F-NC-174

Elephant Field Development Project - GOSP

AGIP Contract No. MFIA Job No.:
F-NC-174 PROJECT MANAGEMENT PROCEDURE 520 02 21270

PROCEDURE NO. GS-MO-Q-PR-00-059-01

Testing and Calibration of the Process Instruments

Contents

1.0 PURPOSE..............................................................................................................................

2.0 PROCEDURE ................................ ................................ ................................ .........................

3.0 EQUIPMENT FOR TESTING AND CALIBRATION................................ ................................ .....

4.0 ATTACHMENT - CALIBRATION AND TEST SHEETS ...............................................................

01 15.12.03 B. Habek S. Karsch J. Rittscher Issue for approval

Rev. Date Prepared Checked Approved Description of revision
Page 1 of 9
Q-PR-00-058-C1
 Procedure No. GS-MO-Q-PR-050-01 Page 2 of 9
Testing and Calibration of the Process Instruments
Revision 01, dated 15.12.2003

1.0 PURPOSE

The Purpose of this Management Procedure is to ensure that all

instrumentation testing and calibration activities are carried out according to
contract requirements and referred codes and standards.

2.0 PROCEDURE

2.1 General
All instruments and instrument systems should be inspected
immediately upon receipt from the manufacturer/supplier to ensure
they are free from defects.
Any defects or deficiencies shall be brought to the attention of the
principal.
However, certain instruments and instrument systems will still need
to be checked, tested and/or calibrated, either before installation in
the instrument workshop or in the field during the pre -commissioning
inspection

2.2 Documentation and test records

All tests conducted shall be recorded on appropriate test sheets and a log
maintained. Recorded data shall include, but not be limited to the following:
- Date of Test
- Identification of Equipment Tested
- Type of Test Applied
- Test Equipment Used
- Test Results

All tests shall be witnessed as and when required. Upon satisfactory

completion of each test and upon analysis of data obtained, the Instrument
Inspector shall sign off test sheets and obtain customer signature for final
acceptance.

2.3 Typical field calibration procedures

2.3.1 Pressure transmitters

Apply a supply pressure of 1.4 bar or a supply voltage of 24 V according to

the type of transmitter.
Apply pressures of 0%, 50%, 100%, 50%, 0% of the range of the transmitter
as indicated in the requisition and observe the transmitter output at each
point.
If the transmitter output is not within the manufacturer's tolerance, re-calibrate
the transmitter in accordance with the manufacturer's recommendations.
After re-calibration, re-apply pressures and record the results on the
calibration sheet.

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Testing and Calibration of the Process Instruments
Revision 01, dated 15.12.2003

2.3.2 Differential-pressure transmitters

Carry out the procedure given above for pressure transmitters and in
addition:
Apply a static pressure, corresponding to the maximum operating pressure as
indicated in the requisition, to both sides of the differential pressure cell and
record the variation of zero output on the calibration sheet.

2.3.3 Filled temperature transmitters

Apply a supply pressure of 1.4 bar.

Place the capillary bulb in a temperature bath and apply three temperatures
corresponding to 0%, 50%, 100%, 50%, 0% of scale and observe the
outputs.
If the transmitter output is not within the manufacturer's tolerance, re-calibrate
the transmitter in accordance with the manufacturer's recommendations.
After re-calibration, re-apply temperatures and observe the results on the
calibration sheet.

2.3.4 Controllers

Apply a supply pressure of 1.4 bar or an appropriate supply voltage according

to the type of controller.
Apply measured variable signals of 0%, 50%, 100%, 50%, 0% of full scale and
record the controller reading.
If the result is not within the manufacturer's tolerance re-calibrate the controller
in accordance with the manufacturer's recommendations. After recalibration,
re-apply the signals and record the results on the calibration sheet.
Switch th e controller to the manual position. Adjust the output to give 0%, 50%,
100%, 50%, 0% of full scale and observe the corresponding output reading on
the controller.
If the reading is not within the manufacturer's tolerance re-calibrate the
controller in accordance with the manufacturer's recommendations.
After re-calibration, manually adjust the output again and record the results on
the calibration sheet.

Alignment check:
- with the controller in manual operation, apply 50% of the measured
variable signal to input and move set point to 50% of scale. Reset adjustment
to minimum setting and rate adjustment to maximum setting. Set output to 50%
and switch to auto. Adjust the proportional band setting to maximum and
observe the deviation of output.
If the results are not within the manufacturer's tolerance re-align the controller
in accordance with the manufacturer's recommendations.
After re-alignment, repeat the manual adjustment of output and record the
results on the calibration sheet.

Reset test:
- with the controller in auto and the proportional band at 100%, apply a
50% measured variable signal to input, with reset adjustment at the minimum
setting and rate adjustment at maximum. Adjust the set point until output is

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 Procedure No. GS-MO-Q-PR-050-01 Page 4 of 9
Testing and Calibration of the Process Instruments
Revision 01, dated 15.12.2003

50% and increase reset adjustment. Output should increase to 100% or

decrease to 0% over a certain period of time.
If the controller does not act as above, refer to manufacturer's data for the
corrective actions to be taken.

Rate test:
- with the controller in auto and the proportional band at 100%, apply a
50% approximately, measured variable signal to input, set reset adjustment to
minimum setting and rate adjustment to middle of range, adjust set point to
50%. Change input signal rapidly to 25% of scale.
Output should fall to zero or near zero before increasing again to approx-
imately 25% over a period of time. If the controller does not act as above, refer
to manufacturer's data for the corrective actions to be taken.
Manual/auto transfer test:
perform an auto/manual transfer test by switching repeatedly between the two
controller modes after balancing the output.

2.3.5 Computing relays

Apply a supply pressure of 1.4 bar.

For 2-input relays, apply 2 input signals. For 3-input relays, apply 3 input
signals. Only one input signal shall vary at any one time, the other signal(s)
shall be set at 50% of scale. Apply for each input 0%, 50%, 100%, 50%, 0% of
scale and observe the outputs.
If an output is not within manufacturer's tolerance for the desired function,
then coefficients need to be changed in accordance with the manufacturer's
recommendations.
After re-setting coefficients, re-apply input signals as above and record the
results on the calibration sheet.

2.3.6 Torque tube transmitters

NOTE: Side-side or side-bottom torque tube transmitters shall be

calibrated only after installation on their vessels.

Top mounted torque tube transmitters shall be calibrated in the workshop.

Apply a supply pressure of 1.4 bar or a supply voltage of 24 V.
Use a lever arm and calibrated weights to simulate the force which will be
exerted on the float by the process fluid. Apply a force equivalent to 0%, 50%,
100%, 50%, 0% of scale to the torque tube float, and observe the outputs.
If the outputs are not within the manufacturer's tolerance then re -calibrate in
accordance with the manufacturer's recommendations.
After re-calibration, re -apply the forces and record the results on the
calibration sheets.

2.3.7 Pressure switches

Apply a pressure to the switch input and record the pressure which activates
the switch.
If the switch does not operate at the pressure stated in the requisition, adjust
the switch until correct operation is obtained.
Increase the pressure and record the result in the calibration report for the
instrument.
Decrease the pressure and record the result.

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Testing and Calibration of the Process Instruments
Revision 01, dated 15.12.2003

2.3.8 Pressure and draught gauges

Apply pressures of 0%, 50% and 100% full scale to the instrument and note
the resulting indication.

If the results are not within the manufacturer's tolerance, re-calibrate the
gauge in accordance with the ma nufacturer's recommendations.
After re-calibration, re-apply pressures and record the results on the
calibration sheet.

2.3.9 Temperature gauges

Mount the gauge with its stem in a temperature bath and apply temperatures
at 0%, 50% and 100% of full scale and record the results.
If the results are not within manufacturer's tolerance, re-calibrate the gauge in
accordance with the manufacturer's recommendations.
After re-calibration, re-apply temperatures and note the results on the
calibration sheet.

2.3.10 Thermocouples

Continuity test:
Connect the thermocouple to a digital temperature indicator (Calibrator), allow
the thermocouple to stabilize at ambient temperature and note the reading.
The thermocouple reading should be within +3°C of ambient temperature as
indicated by the calibration standard.

Earth insulation test:

Measure the resistance between thermocouple and sheath, which shall be
greater than 1 mega ohm

Dimensional check:
Measure and record the length and diameter of the thermocouple probe.
Compare with the requisition data sheet and the corresponding thermowell
dimensions and note any discrepancy.
Record all data on the calibration check sheet. Thermocouples not meeting
the criteria given above shall not be installed.

2.3.11 Resistance temperature devices (RTD)

Continuity test:
allow the instrument to stabilize at ambient temperature then measure and
note the resistance of the sensor with an ohmmeter. Also note ambient
temperature as indicated by the calibrating standard. The resistance of the
sensor shall be within +1 ohm of the value specified by the manufacturer.

Earth insulation test:

measure the resistance between all sensor leads (connected in common) and
the metal sheath, which shall be greater than 1 mega ohm.

Dimensional check:
measu re and record the length and diameter of the sensor. Compare with the
requisition data sheet and the correspond-ing thermowell dimensions, note
any discrepancy.

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 Procedure No. GS-MO-Q-PR-050-01 Page 6 of 9
Testing and Calibration of the Process Instruments
Revision 01, dated 15.12.2003

Record all data on the calibration check sheet. RTDs not meeting the criteria
given above, shall not be installed.

2.3.12 Recorders

Apply the correct power supplies for the chart mechanism and recorder.
Apply an input signal corresponding to 0%, 50%, 100%, 50%, 0% of full scale
to each recorder channel and note the indicated values.
If the results are not within the manufacturer's tolerance, re - calibrate the
recorder in accordance with the manufacturer's recommendations.
After re-calibration, re -apply input signals and record the results on the
calibration sheet.

2.3.13 Indicators

Apply the correct power supply as specified.

Apply an input signal corresponding to 0%, 50%, 100%, 50%, 0% of full scale
and note the indicated values.
If the results are not within the manufacturer's tolerance, re-calibrate the
recorder in accordance with the manufacturer's recommendations.
After re-calibration, re-apply the input signals and note the results on the
calibration sheet.

2.3.14 Converters

Apply the correct power supply as specified.

Apply an input signal corresponding to 0%, 50%, 100%, 50%, 0% of the
range and note the output values.
If the results are not within manufacturer's tolerance, re-calibrate the converter
in accordance with the manufacturer's recommendations.
After re-calibration, re-apply the input signals and note the results on the
calibration sheet.

2.3.15 Monitor switches

Apply the correct power supply as specified.

Apply an input signal and vary it over the range of the monitor switch. Note the
value at which the switch operates.
If the result does not correspond to the trip point as stated in the requisition,
adjust the trip point until the required value is obtained and record the value
on the calibration sheet.

2.3.16 Solenoid valves

Apply the correct power supply as specified.

Apply an air supply to the appropriate connection.
Check the operation of the SOV by operating the power supply switch and
observe correct change-over action (pneumatic).
Check the shut-off tightness by using the bubble method at the stated design
pressure.
If applicable, check manual or electrical reset, override and time delay
features.
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 Procedure No. GS-MO-Q-PR-050-01 Page 7 of 9
Testing and Calibration of the Process Instruments
Revision 01, dated 15.12.2003

Check and record the electrical specification, e.g. coil resistance.

Check the function of the SOV with the power supply at the specified minimum
voltage, e.g. 16 V for correct change-over and tightness.

2.3.17 Control valv es

NOTES: The use of a modern control valve test bench is

fully recommended; if not available, a control valve
test rig shall be installed in a clean and specific
location.
Inspection and functional test

The following tests shall be performed in a clean environment:

1) The valve shall be removed from its packing and mounted on a
suitable support.
2) The valve shall be examined for damage and if necessary, it
should be cleaned. Dismantling, if necessary shall be in
accordance with the manufacturer's instructions.
3) The material specification of the valve shall be checked and all
differences shall be recorded.
4) For valves without positioners, apply clean dry air to the actuator
at a pressure corresponding to the spring range and observe
the stroking of the valve. Check that the valve strokes between 0
and 100% of the range for corresponding pressure variations.
5) For valves with pneumatic positioners, apply clean dry air to the
positioner at a signal pressure of 0.2 to 1.0 barg and check that
valve stroke s over its full range. Check that the positioner can be
by-passed
NOTE: The positioner may be split range, in which case the control
signal shall be adjusted accordingly.
6) For valves with electro -pneumatic positioners, supply clean dry
air to the positioner and apply a signal of 4 to 20 mA and
check that the valve strokes over its full range. For all valves,
observe the stroking times from fully open to fully closed and
from fully closed to fully open.
NOTE: Positioner may be split-range.
7) For all valves, check that the control valve action is in the
required direction.
8) Check operation of all accessories attached to the valve, e.g.
lock-up relays, limit stops, limit switches, stem position
transmitters, etc.
9) Any malfunction shall be investigated and the faulty component
either replaced or serviced in accordance with the
manufacturer's recommendations.

Positioner calibration

1) Valves shall be installed in a control valve test bench, a test

stand, or otherwise suitably supported.
2) Check the positioner type against the requisition.
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 Procedure No. GS-MO-Q-PR-050-01 Page 8 of 9
Testing and Calibration of the Process Instruments
Revision 01, dated 15.12.2003

3) Visually check the linkage, for damage and repair if necessary.

Follow the manufacturer's recommendations for all dismantling
operations.
4) Apply the specified signal input to the positioner in order to
obtain fully closed valve. Then obtain 50%, 100%, 50% and 0%
of the stroke, recording the input signal required to obtain these
values.

These signals shall be within 1% of theoretical values. The

difference between actual and theoretical values necessary to
obtain a closed valve shall not exceed 2%.
5) If the criteria given above are not met, adjust the positioner in
accordance with the manufacturer's recommendations.
6) Complete the calibration check sheet for control valves

3.0 EQUIPMENT FOR TESTING AND CALIBRATION

The following instrument calibration and testing equipment shall be available,

preferrably housed in a purpose built Instrument Field Workshop.

(a) Dead Weight Tester

(b) Processmeter FLUKE 787 s.n. 8191050

(c) V / mA Calibrator FLUKE 715 s.n. 6989209

(d) RTD Calibrator FLUKE 712 s.n.

6987011

(e) Process Calibrator FLUKE 725 s.n. 8322085

(f) Pressure Module FLUKE 700P30 s.n. 84103014

(g) Pressure Calibrator BEAMEX PC-106 s.n. 1551

(h) Pressure Indicator WALLACE & TIERNAN s.n.

0307131

(i) Temperature Calibrator HART SCIENTIFIC s.n.

A3B395

(j) Isolation Tester GOSSEN METRAWATT s.n. M435176

(k) Resistance Decade Box

(l) Hand Pressure Pump

(m) Pressure Colibrator Comparator s.n. 14810

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 Procedure No. GS-MO-Q-PR-050-01 Page 9 of 9
Testing and Calibration of the Process Instruments
Revision 01, dated 15.12.2003

All items of equipment shall have a “Calibration Certificate” signed by

an accepted authority.

4.0 ATTACHMENT

Calibration and Test Sheets:

INSP-II-000 Cover Sheet

INSP-II-001 Pressure Indicator
INSP-II-002 Pressure Switch
INSP-II-003 Pressure Transmitter
INSP-II-004 Differential Pressure Indicator
INSP-II-005 Differential Pressure Transmitter

INSP-II-008 Level Indicator

INSP-II-009 Level Switch
INSP-II-010 Level Transmitter

INSP-II-013 Temperature Indicator

INSP-II-014 Temperature Switch
INSP-II-015 Temperature Transmitter

INSP-II-019 Control Valve

INSP-II-020 Shut Down Valve
INSP-II-021 Safety Relief Valve
INSP-II-022 I/P Converter
INSP-II-023 Solenoid Valve

INSP-II-027 Flow Transmitter

INSP-II-028 Flow Transmitter - Ultrasonic

INSP-II-035 Instrument Air Supply Pressure Test

INSP-II-036 Impulse Line Pressure Test
INSP-II-037 Instrument Cable Road Crossing
INSP-II-038 Instrument Earthing System
INSP-II-039 Orifice Plate Installation
INSP-II-040 Loop Test

Test Sheets:

LGM-MF-25-1 Control Station / Junction Box

LGM-MF-21-1 Control Panel / Cubicle
LGM-MF-31 Cable Test Record
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Testing and Calibration of the Process Instruments
Revision 01, dated 15.12.2003

LGM-MF-36-1 Above Ground Conduit Inspection Check List

LGM-MF-41-1 Trench & U/G Conduit Check Lis t

Q-PR-00-059-01