Second Edition ‘August 1974 COPIA MAESTRA No: Fach, Fema: GUIDE FOR INSPECTION OF REFINERY EQUIPMENT CHAPTER XV INSTRUMENTS AND CONTROL EQUIPMENTAPL specifications [standards] are published as an aid to procurement of standardized equipment and materials. These specifications are not intended to inhibit purchasers and producers from purchasing or producing products made to specifications other than APL Nothing contained in any API specification is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use in connection with any method, apparatus, or product covered by letters patent, nor as insuring anyone against liability for infringement of letters patent, API specifications may be used by anyone desiring to do so, and every effort hhas been made by the Institute fo assure the accuracy and reliability of the data contained in them, However, the Institute makes no representation, warranty, or guarantee in connection with the publication of API specifications and hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use; for the violation of any federal, state, or municipal regulation with which ‘an API specification may conflict; or for the infringement of any patent resulting from the use of an API specification, Copyright @ 1974 American Petroleum InstituteCOPIA MABSTRA No: Foch PREFACE ‘This chapter is one of a series which make up the manual, Guide for Inspection of Refinery Equipment. 1t is based on the accumulated knowledge and experience of eaginecrs of the petroleum industry. All users are invited to submit suggested revisions to the director of the Division of Refining, American Petroleum Institute, 1801 K Suet, N.W., Washington, D.C. 20006, ‘The information contained in this publication has been arranged in its prescnt form 2s a means of facilitating continuity of presentation and convenience of reference. It does not constitute, and should not be construed to be, a code of rules, regulations, or minimum safe practices. It is not intended that the practices described in this publication supplant practices that have proven satisfactory. Nor is it intended that this publication discourage innovation and originality in the inspection of refineries. Users of the publication are reminded that no book or manual is a substitute for the judgment of x responsible engineer. ‘The Guide jor lspection of Refinery Equipment is subdivided as follows: Chapter 1 Introduction Chapter Conditions Causing Deterioration or Failures Chapter UT General Preliminary and Preparatory Work Chapter IV _ Inspection Tools Chapter V_ Preparation of Equipment for Safe Entry and Work Chapter VI Unfired Pressure Vessels, Chapter VIF Heat Exchangers, Condensers, and Cooler Boxes Chapter VIII Direct-Fired Boilers and Auxiliary Equipment Chapter IX _ Fired Heaters and Stacks Chapter X_ Pumps, Compressors, and Blowers, and Their Drivers Chapter XE Pipe, Valves, and Fittings Chapter XIE Foundations, Structures, and Buildings Chapter XII Atmospheric ancl Low-Pressure Storage Tanks Chapter XIV Electrical Systems Chapter XV_ Instruments and Control Equipment Chapier XVI Pressure-Relieving Devices Chapter XVI Auxiliary and Miscellaneous Equipment Chapter XVIII Protection of Idle Equipment Chapter XIX _Inspeetion for Accicent Prevention Chapter XX Inspection for Fire Prevention Appendix Inspection of Welding iitct CONTENTS CHAPTER XV—INSTRUMENTS AND CONTROL EQUIPMENT Pace 15.1 SCOPE 15.2 REFERENCED PUBLICATIONS 15.3 REASONS FOR INSPECTION 15.3.1 General 15.3.2 Safety 15.3.3 Continuity and Efficiency of Operation 15.3.4 Frequency and Time of Inspection (General) 15.4 CAUSES OF DETERIORATION 15.4.1 General 15.42 Corrosion 15.43 Brosion 15.4.4 Mechanical Deterioration 15,5 PREPARATION FOR INSPECTION 15.6 TOOLS RECOMMENDED 15.7 RECORDS AND REPORTS 15.7.1 Records 15.7.2 Reports 15.8 FLOW INSTRUMENTS 15.8.1 Description of Types 15.8.2 Frequency and Time of Inspection 15.8.3 Methods of Inspection u San aee a me wuves venen ne 15.9 LEVEL INSTRUMENTS u 15.9.1 Description of Types u 15.9.2 Frequency and Time of Inspection 12 15.9.3. Methods of Inspection 12 15.9.4 Calibration of Level Instruments 15 15.9.5 Recording Mechanisms 1s 15.10 TEMPERATURE INSTRUMENTS 15 15.10.1 Description of Types 15 1510.2 Frequency and Time of Inspection w7 15.103 Methods of Inspection 7 15.11 PRESSURE INSTRUMENTS 0 15,11. Description of Types 0 15.11.2 Frequeney and Time of Inspection 18 15.1.3 Methods of Inspection 18 15.12 RECEIVERS 19 15.12.1 Description of Types 19 15.122 Frequency and Time of Inspection 19 15.12.3 Methods of Inspection 1915.13, AUTOMATIC CONTROLLERS 15.13.1 Description of Types 15.13.2 Frequency and Time of Inspection 15.13.3 Methods of Inspection 15.14 CONTROL VALVES AND VALVE POSITIONERS 15.14.1 Description of Types 15.14.2 Frequency and Time of Inspection 15.14.3. Methods of Inspection 15.15 TRANSMISSION SYSTEMS FOR MEASUREMENT AND CONTROL 15.15.1 Description of Types 15.15.2 Frequency and Time of Inspection 15,15.3 Methods of Inspection 15.16 SEALS, PURGES, AND WINTERIZATION 15.16.1 Description of Types 15.16.2. Frequency and Time of Inspection 15.16.3 Methods of Inspection 15.17 INSTRUMENT AIR-SUPPLY SYSTEMS 15.17.1 Deseription of Types 1517.2 Prequeney and Time of Inspection 15.17.3, Methods of Inspeetion 15.18 HYDRAULIC-PRESSURE SYSTEMS 15.18.1 Description of Types 15.182 Frequency and Time of Inspection 15.183 Methods of Inspection 15.19 ELECTRIC POWER SYSTEMS FOR INSTRUMENTS 15.19.1 Description of Types 1519.2. Frequeney and Time of Inspection 15,19.3 Methods of Inspection 15.20 INSTRUMENT PANELS 15.20.1 Description of Types 15.20.2 Frequency and Time of Inspection 15.20.3 Methods of Inspection 15.21 ANALYZERS AND SAMPLING SYSTEMS 15.21.1 Description of Types 15.21.2 Frequency and Time of Inspection 15.21.3 Methods of Inspection 15.22. ALARMS AND PROTECTIVE DEVICES 15.22.1 Description of Types 15.2.2. Frequeney and Time of Inspection 15.22.3 Methods of Inspection 15.23 MISCELLANEOUS INSTRUMENTS 5.23.1 Description of Types 15.23.2. Frequeney and Time of Inspection 15.23.3 Methods of Inspection INDEX 23 23 23 24 24 24 28 26 2 a 20 20 27 20 27 27 30 30 30 30 30 30 30 31 3 31 31 31 31 31 33 33 34 34 34 34 35GUIDE FOR INSPECTION COPIA MABSTRA Ni ha Firma OF REFINERY EQUIPMENT CHAPTER XV INSTRUMENTS AND 15.1 Scope ‘The primary purpose of this chapter is to present a guide for instrument inspection. It is not intended as sintenanee manual, although some of the inspection procedures suggested may appear to belong in the ‘category of preventive maintenance, These procedures cover the majority of types of standard commercial instruments and associated equipment used in modern rofineries. Particular attention is given those instruments, which affect safety and continuity of operation. Instruments are classified according to type of measurement or function performed. The broad classi fications of instruments are: Flow. Level Automatic controls 6. Control valves, 7. Alarms and protective devices. 8. Analyzers. ‘The various types of measurement instruments can be further classified according to the principle of operation Some of the principles upon which instrument opera- tion is based are: 1. Differential pressure, created by flow through a re- strietion in the Hine. 2. Buoyancy of a oat. 3. ‘Thermal expansion of liquids oF a volume system, ises in 8 constant- 4, Generation of elect ity. 5. Analysis of a characteristic property of a product. Brief descriptions of various types of instruments and illustrations thereof are presented in this ehapter CONTROL EQUIPMENT The inspection of many instruments includes check- ing transmission systems, power supplies, seals, purges, panels, and other associated equipment, Since the in- spection of all of these types of associated equipment may not be covered in other chapters of this guide, such equipment is illustrated and discussed herein. Refinery operations are, to a great degree, dependent upon accurate and reliable instrumentation. Measure ment sind control systems can be relied upon only if they are inspected periodically and serviced by competent, specially (rained personnel who are famnifiar with both process requirements sind instrument functions. Some insteuments afe inspected by calibration. A thorough understanding of instrument design and funetion, knowl- edge of calibration procedures, and skill with which to make accurate measurements and delicate adjustments are ull necessary to assure proper inspection and calibra tion. ‘Therefore, instruments should be inspected only by qualified personnel. Throughout this chapter, the use of the term “inspector” shall be construed to mean a person or persons qualified to perform the instrument inspection In plants having separate instrument departments where the instruments are not normally inspected by the regular plant inspector, the instrument inspector and the plant inspector should collaborate in the inspection cof control valves, level-float cages, instrument air and hydraulic systems, and similar instrument equipment, where metal thickness measurements or pressure testing, are required. Inasmuch as this chapter is a guide to instrument inspection procedures, a discussion of in- stallation methods is not included herein, For recom- mendations on proper installation of instruments, refer- tence should be made to the various sections of API RP 50, Part 1. ‘This chapter, therefore, outlines only equipment that requires inspection, develops the methods and frequency of inspection, and discusses records and reports that should be maintained on the various types of instruments and systems. For specific information on various makes of instruments, reference should be made to manufacturers’ instruction manuals ‘and (0 any of several publications in this field,‘The types of equipment requiring inspection include: 1. Flow instruments, Level instruments. ‘Tomperature instruments Pressure instruments, Automatic controls. 2 3 4. 5 6. Control valves and positioners. 7. ‘Transmission systems for measurement and control. 8. Seals, purges, and winterization equipment, 9. Instrument air-supply systems. 0. Hydraulicpressure systems. 11. Electric power systems for instruments, 12. Instrument panels 13. Analyzers and sampling systems. 14, Alarms nd proteetive devices. 15. Miscellaneous instruments, such as speed, clee- trical, vibration, and time instruments (including cycle timers), digital systems, and computer equipment 15.2 Referenced Publications ‘The latest editions of the following standards, codes, and specifications shall, to the extent specified herei form a part of this guide AEC U,S. Atomic Energy Commission Rules and Regu- lations, ‘Title 10—Atomic Energy, Part 20— Standards for Protection Against Radiation API RP SO0A Recommended Practice for Classifiea- tion of Areas for Electrical Instal- lations in Petroleum Refine RP 540: Recommended Practice for Electrical Installations in Petroleum Re- fineries RP 550: Manual on Installation of Refinery Instruments and Control Systems: Part 1—Process Instrumentation and Control: Section 2—Level Section 3—Temperature Section 4—Pressure © US. Atomic Enerey Commission, Washington, D.C. 20545, API Guine For INsPecrion oF REFH Section 7—Transmission Sys- tems Section 11—Blectrical Supply Scetion 12—Control Centers Section 13—Alarms and Protec- tive Devices Part I—Process Stream Analyzers Std, 1101: Measurement of Petroleum Liquid Hydrocarbons by Positive Displace- ment Meter Std. 2534: Measurement of Liquid Hydrocarbons by Turbine Meter Systems Power ISAy Standards and Practices for Instrumentation: RP 7.1—Pacumatic Control Circuit Pressure Test OSHA Occupational Safety and Health Standards of the Federal Re; 15.3. Reasons for Inspection 15.3.1 GENERAL Inspections are made to determine the physical eon- dition of equipment as well as the type, rate, and causes of deterioration. Knowledge of such data is useful for maintaining safety, improving continuity of operation, assuring product quality, reducing the rate of deteriora- tion, and predicting and scheduling repair or replace- ment requirements, 15.3.2 SAFETY ‘Thorough inspection will reveal conditions that if eft uncorrected might cause failures that could result in serious process upsets or other conditions detrimental to equipment and perhaps to personnel During any inspection or calibration in. classified areas, the area classification should not be violated by cither opening of explosionproof equipment with live power or using incorrectly classified test instruments, Unless suitable safety permits have been obtained after proper investigation. 15.3.8 CONTINUITY AND EFFICIENCY OF OPERATION Extemal inspections performed during operating Periods may result in the detection of mechanical ostrument Society of America, 40M Stanwix Street, Pits. lourg, Pas 15222, ‘Occupatianal Safety and Health Administration, US, Department of Labor. Washington, D.C. 20210, ddeficiencies. Also, other defects may be found. Such defects include plugyed lines, bent valve stems, loose packing, loose connections, undue vibration, of other evidences of malfunction. Proper analysis and evaltia- lion of these conditions, followed by corrective mai tenance, can result in prolonged equipment life, ex- tended continuous running periods, general improve- ment of operations, and increased overall efficiency, 15.3.4 FREQUENCY AND TIME OF INSPECTION (GENERAL) ‘The need as well as the frequency of instrument in- spections is primarily determined by severity of service and overall effect on plant operation, Additionally, some, items of equipment can be readily isolated, whereas ‘thers can only be inspected dusing shuidowns, These factors are considered in the following general reeam- mendations with respect to frequency and time of inspection for all items of instrument equipment. When these suggestions do not fit a particular set of individual needs, i€ is good practice to make frequent inspections initially end then adjust the interval as a pattern of experience develops. 15.4 Causes of Deterioration 15.4.1 GENERAL Corrosion or erosion cin be expected on the surfaces of all instrument equipment exposed 10 process fluids and on the unprotected surfaces of equipment subject to attack by moisture, salt air, fungi, or any corrosive vapors which may be present in a refinery atmosphere, Fatigue failure, mechanical abuse, wear of moving parts, or overranging or excecding the mechanical or elec. tical limits of the instrument or any component are other general causes of deterioration or failure. 15.4.2 CORROSION Generally, corrosion is not a common cause of instr ‘ment deterioration or failure since the effects of cor- rosion can be minimized or eliminated through the use of proper materials or installation techniques. 15.4.2.1 Internal Corrosion Corrosion may occur on any instrument part that contacts process fluid. The severity of the corrosion depends upon the nature and concentration of the corrosive agents in the fluid and the consteuction ma- terial’s resistance to corrosion. In general, corrosion of instrument parts that contact process fluid is not a serious problem, because these parts are normally made of corrosinn-resistant material or are suitably protected 3 by using seals or purge systems. Corrosion is most ‘often encountered in control-valve bodies, orifice plates, analyzers, chambers of certain level instruments, gage alasses, or other devices that must be installed so that they ure directly exposed to the process fluid. The effeets of corrosion are usually apparent from visual inspection. Obvious signs are pitting and cust formation, 15.4.2.2 Externel Corrosion Deterioration resulting from attack by moisture, salt air, fungi, of cosrosive vapors in the atmosphere is the most common form of external corrosion, In hot, hhunvid climates, these factors are the major causes of instrument component failure. This type of deteriora- tion is especially prevalent in electronic instrument components, Oxide or salt formation on metal surfaces subject (© such corrosion can usually be detected by visual observation, In addition, electrical components may also. show symptoms of corrosion as fungus growths. A “leaky” or distorted capacitor is usually a sure sign of such deterioration, 15.4.3 EROSION Oritice plates, control valves, thermowells, and other components exposed to owing fluids may be subject to erosion, depending upon the charactoristies of the fluid and the operating conditions, Some causes of erosion L. High-pressure drop. High velocity, 3. Solids-bearing streams 4, Fluidized sotids streams 5. Flashing liquids 6. Cavitating liquids 15.4.4 MECHANICAL DETERIORATION Mechanical deterioration is not readily apparent to the inspector, and in most cases the cause can only be ‘mined after failure has occurred, ‘The exception © this is mechanical abuse, which can usually be detected by visual inspection. 15.4.4.1 Fatigue re and Wear of Moving Parte Fatigue failure and wear of moving paris are usually caused by oscillatory operation over a narrow portion of the instrument range. This condition is usually en- countered where mechanical vibration or process oscillations are present15.4.4.2 Mechanical Abuse Mechanical abuse usually results in obvious damage, such as broken glass, bent valve stems, and dented or icked instrument housings. In goneral, failure from mechanical abuse is caused by accidents, misuse, or careless handling of equipment. Control-valve stems hhave been bent or distorted from excessive torque as a result of the use of valve wrenches on the handwhecl, Many failures have also been caused by the use of various instrument components as step stools when, climbing or when trying to reach inaccessible locations, for when using components as supports for additiona equipment 15.4.4.3 Excooding Instrument Limits ‘Overranging or execeding the mechanical or electri limits of an instrument or instrument component is often, a cause of instrument failure. ‘The majority of such failures are the result of improper operation of or specification for the instrument. A common failure of this type results from the use of a pressure gage without sullicient consideration either for its intended operating range or for ils construction material, For example, a. brass bourdon tube may be suitable far 150 pounds per square inch gage (psig) steam serviee but not for 150 psig hydrocarbon service with sulfur compounds. During hydrostatic testing, instrument pressure Timits must be considered, and instruments must be isolated from such pressure if necessary, 15.4.4.4 Overheating Exposure of an instrument to hot process fluicls or to external heat sources, such as sunlight, flash fires, or adjacent hot equipment, can cause overheating and resultant damage to the instrument. Inspection should include a check of instrument components vulnerable to overheating, such as electronic components, gaskets, and packing. 15.5 Preparation for Inspection Unlike major pieces of equipment, such as vessels and furnaces, many measurement and control deviees may be inspected and replaced or repaired. if necessary. while the process plant is in operation. In most cases the device will have to be blocked off, vented, and drained, These operations should be attempted only by fa person familiar with both the process and the safe handling of the equipment and fluids involved. Gen- erally, operating personnel of the unit involved will handle this task. During such operations, knowledge of trouble symptoms is needed 10 determine if special API Guine For INSPECTION oF REFINERY Equipment precautions need be taken, or if protective devices may be required, Fluids at clevated temperatures and toxic chemicals present particular problems. If a deviee is, part of an automatic control system, the plant operator must be in a position to place that portion of the plant affected on manual control ‘The person involved in the inspection and testing of instruments should also be alert to the hazards of hhandling mercury, since it is used in some instruments and test equipment. He should also be aware of how 10 contain and dispose of mercury spills Devievs that may be used in dirty service (such as crude oil, slurry, bottoms, and the like) must be thoroughly cleaned for the inspection to be effective Special care mast be exercised in cleaning devices used in acid or caustic service. For further information on safe procedures, refer to Chapter V of this guide, Preparation of Equipment for Safe Enary and Work 15.6 Tools Recommended Instrument and control equipment is ususlly. small and rather complicated mechanically or clectrically Reliability and precision ate of prime importance. The particular problems associated with measurement and control devices stom from the fact that such equipment ‘operates under the influence of forces and movements, of small magnitude, Delicate parts, clase clearances, and general complexity make the inspection and repaic Of sch devices special problem. Many of the tools required for inspection come under the definition of test equipment. One of the most important items re- guired is a complete set of the manufacturer's parts lists ‘and maintenance instructions for cach make and type of instrument, In addition to the common hand tools (screwdrivers, assorted wrenches, and pliers), the mast useful tools nd test equipment are listed in Tables 1 10 5 15.7 Records and Reports 15.7.1 RECORDS Inspection records are important because they serve as a basis for a scheduled maintenance program. Their value, however, depends upon whether the information recorded is useful ancl sufficiently complete to determine maintenance requirements. Files with meaningless data setve no useful purpose. Therefore, judgment must be exercised in deciding the type and amount of di quested in record forms. Record forms will vary some= what with each type of instrument involved. For ex- ample, with a pressure gage, it would be of little value to record anything more than the size, range, service, dCuapTER XV—INSTRUMBNTS AND ConTRoL Equipment Table 1—Inspection Tools and Test Equipment for Flowmeters Type of Meter Head Machinist's inside micrometers Portable manometer calibrated up to 50 in. HO Portable mercury manometer with scale marked to read in inches of HO (up to $00 in, H,0) Portable mercury manometer marked to read 3 to 15 psig or a precision test gage of the same range Permanently mounted shop manom- eter calibrated up to 500 in, H,0 Permanently mounted shop manon eter calibrated from 3 to 15 psig Seal fluid pump Aspirator Precision air regulator Precision portable pressure gnges of Tools and Test Equipment Rotameter Precision comparison zotameters for calibrating small rotameters, or \weigh-type tanks for calibration of higher volume rotameters* Positives Precision-calibrated volume tanks, displacement} and turbine meters volumetric pipe prover, and/or standard (calibrated) meter Platform scales ‘Stopwateh Clearance gages = Calibration of rotameters may also be made with sic through the use of « volumetric flow prover tank. ‘PRefer co APT Standatds 1101 and 2934, [In custody transfor applications, volumeteic provers should by used to prove at normal operating pressure and temperalire and with narmal process fluids Where pipe provers are used an lecironie counter iy requized (0 reference volume through the meler with volume through the pipe prover Table 2—Inspection Tools and Tost Equipment for Pressure Instruments Range and Type of Instruments (Vacuum to 10,000 psig) Manometer, diaphragm, spiral tube, helical "Calibrated test gages tube, and Bourdon Vacuum pumps tube Water and mercury manometers Pointer pullers and set Comparison testers Tools and Test Equipment Dead weight testers COPIA MAESTRA Fecha. Firma, Table S~inspection Tools and Test Equipment for Temperature Instruments Type of Instrument Tools and Test Equipment Filled-system and ‘Temperature test baths bimetal instruments Resistance element Test thermometer or test_baths, resistance box and volt-ohm- meter, of precision calibrator Thermocouple Test. thermocouple, test potenti- ‘ometer Radiation pyrometer ‘Test potentiometer, muflie furnace Table 4—Inspection Tools and Test Equipment for Level-Measuring Instruments Type of Instrument Float or displacer Toots and Test Equipment Straight spring scale (fish-w type) Mercury manometers Head or differential (See Tables 1 and 2) pressure Table $—Inspection Toals and Test Equipment for Electronic ond Anolytical Instments Spare electronic parts, vacuum tubes, transistors, and circuit boards Volt-ohmmeter (at ferst 10,000 ohms per volt on ditect- current ranges) Differential voltmeter Vacuum tube voltmeter (direct current) Oscilloscope Mutual-conductance-type tube and transistor checker Vacuum tube milivolimeter (alternating current) Frequency signal generator Grid dip meter Radio frequency meter Impedance measuring bridge Resistance bridge Capacitance bridge Portable potentiometer Portable power supply Analog simulator (direct current) Magnetic flow signal simulator Milliammeter (direct current) Hand-operated megger Soldering gun Zeto point onc percent precision calibrating resistors6 API Gulp: ror Inspection oF RePiveny Equipment. location, and frequency of replicement, On the other hhand, the recotd for a flowmeter should contain a fall description of installation, including the primary device, line size, type of taps, serial number, and model numbers, of the various components which make up the metering system, In addition, this record should include notations of parts used, major repairs made, and comments con- cerning unustial problems which affect the reliability of the measuring system, Developing and maintaining inspection records ean become a time-consuming and expensive part of the inspection program if records are not kept simplified. A complete record file may contain four types of records, namely: 1. Basic data 2. Continuous record 3. Loop diagram, 4, Field notes. Basic data includes item number, manufacturer's serial number, model number, and all technical data necessary to determine the function and physical description of the equipment, These data, together with the manufacturer's drawings and instruction sheets, complete a permanent record file, ‘The continuous record should include a history of all inspections performed on the equipment, the date and type of inspections performed, repairs made, ma- terials used, and any other pertinent information helpful in determining future inspection requirements and equip ment retirement, Lonp diagrams should be complete enough so that anyone with this information alone would be able to understand how one part of the system affects and is affected by the remainder of the system. In some cases, the loop diagram will be simple, consisting of only a few symbols. Other cases will require several loops to fully understand the overall operation, Ficld notes are taken by the inspector in the field concerning measurements, conditions as found, repairs made, and parts replaced. Some companies use a field ‘work-order form that outlines the scope of the inspection to be performed and contains space for the inspector's comments and data. Another method of retaining such data is to isstie a loop diagram or sketch of the installa- tion that contains all pertinent information concernis the inspection scope and procedures. This sketch ot diagram would also contain space for the inspector's notes. 15.7.2 REPORTS Upon concluding an inspection, it is desirable to make a report covering the inspection results, the work performed, and any recommendations for future repairs for replacements. “This report should be sent to the appropriate departments for their information and necessary. etio 15.8 Flow Instruments 15.8.1 DESCRIPTION OF TYPES Head meter is the term applied to the elass of flow- metering devices that utilize a differential pressure for measurement. The flow rate is obtained inferentially fiom the differential pressure caused by flow past or through a primary clement inserted in the Rowing stream. A secondary device measures variations it differential pressure, which may range from a few inches fo several hundred inches of water, The device then cither indicates or records this differential oF transmits (o other instruments signals proportional to the differ cential. Figure 1 shows the distribution of pressure in an orifce-type meter run and illustrates the principle of this type of instrument. Area meter is the term applied to the type of instru ment that operates with a constant differential pressure! across a varying area, An area meter is usually in- stalled directly in the flowing stream, eS YD Figure 1—Principle of Flowmeter of Diferential-Pressure Type.€ ee Volumetric meter or positive-displacentent meter are terms applied to the type of meter that measures and Uischarges successive discrete volumes of uid. Such meters are installed directly in the flowing stream and usually indicate flow volume rather than flow rate Turbine meter and propelter meter are the terms applied to a rotating-type instrument usually installed directly in the flowing stream, ‘The readout from such, a meter may be direet and mechanical or by a pickup coil sensing the blade rotation 15.8.1.1 Primary Devices ‘The primary elements commonly used with head meters include: 1. Orifice plates (see Figure 2). 2. Flow nozzles (see Figure 3). 3. Venturi bes (see Figure 4) 4, Pitot tubes (see Figure 5). 5, Flow tubes (see Figure 6). 6 Annubar® (see Figure 7) The primary clement generally used for area meters is the tapered-tube or rotameter (soe Figure 8). Volumetric meters include the nutatingdise, ose! lating-piston, reciprocating-piston, rotary-vune, rotary: bucket, and turbine types (see Figure 9). 15.8.1.2 Socondary Devices Several types of measuring devices are used to deter mine the differential produced by the primary elemes Except for the glass manometer, which is only an it dicating device, secondary devices are available as in- © Registered trademach, Dieterich Standard Corporation Figure 2—Concentric, Eccentric, and Segmental Orifice Plates, COPIA MAESTRA No: dicating, recording, transmitting, or controlling instru- ments in any combination. These deviees, most of which are available for either pneumatic or electric transmission, include: 1. Diaphragm transmitters (see Figure 10). 2. Bellows meters (see Figure 1) 3. Mechanical mercury meter (see Figure 12) (B) Flow Nozzle Installation, Figure 3—Flow Nozzle, Figure 4—Venturi Tube.API Gut ror Inspection oF Rerivsry EQuirMenT: a PITOT TUBES PITOT VENTURI (A) Types of Pitot Tubes. me \/) Po Figure 7—Annubor. (B) Installation of Pitot-Vertusi Flow Element Figure 5—Pitot Tubes. me GENTILE TUBE Figure 6—Flow Tubes. Figure 8—Rotameter Inetellation.GOFIA MAESTRA, Fecha: Flo ne (A) Positive Displacement Meter (B) Toshine Flowmeter Figure 9—Volumetrie Meters. (A) Exploded View. (B) Assembled View. Figure 10—Diaphragm Tremsmiter.10 15.8.2 FREQUENCY AND TIAE OF INSPECTION. 15.8.2.1 Primary Devices Primary flow elements and volumetric metering devices, such as orifice plates, venturi tubes, rotameters, and positive-displacement meters, may become un- reliable or inoperative from fouling, corrosion, erosion, or faulty installation, When they cannot be isolated from the process, primary flow elements should be in- spected visually as determined by previous experience (I) Botlows-Type Flow Recorder Installation Figure 11—Bellows Meter. APL Guie For INSPECTION oF REFINERY EQUIPMENT Figure 12—Recording Mechanical Mercury Meter. The need for further detailed checks, measurements, calibrations, or repairs ean then be determined and ac~ complished at the next shutdown. 15.8.2.2 Secondary Devices Secondary devices, such as transmitters, recorders, and controllers, should be checked for compatibility with primary elements and for conformance with origina signs each Gime they are inspected. Adlonal routine checks and calibrations by qualified personnel witl depend) upon the process requirements, plant practices, nd. previous experience. Devices that are constantly used will automatically receive an inspection each time they are used. Equipment that is remotely located or that, for some other reason, is infrequently subjected toa complete inspection, should be visually checked at regular intervals. Initilly, onee a month is not too frequent an interval for inspection. However, if a highe ChapTen XV—InsteunEnTs degree of accuracy is required, the frequency may have tobe increased. On the other hand, inspection intervals, may be considerably longer as determined by previous, experience, 15.8.8 METHODS OF INSPECTION 15.8.3.1 Primary Devices Inspection of the primary elements requires careful n urement of the orifice throat, low noztle, oF venturi tube and comparison with original design dimensions. On cast-and-yield services, caliper- ing of the meter sun or pipe may be warranted. Pipe approaelies to the prinsiry clement and the leads from the clement to the first block valves shoukd be carefully cleaned of all foreign: matter Costly units, such as the flow nozzle and venturi tube, can sometimes be correeted for even, smooth wear by recomputing the factor snd by making use of the measured element dimensions. This should be done when throat wear increases the srea dimensions from 0.2 to I pereent depending upon the importunce of the measurement, Orilice plates should be inspected for sharpness und syuteness of edges. When the sharp edge of an orilice becomes nicked or noticeably rounded, the plate should he replaced or remachined! and re~ computed. Before recomputing a meter factor, it is good practice to recheck other base meter data, such ais viscosity, temperature, pressure, and the like, for the uid being measured ‘The pitot tube is one primary element usually de- signed for removal while the line is in service, In some ceases the orifice is also mounted in a special fitting that allows inypeetion by removal while the line is in service. ‘The venturi tube and flow nozzle can be inspeeted only uring a shutdown period, rometee 15.8.3.2 Secondary Devices Differential-pressure devices are checked for plugged leads, freedom of travel of balance clements, and proper lubrication, 3s well as for accuracy of calibration, Some ‘manometers of this type can be checked for calibration accuracy by means of special weights supplied by the manufacturer, Using stich weights permits a quick check to determine whether a rigorous calibration is, necessary. If necessary, the use of a water-column head o precision gage specilically designed for this applica tion und periodically checked by means of a water column is recommended. Some instruments eun only be checked by means of watter-column head tests. A water= column head fest accurate t0 0.5 percent of full-scale deflection for the differential pressure device is usually satisfactory for average refinery work an Conrrot. Burren u Manometer inspection usually consists of checking the meter bearing shalt for freedom of movement and proper lubrication, cleaning, checking for mercury quantity and proper sealing, and conducting a water- column head test. ‘Normal inspection of the area meter secondary device consists of checking and calibrating the transmitter ‘The float and tapered tube can be inspected for fouling of wear only during shutdowns if block and bypass valves are not used 15.8.3.3 Volumetric Meters* Field inspection consists af observation of register operation and visual inspeetion for leakage. Strainers should be checked for clogging or breakage, and air eliminatory should be checked for proper operation, Shop inspection consists of dismantling and inspecting component parts for binding, wear, erosion, corrosion, and dirt accumulations, All worn parts must be re placed. ‘The repair of parts is seldom economical or satisfactory. Calibration may be made by comparison with a standard meter or by passing 4 measured volume through the meter to a calibrating tank oF prover, For process work, securacy is usually held to 1 percent on the test run, Some of these instruments ean be calibrated! to within 0.1 percent or less, if required, and normally are s0 calibrated for custody transfer ap- plications, 15.9 Level Instruments 15.9.1 DESCRIPTION OF TYPES Level is measured by observing gage glasses, by sensing the float buoyaney or position, by observing. head or differential pressure or temperature variation, by electronic or sonic measurement, and by instruments measuring changes in conductivity, capacitance, or nuclear phenomena, With the exception of guge glasses (see Figure 13) which serve only to indicate, types of level instruments that may indicate, record, transmit, or control in any combination of liquid levels or liquid liquid imerface levels in open and closed vessels include 1. Floatype tank ges (see Figure 14) Hiyatrostatic head pressure (see Figure 15) 3. Dilferental pressure (see Figure 16), 4. Float (see Figure 17) 8. Displacers (see Figures 13 and 18) lectronie instruments (see Figure 19), TRefar w APL Standoeds 1101 und 2534Figure 13—Vessel with Gage Glasses and Displacer Instruments 7. Nuclear-type instruments (see Figure 20). 8. Sonic instruments (sce Figure 21) 9. Vibrating paddle (see Figure 22) 15.9.2 FREQUENCY AND TIME OF INSPECTION Level instruments installed within process vessels under pressure can only be checked when a vessel is not in operation, They should be inspected visually as determined by previous experience. The need for further detailed checks, measurements, calibrations, or repairs may then be determined and accomplished at the next shutdown, Gage glasses, external displacers, differential-head- type devices, and the like which can be isolated by means of block valves should be visually inspected not less than once a year. More frequent inspection of these devices is needed only if extreme accuracy is re- quired, if they are in severe service, or if they are essential to proper unit operation, 15.9.3 METHODS OF INSPECTION Block valves and piping used with level instruments are discussed in Chapter XI of this guide, Pipe, Valves, and Fittings. Valves and piping will be subject to pres- sure tests with other equipment, and any leaks or defects will usually be detected and eliminated. Level instru- ments should be inspected as follows: APL Guwe Fox Inspection o* Rerinery Equipment 15.9.8.1 Gage Glosses Inspect glasses visually. Cracked glasses should be replaced with the properly specified glass. ‘The vendor's recommendations for torquing up the bolts should be followed carefully to avoid stressing the glass, Cheek packing glands, valve seats (and ball checks if used) in gage cocks. 15.9.3.2 Floct Tonk Gages Float, cable, or tape seal (if used) and pulleys may be inspected visually for defects. Binding or friction, can be determined by manuat operation. Figure 14—FlootType Tank Gage,(CarTER XV—INSTRUMENTS AND ConTroL Equipment 13 @ oe (A) Flush Diaphragm (B) Extended Diaphragm, Figure 15—Flange-Mounted Hydrostatic Head Level Instruments, 15.9.3.3 Differential-Pressure Instruments Inspection procedure is the same as outlined for Howmeters (see Section 15.8.3.2). 154 Dismantle the unit and visually inspect the Moat, float shaft, bearings, and seals for defects. Check for binding oo friction in seals, 4 Floats PRESSURIZED VESSEL. SEAL POT “Ti convecri ies soem WB osten USE our IT (SWOT ecessuniy Tee, eter DIFFERENTIAL, PRESSURE INSTRUMENT Figure 16—~Difforential Pressure Instrument in Level Instrument Servic. 15.9.3. Displacers Dismantle the unit and visually inspect the displacer, torque tube, and bearings or flexure element for defects Make sure the torque tube or flexure element is holding the displacer in proper suspension and that the displacer is not rubbing against the side of the case. Most capacitance or conductivity probes and probe insulators must be free of deposits and dirt, and the probe must not touch any part of the vessel in which itis suspended. Relay action may be checked by shorting the probe to ‘ground or by actually varying the liquid level in the vessel. The manufacturer's literature generally outlines specific troubleshooting and checking procedures and should be referred to when inspecting the instrument. 15.9.3.6 NuclearType Instruments Nuclear-type instruments require a radioactive source mounted on a vessel or a line, These sources are a Figure 17—Float-Aetwated Switeh,4 APE Guine ror INsPecrion oF REFINERY EQUIPMENT EABLoCHIVE 1 ; 1 Pf | | | Figure 20—Nodeor Type Level insrumont on Swell (0.inch Diameter) Vessel. Figure 21—Senic Level Measuring Devices. Figure 19—Electronic Level Instrument.Figure 22—Vibrating Paddle Level Device possible radiation hazard and should be identified by suitable signs as proscribed by OSHA, AEC, or state regulations. Manufacturers’ instruction manuals should be followed closely in checking nucleartype instruments in order to prevent undue tudiation exposure to per- sonnel. Only those individuals trained and licensed where necessary in the handling of radioactive materials and cognizant of agency regulations should be permitied to work directly with the source of radiation, ‘These individuals should also be responsible for the radiation source and for measurement of radiation levels before work is performed in the immediate area by anyone, 15.9.4 CALIBRATION. OF LEVEL INSTRUMENTS Level instruments may be calibrated by checking the indicated level against the gage glass indication when the unit is operating or by manually filling the instru- ments with liquids of suitable gravity. However, for high-temperature service, where the existing temperature differential may cause the gage glass or the other level devices to read inaccurately, it may be preferable to calibrate by means of a water column or test gage. 15.9.5 RECORDING MECHANISMS Refer to Section 15.12, “Receivers.” 15.10 Temperature Instruments 15.10.1 DESCRIPTION OF TYPES ‘Temperature measurements are made by determining the effect temperature produces on primary elemencs, including electrical generation, change of electrical resist: ‘nce, and thermal expansion of solids, liquids, or gases Primary elements requiring inspection are: 1. Resistance bulbs (see Figure 26) 2. Bimetallic elements (see Figure 23). 3. Bulb-ype or filled systems (see Figure 24), 4, Thermocouples (see Figure 25). Secondary devices that may indicate, record, control, or transmit, in any combination, include: 1. Pyrometers and potentiometers (see Figure 27). 2, Filled-systom instruments (see Figure 28° 3. Receivertype electronic instruments (see Figures 2A) and 29) Figure 24—Filled-Systom Thermometer.(8) Installed Thermocouple Figure 25—Thermocouples, el (8) Pyrometer Controller. Figure 27—Pyrometers end Potentiometersf v COPIA MARSTRA No: (B) Filled Temperature Transmitter. Figure 28—Filled Systom Instruments Figure 29-—Electronic Recelver-Recorder and Controller. 15.10.2 FREQUENCY AND TIME OF INSPECTION, Primary devices are generally installed in wells so that they can be removed for inspection any time a device appears to be malfunctioning. In highly corrosive or crosive service, the well should be checked during cach turnaround. ‘The measuring instrument oF second- ary device, or both, usually can be inspected at any time without a shutdown, 15.10.8 METHODS OF INSPECTION Viswal inspection should be made for mechanical defects, loose wires, moisture, and corrosion, Accuraey checks should be made by comparison with a standard. It is recommended that the calibration of primary systems, except thermocouples, be made in the shop by comparison with a standard within three points of the range of the secondary element. Thermocouple wie should be standardized in the shop. A thermocouple should be replaced if its accuracy is questionable. Resistance bulbs, except when used for temperature- difference measurement, should be accurate to within 0.5 F. Thermocouples that calibrate to within 3F in the range of 0 to 1,000 F are considered satisfactory for process work. Other primary elements should be able to produce an accuracy of 1 percent of full-scale deflection of the secondary element, For inspection methods for recording mechanisms, refer to Section 1.12.3, 15.11 Pressure Instruments 15.1.1 DESCRIPTION OF TYPES Pressure measurements are determined by the amount ‘of movement produced by the force a fluid exerts on a18 APL Guipe FoR INsPecTioN OF ReeIvERY Equipment primary element, The force per unit of area is usually expressed in pounds, The word “pressure” includes: 1. Gage pressure as measured by the expansion of bourdon tubes, the displacement of fluid in manometers, fr the motion of or force exerted upon bellows and diaphragms. 2. Differential pressure. 3. Vacuum or absolute pressure, which is also measured by any of the previously mentioned means, ‘Typical primary elements requiring inspection are: 1. Bourdon tubes (C-spring, spiral, and helical) (see Figure 30) 2. Diaphragms (see Figure 31) 3. Bellows (see Figure 32) 15,11.1.1 Secondary Devices Secondary devices may indicate, record, control, or transmit, in any combination, by means of pneumatic, electronic, or hydraulic systems, 15.11,2 FREQUENCY AND TIME OF INSPECTION Primary devices are generally installed with block valves so that these instruments can be isolated from the process. Sccondary indicating, recording, or con- trolling instruments can usually be isolated from the primary device, This allows the instrumentation to be inspected, maintained, and calibrated as. necessary. (A) CSpring Rourdon Tube, (B) Spiral Bourdon Tube. The frequency of inspection required to maintain an instruments serviceability and calibration will in general bbe determined by experience. Instruments subjected to severe process operating conditions or that must be maintained at peak performance will probably require more frequent inspections. Often the process impulse connections ean be checked only during « plant shutdown. They should be inspected for evidence of plugging or corrosion. Those showing signs of deterioration should be checked with extra care and scheduled for replacement if below company- specified standards 15.11,3 METHODS OF INSPECTION Pressuse-mcasuring instruments and their connecting leads should be inspected for leaks, distortion, vibration, plugging, and maintenance of seals. The racks, pinions, ‘and linkages should be inspected for excessive wear and misalignment, Cracked or distorted bourdon tubes, bellows. and diaphragms, as well as worn racks, pinion assemblies, clips, and linkages, should be replaced, Broken glass should be replaced in order to properly protect the instrument from corrosion, moisture, and dirt, Instruments with a range of more than 100 inches ‘of water should be checked on a dead-weight tester with a mercury column or by comparison with an indicating or recording test gage. Indicating or recording test gages are frequently used as secondary standards, both in the shop and in the field, as a basis of comparison, In the field the test gage is connected to the same pressure as the service (C) Helical Bourdon Tube Figure 30—Bourdon Tubes.ChapTeR XV—Instrusens gage, This method of testing is often used when it is Undesirable to remove the service gage from its mount- ing. Test gages should be calibrated by the most curate methods available. Wherever possible, maximum error should be not more than 0.5 percent of the full- eek SSR Bain Figure 32—Bellows-Type Pressure Element | ‘COPIA MAESTRA No: Fecha: Fem AND Controt Equir ment 19 seale gage reading. Differential pressure bellows or ‘phragm instruments should be checked with a water columa, using an air-loading system. Remote transmis- sion receivers should be calibrated as outlined in the manufacturer's service manuals Insofar os practical, the plant should calibrate ctl pressure instruments to the accuracy of the miantt- facturer’s guarantee bofore returning them to service, giving special attention to test gages and gages intended for critical service. Exact calibration should be ob- tained at the expected operating pressure, Test gages lire often furnished with « calibration list checked at, perhaps three or more points, 15.12 Receivers 15.12.1 DESCRIPTION OF TYPES Receivers most commonly utilized are analog indi- eators and recorders that are dedicated to one or more process variables (see Figures 27(A.) and 33). Usually, large case analog recorders are used in the field while miniature strip chart analog recorders are used in control panel displays. ‘Two or three pen trend recorders, which have the facility of selecting one vatiable per pen from a number of process variables, are sometimes utilized. Digital ‘multipoint indicators are also utilized in many monitor- ing applications (see Figure 34). 15,12.2 FREQUENCY AND TIME OF INSPECTION Inspection of recorders and indientors is generally limited to observation of their performance on a ay-to- day basis. ‘Their construction often permits substituting spare components for faulty ones via plug-in modules. 15.12.9 METHODS OF INSPECTION Recorder chart drives should be checked for time accuracy. Sprockets should engage the chart securely. Controner Revorler Figure 33-—Analog Receivers.20 Figue 94—Digital Readout Multipoint Indicator. Pens should be checked for proper inking and pressure fon the chart. The recorder pen and indicator pointer position should be checked for readings of zero, span, and lineacity. 15.13 Automatic Controllers 15,13,1 DESCRIPTION OF TYPES ‘An automatic controller is a mechanism that measures ‘or receives the value of a variable quantity or condition and corrects or limits the deviation of this measured value from a selected reference. An automatic con- Lrotler includes both the measuring means and the controlling means (see Figures 29 and 33) 15.13.1.1 Measuring Means ‘The measuring means are those elements of an auto- matic controller involved in ascertaining and com- municating to the controlling mechanism the value of the process variable. ‘The effect produced by a deviation juipe FOR INSPECTION OF REFINERY Equipment of the process varinble may be a change of pressure, force, or position, or a change of electrical potential, resistance, or current, The measuring means of the automatic controller may indicate or record or may be a blind controller. 15.13.1.2 Controlling Means ‘The controlling means are those elements of an auto~ matic controller involved in producing a corrective action. The controlling means may be powered by a pneumatic, hydraulic, or electronic system. 15.13.2 FREQUENCY AND TIME OF INSPECTION ‘The inspection of automatic controllers, other than by visual observation, requires trained operating or instrument personnel, or both, because performance evaluation requires both understanding of the process ‘and familiavity with the instrument. Unqualified per- sonnal who attempt to check or adjust controller tuning can seriously upset the operation of a unit. Such personnel should restriet their inspection to obser- vation of the record for instability oF cycling, Tf ine stability or cycling is evident, they should notify the operator, who will thea obtain help from qualified personnel. ‘An evaluation of control performance should be made each day until operating experience indicates the desirability of extending this interval. Detailed checks, calibrations, or maintenance will be necessary only when and if performance indicates such need. Pheumatic controllers are generally very reliabfe and will remain dependable for fong periods of time if clean, dry air is used and if the ease is kept intact and tightly closed, Since most pneumatic instruments are designed 50 that a nozzle bleed discharges within the case, the instrument aie ean then purge the case interior. How. fever, weathering and salt air will deteriorate the case ‘and possibly the piping connections thereto unless the materials are completely suitable, External visual spection, as infrequently as once a month, will usually be sulicient for maintenance planning. It is important that the inspector promptly report broken glass, defec- tive doors or door gaskets, or other visual evidence that the case seal is unsatisfactory, since the internal mechanisms of pneumatic controllers may be seriously damaged by continued exposure. Inspection of electronic controllers_is generally Timited to observing their performance. Their modular constrvction often permits substituting a phugein circuit board or component in place of faulty ones. Hydraulic controllers are generally in the minority in the refinery. They are ruggedly built and will givegood results with infrequent attention, Inspection for contamination of the hydraulic fluid is the prineipal inspection requirement. Component deterioration can be ascertained! by qualified personnel, Visual inspection will probably not revesl potential problems except where leakage of hydraulic fluid is evident. An annual inspec tion is desirable until operating experience indicates, otherwise, 15.13.3 METHODS OF INSPECTION The inspection of automatic controllers is almost invariably visual. If the instrument is a recording con- troller, an examination of the control record will usually reveal erratie controller performance. It should be emphasized here, however, that a poor control record does not necessarily indicate rouble with the controller. When there is such a record, an investigation should be made for possible disturbances elsewhere in the process before any adjustments or repairs are made to the eon troller. Trouble may also. be caused by faulty operation of the control valve resulting from excessive stuffing box friction, foreign material in the body of the valve, leaks in the air line, or other causes. Valve operation should, therefore, also be checked before any work is performed on the control instrument. If no trouble is located outside the instrument, the behavior of the output signal with respect to the move- ment of the pen of pointer should be observed. This Will usually reveal sluggishness or lost motion in the control mechanism if either is present, 15.14 Control Valves and Valve Positioners 15.14.1 DESCRIPTION OF TYPES 15.14.1.1 Control Valves Control valves are available in a variety of sizes, body designs, and actuator types. The type of control valve selected for a particular application depends upon the process requirements. Some of the more common types of control valves and their actuators used in refining unit applications are as follows: Globe Body Valve Diaphragm Actuator (see Figure 35(A) ) Eccentric Spherical Plug Rolling Diaphragm Valve Actuator (see Figure 35(B)) Butterfly Valve Diaphragm Actuator (see Figure 35(C}) Split Body Valve Piston Actuator (see Figure 35(D)) COPIA MABSTRA No: Globe Body Valve Electrohydraulic Actuator (see Figure 35(B)). 15.14.1.2 Valve Positioners Valve positioners indicated below are examples of equipment found in any refinery. A typical valve Positioner is illustrated in Figure 35(C). ‘The manu- facturer’s literature should be referred to in every in- stance for a complete description of equipment and operating principles. Some valve positioners encoun fall into the following categories: din refinery work 1. Pneumatic, 2. Blectropneumatic, 3 ectronie. hydrauli, 4. Paeumati hydraulic, Pneumatic positioners are furnished either as side- mounted accessory items or are built onto or into the control valve itself, When furnished as accessory items, they are frequently provided with bypasses that allow a controller to operate its control valve direcily while the positioner is inspected or serviced, or both. This feature is not always possible if a positioner is used to char- acterize valve position to input (other than linear). ‘The physical design of pneumatic positioners varies, depend- ing on the manufacturer, Electropneumatie valve positioners are combinations of clectric-to-pneumatic transducers and pneumatic valve positioners. These are available in side-mounted styles and in styles built into the top diaphragm case of the control valve. Electropneumatic positioners do not require bypass valves, Pacumatic-hydraulie valve positioners are used less frequently than are the straight pneumatic or electto- pneumatic positioners. They are usually installed in combination with hydraulic valve actuators where the large force capability of a hydraulic system is required to operate large valves or dampers in accordance with the signals from pneumatic controllers, Catalyst slide valves on fluid catalytic-cracking units are frequently actuated by a pneumatic-hydraulic positioner and actuator, 15.14.2 FREQUENCY AND TIME OF INSPECTION 15.14.2.1 Control Valves Control valves are frequently installed for isolation with blocks and bypasses. ‘This permits repair oF re-22. AP] GuIDE FoR INSPECTION oF ReFINERY EQUIPMENT {€) Buttery Valve with Diaphzaem Actuator. (A) Gos Has ave wih ID) Sp ogy vate with (E) Globe Body Valve with Hlvetrobyetranic Actiater. 1B) Eccentie Spherical Plug, Valve with Rolling Diaphragm ee “Newalor ( Figure 35—Control Valves.placement without process shutdown, Where this is done, an inspection can be made during operation without seriously alfecting the process. When isolating valves are not provided, the portion of the valve exposed to the process stream can only be cheeked when the process equipment has been prepared for opening, Factors that govern inspection frequeney are’ Erosiveness of the Mowing stream, 2. Corrosiveness of the Mowing stream. 3. High-pressure deop, 4, Extreme ambient temperatures at the valve operator 5. Abnormal. vibration. Frequency of inspections will vary with the severity of these factors and with the construetion materials, Operating requirements and experience in the par- Licular service should govern the frequency of inspection. ‘The frequency can range from once a week for highly erosive oF corrosive services (0 as seldom ss once every five years for mild services, Until a pattem develops, it is good practice to inspect the equipment at least ‘once a year, 15.14.2.2 Valve Positioners Valve positioners generally require infrequent in- spections, The initial aujustment, either at the time of installation or after servicing the control valves, will usually insure good results for a long period of time. If malfunctioning does occur, it will probably be due cal damage or excessive vibeation, A good practice is to inspect the valve positioner when the control valve is inspected. 15.14.3 METHODS OF INSPECTION 15.14.3.1 Control Valves Control valves should be examined visually for leaks fon the packing glands and valve body and for general packing conditions. The valve actuator should be in- speeted for travel, action, and wear. The valve body, stem, and inner valve should be inspected for wear, corrosion, or erosion. The wall thickness of the valve body shoud be checked at soveral points with calipers, and the measurements should be compared with the original values to determine losses resulting from wear 15.14.8.2 Valve Positioners Valve positioners should be checked for leakage and plugging in the air circuit, for grounds, shorts, and loose connections in the electric eirewts, and for wear Cuaprer XV—InsteuMENTS AND ConTROL Eouirment COPIA MAESTRA Nor Fechas, Fens or failure of mechanical parts, including gages. In the, foree-balance type of valve positioner, particular at- tention must be given to the rigidity of the connection between the valve stem and the valve positioner. ‘The action of the valve positioner should be checked. ‘The full travel of the valve should correspond to the foll range of the actuating medium as delivered by the Controlling instrument. A careful check should be made, to insure that the valve stem starts to move ait the lowest specified signal delivered by the control instrument and that the valve completes its travel exactly at the highest signal detivered by the control instrument. Any deviation from these conditions, unless specifically men- tioned in the valve specifications, should be considered the result of possible defvets. All defective parts should be replaced. Leaking connections should be tightened or replaced. The valve positioner should be adjusted so that valve travel eorresponds exactly to the si of the control instrument, Hydraulic positioners should assume a definite posi tion for cael value of the control signal applied by the controlling instrument, The pilot should be cleaned fof foreign matter and examined for wear, ‘The large, main hydraulic piston member should be examined for Piston leakage and wear when unsatisfactory perform- ance indicates wear. Wom parts should be replaced. 15.15 Transmission Systems for Measurement and Control 15.15.1 DESCRIPTION OF TYPES 15.15.1.1 Measurement Transmission Systems Mensurement transmission systems consist of lines conneeting locally mounted transmitters with indicating, recording, or controlling instruments, or any combina tion thereof and are usually mounted on a control panel some distance away. ‘The signal lines may be pneumatic or electronic, 15.15.1.2 Control Transmission Systems Control transmission systems consist of lines con- rceting automatic controllers with other automatic con- trollers, when cascaded, or with final control elements, or with both. ‘The signal fines may be pneumatic or electronic. 15.15.2 FREQUENCY AND TIME OF INSPECTION Problems can be encountered in pneumatic trans- mission systems as a result of component failure or leaks in the system. ‘The difficulty may appear as an erroneous instrument reading or no reading at alls24 API Guioe FoR Inspection oF REI ‘or it may appear as instability or cycting of the measure~ ment oF controller, or both. Properly installed pneu- matic transmission lines that are protected against mechanical damage, damage from fire, or other abuses ‘and that are constructed of suitably corrosion-resistant materials seldom fail in service. ‘Therefore, limited ex- perience is available on which to predict future failure ‘of such equipment. During turnaround, immediately prior to startup, visual inspection should reveal damage to the transmission line from abuse or corrosion. Pres sure fests and other operational checks should also be made during turnaround. If the presence of leaks is suspected such checks should be made, if possible, during operation of the unit Frequency and time of inspection of electrical trans- mission lines is covered in Section 15.19 and in greater detail in Chapter XIV of this guide, Electrical Systems 18.18.3 METHODS OF INSPECTION Air or electronic measurement and control signals should be within the ranges required for proper opeta~ tion of the equipment, ‘Transmission and control tines should be inspected for continuity, tightness, leaks, plugging, shorts, and grounds. Tubing and wire runs should be cheeked for proximity to sources of excessive heat or for stray clectrieal fields that might affect instru ment performance, Electrical leads should be inspected carefully in all eases where shiclding and grounding are necessary for proper operation. Ifa more thorough inspection of pneumatic trans- mission lines by actual testing is desired, ISA RP 7.1 ‘outlines a good procedure, If a leak in a control fine is suspected during operation of the unit, its existence can sometimes be verificd by putting the instrament in a sealed position (when seals are used) and noting the drop in the control valve air pressure. 15.16 Seals, Purges, and Winterization 15.16.1 DESCRIPTION OF TYPES 15.16.1.1 Seals ‘Thore are two types of seals, fuel and mechanical Fluid seals consist of immiscible fluids that are nos reactive with the measured process fluid. Direct uid seals (process fluid over seal fluid) are used when the seal fluid is heavier than the measured process fluid (sce Figure 36(A)). Indircet fluid seals (process fluid under seal fluid) are used when the seal fluid is lighter than the measured process fluid (see Figure 36(B)). ‘Mechanical seals consist of metallic or nonmetallic mechanical diaphragms in contact with the measured process fluid. They are connected to the instrument ey Equieent ly REAvevonen, SUTERANaGR (A) Fluid. Seal Schematic Diogram. (B) Fluid Seal Jostllation, Figure 36—Fluid Seols. mechanism by means of a filled system (see Figures 37 and 38). 15.16.1.2 Purgos Purges are pressurized Muids introduced into the process line at the primary elements, Purge media must, rot be harmful to the process or the instrument. Purging prevents the process fluid from entering the instrument, system. 15.16.1.3 Winterization of {nstruments Winterization of instruments and instrument systems is a preventive measure taken to insure the proper functioning of instruments installed on equipment handling process Buids that may be adversely affecter’ by cold weather conditions. Cold weather may cause process fhuids to freeze, congeal, or form hydrates within,b w ‘SEAL FLUID FLEXIBLE DIAPHRAGM cy Figure 37—Pressure Gage wi Diaphragm Seal. Figure 38—Sealed Differential Pressure Transmitter. the instrument components or piping, or both, Winter ization is accomplished by one or a combination of any of the following 1. Installation of instrument components in heated protection houses, 2. Use of steam jackets around instrument equipment, COPIA MABSTRA Not Foch Flere (CuapTER XV—INSTRUMENTS AND ConTROL EQUIPMENT 25 3, Steam or electric tracing of instrument components or piping, or both, 4. Use of integral heating elements within the instra- ‘ment components. See Figures 39, 40, 41, and 42 for typical winteri practices. tion 15.16.2 FREQUENCY AND TIME OF INSPECTION. 15.16.2.1 Liquid and Mechanical Seal Systems Inspection of seal systems, other than for obvious leaks, is generally impractical. Normally, faulty systems tare handled by 2 routine preventive maintenance check procedure. Operating experience will generally indicate the desirable frequency. However, in the absence of operating experience, good practice is to perform this, procedure on an annual basis for most instruments. For very important processing streams where material bal- ance is critical or where the meter data are used for buying and selling, monthly intervals are indicated. Normally, filled-system mechanical diaphragm seals used with instrament systems can only be inspected visually, Until « history of operating experience has bbeen developed, it is recommended that such diaphragm seals be checked on an annual basis 15.16.2.2 Purge Devices TThe frequency of inspection for purge devices ranges from a daily check where high accuracy is desired to as often as the primary instrument is inspected, 15.16.2.3 Winterization Equipment Winterization measures also require inspections. Usually, the proper functioning of the instrument system Figure 39—Steam-Traced and Insulated Contral Valve.26 API Gutoe ror Figure 40—Steam-Traced ond Insulated Pressure Gage Piping. will attest to the satisfactory condition of the winteriza- tion system, However, more frequent inspections dur ing severe ambient conditions is recommended. Inspec tion of winterization measures can be made concurrently with the inspection of the instrument systems 15.16.38 METHODS OF INSPECTION Seals should be inspected to insure @ proper level of seal Muid in the pot. A check should be made to see that the flowing fluid as not corroded the seating pots and that the instrument fines between the primary and secondary cloments slope continuously from the meus- ured point (o the instrument. Pockets in such Tines may occur as a result of accidental damage. Pockets are a continuous souree of trouble and should be removed Cracked or damaged diaphragms should be replaced “The contents of liquid legs in any seating system should Figure 42—Heated Protection Houses for Field Instrumonts, (Note thatthe electronics cave i not heated.) Figure 41—Steam-Traced ond Insulated Level Transmitter be replaced by pumping liquid into the system from the lowest points of that system. Any pockets in the Iecad lines should be climinated. The valves in any seal- ing system should be examined closely for leakage Leaks in the packing around stuflingboxes in the valves ‘of any sealing system are probably the greatest source of trouble experienced in this type of equipment Purge systems should be inspected to insure that a ‘continuous stream of purge medium is flowing at a con- stant rate through the lead lines. In the case of differ- cential-pressure instruments, the flow of purge medium should be approximately equal and constant in each ead. All steam-traced installations should be checked for overheating, for leaks or plugging in the steam lines, and for proper insulation. Heat enclosures in winterization systems should be inspected for signs of deterioration from accidental physical abuse as well as from environmental condi tions, If used, steam traps om jacketing and tracing applications should be checked for performance. | * = ing traps waste steam. Occasionally, steam traps — ccome entirely inoperative. Normally failure of electricalCuapre XV—INSTRUMENTS AND ConTR ‘race systems is dificult to detect unless pilot lights or ammeters are furnished with such systems, ‘The panel box containing fuses or circuit breakers should he checked periosiically ( detect faults. Thermostats, where furnished, should be checked on turnarounds for proper setting and operation and on stream by changing the setting. Insulation on winterization systems, whether for heat conservation or for protection of personnel, should be inspected for general physical condition as well as for firmness of aitachment to the equipment or piping. 15.17 Instrument Air-Supply Systems 15.17.1 DESCRIPTION OF TYPES Instrument air-supply systems range from small sys- tems for individual operating units to Jarge central systems for serving more than one operating unit simul taneously. The mumber of components in any system, large or small, depends upon many factors, not the Teast of which is the quality of the instrument air desired The supply system shown schematically in Figure 43 is a commonly used system for an individual operating Unit that employs the yard air supply as the main source, With focal compressors strictly in standby service, Some operators prefer to use the local compressors as. the main source, with the yard air supply as the standby. Any number of variations can be found when éompar- ing the instrument ait-supply systems of various re- finesies, for example: 1, Using motoralriven compressors in lieu of steam ‘compressors. 2. Using nonlubricated compressors. 3. Operating pressure levels to suit local conditions or preferences, 4. Using intermediate-pressure instrument air headers, A large central system can be similar to the supply system shown in Figure 43, except that only the final reducing valves and possibly a unit filter may be located ‘within the battery limits of an operating unit 15.17.2 FREQUENCY AND TIME OF INSPECTION ‘The success or failure of instrumentation in a re- finery depends to a large degree upon the quality of the instrument air supplied to the components. Tt should be clean, dry, and at a closely regulated pressure. Fre- ‘went checks should be made to be sure these conditions are met. Observation of system pressure and oil or moisture content by hlowdown from reecivers and low COPIA MABSTRA Ne | EQuiement 0 points in piping should be a daily procedure, Because the instrument air system is so important to plant oper- ation, inspection for anything more than visible faults should be left to qualified personnel. A prewinter ine spection should be made to assure dryer operation at 4 sufficiently low dew point to prevent freeze ups. 15.17.38 METHODS OF INSPECTION Inspection of sir-supply systems should include checks of filters and associated equipment for leaks and for proper operation. ‘The oll-anel-moisture content of, the air should also be checked! so insure that it is not above tolerable limits, Where standby or emergeney sourees of air supply are provide, they should be checke! for proper operition by simulating a failure of the main source, Piping should be inspected as outlined in Chapter Xt of this guide, Pipe, Vaives, and Fittings 15.18 Hydraulic-Pressure Systems 15.18.1 DESCRIPTION OF TYPES Hydraulie-pressure systems may be cither small ‘compact packaged systems or lirge, central supply sys lems for a process unit or complete refinery, In either case, the system will consist of storage drums or an accumulator to store the fluid under pressure, pumps to supply the pressure, and assorted relief valves and controls to assure satisfactory performance, The larger central system muy also inclukle a low-pressure storage drum and spare pumps for operation «luring emergency conditions. A schematic diagram of x commonly used eentral hydraulic supply system is shown in Figure 44(A). An example of a packaged hydraulic supply system is shown in Figure 44(B) 15.18.2 FREQUENCY AND TIME OF INSPECTION ‘The proper functioning of components depends upon the availability of a clean, regulated supply at all vies Ti some instruments contamination may present a prob- tem. Moiithly checks should be made until experience determines that less frequent intervals are adequate. Viswal observation will usually not show potential fail- ures. However, a drop in the hydraulic system pressure may be a hint of impending trouble 15.18.38 METHODS OF INSPECTION Inspection of the hydraulic system consists of check- ing for leaks, proper operating pressures, and cleanliness and physical condition of the filterAPI Guine Fox INSPECTION oF ReviNeny EquipMENT swords sy qwounssu—gy 2unB iy 1's S¥SE gis. 39 28 Yoquss 240N 38078 uaa Bem ossauanioo SUBAKO _BBAONSY 10, wsncpau ge piv anannasne 3 Weiss ue aiwid howd wausas NounaneLsio ue 2N3HMWASNT wouvuvens HLM ox7009 fide wO0NNELSY wo1=7100 1s swasieo USL U0 ae 7]‘COPIA MAESTRA No: Fechat, Firma: Charter XV—InsTeuMENTS AND ConTROL Equipment 29 RESERVOR some © | 8 | [Ltrs Lencru oF ms nsec Sad Eee, 80 °F ha INERT 6a Pressure ownecTion For on. Doce I REQUIRED ae i ee30 API Guwe For INSPECTION oF REFINERY EQuIPMENT Figure 44(B}—Packaged Hydraulic Supply System. Where standby or emergeney sources of hydraulic supply are provided, they should be checked for proper operation by simulating a failure of the main source. 15.19 Electric Power Systems for Instruments 15.19.1 DESCRIPTION OF TYPES Instruments that require electric power for computer systems, chart drives, measuring circuits, or transmis- sion oF control circuits are normally connected to the refinery power system. Many refineries are also equipped with standby electrical power supplies for in- strument circuits and for certain lighting circuits. Some instruments commonly supplied from uninterruptable power supplies are computer installations, electronic in- struments, flame safely instruments, and protective ‘and shutdown devices. Alternate power supplies can be standby generators, batteries, or other suitable devices arranged to cut in either automatically or manually. Sources of descriptive information on power supply systems can be found in API RP SO0A, API RP 540, Section 11 of API RP 550, Part 1, and Chapter X1V of this guide, Eleerrical Systems. 15.19.2 FREQUENCY AND TIME OF INSPECTION Electric power systems for instruments are identical in principle with other electric power systems used in refineries. Therefore, recommendations concerning the frequency and time of inspection outlined in Chapter XIV of this guide, Electrical Systems, apply here also, Generally cach manufacturer has special requirements for his equipment. ‘The manufacturers literature should be consulted for recommendations concerning frequency and time of inspection. Standby electrical power supplies should be inspected as frequently as the regular system, In addition, the alternate powcr supply systems should be operated at Teast once month by simulating faults in the main supply systems. Obviously, such tests should be con- ducted carefully (@ minimize the possibility of plant upsets. Electronic instruments donot lend themselves to periodic inspection since trouble will usually show up as 4 failure, Until a failure occurs, operation is normal, and inspection to head off trouble is difficult if not im- possible, Therefore, preventive maintenance is sefdom done, and maintenance alter a breakslown appears to be the most practical approach. 15.19. METHODS OF INSPECTION Eketrical power supply systems should be checked for shorts, grounds, loose connections dmaged insls~ tion, and corroded conduits to insure that they ate ‘Mlequatly protected against mechanical damage, ‘The operation of the system should be checked to coterie that it at the proper frequency and voltage level and thatthe volige regulation Is within the limits required by the instruments the system supplies ‘Where standby or emergency sources of power are provided, they should be checked as carefully as the nin source, and, in addition, should be checked for proper operation by simulating a failue of the main Source. For a general discussion of electrical power supply systems, see Section 11 of API RP $50, Part I 15.20 Instrument Panels 15.20.1 DESCRIPTION. OF TYPES ‘The purpose of an insirument panel is to enable operating, personnel to maintain efficient and safe per- formance of the unit from « central location. ‘There are three major types of instrument panels: conventional, semigraphic, and console, Figures 45 and 46 show examples of the semigeaphic and console instrument pancls. The piping and wiring for the pane! instruments are located behind the panel. For additional informa- tion, sce Section 12 of API RP 550, Part I 15.20.2 FREQUENCY AND TIME OF INSPECTION Generally, instrument panels and associated equip- ment are inspected by operating and instrument per- sonnel in the course of their normal activities. This is€ Cuapter XV—inst! Figure 45—Semigraphic Panel done st the same time and in the same manner as the ‘automatic controllers are cheeked (see Section 15.13.2). 15.20.8 METHODS OF INSPECTION Generally, any inspection of panelboards is primarily concerned with the piping and wiring of ait of electric Power and transmission leads 10 the individual instru- ments mounted on the panel, “These leads shoukd be checked for leaks, shorts, grounds, oF loose connections (see ISA RP 7.1 for the method employed). In audi tion, the main electrical ground on the panel should be checked for tightness und proper grounding. Individual instrument mountings should also be checked for rigid- ity. (Refer to APL RP 550, Patt I, Section 7,) 15.21 Analyzers and Sampling Systems 15.211 DESCRIPTION OF TYPES Analyzers and sampling systems, which vary in com plexity according to the application, are two distinct subjects. Each could be treated in a very lengthy manner. However, to be practical, only some of the ‘more important points will be mentioned here, An analyzer is a device that performs an analysis (chemical or otherwise) for some component in a stream (for example, oxygen in flue gas) oF for some characteristic of a product or component (for example, initial boiling point or end point). Analyzets can be simple, as in the case of a gas geavity meter wherein the gravity is determined either as a function af dis placement or as a function of fan motor torque, They can also be complicated, as in the case of a chromato- araph or a distillation analyzer, which are actually com- plete systems in themselves. The analyzer manufac turer's instruction manual shoukl be consulted for a complete description of the unit under consideration, COPIA MAESTRA No: Foch: Fir UMENTS AND ConTROL EQUIPMENT 31 Because the success of an analyzer depends greatly ‘upon the sampling system, sampling systems are as im portant as, if not more important than, analyzers, Th the simplest form, a sampling system may be only a piece of pipe or tubing bringing the process material to the analyzer. Hovever, in many cases the sample must be conditioned! before it can be admitied to the analyzer. Pressure regulators, coolers, heaters, scrubbers, pumps, filters, and flow regulators are some of the items required in various sampling systems. Here, 00, the manufac: turer's literature should be consulted for a description of the type of sumpling system furnished for the applica- tion. (Refer to APL RP 550, Part 11.) 15.21.2 FREQUENCY AND TIME OF INSPECTION From a performance and reliability standpoint, ana- lyzers und sample systems are extremely critical, How- ever, because of their complicated nature, they should, be huanded only by thoroughly trained personnel, Not only is the equipment itself complex, but there are also. hazards due to the presence of combustible and danger- ‘ous materials. One who is not thoroughly familiar with the desiyn, operation, and maintenance of the equip- ment should restriet himself to visual inspection for leaks and obvious faults, Inspection by trained person nel is recommended at varying intervals of from onee day tw once a month, depending on the type of ‘analyzer and its importance to the operation, 15.21.3 METHODS OF INSPECTION The proper operation of any analyzer depends upon the proper operation of its sampling system. Therefore, the sample system should be checked for leaks and loose connections and a constant supply of air, water, of steam as required. The sample system should” be checked to insure that the sample I cleaned and that a continual flow of sample is delivered to the analyzer al the required operating pressure and temperature. All cases of excessive buildup of foreign deposits should be reported to the proper supervisory or operating per- sonnel The analyzers should be cleaned and serviced in ace cordance with the manufacturer's recommendations as well as with methods gained through operating experi- ence, For inspection of recording mechanisms, refer to Seetion 15.12. 15.22 Alarms and Protective Devices 15.22.1 DESCRIPTION OF TYPES Alarms and protective deviees may be set up to work independently, simultaneously, or in sequence, depend-yoga ys a7 Big o208 se & 5 Figure 46—Console Panel ing upon the nature of the application. In many in stances an alarm alone is sufficient: for example, on applications where it is desirable that warning be given when certain measured variables (temperatures, flows, pressures, levels, and the like) have deviated beyond sncceptable limits, If shutdowns are required in order fo protect per soanel «ind equipment from any possible hazaids and disasters caused by the deviation of certain measured variables beyond acceptable Limits, particular emphasis should he given to the reliability of the system, Overall system operation should be checked to ensure that sale operation is maintained when & shutdown system is activated, (Refer to APL RP 550, Part 1, Section 13.) Alarms are usually audible or visual, or both. The audible alarm can be sounded fy a horn, buzzer, or any similar deviee capable of creating a noise to catch the unit operator's sitention. Visual alarms take the form fof flags, semaphores, or steady or flashing lights mounted either individually or in groups. In refinery applications it is a fairly common practice to have the audible and visual alarms actuated simultaneously. A first-out type of afarm system should be considered ‘when more thaw one alum is likely to sound simul- taneously. An example of this is an automatic boiler shutdown that triggers several other alarms (signaling Tow temperature, pressure, oxygen, and the like). A. ccontratized alarm system in common use is shown in Figure 47. Protective deviees vary in design according fo their application. In many instances (in pneumatic systems), diaphragm-operated devices with manual reset devices ave used to prevent automatic startup. Other systems cimplay valves that fully close or that divert flow or pressure from a particular process cireuit. In other ees, as in the case of mechanical equipment like turhine drives, protective devices consist of tem- perature oF prossure-activated electrical contacts sup- plied as an integral part of the equipment. These con- tacts also usually require manual resetting before starting up again. Consideration shoukl be given to permissive startup systems, An example of this wouldCc Chapter XV—INsTRUMENTS AND ConTRoL Equirmer 6A) Unmounted Anmunctator. COPIA MABSTRA No: Faces, Fle 33 (2) Anounciator Mounted in Ponelboar. Figure 47—Aanuneiators for Aleem System, be a shutdown override on a low-flow shutdown. (Refer to API RP 550, Part I, Sections 3 and 4.) As stated previously, alarms or protective devices are tuated by the deviation of certain measured! variables beyond acceptable Limits, ‘This actuation can be init in a number of different ways, depending upon the a plication. single-point or multiple-point strip chart temperature recorder will usually cause a switch to be tripped because of the position of its pen or print wheel carriage. Transmitters can activate the alarm system by appropriate devices connected to the transmitter output, Many alarm systems are actuated by pressure or level switches eonnecied directly to the process. In the most common type of refining unit alarm sys- tem it is usually necessary 10 have provision in the circuit to allow for operator acknowledgment for lamp testing, operating parallel noise-producing devices, and the like, No attempt will be made to describe these devices because of the great variety of types that may be required for any group of units. Process flow di- agrams and manufacturer's literature should be con- sulted for a description of the system under considera tion Some alarm systems may function without the benefit of electrical cirewits, although this is not often the case in refineries. An example of a nonelectrical system is 4 process unit with a steam-generating auxiliary Wherein the drum level ball float directly actuates a whistle in the event of either high or low water levels Shutdown systems must be checked to insure reli- ability. This ean be done by overriding the shutdown system for test and inspection, but the override should be alarmed and key-lock operated ed 15.22.2 FREQUENCY AND TIME OF INSPECTION Recommendations for operational inspection fre- ‘queney range from once each shift to once a week. For example, i is recommended that alarm lights be checked fon each shift, whereas the compressor knock-out drum level device can be inspected once a week, The schedule most suitable to each plan depends on the importance of the device 10 the operation or the possible degree of hazard, or both. Alarm devices should also be ine speeted regularly for potential mechanical failures. In any event, inspection of alarm and protective devices, should be made at least once each shutdown or once a year, whichever comes first. A good practice to fol- Jow, if feasible, is to shut down the operating equipment by operating the alarm and shutdown device, Because the consequences of failure of an alarm and shutdown system vary from unit t© unit and plant t plant, it is recommended that each system be studied refully for the risks involved and a suitable inspection interval developed as soon as possible. 15.22. METHODS OF INSPECTION Inasmuch as alarms and emergency devices must operate during emergency conditions, their satisfactory performance is essential to safe operation of refinery units. Alarm devices, such as signal lights and howlers, are generally electrical. Therefore, inspection consists, of checking for shorts, grounds, loose connections, dam- ‘aged insulation, and corroded conduits. Alarms not housed in explosionproot or hermetically sealed con- lainers should also be checked to insure that all relays. are clean and dust-free. Any pitted or burned contact, points should be replaced. Set points should be verifiedto see that they are still accurate with the passage of time. Changes in operations can affect proper set points for alarms and shutdowns, Emergency devices may be electrical, pacumatic, mechanical, hydraulic, or a combination thereat, ‘They may be used to shut down pumps, compressors, oF other items of equipment for protection during abnormal or emergency conditions. They may also actuate standby emergeney equipment, such as auxiliary pumps, com- pressors, or generators. Inspection of electrient emer gency devices should be the same as for the aforemen- tioned alarms. Other emergency devices should be inspected for leaks, freedom of movement ofall moving patts, proper air or hydraulic supply pressure, and operating voltages. Systems that can be put Through a simulated emergency without disrupting. normal opera- tion should be so checked as this is the most effective ‘way of inspecting shutdown equipment. For example, a welding rod could be used to lift the float of a Tevel alarm after isolating it from the process 15.22 Miscellaneous instrumenis 15.23.1 DESCRIPTION OF TYPES There are many devices not discussed in this manual Examples of some of the more common types are: 1. Speed indicators, recorders, and governors. 2, Electrical voltmeters, ammeters, frequeney meters, and wattmeters. 3. Time indicators, running time meters, and eycle or program timers, API Guwe Fok INSPECTION oF Rerinery Equipment 15.23.2 FREQUENCY AND TIME OF INSPECTION Most miscellaneous devices do not require frequent inspection. Visual inspection can be made as often as the instruments are used or read. Inspection of mechan- ical elements for wear or cotrosion ean be accomplished at a tumaround. Inspection that includes calibration, such a8 inspection of electrical meters, speed instrt~ iments, and spring-operated timing devices, should be performed once a year or the first time the equipment can be taken out of service after a year of operation, ‘After the initial inspection, the frequency of inspec tion depends upon the service, the manufacturer's recommenclations, and past experience 15.28.3 METHODS OF INSPECTION In general, miscellaneous equipment, such as eycle or program timers, datalogging equipment, computing equipment, or speed controllers, consists of various mechanical, electrical, or pneumatic components or any combination thereof. The inspection procedures, therefore, are generally concerned with checking for ny Jenks, shorts, grounds, loose connections, or fric- tion ecween moving pasts. ‘This type of equipment is usually adversely affected by dust, high temperatures, and humidity. Care shoul be taken to see shat all open, contacts are clean and free from pitting or corrosion. It is usually possible to check this type of equipment with- ‘out adversely affecting its normal operation. In many data-logging and computer installations, a self-checking. oo scll-inspecting operation is built in by the manufac- turer and can be actuated as required for inspection, purposes.c COPIA MAESTRA Nor Fecha, Fir INDEX ‘Actuators for control valve iluratons of Fip. 38,22 Airstiply system escrito of types. 18.172, 27 Sregutney und tne of iaapecion, 15.17.2,27 tethod or inpsstion, 13.17.37) SShemati dligram of sm, Fig. 43,28 Ato Tanunciatrs for ulaem systeon, ig, 7, 33 description of tyes. 18221, St equeney'an fie of inpection, 15.222 33 methods of inspection, 1332.3, 33 Analog receivers iksration of Fig. 33. 19 ‘Analytical imeraments, ook epited for nspecton of, 156, 4 "Ta Analy desertion of types, 15.2.4, 31 frequency snd tne of appa, 1521.2, 31 ‘methods of inspection, 1501.30 34 Anna, listration fy Fie ‘rca meer 3 Atomic eonivolers m of types, 1513.1, 20 trolling modes, 1813.12, 20 frequeney and tine Of inspection, 15.3.2, 20 iMestetions of, Figs. 29 ud 34,47, 19 metheals of faspectinn, 1813.3, 20 Bellows meter, illustration of, Fig. 11, 10 Bellows-type pressure iasteament,iluseation of, Fig. 32,19 alli thermometer, istration ef, Fig. 23, 18 don tube pressure instruments, astrtions of, Fig, 30, 18 ily control valve llestation Of, Fig, 35tC) 8 Calibration of level instuments, 18.9.4 1S ies of dceriovation, 13.4.3 lesion of numa iS. 4 CConsole-type control panel, ilintralion of, Fig. 46, 32 Continuity of operation, « reason for ingpection, 15.3.3, 2 Contioltratsenision systems description of types, 1515.12. 23 Frequeney und lime of inspection, 15.15.2, 23, methods of inspection. 13. 15.¥. 34 Contiovalve positioners

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