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ICM-SU-11.

12
CHECKOUT & COMMISSIONING OF INSTRUMENTS

This document can be downloaded from the following


Technical Standards website:
http://techstds.ric100.chevron.net
Electronic files may be ordered by phone (510-242-7241),
e-mail (TechStds@Chevron.com),
or fax (510-242-2157).

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Checkout and Commissioning of Instrumentation ICM-SU-11.12

CONTENTS

1.0 SCOPE .........................................................................................................................3


2.0 REFERENCES .............................................................................................................3
2.1 ......Industry Standards ...........................................................................................3
2.2 ......Chevron Specifications .....................................................................................4
3.0 REQUIREMENTS ........................................................................................................4
3.1 ......General .............................................................................................................4
3.2 ......Contractor Responsibilities ...............................................................................5
3.3 ......Visual Inspections ............................................................................................6
3.4 ......Calibration of Test Equipment ..........................................................................7
3.5 ......Instrument Calibration ......................................................................................8
3.6 ......Instrument Testing ..........................................................................................17
3.7 ......Electrical Inspections ......................................................................................18
3.8 ......Cleaning and Start-up Preparation .................................................................19
3.9 ......Documentation ...............................................................................................22
4.0 LOOP CHECK ...........................................................................................................23
4.1 ......Purpose ..........................................................................................................23
4.2 ......Responsibilities ..............................................................................................23
4.3 ......Loop Check Documentation ...........................................................................24
4.4 ......Procedures .....................................................................................................25
5.0 QUALITY ASSURANCE PROVISIONS ....................................................................27
APPENDIX I - TYPICAL CALIBRATION TEST EQUIPMENT REQUIRED...........................28
APPENDIX II - CONTROLLER MODE REQUIREMENTS.....................................................29
APPENDIX III - CALIBRATION METHODS AND PROCEDURES .......................................31
Table 1: Instrument Calibration procedures ...............................................................31
Table 2: Calibration Methods and Designators ..........................................................36
Table 3: Test Equipment Required ............................................................................38
Table 4: Loop Check Methods By Primary Element Type .........................................39
Table 5: Loop Check Methods and Procedures .........................................................40
APPENDIX IV - CALIBRATION AND TESTING DOCUMENTATION...................................42
Table 1: Instrument Discrepancy List..........................................................................42
Table 2: Calibration Documentation Sheet ................................................................43
Table 3: Loop Check Documentation Sheet ..............................................................44

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1.0 SCOPE
1. The purpose of this document is to provide guidance regarding calibration, testing and com-
missioning of the entire instrumentation installation. The thorough checkout and commission-
ing of an installation supports incident free start-up of new facilities.
2. This Specification covers the minimum technical requirements for onsite testing and calibra-
tion of instruments on an offshore platform.
3. This Specification is not intended to specify all the complete details of design and construc-
tion, which are the responsibility of the Detailed Design Contractor.
4. The intended user of this Specification is/are the Contractor(s) who will accomplish the test-
ing, calibration, loop checking and commissioning at vendor's shop, at onshore fabrication
site, onshore at job site, and offshore.
5. All components and subsystems required for a complete and fully operable instrumentation
system shall be included whether or not specifically called out in this or other documents such
as:
Piping & Instrument Diagrams (P&IDs)
Process Flow Diagrams
Engineering Specifications
Data Sheets
Cause and Effect Charts
SAFE Charts
Loop Diagrams
Logic Diagrams
I /O Diagrams
Instrument Index
Control System Displays
6. For a specific platform, this Specification shall be used in conjunction with the project Techni-
cal Requirements and data sheets for that platform.
7. Any exceptions to the requirements of this Specification shall be submitted in writing to Com-
pany.

2.0 REFERENCES

2.1 Industry Standards


American Petroleum Institute (API)
RP 14F, Recommended Practice for the Design and Installation of Electrical Systems for
Fixed and Floating Offshore Petroleum Facilities for Unclassified and Class I, Division 1 and
Division 2 Locations, Section 6.0.
Instrument Society of America (ISA)
RP 7.1, Recommend Practice for Pneumatic Control Circuit Pressure Test
National Fire Protection Association (NFPA)
National Electrical Code Article 110-16, Working Space About Electrical Equipment (600
Volts, Nominal, or Less)

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2.2 Chevron Specifications


ELC-OU-12.02, General Requirements for Installation of Electrical Facilities
ELC-OU-12.23, Checkout and Commissioning of Electrical Equipment
ICM-OC-11.01, Instrumentation Installation
ICM-OU-11.06, Instrument Control Panels
ICM-OU-11.07, Design of Programmable Logic Controller Systems
ICM-OU-11.16, Design of Process Control Systems

3.0 REQUIREMENTS

3.1 General

3.1.1 Precedence
This testing and calibration Specification and the associated Project Specifications shall
take precedence over all other Specifications, standards, and codes.

3.1.2 Calibration
Calibration of the following types of instruments are included in this Specification:
Analytical Instruments
Temperature Instruments
Pressure Instruments
Flow Instruments
Level Instruments
Control Valves, Regulators and Shutdown Valves (SDVs)
Receiver Instruments

3.1.3 Testing
Testing of the following types of devices are included in this Specification:
Safety Relief Valves
Hazard Detectors
Vibration Instruments
Annunciators and Miscellaneous Electrical Devices
Miscellaneous Electronic Instruments

3.2 Contractor Responsibilities


The Contractor shall perform all inspection and test activities described in this Specification and
other Project Instrumentation System Specifications.

3.2.1 General
1. The Contractor shall be solely responsible for providing complete and operable pack-
ages in full accordance with this Specification and Company Technical Requirements.
2. Work shall be executed in strict accordance with Company approved drawings and
Specifications. Written approval from Company is required for any deviations by the
Contractor from the approved drawings and/or Specifications.

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3. The Contractor shall bring to the attention of Company any areas of the drawings and/
or Specification that conflict, or do not meet safe and acceptable instrument practices.
4. Equipment shall be protected from damage due to environmental conditions.
5. The Contractor shall not perform any instrument test or calibration procedure that
would either void the Vendor warranty or damage the equipment.
6. Piping Contractor shall ensure that all instruments, control valves, and regulators are
protected from excessive pressure before piping is flushed or hydrotested. Among oth-
ers, gages and transmitters will typically be isolated and vented during hydrotest.
7. Conflicts and Deviations: Where any conflict is found to exist between this Specifica-
tion and the applicable codes, these shall be submitted to Company in writing for res-
olution. Any deviation must be submitted in writing to Company for approval.

3.2.2 Testing and Calibration Procedures


1. Calibration procedures are detailed in Appendix III, Table 1 and Table 2.
2. The calibration procedure shall demonstrate the proper and accurate operation of the
complete instrument system. The calibration procedure shall also list the final steps to
be performed for all instruments after the testing program is complete to ready them
for actual operation.
3. The following work, plus any other work agreed upon by the Contractor and the Com-
pany, shall be performed by the Contractor in the presence of the Company (unless
otherwise approved by the Company):
a. Visual check of all field instruments.
b. In-place calibration of all field instruments.
c. Leak checking of process connections.
d. Functional electronic and pneumatic loop checking of all instrument and control
systems detailed in the project construction Specification scope.
e. Verification of intrinsically safe instrumentation wiring and devices.
4. Tests may be conducted concurrently with calibrations.
5. The Contractor shall submit a full report to Company Representative following cali-
bration completion.
6. After the testing and calibration procedure has been completed and accepted by Com-
pany, the equipment shall be in the Contractor custody, who shall be responsible for
storing the equipment in a safe and operable condition:
a. Covers, doors, and access plates shall be properly fastened.
b. Wiring shall be complete and testing jumpers shall be removed.

3.3 Visual Inspections

3.3.1 Instruments
1. Contractor shall visually inspect each instrument to verify correctness of range, size,
pressure rating, material, pressure settings, flange ratings, or other parameters as
called for in the detailed instrument Specifications and data sheets.

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2. For electrical instruments, verify whether device has a listing tag (U.L., F.M., CSA, or
other) and conforms to area classification.
3. Advise Company in writing of any discrepancy by completing the form in Appendix
IV, Table 1.
4. Contractor shall verify that all travel and shipping stops have been removed from the
instrument prior to installation.

3.3.2 Installation
1. Contractor shall visually inspect each instrument installation to verify that it is in
accordance with Instrument Installation Specification ICM-OC-11.01 and approved
project drawings. Specifically, the Contractor shall check that:
a. All instruments have been installed in accordance with Instrument Installation
Detail Drawings and P&IDs.
b. Each instrument is located as shown on P&IDs and its measurement point is cor-
rect with respect to vessels, piping, valves and equipment.
c. Locations of meter runs, pressure taps, control valves, relief valves, and other pip-
ing components in the piping system have been verified.
d. Piping system components are mounted with the correct flow direction.
e. Flow instruments are piped with the high pressure side of the meter connected to
the upstream tap, and the low pressure side connected to the downstream tap.
f. Tubing between flow instruments and taps is properly installed and the instrument
is positioned in accordance with installation drawings.
g. Tubing is free of pockets.
h. Level gages cover the entire operating range of the section of the vessel in which
they are installed.
i. The sharp edge of orifice plates is installed upstream in accordance with the
detailed Specifications.
j. The bore is calibrated to check for compliance with Specifications.
k. Local controller settings are set for either direct or reverse acting, as specified.
l. Access to instruments has been provided as required by Project Specifications.
2. Confirm that control valve packing conforms to data sheets and, if specified, the lubri-
cator on each control valve contains specified lubricant.
3. Check all process connections for proper materials and support. Make sure all con-
nections have the proper slope, are free from any pockets or traps, and are connected
to correct vent or drain headers where required.
4. Check that valve manifolds are installed and functional.
5. Make sure valve bonnet locking devices are secure.
6. Verify that level glasses, transmitter output gages and indicating controllers are read-
able from their associated control valve. Check that dial thermometers and pressure
gages can be conveniently read from grade or platforms.
7. Check that all restrictor fittings, when specified, are installed on root valves.

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8. Instruments and Junction Boxes shall be properly installed to prevent ingress of mois-
ture, rain and water.
9. For differential pressure type flow instruments, make sure that the low-pressure side
of the instrument is connected to the downstream tap of the flow element.
10. Inspect and test all heat tracing before it is covered with insulation. Confirm the heat
tracing for each instrument can be serviced without disrupting the operation of other
equipment or processing lines.
11. Check all process connections and leads for proper fittings and instrument valves.
a. Check that proper materials and pressure ratings are used.
b. Be sure the installation follows the installation detail drawings and the piping
classification.
c. Inspect all instrument process leads for proper routing and support to make sure
that movement due to thermal expansion or vibration will not strain the instrument
or interfere with other equipment.
d. Check that all process leads, drain lines and vent lines have the specified slope,
that they are free from any pockets or traps, and are connected to the proper vent
and drain headers.
e. All process leads shall drain empty in place when disconnected at process sensing
point and instrument.
f. Check that vents and drains do not terminate near electrical equipment not
approved for use in the area classification created by the vent or drain.

3.4 Calibration of Test Equipment


1. Test equipment calibration shall be performed and certified by an accredited, indepen-
dent testing laboratory.
2. All test equipment shall bear a valid calibration certificate that includes the calibration
date and the signature of the person who performed the calibration. The certificate
shall be sealed and attached to the test equipment in a prominent place and shall not be
easily removable.
3. The calibration certificate of all test equipment shall be verified by Company before
test equipment is used for the calibration of instruments.
4. A list of the minimum test equipment required for instrument testing and calibration is
listed in Appendix I.
5. Calibration checks of indicating, transmitting, and recording instrumentation shall be
made at four points: 0, 25, 50,and 100 percent of span, i.e., at a process variable input
of 25 percent of span, the output shall be 25 percent of span.
6. Two position devices such as pressure switches and snap acting relays need not be cal-
ibrated over the entire range. Checks of the trip point (either rising or falling, as speci-
fied in the detailed Specifications) and reset point are sufficient.
7. Two point calibration is also sufficient for the analysis portion of analytical instru-
ments.

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8. The Contractor shall verify the correct operation of the proportional, reset, and, if
applicable, derivative modes for all local controllers with the participation of the loop
check team in accordance with Appendix II:

3.5 Instrument Calibration


Appendix III, Table 1 and Table 2 specify the methods to be used in calibrating instruments. Con-
tractor shall follow these guidelines. Appendix III, Table 3 lists testing equipment required. The
remainder of this Section adds to, clarifies or reiterates calibration requirements.

3.5.1 General
1. The purpose of instrument calibration is to obtain a permanent record and to verify
that the instruments measure, indicate, and record within the tolerances guaranteed by
the manufacturer.
2. Smart or digital transmitters normally do not require field calibration. The trans-
mitter should be checked for range, instrument tag number and correct configuration
during loop check. This check may be performed using a hand-held communicator or
shared display graphic.
3. Instruments shall be calibrated with a known input signal.
4. If required, the instrument output shall be measured and adjusted to correlate with the
input signal.
5. The Contractor shall not perform any test or calibration procedure that would either
void Vendor warranty or damage the instrument or associated equipment.
6. Check and adjust power supplies for current loops of transmitters in control room or
field before energizing instruments.
7. Set all instrument air supply regulators to the pressure specified by the instrument data
sheets.
8. Other related miscellaneous devices not covered by this Specification shall be
checked by the Contractor using the project test procedures required by the documen-
tation section of this Specification (see Section 3.9).

3.5.2 Accuracy Required


1. Unless stated otherwise, manufacturers shall state instrument accuracy in terms of the
maximum amount of error.
2. The error shall be recorded as a percentage of the instrument range.
3. As defined in this Specification, an accuracy of plus or minus 1/2 percent shall mean
that any reading of the instrument will be within 1/2 percent of the value indicated on
the certified test equipment.
4. Contractor must review the accuracy specifications of each type of device prior to
testing.
5. These values shall be percent if using a smart transmitter.

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3.5.3 Calibration of Analytical Instruments


1. The Contractor shall calibrate and check all analyzers and sampling systems for oper-
ation in accordance with the Project test procedures required by this Specification.
When provided by Company, special gas or liquid samples shall be used to activate a
system.
2. Package instrument systems, such as compressors, heaters, or special pumps, shall be
calibrated and checked completely by the Instrument Contractor.

3.5.4 Calibration of Temperature Instruments


1. Temperature Transmitters
a. The calibration input source for thermocouple devices shall be produced by a dig-
ital calibrator.
b. The output of thermocouples shall be checked with a reference cell or digital cali-
brator.
c. RTD readout devices shall be calibrated with the input signal from a decade resis-
tance box.
2. Pneumatic Temperature Transmitters
a. Pneumatic temperature transmitters shall be calibrated by immersing the thermal
system bulb and a precision glass stem thermometer (or an RTD with digital read-
out) in a heated oil bath.
b. The output of the thermal system bulb shall be compared with the test instrument
reading and adjustments made as required according to the Project test proce-
dures.
3. Local Indicating Temperature Controllers
a. The calibration procedure for local indicating temperature controllers shall be per-
formed by immersing the thermal system bulb and a precision glass stem ther-
mometer (or an RTD with digital readout) into a heated oil bath.
b. The reading on the precision glass stem thermometer or the RTD digital readout
shall be the reference for comparison with the thermal system bulb indicator.
c. The controller shall be checked in accordance with Section 3.4 item 5 for the pres-
ence of an output and whether or not the output is direct acting or reverse acting as
specified in the detailed Specifications.
d. The operating modes proportional, reset, and derivative shall be checked in accor-
dance with Appendix II to ensure correct operation.
e. If the controller has an auto/manual switch, the switch shall be placed in the man-
ual position and operation checked by measuring the output of the controller at
minimum, mid scale, and maximum settings.
f. Any necessary adjustments and all required checks shall be made in accordance
with the project test procedures required by the documentation section of this
Specification.
4. Temperature Switches
a. Temperature switches shall be calibrated by the same procedure specified for local
indicating temperature controllers.

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b. The switch shall be set in accordance with the project test procedures at the alarm
or trip point for either a rising or falling signal as required by the detailed Project
Specifications.
c. The switch reset or deadband value shall be checked to confirm the alarm or trip
point clears as specified in the detailed Project Specifications.
d. Temperature Switches shall be visually inspected to confirm that the proper fuse
plug is installed per the instrument data sheet.
5. Bimetallic Dial Thermometers
a. Bimetallic dial thermometers shall not be calibrated but shall be checked in a hot
sand bath.
b. Before installation, the dial or pointer reset shall be set to ambient temperature
required by the engineering Specification.
c. Never disassemble liquid-filled dial thermometers.
6. Thermocouples
a. Thermocouples shall be checked by the Contractor to ensure that the devices are
connected to the correct sensing points and that the polarity is correct.
b. The thermocouple to instrument wiring size and type shall be verified in accor-
dance with the wiring diagrams.

3.5.5 Calibration of Pressure Instruments


1. Pressure Transmitters
a. The reference input for a pressure transmitter process port shall be generated by
one of the following methods:
Wallace and Tiernan Pneumatic Calibrator
Precision Regulator and gage with Self Contained Air or Nitrogen
Supply
Manual Hydraulic Pump and Precision Gage
Deadweight Tester
b. Pressure transmitter output shall be measured by one of the following methods:
Wallace and Tiernan Pneumatic Calibrator
Precision gage
Manometer
Milliamp Test Meter (if the output is electrical)
2. Check that, where specified, the correct seal fluid has been used, and that the seal pot
and the seal fluid are properly tagged.
3. Check that valve manifolds are installed and function properly.
4. Check that all valve bonnet locking devices are secure.
5. Local Indicating Pressure Controllers
a. Reference pressure for the local indicating pressure controllers shall be generated
in the manner described in Section 3.5.5 item 1.
b. The reference pressure shall be applied to the local indicating pressure controller
input and the indicator value shall be compared to the reference pressure.

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c. The controller shall be checked in accordance with Section 3.4 item 5 for the pres-
ence of an output and whether or not the output is direct acting or reverse acting as
specified in the detailed Specifications.
d. The operating modes (proportional, reset, and derivative) shall be checked in
accordance with Appendix II to ensure correct operation.
e. If the controller has an auto/manual switch, the switch shall be placed in the man-
ual position and operation checked by adjusting the controller from minimum to
maximum values and comparing the output with the indicator.
f. Necessary adjustments shall be made in accordance with the project test proce-
dures required by the documentation section of this Specification.
6. Pressure Switches
a. Reference pressure for a pressure switch shall be generated in the manner
described in Section 3.5.5 item 1 and applied to the pressure switch input.
b. The pressure switch shall be adjusted in accordance with the Project test proce-
dures to actuate at the set point for either a rising or falling signal as required by
the detailed Specifications.
c. The reset point shall be compared with the value given in the detailed Specifica-
tions, when applicable.
7. Differential Pressure Switches
a. Reference input for the high pressure port shall be generated and controlled by
one of the following methods:
Wallace and Tiernan Pneumatic Calibrator
Precision Regulator and Manometer
Precision gage and Manometer
b. The low pressure port shall be vented to the atmosphere.
c. The switch shall be set in accordance with the project test procedures, at the dif-
ferential pressure set point for either a rising or falling signal as required by the
detailed Specifications.
d. The switch reset or deadband value shall be checked to confirm the alarm or trip
point clears as specified in the detailed Project Specifications.
8. Pressure Gages
a. Check for visible damage. Damaged gages shall be replaced, not repaired.
b. Check zero and adjust if necessary.
(1) No other calibration is permitted. Instead replace the unit.
(2) Never disassemble liquid-filled pressure gages.
c. Do not disassemble pressure gages from their diaphragm gage protectors.
d. Direct connected, Bourdon tube pressure gages shall not be calibrated but shall be
checked and zeroed, if required, prior to installation.
e. Receiver type pressure gages shall be calibrated in accordance with the project
test procedures, at four points: 0, 10, 50, and 100 percent of scale. The gages shall
be calibrated with a precision pressure gage, a precision air regulator, or a Wallace
and Tiernan pneumatic calibrator.

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f. Diaphragm type draft gages shall be calibrated at four points: 0, 10, 50 and 100
percent of scale. The gages shall be calibrated with a water column manometer.
g. Glass tube manometers and draft gages shall be properly zeroed and filled with
the fluid required by the detailed Specifications.

3.5.6 Calibration of Flow Instruments


1. Flow Transmitters
a. Reference pressure for flow transmitters shall be provided by either a precision
regulator and manometer or a Wallace and Tiernan pneumatic calibrator (or equiv-
alent).
b. The reference pressure shall be applied to the high pressure port of the transmitter
and the low pressure port shall be vented to the atmosphere.
(1) If pneumatic, the output shall be measured with a precision gage and manom-
eter or Wallace and Tiernan pneumatic calibrator (or equivalent).
(2) If electrical, the output shall be measured in accordance with Section 3.5.2
item 5 with a calibrated milliamp test meter.
c. Adjustments and further checks shall be made in accordance with the engineering
data sheets and Specifications.
2. For differential pressure (DP) type flow measurement, check that the low pressure
side of the instrument is connected to the downstream tap of the flow element.
a. Check that each DP instrument is installed in accordance with the Installation
Detail for the type of instrument and service.
b. Check that seal pots, when used, are installed and functioning properly and that
both are installed at the same elevation.
3. Local Indicating Flow Controllers
a. Reference pressure shall be produced by means of either a precision regulator and
manometer or a Wallace and Tiernan pneumatic calibrator (or equivalent).
b. The reference pressure shall be applied to the high pressure port of the meter
body. The low pressure port shall be vented to the atmosphere.
c. The reference pressure shall be compared to the indicator readings. Adjustments
and further checks shall be made in accordance with engineering data sheets and
specifications.
d. The controller shall be checked in accordance with Section 3.4 item 5 for the pres-
ence of an output and whether or not the output is direct acting or reverse acting,
as described in the detailed Specifications.
e. The operating modes (proportional, reset and derivative) shall be checked in
accordance with Appendix II to ensure correct operation.
f. If the controller has an auto/manual switch, the switch shall be placed in the man-
ual position and operation checked by measuring the output of the controller at the
minimum, mid scale, and maximum settings.
4. Rotameters

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The Contractor shall verify that all shipping stops have been removed. If the rotame-
ters have transmitting mechanisms, the float shall be mechanically raised and lowered
and the corresponding movement of the output indicator verified.
5. Turbine Meters
Turbine meters and/or positive displacement meters shall be calibrated as follows:
a. A pulse generator signal shall be connected to the meter input as a simulated input
signal. Contractor shall observe manufacturer's operating voltages and shall not
exceed safe levels.
b. Any necessary adjustments and all required checks shall be made in accordance
with the Project test procedures required by the Section 3.9 of this Specification.
6. Flow Switches
Differential pressure flow switches shall be checked as follows:
a. Reference input for the high pressure port shall be generated and controlled by
one of the following methods:
Wallace and Tiernan Pneumatic Calibrator
Precision Regulator and Manometer
Precision gage and Manometer
b. The low pressure port shall be vented to the atmosphere.
c. The switch shall be set in accordance with the Project test procedures at the differ-
ential pressure set point for either a rising or falling signal, as required by the
detailed Specifications.
d. The switch reset or deadband value shall be checked to confirm the alarm or trip
point clears as specified in the detailed Project Specifications.
e. Paddle type flow switches shall be removed from the line and actuated mechani-
cally to check the trip point.

3.5.7 Calibration of Level Instruments


1. Displacer Type Level Transmitters
a. Calibrate each instrument by using water, with the level indicated by a makeshift
gage glass such as Tygon tubing, unless the chamber has a sight glass. The water
level shall be compensated to simulate the operating value of specific gravity.
b. Calibrate interface level transmitters using two liquids having specific gravities
that are close to the plant operating values. This calibration shall be at least ade-
quate to bring the transmitter within the range of plant liquids at startup time.
c. The instrument Contractor shall verify that when completely filled, the displacer
transmitter provides either an output pressure of 15 or 30 pounds per square inch
gage (psig) or an output current of 20 milliamps DC.
d. The Contractor shall verify that when drained the displacer transmitter provides
either an output pressure of 3 or 6 psig or an output current of 4 milliamps DC.
e. The transmitter shall be adjusted in accordance with the Project test procedures
required by the documentation section (Section 3.9) of this Specification.
2. Differential Pressure Level Transmitters

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a. A reference pressure shall be supplied by a precision regulator and a precision


gage or a Wallace and Tieman pneumatic calibrator to the high pressure port of the
transmitter.
b. The reference pressure shall be applied as specified by the project test procedures
required by the documentation section of this Specification.
c. The transmitter output shall be measured in accordance with one of the following:
Wallace and Tiernan Pneumatic Calibrator
Precision gage
Manometer
Milliamp Test Meter (if the output is electrical)
d. The zero/suppression adjustment shall be set at the zero level point in accordance
with the test procedures required by the documentation section of this Specifica-
tion.
e. For DP level measurement with the lower tap of vessel connected to the high pres-
sure side of transmitter, check that the transmitter is adjusted to give zero output
when the leads are filled with the specified seal fluid and that the output will
increase with increasing vessel level.
3. Local Displacer Level Controllers
a. Local displacer controllers shall be verified with the proportional band set at 100
percent.
b. The Contractor shall verify that, when filled, the local displacer controller pro-
vides an output pressure of 15 or 30 PSIG (direct controller) or an output pressure
of 3 or 6 PSIG (reverse controller).
c. The Contractor shall also verify that, when drained, the local displacer controller
provides an output pressure of 3 or 6 PSIG (direct controller), or an output pres-
sure of 15 or 30 PSIG (reverse controller).
d. The operating modes (proportional, reset, and derivative) shall be checked in
accordance with Appendix II to ensure correct operation.
e. The controller shall be checked in accordance with the Section 3.4 item 5 for the
presence of an output and whether or not the output is direct acting or reverse act-
ing as specified in the detailed Specifications.
4. Level Switches
a. Float and displacer operator level switches shall be flooded/drained to test switch
operation but shall not be calibrated.
b. Differential pressure operated level switches shall be calibrated in accordance
with Section 3.5.5 item 7.
c. The switch reset or deadband value shall be checked to confirm the alarm or trip
point clears as specified in the detailed Project Specifications.
5. Gage Glasses
a. Calibration of gage glasses is not required.
b. Installation and orientation of illuminators, frost protectors, and other accessories
shall be checked and verified in accordance with the piping system drawings and
Instrument Installation Details.

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c. Pressure testing of gage glasses shall be per piping requirements.


6. Interface Instruments
Interface instruments shall be calibrated using two liquids having specific gravities
close to true operating values.

3.5.8 Calibration of Control Valves, Shutdown Valves, and Regulators


1. Control Valves
a. All diaphragm and piston operated control valves shall be pneumatically operated
to verify that the spring range corresponds to the spring range on the nameplate.
b. The pneumatic operation shall employ a pressure regulator and pressure gage.
c. The control valve mechanical seating and travel shall be checked in the Contrac-
tors shop prior to installation.
d. The control valve position indicator operation shall be verified by placing the
valve in the closed position then checking the indicator position when the valve is
in the open position.
e. Confirm that each valve stem indicator is correctly installed to indicate valve open
and closed position.
f. Check that each valve operates freely through the full stroke length. Stem shall
show a perceptible movement for a 5% change in control signal. If equipped with
a valve positioner, positioner shall be bypassed and the signal imposed directly on
the actuator.
g. Check that the action of each control valve upon failure of air pressure and/or
instrument signal is in the direction indicated on the Control Valve Data Sheet and
the P&ID. Both instrument air and instrument signal failure should result in the
valve moving to the fail-safe position (open or closed).
h. Check and adjust each control valve so that the valve stem moves through its full
travel when the air pressure on the valve actuator or motor is changed from 3 to 15
psi or through a bench-set range specified on the valve data sheet. These adjust-
ments shall be made with the valves in place. No pressure drop across the inner
valve is required. No adjustments contrary to the data sheets are permitted without
written approval from the Company.
i. Check all valves with air in ANSI Class IV or higher seat leakage to be sure the
seat leakage is not excessive. Readjust the seat if necessary.
j. Make sure that control valves equipped with positioners move from a fully opened
or fully closed position as specified on the data sheet when the control signal
changes from 4 to 20 mA. The air pressure on the valve diaphragm should go to
zero (or supply pressure) whenever the control signal is below 4 mA or above
20 mA.
k. When two or more control valves are operated by a single control signal, make
sure that the split range adjustment conforms to the data sheet specifications.
2. Valve Positioners
a. Valve positioners shall be calibrated on the control valve in accordance with the
nameplate data and instrument Specifications.

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b. The Contractor shall verify that split range or reverse acting positioners do not
have bypasses.
c. Zero position shall be set at a live zero, which is defined as just off the seat at a
minimum setting and on the valve seat at zero air pressure.
3. Volume Bottles
a. Volume bottles shall be checked to ensure proper filling.
b. The failure action shall be verified by reducing the signal line pressure to zero.
c. Orientation and leakage of all check valves shall be verified.
d. Volume bottles shall be ASME coded and pressure tested.
4. Valve Accessories
a. The operation of control valve accessories shall be checked.
b. Handwheels with air operated clutch mechanisms shall be operated both with and
without an air signal to the diaphragm.
c. Verify position switch operation (usually at full open and/or full close) while
stroke-testing the control valve.
5. Regulators
a. The Contractor shall verify that inlet and outlet ports are oriented and connected
in accordance the project drawings.
b. Nameplate data shall be verified against Specifications sheets.
c. Regulators with external connections shall be inspected for proper installation in
accordance with the project data sheets and installation drawing.
6. Butterfly Valves
a. Butterfly valves shall be checked by the Contractor to ensure that the vanes move
freely into the upstream and downstream piping.
b. Vane and activator movements sequence shall be verified.
c. Multiposition actuators shall be checked for connection to the proper cross tubing
and/or piping in accordance with the installation drawings.

3.5.9 Calibration of Receiver Instruments


1. The calibration reference input signal for a pneumatic receiver indicator, controller,
and recorder shall be produced by an air supply with a precision regulator.
a. The reference input pressure shall be varied from 3-15 PSIG (0.2-1.0 Barg) or 6-
30 PSIG (0.4-2.0 Barg).
b. Contractor shall verify that the pointer or pen indication corresponds to the
selected input pressure.
2. The calibration reference input signal for an electric receiver indicator, controller, and
recorder shall be produced by a loop calibrator.
a. The reference input current shall be varied from 4 to 20 milliamps DC.
b. Contractor shall verify that the pointer or pen reading corresponds to the input
current.

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3. The calibration reference signal for the signal indicating controller shall be produced
by a loop calibrator.
a. The reference signal shall be varied from 4 to 20 milliamps DC.
b. Contractor shall verify that the pointer indicates the same value as that supplied by
the loop calibrator.
4. The receiver shall be calibrated with both the pointer and set point at mid scale.
a. The Contractor shall verify that the receiver output is 12 milliamps for electronic
controllers or 9 psi for 3-15 psig (0.2-1.0 Barg) or 18 PSI for 6-30 psig (0.4-2.0
Barg) for pneumatic controllers.
b. The controller shall be checked for the presence of an output and whether or not
the output is direct acting or reverse acting, as described in the detailed Specifica-
tions.
(1) As the pointer is increased with respect to the set point, output shall either
increase for direct acting controllers or decrease for reverse acting controllers.
(2) As the pointer is decreased with respect to the set point, output shall either
decrease for direct acting controllers or increase for reverse acting controllers.
c. The operating modes (proportional, reset, and derivative) shall be checked in
accordance with Appendix II to ensure correct operation.

3.6 Instrument Testing

3.6.1 Testing Hazard Detectors


1. Controller indications, voting logic, shutdown logic, and/or alarms shall be verified in
accordance with the Project test procedures.
2. The gas, smoke, heat, and fire detection points shall be checked in accordance with
Project test procedures and verified as described below.
3. All manual activations of alarm and shutdown stations shall be witnessed.
4. The gas sensors shall be exposed to known concentrations of a test gas in order to ver-
ify the operation of low and high set points.
5. The smoke detectors shall be exposed to a source of smoke in order to verify smoke
alarm and shutdown actions.
6. Resettable heat sensors shall be exposed to a source of heat in order to verify the heat
alarms and shutdown logic inputs. Non-resettable heat sensors shall be simulated at
the sensor to verify alarm and logic functions.
7. The fire sensor elements in the fire detector shall be exposed to an ultraviolet light
source in order to stimulate a fire condition and verify the action of the fire alarm, vot-
ing logic, shutdown logic, and controller action.

3.6.2 Testing Vibration Instruments


1. Proximity probes shall be checked for calibrated amplitude.
2. Vibration monitor shall be calibrated by signal injection per manufacturer's instruc-
tions.

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3. Vibration monitor and switching performance shall be verified while the equipment is
running.
4. Vibration switches shall be calibrated with the equipment under normal load per man-
ufacturers instruction.

3.6.3 Testing Annunciators/Alarm and Shutdown Devices


1. Engraved annunciator nameplates shall be checked for correct engraving, spelling,
and location.
2. Electronic annunciations will be checked for spelling, format, color and operation.
3. Each annunciator point shall be activated by operating the appropriate switch.
a. The Contractor shall ensure that the correct annunciator window lights or message
window appears and that the annunciator operates correctly.
b. This may be done concurrently with other testing.
4. Each shutdown switch shall be actuated. The Contractor shall ensure that the correct
shutdown action occurs for each shutdown point and that the proper shutdown win-
dow lights and/or proper message window appears and confirm the functionality of
each window.
5. The TEST, ACKNOWLEDGE, and RESET functions, and the alarm sequence of the
annunciator shall be verified for correct operation, as applicable.

3.6.4 Testing Miscellaneous Electrical Devices


Solenoid valves, electrical relays, timers, push buttons, switches, and other miscellaneous
electrical devices shall be checked by the Contractor for correct actuation in accordance
with the specific project commissioning procedures.

3.7 Electrical Inspections


1. In general, electrical inspection requirements are called out in detail in specification ELC-OU-
12.02 and ELC-OU-12.23.
a. The electrical inspection requirements in the specifications listed in item 1, above, shall be
followed when checking and commissioning instrumentation installations.
b. The following paragraphs reiterate some important concepts that must be followed.
2. Individual power wiring to instruments shall be tested for resistance to ground per Specifica-
tions listed above. This wiring shall then be tested for continuity from the distribution panel to
the terminals of each instrument and checked for proper termination at the instrument.
3. Ring-out and/or make a continuity test of all electrical signal wires from the control center or
RTU to the field junction boxes and on to each instrument.
a. Check the resistance to ground of each wire.
b. Make sure that all wires, including the shield and drain wires, are terminated in accor-
dance with the construction drawings and manufacturer's wiring diagrams.
4. Ensure that all terminals and wires have permanent labels and tags. Wiring to be tagged at
every termination in the loop. See Project Specifications regarding wire tagging requirements.
5. Check that each thermocouple and lead wire conforms to data sheet Specifications.

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a. Check that the polarity and continuity of the lead wires are consistent through all the junc-
tion boxes from the thermocouple head to the control center or instrument.
b. Check that the shield wire is terminated at each grounded thermocouple head in accor-
dance with the manufacturer's instructions and not at the shield connection on the control
center or instrument terminals.
c. Check that the thermocouple is in contact with the bottom of the thermowell.
6. Verify that all seal fittings have been properly installed after loop checks are complete.
7. Make sure that control and power wires are run in separate conduit and junction boxes from
low voltage signal wires and cables.
8. Make sure the termination and wiring diagrams have been marked and initialed by the Con-
tractor responsible for the installation.
9. Intrinsically safe circuits shall be inspected to ensure that power supplies, barriers and field
devices bear UL or FM labels certifying them as intrinsically safe. All field cables of intrinsi-
cally safe circuits shall be colored bright blue.
10. Inspect all conduit and fittings to ensure compliance with NEC and API RP 14F.
11. Check installation of all conduit runs and calibrate level sensing devices that are inside vessels
by filling the vessel with water (and observing levels in gage glass) where possible.
12. Check installation of all conduit runs and make sure that low point drains are installed. Verify
that all seal fittings have been properly installed.
13. Check to make sure that there is an electrical power disconnect switch for every instrument
that uses 120-volt AC power.
14. Check to see that working space around all electrical equipment conforms to Article 110-16,
Working Space About Electrical Equipment (600 Volts, Nominal, or Less) of the National
Electrical Code.

3.8 Cleaning and Start-up Preparation

3.8.1 Line Flushing/Hydrotesting


1. Before line flushing, remove all in-line instruments. Removable spool pieces, plugs,
or blinds should be installed where needed to assure a flow path or to prevent leakage.
2. In-line flow instrument examples include orifice plates, rotameters, in-line flow
meters, in-line analyzers, analyzer probes (elements), strainer elements, straightening
vanes, pitot devices, silencers, control valves, and relief valves.
3. Impulse instruments shall be disconnected at the root valve prior to hydrotest.
4. The Contractor shall ensure during the process piping/equipment hydrotest that initial
instrument isolations do not leak.
5. Fittings for removable orifice plate flow meters are to be drained and cleaned after
line flushing.

3.8.2 Insulation
1. Insulation for instrumentation should be installed after the visual and mechanical
inspections are complete and the Company has reviewed insulation methods with the
insulation Contractor.

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2. Check that instruments and process lines or leads can be dismantled for maintenance
without destroying the insulation.
3. Check that either fixed or removable insulation is provided, without gaps, on all parts
of the process connection leads, including the root valves and instrument manifolds.
4. Check that all tubing connections including valves, tees and unions are not covered
with insulation to allow leak checking.
5. All outside insulation shall be weatherproofed.

3.8.3 Air Headers


1. All instrument air headers and branch connections, excluding instrument air filters,
shall be blown out with air after disconnecting tubing to the filter regulator.
2. Dripwells shall be blown out with air after air filter regulators are reconnected.

3.8.4 Regulators
All instrument air regulators shall be set at 20 PSIG (1.4 Barg) if supplying 3 15 PSI (0.2-
1.0 Bar) devices or 40 PIG (2.8 Barg) for 6 30 PSI (0.4-2.0 Bar) devices, unless otherwise
stated in detail Specifications.

3.8.5 Control Circuit Pressure Testing


The Contractor shall perform a control circuit pressure test for all instrument air tubing as
described below.
1. Instrument air tubing and supply piping shall not be hydrostatically tested.
Only clean, dry, oil free air shall be used for cleaning and testing of any air tubing.
2. The Contractor shall verify that the 1/4 inch instrument air tubing leakage rate is less
than 1 pound per square inch (PSI) per 100 feet (0.07 Bar per 30 meters) per 5 sec-
onds.
3. The instrument air lines terminated in a control valve topworks shall be converted into
the equivalent 1/4 inch instrument air tubing length as follows:

Air Line Termination Equivalent Length

Valves with Positioners 0 feet (0 meters)

11 inch Outside Diameter (OD) Topworks 104 feet (32 meters)

15 inch OD Topworks 385 feet (117 meters)

17 inch OD Topworks 770 feet (234 meters)

20 inch OD Topworks 1050 feet (320 meters)

3.8.6 Process Impulse Piping


1. Leak testing of process impulse lines shall be defined by the Project Specification.
a. Leak testing typically includes the use of Snoop or soapy water on the external
surfaces of impulse piping and tubing fittings and connections.

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b. The Project Specification should define when leak testing will be completed,
either during commissioning or start-up.
2. Impulse tubing installation quality assurance may include random checking of 10% of
all tubing connections.
a. This check may include a break of the connection, verification of proper fit-up,
and remake of the connection.
b. Alternatively, the installation may be checked using the tubing installations gap
check tool.
3. Critical tubing (e.g., high pressure, sour service, etc.) installations may require leak
testing of 100% of tubing connections prior to placing instruments in service.
a. Critical tubing quality assurance requirements shall be defined in the Project
Specification.
b. Test pressure and test medium shall be described in the Project Specification.
4. Clean, dry, oil-free air or an alternate approved by the Company (i.e. nitrogen, etc.)
shall be used for cleaning and pre-service leak testing of process impulse piping or
tubing.
5. Long sample lines shall be pneumatically tested for leaks, with repairs made as neces-
sary, prior to service testing.
6. All manifold valves shall be checked for tight shutoff.
7. When performing pre-service leak tests, disconnect or blind instruments as required so
that damage will not occur to devices.

3.8.7 Painting
1. Check that painting or galvanizing of all instrument supports and braces has been
completed.
2. Contractor is responsible for ensuring that sand blast grit or paint splatter does not
damage field instruments, control valves, etc. To this end, the Contractor shall wrap all
instruments (i.e., plastic bags taped securely over device) until after painting is com-
pleted.
3. Check that all paint (from plant painting), shipping labels, dirt, grease, etc., have been
removed from instrumentation.

3.9 Documentation

3.9.1 General
1. Company-approved drawings and Specifications shall form the basis for the design
and construction of the instrument system.
2. Project testing and calibration procedures, including detailed check sheets and any
special test and examination procedures, shall be submitted by the Contractor to the
Company 45 days prior to the scheduled date for beginning testing and calibration
activity.
a. The Project test procedures shall generally be derived from the manufacturer's
recommended procedures and project drawings.

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b. The project test procedures shall not violate the manufacturer's recommended pro-
cedures.
c. The person responsible for the testing or calibration shall date, initial, and attach
the calibration decal to the instrument.
3. The Contractor shall make as-built corrections to both the Company-supplied and
Contractor-supplied drawings modified during instrument commissioning.

3.9.2 Check Sheets


1. Detailed check sheets shall be developed as part of the testing and calibration proce-
dures prepared by the Contractor.
2. The check sheets shall have provisions for certifying that the equipment items are
properly installed, that the items are in compliance with the specified performance and
safety requirements, and that the items are suitable for operation.
3. Check sheets shall be standardized for each equipment type and shall contain the fol-
lowing minimum entries:
Nameplate Data
Checks and Tests Conducted
Record of Test Results
Acceptance Signatures
Instrument Tag Number

3.9.3 Discrepancy Lists


1. Defects found during the testing and calibration procedures shall be recorded on the
Instrument Discrepancy List found in Appendix IV, Table 1.
2. The lists shall show the scheduled dates for correcting each defect as well as the date
the defect was actually corrected.

3.9.4 Calibration Report


1. The Contractor shall submit a calibration report to the Company Representative at the
conclusion of testing and calibration.
2. The calibration report shall include, but need not be limited to, the following:
General Description of the Instrument System
Calibration Objectives
Description of Instrument System Operation
Test Equipment Utilized and Serial Numbers
Calibration Procedures
Results
Test Equipment Calibration Records, Serial No., Etc.
Conclusions and Recommendations
Originals of all Check Sheets and Discrepancy Lists
3. All instrument loops shall be calibrated, checked, and documented.
a. A folder for each loop shall be maintained throughout checkout.
b. The folder shall contain the loop diagram, instrument data and calibration sheets,
calibration report, and the loop sign-off sheet for the Contractor and Company
Representatives.

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4. Input and output loops for a panel shall be maintained in a panel folder. The folder
shall contain the panel drawings, instrument data and calibration sheets, calibration
report, and the loop and panel function sign-off sheet for the Contractor and Company
Representatives.
5. All instrument calibration sheets, loop folders, and panel folders shall be turned over
to the Company at the end of the job.

4.0 LOOP CHECK

4.1 Purpose
1. The intent of the loop check is to test and prove the correct functioning of the instrumentation
system as a whole including, but not limited to, all field and panel devices and their signals,
field and control room terminations, the Basic Process Control System (BPCS) including
Human Machine Interface (HMI) displays, Fire and Gas System, and annunciators.
a. Examples of BPCS include Distributed Control Systems (DCS), Programmable Logic
Controllers (PLC), and Supervisory Control and Data Acquisition (SCADA) systems.
a. This specification applies to all types of BPCS.
2. Local loops and skid-mounted instrumentation systems are included.
3. All types of devices are included - analog, discrete (i.e., switches, push buttons), electrical,
hydraulic, or pneumatic.
4. The loop-check verifies that the platform instrumentation system is fully functional and ready
for plant start-up.

4.2 Responsibilities
1. Contractor shall perform a full functional loop check of the entire installed instrumentation
system as outlined in this section.
2. The loop-check work shall be the coordinated effort of teams made up of individuals that are
qualified to verify correct functioning of the various parts of the loop system that they are
assigned to watch.
3. The actual number of teams and the numbers of individuals on each team shall be determined
by the Contractor and approved by the Company.
4. The following is a typical team:

Field Crew: Instrument mechanic(s) and/or electrician(s) to perform work of


simulating process inputs at field devices, and troubleshooting
problems.
Control Room Crew: Instrument technician(s), inspector(s), or engineer(s) to verify sig-
nal inputs, troubleshoot problems and record results. These indi-
viduals shall be experienced in the use of the equipment that they
are assigned to watch (i.e., BPCS, PID Controllers, Fire and Gas
Panel equipment).
Systems Engineer from the Control Systems/Systems Integrator
Contractor to verify proper BPCS inputs/outputs and to correct
logic difficulties.

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Company Personnel: Company has the option of providing any inspection or engineer-
ing personnel to attend or aid in any phase of the loop-check. Com-
pany may also have operations or maintenance personnel in
attendance for training purposes.

4.3 Loop Check Documentation


1. The Contractor shall submit loop-check procedures, proposed forms and documentation, and
scope of the systems to be checked for Company approval at least one month in advance of the
loop-check start date. This timing enables Company to arrange for any Company personnel
who wish to attend.
2. Contractor shall keep up-to-date documentation of the loop check status for each instrument as
the loop-check progresses.
a. The final documentation will be transmitted to Company after completion.
b. A form for documenting loop-check progress is provided as Table 3 in Appendix IV.
c. Company may approve Contractor form if it complies with the intent of Company form
and Specifications.
3. Prior to starting loop check, proper documentation shall be compiled for use by the loop-check
teams. This documentation shall include the following, as a minimum:
Instrument data sheets,
Calibration Documentation Sheet (Appendix IV, Table 2)
Loop Check Documentation Sheet (Appendix IV, Table 3)
Piping and Instrument diagrams
Loop diagrams
Elementary diagrams
Panel wiring drawings
Junction box diagrams
Manufacturer's installation/maintenance/operating manuals
BPCS programs (typical for PLCs) documentation may be provided electronically
Copies of HMI displays or graphics
Instrument installation details
Instrument location plans (if required by the project)
Cable tray routing / junction box location plans (if required by the project)

4.4 Procedures
1. Refer to Appendix III, Table 4 and Table 5 for Loop Check methods and procedures.
2. Contractor shall check instruments as a complete loop.
3. Field instruments and their associated loop devices, whether they be local pneumatic, control
room mounted, or BPCS, shall be checked together at the same time by the loop-check team.
4. Contractor shall have completed the rest of the inspections as described in the preceding sec-
tions of this Specification before beginning loop-check.
5. For individual field and panel devices refer to Appendix III, Table 4 for an explanation of what
is required for these devices.

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6. Obtain an output signal from transmitters, switches and other field or panel devices by simu-
lating the actual pressures, temperatures, levels and flows.
7. Check the transmission of each of these input signals to the BPCS, shutdown panels, alarm
panels, indicators and other devices or systems associated with that loop. This includes check-
ing that signals are displayed properly on all BPCS screens that are associated with that point.
8. Check the transmission of each output signal from the BPCS to the final control element (e.g.,
control valves, solenoids) in the field.
a. Check that each final control element is responding correctly to the transmitted output sig-
nal (e.g., verify valves actually open or close when solenoids function).
b. Field and panel controllers shall be checked for proper function using procedure described
in Appendix II of this Specification.
9. BPCS
a. Check every input into and output leaving the BPCS to the field devices.
b. All inputs and outputs shall be checked for proper display and control action from the
BPCS consoles or displays.
c. Each screen or display associated with the function of a particular device including dis-
play, control, trending, historical data collecting, printouts, and/or alarming shall be
checked.
d. Be sure valves actually open and close when solenoids function (e.g. check to the final ele-
ment).
e. Check instrument configuration in BPCS including tag, range/scaling and units.
10. Verify that motor contactors energize when receiving an output signal from the PLC, and that
auxiliary contact inputs are received by the PLC to verify this.
11. Shutdown and Safety Panels and Devices
a. Check every input and output to these panels and the devices therein whether field
mounted or control room mounted.
b. This may involve features such as bypass or test switches.
c. Check for proper operating and shutdown logic of these panels.
d. Check for proper logic and actuation of the corresponding final control elements for each
of the Platform Shutdowns described in the Project Technical Specification.
12. Annunciators
a. Check the operation of every point on any hardwired annunciator, field or panel mounted.
b. Check for proper operation of the RESET, TEST, and ACKNOWLEDGE push buttons.
c. Check proper operation of electronic display units.
13. Instrumentation and controls on skid-mounted or vendor package equipment shall be loop-
checked using the same procedures described for instruments above.
14. As each loop-check is made, record results on the loop-check documentation sheet such as that
in Appendix IV, Table 3.
a. Note any discrepancies on the form.

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b. When the checks for that loop are completed, both the Contractor and the Company shall
sign in the certification block.
15. As each loop-check is finished, the wiring terminations shall be checked, all test jumpers
removed, electrical junction boxes closed, all piping reconnected and instrument doors and
covers properly fastened.
16. When a system fails to pass the loop-check, the Contractor shall make field corrections and
note such corrections on the loop-check documentation sheet.
a. If such corrections cannot be readily made, the problem should be deferred.
b. The loop-check will be resumed later, after the Contractor has had the opportunity to cor-
rect the problem.
17. After the loop-check has been completed, the Contractor shall conduct a final check to ensure
that all instrumentation has been restored to a safe, operable condition ready for platform start-
up.
18. After all loop check problems/discrepancies have been resolved, a complete S.A.F.E. chart
and/or Cause and Effect chart test, where applicable, shall be run.
19. Complicated or inter-related instrument loops (e.g., process interlocks, shutdown interlocks,
machinery protection systems, etc.) shall be tested in accordance with specific project com-
missioning procedures.
a. The purpose of specific project commissioning procedures is to confirm the logic of the
interlock or protection system functions throughout the entire loop (e.g. to the final ele-
ment) prior to start-up.
b. The commissioning procedures shall also be used to verify the HMI displays (graphics,
annunciators, etc.) function correctly at each sequence or step in the logic.
c. Simulation of process may be required to allow connections in and out of the software
associated with the respective system to be tested.
d. Interlock or protection system commissioning may be completed during or after loop
check.
e. Commissioning documentation indicating Company approval of completed testing shall
be retained by Contractor.

5.0 QUALITY ASSURANCE PROVISIONS


Quality assurance provisions shall be in accordance with the Project Technical Requirements, with
the following additional qualifications:
1. Testing and calibration of the installed instrument systems shall be conducted by the Contrac-
tor and witnessed by Company.
2. Special tests and examinations shall be conducted in accordance with the requirements of this
Specification.

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APPENDIX I
TYPICAL CALIBRATION TEST EQUIPMENT REQUIRED
Test equipment for instrumentation calibration or testing shall be three times as accurate as the
instrument being calibrated or tested, unless otherwise specified.
The following list is a high level generic list of types of equipment required for conducting the
instrument testing and calibration described in this Specification. For specific details, refer to
Appendix III, Table 3.
1. Test gages (Ranges, as required). Accuracy of 1/4 of 1 percent of the full-scale range.
2. Deadweight tester
3. Hydraulic pressure pump
4. Voltmeter/Ohmmeter
5. Hot oil bath and/or hot sand bath
6. Digital calibrator (Transmation Model 1040 or Equivalent)
7. Reference cells to simulate ice point reference for temperature instruments (Transmation
Model 1013 or equivalent)
8. Loop calibrator that can measure, generate, and simulate analog control signals (Transmation
Model 1022 or equivalent)
9. Manometer with a calibrated scale covering a range from 0 to 400 inches of H2O (0 to 996
mBars)
10. Pressure regulators adjustable over a range from 0 to 50 PSIG (0 to 3.4 Barg)
11. Pneumatic calibrator (Wallace and Tiernan Model 65 120 or equivalent)
12. Pulse generator
13. Precision glass stem thermometers (range as required)
14. RTD with digital readout
15. Ultraviolet light source
16. Vibration meter with spectrum analysis
17. Micrometer

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APPENDIX II
CONTROLLER MODE REQUIREMENTS
Proportional Band
1. The controller shall be placed in manual.
2. The proportional band shall be set to 100 percent.
3. The reset shall be set at minimum value.
4. The derivative shall be set a minimum value.
5. The controller set point shall be set at 50 percent of span.
6. The process variable input shall be set at 50 percent of span.
7. The controller output shall be set at 50 percent of span.
8. The controller shall be placed in automatic.
9. The process variable input shall be set to 75 percent of span.
10. The controller output shall be noted when stabilized.
11. The proportional band shall be set to 50 percent.
12. The controller shall be returned to automatic.
13. The process variable shall be set to 75 percent of span.
14. The controller output shall be noted when stabilized.
15. The output signal for direct acting controllers shall be greater than the signal obtained in
step 10, above.
16. The output signal for reverse acting controllers shall be less than the signal obtained in
step 10, above.
Reset
1. The controller shall be placed in manual.
2. The proportional band shall be set to 100 percent.
3. The reset shall be set at a minimum value.
4. The derivative shall be set at minimum value.
5. The controller set point shall be set at 50 percent of span.
6. The process variable input shall be set at 50 percent of span.
7. The controller output shall be set at 50 percent of span.
8. The controller shall be placed in automatic.
9. The process variable input shall be set to 75 percent of span.
10. The controller output shall be noted when stabilized.
11. The controller shall be placed in manual.
12. The reset shall be set to 10 repeats per minute.
13. The process variable input shall be set to 75 percent.
14. The controller shall be placed in automatic.

June 2005 Chevron Corporation 28 of 44


Checkout and Commissioning of Instrumentation ICM-SU-11.12

15. The output signal for direct acting controllers should continuously increase to the maximum
value. The output signal for reverse acting controllers shall continuously decrease to the mini-
mum value.
Deriative
1. The controller shall be placed in manual.
2. The proportional band shall be set to 100 percent.
3. The reset shall be set at the minimum value.
4. The derivative shall be set at the minimum value.
5. The controller set point shall be set to 50 percent.
6. The process variable input shall be set to 50 percent.
7. The controller output shall be set to 50 percent.
8. The controller shall be placed in automatic.
9. The process variable input shall be increased while the rate of change in the controller output
is observed.
10. The controller shall be placed in manual.
11. The controller set point shall be set to 50 percent.
12. The process variable input shall be set to 50 percent.
13. The controller output shall be set to 50 percent.
14. The derivative shall be set to the maximum value.
15. The controller shall be returned to automatic.
16. The process variable input shall be increased while the rate of change in the controller output
is observed.
17. The output of direct acting controllers shall increase at a faster rate in step 16 than in step 9.
The output of reverse acting controllers should decrease at a faster rate in step 16 than in step
9.

June 2005 Chevron Corporation 29 of 44


Checkout and Commissioning of Instrumentation ICM-SU-11.12

APPENDIX III
CALIBRATION METHODS AND PROCEDURES

TABLE 1: INSTRUMENT CALIBRATION PROCEDURES (1 OF 5)


Calib. Method
Calibration (Bench,
Instrument (See Appx III, Remark
In-Line, None)
Table 2)
GENERAL TABLE NOTES
1 Contractor shall refer to the methods and procedures in this Appendix unless otherwise directed by the Company. The methods and procedures de
mented by the manufacturers literature.
2 Smart or digital transmitters normally do not require field calibration, either on the bench or in-line using reference calibration methods (deadweig
3 Smart transmitters should be checked for range, instrument tag number and correct configuration during loop check. This check may be performe
nicator or shared display graphic.
4 Complex instruments and systems (analyzer systems, DCS, Tank Gaging, etc.) may have additional requirements than those described here. Chec
tive and manufacturers literature.
5 The word, calibration when used in this guideline shall also include checkout of certain instruments prior to calibrating. See Specification for more
Some examples are:
Orifice plates, venturies, etc. - check bore or throat diameters with micrometer for conformance with data sheet.
Turbine meter - check that moving parts are free (this may be done by blowing air through the meter), being careful not to over speed. Do n
specified for water service.
Displacer or float instrument - check that travel stops are removed and Displacer or float is free and lifted off bottom of cage when cage is e

Flow
Venturi / Flow Tube None See vendor curves for calibrated
Pitot Tube None See vendor curves for calibrated
Pitot Venturi None See vendor curves for calibrated
Annubar None See vendor curves for calibrated
DP Cell Transmitter - Force Balanc (0.5 up to 0-850 W.C.) In-line B Calibrate with regulated air supp
Bellows Controllers/ Recorders In-line M Calibrate with regulated air supp
Bellows Indicators In-line M Operate with regulated air supp
Bellows Switch In-line M Check actuation at set point
Integral Orifice Transmitter In-line A Calibrate, calculate equivalent f
factors as required
Target Transmitter Bench A Calibrate using calibrated weigh
Vortex Transmitter Bench See manufacturers instructions
Displacement Meter None Note 5
Turbine None Note 5. See also, See Freq/Cur
Propeller Meter None Note 5. See also, See Freq/Cur
Displacement Meter Prover None Note 5. See also, See Freq/Cur
MAG Flowmeter Bench A See manufacturers instructions
Rotameter Bench A Move float linkage to get output
Thermal Flowmeter or Switch Bench A See manufacturers instructions
Paddle-type Flowswitch Bench A Move Paddle to Get Actuation
Level
Bubbler Tube In-line Fill tube and adjust purge rate, z
Admittance/Conductance Transmitter (Drexelbrook, Agar) In-line E/X See Manufacturers instructions

June 2005 Chevron Corporation 30 of 44


TABLE 1: INSTRUMENT CALIBRATION PROCEDURES (2 OF 5)
June 2005

Checkout and Commissioning of Instrumentation


Calib. Method
Calibration (Bench,
Instrument (See Appx III, Remarks
In-Line, None)
Table 2)
Ultrasonic In-line A See Manufacturers instructions
Nuclear Source Bench A Requires manufacturers representative
DP Transmitter - NPT connected In-line B
DP Transmitter - Flange connected to tank In-line C
DP Transmitter with remote seals In-line A/C Verify that seal fluid in system and type are correct
Internal Displacer In-line D
External Cage Displacer In-Line D
Chevron Corporation

External Cage Float Switch In-line D Check for actuation


Tank Gage In-line Check for actuation by moving tank gage. For radar gage,
check per manufacturers recommendation.
Gage Glasses None

ICM-SU-11.12
31 of 44
TABLE 1: INSTRUMENT CALIBRATION PROCEDURES (3 OF 5)
June 2005

Checkout and Commissioning of Instrumentation


Calib. Method
Calibration (Bench,
Instrument (See Appx III, Remarks
In-Line, None)
Table 2)
Temperature
Filled Bulb Transmitter Bench / In-line G
Filled Bulb Switches Bench / In-line G
RTD Devices In-line H Use precision bridge
Thermocouple Devices In-line H Use precision potentiometer to check wire and polarity
Pressure
Gage Pressure Transmitter In-line I/J Check that field indicator operates properly
Chevron Corporation

Absolute / Vacuum Transmitter In-line K Check that field indicator operates properly
Low Range /Draft Transmitter In-line L Check that field indicator operates properly
Differential Pressure Transmitter In-line M Check that field indicator operates properly
Differential Pressure Transmitter with Remote Seals In-line M Check that seal fluid type is correct
Field Gage Pressure Controller / Recorder In-line I/J
Field Absolute / Vacuum controller / Recorder In-line K
Field Low Range Recorder / Controller In-line L
Field Differential Controller / Recorder In-line M
Gage Pressure Switch In-line I/J Check actuation and setpoint
Absolute / Vacuum Switch In-line K Check actuation and setpoint
Low Range Pressure / Draft switch In-line K Check actuation and setpoint
Differential Pressure Switch In-line M Check actuation and setpoint
Pressure Regulator, (Low Pressure Air, Gas, or Water) In-line A Check with air or water

ICM-SU-11.12
Pressure Regulator - Pilot operated In-line A
Pressure Gage In-line Zero only if necessary
32 of 44
TABLE 1: INSTRUMENT CALIBRATION PROCEDURES (4 OF 5)
June 2005

Checkout and Commissioning of Instrumentation


Calib. Method
Calibration (Bench,
Instrument (See Appx III, Remarks
In-Line, None)
Table 2)
Valves, Actuators & Accessories
Control Valve w/ diaphragm or Piston Actuator In-line V
Control Valve w/ rotary actuator In-line V
Control Valve w/ Hydraulic Actuator In-line V
Shutdown or blowdown valve In-line W
I/P Transducer In-line I Also stroke valve per V
Pneumatic Positioner In-line V
Chevron Corporation

Pneumatic Booster Relay In-line A


E/P Transducer In-line V I/P or E/P Positioner or Transducer
On-Off Valve w/ Solenoid Operated Pilot Valve In-line V Also check operation of Solenoid
Limit Switches In-line Check actuation of switches with valve in both positions
Solenoid operated valve (process line mounted) In-line A Operate with Power Source. Check Action.
Self-contained temperature Regulating Valve Bench G
Self-contained float operated level valve In-line A
Butterfly Valve In-line V
Relief Valve None R Test if no Certificate from Vendor
Thermal Relief Valve None R Test if no certificate from vendor
Control Room Instruments
Annunciator In-line A Checkout during loop check. Apply all alarm points, verify
alarms work. Verify test, acknowledge and reset functions
work and proper ISA Annunciator logic is followed.

ICM-SU-11.12
Recorder/Indicator In-line T Verify that correct chart or indicator is installed.
Input/Output signal converter In-line U
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Integrating Counter In-line S Apply inputs and verify outputs.


TABLE 1: INSTRUMENT CALIBRATION PROCEDURES (5 OF 5)
June 2005

Checkout and Commissioning of Instrumentation


Calib. Method
Calibration (Bench,
Instrument (See Appx III, Remarks
In-Line, None)
Table 2)
Computing Relay and Signal Selectors. In-line A Apply inputs and verify outputs.
DC Power Source In-line A Check per Manufacturers instructions
Thermocouple to current converter In-line A Use precision bridge, Manufacturers resistance values
Resistance to Current Converter In-line A See Manufacturers instructions
Frequency to Current Converter In-line A Apply pulse input and verify proper 4-20 MA output
Analyzer Bench or In-line A Calibrate per Manufacturers recommendation
Heat Tracing In-line A Check perManufacturers recommendation
Chevron Corporation

ICM-SU-11.12
34 of 44
TABLE 2: CALIBRATION METHODS AND DESIGNATORS (1 OF 2)
June 2005

Checkout and Commissioning of Instrumentation


Designator Calibration Method
A Calibrate in accordance with the methods given in the vendor's manual. Contractor to calibrate against acceptable calibration standard when
required. Calibration equipment must be certified by an independent testing laboratory and meet or exceed manufacturers Published Perfor-
mance specifications.
B Zero by closing low pressure valve and opening bypass valve on manifold. Span by using air or dry nitrogen connected to high pressure side
with low pressure side vented. Check output signal at 0, 25, 50, and 100% of full range. Recheck zero at atmospheric pressure and at normal
operation pressure.
C Zero and span by varying level in tank to the span limits with low pressure side vented (open tank applications). Check output and re-zero as in
method B. Specific gravity correction shall be made if calibration fluid is different from process fluid.
D External displacer (also applicable to internal displacer except omit the first sentence). Zero by closing block valves and draining cage. Check
span by filling cage slowly with water. Check output signal at 0, 25, 50, and 100% of full scale. On level interface applications adjust for specific
gravity differences.
Chevron Corporation

E Zero and span by calibrating in place using process fluid.


F Insert in container of process fluid (or fluid with similar characteristics). Verify switch action, fail safe, etc. as specified on data sheet.
G Insert in liquid temperature bath or ice water container. Check output signal (or pen/pointer position) at 0, 25, 50, and 100% of full range for lin-
earity and signal direction. Adjust if necessary per manufacturer's instructions. On switches, adjust set point and deadband if applicable.
H Apply appropriate electric input over full range (refer to thermocouple-to-millivolt conversion tables or RTD-to-resistance conversion tables for
input equivalents). Check output signal or pointer position at 0, 25, 50, and 100%.
I Range: 25 to 150 psi - apply pressure with regulated instrument air or dry nitrogen. Check output signal (or pointer position) at 0, 25, 50, and
100% of full range for linearity and signal direction. On switches adjust set point and deadband, if applicable, if sealing fluid is used or if a perma-
nent liquid leg is imposed on the instrument, shift the calibration to offset the effect of the liquid leg.
J Range: 150 psi and higher - apply hydraulic pressure with a dead weight tester and calibrate per method I (if instrument has elevated or sup-
pressed zero, calculate the output and adjust zero and span per manufacturer's instructions).
K Absolute pressure - apply best vacuum attainable to transmitter (if instrument has suppressed range the absolute pressure should not be less
than the lower range value). Calculate the output and adjust zero and span per manufacturer's instructions
L Low pressure and draft - apply pressure to high pressure side with hand pump (with low pressure side vented and calibrate per method I).
M Differential pressure - apply differential pressure with hand pumps or regulated air supply. Calibrate per manufacturer's instructions using a direct

ICM-SU-11.12
reading chart or manufacturer's calibrated scale (midscale on square root chart equals full chart range x .707)
N Simulate trip condition using regulated air or dry nitrogen by dropping the pressure across the set point. Verify that the trip action is on-off and
35 of 44

that the output changes in the right direction. Verify that the manual reset feature functions correctly.
TABLE 2: CALIBRATION METHODS AND DESIGNATORS (2 OF 2)
June 2005

Checkout and Commissioning of Instrumentation


Designator Calibration Method
R Test and reset per vendor instructions if necessary. Set pressure tolerances shall conform to applicable codes as noted in the data sheet. Where
no codes are specified, the requirements of ASME code for unfired pressure vessels shall be used and the set pressure tolerance, plus or minus
of safety or relief valves, shall not exceed 2 psi for pressure up to and including 70 psi, and 3% for pressure above 70 psi.
S Linear inputs - simulate input by using dry air or nitrogen as a pressure source. Check calibration at 10% (4.2 psig/5.6 ma) and 90% (13.8 psig/
18.4 ma) of maximum counts/minute (as determined from the nameplate data). Apply a 10% input for three minutes using a stopwatch and note
the count difference. This should be 3 x 10% of the maximum counts per minute. Adjust if necessary. Repeat and adjust for inputs of 50% and
90% of maximum counts/minute. Square root extracted inputs - for integrators that extract the square root of inputs, simulate inputs as above.
Check calibration at 10% (equivalent of 1% of input or 3.12 psig/4.16 ma), 50% (equivalent of 25% of input or 6 psig/8 ma) and 90% equivalent
of 81% of input or 12.72 psig/16.96 ma) or maximum counts/minute. (as determined by nameplate data). Apply 81% of input for 3 minutes using
a stopwatch and note the count difference. This should be 3 x 90% of maximum counts/minute. Adjust if necessary. Repeat and adjust for inputs
of maximum 50% and 10% of counts/minute. Run square root signal inputs down below 3 psig (to 0 psig or below 4 ma to o ma) to verify that no
counting in either direction occurs.
Chevron Corporation

T Apply full range of input (i.e. 4-20 ma or 3-15 psig) to each input device. Verify that each input reads out over 100% of scale and adjust per man-
ufacturer instruction, if necessary. Verify that charts and scale ranges conform to data sheets.
U Apply full range of input (4-20 ma or 3-15 psig) to input and set point of controller. Verify that the measured variable and set point (if remote set)
read out over 100% of the scale. Adjust per manufacturer's instructions if necessary. With controller in manual apply full range of output. Verify
output and verify that valve output indicator reads over 100% of scale.
V Check actuation and stroke of control valve by application of full range of input signals. Verify conformance with data sheet. Adjust range to
stroke valve per data sheet. Verify fail position.
W Check actuation and stroke of valve by application of on/off input signal. Verify conformance with data sheet. Verify open/close timing require-
ments, limit switch operation, and fail position.

ICM-SU-11.12
36 of 44
TABLE 3: TEST EQUIPMENT REQUIRED
June 2005

Checkout and Commissioning of Instrumentation


Item Tested Equipment Required
Differential Pressure 0-5 inches water: water manometer graduated in inches water
0-100 inches water: water manometer graduated in inches water
5-300 inches water: mercury manometer graduated in inches water
5-25 psig: mercury manometer graduated in psig
Above 25 psig: 0-160 psig or 0-800 psig precision gage (deadweight calibrated)
Electrical Multimeter - field tester (fluke or equal)
Multimeter - bench tester (fluke or equal)
Precision potentiometer with thermocouple
Precision resistance Bridge (decade box)
Oscilloscope pulse generator
DC power supply
Transducer simulator
Chevron Corporation

Electronic instrument calibrator (transmation or equal)


Thermocouple calibrator
Special calibration equipment as required (for mag meters, etc.)
Hand held communicator/ calibrator
Mechanical Micrometer calipers
Vernier calipers
Drill gages
Flange jig
Hand pump
Vacuum pump
Portable temperature calibration bath
Nitrogen bottle (high pressure) equipped with regulator and Nitrogen bottle (low pressure) equipped with regulator
Stopwatch
Pneumatic Pneumatic calibrator
Deadweight tester
Pressure 0-60 inches water - water manometer graduated in inches water
3-25 psig - mercury manometer graduate in psi
25-150 psig - 0 -160 psig precision gage (deadweight calibrated)
150-750 psig - 0-800 psi precision gage (deadweight calibrated)

ICM-SU-11.12
Test gages-Vacuum or Draft 5-25 inches mercury - mercury manometer graduated in inches mercury
0-60 inches water - water manometer graduated in inches of water
37 of 44

Test gages-Temperature -20 to 250F precision thermometer


Other ranges: precision potentiometer with thermocouple
TABLE 4: LOOP CHECK METHODS BY PRIMARY ELEMENT TYPE
June 2005

Checkout and Commissioning of Instrumentation


Loop Check Method
Primary Element Type
(Refer to Appendix III, Table 5 for details)

Differential Pressure Transmitters (Flow, Pressure, Level) A.1

Differential Pressure Transmitters With Diaphragm Seal A.2

Pressure Transmitters A.4

Pressure Switch A.4

Thermocouple A.9

Resistance Temperature Detector A.9

Emf And Rtd Converters A.11


Chevron Corporation

Filled System Temperature Instruments A.5

Level Displacer Transmitters/Controllers A.3

Level Switch (Displacer) A.3

Flow Switch, Differential Pressure A.1

Flow Switch, Paddle Type A.6

Variable Area Flowmeter (Rotameter) A.10

Positive Displacement Meter A.8

Analyzer A.13

Current Converters A.8

Field Mounted Control Panels A.12

Frequency Generating Device A.8

ICM-SU-11.12
Vendor Package Equipment A.12

Vibration Switch A.7


38 of 44

Vibration Transmitter A.8


TABLE 5: LOOP CHECK METHODS AND PROCEDURES (1 OF 2)
June 2005

Checkout and Commissioning of Instrumentation


Loop Check Methods
No. No. Loop Check Procedures
(See table to right for description of procedures)
A.1 Shut off block and equalizing valves, connect test pressure to B.1 Reference instrument conditions
high side of differential pressure instrument and simulate process
conditions in accordance with loop check statements in Proce-
dure B.1 through B.10 as applicable.
A.2 Connect high pressure side diaphragm seal to test flange. Vent B.2 Connect test instrument to output of instrument under test to ver-
low pressure side diaphragm seal and zero transmitter. Connect ify and cross check input variable against output and control
test pressure to high side and simulate process pressure in room reading.
accordance with the loop check statements in Procedure B.1
through B.10 as applicable.
A.3 Shut off all block valves and open vent and drain valves. Connect B.3 Set input variable to a minimum to obtain minimum reading in
Chevron Corporation

external test fluid supply and simulate process conditions. Follow control room. Cross check field and control room readings and
procedures in accordance with loop check statements in Proce- zero transmitter if required.
dures B.1 through B.10 as applicable.
A.4 Shut off block valve or root valve and connect test pressure to B.4 Check permanent plant field indicators.
vent valve. Follow procedures in accordance with loop check
statements in Procedure B.1 through B.10 as applicable.
A.5 Process conditions for temperature instruments with capillary B.5 Check input variable at 0, 25, 50, and 100% of transmitter cali-
bulbs are normally difficult to simulate. However when possible brate range, if applicable. Check control room reading and field
test sensing element in a temperature bath, then physically actu- indicators. Re-range transmitter and check control room instru-
ate switch for contact open or closure for temperature switches ment, if required, to insure corresponding reading. For switches,
or disconnect cable and simulate process by applying 4-20 ma establish setting at which switch actuates.
for transmitters. Follow procedures in accordance with loop
check statement in Procedure B.1 through B.10.
A.6 Remove switch from process line if necessary and physically B.6 With control room instrument in manual mode, have the operator
move flapper/float to actuate switch for contact open/closure. vary the output signal to the field, if required, cross check control
Follow procedure in accordance with loop check statements in room with field end device. I.e. control valve for proper action at
Procedure B.1 through B.10 as applicable 0, 25, 50 and 100% or output signal.
A.7 Simulate vibration effect by tapping switch housing with rubber B.7 With control room instrument in auto mode, apply input variable

ICM-SU-11.12
mallet. Follow procedures in accordance with loop check state- to primary element at 0, 25, 50 and 100% of transmitter range.
ments in Procedure B.1 through B.10, as applicable Check control roomreading and other field devices for proper
action.
39 of 44
TABLE 5: LOOP CHECK METHODS AND PROCEDURES (2 OF 2)
June 2005

Checkout and Commissioning of Instrumentation


Loop Check Methods
No. No. Loop Check Procedures
(See table to right for description of procedures)
A.8 Normally these instruments cannot be or are usually not cali- B.8 Check fail safe action on all devices in all required modes of
brated in a field installation. Disconnect cable and simulate pro- operation.
cess signal output for loop check purposes. Follow procedures in
accordance with loop check statements in Procedure B.1 through
B.10 as applicable.
A.9 Disconnect extension wires at t/c or rtd head. Simulate input from B.9 If cascaded loops are involved, all loops will be checked together
t/c or rtd head, check polarity, check reading on control room if possible.
instrument, check burnout direction, and reconnect wires at
head.
A.10 If possible, vary float position to obtain variable output signal. B.10 Check all alarms associated with loop operation and verify.
Chevron Corporation

Disconnect cable and apply 4-20 ma for loop check purposes.


Follow procedures in accordance with loop check statement in
Procedure B.1 through B.10 as applicable.
A.11 First verify ambient temperature if possible with control room
reading. Disconnect cable at t/c or rtd head and apply millivolt or
resistance signals.follow procedures in accordance with loop
check statements in Procedure B.1 through B.10 as applicable
A.12 Follow procedures according to type of instrument as applicable.
A.13 Analyzers may require vendor representative calibration. Check
with company. Run calibration standard, verify output vs. Cal
value.

ICM-SU-11.12
40 of 44
APPENDIX IV
June 2005

Checkout and Commissioning of Instrumentation


CALIBRATION AND TESTING DOCUMENTATION

TABLE 1: INSTRUMENT DISCREPANCY LIST

Scheduled Actual
Associated
Tag # Plant Area Defect Completion Completion Remarks
Equipment
Date Date
Chevron Corporation

ICM-SU-11.12
41 of 44
TABLE 2: CALIBRATION DOCUMENTATION SHEET
June 2005

Checkout and Commissioning of Instrumentation


PHYSICAL LOOP COMPONENT CHECKOUT INSTRUMENT CALIBRATION (for bench calibration or field calibration check)

LOOP TAG CHECKOUT


COMPONENT NO. COMPLETE? Y/N 100 SWITCH SWITCH
0% 25% 50% RANGE
% SETPOINT ACTIVATED
WIRING TUBING

Process Input
Transmitter
Transmitter Output

Field Device Input


Field End
Device Field Device Output
Chevron Corporation

Controller Input
Controller
Controller Output

Input
Other _______
Output

Input
Other _______
Output

Switch

Switch

Loop Check Methods and Procedures Used (from Appendix III, Table 5):_______________________________________________

Calibration Approved: Yes No Certification: Company_________________________ Date___________________

ICM-SU-11.12
42 of 44
TABLE 3: LOOP CHECK DOCUMENTATION SHEET
June 2005

Checkout and Commissioning of Instrumentation


Loop Device
PROCESS SIGNAL INPUT ALARM SETTINGS
Response (in
0% 25% 50% 100%
engineering ALARM?
SETPOINT
units) Y/N
EXP ACT EXP ACT EXP ACT EXP ACT

Controller Ouput
(Controller in
auto)

Indication

Recorder/Trend
Chevron Corporation

Alarm 1

Alarm 2

Alarm 3

Alarm 4

Controller Output
(Controller in 0 25 50 100
Manual)

Field Device
Response

Loop Check Methods and Procedures Used (from Appendix III, Table 5):_____________________________________________________

Loop Folder Complete and Approved: Yes No Certification: Contractor_________________________ Date___________________

Loop Check Approved: Yes No

ICM-SU-11.12
Certification: Company__________________________ Date___________________
43 of 44
Checkout and Commissioning of Instrumentation ICM-SU-11.12
June 2005 Chevron Corporation 44 of 44