Method Statement for Instrument Calibration

PURPOSE Purpose of this procedure is to describe the minimum requirements for the calibration of instruments before installation, after installation and prior to commissioning. DEFINITIONS The initial non-operational checking for field instruments to be performed at calibration workshop before installation, to ensure that each instrument is functionally correct and correctly calibrated. APPLICABLE CODE, STANDARD AND SPECIFICATION

4

GENERAL PROCEDURES 4.1

All testing and calibration of instruments shall be equipped by subcontractor. All apparatus and testing equipments used for testing and calibrating instruments shall be described in “appendix-1”. The workshop shall be equipped with stabilized power supplies and clean, oil and water free, and dry instrument air supply facilities. Testing Facilities shall be fully equipped atmospherically controlled conditions.

4 4.2

All apparatus and testing equipment shall be validated with certificates from national and international authorized calibration agency.

4.3

All instruments shall be inspected for any visual damage and to ensure that they have been supplied in accordance with Data Requisition Sheets, Instrument Datasheets and Manufacturers (Vendors) Datasheets.

4.4

RFI (Request for Inspection) notification shall be submitted to invite Owner’s supervisors.

4.5

Before commencement of tests or calibration of instruments, reference shall be made to the manufacturer's instructions. These instructions shall be adhered to. Should there be any uncertainty in the interpretation of such instructions, then shall be confirmed to the manufacturer.

4.6

Only personnel fully conversant and qualified with the types of instrument to be tested and calibrated shall be used. Qualification certificates shall be available for review at anytime.

4.7

When testing or calibration is complete, all connections and entries shall be checked that they are sealed to prevent ingress of gasses, vapor,

moisture and dirt. For each instrument a completed test or calibration document in accordance with Contractor’s QC forms shall be submitted to Owner. Calibration Supervisor shall maintain a detailed record of satisfactorily completed inspections, tests and calibrations. 4.8

Measuring or indicating instruments having mechanical movements shall belightly tapped during calibration at each checkpoint to overcome inherenthysterics.

4.9

Ranges, set point, date of calibration and the name of the person calibrating the instrument shall be noted on the self-adhesive labels attached to the calibrated instrument.

4.10

All applicable certificates such as NACE, PMI, Electrical apparatus, Factory Seat Leakage test Record, etc shall be available and form part of the

4

test dossiers. WORKSHOP CALIBRATION 5.1

All transmitters associated with the Process Control System and/or any other safety system shall be calibrated / tested from the primary element through to the output terminals. Actual pressure shall be applied to the transmitter process connection and a full five point calibration carried out. Full calibration tests shall be carried out on all pressure differential pressure and DP type level transmitters.

5.2 Temperature transmitters shall have a simulated RTD input injected at the input terminals for a full five point calibration check. RTD primary elements shall be tested at ambient and 100°C. 5.3 Ranges used in the calibration checks shall be in accordance with the latest instrument specification sheet. Vendor calibration sheet shall only be used as reference documents.

WORKSHOP CALIBRATION PROCEDURE 6.1 Electronic Pressure / Differential Pressure Transmitter (FT, LT, PT AND DPT) Test Equipment Required:

-

Dead Weight Tester / Hand pump

-

Digital multi-meter

-

Hart Communicator

Calibration Procedure: -

Visual inspection to confirm compliance of materials, mechanical construction,

4

process

and

electrical

connection

and

applicable

certification validity and no damage during shipment. -

Apply a supply voltage of 24VDC to of transmitter and make series connection with digital multi-meter for output reading.

-

Apply actuating pressure equivalent to 0%, 25%, 50%, 75%, 100%, 75%, 50%, 25% and 0% of the range specify on data sheet and observe the transmitter output at each point.

-

If the transmitter output is not within the manufacturer’s tolerance, calibrate the transmitter in accordance with the manufacturer’s recommendations.

-

Transmitter with indicating scales shall where necessary have their indicators calibrated during this check.

-

Smart electronic type transmitters shall be functionally tested by using a HART COMMUNICATOR to confirm the device smartness and

4

its required data population. 6.2

Differential Pressure Type Level Transmitter Test Equipment Required: -

Dead Weight Tester / Hand pump

-

Digital multi-meter

-

Hart Communicator

Calibration Procedure: -

Visual inspection to confirm compliance of materials, mechanical construction,

4

process

and

electrical

connection

and

applicable

certification validity and no damage during shipment. -

Apply a supply voltage of 24VDC to of transmitter and make series connection with digital multi-meter for output reading.

-

Apply actuating pressure equivalent to 0%, 25%, 50%, 75%, 100%, 75%, 50%, 25% and 0% of the range specify on data sheet and observe the transmitter output at each point.

-

If the transmitter output is not within the manufacturer’s tolerance, calibrate the transmitter in accordance with the manufacturer’s recommendations.

-

Transmitter with indicating scales shall where necessary have their indicators calibrated during this check.

-

Smart electronic type transmitters shall be functionally tested by using a HART COMMUNICATOR to confirm the device smartness and

4

its required data population. 6.3 Temperature Transmitter Test Equipment Required: -

Temperature Calibrator

-

Digital Multi-meter

-

Decade Box

-

Hart Communicator

Calibration Procedure: -

Visual inspection to confirm compliance of materials, mechanical construction,

4

process

and

electrical

connection

and

applicable

certification validity and no damage during shipment. -

Apply a supply voltage of 24VDC according to the type of transmitter and make series connection with digital multi-meter for output reading.

-

Simulate upstream temperature signal equivalent to 0%, 25%, 50%, 75% and 100%

of the range specify on the data sheet and observe the

transmitter output. Record the corresponding readings. -

Simulate downstream temperature signal equivalent to 100%, 75%, 50%, 25% and 0% of the range specify on the data sheet and observe the transmitter output. Record the corresponding readings.

-

If the transmitter output is not within the manufacturer’s tolerance, calibrate the transmitter in accordance with the manufacturer’s recommendations.

4

Smart electronic type transmitters shall be functionally tested by using a HART COMMUNICATOR to confirm the device smartness and its required data population.

6.4 Temperature Element (RTD) Test Equipment Required:

-

Temperature Calibrator

-

Digital Multi-meter

Calibration Procedure: -

Connect the element to Temperature Calibrator.

-

Allow the temperature to stabilize to ambient temperature and record the reading of the temperature calibrator.

-

Increase heater to 100°C and record the reading of the temperature calibrator. Compare result obtain with temperature indicate on digital thermometer.

-

The results should be within the manufacture’s tolerance of ambient temperature.

6.5

Pressure Gauge Test Equipment Required: -

Dead Weight Tester / Hand pump

-

Digital Manometer

-

Test Gauge

Calibration Procedure: -

Obtain the required actuating pressure by dead weight tester, variable air supply or hand operated air pump.

-

Check that the pointer indicates 0 kpa reading under atmospheric condition. Where necessary zero adjustment shall be made. Record the pointer indication value.

-

Increase actuating pressure equivalent to 0%, 25%, 50%, 75% and 100%. Where necessary span adjustment shall be made. Record the pointer indication values.

-

Decrease actuating pressure equivalent to 100%, 75%, 50%, 25% and 0%. Record the pointer indication value.

-

The percentage error calculated from the above readings shall not exceed Manufacturer’s Stated Limit.

6.6 Differential Pressure Gauge Test Equipment Required: -

Hand pump

-

Digital Manometer

-

Test Gauge

Calibration Procedure: -

Obtain the required actuating pressure by hand-operated air pump.

-

Check

that

the

pointer

indicates 0 mmH2O

reading

under

atmospheric condition. Where necessary zero adjustment shall be made. Record the pointer indication value. -

Increase actuating pressure equivalent to 0%, 25%, 50%, 75% and 100%. Where necessary span adjustment shall be made. Record the pointer indication values.

-

Decrease actuating pressure equivalent to 100%, 75%, 50%, 25% and 0%. Record the pointer indication value.

-

The percentage error calculated from the above readings shall not exceed Manufacturer’s Stated Limit.

6.7 Temperature Gauge Test Equipment Required: -

Temperature Calibrator/Oil Bath

-

Thermometer

Calibration Procedure: -

Compare

Thermo

Gauge

digital thermometer

at

pointer

ambient

indication

temperature.

with

the

Where

certified necessary

Thermo Gauge pointer adjustment shall be made for synchronization with the digital thermometer. Record the pointer indication value. -

Immerse

Thermo

Gauge

in

temperature

bath

with

certified

glass thermometer. -

Increase bath temperature equivalent to

100°C.

Record

the

pointer indications. -

The percentage error calculated from the above readings shall not exceed Manufacturer’s Stated Limit.

-

The negative range (minus degree °C) does not require any check.

6.8 Local Indicator (Electronic Type) Test Equipment Required: -

Digital Multi-meter

-

Current Injector (mA)

Calibration Procedure: -

Apply calibration signal 4 ~ 20 mA to the Local indicator and observed the output percentage on the display.

-

Increased and decrease the applied signal to 0%, 25%, 50%, 75% and 100% of mA. Observed the output which displayed on the local indicator is equivalent to 0%, 25%, 50%, 75% and 100%.

-

Confirm “Open” and “Close” limit switches status.

6.9 Orifice Plate Test Equipment Required: -

Digital Caliper

Verification Procedure: -

Visual check on the surface for the presence of scratches or bowing.

-

The correct bore size as measured by internal digital caliper.

-

Correctly stamped identification and bore dimensions on upstream face of tag handle.

6.10 Restriction Orifice Test Equipment Required: -

Digital Caliper

Verification Procedure: -

Visual check on the surface for the presence of scratches or bowing.

-

The correct bore size as measured by internal digital caliper.

-

Correctly stamped identification and bore dimensions on upstream face of tag handle.

6.11 Control Valves 6.11.1

Test Equipment

a. Nitrogen cylinder. b. mA generator c. 24VDC power supplier d. Digital Multi meter. e. P&F amplifier for proximity switch 6.11.2

Calibration Procedure

a. Check and confirm control valve air supply (kg/cm2) required and transducer/valve positioner and accessories data against manufacturer’s data sheet. b. Review manufacturer factory certificates and FAT Report, PMI, etc… c. Check control valve damaged parts by visual d. Adjust the instrument air supply pressure to valve (pressure shall be refered to vendor data.) by air filter and regulator on valve. e. Stroke valve from full open to fully closed position and vice versa. Adjust zero and span adjustment if required to obtain full open/full close at 4/20 mA limits. f. Apply 5 points calibration check on I/P converters with corresponding to output pressure and valve position up scale and down scale. g. Check solenoid function and fail position, if any. • Loss of air supply: if air supply isn’t enough, stroke time shall be long and valve shall not be in operating position. • Loss of control signal: if power supply isn’t enough to attract solenoid coil, valve shall not be operated. h. Check position switch function with P&F contact amplifier, if any. i. Check position transmitter functions, if any. j. Record all results in Control Valve Calibration Report. k. If required, defined by P&ID, stroke time shall also be verified. 6.12 On-Off Valves Function Test 6.12.1

Test Equipment

a.

Nitrogen cylinder.

b.

24VDC power supplier

c.

Digital Multi meter.

d.

P&F amplifier for proximity switch

6.12.2

Calibration Procedure

e.

Check and confirm on-off valve air supply required and valve positioner and accessories data against manufacturer’s data sheet.

f.

Check On-off valve damaged parts by visual.

g.

Adjust the instrument air supply to valve (pressure shall be refered to vendor data.) by air filter and regulator on valve.

h.

Stroke valve from full open to fully closed position and vice versa and record stoke time.

i.

Check solenoid function and fail position. • Loss of air supply: if air supply isn’t enough, stroking time shall be long and valve shall not be in operating position. • Loss of control signal: if power supply isn’t enough to attract solenoid coil, valve shall not be operated.

j.

Check position switch function with P&F contact amplifier.

k.

Record all results in On-offl Valve Calibration Report.

6.13 Pressure Safety Valves (By Air) 6.13.1 a. b. c. 6.13.2

Test Equipment Test Gauge. Air Regulator. Test Bench c/w Manifold. Calibration Procedure

a. Check the manufacturer’s data/instrument nameplate against CLIENT Specifications. b. Connect up pressure relief valve. c. Check the manufacturer’s seal for setting. d. Hook-up Nitrogen or compress air cylinder to test manifold. e. Adjust pressure via regulator. Gradually increase pressure until the pressure relief valves “pop”. Note: Reading on the test gauge. f. Ensure the reset value within the tolerance. Reset value shall be recorded. g. DO NOT attempt to remove “Manufacturer’s Seal” or attempt to adjust setting. h. Compile all results in “SAFETY RELIEF VALVE”. Test Gauge 1

Air Compres sor

Manifold No.1 Drain

Test Gauge 1

PSV Water Containe r

Manifold No.2 Drain

Release Point

Figure 25: TYPICAL TEST SET-UP FOR PRESSURE RELIEF VALVE 6.14 Pressure Safety Valves (By Liquid) 6.14.1 a. b. c. d.

Test Equipment Test Gauge. Regulator. Test Bench c/w Manifold. Pump.

6.14.2

Calibration Procedure

a. Check the manufacturer’s data/instrument nameplate against CLIENT Specifications. b. Connect up pressure relief valve c. Check the manufacturer’s seal for setting. d. Hook-up Pump and Liquid Source to test manifold. e. Adjust pressure via regulator. Gradually increase pressure until the pressure relief valves “pop”. Note: Reading on the test gauge. f. Ensure the reset value within the tolerance. Reset value shall be recorded. g. DO NOT attempt to remove “Manufacturer’s Seal” or attempt to adjust setting. h. Compile all results in “SAFETY RELIEF VALVE”.

5 3 2 1 4

Figure 26 ITEM 1

DESCRIPTION Air Regulator

2 3 4 5

Test Gauge Test Bench with Manifold Valve Relief Valve/Safety Valve under Testing

OTHERS INSTRUMENTS The following instruments will not be tested in the workshop due to safety reason and the unavailability of the required test equipment and facilities. However, they have to be checked by visual check and need to be calibrated on-line during Commisioning phase. •

Smart electronic type transmitters shall be functionally tested by using a HART COMMUNICATOR to confirm the device smartness and data population.

•

Factory Test Certificates shall be reviewed as part of visual check to confirm it’s validity.

•

Site Calibration

and

commissioning procedure

for

these

particular

instruments shall be available and be used as mandatory requirement for site works.

Vortex Flow Meter Calibration and tested in factory. Visual check only. Coriolis Mass Flow Meter Calibration and tested in factory. Visual check only. Rotameters Calibration and tested in factory. Visual check only. Purge Meters

Calibration and tested in factory. Visual check only. PD Meter Calibration and tested in factory. Visual check only. Chromatographs Analyzer Calibration and tested by vendor supervisor at site. Visual check only. Moisture Analyzer Calibration and tested by supervisor at site. Visual check only. Conductivity Analyzer Calibration and tested by supervisor at site. Visual check only. Gas Detectors Calibration and tested in factory. Visual check only. Radiation Level Switch/Transmitter Calibration and tested by supervisor at site. Visual check only. Visual / Audible Alarm Devices Calibration and tested in factory. Visual check only. Level Gauge Tested in factory. Visual check only. Load Cell Calibration and tested by supervisor at site. Visual check only. Guided Wave Level Transmitter

Calibration and test will be done after installation. Visual check only. Radar Type Level Transmitter Calibration and tested by supervisor at site. Visual check only. Vibration Level Switch Tested by Vendor. Visual check only. Venturi Tube, Annubar Tested by Vendor. Visual check only. Integral Orifice Transmitter Calibration and tested in factory. Visual check only.

Appendix-1.

Instrument Apparatus for Calibration and Test

No

Description

Model

Accuracy

Range

Make

1

Air Pressure Calibrator

DPI 610

0.025%FS

-1 to 20bar

Druck

2

Oil Pressure Calibrator

DPI 610

0.025%FS

Druck

3

Oil Pressure Calibrator

DPI 615

0.025%FS

0 – 135 bar With Ext. Sensor 700bar 0 to 400bar

4

Air Pressure Calibrator

DPI 603

0.075% FS

-1 to 20bar

Druck

5

Air Pressure Calibrator

DPI 610

0.075% FS

-1 to 2bar

Druck

6

Hand held Pressure Calibrator

IS3336/3000PSI

0.05%FS

0 - 3000PSI

7

Multifunction Calibrator

MC5/MC5IS

0.025%FS

-1 to 700bar

Beameax

8

Documenting Calibrator

Fluke 726

0.01%Rdg

mA, mV, RTD, TC

Fluke

Druck

CRYSTAL Eng

9

Documenting Calibrator

Fluke 741B

0.01%Rdg

mA, mV, RTD, TC

Fluke

10

Documenting Calibrator

Fluke 743B

0.01%Rdg

mA, mV, RTD, TC

Fluke

11

Multifunction Calibrator

Fluke 725

0.01%Rdg

mA, mV, RTD, TC

Fluke

12

Loop Milliamp Calibrator

UPS.IS

0.01%Rdg

mA

Druck

13

Multi-meter

Fluke 87II

0.03%Rdg

mA, A, mA, V, Ohm, Hz

Fluke

14

Hart Communicator

275

N/A

communication

Hart

15

Hart Communicator

375

N/A

communication

Hart

16

Unomat Calibrator

TRX -IS

0.01%Rdg

mA, mV, RTD, TC

Druck

17

Dry -Well Calibrator

DBC150TC

0.1oC

-45 to 150oC

Druck

18

Dry -Well Calibrator

9011

0.10oC 0.15oC

-45 to 150oC 50 to 670oC

Hart

19

Dry -Well Calibrator

9170

0.15oC

-45 to 140oC

Hart

20

Dry -Well Calibrator

9173

0.35oC

50 to 650oC

Hart

Appendix-2.

Quality Control Form (QCF) List

QCF-I002

Instrument Unpacking Inspection

QCF-I003B

Instrument Transmitter Calibration

QCF-I004B

Pressure Gauge Calibration

QCF-I004C

Diffrential Pressure Gauge Calibration

QCF-I005B

Temperature Gauge Calibration

QCF-I005C

Temperature Element (RTD) Inspection

QCF-I006B

Orifice Plate and Restriction Orifice Control

QCF-I014

Pneumatic Control Valve Calibration

QCF-I015

On-Off Valve Function Test

QCF-I016

Pressure safety/relief valve Calibration