SB_PLN_Statutory Codes and standards for TI system design- Part 1_V1.pptx

Statutory codes

1. Statutory Codes and standards for T&I system design Course outline Course title Statutory Codes and standards for T&I system design Learning objectives Upon completion of the course, learners will be able to : Refresh the Concept of Hazardous area classifications Understand Various packages dealt in T&I system Design Describe various Standards applicable for T&I system Design Understand the selection of T&I equipment's for different Applications Applying Statutory Codes and Standards in T&I system Design.  Intended Audience Grade – C & Above Course outline Introduction to the course- Part 1 Topic 1: Refresh Basic concepts of hazardous Area Classification of Hazardous Area Grouping of Industrial Gases Temperature Class Protection concepts Knowledge Check Topic 2: Understand Various packages dealt in T&I system Design Topic 3: V arious Standards applicable for T&I system Design Applicable Standards & Codes Certifying Agencies OISD Codes Topic 4: Understand the selection of T&I equipment's for different Applications Instrumentation Final assessment Introduction to the course- Part 2 Topic 4: Understand the selection of T&I equipment's for different Applications Control system & Automation (Module -2) Fire Alarm & Detection system (Module -2) SCADA & PAS (Module -2) Telecommunications (Module -2) Topic 5: Applying Statutory Codes and Standards in T&I (Module -2) Conclusion Final assessment

2. Introduction to the Statutory Codes and standards for T&I system design- Part 1 Developer Notes Static text with VO Use textured background throughout the course. Audio Narration Welcome to the “ Introduction to the Statutory Codes and standards for T&I system design ” e-learning course! This is part 1 of the course and will take approximately 25 minutes to complete. Select “Next” to begin the course. Query/Notes Instead of T&I –Telecom & Instrumentation (T&I) may be used

3. Learning objectives By the end of this course, you should be able to: L2-Learning Objectives – Mascot Client Query/Notes Developer Notes OST to come one by one with VO. SSID: 1059890420 Remove the icons Audio Narration This course will help you refresh the concepts of hazardous area classifications and understand the packages dealt in T&I system Design along with the selection of T&I equipment's for different applications. Not only that, you’d be able to describe the standards which are applicable for T&I system design and apply the statutory codes and standards. Concept of hazardous area classifications Various packages dealt in T&I system Design The selection of T&I equipment's for different applications Various standards applicable for T&I system design Statutory codes and standards in T&I system design

4. L2-Learning Objectives – Mascot Client Query/Notes Developer Notes OST to come one by one with VO. SSID: 397204639 Audio Narration In this part of the course we shall cover the basic concepts of hazardous area, understanding the various packages dealt in T&I system design and understanding the selection of T&I equipment for instrumentation. Part 1: Basic concepts of hazardous area Various packages dealt in T&I system design Standards applicable for T&I system Design Understand the selection of T&I equipment's for different Applications (instrumentation) Part 2: Understand the selection of T&I equipment's for different Applications Control system & automation Fire Alarm & Detection system SCADA & PAS Telecommunications Applying statutory codes and standards in T&I

5. Developer Notes Audio plays after displaying OST SSID: 1415884067 Audio Narration Before we begin discussing the Codes and Standards for T&I system design, let us first revise the basics of hazardous area. Client Query/Notes 5 L1-Divider Basic concepts of hazardous area

6. Developer Notes OST to come one by one with VO Item 2 to come together with VO2 Make the tabs click through. On clicking each tab a new page should open. Once a tab is completed put a tick mark. Audio Narration Every industry will have certain operations that may be hazardous. To prevent a hazardous environment from developing, there are many regulations and guidelines in the industry. The type of equipment safe to be used in such an environment is regulated by various bodies. Atmosphere Explosible provides a widely accepted standard which is recognized internationally. Hence choosing the right ATEX certified equipment is non-negotiable Client Query/Notes Hazardous area classification Every industry will have certain operations that may be hazardous. ATEX (Atmosphere Explosible) provides a widely accepted standard which is recognized internationally. Choosing the right ATEX certified equipment is non-negotiable

7. Developer Notes OST to come one by one with VO Item 2 to come together with VO2 Make the tabs click through. On clicking each tab a new page should open. Once a tab is completed put a tick mark. Audio Narration Hazardous area standards require the use of equipment specifically certified for use in areas that have all three of the following ingredients for an explosion. Though the goal of all hazardous area equipment is to prevent an explosion, the methods that they use vary depending on their manufacturer and the intended application. Hazardous areas are classified based on following four categories: Classification of zones Grouping of industrial gases Various Temperature classes Various Protection concepts Let us learn about them one by one Client Query/Notes Hazardous area classification Group of industrial gases Temperature classes Protection concepts Zone classifications 2 Every industry will have certain operations that may be hazardous. Hazardous area standards that require the use of equipment specifically certified for use in areas that have all three of the following ingredients for an explosion.

8. Developer Notes OST to come one by one with VO SSID: 524779222 Remove the world backdrop and the icons. Fade in 2 elements with VO and then fade out to make room for the other two. On clicking the cross button the user to be taken back to slide 7. Audio Narration A hazardous area can be defined as any location where there is risk of an explosion. But every hazardous area is different and each has specific requirements depending on the nature of the atmosphere and the elements that are present. Fundamentally, for an explosion to take place, flammable or explosive gases, vapours , mists or dusts will be present. Then, the level of risk of an explosion is based on the frequency and duration of the occurrence of an explosive atmosphere. This level of risk is represented by classifying the hazardous area as Zone 0, Zone 1 or Zone 2 (for gas, vapour and mist atmospheres) Select each zone to learn more Client Query/Notes Zone 1 & Zone 0 is appearing twice . Only 1 click should be kept for each Zones. . Zone Classification Trial Pits A hazardous area can be defined as any location where there is risk of an explosion. NEC Classification: Div 1 (Zone 0 and Zone 1) and Div 2 (Zone 2) Select each zone to learn more

9. Developer Notes OST to come one by one with VO SSID: 524779222 Remove the world backdrop and the icons. Fade in 2 elements with VO and then fade out to make room for the other two. On clicking the cross button the user to be taken back to slide 7. Audio Narration Zone 0 is an area in which an explosive atmosphere is present continuously for long periods of time or will frequently occur Client Query/Notes Zone Classification Trial Pits A hazardous area can be defined as any location where there is risk of an explosion. NEC Classification: Div 1 (Zone 0 and Zone 1) and Div 2 (Zone 2) X Continuous presence of an explosive atmosphere.

10. Developer Notes OST to come one by one with VO SSID: 524779222 Remove the world backdrop and the icons. Fade in 2 elements with VO and then fade out to make room for the other two. On clicking the cross button the user to be taken back to slide 7. Audio Narration Zone 1 is an area in which an explosive atmosphere is likely to occur occasionally in normal operation. It may exist because of repair, maintenance operations, or leakage Client Query/Notes Zone Classification Trial Pits A hazardous area can be defined as any location where there is risk of an explosion. NEC Classification: Div 1 (Zone 0 and Zone 1) and Div 2 (Zone 2) X Occasional presence of an explosive atmosphere.

11. Developer Notes OST to come one by one with VO SSID: 524779222 Remove the world backdrop and the icons. Fade in 2 elements with VO and then fade out to make room for the other two. On clicking the cross button the user to be taken back to slide 7. Audio Narration Zone 2 is a place in which an explosive atmosphere is not likely to occur in normal operation but, if it does occur, will persist for a short period only. These areas only become hazardous in case of an accident or some unusual operating condition Client Query/Notes Zone Classification Trial Pits A hazardous area can be defined as any location where there is risk of an explosion. NEC Classification: Div 1 (Zone 0 and Zone 1) and Div 2 (Zone 2) X Unlikely occurrence of explosive atmosphere.

12. Developer Notes OST to come one by one with VO SSID: 1025501680 Audio Narration The next category is gas groups based on the gas present in the atmosphere. Grouping of industrial gases is categorized into Group I and Group II gases as per IS 9570. Group I consists of Methane typically found in Coal Mining Group II subgroups in increasing order of explosiveness. Group II A: Acetone, Ammonia, Ethyle Alcohol, Gasolene , LPG/Propane. Group II B: Ethylene, Acetaldehyde. Group II C: Acetylene, Hydrogen Client Query/Notes Grouping of industrial gases Trial Pits Group I basically consists of Methane typically found in Coal Mining Group II subgroups in increasing order of explosiveness – Group II A, II B and II C Grouping of industrial gases is categorized into Group I and Group II gases as per IS 9570

13. Developer Notes OST to come one by one with VO SSID: 1135646558 Audio Narration Temperature classification is method to classify a flammable gas or vapour by its ability to get ignited by a hot surface The temperature class defines the maximum surface temperature an electrical apparatus is allowed to operate at. The maximum surface temperature of an apparatus should always be lower than the ignition temperature of the surrounding gases. Apparatus that are certified for use in hazardous area, should be marked with their temperature class as shown in the table. Client Query/Notes Temperature class Trial Pits The temperature class defines the maximum surface temperature an electrical apparatus is allowed to operate at The maximum surface temperature of an apparatus should always be lower than the ignition temperature of the surrounding gases Apparatus that are certified for use in hazardous area, should be marked with their temperature class as shown in the table Temperature classification is method to classify a flammable gas or vapour by its ability to get ignited by a hot surface X

14. Developer Notes OST to come one by one with VO SSID: 420606778 On clicking the cross button the user to be taken back to slide 7. Audio Narration Various types of equipment are placed in enclosures and protections in the hazardous environment and the enclosure is labeled as per the protection it provides. There are 8 types of protections listed in ATEX but the most common ones are: Increased safety – no arcs, sparks, or hot surface Explosion proof, Flame proof – containing the explosion and extinguishing the flame Intrinsic safe – limiting energy Pressurized, encapsulated, oil immersed – keeping the flammable material out Ingress protection – in most cases, the IP rating consists of two numbers. The first describes protection against solids. The second number describes protection against liquids Client Query/Notes Protection concepts Trial Pits Increased safety – no arcs, sparks, or hot surface Explosion proof, Flame proof – containing the explosion and extinguishing the flame Intrinsic safe – limiting energy Pressurized, encapsulated, oil immersed – keeping the flammable material out Ingress protection – in most cases, the IP rating consists of two numbers. The first describes protection against solids. The second number describes protection against liquids Various types of equipment are placed in enclosures and protections in the hazardous environment and the enclosure is labeled as per the protection it provides. There are 8 types of protections listed in ATEX but the most common ones are: X 2 1 1 2

15. Knowledge check Developer Notes Audio Narration Let’s check your understanding of what we’ve learned so far Client Query/Notes

16. Knowledge Check #1 Zone 0 Zone 1 Zone 2 __________is an area in which an explosive atmosphere is likely to occur occasionally in normal operation. It may exist because of repair, maintenance operations, or leakage. All of the above Select correct option and then click submit Developer Notes Screen Type: Single Select Question 2 attempts Includes Submit Button Correct choice: choice number 2 Correct Feedback: Well done! Its Zone 1 1 st Incorrect Feedback: Incorrect. Please try again. 2 nd Incorrect Feedback: Incorrect. The correct answer is “Zone 1”. Audio Narration _______ is an area in which an explosive atmosphere is likely to occur occasionally in normal operation. It may exist because of repair, maintenance operations, or leakage. Select correct option and then click submit. Client Query/Notes None of the above

17. Developer Notes Audio plays after displaying OST SSID: 744825085 Audio Narration We will now introduce you to various packages dealt in the T&I system design. Client Query/Notes 17 L1-Divider Introduction to various packages dealt in T&I system design

18. Developer Notes OST to come one by one with VO SSID: 1192868500 Use this for 4 headers. The below text to be placed in boxes. Audio Narration There are various packages in T&I system design. However, for statutory codes and standards, they are classified on the basis of the area of installation and the function it performs. In addition, it is always essential to understand that the T&I equipment are electrically operated gadgets, hence proper safety measures need to be ensured for the equipment to perform in the hazardous environment. Broadly T&I Packages are classified as: Instrumentation Telecommunications Control system & Automation Fire Alarm & Detection system Select each tab to explore various instruments in these packages There are various packages in T&I system design. However, for statutory codes and standards, they are classified on the basis of the area of installation and the function it performs. In addition, it is always essential to understand that the T&I equipment are electrically operated gadgets, hence proper safety measures need to be ensured for the equipment to perform in the hazardous environment Instrumentation Telecommunications Control System and Automation Fire Alarm and Detection System Client Query/Notes Packages in T&I system design Select each tab to learn more

19. Developer Notes OST to come one by one with VO SSID: 1192868500 Use this for 4 headers. The below text to be placed in boxes. Audio Narration There are various packages in T&I system design. However, for statutory codes and standards, they are classified on the basis of the area of installation and the function it performs. In addition, it is always essential to understand that the T&I equipment are electrically operated gadgets, hence proper safety measures need to be ensured for the equipment to perform in the hazardous environment. Broadly T&I Packages are classified as: Instrumentation Telecommunications Control system & Automation Fire Alarm & Detection system Select each tab to explore various instruments in these packages There are various packages in T&I system design. However, for statutory codes and standards, they are classified on the basis of the area of installation and the function it performs. In addition, it is always essential to understand that the T&I equipment are electrically operated gadgets, hence proper safety measures need to be ensured for the equipment to perform in the hazardous environment Instrumentation Field Instrumentation such as PT, TT, PS, RTD, etc. Actuators of Control Valve, ROV, MOV, Cables Control and Signal Cables Junction Boxes, ESD, MCP, etc. Field fittings Custody transfer metering such as MFM, TFM, UFM, etc. Process PLC SCADA Leak detection system or PAS IT hardware Flow Computers UPS and Batteries Telecommunications Control System and Automation Fire Alarm and Detection System Telecom Networks and DC power system OFC Cable Solar Power system Telecom Batteries etc. VHF Radio Earthing and lightening Protections Safety PLC Fire Alarm Panels Hazardous area detectors Safe Area Detectors and MCPs FM 200 flooding Client Query/Notes Packages in T&I system design Select each tab to learn more Pop outs when the leaner selects each T&I Package

20. Developer Notes Audio plays after displaying OST SSID: 1376089571 Audio Narration We will now look at the Standards applicable for T&I system Design. Client Query/Notes 20 L1-Divider Standards applicable for T&I system Design

21. Developer Notes Images to come one by one with VO SSID: 547198300 Images to come one by one in hexagon shapes. Audio Narration The following are some of the standards and the certifying agencies for T&I system design. Oil Industry Safety Directorate Petroleum and Explosives Safety Organization Petroleum and Natural Gas Regulatory Board National Fire Protection Association Bureau of Indian Standards SA UL Safety Integrity Level ATmosphere Explosibles FM Approved Client Query/Notes Full form of SA UL needed Standards and certifying agencies for T&I system design The following are some of the standards and the certifying agencies for T&I system design

22. Developer Notes Create the table in IOCL colors. And include two scroll bars for learner to see the table. Provide internal navigation tool for movement from screen 21 to 22 Audio Narration The following are some of the applicable standards used for T&I packages. Kindly take a minute to go through. Client Query/Notes Applicable Standard lists for T&I packages ANSI / ASME American National Standards Institute / American Society of Mechanical Engineers B.1.20.1 Pipe Threads B.16.5 Steel Pipe Flanges and Flanged Fittings B.16.20 Metallic Gaskets for pipe Flanges, Ring Joint, Spiral wound and Jacketed. ANSI / FCI American National Standards Institute / Fluid Control Institute API American Petroleum Institute RP 71.04 Control room environment. RP 500 Recommended practice for classification of locations for electrical installations at Petroleum Facilities classified as class 1, Division1, and Division 2 RP 505 Recommended practice for classification of locations for electrical installations at petroleum facilities classified as class 1, Zone 0, Zone 1 and Zone 2 RP 551 Process Measurement Instrumentation Part 1 – Process Control and Instrumentation RP 552 Transmission Systems S 2534 Measurement of liquid hydrocarbons by turbine meter systems ASME American Society of Mechanical Engineers ASTM American Society for Testing of Materials ATEX ATmosphere Explosibles BASEEFA British Approvals Service for Electrical Equipment in Flammable Atmospheres BIS Bureau of Indian Standards BS British Standards BS-5308 Part-I Specification for PE insulated cables BS-5308 Part-II Specification for PVC insulated cables CENELEC European Committee for Electro-technical Standardization CMRI Council of Mining & Research Institute, India CIMFR Central Institute of Mining and Fuel Research CSA Canadian Standards Association DIN German Standards DIN-43760 Temperature Vs Resistance curves for RTDs (Class A) EN50014 Electrical Apparatus for Potentially Explosive Atmospheres – General Requirements EN50018 Electrical Apparatus for Potentially Explosive Atmospheres –Flameproof Enclosures ‘d’ EN50020 Electrical Apparatus for Potentially Explosive Atmospheres –Intrinsic safety ‘ i ’

23. Developer Notes Create the table in IOCL colors. And include two scroll bars to fit the complete tables. Audio Narration The following are some of the applicable standards used for T&I packages. Kindly take a minute to go through. Client Query/Notes Applicable Standard lists for T&I packages FM Factory Mutual IEC International Electro technical Commission IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere IEC 60529 Degree of protection provided by enclosures. IEC 60584-2 Thermocouples – Tolerances IEC 60751 Industrial Platinum Resistance Thermometer Sensors IEC 61131 Parts 1-4 Programmable Controllers IEC 61158 Digital data communication for measurement & control field bus for use in Industrial Control system. IEC 61508 Functional Safety of Electrical/Electronic/ Programmable safety related system IEC 61511 Functional Safety – Safety Instrumented Systems for the Process Industry IEC 61804 Functional Blocks for process Control IEC 60801 Electromagnetic compatibility for Industrial Process IEEE Institute of Electrical & Electronic Engineers IS Indian Standard IS-5 Colors for ready mixed paints IS-1239 Mild steel tubes, tubular and other wrought steel fittings. IS-1271 Specification of Thermal Evaluation and Classification of Electrical Insulation. IS-1554 Part I PVC insulated (heavy duty) electric cables working voltage up to and including 1100V IS-2 147 Degree of Protection provided by enclosures for low voltage switch gear and control gear. IS-2 148 Flame proof enclosures for electrical apparatus IS-3624 Specification for pressure and vacuum gauges IS-5831 PVC insulation and sheath of electric cables IS-7358 Specifications for Thermocouples IS-8784 Thermocouple compensating cables ISA International Society of Automation NACE National Association of Corrosion Engineers NEC National Electric Code NEMA National Electric Manufacturer’s Association ICS-6 Enclosures for Industrial control and systems NFPA National Fire Protection Association NFPA-496 Purged and pressurized enclosures for electrical equipment NFPA-72 National Fire Alarm Code OISD Oil Industry Safety Directorate PESO Petroleum and Explosives Safety Organization PTB Physikalisch Technische Bundesanstalt (Germany) UL Underwriters Laboratories Incorporated

24. Developer Notes Create the table in IOCL colors. Make the first column clickable. On clicking it the text in the second column to appear. Audio Narration Majorly the OISD and PNGRB Guidelines are followed in the T&D design which encapsulates most of the Standards and Design requirements. Here are some of the applicable OISD guidelines. Click on each guideline to know more about it. Client Query/Notes Applicable Standards and Guidelines for major T&I design OISD-STD-117 OISD-STD-141 Click on each guideline to know more about it OISD-STD-144 OISD-STD-163 OISD-STD-173 OISD-STD-214 OISD-STD-244 G.S.R. Infra/T4S/P&PPPL/01/2014. (PNGRB)

25. Developer Notes Create the table in IOCL colors. Make the first column clickable. On clicking it the text in the second column to appear. Audio Narration Majorly the OISD and PNGRB Guidelines are followed in the T&D design which encapsulates most of the Standards and Design requirements. Here are some of the applicable OISD guidelines. Click on each guideline to know more about it. Client Query/Notes Applicable Standards and Guidelines for major T&I design OISD-STD-117 Fire Protection Facilities for Petroleum Depots, Terminals, Pipeline Installations and Lube Oil Installations OISD-STD-141 Design, Construction and Inspection Requirements for Cross Country Liquid Hydrocarbon Pipelines (Does not cover LPG Pipelines) (shall be read in conjunction with OISD-STD-214) OISD-STD-144 Liquefied Petroleum Gas (LPG) Installations (Does not cover Pipelines Operations) OISD-STD-163 Safety of Control Room for Hydrocarbon Industry OISD-STD-173 Fire Prevention And Protection System For Electrical Installations OISD-STD-214 Cross Country LPG Pipelines OISD-STD-244 Storage and handling of Petroleum Products at depots and terminals including standalone crude oil storage facilities (Does not cover Cross-Country Pipelines) G.S.R. Infra/T4S/P&PPPL/01/2014. (PNGRB) Technical Standards and Specifications including Safety Standards for Petroleum and Petroleum Products Pipelines   Click on each guideline to know more about it

26. Knowledge check Developer Notes Audio Narration Let’s check your understanding of what we’ve learned so far Client Query/Notes

27. Knowledge Check #2 OISD-STD-117 OISD-STD-144 OISD-STD-214 OISD code that deals with the c ross country LPG pipelines is _____ OISD-STD-244 Select correct option and then click submit Developer Notes Screen Type: Single Select Question 2 attempts Includes Submit Button Correct choice: choice number 3 Correct Feedback: Well done! Its OISD STD 214 1 st Incorrect Feedback: Incorrect. Please try again. 2 nd Incorrect Feedback: Incorrect. The correct answer is “OISD STD 214” Audio Narration OISD code that deals with the cross country LPG pipelines is. Select correct option and then click submit Client Query/Notes None of the above

28. Developer Notes Audio plays after displaying OST SSID: 397204639 Audio Narration Let us now look at the selection of T&I equipment for different applications. Instrumentation, Control, SCADA, leak detection, Fire Alarm and Gas detection system along with dedicated telecommunication system are deployed for real time monitoring, control, and process requirement of the pipelines. Client Query/Notes 28 L1-Divider Selection of T&I equipment for different applications Instrumentation, Control, SCADA, leak detection, Fire Alarm and Gas detection system along with dedicated telecommunication system are deployed for real time monitoring, control, and process requirement of the pipelines

29. Developer Notes OST to come one by one with VO. Image to come with first VO Audio Narration Instrumentation is provided in Pipeline System to facilitate Measurement, Safety and Control to optimize operation & maintenance of pipeline system. Field instrumentation at stations will comprise of pressure transmitters, temperature transmitter, pressure gauges, temperature gauge, level switch, level transmitters, flow meters, density meter, viscosity meter, digital indicator, etc. as per approved P&IDs The instrumentation system shall be designed to ensure: Measurement of process & equipment parameters Safety to personnel and equipment Providing measurement parameters for Control System Reliability of Service Ease of maintenance and convenience of operation Adequate provision for future expansion and modification Maximum interchangeability of equipment Fail safe features Client Query/Notes Instrumentation system The instrumentation system shall be designed to ensure : Measurement of process & equipment parameters Safety to personnel and equipment Providing measurement parameters for Control System Reliability of Service Ease of maintenance and convenience of operation Adequate provision for future expansion and modification Maximum interchangeability of equipment Fail safe features Instrumentation is provided in Pipeline System to facilitate Measurement, Safety and Control to optimize operation & maintenance of pipeline system. Field instrumentation at stations will comprise of pressure transmitters, temperature transmitter, pressure gauges, temperature gauge, level switch, level transmitters, flow meters, density meter, viscosity meter, digital indicator, etc. as per approved P&IDs

30. Developer Notes OST to come one by one with VO. Create the tables in IOCL colors Audio Narration The following sections provide general guidelines on the environmental conditions for systems in India. However, in case of conflict between the conditions specified herein and requirement specified in standard specifications, requirement specified in standard specifications shall supersede. For internationals pipelines, these conditions may change depending on weather conditions in other countries. Kindly take a minute to go through the table & Select next once done. Client Query/Notes Environmental conditions for Instrumentation system design The following sections provide general guidelines on the environmental conditions for systems in India. However, in case of conflict between the conditions specified herein and requirement specified in standard specifications, requirement specified in standard specifications shall supersede. For internationals pipelines, these conditions may change depending on weather conditions in other countries Field Instruments for outdoor applications Ambient Temperature 0 – 50oC Relative Humidity 98% Precipitation Heavy rain during monsoon Installation Outdoor unprotected & above ground Hazardous Area Classification Instrument shall be suitable for installation in Zone 1, Group IIA, IIB & T4 as per IEC 60079 or equivalent standards Weather Protection IP 65 as per IEC 60529 or equivalent standards IT Hardware like Servers, Workstations, PCs, Printers, etc. RTUs along with all accessories: All other equipment Environmental Operating Non-Operating Operating Non-Operating Operating Non-Operating Temperature 5° to 40° C –20° to 60° C 0° to 70° C –20° to 70° C 0° to 50° C –20° to 70° C Relative Humidity (non-condensing) 10% to 90% 5% to 95% 10% to 95% 5% to 95% 10% to 95% 5% to 95%

31. Developer Notes OST to come one by one with VO. SSID: 1135648520 This and the next slide are in continuation. Audio Narration Field instrumentation shall be suitable for installation in Zone 0/Zone 1/Zone 2 as per IEC 60079 or IS 5572 or equivalent standard and as per Hazardous area drawing of the locations. The instrument shall meet the following standard/requirement as minimum: Intrinsically safe as per Ex ib IIA and IIB T4 as per IEC 60079 or IS 5780 or equivalent standard Explosion proof Ex d IIA and II B T4 as per IEC 60079 or IS 2148 or equivalent standard Weatherproof to IP 65 or better as per IEC 60529 or IS 12063 or equivalent standard Client Query/Notes Classification of hazardous area and certification required for field instruments Field instrumentation shall be suitable for installation in Zone 0/Zone 1/Zone 2 as per IEC 60079 or IS 5572 or equivalent standard and as per Hazardous area drawing of the locations Intrinsically safe as per Ex ib IIA and IIB T4 as per IEC 60079 or IS 5780 or equivalent standard Explosion proof Ex d IIA and II B T4 as per IEC 60079 or IS 2148 or equivalent standard Weatherproof to IP 65 or better as per IEC 60529 or IS 12063 or equivalent standard

32. Developer Notes OST to come one by one with VO. SSID: 1356753965 Audio Narration Field instrumentation shall be suitable for installation in Zone 0/Zone 1/Zone 2 as per IEC 60079 or IS 5572 or equivalent standard and as per Hazardous area drawing of the locations Acceptable certifying authorities for Explosive/Hazardous Area Certifications for instruments/accessories: CCoE /PESO ATEX PTB BASEEFA NEC FM CENELEC/EN Internationally Recognized Bodies for Explosive area Zone/Division certification Certification by the Indian statutory authorities - CCoE (Chief Controller of Explosives)/PESO are mandatory. Client Query/Notes Repetition occurring for opening remarks – to be edited Classification of hazardous area and certification required for field instruments Acceptable certifying authorities for Explosive/Hazardous Area Certifications for instruments/accessories: CCoE /PESO ATEX PTB BASEEFA NEC FM CENELEC/EN Internationally Recognized Bodies for Explosive area Zone/Division certification Certification by the Indian statutory authorities - CCoE (Chief Controller of Explosives)/ PESO are mandatory

33. Developer Notes OST to come one by one with VO. SSID: 1055909129 Make these tabs clickable. On clicking the information corresponding to each tab available in the next slide should appear. Audio Narration Various Field Instruments are used in T&I Applications. They are: Level Measurement Pressure Measurement Pressure Switch Differential Pressure Measurement Temperature Measurement Scrapper Detectors Density Measurement Viscosity Cum Density measurement Flow Switch Click on each tab to know more. Client Query/Notes Field instruments Various field instruments are used in T&I applications: Click on each tab to know more Level Measurement Pressure Measurement Pressure Switch Differential Pressure Measurement Temperature Measurement Density Measurement Viscosity Cum Density measurement Flow Switch Scrapper Detectors

34. Developer Notes Client Query/Notes Field instruments Various field instruments are used in T&I applications: Level Measurement As per clause 7.11 (ii) of OISD 244, following instrumentation is to be provided for above ground tanks: a) Two numbers of independent level instruments should be provided. One shall be radar gauge type and other one shall be servo type or Radar type b) Over fill hard wired level switch like vibrating fork etc. shall be provided for actuating ROSOV Pressure Measurement In general, Pressure Transmitter are to be provided at station suction & station discharge headers, suction & discharge arms of mainline pumps, suction & discharge arms of booster pumps, before and after of the control valve, inlet & outlet exchange manifold at tank farm locations, inlet and outlet booster manifold, before/after station limit valves (towards previous/next station), tank delivery pressure, station inlet & outlet pressure near SRB/SLB, pressure monitoring of fire water network, air vessels and other locations as per P&ID Pressure Switch In general, Pressure Switch are to be provided at station inlet on the mainline, station outlet on the mainline, suction and discharge headers of MLPUs, suction & discharge arms of mainline pumps, suction arms of booster pumps, tank delivery line, and other locations as per P&ID Differential Pressure Measurement Differential Pressure Transmitter to be provided for continuous remote monitoring of differential pressure Temperature Measurement For measurement of process temperature measurement of the process fluid, temperature transmitter with RTD inserted in thermo-well to be installed. Thermo-well is to be inserted in the pipeline to be in direct contact with process fluid For measurement of temperature in piggable section of the pipe (i.e. at RCP/MOV locations, before/after station limit valve etc.), temperature transmitter with surface mounted weld pad welded to the main pipeline to be installed. In such case the RTD shall be inserted inside the weld pad welded on the main pipe Scrapper Detector Scrapper detector is to be installed at each inlet and outlet section of the pipeline before the station limit valve (towards station) Density Measurement Density measurement to be provided at all mother stations, product delivery stations, tank farm locations and terminal stations of petroleum product pipelines to monitor density   Density measurement is the primary means of identifying the product flowing in the pipeline Viscosity cum Density Measurement Viscosity plays a critical part in establishing the flow condition in pipeline especially for crude oil pipeline where viscosity of the crude changes drastically along with density   Viscosity cum Density measurement to be provided at all mother stations, refinery delivery stations, tank farm locations and terminal stations of crude oil pipelines to monitor density & viscosity Flow Switch   Flow Switch to be provided at the sump pump discharge / transmix pump discharge to indicate low flow and in the surge relief line to indicate flow in surge line and other locations as per P&ID Flow switch in sump pump/ transmix pump discharge should be set for falling flow (which is to be based on the pump flow capacity)   Flow switch in surge relief line should be set for rising flow to detect minimum possible flow in the surge line Click on each tab to know more

35. Developer Notes Fade in the OSIs is sync with VO 1 . Play VO 2 in the background Audio Narration Various instruments such as flow meters for measurement of flow, control valves for flow and pressure control, density meters, intelligent pressure & temperature transmitters, RTDs, pressure & flow switches, level transmitters, radar type tank gauging system, and other instruments to monitor level, flow, pressure & temperature etc. form an integral part of station control system. In addition to field instrument, other systems/equipment like VFDs, HT/LT panels, MLPUs, boosters etc. shall also be interfaced with the PLC based control system Client Query/Notes Field instruments Various Field instruments required for reliable, fault-avoidant, safe and continuous operation of plant/station with monitoring and control from PLC system. Flow meters Density Meter Intelligent pressure Temperature transmitters RTD’s Pressure & Flow Switches Level Transmitters Tank Gauge

36. Developer Notes OST to come one by one with VO. Make the tab clickable. On clicking the tab the below info to appear. Include a scroll bar to fit in all the info. Audio Narration As per ASME B31.3 instrument piping “includes all piping and piping components used to connect instruments to other piping or equipment, and control piping used to connect air or hydraulically operated control apparatus. It does not include instruments, or permanently sealed fluid-filled tubing systems furnished with instruments as temperature or pressure responsive devices” Click on the tab to read more about Instrumentation field fitting. Client Query/Notes Instrumentation field fittings As per ASME B31.3 instrument piping “includes all piping and piping components used to connect instruments to other piping or equipment, and control piping used to connect air or hydraulically operated control apparatus Click on the tab to read more about Instrumentation field fitting Instrumentation field fittings

37. Developer Notes OST to come one by one with VO. Make the tab clickable. On clicking the tab the below info to appear. Include a scroll bar to fit in all the info. Audio Narration As per ASME B31.3 instrument piping “includes all piping and piping components used to connect instruments to other piping or equipment, and control piping used to connect air or hydraulically operated control apparatus. It does not include instruments, or permanently sealed fluid-filled tubing systems furnished with instruments as temperature or pressure responsive devices” Click on the tab to read more about Instrumentation field fitting. Client Query/Notes Last line may be changed as : - “All these Primary connection fittings shall be interconnected via welding and is considered by PJ-Mechanical in its design (except for bushing). For details on the tapping/connection, standard drawing of PJ-Mechanical may be referred”. Instrumentation field fittings As per the present practice, for connecting field instruments (like pressure transmitter, pressure switch etc.) with process pipe/equipment, double/twin ferrule compression type Stainless Steel (SS316) fitting and SS tubes are to be used.   Generally, ½” tube & fittings are to be used for installation of field instruments. Twin ferrule compression fitting consists of components such as Nut, Back Ferrule, Front Ferrule and Body.   Primary connection/tapping on the process pipe shall be provided by welding the weldolet (preferably of 1” size) followed by nipple, bend, valve etc. followed by the bushing (1” welded end to ½” NPTF end) to provide threaded connection. All these fittings shall be interconnected via welding and is considered by PJ-Mechanical in its design (except for bushing). For details on the tapping/connection, standard drawing of PJ-Mechanical may be referred. Instrumentation field fittings

38. Developer Notes OST to come one by one with VO. Make the tab clickable. On clicking the tab the below info to appear. Include a scroll bar to fit in all the info. Audio Narration As per ASME B31.3 instrument piping “includes all piping and piping components used to connect instruments to other piping or equipment, and control piping used to connect air or hydraulically operated control apparatus. It does not include instruments, or permanently sealed fluid-filled tubing systems furnished with instruments as temperature or pressure responsive devices” Click on the tab to read more about Instrumentation field fitting. Client Query/Notes Instrumentation field fittings In liquid pipelines, it is preferred to have an instrumentation tapping at 3’O clock /9’O Clock position from the process piping, to avoid any air/water/sediments in the instrumentation tubing.   Threaded connection of the bushing shall be used to connect the SS tube & twin ferrule compression fittings for further connection of the respective instrument.   Various type of fittings used in the instrumentation tubing consists of male connector, female connector, equal tee, end caps, seal pots, plug, hex nipple etc. Instrumentation field fittings

39. Developer Notes OST to come one by one with VO. Make the tab clickable. On clicking the tab the below info to appear. Include a scroll bar to fit in all the info. Audio Narration As per ASME B31.3 instrument piping “includes all piping and piping components used to connect instruments to other piping or equipment, and control piping used to connect air or hydraulically operated control apparatus. It does not include instruments, or permanently sealed fluid-filled tubing systems furnished with instruments as temperature or pressure responsive devices” Click on the tab to read more about Instrumentation field fitting. Client Query/Notes Instrumentation field fittings The hardness of the tubes shall be Rockwell RB 70 – 79. Field fittings with a minimum working pressure of 3000 PSI (211 kg/cm2) are to be considered in design, irrespective of pressure rating of process pipelines. For lower pressure ratings of field fittings, project specific approval may be obtained.   For installation near coastal area & installation of LPG pipelines, fittings with a type test certification as per ASTM F1387-99 are to be considered in design.   For crude oil pipeline installation, field instruments are to be connected with the provided pipe through the Glycol filled Seal Pot. This being considered in design to avoid entry of dirt/wax etc. in the instrument entry which can cause its failure. During the installation of the field instrument with seal pot, it is to be ensured that bottom of the seal pot is higher than the sensor of the instrument by 3-4 inch. Instrumentation field fittings

40. Knowledge Check #3 5° to 40° C –20° to 60° C 0° to 70° C The operating temperature for RTUs is in the range of _____ –20° to 70° C Select correct option and then click submit Developer Notes Screen Type: Single Select Question 2 attempts Includes Submit Button Correct choice: choice number 3 Correct Feedback: Well done! The operating temperature for RTUs is in the range of 0° to 70° C. 1 st Incorrect Feedback: Incorrect. Please try again. 2 nd Incorrect Feedback: Incorrect. The operating temperature for RTUs is in the range of 0° to 70° C. Audio Narration The operating temperature for RTUs is in the range of _____ Select correct option and then click submit Client Query/Notes None of the above

41. Knowledge Check #4 RB 71 – 69 RB 70 – 79 RB 07 – 97 The hardness of the instrument field fittings SS tubes shall be in the range of Rockwell _______ RB 70 – 97 Select correct option and then click submit Developer Notes Screen Type: Single Select Question 2 attempts Includes Submit Button Correct choice: choice number 2 Correct Feedback: Well done! The hardness of the instrument field fittings SS tubes shall be in the range of Rockwell RB 70 – 79. 1 st Incorrect Feedback: Incorrect. Please try again. 2 nd Incorrect Feedback: Incorrect. The hardness of the instrument field fittings SS tubes shall be in the range of Rockwell RB 70 – 79. Audio Narration The hardness of the instrument field fittings SS tubes shall be in the range of Rockwell _______ Select correct option and then click submit Client Query/Notes None of the above

42. Developer Notes OST to come one by one with VO. Make the tab clickable. On clicking the tab the below info to appear. Include a scroll bar to fit in all the info. Audio Narration In addition to field instruments as covered earlier in this module, additional flame proof fittings like junction boxes, flame proof ESD switch etc. are also considered in design. Different type of flame proof fittings are covered here under: Junction Boxes Emergency Shutdown (ESD) Switch Click on each tab to read more about it. Client Query/Notes Flame proof fittings Different type of flame proof fittings are covered here under: Click on the tab to read more about it Junction Boxes Emergency Shutdown (ESD) Switch SME to provide image

43. Developer Notes OST to come one by one with VO. SSID: 1459162652 Audio Narration For connecting various branching cables from main cable, junction boxes are installed in the filled Flame proof junction box body shall be corrosion resistant and suitable for group IIA & IIB gases for hazardous area Installation The construction of junction box shall comply to IS 2148:2004/IEC 60097-1 standard Terminals inside the junction box shall be vibration proof Captive Screw clamp type 2.5 Sq mm with minimum 500V, 24 A rating Insulating material for terminals shall be polyamide Based on the various requirements, types of junction boxes to be installed in the field have been standardized as Type A, Type B, Type C & Type D. Client Query/Notes Flame proof fittings Different type of flame proof fittings are covered here under: Click on the tab to read more about it Junction Boxes Emergency Shutdown (ESD) Switch Box body shall be corrosion resistant Suitable for group IIA & IIB gases for hazardous area Installation Construction shall apply to IS 2148:2004/IEC 60097-1 standard Terminals inside the junction box shall be vibration proof Captive Screw clamp type 2.5 Sq mm with minimum 500V, 24 A rating Polyamide must be used as an Insulating material for terminals Junction box is standardized as Type A, Type B, Type C & Type D Standardization is done considering cable sizes & numbers of cables

44. Developer Notes OST to come one by one with VO. Audio Narration Emergency shutdown switches type are to be provided at critical locations inside the plant area for initiation of stations shutdown from the field The construction of termination box shall comply to IS 2148:2004 / IEC 60097-1 standard Terminals inside the termination box shall be vibration proof Captive Screw clamp type 2.5 Sq mm with minimum 500V, 24 A rating. Terminals shall be mounted in the DIN rail with two spare terminals to be provided in each enclosure Front cover shall be provided with clear breakable glass to facilitate operation by breaking Emergency stop push button shall be of “Self-latching” type The inside switch assembly compartment shall be written/ printed with message “BREAK GLASS IN CASE OF EMERGENCY” Glass break stainless steel hammer to be chained with main unit and provided with each switch Contact element shall have minimum 1 number of Normally Close and minimum 1 number of Normally Open contact NC contact of ESD switch to be wired with the PLC as healthy state Client Query/Notes Flame proof fittings In addition to field instruments as covered earlier in this module, additional flame proof fittings like junction boxes, flame proof ESD switch etc. are also considered in design. Different type of flame proof fittings are covered here under: Click on the tab to read more about it Junction Boxes Emergency Shutdown (ESD) Switch Construction of termination box shall comply to IS 2148:2004 / IEC 60097-1 standard Captive Screw clamp type 2.5 Sq mm with minimum 500V, 24 A rating Terminals mounted in the DIN rail with two (02 nos.) spare terminals, provided in each enclosure Front cover shall have clear breakable glass to facilitate operation by breaking Emergency stop push button shall be of “Self-latching” type “BREAK GLASS IN CASE OF EMERGENCY” must be printed in inside switch assembly Glass break stainless steel hammer to be chained with main unit and provided with each switch Minimum 1 number of Normally Close (NC) and minimum 1 number of Normally Open (NO) contact NC contact of ESD switch to be wired with the PLC as healthy state

45. Developer Notes OST to come one by one with VO. Use the given image in the course SSID: 758207527 This and the next slide to be in continuation. Audio Narration Different technologies are available in the market to provide the flow measurement. Different types of flow meters are being installed at pipeline locations as per operations, process and statutory requirements Flow metering in pipelines is provided at different locations to achieve the following objectives: For custody transfer purpose For flow indications purpose related to pipeline process For integration with leak detection system for identification of the leaks Client Query/Notes Flow Metering System Design Flow metering in pipelines is provided at different locations to achieve the following objectives: For flow indications purpose related to pipeline process For integration with leak detection system for identification of the leaks For custody transfer purpose 1 2 3

46. Developer Notes OST to come one by one with VO. SSID: 636726706 Use this for 4 elements Audio Narration Following are some other points to take care during the flow metering system design. In case of custody transfer locations, requirement of proving these meters may also be kept in design. For high flow rate requirement permanent proving system may be included in the design whereas for location with low flow rate requirement provision of mobile prover based proving to be kept in design Flow conditioning requirement of the flow meters are also be taken care during design stage and required flow conditioners may be procured along with the meters Client Query/Notes Flow Metering System Design Flow metering in pipelines is provided at different locations to achieve the following objectives: Flow conditioning requirement of the flow meters are also be taken care during design stage and required flow conditioners may be procured along with the meters For high flow rate requirement permanent proving system may be included in the design whereas for location with low flow rate requirement provision of mobile prover based proving to be kept in design

47. Developer Notes OST to come one by one with VO. SSID: 636726706 Use this for 4 elements Audio Narration Necessary certification like Hazardous area classification certificate, custody transfer approval etc. may be reviewed during the procurement stage of flow meters MFMs shall have Custody transfer approvals as per OIML R117 (NMI/PTB labs). Also it shall have approvals from Weights and measures as per Government of India must be there Client Query/Notes Flow Metering System Design Flow metering in pipelines is provided at different locations to achieve the following objectives: MFMs shall have Custody transfer approvals as per OIML R117 (NMI/PTB labs). Approvals from Weights and measures as per (Govt. of India) must be there Certification required: Hazardous area classification certificate Custody transfer approval etc.

48. 01. There are various Packages dealt in T&I system design. However, for statutory codes and standards, they are classified on the basis of the area of Installation and the function it performs. In addition, It is always essential to understand that the T&I equipments are electrically operated gadgets, hence proper safety measures need to be ensured for the equipment to perform in hazardous environment. 02. Fundamentally, for an explosion to take place, flammable or explosive gases, vapours, mists or dusts will be present. Then, the level of risk of an explosion is based on the frequency and duration of the occurrence of an explosive atmosphere. This level of risk is represented by classifying the hazardous area as Zone 0, Zone 1 or Zone 2 (for gas, vapour and mist atmospheres) 03 . Instrumentation, Control, SCADA, leak detection, Fire Alarm & Gas detection system along with dedicated telecommunication system are deployed for real time monitoring, control and process requirement of the pipelines. Developer Notes OST to come one by one. Use scroll bar to include the complete text in the slide. Audio Narration Now that you have reached the end of the course. Kindly take a minute to go through the key points that were discussed in the course. Client Query/Notes Course Summary 05 . Different technologies are available in market to provide the flow measurement as per the requirement. 04 . Field instrumentation shall be suitable for installation in Zone 0/Zone 1/Zone 2 as per IEC 60079 or IS 5572 or equivalent standard and as per Hazardous area drawing of the locations.

49. Final Assessment To complete the course, you must take the final assessment. The passing score on the assessment is 80%. While taking the assessment, you will not be able to access any other part of the course. The assessment has 5 questions. Note that some questions could have more than one answer. You have unlimited attempts to take this assessment. Begin Assessment Developer Notes NIL Audio Narration NIL Client Query/Notes

50. Question 1 Construction of Junction Boxes shall comply to IS 2148:2004/IEC 60097-1 standard IEC 61115 Ed 2 , IEC61730 Part 1&2 standard ASTM F1387-99 standard IS 2148:2004/IEC 60097-1 standard None of the above Select correct option and then click submit Developer Notes Screen Type: Single Select Question Includes Submit Button Correct choice: choice number 3 Audio Narration Client Query/Notes

51. Question 2 MFMs shall have custody transfer approvals as per _______ OIML R111 (NMI/PTB labs) OIML R117 (NMI/PTB labs) OIML R116 (NMI/PTB labs) OIML R127 (NMI/PTB labs) Select correct option and then click submit Developer Notes Screen Type: Single Select Question Includes Submit Button Correct choice: choice number 2 Audio Narration Client Query/Notes

52. Question 3 Standard dealing with the Electrical Apparatus for Potentially Explosive Atmospheres –Flameproof Enclosures ‘d’ EN50018 EN50014 Select correct option and then click submit Developer Notes Screen Type: Single Select Question Includes Submit Button Correct choice: choice number 2 Audio Narration Client Query/Notes EN50020 DIN-43760

53. Question 4 Standard dealing with the Functional Safety – Safety Instrumented Systems for the Process Industry IEC 61158 IEC 61508 IEC 61511 IEC 61804 Select correct option and then click submit Developer Notes Screen Type: Single Select Question Includes Submit Button Correct choice: choice number 1 Audio Narration Client Query/Notes

54. Question 5 Grouping of industrial gases is categorized into Group I and Group II gases as per IS 9570 IS 1239 IS 9570 Select correct option and then click submit Developer Notes Screen Type: Single Select Question Includes Submit Button Correct choice: choice number 2 Audio Narration Client Query/Notes IS-1554 Part I BS 5384

55. Quiz Results Your Score Passing Score Review Quiz Print Result Retry Quiz Developer Notes Notes to developers will appear here Audio Narration Client Query/Notes

56. Thank you. You have successfully completed the course. You may now exit or take the course again. Restart Exit Course Developer Notes This screen will only appear if the person has passed the final assessment Audio Narration Client Query/Notes 56