0905.1.0 - Instrument Installation Requirements

7/28/2019 0905.1.0 - Instrument Installation Requirements

1/12

Polaris

Engineering

Standard

0905.1.0

Rev.: 7

Page: 1 of12

Date: 11/11/04INSTRUMENT INSTALLATION REQUIREMENTS

TABLE OF CONTENTS PAGE

I. SCOPE 1

II. REFERENCES 2

III. INSTRUMENT IDENTIFICATION 3

A. General 3

B. Safety Instruments Identification 3

C. Control and Rack Panel Instruments and Accessories 3

IV. INSTRUMENT MOUNTING LOCATION 4

V. INSTRUMENT TUBING AND

MOUNTING SUPPORTS SECTION 5

VI. INSTRUMENT PROCESS CONNECTIONS 6

A. General 6

B. Purging of Process Connections 7

VII. INSTRUMENT ENVIRONMENTAL PROTECTION 7

A. Enclosures 7

B. Heat Tracing 8

C. Fire Protection 12

911121

d. Electric Heat Tracing 10

e. Fire Protection 12


2/12

Polaris

Engineering

Standard

0905.1.0

Rev.: 7

Page: 2 of12

Date: 11/11/04INSTRUMENT INSTALLATION REQUIREMENTS

I. SCOPE

A. This Standard covers general requirements for installation of instruments and isintended to supplement specific job installation procedures and the Client and

Polaris design drawings showing details of installations. Should conflict occur,

specific job installation instructions along with the Client and Polaris design

drawings shall govern.

B. Where conflicts exist between this POLARIS Standard and other POLARIS

Engineering Standards and/or applicable codes or regulations, the more stringent

requirement shall govern. All conflicts shall be brought to the Client and

Polariss attention for resolution. The Client and Polaris shall be the sole arbiter

of any conflicts.

C. No omission in these Standards shall be construed as relieving the Contractor of

their responsibility to perform work in accordance with said codes and industry

standards.

II. REFERENCES

This POLARIS Standard is to be used in conjunction with the latest revision of the

standards and codes listed below, unless specifically noted. The terminology "latest

revision" shall be interpreted as the revision in effect at the time of contract award. This

POLARIS Standard may reference specific sections of some of these codes and

standards. The revision of the codes and standards being referenced is noted below in

parenthesis. This information is provided to identify the subject matter being referenced.

Changes or exceptions made to the referenced code or standard shall apply to later

revisions as applicable.

A. POLARIS Engineering Standards:

1. 190.1 General Plant Design Criteria

2. 800.1 Piping General Design

3. 810.1 Heat Tracing

4. 890.1 Piping Material Specifications

5. 898.1 Piping General Notes And Details

6. 898.14 Standard Steam Tracing Details

7. 900.1 General Instrumentation Requirements


3/12

Polaris

Engineering

Standard

0905.1.0

Rev.: 7

Page: 3 of12

Date: 11/11/048. 905.2 Instrument Piping Materials

9. 906.1 Instrument Piping Design, Layout and Drawing Procedures

10. 920.1 Temperature Instruments

11. 1000.1 Electrical - General Requirements

12. 1073.1 Electric Heat Tracing

B. Process Industry Practices (PIP) Standards:

1. PIP PCCGN002 General Instrument Installation Criteria

(October 2001)

III. INSTRUMENT INDENTIFICATION

A General

1. All instruments, equipment, and enclosures shall be identified by thevendor before shipment by using at least one of the following methods:

a. A permanently affixed nametagb. An engraving on the instrumentc. A stainless steel tag affixed with a stainless steel wire

2. Nameplates shall have, as a minimum, the device tag number engraved.3. The engineering contractor/designer shall include tagging requirements on

instrument data sheets.

4. All instrument tubing and wiring connections, including spares, shall beidentified with permanent nametags, nameplates, or wire markers at tubing

or wiring junctions. Paper nametags and hand written wire markers are

not acceptable.

B. Safety Instruments Identification

1. See Engineering Standard 900.1 Section XI for details on identification ofsafety instruments.


4/12

Polaris

Engineering

Standard

0905.1.0

Rev.: 7

Page: 4 of12

Date: 11/11/04C. Control and Rack Panel Instruments and Accessories

1. Instruments and accessories that require identification nametags ornameplates shall include, as a minimum, the following:

a. Control panel front-mounted instruments (complete nameplate on the

front, nameplate or nametag with only the device number on the back)

b. Control panel rear-mounted instruments

c. Junction boxes, relay cabinets, and similar enclosures

d. Control panel sections and racks

e. Control system modular components (e.g., computers, programmable

logic controllers, printers, I/O enclosures, racks, modules)

f. Instrument electrical distribution equipment (e.g., fuses, breakers,

switches)

g. Control and indicating devices (e.g., hand switches, indication lights)

2. Nameplates for recorders shall include a color-coded legend to designate

the recorder pen color dedicated to the respective instrument tag number.

IV. INSTRUMENT MOUNTING LOCATION

A. Instrument mounting locations shall be selected with consideration of

requirements for functional operation and maintenance.

B. Field instruments shall be mounted to minimize the length of instrument impulse

lines connected to process pipelines or equipment.

C. All instruments that require calibration or maintenance shall be accessible from

grade or from a permanent platform or ladder. These instruments shall be located

between 2 and 5 feet above grade or platform. In flooding areas, these instruments

shall be located at least 4 feet above ground. Safety/Emergency related

instruments shall be accessible from grade or permanent platform.

D. Instruments mounted outside a platform handrail shall be located to allow

maintenance from the platform without reaching through or leaning over the

hand rail. These instruments shall be located less than 5 feet above the platform

and less than 1 foot horizontally outside the platform edge.

E. Instruments shall be located no farther than 1.5 feet from fixed ladders to allow

maintenance of the instrument from the ladder.

F. Instruments including pressure gauges, dial thermometers, and gauge glasses shall

be readable from grade, platforms, or permanent ladders.

G. Instruments shall not protrude into or obstruct access ways so as to inhibit area

personnel egress.


5/12

Polaris

Engineering

Standard

0905.1.0

Rev.: 7

Page: 5 of12

Date: 11/11/04H. Instruments shall be located to allow performance of routine services with

unobstructed access to the instrument.

Comment: Clearances shall be provided for the removal of covers andcases and the opening of doors and enclosures. Access for

appropriate lifting equipment shall be provided when

necessary for control valves. Control valve bypass piping

shall not interfere with mounting the control valve operator

vertically.

I. Local controllers and receiver instruments shall be located and readable in the

vicinity of the final control element. Actions resulting from operational changes

of a local instrument (e.g., control valve movement or vessel level changes) shall

be observable from the receiver instrument location.

V. INSTRUMENT AND TUBING MOUNTING SUPPORTS

A. Direct-reading instruments shall be supported by piping or equipment. (e.g.,

pressure gauges and dial thermometers).

B. Field instruments shall be mounted on instrument supports designed for that

purpose. Instruments shall not be supported from the process piping except for

primary devices that must mount inline.

Comment: Size and weight of instruments as well as heat or vibration

in piping systems affect the mounting location and support

requirements.

C. A prefabricated, 2-inch, schedule 40 pipe stand support shall be used for field

instrument mounting. The pipe stand shall be hot-dipped galvanized as a

minimum requirement. The top of the pipe shall be plugged or sealed to prevent

water entry.

D. Welded areas, drilled holes, and pipe threads on galvanized steel shall be prepared

and sprayed with cold galvanized coating.

E. In general, single pipe stands dedicated to single instruments shall be used. When

necessary, a single pipe stand fabricated to support multiple support arms may be

used.

F. Pipe stands shall be securely anchored. Where pipe stands are mounted to

concrete surfaces, a 1 space between the mounting plate and grade shall be

required to allow for grouting. Pipe stands directly embedded into concrete

surfaces shall not be an acceptable practice.


6/12

Polaris

Engineering

Standard

0905.1.0

Rev.: 7

Page: 6 of12

Date: 11/11/04G. Instrument process piping and tubing shall be supported as necessary to maintain

structural integrity.

H. All instrument piping and tubing between the instrument and process equipment

or pipeline shall be properly supported to prevent strain on the instrument,equipment, and piping connections. Care shall also be taken to accommodate

thermal expansion or relative motion of piping or equipment to which such

instrument items are connected. Supporting instrument piping from bare hot or

cold pipe shall be avoided.

I. When fire protection is required for stainless steel tubing, it must be supported by

stainless steel tray.

VI. INSTRUMENT PROCESS CONNECTIONS

A. General

1. A line class root or isolation valve shall be provided at each process

connection. This valve shall be specified and provided by the piping

discipline.

2. Instrument process connections shall be made to either the side, top, or

upper or lower 45-degree angle of process piping or equipment as directed

by the Client and Polaris. When low-side connections are specified, these

connections shall be sufficiently high to prevent plugging by dirt or

suspended solids.

Connections shall be short and without pockets.

3. Special attention shall be given to the location of process connections on

vessels. Temperature sensors shall be placed in flowing streams, not in

stagnant fluid. Where equipment has piped bypass, temperature sensors

shall be installed outside the bypass piping.

4. Pressure-sensing points (for pressure, differential, and level

measurements) shall be located such that error from fluid impact and

velocity effects is avoided.

5. Instrument process connections shall conform to the requirements in the

piping or equipment specifications.

B. Purging of Process Connections

1. Purging of process connections shall be used to prevent plugging, freezingand corroding.

2. The purge fluid shall be compatible with the process fluid.


7/12

Polaris

Engineering

Standard

0905.1.0

Rev.: 7

Page: 7 of12

Date: 11/11/043. When purging is required, the purging system shall not induce error in the

process measurement.

4. Gas purges shall not exceed 3 standard cubic feet per hour, and liquidpurges shall not exceed 3 gallons per hour, unless specifically required by

design conditions.

5. Gas purges shall be traced and insulated if condensation is a problem.6. Provision shall be made for draining condensed liquids from gas purge

systems at low points in the piping system.

7. For solids-bearing streams, the purge instrument connections to theprocess equipment or piping shall be vertical or angled up.

8. Purge should be near the process connection. The purge may be located

nearer to the instrument when impulse tubing lines are long.

9. The temperature of the purge fluid shall not cause a change of state(flashing, condensation, or solidification) of the process or purge fluid.

10. The supply source of the purge fluid shall be independent from the processfluid so that it is available even when the process is not operating

normally.

11. The purge fluid flow rate shall be the same to each tap on an orifice meterinstallation.

12. Purging systems shall include a check valve and shutoff valve.VII. INSTRUMENT ENVIRONMENTAL PROTECTION

A. Enclosures

1. Instruments requiring protection from freezing shall be provided with an

insulating protective enclosure. Manifold valves, where required, shall be

included within the enclosure.

2. The temperature for instrument electronics shall be maintained within the

manufacturers recommended minimum and maximum values.

3. Use of soft type instrument enclosures is acceptable where space

requirements are not adequate for hard-pack enclosures.

4. Electrical heating elements used in the enclosure shall meet the electrical


8/12

Polaris

Engineering

Standard

0905.1.0

Rev.: 7

Page: 8 of12

Date: 11/11/04area classification.

5. Space inside an enclosure and around the instrument shall be adequate for

routine maintenance and for removal of the instrument. Properly sized and

positioned access doors are required.

6. Process impulse lines shall enter through the side or bottom of the

enclosure (never through the top) and shall be located to minimize piping

requirements. All penetrations through the side or bottom shall be sealed.

7. Full hard-pack enclosures shall be wall-mounted or attached to an

instrument pipe stand.

8. Metal enclosures shall be corrosion resistant. The hardware, assembly

bolts, and screws shall be stainless steel. NEMA 4X enclosures shall be

the minimum rating for outdoor instrumentation.

B. Heat Tracing

1. General

a. Process impulse lines and instruments containing either

vapors that may condense at ambient temperatures or

liquids that will freeze or congeal shall be insulated and/or

heat traced. Each potential application shall be investigated

to determine the degree and type of heat tracing that is

required. This section does not cover heat tracing for

process pipelines.

b. Self-limiting electric tracing shall not be used when

temperatures exceed 250F.

c. Steam tracing can be used when required system

temperatures are above 200F.

d. Constant-resistance electric tracing shall be used when

temperature control is required.

e. Insulation and heat tracing shall be applied to the process-

wetted parts of the instrument, never to electronics or to

pneumatic parts.

2. Steam Tracing

a. The use of prefabricated heat-tracing bundles is preferred.

When short leads or configuration prevents reasonable use


9/12

Polaris

Engineering

Standard

0905.1.0

Rev.: 7

Page: 9 of12

Date: 11/11/04of this material, individually designed systems shall be

provided. See POLARIS Standard 810.1 for (steam) Heat

Tracing.

b. For maximum heat transfer, the tracer shall be held indirect contact with the instrument line or equipment. Steam

pressure shall be selected for the desired heating; however,

consideration must be given to boiling or process

degradation.

c. When the process fluid in the instrument line is temperature

sensitive or has a boiling point lower than the steam

temperature, the tracer shall be separated from the line

using a spacer or insulation to prevent hot spots in the

heated line. Asbestos-free insulation tape or blocks shall be

used to separate steam tracing tubing from meter body,

instrument enclosure, and impulse tubing and piping.

Spacing shall be a minimum of 1/2 inch.

d. All steam tracing connections shall be made outside the

instrument enclosure.

e. Low-pressure steam (less than 75 pounds per square inch

gage [psig]) shall be used for steam tracing of impulse

lines.

f. Pre-insulated tubing shall be used to carry steam tracing

from a steam

tracing station to the instrument to be traced.

g. If a condensate return system is available condensate from

individual steam traps shall be returned by pre-insulated

tubing.

h. Instrument tracing tubing shall be 3/8-inch or - inch

outside diameter (OD) 316SS x 0.035 inch wall.

i. The steam supply to the tracing leads shall enter at the high

point of the tracing system. The tracing leads shall be

horizontal or continuously sloped downward to a steam

trap, low-point drain, or condensate return header.

j. A separate trap shall be installed for each tracer circuit.

k.. All bare steam tracers shall be insulated for protection of

personnel.


10/12

Polaris

Engineering

Standard

0905.1.0

Rev.: 7

Page: 10 of12

Date: 11/11/04l. Ends of tubing bundles and any other openings shall be

sealed to prevent entrance of moisture.

m. Tracing of individual instruments shall be done to allowremoval of the instrument for maintenance.

Comment: To prevent removal of the tracing line to an

instrument, a tubing block valve may be

installed in the racer line at each instrument.

This installation avoids closing the header

valve for maintenance. A valve is also

required on the condensate return line if the

condensate discharges to a header. Tubing

unions shall be supplied on both ends of

tracing wrap for the instrument. Unions

installed in tracer systems shall be left un-

insulated for easy access, unless protection

is required.

n. Steam branches shall be taken from the top of the header to

assure that dry steam will be supplied. Each branch shall

have an individual shutoff valve to eliminate bypassing and

recycling within the tracer system. Each tracer shall be

individually trapped.

o. Traps shall be accessible for inspection and maintenance.

p. Siphons, flanges, etc., are to be wrapped completely with

fiberglass tape to enclose tracer and instrument piping,

even though the tracer may not follow the siphon or full-

flange surface.

q. Condensate pots shall not be insulated.

3. Electric Heat Tracing

a. Electric heat tracing shall only be used in the absence of

steam, other economic considerations, or other technical

reasons deem it advisable. Use of electric tracing requires

the Client and Polariss approval. See POLARIS Standard

1073.1 for Electrical Heat Tracing. Wind velocity of 25

miles per hour (mph) shall be used in determining the

required heat input. The system shall be designed to

maintain the temperature of all freeze-protected lines

and/or instruments at 50F or greater, as required. In


11/12

Polaris

Engineering

Standard

0905.1.0

Rev.: 7

Page: 11 of12

Date: 11/11/04addition, an energy disconnect device must be provided for

each electric traced instrument.

b. When designing an electric tracing system, abnormal

situations such as steam outs shall be considered. The heattracing cable shall be designed to withstand the maximum

steam out temperature.

c. Electric heat tracing shall be designed to meet the electrical

area classification of the area in which the tracing will be

installed Components used in the system shall be approved

by nationally recognized laboratory for the area

classification involved.

d. Self-limiting parallel resistance or constant-watt parallel

resistance type heating cable shall be used for electric heat

tracing. Heating cables shall be selected with a watts per

foot rating to prevent overheating.

e. Only mineral-insulated or high-temperature-rated constant-

watt-type heating cable shall be used.

f. Prefabricated tubing bundle systems (consisting of process

compatible instrument tubing, self-limiting or constant-watt

heater cables with insulation, and outer jacket) shall be the

preferred method of freeze protecting and heat tracing

instrument impulse lines.

g. Each heat tracing cable shall be permanently tagged with a

stainless steel identification tag attached at the power

connection box end of the circuit. The tag for each cable

shall indicate the panel identification (ID) and circuit

number.

h. Heat trace cables shall be installed according to the

manufacturers recommended standards. Detail drawings

shall give information concerning specific application to

instrumentation and impulse lines. The manufacturers

installation procedures shall be followed.


12/12

Polaris

Engineering

Standard

0905.1.0

Rev.: 7

Page: 12 of12

Date: 11/11/04i. Tracing of individual instruments shall be done to allow

removal of the instrument for maintenance.

Comment: A breaker panel may be provided to de-energize circuits, or physical disconnects

may be provided in tracers to permit the

removal of instruments without distorting or

cutting the wire.

j. All electrically traced instruments shall be properly tagged

with a warning about the danger of cutting into an

energized cable when removing insulation.

C. Fire Protection

1. Instrumentation systems shall be provided with protection from an

external fire when specified in Engineering Standard 1300.1

Protection shall be provided for instrument components, tubing,

wiring, conduit, and control valves.

2. Fire protection shall be specific to the type of hazard and can be

achieved by using intumescent coating, insulation, jacketing, deluge,

or a combination of methods.

Documents

0905.1.0 - Instrument Installation Requirements