LOOP TESTING & CALIBARATION
PROCEDURE Page No: 3 of 9
[Abstract]
TABLE OF CONTENTS
PURPOSE & SCOPE ....................................................................................................... 4
ACRONYMS & ABBREVIATIONS ................................................................................... 4
CALIBARATION .............................................................................................................. 4
3.1 GENERAL NOTES FOR INSTRUMENT CALIBRATION ........................................................... 4
3.2 PRESSURE INDICATOR CALIBRATION PROCEDURE ........................................................... 5
3.3 PRESSURE TRANSMITTER CALIBRATION PROCEDURE ..................................................... 5
3.4 DP TRANSMITTER CALIBRATION PROCEDURE ................................................................... 5
3.5 FLOW TRANSMITTER (ORIFICE TYPE) CALIBRATION PROCEDURE .................................. 5
3.6 LEVEL TRANSMITTER (DIAPHRAGM TYPE) CALIBRATION PROCEDURE .......................... 5
3.7 TEMPERATURE TRANSMITTER CALIBRATION PROCEDURE ............................................. 6
LOOP TESTING ............................................................................................................... 6
4.1 GENERAL NOTES FOR LOOP TESTING ................................................................................. 6
4.2 LOOP CHECK OF ESD PRESSURE TRANSMITTER ............................................................... 6
4.3 LOOP CHECK OF PCS PRESSURE TRANSMITTER ............................................................... 6
4.4 LOOP CHECK OF DIFFERENTIAL PRESSURE TRANSMITTER ............................................. 7
4.5 LOOP CHECK OF LEVEL TRANSMITTER ............................................................................... 7
4.6 LOOP CHECK OF TEMPERATURE TRANSMITTER ................................................................ 7
4.7 LOOP CHECK OF FIRE DETECTOR......................................................................................... 7
4.8 LOOP CHECK OF GAS DETECTOR ......................................................................................... 8
4.9 LOOP CHECK OF CONTROL VALVE ....................................................................................... 8
4.10 LOOP CHECK OF MOTOR SIGNAL........................................................................................ 8
4.11 LOOP CHECK OF SHUTDOWN VALVE.................................................................................. 8
4.12 LOOP CHECK OF ON/OFF VALVE ......................................................................................... 9
4.13 LOOP CHECK OF DIGITAL INPUT SIGNAL ........................................................................... 9
4.13 LOOP CHECK OF DIGITAL OUTPUT SIGNAL ....................................................................... 9
LOOP TESTING & CALIBARATION
PROCEDURE Page No: 4 of 9
[Abstract]
PURPOSE & SCOPE
The Scope of work of this document is to provide the general guidelines for loop testing
acronyms & abbreviations
EPCC : Engineering, Procurement, Construction and Commissioning
DP : Differential Pressure
HMI : Human Machine Interface
MA : Milli-Amp
MCC : Motor Control Centre
SCADA : Supervisory Control and Data Acquisition
:
CALIBARATION
3.1 GENERAL NOTES FOR INSTRUMENT CALIBRATION
Calibration procedures will be utilized in the case where the instrument requires
calibration, or the calibration due date has expired, and a more recent test result is
required.
Confirm the range of the transmitter against the instrument index or instrument data
sheet.
Ensure that the calibration source has a valid calibration from an independent authority.
If the instrument being tested fails the calibration test, remove it from service and
repair/replace as required.
All pressure and differential pressure instruments (indicators, transmitters, and
switches) will be tested using clean water or air using a certified pressure test set for
primary injection.
The instrument will be calibrated with 5 points rising and 5 points falling to establish
accuracy, deadband and hysteresis. The only exceptions being analytical instruments
where the standard form of calibration would be a ZERO check accompanied by an on-
line “grab sample” which can be verified by a separate standard. In all such cases the
manufacturers’ recommended procedures will be followed.
All voltages and currents will be measured by a digital multimeter with a current
calibration certificate. Values are to be measured with two decimal places.
For a temperature transmitter, a process simulator will be connected to the transmitter
sensor input with the output being measured by a digital multimeter.
Record the results of all tests / calibration on the relevant Check Sheets.
LOOP TESTING & CALIBARATION
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3.2 PRESSURE INDICATOR CALIBRATION PROCEDURE
The calibration of a Pressure Indicator shall be performed as follows:
Connect the pressure calibrator to the input of the Pressure indicator.
Apply 0, 25, 50, 75, 100, 75, 50, 25 and 0% of the pressure range.
Record the corresponding indicated values of the indicator on the test sheet.
3.3 PRESSURE TRANSMITTER CALIBRATION PROCEDURE
The calibration of a Pressure Transmitter shall be performed as follows:
Connect the pressure calibrator to the input of the pressure transmitter.
Apply 0, 25, 50, 75, 100, 75, 50, 25 and 0% of the pressure range.
Record the corresponding output values of the transmitter on the test sheet.
3.4 DP TRANSMITTER CALIBRATION PROCEDURE
The calibration of a DP Transmitter shall be performed as follows:
Connect the pressure calibrator to the high-pressure tapping point of the DP transmitter
while the low-pressure tapping point is left open to atmosphere.
Apply 0, 25, 50, 75, 100, 75, 50, 25 and 0% of the pressure range.
Record the corresponding output values of the transmitter on the test sheet.
3.5 FLOW TRANSMITTER (ORIFICE TYPE) CALIBRATION PROCEDURE
The calibration of a Flow Transmitter shall be performed as follows:
Connect the pressure calibrator to the high-pressure tapping point of the transmitter
while the low-pressure tapping point is left open to atmosphere.
Apply 0, 25, 50, 75, 100, 75, 50, 25 and 0% of the measurement range.
Record the corresponding output values of the transmitter on the test sheet.
3.6 LEVEL TRANSMITTER (DIAPHRAGM TYPE) CALIBRATION PROCEDURE
The calibration of a Level Transmitter shall be performed as follows:
Connect the pressure calibrator to the high-pressure tapping point of the level
transmitter while the low-pressure tapping point is left open to atmosphere. This can be
done in-situ if the diaphragm can be isolated from the vessel or tower.
Apply 0, 25, 50, 75, 100, 75, 50, 25 and 0% of the measurement range.
Record the corresponding output values of the transmitter on the test sheet.
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3.7 TEMPERATURE TRANSMITTER CALIBRATION PROCEDURE
The calibration of a Temperature Transmitter shall be performed as follows:
A temperature process simulator will be connected to the transmitter input (the output
being measured by a digital multimeter).
Apply 0, 25, 50, 75, 100, 75, 50, 25 and 0% of the temperature range.
Record the corresponding output values of the transmitter on the test sheet.
Repeat the test with the same steps falling by applied signal.
LOOP TESTING
4.1 GENERAL NOTES FOR LOOP TESTING
Prerequisite for Loop testing are as follows:
Documents pertaining to the loops being tested will be available for review at site. This
includes data sheets, calibration reports, location plan, P&IDs, loop drawings, and
wiring diagrams for the junction boxes and marshalling cabinets.
The system mechanical completion certificate issued by Company.
Appropriate test equipment is available, operational, with valid calibration certificates as
required.
The relevant system is not yet filled / pressurized with process media and there is no
process limitation in dismantling field instruments.
Transmitters have a valid calibration certificate or will have a service test performed.
The control system is operational, and the required HMI/SCADA are available.
4.2 LOOP CHECK OF ESD PRESSURE TRANSMITTER
Connect a pressure source to the inlet of the pressure transmitter.
Connect a Hart communicator to the transmitter.
Verify the range, units and display of the transmitter.
Verify alarm setpoints. Ensure to trip/clear each alarm as the loop test is occurring,
verifying the alarm setpoint and description in the alarm table.
Verify HMI/SCADA display matches the pressure being applied to the transmitter.
Increase the pressure input by 0%, 50%, 100%. Then decrease 50% and 0%.
4.3 LOOP CHECK OF PCS PRESSURE TRANSMITTER
Connect a Hart communicator to the transmitter.
Verify the range, units and display of the transmitter.
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Verify alarm setpoints. Ensure to trip/clear each alarm as the loop test is occurring,
verifying the alarm setpoint and description in the alarm table.
Verify HMI/SCADA display matches the pressure being applied to the transmitter.
Simulate the 4-20ma output at 4, 12 and 20ma. Then decrease to 12 and 4ma.
4.4 LOOP CHECK OF DIFFERENTIAL PRESSURE TRANSMITTER
Note: This applies to differential pressure, flow and level transmitters measuring DP.
Connect a Hart communicator to the transmitter.
Verify the range, units and display of the transmitter.
Verify alarm setpoints. Ensure to trip/clear each alarm as the loop test is occurring,
verifying the alarm setpoint and description in the alarm table.
Verify HMI/SCADA display matches the pressure being applied to the transmitter.
Simulate the 4-20ma output at 4, 12 and 20ma. Then decrease to 12 and 4ma.
4.5 LOOP CHECK OF LEVEL TRANSMITTER
Connect a Hart communicator to the transmitter.
Verify the range, units and display of the transmitter.
Verify alarm setpoints. Ensure to trip/clear each alarm as the loop test is occurring,
verifying the alarm setpoint and description in the alarm table.
Verify HMI/SCADA display matches the pressure being applied to the transmitter.
Simulate the 4-20ma output at 4, 12 and 20ma. Then decrease to 12 and 4ma.
4.6 LOOP CHECK OF TEMPERATURE TRANSMITTER
Connect a Hart communicator to the transmitter.
Verify the range, units and display of the transmitter.
Verify alarm setpoints. Ensure to trip/clear each alarm as the loop test is occurring,
verifying the alarm setpoint and description in the alarm table.
Verify HMI/SCADA display matches the pressure being applied to the transmitter.
Simulate the 4-20ma output at 4, 12 and 20ma. Then decrease to 12 and 4ma.
4.7 LOOP CHECK OF FIRE DETECTOR
Verify the detector is clear of faults and ready for operation.
Use a UV/IR source to cause a confirmed fire response from the detector.
Verify the alarm description in the alarm field.
Verify HMI/SCADA display graphic.
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4.8 LOOP CHECK OF GAS DETECTOR
Verify the gas detector is showing “0” and ready for operation. If not, perform a
calibration.
Apply a calibrated gas source to the detector. Verify gas concentration matches
HMI/SCADA.
Verify the alarm description in the alarm field.
Verify HMI/SCADA display graphic.
4.9 LOOP CHECK OF CONTROL VALVE
Ensure the control system is requesting 0% output.
Verify the failure safe position of the valve.
Increase the control system output to 50% and 100%.
Check mid travel and full stroke of the valve.
If the valve has a positioner with position feedback, verify the feedback is within 2% of
the actual valve position.
Set the control output to 0%. Record the travel time.
Set the control output to 100%. Record the travel time.
4.10 LOOP CHECK OF MOTOR SIGNAL
Note: The motors should be decoupled from pumps. This test will be both a bump test
plus will verify the control signals and status feedback to the control system.
Verify or set the ESD output to the motor is set to ON.
Verify the FAULT signal is OFF.
Issue a start command from the control system.
Check the rotational direction is correct.
Verify the RUN feedback is ON.
Set the ESD output to the motor is set to OFF – verify the motor stops.
Either trip the overload in the motor OR put a jumper wire across the FAULT terminals
to verify the circuit to the control system.
All the above tests are to be viewed from the HMI/SCADA to ensure correct graphics
and alarm display.
4.11 LOOP CHECK OF SHUTDOWN VALVE
Verify the control system output to the solenoid is OFF.
Verify the fail-Safe position of the valve.
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Visually verify the Top display matches the position of the valve.
Verify the position switch is correctly energized, verify display to HMI/SCADA.
Energize the solenoid.
Record the travel time.
When the valve is in the energized position, verify the Top display is correct.
Verify the correct position switch is energized, verify the display to the HMI/SCADA.
Deenergize the solenoids
Record the travel time.
If the valve has a partial stroke apparatus, energize the solenoid.
Test the partial stroke function from the control system.
4.12 LOOP CHECK OF ON/OFF VALVE
Verify the control output is de-energized.
Verify the fail-safe position of the valve.
Energize the solenoid, verify the valve fully opens.
Verify the graphic display on the HMI/SCADA.
Record the travel time.
De-energize the solenoid.
Record the travel time.
4.13 LOOP CHECK OF DIGITAL INPUT SIGNAL
Note: This includes hand switches, flame feedback, manual call points, level and
vibration switches.
If possible, activate the digital input. For instance, press the button or activate the
manual call point. If not possible, jump the switch or remove the control wires
depending on the relay action. This will verify correct electrical connections.
Verify correct display and/or alarms on the HMI/SCADA.
4.13 LOOP CHECK OF DIGITAL OUTPUT SIGNAL
Note: This includes lights, horns and beacons.
Activate the control output and verify the device works correctly.
