Calibration Checkout, Loop Check, and Commissioning of Process Controls

Table of Contents

1.	Purpose
2.	Scope
3.	Related Documents
4.	Definitions of Terms
5.	General
6.	Instrument Inspection
7.	Calibration
8.	Precommissioning (Loop Checks)
9.	Change Log
Appendix A	Control Valve Commissioning Checklist
Appendix B	Switch Valves, TSA, and PSA Valves Commissioning Checklist
Appendix C	Pressure Transmitter Commissioning Checklist
Appendix D	Filled System Temperature Transmitter Commissioning Checklist
Appendix E	Differential Pressure Transmitter Commissioning Checklist
Appendix F	Displacement Level Instrument Commissioning Checklist
Appendix G	Multipoint Recorder Commissioning Checklist
Appendix H	Orifice Plate/Flow Nozzle Commissioning Checklist
Appendix I	Analyzers Commissioning Checklist
Appendix J	Machine Controls Commissioning Checklist
Appendix K	Vibration Monitors Proximity/Inertia Commissioning Checklist
Appendix L	Surge Control System Commissioning Checklist
Appendix M	Thermocouple RTD and Well Commissioning Checklist
Appendix N	Pressure Gauge Commissioning Checklist
Appendix O	Thermometers and Wells Commissioning Checklist
Appendix P	Relief and Safety Valves Commissioning Checklist
Appendix Q	Alarm Switches Commissioning Checklist
Appendix R	Locally Mounted Controller Commissioning Checklist
Appendix S	Panel Controller Pneumatic Commissioning Checklist
Appendix T	Panel Controller Electronic Commissioning Checklist
Appendix U	Electronic Recorder Commissioning Checklist
Appendix V	Pneumatic Recorder Commissioning Checklist
Appendix W	Signal Modifiers (Computing Relays) Electronic Commissioning Checklist
Appendix X	Signal Modifiers (Computing Relays) Pneumatic Commissioning Checklist
Appendix Y	Power Supply Systems Commissioning Checklist
Appendix Z	DCS Systems Commissioning Checklist
Appendix AA	Programmable Controllers Commissioning Checklist

PURPOSE

1.1 This engineering specification defines the minimum requirements for contractor calibration checkout, loop check, and commissioning of process controls.

SCOPE

2.1 This specification applies to all control systems undergoing commissioning by Air Products and contractors under Air Products direction.

2.2 The scope of work includes all costs relating to overhead, site accommodations, supervision, labor, tools, construction equipment, test equipment, expendable items and services as necessary for the execution of all work required in connection with receipt and storage, inventory, specification, calibration, function and precommissioning checkout of (a) the complete instrumentation and (b) the 110 volt ac process monitoring and control systems and (c) the 24 VDC control systems.

RELATED DOCUMENTS

3.1 Engineering Articles

General Scope of Work for Construction Contracts

Electrical Work

Installation of Field Instrumentation

Pressure Testing of Process Piping and Equipment

DEFINITION OF TERMS

4.1 Complete instrumentation system: The system of instruments which includes every item on the instrument specification summary.
4.2 Ancillary Items: Included, but not listed separately, are all related ancillary items (for example, block, bleed, drain, and manifold valves). Also, regulators, catchpots, positioners, solenoid valves, charts, pens, ink, miniature dial indicators, lubricators, signal conditioners, thermowells, and such other ancillary items which form an integral part of the completed installation.
4.3 Process monitoring and control systems: All distributed control systems and related devices, items of electrical equipment and devices that extend from the secondary side of the
110 volt ac control voltage transformers or power distribution panels which pertain to the monitoring, indication, and/or control of the permissive starts, shutdowns, interlock, power measurement, and alarms circuitry for the entire main process and utility process systems.
4.4 Related ancillary items: Items such as relays, timers, circuit breakers, power supplies, switches, lamps, alarm units, and other items that will form part of the completed installation.

GENERAL

5.1 Training

5.1.1 All personnel employed by the contractor shall be qualified by training and experience to capably perform the specific activities required to accomplish the work. Documentary evidence of such training and experience is required.

5.2 Equipment

5.2.1 The contractor shall maintain to new equipment specifications all tools and test equipment.

5.2.2 The contractor shall make available sufficient quantities of hand tools to ensure timely performance and completion of the required work.

5.3 Work Shop Facilities

5.3.1 The contractor shall on request make provision for a fully equipped shop/trailer with sufficient work area, workbench space, and an air header manifold. A clean and orderly work environment shall be maintained.

5.4 Test Equipment

5.4.1 Test equipment will be provided by Air Products unless additional test equipment is requested by the field services supervisor.
5.4.2 Other than for purposes of recertification, repair, or replacement, no test equipment shall be moved from the job site for the duration of the contract.
5.4.3 All calibration test equipment supplied by the contractor shall be certified for accuracy by an independent testing laboratory before use.
5.4.4 Each item of calibration test equipment supplied by the contractor shall exhibit a permanently fixed validation label indicating the serial number, name of certifier, and the date and duration of certification. Copies of relevant test certificates will be kept on file by Air Products field services supervisor and equipment verified before use.
5.4.5 Equipment that shall be considered calibration test equipment shall comprise, but not be limited to, the following: Hart Communicators, “Ralston” type hand pump, precision test gauges, VOMs, portable potentiometers, deadweight tester (pneumatic only), manometers, constant temperature generator, thermocouple calibrator, RTD calibrator, transmitter simulators, pneumatic calibrators, signal generator and counter, portable oscilloscope, leak detection unit, and instrument manufacturer’s specially designed portable test sets.

5.5 Schedule

5.5.1 All work shall be conducted and completed on an area-by-area basis in accordance with the latest construction schedules (which may be subject to change). Authority for initiating all schedule changes rests with the Air Products representative.

5.6 Technical Liaison

5.6.1 The contractor shall provide any technical liaison requirements with other contractors, Air Products engineering departments, and the coordination of any warranty work and/or site visits through local supplier representatives and their factories. No agreement which will result in additional cost to Air Products shall be entered into without written authorization from the Air Products representative.

5.7 Temporary Air and Electrical Test Supplies

5.7.1 The construction superintendent shall provide temporary air and any temporary electrical power connections from the 110 volt ac site service boards for required test equipment or field testing.

5.8 As-built Information

5.8.1 All drawings and information relating to design changes or field changes shall be systematically recorded and reported on the appropriate documents at the time they occur. The contractor shall also be required to retain copies of such information for final presentation at the conclusion of the contract.
5.8.2 The compilation and correlation of all documentation necessary for the quality assurance and as-built records shall be a condition for acceptance of the completed works and release of the contract retention. Copies of transmittals (not the documentation) shall accompany the last invoice for payment.

5.9 Administrative Responsibility

5.9.1 Administrative responsibility for all procedures relating to contract dealings, schedules, progress, and payments shall rest with the Air Products representative.

5.10 Technical Responsibility

5.10.1 Technical responsibility for all procedures relating to methods, design, quality control, and documentation rests with the supervisor of Air Products Field Instrumentation.

5.11 Storage Facilities

5.11.1 When requested the contractor shall make provision for a segregated, secure, environmentally enclosed conditioned area of sufficient size for interim storage of loose shipped items for the duration of this contract.

INSTRUMENT INSPECTION

6.1 Daily Log

6.1.1 The contractor shall maintain a log of each item checked against the appropriate tag on the instrument summary checklist. On a daily basis, the contractor shall compile a listing of shortages which are affecting or will affect the scheduled progress of the work for the Air Products representative.

6.2 Specification Check

6.2.1 All items as defined under paragraphs 4.2 and 5.4.1 shall be inspected for general condition and conformance to the relevant Air Products and/or the manufacturer’s specifications. The following factors as applicable of each item shall be checked and recorded.

Tag number
General condition
Type/model
Size
Materials used
Accessories
Pressure rating
Voltage rating
Current rating
Temperature rating
Special features
Correct action
Correct range
Correct scale
Oxygen clean requirements
Weatherproof
Explosion proofing

6.2.2 All results shall be recorded on the appropriate calibration forms and handed to the Air Products representative on a daily basis.

CALIBRATION

7.1 The methodology and standards employed for equipment calibration shall conform to this specification and the manufacturer’s instructions and recommended practices.

7.2 Extent of Work

7.2.1 With the exception of safety valves, the scope of calibration and any adjustments found necessary extends to all calibratable items (whether shipped loose or preinstalled) and as otherwise defined.

7.3 Special Features

7.3.1 All items shall be checked for any special features as required by the relevant instrument specification and/or other Air Products or supplier data.
7.3.2 The following factors as applicable for each item shall be checked and recorded.

Split range
Elevated zero
Suppressed zero
Anti-reset windup
Remote set point
Pulse train output
External reset
Reverse action

7.4 Failure Modes

7.4.1 The contractor shall check and record the following failure modes as appropriate against the requirements of the flow sheet, relevant schematic drawings, and instrument specifications:

T/couple burnout Fail open
Close – air failure Fail close
Open – air failure Fail – last position
Fail – energized Fail – de-energized

7.5 Deviations

7.5.1 Calibrations shall only be performed with the use of certified test equipment. Nonstandard modifications or adjustments shall not be made without written approval from the Air Products representative.

7.6 Safety Valves

7.6.1 Safety valves will have been pretested and certified at the supplier’s works. No further job site calibration checks are required. All valves should, however, be checked for conformance to the specification.

7.7 Control Valves/Pressure Testing

7.7.1 See provisions in 4WPI-EW44001 for the reassembly and testing of control valves and associated ancillaries dismantled for shipment. The contractor shall also be responsible for providing support during the pressure testing phase, for example, certain “fail close” valves will be required to be opened; some “fail open” valves will be required to be closed.
7.7.2 In certain instances, pressure test conditions which exceed the design bench sets and spring tensions and/or diaphragm loading pressures will require temporary compensatory adjustments. All such valves shall be readjusted to conform to the design specification at the conclusion of the pressure test.

7.8 Analyzers

7.8.1 Analyzer calibrations and adjustments shall only be performed by persons holding certified training certificates from the manufacturer issued within the past two years from the appropriate manufacturers. Where these are not available, the contractor shall require that the supplier service representatives complete this work. Calibrations shall only be performed on fully completed systems.
7.8.2 All test gases required for analyzer calibrations will be supplied by Air Products.
7.8.3 Also included in the scope of items to be calibrated by the contractor are related ancillary items such as calibration test gas sample systems, instrument air supply(s), sample vent systems and other items that will form part of the completed installation.

7.9 Certification

7.9.1 Calibration reports as provided by Air Products shall be diligently completed in duplicate as work proceeds. One copy shall be provided to the Air Products representative and the other copy retained for the contractor site file. Calibration reports shall be subject to routine inspections for accuracy and content by the Air Products supervisor of field instrumentation or assignee.

PRECOMMISSIONING (LOOP CHECKS)

8.1 The contractor shall conduct all tests required and as otherwise necessary to provide a complete, operable, and trouble-free system.

8.1.1 The work shall comprise the following:
- Flow sheet verification
- Installation completion checkout
- Calibrated and functional loop checks
- Alarm, shutdown, and demonstration check
- Test certification and as-built records
8.1.2 Punchlists for defective installations shall be developed on an area-by-area basis and provided to the Air Products representative as work proceeds.

8.2 Flow Sheet Verification

8.2.1 Following “hand over” of a completed work area to the contractor by the Air Products representative, the contractor shall (by reference to the flow sheet) check each and every in- line device and process connection covered by the scope of work for conformity to the flow sheet and relevant drawings and specifications.
8.2.2 Items will include block, bleed, and drain valves, thermowells, orifice plates, safety valves, rotameters, sight glasses, pressure taps, flow taps, level taps, sample taps, control valves, and local temperature indicators.
8.2.3 Instrument items and connections shall be checked for:
- Tag number
- Orientation
- Completeness
- Maintenance access
- Type/model number
- Location
- Workmanship
- Damage
8.2.4 All defects and deficiencies shall be reported to the Air Products representative.
8.2.5 The contractor shall systematically record all satisfactory checks on the instrument specification summary checklist and highlight that portion of a master copy of the flow sheet. The flow sheet shall be carefully and diligently updated as work proceeds and shall be available for periodic inspection as required.

8.3 Installation Completion Checkout

8.3.1 The contractor shall conduct a final inspection of the completed instrument installation and that part of the electrical control installation which is required to complete all work.
8.3.2 The completed installation shall be checked in accordance with the requirements of 4ACE-600001, 4WCE-600001, 4AEL-620300, 4APS-630290 and such other contract installation drawings and data as applicable. Defects shall be reported to the Air Products construction superintendent as work proceeds.
8.3.4 The contractor shall verify the physical integrity of the completed systems. Particular attention shall be given to the following:

- Location
- Orientation
- Condition
- Mounting
- Labeling
- Painting
- Weatherproofing
- Winterization
- Heat tracing
- Materials used
- Process parameters
- Air supplies
- Impulse lines
- Sample lines
- Signal lines
- Oxygen cleaning
- Wiring terminations

8.4 Calibrated and Functional Loop Checks

8.4.1 The loop check or precommissioning shall be construed as all work necessary to provide a fully completed, energized and operable system.
8.4.2 The contractor shall be fully cognizant that this work is on the critical path of the project and that proper manning levels will be required throughout.
8.4.3 The contractor shall conduct loop checks consisting of, but not limited, to all of the following:

- Temperature indicating loops
- Pneumatic control, indicating, and recording loops
- Electronic control, indicating, and recording loops
- Computer interface equipment and loops
- Alarm circuits
- Shutdown and interlock circuits
- Ac and dc instrument and control power supply systems
- Analyzer systems
- Isolated grounding systems
- DCS system power and grounding
- DCS control, interlock, and shutdown loops

8.5 Alarm and Shutdown Verification

8.5.1 The calibration and final switch setting of any field-mounted alarm and shutdown device shall only be undertaken after its installation and connections have been finalized.
8.5.2 The contractor shall include provision for a duplicate checkout to demonstrate to the Air Products representative the satisfactory calibration and energized operation of all shutdown and alarm devices and associated circuitry.
8.5.3 The contractor shall list all switches on the alarm and shutdown summary sheet and obtain a signature from the Air Products representative for each item handed over as work proceeds.
8.5.4 All primary control, transmitting/indicating, signal conditioning, and recording elements shall be given a final three-point-calibration check as part of full loop simulation.
8.5.5 The contractor shall check all items and loops to a state of operational readiness in regard to all the following:
- Air supply pressure
- Continuity
- Insulation resistance
- Polarity
- Supply voltages
- Loop simulation
- Manual operation
- Automatic operation
- Alarm function
- Interlock/trip function
8.5.6 All checks shall be performed in accordance with this specification, the manufacturer’s recommended practices, and the instrument commissioning checklists (Appendixes A through AA).

8.6 Test Certification and As-built Records

8.6.1 A calibration and loop check acceptance certificate will be completed and issued by the contractor for each item on an area-by-area basis. The contractor shall include provision for an Air Products witnessed demonstration of up to 5% of a random selection of loops previously certified by the contractor.
8.6.2 The issuance of an area loop test certificate shall be construed to mean that all loops listed thereon are fully operable.

Appendix A

Control Valve Commissioning Checklist

Switch Valves, TSA, and PSA Valves Commissioning Checklist

Pressure Transmitter Commissioning Checklist

Temperature Transmitter (Filled System) Commissioning Checklist

Differential Pressure Transmitter Commissioning Checklist

Displacement Level Instrument Commissioning Checklist

Multipoint Recorder Commissioning Checklist
Orifice Plate/Flow Nozzle Commissioning Checklist

Analyzers Commissioning Checklist

Machine Controls Commissioning Checklist & Instrumentation

Vibration Monitors Proximity/Inertia Commissioning Checklist

Surge Control System Commissioning Checklist