Engineering Standard: IPS-E-IN-105
Engineering Standard: IPS-E-IN-105
Engineering Standard: IPS-E-IN-105
ENGINEERING STANDARD
FOR
ORIGINAL EDITION
DEC. 1997
This Standard is the property of Iranian Ministry of Petroleum. All rights are reserved to the owner.
Neither whole nor any part of this document may be disclosed to any third party, reproduced, stored in
any retrieval system or transmitted in any form or by any means without the prior written consent of the
Iranian Ministry of Petroleum.
Dec. 1997 IPS-E-IN-105
1. SCOPE ............................................................................................................................................ 2
2. GENERAL REQUIREMENTS......................................................................................................... 2
3. INSTRUMENT TECHNICAL CENTER AND WORKSHOP............................................................ 2
3.1 General..................................................................................................................................... 2
3.2 Central/Main Instrument Technical Center and Workshop................................................. 3
3.3 Satellite Instrument Workshops .......................................................................................... 3
3.4 The Offshore Platform-Instrument Workshop ..................................................................... 3
3.5 The Sizing of Instrument Technical Centers and Workshops............................................ 3
3.6Typical Internal Layout for an Instrument Technical Center and Workshop..................... 4
3.7 Utilities ..................................................................................................................................... 5
3.8 Workshop Buildings ............................................................................................................... 5
4. EQUIPMENT FOR THE TECHNICAL CENTER AND INSTRUMENT WORKSHOP .................... 6
4.1 General ......................................................................................................................................... 6
4.2 Central/Main Technical Center and Workshop......................................................................... 6
4.3 The Exploration and Production-Offshore Instrument Workshop ......................................... 8
4.4 Small Tools for the Instrument Workshop................................................................................ 9
4.5 Equipment Inventory................................................................................................................... 9
5. FIELD MAINTENANCE EQUIPMENT AND TOOLS.................................................................... 15
5.1 General................................................................................................................................... 15
5.2 Small Tools for Field Maintenance...................................................................................... 16
APPENDICES:
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1. SCOPE
This Engineering Standard is intended as a guide for the design, selection of layouts, equipment
and tools required for the instrument workshop and on the plant, to cover a normal range of
maintenance work on new and existing Petroleum Industries of Iran.
2. GENERAL REQUIREMENTS
2.1 Building and layouts of an instrument repair, test and calibration workshop shall be the users
particular needs and shall be furnished with necessary tools and equipment.
As an example, an instrument workshop has been sized and illustrated in the Appendices to house
the tool and equipment inventory considered necessary for the calibration and maintenance of the
instruments and instrument systems, installed in a medium sized refinery or chemical and
petrochemical plants carrying out their own maintenance. The estimated size required approximates
to an area of 360 m for the instrument section of such workshop complex.
2.2 The engineering contractor shall develop a tool and equipment inventory and a workshop
layout, based on the actual requirements of the operating Company concerned using this
procedural specification. The proposal shall then be presented for the user (owner) for his approval
in writing.
3.1 General
It is necessary to provide engineering maintenance with well equipped and efficiently organized
instrument technical centers and/or workshop facilities.
The following facilities described in this Standard are typical min. requirements necessary for the
Contractors design of:
- Pneumatic instrumentation,
- electronic instrumentation,
- digital systems, including process computers,
- Distributed Control System (DCS),
- Programmable Logic Controller (PLC),
- analyzer systems.
Notes:
1) Computer maintenance should include hardware and when applicable peripheral
equipment and storage of software packages.
2) The accommodation inside the building(s) shall include offices, storage, calibration and
light machining facilities.
For the small plants, the central/main instrument technical center and workshop may form part of a
larger maintenance complex together with the mechanical and electrical engineering disciplines,
see Appendix A of this Standard. However, for large plants a dedicated instrument technical center
should be considered.
Whatever the arrangement, facilities should also be provided in control rooms and analyzer houses,
together with the equipment necessary for carrying out certain local maintenance activities.
Note:
The mechanical maintenance of items, such as control valves, could be carried out in the
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Notes:
1) The internal design of the building should be based on a central corridor providing access
to individual offices and work areas.
2) The standards equipment room should be located away from machining areas or other
sources of vibration, and preferably have an air lock type entrance.
3) Special attention shall be given to provide acceptable noise levels inside offices,
computer and standard equipment rooms.
4) The internal partition walls, between rooms, should be removable to allow re-
arrangements for future developments.
5) Inside walls should be partially glazed where necessary, to provide a clear view.
Apart from variations in size and layout of the buildings, the equipment to be installed in
central/main and satellite instrument technical centers and workshops, will ultimately depend on
the type and size of the process installations and the number of installed instruments.
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3.6.1 General
The instrument technical center and workshop building, as illustrated in Appendix B, should typically
comprise the following:
1) Office accommodation for:
- engineers,
- supervisors/foremen.
Provisional offices inside the workshop should be allowed to direct supervisory personnel.
- planning personnel.
This office should be of an adequate size to accommodate day-to-day planning/meetings.
2) Workshop facilities for:
- receipt and despatch.
This Section of the workshop should have direct access from outside and be divided into:
- receipts, for incoming instruments/material,
- despatch, for repaired instruments/components,
- cleaning and painting,
- heavy duty area (handling large control valves, etc.),
- pneumatic instrumentation
- electronic instrumentation Includes,
- Distributed Control System (DCS) inspection, repairs, testing,
- Programmable Logic Controller (PLC) and calibration,
- industrial analyzers,
- machining operations.
Depending on layout and space available, this area for handling large instruments such as
control valves and for the carrying out of general mechanical work on them, can either be
separate from, or combined with the machine shop as shown in Appendix B, with sufficient
access way to facilitate transportation.
Note:
When the instrument workshop is part of a mechanical/electrical workshop complex, the
sharing of facilities such as machining, welding, cleaning and painting, etc., should be
considered to avoid duplication.
3) Storage facilities for:
- instrument spare parts,
- consumable items (gaskets bolts and nuts, etc.),
- chemical products,
- portable analyzers,
- computer spare parts (including disks, etc.).
4) Special workshop facilities for:
- standards equipment (of measuring and calibration, etc.),
- high-precision (machining and instrument fitting, etc.),
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Note:
See also Section 6 and Appendix E, for alternative arrangements for chemical and
petrochemical plants and crude production areas.
3.7 Utilities
3.7.1 The relevant workshops of the technical center shall be provided with steam, water and tool
air, etc., from the plant for workshop utilities system, and an instrument air supply, as appropriate
3.7.2 Electricity for power and lighting shall be installed in accordance with the requirements.
Voltages that may be required are for example,110 V, 220 Volts AC at 50 Hz, 24 Volts DC. The
voltages required shall be indicated in the project specification and the requisitions.
Note:
The level of lighting required in the analyzer, electronic, computer and standards equipment
rooms may be as high as 1000 lux.
3.8.1 Construction
The building shall be designed in accordance with the general requirements of Standard Drawings
IPS-D-CE-210 to 222.
Note:
An oil contaminated drainage system will also be required in the analyzer room.
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- electronic shop,
- analyzer test and calibration room,
- other offices, shops and rooms as appropriate.
The HVAC System will then be in accordance with the requirements of:
IPS-E-AR-120 "Building Air Conditioning System" and,
IPS-E-AR-160 "Venting, Ventilation and Pressurization System".
3.8.3.2 Ventilation is particularly required for the following rooms:
- cleaning and painting,
- analyzer test and calibration room.
Notes:
1) Chemical cleaning and painting areas shall comply with national and/or local regulations
with regards to ventilation, which should typically give a minimum of 30 to 50 air changes
per hour, and static electricity/electrical safety in explosive gas atmospheres.
2) When forming part of a building complex, analyzer workshops and test rooms, etc.,
should have induced ventilation to maintain a pressure below that of the other rooms, in
order to prevent escape of gases. There should also be a minimum of 30 to 50 air changes
per hour.
4.1 General
4.1.1 The equipment contained in a modern instrument workshop shall be of sufficient quality to
ensure that all repaired and re-calibrated instruments will meet the original manufactures
specifications.
4.1.2 The offices, shops and rooms of the technical center and workshop considered in this
Standard are provided with a proposed inventory of furniture, equipment, machines and tools and
which is shown on the drawings of Appendix C.
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- analyzers,
- computer spare parts (including discs and software, etc.),
- DCS spare parts (including diskettes and software, etc.).
Note:
The computer room will require air conditioning.
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- a signal generator,
- a variable power supply unit,
together with equipment specifically selected for the particular platform. Test equipment for
pneumatic instruments can be selected from (Sub-sections 4.5) to suit the particular requirements.
However, special test equipment for the particular platform will also be required.
Notes:
1) Calibration equipment for fiscal metering should also be located in this area.
2) This area should be free from the effects of vibration.
4.5.1 General
Appendix C shows proposed items of equipment and their suggested location in the instrument
technical center and workshop, superimposed on the layout drawings of Appendix B.
The equipment is identified by the item number of the following inventory which is sub-divided
according to type. It also includes normal items of office furniture and specific test equipment (see
also 4.5.8).
4.5.2 Furniture
Item
- work desk 1
- chairs 2
- work table 3
- blackboard 4
- shelves 5
- filing cabinet 6
- high cabinet (with hinged doors) 7
- high cabinet (for machine tools) 8
- low cabinet (for machine tools) 9
- low cabinet (with sliding doors) 10
- table(for computer) 11
- computer equipment storage facilities 12
- planning board, etc. 13
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1) Standard work-benches
- general duty 30
- heavy duty 31
2) Special work-benches
- extra heavy duty 32
- mechanical 33
- laboratory. 34
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- vacuum 41
- medium/high pressure 42
- electro/pneumatic. 43
4) Special test-benches
- control valve 44
- hydraulic (portable type) 45
- temperature. 46
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Notes:
1) Voltage - Two standard cells to be checked every 6 months (derived from
stancell/current resistance with high accuracy requirement i.e. 10-8 V).
2) Frequency - Check frequently if necessary.
3) All testing equipment in this room shall be certified as primary testing equipment and
should not be taken outside the room.
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5.1 General
In addition to the calibration and maintenance of instruments which is carried out in the various
workshops, calibration and maintenance is also necessary for certain instruments or instrument
systems in situ on the plant and/or in the instrument auxiliary rooms and control rooms. To
facilitate this work, a selection from the tools and equipment given in the following section should be
available as applicable.
For complete flexibility, separate tools and equipment for the field maintenance team should be
considered, however some expensive and/or infrequently used items could be borrowed from the
workshop(s) inventory.
The maintenance tools and equipment should be located in the workshop(s), but for convenience
certain items should be available in the maintenance room of control rooms and analyzer houses.
However, certain specific and special test equipment should remain in the main instrument
workshop.
The quantities of equipment required will depend on the size of the plant, and whether maintenance
is to be carried out as a centralized system from a central workshop or independently from satellite
workshops in conjunction with a main workshop.
The equipment listed below is typical for the in situ checking of pneumatic and electronic
instruments installed in the average plant as considered in this Standard.
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- portable tachometer
- manufacturers calibrator(s)
- portable pulse and function generator
- portable variable power supply (amps/volts).
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APPENDICES
APPENDIX A
TYPICAL LAYOUT OF A MECHANICAL, ELECTRICAL AND INSTRUMENT WORKSHOP
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APPENDIX B
TYPICAL LAYOUT OF AN INSTRUMENT TECHNICAL CENTER AND WORKSHOP
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APPENDIX C
TYPICAL LAYOUT OF EQUIPMENT IN AN INSTRUMENT TECHNICAL
CENTER AND WORKSHOP
(to be continued)
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APPENDIX C (continued)
EQUIPMENT INVENTORY
Furniture Non-Standard Work-Benches
1- Work desk 32- Extra heavy duty
2- Chairs 33- Mechanical
3- Work table 34- Laboratory
4- Blackboard 35- Light duty
5- Shelves 36- Pneumatic
6- Filing cabinet 37- Electronic
7- High cabinet - with hinged doors 38- Telecommunication
8- High cabinet - for machine tools 39- Analyzer (general duty)
9- Low cabinet - for machine tools 40- Analyzer (specific duty)
10- Low cabinet - with sliding doors 41- Vacuum
11- Table - for computer 42- Medium/high pressure
12- Computer equipment storage facilities 43- Electro/pneumatic
13- Planning board, etc. 44- Control valve
45- Hydraulic (portable type) 46- Temperature
Utilities Equipment
14- Acid resistant sink
15- Acid resistant sink Miscellaneous Equipment
(combined with a fume hood) (Note: Only the larger stationary items are
16- Rack for sample bottles shown on the layout.)
17- Sample conditioning system 47- Hoisting facilities (electric or pneumatic)
18- Storage facilities 48- Painting booth
(complete with gas cylinders) 49- Small welding booth
19- Safety shower with eye bath 50- Mobile hand volume pump
(with folding tripod stand) 51- Portable vice
Cleaning Equipment 52- Pipebending machine
20- Cleaning table 53- Cutting shears (hand lever operated)
21- Grit blasting facilities 54- Magnifying glass (with electric light)
22- Chemical 55- Ultra violet light facilities
23- Ultrasonic bath - small size 56- Test rig for storage tank gages
Machine Tools 58- Trolley for oscilloscope
57- Test stand for control valves
24- Lathe - instrument type 59- Portable oxy-acetylene welding set
25- Drilling machine - pedestal type 60- Arc welding set
26- Grinding machine 61- Heating oven
27- Polishing machine 62- Electrical heating plate
28- Engraving machine 63- Pipe vice - chain type
29- Mobile pipe threading machine 64- Portable pipe vice (with floding tripod stand)
65- Set of laboratory glass ware
Standard Work-Benches 66- Rack for PLC and GLC equipment
30- Work-bench (general duty) 67- Deep freeze - laboratory type
31- Work-bench (heavy duty) 68- Trailer - low loader type
69- Mobile crane - 3 tonne max. capacity
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APPENDIX D
TYPICAL LAYOUT AND EQUIPMENT LOCATI
ON FOR ASATELLITE INSTRUMENT WORKSHOP
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APPENDIX E
TYPICAL WORK-BENCH AND INSTRUMENT TEST-BENCH REQUIREMENTS
E.1 General
Work-benches and instrument test-benches can be either to Manufacturers Standard or of Special
Construction.
E.5.1.1 Work-benches
E.5.1.2 Test-benches
(to be continued)
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APPENDIX E (continued)
(to be continued)
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APPENDIX E (continued)
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APPENDIX E (continued)
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APPENDIX E (continued)
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APPENDIX E (continued)
1) Bench
- size, 1500 800 900 (mm),
- with a Melamine faced top,
- and an insulated steel frame.
2) Under bench
- with 9 lockable drawers on roller,
- guides fitted with drawer dividers.
3) Bench top unit
- suitable for fitting on the bench as 3 19 inch racks complete with Part Nos. 3, 5
& 7.
4) Power supply unit
- complete with safety devices.
5) Pneumatic supply unit
- with regulators and pressure gages.
6) Socket outlet panel
- complete with plugs for:
220 V 50 Hz
110 V 50 Hz or to suit local conditions see Sub-section 3.7
24 V DC
Each socket should be in a dedicated color
7) Light source
- fitted with 2 60 W bulbs on an articulated arm.
8) Magnifying lens
- for use with Part No. 7.
1) Bench
- size 1800 1000 900 (mm),
- with Melamine faced top,
- and an insulated steel frame.
2) Under bench
- with 9 lockable drawers on roller guides fitted with drawer dividers.
3) Power supply
- 220 V 50 Hz complete with miniature circuit breaker having overcurrent protection
of 16 A, with a combined or separated earth leakage device of 30 mA.
(to be continued)
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APPENDIX E (continued)
7) Light source
- fitted with 2 60 W bulbs on an articulated arm.
8) Magnifying lens
- for use with Part No. 7.
9) Slide unit with:
- transmitter calibrator,
- power supply 220 V 50 Hz,
- output 0 to 60 V DC and 0 to 50 mA, to be adjustable by a 10 turn potentiometer,
- a display of 4 to 5 digits,
- and an accuracy of 0.1% of the measured valve.
10) Slide unit with:
- digital pressure indicator 0 to 300 mbar,
- accuracy 0.1 % of full scale,
- a display of 4 to 5 digits,
- pneumatic adjustable switches,
- leak test and pressure limiting valves.
11) Slide unit (as 10 above but for 0 to 1.6 bar)
12) Slide unit (as 10 above but for 0 to 6 bar)
13) Slide unit (as 10 above but for 0 to 10 bar)
14) Slide unit (as 10 above but for 0 to 60 bar)
15) DC power supply 0 to 50 mA
(to be continued)
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APPENDIX E (continued)
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Note:
The length of this bench is 4 meters.
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APPENDIX E (continued)
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APPENDIX E (continued)
1) Power supply unit (for the bench, and for the pump)
- 220 V 50 Hz complete with a miniature circuit breaker having overcurrent
protection of 16 A, with a combined or separate earth leakage device of 30 mA.
2) Digital vacuum indicator (with connection)
3) Digital pressure indicator-0 to 1.5 bar
4) Digital pressure indicator-0 to 6 bar
5) Socket outlet panel
- complete with plugs for:
220 V 50 Hz
110 V 50 Hz
24 V DC
Note:
Sockets for different voltages should have different contact arrangements and be in a
dedicated color.
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APPENDIX E (continued)
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APPENDIX E (continued)
15) Slide unit
- with plugs for:
220 V 50 Hz
115 V 50 Hz.
16) Pneumatic slide unit
- with regulators and gages.
17) Electrical junction box
E.5.2.1 Work-benches
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APPENDIX E ( continued)
1) General
- Typical size 1750 (or 2000) 750 mm, overall height 1630 mm.
2) Work top
- beechwood, plastic faced with aluminum angle sides,
- 50 mm thick.
3) Drawer-cabinet/supports
- each cabinet to have 4 large capacity drawers with a locking system,
- 2 drawers to be fitted with compartments,
- constructed in heavy gage sheet steel.
4) Shelf
- fitted between the cabinets complete with back cover constructed in heavy gage
sheet steel.
5) Top unit
- with sliding roller shutter type lockable doors,
- fitted with a tool storage system,
- constructed in heavy gage sheet steel.
6) Base
- of hardwood or equivalent.
7) Accessories
- a light source,
- a parallel jaw vice.
1) General
The control valve test-bench should provide all the facilities necessary for the complete
testing and calibration of control valves such as:
2) The bench
- of welded steel frame complete with:
- 2 control desks,
- 1 hydraulic lifting table fitted with safety devices,
- special connections for 3-way valves,
- complete set of interchangeable flanges in stainless steel.
(to be continued)
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APPENDIX E (continued)
3) Capacity
- suitable for the testing of control valves up to 16 in nominal bore and 1200 mm
between flanges,
- and for calibrating 3-way valves.
4) Equipment and facilities
- required to carry out the following tests:
a) leak tests - in accordance with:
- ANSI B 16- 106 up to Class VI (Ref. IPS-G-IN-160, "Control Valves"),
- manufacturers standards.
with: air or water.
The equipment shall include:
- a set of leakage rotameters for 6 l/h up to 30 l/h,
- a manifold for rotameter selection.
b) pneumatic tests-requiring:
- air supply variable with variable control to a pressure of 6 bar maximum,
- a complete air manifold with accurate manometers:
- fixed outputs of: 0.2 bar,
1.0 bar,
- pneumatic connections made with stainless steel tubing and compression
fittings,
- variable output.
c) hydraulic tests-requiring:
- mechanical protection for the hydraulic tests.
d) Electronic tests-requiring:
- electricity supply of 220 V 50 Hz complete with a miniature circuit breaker
having over current protection of 16 A, with combined or separate leakage
device of 30 mA,
- 24 V DC,
- fixed output 4 mA,
- fixed output 20 mA,
- variable output 0-60 mA with digital indication for input measurement,
- electronic timer for start/stop.
e) electronic leak test-requiring:
- electronic leak detection apparatus.
f) PLC capabilities-requiring
- automatic clamping with safety features,
- automatic control of clamping pressure,
- automatic sequence procedures,
- configuration via the keyboard.
(to be continued)
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APPENDIX E (continued)
g) micro-computer equipment-comprising:
- bench filing capabilities,
- storage for manufacturers data,
- filing all test procedures,
- control valve data,
- control valve records,
- calibration via keyboard.
h) printer:
- procedures,
- calibration,
- control valve data and specification,
- control valve records, by tag number.
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1) Construction
- all metal with totally enclosed back and removable doors,
- working surface for the bath to be stainless steel,
- high temperature baths to be insulated,
- with internal forced ventilation,
- all control and visual systems to be mounted in the top unit.
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APPENDIX E (continued)
3) Bath characteristics
- refer to bath specifications Table E.2 of this Appendix.
4) Indication and control
- baths to be continuously monitored by analog (or digital) indicators,
- thermometers to be of the mercury precision type,
- a safety cut out device shall be fitted to prevent overheating and fire damage,
- bath on/off control to be programmable,
- connection for instrument air supply,
- socket outlets for 110/120 V.
5) Accessories
- mercury in glass thermometer,
- instrument air filter/reducer,
- set of supports for the instruments under test,
- individual temperature control system for each bath.
6) Dimensions
- 2400 850 1220 mm for a four bath unit.
7) Power supply
- normally 380 V 3 phase.
SPECIFICATION 1 2 3 4
(to be continued)
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APPENDIX E (continued)
1) General
To be suitable for the liquid testing of equipment with hand operated pumps of 300 bar max.
capacity.
2) Hydraulic oil reservoir
- capacity 20 liters, constructed from heavy gage steel plate.
3) Hand pump
- built into the reservoir and fitted with a release valve.
4) Strainer plate
5) Test stand
6) Deflector/safety guard
- of transparent material.
7) Pressure gages-for setting and control
0 to 10 bar
0 to 60 bar
0 to 100 bar
0 to 300 bar.
8) Selection valve for each gage
9) Control panel-for gages etc.
10) Dimensions
- 660 555 350 mm.
11) Weight 70 kg approx.
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