I&E

Department
Manual
EPCL ,
PORT
QASIM,
KARACHI

PREPARED BY

Al-301 A/B
ROSEMOUNT
OXYGEN ANALYZER
CALIBRATION
PROCEDURE

Document No.

IP

Rev No. / Date

00

Issue No. / Date

Effective Date
Page No.

21/OCT/11/2006

Prepared by: MRA

:
I&E ENGINEER (MRA)

REVIEWED BY

APPROVED BY

2
Page 1 of 9

DATE

______________________________________
SENIOR ENGINEER I&E (SMKR)

____________________
DATE

MAINTENANCE UNIT MANAGER (NS)

____________________
DATE

SUB SOC (I&E) CHAIRMAN (NIR)

DATE

I&E
Department
Manual
EPCL ,
PORT
QASIM,
KARACHI

Al-301 A/B
ROSEMOUNT
OXYGEN ANALYZER
CALIBRATION
PROCEDURE

Document No.

IP

Rev No. / Date

00

Issue No. / Date

Effective Date
Page No.

21/OCT/11/2006
2
Page 2 of 9

Prepared by: MRA

1. PURPOSE
The purpose of this procedure is to ensure compliance with the requirements of Rosemount Oxygen analyzer(Furnace Stack)
calibration and testing given in OEM manuals. The document is prepared to satisfy the requirement on safety
critical devices.
2. SCOPE
The scope of this section covers those steps necessary to perform and document oxygen analyzer calibration and
testing.
EMERGENCY HEALTH INFORMATION:
Before embarking on any activity make sure to read the relevant material safety data sheet for potential health Hazards, first
aid measures, PPEs .Always follow the work permit information.
Fire Hazard:
In the event of a fire, wear approved positive pressure, self-contained breathing apparatus, and full protective gear. Fight fire
from protected location or maximum possible distance. Stop flow of gas before extinguishing fire. Immediately evacuate area.
Cool exposed equipment with water spray until fire is out. VCM Vapors are heavier than air and may travel along the ground.
VCM may be moved by ventilation and ignited by flame, sparks, heaters or other ignition sources at distant locations. Vapors
can form flammable mixtures in air.
Potential Health Effects and Symptoms of Over-Exposure:
Eye Contact:
Skin Contact:
Inhalation:

Excessive exposure to gas or liquid may cause irritation. Contact with liquid may cause burns or
frostbite.
Contact with liquid may cause burns or frostbite.
Short-term, high level exposure may lead to asphyxia, anesthesia, dryness of nose and throat,
headache, rapid respiration, respiratory irritation, mental dullness, in-coordination, nausea,
unconsciousness and death. Long-term exposure may increase the risk of cancer, joint and muscle
pain, toxicity to the liver, kidney, brain, cardiovascular system and lungs.

First Aid Measures:

Eye Contact:
Skin Contact:

Inhalation:
Ingestion:

Immediately flush eyes with large amounts of water for 15 to 30 minutes. Seek medical attention.
Immediately flush affected skin with large quantities of water under emergency safety shower while
removing contaminated clothing and shoes. Wash affected area with mild soap. Call a physician if
irritation, frostbite or chemical burns occur. For frostbite, do not rub but warm affected area by placing
in lukewarm water.
Remove from exposure to fresh air. If breathing is difficult, give oxygen. Call a physician.
If swallowed, call a physician immediately. Only induce vomiting at the instruction of a physician.

Personal Protective Equipments:

I&E
Department
Manual
EPCL ,
PORT
QASIM,
KARACHI

Al-301 A/B
ROSEMOUNT
OXYGEN ANALYZER
CALIBRATION
PROCEDURE

Eye Protection:
Skin Protection:
Respiratory Protection:
Engineering Control:
Prevention:

Document No.

IP

Rev No. / Date

00

Issue No. / Date

Effective Date
Page No.

21/OCT/11/2006
2
Page 3 of 9

Prepared by: MRA

Chemical goggles, splash proof face shield

Full protective clothing, neoprene or rubber gloves, boots to prevent skin contact.
Approved air-supplied respirator or SCBA for non-routine and emergency work.
Ventilation Requirements, Local Exhaust, General ventilation should be adequate to
maintain the ambient workplace atmosphere.
Avoid contact with skin and avoid breathing vapor. Do not eat, drink, or Work/Hygiene
smoke in work area. Wash hands thoroughly after handling, especially before eating,
drinking, smoking, chewing, or using restroom facility. Contaminated clothing and shoes
should be thoroughly cleaned before re-use or properly disposed of.

3.1 TOOLS REQUIRED:

Standard tool kit (for instrument technician)
Calibration gas (Oxygen with range between of (0.4~10% )
cylinder with pressure regulator.
3.2 CONSUMABLE:
Cotton waste
Brush
3.3 MANPOWER:
Instrument Technician
Asst. Technician

01
01

3.4 ESTIMATED TIME:

3 hrs
3.5 JOB PREPARATION:
1) Arrange material and man power for the job.
2) Perform Job Safety requirement and analysis
3) Get the work permit for calibration.

3. 6 CALIBRATION THROUGH KEYPAD:

Oxygen analyzer will be calibrated as per frequency specified in the calibration matrix maintained by the Instrument
Section or as per Operations requirement.
1. Place the control loop in manual.
2. Press the CAL key. The CAL LED will light solid.
3. Apply the Zero (0.4%) calibration gas.
4. Press the CAL key. When the unit has taken the readings using the zero calibration gas, the CAL LED will flash
continuously.
ENSURE THE ZERO CALIBRATION WITH (0.4%) GAS.

I&E
Department
Manual
EPCL ,
PORT
QASIM,
KARACHI

Al-301 A/B
ROSEMOUNT
OXYGEN ANALYZER
CALIBRATION
PROCEDURE

Document No.

IP

Rev No. / Date

00

Issue No. / Date

Effective Date
Page No.

21/OCT/11/2006
2
Page 4 of 9

Prepared by: MRA

5. Remove the first calibration gas and apply the (span) calibration gas.
6.Push the CAL key. The CAL LED will light solid. When the unit has taken the readings using the second calibration gas,
the CAL LED will flash a two-pattern flash or a three pattern flash. A two-pattern flash equals a valid calibration, three-pattern
flash equals an invalid calibration.
7. Remove the span (10%) calibration gas and cap off the calibration gas port.
ENSURE THE SPAN CALIBRATION WITH (10%) GAS.
8.Press the CAL key. The CAL LED will be light solid as the unit purges. When the purge is complete, the CAL LED will turn
off.
9.If the calibration valid, the DIAGNOSTIC ALARMS LEDs indicate normal operation. If the new calibration values are not
within the
parameters, the DIAGNOSTIC ALARMS LEDs will indicate an alarm.
3.7 CALIBRATION THROUGH HART COMMUNICATOR

Use the following procedure to perform a calibration using the HART Communicator.
If necessary, use the menu tree in Figure for reference.
1. From the PERFORM O2 CAL screen, select menu item 1, O2 CAL, to
access the O2 calibration procedure.
2. In the first O2 CAL screen, a "Loop should be removed from automatic
control" warning appears. Remove the Oxymitter 4000 from any automatic
LOOP SHOULD BE REMOVED FROM AUTOMATIC CONTROL

I&E
Department
Manual
EPCL ,
PORT
QASIM,
KARACHI

Al-301 A/B
ROSEMOUNT
OXYGEN ANALYZER
CALIBRATION
PROCEDURE

Document No.

IP

Rev No. / Date

00

Issue No. / Date

Effective Date
Page No.

21/OCT/11/2006

Prepared by: MRA

2
Page 5 of 9

I&E
Department
Manual
EPCL ,
PORT
QASIM,
KARACHI

Al-301 A/B
ROSEMOUNT
OXYGEN ANALYZER
CALIBRATION
PROCEDURE

Document No.

IP

Rev No. / Date

00

Issue No. / Date

Effective Date
Page No.

21/OCT/11/2006

Prepared by: MRA

2
Page 6 of 9

I&E
Department
Manual
EPCL ,
PORT
QASIM,
KARACHI

Al-301 A/B
ROSEMOUNT
OXYGEN ANALYZER
CALIBRATION
PROCEDURE

control loops to avoid a potentially dangerous operating condition

and press OK.
3. The next several screens indicate the calibration status. At each of the
following status prompts, select menu item 2, NEXT CAL STEP:
COMPLETE
CAL RECOMMENDED
APPLY GAS 1
GAS 1 FLOW
4. At this point, select menu item 4, EXIT, to leave the O2 CAL procedure.

Document No.

IP

Rev No. / Date

00

Issue No. / Date

Effective Date
Page No.

21/OCT/11/2006

Prepared by: MRA

2
Page 7 of 9

I&E
Department
Manual
EPCL ,
PORT
QASIM,
KARACHI

Al-301 A/B
ROSEMOUNT
OXYGEN ANALYZER
CALIBRATION
PROCEDURE

Document No.

IP

Rev No. / Date

00

Issue No. / Date

Effective Date
Page No.

21/OCT/11/2006

Prepared by: MRA

5. From the PERFORM O2 CAL screen, view menu item 3, CALSTATE, to

monitor the calibration status as it updates. Or, access the O2 CALIBRATE
screen and select menu item 2, O2 CAL STATUS, to view menu
item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3,
PRESENT O2, as the calibration status updates.
6. When CALSTATE displays APPLY GAS 2 (10.0%) , return to the O2 CAL
procedure.
ENSURE THE SPAN CALIBRATION WITH (10%) GAS.

7. When the "Loop should be removed from automatic control" warning

appears, return the Oxymitter 4000 to the automatic control loops previously
removed and press OK.
8. At the STOP GAS status prompt, select menu item 2, NEXT CAL STEP.
When the status displays PURGING, select menu item 4, EXIT, to leave
the O2 CAL procedure.
9. From the PERFORM O2 CAL screen, view menu item 3, CALSTATE, to
monitor the calibration status as it updates. Or, access the O2 CALIBRATE
screen and select menu item 2, O2 CAL STATUS, to view menu
item 1, CALSTATE; menu item 2, TIMEREMAIN; and menu item 3,
PRESENT O2, as the calibration status updates.
10. When CALSTATE displays STOP GAS, return to the O2 CAL procedure.
Failure to remove the Oxymitter 4000 from automatic control loops prior to performing this
procedure may result in a dangerous operating condition.
ENSURE THE SPAN CALIBRATION WITH (10%) GAS.
11. When the "Loop should be returned to automatic control" message
appears, return the Hazardous Area Oxymitter 4000 to the automatic
control loops previously removed and press OK.
12. At the STOP GAS status prompt, select menu item 2, NEXT CAL STEP
When the status displays PURGING, select menu item 4, EXIT, to leave
the O2 CAL procedure.
13. From the PERFORM O2 CAL screen, view menu item 3, CALSTATE, to
monitor the calibration status as it updates. Or, access the O2 CALIBRATE
screen and select menu item 2, O2 CAL STATUS, to view menu
item 1, CAL-STATE; menu item 2, TIMEREMAIN; and menu item 3,
PRESENT O2, as the calibration status updates.
14. When CALSTATE displays COMPLETE, the calibration is finished.

2
Page 8 of 9

I&E
Department
Manual
EPCL ,
PORT
QASIM,
KARACHI

Al-301 A/B
ROSEMOUNT
OXYGEN ANALYZER
CALIBRATION
PROCEDURE

Document No.

IP

Rev No. / Date

00

Issue No. / Date

Effective Date
Page No.

21/OCT/11/2006
2
Page 9 of 9

Prepared by: MRA

TEMPORARY REPAIR:
If a repair is required at this instrument, it will fall under temporary repair definition thus proper temporary repair approval
should be taken on approved form.
REPLACEMENT OF PARTS:
If some part(s) of the instrument needs replacement, then ensure that in-kind parts are replaced, otherwise follow temporary
repair procedure or sub soc (I & E) approvel; whichever is appropriate for this change.
VERIFICATION OF SAFETY CRITICAL DEVICES:
Operational should verify the calibration of safety critical devices whether from field or from DCS, before taking it in service.
RECORD KEEPING:
Fill the checklist of the particular instrument and record it for future reference, also the calibration record should be
maintained in maximo, where applicable.
Appendix A: List of Devices Covered

S.No.

Tag

1.

AT-301A

2.

AT-301B

Equipment

Type

HF-301A Stack 02 Analyzer meter

HF-301B Stack 02 Analyzer meter

Zirconia
Zirconia