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PRECOMMISSIONING CHECKS IN PYRO Instrumentation section

1. All instrumentation needs to be verified to the central control room. A


checklist of all instruments can be generated from the electrical devices flow
diagrams and the equipment one line diagrams. Each instrument should be checked
from the field device to CCR. At some plants the electrical engineer responsible
for instrumentation has already generated this list during his point check. During
the commissioning check we verify that each instrument is:
In the correct location both in the field and on the display.
That the transmitter is functioning.
That the engineering units are correct.
That the instrument is calibrated to the correct range and that the DCS is ranged
correctly.

Pressure transmitters. For process pressure transmitters in the preheater and


cooler it is best to induce either a positive or negative pressure with the process
equipment (fans). The commissioning personnel can go directly to each
pressure tap, disconnect that point. Check that the proper point zeros in the
control room, take a manual reading, and then compare to the signal in the
control room after reconnecting. This verifies piping, wiring, DCS addressing,
and calibration all at one time. If it is not possible to run the equipment, or to
obtain a calibrator, the engineer can simply disconnect the tap and induce a
positive or negative pressure by simply blowing or sucking into the instrument
tubing. This verifies piping, wiring, and DCS addressing. The person working
the check out from the control room can verify range. Calibration can then be
checked during the initial stages of start-up. For pneumatic and hydraulic
pressure transmitters an analog gauge should be installed inline with the
transmitter and the pressure crosschecked to the control room.
Temperature transmitters. For process temperature readings, the most often
used method of checking, is to go to the thermocouple or RTD at the point that it
enters the process, open the back of the probe and disconnect one lead. The
person checking from the control room should see the temperature reading go
from ambient to out of range. Reconnect the probe and verify that the
temperature goes back to ambient. For fluid temperatures again a field reading is
best used.
Gas analyzers. It is best to work with the instrumentation specialist calibrating
the analyzers using test gasses. During this time the signal going back to the
control room can be checked. Ensure that the kiln inlet probe is located properly