Professional Documents
Culture Documents
FOR RESTRICTED
CIRCULATION ONLY
No.
FOR RESTRICTED
CIRCULATION ONLY
No.
Prepared by:
NOTES
OIL INDUSTRY SAFETY DIRECTORATE (OISD) publications
are prepared for use in the Oil and gas industry under Ministry of
Petroleum and Natural Gas. These are the property of Ministry of
Petroleum and Natural Gas and shall not be reproduced or copied
and loaned or exhibited to others without written consent from OISD.
Though every effort has been made to assure the accuracy and
reliability of data contained in these documents, OISD hereby
expressly disclaims any liability or responsibility for loss or damage
resulting from their use.
These documents are intended only to supplement and not to
replace the prevailing statutory requirements.
Note
in
superscript
modification/changes/addition
indicates
based
on
the
the
FOREWORD
The Oil Industry in India is nearly 100 years old. Because of
various collaboration agreements, a variety of international codes,
standards and practices have been in vogue. Standardisation in
design philosophies and operating and maintenance practices at a
national level was hardly in existence. This, coupled with feed back
from some serious accidents that occurred in the recent past in India
and abroad, emphasized the need for the industry to review the
existing state of art in designing, operating and maintaining oil and
gas installation particularly using sophisticated instrumentation.
With this in view, the Ministry of Petroleum & Natural Gas,
in 1986, constituted a Safety Council assisted by Oil Industry Safety
Directorate (OISD), staffed from within the industry, in formulating
and implementing a series of self regulatory measures aimed at
removing obsolescence, standardising and upgrading the existing
standards to ensure safe operations. Accordingly, OISD constituted
a number of Functional Committees of experts nominated from the
industry to draw up standards and guidelines on various subjects.
The present document on Maintenance & Inspection of
Safety Instrumentation in Hydrocarbon Industry is prepared by the
Functional Committee on Process Instrumentation Maintenance
and Inspection. This standard is based on the accumulated
knowledge and experience of Industry members and the various
national and international codes and practices. It is hoped that
provisions of this document, when adopted, may go a long way to
improve the safety and reduce accidents in Oil and Gas Industry.
Users of this standard are cautioned that no standard can be a
substitute for a responsible, qualified Instrumentation Engineer.
Suggestions are invited from the users after it is put into practice to
improve the document further.
This standard in no way supercedes the statutory regulations
of Chief Controller of Explosives (CCE), Factory Inspectorate or any
other statutory body which must be followed as applicable.
Suggestions for amendments to this document should be
addressed to:
The Co-ordinator,
Committee on
Process Instrumentation, Maintenance & Inspection
Oil Industry Safety Directorate,
2nd Floor, Kailash
26, Kasturba Gandhi Marg
New Delhi-110 001
.
COMMITTEE
ON
PROCESS ISNTRUMENTATION, MAINTENANCE AND INSPECTION
LIST OF MEMBERS
-------------------------------------------------------------------------------------------------------------------------------------Name
Designation / Organisation
Status
-------------------------------------------------------------------------------------------------------------------------------------S/Shri
A. Majumdar
Leader
V.K. Agarwal
Member
S. Raghuraman
Member
C.S. Ooman
Member
R.D. Shira
Member
P. Kajendran
Member
S. Rammohan
Member
V.M.Ranalkar
Member
Co-ordinator.
-------------------------------------------------------------------------------------------------------------------------------------In addition to the above several experts from industry contributed in the preparation, review and
finalisation of the document.
INTRODUCTION
2.0
SCOPE
3.0
PRE-COMMISSIONING CHECKS
3.1
IMPULSE PIPING
3.2
3.3
3.4
3.5
3.6
SPECIAL INSTRUMENTS
3.7
MISCELLANEOUS ACTIVITIES
4.0
INSPECTION CHECKS
4.1
4.2
4.3
FIELD TRANSMITTERS
4.4
4.5
4.6
INSTRUMENT ACCESSORIES
5.0
MAINTENANCE CHECKS
5.1
5.2
LEVEL ALARMS
5.3
TEMPERATURE ALARMS
5.4
FLOW ALARMS
---------------------------------------------------------------------------------------------------------------------------------
CONTENTS (Contd.)
----------------------------------------------------------------------------------------------------------------------------SECTION
DESCRIPTION
----------------------------------------------------------------------------------------------------------------------------5.5
PRESSURE ALARMS
5.6
GAS ALARMS
5.7
MISCELLANEOUS ALARMS
5.8
TRIP SYSTEM
5.9
MISCELLANEOUS CHECKS
6.0
TEST EQUIPMENT
6.1
WORKSHOP EQUIPMENT
6.2
FIELD EQUIPMENT
7.0
TRAINING
7.1
7.2
TRAINING OF OPERATION STAFF
--------------------------------------------------------------------------------------------------------------------------------
2.0 SCOPE
3.14
This standard covers safety instrumentation
with pneumatic, electrical & electronic/
microprocessor system used in oil & gas
installations.
It gives pre-commissioning checks to assist
the owner to review the completion of
erection/installation work in a project. It also
broadly covers the inspection checks &
procedures with schedules to be followed for
these instrumentations in an operating plant.
For various Alarms and Trip system, it gives
maintenance check lists with recommended
frequencies for ensuring proper functioning. it
also covers the test equipment used in
workshops and fields, required for the
calibration of these instruments.
3.2
3.2.1
3.2.2
3.2.3
3.3
3.3.1
3.3.2
testing/flushing
pipelines.
operation
of
the
3.4.4
3.5
CALIBRATION OF INSTRUMENTS,
LOOP CHECKING ETC.:
3.5.1
3.5.2
Control valve
shall be made
mechanically free.
Adjustment of
stroke and field calibration of the
control valve shall be made.
3.5.3
Loop
checking
by
giving
pneumatic/electric signal at primary
sensors side shall be done and the
response of final control element shall
be observed.
3.3.3
3.3.4
3.5.4
3.6
SPECIAL
INSTRUMENTS
(ANALYSERS, WEIGH BRIDGES,
SAMPLING
SYSTEMS
GAS
DETECTORS ETC.):
3.6.1
Pre-commissioning
checks
for
installations,
testing,
calibration
checking etc. shall be carried out as
recommended by the manufacturer/as
per code/as recommended by the
owner.
3.7
MISCELLANEOUS ACTIVITIES:
3.7.1
Checks
shall
be
made
for
Electrical/Electronic equipment for
their suitability with respect to area
classification.
3.7.2
Checks
for
proper
filling
of
recommended sealing liquid wherever
required, shall be carried out.
3.7.3
3.7.4
3.3.5
3.3.6
3.4
ORIFICE
PLATES,
CONTROL
VALVES,
SHUTDOWN
VALVES,
ROVs, ON-LINE METERS AND
DIAPHRAGM SEAL TYPE METERS:
3.4.1
3.4.2
3.4.3
3.7.5
3.7.6
screwed
ensured
3.7.7
3.7.8
Checks
shall
be
made
for
microprocessor based systems for
proper environmental conditions as
recommended
by
manufacturers
(temp., humidity, dust, illumination
etc.).
3.7.9
4.0
INSPECTION CHECKS
Inspection checks and procedures to
be followed for instruments that are
normally in use in oil industry are
covered here with minimum time
schedule for inspection. All inspection
checks shall be properly documented.
4.1
4.1.1
4.1.2
4.2.2
4.2.3
4.2.4
4.2.5
4.1.3
4.1.4
4.2.7
FIELD TRANSMITTERS:
4.3.2
4.5.3
4.3.3
4.4
THERMOCOUPLES
THERMOWELLS :
4.4.1
4.4.2
4.43
MAINTENANCE CHECKS
All alarms and trips are considered as
safety instruments.
Most of the
alarms can be checked when the plant
is on, whereas many trips including
the final tripping element cannot be
checked when the plant is on. So
whenever the plant is down for more
than 72 hours, all trips should be
activated upto the final control
elements. All maintenance checks
shall be properly documented.
5.1
FREQUENCY : Once in six years in
general and once in every planned
shutdown where pitting and corrosion
effects are severe.
INSTRUMENT ACCESSORIES
Physical inspection of all the field
instrument accessories like air filters,
regulators, valve positioners. O/P
convertors,
limit
switches
and
solenoid valves shall be carried out
periodically.
&
4.5
4.5.1
4.5.2
5.2
LEVEL ALARMS:
5.2.1
B) Using Transmitters
5.2.3
5.6
GAS ALARMS :
TEMPERATURE ALARMS :
FREQUENCY : Once in 6 months.
A) Using thermocouple or RTD :
5.7
Disconnect at the Thermocouple or
RTD head and feed millivolts or
connect variable resistance box from
the head and check alarm.
MISCELLANEOUS ALARMS :
Alarm system for PH/conductivity/
flame/speed/Vibration as applicable
shall be checked and calibrated with
the help of appropriate equipment.
5.8
Trip
system
(complete
system
including power supply system,
switches, relays, logic system of
DDC/PLC, solenoid valves, lamps,
interconnecting cables, emergency
controllers, shut off valves etc.)
should be checked for the proper
functioning.
This checking should
include
overhauling,
lubrication,
calibration and setting etc. for
complete loop. The set points for the
trip system shall be officially
documented.
Any change to the
above shall be made only after due
authentication.
FLOW ALARMS:
A) Using Flow Switches :
If
possible,
close
the
valve
momentarily and check the alarm.
Open
the
valve
immediately
afterwards.
B) Using Transmitters:
Create low or high flow condition flow
condition from the transmitter and
check.
MISCELLANEOUS CHECKS
Checks shall be made for functioning
of microprocessor system with proper
redundancy as per design for power
supply, CPU, communication bus etc.
PRESSURE ALARM :
A)
Using
Pressure
Switches
Isolate and remove the switch and
check it on a dead weight tester or
any standard equipment.
FREQUENCY : Every
shutdown.
6.0
TRIP SYSTEM:
TEST EQUIPMENT
planned
Workshop
Equipment
2.
Accuracy 0.1%
Testing
(vi)
(vii)
WORKSHOP EQUIPMENT
(viii)
Mercury Manometers
Range : 0-2.0 Kg/sq.cm.
(ix)
Inclined Manometer
Range : 0-200 mm WC
(x)
(xi)
Precision Pressure
various ranges
6.1.2
6.1.1
(a)
Pressure Instruments
(b)
Temperature Instruments.
(c)
Control Valves
(d)
Electronic Instruments
(e)
Gas detectors.
Testing Equipment
Instruments:
(i)
for
Pressure
(ii)
(I)
Regulators
of
iii)
(iii)
Vacuum Pumps
Range : 0- 760 mm of Hg.
iv)
(iv)
Detector
v)
--------------------------------------------------------Scale
Divisions
--------------------------------------------------------38 to 2 Deg.C 1/10 Deg.C
- 8 to 32 Deg.C 1/10 Deg.C
25 to 55 Deg.C 1/10 Deg.C
50 to 80 Deg.C 1/10 Deg.C
75 to 105 Deg.C 1/10 Deg.C
95 to 155 Deg.C 1/5 Deg.C
145 to 205 Deg.C 1/5 Deg.C
195 to 305 Deg.C 1/2 Deg.C
295 to 405 Deg.C 1/2 Deg.C
------------------------------------------------------------(vi)
Temperature Calibration
Test Bath
(5)
(6)
Work
Bench
Instruments
(7)
DC Current source.
6.1.5
Testing
Equipment
Detectors:
(1)
6.2
FIELD EQUIPMENT
for
Electronic
for
Gas
6.2.2
for
6.2.3
for
(viii)
6.2.4
6.2.5
Multimeters
6.2.6
Intrinsically
safe
Calibrator/Simulator
6.2.7
6.2.8
6.2.9
Accuracy : 0.02%
(ix)
6.1.3
Control
RTD
(a)
Hydraulic
system
for
pressure testing of control
valves.
6.2.10 Portable
Frequency
(Explosion proof)
(b)
Lapping Arrangement.
(c)
Electronic
for
plus
Counter
small
signal
6.2.12 Megger.
6.1.4
Test Equipment
Equipment
(1)
(2)
Function Generator
(3)
Frequency Counter
(4)
Oscilloscope
TRAINING
The
instruments
interlocks.
7.1.4
TRAINING
STAFF
7.1.1
Training in Process:
7.1.2
OF
MAINTENANCE
other
safety
Service Manual :
Detailed and updated service manual
shall be made available.
7.2
7.2.1
Training
on
Interlock Logic:
Instrumentation
&
and
7.2.2
Refresher Course :
In-house refresher course should be
given to maintenance staff at regular
intervals
about
calibration/
maintenance procedures for vital
equipment
with
sophisticated
Refresher Course :
7.2.3
Operating Manual :
Detailed and updated operation
manual shall be made available.