Tank Gauging

Sohar Refinery Company SOHAR Refinery Project

JOB No.

DATE 24

PROJECT SPECIFICATION

JGC DOC.

0-3100-25 −

SEP

−

T.

Kannan

PREP’D CHK’D APP’D

No.

REV.

S-000-1377-001

S. K.

2003

1

SHEET

R1 OF

33

Jacobsson Hirabuki

SPECIFICATION FOR TANK GAUGING SYSTEM

UNIT 000 GENERAL

FOR CONSTRUCTION

SOHAR REFINERY COMPANY L. L. C. SOHAR REFINERY PROJECT SOHAR, SULTANATE OF OMAN

REV.

DATE

PAGE

0

24SEP 2003

All

R

2 FEB 2004

All

R1

10Nov 2004

All

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N

Reference ITT Doc. No.

Rev

S-000-1377-001

D

PREP’D

CHK’D

APP’D

TK

SGJ

KH

For Construction as per JY-OY-E-20677, 20921

TK

SGJ

KH

For Construction as per JY-OY-M-20858

TK

S.W

HF

DESCRIPTION For Approval

JOB CODE: 0-3100-25 DOC NO: S-000-1377-001 rev.R1 SHEET : 2 of 33

Sohar Refinery Company SOHAR Refinery Project Specification for Tank Gauging System

CONTENTS 1

INTRODUCTION...................................................................................................................................... 3

1.1

Scope....................................................................................................................................................... 3

1.2

Applicable Documents .......................................................................................................................... 3

1.3

Conflict and Deviations......................................................................................................................... 4

1.4

Abbreviations......................................................................................................................................... 4

2

GENERAL.................................................................................................................................................. 5

2.1

Scope of Supply ..................................................................................................................................... 5

2.2

Accuracy ................................................................................................................................................ 5

2.3

Miscellaneous Hardware ...................................................................................................................... 5

2.4

Installation Environment...................................................................................................................... 6

2.5

Hazardous and Environmental Protection.......................................................................................... 6

2.6

Power Supplies....................................................................................................................................... 7

3

GENERAL REQUIREMENTS ................................................................................................................ 8

3.1

Measurement Technologies................................................................................................................... 8

3.2

Scope of Supply ..................................................................................................................................... 8

3.3

Functional Requirements...................................................................................................................... 9

3.4

Cables ................................................................................................................................................... 10

4

FIELD INSTRUMENT REQUIREMENTS.......................................................................................... 11

4.1

Temperature......................................................................................................................................... 11

4.2

Name Plate ........................................................................................................................................... 11

4.3

Flange Face Finish............................................................................................................................... 11

5

FACTORY ACCEPTANCE TESTS (FAT) ............................................................................................ 12

5.1

Test Records and As Built Documents............................................................................................... 12

6

DOCUMENTATION ............................................................................................................................... 13

7

PACKAGING AND DELIVERY............................................................................................................ 13

8

SITE ACCEPTANCE TESTS (SAT)...................................................................................................... 13

9

DATA SHEETS ........................................................................................................................................ 14

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N

Sohar Refinery Company SOHAR Refinery Project

JOB CODE: 0-3100-25 DOC NO: S-000-1377-001 rev.R1 SHEET : 3 of 33

Specification for Tank Gauging System

1

INTRODUCTION This specification defines requirements or the Tank Gauging System (TGS), for the Sohar Refinery Project.

1.1 Scope The tank gauging system shall consist of tank level gauges, temperature sensors, field signal transmission equipment, volume calculation computers, DCS interface, HMI workstations, report printers, and other auxiliary system equipment. The TGS shall be used as a back up for custody metering systems. The Vendor shall provide fully assembled, wired, programmed and functionally tested tank gauging systems.

They shall include the hardware, software, testing, licenses, documentation and all the design,

engineering, programming, project services, packing, delivery and commissioning.

1.2 Applicable Documents The following documents are to be referenced for detailed requirements of the TGS. •

P&IDs

•

This specification

•

Other applicable documents S-000-1370-002 Instrument and Control Philosophy S-000-1371-201 Specification for Cabinet/Rack Design S-000-1373-001 Specification for transmitters D-000-1225-002 Refinery General Plot Plan D-000-1371-102 Tank Gauging System Configuration D-000-1378-201 Equipment Layout in Main Control Building

•

Other international standards API Manual of Petroleum Measurement Standards Part 5 API Volume Correction Tables IEC60079

Electrical apparatus for explosive gas atmospheres

IEC60529 Degree of protection provided by enclosure

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N

Sohar Refinery Company SOHAR Refinery Project

JOB CODE: 0-3100-25 DOC NO: S-000-1377-001 rev.R1 SHEET : 4 of 33

Specification for Tank Gauging System

1.3 Conflict and Deviations If any inconsistency or conflict exists between this specification and other documents, industrial standards or drawings, it shall be the responsibility of the Vendor to bring the inconsistency to the attention of the Contractor in writing. The Contractor will resolve the inconsistency / conflict and will notify to the Vendor.

1.4 Abbreviations The following abbreviations are used within this document:

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N

DCS

Distributed Control System

ESD

Emergency Shutdown System

EWS

Engineering Workstation

FAT

Factory Acceptance Tests

ICIMS

Integrated Control Information Management System

MCB

Main Control Building

MCR

Main Control Room

MOV

Motor Operated Valve

HMI

Human Machine Interface

MTBF

Mean Time Between Failures

OPC

OLE for Process Control

OPS

Operator Station

PC

Personal Computer

SAT

Site Acceptance Tests

S&W

Sediment & water

SIH

Satellite Instrument House

TLAS

Truck Loading Automation System

TGS

Tank Gauge System

VDU

Visual Display Unit

Sohar Refinery Company SOHAR Refinery Project

JOB CODE: 0-3100-25 DOC NO: S-000-1377-001 rev.R1 SHEET : 5 of 33

Specification for Tank Gauging System

2

GENERAL

2.1 Scope of Supply Attachment-1 provides a list of tanks for the Sohar Refinery Project. The Vendor shall be responsible for the design, supply, fabrication, testing, system configuration, delivery, and commissioning.

The following

list of the major equipment shall be supplied as part of the tank gauging system: •

Tank level gauges

•

Temperature sensors

•

Pressure transmitters for pressurised storage tanks

•

Field display units

•

Field network controllers

•

Inventory management data servers located in SIH

•

MCB operator interface complete with Vendor standard graphic displays

•

DCS interface

The above equipment shall be supplied based on the API standards referred above as applicable documents.

2.2 Accuracy The required accuracy shall be within +/- 2 mm over the entire temperature range. This accuracy shall be based on the maximum error.

2.3 Miscellaneous Hardware 2.3.1

Personal Computers

The Vendor shall supply three (3) PCs and two (2) printers to suit the tank gauging system requirements as part of this specification. The following general requirements shall apply to PC type equipment in the absence of more specific requirements:

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N

•

Pentium IV processor, 40 GB Hard disk and 128MB RAM, 14 inch TFT screen for a laptop.

•

Pentium IV processor, 80 GB Hard disk and 256MB RAM, 17 inch LCD for a desktop PC.

•

Ink-Jet type printers with A4 plain paper tray and feeder, colour and black ink cartridges.

•

All keyboards, operating software and documentation shall be English language based.

JOB CODE: 0-3100-25 DOC NO: S-000-1377-001 rev.R1 SHEET : 6 of 33

Sohar Refinery Company SOHAR Refinery Project Specification for Tank Gauging System

The Vendor shall note that, as the life span of a PC is relatively short, and to have the latest state-of-the-art equipment, the ordering and supply of PC equipment shall be as late as possible prior to start of Factory Acceptance Testing of the tank gauging system.

2.4 Installation Environment (1) Indoor All control equipment and system cabinets shall be installed within climate-controlled buildings with the following conditions: Temperature

24 +/- 2 deg C

Relative Humidity

50 +/- 10 %

(2) Outdoor Maximum ambient temperature

+47.5°C

Design maximum

+42°C

Design minimum

+5°C

Winterizing temperature

+5°C

Elevation above sea level

5m

Humidity (relative humidity)

Max 100%/ Nor 80%/ Min 6%

Location

Sea coast

Note 1: The Vendor shall study the effect of the maximum ambient temperature and advise The Contractor of any additional design provisions which should be included to ensure best TGS performance and reliability.

The study and result shall be included with Vendor’s proposal.

2.5 Hazardous and Environmental Protection 2.5.1

Electrical Hazardous Area Classification for field equipment. •

Zone 1, IIC, T3 for within 3 meter from the surface of the storage tank.

•

Zone 0 for inside of the storage tanks

2.5.2

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N

Electrical Hazardous Certification for field instruments. •

Exd for radar tank gauges

•

EExi or Exi for auxiliary instruments, (temperature, pressure etc.)

•

A certificate from an appropriate approval agency is required

JOB CODE: 0-3100-25 DOC NO: S-000-1377-001 rev.R1 SHEET : 7 of 33

Sohar Refinery Company SOHAR Refinery Project Specification for Tank Gauging System

2.5.3

Classification of degree of protection provided by enclosure (IEC-60529) •

IP 55 as a minimum

2.6 Power Supplies Redundant UPS AC feeders by the contractor will be available to power the tank gauging system equipment with 30min backup time in case of site power failure conditions. Redundant central equipment shall be powered from different circuits so that one power feeder failure shall not cause the failure or shutdown the system and shall maintain continuous operation. Voltage and Frequency

240VAC +/-10% and 50 Hz +/- 5 %

Individual PCs will be provided with single power supply, but redundant pairs shall be distributed to suit the dual supply. Field equipment shall be powered with a single supply at 240VAC 50 Hz. The Vendor shall provide a power distribution system for all field instruments.

Power distribution equipment in the cabinet, ie

breaker with fuse, terminal, shall be prepared as per Attachment-1. The Contractor will supply power cable to field instruments.

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N

Sohar Refinery Company SOHAR Refinery Project

JOB CODE: 0-3100-25 DOC NO: S-000-1377-001 rev.R1 SHEET : 8 of 33

Specification for Tank Gauging System

3

GENERAL REQUIREMENTS

3.1 Measurement Technologies The Vendor shall supply Radar type tank gauges for the accurate measurement of levels within the tanks. The gauges shall be microprocessor based with capability for stand-alone operation with a local display and communication with a central PC for inventory management display and logging/alarm features.

3.2 Scope of Supply The number of storage tanks and operating conditions, to which the tank gauge system shall be supplied, are listed in Attachment-1. The Contractor will provide stilling wells for radar gauges except for cone roof type tanks, and for multi-point temperature sensors except for cone roof type tanks and sphere tanks. The Vendor shall supply field TGS instruments as follows: 3.2.1

Sphere Tanks

For tanks T-6214 A to J, T-6215 and T-6216 A to E •

Two (2) radar type tank gauges

•

One (1) field indicator mounted at grade level

•

One (1) single-point temperature sensor in liquid

•

One (1) pressure transmitter in the vapour space

3.2.2

Intermediate Storage Tanks

For tanks T-6102 to 6106, and T-6108 •

One (1) radar type tank gauge

•

One (1) field indicator mounted at grade level

•

One (1) single-point temperature sensor

3.2.3

Other Tanks

For other storage tanks

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N

•

One (1) radar type tank gauge

•

One (1) field indicator mounted at grade level

•

One (1) multi-point temperature sensor

JOB CODE: 0-3100-25 DOC NO: S-000-1377-001 rev.R1 SHEET : 9 of 33

Sohar Refinery Company SOHAR Refinery Project Specification for Tank Gauging System

Stainless steel sunshade shall be provided for each tank gauge. 3.2.3

Field Communication

The Vendor shall supply all redundant communication equipment to connect the level gauges to the central inventory management system to be installed in SIH-4. redundant communications path.

Field wiring shall be looped to provide a

The Vendor shall submit a system configuration drawing and confirm

the redundancy provisions in his bid proposal.

3.2.4

Tank Inventory System

The Vendor shall provide the tank inventory system PCs and printers as follows: •

Two (2) PCs and one (1) printer, in redundant configuration, shall be provided in SIH-4 for maintenance and DCS communication.

•

One (1) PC and one (1) printer shall be provided in the system room in the MCB for monitoring and maintenance.

The cabling distance between SIH-4 and the MCB is approximately 1,100m. a shared Ethernet LAN communication network between SIH-4 and the MCB.

The Contractor will provide The Vendor shall confirm

the suitability of this communication method and estimated data traffic in his bid proposal.

3.2.5

System Cabinet

The Vendor shall provide system cabinet to house communication equipment, terminal blocks for field wiring, etc. The cabinet shall conform to the requirements of S-000-1371-201.

3.3 Functional Requirements 3.3.1

TGS Functions

The TGS shall provide the following general requirements:

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N

•

Automatic scanning of all tank levels, temperature and pressure if any.

•

Continuous calculation of total volume from the level measurement and stored calibration table.

•

Operator interface with graphic displays of tanks

•

Average temperature calculation from the measured temperatures from the immersed multi-point temperature sensor.

Sohar Refinery Company SOHAR Refinery Project

JOB CODE: 0-3100-25 DOC NO: S-000-1377-001 rev.R1 SHEET : 10 of 33

Specification for Tank Gauging System

•

Continuous calculation of corrected standard volumes in accordance with API Volume Correction Tables and Weight-In-Air based on downloaded density.

•

Historical and real time trending of level and temperature

•

Reports, scheduled and on demand. The format of reports shall be user configurable.

3.3.2

DCS Interface

The Vendor shall provide serial communication, using Modbus RTU protocol, between each tank inventory PC in SIH-4 and the DCS.

All measured values, calculated values and system status shall be transferred

to the DCS. The tank density and S&W (for Crude feed tank) shall be sampled from laboratory and input to the TGS PC. Both data links shall be identically configured to provide a redundant communications path. The DCS will transfer data from the tank inventory system to the Integrated Control and Information Management System (ICIMS). The distance between the TGS and the DCS is approximately 15m.

The Vendor shall provide all

communication equipment between TGS and DCS.

3.4 Cables Field signal transmission may be via a two wired redundant multi-drop field bus system.

The Vendor

shall provide any special communications cables and connectors if necessary. The Vendor shall quote unit prices and the Contractor will determine the quantity. The Contractor will provide normal field cables as part of system installation.

The cable specification

will be in accordance with BS 5308 Part 1, steel wire armoured (SWA). The Vendor’s shall advise standard cable requirements in his bid.

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N

JOB CODE: 0-3100-25 DOC NO: S-000-1377-001 rev.R1 SHEET : 11 of 33

Sohar Refinery Company SOHAR Refinery Project Specification for Tank Gauging System

4

FIELD INSTRUMENT REQUIREMENTS The Vendor shall supply instruments as follows: •

Radar type tank gauge

53 pcs

•

Radar type tank gauge for utilizing as level switch

16 pcs

•

Single-point temperature sensor with thermowell

22 pcs

•

Multi-point temperature sensor

31 pcs

•

Pressure transmitter for sphere tank

16 pcs

These instruments except pressure transmitters shall be supplied as the following data sheets (Section 9). Pressure transmitters shall conform to the requirements of S-000-1373-001. All electrical connection shall be ISO metric (female). HH and LL alarm shall be available for 16 pcs radar tank gauges for utilizing as level switch. 4.1 Temperature Single-point temperature elements shall be 3 wire connection RTD Pt 100Ω type, 6.4mm OD sheath and 316 SS sheath material as minimum unless otherwise specified on the instrument specification. Thermowell shall be bar stock fabrication and assembled with NPT threaded flange with seal weld. Multi-point temperature element type shall be TC with reference RTD Pt 100Ω. The measurement point will be 16 points per tank. The vendor shall apply manufacture’s standard to sheath material.

4.2 Name Plate All field instruments and accessories shall be provided with manufacturer’s standard corrosion resistant name plate, showing Manufacture name, Tag No., Serial No., Model No., Material, Rating, Range, etc. So-called Dymo tape or equivalent is not allowed.

4.3 Flange Face Finish Flange face finish shall be smooth.

Smooth face finish specification is as follows.

The gasket contact surface shall be serrated either a concentric or continuous spiral in accordance with ASME B16.5 para.6.4.4.3 or B16.47 para.6.1.4.2. The resultant of face shall be in a roughness between Ra 3.2 and Ra 6.3µm (125µin. to 250µin.)

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N

Sohar Refinery Company SOHAR Refinery Project

JOB CODE: 0-3100-25 DOC NO: S-000-1377-001 rev.R1 SHEET : 12 of 33

Specification for Tank Gauging System

5

FACTORY ACCEPTANCE TESTS (FAT) The Vendor shall carry out the FAT to confirm that all of system hardware, system software, application software and interface to other system conform to requirements specified on relevant specification sheets and drawings. The Vendor shall issue detailed lists of test items and test procedures for approval by the Contractor.

The Contractor and the Owner shall attend the FAT.

The following tests shall be completed and its’ test report shall be issued by the Vendor before FAT. •

System test i.e. redundancy and diagnostic check etc.

•

I/O test

•

Debugging

•

Sphere gauges hydrostatically tested to 1.5 times the maximum design pressure of the sphere tanks

•

Gauges individually calibrated.

5.1 Serial Communications Test with DCS The Vendor shall provide a TGS PC operator station, and software engineer, to the DCS vendor’s factory (Singapore) to perform a serial communication test with the DCS. Fully integrated serial communication testing shall be performed at site.

5.2 Test Records and As Built Documents Test records shall be supplied at the end of successful witness tests and shall include all marked-up engineering documents, if corrections or further developments are made. Test records shall clearly indicate the equipment serial number and shall include an equipment list recording the location of each item. The Vendor shall issue revised “As Built” documents to cover any changes made as a result of the testing. All test results shall be recorded and supplied to the Contractor. Faults discovered during inspection and testing shall be rectified at Vendor cost before proceeding further. All previously tested circuits affected by the repair work shall be re-tested. The supply voltage to the cabinets at the time of the test shall be noted in the test report.

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N

Sohar Refinery Company SOHAR Refinery Project

JOB CODE: 0-3100-25 DOC NO: S-000-1377-001 rev.R1 SHEET : 13 of 33

Specification for Tank Gauging System

6

DOCUMENTATION The Vendor’s deliverable documentation schedule shall be included in his scope which shall contain, as a minimum: •

Document list

•

System design specification

•

Hardware specification including 3rd party supply equipment

•

System software specification

•

Project schedule

•

Power consumption and heat dissipation

•

Quality control procedure of design and test for hardware and software

•

Detail I/O signal and cabinet assignment,

•

Power distribution plan and earthing system

•

Serial link address map

•

Operation and maintenance manuals

•

FAT and SAT procedure

•

Manufacturing data record

•

Other documents as specified on the requisition

All documents shall be written in the English language. Documents shall also be submitted on electronic media.

7

PACKAGING AND DELIVERY The Vendor scope shall include packing for ocean transportation and FOB delivery in accordance with project shipping specifications. The Vendor shall provide adequate vacuum packing and protection.

8

SITE ACCEPTANCE TESTS (SAT) The SAT shall be included in the scope of the Vendor’s activities. SAT shall include the installation check, I/O check, full function/calibration check and integrated communication check to the DCS. The Vendor shall perform system tests to confirm the correct installation and standard system function, (e.g. network and redundancy tests), to indicate that the systems are working properly as tested during FAT. SAT shall also include integrated communication tests with all subsystems.

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N

JOB CODE: 0-3100-25 DOC NO: S-000-1377-001 rev.R1 SHEET : 14 of 33

Sohar Refinery Company SOHAR Refinery Project Specification for Tank Gauging System

9

DATA SHEETS Code and notes shown on the data sheets shall be follows. (1) -E : Electronic

-T : Transmitter

-LI : Local indicator at grade

(2) RF : Raised face

-SM : Smooth Face Finish

(3) MFR’s STD : Manufacturer’s standard (4) CRT :

Cone roof type tank

FRT :

External floating roof type tank

IFRT :

Internal floating roof type tank

Sphere :

Pressured sphere type tank

(5) Engineering unit of Pressure barg

: Pressurized Spherical Tank (T-6214A-J, T-6215, T-6216A-E)

mmH2O

: Storage Tank (the other Tanks)

(6) Tank Class A1A1: 150# Carbon Steel A1A2: 150# Carbon Steel A2A1: 300# Carbon Steel B2A1: 300# Killed Carbon Steel

Note: Meter range of temperature, level and pressure shall be advised by Vendor based on following data sheet. Regarding multi-temperature element, detail information shall be also advised by Vendor.

_ _ _ __ RA| D __| N I ||___ -2004

OV 17-N