Instrument Field documents and Commissioning Activities

Table of Contents

1. 2. 3.

Symbols and abbreviations .................................................................................................... 3 General.................................................................................................................................. 3 Instrumentation receiving and storage ................................................................................... 4 3.1. General ....................................................................................................................... 4 3.2. Electronic instruments................................................................................................. 4 3.3. Pneumatic instruments ............................................................................................... 4 3.4. Local control panels .................................................................................................... 5 3.5. Dial thermometers, pressure gauges, and gauge glasses ........................................... 5 Documentation....................................................................................................................... 5 4.1. General ....................................................................................................................... 5 4.2. Records ...................................................................................................................... 6 Installation inspection............................................................................................................. 6 5.1. Prerequisites ............................................................................................................... 6 5.2. General ....................................................................................................................... 6 5.3. Instrument inspection checks ...................................................................................... 7 5.4. Piping, conduit, cable, and tubing ............................................................................... 8 5.5. Control valves inspection checks ................................................................................ 9 5.6. Temperature instruments inspection checks ............................................................... 9 5.7. Flow instruments....................................................................................................... 10 5.8. Level instruments ...................................................................................................... 11 Loop check and system checkout ........................................................................................ 11 6.1. Prerequisites ............................................................................................................. 11 6.2. General ..................................................................................................................... 12 6.3. 6.4. 6.5. Instrument calibration and checkout........................................................................ 122 Systems checkout................................................................................................... 200 Alarm system components ...................................................................................... 211

4.

5.

6.

7.

6.6. Logic system components....................................................................................... 211 Commissioning completion 22

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1.

Symbols and abbreviations

a.c. DCS d/p I/E I/P IS LRV P&ID PAS PLC RTD SIS URV Alternating current. Distributed control system. Differential pressure. Instrument/Electrical. Current-to-pressure. Intrinsic safety. Lower range value. Piping and instrument diagram. Process automation system. Programmable logic controller. Resistance temperature detector. Safety instrumented system. Upper range value.

2.

General
a. For all checkout and commissioning activities, safety shall be the primary concern and responsibility of all involved personnel. It is required that all commissioning personnel be qualified to perform their assigned activities. Personnel involved in calibration and commissioning of instrument systems shall have experience and verifiable training to included but not limited to the following: 1. 2. 3. c. d. Calibration of instruments being installed. Use of compression fittings. Installation/inspection of electrical equipment in hazardous areas.

b.

Commissioning personnel shall review, be familiar with, and adhere to all relevant portions of Health, Safety and Environmental (HSE) documents and procedures. Prior to commencing any work, a Job Safety Analysis (JSA) or other equivalent, site specific, procedure shall be conducted to confirm that persons involved are trained and competent, ensure that appropriate Personal Protection Equipment (PPE) is worn, review emergency response plans, and emphasize that each person is empowered to stop the work if it is perceived to be unsafe. If hazardous materials (chemicals, fluids, etc.) are part of the commissioning procedure, Material Safety Data Sheets (MSDS) shall be reviewed by all involved personnel prior to proceeding with any related commissioning activity. The safe and efficient commissioning of any facility requires associated instrumentation to be installed completely, checked for integrity and commissioned for use. The steps involved in achieving this process should be clearly understood and followed.
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e.

f.

g. h.

Refer to Annex A for examples of checkout and pre-commissioning of instrument and control systems. Prior to initiating any checkout and/or commissioning activities, mechanical completion checklists and other appropriate documents shall be reviewed and confirmed as complete and all components are acceptable for subsequent commissioning efforts. Defective instruments shall be replaced or repaired.

i.

3.
3.1.

Instrumentation receiving and storage

General a. Upon receipt, instruments shall be checked for: 1. 2. 3. 4. b. 1. 2. 3. c. d. e. f. Compliance with purchase specifications. Correct tagging. Shipping damage. Relevant documentation (installation and handling instructions). Replaced in their original factory boxes. Correctly tagged. Stored on shelves in a dry, enclosed area.

After inspection, instruments shall be:

Pneumatic and electrical openings should be closed with proper plugs and screw caps should be securely in place if storing instruments prior to installation. Integrity of sealed protective covers shall be maintained during storage. For instruments or control panels that have been pre-mounted on the machinery package and cannot be stored in a dry, enclosed area, special arrangements should be made. Removal and indoor storage of pre-mounted instruments and control panels may be required if such devices cannot be protected from rain, humidity, temperature, or dusty conditions.

3.2.

Electronic instruments a. b. c. d. Electronic instruments shall be stored in a dust-free room between 8C and 45C (45F and 110F). If humidity is excessive, instruments shall be sealed and stored in plastic wrap, placed in a box with desiccant outside the plastic wrapping, and stored indoors. Manufacturer recommendations shall be reviewed to determine if climate-controlled storage facilities are required. Electronic instruments that cannot be stored in a protective environment, shall be protected as follows: 1. 2. 3. Desiccant should be placed in instrument enclosures. Instruments should be covered to protect against water entry. Control valve ports should be protected against contamination by solids (example stones, soil, etc).

3.3.

Pneumatic instruments Pneumatic instruments shall be stored in a dry area, protected from the elements.

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3.4.

Local control panels a. b. Panel labelling should be visible through packaging to avoid opening. If labelling is not visible, packaging shall be opened just enough to identify the control panel, then resealed and placed in a dry, enclosed or protected area with temperature between 8C and 45C (45F and 110F). In high-humidity areas, desiccant shall be placed inside the packaging before resealing. Panels with internal heaters shall be energized during storage.

c. d. 3.5.

Dial thermometers, pressure gauges, and gauge glasses a. b. Dial thermometers, pressure gauges, and gauge glasses shall be protected against physical damage from construction activities. Such protection may require tagging and storage in a dry, enclosed area. In that case, process connections shall be capped or plugged with metal caps/plugs until the instruments are installed.

4.
4.1.

Documentation
General a. b. Pre-commissioning documentation shall be organized either by system or by area. Commissioning activities shall be performed using the current edition of the following project documents: 1. 2. 3. 4. 5. 6. 7. 8. Loop diagrams. * Piping and instrument diagrams (P&IDs). * Instrument index. Instrument data sheets and/or specifications. * Instrument calculation sheets. * Level transmitter URV and LRV calculations (if applicable). * Orifice inspection records. * Instrument design drawings. a) b) c) d) e) f) g) h) i) 9. Instrument location drawings. Wiring diagrams. Junction box drawings. Cable schedules. Instrument installation detail drawings. Relevant motor schematics. * Marshalling cabinet drawings. Shutdown schematics (if applicable). * Specialized documentation unique to specific loop types (for example, trip point calculation for current switches, panel drawings, etc.). *

Instrument supplier data.

10. Factory calibration certification. * 11. Control Strategy Diagrams (if applicable). *

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c. 4.2.

The items indicated above with an asterisk (*) should be the minimum assembled drawings in a loop check folder for ready reference:

Records a. As each instrument is checked, calibrated, and commissioned, a certification record shall be completed. These records shall include the following information: 1. 2. 3. 4. 5. 6. b. c. Complete listing of calibration test equipment being used and acceptable tolerances. Record of test equipment calibration checks that have been performed. Readout or output values from the calibration. Commissioning services performed. Deficiencies noticed. Concerns identified.

Factory certification shall be included for factory-calibrated instruments. These instruments should be verified, but not recalibrated, in the field. For each instrument loop, a separate document file shall be maintained. The following items shall be included in the file: 1. 2. 3. As-built status of installation. Calibration, testing, and final instrument loop certification of control system components. Subsystems provided for the facility.

d. e.

A complete set of project drawings, marked up to reflect the as-built condition of all instruments and subsystems, shall be required at the end of the project. Changes to documents shall be recorded to show the as-built condition of the document. The following colour-coded format should be used: 1. 2. 3. Additions shall be in red. Deletions shall be in green Comments should be in blue or grey.

5.
5.1.

Installation inspection
Prerequisites a. b. Air headers, takeoff lines, and signal tubes shall be cleaned by blowing clean, dry air before connecting to instrument components. Before the installation of inline instrumentation components, process lines, tanks, and pressure vessels shall be prepared as follows: 1. 2. 3. 4. 5. Cleaned. Flushed. Pressure-tested. Blown down, if applicable. Placed in service, if feasible.

5.2.

General a. b. Some installation inspection activities may be deferred and combined with system checkout or loop check. A mechanical completion documentation (including a punch list) shall be submitted.
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c. d. e.

Inspection of local gauges shall be performed just before commissioning activities are started. Miscellaneous and special instruments shall be checked for correct installation in accordance with manufacturer instructions and instrument specifications. Instruments shall be isolated during initial field inspection as follows: 1. 2. Signal and process valves shall be closed. Instruments shall be electrically de-energized.

5.3.

Instrument inspection checks Installation inspection for instruments and associated components (including junction boxes, control valves, relief valves, and meters) shall include checks for the following, as applicable: a. Identification tags shall be checked as follows: 1. 2. 3. 4. b. c. Comply with the instrument Data Sheet. Properly engraved. Properly attached. Identify each device.

Missing or damaged tags shall be replaced. Engraved nameplates have been provided and correctly installed with stainless steel holders for all field instruments, including: 1. 2. 3. 4. Transmitters. Process switches. Remote mounted indicators. Control valves.

d. e. f. g. h. i. j. k. l.

Consideration should be given to tagging the location of the instrument as well, so that when the instrument is removed the location is still identified. Location, material, and orientation comply with Manufacturer recommendations and installation design drawings. Instrument and system configuration is correct. Access for observing, adjusting, setting, and calibrating does not require climbing over, under, or through equipment and piping. Piping connections have been made, and piping and valving comply with Manufacturer recommendations and installation design drawings. Capability to rod out instrument piping has been provided, if required. Sloping of instrument piping and tubing is in the correct direction and at adequate gradient. Instruments are supported in accordance with specified requirements and no excessive strain is placed on connected tubing. Electrical equipment is certified for the process area in which it is being used, as required by the area classification drawing. Manufacturer nameplates or stickers shall indicate that the instruments or systems are listed or approved for use in the specified electrical area classification. Case bolts, stem clamps, yoke lockouts, and travel indicators are tight and packing gland bolts are torqued in accordance with Manufacturer instructions. Low-temperature thread sealants have not been used in high temperature applications. High point vents and drains have been provided, if required, and verified that they have pipe plugs.
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m. n. o.

p. q. r. s.

Air vents and exhaust ports have bug screens installed. No physical damage, including paint damage or cracked glass, has occurred to the equipment. Unused instrument and electrical equipment are plugged with proper plugs. For instruments and tubing that require heat tracing, installation inspection shall be according to the following: 1. 2. 3. Verification of adequate coverage, arrangement, and accessibility. Continuity testing of the heat tracing installation. Heat limiting arrangement to prevent boiling in impulse lines and accelerated corrosion.

5.4.
5.4.1.

Piping, conduit, cable, and tubing

General

a. b. c. d. e. f.

Piping, conduit, cable, and tubing shall be inspected for proper support in accordance with specified requirements. Piping and tubing in instrument signal air service shall be tested in accordance with ISA 7.0.01. Tubing connections shall be tight and in accordance with Manufacturer specifications. Tubing connectors (nuts, ferrules, and fittings) shall be from the same manufacturer and of the same type. Tubing and instruments shall be leak-tested and the inside diameter of tubing and piping verified. Leak test should consist of the following: 1. 2. 3. 4. Apply the maximum input signal input pressure to the process connection. Close the inlet and disconnect the pressure source. Observe the gauge on the signal inlet and ensure there is no fall-off of pressure over a given period. If leaks are evident, these shall be eliminated and the test repeated.

g.
5.4.2.

Field mounted electrical instruments using conduit shall have seals installed with sealant as specified.

Tubing compression fittings

a.

For instrument tubing runs, each compression fitting shall be inspected by one of the following methods: 1. 2. Manufacturer go/no-go inspection gauges. Disassembly, whereby the fitting is disconnected after makeup, inspected, and made up again. At least 10% of the fittings in process service (primary tubing runs) shall be disassembled for inspection. For each improperly made up fitting, an additional two fittings shall be inspected by disassembly. Cleanliness. Burrs or deep longitudinal scratches. Square tube ends. Galling of the ferrule or fitting seat. Tubing is out of round from bends being located too close to the fitting.
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b.

Inspection criteria for tubing compression fittings shall include: 1. 2. 3. 4. 5.

6. 7. 8.
5.4.3.

Tube bottoms in fitting body. Ferrule adequately biting the tube and back from the tube end. Ferrule(s) fitted correct way round.

Wire and cable

a.

Field wiring shall be inspected according to the following: 1. 2. 3. 4. 5. 6. Check wiring against drawings. Confirm wire labelling is correct. Verify wire size and type. Check for proper circuit isolation at junction boxes and terminations. Low voltage signals shall be isolated from power. IS circuits require barriers and isolation. Verify wiring terminals are the correct type and wiring has been properly dressed-out to provide easy access to terminations.

b. 5.5.

Electrical gland connections shall be tight and electrical tape not added as filler.

Control valves inspection checks a. b. c. d. e. f. g. h. Control valves and regulators shall be checked to ensure that installation orientation agrees with process flow direction. Lubricators and isolating valves shall be checked for proper installation and loading. Valve plugs and shaft orientation on rotary valves shall be checked. Control valves and regulators shall not be inline during piping hydrostatic tests or line flushing. If left installed, they shall either be blocked-in or slip-blinded. Control valves, regulators, and accessories shall be checked against nameplate data and instrument data sheets, and the results recorded. Pressure regulator nameplate set pressure value shall be checked against Manufacturer specification data. Split range positioners and positioners that require air loadings greater than 0,2-1,0 bar(g) (3-15 psig) should be checked to ensure that bypasses are either secured or not included. Diaphragm and piston-operated control valves shall be bench checked as follows: 1. 2. i. j. Stems shall be inspected for burrs or paint, which shall be removed if present to prevent valve packing damage. If required, valves shall be lubricated in accordance with Manufacturer instructions.

Throttling butterfly valves shall be checked for a mark to indicate vane position. Valve visual inspection and checks shall include at least the following: 1. 2. 3. 4. Verify that internal moving parts of valve actuators are correctly lubricated (where applicable) to ensure safe operation. Ensure that required extension stems or other operating devices that are necessary for operation but are not indicated by drawings or specification have been installed. Visually inspect facility piping systems and valve internals for damage and verify the correct installation of internals. Verify that valves are in the correct open or closed operating mode.

5.6.

Temperature instruments inspection checks a. Thermocouple systems shall be checked for:

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1. 2. 3. 4. 5. b. 1. 2. c.

Type. Polarity. Double reversals. Proper point identification. Proper burnout indication. Element type is as specified (for example, E, K, R). Junction type is correct (earthed/grounded or unearthed/ungrounded).

For thermocouple elements, the following shall be verified:

Thermowells shall be checked to verify that they comply with the Data Sheet. This check may include verifying the correctness of: 1. 2. 3. Material. Flange rating. Insertion length.

d. 5.7.

RTD transmitters and receivers shall be checked to ensure that RTD material matches the Data Sheet.

Flow instruments a. b. Correct flow direction shall be verified. For differential pressure type flow instruments, the primary instrument piping connections shall be verified that they are properly made up at both the element connection and differential pressure instrument connections. The correct orientation of the high side versus the low side shall be verified. Lines containing inline flow elements shall be cleaned and flushed before installation of the flow element. Inline flow elements shall be removed before lines are flushed or hydrostatically pressure tested. Differential pressure type flow instruments, during hydrostatic pressure tests: 1. 2. f. 1. 2. g. 1. 2. 3. h. i. Orifice tap shutoff valves shall be closed. Instrument drain valves shall be opened. Installation is plumb. Shipping stops shall be removed and floats inserted. Rotameters. Turbine meters. Positive displacement meters.

c. d. e.

Rotameters shall be checked to ensure:

The following meters shall be checked for free operation of internal parts:

Differential flow elements and meter runs shall be checked for compliance with Manufacturer and relevant specifications. The following shall be checked for dimension and material compliance with the Data Sheet: 1. 2. 3. Flow orifice meter runs. Venturi tubes. Flow nozzles.
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j.

For orifice plates, bores shall be callipered before installation as follows: 1. 2. Bores shall comply with the specification. Bores shall be within tolerances shown in Table 1.
Table 1 - Practical tolerances for orifice diameters
Orifice diameter mm in 6 9,5 12 25 25+ 0,250 0,375 0,500 1,0 1,0+ Practical tolerance (+/-) mm in 0,0075 0,01 0,0125 0,0125 0,0005 (per mm of diameter) 0,0003 0,0004 0,0005 0,0005 0,0005 (per inch of diameter)

3. k. l. m. 5.8.

Results shall be recorded on certification documentation.

Orifice plates shall be visually checked for an upstream sharp edge. Orifice plates shall be installed after flushing and cleaning operations are complete. Orifice plate installation shall be checked to ensure that orifice plate is in the correct line.

Level instruments a. Installation of the following shall be checked for proper installation: 1. 2. 3. 4. 5. 6. b. 1. 2. 3. c. Gauge glasses. Gauge cocks. Illuminators. Ball checks. Heat tracing. Other accessories. The float chamber shall be blocked, drained, and vented during hydrostatic testing. The operation shall be field checked mechanically by raising and lowering the displacer with water. The cage shall be checked to ensure it is plumb.

External float and displacer type level instruments shall be checked as follow:

Internal float and displacer type level instruments shall be removed during hydrostatic testing.

6.
6.1.

Loop check and system checkout

Prerequisites a. The following shall be verified before loop check or system checkout: 1. 2. 3. b. All items are mechanically completed. Installation inspection is completed. Compliance with local requirements and regulations.

Pressure testing and blowing out of tubing runs shall be completed before initial connection to instruments.
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c. 6.2.

All documentation pertaining to the loop should be available as per section sub-clause 4.1.c

General a. The following procedure should be followed to ensure all elements in the loop are checked: 1. 2. 3. 4. Check each loop in accordance with the latest revision of the approved for construction loop diagram. As the loop check proceeds and elements are checked, highlight verified portions of the loop drawing. Complete the appropriate loop check documentation. When a loop check is complete and signed off, place a green dot on all major components. If any work that could affect the loop is subsequently performed, notify instrument personnel to recheck the loop. The loop check should include a test label, with testers initial and date for traceability.

5. b. c. d. e. f. g. 6.3.
6.3.1.

Discrepancies, errors, or deficiencies shall be corrected and rechecked. The sequence of loop certification shall be coordinated with area construction schedules. Loops shall be checked as a complete system, from inputs to outputs. Loop checks shall involve checking components in all positions and under all scenarios to ensure they work correctly, both locally and from the process automation system (PAS). If an impact to operations may occur, Operations shall be advised of the loop to be checked. In such cases, the state of the input shall be verified before proceeding. A functional loop check shall be made while all loop instruments are energized.

Instrument calibration and checkout

General

a. b. c.

Factory calibrated instruments should be verified by corresponding certification. Instruments that have been factory calibrated shall not be recalibrated in the field. Calibrate in the field only if not already factory calibrated. If certified factory calibration is found to be wrong, the Manufacturer should be notified and the instrument replaced. Do not recalibrate onsite. If the calibration check indicates that the instrument will operate within the manufacturer stated accuracy, additional calibration shall not be required. Calibration of instruments shall be reserved only for those devices that, upon checking, are not within their specified operating range. Calibration checks shall be documented. Stickers with the following information shall be attached to instruments that have been checked and calibrated: 1. 2. Date and time of calibration verification. Technician identification. At a minimum of three calibration points (0%, 50%, and 100% of operating range), or otherwise indicated. For smart transmitters, use electronically simulated outputs.
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d. e. f. g.

h.

To verify, calibration checks should be performed as follows: 1. 2.

3. 4.

For standard analogue transmitters, use simulated process variable inputs. Check calibration from each field device through the PAS to each device that uses the selected variable and any combination of devices that use the selected variable and other variables. Correct readout or response at each transmitter input level. Correct action of the controller, positioner, and control valve. Incorrect response or readout shall be reported for correction.

i.

Check loop components for: 1. 2. 3.

j. k. l. m.

Instrument covers and enclosures that were removed for calibration shall be replaced. Loop check personnel shall not change calibration or system ranges without approval. Conflicting data encountered between calibration ranges of field devices and displayed or configured ranges within the PAS shall be brought to attention for resolution. Signals shall be simulated at the input of the end device as shown in Table 2 (for analogue transmitters) and Table 3 (for switches).
Table 2 - Simulating signals at analogue transmitters

Type of transmitter Pressure, orifice meter, and d/p Temperature Level (d/p type)

Procedure Pump up at 0%, 50%, and 100%. Read the temperature. Fill column with approved liquid to 0%, 50%, and 100%.

Analogue transmitters, for which the process parameter cannot be simulated

Check at zero. Use a calibrator (for example, Altek) to input a current at 0%, 50%, and 100%.

Table 3 - Simulating signals at switches

Type of switch Level Pressure or d/p Transmitter current Procedure Fill float chamber with approved liquid to trip the switch. Pump it up to trip the switch. Pump up the transmitter (pressure, d/p, or orifice d/p), use a temperature calibrator (for example, Altek), or fill the column with liquid.

n. o. p.

Digital communications devices may be used to set smart transmitter output to the required levels for loop checking. Smart transmitters shall be operationally tested and digitally ranged. Input devices should be checked as follows: 1. 2. Read and confirm correct value(s), as appropriate, on the PAS, at the panel, and at the marshalling cabinet (if the device is a relay input). For signals that enter multiple locations [for example, surge control points and programmable logic controller (PLC) points], values should be checked at all input locations. For PLC inputs, use a voltmeter or check the input card indication light. For relays, use a voltmeter or visually check the relay state. Check local indicators or other remote indicator readings.

3. 4. 5. q.

If feasible, correct outputs should be verified as shown in Table 4.

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Table 4 - Output verification

Type of output Controllers with control valves Discrete outputs Automated valves Valves with a failure position Procedure Put controller in manual and check valve movement corresponding to 0%, 50%, and 100% output. Confirm that the output state (either DCS, PLC, or relay) at the end device matches the expected output state. Check the valve at 0% and 100%. Shut off air supply (typically block and vent) and check for failure.

r.

Using loop drawings or shutdown schematics, input and output interaction should be checked for action direction as follows: 1. 2. For control loops, increasing or decreasing transmitter input should open or close the control valve, as applicable. For shutdowns, toggling the inputs should cause solenoid valves or other end devices to open or close or be on or off, as applicable.

s.

After input wiring has been confirmed to the shutdown panel, subsequent toggling of the input may be accomplished by removing the appropriate fuses at the input termination strip.

6.3.2.

Calibration test equipment

a. b.

If calibration is required the test equipment shall be according to this section. Shop test equipment (excluding pressure generating devices, such as manometers and dead weight testers) shall require certification. Certification shall be: 1. 2. 3. Current within one year of testing activity. Traceable to a recognized, approved certification agency. Kept on file.

c. d. e. f. g.

Calibration test equipment shall be selected to be more accurate than the manufacturer advertised accuracy of the equipment being tested. Order of magnitude of 10 if feasible. Transmitting or receiving signal accuracy of calibration equipment shall be greater than the instrument to be calibrated. Pneumatic calibration gauges, electronic test meters and equipment, and digital strain gauge instruments shall have an accuracy of at least 0,1% full scale. Portable field test devices shall be tested for accuracy at least twice a week against shop calibration equipment. Air for the calibration of pneumatic-actuated instruments shall be instrument-quality air. If instrument air is not available onsite at the time of calibration, dry bottled filtered air shall be used.

6.3.3.

Receiving instruments

a. b. c.
6.3.4.

Controllers, recorders, and indicators shall be checked for alignment in accordance with the Manufacturer-supplied manual. Recorder charts and pens shall be prepared for use. Charts and scales shall be checked for range in accordance with specifications.

Switches

a.

Instruments that are two-position devices should not be calibrated over their full range. Only the trip point and dead band (reset point) should be checked.
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b. c.
6.3.5.

Switches used in alarms, shutdown, or signal switching service shall be set to specified values by applying a rising and falling signal. Dead bands shall be checked to ensure they are within the Manufacturer published tolerance.

Control valves and pressure regulators

a. b. c. d.

Valve function tests shall be performed to ensure that valves operate effectively, have no damage, and have correct fail functions. Valve failure position shall be checked to ensure failsafe operation on loss of motive fluid. Solenoid valves mounted on control valves shall be energized and de-energized to ensure that the control valve fails correctly. Butterfly valves shall be checked to ensure that: 1. 2. The vane moves freely in upstream and downstream piping. Mechanical stops are set as specified on the Data Sheet.

e. f.

Throttling butterfly valves are set for maximum travel restrictions in accordance with specifications. The following shall be completed and recorded: 1. 2. Check valve failure action. Set position indicator. Handwheels. Solenoid valves. Limit switches. Boosters. Relays.

g.

Operation of valve accessories shall be checked, including: 1. 2. 3. 4. 5.

h. i. j.

Handwheels shall be in neutral position before stroking valves. Diaphragm and piston-operated control valves shall be pneumatically stroked using a regulator and test gauge. The following shall be verified to be in accordance with Manufacturer nameplate data and job specifications (if applicable) and recorded: 1. 2. 3. 4. 5. 6. 7. 8. 9. Valve action. Mechanical seating. Spring range or bench setting shown on valve nameplate. Valve travel (including bench set). Valve failure position. Actuator setting (either reverse or direct action) is in accordance with Manufacturer specifications. Limit switches indicate full open and close. Solenoid valves bleed the actuator when energized or de-energized. Boosters amplify the pneumatic signal in compliance with Manufacturer specifications.

10. Handwheel, if provided, opens and closes the valve and in neutral position, permits automatic control. 11. Relays, if provided, activate in accordance with Manufacturer specifications.
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12. Rotary valve plugs seat properly and are operating in the proper quadrant. 13. Local valve position indicators are installed properly to match valve position. k. l. If valve includes a volume booster bypass valve, the gain shall be set by backing out the adjusting screw 1-1/2 to 2 turns from closed and shall be checked for stable operation. I/P transducers that output to control valves shall be calibrated to be direct acting, with an output range of 0,2-1,0 bar (g) (3-15 psig) or 0,4-2,0 bar (g) (6-30 psig) for a corresponding input of 4 to 20 mA. Valve positioners and other auxiliary devices (for example, limit switches, position transmitters, and trip relays) shall be verified in accordance with nameplate data and Manufacturer specifications. Manually operated valves (including skid mounted valves) shall be manually sequenced and spindle rotation and integrity shall be verified.

m.

n.
6.3.6.

Automated Valves

a.

Automated valve shall be checked as follows: 1. 2. 3. Stroke valve from the PAS. Check limit switch settings, open and closed. Limit switches should be less than 90 degrees apart from each other (approximately 85 degrees). Verify that the following all match the valve position: a) b) c) 4. a) b) 5. 6. Valve shaft. Beacon. PAS. For fail last, open the valve, turn off power at the field junction housing, and ensure the valve holds the open position. Repeat the same procedure for closed valve position.

Verify the valve fail position as follows:

If valves are fitted with handwheels, manually stroke the valve with the handwheel. Check travel stops.

b.
6.3.7.

After automated valves are checked, valves shall remain energized.

Temperature instruments

a. b. c. d.

Temperature indicators shall be checked at ambient conditions, where practical. Certification of calibration should be provided by equipment Manufacturers that embed devices in their products (for example, motor winding RTDs). Thermocouples and RTDs should not require calibration checks if accompanied with vendor test certification and/or if they are removable in service. Thermocouples and RTDs that are wired directly to any type of readout device (for example, digital control system, multipoint temperature indicator, or recorder) shall be field checked to verify operation as follows: 1. 2. 3. Check for ambient reading. Remove RTD/thermocouple to verify the correct point is being read. Check output of RTD and thermocouple elements: a) b) For RTD elements, measure element resistance and compare measurement to the ambient temperature. For thermocouple elements, measure millivolt output and compare measurement to the ambient temperature.
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4. e.

Verify the signal at the receiving instrument and/or PAS.

For thermocouples or RTDs that are not replaceable while process equipment is running (for example, reactor thermocouples and tube skin thermocouples), checkout of temperature elements shall be performed and shall consist of a three-point calibration check using a controlled temperature bath before installation, if feasible. After installation, the measurement shall be compared to ambient temperature. Bimetallic dial thermometers shall not be field calibrated. The dial or pointer shall be set to the ambient temperature known at the time of installation. For instruments with suspected calibration and/or calibration is deemed necessary the following guidance should apply: 1. Thermal-filled system temperature instruments shall be calibrated as follows: a) b) 2. At three calibration points, minimum (0%, 50%, and 100% of operating range). By immersing the sensing bulb in a precisely controlled and agitated temperature bath that is continuously monitored with a precision thermometer.

f. g.

Non-factory calibrated thermocouple transmitters and receivers shall be calibrated, if required, as follows: a) b) c) Apply upscale and downscale millivolt signals from a precision voltage source. Verify and adjust upper and lower operating limits. Recheck the three-point calibration.

3.

Non-factory calibrated RTD transmitters and receivers shall be checked, if required, as follows: a) b) c) Use a precision decade resistance box. Verify and adjust upper and lower operating limits. Recheck the three-point calibration.

h.

Temperature switches shall be checked and set in accordance with procedures in Table 5.
Table 5 - Checks for different types of temperature switches
Switch type All types Filled Checking procedure Check dead band to confirm that it is within Manufacturer stated tolerance. Check and set to specified trip point by immersion in fluidised sand bath or controlled temperature bath (depending on temperature range). Check using a precision voltage source. Check using a precision decade resistance box.

Thermocouple RTD

6.3.8.

Flow instruments

a. b.

Flow indicators shall be zeroed. Transmitting and indicating rotameters in which the float is not visible shall be calibrated as follows: 1. 2. Manually position the float. Adjust the indicator or transmitter output to the correct value at 0% and 100%.

c.

Equipment associated with meters, regardless of whether or not they are used for custody transfer and allocation, calibration should be verified according to Manufacturer standards and relevant specifications.

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d.

The following meters shall have their zero and span checked in accordance with Manufacturer recommended procedure: 1. 2. 3. 4. 5. 6. 7. Turbine meters. Positive displacement meters. Vortex meters. Ultrasonic meters. Coriolis meters. Magnetic meters. Target meters.

e. f.

Thru-flow type flow switches shall be mechanically checked only. Differential pressure type flow switches shall be checked as follows: 1. 2. Calibration shall be against a standard water column manometer or precision gauge. Dead band of switches shall be verified against the Data Sheet.

6.3.9.

Level instruments

a.

For cage displacer type instruments, the following shall be checked: 1. 2. Pneumatic or electronic transmitter with output gauges or meters for smooth and full output change. Operation of the pneumatic controller and verification that the set action (direct or reverse) complies with the Data Sheet.

b. c.

Level indicators shall be zeroed. External displacer type level instruments shall be calibrated as follows: 1. 2. 3. 4. 5. Set specific gravity adjustment to 1,0. Fill chamber with clean water, while using clear plastic tubing connected at the bottom drain as a gauge glass. Check calibration at three points (0%, 50%, and 100% of span). After each calibration adjustment, recheck for zero. Reset specific gravity adjustment to operating conditions.

d.

Internal displacer type level instruments shall be removed from the vessel and bench calibrated as follows: 1. 2. 3. 4. Set specific gravity adjustment to 1,0. Check calibration at three points (0%, 50%, and 100% of span). After each calibration adjustment, recheck for zero. Reset specific gravity adjustment to operating conditions.

e. f.

To verify calibration of differential pressure (d/p) level instrument checks should be performed at three points (0%, 50%, and 100% of span). Level instrument switches shall be checked and set as follows: 1. 2. 3. Float operated level switches shall be checked for switch operation by filling the float chamber with water. Head, displacer, or differential pressure operated level switches shall be set at the required trip points. Dead band of the switches shall be verified against the Data Sheets.

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g.
6.3.10.

Ultrasonic, radar, capacitance, and other special types of level instruments shall be checked in accordance with Manufacturer recommendations.

Pressure instruments

a. b. c.

Pressure gauges shall be checked at ambient conditions. To verify calibration of pressure and differential pressure (d/p) transmitters checks should be performed at three points (0%, 50%, and 100% of span). Switches shall be checked and calibrated as follows: 1. 2. Calibrate pressure switches using hydraulic tester, dead-weight tester, or precision air regulator and an output gauge to set the required alarm and trip point. Verify dead band of the switches against the Data Sheet.

d. e.

If pressure gauge reading suspect, the manufacturer should be notified and the instrument replaced. For critical pressure gauges the following may apply: 1. Bourdon tube type pressure gauges should be checked at 10%, 50%, and 90% of full scale. If gauge varies more than 1,0% from true reading at any of the three points, gauge should be replaced and/or recalibrated. Draft type instruments shall be bench calibrated using an inclined-tube manometer or precision accuracy strain gauge at 0%, 50%, and 100% of range. Receiver type pressure gauges should be field checked to verify calibration at three points (0%, 50%, and 100% of span). Diaphragm type draft gauges shall be field checked to verify calibration as follows: a) b) Verify calibration at three points (0%, 50%, and 100% of span). Use a water column or inclined tube manometer in accordance with Manufacturer recommended procedure.

2. 3. 4.

6.3.11.

Analytical instruments

a.

Sample systems shall not be connected to process piping before commissioning, at which point they should be: 1. 2. Installed and cleaned to meet analyser system requirements. Inspected for proper installation, operation, and tightness.

b.

If specification calls for the instrument Manufacturer to furnish the services of a factory service engineer for checkout and calibration purposes, this work shall be performed under the factory service engineers direction. The following shall be verified: 1. 2. 3. Necessary standard and calibration samples are available. Spare parts (including filters. coalescers, and consumables) necessary for initial calibration, startup, and testing are available. Analyser housing has appropriate approvals for the area classification.

c.

d. e.

Calibration shall be in accordance with Manufacturer recommended procedure using sample gases or liquids provided. Analytical instruments shall be checked as follows: 1. 2. Analysers shall be inspected for correct installation of piping and wiring. A two-point field calibration check shall be performed.

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f.

Analysers and sampling systems shall be checked as calibrated using standard samples, if available, to verify analyser output against laboratory analysis. The following tests and checks shall be performed, as applicable: 1. 2. 3. 4. 5. 6. 7. Analyser is recording properly. All alarms are functional. Peak picking capability is operating. Interrupt functions operate correctly. Automatic shutoff of sample flow is functioning. Sample flow rate is adequate. Sample transport time is acceptable. Sample taps shall be isolated. Analyser tubing shall be disconnected. After completion of the hydrostatic testing, sample piping shall be dried with dry air and sealed.

g.

Analysers shall be protected during hydrostatic testing as follows: 1. 2. 3.

h.

If housing is purged, proper operation of the purging system shall be verified, including alarms when purge pressure is lost. Settings and results shall be recorded on the certification documentation. Power connections to the analyser and a.c. circuits to the distribution panel shall be verified. Process connections shall remain closed until after startup. Sample system piping shall be flushed with process fluid for several hours before allowing samples to enter analyser.

i. j. k.
6.3.12.

Miscellaneous field instruments

a. b. 6.4.
6.4.1.

Density or specific gravity meters as a minimum shall have their zero and span checked in accordance with Manufacturer recommended procedure. Special instruments not discussed in this document shall be checked and calibrated in accordance with Manufacturer instructions and relevant specifications.

Systems checkout
General

a. b. c.

The complete functions tested during FAT should not be retested onsite. Retesting or an acceptable subtest should be required only to verify proper installation and integration with other systems onsite. Control systems components shall be checked as follows: 1. 2. 3. Check dynamic variables on each graphic screen during loop checks and verify readings are correct. Verify commands from operator consoles and screens. Check printed logs and reports. Primary loop control set points. Secondary loop. Control action.
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d.

Cascade systems shall be checked to ensure proper functioning of: 1. 2. 3.

e. f.

Interlock, safety, and sequential control systems shall be checked for continuity and verified with a functional test of each circuit. Control system loop continuity and output action shall be checked as follows: 1. 2. 3. Verify that control actions are set in accordance with specifications. Observe control outputs and controller responses. Check and observe auxiliary functions (for example, alarms, ratioing, etc.).

g. h.
6.4.2.

Loop points shall remain disabled until they are loop checked. Points that are loop checked shall remain active on the control system.

Controllers

a. b. c. 6.5.

Ratio controllers shall be checked by feeding a known signal into the station and observing the output for various set ratios. Set control modes, set points, and tuning parameters. After loop checking, controllers shall be left in manual mode.

Alarm system components a. Annunciators shall be checked through to the final display window or PAS screen as follows: 1. Verify operation and point continuity by a functional test of each circuit using the primary instrument. This test shall involve actuating all field contacts, as shown on the instrument loop diagrams or elementary diagrams, for the following: a) b) c) 2. b. c. Low, high, or deviation alarm operation. Auxiliary contact operation. Proper sequence.

Verify correct actuation of each device as described in the specification for the particular type of instrument.

Alarm windows and nameplates shall be verified for accuracy and correct location. For alarm and switch sensing elements, the following shall apply: 1. Abnormal conditions shall be simulated by either of the following methods: a) b) 2. 3. Simulate the process variable. Manually trip the switch.

The correct operational sequence and actions of related devices shall be checked. Switch terminals shall not be jumpered to simulate actuation without approval.

6.6.

Logic system components a. Electrical devices that are part of an interlock, shutdown, or auto start circuit shall be checked as follows using a pre-developed test plan: 1. 2. b. Devices shall be thoroughly checked as an integrated system for continuity and operation. Shutdown and interlock responses shall be checked against shutdown and interlock logic diagrams. Perform check from the originating device to the switching or shutdown function. Verify the operation of each circuit using the latest issue of the designated logic/ladder drawings.
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Switching and shutdown systems shall be checked as follows: 1. 2.

3. 4. c. 1. 2. d. 1. 2.

Record changes to logic/ladder drawings and show on as-built logic/ladder drawings. Check PLC systems using Manufacturer-provided system test procedures. Activate by simulating the process variable or by manual trip. Perform functional test, without use of jumpers. Verify failsafe design philosophy. Verify the correct state of each output on loss of power to the logic system and on loss of power to the field devices.

Process-actuated switches and process transmitters shall be checked as follows:

Each shutdown system shall be checked as follows:

7.

Commissioning completion
a. b. Before commissioning, mechanical completion documentation (including a punch list) shall be submitted. Pre-commissioning shall consist of preparing instrumentation for plant startup, including the following tasks: 1. 2. 3. 4. 5. 6. 7. 8. 9. Confirm that installation inspection, calibration and loop check tasks have been completed. Place process control valves and other final elements in the status specified by the startup requirements. Open or close instrument block valves as specified by the startup requirements. Pour electrical seals where conduit is used. Fill condensate pots and check that legs are filled with the specified seal fluids. Place controllers in manual mode. Warm up instruments, such as analysers, as required. Set airsets at the correct pressure and open instrument air valves to place enclosure air purges in service. Make electrical power supplies and pneumatic pressure sources ready for service.

10. Confirm electrical and pneumatic power systems are operating correctly. 11. Energize electric heat tracing or cut in steam tracing on instrument tubing and instrument enclosures. 12. Ensure protection devices are in working order and are not bypassed or overridden. 13. Place instruments in service by opening or closing instrument shutoff valves and equalizing valves in instrument manifolds. 14. Vent air from instrument sensing lines in liquid service. 15. Drain liquids from instrument sensing lines in gas service. c. d. Instruments and loops shall remain powered or pressurized with switches and valves set in accordance with the startup requirements. Control and instrumentation is considered to be commissioned and ready for startup when: 1. 2. 3. 4. Mechanical completion checklists are signed off as complete. All loop checks and system checkout are signed off as complete. All punch lists are signed off as complete. All commissioning activities are signed off as complete and ready for startup.
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