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PETROTEL - LUKOIL
ANNUAL TEST PROCEDURE
02/02/04
1. GENERALITIES
The SIL2 agreement forces the maintenance operator to check annually the good functioning of the SIL2
items.
In order to realise this tests, one “Annual test push button” is placed inside the control panel.
Moreover, the maintenance operator will need a computer with the programming software
RSLOGIX5000 revision 10.0 (ROCKWELL).
- Trip signals : All trip & stop signals shall be activated in order to verify that process
parameters are monitored properly and that the system reacts properly when a
fault condition arises.
- Proof test for inputs : This test must be performed to make sure that no inputs are stuck in
ON or OFF position.
- Proof test for outputs : This test must be performed to make sure that no outputs are stuck in
ON or OFF position.
- Pulse test for outputs : This test must be performed to make sure that all outputs are capable
of changing state
- Proof test for analog inputs : This test must be performed to make sure that all inputs are
operational and can vary data values.
- Calibrate analog inputs : Each analog inputs shall be calibrated to make sure the accuracy of
the signal.
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The maintenance operator have to actuate the following signals and verify that process parameters are
monitored properly and that the system reacts properly when a fault condition arises:
Check that the correct trip appears on the Panel View and on the DCS.
Check that the compressor stops.
The results of the test shall be noted on the corresponding sheet (see appendix 1).
The maintenance operator have to push the “Annual test push button” and verify that no input alarms
appears.
The results of the test shall be noted on the corresponding sheet (see appendix 2).
The maintenance operator have to push the “Annual test push button” and verify that no output alarms
appears.
The results of the test shall be noted on the corresponding sheet (see appendix 3).
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The maintenance operator use the RSLOGIX5000 revision 10.0 to perform this test.
Select the I/O configuration menu, then select the outpouts cards (1756-OB16D), the following screen
appears.
PETROTEL - LUKOIL a2c788231
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The results of the test shall be noted on the corresponding sheet (see appendix 4).
The maintenance operator have to push the “Annual test push button” and verify that no input alarms
appears.
The results of the test shall be noted on the corresponding sheet (see appendix 5).
PETROTEL - LUKOIL a2c788231
02/02/04
When all transmitters are calibrated, the operator have to calibrate the analog inputs in the PLC with the
RSLOGIX5000 revision 10.0 software.
Select the I/O configuration menu, then select the analog inputs cards (1756-IF8), the following screen
appears.
PETROTEL - LUKOIL a2c788231
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Remove the terminal block from the analog input card and replace it with a spare terminal block.
Refers to the ROCKWELL documentation “1756-6.5.9 CONTROLLOGIX Analog I/O modules user
manual” (chapter 11) to operate the calibration (see appendix 7).
The results of the test shall be noted on the corresponding sheet (see appendix 6).
PETROTEL - LUKOIL a2c788231
02/02/04
DIGITAL INPUTS
ANALOG INPUTS
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Transmitters Software
INPUT Tag Description calibration calibration
(OK / NOK) (OK / NOK)
INPUT 1 TT0127 LUBE OIL RESERVOIR TEMPERATURE (input 1)
INPUT 2 PT0113A LUBE OIL SUPPLY HEADER PRESSURE (input 1)
INPUT 3 PDT0216A SEPARATION GAS PRESSURE (input 1)
INPUT 4 SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT
PT0222A (SUCTION SIDE) (input 1)
INPUT 5 SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT
PT0223A (DISCHARGE SIDE) (input 1)
INPUT 6 SPARE
INPUT 7 SPARE
INPUT 8 SPARE
Transmitters Software
INPUT Tag Description calibration calibration
(OK / NOK) (OK / NOK)
INPUT 1 TT0127 LUBE OIL RESERVOIR TEMPERATURE (input 2)
INPUT 2 PT0113B LUBE OIL SUPPLY HEADER PRESSURE (input 2)
INPUT 3 PDT0216B SEPARA TION GAS PRESSURE (input 2)
INPUT 4 SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT
PT0222B (SUCTION SIDE) (input 2)
INPUT 5 SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT
PT0223B (DISCHARGE SIDE) (input 2)
INPUT 6 SPARE
INPUT 7 SPARE
INPUT 8 SPARE
PETROTEL - LUKOIL a2c788231
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APPENDIX 7
What This Chapter Contains This chapter describes how to calibrate ControlLogix analog
modules. The following table describes what this chapter contains
and its location.
For information about: See page:
Difference Between Calibrating An Input 11-2
Module and Calibrating An Output Module
Calibrating Input Modules 11-3
Calibrating the 1756-IF16 11-3
or 1756-IF8 Modules
Calibrating the 1756-IF6I Module 11-7
Calibrating the 1756-IR6I Module 11-12
Calibrating the 1756-IT6I Module 11-15
Calibrating Output Modules 11-18
Calibrating the 1756-OF6CI Module 11-18
Calibrating the 1756-OF6VI Module 11-22
Calibrating the 1756-OF4 11-26
or 1756-OF8 Modules
Chapter Summary and What’s Next 11-30
Your ControlLogix analog I/O module comes from the factory with a
default calibration. You may choose to recalibrate your module to
increase its accuracy for your specific application.
This chapter is broken into two sections, calibrating input modules
and calibrating output modules.
You do not have to configure a module before you calibrate it. If you
decide to calibrate your analog I/O modules first, you must add them
to your program. To see how to add a new module to your program,
see page 10-4.
Important: Analog I/O modules can be calibrated on a channel by
channel basis or with the channels grouped together.
Regardless of which option you choose, we recommend
you calibrate all channels on your module each time you
calibrate. This will help you maintain consistent
calibration readings and improve module accuracy.
Difference Between Calibrating Although the purpose of calibrating analog modules is the same for input
An Input Module and and output modules, to improve the module’s accuracy and repeatability, the
Calibrating An Output Module procedures involved differs for each.
When you calibrate input modules, you use current, voltage or ohms
calibrators to send a signal to the module to calibrate it.
When you calibrate output modules, you use a digital multimeter (DMM) to
measure the signal the module is sending out.
Table 11.A
Recommended Calibration Instruments for ControlLogix Analog Modules
Modules: Recommended instrument ranges:
1756-IF16 & 1756-IF8 0 to 10.25V source +/-150µV Voltage
1756-IF6I 0 to 10.00V source +/-150µV Voltage
1.00 to 20.00mA source +/-0.15µA Current
1756-IR6I 1.0 and 487.0Ω resistors1 +/-0.01%
1756-IT6I -12mV to 78mV source +/-0.3µV
1756-OF4 & 1756-OF8 DMM better than 0.3mV or 0.6µA
1756-OF6VI DMM with resolution better than 0.5mV
1756-OF6CI DMM with resolution better than 1.0µA
1
We suggest you use the following precision resistors:
KRL Electronics
534A1-1R0T 1.0 Ohm 0.01% / 534A1-487R0T 487 Ohm 0.01%
A precision decade resistor box can also be used that meets or exceeds the required
accuracy specifications. The user is responsible for assuring that the decade box
maintains accuracy by periodic calibration as specified by the following vendors:
Electro Scientific Industries IET Labs Julie Research Labs
Portland, OR Westbury, NY New York, NY
Series DB 42 HARS-X Series DR100 Series
Calibrating Input Modules Input calibration is a multi-step process that involves multiple services
being sent to the module. This section has three parts. Each input module
requires attention be paid to specific calibration ranges.
This module can be used for applications requiring voltage or current. You
can only calibrate the module using a voltage signal.
• -10 to 10V
• 0 to 5V
• 0 to 10V
• 0 to 20mA
While you are online, you must access the modules’ properties page. To see
how to reach this page, see page 10-19.
Click here to
start calibration
Click here to continue calibration with the Click here to change to Program Mode be-
channels frozen at their current values fore continuing with calibration
4. Set the calibrator for the low reference and apply it to the module.
This screen displays the status of each channel after calibrating for a low
reference. If all channels are OK, continue, as shown below. If any
channels report an Error, retry Step 5 until the status is OK.
5. Set the calibrator for the high reference and apply it to the module.
This screen displays the status of each channel after calibrating for a high
reference. If all channels are OK, continue, as shown below. If any
channels report an Error, retry Step 6 until the status is OK.
After you have completed both low and high reference calibration, this
screen shows the status of both.