STD 153
STD 153
STD 153
FOR RESTRICTED
CIRCULATION ONLY
No.
Prepared by:
NOTES
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
th
7 Floor, New Delhi House
27, Barakhamba Road
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
--------------------------------------------------------------------------------------------------------------------------------
3.2
3.2.1
3.2.2
3.4.3
3.2.3
3.3
3.4.4
3.3.1
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.
3.5.4
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
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.4
3.4.1
3.4.2
3.7.4
3.7.5
4.1.4
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
4.1.3
INSTRUMENT JUNCTION
AND CABLE GLANDS:
BOXES
4.2.2
4.2.3
4.2.4
4.2.5
Instrumentation earthing
checked and tested.
shall
be
4.2.7
FIELD TRANSMITTERS:
4.3.1
4.3.2
4.3.3
4.4
THERMOCOUPLES
THERMOWELLS :
4.4.1
Visual
check
of
thermowells,
flanges and conduits for external
pitting and corrosion.
4.4.2
4.43
4.5.1
4.5.3
4.6
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
4.5.2
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
5.2
LEVEL ALARMS:
5.2.1
a)
A)
Using
Pressure
Switches
Isolate and remove the switch and
check it on a dead weight tester or any
standard equipment.
5.6
TEMPERATURE ALARMS :
5.7
MISCELLANEOUS ALARMS :
Alarm system for PH/conductivity/
flame/speed/Vibration as applicable
shall be checked and calibrated with
the help of appropriate equipment.
TRIP SYSTEM:
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.
GAS ALARMS :
FLOW ALARMS:
A) Using Flow Switches :
If
possible,
close
the
valve
momentarily and check the alarm.
Open
the
valve
immediately
afterwards.
B) Using Transmitters:
MISCELLANEOUS CHECKS
PRESSURE ALARM :
Accuracy : 0.1%
(iii)
Vacuum Pumps
Range : 0- 760 mm of Hg.
(iv)
(v)
planned
TEST EQUIPMENT
Test equipment, whether it is for shop
or plant use, should be of very good
quality.
For
getting
correct
calibration/test results quickly, good
and reliable test equipment is a must.
It is recommended that while procuring
the test equipment, stress must be laid
on the quality of the test equipment.
Scope of this standard includes two
types of test equipment:
1.
Workshop
Equipment
2.
Accuracy 0.1%
(vi)
Testing
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
Regulators
of
Pressure
(I)
ii)
Accuracy : 0.1%
Accuracy : 1 least significant digit.
(ii)
iii)
iv)
--------------------------------------------------------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)
Test
Equipment
Equipment
(1)
(2)
Function Generator
(3)
Frequency Counter
(4)
Oscilloscope
(5)
(6)
Work
Bench
Instruments
(7)
DC Current source.
6.1.5
Testing
Equipment
Detectors:
(1)
6.2
FIELD EQUIPMENT
Temperature Calibration
Test Bath
for
Electronic
for
Gas
6.2.1
Dead
Weight
Tester/Comparator
with standard gauges.
6.2.2
Small
Calibration
Electronic Instruments.
Bench
for
6.2.3
Small
Calibration
Bench
Pneumatic Instruments.
for
6.2.4
6.2.5
Multimeters
6.2.6
Intrinsically
safe
Calibrator/Simulator
(viii)
Electronic
(vii)
for
Detector
6.1.4
(ix)
6.2.7
Intrinsically
safe
Calibrator/Simulator.
6.1.3
Testing
Equipment
for
Valves/Shut off Valves:
6.2.8
6.2.9
4-20 MA current
Transmitter Simulator.
(a)
Control
Hydraulic
system
for
pressure testing of control
valves.
(b)
Lapping Arrangement.
(c)
Thermocouple
source
6.2.10 Portable
Frequency
(Explosion proof)
6.2.11 Squeeze Bulb
generation.
6.2.12 Megger.
for
RTD
small
plus
Counter
signal