Zelan ~ Priamanaya ~ Tronoh Consortium

Imran

Chin LC

Project

PlTUl JAWATENGAH 2 X (300 - 400 MW) COAL-FIRED POWER PLANT IN REMBANG, INDONESIA

Status

Document Number

Document No: RCP~ZPT(RS)~I&C~D002

Document Title

INSTRUMENT CALIBRATION PROCEDURE FOR

TURBINE & BOILER AREA

PL TU1 JAWA TENGAH 2 X ( 300 .. 400 MW ) COAL-FIRED POWER PLANT REMBANG, JAWA TENGAH, INDONESIA CONTRACT No. 053.PJI0411DIRl2007/21ST MARCH 2007

SPECIFICATION VOLUME AND FilE NUMBER

Date

Released by

Revision

31-Jan-09

Rev.O

ONOC Manager

PT. Wa Mitra Engineering

ZPT - I & C Manager

Sutomo

No of Page: 38 (inc. this page)

, INSTRUMENT CALIBRATION, INSPECTION, LOOP CHECK OUT & FUNCTIONAL TESTING PROCEDURE

CONTENTS

Page

- ORGANIZATION CHART

1. 0 GENERAL

2

1.1 Scope

1.2 Calibration Procedure 1.3 Documentation / picture

2 2 3

2. 0 INSTRUMENTS 5

2.1 Flow transmitters 5

2.2 Flow switch 6

2.3 Level transmitter 7

2.4 Level switch 8

2.5 Pressure transmitter 9

2.6 Pressure switch 10

2.7 Pressure gauge 11

2.8 Differential press. Transmitter 12

C) 2.9 Differential press. Switch 13

2.10 Temperature element / R TD 14

2.11 Thermocouple 15

2.12 Temperature transmitter 16

2.13 Temperature indicator 17

2.14 Solenoid valve, onloffvalve, pneumatic valve 18

2.15 Control valve 19

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1.0 GENERAL

1.1 SCOPE

This document provides procedure for:

• Calibration of instnunent field devices

• Testing & Electric / Electronic loop checking.

The contractor shall thoroughly perform the calibration & pre-commissioning of all Equipment, or piece of equipment, either purchased as individual items, or as part of vendor purchase, or as part of a company supplied item, of all facilities defined in the contract.

This scope of consist of:

• Conformity check of equipment items

• Static / de-energized test of equipment items

• Specific operation, such as the instrument tube / pipe flashing, cleaning or pressure test

The contractor scope of work is only the calibration.

1.2

CALIBRATION PROCEDURES

Calibration test shall be made, according vendor calibration manual using the test equipment as the test equipment, or equal bearing dated authority for certification traceable to the National bureau of standards, shall be available for calibration instrument. All test equipment shall be in a good operating condition and bear a current certification of accuracy; as appropriate for each instrument.

All devices shall be calibrated to be within the tolerances specified by the manufacturer and / or tolerances and accuracy units specified on the instrument data sheets.

Final calibration tests by CONT ACTOR shal1 be witness by COMPANY representative at their discretion. Only qualify instrumentation technician shall be provided by COTRACTOR to completely check out and calibrate all components and instrument in the control system. Pre-commissioning form has to make after calibration work.

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INSTRUMENT CALIBRATION, INSPECTION, ~OOP CHECK OUT & FUNCTIONAL TESTING PROCEDURE

A. The result of the check and test will be reported on the check list and the sheet provided in the specification.

In the event that test sheet are oriented for any item of equipment, the CONTRAXCTOR shall inform the COMPANY, reviewed the requirement and issue a new test sheet for company approvaL

Each analog field mounted instrument shall be calibrated simulating an appropriate process signal. The output will be recorded at 5 points corresponding to zero, twenty five, fifty, seventy five and one hundred percent of input range. The calibration will be verified for descending as well as ascending ranges.

A Calibration Sticker shall be placed on all components successfully tested all test result shall be logged on the appropriate test forms and submitted to customer for approval and signature.

B. Any test sheet which can not be completed or does not give satisfactory results because of any default shall be reported to COMPANY, indicated on the test sheet and included in the punch list CONTRACTOR shall take all necessary action to have this item clearest.

1.3 DOCUMENTATION

CONTRACTOR shall provide testing and acceptance documentation. The following packages shall be maintained:

• Calibration sheets for each instrument. .

• Installation I attachment sticker at eaeh instrument after each the instnunent equipment already calibration & inspection.

The detailed requirements for the documentation package and maintenance are specified in the following subsections.

Calibration documentation

A Calibration form for each instrument calibrated shall be completed by CONTRACTOR at the time when the instrument is tested / inspected and / or calibrated prior to installation.

The form shall included the following as a minimum:

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INSTRUMENT CALIBRATION, INSPECTION, LOOP CHECK OUT & FUNCTIONAL TESTING PROCEDURE

)..>- Project description and project No.

)..>- Customer (as applicable)

)..>- Equipmenttag number ofidentification marking

» Equipment location

» Equipment description

}- Equipment model number

}- Equipment serial number

}- Date received

}- Date calibrated or tested

)0> Calibration / testing parameters and result / readings

J> Test equipment employed

J> Calibrated / tested by .

}- Calibration / test witnessed by .

J> Calibration I test customer inspected by .

» Calibration / test accepted approved by .

The completed form shall be available at all times for inspection by customer.

Page 4 oj 19

INSTRUMENT CALIBRATION, INSPECTION, LOOP CHECK OUT & FUNCTIONAL TESTING PROCEDURE

2.0 INSTRUMENTS

2.1 FLOW TRANS.MITTERS

2.1.1 Tolls and equipment for calibration.

All the toll and equipment should is maintained, tested and certificated in accordance with manufacturer's recommendation and in accordance with applicable regulations. Standard tools and equipment are.

1. 24 V DC Power supply.

2. Multi tester

3. Digital pressure indicator

4. rnA calibrator

5. Hart communicator (HHC / Hand held communicator)

6. Pneumatic hand pump

7. Tool kit (Containing screwdrivers; pliers; wrenches and specials tools)

8. Load resistor 2500 or more than

2.1.2 Calibration procedure:

Verify that the instrument nametag matches the specification.

Connect a current calibrator (24 V DC Source and digital test ammeter) at instrument output.

With a WIT pneumatic calibrator apply pressure to the high side (Low side vented) equal to 0% 25% 50% 75% and 100% of the calibration range, both ascending and descending. Verify that proper current output ( 4 ~ 20 rnA) is obtained for the above five points; if not, adjust to manufacturers specifications.

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2.1 FLOW SWITCH

2.2.1 Tons and equipment for calibration.

All the toll and equipment should is maintained, tested and certificated in accordance with manufacturer's recommendation and in accordance with applicable regulations. Standard tools and equipment are.

1. Multi tester

2. Digital pressure indicator

3. Pneumatic hand pump

4. Tool kit (Containing screwdrivers, pliers, wrenches and specials tools)

2.2.2 Calibration procedure:

Verify that the instrument nametag matches the specifications. Connect an ohmmeter at instrument electrical terminals,

Connect wrr Pneumatic calibrator to the high pressure process sided of the switch body.

The pressure past the trip point slowly raises / lower. The switch should activate at the desired trip point. Record trip and reset point, if not adjust to specifications.

Repeat as often as required to verify proper trip point. Record trip and reset point and check for dead band and repeatability.

When instrument is within specification, attach calibration tag and record readings on calibration sheet. Sign and date and restore instrument to the proper condition.

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2.2 LEVEL TRANSMITTER

2.3.1 Tolls and equipment for calibration

All the toll and equipment should is maintained, tested and certificated in accordance with manufacturer's recommendation and in accordance with applicable regulations. Standard tools and equipment are.

1. 24 V DC Power supply.

2. Multi tester

3. Digital pressure indicator

4. rnA calibrator

5. Pneumatic hand pump

6. Tool kit (Containing screwdrivers, pliers, wrenches and specials tools)

2.3.2 Calibration Procedure

Verify that the instrument nametag matches the specifications. Connect an ohmmeter at instrument electrical terminals,

With a wrr pneumatic calibrator apply a pressure to 0% 25% 50% 75% and 100% level to the appropriate side (HP) of the transmitter, both ascending and descending, while the other side (LP) is vented. Verify that the proper current output ( 4 ~ 20 rnA ) is obtained for all five points.

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persentages If transmitter has filled reference leg, apply a pressure equal to the height of the leg to the. Appropriate side of the transmitter; adjust zero suppression according to manufacturer's recommendations, compensating for specific gravity as necessary.

When instrument are within manufacturer's tolerances, attach calibration tag and record reading on calibration sheet. Sign and date then restore transmitter to the proper configuration.

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2.3 LEVEL SWITCH

2A.1 Tolls and equipment for ca1ibration

All the toll and equipment should is maintained, tested and certificated in accordance with manufacturer's recommendation and in accordance with applicable regulations. Standard tools and equipment are.

1. Transparent tube 2 Multi tester

3 rnA Calibrator

4 Tool kit (Containing screwdrivers, pliers, wrenches and specials tools)

2.4.2 Calibration procedure

Verify that the instrument nametag matches the specifications. If level is the internal type, remove and place in a test tank.

Attach clear, plastic tubing and accurately engraved steel ruler of suitable length, between the drain valve and the vent valve of the test tank or the instrument level cage Chamber. Connect water source to drain vale.

Connect and ohmmeter to the appropriate terminals of the switch

Raise I Lower the water to the appropriate terminal or switch trip and reset point. Repeat as many times as necessary to verify dead band and repeatability. Adjust to specifications.

If a liquid other than the process liquid is used for calibration (i.e. water) Compensation must be made for any difference, in specific gravity.

When instrument is within specification is within specification, attach calibration tag and record reading on calibration sheet, sign date and restore instrument to its normal state.

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2.5 PRESSURE TRANSMITTER

2.5.1 Tolls equipment for calibration

All the toll and equipment should is maintained, tested and certificated in accordance with manufacturer's recommendation and in accordance with applicable regulations. Standard tools and equipment are.

1. DC 24 V Power Supply

2. Dead weight

3. Multi tester

4. Smart Comunicator

5. Manual hand pump

6. Tool kit (Containing screwdrivers, pliers, wrenches and specials tools)

2.5.2 Calibration procedure

Verify that the instrument nametag matches the data sheet.

Connect certified variable pressure source (Hydraulic pump and gauge or dead weight tester) at pressure chamber process connection. Verify calibration by 5 point simulation. The readings should be 4.0 rnA, 8,0 rnA, 12.0 rnA, 16.0 rnA, and 20.0 rnA at 0%, 25%,50%, 75%, and 100% of the pressure span applied respectively. Test will be performed both ascending and descending.

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persentages When instrument are within manufacturer's tolerances, attach calibration tag in a position that will insure a seal on adjustment setting record reading on calibration sheet. Sign and date then restore transmitter to the proper configuration.

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2.6 PRESSURE SWITCH

2.6.1 T.()]Js and equipment for calibration

All the (011 and equipment should is maintained, tested and certificated in accordance with manufacturer's recommendation and in accordance with applicable regulations. Standard tools and equipment are.

1. Test gauge

2. Multi tester

3. Manual hand pump

4. Tool kit (Containing screwdrivers, pliers, wrenches and specials tools)

2.6.2 Calibration procedure

Verify that the instrument nametag matches the specifications.

Connect either a test set with precision gauge, or dead weight tester to process connection.

Connect an Ohmmeter to appropriate electrical terminal of the switch.

Slowly increase (or decrease) pressure to switch slightly pas trip point. Decrease (or increase) pressure on switch and observe reset point.

When instrument is within proper trip point and reset point, attach calibration seal.tag and record trip and reset point or calibration sheet, sign and date.

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2.7 PRESSURE GAUGE

2.;7~1 Tools and EQuipmentJor Calibration.

All the tools and equipments should is maintained, tested and certificated in accordance with manufacturer's recommendations and in accordance with applicable regulations. Standard tools and equipment are

1. Dead Weight Tester.

2. Test Gauge.

3. Tool kit (containing screwdrivers, pliers, wrenches and specials tools).

2.7.2 Calibration Procedure

All local pressure indicating gauges will be bench tested and calibrated. Connect the gauge to dead weight tester or pressure pump with calibrated precision test gauge as appropriate.

Adjust zero as required.

Record gauge reading and verify the accuracy at input pressure of zero, fifty and one hundred percent of full scale.

When instnunent is verified to read within the manufacturer's tolerances, return indicator to its normal state and attach calibration tag, record readings on calibration sheet, sign and date.

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2.8 DIFFERINTIAL PRESSURE TRANSMITTER

2.8.1 Tools and Equipment for Calibration

All the tools and equipments should is maintained, tested and certificated in accordance with manufacturer's recommendations and in accordance with applicable regulations. Standard tools and equipment are:

1. 24 V DC Power supply

2. Multi Tester

3. Digital pressure indicator

4. Smart comunicator

5. Pneumatic Hand Pump

6. Tool kit (containing screwdrivers, pliers, wrenches and specials tools)

2.8.2 Calibration Procedure

Verify that the instrument nametag matches the specification.

Connect a current calibrator (24V DC source and digital test ammeter) at instrument output.

With a WIT pneumatic calibrator, apply pressure to the high side (low side vented) equal to 0%, 25%, 50%, 75% and 100% of the calibration range, both ascending and descending. Verify that proper current output is obtained for the above five points, if not adjust to manufacturers specifications.

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2.9 DIFFERENTIAL PRESSURE SWITCH

, 2~9.1

Tools and Equipment for Calibration

All the tools arid equipments should is maintained, tested and certificated in accordance with manufacturer's recommendations and in accordance , with applicable regulations. Standard tools and equipment are: "

1. Multi Tester

2. Digital pressure indicator

3. Pneumatic Hand Pump ,

4. Tool kit (containing screwdrivers. pliers, 'wrenches and specials tools)

2.9.2 Calibration 'Procedure

Verify 'that the instrument nametag matches the specifications. , Connect ,an Ohmmeter at instrument electrical terminals.

Connect W rr Pneumatic calibrator to the high pressure process sided of the switch body.

The pressure past the trip point slowly raise/lower, The switch should, activate at 'the desired trip point. Record trip and reset point, if not adjust to specification,

When instrument is within specification, attach calibration tag and record readingon calibration sheet. Sign and date and restore instrument to the proper condition.

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2.10 TEMPERATURE. ELEMENT IRTD

2.10.1 Tolls and equipment for calibration •.

All the tools and equipments should is maintained. tested and certificated in accordance with manufacturer's recommendations and in accordance With applicable regulations.· Standard tools and equipment are:

- - - - - -

1) RTD Calibrator

2) Temperature bath

3) Tool kit (containing screwdrivers, pliers, wrenches and specials tools)

2.10.2 Calibration procedure

Verify that thermo well is correctly tagged also check for COITeet insertion length, flange rating is correct and that the RID element bottoms in the . thermo well,

Verify proper range of temperature element per data sheet. . Disconnect temperature element electrical connection from transmitter and remove from well.

Immerse in calibrated temperature bath and test at points less than 24% and more than 90%.of full range.

Record all result on temperature element calibration sheet, sign and date. After transmitter calibration is complete reconnect and return to proper arrangement.

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2.11 THERMOCOUPLE

2.10.1 Tolls and equipment for calibration.

All the tools and equipments should is maintained, tested and certificated in accordance with manufacturer's recommendations and in accor-dance with applicable regulations. Standard tools and equipment are:

1) Temperature bath (Dry Block Temperature)

2) MuItimeter

3) Tool kit (containing screwdrivers, pliers, wrenches and specials tools)

2.11.2 Calibration procedure

Verify that thermo well is correctly tagged also check for correct insertion length, flange rating is correct and that the element bottoms in the thermo well.

Verify proper range of temperature element per data sheet.

Immerse in calibrated temperature bath / Dry block temperature and test at points of full range.

Record all result on temperature element calibration sheet, sign and date. After tennocouple calibration is complete reconnect and return to proper arrangement.

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2.12 TEMPERATURE TRANSMITTER

2.12.1 Tools and Equipment for Calibration

All the tools and equipments should is maintained, tested and certificated in accordance with manufacturer's recommendations and in accordance with applicable regulations. Standard tools and equipment are:

1. Multi Tester

2. Temperature bath

3. Decade resistance box

4. Tool kit (containing screwdrivers, pliers, wrenches and specials tools)

2.12.2 Calibration Procedure:

Verify that temperature transmitter tag and name plate meets the requirements of the specification.

The calibration shall be accomplished by substituting certified test equipment for the resistance temperature detector (RTD), energizing the transmitter with the 24V DC and comparing the signal with know values.

To calibrate the transmitter remove aU RTD connections and install the decade resistance boxes to the transmitter.

With decade box set a resistance values to correspond with 0%, 25%, 50%, 75% and 100% range of transmitter, both ascending and descending, verify that the proper current is obtained for the above five points .

If the transmitter is out of calibration, the temperature transmitter shall be calibrated to the value per the manufacturer's instruction manual.

When instrument is within manufacturer tolerance, attached calibration seal record readings on calibration sheet, sign and date. Then reconnect RTD and Thermo well and restore transmitter to the proper configuration.

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2.13 TEMPERATURE INDICATOR / GAUGE

2.13.1 Tolls and Requirement for CaUbration

; All the tools and equipments should is maintained, tested and certificated _: in accordance with manufacturer's recommendations and in accordance with applicable regulations. Standard tools and equipment are:

1. Temperature bath

2. Tool kit (containing screwdrivers, pliers, wrenches and specials tools)

2.13.2 Calibration Procedure:

All local Bi-metal and capillary type temperature indicating gauges to be installed will be tested

Verify that the thermo well and ! or gauge is tagged correctly, that the insertion length is as specified, that flange rating is correct and that element bottom in thermo well.

Remove gauge from thermo well.

Immerse in temperature bath or temperature generator with a certified mercury thermometer.

Slow raise and / or lower temperature and check at 0% (IF possible) 25%, 50%, 75%, and 100% of full range.

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Verify calibration or adjust to within manufacturer's tolerance specified and on date sheet.

When gauge calibration is within tolerance, re-install in thermo well and return instrument to normal state. Note reading on calibration sheet, sign and date attach calibration seal to gauge.

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2.14 SOLENOID VALVE / ON-OFF VALVE / PNEUMATIC

2.14.1 Tools and Equipment for Calibration

.:All the tools and equipments should is maintained, tested and certificated in accordance with manufacturer's recommendations and in accordance with applicable regulations. Standard tools and equipment are:

1. 24V DC Power Supply

2. 110/220 V DC Power Supply

3. Multi Tester

3. Tool kit (containing screwdrivers, pliers, wrenches and specials tools)

2.14.2 Calibration Procedure:

Verify that the instrument nametag matches the specifications. Verify that suppression diodes are installed correctly.

Attach WIT pneumatic calibration directly to valve diaphragm (IF 3-15 PSI or 6-30 PISG or refer to SDV calibration procedure if mounted on SDV). Apply pressure slowly and verify that the control or shutdown valve begins travel at the correct pressure; if not adjust spring tension.

Energized and de-energized solenoid valve and verify valve stroking actions and fail position.

Apply pressure equal to 100% of input and verify the value stem or ball travel is correct; if not, adjust stem length.

Repeat above as necessary. Verify valve position at 0% and 100% of input pressure.

When instrument is within specification, attach calibration striker and record reading on calibration sheet. Sign date, return valve to normal state.

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2.15 CONTROL VALVE

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2.15.1 Tolls and equipment for calibration

All the tools and equipments should is maintained, tested and certificated in accordance with manufacturer's recommendations and in accordance with applicable regulations. Standard tools and equipment are:

1. Test gauge 0~2 Kg

2. MuJti tester

3. rnA Calibrator

4. Tool kit (containing screwdrivers, pliers, wrenches and specials tools)

2.15.2 Calibration procedure

Verify that the instrument name tag matches the specification and that all control items are installed.

Before proceeding further, complete the calibration check on the liP transducer as per section 8.1.

If positioner is installed than apply clean dry air / nitrogen supply to positioner inlet and WIT test gauges to positioner outlet and signal inlet.

Remove input to IIP converter and air supply to positioner and verify that valve fails in proper position for each input removed.

Stroke valve with positioner in bypass mode

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Return positioner to normal (Forward acting mode) Apply calibration signal to JIP Converter and check valve mechanical action and stoking positions and signal to actuator on WIT test gauge.

Check action of valve with positioning / limit switch in reverse mode. Check bench set calibration, is correct per manufacturers test certificate. Repeat above as necessary. Verify valve position at 0% and 100% of input pressure.

When instrument is within manufacturer's tolerances, return instrument to its normal state and attach calibration tag.

For valves without positioning perform all tests except those with positioning reference.

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