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Table of Contents
Attachments:
I Facilities and Equipment for Testing and Calibration II Classification of Instruments for Testing and Calibration III Checklist for the Verification of Instrumentation IV Loop Check Requirements V Instrument Calibration and Loop Check Progress Recording
Reference Specifications:
BN-SP-K8 Specification for the Installation of Instruments BN-SP-K2 Engineering Design Specification for the Accessibility of Instruments and Instrument Connections - Requisition for Installation of Instrumentation.
1. Scope
1.1 This specification outlines the technical requirements and procedures for the inspection, verification, testing, calibration and loop check of instrument installations. For the scope of work reference is made to the requisition for instrument testing and calibration.
To this extent a loop also comprises dedicated systems such as alarm systems, safety and interlocking systems, scanners, process computers, PLC systems, logging systems, ICS, DCS, etc.
2.2 Inspection
Examination of equipment for any physical defect or damage.
2.3 Verification
A visual examination to ensure that each instrument has been correctly installation is satisfactory.
2.4 Testing
To prove that the equipment stands the environment and functions in the manner expected.
2.5 Calibration
Comparison with approved standards of adequate precision and subsequent adjustment to meet the manufacturers specification or the functional requirement.
3. General
3.1 Contractor shall provide sufficient skilled labour and technically capable supervision to complete all aspects of the testing and calibration within the agreed schedule for the contract.
3.2 The testing must be considered inclusive of all the operations necessary to have the instrumentation perfectly operating. 3.3 Although it should be unnecessary for engineers personnel to participate in or witness every aspect of the work described, the engineer shall have the right to do so without the need for justification. Engineer shall be able to see a repeat of any particular test on request.
4.2.2 All test apparatus used for calibration must be checked regularly against standards of at least comparable
Discrepancies shall be noted, recorded and the source of discrepancy established. The discrimination and absolute accuracy of the test apparatus for a given test must be better than the accuracy and discrimination value quoted by the instrument manufacturer for the particular equipment under test.
5.1.2 Any air system, permanent or temporary used for instrumentation purposes should be blown down throughly before use.
5.1.3 Any connection between any air supply system and an instrument under test shall be via an adequate filter and regulator. Pneumatic instrumentation and related equipment requires a clean and dry instrument air supply at all times. Excessive air supply pressure shall be avoided.
5.1.4 Care should be observed when connecting electrical power supplies to electric and electronic instrumentation. Ensure correct voltage and frequency on AC suppliers, and where DC is used check that the voltage regulation and any superimposed ripple is within the instrument manufacturers specification.
Disconnect all circuitry before the execution of HV cable insulation test (meggering), and point-point identification (ringing out).
5.1.5 Filling, test and drain plugs of instruments etc, should be put in place after use and checked for leakage.
5.1.6 Where a part of plant is deemed to be a hazardous or remotely hazardous area (zone 0, zone 1, and zone 2) caution is necessary if testing is performed after introduction of hydrocarbons, or other potentially hazardous material into the plant, observe permit systems.
Where field devices are made safe by means of suitable enclosures (i.e. flameproof, explosionproof) some restriction may be met in simulation if direct operation of float, displacer, pressure element, etc, is not possible,
The appropriate codes, permits and local regulations should be followed in these circumstances, normally involving a periodic gas test in the area where covers are to be removed from enclosures.
Note that in any case power should be switched off prior to removing, and prior to replacing enclosure covers. Contractor to provide portable gas test equipment.
5.2.2 Instruments not calibrated in accordance with the documents shall be readjusted.
5.2.3 Pressure switches shall be checked for the correct switch point and differential.
Control valves
Control valves, pressure regulators, etc, shall not be hydrostatically tested with the line, as such testing can damage the packing and diaphragms.
5.3.2 The contractor shall observe the correct handling of instrument components, avoid abuse and disconnect/reconnect instrument tubing and cabling.
5.3.3 All process piping connections to instruments shall be removed and reinstalled before/after pickling, flushing and pressure testing operations. Instrument primary block valves to in line instrument shall be closed. Instrument process piping shall be subject to the same test pressure as the piping or equipment to which they are connected. During this test any leakage and/or faults shall be eliminated.
The contractor shall verify that all instrument process lines and fittings are clean and free from obstruction before connection to the instrument.
5.3.4 Pneumatic piping shall be tested for leaks in accordance with ISA-RP. Final instrument connections shall
be tested with a corrosion free soap solution. The normal instrument air supply pressure shall be used for testing piping upstream of regulators, normally 4 to 7 bar.
5.4.1 All instruments defined in Attachment II (paragraph 1.0) shall be calibrated in the field work shop for bench calibration. This list is indicative not restrictive.
Instrument calibration shall be performed prior to mechanical completion. 5.4.2 The vendors published instructions for test and calibration shall be followed.
5.4.3 The calibration of indicating, recording and/or transmitting instruments shall be made at five points (10, 0,25, 50, 75 x 100 percent of range).
5.4.4 The instrument shall be suitably supported on the test bench (or in a dummy panel rig as appropriate) in the position it would normally assume when installed. The applicable test equipment shall be connected to the instrument and in the case of pneumatic instruments all external connections tested for leaks before commencing calibration. Only those adjustments provided for the purpose of calibration shall be used to effect correct calibration. Should calibration by means be impossible then the manufacturer should be consulted by the engineer.
An indicative list of which may be field calibrated is presented in Attachment II, Section 2.0.
Detailed testing of these instruments should therefore not be necessary unless the loop check reveals an abnormal behavior or demonstrates misalignment.
However, contractor is requested to supply assistance as required to the manufacturer for the field testing and
calibration.
5.7.2 When testing of special instruments have been included in contractors scope but the contractor does not have the skills required to test or calibrate special instruments the contractor must obtain the assistance of an outside source, such in agreement with the engineer.
5.8 Verification
5.8.1 The instrument installation shall be verified to ensure that each instrument has been correctly installed in accordance with the documents issued for the project.
- Visual examination to determine the good state of field instruments, accesories, supports, mounting stands, process piping, air piping, electrical installation, etc.
- Visual examination of the correct installation of instruments in the control room, panel, and accesories.
Loop checks are an oportunity to demonstrate that the instrumentation system performs satisfactorily. Each loop check therefore should be witnessed by the engineer.
All calibration, wherever carried out, and all aspects of field inspection, verification and testing shall have been satisfactorily completed before loop checks are performed.
- Check against flowsheet to enclosure that all instruments and components are installed in the right place, right direction of flow, etc.
- Apply a calibrated signal to the transmitter primary and check loop operation
5.9.3 All defects in apparatus, wiring, tubing and connection errors, etc. should have been eliminated during the various tests, prior to final loop check.
Loop checks are functional checks, and if an inoperative or badly calibrated or otherwise unsatisfactory loop check result is encountered, all results for that loop should be considered null and void, and the relevant earlier tests repeated, as necessary, after rework, replacement or repair. The loop check shall then be repeated completely for that particular loop.
6. Commissioning
6.1 Commissioning includes all instrument activities associated with the initial start-up of the plant such as but not limited to:
6.2 Control loops shall be commissioned in close cooperation with the plant operators.
Note: Commissioning belongs only to the scope of work of contractor if specifically stated so in the requisition for instrument installation work.
Commission shall only proceed after a written order has been given to the contractor indicating coordination procedures with plant operations department.
7. Administration
7.1 Contractor shall arrange for accurate and continuously record and keep engineer informed of progress by regular formal reports, including an updated copy of the critical path diagram, and by cooperative day to day communication when requested.
7.2 Contractor shall maintain his own filing system and organize the calibration and loop check recording as detailed in Attachment V.
7.3 Engineer to be notified of the planned commencement of each major activity, if different from latest published time schedule.
Engineer shall be given the opportunity to review methods and procedures for the first test of a major type, first inspection of a common type installation, etc.
7.4 Contractor shall pursue anomalies, clarify discrepancies in results, identify faulty instruments/materials, progress replacement or repair of defective items and expedite/initiate rework or modification of unacceptable installations with vendors or other contractors.
Attachment I
Facilities and Equipment for Testing and Calibration
1. Facilities
1.1 The contractor shall provide a mobile or temporary site workshop suitably clean and equipped for instrument calibration.
A vacuum cleaner shall be available for the maintenance of dustfree shop cleanliness, when electronic and pneumatic instrumentation is to be tested.
Where digital ICS or DCS systems or mV/phase equipment is used no ratio transmission is allowed within 3 m of ant panels. This may necessitate the use of external (remote) arials for the control room end of radio systems.
2.2.2 Air filter regulator sets for use as sources of air signals.
2.2.4 Absolute pressure gauge. 2.2.5 Wallace and Tiernan pneumatic calibrator (dual scale), calibrated in mbar and bar. 2.2.6 Wallace and Tiernan precision low pressure gauge 0-250 mbar.
2.2.8 Certified test gauges with an accuracy of 0.1% of range, calibrated for the required units of the following ranges (barg) 0-1/0-2, 5/0-6/0-10/0-25/0-60/0-100.
2.3.5 Cable continuity testers, as required. 2.3.6 Vendors recommended calibration and test gear where this is unique to his equipment.
2.3.7 Stopwarch.
Note: For testing of circuits and cables within an operating plat, test equipment must have appropriate safety certification.
2.4.4 Portable potentiometer and millivolt generator for field use, accuracy 0.05%.
2.4.5 One decade box 0.1-100.000 ohms accuracy 0.05% on any resistance value.
Attachment II
1. Bench Test and Calibration 1.1 Flow Instruments 1.1.1 Orifice Plates
All orifice plates should be checked visually for:
- A sharp nonreflecting edge on the upstream face where relevant, or radius on quadrant edge type orifices
- Correctly stamped identification and bore dimensions on upstream face of tag handle.
It is normally impracticable to validate exactly the dimensions of these elements under site conditions. However, every effort should be made to estimate dimensions internally and equipment should be visually checked to ensure a good finish and freedom from damage.
Check for any damage to the pick-up head and electrical/mechanical connections.
In case of transmitting devices check the output signal as detailed for miscellaneous instruments.
1.3.1 Transmitters
Apply calibrated hydraulic pressure or vacuum to the measuring element(s) at 0, 25, 50 and 100% of full range.
Observe and record output corresponding to each calibrated input both going up and down scale. Adjust as necessary, to obtain correct indicated process variable. After adjustment repeat above procedure until calibration is within the tolerance stated by the manufacturer. Adjustment and alignment procedures shall be carried out in accordance with the manufacturers instruction book.
1.3.2 Switches
Apply a test pressure in a similar manner as under paragraph 1.3.1. The switch point may be sensed by multimeter or ohmmeter. The repeatability and hysteresis (differential) shall be determined and shown to lie within the manufacturer;s published specification. The calibration shall be made with respect to the function (high or low trip setting).
The procedure shall be the same as above for transmitter calibration, except that two calibration points (temperatures) only may be arranged, and they need not be at 0 and 100% of scale. The two temperatures selected should, however, be sufficiently different to ensure satisfactory calibration. For temperature switches, the tests should demonstrate the capacity of the device to sense and switch at any desired point within its specified range. The repetability and differential should be checked to ensure that they are within the manufacturers published specification. Adequate immersion of the sensing element, and steady conditions within the temperature bath, is essential for accurate calibration.
However, an insulation resistance test from thermocouple to metal sheath should be performed. Insulation resistance should exceed 20 M at 20 C measured at 500 volts DC. Lower values may be indicative of moisure ingress through a faulty seal of a batch of thermocouples check one for correct output whilst performing
e. Air shall be applied to the valve and starting pressure and stroke checked and adjusted as necessary. Stroking time shall be checked on applications with speed adjusters and quick release pilots
f. The valve positioner shall be checked and adjusted if necessary for correct stroking of the valve. All pivots on
the feedback mechanism shall be lubricated and checked that it is securely fastened to the valve stem
g. The stroke indicator shall be checked for readings 0, 25, 50, 75 and 100% on correctness and readability
h. Valve testing shall only be done after a specific check to determine that valve or solenoid is not under process pressure.
If vertical orientation is specified by the vendor the valve should be so mounted during the test. If orientation is not specified, it should be varied during the test to anticipate any field mounting problems that may arise.
Application or removal, depending on mode, of electrical power should close the valve or close and divert the pressure, depending on whether a two or three port valve is involved. Check valve porting arrangement with pneumatic hook-ups. Air leakage through the closed-off port should be virtually zero.
Where normal city water pressure does not equal or exceed the working pressure on which the valve will be used, temporary means of raising a higher pressure shall be provided by means of a small rotary pump.
2.2 Level Instruments 2.2.1 Level and Interface Switches (Float, Displacer)
Level switches shall be checked by partial immersion of the displacer or float with water in the float or displacer chamber or stilling tube. Due recognition should be given, when appraising results, to the difference in gravity between water and the application fluid. Interface level switches shall be checked by the total immersion of the displacer or float in water to a depth calculated by equating the upthrust to an equivalent volume. All test liquids
should be fully drained from the system after test. The trip of the switch should be checked for both a rising and a falling level (and/or interface). Normally the trip point should be at the centre of the float chamber or some other well defined points.
Where location or circumstances prohibit the use of water and/or other fluids for the calibration of displacement transmitters/controllers, testing may be performed by removing the displacer from the torque or equivalent suspension and hanging carefully calculated precision weights on the suspension. Weight combinations should check the transmitter/controller at 0,50 and 100% of span.
Where weight calibration is used, displacers shall be tested for leaks by immersing in cold water and heating towards, but not to, boilding point. Any released bubbles, particularly at welding lines, is an adequate cause for rejection to the manufacturer. If such tubes are weighed before immersion, and weighed again after allowing the immersion water to cool before removing the displacer, any increase in weight is a clear indication of leakage. Check knife edges for clean lines.
Calibration should be made during plant start-up unless otherwise prescribed by the engineer.
Detailed checking of the associated electronics, transducer, programmer and read-out systems is not required unless loop checking reveals abnormal operation.
2.3.2 The analytical section shall receive an operational field test. When calibration references/standards are not available the calibration shall be made during plant start-up.
Attachment III
1.1.1 The right instrument is in the right location and correctly identified.
1.1.3 The junction boxes are fabricated and located per specification.
1.1.4 Supporting of equipment, cable trays, piping and tubing is adequate and vibration free.
1.2 Installation
Contractor shall check that:
1.2.1 The instrument is installed in accordance with the process, air- and purge-piping details including any recommendation given by the manufacturer.
1.2.2 Connections of piping and process equipment confirm to specification and instrument design.
1.2.3 Drains, purges, winterizing and isolation valves are properly installed.
1.2.5 The necessary instrument bypass, shutoff, process block valves are provided as specified.
1.2.6 Each instrument item, controller, transmitter, motor valve, pressure switch, etc, meets purchase specifications (check power supply level).
1.2.8 All covers are installed and openings plugged (where required).
1.2.9 Check each thermocouple to verify type of metal used and polarity of couple.
Check length of each thermocouple and thermometer, and corresponding depth of thermowell. Make sure thermocouple bottoms in well.
1.2.10 Verify mechanical completion of the installation including the correct installation of nameplates.
1.3.1 In line instruments are installed in the right location and properly oriented.
- Valves
- Flow meters such as variable area meters, positive displacement meters, turbine meters, orifice plates, sight flow glasses, flow switches, etc.
1.5.1 All cable, wiring, ducting, tray, conduit and fittings should be complete and secured in position.
1.5.2 All cables and wiring, completely disconnected from any equipment, shall have been checked for continuity from end and for insulation resistance from core to core and each core to earth, using a 500 volt insulation resistance tester. Correct routing of each conductor/pair shall be checked. Screens shall be checked
as common conductor.
a. Enables the verification of all control room components including cross wiring, system cabling, ICS, logic inputs/outputs, I/I converters, etc.
b. Often the control room(s) can be made ready before field equipment is installed, thus partial loop check can be performed early
e. A better indication can be obtained as to where any faults found at final loop check lie
g. Loop check packages can be prepared in advance and partially marked up.
2.1.2 Check operation of automatic transfer systems, earth fault detection systems, reset mechanisms,etc, and monitor performance.
Allow for filled legs on level applications. Zero adjustment is allowed at this stage, but for recalibration and frange, transmitter must be returned to a workshop. Transmitter simulators may be used for remote seal
transmitters.
3.2 Check each loop component at 1,50 and 100% of transmitter range.
Where a recorder forms part of the loop it should also be checked at this time.
3.3 Set any trip or alarm in the loop at the desired value. Adjust the transmitter output to initiate the device and check the action of the interlock/alarm circuit.
3.4 Set transmitter output to say 50%. Switch to automatic and check, and if necessary set the correct action of the controller.
3.6 On pneumatic loops perform bubble testing of pneumatic transmission lines from field to control room to check for leaks.
3.7 Switch to manual, check controller output and control valve action. Check open and closed position and any override control forming part of the control loop.
3.8 Correct any wiring or piping defect and adjust any faulty component as required.
3.9 Check that the instrument in the panel is in the correct location, that the nameplate is affixed. Leave all controllers with conservative control mode settings prior to start-up.
3.10 Check burn-out protection, polarity and continuity of thermocouple and resistance bulb installations. Verify correct indication and point selection of multipoint/datalogger systems.
Where interlock inputs have already been proved during measurement and control loop tests these inputs shall be bypassed.
All other inputs shall be proven. The complete interlock system shall then be checked for correct sequence of operation and all output devices shall be proven to work satisfactorily.
Attachment V
1. General
1.1 Accurate records are essential for the satisfactory, timely completion of the calibration and loop check.
In order to keep accurate records of all settings and work carried out, and subsequent re-work and re-test where applicable, an acceptable and mutually agreed form of documentation is necessary.
Although the standard format of contractors may differ, a document shall be selected for use which is convenient and appropriate for each type of inspection or test involved.
1.2 Record documentation of test and calibration is likely to be of only transident value to the ultimate customer or operating company, once a plant is fully commissioned. However, value exists, at or about such a time, for the purposes of ensuring accurate, as-built drawings and instrument schedules.
This document will be used for overall record purposes by keeping a master copy and signing-off instruments and instrument loops as checked.
2.2.2 For field verification a meaningful record of installation, process piping, steam tracing, etc, can be made by the use of relevant hook-up drawings.
Contractor shall submit a form which has to be approved by the engineer. However, the engineer has the right to prescribe the use of particular documents.
2.3.2 Test reports shall be submitted not later than 40 hours after the date of testing.
2.3.3 Revisions to ranges, alarm and shutdown settings, etc, shall be recorded on appropriate documents.
2.4.2 For special loops on such diagrams which are grossly simplified, additional documentation may be necessary in order to provide a checklist for every detail, setting, test, etc. This may take the form of the loop sheet, with or without supplementary sheets, and/or control/shutdown/interlock schematic diagrams.
Labels shall be supplied by contractor but the application will be supervised by the engineer.
Labels should be installed on visible and fixed parts of the instrument so they will not become removed during the installation and connection of instruments.
the instrument is accesible, air or electronic connections are completed and instrument is ready to be energized for loop checking.
At this stage the loop is completed and the instrument bears following information. This sticker can only be applied after agreement with engineers instrument installation supervisor.