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HCD

The document outlines the installation and maintenance requirements for Hydrocarbon Detectors (HCD) as per M B Lal Committee recommendations, focusing on their role in detecting hydrocarbon gas leaks from Class 'A' and 'B' petroleum products. It details the operation of infrared HCDs, types of detectors, and minimum system requirements, including alarm settings and power supply. Additionally, it provides maintenance procedures for both point type and open path type HCDs, emphasizing routine inspections, cleaning, and calibration protocols to ensure optimal performance.

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7 views

HCD

The document outlines the installation and maintenance requirements for Hydrocarbon Detectors (HCD) as per M B Lal Committee recommendations, focusing on their role in detecting hydrocarbon gas leaks from Class 'A' and 'B' petroleum products. It details the operation of infrared HCDs, types of detectors, and minimum system requirements, including alarm settings and power supply. Additionally, it provides maintenance procedures for both point type and open path type HCDs, emphasizing routine inspections, cleaning, and calibration protocols to ensure optimal performance.

Uploaded by

brahmshankarmishra
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Issue No.

05/2017-18

Hydrocarbon Detector (HCD)

As per M B Lal Committee recommendations, Hydrocarbon


(HC) detectors shall be installed near all potential leak
sources of class ‘A’ & Class ‘B’ petroleum products e.g. tank
dykes, tank manifolds, pump house manifolds, etc.
Main Objective of installing a hydrocarbon detector is to
measure hydrocarbon gas before it reaches hazardous
concentration and provide alarm outputs for emergency
action.
Fig.1: Open path type HCD

Theory of operation of Infra-red type HCD:


 Flammable hydrocarbon gases diffuse through the weather
baffle assembly into the internal measurement chamber,
which is illuminated by an infrared (IR) source.
 As the IR passes through the gas within the chamber, certain
IR wavelengths are absorbed by the gas, while other IR
wavelengths are not.
 The amount of IR absorption is determined by the
concentration of the hydrocarbon gas.
 The measurement made is the change in ratio between the
sample and reference signals.
 A pair of optical detectors and associated electronics measure
the absorption. The change in intensity of the absorbed light
(active signal) is measured relative to the intensity of light at
a non-absorbed wavelength (reference signal).
 The microprocessor computes the gas concentration and converts the value into a 4 to 20 mA current output or
digital process variable signal, which is then communicated to external control and annunciation systems.

Minimum Requirements in HCD system as specified in OISD 244:

Hydrocarbon Detector (HCD) system shall have following features:


 Hydrocarbon (HC) detectors shall be installed near all potential leak sources of Class-A Petroleum
products e.g. tank dykes, tank manifolds and pump house manifold.
 These detectors shall be placed in a way that entire possible source of leaks and collection of products
is continuously detected and alarm is set at 20% of lower explosive limit of Class-A.
 The control equipment should be able to generate at least two alarms at different levels of LEL
concentration of Hydro Carbons.
 The supply to the system shall be through a reliable on line uninterrupted power supply. (online UPS)

 Appropriate annunciation system shall be available to ensure that all the alarms generated, both, audio
and visual are reported to the installation personnel at local and remote control panel.
Types of infra-red HCD:
 Point Type HCD
o Point type HCDs are installed in the Class-A (as recommended
in OISD 244) Dyke at the Sump inside the dyke leading to OWS.
o It is a diffusion based infrared (IR) gas detector.
o Point type HCD measures concentration at the point where it is
located and reads the percentage of LFL
o The detector must be in the vapour cloud to detect it.

 Open Path Type HCD


o Open Path type HCDs are installed in Class A pump
House to detect the possible leaks from the pump
seal area/ flange joints etc.
o It is also installed in Class-A Storage Tank farm/
dyke, across the pipe manifolds (as recommended
in OISD 244).
o Open path HCD measures the concentration
between two points and reads the percentage of
LFL meters.
o The detector need not be in the cloud to detect it,
but the cloud must be in the path of the open path beam of light.

Maintenance of Point type HCD:


a. Routine Inspection
i. The Point type HCD detector should be inspected periodically to ensure that external obstructions
such as plastic bags, mud, snow, or other materials do not block the weather baffle, thereby
impairing the performance of the device.
ii. In addition, the weather baffle assembly should be removed and inspected to ensure that the
diffusion paths into the measurement chamber are clear.

b. Weather Baffle Cleaning


i. Remove the weather baffle assembly and clean with a soft brush and soap and water. Rinse and
allow to dry.
ii. Replace the weather baffle if damaged or if fouling of the baffle vents is evident.
iii. Solvents may damage the weather baffle assembly.
iv. If contamination is not removed using soap and water, then replacement of the baffle may be
required.

c. Optics Cleaning
i. Cleaning of the Eclipse optical surfaces is normally required only if an optical fault is indicated.
ii. Thoroughly douse the mirror and window using a liberal amount of soap solution to clear away
contaminant particles.
iii. Repeat the soap solution flush to remove any remaining contaminants. Allow the assembly to air-
dry in a dust-free location.

d. O-Ring
i. Periodically the O-ring should be inspected for breaks, cracks and dryness.
ii. To test the ring, remove it from the enclosure and stretch it slightly. If cracks are visible, it should
be replaced. When re-installing the ring, be sure that it is properly seated in the groove.
e. Protective caps and covers
i. The calibration nozzle cap must always be installed, except while performing calibration.
ii. Also ensure that the HART Communication Port cover and the wiring compartment cover are
installed and fully engaged.

Maintenance of Open Path type HCD


a. Routine Maintenance:
i. Recommended cleaning of optical surfaces to be performed periodically.
ii. The optical surfaces of the Source and Detector viewing windows should be kept as clean as
possible as it is an active device.
iii. Alignment procedures must be performed each time that the Source or the Detector unit has
been opened or moved for any reason.
iv. The Signal Verification Check corroborates the current signals from the Flash Source compared
to that of previous alignments. It is recommended to perform this check every 6-12 months. The
signal should be checked according to threshold levels
v. Zero calibration must be done every time the Detector or Source is realigned or windows
cleaned.

b. To clean the optical window, proceed as follows


i. Turn off the power to the HCD
ii. In places where dust or dirt has accumulated on the optical surface, clean the surface with a
small, soft-bristle brush.
iii. The surfaces must then be washed thoroughly with water and a mild non-abrasive detergent.
iv. Thoroughly rinse the glass surface with clean water; ensuring no residue is left behind.
v. Dry the glass with a clean dry soft cloth.

c. Signal Verification
i. The signal verification check determines the proper operation of the open path. It checks the
alignment and cleanliness of the window or any problem in Source or Detector. Use the PC Host
software to measure the signal verification

d. Function Check of Unit


i. The functional check must be done periodically.
Caution: Automatic activation or any external device that should not be activated during the
calibration check should be disconnected
ii. Test Films provided for 20% & 40% LEL levels shall be placed in front of the receiver.
iii. This shall generate predetermined alarms in the system.

Inspection and Testing:


1. Calibration of the detectors shall be done as per OEM
recommendation or once in six months whichever is earlier.

2. The drift in the sensitivity of the individual detectors shall be


recorded in maintenance history log book during calibration
and the detectors with abnormal or wide drift in sensitivity
shall be rectified / replaced.

3. Standard calibration kit must be available in the location for


periodic performance test of hydrocarbon detectors.

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