TSP-POGC-NIGC 1 Ø

COURSE OIL AND GAS TECHNOLOGHY CODE

SUBJECT INSTRUMENT SAFETY MEASURES P/TM/TRG/I.IM /001

Objectives: Upon completion of this unit the trainees should be able to:
• Keep away from different kind of Hazardous actions.
• Understand the meaning of wet part and electrical part and the safety measure on
both categories.

Content:
Introduction
1. Wet Parts
2. Electrical Parts
3. Special Safety Instructions

Prepared by D.Ghasempour Checked by Yeganeh Approved by

R. Moshtaghi Larijani
Date May.14.00 Date May.17.00 Date
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CODE
SUBJECT INSTRUMENT SAFETY MEASURES
P/TM/TRG/I.IM/001

INSTRUMENTS SAFETY MEASURES

INTRODUCTION
All equipment and machines have their own safety instructions, and so do the instruments.
When a group of instruments with different natures are in service in a certain industrial plant,
their hazard points shall be studied to prevent possible accidents. From the viewpoint of
safety, instrumentation equipment can be divided in two groups as follows:

1. WET PARTS
Those parts of instruments that are in direct contact with the fluids are called the wet parts,
inner part of a control valve body, pressure gauge sensing elements orifice plants, flow meters
& their connecting leads, level instruments, thermo-wells, analyzer sampling systems and
others. are some examples of this category.

These parts are exposed to pressure, temperature, wear due to corrosion & erosion and break
down. Some times the pressure and/or the temperature could be very high and in most cases
the fluids are toxic, flammable or explosive. Therefore all safety instructions regarding
installation, commissioning, routine maintenance and overhaul should be followed very
carefully.

Note:
• No attempt for doing a job should be made unless the responsible person for process
unit issues the required work permit.
• The instruments that need to be checked or repaired should be released from the
operation and, you should make sure that they are fully isolated from the control loop
and no disturbance will occur during their absence in process operation.
• The instruments should be free from pressure and the content of instrument should be
drained into a safe sewage sump prior to dismantling the instrument. Special care
should be taken when draining or venting an instrument where the leakage hazard of
toxic gases (e.g. H2S) or combustible gases or liquids exists.

Example 1
A Control valve is leaking from its body gland so you need to replace its packing material. The
procedure for doing the job is as follows:
1. Work permit is issued.
2. Process is changed from automatic control to manual control
3. The control valve is by-passed (i.e. the process fluid is passed through the by-pass
line).
4. The content of the C.V., and also the residual fluid between the two block valves
should be completely drained to the drain pit by using a proper hose.
5. After completion of the Job:
• Drain valves should be closed & the hose removed.
• Return the C.V. in service.
• Clean the site.
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SUBJECT INSTRUMENT SAFETY MEASURES
P/TM/TRG/I.IM/001

Always make sure (before starting the job) that there is no accumulation of poisonous gas
inside the line or equipment.

Example 2:
A pressure gauge shall be repaired in workshop. The work procedure is as follows:
• Work permit shall be issued.
• Use safety equipment and safety wear as required.
• Close the isolating valve of the pressure gauge.
• Connect a hose to the P.G. drain valve and lead it to drain pit.
• Open the pressure gauge drain valve.
• Remove the pressure gauge according to the vendor maintenance instructions.

After returning the pressure gauge from the workshop:

• Re-install the pressure gauge.
• Close drain valve and remove the hose.
• Make sure that there is not any process leakage from the fitting (check with water and
soap solution in gas services)
• Clean the site.

The same safety advices will be applied for other instruments that are in a similar condition as
the above-mentioned items.
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CODE
SUBJECT INSTRUMENT SAFETY MEASURES
P/TM/TRG/I.IM/001

2. ELECTRICAL INSTRUMENTS / PARTS

Most of the instruments in the new plants are somehow electrical. For example I/P converters,
transmitters and switches need electrical supply or make a kind of electrical signal. The parts
of the instruments, which are related to its electrical system, are called the electrical parts.
Examples of these are the actuator of motor operated or solenoid valves and converter of
transmitters with current out put signals.
• All electrical instruments and the accessories in an oil or gas refinery or in
petrochemical complexes that are installed or used outside the control room shall be of
type “certified as explosion proof”.
• The cover of all electric junction boxes must be kept tight by using the bolts.
• There should be no leakage between transmission cables and the earth.
• If you want to work on the electrical parts of any instrument, first make sure about the
level of voltage in the compartment.
• Any spark generating action must be avoided.
• The earthing system should be safe and sound.
• All instruments should be accessible, otherwise, proper and safe access aids should
be provided.
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SUBJECT INSTRUMENT SAFETY MEASURES
P/TM/TRG/I.IM/001

3. SPECIAL SAFETY INSTRUCTIONS

• Proper and safe tools must be used.
• Flashing or draining of fluids in open atmosphere should be avoided.
• Performing a job on equipment under the process pressure is unsafe. Never attempt
to do risky jobs in any conditions.
• Do not use oxygen pressure gauge in oil service.
• Do not use low range pressure gauge for measuring high pressure, it will damage
the gauge and cause accident.
• Mercury is a poisonous liquid and its vapor is harmful for the health.
• When replacing a control valve, make sure that the valve characteristic, especially
the action of the valve (Air to open or air to close) is same as the original one.
• Any unusual vibration of instruments shall be reported for taking corrective action.
• Any small leakage of flammable fluid, may also cause a terrible fire or explosion,
Never ignore it! Blowing of air on sandy ground should be avoided.
• All applied standards regarding the instrument installation should be followed very
strictly and also maintenance manuals should be understood and followed to
eliminate the possibility of accident.
• Safety barriers are very important if they are in use, it is necessary to keep them in
good operating condition.
• When working on local control panels which are installed in hazardous area, always
read the vendor safety instructions before attempting to open the panel door.
• Do not open the door of local control panels that have a pressurizing system. If you
are requested to do maintenance Job on any of these panels, first consult your
operation supervisor to put the related equipment out of service and turn the mains
off.

Do not try to do a job that you are not familiar with. It is a fact that “The best way is the safe
way”, therefore if you don’t know the safe way, you should ask one who knows it.