TABLE OF CONTENTS

1. SCOPE 2
2. PURPOSE 2
3. REFERENCES 2
4. DEFINITION 2
5. RESPONSIBILITIES 3
6. PROCEDURE 3-6
7. ATTACHMENTS 7-10

1. SCOPE

This procedure sets out the requirement, principle & responsibilities for the calibration of pressure gauges and
pressure relief valve to be utilized in the hydro testing of fabricated and erected piping system in accordance with

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 Quality control procedure control of inspection, measuring and test equipment “(DRO001-OUF-PRO-Q-000-515)”
requirements.

2 PURPOSE

The purpose of this procedure is to provide guidelines for the Calibration of pressure gauges and pressure relief
valves and determine individual setting such as pressure test and range are correct and within allowable tolerance
for their safe efficient operation.

3 REFERENCES

DRP-OUF-SPE-Y-650-005 : Specification for pipe line Hydro testing

DRP-OUF-PRO-Q-000-515 : Quality control procedure control of Inspection, Measuring and test

Equipment

ISO-10012-2003 : Measurement Management Systems-Requirement s for measurement

Processes and measuring equipment

API -576 : Inspection of pressure relieving device

4 DEFINITION

4.1 Calibration

The set of operations which will establish under specified conditions the relationship between values indicated
by measuring instrument and the corresponding value of a quantity by a reference standard.

4.2 Testing

The operation of proving items ability criteria by subjecting it to simulated operational conditions to verify its
conformance and accuracy.

4.3 Calibration and test facility

A location where permanent calibration and testing laboratory, A portable unit prepared specifically for the
purpose of completing calibration and testing at premises or site location.

5. RESPONSILITIES

QA/QC Manager

Responsibilities for maintaining the calibration record to assure re-calibration and testing to QA/QC Manager has
the overall responsibility for the quality aspect associate with any calibration and test activities conducted
throughout the project.

QC Instrument inspector

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 Responsible to report all quality aspects associated with the calibration and testing to QA/QC Manager.
He shall be responsible for all required action and activities during the calibration and test equipment. He shall
maintain a library of procedure work instruction and any required reference documents to provide direction and
guidance during calibration.

Instrument technician

Responsible to conduct calibration and testing of equipment as per procedure and reference standard. He shall
report and take their direction from QC instrument inspector and shall complete required calibration and test in
accordance with documented requirement report and report of the findings.

6. PROCEDURE

6.1 Calibration and Test Facilities

6.1.1 The following general equipment and documents shall be available as a minimum requirement for any
operational activity.

a) Appropriate work benches and shelves or rack for the instrument being inspected, repaired, calibrated and
stored

b) Temperature/Humidity controlled atmosphere with a relatively dust-free environment restriction shall be

placed on vibration or electromagnetic disturbance to an extent that permissible level shall no effect the
calibration and testing activity

c) A complete set of relevant hand tools and aids

d) A full of set of inspection, measuring and test equipment calibrated by an approved authority/third party
laboratory to the required accuracy and shall be traceable to a known International standard. This shall be
classed as the reference or a master instrument.

e) A copy of the calibration data sheet for each referenced instrument.

f) Relevant instrument operating and repair manuals, where specifically referenced.

6.1.2 A separate safe and secure area will be established for high pressure and relief valve testing
equipped as a hydrostatic test facility with the required volume manifolds and ancillary equipment.

6.1.3 All calibration and test equipment will be suitable for its intended use and will be certified for that specific use.
As a general rule volume manifolds will be manufactured in accordance with relevant applicable codes. Fluid
manifolds will be tested at 1.5 times the maximum required manifolds for air testing 1.1 times maximum
operating pressure. The maximum test operating pressure must be identified in while paint lettering of
maximum of 1” in height in a prominent place on the manhole. All volume manifolds will have a suitable
safety relief valve fitted set to be maximum operating pressure.

6.2 Calibration

6.2.1 Before any calibration or test is undertaken reference instruments or equipment shall be checked for
conformity and calibration validity. Only instruments specifically identified on the measuring and test
equipment calibration log sheet shall be used by ATE.

6.2.2 Calibration shall only be performed by suitably qualified and experienced personnel who have been assigned to
the work by the facility.

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6.2.3 Only approved testing medium.

6.2.4 Unless identified with current calibration sticker all items or equipment will be considered out of calibration.

6.2.5 All items returned for calibration will be immediately have any previous stickers removed and the items places
in a holding area and fitted with an identification tag.

6.2.6 All items checked with reference equipment which are subsequently found to be inaccurate shall be regarded
as non-conforming until they are re-examined or tested with equipment of proven accuracy. At this reason
absolute traceability is essential so that equipment can be recalled.

6.2.7 Where an instrument or items of equipment as found to have initial readings excessively high or low during
calibration a query shall be raised with PSJV to enable them to re-check any on site readings taken with that
instrument.

6.2.8 After calibration or test the adjustment point (s) of any instrument or equipment shall be sealed to prevent any
unauthorized access.

6.2.9 A calibration label shall be fixed to each calibrated instrument if the item is too small for the label to be affixed
then it shall fixed to its box or container if traceability can be assured. The label shall indicate the instrument
serial number, date calibrated and due date of next calibration.

6.2.10 A calibration test report and certificates shall be completed for each calibration and test performed and shall
indicate the following:

a) The instrument serial no

b) Instrument reading

c) Reading as received

d) Reading after adjustment

e) Calibration date and next calibration due date

f) Date

6.3 Inspection and witness

Prior to any calibration activities the RFI shall be raised by the QA/QC inspector to witness the calibration of
pressure relief valve and pressure gauges.

6.4 Calibration of instruments

6.4.1 Pressure gauges

 The pressure gauges shall be calibrated by a dead weight tester shall be at +/-2% tolerance
 Align equipment at zero
 Apply actuating pressure full range and lock-in signal pressure check system for leaks then reset to zero
 Apply actuating pressure of 25, 50, 75 and 100% of range and record in calibration data sheet
 Reduce actuating pressure 75, 50, 25 and 0 % of range and record in calibration data sheet
 When necessary adjustment according to manufacturing shall be made until the quoted accuracy in
obtained
 After successful calibration the pressure gauges stickers shall put in the place and specified the “serial
number, date of calibration, due for calibration and initial of instrument technician
 All pressure gauges shall be (1) month validity after calibration as per DRP001-OUF-PRP-Q-000-515 .

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6.4.2 Pressure relief valve

 Prior to testing the pressure relief valves shall be subject to a thorough visual inspection for any obvious
surface damage
 The valves shall be mounted on test rig
 Test gauges used for checking the set value shall be at +-1%
 The pressure of the test medium shall be increased gradually until valve lifts at the cold set pressure
specified on the data sheet
 The result shall be recorded (see attached calibration data sheet)
 After successful testing of the cold set pressure the valve shall be subject to a seat tightness test
 The applied pressure of the testing medium shall increase gradually to 90% of the cold set pressure.
 The result shall be recorded on calibration data sheet.
 Acceptance criteria-For a valve with a metal seat the leakage rate in bubbles per minute shall not exceed
50% of the appropriate value in API 576 table1. For soft-seated valve, there shall be no leakage for 1
minute (0 bubbles per minute).

All pressure relief valves shall have one month validity after the calibration.

6.5 Calibration Record & status

6.5.1 Calibration and testing operation on instrument or equipment shall be recorded and maintained on a
calibration log. This wherever possible should be a computerized format.

6.5.2 Newly purchased calibrated items shall be included in the calibration and test log. These shall be substantiated
by relevant manufacturers calibration certificates, which shall be clearly identify calibration and due date.

6.5.3 The calibration and test log shall be maintained to provide traceability and status of all instruments and
equipment including but not limited to those distributed or allocated projects the fabrication shop or outside
customers.

6.5.4 An instrument status report shall be issued for any test instrument/equipment that has failed performance test
conducted. Any defects or deviation of the instrument on its specified tolerance shall be indicated on this report.

6.5.5 Any instrument that has not been returned by the calibration due date will result in a non-conformance report
being issued. The above does not apply to where a site mobile laboratory has been established apart from the
requirements for the reference or mater instruments or equipment.

6.5.6 All reference instrument shall themselves require periodic calibration in accordance with the manufacturer’s
instructions and all reference instruments shall be calibrated to a prescribed tolerance which shall in all cases be
higher than the requirement for which they are to be used.

6.5.7 All calibration report for reference instruments shall identify all recorded deviations prior to adjustment. On
return to the QA/QC manager shall review these records to evaluate whether recorded deviations will impact the
validity of tests on instruments or equipment previously conducted with the particular item. Where the impact is
considered to be detrimental items shall be recalled for verification.

6.6 Handling and storage

6.6.1 All instrument and equipment for calibration and testing shall be checked on receipt for damage and deficiency
any, item found to be defective or incomplete at this stage or, during subsequent calibration or, testing shall be
reported to the originator and their disposition agreed before any further action.

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 6.6.2 Instruments or equipment once certified as being a current calibrated or tested condition must be in handled with
care and protected from any impact vibration or electromagnetic disturbance that could affect the accuracy of
the instrument.

6.6.3 Calibrated or test instrument and equipment shall be stored in a vibration impact, and dust free environment away
from direct sunlight and sudden change in temperature.

7 ATTACHMENTS

Attachment 1 – Calibration Data Sheet (pressure gauge)

Attachment 2 – Calibration Data Sheet (pressure Relief valve)

Attachment 3 – Calibration Sticker

Attachment 4 – Measuring and Test instrument calibration log sheet

 ATTACHMENT 1

CALIBRATION DATA SHEET

PRESSURE GUAGE

Cert. NO :

Manufacture: Tag Number:

Model Type: Calibration Data:
Serial Number: Calibrated By:
Set Pressure: Witnessed By:

Percent Desired Value (PSI) Actual Value (PSI) Error

Rising/Decreasing Rising/Decreasing

0%
25%
50%
75%
100%
75%
50%
25%

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0%

CALIBRATION DEVICED DATA

Description Dead Weight Tester

Manufacture
Model
Serial Number
Control Number
Last Calibration
Remarks

 ATTACHMENT 2

CALIBRATION DATA SHEET

PRESSURE RELIEF VALVE

Cert. NO :

Manufacture: Tag Number:

Model Type: Calibration Data:
Serial Number: Calibrated By:
Set Pressure: Witnessed By:

CALIBRATION RESULT

Number Of Trials Set Pressure (psig) Error % Reset Pressure

(psig)
1
2
3

CALIBRATION DEVICED DATA

Description Pressure Test Gauge Dead Weight Tester Precision Pressure

Calibration
Manufacturer
Model

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Serial Number
Control Number
Last Calibration
Remarks:

 ATTACHMENT 3

CALIBRATION LABEL/ STICKER FOR

PRESSURE GAUGE

PG SR NO :
CAL. DATE :
DUE DATE :
CAL BY :

Actual size: 2cm × 4cm

CALIBRATION LABEL/ STICKER FOR

PRESSURE RELIEF VALVE

PSV SR NO :
CAL. DATE : DUE DATE :
SET PRESSURE :
CAL BY :

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 Actual size: 2cm × 4cm

 ATTACHMENT 4
INSPECTION/MEASUREMENT & TEST EQUIPMENT REGISTER
Regn. Equipment Type No Manufacturer. Freq. Date Today Remaining Current Expiry QA/QC Equipment
Number name & Serial Name Month calibrated or Expired calibration date File location
No. days status

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