PRECOMMISSIONING CHECKS IN PYRO Instrumentation section
1. All instrumentation needs to be verified to the central control room. A
checklist of all instruments can be generated from the electrical devices flow diagrams and the equipment one line diagrams. Each instrument should be checked from the field device to CCR. At some plants the electrical engineer responsible for instrumentation has already generated this list during his point check. During the commissioning check we verify that each instrument is: In the correct location both in the field and on the display. That the transmitter is functioning. That the engineering units are correct. That the instrument is calibrated to the correct range and that the DCS is ranged correctly.
Pressure transmitters. For process pressure transmitters in the preheater and
cooler it is best to induce either a positive or negative pressure with the process equipment (fans). The commissioning personnel can go directly to each pressure tap, disconnect that point. Check that the proper point zeros in the control room, take a manual reading, and then compare to the signal in the control room after reconnecting. This verifies piping, wiring, DCS addressing, and calibration all at one time. If it is not possible to run the equipment, or to obtain a calibrator, the engineer can simply disconnect the tap and induce a positive or negative pressure by simply blowing or sucking into the instrument tubing. This verifies piping, wiring, and DCS addressing. The person working the check out from the control room can verify range. Calibration can then be checked during the initial stages of start-up. For pneumatic and hydraulic pressure transmitters an analog gauge should be installed inline with the transmitter and the pressure crosschecked to the control room. Temperature transmitters. For process temperature readings, the most often used method of checking, is to go to the thermocouple or RTD at the point that it enters the process, open the back of the probe and disconnect one lead. The person checking from the control room should see the temperature reading go from ambient to out of range. Reconnect the probe and verify that the temperature goes back to ambient. For fluid temperatures again a field reading is best used. Gas analyzers. It is best to work with the instrumentation specialist calibrating the analyzers using test gasses. During this time the signal going back to the control room can be checked. Ensure that the kiln inlet probe is located properly