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. 4 APPLICABLE CODE, STANDARD AND SPECIFICATION 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 4 4.2 4.3 equipped atmospherically controlled conditions. All apparatus and testing equipment shall be validated with certificates from national and international authorized calibration agency. 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 4.5 RFI (Request for Inspection) notification shall be submitted to invite Owners supervisors. 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 Contractors 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 4 All applicable certificates such as NACE, PMI, Electrical apparatus, Factory Seat Leakage test Record, etc shall be available and form part of the 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 100C. 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:

4 -

Dead Weight Tester / Hand pump Digital multi-meter Hart Communicator Visual inspection to confirm compliance of materials, mechanical construction, 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.

Calibration Procedure:

If the transmitter output is not within the manufacturers tolerance, calibrate the transmitter in accordance with the manufacturers recommendations.

4 6.2

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 its required data population.

Differential Pressure Type Level Transmitter Test Equipment Required: Dead Weight Tester / Hand pump Digital multi-meter Hart Communicator Visual inspection to confirm compliance of materials, mechanical construction, 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.

Calibration Procedure: 4

If the transmitter output is not within the manufacturers tolerance, calibrate the transmitter in accordance with the manufacturers 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 its required data population.

6.3 Temperature Transmitter Test Equipment Required: 4 Temperature Calibrator Digital Multi-meter Decade Box Hart Communicator Visual inspection to confirm compliance of materials, mechanical construction, 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 manufacturers tolerance, calibrate the transmitter in accordance with the manufacturers 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:

Calibration Procedure:

Temperature Calibrator Digital Multi-meter 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 100C and record the reading of the temperature calibrator. Compare result obtain with temperature indicate on digital thermometer.

Calibration Procedure:

6.5

The results should be within the manufactures tolerance of ambient temperature.

Pressure Gauge Test Equipment Required: Dead Weight Tester / Hand pump Digital Manometer Test Gauge 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 Manufacturers Stated Limit.

Calibration Procedure:

6.6 Differential Pressure Gauge Test Equipment Required: Hand pump Digital Manometer

Test Gauge 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.

Calibration Procedure:

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 Manufacturers Stated Limit.

6.7 Temperature Gauge Test Equipment Required: Temperature Calibrator/Oil Bath Thermometer Compare Thermo Gauge at pointer indication with the certified necessary

Calibration Procedure: digital thermometer ambient temperature. Where

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 the glass thermometer. Increase bath temperature equivalent to pointer indications. The percentage error calculated from the above readings shall not exceed Manufacturers 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) 100C. Record

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 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 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 Verification Procedure: Verification Procedure:

a. Check and confirm control valve air supply (kg/cm2) required and transducer/valve positioner and accessories data against manufacturers 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 isnt enough, stroke time shall be long and valve shall not be in operating position. Loss of control signal: if power supply isnt 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 a. b. c. d. 6.12.2 e. f. g. h. Test Equipment Nitrogen cylinder. 24VDC power supplier Digital Multi meter. P&F amplifier for proximity switch Calibration Procedure Check and confirm on-off valve air supply required and valve positioner and accessories data against manufacturers data sheet. Check On-off valve damaged parts by visual. Adjust the instrument air supply to valve (pressure shall be refered to vendor data.) by air filter and regulator on valve. 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 isnt enough, stroking time shall be long and valve shall not be in operating position. Loss of control signal: if power supply isnt enough to attract solenoid coil, valve shall not be operated.

j. k.

Check position switch function with P&F contact amplifier. 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 manufacturers data/instrument nameplate against CLIENT Specifications. b. Connect up pressure relief valve. c. Check the manufacturers 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 Manufacturers Seal or attempt to adjust setting. h. Compile all results in SAFETY RELIEF VALVE. Test Gauge 1 Test Gauge 1 PSV Water Containe r

Air Compres sor

Manifold No.1 Drain

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

a. Check the manufacturers data/instrument nameplate against CLIENT Specifications. b. Connect up pressure relief valve c. Check the manufacturers 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 Manufacturers 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 its validity. Site Calibration site works. and commissioning procedure for these particular

instruments shall be available and be used as mandatory requirement for

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.
No 1 2 3 4 5 6 7 8

Instrument Apparatus for Calibration and Test

Model DPI 610 DPI 610 DPI 615 DPI 603 DPI 610 IS3336/3000PSI MC5/MC5IS Fluke 726 Accuracy 0.025%FS 0.025%FS 0.025%FS 0.075% FS 0.075% FS 0.05%FS 0.025%FS 0.01%Rdg Range -1 to 20bar 0 135 bar With Ext. Sensor 700bar 0 to 400bar -1 to 20bar -1 to 2bar 0 - 3000PSI -1 to 700bar mA, mV, RTD, TC Make Druck Druck Druck Druck Druck CRYSTAL Eng Beameax Fluke

Description Air Pressure Calibrator Oil Pressure Calibrator Oil Pressure Calibrator Air Pressure Calibrator Air Pressure Calibrator Hand held Pressure Calibrator Multifunction Calibrator Documenting Calibrator

9 10 11 12 13 14 15 16 17 18 19 20

Documenting Calibrator Documenting Calibrator Multifunction Calibrator Loop Milliamp Calibrator Multi-meter Hart Communicator Hart Communicator Unomat Calibrator Dry -Well Calibrator Dry -Well Calibrator Dry -Well Calibrator Dry -Well Calibrator

Fluke 741B Fluke 743B Fluke 725 UPS.IS Fluke 87II 275 375 TRX -IS DBC150TC 9011 9170 9173

0.01%Rdg 0.01%Rdg 0.01%Rdg 0.01%Rdg 0.03%Rdg N/A N/A 0.01%Rdg 0.1oC 0.10oC 0.15oC 0.15oC 0.35oC

mA, mV, RTD, TC mA, mV, RTD, TC mA, mV, RTD, TC mA mA, A, mA, V, Ohm, Hz communication communication mA, mV, RTD, TC -45 to 150oC -45 to 150oC 50 to 670oC -45 to 140oC 50 to 650oC

Fluke Fluke Fluke Druck Fluke Hart Hart Druck Druck Hart Hart Hart

Appendix-2.
QCF-I002 QCF-I003B QCF-I004B QCF-I004C QCF-I005B QCF-I005C QCF-I006B QCF-I014 QCF-I015 QCF-I016

Quality Control Form (QCF) List

Instrument Unpacking Inspection Instrument Transmitter Calibration Pressure Gauge Calibration Diffrential Pressure Gauge Calibration Temperature Gauge Calibration Temperature Element (RTD) Inspection Orifice Plate and Restriction Orifice Control Pneumatic Control Valve Calibration On-Off Valve Function Test Pressure safety/relief valve Calibration