Reliance Industries Ltd.

Hazira Instrument Maintenance Procedure Manual

Page No. 1 of 5

4.30 PM / CALIBRATION PROCEDURE FOR FIRE & GAS DETECTION SYSTEM INSTALLED AT DIFFERENT PLANT LOCATION ACROSS THE COMPLEX.

4.30.1 Introduction : This Procedure Contains how to carried out PM/Calibration of Fire and Gas Detector system installed at different plant location across the complex. Potential Environmental Issues : Release of Hydrocarbon to atmosphere during Process. Generation of cotton waste during PM/Calibration. Refer relevant plant annexure for significant environment aspect analysis if aspect is significant. Potential Safety/Occupational Health issues : 1. 2. 3. 4. Falling from height. Chances of Hydrocarbon leakage. Cuts / abrasion on fingers due to slippage of tools. Refer relevant plant annexure for risk assessment analysis. Any Make of F&G System RILH/INST/3.430 Make : Any Model : As applicable RILH/INST/4430

4.30.2 Scope : 4.30.3 Procedure No.

4.30.4 Format No. 4.30.5 Precautions :

1. Take all safety precautions as mentioned in PTW. 2. Ensure that Override switch is override by panel superintendent. 3. Inform Fire control room 4.30.6 Calibrating Instrument Required : 1. Multimeter. 2. Calibration gas and accessories. 4.30.7 Sketch for Calibration : STEPS : (A) Calibration of Flammable/Combustible (LEL) gas sensors/Transmitter Section No. : 3.430 Rev. : 02 Date: 10.01.2005 NA

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Hazira Instrument Maintenance Procedure Manual

Page No. 2 of 5

1. 2. 3. 4.

Obtain Permit to Work (PTW). Inform Area Operator regarding the job. Ensure that LEL System is isolated and decommissioned. Do not use cleaning solvents, silicon based lubricants, sealant, corrosion inhibitors and water repellent agents on or near sensors or transmitters. Such compounds poison the sensor. 5. Ensure sensor head is clean 6. Ensure sensor connector to secure. 7. Inspect unit for external mechanical damage. 8. To ensure proper functioning of the catalytic type of LEL sensor, check & set proper Head voltage/current as given below. Make Head voltage/current Crowcon/DI 2.0 0.1 Volt Sieger 200 mA Buveco/I.care 2.3 Volt 9. Perform Head balancing in case of Crowcon Gasmonitor panel. 10. Remove the sensor from the transmitter in case of Sieger make 2000 series model and fit it to the test jig, else perform the calibration without disconnecting the sensor. 11. Place zero cap on the sensor head. Allow the reading to stabilise. Adjust zero at the sensor and/or on gas monitor panel. 12. Remove zero cap and fit accessory with gassing nozzle and apply test gas at a rate of 0.5 2.0 litres/min. Allow the reading to stabilise. Adjust span at the sensor and/or on Gas monitor panel. 13. Repeat steps 11 & 12 till no further adjustment is required. 14. Install sensor back to the transmitter in case it is removed.
15. Return PTW.

(B) Calibration of Toxic gas sensors/Transmitters 1. Ensure sensor head is clean. 2. Ensure sensor connector to secure. 3. Inspect unit for external mechanical damage. 4. Check for any water ingress. 5. Fit accessory with gassing nozzele & pass instrument air at a rate of 0.5-1 litres/min. Allow reading to stabilise. Adjust zero at sensor and/or gas monitor panel. 6. Apply test gas for calibration at a rate of 0.5-1 litres/min . Allow reading to stabilise. Adjust span at sensor and/or gas monitor panel. 7. Repeat steps 5 & 6 till no further adjustment is required
8. Return PTW.

(C) Calibration of Oxygen gas sensors/Transmitters 1. Ensure sensor head is clean. 2. Ensure sensor connector to secure. 3. Inspect unit for external mechanical damage. 4. Check for any water ingress. 5. Fit accessory with gassing nozzele & pass Pure Nitrogen at a rate of 0.5-1 litres/min. Allow reading to stabilise. Adjust zero at sensor and/or gas monitor panel. Section No. : 3.430 Rev. : 02 Date: 10.01.2005

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Hazira Instrument Maintenance Procedure Manual

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6. Apply Instrument air for calibration at a rate of 0.5-1 litres/min. Allow reading to stabilise. Adjust span at sensor and/or gas monitor panel. 7. Repeat steps 5 & 6 till no further adjustment is required
8. Return PTW.

(D)

P.M. Of Series 30 Ionization Smoke Detectors 1. Check that cables to and from the detector are undamaged and secure. 2. Tighten all connections in detector base for prevention of fluse alarm actuation. Measure power supply between L1 & L2, it should be between 17 &28 Vdc. 3. Check proper termination of EOL resistance. 4. Clean detector with vacuum cleaner to remove accumulated dust from exposed area of gauge: this will remove light deposit of dust from the smoke sensing chamber. 5. Check the age of the detector by reference of its serial number; it has to be replaced after 10 year of usage. 6. Test the detector in site by using freon aerosol spray or smoke cans. Check that proper alarm signals are generated on mimics and graphic package in specified areas. N.B. : In case, the Smoke detectors are not approachable (e.g. that are installed above false ceiling and below false floor), regular PM can be avoided. These detectors to be checked only when the fault alarm comes or the sensitivity of the sensors has reduced.

(E)

P.M. OF Manual Alarm Call Points : 1. Check that cables to and from MAC are undamaged and secure. 2. Check that glass is in good condition. 3. MAC it to be simulated using allen key, observe the alarm on mimic panels located at plant control room and fire station for correctness of actuation area and tag. P.M. Of IR Detectors Inspect unit for external mechanical damage. Inspect cabling and glands, check sensor is fixed securely. Check for any water or moisture ingress. The detector windows should be checked to confirm that they are not blocked and that no physical obstructions have been placed between the detector and the protected area. 5. Any deposits of dirt and oil should be cleaned from sensor window (reflector and saphire window). It can be cleaned using water or detector solution with stiff bristle. 6. Healthiness of IR detector should be checked using any IR source. The actuation of alarm should be checked on mimic and graphic package for right location. 1. 2. 3. 4. 4.30.8 Authority & Responsibility :

(F)

Section No. : 3.430

Rev. : 02

Date: 10.01.2005

Reliance Industries Ltd.

Hazira Instrument Maintenance Procedure Manual

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Authority & Responsibility for PM/Calibration as per Common Tier II Maintenance Procedure Manual, Procedure No. RILH/MM/2601. 4.30.9 References : Manual of Fire and Gas Detector System 4.30.10 Records :

As per Common Tier II Maintenance Procedure Manual Procedure No. RILH/MM/2602. (Format No.RILH/INST/4430,ESS No.COMN/I/110)

Reason for Revision : 00 IMS First Issue By : MDT

Approved by : SND
REV :01

Reliance Industries Ltd. Hazira. CALIBRATION FORMAT FOR F & G SYSTEMS Format No : RILH/INST/4430 Make : TCI used Model Reqd. accuracy : % Full scale I/P range : Date : Tag No.

Calib. Due date

Section No. : 3.430

Rev. : 02

Date: 10.01.2005

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Hazira Instrument Maintenance Procedure Manual

Page No. 5 of 5

O/P range : Next Cal . Due Date : CALIBRATION GAS : Sr. No. 1 2 3 4 5 6 7 8 TAG NO

SPAN GAS READING BEFORE ADJUSTMENT ZERO ( 0 % ) SPAN ( 50 % ) READING AFTER ADJUSTMENT ZERO ( 0 % ) SPAN ( 50 % )

Calibrated By Tech.'s Name Signature Action Taken Calibrated Adjusted Repaired Replaced
Note : (1) Tick mark appropriate box. (2) Fill in necessary details.

: : : Signature

Observation Deviation within allowable limits

Advise Certified for use

DM / AM

Section No. : 3.430

Rev. : 02

Date: 10.01.2005