards may be used provided it can be shown that they meet or exceed the requirements of the standards referenced below. 2.1 Normative references ANSI B16.10, Face-to-face and end-to-end dimensions of valves ANSI B16.36, Steel orifice flanges ANSI/ASME B1.20.1, Pipe threads general purpose (inch) ANSI/ASME, Performance Test Codes 19.3 - 1974, chapter 1, section 8-19 Thermowells ANSI B16.5, Pipe Flanges and Flanged Fittings API RP 520, Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries, Part I and II API RP 526, Flanged steel safety relief valves API RP 527, Seat Tightness of Pressure Relief Valves API RP 670, Vibration, axial position and bearing temperature system API RP 678, Accelerometer-based Vibration Monitoring System ASME VIII, Boiler and pressure vessel code - Section VIII, Div. 1 DIN 3852-1, Ports and stud ends with metric fine pitch thread, for use with compression couplings, valves and screw plugs EN 50081-2, Electromagnetic compatibility generic emission standard EN 50082-2, Electromagnetic compatibility generic immunity standard EN 60751, Resistance Temperature Detectors (RTD) IEC 60079-14, Electrical apparatus for explosive atmospheres – Part 14: Electrical installations in hazardous areas (others than mines) IEC 60534-2-1, Industrial-Process Control Valves – Part 2-1: Flow-Capacity Sizing Equations for Fluid Flow under Installed Conditions IEC 61508, Functional safety of electrical/electronic/programmable electronic safety- related Systems IEC 61892-6, Mobile and fixed offshore units - Electrical installations ISA 75.01.01–2002, Flow equations for sizing control valves ISO 1000, SI Units and recommendation for the use of their multiples and of certain other units ISO 4126-2, Safety devices for protection against excessive pressure – part 2: Bursting Disc Safety Devices ISO 4406, Hydraulic fluid power - Fluids - Method for coding the level of contamination by solid particles ISO 5167 (all parts), Measurement of fluid flow by means of pressure differential devices inserted in circular cross-section conduits running full - NORSOK E-001, Electrical systems NORSOK I-002, Safety and Automation System NORSOK L-002, Piping Design, Layout and Stress Analysis NORSOK L-CR-003, Piping Details NORSOK L-004, Piping fabrication NORSOK L-005, Compact flanged connections NORSOK M-001, Materials selection NORSOK M-501, Surface Preparation and Protective Coating NORSOK S-001, Technical safety OLF 070, "Guidelines for the Application of IEC 61508 in the petroleum activities on the continental shelf" 89/336/EEC, Electromagnetic Compatibility Directive PED, Pressure Equipment Directive (97/23/EC) NORSOK standard I-001 Edition 4, January 2010 NORSOK standard Page 6 of 29 2.2 Informative references ATEX 94/9/EEC, | Explosive atmosphere IEC 60529, International Protection or Ingress Protection EN 60584-1, Thermocouples - Part 1: Reference tables EN 60584-2, Thermocouples - Part 2: Tolerances BS 2915, Specification for bursting discs and bursting disc devices 3 Terms, definitions, abbreviations and units 3.1 Terms and definitions For the purposes of this NORSOK standard, the following terms, definitions and abbreviations apply. 3.1.1 can verbal form used for statements of possibility and capability, whether material, physical or casual 3.1.2 instruments devices used for indicating and/or control purposes NOTE The term ‘instruments’ also includes actuated valves and safety valves. 3.1.3 may verbal form used to indicate a course of action permissible within the limits of this NORSOK standard 3.1.4 shall verbal form used to indicate requirements strictly to be followed in order to conform to this NORSOK standard and from which no deviation is permitted, unless accepted by all involved parties 3.1.5 should verbal form used to indicate that among several possibilities one is recommended as particularly suitable, without mentioning or excluding others, or that a certain course of action is preferred but not necessarily required 3.2 Abbreviations AISI American Iron and Steel Institute API American Petroleum Institute APS abandon platform shutdown ASME The American Society of Mechanical Engineers ATEX Equipment intended for use in potentially explosive atmospheres BS British Standard BSPP British Standard Pipe Parallel DIN Deutsches Institut für Normung EN European Standard ESD emergency shut down FF® Foundation Fieldbus GRP glass fibre reinforced plastic HART® Highway Addressable Remote Transducer HVAC heating, ventilation and air conditioning IE instrument earthing IEC The International Electrotechnical Commission IS intrinsically safe ISA international organization of engineers ISO International Organization for Standardization IP ingress protections IR infra red MCT multi cable transit NORSOK standard I-001 Edition 4, January 2010 NORSOK standard Page 7 of 29 N/A not applicable NAMUR Normenarbeitsgemeinschaft für Mess- und Regelungstechnik in der Chemischen Industrie NPT National Pipe Thread OD outer diameter OLF The Norwegian Oil Industry Association OPC open connectivity (a series of standards specifications) PED Pressure Equipment Directive (97/23/EC) Profibus DP, -PA® Profibus Nutzerorganization PSD process shut down RTD resistance temperature detector SAS safety and automation system SI System International SIL safety integrity level SMART field instrument with distributed intelligence SPL sound pressure level SS stainless steel UPS uninterrupted power supply V a.c voltage alternating current V d.c voltage direct current 3.3 Engineering units Pressure: bar, mbar, barg, bara Level: mm, % for indication (for guidelines, see Annex A) Volume flow: m3/h (flowing condition), Sm3/h (standard condition, see ISO 1000) Mass flow: kg/h Temperature: ºC For other physical properties, SI units shall be utilised as per ISO 1000. 4 Functional requirements 4.1 General This NORSOK standard shall be read in conjunction with NORSOK I-002. 4.2 Instrument supplies Electrical supply to instrument panels in LERs: 230V a.c. 50 Hz (standard) or 24V d.c. Electrical supply to field instruments: 24V d.c. (standard) or 230V a.c. 50 Hz. Electrical supply to instrument field panels: 24V d.c. (standard) or 230V a.c. 50 Hz. A minimum of two independent power supplies shall be used, one UPS and one main supply. For critical systems/safety related systems power shall be supplied with fully redundant UPS. 24 V d.c. supply systems shall be floating and preferably adjustable within the range 24V d.c.to 28V d.c. Earth fault and power fault monitoring shall be implemented in the 24V d.c. distribution system. Pneumatic ring main supply: minimum 7 barg, maximum 10 barg. Pneumatic instrument supply: 1,4 barg (standard) or as required. Hydraulic ring main/instrument supply: minimum 180 barg, normal 200 barg, maximum 210 barg. Hydraulic supply for wellhead/downhole depending on reservoir pressure. An instrument air supply system with an online dew point analyzer connected to the SAS for alarm monitoring shall be installed. NORSOK standard I-001 Edition 4, January 2010 NORSOK standard Page 8 of 29 4.3 Signal types The following signal types shall be used: • analogue input/output: 4 mA to 20 mA with HART® superimposed digital signal; NOTE HART® shall be included if supported by existing technology for this type of instrument. • digital input: potential free contact; • digital output: 24V d.c.; • signals between control systems and other panels shall be powered from SAS; • position: proximity switches with NAMUR interface; • pneumatic signals: 0,2 barg to 1,0 barg; • fieldbus type and wireless communications may also be used, dependant on user approval. 4.4 Instrument design principles Instrument performance/accuracy shall be sufficient to fulfil process/unit performance requirements and should be selected to reduce calibration intervals and maintenance to a minimum. Suppliers shall provide data for long-term stability and confidence level for performance specifications. Instruments shall have advanced diagnostics to enhance safety and reduce maintenance. Only industry standard communication protocols such as HART®, HART WIRELESS®, Foundation Fieldbus® or Profibus DP/PA® shall be used. Instruments using Foundation Fieldbus® or Profibus DP/PA® shall have documented interoperability, e.g. tick-marked. Instrumented safety system shall satisfy the OLF 070 guideline and have a minimum SIL requirement according IEC 61508. A safety analysis Report shall be part of any delivery. For off-the-shelf instruments where a failure mode effect and diagnostic analysis report or a certificate is available this can be regarded as a safety analysis report, provided it presents the data required in the OLF 070 in an easily accessible manner. Variation of instrument types and ranges shall be kept to a minimum, e.g. thermowell lengths/transmitter ranges. Analogue instruments shall be used instead of field switch functions, e.g. pressure transmitters versus pressure switches. Galvanic isolation barriers shall be used for input/output signals. These barriers shall have full HART® signal transmission capability. Field instruments and controllers of pneumatic type shall be avoided. Where local indicators are required, local indicators and transmitters shall be combined. Separate local indicators may only be installed if necessary for local operation if process control system is not in function. Any arrangement of instruments shall allow for the removal of a sensor/detector head while maintaining the integrity of the other sensors, e.g. in addressable systems. Instruments shall meet requirements according to 89/336/EEC, and EN 50081-2 and EN 50082-2 regarding electromagnetic compatibility. Flange connection for inline instruments shall follow piping class and specification, see ANSI B16.5 or compact flanges according to NORSOK L-005. All in-line flow elements (when part of the process line) shall be flanged for removal from the process line. Pressure vessel design (e.g. accumulators for on/off valves) shall follow NORSOK L-002 and meet the requirements of the PED. The most frequently used measuring principles are specified in separate sections of this NORSOK standard. Other types may be used on special applications. For field instruments not specifically dealt with in this NORSOK standard, the design shall be based on recognised international standards. NORSOK standard I-001 Edition 4, January 2010 NORSOK standard Page 9 of 29 4.5 Instrument installation design principles Instrument lines that can be clogged due to high viscosity fluids or hydrates or other factors, shall either have the instrument close-coupled to the process pipeline/equipment or protected with a chemical seal. If chemical seals are installed, a flushing ring arrangement should also be provided for flushing of diaphragm surface. Double block/bleed (3-way modular) valves to enable in-situ calibration shall be fitted. All equipment which require maintenance or calibration etc. shall have easy access, e.g. permanent platforms or fixed ladders. Instrumentation used for hydrocarbon services shall be constructed in such a way that any fault in the primary process barrier will not leak into the main compartment or junction box. If a leakage occurs, it shall not be possible to build up any pressure inside the instruments. Pressure instruments shall have individual process isolation valves. Combined solutions may be used providing they do not cause an operational disadvantage or safety reduction during servicing of instruments etc. Each pressure instrument with process connection shall be fitted with instrument block/bleed manifold (2/5 - way valve). Instruments for ESD/PSD shall in addition have locking devices for latching of the valves in open position. Full functional independence between control and safety devices shall be assured, including vessel/pipeline connections, e.g. common pressure tap for control and safety devices shall not be used. Use of combined manifolds for piping and instruments valves shall be evaluated. Combined manifolds should be used when instruments are direct mounted on or in the immediate vicinity of the pipe/vessel. Package suppliers shall terminate hydraulic and pneumatic tubing at skid edge with bulkhead male connectors or unions. Package suppliers shall terminate instrumentation cables in junction boxes at skid edge or at agreed termination point. Ex-certified equipment should be selected in accordance with the following guidelines and be certified according to ATEX 94/9/EEC: • Ex i and Ex e should be used; • if Ex d is used, it shall be provided with an Ex e indirect entry. Compression type Ex d gland may be accepted if the equipments ATEX certificate cover gland and installed cable type, actual gas group and Ex d compartment volume (normally under 2 litre.). References to figure 1 in IEC 60079-14. Ex d compression glands shall be of the type where the braid is terminated in the gland and compression takes place on inner cable sheath; • Ex q and Ex p should be avoided. Use of these will be upon approval from user and if used should be via an Ex e junction box; • Ex e, Ex s, Ex m or Ex i solenoid valves shall be used. Ex d may be used upon approval from user; • equipment, which remains energized after an APS/ESD situation, shall follow the requirements specified in NORSOK S-001, 9.4. If safety and functional requirements are fulfilled, the following shall apply: • field instrument process connection: 1/2 in NPT, see ANSI/ASME B1.20.1; • field instrument pneumatic connection: 1/4 in NPT; • field instrument hydraulic connection: 1/2 in NPT, or 1/2 in BSPP to DIN 3852-1; • field instrument cable entry: ISO threads - size depending on cable size. 4.6 Provision for future modifications This subclause defines the spare capacity that shall be provided at the time of plant start-up. The installation should be prepared as follows: • interface cabinets, junction boxes, multicore cabling etc. shall be sized to meet a 10 % increase; NORSOK standard I-001 Edition 4, January 2010 NORSOK standard Page 10 of 29 • main cable ladders and transits shall be sized to meet a 10 % increase; • a minimum of 20 % spare branches, each fitted with a valve and plug, shall be provided for each air and hydraulic distribution manifold. 4.7 Degrees of protection by enclosures Minimum degree of protection provided by enclosures shall be as follows: • for outdoor, in naturally ventilated areas and wash down areas: IP 56 • dry indoor areas: IP 20 • other areas: IP 44 NOTE Above represents minimum requirements. It should be noted that regulations may contain more stringent requirements and shall be consulted, see IEC 60529. 4.8 Instrument materials 4.8.1 General Instrument materials defined in this subclause shall apply. However, instruments may be specified with superior materials due to service requirements (particularly for internals). 4.8.2 In-line instruments The following apply: • control valves, safety valves and other in-