Guidance On Practice For Commissioning of Instrument and Control Systems

Document No.
GP 30-90
Applicability Group
Date 10 June 2003
Guidance on Practice for

Commissioning of Instrument and Control
Systems
GP 30-90
BP GROUP
ENGINEERING TECHNICAL PRACTICES
10 June 2003 GP 30-90
Guidance on Practice for Commissioning of Instrument and Control Systems
Foreword
This is the first issue of Engineering Technical Practice (ETP) BP GP 30-90. This Guidance on
Practice (GP) is based on parts of heritage documents from the merged BP companies as follows:
Amoco
A CO-PCOM-GEN-E Commissioning—Pre-Commissioning—General—Engineering
Specification.
A CO-PCOM-GEN-G Commissioning, Pre-Commissioning—General Guide.
A PC-PCOM-IN-C Process Control, Checkout, and Pre-Commissioning—Instrumentation
Construction Specification.
ARCO
Standard 316 Instrument Calibration, Certification, and Commissioning.
Copyright  2003, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organization. None of the information
contained in this document shall be disclosed outside the recipient’s own organization
without the prior written permission of Manager, Standards, BP Group, unless the terms of
such agreement or contract expressly allow.
Downloaded Date: 5/16/2007 10:20:27 PM

The latest update of this document is located in the BP ETP and Projects Library
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10 June 2003 GP 30-90
Table of Contents
Page
Foreword.......................................................................................................................................... 2
1. Scope...................................................................................................................................... 5
2. Normative references.............................................................................................................. 5
3. Symbols and abbreviations.....................................................................................................6
4. General................................................................................................................................... 6
5. Instrumentation receiving and storage....................................................................................7
5.1. General........................................................................................................................ 7
5.2. Electronic instruments..................................................................................................7
5.3. Pneumatic instruments.................................................................................................8
5.4. Local control panels.....................................................................................................8
5.5. Dial thermometers, pressure gauges, and gauge glasses............................................8
6. Documentation........................................................................................................................ 8
6.1. General........................................................................................................................ 8
6.2. Records........................................................................................................................ 9
7. Installation inspection............................................................................................................ 10
7.1. Prerequisites..............................................................................................................10
7.2. General...................................................................................................................... 10
7.3. Instrument inspection checks.....................................................................................10
7.4. Piping, conduit, cable, and tubing...............................................................................12
7.5. Control valves inspection checks...............................................................................13
7.6. Temperature instruments inspection checks...............................................................14
7.7. Flow instruments........................................................................................................14
7.8. Level instruments.......................................................................................................15
7.9. Pressure instruments.................................................................................................16
8. Loop check and system checkout.........................................................................................16
8.1. Prerequisites..............................................................................................................16
8.2. General...................................................................................................................... 16
8.3. Instrument calibration and checkout...........................................................................17
8.4. Systems checkout......................................................................................................26
8.5. Alarm system components.........................................................................................27
8.6. Logic system components..........................................................................................28
9. Commissioning completion...................................................................................................28
Annex A (Informative) Figure A1 - Commissioning control loops flowchart.....................................30
Annex A (Informative) Figure A2 - Commissioning field switches flowchart....................................31
Annex A (Informative) Figure A3 - Commissioning local gauges flowchart.....................................32
Annex B (Informative) Instrument installation loop check sheet......................................................33

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10 June 2003 GP 30-90
List of Tables
Table 1 - Practical tolerances for orifice diameters.........................................................................15

Table 2 - Simulating signals at analogue transmitters.....................................................................18
Table 3 - Simulating signals at switches.........................................................................................18
Table 4 - Output verification............................................................................................................ 19
Table 5 - Checks for different types of temperature switches..........................................................23

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10 June 2003 GP 30-90
1. Scope
This GP provides guidance on commissioning activities to include receiving and storage, installation
inspection, loop check, and system checkout of process controls and instrumentation.
2. Normative references
The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For dated references, subsequent amendments to, or
revisions of, any of these publications do not apply. However, parties to agreements based on this
technical practice are encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references, the latest edition of the normative
document referred to applies.
BP
GIS 30-401 Guidance on Industry Standard for Process Automation Systems (PAS).
GIS 30-402 Guidance on Industry Standard for Programmable Logic Controllers
(PLC).
GIS 30-451 Guidance on Industry Standard for Human Machine Interface.
GIS 30-801 Guidance on Industry Standard for Safety Instrumented Systems (SIS).
GIS 30-851 Guidance on Industry Standard for Fire and gas Detection.
GP 12-XX Guidance on Practice for Field Wiring.
GP 12-XX Guidance on Practice for Heat Tracing.
GP 30-01 Guidance on Practice for Temperature Instruments.
GP 30-05 Guidance on Practice for Pressure Instruments.
GP 30-10 Guidance on Practice for Non-Fiscal Flow Instruments (Class 2 & 3).
GP 30-15 Guidance on Practice for Level Instruments.
GP 30-20 Guidance on Practice for Miscellaneous Instruments.
GP 30-30 Guidance on Practice for Field Communication Buses.
GP 30-35 Guidance on Practice for Control Valves and Pressure Regulators.
GP 30-40 Guidance on Practice for Process Automation Systems (PAS).
GP 30-45 Guidance on Practice for Human Machine Interface.
GP 30-65 Guidance on Practice for Control Panels.
GP 30-70 Guidance on Practice for Commissioning of Instrument and Control
Systems.
GP 30-80 Guidance on Practice for Safety Instrumented Systems (SIS) –
Implementation.
GP 30-81 Guidance on Practice for Safety Instrumented Systems (SIS) –
Operations and Maintenance.
GP 30-85 Guidance on Practice for Fire and gas Detection.
GP 30-95 Guidance on Practice for Control Loop Tuning
GP 31-XX Guidance on Practice on Analysers
GP 64-XX Guidance on Practice for Fiscal Flow Instruments (Class 1)
The Instrumentation, Systems, and Automation Society (ISA)

ISA 7.0.01 Quality Standard for Instrument Air.

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10 June 2003 GP 30-90
3. Symbols and abbreviations
a.c. Alternating current.
DCS Distributed control system.
d/p Differential pressure.
I/E Instrument/Electrical.
I/P Current-to-pressure.
IS Intrinsic safety.
LRV Lower range value.
P&ID Piping and instrument diagram.
PAS Process automation system.
PLC Programmable logic controller.
RTD Resistance temperature detector.
SIS Safety instrumented system.
URV Upper range value.
4. 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.
b. Personnel involved in calibration and commissioning of instrument systems shall have
experience and verifiable training to included but not limited to the following:
1. Calibration of instruments being installed.
2. Use of compression fittings.
3. Installation/inspection of electrical equipment in hazardous areas.
c. Commissioning personnel shall review, be familiar with, and adhere to all relevant portions
of Health, Safety and Environmental (HSE) documents and procedures.
d. 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.
e. 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.
f. BP personnel will witness selected pre-commissioning and commissioning activities, at the
discretion of BP.
g. This GP groups tasks by phases of the construction cycle. Some testing and verification
steps were combined to facilitate efficient workflow.
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10 June 2003 GP 30-90
h. 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.
i. Refer to Annex A for examples of checkout and pre-commissioning of instrument and
control systems.
j. 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.
k. Defective instruments shall be replaced or repaired.
5. Instrumentation receiving and storage
5.1. General
a. Upon receipt, instruments shall be checked for:
1. Compliance with purchase specifications.
2. Correct tagging.
3. Shipping damage.
4. Relevant documentation (installation and handling instructions).
b. After inspection, instruments shall be:
1. Replaced in their original factory boxes.
2. Correctly tagged.
3. Stored on shelves in a dry, enclosed area.
c. Pneumatic and electrical openings should be closed with proper plugs and screw caps
should be securely in place if storing instruments prior to installation.
d. Integrity of sealed protective covers shall be maintained during storage.
e. 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 between
representatives from the Manufacturer and BP.
f. 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.
5.2. Electronic instruments

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

Pneumatic instruments shall be stored in a dry area, protected from the elements.
5.4. Local control panels

a. Panel labelling should be visible through packaging to avoid opening.
b. 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 8°C and 45°C (45°F and 110°F).
c. In high-humidity areas, desiccant shall be placed inside the packaging before resealing.
d. Panels with internal heaters shall be energized during storage.
5.5. Dial thermometers, pressure gauges, and gauge glasses

a. Dial thermometers, pressure gauges, and gauge glasses shall be protected against physical
damage from construction activities.
b. 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.
6. Documentation
6.1. General
a. Pre-commissioning documentation shall be organized either by system or by area.
b. Commissioning activities shall be performed using the current edition of the following
project documents:
1. Loop diagrams. *
2. Piping and instrument diagrams (P&IDs). *
3. Instrument index.
4. Instrument data sheets and/or specifications. *
5. Instrument calculation sheets. *
6. Level transmitter URV and LRV calculations (if applicable). *
7. Orifice inspection records. *
8. Instrument design drawings.
a) Instrument location drawings.
b) Wiring diagrams.
c) Junction box drawings.
d) Cable schedules.
e) Instrument installation detail drawings.
f) Relevant motor schematics. *
g) Marshalling cabinet drawings.
h) Shutdown schematics (if applicable). *
i) Specialized documentation unique to specific loop types (for example, trip point
calculation for current switches, panel drawings, etc.). *
9. Instrument supplier data.
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10 June 2003 GP 30-90
10. Factory calibration certification. *

11. Control Strategy Diagrams (if applicable). *
c. The items indicated above with an asterisk (*) should be the minimum assembled drawings
in a loop check folder for ready reference:
6.2. Records
a. As each instrument is checked, calibrated, and commissioned, a certification record shall
be completed. These records shall include the following information:
1. Complete listing of calibration test equipment being used and acceptable tolerances.
2. Record of test equipment calibration checks that have been performed.
3. Readout or output values from the calibration.
4. Commissioning services performed.
5. Deficiencies noticed.
6. Concerns identified.
b. Factory certification shall be included for factory-calibrated instruments. These
instruments should be verified, but not recalibrated, in the field.
c. For each instrument loop, a separate document file shall be maintained. The following
items shall be included in the file:
1. As-built status of installation.
2. Calibration, testing, and final instrument loop certification of control system
components.
3. Subsystems provided for the facility.
d. 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.
e. Changes to documents shall be recorded to show the “as-built” condition of the document.
The following colour-coded format should be used:
1. Additions shall be in red.
2. Deletions shall be in green
3. Comments should be in blue or grey.
7. Installation inspection
7.1. Prerequisites
a. Air headers, takeoff lines, and signal tubes shall be cleaned by blowing clean, dry air
before connecting to instrument components.
b. Before the installation of inline instrumentation components, process lines, tanks, and
pressure vessels shall be prepared as follows:
1. Cleaned.
2. Flushed.
3. Pressure-tested.
4. Blown down, if applicable.
5. Placed in service, if feasible.

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10 June 2003 GP 30-90
7.2. General
a. Some installation inspection activities may be deferred and combined with system
checkout or loop check.
b. A mechanical completion documentation (including a punch list) shall be submitted to BP.
c. Inspection of local gauges shall be performed just before commissioning activities are
started.
d. Miscellaneous and special instruments shall be checked for correct installation in
accordance with manufacturer instructions and instrument specifications.
e. Instruments shall be isolated during initial field inspection as follows:
1. Signal and process valves shall be closed.
2. Instruments shall be electrically de-energized.
7.3. 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. Comply with the instrument Data Sheet.
2. Properly engraved.
3. Properly attached.
4. Identify each device.
b. Missing or damaged tags shall be replaced.
c. Engraved nameplates have been provided and correctly installed with stainless steel
holders for all field instruments, including:
1. Transmitters.
2. Process switches.
3. Remote mounted indicators.
4. Control valves.
d. 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.
e. Location, material, and orientation comply with Manufacturer recommendations and
installation design drawings.
f. Instrument and system configuration is correct.
g. Access for observing, adjusting, setting, and calibrating does not require climbing over,
under, or through equipment and piping.
h. Piping connections have been made, and piping and valving comply with Manufacturer
recommendations and installation design drawings.
i. Capability to rod out instrument piping has been provided, if required.
j. Sloping of instrument piping and tubing is in the correct direction and at adequate gradient.
k. Instruments are supported in accordance with specified requirements and no excessive
strain is placed on connected tubing.
l. 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

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the instruments or systems are listed or approved for use in the specified electrical area
classification.
m. Case bolts, stem clamps, yoke lockouts, and travel indicators are tight and packing gland
bolts are torqued in accordance with Manufacturer instructions.
n. Low-temperature thread sealants have not been used in high temperature applications.
o. High point vents and drains have been provided, if required, and verified that they have
pipe plugs.
p. Air vents and exhaust ports have bug screens installed.
q. No physical damage, including paint damage or cracked glass, has occurred to the
equipment.
r. Unused instrument and electrical equipment are plugged with proper plugs.
s. For instruments and tubing that require heat tracing, installation inspection shall be
according to GP 12-XX and the following:
1. Verification of adequate coverage, arrangement, and accessibility.
2. Continuity testing of the heat tracing installation.
3. Heat limiting arrangement to prevent boiling in impulse lines and accelerated
corrosion.
7.4. Piping, conduit, cable, and tubing
7.4.1. General
a. Piping, conduit, cable, and tubing shall be inspected for proper support in accordance with
specified requirements.
b. Piping and tubing in instrument signal air service shall be tested in accordance with
ISA 7.0.01.
c. Tubing connections shall be tight and in accordance with Manufacturer specifications.
d. Tubing connectors (nuts, ferrules, and fittings) shall be from the same manufacturer and of
the same type.
e. Tubing and instruments shall be leak-tested and the inside diameter of tubing and piping
verified.
f. Leak test should consist of the following:
1. Apply the maximum input signal input pressure to the process connection.
2. Close the inlet and disconnect the pressure source.
3. Observe the gauge on the signal inlet and ensure there is no fall-off of pressure over a
given period.
4. If leaks are evident, these shall be eliminated and the test repeated.
g. Field mounted electrical instruments using conduit shall have seals installed with sealant
as specified.
7.4.2. Tubing compression fittings

a. For instrument tubing runs, each compression fitting shall be inspected by one of the
following methods:
1. Manufacturer go/no-go inspection gauges.
2. 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
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disassembled for inspection. For each improperly made up fitting, an additional two
fittings shall be inspected by disassembly.
b. Inspection criteria for tubing compression fittings shall include:
1. Cleanliness.
2. Burrs or deep longitudinal scratches.
3. Square tube ends.
4. Galling of the ferrule or fitting seat.
5. Tubing is out of round from bends being located too close to the fitting.
6. Tube bottoms in fitting body.
7. Ferrule adequately biting the tube and back from the tube end.
8. Ferrule(s) fitted correct way round.
7.4.3. Wire and cable

a. Field wiring shall be inspected according to GP 12-XX and the following:
1. Check wiring against drawings.
2. Confirm wire labelling is correct.
3. Verify wire size and type.
4. Check for proper circuit isolation at junction boxes and terminations.
5. Low voltage signals shall be isolated from power. IS circuits require barriers and
isolation.
6. Verify wiring terminals are the correct type and wiring has been properly dressed-out
to provide easy access to terminations.
b. Fieldbus wiring verification and cable acceptance testing shall be in accordance with
GP 30-30.
c. Electrical gland connections shall be tight and electrical tape not added as filler.
7.5. Control valves inspection checks

a. Control valve and regulator installation shall be in accordance with GP 30-35 and this GP.
b. Control valves and regulators shall be checked to ensure that installation orientation agrees
with process flow direction.
c. Lubricators and isolating valves shall be checked for proper installation and loading.
d. Valve plugs and shaft orientation on rotary valves shall be checked.
e. 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.
f. Control valves, regulators, and accessories shall be checked against nameplate data and
instrument data sheets, and the results recorded.
g. Pressure regulator nameplate set pressure value shall be checked against Manufacturer
specification data.
h. 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.
i. Diaphragm and piston-operated control valves shall be bench checked as follows:
1. Stems shall be inspected for burrs or paint, which shall be removed if present to
prevent valve packing damage.
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2. If required, valves shall be lubricated in accordance with Manufacturer instructions.

j. Throttling butterfly valves shall be checked for a mark to indicate vane position.
k. Valve visual inspection and checks shall include at least the following:
1. Verify that internal moving parts of valve actuators are correctly lubricated (where
applicable) to ensure safe operation.
2. 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.
3. Visually inspect facility piping systems and valve internals for damage and verify the
correct installation of internals.
4. Verify that valves are in the correct open or closed operating mode.
7.6. Temperature instruments inspection checks

a. Temperature instruments installation shall be in accordance with GP 30-01 and this GP.
b. Thermocouple systems shall be checked for:
1. Type.
2. Polarity.
3. Double reversals.
4. Proper point identification.
5. Proper burnout indication.
c. For thermocouple elements, the following shall be verified:
1. Element type is as specified (for example, E, K, R).
2. Junction type is correct (earthed/grounded or unearthed/ungrounded).
d. Thermowells shall be checked to verify that they comply with the Data Sheet. This check
may include verifying the correctness of:
1. Material.
2. Flange rating.
3. Insertion length.
e. RTD transmitters and receivers shall be checked to ensure that RTD material matches the
Data Sheet.
7.7. Flow instruments

a. Flow instruments installation shall be in accordance the following ETPs and this GP:
1. GP 64-XX, for fiscal flow instruments (Class 1).
2. GP 30-10, for non-fiscal flow instruments (Class 2 and 3).
b. Correct flow direction shall be verified.
c. 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.
d. Lines containing inline flow elements shall be cleaned and flushed before installation of
the flow element.
e. Inline flow elements shall be removed before lines are flushed or hydrostatically pressure
tested.
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f. Differential pressure type flow instruments, during hydrostatic pressure tests:

1. Orifice tap shutoff valves shall be closed.
2. Instrument drain valves shall be opened.
g. Rotameters shall be checked to ensure:
1. Installation is plumb.
2. Shipping stops shall be removed and floats inserted.
h. The following meters shall be checked for free operation of internal parts:
1. Rotameters.
2. Turbine meters.
3. Positive displacement meters.
i. Differential flow elements and meter runs shall be checked for compliance with
Manufacturer and BP specifications.
j. The following shall be checked for dimension and material compliance with the Data
Sheet:
1. Flow orifice meter runs.
2. Venturi tubes.
3. Flow nozzles.
k. For orifice plates, bores shall be callipered before installation as follows:
1. Bores shall comply with the specification.
2. Bores shall be within tolerances shown in Table 1.
Table 1 - Practical tolerances for orifice diameters
Orifice diameter Practical tolerance (+/-)

mm in mm in
6 0,250 0,0075 0,0003
9,5 0,375 0,01 0,0004
12 0,500 0,0125 0,0005
25 1,0 0,0125 0,0005
25+ 1,0+ 0,0005 0,0005
(per mm of (per inch of
diameter) diameter)
3. Results shall be recorded on certification documentation.

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

a. Level instruments installation shall be in accordance with GP 30-15 and this GP.
b. Installation of the following shall be checked for proper installation:
1. Gauge glasses.
2. Gauge cocks.
3. Illuminators.
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10 June 2003 GP 30-90
4. Ball checks.
5. Heat tracing.
6. Other accessories.
c. External float and displacer type level instruments shall be checked as follow:
1. The float chamber shall be blocked, drained, and vented during hydrostatic testing.
2. The operation shall be field checked mechanically by raising and lowering the
displacer with water.
3. The cage shall be checked to ensure it is plumb.
d. Internal float and displacer type level instruments shall be removed during hydrostatic
testing.
7.9. Pressure instruments

Pressure instruments installation shall be in accordance with GP 30-05.
8. Loop check and system checkout
8.1. Prerequisites
a. The following shall be verified before loop check or system checkout:
1. All items are mechanically completed.
2. Installation inspection is completed.
3. Compliance with local requirements and regulations.
b. Pressure testing and blowing out of tubing runs shall be completed before initial
connection to instruments.
c. All documentation pertaining to the loop should be available as per section sub-clause
6.1.1.1.c
8.2. General
a. For loop checking, 24-hours notice should be given to BP. This advance notice allows the
following BP personnel to plan to attend the loop check:
1. Instrument/Electrical (I/E) representative, who is responsible for signing off on the
loop check sheet,
2. Operations representative.
b. The following procedure should be followed to ensure all elements in the loop are
checked:
1. Check each loop in accordance with the latest revision of the “approved for
construction” loop diagram.
2. As the loop check proceeds and elements are checked, highlight verified portions of
the loop drawing.
3. Complete the appropriate loop check documentation.
4. 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.
5. The loop check should include a test label, with tester’s initial and date for
traceability.
c. Discrepancies, errors, or deficiencies shall be corrected and rechecked.
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d. The sequence of loop certification shall be coordinated with area construction schedules.
e. Loops shall be checked as a complete system, from inputs to outputs.
f. 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).
g. 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.
h. A functional loop check shall be made while all loop instruments are energized.
8.3. Instrument calibration and checkout
8.3.1. General
a. Factory calibrated instruments should be verified by corresponding certification.
b. Instruments that have been factory calibrated shall not be recalibrated in the field.
c. 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.
d. If the calibration check indicates that the instrument will operate within the manufacturer
stated accuracy, additional calibration shall not be required.
e. Calibration of instruments shall be reserved only for those devices that, upon checking, are
not within their specified operating range.
f. Calibration checks shall be documented.
g. Stickers with the following information shall be attached to instruments that have been
checked and calibrated:
1. Date and time of calibration verification.
2. Technician identification.
h. To verify, calibration checks should be performed as follows:
1. At a minimum of three calibration points (0%, 50%, and 100% of operating range), or
otherwise indicated.
2. For smart transmitters, use electronically simulated outputs.
3. For standard analogue transmitters, use simulated process variable inputs.
4. 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.
i. Check loop components for:
1. Correct readout or response at each transmitter input level.
2. Correct action of the controller, positioner, and control valve.
3. Incorrect response or readout shall be reported for correction.
j. Instrument covers and enclosures that were removed for calibration shall be replaced.
k. Loop check personnel shall not change calibration or system ranges without BP approval.
l. Conflicting data encountered between calibration ranges of field devices and displayed or
configured ranges within the PAS shall be brought to BP’s attention for resolution.
m. Signals shall be simulated at the input of the end device as shown in Table 2 (for analogue
transmitters) and Table 3 (for switches).

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Table 2 - Simulating signals at analogue transmitters
Type of transmitter Procedure

Pressure, orifice meter, and d/p Pump up at 0%, 50%, and 100%.
Temperature Read the temperature.
Level (d/p type) Fill column with BP approved liquid to 0%, 50%, and 100%.
Analogue transmitters, for which the process Check at zero. Use a calibrator (for example, Altek) to input a
parameter cannot be simulated current at 0%, 50%, and 100%.
Table 3 - Simulating signals at switches
Type of switch Procedure

Level Fill float chamber with BP approved liquid to trip the switch.
Pressure or d/p Pump it up to trip the switch.
Transmitter current 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. Digital communications devices may be used to set smart transmitter output to the required
levels for loop checking.
o. Smart transmitters shall be operationally tested and digitally ranged.
p. Input devices should be checked as follows:
1. 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).
2. 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.
3. For PLC inputs, use a voltmeter or check the input card indication light.
4. For relays, use a voltmeter or visually check the relay state.
5. Check local indicators or other remote indicator readings.
q. If feasible, correct outputs should be verified as shown in Table 4.
Table 4 - Output verification
Type of output Procedure

Controllers with control valves Put controller in manual and check valve movement
corresponding to 0%, 50%, and 100% output.
Discrete outputs Confirm that the output state (either DCS, PLC, or relay) at the
end device matches the expected output state.
Automated valves Check the valve at 0% and 100%.
Valves with a failure position 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. For control loops, increasing or decreasing transmitter input should open or close the
control valve, as applicable.
2. For shutdowns, toggling the inputs should cause solenoid valves or other end devices
to open or close or be on or off, as applicable.

Page 17 of 31
10 June 2003 GP 30-90
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.
8.3.2. Calibration test equipment

a. If calibration is required the test equipment shall be according to this section.
b. Shop test equipment (excluding pressure generating devices, such as manometers and dead
weight testers) shall require certification. Certification shall be:
1. Current within one year of testing activity.
2. Traceable to a recognized, BP-approved certification agency.
3. Kept on file.
c. 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.
d. Transmitting or receiving signal accuracy of calibration equipment shall be greater than the
instrument to be calibrated.
e. Pneumatic calibration gauges, electronic test meters and equipment, and digital strain
gauge instruments shall have an accuracy of at least 0,1% full scale.
f. Portable field test devices shall be tested for accuracy at least twice a week against shop
calibration equipment.
g. 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.
8.3.3. Receiving instruments

a. Controllers, recorders, and indicators shall be checked for alignment in accordance with
the Manufacturer-supplied manual.
b. Recorder charts and pens shall be prepared for use.
c. Charts and scales shall be checked for range in accordance with specifications.
8.3.4. 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.
b. Switches used in alarms, shutdown, or signal switching service shall be set to specified
values by applying a rising and falling signal.
c. Dead bands shall be checked to ensure they are within the Manufacturer published
tolerance.
8.3.5. Control valves and pressure regulators

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

Page 18 of 31
10 June 2003 GP 30-90
e. Throttling butterfly valves are set for maximum travel restrictions in accordance with
specifications.
f. The following shall be completed and recorded:
1. Check valve failure action.
2. Set position indicator.
g. Operation of valve accessories shall be checked, including:
1. Handwheels.
2. Solenoid valves.
3. Limit switches.
4. Boosters.
5. Relays.
h. Handwheels shall be in neutral position before stroking valves.
i. Diaphragm and piston-operated control valves shall be pneumatically stroked using a
regulator and test gauge.
j. The following shall be verified to be in accordance with Manufacturer nameplate data and
job specifications (if applicable) and recorded:
1. Valve action.
2. Mechanical seating.
3. Spring range or bench setting shown on valve nameplate.
4. Valve travel (including bench set).
5. Valve failure position.
6. Actuator setting (either reverse or direct action) is in accordance with Manufacturer
specifications.
7. Limit switches indicate full open and close.
8. Solenoid valves bleed the actuator when energized or de-energized.
9. 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.
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. 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.
l. 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.
m. 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.
n. Check valve for smoothness of operation (hysteresis and stiction) according to the
pertinent sections on control loop tuning, GP 30-95.

Page 19 of 31
10 June 2003 GP 30-90
o. Manually operated valves (including skid mounted valves) shall be manually sequenced
and spindle rotation and integrity shall be verified.
8.3.6. Automated Valves

a. Automated valve shall be checked as follows:
1. Stroke valve from the PAS.
2. Check limit switch settings, open and closed. Limit switches should be less than
90 degrees apart from each other (approximately 85 degrees).
3. Verify that the following all match the valve position:
a) Valve shaft.
b) Beacon.
c) PAS.
4. Verify the valve fail position as follows:
a) For fail last, open the valve, turn off power at the field junction housing, and
ensure the valve holds the open position.
b) Repeat the same procedure for closed valve position.
5. If valves are fitted with handwheels, manually stroke the valve with the handwheel.
6. Check travel stops.
b. After automated valves are checked, valves shall remain energized.
8.3.7. Temperature instruments

a. Temperature indicators shall be checked at ambient conditions, where practical.
b. Certification of calibration should be provided by equipment Manufacturers that embed
devices in their products (for example, motor winding RTDs).
c. Thermocouples and RTDs should not require calibration checks if accompanied with
vendor test certification and/or if they are removable in service.
d. 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. Check for ambient reading.
2. Remove RTD/thermocouple to verify the correct point is being read.
3. Check output of RTD and thermocouple elements:
a) For RTD elements, measure element resistance and compare measurement to the
ambient temperature.
b) For thermocouple elements, measure millivolt output and compare measurement
to the ambient temperature.
4. Verify the signal at the receiving instrument and/or PAS.
e. 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.
f. 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.

Page 20 of 31
10 June 2003 GP 30-90
g. 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) At three calibration points, minimum (0%, 50%, and 100% of operating range).
b) By immersing the sensing bulb in a precisely controlled and agitated
temperature bath that is continuously monitored with a precision thermometer.
2. Non-factory calibrated thermocouple transmitters and receivers shall be calibrated, if
required, as follows:
a) Apply upscale and downscale millivolt signals from a precision voltage source.
b) Verify and adjust upper and lower operating limits.
c) Recheck the three-point calibration.
3. Non-factory calibrated RTD transmitters and receivers shall be checked, if required,
as follows:
a) Use a precision decade resistance box.
b) Verify and adjust upper and lower operating limits.
c) 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 Checking procedure

All types Check dead band to confirm that it is within Manufacturer stated
tolerance.
Filled Check and set to specified trip point by immersion in fluidised
sand bath or controlled temperature bath (depending on
temperature range).
Thermocouple Check using a precision voltage source.
RTD Check using a precision decade resistance box.
8.3.8. Flow instruments

a. Flow indicators shall be zeroed.
b. Transmitting and indicating rotameters in which the float is not visible shall be calibrated
as follows:
1. Manually position the float.
2. 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 BP specifications.
d. The following meters shall have their zero and span checked in accordance with
Manufacturer recommended procedure:
1. Turbine meters.
2. Positive displacement meters.
3. Vortex meters.
4. Ultrasonic meters.
5. Coriolis meters.

Page 21 of 31
10 June 2003 GP 30-90
6. Magnetic meters.
7. Target meters.
e. Thru-flow type flow switches shall be mechanically checked only.
f. Differential pressure type flow switches shall be checked as follows:
1. Calibration shall be against a standard water column manometer or precision gauge.
2. Dead band of switches shall be verified against the Data Sheet.
8.3.9. Level instruments

a. For cage displacer type instruments, the following shall be checked:
1. Pneumatic or electronic transmitter with output gauges or meters for smooth and full
output change.
2. Operation of the pneumatic controller and verification that the set action (direct or
reverse) complies with the Data Sheet.
b. Level indicators shall be zeroed.
c. External displacer type level instruments shall be calibrated as follows:
1. Set specific gravity adjustment to 1,0.
2. Fill chamber with clean water, while using clear plastic tubing connected at the
bottom drain as a gauge glass.
3. Check calibration at three points (0%, 50%, and 100% of span).
4. After each calibration adjustment, recheck for zero.
5. 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. Set specific gravity adjustment to 1,0.
2. Check calibration at three points (0%, 50%, and 100% of span).
3. After each calibration adjustment, recheck for zero.
4. Reset specific gravity adjustment to operating conditions.
e. To verify calibration of differential pressure (d/p) level instrument checks should be
performed at three points (0%, 50%, and 100% of span).
f. Level instrument switches shall be checked and set as follows:
1. Float operated level switches shall be checked for switch operation by filling the float
chamber with water.
2. Head, displacer, or differential pressure operated level switches shall be set at the
required trip points.
3. Dead band of the switches shall be verified against the Data Sheets.
g. Ultrasonic, radar, capacitance, and other special types of level instruments shall be checked
in accordance with Manufacturer recommendations.
8.3.10. Pressure instruments

a. Pressure gauges shall be checked at ambient conditions.
b. To verify calibration of pressure and differential pressure (d/p) transmitters checks should
be performed at three points (0%, 50%, and 100% of span).
c. Switches shall be checked and calibrated as follows:
Page 22 of 31
10 June 2003 GP 30-90
1. 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.
2. Verify dead band of the switches against the Data Sheet.
d. If pressure gauge reading suspect, the manufacturer should be notified and the instrument
replaced.
e. For critical pressure gauges and/or as required by the BP engineer 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.
2. Draft type instruments shall be bench calibrated using an inclined-tube manometer or
precision accuracy strain gauge at 0%, 50%, and 100% of range.
3. Receiver type pressure gauges should be field checked to verify calibration at three
points (0%, 50%, and 100% of span).
4. Diaphragm type draft gauges shall be field checked to verify calibration as follows:
a) Verify calibration at three points (0%, 50%, and 100% of span).
b) Use a water column or inclined tube manometer in accordance with
Manufacturer recommended procedure.
8.3.11. Analytical instruments

a. Analytical instrument checkout and calibration shall be in accordance with GP 31-XX and
this GP.
b. Sample systems shall not be connected to process piping before commissioning, at which
point they should be:
1. Installed and cleaned to meet analyser system requirements.
2. Inspected for proper installation, operation, and tightness.
c. 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 engineer’s direction.
d. The following shall be verified:
1. Necessary standard and calibration samples are available.
2. Spare parts (including filters. coalescers, and consumables) necessary for initial
calibration, startup, and testing are available.
3. Analyser housing has appropriate approvals for the area classification.
e. Calibration shall be in accordance with Manufacturer recommended procedure using
sample gases or liquids provided.
f. Analytical instruments shall be checked as follows:
1. Analysers shall be inspected for correct installation of piping and wiring.
2. A two-point field calibration check shall be performed.
g. 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. Analyser is recording properly.
2. All alarms are functional.

Page 23 of 31
10 June 2003 GP 30-90
3. Peak picking capability is operating.

4. Interrupt functions operate correctly.
5. Automatic shutoff of sample flow is functioning.
6. Sample flow rate is adequate.
7. Sample transport time is acceptable.
h. Analysers shall be protected during hydrostatic testing as follows:
1. Sample taps shall be isolated.
2. Analyser tubing shall be disconnected.
3. After completion of the hydrostatic testing, sample piping shall be dried with dry air
and sealed.
i. 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.
j. Power connections to the analyser and a.c. circuits to the distribution panel shall be
verified. The power feed breaker(s) shall not be closed without BP approval.
k. Process connections shall remain closed until after startup.
l. Sample system piping shall be flushed with process fluid for several hours before allowing
samples to enter analyser.
8.3.12. Miscellaneous field instruments

a. Miscellaneous instrument checkout and calibration shall be in accordance with GP 30-20
and this GP.
b. Density or specific gravity meters as a minimum shall have their zero and span checked in
accordance with Manufacturer recommended procedure.
c. Special instruments not discussed in this GP shall be checked and calibrated in accordance
with Manufacturer instructions and BP specifications.
8.4. Systems checkout
8.4.1. General
a. The complete functions tested during FAT should not be retested onsite.
b. Retesting or an acceptable subtest should be required only to verify proper installation and
integration with other systems onsite.
c. Additional requirements for specific systems shall be in accordance with the following:
1. GP 30-30 for fieldbuses.
2. GP 30--40/45 and GIS 30-401/402/451 for process automation systems.
3. GP 30-65 for local control panels.
4. GP 30-70 for vendor package equipment.
5. GP 30-80/81 and GIS 30-801 for safety instrumented systems (SIS)
6. GP 30-85 and GP 30-851 for fire and Gas (F&G) systems.
d. Control systems components shall be checked as follows:
1. Check dynamic variables on each graphic screen during loop checks and verify
readings are correct.
2. Verify commands from operator consoles and screens.
Page 24 of 31
10 June 2003 GP 30-90
3. Check printed logs and reports.

e. Cascade systems shall be checked to ensure proper functioning of:
1. Primary loop control set points.
2. Secondary loop.
3. Control action.
f. Interlock, safety, and sequential control systems shall be checked for continuity and
verified with a functional test of each circuit.
g. Control system loop continuity and output action shall be checked as follows:
1. Verify that control actions are set in accordance with specifications.
2. Observe control outputs and controller responses.
3. Check and observe auxiliary functions (for example, alarms, ratioing, etc.).
h. Loop points shall remain disabled until they are loop checked.
i. Points that are loop checked shall remain active on the control system.
8.4.2. Controllers
a. Ratio controllers shall be checked by feeding a known signal into the station and observing
the output for various set ratios.
b. Set control modes, set points, and tuning parameters.
c. If controller tunings are not known, refer to GP 30-95 for guidance on control loop tuning.
d. After loop checking, controllers shall be left in manual mode.
8.5. 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) Low, high, or deviation alarm operation.
b) Auxiliary contact operation.
c) Proper sequence.
2. Verify correct actuation of each device as described in the specification for the
particular type of instrument.
b. Alarm windows and nameplates shall be verified for accuracy and correct location.
c. For alarm and switch sensing elements, the following shall apply:
1. Abnormal conditions shall be simulated by either of the following methods:
a) Simulate the process variable.
b) Manually trip the switch.
2. The correct operational sequence and actions of related devices shall be checked.
3. Switch terminals shall not be jumpered to simulate actuation without written BP
approval.
8.6. Logic system components

Page 25 of 31
10 June 2003 GP 30-90
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. Devices shall be thoroughly checked as an integrated system for continuity and
operation.
2. Shutdown and interlock responses shall be checked against shutdown and interlock
logic diagrams.
b. Switching and shutdown systems shall be checked as follows:
1. Perform check from the originating device to the switching or shutdown function.
2. Verify the operation of each circuit using the latest issue of the designated
logic/ladder drawings.
3. Record changes to logic/ladder drawings and show on “as-built” logic/ladder
drawings.
4. Check PLC systems using Manufacturer-provided system test procedures.
c. Process-actuated switches and process transmitters shall be checked as follows:
1. Activate by simulating the process variable or by manual trip.
2. Perform functional test, without use of jumpers.
d. Each shutdown system shall be checked as follows:
1. Verify failsafe design philosophy.
2. Verify the correct state of each output on loss of power to the logic system and on loss
of power to the field devices.
9. Commissioning completion
a. Before commissioning, mechanical completion documentation (including a punch list)

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

Page 26 of 31
10 June 2003 GP 30-90
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. Instruments and loops shall remain powered or pressurized with switches and valves set in
accordance with the startup requirements.
d. Control and instrumentation is considered to be commissioned and ready for startup when:
1. Mechanical completion checklists are signed off as complete.
2. All loop checks and system checkout are signed off as complete.
3. All punch lists are signed off as complete.
4. All commissioning activities are signed off as complete and ready for startup.

Page 27 of 31
10 June 2003 GP 30-90
Annex A
(Informative)
Figure A1 - Commissioning control loops flowchart
MAKE A PACKAGE
CONTROL LOOPS FOR EACH LOOP
START
WITH ALL
PERTINENT INFO
CHECK CONTROL
VALVE OPERATION
VERIFY FROM CONTROLLER
INSTRUMENT PER & VERIFY FAILURE
DATA SHEET/ MODE
SPECIFICATION
CHECK LINEARITY (0,

50 & 100%) RECORD
RESULTS & COPYTO
FACTORY YES LOOP PACKAGE
CALIBRATED?
SIMULATE 50% PV
NO AT TRANSMITTER &
VERIFY SET CONTROLLER
CALIBRATE IN SHOP, CALIBRATION OUTPUT TO 50% IN
RECORD RESULTS, CERTIFICATION MANUAL MODE
COPY TO LOOP COPY TO LOOP
PACKAGE PACKAGE. DO NOT
RECALIBRATE PUT LOOP IN AUTO &
INCREASED
SIMULATED PV,
CHECK VALVE
INSTALL ACTION AND
INSTRUMENTS RECORD RESULTS
RECORD FINDINGS
REWORK TO
AND COPY TO LOOP
INSPECT IS LOOP NO CORRECT
PACKAGE
INSTALLATION PER SATISFACTORY? DEFICIENCIES
INSTALLATION & RETEST AS
DETAILS, RECORD REQUIRED
RESULTS & COPY TO VERIFY ALL PAS YES
LOOP PACKAGE INDICATIONS
ALARMS, PAS
GRAPHICS, ETC. SIGN OFF AS
COMPLETE
YES INSTALLATION &
SPECIFICATION
OK? ENSURE
SIMULATE PROCESS PAPERWORK IS
THREE POINTS COMPLETED &
NO
CHECK (0%. 50%, PROPERLY FILED IN
100%) LOOP
REWORK TO DOCUMENTATION
CORRECT PACKAGE
DEFICIENCIES
CHECK WIRING PER END

SPECIFICATIONS

Page 28 of 31
10 June 2003 GP 30-90
Annex A
(Informative)
Figure A2 - Commissioning field switches flowchart
FIELD SWITCHES MAKE A PACKAGE

(PRESSURE, FOR EACH LOOP
START
TEMPERATURE, WITH ALL
LEVEL, ETC.) PERTINENT INFO
VERIFY
INSTRUMENT PER
DATA SHEET/
SPECIFICATION
FACTORY YES
CALIBRATED?
NO
VERIFY
CALIBRATE IN SHOP, CALIBRATION
RECORD RESULTS, CERTIFICATION
COPY TO LOOP COPY TO LOOP
PACKAGE PACKAGE. DO NOT
RECALIBRATE
INSTALL
INSTRUMENTS
RECORD FINDINGS
AND COPY TO LOOP
PACKAGE
INSPECT
INSTALLATION PER
INSTALLATION
DETAILS, RECORD
RESULTS & COPY TO
VERIFY ALL
LOOP PACKAGE
INDICATIONS SIGN OFF AS
ALARMS ETC. COMPLETE
YES INSTALLATION &

SPECIFICATION
OK? ENSURE
CHECK DEADBAND & PAPERWORK IS
NO COMPLETED &
TRIP POINTS
PROPERLY FILED IN
LOOP
REWORK TO DOCUMENTATION
CORRECT PACKAGE
DEFICIENCIES
CHECK WIRING PER

SPECIFICATIONS.
END

Page 29 of 31
10 June 2003 GP 30-90
Annex A
(Informative)
Figure A3 - Commissioning local gauges flowchart
START
LOCAL INSTUMENT
(GAUGE,
THERMOMETER,
SIGHT GLASS)
VERIFY
INSTRUMENT
AGAINST DATA
SHEET/
SPECIFICATIONS
INSTALL
INSTRUMENTS PER
INSTALLATION
DETAIL
INSPECT
INSTALLATION PER
INSTALLATION
DETAILS, RECORD
RESULTS & COPY TO
LOOP PACKAGE
YES INSTALLATION &

SPECIFICATION
OK?
NO
REWORK TO
CORRECT
DEFICIENCIES
SIGN OFF AS
COMPLETE
END

Page 30 of 31
10 June 2003 GP 30-90
Annex B
(Informative)
Instrument installation loop check sheet
INSTRUMENT INSTALLATION LOOP CHECK SHEET
Project: Instr. Loop No.

Service: Unit:
Primary Element
Installed per installation detail (incl flow direction) Orifice taps orientation (top, side, bot)
Isolating valves correct Materials correct
Location, accessibility Orifice diameter 'd'
Thermowell Depth Orifice inspection report completed
Impulse Connections
Installation correct (including slope, supports) Insulation installed correctly
Electrical/Steam tracing correct Fittings correct/tight
Air Supplies
Visually inspected, blown clear & leak tested Correctly connected to utility lines
Pneumatic and Electronic Signal Transmission Lines
Pneumatic - visually inspect, blown clear & leak chk Electronic - continuity checked
Electronic - polarity checked Electronic - wires/cables labelled
Electronic - Network communications
Field Instruments
Installation correct (including grouting of stands) Weather protected (including instr encl if applic)
Power supply correct Air supply correct
Location, accessibility Hazardous area classification correct
Remote indicator viewable from control valve HW xmitter mode: 4-20ma digital
Panel or Other Instruments
Name plates on panel Scales, charts, factors correct
Alarm switch ma= (inc/dec) Analyzer sample system correct
Power supply correct Air supply correct
Regulator/Relief/other pressure set:
Automated/ Control Valves
Installation/flow direction correct Type & size correct
Location/accessibility Handwheel and/or bypass
Solenoid operation
General
Tagging correct (all components) Gage glasses installed correctly
Wiring and tubing per specs Checked from AMS: yes no opportunity
Instruments verified with ISA data sheets DCS graphics checked: yes no opportunity
Calibration/Direction
Transmitter check: Controller output/valve position check:
0% 50% 100% 0% 50% 100%
URV Vlve Failure: FO FC FH
LRV Controller tuning parameters ok
Switch trip tripped at: Overall Loop Checked as a complete system
Calculation checked (level)
Procedures
FIN FANS
Verify HW shows OFF HOA-> OFF Try HW Start, Shouldn't HOA->HAND Try HW Stop, Shouldn't Verify HW Shows On
HOA->OFF Verfy no HW Strt signl HOA ->AUTO Start f/ HW Stop f/ HW Start f/ HW
HOA->OFF Watch HW command switches from START->STOP HOA->AUTO, verify doesn't restart Verify Vibration S/D
VALVE AUTOMATION Valve Address: _____________________________

24V Power On/Off Limit Switches Failure Posn Handwheel Limit Stops
Comments/Special Considerations
BP Rep Contractor Rep Date

Page 31 of 31

Guidance On Practice For Commissioning of Instrument and Control Systems

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Guidance on Practice for

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Table 1 - Practical tolerances for orifice diameters.........................................................................15

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The Instrumentation, Systems, and Automation Society (ISA)

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3. Symbols and abbreviations

a.c. Alternating current.

DCS Distributed control system.

d/p Differential pressure.

LRV Lower range value.

P&ID Piping and instrument diagram.

PAS Process automation system.

PLC Programmable logic controller.

RTD Resistance temperature detector.

SIS Safety instrumented system.

URV Upper range value.

5. Instrumentation receiving and storage

5.2. Electronic instruments

5.3. Pneumatic instruments

5.4. Local control panels

5.5. Dial thermometers, pressure gauges, and gauge glasses

10. Factory calibration certification. *

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7.3. Instrument inspection checks

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7.4. Piping, conduit, cable, and tubing

7.4.2. Tubing compression fittings

7.4.3. Wire and cable

7.5. Control valves inspection checks

2. If required, valves shall be lubricated in accordance with Manufacturer instructions.

7.6. Temperature instruments inspection checks

7.7. Flow instruments

f. Differential pressure type flow instruments, during hydrostatic pressure tests:

Table 1 - Practical tolerances for orifice diameters

Orifice diameter Practical tolerance (+/-)

3. Results shall be recorded on certification documentation.

7.8. Level instruments

7.9. Pressure instruments

8. Loop check and system checkout

8.3. Instrument calibration and checkout

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Table 2 - Simulating signals at analogue transmitters

Type of transmitter Procedure

Table 3 - Simulating signals at switches

Type of switch Procedure

Table 4 - Output verification

Type of output Procedure

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8.3.2. Calibration test equipment

8.3.3. Receiving instruments

8.3.5. Control valves and pressure regulators

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8.3.6. Automated Valves

8.3.7. Temperature instruments

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Table 5 - Checks for different types of temperature switches

Switch type Checking procedure

8.3.8. Flow instruments

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