INSTRUMENTATION ENGINEERING

INSTRUMENTATION ENGINEERINGENGINEERING DELIVERABLES

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HAZARDOUS AREA PROTECTION

ENGINEERING DELIVERABLES PHILOSOPHY DOCUMENTS Instrumentation & Control Philosophy Instrument Design Basis Instrument Signal Earthing Philosophy Drawing

STUDIES HAZOP / SIL CALCULATIONS Sizing Calculations-Valves Sizing Calculations-Safety Valves Sizing Calculations-Flow Elements Utility Consumption-(Air) Utility Consumption-(Power)

ENGINEERING DELIVERABLES DRAWINGS AND SKETCHES Instrument Control Block Diagram Instrument Index FGS Index I/O List DCS I/O List - ESD I/O List - F&G I/O List SCADA I/O List Serial Data Level Sketches Graphics Control Narratives/ Loop Function Schemes Logic Diagrams Cause and Effects - ESD

ENGINEERING DELIVERABLES

Cause and Effects- F&GAlarm and Trip ScheduleCable Block DiagramsControl Room Layout DrawingsInstrument and JB Location Drawings Fire and Gas Detector Layouts Plant Fire and Gas Detector Layouts Buildings Cable/ Tray-Trench Routing & Layouts Junction Box Schedule Cable ScheduleCable Drum ScheduleInterconnection/ Termination DrawingsInstrument Loop Drawings

ENGINEERING DELIVERABLESProcess Hook-up DrawingsPneumatic & Hydraulic Hook-up DrawingsElectrical Hook-up DrawingsBulk Material Take-off ListAs-built Drawings

SPECIFICATIONSControl and Safety System SpecificationsSpecifications for Metering SystemsSpecifications for Well Head Control SystemsSpecifications for HIPPS SystemsSpecifications for SCADA SystemsInstrument Installation SpecificationsSpecification for Control Valves

ENGINEERING DELIVERABLESSpecifications for On-Off ValvesSpecifications for Relief ValvesField Instrument SpecificationsBulk Material SpecificationsInstrument Requirement for Packages

INSTRUMENT DATASHEETSValves DatasheetsSpecial Instruments DatasheetsAnalysers DatasheetsField Instrument Datasheets

ENGINEERING DELIVERABLESMATERIAL REQUISITIONS System Requisitions System Bid EvaluationsValves RequisitionsValves Bid EvaluationsField Instrument RequisitionsField Instruments Bid EvaluationsBulk Material RequisitionsBulk Bid EvaluationsVPRM

FORMATS & CONTENTSStandard Field Instruments data sheets FormatsStandards BOQ Bill No.7 for proposal(PEC-BMS-EN-GDE-J-0375)Man-Hour Estimation Format for Proposal(PEC-BMS-EN-GDE-J-0376)Standard Pricing format for Proposal(PEC-BMS-EN-GDE-J-0377)Standard Format for Inquiry/ Purchase RequisitionStandard Format for Level SketchesBOQ Format for Instrument Tubes, fittings, isolation valves etc.Vendor Data Requirement forms (VDR) (PEC-BMS-EN-FRM-J-0385)Vendor Quality Requirement Forms (VQR)

INPUT REQUIREMENTPiping & Instrument Diagram (P&ID)Piping Material Specification (PMS)Process Data for all InstrumentsEquipment Dimensional Drawings / Process DatasheetsAlarm & Set PointProcess Control NarrativesContract Documents / FEED DocumentsPlot Plan / Equipment LayoutVendor DataInput Matrix

HAZARDOUS AREA PROTECTIONHazardous Area ClassificationGas and Dust ClassificationTemperature ClassificationApprovalStandardsProtection MethodsEx MarkingsIngress Protection for Enclosure

HAZARDOUS AREA PROTECTIONHAZARDOUS ATMOSPHEREThe atmosphere in which the Hazardous substances i.e flammable, combustible materials, dusts and vapors are present, which can be ignited by thermal or electrical energy are known as Hazardous atmosphere.

HAZARDOUS AREA PROTECTIONHAZARDOUS AREA CLASSIFICATION ( IEC)Hazardous area are divided into zones to indicate the probability of a hazardous material and air being present. The present IEC standard defines the zones as follows-

Zone 0: explosive gas-air mixture continuously present or present for long periods (>1000 hr).

Zone 1: explosive gas-air mixture is likely to occur in normal operation (10 ~ 1000 hr).

Zone 2: explosive gas-air mixture not likely to occur and if it occurs, it will exist only for a short time (0 ~ 10 hr).

HAZARDOUS AREA PROTECTIONZone 20: a place in which an explosive atmosphere in the form of a cloud of combustible dust in air is present continuously, or for long periods or frequently.

Zone 21: a place in which an explosive atmosphere in the form of a cloud of combustible dust in air is likely to occur in normal operation occasionally.

Zone 22: a place in which an explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normal operation but, if it does occur, will persist for a short period only.

HAZARDOUS AREA PROTECTIONHAZARDOUS AREA CLASSIFICATION FOR (NEC)

DIVISION 1: hazardous concentrations of flammable gases or vapours-or combustible dusts in suspension-continuously, intermittently or periodically present under normal operating conditions.

DIVISION 2 : volatile flammable liquids or flammable gases present, but normally confined within closed containers or systems from which they can escape only under abnormal operating or fault conditions. Combustible dusts not normally in suspension nor likely to be thrown into suspension.

HAZARDOUS AREA PROTECTIONIEC Vs NEC

IEC NECZone-0(Zone-20 dust)Division 1

Zone-1(Zone-21 dust)Zone-2(Zone-22 dust)Division 2

HAZARDOUS AREA PROTECTIONGAS AND DUST CLASSIFICATION (IEC)Flammable gases, vapours and mists are classified according to the spark energy required to ignite the most easily-ignitable mixture with air. Apparatus is grouped according to the gases that it may be used with .

Test gasIEC GroupsIgnition EnergyPropaneIIA180EthyleneIIB60HydrogenIIC20AcetyleneIIC20

HAZARDOUS AREA PROTECTIONGAS AND DUST CLASSIFICATION (NEC)Flammable gases, vapours and mists are classified according to the spark energy required to ignite the most easily-ignitable mixture with air. Apparatus is grouped according to the gases that it may be used with .

Test gasIEC GroupsIgnition EnergyAcetyleneA20HydrogenB20Ethylene C60PropaneD180

HAZARDOUS AREA PROTECTIONTEMPERATURE CLASSIFICATIONHazardous- area apparatus is classified according to the maximum surface temperature produced under fault conditions at an ambient temperature of 40 degrees C or as otherwise specified.

ClassMaximum surface temperature T1 450 T2 300 T3 200 T4 135 T5 100 T6 85

HAZARDOUS AREA PROTECTIONAPPROVAL (IEC)National certifying authorities issue certificates for approved equipment, defining how it may be used.

APPROVAL (NEC)FM (USA) and CSA (Canada) issue certificates for approved equipment, defining how it may be used. FM and UL (USA) and CSA (Canada) issue reports and publish listings of approved equipment, defining how it may be used.

HAZARDOUS AREA PROTECTIONSTANDARDS (IEC) All countries in Western Europe work to CENELEC standards EN 50020(apparatus) and EN 50039(systems). EC members countries issue Certificates of Conformity to these standards and accept products and systems certified by other members. Other countries either work to their own standards based on IEC 60079-11(eg Australia, Brazil, Japan, USSR) or accept products and systems certified to European and/or North American standards.

STANDARDS (NEC)FM and UL work to their own standards; FM 3610 and UL 913 are based on ANSI/UL913. Canada works to CSA C22.2,No.157.

PROTECTION METHODS

Method of ProtectionCENELEC StandardOil Immersion (EEx o)EN-50015Pressurized / Purged (EEx p)EN-50016Powder Filled (EEx q)EN-50017Flame Proof (EEx d)EN-50018Increased Safety (EEx e)EN-50019Intrinsic Safety (EEx i) EN-50020Encapsulation (EEx m)EN-50028Non-incendive (EEx n)EN-50021

PROTECTION METHODSBASIS OF PRINICIPLEFuel

Oxygen Ignition Source

Ignition Triangle

PROTECTION METHODS

Method of ProtectionProtection PrinciplePressurized / Purged

Keep flammable gas outEncapsulationOil ImmersionNon-incendiveNo arcs, sparks or hot surfaceIncreased SafetyPowder FilledContain the ion and quench the flameFlame ProofIntrinsic SafetyLimit energy of sparks and surface temp.

PROTECTION METHODS

Method of ProtectionZones of UseOil Immersion (EEx o)Zones 1 & 2Pressurized / Purged (EEx p)Zones 1 & 2Powder Filled (EEx q)Zones 1 & 2Flame Proof (EEx d)Zones 1 & 2Increased Safety (EEx e)Zones 1 & 2Intrinsic Safety (EEx ia)Zones 0,1 & 2Intrinsic Safety (EEx ib)Zones 1 & 2Encapsulation (EEx m)Zones 1 & 2Non-incendive (EEx n)Zone 2 only

PROTECTION METHODSEx Markings (CENELEC) EEx d [ia] IIC T5 WhereEEx European Standardd Method of Protection[ia] I.S OutputIIC Gas GroupT5 Temperature Class

PROTECTION METHODSEx Markings (NEC) Explosion proof with I.S output, Class-1, Div-1, Gr A,B,C,D, T5 WhereEx-proof with IS O/P Method of ProtectionClass-1 Permitted ClassDiv-1 Permitted DivisionGr A,B,C,D Permitted Gas GroupT5 Temperature Class

INGRESS PROTECTION

1st Number2nd NumberIPProtection against solid bodiesIPProtection against liquids0No protection0No protection1Protected against solid bodies larger than 50mm(eg. Accidental contact with the hand)1Protected against vertical water drops falling (condensation)2Protected against solid bodies larger than 12mm(eg. Hand fingers)2Protected against drops of water falling up to 150C from the vertical3Protected against solid bodies larger than 2.5mm(eg. Tools and small wires)3Protected against drops of water falling up to 600 C from the vertical4Protected against solid bodies larger than 1mm(eg. Fine tools, wires)4Protected against water projected from all directions5Protected against dust (no harmful deposit)5Protected against jets of water from all directions.6Completely protected against dust6Protected against jets of water of similar force to heavy sea waves7Protected against effects of immersion8Protected against the continuous effects of immersion under pressure