c-55 NOC

NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES C.55

FIELD INSTALLATION, CALIBRATION AND TESTING OF INSTRUMENTS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

GENERAL ENGINEERING SPECIFICATION FIELD INSTALLATION, CALIBRATION AND

GES C.55 Page 2 of 44

TESTING OF INSTRUMENTS Rev 0 1999 INDEX SEC HEADING PAGE 1.0 SCOPE OF SPECIFICATION 4 1.1 Introduction 4 1.2 Other NOC Specifications 4 2.0 DEFINITIONS 5 2.1 Technical 5 2.2 Contractual 5 3.0 FIELD, CALIBRATION, INSPECTION AND TESTING OF INSTRUMENTATION 6 3.1 Codes and Standards 6 3.2 Instrument Testing and Instrument Installation Testing 8 3.3 Pressure Testing 24 3.4 Testing of Instrument Cables 26 3.5 Loop Testing 27 3.6 Test Equipment 29 3.7 Painting and Insulation 31 4.0 INSTRUMENT INSTALLATIONS 31 4.1 General 31 4.2 Compliance with Drawings/Specifications 33 4.3 Instrument Mounting and Accessibility 33 4.4 Instrument Piping/Tubing 36 4.5 Piping and Tubing Supports 37 4.6 Instrument Cable Installation 38 4.7 Earthing 38 4.8 Materials 38 4.9 Air Supply Piping 38 4.10 Fabrication 38 5.0 QUALITY ASSURANCE AND QUALITY CONTROL 39 5.1 Quality Assurance 39 5.2 Quality Control 39



TESTING OF INSTRUMENTS Rev 0 1999 SEC HEADING PAGE 6.0 INSPECTION AND ACCEPTANCE 40 6.1 Inspection 40 6.2 Acceptance 41 7.0 DOCUMENTATION 41 7.1 Calibration, Certificates and Check Lists 41 7.2 Vendor/Contractor's Data 42 7.3 `As Built' Drawings 42 8.0 SUB INDEX OF GENERAL FORMS, CALIBRATION AND TEST CERTIFICATES, INSTALLATION CHECKLIST AND ACCEPTANCE FORMS 42 8.1 Instrument Inspection General Forms 42 8.2 Instrument Calibration and Test Certificates 42 8.3 Instrument Installation Check List Forms 43 8.4 Pre-Commissioning Check List Forms 43 8.5 Fire and Gas Instruments Isolation Check List Forms 43 8.6 Instrument Loop Acceptance 44 8.7 Instrument Pre-Commissioning (Installation) Check List 44 Data Sheets (67 forms, comprising 90 sheets total)



TESTING OF INSTRUMENTS Rev 0 1999 1.0 SCOPE 1.1 Introduction 1.1.1 This specification covers the minimum requirements for the calibration, inspection and testing of

instrumentation prior to commissioning. The user should bear in mind that this is a general specification which must be matched to project operational and functional requirements to provide an installation which is fit for the purpose intended.

1.1.2 In the event of any conflict between this specification and the attachments, or with any of the applicable

Codes and Standards, the Vendor/Contractor shall inform the Owner and obtain written clarification or authorisation from the Owner before proceeding with the work as failure to do so shall indicate full compliance; any remedial work then necesary shall be at the Vendor/Contractor's expense.

1.1.3 This General Engineering Specification together with the Scope of Work defined for the project will

form part of the Purchase Order/Contract and applies to equipment for refineries, onshore oil and gas installations and processing facilities, including equipment purchased either directly or as part of a package.

1.1.4 The Vendor/Contractor should note that this specification and its reference documents do not cover

each and every detail, the Vendor/Contractor is expected to be familiar with current good practice for the installation and testing of instruments and hardware indicated.

1.1.5 This specification does not cover non-commodity type instrumentation such as analysers, control and

safety systems as well as computer based systems. The specific requirements of these shall be specified on project specific basis.

1.1.6 It is the Vendor/Contractor's responsibility to ensure that the complete system is inspected and tested

throughout all stages to ensure a smooth and trouble free start of the plant and without any danger to the operations personnel.

1.1.7 In the event of any conflict between this specification, the Purchase Order/Contract and any other

applicable Codes and Standards the Vendor/Contractor shall inform the Owner. Written clarification on how to proceed shall be obtained from the Owner before proceeding with the affected portion of the work.

1.2 Other NOC Specifications Section 6.0 "Installation" of the relevant J series instrument specification shall apply to this specification

as if it were part of this specification. Additionally, the following NOC General Engineering Specifications are an integral part of this specification and any exceptions shall be approved in advance by the Owner:

GES A.06 Site Data GES C.01 Protection of Materials and Equipment during Storage GES C.02 Protection of Materials and Equipment during Construction GES C.54 Commissioning of Microprocessor Based Instrument Systems GES J.01 Standard Instrument Symbols and Tags GES J.12 Indoor Control Panels and Cabinets GES J.13 Field Panels and Junction Boxes



TESTING OF INSTRUMENTS Rev 0 1999 GES J.15 Instrument Air Systems GES J.16 Instrument Cable and Cabling GES J.17 Earthing of Instrument Systems GES L.35 Electrical Equipment in Hazardous Areas GES X.06 Factory Coatings for Electrical Equipment and Instruments 2.0 DEFINITIONS 2.1 Technical The technical terms used in this specification are defined as follows: Inspection Upon Receipt The physical check of all instrument equipment upon receipt on site and prior to pre-installation testing. Pre-Installation Testing The testing of all instrument equipment prior to installation to ensure that each individual instrument is

functionally correct and is correctly calibrated. Pressure Testing of Instrument Piping The testing of all instrument piping installations within the instrument contract to ensure that they are

pressure tight to the specified test conditions. Testing of Instrument Cables The testing of interconnecting cables in electrical and electronic instrument loops for continuity,

insulation, resistance and other parameters. Pre-Commissioning (including `Loop Testing') The checking for correct installation and operation of all instrument systems and loops and the

preparation of all instrument systems for commissioning. Commissioning The tuning of all instruments and controls to the process, e.g. the correct setting of proportional, integral

and derivative functions, together with the setting up of any pulsation dampers, time delay functions and final alarm/trip settings.

2.2 Contractual The commercial terms used in this specification are defined as follows: Owner The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.



TESTING OF INSTRUMENTS Rev 0 1999 Vendor The company supplying the equipment and material. Contractor The main contractor for a defined piece of work Sub-Contractor A company awarded a contract by a Contractor to do part of the work awarded to the Contractor. Inspection Authority The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and

facilities have been designed, constructed, inspected and tested in accordance with the requirements of this specification and the Purchase Order/Contract.

Inspector A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,

who verifies that the equipment and facilities have been designed, constructed, inspected and tested in accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 FIELD, CALIBRATION, INSPECTION AND TESTING OF INSTRUMENTATION 3.1 Codes and Standards Calibration, installation and testing of instrumentation shall conform to the current edition of the

following Codes and Standards. American Petroleum Institute (API) API 520 Sizing, Selection and Installation of Pressure-Relieving Devices in Refineries API 527 Seat Tightness of Pressure Relief Valves (ANSI Approved) API 550 Design and Installation of Instruments API 551 Process Measurement Instrumentation API 552 Transmission Systems API 554 Process Instrumentation and Control API 555 Process Analysers British Standards Institution (BSI) BS 5345 Selection, installation and maintenance of electrical apparatus for use in

potentially explosive atmospheres. BS 5501 Electrical Apparatus for potentially explosive atmospheres.



TESTING OF INSTRUMENTS Rev 0 1999 BS 6739 Code of Practice for Instrumentation in Process Control Systems: Installation Design and Practice BS 7671 Requirements for Electrical Installations (IEE Wiring Regulations) Energy Industries Council (EIC) EIC CCI/P1 Instrument Installation Testing International Electrotechnical Committee (IEC) IEC 801:3 Electromagnetic Compatibility for Industrial - Process Measurement and Control Equipment: Part 3: Method of Evaluating Susceptibility to Radiated

Electromagnetic Energy IEC 60529 Degrees of Protection Provided by Enclosures IEC 60751 Industrial Platinum Resistance Sensors (BS EN 6667) Institute of Petroleum (UK) IP Model Code of Practice International Standards Organisation (ISO) ISO 9001 Quality Systems - Model for QA in Design/Development, Production,

Installation and Servicing ISO 9003 Quality Systems - Model for Quality Assurance in Final Inspection and Test National Aeronautical Space Administration (NASA) NAS 138 Cleanliness Requirements of Parts Used in Hydraulic Systems National Electrical Manufacturers Association (NEMA) NEMA ICS 6 Industrial Controls and Systems Enclosures National Codes National Health and Safetyy Codes and Practices shall govern. In the absence of any such Codes and

Practices the following latest edition of the following UK (or its USA equivalent) shall be applied. Health and Safety at Work Act Health and Safety - Electricity at Work Regulations Factories Act Institute of Petroleum - Model Code of Practice Owners - Safety Handbook Owners - Safety Procedures Manual Hazardous Area Requirements This specification is based on the International Electro-Technical Commission (IEC) 79 and the

CENELEC series of standards. There are significant differences between the IEC/CENELEC specifications and those used in North America and certain other countries which are based on the National Electrical Code Article 500-503 (and API RP 500A, 500B and 500C). The differences include



TESTING OF INSTRUMENTS Rev 0 1999 the system of area classification, equipment protection classifications, gas groups and the classification of maximum surface temperatures. Whilst in general, equivalences exist between the two systems, it should not be assumed that equipment suitable for use under one system, is necessarily suitable for use under the other system. Reference shall be made to GES L.35 and the latest issue of NFPA 70 and the NEC Electrical Code Handbook.

3.2 Instrument Testing and Instrument Installation Testing 3.2.1 General 3.2.1.1 The Vendor/Contractor's personnel shall be competent, qualified and fully conversant with the types of

equipment to be tested. They shall also be familiar with Owner's Safety Regulations as all work shall be carried out in accordance with these regulations.

3.2.1.2 A schedule (down to a loop level) shall be provided by the Vendor/Contractor and agreed by the Owner.

This schedule will define the overall sequence of the testing on the project. Any subsequent deviations from this schedule shall be agreed in writing.

3.2.1.3 The Vendor/Contractor responsible for the pre-installation testing of instruments shall supply a fully

equipped workshop for this purpose, unless otherwise agreed. The workshop shall have a clean section of bench reserved for electronic instruments and test gear isolated from the area used for mechanical tests. The workshop shall be dust free and shall incorporate clean, dry and secure storage facilities. Clean sterile areas and lifting facilities and appropriate utilities shall also be available.

3.2.1.4 The Vendor/Contractor shall submit with his Tender a comprehensive list of the test equipment to be

used. This will be reviewed and agreed with the Owner before testing is commenced. A list of typical test equipment is shown in Section 3.6. The Vendor/Contractor shall be responsible for supplying all test equipment, tools and consumables

used during testing and calibration. 3.2.1.5 All test equipment shall be approved by the Owner and shall have a standard of accuracy better than the

manufacturer's stated accuracy for the instrument(s) to be tested. All test equipment shall have a valid calibration certificate from a recognised authority and be suitable for use in a hazardous area (where appropriate). It is the Vendor's/Contractor's responsibility to ensure that his equipment is suitable for use within the area of testing.

The test and calibration equipment shall be calibrated in the units of measurement selected for the

project. 3.2.1.6 The cable testing shall be carried out as described in the BS 7671 IEE Wiring Regulation latest Edition

unless specified otherwise in this specification or in the Purchase Order/Contract. 3.2.1.7 The Vendor/Contractor shall obtain approval from the Owner before power or pneumatic supplies are

switched on to any panel or section of plant. 3.2.1.8 The Owner shall be informed immediately of any defects which cannot be rectified or of any instrument

which cannot be calibrated within a reasonable period of time. This notification shall be confirmed in writing.

3.2.1.9 The approval of the Owner shall be obtained in writing before any non-standard modifications or adjustments are made. 3.2.1.10 The Vendor/Contractor should take note that certain areas of the plant may be supplied as pre-

assembled units (PAU). These are to be delivered to site completely piped and wired to interface points. Upon completion of the hook-up of these PAUs the Vendor/Contractor shall complete the loop



TESTING OF INSTRUMENTS Rev 0 1999 testing and pre-commissioning of all instrumentation including those located on PAUs.

In those instances where instruments are removed from PAUs at the fabrication yard and shipped loose,

the Vendor/Contractor is to carry out pre-installation checks prior to re-installation. 3.2.1.11 On completion of each test, the stage reached in the testing procedure shall be indicted by fixing to each instrument or installation a coloured label conforming to the following code:- Blue Pre-Installation Tested or Calibrated Yellow Pressure Tested Green Cables Tested Red Pre-Commissioned White Test Failed (written message may be added giving reason for failure) This identification shall be shown on all components in the loop, thereby making all personnel aware of

the current status of any installation. 3.2.1.12 All instruments that fail under test are to be returned to the project warehouse and the details of the failure are to be passed to the Owner who will determine the action to be taken. 3.2.1.13 Where the pre-installation test is not specified or where circumstances prohibit the carrying out of the prescribed test, the Vendor/Contractor shall agree a test method with the Owner. This will apply to

those instruments delivered as an integral part of a PAU, in which case the Vendor/Contractor shall, upon delivery of PAU, carry out an `inspection upon receipt' to ensure that no physical damage has occurred during transit from the fabrication yard. This premise will only apply if the loop dossier prepared by the PAU Fabricator included documentary evidence that the instrument has undergone all the necessary pre-installation test, pressure test, piping and cable tests.

Should this documentary evidence not be available for any item then the Vendor/Contractor shall carry

out all such tests as part of his scope. 3.2.1.14 Upon completion of pre-commissioning the installation shall be made ready for process commissioning

and all extra work such as setting zero elevations and suppressions, filling liquid seals, adjusting purge rates, etc. will be completed by the Vendor/Contractor.

3.2.1.15 All test and check results shall be recorded, on the standard forms listed in Section 8 and attached to this

specification. Approval signatures shall be obtained where appropriate. 3.2.1.16 The Vendor/Contractor is responsible for producing Quality Assurance dossier for each installation and

type of material employed. One dossier shall be produced for each loop (or part loop). The content of a dossier will contain, as a minimum, the following:

Certification documents; Engineering Data Sheets for all instruments; Installation Hook-Up Drawings (where relevant); Check/Test record sheets duly completed for each instrument and the materials used; Instrument Loop Diagram; Mark-ups required for any corrective measures to be undertaken by others. 3.2.1.17 All equipment for use in hazardous areas must be tested in accordance with the requirements of BS

5345 or equivalent standards. 3.2.2 Pre-Installation Testing 3.2.2.1 The object of pre-installation testing is to ensure that each instrument and all bulk material has been

supplied in accordance with its specification, is functionally correct and is in working order.



TESTING OF INSTRUMENTS Rev 0 1999 3.2.2.2 All instruments shall, wherever possible, be subjected to pre-installation test and this test shall

commence as soon as practicable after the receipt of the instrument on site. If the equipment is to be stored for a long period of time then these tests shall be carried out near the date of instrument installation. The tests shall be performed in the manner described herein, any adjustment being made in accordance with the manufacturer's instruction.

3.2.2.3 In general all tests shall simulate as closely as possible design process conditions, by the use of

Manometers, Potentiometers, Resistance Bridges, Dead Weight Testers, Test Pressure Gauges, etc., utilising hydraulic, electric or pneumatic supplies.

3.2.2.4 No tests shall be carried out on electronic instruments until an adequate warm-up period has elapsed.

Wherever possible, instruments shall be energised for at least 24 hours prior to testing. 3.2.2.5 All shipping stops shall be removed from the instruments before starting the test procedures.

Miscellaneous components, e.g. charts, oil, ink cartridges shall be correctly installed. 3.2.2.6 All instruments, except as noted herein, are to be calibrated in both the upscale and downscale

directions and, if necessary, adjusted until their accuracies are within the limits stated by the manufacturer. Upon completion the results of each test shall be recorded on the appropriate form, witnessed by the Owner's representative and the completed forms added to the loop dossier and handed to the Owner.

3.2.2.7 Upon completion of tests the instrument shall be drained, as a precaution against mixing with dangerous

process fluid and if necessary blown through with dry air. Where applicable, shipping stops shall be replaced.

3.2.2.8 After testing, all connections and entries shall be temporarily sealed to prevent subsequent ingress of

moisture and dirt. 3.2.2.9 Insulation and continuity tests shall be made on drummed electrical cable prior to use. 3.2.3 Pre-Installation Test Procedure 3.2.3.1 General: a) Instrument testing should preferably be carried out in a calibration workshop, except where

instruments form part of an integrated system or control panel where tests may be carried out in the control room after installation using portable test gear and/or simulation equipment.

b) The instrument to be tested should be mounted in the correct plane on a rigid and vibration-free

stand or structure. c) Before commencing any tests, the following checks shall be carried out: - The instrument shall be checked for damage in any way (e.g. damage to doors, linkages,

etc). Any such damage must be rectified before any tests are attempted; - The data plate on the instrument shall be checked against the information contained on

the instrument specification sheet; - The available power source, whether electric, pneumatic or hydraulic, shall be checked

against what is called for on the instrument specification; - A check shall be carried out to make sure that a suitable means is available for simulating

the required process conditions and that test gauges or meters are available with a sufficient degree of accuracy for the tests to be performed;



TESTING OF INSTRUMENTS Rev 0 1999 - Availability of the manufacturer's `Instruction Manual' shall be checked. 3.2.3.2 Energy Supply Source and Signal Output: The following procedure is common to all instruments requiring a power supply source and which

generate a signal output. a) Pneumatic - Make sure that the air supply to pneumatic instruments is clean, dry and oil free. - Connect the air supply and adjust the air supply regulator to the correct setting e.g. for a

standard transmitter with operating range of 3-15 psig (20 - 100kPag). - Connect the output to a suitable test gauge via a capacity chamber approximately 0.1

gallons (0.5 litre) capacity. - Take care to ensure that all pneumatic connections are leak-free. If in doubt, test joints

with soap solution or similar. - Where instrument air is not available from the normal instrument air supply system, the

Vendor/Contractor shall provide a source of dry air for calibration purpose. b) Electronic - Connect a suitable power supply. Electronic instruments shall be energised continuously

for 24 hours prior to attempting calibration tests. Correct polarity of supply shall be maintained at all times.

- Electrical supply shall have frequency and stability characteristics equal to the permanent

supply. - Transformers shall be made available by the Vendor/Contractor as required. - Instrument power packs - where the equipment of the final system cannot be used, the

Vendor/Contractor shall provide a direct current (DC) supply of the required voltage and characteristics.

- Care should be observed when connecting electrical power supplies to the electrical and

electronic instrumentation. Checks shall be made to ensure correct voltage and frequency on AC supplies and where DC is used, check that the voltage regulation and any suppressed ripple are within instrument manufacturer's specifications. Correct polarity of supply and proper grounding are crucial to solid state equipment.

- Connect the output to a suitable test meter, preferably a Digital Volt Meter, across the

circuit dropping resistor. 3.2.3.3 Process Variable Source: Connect a suitable signal generating source to the process connection together with the means of

isolating and regulating the same, with a suitably accurate indicator. The process variable source will depend upon the type of a signal to be simulated and the following Sections cover typical signal generating methods for various types of instruments. When special hazardous fluids are involved (e.g. oxygen or H2S), suitable safety precautions must be observed and the test method agreed with the



TESTING OF INSTRUMENTS Rev 0 1999 Owner.

3.2.4 Pressure Instruments 3.2.4.1 A compressed air source or nitrogen can usually be used for pressure ranges up to 100 psig (700 kPag). 3.2.4.2 Pneumatic calibrators are available with a variety of pressure ranges, but generally are not suitable for

ranges below 60"wg (0-15 kPa). 3.2.4.3 For ranges below 60"wg (15 kPa), liquid filled manometers should be used with a suitable precision air

reducing valve. 3.2.4.4 For pressure ranges above 100 psi (700 kPa) a hydraulic dead weight tester should be used. 3.2.4.5 Hand held pressure pumps may also be used for signal generation for pressures up to 1psi (0.7 kPa).

These are particularly useful where testing is being carried out in the field, e.g. for loop testing. 3.2.5 Differential Pressure Instruments 3.2.5.1 On pre-installation testing DP transmitters, the variable pressure source is normally connected to the

High Pressure Connection and the Low Pressure Connection must be freely vented to the atmosphere. 3.2.5.2 After the initial calibration test, the high and low pressure sides of the meter element shall be subjected,

in turn, to a static pressure equal to the maximum expected working pressure. The calibration test shall then be repeated to ensure that the results are unaffected by the static pressure loading.

3.2.5.3 Differential pressure transmitters used for fiscal metering and high accuracy metering applications shall

be calibrated at the operating pressure. 3.2.6 Diaphragm Sealed Instruments For external diaphragm sealed type pressure sensors it is necessary to fabricate a test rig comprising a

mating flange with a pressure connection to which pressure sources described in Section 3.2.4 may be attached.

3.2.7 Temperature Instruments 3.2.7.1 Filled Systems: For calibration of thermal systems, a temperature calibration bath equipped with an agitator and a

certified thermometer is required. Several types are generally available, the most common being:- Liquid Filled: Glycol/Water for ranges -40F to +41F (-40C to + 5C) Water for ranges +41F to +203F (+5C to + 95C) Oil for ranges -40F to +356F (-40C to + 180C) Fluidised Bed: for ranges +104F to +2012F (+40C to + 1100C) Temperature calibration baths are generally only suitable for use in workshop. If required for use in the

field, they must only be used under cover and in a non-hazardous environment. 3.2.7.2 Resistance Temperature Detectors (RTDs): RTDs are to be simulated by means of a resistance decade box. 3.2.7.3 Thermocouple:



TESTING OF INSTRUMENTS Rev 0 1999 Thermocouple emfs are to be normally simulated by the use of a precision milli-volt signal generating

source in conjunction with standard calibration tables. 3.2.8 Variable Area Flow Meters (Transmitting Type) VA Meters are to be tested by mechanical means, i.e. the float position is varied by means of a wooden

or plastic rod inserted through the bottom connection. The actual calibration required shall be checked before testing, as the minimum graduation on a VA

Meter is usually 10% flow, whereas the full transmitted output may correspond to 0-100% flow. 3.2.9 Level Displacers External cage displacers are generally tested in situ owing to their physical size but alternatively may be

tested in a test rig or by the suspended weight method. If checked in a test rig the instrument shall be dried after testing and appropriate preservative applied prior to reinstallation in permanent location.

3.2.9.1 'In Situ' Testing: a) Check that the process conditions permit the use of water. b) Where the instrument ultimate service is other than water, check the manufacturer's instructions

for the method of compensating for the SG at the operating temperature. c) Make sure that the vessel isolation valves are completely closed. d) Connect a graduated glass or plastic column parallel to the displacer chamber via the bottom drain

connection or gauge tapping. e) Make sure that the top of the displacer chamber is freely vented to the atmosphere. f) The level can then be varied by injecting water into the chamber. This is usually done by using a

water container and a hand pump connected via the bottom drain connection. 3.2.9.2 Weight Method Testing: a) This method involves the substitution of the displacer by calibration weights equal to the resultant

downwards force of the displacer at the required calibration points (refer to the manufacturer's handbook for method of calculation).

b) This method is generally used for displacers designed for top of tank mounting or with extra large

float chambers. c) In order to use the `weight method' it is necessary to fabricate a test rig in the workshop and to

remove the top section of the instrument containing the float arm, from the displacer caging. 3.2.10 Analysis Instruments Calibration checks are usually carried out on analysers by injecting known samples into the sample

conditioning systems. This must be decided for each type of analyser by reference to the manufacturer's handbook or by consultation with the instrument Vendor/Contractor and shall be agreed with the Owner.

Complex analyser systems usually require specialist personnel from the analyser manufacturer to assist

in pre-calibration and commissioning and are generally outside the scope of the Vendor/Contractor's responsibility.



TESTING OF INSTRUMENTS Rev 0 1999 3.2.11 Calibration Test 3.2.11.1 This procedure applies to transmitting, receiving and direct reading instruments other than local

pressure gauges, temperature gauges or switches. 3.2.11.2 Where instruments form part of a distributed system and where factory tests have been carried out, the

testing procedure shall be agreed with the Owner. a) Leak Test (Pressure Systems) Apply maximum signal input pressure to the process connection, close the inlet valve and

disconnect the pressure source. Observe the gauge on the signal inlet and ensure that there is no fall-off of pressure over a three minute period. Where leaks are suspected, these shall be eliminated and the test repeated.

b) Calibration Test - Check instrument at `zero' reading and adjust if necessary. - Raise the process input signal and record the corresponding output signal and/or scale

readings at 0, 25, 75, 100% of the instrument range. The readings must always be taken when the signal is in a `rising' state.

- Lower the process input signal and again record the corresponding output signal and/or

scale reading at 100, 75, 25, 0% of the instrument range. The readings must always be taken when the signal is in a 'falling' state.

- The percentage error calculated from the above tests shall not exceed the

manufacturer's stated limits for accuracy and hysteresis. - Where necessary, adjustments shall be made according to the manufacturer's instructions

and the tests repeated. Accuracy of readings must be better than or equal to the accuracy limits stated in the manufacturer's specification.

- After the tests have been completed the instrument shall be identified with a coloured

sticker. 3.2.12 Controller Functional Test - General This procedure is applicable to conventional analogue controllers, either field or panel mounted and

would not apply to microprocessor type controllers which form part of an integrated system. Such systems would normally be factory calibrated and any field tests or adjustments would be subject to special agreement with the Owner.

3.2.13 Receiver Controllers (Closed-Loop Method) Receiver Controllers, either pneumatic or electronic, shall be tested by the closed-loop method. This

entails connecting the controller output to the process input connection via, in the case of pneumatic instruments, a capacity chamber e.g. 0.1 gallons (0.5 litre) or, in the case of an electronic instrument, through a resistor equivalent to the average load resistance and a parallel connected 1F capacitor to the input to give the system stability. The following steps should then be performed:

a) Place controller action in `reverse' (decreasing output for increasing input); b) Set Proportional Band to a low value (high gain);



TESTING OF INSTRUMENTS Rev 0 1999 c) Set Integral or Derivative actions (if fitted) to minimum action (integral to maximum time setting

and derivative to minimum); d) Check that the settings of any set point limit stops allow full scale pointer movement; e) Adjust the set-point to 50% of scale and set the auto/manual transfer switch to 'Auto'; f) The controller output should now read 50% i.e. 8 psi (60 kPa) or 12mA or if there is a deviation

scale, it should be at null balance point (centre scale); g) Move the set-point upscale and downscale whilst observing the output meter. The output meter

should continuously track (follow) the set point and the deviation pointer should always read null. Always allow time (say two minutes) at each set-point setting to permit the controller to balance correctly;

h) With the controller set-point and output at 50% as described in step 6 above, move the

proportional band setting from minimum to maximum. During this movement, the output or null balance pointer should remain stationary;

i) Then change the auto/manual transfer switch to `manual', whence it should be possible to vary the

output manually from 0 to 100% of the output scale; j) In the event of the controller performing incorrectly, adjustments should be made in accordance

with the manufacturer's instructions until satisfactory test results are obtained; k) After completing the above tests satisfactorily, return the controller action to the correct mode

required for service operation. The controller adjustments should be left with settings of 100% Proportional Band and minimum Integral and Derivative action;

NOTE : The full calibration checking of Proportional, Integral or Derivative functions is not

normally required but the Owner reserves the right to request the checking of these functions in accordance with the manufacturer's instructions.

3.2.14 Direct Connected Controllers (Open-Loop Method) 3.2.14.1 For controllers connected directly to the process, it is necessary to simulate the process variable as

described under 3.2.3.3. 3.2.14.2 A suitable power supply shall be connected and in the case of pneumatic controllers a capacity chamber

0.1 gallons (0.5 litre) shall be connected to the output to give the system stability. 3.2.14.3 An output gauge must also be provided if one does not already exist on the controller. 3.2.14.4 Checks must be made for controller alignment and synchronisation as follows: 3.2.14.5 Controller Alignment: a) Set the controller action to 'direct' and the auto/manual transfer switch to 'Auto'. b) Set the Proportional Band to a low value (high gain). c) Adjust the Integral or Derivative settings (if fitted) to minimum action. (Integral to maximum time

setting and derivative to minimum). d) Set the set-point to 50% (mid-scale). e) Increase the process variable to mid-scale at which point the controller output should change from



TESTING OF INSTRUMENTS Rev 0 1999 minimum to maximum.

f) If this does not occur, make adjustment in accordance with the manufacturer's instructions. g) When correct changeover occurs, reverse the controller action and re-check the operation to

ensure that the controller is correctly aligned. h) If not, adjust in accordance with the manufacturer's instructions and re-test. 3.2.14.6 Controller Synchronisation: a) Having checked the alignment as above in 3.2.14.5, set the controller action to the required mode

for operation, and set the Proportional band to 100%. b) Set the process variable and set-point to 50% (mid-scale). c) The controller is normally synchronised at 50% of the output range e.g. 8 psi (60 kPa) or 12 mA

and should therefore indicate mid output range when the set-point and the process variable are at mid-scale.

d) With the controller set up at mid-scale as above, adjust the Proportional Band setting from

minimum to maximum, during which the output pointer should remain stationary. e) In the event of the controller performing incorrectly, adjustments should be made in accordance

with the manufacturer's instructions and the tests repeated. f) Change the auto/manual transfer switch to 'manual', whence it should be possible to vary the

output manually from 0 to 100% of the output scale. g) After completing the above tests satisfactorily, return the controller action to the correct mode

required for service operation. The controller adjustment should be left with settings of 100% Proportional Band and minimum Integral and Derivative action.

NOTE : The full calibration checking of Proportional, Integral or Derivative functions is not normally

required but the Owner reserves the right to request the checking of these functions in accordance with the manufacturer's instructions.

3.2.15 Pressure Gauges 3.2.15.1 Pressure gauges shall be checked by means of a Hydraulic Pressure Gauge comparator. 3.2.15.2 The Gauge Comparator should be firmly fixed to a bench. A test gauge of range comparable to the

gauge under test is fitted to one branch of the comparator. The gauge to be tested is fitted to the other branch and the hand pump on the comparator operated in order to check the gauge against the readings of the test gauge.

Readings shall be checked for pressures corresponding to 0, 50 and 100% of the range of the gauge

under test. Actual gauge readings shall be noted for both rising and falling signals. 3.2.15.3 Test gauges shall have an accuracy of or better than 0.25% of full scale and shall be periodically

checked (12 months maximum) for accuracy against a dead-weight tester. 3.2.16 Pressure Switches 3.2.16.1 Pressure switches shall be tested at their operating point using either a compressed air source or a dead-



TESTING OF INSTRUMENTS Rev 0 1999 weight tester depending upon the range of the switch under test. A continuity test-circuit shall be connected across the contacts to ensure correct operation.

3.2.16.2 Care should be taken to ensure that the switch operation is in the correct mode, i.e. with a rising or

falling signal according to the instrument specification. 3.2.16.3 Where the switching differential is stated in the specification, this shall also be checked. 3.2.17 Temperature Indicators (Local) 3.2.17.1 Local temperature indicators (dial thermometers) shall be checked using a temperature bath as described

in 3.2.7.1. 3.2.17.2 They shall normally be checked at approximately 50% of the range unless agreed otherwise with the

Owner. 3.2.18 Temperature Switches 3.2.18.1 Temperature switches shall be tested at their operating point using a temperature bath as described in

Section 3.2.7.1. A continuity test-circuit shall be connected across the contacts to ensure correct operation.

3.2.18.2 Care shall be taken to ensure that the switch operation is in the correct mode, i.e. with a rising or falling

signal according to the instrument specification. 3.2.18.3 Where the switching differential is stated on the specification this shall also be checked. 3.2.19 Level Switches Float switches shall be tested mechanically prior to installation with a continuity test-circuit connected

across the contacts to ensure correct operation. Care shall be taken to ensure that the switch operation mode is correct.

3.2.20 Solenoid Valves 3.2.20.1 Connect an appropriate power supply via a switch. 3.2.20.2 Connect an air supply to the appropriate port or ports. 3.2.20.3 Check the operation of the valve by operating the switch and observing correct changeover action. 3.2.20.4 Check the tightness of shut-off by connecting a flexible tube to the outlet port or ports and immersing

the free end in water to ensure that the valve closure is bubble-tight at the stated design pressure. 3.2.20.5 Check, where applicable, time to activate, electrical and manual reset, override and time delay features

as called for in the valve specification. 3.2.20.6 Check that the coil resistance and voltage is correct to specification. 3.2.21 Flow Elements 3.2.21.1 Flow elements, e.g. orifice plates, venturis, V/A meters, turbine meters, etc., shall not be installed until

line flushing has been completed. 3.2.21.2 Manufacturers' test certificates shall normally be accepted for flow elements which cannot usually be

tested in the field including turbine meters and magnetic flow meters. Omission of tests shall be agreed



TESTING OF INSTRUMENTS Rev 0 1999 with the Owner.

3.2.21.3 Before installation the flow element should be checked to ensure that the data and material specification

stamped on the data plate or tab handle agree with the specification. 3.2.21.4 After installation turbine meters shall be tested regularly, preferably in the medium they usually carry. If

used on custody transfer application they must be regularly and frequently checked by the meter prover. Electromagnetic flowmeters do not, as a rule, require testing unless suspected of being faultly. If so, electodes should be checked for cleanliness. Electronics can be checked in the lab if suitable test equipment is available. Alternatively, exchange for new to see if the problem is rectified.

Orifice plates shall be regularly checked for flatness and quality of profile. Sharp edged plates shall

have a sharp upstream edge that is free from cuts. Only if there is any suggestion that the bore may have changed must it be checked with Vernier callipers; if a change has occured, the cause must be determined and eliminated before a new plate is installed.

3.2.21.5 Orifice plate installation will be witnessed by the Owner. 3.2.22 Control Valves 3.2.22.1 General: a) These tests may be carried out in the instrument workshop or, as is more often the case, in situ

after the valve has been installed in the line. Tests should preferably not be carried out until the valve is in its final operating state, i.e. after line flushing operations have been completed.

NOTE : Where circumstances dictate that line flushing and hydrostatic testing have to occur with

the valve in situ, the valve packing must be checked and replaced if damaged. b) Check that the valve and data plate agree with the control valve specification. c) Check that, where specified, a lubricator is fitted and that it is charged with the correct lubricant. d) All On/Off valves shall be leak tested. 3.2.22.2 Diaphragm Valves Without Positioners: a) Note the dry operating range (bench-set) of the diaphragm actuator from its data plate or

specification sheet. Do not use an additional positioner with the valve. b) Connect a suitable regulated air supply together with an accurate test gauge to the diaphragm case

connection. c) Increase the air pressure to load the diaphragm and check the valve spindle position from the valve

stem position indicator. The travel should be checked at the following positions: 0, 25, 75, 100% of the valve stroke.

d) Where necessary, adjust the valve spring tension nut to obtain the correct start point and re-test. e) Where necessary, check that the speed of operation from fully open to fully closed is within the

limits stated on the specification sheet. f) When requested by the Owner, the hysteresis shall be checked by using a micrometer dial

indicator clamped to the valve stem and repeating the travel test with rising and falling signals at 0, 25, 75, or 100% of valve stroke. The hysteresis should be within + 5% of the valve stroke



TESTING OF INSTRUMENTS Rev 0 1999 unless otherwise specified.

g) When tight shut-off is an important criterion, a test rig must be fabricated comprising a blind

flange on the valve outlet fitted with a 0.25" (6mm) bleed pipe and a suitable rated isolation valve from the centre of the flange. The open end of the bleed pipe shall be immersed in a container of water so that discharge bubbles can be observed. The valve inlet shall be connected to a source of pressure equal to the valve shut-off pressure.

The specified signal corresponding to the valve closed position under normal operating conditions

shall be applied to the valve actuator and, if necessary, adjustments made to the valve until the leakage bubble-rate is within the specified tolerance.

h) Where an air failure lock-up relay or other accessory device is incorporated, it shall be checked for

correct operation (on air failure) in accordance with the instrument specification. 3.2.22.3 Diaphragm Valves With Positioners: a) Note the dry operating range (bench-set) of the diaphragm actuator from its data plate or

specification sheet, i.e. bench-set of actuator irrespective of positioner. b) Note the operating range of the positioner, input and output. c) Where the positioner is fitted with a bypass valve (normally omitted on split-range service), switch

the valve to the `bypass' position and connect a variable air supply with test gauge to the signal input connection.

d) Where no positioner bypass is fitted, disconnect the air connection from the actuator case and

connect in the variable air supply with test gauge direct to the diaphragm head. e) The actuator must then be checked for travel, independent from the positioner, with rising and

falling signals at 0, 25, 75 and 100% of valve stroke. f) Where necessary, check that the speed of operation, from fully open to fully closed, is within the

limits stated on the specification sheet. g) After checking the valve stroke without the positioner, the stroke shall be checked with the

positioner in service. Connect an air supply to the positioner 'supply' connection and adjust to 6psig (42kPag) above the maximum operating range of the actuator.

Switch the positioner bypass valve to the `on' position. If no bypass is fitted, reconnect the

positioner output to the actuator and connect the variable air supply to the positioner signal connection.

If necessary, adjust in accordance with the manufacturer's instructions and then re-test. h) If required, hysteresis, tight shut-off and air failure tests shall be carried out. 3.2.22.4 Other Actuators: a) Control valves with other types of actuators, e.g. piston operators, air cylinder operators,

electro/hydraulic or electric motor operators, shall be tested for stroking and failure action in accordance with the manufacturer's instructions. Tests shall be carried out using correct pressures.

b) Where limit switches or torque switches are fitted these shall be checked using a continuity test

set, for correctness of setting and for operation. On motorised valves, care shall be taken to check



TESTING OF INSTRUMENTS Rev 0 1999 the setting of the limit switches before putting power on to the actuator.

3.2.23 Safety Relief Valves 3.2.23.1 General: a) The testing of safety relief valves shall be carried out by qualified personnel and the following

tests are given as a guidance when within the Vendor/Contractor's scope. All test methods must be agreed with the Owner before being put into operation.

b) The following standard is applicable to this procedure:- API Standard 527 - Seat Tightness of Pressure Relief Valves c) It is important that Safety Relief Valves are stored in a secure warehouse with the valves standing

vertically. When received, the valve blanking plates should be checked for damage which could have allowed the passage of foreign material into the inlet nozzle and the body cavity.

d) If Safety Relief Valves are shipped without test-gags in place, then it will be necessary to strip

down every valve to ensure that there has been no damage on seats or discs during transit and to remove any loose material.

3.2.23.2 Test Rig: a) Safety relief valves are normally tested in a workshop which shall be equipped with a suitable test

rig. The test rig design shall be such that there is no possibility of the formation of rust or scale which

could be blown through into the valve under test. A suitable nozzle with gaskets, adaptor flanges and bolts or clips shall be incorporated so that the relief valve under test may be mounted rigidly in a vertical position.

b) Compressed air is preferred as a test fluid but bottled inert gas may be used if air is not available at

the required pressure. The test fluid should be filtered to ensure that no particles of foreign matter are passed through into the valve under test.

c) If a test gas other than air is used, the test rig must be installed in a freely ventilated location. d) For High Pressure duties, hydrostatic testing may be required using a purpose built test rig which

should be operated in accordance with the manufacturer's instructions. On hydrostatic test rigs, all piping and fittings in contact with water shall be of stainless steel.

e) To control the test pressure, a precision reducing valve and test pressure gauge (minimum 150mm

diameter) with recitable maximum pointer shall be provided on the inlet side. The reducing valve and gauge ranges shall be selected to cover the range of relief valve set pressures to be tested.

f) The outlet flange of the relief valve shall be provided with a suitable mating flange or clamp-on

cover plate which shall be fitted to the valve only when the seat leakage test is carried out. This flange shall incorporate the following:

- a " (6mm ) bore bleed pipe in accordance with API 527; - a safety plug to prevent the downstream side of the relief valve from becoming over

pressurised in the event of inadvertent popping of the relief valve. The safety plug shall be designed to blow at, say 3 psig (20 kPag).

NOTE : The bleed pipe and safety plug may be combined into one item by inserting the



TESTING OF INSTRUMENTS Rev 0 1999 bleed pipe through the safety plug.

3.2.23.3 Test Procedure: a) Safety relief valves shall be tested immediately prior to installation. If installation is deferred, the

protective flange covers shall be refitted and the valve stored in a vertical position. When required for service the valve must be re-tested.

b) All tests on safety relief valves shall be recorded on the test sheet and the signatures of witnesses

shall be obtained as required. c) The relief valve tests are in two stages: - Popping and reseating; - Seat leakage test. 3.2.23.4 Popping and Reseating: a) Before popping the relief valve the outlet flange shall be removed. b) The inlet nozzle should be wiped clean prior to testing. c) The relief valve "cold set pressure" shall be ascertained and entered on the test record sheet. This

pressure should be found on the valve data plate or on the valve data sheet. d) The test pressure shall be increased slowly until the relief valve is observed to pop and the

pressure (as indicated by the `maximum' pointer on the test gauge) shall be noted on the test record sheet. If the difference between the measured popping pressure and the cold set pressure is outside acceptable tolerances, the valve setting shall be adjusted in accordance with the manufacturer's instructions.

e) The test pressure shall then be lowered and the reseating pressure noted and checked that it agrees

with the relief valve manufacturer's data. 3.2.23.5 Seat Leakage Test: Unless otherwise specified the seat leakage rate shall be tested in accordance with API 527. This test

procedure is summarised as follows: a) Immediately after the popping test as described in Section 3.2.23.4, the test pressure shall be

lowered and held at 10% below the set pressure or 5 psig (35 kPag) minimum for the duration specified in API 527.

b) The outlet flange shall be refitted complete with safety plug and the open end of the bleed pipe

shall be immersed in water to a depth of 0.5" (13mm) below the surface. The leakage rate in bubbles per minute will then be checked in accordance with API 527.

c) Failure of the leakage test shall be corrected by dismantling the valve and lapping the disc and seat

in accordance with the manufacturer's instructions. d) After testing, the valve shall be identified by a suitably coloured sticker, see Section 3.2.1.12. NOTE : During testing to API 527 using the cup method, it is possible for air leakage to occur

around the top bonnet flange, the outlet flange made off for the test and the cap. These should be soap tested during the test to prove that there is no leakage. Alternatively, a flooded seat test should be nominated for valves having discharge flanges greater than 2" (50mm) and, after such a



TESTING OF INSTRUMENTS Rev 0 1999 test, the body cavity shall be thoroughly dried with instrument air.

3.2.24 Vibration Proximity Type Probe 3.2.24.1 This typical procedure (Vendor/Contractor's actual procedure must be followed) assumes that the probe

requiring check is installed on the machine and powered up. a) Before calibration procedure is carried out, the following should be noted: 1 mil = 1 thou (1 mil is an American terminology for 1 thou); 1 thou = 25.4 micrometers; 1 mm = 1000 micrometers. b) Remove J/B lid that contains the relevant proximeters. c) Connect a digital voltmeter (D.V.M) (selected to measure D.C voltage) to the common and

negative signal connections on the proximeter without disconnecting the circuit. d) Remove the vibration probe from its permanent position and mount on horizontal mounting on the

wobulator (rotating tilted table). e) Re-connect cable to probe. f) The indication on the D.V.M. will now read -21 volts or above. g) Mount the micrometer on the wobulator, ensuring that the correct target is on the micrometer (the

target should be of the same material as the machine shaft that is to be monitored). h) Before clamping move the micrometer (and thus the target) towards the probe gently until the

target just touches the probe. i) The micrometer is now set to zero and clamped. j) The D.V.M. will read approx 0 volts. k) The micrometer is now backed off by 0.1mm and reading taken from the D.V.M. This process is

repeated until a complete set of figures are obtained (the final plot should be when a reading of -16 volts is indicated).

l) Now plot the graph. m) The vibration probe will be used in the range -7 to -11 volts so the nearest readings to -7 volts on

the D.V.M. are plotted. The same applies for the -11 value. n) The span is calculated by subtracting these values the resultant different i.e. the span in mm is

divided by 25.4 to convert to imperial measurement. This figure is now thousands of an inch. o) The span figure in imperial can now be divided into the recorder span volts, this should give a

value of 200mv/0.001". p) If the figure is around 200mv/0.001 inch 5% the probe is O.K. q) If the probe is measuring radial vibration replace the probe to its permanent position and adjust the

gap to -9 volts. r) Axial probes will require the shafts to be centralised and then gap set to -9 volts.



TESTING OF INSTRUMENTS Rev 0 1999 3.2.25 Microprocessor Based Systems 3.2.25.1 Microprocessor based control systems are not covered by this procedure except in so far as the tests

detailed can be applied to components of a system. 3.2.25.2 On site check-out and pre-commissioning should usually be carried out by specialist personnel from the

equipment vendor or alternatively by reference to the manufacturer's instructions. 3.2.25.3 Nevertheless, the basic requirement remains that every input and output signal must be checked through

from its field initiation point to control room display unit or vice versa. All control and logic functions must be checked for operability in accordance with the manufacturer's stated performance characteristics.

3.2.25.4 All checks must be recorded on loop tests sheets and included in the appropriate loop dossier. 3.2.25.5 All test methods must be agreed with the Owner. 3.2.25.6 For further details refer to GES C.54. 3.2.26 Special Control Systems The procedures for pre-testing of complex control systems (e.g. multi-fuel combustion controls) need to

be agreed with the Owner before the work begins. Similarly, complex interlocking and shut down systems with many inputs and outputs normally call for a carefully thought out testing procedure which must be formulated and agreed in advance.

3.3 Pressure Testing 3.3.1 General 3.3.1.1 The object of this phase of the testing procedure is to ensure that all instrument piping and tubing is

pressure tight to the specified working/testing conditions. 3.3.1.2 The pressure testing of any site fabricated equipment, i.e. cooling chambers, capacity pots, catch pots,

etc., shall be witnessed by the Owner unless this has been waived, in which case test certificates must be submitted.

3.3.1.3 Under no case shall any instrument, other than control valves and thermowells, be subject to test

pressures. 3.3.1.4 Prior to testing and cleaning all lines shall be disconnected from the instrument and blocked off. Before

and after testing, all lines shall be flushed and blown down with water or air (as appropriate) to remove all contamination.

3.3.1.5 The instrument piping and tubing to be tested can be classified in the following categories: a) Air supply piping (3.3.2) b) Transmission/signal tubing (3.3.3) c) Process Impulse Piping (3.3.4) The pressure testing of air supply piping, transmission tubing and process impulse pipework on a given

loop shall be completed before the final loop testing. Thus, if the transmitter has to be disconnected for loop testing, only one connection has to be re-checked.



TESTING OF INSTRUMENTS Rev 0 1999 3.3.2 Air Supply Piping 3.3.2.1 The main instrument air header from the source up to and including the first isolation, i.e. branch shut

off valves usually on the pipe track, will be tested by others unless otherwise specified. The following tests assume that the instrument air compressors and dryers have been commissioned and

an instrument air supply established at the specified working conditions, i.e. clean, dry and oil free. 3.3.2.2 Branch air lines to individual instruments shall be disconnected immediately upstream of, and adjacent

to, the instrument air filter regulator and blown through with clean air, until clear of all foreign materials.

3.3.2.3 The open end(s) shall be blanked off and a suitable test pressure gauge connected into the system. 3.3.2.4 The isolation valve immediately upstream of the piping to be tested should be opened and, when the line

is pressurised, the valve is closed. This test shall have a duration of 10 minutes and the test gauge shall be observed in order to detect leakage. In addition all joints shall be checked by the application of soap solution or similar and leaking joints remade as necessary.

3.3.2.5 On completion of the test, the line shall be reconnected and the joint(s) not previously proven checked

with soap solution or similar. 3.3.2.6 The pipe shall then be identified by a suitably coloured sticker as stated in Section 3.2.1.12. 3.3.2.7 If a permanent air supply has not been established prior to these tests, an alternative source of clean, oil-

free, dry air or nitrogen from either storage cylinders or an oil-free compressor with dryer shall be used. 3.3.3 Transmission Tubing 3.3.3.1 Each individual tube shall be disconnected at both ends and blown through with clean, oil-free, dry air. 3.3.3.2 The tubes shall then be blanked off and pressurised to 20 psig (137 kPag) from an existing air supply,

via a pneumerstat or bubble bottle. After pressurising, the bubble rate shall be less than one bubble in 10 seconds. If an air supply is not readily available, the tubes may be pressurised using a foot pump and with a manometer teed into the system. With the pressure source isolated the reading shall not fall.

3.3.3.3 The tube shall then be reconnected and, when an air supply is established, the joints not proven shall be

tested with soap solution. This may be achieved by setting the transmitter/controller outputs to maximum.

3.3.3.4 Underground tubing shall be tested before trenches are backfilled. 3.3.3.5 The tubing shall then be identified by a suitably coloured sticker as stated in Section 3.2.1.12. 3.3.4 Process Impulse Piping and/or Hydraulic Lines 3.3.4.1 After fabrication, process impulse piping shall, where practical, be disconnected at both ends for

flushing and testing. 3.3.4.2 After flushing the line with water, one end shall be blanked off and the other shall be connected to a

hydraulic pump with a suitable test gauge fitted. The line shall then be pressurised to 1 times the maximum working pressure (corrected for temperature) or the test pressure of the associated process line or vessel, whichever is the greater. The line shall then be isolated from the pressure source and the pressure must not fall.



TESTING OF INSTRUMENTS Rev 0 1999 3.3.4.3 After testing, the lines shall be blown dry and reconnected to the instrument manifold and all manifold

valves shall be checked for tight shut-off. 3.3.4.4 For close coupled instruments, e.g. line mounted d/p cells, the pipes shall be disconnected at the

instrument only and tested as per Sections 3.3.4.1, 3.3.4.2 and 3.3.4.3 up to the initial isolation. 3.3.4.5 During hydraulic tests on the main process lines, instruments must be disconnected to ensure that initial

isolation are leak proof. During flushing, it is the Instrument Tester's responsibility to ensure that all installed instruments are suitably and positively isolated from the process line. Instruments fitted with manifolds must have their bypass valve open.

3.3.4.6 The Instrument Tester must ensure that all instrument pressure tappings have been drilled through the

pipe wall. 3.3.4.7 All instrument equipment and piping hydro-statically tested with water shall be thoroughly dried out on

completion of the test. 3.3.4.8 No pressure tests shall be carried out on the process impulse piping or hydraulic lines unless these are

authorised by the Owner in writing. 3.4 Testing of Instrument Cables 3.4.1 `Power Off' Tests 3.4.1.1 Immediately after cables are laid and before any connection* all thermocouple, electric and electronic

instrument wiring shall be checked for polarity, continuity and insulation resistance between conductors and between conductors to earth. These tests MUST be carried out before final loop tests.

*WARNING - Severe damage may be caused to barriers and electronic equipment if inadvertent

meggering of cables is carried out after connection. Continuity and insulation resistance checks shall be carried out using the proper test equipment to

comply with the requirements of BS 7671 (IEE Requirements for Electrical Installations), or the rules and regulation with which the installation has to comply.

3.4.1.2 Underground cables shall be tested before backfilling is commenced. 3.4.1.3 Other tests on IS circuits (e.g. for loop impedance, inductance, L/R ratio, etc), shall be carried out,

where required, by agreement with the Owner. 3.4.1.4 The cables shall then be identified by a suitably coloured label as stated in Section 3.2.1.12. 3.4.2 Network Cables and Components Refer to GES J.16.



TESTING OF INSTRUMENTS Rev 0 1999 3.5 Loop Testing 3.5.1 General 3.5.1.1 The object of loop testing is to ensure that all instrumentation components in a loop are correctly

calibrated and are in a state ready for plant commissioning. 3.5.1.2 The procedures to be adopted in carrying out these tests is detailed below, but in general the completed

instrument loop shall be tested as one system and, where necessary, adjustments shall be made to ensure that the loop is fully operational as a system and is correctly calibrated. All associated alarms, trips and indicators shall be checked during loop testing.

3.5.1.3 Those loops of which part is located on a process package unit shall be tested in their entirety; i.e. the

total loop shall be functionally tested including those items located on the process package units. 3.5.1.4 A pre-requisite to testing of equipment is mechanical completed/acceptance of associated pipework,

wiring, mounting and the general acceptability of the installation as a professional piece of work of all items related to the loop. This is obtained from the mechanical completion dossier held by the Vendor/Contractor.

3.5.1.5 Loop testing of remote control loops is a two-man operation, one man in the field and one man in the

control room. These men must be provided with adequate means of remote communication, i.e. field telephones or two-way radios, as approved by the Owner.

3.5.1.6 During loop testing, the Vendor/Contractor's electrical section representative shall normally be in

attendance to check his inter-related sections of work during trip and alarm checks. The instrument tester will request his attendance giving adequate notice.

3.5.1.7 Loop testing shall not be carried out on electronic equipment until an adequate warm-up period has

elapsed. Where possible instruments shall be energised for at least 24 hours prior to testing. 3.5.1.8 In all instances, the Owner's representative will witness the final loop tests and countersign the test

certificates. The Owner shall be given adequate notice of final tests so that the necessary witnesses may be made available.

3.5.1.9 Upon completion, a test certificate for every installation recording all results, shall be handed to the

Owner. The certificates for any tests not witnessed shall be accompanied by the Owner's written confirmation that witnessing has been waived.

3.5.1.10 On completion of loop testing all controllers shall be left with CORRECT ACTION and with 100%

Proportional Band setting. Derivative and Integral functions shall be set at minimum action. 3.5.1.11 Before commencement of tests, inspect the loop, setting air/electrical supplies where appropriate.

Check in particular that control valves air supply pressures are set in accordance with the specification.

3.5.1.12 For electronic loops check polarities, measure the loop impedance and make the necessary

compensating adjustments. Ensure the loop impedance tester is of a type that will not damage a field connected instrument.

3.5.1.13 Manually or by simulated process input signals instrument output signals equivalent to at least 0, 50 and

100% of the instrument range shall be generated, both rising and falling, to check the response of all other instruments and control valves in the loop.

3.5.1.14 No electronic loop shall be powered until proof of continuity and insulation tests having been

successfully completed is available.



TESTING OF INSTRUMENTS Rev 0 1999 3.5.1.15 Instrument zero settings and calibration adjustments shall be made as necessary. 3.5.1.16 For special notes on electrical temperature instruments see Sections 3.2.7 and 3.5.3. 3.5.2 Loop Testing Procedure 3.5.2.1 Switch the controller to manual operation and by applying the appropriate signals ensure that the control

valve or valves stroke correctly. Valve positioner gauges shall also be checked during this stage. 3.5.2.2 Apply an actuating signal to the controller equivalent to 50% of the instrument range and adjust the

manual regulator output to 50%. Adjust the controller set-point to 50% and, by switching the auto/manual transfer switch, check for `bumpless' transfer. Using the manufacturer's instructions, adjust where necessary until satisfactory `bumpless' transfer is achieved.

3.5.2.3 Check alarm and trip actions by varying the actuating signals and adjust as necessary. 3.5.2.4 Where interlock inputs have already been proven during measurement and control loop tests, these

inputs shall be by-passed. All other inputs shall be proven. The complete interlock system shall then be checked for correct sequence of operation, and all output devices shall be shown to work satisfactorily.

3.5.2.5 Where a part of the plant has been classified as a hazardous area caution is necessary if final loop

testing is performed after the introduction of hydrocarbons, or other potentially hazardous material into the plant. Such tests shall be under the direct supervision of the Owner under the Work Permit system.

3.5.2.6 The appropriate national codes and local regulations shall be followed where a flameproof or explosion-

proof or safety purged enclosure needs to be opened to simulate operation. This normally involves a periodic gas test in the area. Note that, in any case, power should be switched off prior to removing and replacing enclosure covers.

3.5.2.7 Where intrinsically safe circuits are used at field sensors, no restriction is normally encountered,

providing test equipment does not infringe intrinsic safety certification. 3.5.2.8 Locally mounted controller or transmitting only loops shall be tested in a similar manner to that

specified above omitting transmitter and/or auto/manual checks as necessary. 3.5.2.9 After each loop is satisfactorily tested, the controller shall be switched to manual and identified by a

suitably coloured sticker as specified in Section 3.2.1.12. 3.5.3 Temperature Loops (Thermocouple and Resistance Thermometer) 3.5.3.1 Thermocouples and resistance thermometers shall be removed from their wells and checked for damage.

The resistance of each resistance thermometer shall be measured at ambient temperature and resistance and temperature noted.

3.5.3.2 After testing, thermocouples/resistance thermometers shall be replaced in their thermowells and

reconnected. It is important to ensure that the element is 'bottomed' in the thermowell and that the polarity of the thermocouple connections is correct.

3.5.3.3 To assist in the identification of thermocouple compensating cable conductors, the following guide is

given: a) For compensating cables having insulation colour coded to British Standard BS 1843 : 1987, the

negative wire is always coloured BLUE. b) For type T thermocouples (copper/constantan) the positive wire is COPPER coloured.



TESTING OF INSTRUMENTS Rev 0 1999 c) For type K thermocouples (chrome/alumel) the negative wire is slightly magnetic. 3.5.3.4 For galvanometer deflection type installations using thermocouples, compensating lead resistances shall

be adjusted. 3.5.3.5 Where a two-wire resistance thermometer system is employed, 'make up' resistances shall be adjusted. 3.5.3.6 For three and four-wire resistance thermometer installations, extra care must be taken to ensure the

correct connections. 3.5.3.7 See also Section 3.5.4.3. 3.5.4 Miscellaneous (Analysers, Special Installations) 3.5.4.1 Analytical and Special Installation shall be checked according to manufacturer's instructions and/or by

agreement with the Owner (see also Section 3.2.10). 3.5.4.2 Trips and alarms not previously covered in the loop tests, e.g. initiating devices which stop/start pumps,

etc. shall be checked in conjunction with the Owner. (See Section 3.5.1.2). 3.5.4.3 All systems shall be checked for 'fail safe' operation which will include the checking of 'burn out'

features on thermocouple installations. 3.6 Test Equipment 3.6.1 General The following is a list of typical test or calibration equipment which may be required by a

Vendor/Contractor for on-site Instrument testing and Pre-commissioning and loop testing. The test and calibration equipment shall be calibrated in the units of measurement selected for the

project. All test equipment shall be approved by the Owner. 3.6.2 Pressure Testing and Calibration Equipment - Portable Manually Operated Hydraulic Pump (bucket pump). - Low Pressure, Hand-Held Pressure Pump (ranges up to 14.8 psi (100 kPa)). - Vacuum Pump, manually operated. - Dead Weight Tester. - Pressure Gauge Comparison Test Pump. - Precision Air filter/Regulator Sets (2 off minimum). - Liquid filled Manometer (for ranges below 1.45 psi (10 kPa)). - U-Tube Manometer (ranged approx. +/- 0.38 psi (2.5 kPa)). - Precision Inclined Manometer (ranges below 0.145 psi (1kPa)). - Precision Sealed Mercury Manometer (ranges up to approx. 14.5 psi (100 kPa)).



TESTING OF INSTRUMENTS Rev 0 1999 - Certified Test Gauges, 0.25% accuracy or better. - Portable Pneumatic Calibration boxes (2 off minimum). - Portable Air Compressor (where air is not available). 3.6.3 Temperature Test and Calibration Equipment - Thermostatically Controlled Temperature Bath(s). - Thermostatically Controlled Oven for checking cold junction compensation. - Sets of Standard (Precision) Mercury in Glass Thermometers. - Precision Potentiometer and Millivolt Generator. - Precision Wheatstone Bridge incorporating a detachable resistance box where resistance

thermometers are to be installed. Accuracy 0.05% on any resistance value. - Decade Resistance Box 0.1% accuracy. NOTE: All test instruments to be provided with test leads complete with test probes, clips and

distribution terminals. 3.6.4 General Electronic/Electrical Test and Calibration Equipment - Digital voltmeters (DVM) with an accuracy of +/- 0.1% of range or better and with a

discrimination of 10v or better and incorporating an internal calibration/standardising feature and 0.1% calibration resistors.

- Precision Millivolt, volt and Milliamp Source and Measuring Device. - Portable Multimeter. - Insulation Resistance Testers. - Stop-watch and Relay Contact Timing Device. - Dual-Beam Oscilloscope. - Client approved portable radio transmitter/receiver sets for loop testing. These should be certified

intrinsically safe if they are to be used during plant start-up and they should not conflict with the plant radio system.

- Portable IBM compatible PC with protocol test software loaded for testing serial links. - Serial link break out box. - Sine wave reflective testing equipment. NOTE: Test certificates shall be provided showing when the test equipment was last calibrated.

Calibration should have been within the previous three months. 3.7 Painting and Insulation 3.7.1 Brackets and supports supplied by the Vendor/Contractor and other materials not already protected in an

approved way shall be primed and painted in accordance with GES X.06, with the exception of



TESTING OF INSTRUMENTS Rev 0 1999 instrument stainless steel boxes, compression fittings and tubing which shall not be painted.

3.7.2 Where supporting steelwork or cable trays are cut or drilled, the exposed surfaces shall be primed and

painted in accordance with the painting specifications to the satisfaction of the Owner. 4.0 INSTRUMENT INSTALLATIONS 4.1 General 4.1.1 The Vendor/Contractor shall carry out the Contract work in accordance with the contract documentation

and this Specification. including the completion and obtaining of approval signatures for all the General Forms, Calibration and Test certificates of Installation Checklist and Acceptance forms listed in Section 8.0 of this specification.

4.1.2 The Vendor/Contractor is expected to handover a fully operable system and any defects in the design,

omissions or discrepancies found which would impede the achievement shall be brought to the Owner's attention without delay.

4.1.3 The Vendor/Contractor may or may not be responsible for the purchase of bulk items such as tubing,

pipe, instrument isolation valves, air filter regulators in accordance with the Scope of Work documentation issued by the Owner.

The Vendor/Contractor is to provide and install all items such as channel, clips, supports, clamps,

brackets, stands, sunshades as well as all necessary welding, painting, wiring, junction boxes, tubing, fittings etc., that are required to complete the installation and connection of instruments as there are acquired from the suppliers, Any further items to be supplied by the Vendor/Contractor e.g. 3 way manifolds, airsets will be clearly marked on the material take-off Instrument Schedule (Index).

4.1.4 The Vendor/Contractor shall include for a project status reporting system. At least one report shall be

provided per week. The report shall be generated using a database format to be agreed and a hard copy and a floppy diskette transfer shall be required. The report shall list all the items covered under the Scope of Work on the vertical side and the following activities on the horizontal side:

- Receiving; - Calibration; - Installation - Process hook-up; - Pressure tested; - Electronic hook-up to instrument; - Conduit run; - Cable run/wire connected; - Panel Connection; - Power Supply Connection; - Pneumatic Air Supply; - Tubing Connected; - Tested; - Documentation complete; - Commissioning; - Loop Check; - Start-Up; - Comments/remarks. 4.1.5 In order to avoid damaging the instrument or degrade its accuracy, all in-line devices including control

valves but except thermowells shall be removed when the piping is being flushed, cleaned or pressure tested. The device shall be replaced by a spool piece during the tests.

4.1.6 Air header supply piping shall be part of the Vendor/Contractor's scope of work.



TESTING OF INSTRUMENTS Rev 0 1999 4.1.7 When accepting deliveries, the Vendor/Contractor shall inspect the equipment and materials against the

Instrument Index, Specifications and Purchase Order/Contract to ensure that quantity, type, ranges etc, are as specified. By receipt of the delivered supplies the Vendor/Contractor shall be deemed to have acknowledged that all equipment and materials are complete and satisfactory in every respect. Any damage shall be notified in writing using the Damage/Fault Report Form (Section 8.1) to the Owner for immediate action.

4.1.8 The Vendor/Contractor may also be responsible for safe storage of the instruments and materials. The

Vendor/Contractor shall report any defects or shortages immediately to the Owner. Equipment damaged or broken subsequent to issue and prior to final acceptance, in terms of the contract, shall be re-issued by the Owner and fitted by the Vendor/Contractor. All the costs of such replacements shall be borne by the Vendor/Contractor.

4.1.9 If the Vendor/Contractor is required to store the received instruments and control systems, then he shall

provide adequate storage space whilst indoors, secure, protected from unauthorised tampering, free from fire hazard and clean and dry.

4.1.10 All instruments, wherever possible, shall be kept in their original shipping cartons until these are

installed. To avoid damage to the instruments, separate storage space shall be maintained apart from areas in which large items and equipment are stored.

4.1.11 All electronic equipment shall be kept in an air conditioned store. The contractor shall discuss the need

for a bonded store. 4.1.12 Where instruments are taken from the stores temporarily, e.g. for pre-installation testing, they shall be

returned and stored in this original packing. 4.1.13 If the Vendor/Contractor is responsible for storing all instrumentation and control systems, it shall be

the Vendor/Contractor's responsibility to issue all stored equipment prior to the installation. The Vendor/Contractor shall maintain accurate records showing equipment and material received, stored, issued and installed.

4.1.14 Special tools shall be handed over to the Instrument Engineer in the Construction Team, 4.2 Compliance with Drawings/Specifications 4.2.1 The Vendor/Contractor is expected and required to comply in detail with the documentation and

drawings issued by the Owner. 4.2.2 Where the Vendor/Contractor feels that slight deviations, slight modifications or slight additions

improve the design, or expedite his work, he may bring these to the attention of the Owner. However, any such modifications, exceptions deviations or additions must be agreed and confirmed in writing and approved by the Owner prior to commencing the work. If such modifications affect price, any price alterations must also be agreed in writing prior to commencing the work.

4.2.3 The Vendor/Contractor shall keep a record of all agreed changes and shall, immediately following

completion, provide `As-Built' copies of the drawings showing the implementation of the agreed alteration.

4.2.4 The Vendor/Contractor shall be responsible for correcting free of charge any part of the installation

which is found not to be in accordance with the Owner's documentation (except for a previously identified agreed and documented deviation Sections 4.2.2 and 4.2.3 above). The Vendor/Contractor shall also replace at his cost any materials necessary to complete such corrective work.

4.2.5 The Vendor/Contractor shall also be responsible for obtaining material certificates, letters of

conformity, hazardous area certificates and where appropriate detail drawings for submission to the



TESTING OF INSTRUMENTS Rev 0 1999 Owner for approval.

4.3 Instrument Mounting and Accessibility 4.3.1 Each instrument or item of equipment to be installed shall be inspected to check that its data plate and

other details (especially the pressure rating) agrees with the specification and, where appropriate, that is has been pre-calibrated. The instrument shall then be installed in the correct orientation in its intended location on brackets, a sub-panel, mounting post or pedestal ensuring that it is levelled, plumbed and firmly secured.

4.3.2 Instruments shall not be installed until heavy duty mechanical work adjacent to their installation has

been completed. 4.3.3 The installation of instruments which are mounted in-line or direct to a vessel nozzle and which will be

mechanically installed by others, shall be supervised by the Vendor/Contractor's instrument personnel where necessary and checked for correct installation.

These items typically include the following: Orifice plates; Control valves; Relief valves; Bursting discs; In-line flowmeters (PD meters, VA meters, etc); Level displacers; Special analyser probes; Thermowells; Level gauge glasses; Level switches. NOTE: The Vendor/Contractor will retain responsibility for the correctness of the above installation

and shall ensure that suitable flushing or cleaning has been carried out prior to installation. 4.3.4 The installation of fire and gas detectors especially those in ducts and voids and the extinguishant

system will be supervised by the Owner. 4.3.5 Where necessary, instruments shall be secured to the nearest suitable firm steelwork so as to be, as far

possible, unaffected by vibration. Process lines or handrails shall not be used for supporting instruments, unless specifically allowed by project documentation.

4.3.6 Welding or drilling of any structural steelwork, piping equipment or vessel for the purpose of mainly or

supporting items of instrumentation shall be done only after the Vendor/Contractor has obtained acceptance from the Owner. Drilling of vessels is normally prohibited in any event.

4.3.7 Instruments shall be located so that they do not obstruct access or walkways and so that they are

protected from damage by passing or falling objects and clear of venting and drainage points of condensate, water and process fluids from adjacent plant equipment. They shall be located away from potential fire risk and spillage areas and sources of vibration. The location of instrumentation, impulse pipe runs, vents, drains, cable trays, etc, shall not cause a hazard to either personnel or equipment.

4.3.8 Where welds are allowed, these shall be ground smooth, prepared and painted in accordance with the

painting specifications used on the project to match support or stand prior to the installation of tubing tray or instrument.

4.3.9 Supports and stands shall be fabricated so that these do not become a trough or trap for spilled liquids.

They shall be painted by the Vendor/Contractor to match the s

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