Model Curriculum · flow meter depending on the type - eg - American Gas Association (AGA) report 7 for turbine flowmeter, AGA report 9 for ultrasonic flowmeter etc. • Interpret

Process Instrument Technician (Oil & Gas)

Model Curriculum


SECTOR: SUB-SECTOR: OCCUPATION:

REF ID: NSQF LEVEL:

HYDROCARBON MIDSTREAM CALIBRATION & INSTRUMENTATION HYC/Q6201, V1.0 4



TABLE OF CONTENTS

1. Curriculum 01

2. Trainer Prerequisites 08

3. Annexure: Assessment Criteria 09

Process Instrument Technician (Oil & Gas) 1

Process Instrument Technician (Oil & Gas) CURRICULUM / SYLLABUS

This program is aimed at training candidates for the job of a “Process Instrument Technician (Oil & Gas)”, in the “Hydrocarbon” Sector/Industry and aims at building the following key competencies amongst the learner.

Program Name Process Instrument Technician (Oil & Gas)

Qualification Pack Name and Reference ID

HYC/Q6201, V1.0

Version No. 1.0 Version Update Date 16-07-2019

Pre-requisites to Training

Class XII (Science stream)

Training

Outcomes

After completing this program, participants will be able to:

• Check hydraulic, pneumatic, mechanical measuring and control equipment for correct operation, calibrate, and analyze and report the test result.

• Check the electrical and electronic measuring and control equipment for correct operation, calibrate, and analyze and report the test results.

• Perform maintenance activities on instrumentation and control equipment, escalations of unresolved and delayed issue as per protocol.

• Perform installation of custody meters; observe the process and diagnostic parameters; calibrate custody meters and auxiliary instruments; and analyze and report test results.

• Prepare Pressure Safety Valves (PSV) for inspection, testing and calibration, perform maintenance of PSV and repot preparation.

• Prepare for LEL gas detection system testing and calibration, maintain LEL detection equipment and prepare reports.

• Work effectively with colleagues, superiors, members of own work group, people in other work groups within or outside the organization

• Follow health, safety and security procedures as defined by the organization.


2

This course encompasses 8 out of 8 National Occupational Standards (NOS) of “Process Instrument

Technician-Oil & Gas” Qualification Pack issued by “Hydrocarbon Sector Skill Council”.

Sr. No.

Module Key Learning Outcomes Equipment Required

1

Introduction to Hydrocarbon Sector

Theory Duration (hh:mm) 08:00 Practical Duration (hh:mm) 02:00

Corresponding

NOS Code

Bridge Module

• Explain about the Oil & Gas Sector/Sub-Sector

• List the three major segments in the hydrocarbon sector

• State the functions of midstream and downstream segment

• List the different types of hydrocarbons

• State the different types of fuel

• List the roles and responsibilities of Process Instrument Technician (Oil & Gas)

2

Calibrate hydraulic, pneumatic and mechanical measuring and control equipment

Theory Duration (hh:mm) 40:00

Practical Duration

(hh:mm) 100:00

Corresponding NOS Code

CSC/N0801

• Explain procedures and guidelines for personal protective equipment (PPE) and other relevant safety regulations

• Check components, leads, fasteners, etc. for wear, loose connections or other faults

• Carry out the testing/calibration activities in the specified sequence and in an agreed timescale

• Identify work/test requirements and define as per standard operating procedures

• Test the operation of instruments and systems to diagnose faults using testing devices

• Select correct test application principles after inspection of instrumentation systems, equipment/components

• Select appropriate test equipment in accordance with defined requirements Observe device isolation methods/requirements and localize

• Apply appropriate test procedures and application principles in assessing operation of instrumentation systems, equipment/components

• Report any instances where the testing/calibration activities cannot be fully met or where there are identified defects outside the planned schedule

• Complete relevant testing/calibration documentation accurately

• evaluate faulty conditions and plan corrective action

• Assortment of wrenches

• Screwdrivers

• Pliers

• Wire cutters

• Wire strippers

• Channel locks

• Punches, hammers

• Dataloggers


3

Sr. No.


• Record action plan and document according to standard operating procedures

• Report potential and real faults using standard operating procedures

• Calibrate equipment against appropriate physical standards using correct calibration tools, equipment, techniques using predetermined procedures

• Perform methods of adjustment using calibration devices and document prescribed procedures and operational specifications

• obtain help or advice from specialist if the problem is outside his/her area of competence or experience

• monitor the problem and keep the supervisor informed about progress or any delays in resolving the problem

• complete documentation post operations as per organizational procedures

3 Calibrate electrical and electronic measuring and control equipment


Practical Duration

(hh:mm) 100:00


CSC/N0802

• Comply with health and safety, environmental and other relevant regulations and guidelines at work

• Ensure work area is clean and safe from hazards

• Ensure that all tools, equipment, power tool cables, extension leads are in a

• safe and usable condition

• Check components, leads, fasteners, etc. for wear, loose connections or other faults

• Prepare and update relevant testing/calibration schedules and plans

• carry out the testing/calibration activities in the specified sequence and in an agreed timescale

• Identify work/test requirements and define as per standard operating procedures

• Test the operation of instruments and systems to diagnose faults using testing devices

• Select appropriate test equipment in accordance with defined requirements

• Ensure appropriate device isolation methods/requirements are observed

• Apply appropriate test procedures and application principles in testing the operation of instrumentation systems, equipment/components

• complete relevant testing/calibration documentation accurately

• Digital multimeter

• Multifunction calibrator

• Loop calibrator

• Temperature bath

• Manometers

• Precision pressure gauges

• Tachometer

• Electronic thermometer

• Electronic pressure gauge

• Field calibrators


4

Sr. No.


• Report any instances where the testing/calibration activities cannot be fully met or where there are identified defects outside the planned schedule

• Report potential and real faults using standard operating procedures

• Evaluate faulty conditions and plan corrective action

• Perform methods of adjustment using calibration devices and document prescribed procedures and operational specifications

• Re-commission equipment in accordance with standard operating procedures

• Refer the problem to a competent internal/external specialist if it cannot be resolved

• Obtain help from specialist if the problem is outside his/her area of competence or experience

• Monitor the problem and keep the supervisor informed about progress or any delays in resolving the problem

4 Maintenance of instrumentation and control equipment


Practical Duration

(hh:mm) 100:00


CSC/N0803

• Comply with health and safety, environmental and other relevant regulations and guidelines at work

• Ensure work area is clean and safe from hazards

• Ensure that all tools, equipment, power tool cables, extension leads are in a safe and usable condition

• Obtain and use the correct version of company and/or manufacturer’s drawings and maintenance documentation

• Produce and update relevant maintenance schedules and plans

• Carry out the maintenance activities by appropriate techniques and procedures on a range of instrumentation and control equipment

• Re-connect and return the system to service on completion of activities

• Conduct maintenance activities within the limits of their personal authority

• Carry out the maintenance activities in the specified sequence and in an agreed timescale

• Report any instances where the maintenance activities cannot be fully met or where there are identified defects outside the planned schedule

• Complete relevant maintenance documentation accurately


5

Sr. No.


• Dispose of waste materials in accordance with safe working practices and approved procedures

• Identify on making improvements to maintenance processes and procedures

• Refer the problem to a competent internal/external specialist if it cannot be resolved

• Obtain help or advice from specialist if the problem is outside candidate’s area of competence or experience

• Monitor the problem and keep the superior informed about progress or any delays in resolving the problem

• Comply with relevant legislation, standards, policies and procedures

5 Perform custody transfer metering


Practical Duration

(hh:mm) 158:00


HYCC/N6201

• Identify type of custody flow meter - eg-Turbine, Ultrasonic, Coriolis and principle of their operation

• Check installation as per design considerations like maximum/minimum operating process parameters of the fluid, the general characteristics of the fluid, ambient conditions and location of skid

• Check installation as per design consideration for uni-directional or bi-directional flow

• Read general arrangement design for flowmeter skid as per the selected type of flowmeter

• Apply relevant standard while installing flow meter depending on the type - eg - American Gas Association (AGA) report 7 for turbine flowmeter, AGA report 9 for ultrasonic flowmeter etc.

• Interpret installation requirements for auxiliary instruments as per standard

• Identify upstream and downstream header piping and pipe components as per relevant standard specifications eg- straight run requirements, flow condition etc.

• Identify material of construction (MOC) and corrosion resistance of the materials used, hot/cold insulation requirements

• Check meter body, bore, tapping, electronic housing, ports and cable entry as per relevant standard recommendations for the hazardous zone classification

• Observe the physical condition of upstream & downstream piping, pipe components, hot/cold insulation, auxiliary instruments

• Ultrasonic flow meter

• Turbine flow meter

• Coriolis mass flow meter

• Flow straightner

• Pressure Transmitter (PT)

• Temperature Transmitter (TT)

• Gas Chromatograph (GC)

• Calorimeter

• Densitometer

• Typical Control system PLC, SCADA.


6

Sr. No.


• Analyse process parameters and their variation over time, sudden peak or fluctuations

• Interpret flowmeter parameters, various component status, self-diagnostics, alarms and events logging

• Analyse input sensor status, output signals and process diagnostic parameter and history trends

• Perform leak test on joints, tapings, flanges, gasket etc.

• Record line condition values on display such as flowrate, velocity, meter diagnostic parameters like gain, performance, signal t noise ratio etc.

• Check zero flow verification with wet or dry calibration

• Calculate error by comparing reading with reference/master flowmeter

• Implement appropriate error correction method like flow weighted mean average, second order polynomial or piecewise linearization

• Calculate calibration constants for meter configuration and prepare calibration report

• Record configuration parameters

• Calibrate auxiliary instruments like pressure and temperature transmitter, gas chromatograph etc.

• Validate the calculation of flowmeter and calibration reports of Pressure Transmitter (PT), Temperature Transmitter (TT) and Gas chromatograph (GC)

• Prepare spare parts list for repairing tools and special tools

• Analyse OEM factory calibration report, factory configuration and calibration constants report.

• Facilitate third party to witness calibration report based on as-found and as-left parameter records

• Validate the calculation of flowmeter and calibration reports of Pressure Transmitter (PT), Temperature Transmitter (TT) and Gas chromatograph (GC)

• Analyse reports specific to the type of flowmeter chosen like speed of sound and test report for ultrasound meter as per AGA report 10

• Perform repeatability test results for GC


7

Sr. No.


• Upgrade firmware, hardware and related parts replacement

• Maintain diagnostic software upgradation

6 Maintain and calibrate pressure Safety Valves (PSV)


Practical Duration

(hh:mm) 100:00


HYCC/N6202

• Obtain proper work permit from operation

• Check availability of proper non-sparking tools

• Ensure proper PPEs are used while carrying out the maintenance of ressure safety valve

• Check proper isolation of the safety valve from the process line and communicate the status to process department

• Remove PSV from line with applicable safety permits and precautions

• Provide necessary blind after removal of PSV

• Check any hydrocarbon gas leakage by Lower Explosive Limit (LEL) meter

• Shift PSV to work shop for physical internal inspection and testing

• Dismantle PSV for internal inspection

• Calibrate pressure gauges used for Calibration of PSV with secondary master test equipment.

• Fix PSV on test bench, check all connections and pressurize the system near Cold Differential Set Pressure CDSP level (as provided in data sheet)

• Test pressure safety valve for “Poping” at its cold differential set pressure (CDSP) value.

• Remove blind from line and install back PSV with proper gasket with safety precautions, after tightening of flange bolts check leakages if any and then take back in-line

• Return the work permit to shift in-charge with confirmation from field operator

• Prepare calibration certificate

• Update calibration data in the applicable format.

• Maintain records of tests and results in accordance with procedures

• PSV calibration test bench

• Air compressor

• Digital Pressure Gauge

• Weight Tester

• Pneumatic and hydraulic boosters and control system

7 Calibrate LEL gas detector


• Check healthiness of cylinder pressure regulator and flow meter

• Check LEL cylinder gas composition and validity certificate

• Ensure PPEs are used while handling the cylinders

• Identify hazards from possible gas leakage

• Calibrated standard gas cylinder

• Digital multi meter

• Gas detector

• Gas analysis systems for monitoring


8

Sr. No.


Practical Duration

(hh:mm) 100:00


HYC/N6203

• Check LEL detector and ensure junction box is thoroughly inspected for any abnormality

• Purge the detector with air and observe the reading on the display unit as applicable. If required, adjust the “zero” reading

• Apply calibration gas, as applicable, to the detector and observe the reading on the display as per gas concentration. If required, adjust by “span” reading.

• Apply suitable correction factors for the intended LEL application as per OEM manual

• Clean and maintain LEL gas detection system and testing kit in accordance with procedures and return the work permit to operation shift in-charge

• Update calibration data in the applicable format

toxic and combustible gases

8

Basic, health, safety and security procedures


Practical Duration (hh:mm) 20:00 Corresponding NOS Code

HYC/N6104

• Identify job-site hazardous work and state possible causes of risk or accident in the workplace

• Carry out safe working practices while dealing with hazards to ensure the safety of self and others

• State location of general health and safety equipment in the workplace

• Inspect for faults, set up and safely use steps and ladders in general use

• Work safely in and around trenches, elevated places and confined areas

• Lift heavy objects safely using correct procedures

• Identify common hazard signs displayed in various areas

• Use the various appropriate fire extinguishers on different types of fires correctly

• Demonstrate rescue techniques applied during fire hazard

• Record all incidents, damages, illness or injury

• Comprehend the applicable laws, regulations and codes as per standard

• Assess the threats and to protect from the threats

• Report all incident to the supervisor

• Identify and describes the property of different petroleum products

• Operates and handle spills and respond to the spills

• Hard hats

• safety glasses

• ear protectors

• steel-toe shoes


9

Sr. No.


• Demonstrate to free a person from electrocution

• Respond promptly and appropriately to an accident situation

• Perform and organize loss minimization or rescue activity during an accident in real or simulated environments

• Administer first aid to victims in case of a heart attack or cardiac arrest due to electric shock, before the arrival of emergency services in real or simulated cases

9

Work effectively in a team


Practical Duration (hh:mm) 20:00


HYC/N6103

• Maintain clear communication with colleagues

• Pass on information to in line with organisational requirements

• Work in ways that show respect for colleagues

• Carry out commitments made to colleagues

• Identify problems in team working take initiative to resolve

• Follow the organisation’s policies and procedures for working with colleagues

• Share resources with other members as per priority of tasks

Total Duration

Theory Duration 300:00

Practical Duration 700:00

Unique Equipment Required:

Meter Skid (Flow Metering System) Ultrasonic flow meter, Turbine flow meter, Coriolis flow meter, Pressure Transmitter (PT), Temperature Transmitter (TT), Gas Chromatograph (GC), Ultrasound meter, Calorimeter, Densitometer and Typical Control system based on PLC, SCADA. Electrical Meters, Lab Grade Thermometers, Inclined Manometers, Precision Pressure Gauges, Anemometer Tachometer, Electronic Thermometer, Electronic Pressure Gauge, Field Calibrators, and other tools and equipment involved in the calibration.

Grand Total Course Duration: 1000Hours, 0 Minutes (This syllabus/ curriculum has been approved by Hydrocarbon Sector Skill Council)


10

Trainer Prerequisites for Job role: “Process Instrument Technician (Oil & Gas)” mapped to Qualification Pack: “HYC/Q6201, v1.0”

Sr.

No. Area Details

1 Description To deliver accredited training service, mapping to the curriculum detailed above, in accordance with the Qualification Pack “HYC/Q6201, V1.0”.

2

Personal Attributes

Aptitude for conducting training, and pre/ post work to ensure competent, employable candidates at the end of the training. Strong communication skills, interpersonal skills, ability to work as part of a team; a passion for quality and for developing others; well organised and focused, eager to learn and keep oneself updated with the latest in the mentioned field.

3

Minimum Educational Qualifications

Diploma in Mechanical Engineering/ Petroleum Engineering

4a Domain Certification

Certified for Job Role: “Process Instrument Technician (Oil & Gas)” mapped to QP: “HYC/Q6201, V1.0. Minimum accepted score is 80%

4b

Platform

Certification

Recommended that the Trainer is certified for the Job Role: “Trainer”, mapped to the Qualification Pack: “MEP/Q0102”. Minimum accepted score is 80%.

5 Experience Minimum 5 years of industry experience in relevant job role and a Minimum of 2 years Training experience in relevant job role.


11

Annexure: Assessment Criteria

Compulsory

NOS

Total Marks: 500

Marks Allocation

Assessment

outcomes Assessment Criteria for outcomes Total Marks Out of Theory

Skills

Practi

cal

CSC/N0801 Calibrate hydraulic, pneumatic and mechanical measuring and control equipment

PC1.comply with health and safety, environmental and other relevant regulations and guidelines at work

100

3

1

2

PC2.adhere to procedures and guidelines for personal protective equipment (PPE) and other relevant safety regulations while performing calibration operations

3

1

2

PC3.work following laid down procedures and instructions 3 1 2

PC4.ensure work area is clean and safe from hazards

2

0

2

PC5.ensure that all tools, equipment, power tool cables, extension leads are in a safe and usable condition

2

0

2

CRITERIA FOR ASSESSMENT OF TRAINEES

Job Role Process Instrument Technician (Oil & Gas)

Qualification Pack HYC/Q6201

Sector Skill Council Hydrocarbon Sector Skill Council

Guidelines for Assessment

1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each

Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay

down proportion of marks for Theory and Skills Practical for each PC.

2. The assessment for the theory part will be based on knowledge bank of questions created by the SSC.

3. Assessment will be conducted for all compulsory NOS, and where applicable, on the selected

elective/option NOS/set of NOS.

4. Individual assessment agencies will create unique question papers for theory part for each candidate at

each examination/training center (as per assessment criteria below).

4. Individual assessment agencies will create unique evaluations for skill practical for every student at each

examination/training center based on this criterion.

5. To pass the Qualification Pack, every trainee should score a minimum of 70% of aggregate marks to

successfully clear the assessment.

6. In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.


12

PC6.check components, leads,

fasteners, etc. for wear, loose

connections or other faults

3

0

3

PC7.prepare and update relevant testing/calibration schedules and plans

3

0

3

PC8.carry out the testing/calibration activities in the specified sequence and in an agreed timescale

5

2

3

PC9.identify work/test requirements and define are per standard operating procedures

4

2

2

PC10.inspect and test the operation of instruments and systems to diagnose faults using testing devices

4

1

3

PC11.select correct test application principles after inspection of instrumentation systems, equipment/components

5

2

3

PC12.select appropriate test equipment in accordance with defined requirements 3 1 2

PC13.observe device isolation methods/requirements and localize

3

0

3

PC14.apply appropriate test procedures and application principles in assessing operation of instrumentation systems, equipment/components

5

1

4

PC15.report any instances where the testing/calibration activities cannot be fully met or where there are identified defects outside the planned schedule

2

0

2

PC16.complete relevant testing/calibration documentation accurately

2 0 2

PC17.analyse and verify test results against operational specifications to identify and localise faults

4

1

3

PC18.report potential and real faults using standard operating procedures

4

1

3

PC19.evaluate faulty conditions and plan corrective action

4

1

3

PC20.record action plan and document according to standard operating procedures

3

1

2


13

PC21.assess calibration of measuring and control equipment to manufacturers'specifications and/or standard operating procedures

6

2

4

PC22.calibrate equipment against appropriate physical standards using correct calibration tools, equipment, techniques using predetermined procedures

5

2

3

PC23.undertake zero, span and range checks on indicators/controllers using correct and appropriate configuration

5

2

3

PC24.perform methods of adjustment using calibration devices and document prescribed procedures and operational specifications

5

2

3

PC25.re-commission equipment in accordance with standard operating procedures

4

1

3

PC26.obtain help or advice from specialist if the problem is outside his/her area of competence or experience

3

0

3

PC27.monitor the problem and keep the supervisor informed about progress or any delays in resolving the problem

2

0

2

PC28.complete documentation post operations as per organizational procedures

3

1

2

Total 100 26 74

Compulsory NOS

Total Marks: [100] Marks Allocation

Assessment

outcomes Assessment Criteria for outcomes

Total

Marks Out Of

Theory

Skills

Practical

CSC/N0802 Calibrate electrical and electronic measuring and control equipment


10

3

1

2

PC2.adhere to procedures and guidelines for personal protective equipment (PPE) and other relevant safety regulations while performing calibration operations

3

1

2

PC3.work following laid down procedures and instructions 3 1 2

PC4.ensure work area is clean and safe from hazards 2 0 2

PC5.ensure that all tools, equipment, power tool cables, extension leads are in a safe and usable condition

2

0

2


14

Compulsory NOS


Assessment


Total

Marks Out Of

Theory

Skills

Practical

PC6.check components, leads, fasteners, etc. for wear, loose connections or other faults

0

3

0

3

PC7.prepare and update relevant testing/calibration schedules and plans 3 0 3

PC8.carry out the testing/calibration activities in the specified sequence and in an agreed timescale

5

2

3

PC9.identify work/test requirements and define are per standard operating procedures

4

2

2

PC10.inspect and test the operation of instruments and systems to diagnose faults using testing devices

4

1

3

PC11.select correct test application principles after inspection of instrumentation systems, equipment/components

5

2

3

PC12.select appropriate test equipment in accordance with defined requirements 3 1 2

PC13.ensure appropriate device isolation methods/requirements are observed 4 1 3

PC14.apply appropriate test procedures and application principles in testing the operation of instrumentation systems, equipment/components

4

1

3

PC15.report any instances where the testing/calibration activities cannot be fully met or where there are identified defects outside the planned schedule

2

0

2

PC16.complete relevant testing/calibration documentation accurately 2 0 2

PC17.analyse and verify test results against operational specifications to identify and localise faults

4

1

3

PC18.report potential and real faults using standard operating procedures 4 1 3

PC19.evaluate faulty conditions and plan corrective action 4 1 3

PC20.record action plan and document according to standard operating procedures 3 1 2

PC21.assess calibration of measuring and control equipment to manufacturers'specifications and/or standard operating procedures

4

1

3


15

Compulsory NOS


Assessment


Total

Marks Out Of

Theory

Skills

Practical

PC22.calibrate equipment against appropriate physical standards using correct calibration tools, equipment, techniques using predetermined procedures

6

2

4

PC23.undertake zero, span and range checks on indicators/controllers using correct and appropriate configuration

4

1

3

PC24.perform methods of adjustment using calibration devices and document prescribed procedures and operational specifications

5

2

3

PC25.re-commission equipment in accordance with standard operating procedures

3

1

2

PC26.refer the problem to a competent internal/external specialist if it cannot be resolved

3

0

3

PC27.obtain help or advice from specialist if the problem is outside his/her area of competence or experience

3

0

3

PC28.monitor the problem and keep the supervisor informed about progress or any delays in resolving the problem

2

0

2

PC29.complete documentation post operations as per organizational procedures

3

1

2

Total 100 25 75

Compulsory NOS


Assessment


Total

Marks Out Of

Theory

Skills

Practical

CSC/N0803 Carry out maintenance activities on instrumentation and control equipment


6

2

4

PC2.adhere to procedures and guidelines for personal protective equipment (PPE) and other relevant safety regulations while performing instrumentation operations

7

2

5

PC3.ensure work area is clean and safe

from hazards

4

0

4


16

Compulsory NOS


Assessment


Total

Marks Out Of

Theory

Skills

Practical

PC4.ensure that all tools, equipment, power tool cables, extension leads are in asafe and usable condition

4

0

4

PC5.obtain and use the correct version

of company and/or manufacturer’s

drawings and maintenance

documentation

7

2

5

PC6.produce and update

relevant maintenance

schedules and plans

6

0

6

PC7.carry out the maintenance activities by appropriate techniques & procedures on a range of instrumentation and control equipment

8

2

6

PC8.re-connect and return the system to

service on completion of activities

5

0

5

PC9.conduct maintenance activities

within the limits of their personal

authority

6

2

4

PC10.carry out the maintenance activities in the specified sequence and in an agreed timescale

6

2

4

PC11.report any instances where the maintenance activities cannot be fully met or where there are identified defects outside the planned schedule

3

0

3

PC12.complete relevant

maintenance documentation

accurately

4

0

4

PC13.dispose of waste materials in

accordance with safe working practices

and approved procedures

6

2

4

PC14.identify and lead on making

improvements to maintenance

processes and procedures

7

2

5

PC15.refer the problem to a

competent internal/external specialist

if it cannot be resolved

6

2

4

PC16.obtain help or advice from specialist if the problem is outside candidate’s area of competence or experience

5

0

5


17

Compulsory NOS


Assessment


Total

Marks Out Of

Theory

Skills

Practical

PC17.monitor the problem and keep

the superior informed about progress

or any delays in resolving the problem

4

0

4

PC18.comply with relevant

legislation, standards, policies and

procedures

6

2

4

Total 100 20 80

Compulsory NOS


Assessment


Total

Marks

Out

Of

Theory

Skills

Practical

HYC/N6201 Perform Custody Transfer Metering

PC1. identify type of custody flow meter - eg-Turbine, Ultrasonic, Coriolis and principle of their operation

100

3 1 2

PC2. check installation as per design considerations like maximum/minimum operating process parameters of the fluid, the general characteristics of the fluid, ambient conditions and location of skid

3 1 2

PC3. check installation as per design consideration for uni-directional or bi-directional flow

3 1 2

PC4. read general arrangement design for flowmeter skid as per the selected type of flowmeter

3 1 2

PC5. apply relevant standard while installing flow meter depending on the type - eg - American Gas Association (AGA) report 7 for turbine flowmeter, AGA report 9 for ultrasonic flowmeter etc.

3 1 2

PC6. interpret installation requirements for auxiliary instruments as per standard

2 1 1

PC7. identify upstream and downstream header piping and pipe components as per relevant standard specifications eg- straight run requirements, flow condition etc.

3 1 2

PC8. Identify material of construction (MOC) and corrosion resistance of the materials used, hot/cold insulation requirements

2 1 1

PC9. check meter body, bore, tapping, electronic housing, ports and cable entry as per relevant standard recommendations for the hazardous zone classification

3 1 2

PC10. follow Original Equipment Manufacturer (OEM) recommendations specific for the installation of flowmeter e.g.- electro-magnetic interference, skid vibration limits etc.

3 1 2


18

Compulsory NOS


Assessment


Total

Marks

Out

Of

Theory

Skills

Practical

PC11. observe the physical condition of upstream & downstream piping, pipe components, hot/cold insulation, auxiliary instruments

3 1 2

PC12. operate process parameters and their variation over time, sudden peak or fluctuations

2 1 1

PC13. interpret flowmeter electronic systems and various component status, self-diagnostics, alarms and events logging

3 1 2

PC14. analyse input sensor status, output signals and process diagnostic parameter history trends in control system/flowmeter

3 1 2

PC15. verify meter reading using meter prover system

3 1 2

PC16. perform leak test on joints, tapings, flanges, gasket etc.

3 1 2

PC17. describe period of calibration as per standard requirement

3 1 2

PC18. check configuration database, calibration constant, meter dimensions, parameter constant values, time averaging and sampling rate, hysteresis, flow cut-offs etc. and record it in calibration report "As-found"

3 1 2

PC19. check and record line condition values on display such as flowrate, velocity, meter diagnostic parameters like gain, performance, signal t noise ratio etc.

3 1 2

PC20. undertake zero flow verification with wet or dry calibration

3 1 2

PC21. calculate error by comparing reading with reference/master flowmeter

3 1 2

PC22. implement appropriate error correction method like flow weighted mean average, second order polynomial or piecewise linearization

3 1 2

PC23. calculate calibration constants for meter configuration and prepare calibration report

3 1 2

PC24. record configuration parameters 2 1 1

PC25. calibrate auxiliary instruments like pressure & temperature transmitter, gas chromatograph etc.

3 1 2

PC26. perform auto calibration setting and configuration for gas chromatograph

3 1 2

PC27. validate calculations and constants used in flow-computer

2 1 1

PC28. trace master calibration instruments used 3 1 2

PC29. prepare spare parts list, repair tools, special tools requirements, parts replacement procedures for repair

3 1 2

PC30. analyse OEM factory calibration report, factory configuration and calibration constants report.

2 1 1


19

Compulsory NOS


Assessment


Total

Marks

Out

Of

Theory

Skills

Practical

PC31. facilitate third party witness calibration report, as-found and as-left parameter records

3 1 2

PC32. validate calculation of flow-computers and calibration reports of PT, TT and GC

3 1 2

PC33. analysis reports specific to the type of flowmeter chosen like speed of sound test report for ultrasound meter as per AGA report 10

3 1 2

PC34. perform repeatability test results for GC 2 1 1

PC35. Upgrade firmware, hardware and related parts replacement

2 0 2

PC36. maintain diagnostic software upgrade 3 1 2

35 65

Compulsory NOS


Assessment


Total

Marks Out Of

Theory

Skills

Practical

HYC/N6202 Calibration & Maintenance of Pressure

Safety Valves

(PSV) & Calibration of

LEL Gas Detector

PC1 Obtained proper work permit from operation.

55

3 1 2

PC2.Check availability of proper non sparking tools.

2 1 1

PC3. Check proper PPEs are used while carrying out the job.

3 1 2

PC4. Check proper isolation of the Safety Valve from the process line. In case isolation cannot be achieved then communicate the same to process department.

2 0 2

PC5.Remove PSV from line with applicable safety permits & precautions.

3 1 2

PC6. Provide necessary blind after removal of PSV.

2 1 1

PC7. Check any hydrocarbon gas leakage by LEL meter.

2 0 2

PC8. Shift PSV to work shop for physical internal inspection and testing.

2 1 1

PC9. Dismantled PSV for internal inspection. 2 1 1

PC10. On inspection, the following activities are to be carried out depending upon the internal inspection: (i). Lapping of disk / Nozzle. (ii). Machining of disk / Nozzle. (iii). Replacement of Disk / Nozzle / spring etc.,

3 1 2

PC11. The valve is assembled back and placed in test bench for testing & calibration

3 1 2

PC12. Calibrate Pressure gauges used for Calibration of PSV with secondary master test equipment.

2 1 1


20

Compulsory NOS


Assessment


Total

Marks Out Of

Theory

Skills

Practical

PC13. Fix PSV on test bench, check all connections and pressurise the system near Cold Differential Set Pressure CDSP level ( as provided in data sheet)

2 1 1

PC14.Test Pressure safety valve for “Poping” at its cold differential set pressure (CDSP) value.

3 1 2

PC15. After satisfactory “pop” test, leakage / passing test is established as per permissible limit. Normally, ‘no passing’ is ensured up to 90% of set (CDSP) pressure.

3 1 2

PC16. On acceptance of calibration, sticker containing relevant data is pasted on PSV.

3 1 2

PC17. Remove PSV from test bench after satisfaction of above testing and shift back to site for re-installation.

3 1 2

PC18. Remove blind from line and installed back PSV with proper gasket with same safety precautions ,after tightening of flange bolts check leakages if any and then take back in-line

2 1 1

PC19. With confirmation / witness from field operator or shift in-charge, the work permit is returned back to shift in-charge.

3 1 2

PC20. Prepare calibration certificate 2 1 1

PC21. Update calibration data in the applicable format.

3 1 2

PC22. Maintain records of tests and results in accordance with procedures

2 1 1

20 35

Compulsory NOS


Assessment


Total

Marks Out Of

Theory

Skills

Practical

HYC/N6203 Calibration of

LEL Gas Detector

PC1. obtain proper work permit from operations team

50

3 1 2

PC2. check healthiness of cylinder pressure regulator and flow meter

3 1 2

PC3. check LEL cylinder gas composition and validity certificate

2 1 1

PC4. ensure PPEs are used while handling the cylinders

3 1 2

PC5. identify hazards from possible gas leakage

4 2 2


21

Compulsory NOS


Assessment


Total

Marks Out Of

Theory

Skills

Practical

PC6. implement hazard control measures and use of appropriate personal protective equipment (PPE)

2 1 1

PC7. check LEL detector and ensure junction box is thoroughly inspected for any abnormality

3 1 2

PC8. check the following: a. 24V DC supply indicator and alarm indicator. If not, check for blown fuse or power supply from control room (Type 1) b. Head Voltage (2V DC). If required, adjust voltage from control module installed in control room (Type2)

3 1 2

PC9. purge the detector with air and observe the reading on the display unit as applicable. If required, adjust the “zero” reading

3 1 2

PC10. apply calibration gas, as applicable, to the detector and observe the reading on the display as per gas concentration. If required, adjust by “span” reading.

4 2 2

PC11. apply suitable correction factors for the intended LEL application as per OEM manual

3 1 2

PC12. repeat steps at PC 9 to PC 11 till the readings are within required range

3 1 2

PC13. check the execution of alarm 1 and 2 (20% of reading for alarm 1 & 60 % of reading for alarm 2). Adjust respective pot-meters if required

4 2 2

PC14. take detector in line after satisfactory completion of calibration and purging

3 1 2

PC15. after completion of job Clean and maintain LEL Detection system and testing kit in accordance with procedures. Return the work permit to operation shift in-charge

0

PC16. update calibration data in the applicable format

4 2 2

PC17. maintain records of tests and results in accordance with procedures

3 1 2

20 30


22

Compulsory NOS


Assessment


Total

Marks Out Of

Theory

Skills

Practical

HYC/N6103 Work effectively in a team

PC1. maintain clear communication with colleagues

100

10 5 5

PC2. work with colleagues as a team 10 5 5

PC3. pass on information to in line with organisational requirements

10 5 5

PC4. work in ways that show respect for colleagues

10 5 5

PC5. carry out commitments made to colleagues

10 5 5

PC6. let colleagues know in good time if cannot carry out commitments, explaining the reasons

10 5 5

PC7. identify problems in working with colleagues and take the initiative to solve these problems

10 5 5

PC8. follow the organisation’s policies and procedures for working with colleagues

15 5 10

PC9. ability to share resources with other members as per priority of tasks

15 5 10

45 55

Compulsory NOS


Assessment


Total

Marks Out Of

Theory

Skills

Practical

HYC/N6104 Follow health, safety and security procedures

PC1. Use protective clothing/equipment for specific tasks and work Conditions

100

3 1 2

PC2. State the name and location of people responsible for health and safety in the workplace

2 1 1

PC3. State the names and location of documents that refer to health and safety in the workplace

2 1 1

PC4. Identify job-site hazardous work and state possible causes of risk or accident in the workplace

2 1 1

PC5. Carry out safe working practices while dealing with hazards to ensure the safety of self and others

3 1 2

PC6. State methods of accident prevention in the work environment of the job role Methods of accident prevention: training in

3 1 2


23

Compulsory NOS


Assessment


Total

Marks Out Of

Theory

Skills

Practical

health and safety procedures; using health and safety procedures; use of equipment and working practices (such as safe carrying procedures); safety notices, advice; instruction from colleagues and supervisors

PC7. State location of general health and safety equipment in the workplace

3 1 2

PC8. Inspect for faults, set up and safely use steps and ladders in general use

3 1 2

PC9. Work safely in and around trenches, elevated places and confined areas

2 1 1

PC10. Lift heavy objects safely using correct procedures

3 1 2

PC11. Apply good housekeeping practices 3 1 2

PC12. Identify common hazard signs displayed in various areas

3 1 2

PC 13. Retrieve and/or point out documents that refer to health and safety in the workplace

2 1 1

PC14. Use the various appropriate fire extinguishers on different types of fires correctly

3 1 2

PC15. Demonstrate rescue techniques applied during fire hazard

2 1 1

PC16. Demonstrate good housekeeping in order to prevent fire hazards

2 1 1

PC17. Demonstrate the correct use of a fire extinguisher

2 1 1

PC18. List issue concerning the safety and familiar in your work style

2 1 1

PC19. Empower to address the unsafe condition in your work place or to stop the unsafe behaviour

3 1 2

PC20. Record all miss incidents, damages, illness or injury

3 1 2

PC21. Comprehend the applicable laws, regulations and codes as per standard

3 1 2

PC22. Promote and maintain a positive safety culture

2 1 1

PC23. Apply and appraise the use and storage of hazardous substance and their safety

2 1 1

PC24. Assess the threats and to protect from the threats

3 1 2

PC25. Awareness of own safety and safety of others

3 1 2

PC26. Bring the concern and report the HSE concern

3 1 2


24

Compulsory NOS


Assessment


Total

Marks Out Of

Theory

Skills

Practical

PC27. Report all incident to the supervisor 3 1 2

PC28. Identifies and describes the property of different petroleum products.

3 1 2

PC29. Operates and handle spills and respond to the spills

2 1 1

PC30. Demonstrate how to free a person from electrocution

2 1 1

PC31. Administer appropriate first aid to victims were required eg. in case of bleeding, burns, choking, electric shock, poisoning etc.

3 1 2

PC32. Demonstrate basic techniques of bandaging

2 1 1

PC33. Respond promptly and appropriately to an accident situation or medical emergency in real or simulated environments

2 1 1

PC34. Perform and organize loss minimization or rescue activity during an accident in real or simulated environments

2 1 1

PC35. Administer first aid to victims in case of a heart attack or cardiac arrest due to electric shock, before the arrival of emergency services in real or simulated cases

2 1 1

PC36. Demonstrate the artificial respiration and the CPR Process

3 1 2

PC37. Participate in emergency procedures 3 1 2

PC38. Complete a written accident/incident report or dictate a report to another person, and send report to person responsible Incident

3 1 2

PC39. Demonstrate correct method to move injured people and others during an emergency

3 1 2

39 61

Documents

Model Curriculum · flow meter depending on the type - eg - American Gas Association (AGA) report 7 for turbine flowmeter, AGA report 9 for ultrasonic flowmeter etc. • Interpret