INSTRUMENT INSTALLATION REQUIREMENTS TABLE OF ...

Polaris
Engineering
Standard
0905.1.0
Rev.: 7
Page: 1 of 12
Date: 11/11/04
INSTRUMENT 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

Polaris
Engineering
Standard
0905.1.0
Rev.: 7
Page: 2 of 12
Date: 11/11/04
INSTRUMENT INSTALLATION REQUIREMENTS
I. SCOPE
A. This Standard covers general requirements for installation of instruments and is
intended 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
Polaris’s 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

Polaris
Engineering
Standard
0905.1.0
Rev.: 7
Page: 3 of 12
Date: 11/11/04
8. 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 the
vendor before shipment by using at least one of the following methods:
a. A permanently affixed nametag
b. An engraving on the instrument
c. 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 be
identified 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 of
safety instruments.

Polaris
Engineering
Standard
0905.1.0
Rev.: 7
Page: 4 of 12
Date: 11/11/04
C. Control and Rack Panel Instruments and Accessories
1. Instruments and accessories that require identification nametags or
nameplates 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.

Polaris
Engineering
Standard
0905.1.0
Rev.: 7
Page: 5 of 12
Date: 11/11/04
H. 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 and
cases 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.

Polaris
Engineering
Standard
0905.1.0
Rev.: 7
Page: 6 of 12
Date: 11/11/04
G. 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, freezing
and corroding.
2. The purge fluid shall be compatible with the process fluid.

Polaris
Engineering
Standard
0905.1.0
Rev.: 7
Page: 7 of 12
Date: 11/11/04
3. 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 liquid
purges 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 the
process 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 process
fluid 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 meter
installation.
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
manufacturer’s 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

Polaris
Engineering
Standard
0905.1.0
Rev.: 7
Page: 8 of 12
Date: 11/11/04
area 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
2. Steam Tracing
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 250°F.
c. Steam tracing can be used when required system
temperatures are above 200°F.
d. Constant-resistance electric tracing shall be used when
temperature control is required.
e. Insulation and heat tracing shall be applied to the processwetted
parts of the instrument, never to electronics or to
pneumatic parts.
a. The use of prefabricated heat-tracing bundles is preferred.
When short leads or configuration prevents reasonable use

Polaris
Engineering
Standard
0905.1.0
Rev.: 7
Page: 9 of 12
Date: 11/11/04
of 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 in
direct 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 ½- 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.

Polaris
Engineering
Standard
0905.1.0
Rev.: 7
Page: 10 of 12
Date: 11/11/04
l. 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 allow
removal 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 uninsulated
for easy access, unless protection
is required.
3. Electric Heat Tracing
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 fullflange
surface.
q. Condensate pots shall not be insulated.
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 Polaris’s 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 50°F or greater, as required. In

Polaris
Engineering
Standard
0905.1.0
Rev.: 7
Page: 11 of 12
Date: 11/11/04
addition, 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 heat
tracing 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 constantwatt-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
manufacturer’s recommended standards. Detail drawings
shall give information concerning specific application to
instrumentation and impulse lines. The manufacturer’s
installation procedures shall be followed.

Polaris
Engineering
Standard
0905.1.0
Rev.: 7
Page: 12 of 12
Date: 11/11/04
i. Tracing of individual instruments shall be done to allow
removal of the instrument for maintenance.
Comment:
A breaker panel may be provided to deenergize
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.