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Method Statement for Instrument Calibration

1. PURPOSE AND SCOPE

1.1
PURPOSE
The purpose of this procedure is to ensure that all instrumentation works
regarding calibration shall be done in accordance with the SABIC
STANDARDS and all other applicable international codes and standards.
1.2
SCOPE
The scope covers the steps to be followed for bench/field calibration of
instruments and related documentation. SINOPEC shall ensure that the
calibration procedures are adhered to the SABIC Standards with reference
to SABIC specifications.

2. Responsibilities

The E&I construction manager is responsible to plan and schedule


activities for the calibration of instruments in co-ordination with client
instrumentation personnel. It is the responsibility of the materials personnel,
to receive & visually inspect all instruments delivered on site before handing
them over to E&I Dept. E&I Dept. shall be responsible for the storage and
preservation of all instruments received. It is the responsibility of the
instrument QC inspector to carry out inspection, witness Bench and field
calibration of instrument calibration, filling of test results recorded during
calibration.

3. REFERENCES

3.1. Project specification references 000-70S-0015 REV03. Site calibration,


testing and checkout of instruments and control system equipment
3.2. Projects specification references 000-70S0016 REV 3, specification for
receiving and ware housing for instruments and control system
equipment
3.3. Project specification reference 000-70S0021 REV5, field
instrumentation
3.4. Instrument data sheet.
3.5. Instrument calibration report from vendor
3.6. Project specification reference 000-70S-0025 REV3 specification for
analyzers and analyzer shelters
3.7. Project specification references R07-E01 REV 1, globe control valve
3.8. Project specification references 000-65S0057 REV 3, Specification for
site inspection and testing for acceptance of electrical equipment and
materials

4. METHOD OF PREPARATION

4.1. Dust-free, air-conditioned instrumentation test facility, properly


isolated from the areas shall be used for calibration and filed test shop
shall be equipped with clean, dry, oil-free air, transformers, DC supply,
portable radios, miscellaneous tools fittings, and consumable material.

4.2. Forms, procedures and sign off sheets for each individual activity shall
be prepared and submitted for review and approval of the client prior to
beginning of any activity.
4.3. Availability of all manufactures installation and calibration instructions
shall be ensured prior to commencement of the calibration activity.
4.4. Prior to the start of instrument calibration, prepare a calibration check
list for each instrument which shall contain all documents necessary to
support the checkout and signoff of the associated instrument (e.g.,
P&ID, manufactures instruction, instrument data sheet, alarm/trip setting
summary, signoff forms for calibration, sticker, etc.) Format and contents
of calibration check list, C&E, megger sheet, punch list, location drawing
shall be approved by the client.
4.5. All activities are covered by relevant ITP.
4.6. All test equipment should be approved by the company and shall have
a standard of accuracy better than the manufacturers stated accuracy
for instruments to be tested.
4.7. All test equipment shall have a valid calibration certificate from a
SABIC recognized authority and shall be re-checked periodically at an
interval, agree by the company the test and calibration equipment shall
be calibrated in the unit of measurement selected for project.
4.8. Validity certificate not more than 3 months old prior to its use.
4.9. Calibration equi9pment shall be in sufficient quantity.
4.10.
Test equipment list shall be submitted to company.

5. SAFETY REQUIREMENTS

5.1. The safety officer shall verify that all the necessary and applicable
document, related to the safest operation are in possession before
commencing the job.
5.2. Check adequacy and availability of all tools, before commencement of
calibration work.
5.3. Safety procedures shall be followed at all times.

6. QA/QC REQUIREMENTS

6.1. The quality control program shall be as per Daelim project procedures
in conjunction with Saudi Kayan project specifications and the SABIC
engineering standards. The detailed inspection stages and methods shall
be as per the approved inspection and test plans.
6.2. Test equipment shall be calibrated and must conform to the instrument
manufacturers recommendations. As stated in the calibration and
maintenance instructions. Test equipment shall include special tools that
are required for any particular type of instrument.
6.3. Construction methods statement and inspection & test plan shall be
submitted ahead of time
6.4. All RFIs shall be submitted 24. hrs ahead of scheduled date of
inspection.

6.5. All relevant attachments including IFC drawing must be attached on all
submitted RFI.
6.6. Calibration shall be monitored, witnessed and recorded by the QC
inspector in accordance with inspection check list, QC forms given by the
applicable ITP.
6.7. QC instrument inspector shall verify the instrument manufacturers
specification and complies with common standards.

7. CALIBRATION PROCEDURES

7.1. General
7.1.1. The work shall be performed by qualified personnel, In compliance
with established safety practices. All work shall be performed using
correct tools for the purpose.
7.1.2. Care shall be observed when connecting electrical power supplies
to electrical and electronic instrumentation. Ensure correct voltage
and frequency on alternating currents (AC) supplies and also
polarity where DC is used; check that that voltage regulation and
any superimposed ripple are within instrument manufacturers
specification. Correct polarity of supply and proper grounding is
critical to instrument electronics.
7.1.3. No tests shall be carried out on electronic instruments until
adequate warm-up period had elapsed.
7.1.4. Ensure all work/activities are in full compliance with SABIC
standards and approved SK projects specifications.
7.2. Instrument calibration facility
A field test shop adequately equipped for instrument calibration
and contractor shall provide adequate storage for calibrated
instruments. As a minimum, the test shop shall be equipped as
follows.
7.2.1. Source of clean, dry, oil-free instrument air.
7.2.2. Lifting and handing gear.
7.2.3. Transformers, as required.
7.2.4. Miscellaneous tools, fittings and consumable materials.
7.2.5. Dust-free air-conditioned instrumentation test facility, properly
isolated from the areas used for the testing of other equipment.
7.2.6. Basic cleaning facilities.
7.2.7. Contractor shall provide a direct current supply of the required
voltage and characteristics.
7.2.8. Sets shall be certified intrinsically sage if they are to be used during
plant start-up, shall have a suitable power level (not too high or
low) and they shall not conflict with the plant radio system or
interfere with the plant control systems.
7.2.9. Field calibration, such as PH, analyzer gas detectors, conductivity,
analyzer heavy valves & special switches and cortex flow meter,
coriolis flowmeter, radar, ultrasonic, nuclear instrument, pilot tubes
anubars etc. vendor will calibrate them and Sinopec will supply
manpower to help vendor.

7.2.10. Higher pressure range instruments and PSVs calibration will be


sent to third party for calibration. We will submit the third partys
procedure for approval by DAELIM and PMT.
7.2.11. Vendor will calibrate MOV and Sinopec will support manpower to
help vendor. Mov calibration procedure will be submitted for DAELIM
& PMT approval.

7.3. Receipt and inspection of instruments


7.3.1. Every instrument received shall be visually inspected to ensure that
it is free from any physical defects and shall be verified against the
name plate details & date sheets to ensure compliance.
7.3.2. Receipt of each instrument shall be documented with details such
as received date, type of instrument data sheet, material test
certificate etc.
7.3.3. The warehouse should be cleaned with adequate rain, dust and
vibration protection.
7.3.4. Plastic sealing plugs should be firmly fixed in all
pneumatic/hydraulic instruments connections except during
test/calibration.
7.3.5. Instrument shall be identified by tag no. and checked against its
corresponding date/specification sheet, ensuring that it is supplied
with correct calibration range; all name plate details shall be noted
on the calibration date sheet.

7.4.Specific Procedures

7.4.1. DIFFERENTIAL PRESSURE TRANSMITTER (For Flow, Level and


Differential Pressure Measurement)
TEST EQUIPMENT:
7.4.1.1.
Regulated DC power supply 24 Vdc
7.4.1.2.
Load resistor 2500+005% 3W
7.4.1.3.
Precision digital multi-meter (VOM) or equivalent
7.4.1.4.
Pneumatic calibrator or test equipment
7.4.1.5.
Pressure source-compressed dry air, Nitrogen cylinders or
pressure pump.
7.4.1.6.
Digital HART communicator (supplied by Daelim)
7.4.1.7.
Calibration standard test pressure gauge/manometer
PROCEDURE:
7.4.1.8.
Mount the transmitter on support stands firmly fixed on
top of the bench.

7.4.1.9.
Open to the atmosphere low pressure side of the
transmitter.
7.4.1.10.
Connect signal pressure tube on the port of high pressure
side of the transmitter, close the equalizing valve.
7.4.1.11.
Connect digital HART communicator, milliamp meter and
power supply 24V DC to specified transmitter terminal points, as
shown in attached calibration hook-up figure # 1A for both
wiring and test equipment arrangement.
7.4.1.12.
Switch on power supply and proceed for calibration.
7.4.1.13.
Check transmitter date sheet for calibration range.
7.4.1.14.
Apply pressure equivalent to lower range value of the
transmitter. Current output read out should be 4.0 Ma on multimeter and 0% on the transmitter indicator. If not, proceed to
zero adjustment using the digital HART communicator.
7.4.1.15.
Apply pressure equivalent to upper range value of
transmitter. Current output read out should be 20mA on multimeter and a display of 100% on the transmitter indicator. If not,
proceed to span adjustment using the digital HART
communicator.
7.4.1.16.
Apply reference pressure of
0%,25%,50%,75%,100%,75%,50%,25% and 0% of the
measurement ranges of the transmitter and check
corresponding Ma output for both upscale & downscale reading
and do the necessary adjustments, until calibration read outs
are satisfactory and linearity is attained.
7.4.1.17.
Place the sticker on the transmitter as CALIBRATED with
date and signature.
7.4.1.18.
Record the test reading in the calibration sheet, and shall
be signed by the client as witness representative.
7.4.2.PRESSURE TRANSMITTER
TEST EQUIPMENT:
7.4.2.1.
Regulated DC power supply 24Vdc
7.4.2.2.
Load resistor 2500+005% 3W
7.4.2.3.
Precision digital multi-meter (VOM) or equivalent
7.4.2.4.
Pneumatic calibrator or test equipment
7.4.2.5.
Pressure source-compressed dry air, nitrogen cylinders or
pressure pump.
7.4.2.6.
Digital HART communicator (supplied by Daelim)
7.4.2.7.
Calibrated standard test pressure gauge/manometer
PROCEDURE:
7.4.2.8.
Mount the transmitter on support stands firmly fixed on
top of the bench.
7.4.2.9.
Connect signal pressure tube on the inlet port of the
pressure side of the transmitter.

7.4.2.10.
Connect digital HART communicator, milliamp meter and
power supply24V DC to specified transmitter terminal points, as
shown in attached calibration hook-up figure #2A for both wiring
and test equipment arrangement.
7.4.2.11.
Switch on power supply and proceed for calibration.
7.4.2.12.
Check transmitter data sheet for calibration range.
7.4.2.13.
Apply pressure equivalent to lower range value of
transmitter. Current output read out should be 4.0mA on multimeter and 0% on the transmitter indicator. If not, proceed to
zero adjustment using the digital HART communicator.
7.4.2.14.
Apply pressure equivalent to upper range value of
transmitter. Current output read out should be 20.0mA on multimeter and 100% on the transmitter indicator. If not, proceed to
span adjustment using the digital HART communicator.
7.4.2.15.
Apply reference pressures of 0%, 25%, 50%, 75%, 100%,
75%, 100%, 75%, 50%, 25% and 0% of the measurement ranges
of the transmitter and check corresponding ma output for both
upscale & downscale reading and do the necessary adjustment,
until calibration read outs are satisfactory and linearity is
attained.
7.4.2.16.
Put sticker on the transmitter as CALIBRATED with date
and signature.
7.4.2.17.
Record the test reading the calibration sheet and shall be
signed by the client as witness representative.

7.4.3.TEMPERATURE TRANSMITTER
TEST EQUOPMENT:
7.4.3.1.
7.4.3.2.
7.4.3.3.
7.4.3.4.
7.4.3.5.
7.4.3.6.

Regulated DC power supply 24 VDC


Load resistor 2500+0.005% 3W
Precision digital multi-meter (VOM) or equivalent
Universal temperature calibrator
Variable resistance decade box for RTD elements
Digital HART communicator (supplied by Daelim)

A: TEMPRETURE TRANSMITTER THERMOCOUPLE AS AN


ELEMENT
PROCEDURE:
7.4.3.7.
Mount the transmitter on support stands firmly fixed on
top of the bench.
7.4.3.8.
Identify in the transmitter, types of the thermocouple
element wiring connection; connect universal temperature

calibrator wires (or equivalent) at thermocouple element input


terminal.
7.4.3.9.
Connect digital HART communicator, milliamp meter and
power supply 24V DC to specified transmitter terminal points, as
shown in attached calibration hook-up figure #3A for both wiring
and test equipment arrangement.
7.4.3.10
Switch on power supply and proceed for calibration.
7.4.3.11
Check transmitter data sheet for calibration range.
7.4.3.12
Simulate lower range temperature value (mv values)
corresponding to the temperature values on transmitter, current
output read out should be 4.0ma on multi-meter and 0% on the
transmitter indicator. If not, proceed to zero adjustment using
the digital HART communicator.
7.4.3.13
Simulate upper range temperature value (mc values)
corresponding to the temperature values on transmitter, current
output read out should be 20.0ma on multi-meter and 100% on
the transmitter indicator. If not, proceed to span adjustment
using the digital HART communicator.
7.4.3.14
Simulate reference temperature values of 0%, 25%, 50%,
75%, 100%, 75%, 100%, 75%, 50%, 25% and 0% of the
measurement ranges of the transmitter and check
corresponding ma output for both upscale & downscale reading
and do the necessary adjustments, until calibration read outs
are satisfactory and linearity is attained.
7.4.3.15
Place the sticker on the transmitter as CALIBRATED with
date and signature.
7.4.3.16
Record the test reading in the calibration sheet and shall
be signed by the client as witness representative.
B: TEMPERATURE TRANSMITTER-RTD AS AN ELEMENT
PROCEDURE:
7.4.3.17
Mount the transmitter on support stands firmly fixed on
top of the bench.
7.4.3.18
Identify in the transmitter, the RTD element wiring
connection; connect
universal temperature calibrator or
resistance decade box wire at TRD element input terminal.
7.4.3.19
Connect digital HART communicator, milliamp meter and
power supply 24V DC to specified transmitter terminal points, as
shown in attached calibration hook-up figure#3B for both wiring
and test equipment arrangement.
7.4.3.20
Switch on power supply and proceed for calibration.
7.4.3.21
Check transmitter data sheet for calibration range.
7.4.3.22
Simulate lower range temperature value (resistance
values corresponding to the temperature values) on transmitter,
current output read out should be 4.0ma on multi-meter and 0%
on the transmitter indicator. If not, proceed to zero adjustment
using the digital HART communicator.

7.4.3.23
Simulate upper range temperature value (resistance
values corresponding to the temperature values) on transmitter,
current output read out should be 20.0ma on multi-meter and
100% on the transmitter indicator. If not, proceed to span
adjustment using the digital HART communicator.
7.4.3.24
Simulate reference temperature values of 0%, 25%, 50%,
75%, 100%, 75%, 100%, 75%, 50%, 25% and 0% of the
measurement ranges of the transmitter and check
corresponding ma output for both upscale & downscale reading
and do the necessary adjustment, until calibration read outs are
satisfactory and linearity is attained.
7.4.3.25
Place the sticker on the transmitter as CALIBRATED with
date and signature.
7.4.3.26
Record the test reading in th calibration sheet and shall
be signed by the client as witness representative.
7.4.4. TMEPERATURE ELEMENT-RTD AND THERMOCOUPLES
TEST EQUIPMENT:
7.4.4.1.
Temperature bath
7.4.4.2.
Precision digital multi-meter (VOM) or equivalent
7.4.4.3.
Universal temperature calibrator
7.4.4.4.
Standard temperature indicator
7.4.4.5.
Millivolt/temperature and resistance/temperature
conversion charts [ANSI/ASTME(ITS-90), DIN43 760]
PROCEDURE:
7.4.4.6.
Insert RTD or thermocouple element into a well of
temperature bath.
7.4.4.7.
Identify RTD or thermocouple element wiring connection;
connect universal temperature calibrator or multi-meter wires in
place of element input terminal, as shown in attached calibration
hook-up figure # 4A for both wiring and test equipment
arrangement.
7.4.4.8.
Check temperature element date sheet for calibration
range.
7.4.4.9.
Set temperature bath temperature sitting to room
temperature and check resistance or millivolt values
corresponding to the temperature values on multi-meter or
universal temperature calibrator and verify values with
temperature conversion chart.
7.4.4.10.
Gradually increase temperature set point values of 0%,
25%, 50%, 75%, 100%, 75%, 100%, 75%, 50%, 25% and 0% of
the temperature bath and check element resistance or millivolt
values corresponding to the temperature values on multi-meter

or universal temperature calibrator and verify values with


temperature conversion chart.
7.4.4.11.
Place the sticker on the element As: CALIBRATED with
date and name and sign of person.
7.4.4.12.
Record the test reading in the calibration sheet and shall
be signed by the client as witness representative.
7.4.5. TEMPERATURE GAUGE
TEST EQUIPMENT:
7.4.5.1.
7.4.5.2.

Temperature bath
Standard temperature indicator

PROCEDURE:
7.4.5.3.
Insert temperature gauge element into a well of
temperature bath, as shown in attached calibration hook-up
figure #5A test equipment arrangement.
7.4.5.4.
Check temperature gauge range for calibration.
7.4.5.5.
Set temperature bath at 0 and check corresponding
temperature reading on temperature gauge and adjust to zero
point.
7.4.5.6.
Set temperature bath temperature setting to room
temperature and check corresponding temperature reading on
temperature gauge, compare with the standard temperature
indicator, if not matching make pointer adjustment until the
error is eliminated.
7.4.5.7.
Gradually increase temperature set point values of
temperature bath 0%, 25%, 50%, 75%, 100%, 75%, 100%, 75%,
50%, 25% and 0% and verify corresponding temperature reading
on temperature gauge, if not matching make span adjustment
until the error is eliminated.
7.4.5.8.
Place the sticker on the temperature gauge as
CALIBRATED with date and signature.
7.4.5.9.
Record the test reading in the calibration sheet and shall
be signed by the client as witness representative.
7.4.6.PRESSURE GAUGE
TESTEQUIPEMENT:
7.4.6.1.
Comparison test pump/dead weight pressure tester.
7.4.6.2.
Different range of calibrated standard test pressure
gauge
PROCEDURE:

7.4.6.3.
Place the comparison test pump on a flat level base
surface.
7.4.6.4.
Fill the hydraulic oil in the oil cup of comparison test
pump; remove air bubble from oil cup.
7.4.6.5.
Mount both the standard test gauge (for reference) and
the gauge to be calibrated on the comparison test pump
mounting post , as shown in attached calibration hook-up figure
#6A for test equipment arrangement.
NOTE:
Reference standard gauge range should be at least 20% higher
than the gauge to be calibrated. Always keep the release valve
close when instrument is not in use to prevent air entrapment
and repeat priming.
7.4.6.6.
Without applying any pressure, check the gauge under
calibration. Pointer position must be on exact 0 mark on its
scale. If not, adjust the zero adjustment screw.
7.4.6.7.
After zeroing, rotate the hand wheel slowly clockwise to
generate the pressure gradually to reach the full range of the
gauge under calibration. Compare with the standard test gauge
for exact value, if not matching make span adjustment until the
error is eliminated.
7.4.6.8.
Repeat step 6&7 until tolerance is met.
7.4.6.9.
After zero, gradually increase the pressure for 0%, 25%,
50%, 75%, 100%, 75%, 100%, 75%, 50%, 25% and 0% of
pressure range.
7.4.6.10.
Place the sticker on the pressure gauge as CALIBRATED
with date and signature.
7.4.6.11.
Record the test reading in the calibration sheet and shall
be signed by the client as witness representative.

7.4.7.PRESSURE SWITCH
TEST EQUIPMENT:
7.4.7.1.
Precision digital multi-meter
7.4.7.2.
Calibrated standard test pressure gauge or manometer
7.4.7.3.
Pressure source compressed dry air , hand pump or
comparison test pump
PROCEDURE:
7.4.7.4.
Mount pressure switch to be calibrated on support stand,
as shown in attached calibration hook-up figure #7A for test
equipment arrangement.

7.4.7.5.
Connect pressure source-compressed dry air hand pump
or dead weight tester.
7.4.7.6.
Connect multi-meter on pressure switch contact terminals
depending on the requirement, multi-meter should be in alarm
mode for the make or break contact set point monitoring.
7.4.7.7.
Slowly apply pressure for PSHH and determine the factory
setting of the pressure switch. For PSLL apply pressure higher
than trip and release slowly until switch trip.
7.4.7.8.
Adjust pressure switch adjusting screw to set for the
breaking or making of switch at required set point.
7.4.7.9.
Place the sticker on the pressure switch as CALIBRATED
with date and signature.
7.4.7.10.
Record the test reading in the calibration sheet and shall
be signed by the client as witness representative.

7.4.8.CONTROL VALVE
TEST EQUIPMENT:
7.4.8.1.
Pressure source-compressed dry air or nitrogen gas
cylinder
7.4.8.2.
Universal calibrator or milliamps source
7.4.8.3.
Precision air pressure regulator
PROCEDURE:
7.4.8.4.
Check control valve date sheet for valve calibration.
Check that valve and name plate correspond with control valve
specification check that, where specified, a lubricator is fitted
and that it is charged with the correct lubricant.
7.4.8.5.
Check calve action (air to close or air to open)
7.4.8.6.
Connect air supply to control valves air inlet port.
7.4.8.7.
Connect millinamps source to control valve built in
transducers (I/P) terminal polarity wise, as shown in attached
calibration hook-up figure #8A for test equipment arrangement.
7.4.8.8.
Slowly open air supply or nitrogen cylinder and adjust air
regulator to desired pressure if necessary.
7.4.8.9.
Switch on milliamps source, set to 4 milliamps, check I/P
output gauge to positioned (3 PSI) and verify valve travel
indicator, valve should be close (for air to open) or open (for air
to close).
7.4.8.10.
Set milliamps source to 20 milliamps, valve should be
fully closed or fully open depending on the valve action.
7.4.8.11.
Check valve position at 0%, 25%, 50%, 75%, 100%, 75%,
100%, 75%, 50%, 25% and 0% respectively by rising and

decreasing the signal of milliamps source and do the necessary


adjustment to attain the desired calibration.
7.4.8.12.
Set milliamps source to 20 milliamps and close air supply
valve and confirm valve air fail position.
7.4.8.13.
Place the sticker on the control valve as CALIBRATED
with date name and signature.
7.4.8.14.
Record the test reading in the calibration sheet and shall
be signed by the client as witness representative.
7.4.8.15.
Where an air failure lock-up relay or any other accessory
device is incorporated, it shall be checked, calibrated for correct
operation in accordance with the specification.
7.4.8.16.
If required, hysteresis, tight-shut off and air failure tests
shall be carried out as per specification.
7.4.8.17.
Control valves with other types of actuators for example,
piston operator, air cylinder operators, shall be tested for
stroking and failure action in accordance with the manufactures
instructions.

7.4.9.CURRENT TO PRESSURE CONVERTER


I/P converter is calibrated using a standard 4-20ma source and a
standard pressure indicator.
7.4.9.1.
Apply 4ma and note the output pressure reading in the
indicator. It shall be 3 psi, for any deviation adjusts the zero
setting, record the reading.
7.4.9.2.
Apply 20ma and note the output pressure reading in the
indicator. It shall be 15 psi. Adjust span settings for any
deviation.
7.4.9.3.
Check the intermediate values 25%, 50%, 75%, 100%,
75%, 50%, 25% and 0%also.
7.4.9.4.
Record the reading on the calibration sheet. Repeat the
process 2 or 3 times.
7.4.9.5.
Place the sticker on the I/P as CALIBRATED with date
and signature.
7.4.9.6.
Record the test reading in the calibration sheet and shall
be signed by the client as witness representative.

7.4.10. ON/OFF VALVES


ON/OFF valve to be calibrated to be arranged as shown in the figure
# 10A.

7.4.10.1.
Connect pressure source compressor or nitrogen gas
cylinder. Slowly open air supply or nitrogen cylinder and adjust
air regulator to the desired pressure.
7.4.10.2.
Apply 24VDC; valve should be open/close in the specific
time. Disconnect DC power supply and the valve should be
open/close in the specific time. The time of opening and closing
of the valve must be recorded.
7.4.10.3.
Check the coil solenoid resistance in accordance with
specification.
7.4.10.4.
Place the sticker on the control valves as CALIBRATED
with date and signature.
7.4.10.5.
Record the test reading in the calibration sheet and shall
be signed by the client as witness representative.
7.4.11. FLOW ELEMENT (ORIFICE PLATE)
Orifice plates shall be checked visually for the following and for
compliance with project specification 000-70S-0021.
7.4.11.1.
Smooth perfectly flat surfaces without scratches or
bowing are checked.
7.4.11.2.
A sharp edge should be on the upstream face if there.
7.4.11.3.
The correct before is measured by internal micrometer
against data sheet. Thickness is measured and compared from
datasheet.
7.4.11.4.
Correctly stamped identification, tag number, materials of
construction and bore dimensions on upstream face of tag
handle.
7.4.11.5.
After visual checking put sticker on the elements as
CALIBRATED with date and signature with name. Record the
check reading in the calibration sheet and shall be signed by
client as witness representative.

7.4.12. LEVEL AND INTERFACE SWITCH (FLOAT OR DISPLACER)


7.4.12.1 Level switch shall be checked by partial immersion of the
displacer or float with water in the float or displacer chamber
or stilling tubes.
7.4.12.2 Due recognition shall be given to the gravity in between
water and the application fluids. All these liquids shall be fully
drain from the system after testing.
7.4.12.3 The switch point shall be checked for both rising and
falling levels. Connect multimeter on switch contact
terminals depending on requirement.
7.4.12.4 This trip points shall be at the defined point (normally,
center of the float chamber). Adjust switch adjusting screw to
set for the breaking or making of switch at required set point.

7.4.12.5 Place the sticker on the switch as CALIBRATED with


date.
7.4.12.6 Record the test reading in the calibration sheet and shall
be signed by the client as witness representative.
7.4.13. DISPLACER TYPE LEVEL TROLL TRANSMITTER(WET
CALIBRATION)
SET UP:
7.4.13.1.
Set up the test rig as suitable for different size of
displacer type transmitters.
7.4.13.2.
Testing rig should have a suitable flange fitting to connect
the displacer.
7.4.13.3.
Provide suitable isolation valves for the purpose. Use
water for calibration.
7.4.13.4.
Connect a graduated glass or plastic column parallel to
the displacer chamber via the bottom drain connection or gauge
taping.
7.4.13.5.
The level can be varied by water into the chamber. This is
usually done by using a water container and a hand pump via
the bottom drain connection.
PROCEDURE:
7.4.13.6.
Note the given range of the level troll as per specification
sheet. The liquid, inside of the process vessel and calibration
media are different, there will be a new range for the level troll
and the range calculation will be as per manufacturers
instructions.
7.4.13.7.
Find out the 0%of the level troll position. The 0%luine of
the level troll is marked to the center line of the bottom side
flange, in case of the single fluid application in case of the
interface level 0%marking depend on the specific gravity of the
fluid
7.4.13.8.
Fill the water in the chamber up to 0% marking. Adjust for
the 4mA using HART communicator or by the bottom on the
transmitter as per the manufactures recommendations.
7.4.13.9.
Fill the water up to 100% and set for 20mA using HART
communicator or by the switches provided on the transmitter.
Check for intermediate values by filling 25%, 50%, 75%, 100%,
75%, 50%, 25%and 0%. Repeat the calibration procedure 2 or 3
times and record the reading.
7.4.13.10. Place the sticker on the transmitter as CALIBRATED
with date and signature.
7.4.13.11. Record the test reading in the calibration sheet and shall
be signed by the client as witness representative.

7.4.14. FLOW SWITCHES


7.4.14.1

Flow switches shall be checked by triggering the paddle


by hand in swinging back and forth or up and down.

7.4.14.2

Connect multimeter tester on switch contact terminal


depending on the requirements, multimeter should be in
alarm mode for make or break of contact set point.

7.4.14.3

Adjust pressure switch adjusting screw to set for the


breaking or making of switch at required set point.

7.4.14.4

After manual adjustment place the sticker on the flow


switch as CALIBRATED with date and signature.

7.4.14.5

Record the test reading in the calibration sheet and shall


be signed by the client as witness representative.

7.4.15

TEMPERATURE SWITCHES

7.4.15.1

Temperature switches be check by comparing the


temperature switches to corresponding temperature
reading on the test temperature gauge and with the
standard temperature indicator, if not matching make
pointer adjustment until the error is eliminated.

7.4.15.2

Connect multimeter tester on switch contact terminals


depending on the requirements multimiter should be in
alarm mode for the make or break of contact point.

7.4.15.3

Gradually increase temperature set point values of


temperature bath to switch point depending on the
requirements, multi-meter should be in alarm mode for
contact set point and verify corresponding temperature
reading on temperature gauge, if not matching make an
adjustment until the error is eliminated.

7.4.15.4

Place the sticker on the temperature gauge as


CALIBRATED with date and signature.

7.4.15.5

Record the test reading in the calibration sheet and shall


be signed by the client as witness representative.

7.4.16. SOLENOID VALVES

7.4.16.1. Connect the appropriate power supply via a switch.


7.4.16.2. Connect an air supply to the appropriate port.
7.4.16.3. Operate the switch and observe the correct changed over
action.
7.4.16.4. Check the tightness of shut off by connecting a flexible
tube to the
outlet port or ports and immersing the other
free end in the water to ensure that the valve closure is
bubble-tight shut-off at stated designed pressure.
7.4.16.5. If applicable, check for electrical and manual reset,
override and time delay features as per the valve specification.
7.4.16.6. Check the coil resistance in accordance with specification.
7.4.17. THERMOWELL
7.4.17.1. Thermowell shall be checked visually with measurements
for the following and for compliance with project specification
000-70S-0021.
7.4.17.2. Smooth and perfect surfaces without scratches damages
or bowing.
7.4.17.3. The correct bores, sizes as measured by dernier caliper
with date sheet.
7.4.17.4. Correctly stamper identification, tags number, materials
of construction and bore and length dimensions or insertion
sizes shall be as per data sheet.
7.4.17.5. All test thermowell shall be threaded SS316 plugs.
7.4.17.6. After visual and measurement checks place the sticker on
as CALIBRATED with date and signature. Record the check
reading in the calibration sheet and shall be signed by the
client as witness representative.

7.4.18. ELECTRONIC INDICATOR


7.4.18.1. Electronic indicator shall be checked visually with
measurements for the following and for compliance with
specification 000-70S-0021.
7.4.18.2. Apply 4mA and note the output values reading in the
indicator. It shall be 3 psi, for any deviation adjusts the zero
setting, record the reading.
7.4.18.3. Apply 20mA and note the output values reading in the
indicator. It shall be 15 psi, Adjust span setting for any
deviation.
7.4.18.4. Check the intermediate values 25%, 50%, 75%, 100%,
75%, 50%, 25%and 0% and 0% also.
7.4.18.5. Record the readings on the calibration sheet. Repeat the
process 2 or 3 times.
7.4.18.6. Place the sticker on the indicator as CALIBRATED with
date.

7.4.18.7. Record the test reading in the calibration sheet and shall
be signed by the client as witness representative.

7.4.19. VIBRATION SENSING PROBES


Proximity measurement is used to detect radial, radial motion and
shaft speed measurement.
7.4.19.1. PROXIMITTER TRANSDUCER SYSTEM
a) The system has three individual parts. Probe, extension cable,
proximitter and 24V DC supply applied to the system.
b) The proximitter is basically a signal generator with a demodulator
circuit. When supplied a DC voltage its electronic circuit produces
a high frequency RF signal which sent to the tip of the coil.
c) The strength of the probe electromagnetic field is directly
proportional to the distance from the probe to the target surface.
According to the magnetic strength variation the current going
through the probe coil also changes. This change is detected by
the modulator and concerts to the proportional voltage.

7.4.19.2. CALIBRATION
7.4.19.2.1. TK3 kit an instrument used for calibration purpose
of that vibration probes. Its main components are the
servomotor, dial gauge, rotating disc holding system
etc.
7.4.19.2.2. To calibrate the probe, first fix the probe for
required gap by the help of a dial gauge, dial gauge is
used to detect the gap between the surface of the disc
and probe tip.
7.4.19.2.3. Apply 24V DC to the system, simulate radial and
axial vibration and note the voltage with millimeters.
Compare the gap voltage with the data sheet supplied
by the manufacturer. Repeat the process for 2 or 3
times.
7.4.19.2.4. Put the sticker on the transmitter as CALIBRATED
with date, name and sign of calibrator person.
7.4.19.2.5. Record the test reading in the calibration sheet and
shall be signed by the client as witness representative.

7.4.20. PANEL TEST


If instruments mounted on panel, they shall be tested in the panel
or the bench testing depending upon the feasibility &
manufacturers instruction.

7.4.21. NON-CONFORMANCE ITEM


If the inspection result or measurement valves cannot meet
acceptance rules or requirements, then the instrument/equipment
cannot be accepted, the check sheet and nonconformance report
should be filled (including nonconformance causation) and the
marking plate (including nonconformance item NO., date, name,
etc.) should be filled, which shall be hang on the equipment, then
the equipment/instrument should be stored at the area checked
but not accepted in the original packing and report to related
department.