Document No.

PLTGU-GRATI-C-MS-24
:PLTGU
Revision/Date : 0 / 18 August 2018
Review Date :

METHOD STATEMENT OF
INSTRUMENTATION CALIBRATION

CLIENT:
PT. INDONESIA POWER
NAME OF PROJECT:
ADD ON GRATI BLOCK-2
2 PROJECT WITH MINIMUM
OF 150MW, PASURUAN EAST JAVA

CONTRACT NO. : 017/SPB/SCM/PP/PLANT 5

–EPC/781611/XI/2017
EPC/781611/XI/2017

PROJECT CODE :
JOB NO. :
DOC. NO. : PLTGU-GRATI
GRATI-C-MS-24
DOC. STATUS : IFR / IFA / ISU

CONTRACTOR : PT. KOIN KONSTRUKSI

Prepared by Checked by Approved by

Rev. Date
ENGINEER H.S.E. QA / QC CM/ SM PT. PP CLIENT

Yayat
0 18/08/2018 Imam S. Ghufron Seo, Won Sok
Hendayana
Distributed to: PM, CM, Consultant, Client

Doc.No.: PLTGU-GRATI-C-MS-24 i
Method Statement of Instrumentation Calibration
alibration
 Document No. : PLTGU-GRATI-C-MS-24
Revision/Date : 0 / 18 August 2018
Review Date :

METHOD STATEMENT OF
INSTRUMENTATIONCALIBRATION
INSTRUMENTATIONCALIBRATION

CLIENT:
PT. INDONESIA POWER
NAME OF PROJECT:
ADD ON GRATI BLOCK-2
BLOCK PROJECT WITH
MINIMUM OF 150MW, PASURUAN EAST JAVA

CONTRACT NO. :

PROJECT CODE :
JOB NO. :
DOC. NO. : PLTGU-GRATI-C-MS-24
PLTGU
DOC. STATUS : IFR / IFA / ISU

CONTRACTOR : PT. PP (PERSERO)

Prepared by Checked by Approved by

Approved by
Rev. Date ENGINEER H.S.E. QA / QC CM/ SM
PT.Koin PT.PP PT.Koin PT.PP PT.Koin PT.PP PT. Koin PT. PP CLIENT

Yayat Arif Bagus

0 18/08/2018 Imam S. Ghufron Subur Seo, Won Sok
Hendayana Maulana Wibawa
Distributed to: PM, CM, Consultant, Client

Doc.No.: PLTGU-GRATI-C-MS-24 ii
Method Statement of Instrumentation Calibration
alibration
 CONTENTS

1. TITLE .......................................................................................................................................... 1
2. SCOPE AND PURPOSE ............................................................................................................ 1
3. REFERENCES ............................................................................................................................ 2
4. DESCRIPTION OF PROCEDURE ........................................................................................... 2
4.1 Preparation Preliminary to Calibration....................................................... 2
4.2 Calibration................................................................................................. 3
4.2.1 Temperature Indicator.................................................................... 3
4.2.2 Temparature Switch........................................................................ 4
4.2.3 Differential Pressure Transmitter.....................................................5
4.2.4 Pressure Indicator........................................................................... 7
4.2.5 Pressure / Flow Transmitter............................................................ 8
4.2.6 Temperature Transmitter................................................................ 9
4.2.7 Typical Checkout - Input Signal ( Analog to Digital )....................... 10
4.2.8 Typical Checkout - Input Signal ( Digital to Analog )....................... 11
4.3 Typical Test Set-up....................................................................................................13
5. MAN POWER .................................................................................................................... ......16
6. EQUIPMENT, TOOLS & CONSUMABLES .......................................................................... 16
7. RISK AND SAFETY ANALYSIS ............................................................................................. 17
8. ATTACHMENT ........................................................................................................................ 17

Doc.No.: PLTGU-GRATI-C-MS-24 iii

Method Statement of Instrumentation Calibration
 1.0 TITLE
JUDUL

Instrument Calibration Procedure for ADD ON GRATI BLOCK-2 PROJECT WITH

MINIMUM OF 150MW, PASURUAN EAST JAVA.

2.0 SCOPE AND PURPOSE

RUANG LINGKUP DAN TUJUAN

- This procedure is to describe of guidelines and requirements for calibration of

instrument devices (RTD, Thermocouple, temperature transmitter, temperature
switch, temperature indicator, pressure transmitter, pressure switch, pressure
(vacuum) indicator, differential pressure transmitter, differential pressure switch,
etc.)

Prosedur ini untuk menggambarkan pedoman dan persyaratan untuk kalibrasi

perangkat instrument (RTD, Thermocouple, temperature transmitter,
temperature switch, temperature indicator, pressure transmitter, pressure
switch, pressure (vacuum) indicator, differential pressure transmitter, differential
pressure switch, dll.)

- All instrument calibrations which are connected to a measurement and control

loop plus process alarm and shutdown switches will be subject to the following
inspections:

Semua kalibrasi instrumen yang terhubung ke pengukuran dan kontrol loop plus
alarm proses dan sakelar pemutus menjadi subjek pada pemeriksaan berikut:

a) Transmitter will be inspected for zero, span and linearity throughout its range.
Transmitter akan diperiksa untuk Zero, Span dan linearitas di seluruh range
nya.
b) Local controllers will be inspected for zero, span and linearity throughout its
range.
Pengontrol lokal akan diperiksa untuk Zero, Span dan linearitas di seluruh
range nya.
c) Local controllers will be inspected for proper operation of gain or
proportional.
Pengontrol lokal akan diperiksa untuk hasil operasi yang tepat atau
proporsional.

Doc.No.: PLTGU-GRATI-C-MS-24 1
Method Statement of Instrumentation Calibration
 d) All process switches (e.g. pressure, temperature, etc.) will be verified for
correct activation point.
Semua switch proses (misalnya tekanan, suhu, dll.) akan diverifikasi untuk
titik aktivasi yang benar.

- The goal of the procedure is to provide a uniform protocol for preserving

instrumentation in a manner that will result in accurate, precise, and reliable
readings from the instruments.

Tujuan dari prosedur ini adalah untuk menyediakan protokol yang seragam untuk
melestarikan instrumentasi dengan menghasilkan pembacaan yang akurat, tepat,
dan pembacaan yang dapat diandalkan dari instrumen.

3.0 REFERENCES
REFERENSI

3.1 CMI Instrument Data and Specification.

3.2 DHI Instrument Data and Specification.
3.3 Vendor’s/Manufacturer’s instructions and specification.

4.0 DESCRIPTION OF PROCEDURE

DESKRIPSI PROSEDUR

4.1 Preparation Preliminary to Calibration

Persiapan Awal untuk Kalibrasi

1. Prepare instrument document, such as Instrument Index, P & ID

diagrams and Instrument Calibration Data Sheet.
Siapkan dokumen instrumen, seperti Indeks Instrumen, diagram P & ID
dan Lembar Data Kalibrasi Instrumen.

2. Prepare standard test device (calibrator) including air compressor and

DC Power supply.
Siapkan perangkat uji standar (kalibrator) termasuk kompresor udara
dan suplai daya DC.

Doc.No.: PLTGU-GRATI-C-MS-24 2
Method Statement of Instrumentation Calibration
 3. Compare equipments nameplate data with packing list, drawings, and
data sheet specifications.
Bandingkan data pelat nama perangkat dengan daftar kemasan,
gambar, dan spesifikasi lembar data.

4. Inspect physical and mechanical condition of instrument equipments

and parts.
Periksa kondisi fisik dan mekanis peralatan instrumen dan bagian
bagiannya.

5. Clean the calibration room from dust and waste material, use the
vacuum cleaner to eliminate the dusts and other small stuffs.
Bersihkan ruang kalibrasi dari debu dan bahan limbah, gunakan
penyedot debu untuk menghilangkan debu dan barang-barang kecil
lainnya.

4.2 Calibration
Kalibrasi

4.2.1 TEMPERATURE INDICATOR

Calibration Equipment :
Peralatan Kalibrasi :

- Sight glass and water tank

- Digital multimeter ( Ohm meter )

Pre-requisite :
Prasyarat :

1. Connect Temperature Indicator to a calibrated temperature source and

stabilize unit.
Hubungkan Temperatur Indikator ke sumber temperatur terkalibrasi
dan mengstabilkan unit.

2. Remove adjustment cover.

Lepas penutup penyesuaian.

Doc.No.: PLTGU-GRATI-C-MS-24 3
Method Statement of Instrumentation Calibration
 Procedure :
Prosedur :

1. Refer to Vendor's Manual Instruction.

Mengacu pada instruksi manual vendor.

2. Verify the suitable result between temperature indicator with

temperature calibrator.
Verifikasi hasil yang sesuai antara indikator suhu dengan kalibrator
suhu.

3. Review the result and accept or reject the Temperature Indicator.

Tinjau hasil dan terima atau tolak alat temperatur.

4.2.2 TEMPERATURE SWITCH

Calibration Equipment :
Peralatan Kalibrasi :

- Dry Block Temperature Calibrator.

- Multimeter (Ohm-meter) for continuity.

Pre-requisite :
Prasyarat :

1. Connect Temperature Control to a calibrated temperature source and

stabilize unit.
Hubungkan Temperatur Indikator ke sumber temperatur terkalibrasi
dan mengstabilkan unit.

2. Remove adjustment cover.

Lepas penutup penyesuaian.

Procedure :
Prosedur :

1. Refer to Vendor's Manual Instruction.

Mengacu pada instruksi manual vendor.

Doc.No.: PLTGU-GRATI-C-MS-24 4
Method Statement of Instrumentation Calibration
 2. Make sure the switch is drained and electricity disconnected.
Pastikan saklar dikeringkan dan listrik terputus.

3. Turn the knob for achieve temperature setting and pointer against a
reference scale.
Putar kenop untuk mencapai pengaturan suhu dan penunjuk mengarah
ke skala referensi.

4. Adjust set point after replacing switch or temperature assembly.

sesuaikan titik setel setelah mengganti sakelar atau rakitan suhu.

5. Turn adjustment knob slowly until switch transfers.

Putar tombol penyesuaian secara perlahan sampai beralih transfer.

6. Compare switch transfer point to actual temperature.

Bandingkan titik peralihan transfer ke suhu aktual.

7. If don not agree, loosen Allen set screws on adjustment knob and align
pointer to indicate actual temperature.
Jika tidak setuju, longgarkan perangkat sekrup Allen pada tombol
penyesuaian dan arahkan penunjuk untuk menunjukkan suhu
sebenarnya.

8. Retighten Allen set screws.

Kencangkan kembali perangkat sekrup Allen.

4.2.3 DIFFERENTIAL PRESSURE TRANSMITTER

Calibration Equipment :
Peralatan kalibrasi :

1. Dead Weight Tester (DWT) or Hand Pump with Precision Pressure

Gauge.

2. Multimeter (AVO-meter) for continuity.

3. Hart Communicator.

4. Pneumatic Calibrator or Digital Manometer Modcal II.

Doc.No.: PLTGU-GRATI-C-MS-24 5
Method Statement of Instrumentation Calibration
 Pre-requisite :
Prasyarat :

- Set the transmitter ready in place, wire and pipe.

Atur transmitter siap pada tempatnya, kawat dan pipa.

Procedure :
Prosedur :

1. Refer to Vendor's Manual Instruction.

Mengacu instruksi manual vendor.

2. Make sure the transmitter is drained and electricity disconnected.

Pastikan perangkat Transmitter dikeringkan dan listrik terputus.

3. With the low side vented, apply the manometer Modcal II to high
pressure side.
Dengan sisi rendah yang dilepaskan, aplikasikan alat Manometer
Modcal II ke sisi tekanan tinggi.

4. Adjust and set zero / span using manometer Modcall II and multimeter.
Repeat until zero and span are proper.
Sesuaikan dan atur Zero / Span menggunakan manometer Modcall II
and multimeter. ulangi hingga Zero dan Span yang tepat.

5. Verify the DWT or Manometer Modcal II output for 0 %, 25 %, 50 %, 75

%, 100 % and record output value.
Verifikasi alat DWT atau Manometer Modcal II output untuk 0%, 25%,
50%, 75%, 100% dan 75%, 50%, 25%, 0% dan catat hasil nilai.

6. Review the result.

Meninjau Hasil.

7. Remove the test connection and leave the transmitter ready for
operation.
Lepaskan alat koneksi uji dan biarkan Transmitter untuk operasi.

Doc.No.: PLTGU-GRATI-C-MS-24 6
Method Statement of Instrumentation Calibration
 4.2.4 PRESSURE INDICATOR

Calibration Equipment :
Peralatan Kalibrasi :

1. Dead Weight Tester (DWT) or Hand Pump with Precision Pressure

Gauge.

5. Pneumatic Calibrator or Digital Manometer Modcal II.

Pre-requisite :
Prasyarat :

- Set the Gauge in place.

Atur Perangkat pengukur pada tempatnya.

Procedure :
Prosedur :

1. Refer to Vendor's Manual Instruction.

Mengacu instruksi manual vendor.

2. Make sure the gauge is drained.

Pastikan perangkat pengukur dikeringkan.

3. Apply the DWT or Manometer Modcal II to input of pressure side.

Terapkan alat DWT atau Manometer Modcal II untuk memasukan sisi
tekanan.

4. Adjust and set zero / span available repeat until Zero and Span are
proper.
Sesuaikan dan atur Zero / Span tersedia, ulangai hingga Zero dan Span
benar.

5. Verify the DWT or Manometer Modcal II output for 0 %, 25 %, 50 %, 75

%, 100 % and 75 %, 50 %, 25 %, 0 % and record the reading result.
Verifikasi alat DWT atau Manometer Modcal II output untuk 0%, 25%,
50%, 75%, 100% dan 75%, 50%, 25%, 0% dan catat hasil pembacaan.

Doc.No.: PLTGU-GRATI-C-MS-24 7
Method Statement of Instrumentation Calibration
 6. Review the result and accept or reject the gauge.
Tinjau hasil dan terima atau tolak alat pengukur.

7. Remove the test connection and leave the gauge for operation.
Lepaskan koneksi alat uji dan biarkan perangkat gauge untuk operasi.

4.2.5 PRESSURE / FLOW TRANSMITTER

Calibration Equipment :
Peralatan Kalibrasi :

1. Dead Weight Tester (DWT) or Hand Pump with Precision Pressure

Gauge.

2. Digital multytester.

3. Hart Communicator.

4. Pneumatic Calibrator or Digital Manometer Modcal II.

Pre-requisite :
Prasyarat :

- Set the Transmitter in place.

Atur perangkat Transmitter pada tempatnya.

Procedure :
Prosedur :

1. Refer to Vendor's Manual Instruction.

Mengacu instruksi manual vendor.

2. Make sure the transmitter is drained and power or air supply is proper.
Pastikan perangkat Transmitter dikeringkan dan daya atau suplai udara
sudah sesuai.

3. With the low side vented, apply the DWT to high pressure side.

Doc.No.: PLTGU-GRATI-C-MS-24 8
Method Statement of Instrumentation Calibration
 Dengan sisi rendah yang dilepaskan, aplikasikan alat DWT ke sisi
tekanan tinggi.

4. Adjust and set zero / span using Manometer Modcal II,Hart

Commnicator and Digital Multimeter,repeat until zero and span are
proper.
Sesuaikan dan atur Zero / Span menggunakan Manometer Modcal II,
Hart Communicator dan Digital Multimeter, ulangi hingga Zero dan
Span yang tepat.

5. Verify the DWT or Manometer Modcal II output for 0 %, 25 %, 50 %, 75

%, 100 % and 75 %, 50 %, 25 %, 0 % and record the reading result.
Verifikasi alat DWT atau Manometer Modcal II output untuk 0%, 25%,
50%, 75%, 100% dan 75%, 50%, 25%, 0% dan catat hasil pembacaan.

6. Review the result and accept or reject the transmitter.

Tinjau hasil dan terima atau tolak perangkat transmitter.

7. Remove the test connection and leave the transmitter for operation.
Lepaskan koneksi alat uji dan biarkan Transmitter untuk operasi.

4.2.6 TEMPERATURE TRANSMITTER

Calibration Equipment :
Peralatan Kalibrasi :

1. Temperature Calibrator RTD / Thermocouple.

2. Hart Communicator.

3. Digital multitester.

Pre-requisite :
Prasyarat :

- Set the Transmitter in place.

Atur perangkat Transmitter pada tempatnya.

Doc.No.: PLTGU-GRATI-C-MS-24 9
Method Statement of Instrumentation Calibration
 Procedure :

1. Refer to Vendor's Manual Instruction.

Mengacu instruksi manual vendor.

2. Adjust and set zero / span using Temperature Calibrator,Hart

Commnicator repeat until zero and span are proper.
3. Sesuaikan dan atur Zero / Span menggunakan Temperature Calibrator,
Hart Communicator, ulangi hingga Zero dan Span benar.

4. Verify the Temperature Calibrator output for 0 %, 25 %, 50 %, 75 %, 100

% and 75 %, 50 %, 25 %, 0 % and record the reading result.
Verifikasi alatTemperatur Calibrator Output untuk 0%, 25%, 50%, 75%,
100% dan 75%, 50%, 25%, 0% dan catat hasil pembacaan.

5. Review the result and accept or reject the transmitter.

Tinjau hasil dan terima atau tolak perangkat transmitter.

6. Remove the test connection and leave the transmitter for operation.
Lepaskan koneksi alat uji dan biarkan Transmitter untuk operasi.

4.2.7 Typical Check Out - Input Signal (Analog to Digital)

Tipikal pengecekan keluar-masuk sinyal (Analog ke Digital)

1. Develop / review "Control Loop Function Test Record".

Kembangkan / tinjau "Catatan Uji Fungsi Kontrol Loop".

2. Provide applicable test record such as :

sediakan catatan pengujian yang berlaku seperti:

• Instrument calibration sheet.

Lembar kalibrasi instrumen.
• Wiring layout from client.
Tata letak pengkabelan dari klien.
• Piping test result sheet.
Lembar hasil tes pemipaan.
• Installation complete test sheets.
Lembar uji kelengkapan pemasangan.

Doc.No.: PLTGU-GRATI-C-MS-24 10
Method Statement of Instrumentation Calibration
 3. Visually inspect the configuration to ensure wiring and controlled
components are ready to be energized and installation is complete.
Periksa secara visual konfigurasi untuk memastikan komponen kabel dan
terkontrol siap untuk diberi energi dan pemasangan telah selesai.

4. Actuate the device and / or simulate the process variable.

Aktivasi perangkat dan / atau simulasikan variabel proses.

5. Confirm the variable input is received at both I / V block and program

address.
Konfirmasikan input variabel diterima di blok I / V dan alamat program.

6. Restore equipment and circuit to original configuration.

Kembalikan peralatan dan sirkuit ke konfigurasi asli.

7. Highlight associated "input block" on both system ( logic diagram and I /

O block wiring diagrams).
Menggaris bawahi terkait "Input Block" pada kedua sistem (diagram
logika dan I / O blok diagram pengkabelan).

8. Sign and date "Control Loop Diagram Functional Test Record".

Tanda tangan dan tanggal "Catatan uji funsional Diagram Loop Kontrol ".

9. Complete "As Built Drawings".

Lengkapi gambar yang dibuat.

10. Complete test pack documentation.

Dokumentasi uji paket kelengkapan.

11. Apply "TESTED" or "CALIBRATED" stickers to all devices tested.

Terapkan stiker "TERUJI" atau "KALIBRASI" ke semua perangkat yang diuji.

4.2.8 Typical Check Out - Input Signal (Digital to Analog)

Tipikal pengecekan keluar-masuk sinyal Digital ke Analog)

1. Develop / review "Control Loop Function Test Record".

Kembangkan / ulas "Catatan Uji Fungsi Kontrol Loop".

Doc.No.: PLTGU-GRATI-C-MS-24 11
Method Statement of Instrumentation Calibration
 2. Provide applicable test record such as :
Sediakan catatan pengujian yang berlaku seperti :

• Breaker test record.

Catatan pengujian breaker.
• Cable and motor meggering sheet.
Lembar meggering kabel dan motor.
• Wiring layout from client.
Tata letak pengkabelan dari klien.
• Local panel inspection sheet.
Lembar pemeriksaan panel lokal.

3. Visually inspect the configuration to ensure wiring and controlled

components are ready to be energized and installation is complete.
Periksa secara visual konfigurasi untuk memastikan komponen kabel dan
terkontrol siap untuk diberi energi dan pemasangan telah selesai.

4. Obtain applicable safety tags for breakers and equipment.

Dapatkan tag keamanan yang berlaku untuk pemutus dan peralatan.

5. Force the output at program address.

Memaksa output pada alamat program.

6. Confirm the output variable is received at both system (I/O block relay
and external device).
Konfirmasikan variabel output diterima di kedua sistem (I / O block relay
dan perangkat eksternal).

7. Restore equipment and circuit to original configuration.

Kembalikan peralatan dan sirkuit ke konfigurasi asli.

8. Highlight associated "output block" on both system (logic diagram and

I/O block wiring diagram).
Menggaris bawahi terkait "Output Block" pada kedua sistem (diagram
logika dan I / O blok diagram pengkabelan).

9. Sign and date "Control Loop Diagram Functional Test Record".

Tanda tangan dan tanggal "Catatan uji funsional Diagram Loop Kontrol ".

Doc.No.: PLTGU-GRATI-C-MS-24 12
Method Statement of Instrumentation Calibration
 10. Complete "As Built Drawings".
Lengkapi gambar yang dibuat.

11. Complete test pack documentation.

Dokumentasi uji paket kelengkapan.

12. Apply "TESTED" or "CALIBRATED" stickers to all devices tested.

Terapkan stiker "TERUJI" atau "KALIBRASI" ke semua perangkat yang
diuji.

4.3 Typical Test Set-up :

Setelan Tipikal Tes :

1. Displacement Type Level Transmitter

2. Magnetic Float Type Level Transmitter

Doc.No.: PLTGU-GRATI-C-MS-24 13
Method Statement of Instrumentation Calibration
 3. Level Switch Float Type

4. Temperature Switch

5. Differential Pressure Transmitter

Doc.No.: PLTGU-GRATI-C-MS-24 14
Method Statement of Instrumentation Calibration
 6. Pressure Indicator

7. Pressure Transmitter

8. Flow Transmitter

Doc.No.: PLTGU-GRATI-C-MS-24 15
Method Statement of Instrumentation Calibration
 9. Temperature Transmitter RTD or TC-Type

5.0 MANPOWER
TENAGA KERJA

5.1 Engineer = 1 Person

5.2 Supervisor = 1 Person
5.3 Foreman = 1 Person
5.4 Technicians = 2 Person
5.5 Helper = 2 Person
5.6 Q/C = 1 Person
5/7 Safety = 1 Person

6.0 EQUIPMENTS, TOOLS AND CONSUMABLES

PERLENGKAPAN, ALAT, DAN KONSUMSI

6.1 Air Compressor = 1 Unit

6.2 DC Power Supply = 1 Unit
6.3 AMETEK Digital Manometer MODCAL II = 1 Unit
6.4 FLUKE Documenting Process Calibrator = 1 Unit
6.5 FLUKE Thermocouple Calibrator = 1 Unit
6.6 FLUKE RTD Calibrator = 1 Unit
6.7 FLUKE Press. Calibrator 300 Psig = 1 Unit

Doc.No.: PLTGU-GRATI-C-MS-24 16
Method Statement of Instrumentation Calibration
 6.8 ALTEK Loop Calibrator = 1 Unit
6.9 Hart Scientific Dry Block Calibrator = 1 Unit

7.0 RISK AND SAFETY ANALYSIS

RESIKO DAN ANALISA KESELAMATAN

7.1 All tests be performed with apparatus de-energized except where otherwise
specially required.
Semua pengujian dilakukan dengan peralatan yang tidak diberi energi kecuali
sebaliknya jika diperlukan.

7.2 The testing organization shall have a designated safety representative on the
project to supervise operations with respect to safety.
Organisasi pengujian harus memiliki perwakilan keselamatan yang ditunjuk
pada proyek untuk mengawasi operasi sehubungan dengan keselamatan.

8.0 ATTACHMENT
LAMPIRAN

- Schedule
- JSA
- IBPR
- Vendor’s / Manufacture’s Instruction and Specification

Doc.No.: PLTGU-GRATI-C-MS-24 17
Method Statement of Instrumentation Calibration