Protocol For Working On Instrumentation System in Workshop

 Guidelines for working on test bench in a workshop

OBJECTIVE

The aim of this document is to provide detailed guidelines regarding maintenance of instrumentation system performed in the workshop.

SCOPE

During maintenance at plant and satellite facilities, various instruments require detailed check or corrective maintenance and subsequent calibration/function test on test bench in workshop. The scope of this document comprises of guidelines for carrying out maintenance/refurbishment and subsequent function test/ calibration of instruments in workshop.  

ACRONYM

LIT: Level Indicator Transmitter
TIT: Temperature Indicator Transmitter
PIT: Pressure Indicator Transmitter
HSE: Health Safety And Environment

PROCEDURE

MAINTENANCE AND FUNCTION TEST OF ELECTRONIC INSTRUMENTS

1. Make sure that supply voltage is available as per OEM recommended voltage.
2. Make sure that correct termination of power supply is connected to avoid transmitter damage.
3. Make sure all electrical connections are tightened properly.
4. Connect HART communicator or Document Calibrator with the transmitter and record all relevant parameters.
5. Check diagnostics and perform necessary action as per requirement in line with OEM manual.
6. Perform parts replacement, if required and do parameters configuration as per OEM manual.
7. Carry out calibration / function test post rectification as per above steps.
8. Check transmitter reading on its local display, if available, and cross verify it with sourced value from configurator/calibrator.
9. Check transmitter reading on its local display, if available, and cross verify it with measured value from configurator/calibrator.
10. Calibration and verification of TITs to be carried out using document calibration and temperature bath available in workshop.
11. Make sure that regulated supply is provided, and tubing connections are properly secured while working on PITs.

NOTES While working on Electronic cards/PCB boards, wear Electrostatic discharge band/ribbons to avoid card damage due to electrostatic charges.

MAINTENANCE AND FUNCTION TEST OF PNEUMATIC INSTRUMENTS

• Dismantle the pneumatic instrument as per guidelines provided in relevant manual.
• Perform inspection and servicing of pneumatic instruments as per related drawings and following OEM guidelines.
• Make sure that regulated air supply is available, and tubing/fittings are tightened properly.
• Avoid manual lifting and use overhead crane in case of heavy lifting.
• Job performer to ensure workpiece/ item is properly secured in vice while working on workbench.
• Drain and depressurize properly if the equipment/instrument is pressurized or under spring tension.
• Job performer to ensure that well inspected and new spares are being used for refurbishment of pneumatic injection pumps, regulators etc.
• Make sure that liquid used for testing injection pumps are properly labelled and having MSDS.

NOTE: Violation of OEM guidelines may lead to serious personal injury due to trapped pressure or spring tension force etc. Make sure that test gauges are inspected and calibrated. Ensure that gauge installed on instrument air supply line is calibrated and functional. Check and verify that there is no leakage from tubing/fitting connections while in use. Ensure to use safety goggle while working on pneumatic instrumentations. Presence of spill kit in workshop is a mandatory requirement.

DELIBERATELY LEFT BLANK

ITEMS SHELVING IN WORKSHOP

1. Items/spares placement on shelves should be below load capacity of each rack.
2. Heavy items should not be placed in upper racks rather in the lowest rack.
3. Item sorting based on its nature and type is highly appreciated.
4. Item should not be placed loosely on the shelves so to avoid falling from its location.
5. Every item on racks should be well document in instrument workshop material register.
6. It is responsibility of workshop supervisor to constantly check and discard junk items by handing over to warehouse team as per SOP.
7. Items/spares/instruments removed from plant or well site and placed on shelves for temporary period should be recorded in register and should be tagged in detail with the name of Job performer, date, current status and short reason of its removal from location.
8. Placement of new items/spares in workshop is highly discouraged except for shorter duration during emergency cases only.

HSE PRECAUTIONS

• Use proper PPEs as per job requirement.
• Conduct gas tests whenever required.
• Verify that energy is isolated before starting work.
• Make sure that gauges and tools are inspected and properly calibrated.
• Barricade the area while using overhead crane in workshop area for lifting operation.
• Perform housekeeping of workplace/test bench after completion of maintenance activity before leaving the site.
• Junks to be disposed off as per SOP.