You are on page 1of 14

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.

APPLICABLE CODE, STANDARD AND SPECIFICATION


4
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
equipped atmospherically controlled conditions.
4
4.2 All apparatus and testing equipment shall be validated with certificates
from national and international authorized calibration agency.
4.3 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 RFI (Request for Inspection) notification shall be submitted to invite
Owner’s supervisors.
4.5 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 Contractor’s 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 All applicable certificates such as NACE, PMI, Electrical apparatus,
4 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 100°C.
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:
- Dead Weight Tester / Hand pump
- Digital multi-meter
- Hart Communicator
Calibration Procedure:
- Visual inspection to confirm compliance of materials, mechanical
4 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.
- If the transmitter output is not within the manufacturer’s tolerance,
calibrate the transmitter in accordance with the manufacturer’s
recommendations.
- Transmitter with indicating scales shall where necessary have their
indicators calibrated during this check.
- Smart electronic type transmitters shall be functionally tested by

4 using a HART COMMUNICATOR to confirm the device smartness and


its required data population.
6.2 Differential Pressure Type Level Transmitter
Test Equipment Required:
- Dead Weight Tester / Hand pump
- Digital multi-meter
- Hart Communicator
Calibration Procedure:
- Visual inspection to confirm compliance of materials, mechanical
4 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.
- If the transmitter output is not within the manufacturer’s tolerance,
calibrate the transmitter in accordance with the manufacturer’s
recommendations.
- Transmitter with indicating scales shall where necessary have their
indicators calibrated during this check.
- Smart electronic type transmitters shall be functionally tested by

4 using a HART COMMUNICATOR to confirm the device smartness and


its required data population.
6.3 Temperature Transmitter
Test Equipment Required:
- Temperature Calibrator
- Digital Multi-meter
- Decade Box
- Hart Communicator
Calibration Procedure:
- Visual inspection to confirm compliance of materials, mechanical
construction, process and electrical connection and applicable
4
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 manufacturer’s tolerance,
calibrate the transmitter in accordance with the manufacturer’s
recommendations.
- Smart electronic type transmitters shall be functionally tested by
4 using a HART COMMUNICATOR to confirm the device smartness and
its required data population.
6.4 Temperature Element (RTD)
Test Equipment Required:
- Temperature Calibrator
- Digital Multi-meter
Calibration Procedure:
- 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 100°C and record the reading of the temperature
calibrator. Compare result obtain with temperature indicate on digital
thermometer.
- The results should be within the manufacture’s tolerance of ambient
temperature.
6.5 Pressure Gauge
Test Equipment Required:
- Dead Weight Tester / Hand pump
- Digital Manometer
- Test Gauge
Calibration Procedure:
- 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 Manufacturer’s Stated Limit.
6.6 Differential Pressure Gauge
Test Equipment Required:
- Hand pump
- Digital Manometer
- Test Gauge
Calibration Procedure:
- 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.
- 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 Manufacturer’s Stated Limit.
6.7 Temperature Gauge
Test Equipment Required:
- Temperature Calibrator/Oil Bath
- Thermometer
Calibration Procedure:
- Compare Thermo Gauge pointer indication with the certified
digital thermometer at ambient temperature. Where necessary
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
glass thermometer.
- Increase bath temperature equivalent to 100°C. Record the
pointer indications.
- The percentage error calculated from the above readings shall not
exceed Manufacturer’s 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)
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
Verification Procedure:
- 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
Verification Procedure:
- 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
a. Check and confirm control valve air supply (kg/cm2) required and
transducer/valve positioner and accessories data against
manufacturer’s 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 isn’t enough, stroke time shall
be long and valve shall not be in operating position.
• Loss of control signal: if power supply isn’t 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 Test Equipment
a. Nitrogen cylinder.
b. 24VDC power supplier
c. Digital Multi meter.
d. P&F amplifier for proximity switch
6.12.2 Calibration Procedure
e. Check and confirm on-off valve air supply required and valve
positioner and accessories data against manufacturer’s data sheet.
f. Check On-off valve damaged parts by visual.
g. Adjust the instrument air supply to valve (pressure shall be refered
to vendor data.) by air filter and regulator on valve.
h. 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 isn’t enough, stroking time
shall be long and valve shall not be in operating position.
• Loss of control signal: if power supply isn’t enough to attract
solenoid coil, valve shall not be operated.
j. Check position switch function with P&F contact amplifier.
k. Record all results in On-offl Valve Calibration Report.

6.13 Pressure Safety Valves (By Air)


6.13.1 Test Equipment
a. Test Gauge.
b. Air Regulator.
c. Test Bench c/w Manifold.
6.13.2 Calibration Procedure
a. Check the manufacturer’s data/instrument nameplate against CLIENT
Specifications.
b. Connect up pressure relief valve.
c. Check the manufacturer’s 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 “Manufacturer’s Seal” or attempt to adjust


setting.
h. Compile all results in “SAFETY RELIEF VALVE”.
Test Test
Gauge Gauge 1 PSV
1 Water
Containe
r

Release
Air Manifold Manifold Point
Compres No.1 No.2
sor

Drain Drain
Figure 25: TYPICAL TEST SET-UP FOR PRESSURE RELIEF VALVE

6.14 Pressure Safety Valves (By Liquid)


6.14.1 Test Equipment
a. Test Gauge.
b. Regulator.
c. Test Bench c/w Manifold.
d. Pump.
6.14.2 Calibration Procedure
a. Check the manufacturer’s data/instrument nameplate against CLIENT
Specifications.
b. Connect up pressure relief valve
c. Check the manufacturer’s 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 “Manufacturer’s Seal” or attempt to adjust
setting.
h. Compile all results in “SAFETY RELIEF VALVE”.

3
2

Figure 26
ITEM DESCRIPTION
1 Air Regulator
2 Test Gauge
3 Test Bench with Manifold
4 Valve
5 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


it’s validity.

• Site Calibration and commissioning procedure for these particular


instruments shall be available and be used as mandatory requirement for
site works.

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. Instrument Apparatus for Calibration and Test

No Description Model Accuracy Range Make

1 Air Pressure Calibrator DPI 610 0.025%FS -1 to 20bar Druck

2 Oil Pressure Calibrator DPI 610 0.025%FS 0 – 135 bar With Druck
Ext. Sensor 700bar
3 Oil Pressure Calibrator DPI 615 0.025%FS 0 to 400bar Druck

4 Air Pressure Calibrator DPI 603 0.075% FS -1 to 20bar Druck

5 Air Pressure Calibrator DPI 610 0.075% FS -1 to 2bar Druck

6 Hand held Pressure IS33- CRYSTAL


0.05%FS 0 - 3000PSI
Calibrator 36/3000PSI
Eng
7 Multifunction Calibrator MC5/MC5IS 0.025%FS -1 to 700bar Beameax

8 Documenting Calibrator Fluke 726 0.01%Rdg mA, mV, RTD, TC Fluke


9 Documenting Calibrator Fluke 741B 0.01%Rdg mA, mV, RTD, TC Fluke

10 Documenting Calibrator Fluke 743B 0.01%Rdg mA, mV, RTD, TC Fluke

11 Multifunction Calibrator Fluke 725 0.01%Rdg mA, mV, RTD, TC Fluke

12 Loop Milliamp UPS.IS 0.01%Rdg mA Druck


Calibrator
13 Multi-meter Fluke 87II 0.03%Rdg mA, A, mA, V, Fluke
Ohm, Hz
14 Hart Communicator 275 N/A communication Hart

15 Hart Communicator 375 N/A communication Hart

16 Unomat Calibrator TRX -IS 0.01%Rdg mA, mV, RTD, TC Druck

17 Dry -Well Calibrator DBC150TC 0.1oC -45 to 150oC Druck

18 Dry -Well Calibrator 0.10oC -45 to 150oC Hart


9011
0.15oC 50 to 670oC
19 Dry -Well Calibrator 9170 0.15oC -45 to 140oC Hart

20 Dry -Well Calibrator 9173 0.35oC 50 to 650oC Hart

Appendix-2. Quality Control Form (QCF) List

QCF-I002 Instrument Unpacking Inspection


QCF-I003B Instrument Transmitter Calibration
QCF-I004B Pressure Gauge Calibration
QCF-I004C Diffrential Pressure Gauge Calibration
QCF-I005B Temperature Gauge Calibration
QCF-I005C Temperature Element (RTD) Inspection
QCF-I006B Orifice Plate and Restriction Orifice Control
QCF-I014 Pneumatic Control Valve Calibration
QCF-I015 On-Off Valve Function Test
QCF-I016 Pressure safety/relief valve Calibration