INTERNSHIP REPORT

Petrofac Engineering Services India Pvt. Ltd.,

DLF Infocity SEZ, Manapakkam,
Chennai – 600089.

Submitted by
Arunachalam. S,
Shridar. S,
Sri SaiRam Engineering College,
Chennai – 44.

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 ACKNOWLEDGEMENT

First, we would like to thank the Petrofac Management for giving us

this opportunity to have the Internship in such an esteemed company.
We express immense gratitude to Mr Gurumurthy.S, HOD-
Instrumentation Department and Mr Swaminnathan. S, Principal
Engineer for being our mentor and supporting us throughout the
internship period.
Our sincere thanks to Mrs Kavitha, Instrumentation, who personally
guided us during this period and also sourced out other people who
could help us.
Our heartfelt gratitude to Mr Fazil, Mr Karthi, Mr Balaji.R, Ms
Vijayalakshmi, Ms Saranya, Ms Pragyanjali.S , Ms Nageswari.S for
lending their expertise in their respective fields.
Also we would like to extend our gratitude to Mr Balaji.K HR, for
getting us this opportunity in time and without whom this opportunity
would have been impossible.
We are also grateful to the other Senior Engineers, Engineers, GE’s,
GET’s who have given us an insight on what an office experience looks
like and how Instrumentation Engineers form an important part of this
Industry.

Regards,
Arunachalam.S,
Shridar.S.

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 INDEX
S.NO CONTENT PAGE NO

1. About Petrofac 4

INSTRUMENTATION & TELE COMMUNICATION

2. Introduction to Instrumentation 10

3. Measuring Instruments 14

4. Control Valve 23

5. Actuators 27

6. Positioners 29

7. ICSS 30

8. HAZOP 38

9. P&ID 43

10. Software used in instrumentation 46

11. Telecommunication 47

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 ABOUT PETROFAC

 PETROFAC provides complete solutions for Oil & Gas

production facilities.
 Petrofac is a leading service provider to the oil and gas production
and processing industry.
 The company was established as a producer of a modular plant
in Tyler, Texas, Unkited States in 1981.
 Petrofac is an ISO 9001 EPC contractor and certified provider of
technical related services to the oil production, oil refining, natural
gas and petrochemical industries.
 Petrofac is a diverse company, operating out of seven
operational centres in Sharjah, Abu
Dhabi, Chennai, Mumbai, Aberdeen, Woking and Kuala
Lumpur, plus a further 24 offices and 12 training facilities
worldwide.

ABOUT PETROFAC, CHENNAI

 It was established in 2007 with an employee count of 1,450.
 It is located in DLF Infocity, Chennai and acts as an operational
center which provides the Engineering services to both onshore
and offshore projects and proposals.
 This includes large-scale modularization projects from concept to
commissioning, as well as asset management services, using a
variety of execution models such as EPC and EPCm.
 Over the years, Petrofac have supported the Group execution of
projects across many geographical and technical sectors, such as:
 Reggane North Development project, Algeria.
 ZADCO, Upper Zakum UZ 750 Project, Abu Dhabi.
 Jazan Refinery Project, Saudi Arabia.

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  BorWin 3 Offshore HVDC Conversion Platform Project,
German North Sea.
 Karachaganak, 4th Train Project, Kazakhstan.
 Qatar Petroleum – AGRU & SRU Project, Qatar.
 Majnoon Field Development Project, Shell Iraq.
 Ithaca Energy FPF-1 Floating Production Facilities,
Poland.
 Rabab Harweel Integrated Project, Oman.
 Yibal Khuff Project, Oman.

INTRODUCTION
 Petrofac is an EPC (Engineering Procurement & Construction)

based company.

 EPC consist of three major steps Proposal, Feed, Detail

Engineering.

 Proposal-To get the Project from the Client.

 Detailed Engineering- They Involves solving vendor queries, Bid

evaluation, Purchase requisition & Purchase Order.

 It basically forms the Midstream Sector.

 Being an EPC company, Petrofac acts as a contractor between the
client and the vendor.
 Client usually takes care of the upstream work and most probably
using a third-party organisation.

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 Petrofac as a contractor takes care of all the engineering work
involved in the midstream and procures all the necessary packages
or equipment from the Vendors. Vendor may also source out these
from sub-vendors.

WORK FLOW PROCESS

FEED → Proposal → Detail Engineering
 The foremost document is the “FEED” i.e., the “Front End
Engineering Design” which is provided by the client or
sometimes may be done by Petrofac.
 This is sent to various other eminent contractors, who send their
own “Proposals” to the client. Once the client is satisfied with the
proposal, he’ll award the contract to the most suitable contractor.
 Next step is the “Detail Engineering”.
 On receiving the contract, the contractor prepares the
“Mechanical Data Sheet (MDS)” which is an integral part of
detail engineering.
 Based on the requirements from the MDS, the contractor sends the
“Requisition for Quotation (RFQ)” to various quality and cost
conscious vendors.
 Each vendor gives his quotation to the contractor. The contractor
selects the most suitable vendor after a series of clarifications with
him through “Technical Queries (TQ)” and/or “Bid
Clarification Meetings”.
 Then comes the “Technical Bid Evaluation (TBE)” where the
contractor evaluates the best vendor among all and then it is the
“Purchase Requisition (PR)” to the selected vendor and they
procure the equipment/package. The vendor may send a
completely assembled package or may assemble it on site,
depending on his convenience.

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 VARIOUS DISCIPLINES
The company has a number of departments and each taking care of
their respective works. The various departments involved are:

 Process
 This department forms the heart of the company.

 P&ID’s, process data sheet and equipment lists are

received from the process department, which involves the
processes that take place from start to end of plant while
working.
 Utility schedule for all packages are sent to them.

 Civil
 This department takes care of all the structural support
required in a plant.
 They calculate the differing load conditions and bearings
for different equipment/packages and also for many
connections for which input is given by other departments
and so, they draft the layout of the plant.

 Mechanical
 This department is responsible for the various mechanical
equipment used in the industry.
 This department will be dealt in detail in the following
portion.

 Piping
 This department takes care of how the piping, pipelines for
transporting the extracted hydrocarbons which is to be
laid.
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  Electrical
 This department takes care of all the electrical equipment
and electrical wiring that are required in a plant, like local
electric supply, control panel for different equipment that
like compressors, blowers etc.

 Instrumentation
 The department takes care of all the measuring
instruments, control panel, local control systems, DCS etc.
and also the wirings or transmitters if required.

 Telecom
 This department takes care of the communication and
safety security systems in the plant.
 They provide location of the security cameras through
telecom wiring and different alarm systems in case of
emergency and also the intercoms and speakers for public
awareness systems.

 Metallurgy

 This department is responsible for the analysis of the

process environment where the plant is to be installed.
 Sometimes, this information is provided the client
himself.

 Client relation – Sharjah Office take care of the client

relation and decides the bid to be placed for a project.
 Inter Disciplinary Check (IDC)
 It is where all the departments ensure that there plan has
been executed as given and has not been modified to suit
the requirements of the other departments.
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 Inter Disciplinary Information Transfer (IDIT)
 It is the communication or knowledge transferred between
various departments.

General Flow diagram of Oil & Gas Industry

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 INSTRUMENTATION
 The department works on Engineering, Construction, Operation
and Maintenance

The 3 major steps in this unit are

 PROPOSAL/BIDDING,
 FEED (Front End Engineering Design),
 DETAILED ENGINEERING.

PROPOSAL/BIDDING

Before every bid to be placed, each department in the company has to

deliver their estimated work within the project time for a complete
review.
 Estimating the working-hours required to do the proposal.
 kick off meeting - Client’s organization, requirements, strategies,
past similar projects etc.
 Review of ITT(Invitation to Tender) documents and raise
TQS(Total Quality service)
 Participating in Risk reviews.
 Interdisciplinary engineering activities which provide inputs to
other disciplines who are involved with instrumentation and
receive inputs from HSE, Telecom, Mechanical etc., to take care
of their requirements.
 Participate in mini HAZOP / mini SIL review, if carried out.
 Generate the list of items (BOQs) with specifications, estimated
working-hours and cost price.
 Bench Marking to finalize the cost.
 Generate proposal submission documents like Technical
Qualifications, Feed Verification report, Block diagrams etc.
 Create risk and qualification lists for internal review.

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 Attend bid clarification and Feed endorsement meeting with the
Client if required.
 Provide post submission clarifications to the Client.
 The main calculation is the estimation of cable length required for
connecting all the transmitter and other measuring and recording
instruments to the processing units like PLC, SCADA ,DCS and
to emergency systems like FGS, PAGA, etc.,.

FEED – FRONT END ENGINEERING DESIGN

 Contract Reviews/Planning/TDR,
 C&A Philosophy / Design Basis/ Job Notes/Concept Notes,
 Site surveys and Conceptual Layouts,
 Interdisciplinary engineering reviews,
 Block diagrams/Schematics,
 Tagging/Numbering Philosophies,
 Specifications and Datasheets.

DETAILED ENGINEERING

 System studies and Relay coordination

 Earthing Design and Calculation
 Lighting Protection Design
 Layouts and plot plans
 Interconnection Schedule
 MTO for cables and cable accessories, Earthing materials, Junction
boxes etc…

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 MEASURING INSTRUMENTS
Measuring Instruments generally used are flow meters, pressure
transmitters, level sensors, temperature sensors.

PROCESS CONTROL
 Generally, a process is controlled by the basis parameter which are Pressure,
Flow, Temperature and Level. There are other variables which are taken
into consideration such as Viscosity, density and quality whenever required.
 Measuring devices are selected based on the below terms
 Measurement
 Accuracy & Precision
 Repeatability
 Redundancy
 Response time
 Monitoring & control
 Measurement :
– Measurement is based on the capability and necessity of the
instrument.
– Measurement is generally carried out using the measuring devices
like Transmitters, Indicators, based on the process parameters.
 Accuracy & Precision :
– Accuracy of a measurement system is the degree of closeness of
measurements of a quantity to that quantity's true value.
– The precision of a measurement system, related to reproducibility
and repeatability and is the degree to which repeated measurements
under unchanged conditions show the same results.
 Repeatability:
– Repeatability is the variation in measurements taken by a single
person or instrument on the same item, under the same
conditions, and in a short period of time.
– A measurement may be said to be repeatable when this variation
is smaller than a pre-determined acceptance criteria.
 Redundancy:

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 – Redundancy is the duplication of critical components or
functions of a system with the intention of increasing reliability
of the system, usually in the form of a backup or fail-safe.

– They are of three types

•Cold Redundancy
•Warm Redundancy
•Hot Redundancy

 Cold Redundancy
o Cold redundancy is for non-critical processes where time is not a
high priority and human intervention is acceptable.
 Warm Redundancy
o When time and a response result to a failure which is important
but not critical, a warm redundancy strategy may suffice if a
temporary outage is acceptable across it.
 Hot Redundancy
o Hot & warm redundancies are similar in architecture where hot
redundancy offers instant process correction when a failure is
detected.
 Response time:
– Response time is the total amount of time it takes to respond to a
request for service.
– The service can be anything from a memory fetch to a disk IO or to
a complex database query or loading a full web page.
– Ignoring transmission time for a moment, the response time is the
sum of the service time and wait time.
– The service time is the time it takes to do the work you requested.
 Monitoring & control:
– Monitoring and Controlling process overviews all the tasks and
metrics necessary to ensure that the approved and authorized project

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 is within scope, on time, and on budget so that the project proceeds
with minimal risk.
– This process involves comparing actual performance with planned
performance and taking corrective action to yield the desired
outcome when significant differences exist

FLOW METER

 It is important to know the quantity of oil being transported

at numerous points along the pipeline.
 This requirement also holds for natural gas.
 Flow meters are generally of vortex, positive displacement
(PD), differential pressure (DP), coriolis, and ultrasonic
varieties.

FLOW MEASURING INSTRUMENTS

 Flow meter generally classified as volumetric flow and mass flow
meter.
 Volumetric flow is defined as the rate of volume of liquid crossing
a given surface area at any instant of time.
 Mass flow is defined as the rate of mass of the fluid crossing a
given area at any instant of time.
 Flow is generally an important parameter, it is used to determine
quantity of product being transported in a pipe. E.g. transportation
of methane through pipe.

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Types of flow meter:

1. Differential Pressure (Head) Type:

• Flow Nozzles
• Venturi Tube
• Orifice plate
• Elbow
• Pitot Tube, Averaging Pitot Tube (Annubar)
• Variable Area (Rota meter)
2. Mass Type:
• Coriolis flow meter
• Thermal flow meter

3. Velocity Type:

• Magnetic type,
• Ultrasonic - Transit Time, Doppler
• Turbine,
• Vortex type.

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4. Open Channel Type:

• Weir type
________________________________________________________

TEMPERATURE SENSOR

• The measurement of temperature is a vital part of instrumentation

in petrochemical industries.
• Platinum Resistance Temperature Detectors (RTD's) are often used
for their excellent temperature response.
• Thermocouples are used in locations that need a more durable
sensor. Thermocouples come in many types.

TEMPERATURE
 Temperature is a measure of the average kinetic energy of particles
that make up body .

 The greater the kinetic energy of the particles is, the higher the
temperature of the body will be.

 Temperature is the ability of one body to transfer thermal energy to

another body.

 If two bodies are in equilibrium and no thermal energy is

exchanged, then the bodies are at the same temperature. Molecular
motion creates heat known as thermal energy.

 Thermal movement from hot to cold is called thermodynamics.

 Absolute zero ( no molecular motion ) means no heat is reproduced.

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Types:
Temperature devices are specified according to their construction and
are classified as below:

1. Thermocouple (T/C) ( -300oF to +3100oF):

2. Resistance Temperature Detector (RTD): [ -300oF to

>1800oF]

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3. Thermistor

• It is the sensitive and accurate Instrument than any other

temperature device.
• Thermistors also measure the change in resistance with
temperature.

4.Bi Metallic Thermometer

• Thermometers for auxiliary service applications (compressor

lube oil, etc.) & control valve/ESDV may be a 2” or 3" diameter
when supplied as a component in a package.
• Standard ranges shall be selected in order to avoid too many
ranges in specific project.
• The standard ranges available in the market almost cover all
process temperature measurement requirements. All
Manufacturers have lists of standard ranges that should be used
to avoid extra charges for non-standard ranges.
5. Filled System Thermometer

• When a measuring instrument couldn’t receive any electric

supply to work, under such circumstances the filled in system
thermometer used.
• A liquid filled thermometer should be considered for corrosive
hazardous areas or where vibration is a problem.

Types:

1. Liquid column filled in system,

2. Gas column filled in system,
3. Vapour column filled in system,
4. Mercury column filled in system.

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6. Infrared Thermometry. [100oC to 3500oC]

• It has an accuracy of ± 1/2 % full scale.

• It is used in places where more precision of Thermocouple is
required.

The Units of Measurement:

• °C – degrees Celsius (or Centigrade)
• °F – degrees Fahrenheit
• K – Kelvin
• R – Rankine

Standards followed:
• NEMA (National Electrical Manufacturers Association)
• UL (Underwriters Laboratories)
• CSA (Canadian Standards Association)

__________________________________________________________

PRESSURE TRANSMITTER

 A pressure to current converter (P/I converter) in petrochemical

industries is used to measure the pressure developed by liquefied
petroleum gas (LPG), crude oil, petrol, and various other
petroleum byproducts.
 In the P/I converter, the indicated pressure can be a digital or an
analog form.
 The main advantage is that it can be directly shown on the control
panel in the control room. This is true for temperature
measurement also.

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PRESSURE MEASURUNG INSTRUMENTS

 Pressure is defined as the force acting per unit area.

 Units of pressure: Kg/cm2, Kg/m2, pascal, bar, atm, psi, etc..
 Pressure plays a vital role in power plant because, it decides the
amount of power being generated.
 STANDARD FOR PRESSURE:
1. European (CEN) Standard:
 EN 472 : Pressure gauge - Vocabulary.
 EN 837-1 : Pressure gauges. Bourdon tube pressure
gauges. Dimensions, metrology, requirements and testing.
 EN 837-2 : Pressure gauges. Selection and installation
recommendations for pressure gauges.
 EN 837-3 : Pressure gauges. Diaphragm and capsule
pressure gauges. Dimensions, metrology, requirements,
and testing.
2. US (ASME) Standards
 B40.100-2005: Pressure gauges and Gauge attachments.
 PTC 19.2-2010 : Performance test code for pressure
measurement.
 API 551: Process Measurement Instrumentation

Pressure Measuring Instruments Types:

• Manometer
• Pressure Gauges (Vacuum, Compound, Absolute, Gauge)
• Differential Pressure Gauge
• Pressure Switch (Vacuum, Absolute, Gauge)
• Differential Pressure Switch
• Pressure Transmitter (Vacuum, Absolute, Gauge)
• Differential Pressure Transmitter
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Page 21 of 57
 LEVEL SENSOR:

o Petroleum and natural gas industries need very accurate level

measurement. Besides traditional technologies like differential
pressure level meters, radar, magnetostrictive, and magnetic float
are also used extensively.
o One of the problems with a significant number of technologies is
that they are installed through a nozzle and are exposed to
products. This can create several problems, especially when
retrofitting new equipment to vessels that have already been stress
relieved, as it may not be possible to fit the instrument at the
location required.
o Also, as the measuring element is exposed to the contents within
the vessel, it may either attack or coat the instrument causing it to
fail in service.
o One of the most reliable methods for measuring level is using a
Nuclear gauge, as it is installed outside the vessel. The measuring
element is installed outside the process and can be maintained in
normal operation without taking a shutdown. Shutdown is only
required for an accurate calibration.

LEVEL MEASURING INSTRUMENTS

• Level is the height of any process fluid in a container or in any
storage unit.
• Unit of Level : meter(m)
• Types of level measuring devices:
1. Level Gauges
2. Guided Wave Radar
3. Radar
4. Differential Pressure
5. Float / Displacer
6. Ultrasonic
7. Capacitance

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 8. Nuclear
9. Magnetic
10. Differential Pressure
11. Bubbler
12. Buoyancy
13. Level Switch
• Selection Criteria:
− Vessel Type – Atmospheric or Pressurized
− Vessel Nozzle Orientation , internal structures
− Material to be Measured – Liquid, Interface or Solid
− Process Conditions - Temperature, Pressure, Density, Viscosity,
Conductive, Turbulence, Foam, Vaporization Occur at the Surface,
Sour or Corrosive Service, dust and build up
− Measurement Range
− Measurement Type – Continuous (Transmitter), Point (Switch),
Local (Gauge)
− Contact or Non-Contact Measurement

SEAL POT
BRIDDLE

TANGENT LINE

Basic description of level through valves in a Storage tank

_________

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 ANALYTICAL INSTRUMENTS
Industrial chromatographs are generally used in olefin processing
in the petrochemical industry. Continuous gas analysers are also widely
used.

CONTROL VALVE
A control valve is a final control element which regulates the rate of
fluid flow or balances the pressure drop in a pipeline or across an
equipment by adjustment of valve plug & seat / disc position using the
actuator.The schematic representation of Control loop of Control valve
is shown.

Control Valve Assembly Parts are:

• Valve Body Assembly
− Body
− Bonnet
− Trim (Plug, Seat, Cage, Disc, Ball, Stem / Shaft)
• Actuator
• Positioner
• Accessories like air filter regulator, limit switches, boosters,

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 solenoid valve etc.

Control Valves can be broadly classified as:

• Linear Motion Control Valves.
• Rotary Motion Control Valves.
• Angle Control valve
• Diaphragm Control Valve

Linear Motion Control Valves are further classified as below :

a) Globe Control valve:
i. Single Seated Valve
ii. Double Seated Valve
iii. 3 Way

Rotary Control Valves are further classified as below :

1) Butterfly Control valve:
(1) Concentric Design
(2) Eccentric Design

2) Plug Control valve:

(1) Single Seated Valve

3) Ball Control Valve:

(1) Segmented Design

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 (2) V-Notch Design
(3) Full Bore Design

Different characteristics of a control valve are :

• Linear – input and output are linearly related (e.g- Y=MX eqn.)
• Equal Percentage – percentage of change input is equal to the
percentage of change in output.(e.g. if the input is increased by
50% then output is also increased by 50%)
• Quick Opening – for a small change input the change in output is
drastic.

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 ACTUATORS
Actuator a devices that used to control the opening and closing of
valve. It uses Pneumatic, Hydraulic or Electrically powered device
that supplies force & motion to open or close the valve.
Actuators requires signal and a source of energy (Can be
Pneumatic, Hydraulic or Electrically) and the electric signal is usually
[4-20mA] dc supply.

Pneumatic actuator Types:

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Following details are generally required to be filled for actuator in a
datasheet:
• Type – Spring & Diaphragm type, Spring Return piston type ( as
per manufacturer datasheet).
• Size / Area – As per actuator sizing by manufacturer.
• Failure position – As per P&ID.
• Air / Oil Supply Pressure – E.g. 4.5 bar g (as per Project
philosophy & actuator sizing).
• Bench range - From manufacturer datasheet.
• Travel Stop - As per process requirement.
• Hand wheel – Generally indicated in P&ID.
• Volume Tank – Required for double acting actuators (without
spring) to achieve the fail safe position.

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 POSITIONERS
 A Valve Positioner is a device used to increase or decrease the air
pressure operating the actuator until the valve stem reaches the
position called for by the instrument controller.
 Positioners are generally mounted on the side or top of the
actuator. They are connected mechanically to the valve stem so
that stem position can be compared with the position dictated by
the controller.
 An Electro pneumatic positioners are used in electronic control
loops to operate pneumatic diaphragm control valve actuators.
 The Positioner receives a [4-20mA]DC as input signal, and uses
I/P converter, nozzle flapper, and pneumatic relay to convert the
input current signal to a pneumatic output signal.
 The Output signal is applied directly to the actuator diaphragm.
The valve plug position is proportional to the input signal.
 Amplifies pneumatic signal to improve stroking speed.
 Whereas in case of a valve with a positioner, the signal from the
controller is given to the positioner.
 The positioner then compares it with current valve position and
gives an output suitable to the valve diaphragm until the desired
position is achieved.
 The output from the positioner stabilizes when the desired position
(signal matches feedback from valve stem) is achieved.
 In recent days Smart Positioner are being used in valves which is
combined with I/P converter, relays and has many features like
advanced valve diagnostics, partial stroke testing, remote
communication etc.

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 ICSS : INTERGRATED CONTROL AND SAFETY SYSTEM
On board these oil producing vessels is a Central Control Room
(CCR), where all the daily activities are being carefully monitored and
controlled to guarantee smooth oil production and to ensure
environmental and personnel safety.
The heart of the CCR is the Integrated Control and Safety
System (ICSS), which quietly regulates the production process by
means of the Process Control System (PCS), Safety Instrumented
System (SIS), Fire and Gas detection System (FGS) and High
Integrity Pressure Protection System (HIPPS).
Key Benefits & Highlights of an Excel Marco ICSS:
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  Seamless integration of PCS, SIS and FGS,
 Operator-friendly Human Machine Interface,
 Dedicated software library,
 Real-time data acquisition and display,
 Functionally separated safety systems approved by TUV to SIL3,
 Optimized Performance to Cost of Ownership,
 Fit for Purpose design.
The benefits of ICSS:
 Operational and Cost Efficiency due to resource sharing such as
Engineering Station (ES), PLC, Operator Station Client (OS
Client), Operator Station (OS Server), Historian.
 Total Integration: Process and safety are totally integrated,
allowing standard and safety programs to reside in the different
part of same CPU.
 Customized Solution: Dedicated software library developed based
on industrial standards and has a wide range of field proven
function blocks to cater for requirement of our customers.
 Communication gateway is not required between the PCS and
Safety System, thus eliminating another possible point of failure

 Common EWS (Engineering Workstation) for PCS, SIS, EGS

and HIPPS
 Common hardware platform significantly reduces range of spares
required
Typical Integration of Process Control and Safety
System:

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ee

ICSS with Process Control and Safety

Systems:

System Architecture
A typical architecture of ICSS includes Automation Station (AS),
Redundant Operator Station Server (OS Server), Operator Station Client
(OS Client), and Central Archive Server (CAS) and 3rd party OPC
Server.
"AS" refers to PLC and I/O modules whereas "OS" refers to HMI
station and database server.

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 Communication between Servers and Clients, Servers and PLC is
achieved through redundant ring network via Industrial Ethernet with
speeds of 10 or 100Mbps. Ethernet Network Heartbeats for PC stations
are constantly monitored, and their status displayed on the HMI. Safe
communication between the safety program in the F-CPU and the fail-
safe inputs and outputs takes place via the standard PROFIBUS DP with
superimposed PROFI-safe safety profile. Since both standard and safety
communication take place on the same bus, there is no additional
hardware requirement.
Central Archive Server stores alarm messages, process values,
reports and batch data. Historical data can be reviewed in trend view at
the client station or exported to excel for data analysis.
Time synchronization can be configured via GPS Clock or Server
PC Clock as Time Master. With GPS clock, the plant network is
synchronized at a defined time interval with a GPS satellite signal and
time resolution up to 1ms. The more economical solution will be
"Assigning Server as Time Master". The accuracy of Server PC Clock
cannot be as accurate as GPS clock unless PC time synchronizes with
the Internet time server with time resolution up to is.
High Integrity Pressure Protection System (HIPPS) is designed to
control over- pressurization of a plant such as production header of
FPSO. HIPPS can be placed in Zone 2 environment.

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 FIRE & GAS SYSTEM – FGS
The main objectives of the fire and gas system are to protect
personnel, environment, and plant (including equipment and structures).
The FGS shall achieve these objectives by:
 Detecting at an early stage, the presence of flammable gas,
 Detecting at an early stage, the liquid spill (LPG and LNG),
 Detecting incipient fire and the presence of fire,
 Providing automatic and/or facilities for manual activation of the
fire protection system as required,
 Initiating environmental changes to keep liquids below their flash
point.
 Initiating signals, both audible and visible as required, to warn of
the detected hazards,
 Initiating automatic shutdown of equipment and ventilation if 2 out
of 2 or 2 out of 3 detectors are triggered,
 Initiating the exhausting system.
There has been much industry debate over the categorization of
Fire and Gas Systems (FGS) as Safety Instrumented Systems (SIS),
especially as the concept of functional safety matures in the marketplace
and compliance to IEC 61508 / 61511 standards is more prevalent.
Fire and gas detection products and technologies are
fundamentally different from other forms of instrumentation in a plant.
Incorrect detector placement and poor environmental conditions can
prevent the product from detecting a hazardous gas leak or flame, even
when the unit is functioning properly.
When a safety hazard is undetected, then the appropriate safety
action (shut down, deluge, venting, etc.) cannot be initiated. Because of
this, many end-users and system integrators are wondering if the
functional safety standards are applicable to a FGS.

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 A legitimate argument can be made both for and against the
classification of a FGS as a SIS. Those that oppose the concept typically
believe that because of the inherent limitations of fire and gas detection
equipment, a FGS should only augment a plant safety system and not be
considered a critical safety function.
If a properly functioning FGS comprises a SIL 2 logic solver, a
SIL 2 sensor, and a SIL 2 final element, but fails to see the hazardous
gas or flame and effectively eliminate or mitigate the hazard, then the
SIL 2 risk reduction factor of 100 has not been achieved. For this reason,
many people think that too much emphasis and importance is placed on
the hardware of the system which can instill a false sense of security.
To eliminate this false sense of security, many industry experts feel
that a FGS should not comply to the IEC 61508 / 61511 standards.
Rather a new performance standard should be developed specifically for
FGS and adequately address the issue of detector placement, coverage,
and related issues.
The advocates for classifying a FGS as a SIS claim that a system
of gas and flame detectors is an effective mitigation layer of protection
and should fall within the scope of IEC 61508 / 61511. The system
should conform to the guidelines put forth in both 61508 and 61511. A
FGS that automatically initiates process actions to prevent or mitigate a
hazardous event and subsequently takes the process to a safe state can be
considered a Safety Instrumented Function (SIF) or SIS. The FGS would
need to be composed of appropriate logic solver(s), sensor(s), and final
element(s),
However, it is absolutely critical to ensure proper sensor placement
within a FGS. If there is incorrect placement of the gas or flame
detectors and hazardous gases and flames are not adequately detected,
then the SIF / SIS will not be effective, regardless of the SIL level of the
system. Correct sensor placement is more important than deciding
whether a FGS should be SIL 2 or SIL 3.

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 [1]
The bottom line is “you can’t buy safety out of a box” . The FGS
system must be designed based on the unique requirements of each plant
and application. Just purchasing a SIL 2 logic solver, a SIL 2 sensor, and
SIL 2 final element, does not guarantee a SIL 2 system.
A FGS can effectively mitigate a hazardous event. Risk reduction
targets can be established and a FGS can effectively achieve those
targets. Fire and gas detection manufacturers are enhancing the safety of
their products and improving their processes by designing to comply
with IEC 61508 standards. Systems integrators and end-users are
designing safer fire and gas systems by conforming to IEC 61511
standards.
Ultimately, the heart of functional safety is preventing and
mitigating risk to an acceptable level through the safety lifecycle. FGS
can be a critical and successful layer of protection that reduces risk to an
acceptable level.
Therefore, when applied appropriately and with the knowledge of
the limitation of the technology, a FGS can successfully be considered a
SIS.

ESD – EMERGENCY SHUTDOWN SYSTEM

An industrial safety system or Instrumented Protective
System(IPS) is a counter measure crucial in any hazardous plants such
as oil and gas plants and nuclear plants.
They are used to protect human, industrial plant, and the
environment in case of the process going beyond the allowed control
margins.
As the name suggests, these systems are not intended for
controlling the process itself but rather protection. Process control is
performed by means of Process Control Systems (PCS) and is

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interlocked by the safety systems so that immediate actions are taken
should the process control systems fail.
Process control and safety systems are usually merged under one
system, called Integrated Control and Safety System (ICSS).
Industrial safety systems typically use dedicated systems that are
SIL 2 certified at minimum; whereas control systems can start with SIL
1. SIL applies to both hardware and software requirements such as cards,
processors redundancy and voting functions.
Types of industrial safety systems:
There are three main types of industrial safety systems in process
industry.
1. Process Safety System or Process Shutdown System, (PSS).
2. Safety Shutdown System (SSS): This includes Emergency Shutdown-
(ESD) and Emergency Depressurization-(EDP) Systems.
PROCESS SHUTDOWN SYSTEM:
It is used to shut a particular process in a large industry in case of
any emergency caused in the particular process.
EMERGENCY SHUTDOWN SYSTEM:
These systems may also be redefined in terms of ESD/EDP levels
as:
ESD level 1: In charge of general plant area shutdown, can activate ESD
level 2 if necessary. This level can only be activated from main control
room in the process industrial plants.
ESD level 2: This level shuts down and isolates individual ESD zones
and activates if necessary EDP.
ESD level 3: provides "liquid inventory containment".
SAFETY SHUTDOWN SYSTEM:
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 The safety shutdown system (SSS) shall shut down the facilities to
a safe state in case of an emergency situation, thus protecting personnel,
the environment and the asset. The safety shutdown system shall manage
all inputs and outputs relative to emergency shutdown (ESD) functions
(environment and personnel protection). This system might also be fed
by signals from the main fire and gas system.
EMERGENCY PRESSURIZED SYSTEM:
Due to closing ESD valves in a process, there may be some
trapped flammable fluids, and these must be released in order to avoid
any undesired consequences (such as pressure increase in vessels and
piping). For this, emergency depressurization (EDP) systems are used in
conjunction with the ESD systems to release (to a safe location and in a
safe manner) such trapped fluids.
Pressure safety valves:
Pressure safety valves or PSVs are usually used as a final safety solution
when all previous systems fail to prevent any further pressure
accumulation and protect vessels from rupture due to overpressure by
their designed action.

HAZOP – HAZard and OPerateability study

A Hazard and Operability study (HAZOP) is a structured and
systematic examination of a complex planned or existing process or
operation in order to identify and evaluate problems that may represent
risks to personnel or equipment.
The intention of performing a HAZOP is to review the design to
pick up design and engineering issues that may otherwise not have been
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found. The technique is based on breaking the overall complex design of
the process into a number of simpler sections called 'nodes' which are
then individually reviewed. It is carried out by a suitably experienced
multi-disciplinary team (HAZOP) during a series of meetings.
The HAZOP technique is qualitative, and aims to stimulate the
imagination of participants to identify potential hazards and operability
problems. Structure and direction are given to the review process by
applying standardized guide-word prompts to the review of each node.
The relevant international standard calls for team members to
display 'intuition and good judgment’ and for the meetings to be held in
'a climate of positive thinking and frank discussion'.
For processes plant, the nodes are chosen so that for each a
meaningful design intent can be specified and they are commonly
indicated on piping and instrumentation diagram (P&IDs) and
process flow diagram (PFD).
The extent of each node should be appropriate to the complexity of
the system and the magnitude of the hazards it might pose.
However, it will also need to balance between "too large and
complex" (fewer nodes, but the team members may not be able to
consider issues within the whole node at once) and "too small and
simple" (many trivial and repetitive nodes, each of which has to be
reviewed independently and documented).
The degree of preparation for the HAZOP is critical to the overall
success of the review - 'frozen' design information provided to the team
members with time for them to familiarize themselves with the process,
an adequate schedule allowed for the performance of the HAZOP,
provision of the best team members for their role.
Those scheduling a HAZOP should take into account the review
scope, the number of nodes to be reviewed, the provision of completed

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design drawings and documentation and the need to maintain team
performance over an extended time-frame.
The team members may also need to perform some of their normal
tasks during this period and the HAZOP team members can tend to lose
focus unless adequate time is allowed for them to refresh their mental
capabilities.
Guide words and parameter:
 In order to identify deviations, the team applies
(systematically, in order) a set of Guide Words to each node
in the process.
 To prompt discussion, or to ensure completeness, it may also
be helpful to explicitly consider appropriate parameters
which apply to the design intent.
 These are general words such as Flow, Temperature,
Pressure, Composition.
 The current standard notes that Guide words should be
chosen which are appropriate to the study and neither too
specific (limiting ideas and discussion) nor too general
(allowing loss of focus).
 A fairly standard set of Guide Words (given as an example in
Table ) is as follows:
Guide Word Meaning
Complete negation of the design
NO OR NOT
intent
MORE Quantitative increase

LESS Quantitative decrease

AS WELL AS Qualitative modification/increase

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 Qualitative
PART OF
modification/decrease

Logical opposite of the design

REVERSE
intent

OTHER THAN /
Complete substitution
INSTEAD

EARLY Relative to the clock time

LATE Relative to the clock time

BEFORE Relating to order or sequence

AFTER Relating to order or sequence

Where a guide word is meaningfully applicable to a parameter e.g.

NO FLOW, MORE TEMPERATURE, their combination should be
recorded as a credible potential deviation (from the design intent) that
requires review.

Paramet
er / As well Other
More Less None Reverse Part of
Guide as than
Word
deviatin
deviatin
no reverse g contami
Flow high flow low flow g
flow flow concentr nation
material
ation

high low Vacuu explosio

Pressure delta-p
pressure pressure m n

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 high low
Temperat
temperatu temperat
ure
re ure

no different
Level high level low level
level level

sequen
too short
too long / ce step backwar missing extra wrong
Time / too
too late skippe ds actions actions time
soon
d

fast slow no
Agitation
mixing mixing mixing

fast no unwante
slow
Reaction reaction / reactio d
reaction
runaway n reaction
Start-up /
actions wrong
Shut- too fast too slow
missed recipe
down
deviatin
Draining wrong
too long too short none g
/ Venting timing
pressure

high low contami wrong

Inertising none
pressure pressure nation material

Utility
failure
(instrume failure
nt air,
power)

DCS
failure
failure [b]

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Maintena
none
nce

wrong
Vibration
too low too high none frequenc
s
y

P &ID – PIPING & INSTRUMENTATION DIAGRAM

Piping and Instrumentation Diagram/drawing (P&ID) is a
diagram in the process industry which shows the piping and vessels in
the process flow, together with the instrumentation and control
Piping and instrumentation diagram of pump with storage tank.
Symbols according to EN ISO 10628 and EN 62424.
− A piping and instrumentation diagram/drawing (P&ID) is defined
by the Institute of Instrumentation and Control as follows:
− A diagram which shows the interconnection of process equipment
and the instrumentation used to control the process. In the process
industry, a standard set of symbols is used to prepare drawings of
processes. The instrument symbols used in these drawings are
generally based on International Society of Automation (ISA)
Standard S5.1
They usually contain the following information:
• Instrumentation and with unique tag identifiers
• Mechanical equipment with names and numbers
• All valves and their identifications
• Process piping, sizes and identification
• Miscellanea - vents, drains, special fittings, sampling lines,
reducers, increasers and swaggers
• Permanent start-up and flush lines
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 • Flow directions
• Interconnections references
• Control inputs and outputs, interlocks
• Interfaces for class changes
• Computer control system
• Identification of components and subsystems delivered by others
P&IDs helps in safety and operational investigations, such as a
Hazard and operability study (HAZOP). To do this, it is critical to
demonstrate the physical sequence of equipment and systems, as well as
how these systems connect.
P&IDs also play a significant role in the maintenance and
modification of the process after initial build. Modifications are red-
penned onto the diagrams and are vital records of the current plant
design.
They are also vital in enabling development of;
 Control and shutdown schemes
 Safety and regulatory requirements
 Start-up sequences
 Operational understanding.
P&IDs form the basis for the live mimic diagrams displayed on
graphical user interfaces of large industrial control systems such as
SCADA and distributed control systems.

STANDARDS USED IN CONSTRUCTION OF P & ID:

 ANSI/ISA S5.1
 ISO 14617-6,
"TAG" is used as identifier of the field device, which is normally given
to the location and function of the instrument.

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P&ID LEGEND DIAGRAM OF VALVES

SAMPLE P & ID

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______________________________________________________________

SOFTWARE USED IN INSTRUMENTATION

The main set of software used in Petrofac Chennai are
 Smart Plant 3D (SP3D) and Smart Plant Review(SPR)
 Smart Plant Instrumentation (SPI)
Smart Plant 3D (SP3D) and Smart Plant Review(SPR):
Smart plant 3D also known as SP3D. Is used in construction of
three-dimensional representation of the P&ID. These diagrams are used
in construction reference material in the field.
In SP3D consume lot of RAM memory. In SP3D the plant is
constructed area by area.

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 The SP3D diagrams includes instruments, pipeline, piping and
HVAC, etc., in detail. Hence viewing the plan become difficult SP3D.
So Smart Plant Review(SPR) is used to view the plant in 3D the plant
can be viewed at any distance, plan can be bisected for view. Using SPR
it is possible to view every fine detail in the plant for that matter.
SPR is updated here every night to avoid clash of update in the
plan done by other department.
Smart Plant Instrumentation (SPI):
This software is used by instrumentation department here in
Petrofac for preparing and maintaining of data sheet. Previously, MS-
Excel was used for this purpose but compared to SPI it was less secure

TELECOMMUNICATION
Telecom systems are used for providing communication, safety &
security in Oil & Gas industries.
Telecom Systems can be categorized as :
 Communication System
 Safety & Security System

Communication Systems Safety & Security Systems

FOC System PAGA System
Structured Cabling System Access Control System
Telephone System CCTV System
LAN / WAN System
Entertainment System
VSAT System
Radio System

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 FOC SYSTEM
• A fiber optic cable is essentially a light pipe that is used to carry a
light beam from one place to another.
• To communicate signals over long distance with very less EMI &
noise.
• Advantages:
– Wider bandwidth
– Lower loss
– Light weight
– Small size
– safety
• Application
To communicate signals over long distance with very less EMI &
noise.
• Main Components
 Fibre optic Cable – Single Mode/Multimode
 Connectors
 Fibre Optic Patch cords
 Fibre Optic Panel
 Splice kits

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 STRUCTURED CABLING SYSTEM
• Communicating data/voice signals within/outside the
building/plant
• Integrates the voice,data,video and various management system of
a building
– Horizontal cabling with 4 pr 24 AWG Cat5e, 100Ω UTP
– copper cable for indoor voice and data services
– Vertical cabling shall be between floor to floor
for voice and data services
– 4 core armored multimode FO cable for inter and intra
building connectivity ITU-TG.651

• Application
Communicating data/voice signals within/outside the building/plant
• Main Components
 Main Cabinet
 Distribution Frame
 Patch Panels
 Patch cord
 Cables – Cat 5/Cat 6
 Outlets – Single, Dual, Triplet, Quad

LAN/WAN SYSTEM
• To transmit data/voice signals in a small/big network

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 • LAN connects network devices over a relatively short distance that
is within office buildings and home.
• LAN is connected by Ethernet.
Main Components
• Switches
• Routers
• Hubs
• Bridges
• Repeaters
Application
Active device to transmit data/voice signals in a small/big network

ENTERTAINMENT SYSTEM

Providing TV Entertainment to personnel in camps near to plants.

Types:
1. MATV( Master Antenna TV)
2.CATV (Cable TV)
CATV:
• Distibute signals over public areas and cabins in the living quarter.
• Distributed with use of modulator/amplifiers and head end
equipement.
• Entertainment System shall be interfaced with

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  PA/GA
 F&G

SATELLITE COMMUNICATION
Provides “point to point” or “point to multi point” data
connectivity using geo-stationary satellite as repeater.
Main Components
• Earth Station – Hub/Earth
• Satellite Transponder & Space Link
• Network control centre
• Interface Equipment

RADIO SYSTEM
Providing wireless communication to users
Main Components
• Radio - Handheld-portable, Vehicle mounted, Fixed
• Controllers
• Radio Tower
• Antenna
• Channels
• Radio Accessories
• Battery

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 TELEPHONE SYSTEM
For communicating voice signals within/outside plant
Main Components
• EPABX
• Patch Panel and Cables
• Operator Console
• RJ-11/RJ-45 sockets
• Telephone sets(Analog/Digital/VOIP/Hotline)
• MDF/IDF

PAGA system
Purpose of PAGA system
The PAGA (Public Address and General Alarm) system is used to
Broadcast the announcements, Alarms under Normal & Emergency
Situations and Routing speech messages to all areas of the plant
including buildings.It also provide visual alarms through beacons for
areas of high ambient noise.
Components of PAGA systems
Central equipment cabinet
Amplifier
Access panel
PA/GA operator Console
Cables – Fiber optic cables / Copper cables
Junction Box
Loudspeakers ( Indoor / Outdoor)

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 Flashing Beacon
PAGA speaker/flashing beacon poles

Access Control & CCTV

ACCESS CONTROL SYSTEM:
 Access control is a method of controlling passage into or out of an
area.
 The control can apply to people, assets, vehicles etc.
 We use different types of card systems like swipe, proximity and
insertion cards.
Application:
Controlling the personnel & vehicle movements in & out of the
buildings/plant areas through specific doors & gates.
Main Components
• Main Cabinet
• Door strike- E-M lock
• Cards – Proximity, Swipe, insertion.

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• Card Reader
• Exit Push button
• Emergency Break glass Unit
• Controller – Door & Main
• Server
• Cables

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 CCTV
CCTV is an acronym for Closed Circuit Television
It is a group of components connected together to form a closed
circuit so that the access to the camera and its components is restricted to
persons outside the authorized group.

CCTV system in oil and gas field is provided to

1. Monitor
2. Detect
3. Recognize
4.Identify
• Monitor-Observing an area
• Detection – indicate something is happening in the field of interest
• Recognition – determine exactly what is happening
• Identification – determine who is involved in the activity

COMPONENTS OF A CCTV SYSTEM:

1. Camera and its junction box
2. Video Encoder/Video Decoder
3. DVR / NVR
4. Matrix Switcher
5. PTZ Controller
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6. Monitor
7. Camera mechanical unit-Housing and PTZ unit
8. Cables
CAMERA JUNCTION BOXES
JBs are used for field cameras for terminating the cables
Selected based on the area classification in which they are installed
JUNCTION BOXES (JB)
Weather proof Explosion Proof Interdisciplinary Rotation Report on
Telecoms Department – Piping GET 2015
VIDEO ENCODER/VIDEO DECODER
By using Video encoders one can remotely access and control
analog video cameras over an IP network.
Video decoders convert digital video signals from IP cameras into
analog signals so that they can be displayed on TV sets/ analog
monitors.
MATRIX SWITCHER
Is used to distribute the images from single/ multiple cameras to
multiple monitors simultaneously.
PTZ CONTROLLER:
Controls pan, tilt and zoom operations of PTZ cameras using
joystick
Camera can be rotated to a desired location
Camera can be moved to a multiple preset locations in sequence
Each camera can be assigned with a unique number

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Architecture of CCTV

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