INSTRUMENT DOC. NO.

BPK-PROC-IC-002
PT. BAHARU PENTA PAGE 1 OF 13
TESTING
KENCANA REV. 0
PROCEDURE

DOC. TITLE : INSTRUMENT TESTING PROCEDURE

CLIENT : PT. GRESIK POWER INDONESIA

CONTRACTOR : PT. BAHARU PENTA KENCANA

PROJECT TITLE : SUPERHEATER PROJECT

LOCATION : GRESIK, JAWA TIMUR

NO DATE PAGE DESCRIPTION PREP'D CHK'D APP'D

0 February 11, 2010 ALL Issued for Bid
 Doc. No. BPK-PROC-IC-002
PT. BAHARU PENTA
INSTRUMENT TESTING PROCEDURE Page No. 2 of 13
KENCANA Date February 10, 2010

CONTENTS

Section Page

1. SCOPE............................................................................................................................................3
2. GENERAL.....................................................................................................................................3
3. DEFINITIONS...............................................................................................................................3
3.1 Instrument Receiving Inspection..................................................................................3
3.2 Field Shop Test.............................................................................................................3
3.3 Field Test......................................................................................................................3
3.4 Loop Test......................................................................................................................4
4. CLASSIFICATION OF INSTRUMENTS TO BE TESTED AND CALIBRATED....................4
5. TEST EQUIPMENT......................................................................................................................4
5.1 ELECTRIC/ELECTRONIC.........................................................................................5
5.2 PRESSURE..................................................................................................................6
5.3 TEMPERATURE.........................................................................................................6
5.4 OTHERS.......................................................................................................................6
6. INSTRUMENT RECEIVING INSPECTIONS.............................................................................6
7. FIELD SHOP TEST.......................................................................................................................7
8. INSTALLATION...........................................................................................................................7
8.1 Panels............................................................................................................................7
8.2 Measuring Instruments.................................................................................................7
8.3 Ducts and Racks...........................................................................................................7
9. INSTRUMENT PRESSURE LEAD PIPING................................................................................8
9.1 Outside Appearance......................................................................................................8
9.2 Pressure and airtight test...............................................................................................8
9.3 Pressure Test.................................................................................................................8
9.4 Air tightness test...........................................................................................................8
9.5 Pressure and Air tightness, simultaneous test...............................................................8
10. WIRING.........................................................................................................................................9
10.1 Outside appearance.......................................................................................................9
10.2 Continuity Test.............................................................................................................9
10.3 Insulation resistance test...............................................................................................9
10.4 Earth resistance test....................................................................................................10
11. FIELD TEST................................................................................................................................10
11.1 System Test................................................................................................................10
11.2 Conventional Analogue Instruments..........................................................................11
11.3 Distributed Control System (DCS) and Programmable Logic Controller (PLC).......11
12. LOOP TEST.................................................................................................................................11
13. APPENDIXES..............................................................................................................................12

642500738.doc
Page
 Doc. No. BPK-PROC-IC-002
PT. BAHARU PENTA
INSTRUMENT TESTING PROCEDURE Page No. 3 of 13
KENCANA Date February 10, 2010

1. SCOPE

This procedure covers the requirements for the acceptance of instruments,

calibration and loop testing before/after installation and prior to commissioning.
These testing will be performed for Steam Superheater Project, PT. Gresik
Power Indonesia.

2. GENERAL

This specification describes the procedures necessary to confirm that the

instrumentation systems function correctly prior to plant start-up.
The sequence of inspection/testing will be as follows:

(1) Visual inspection of instruments and equipments (instrument control

panels, Analyzer house, etc) for signs of physical defects or other
damage.
(2) Installation Test
(3) Instrument Pressure Tubing
(4) Wiring Test
(5) Calibration and testing of instruments and panels.
(6) Instrumentation loop function checks.
(7) Test reports shall be submitted for Paragraphs (2) and (3) of subsection
3.1 (Refer to appendix 2)

3. DEFINITIONS

3.1 Instrument Receiving Inspection

A visual inspection will be made of instruments for any physical on receipt from
the Supplier. This inspection will also include a check against procurement
specifications and relevant drawing details to ensure the instruments completely
meet the system requirements.

3.2 Field Shop Test

Instruments shall be functionally tested and/or calibrated in the field test shop
(bench tested) prior to installation them.

3.3 Field Test

(1) Field Test

Instruments shall be functionally tested and/or calibrated at the
designated field location and/or local panel(s).

(2) System Test

Instrument systems in the control room or satellite house shall be
functionally tested and/or calibrated at the panels, consoles and terminals

642500738.doc
Page
 Doc. No. BPK-PROC-IC-002
PT. BAHARU PENTA
INSTRUMENT TESTING PROCEDURE Page No. 4 of 13
KENCANA Date February 10, 2010

3.4 Loop Test

The final check shall be done to ensure that the instrumentation system function
is correct and satisfactory and is in a fit condition for handling over to Client.

4. CLASSIFICATION OF INSTRUMENTS TO BE TESTED AND

CALIBRATED

All inspection tests and calibrations will conform to the manufacturer’s

instructions. Assistance by the manufacturer’s representative will also be
required for special equipment.
The detailed items to be tested and calibrated are as shown in Appendix-1.
All instrumentation inspection test and calibrations will be witnessed by Client.
The completed reports shall be submitted by the Subcontractor and/or
manufacturer’s representative to Client.

5. TEST EQUIPMENT

The Subcontractor shall provide all test equipment (except Hand Held
communicator for smart transmitter) necessary to conduct the calibration and
loop tests. The test equipment shall be calibrated periodically by the
Test reports will be completed and retained by the Subcontractor for checking by
Client.
All instruments being for calibration will also have a calibration label attached
showing:

(1) Date of Calibration

(2) Signature of the person authorized to carry out the calibration.

A list of the calibration equipment required includes, but is not limited to the
following.

642500738.doc
Page
 Doc. No. BPK-PROC-IC-002
PT. BAHARU PENTA
INSTRUMENT TESTING PROCEDURE Page No. 5 of 13
KENCANA Date February 10, 2010

5.1 ELECTRIC/ELECTRONIC

Equipment Application Preferable Model,

Manufacturer, and
Specification (or
Equivalent)
(1) Digital Multi-meter  AC/DC voltage, DC current, and Model TR-68530,
resistance measurement YOKOGAWA or
 Ditto, hand use Equivalent
Model TR-6824,
YOKOGAWA

(2) DC standard voltage  Millivolt generator Model 2554,

YOKOGAWA accuracy
 Milliampere generator/ current +/-0.05% of setting
generator Model 2786-10.
YOKOGAWA

(3) Variable resistor  Standard resistance Model 2793-01.

YOKOGAWA Accuracy
+/-(0.01% At setting = 2
M ohm)

(4) Standard resistor  100 ohm Model 2792-06,

YOKOGAWA

(5) DC current meter  Milliampere measurement Model 2041,

YOKOGAWA Accuracy
+/-0.5% F.S.

(6) DC voltage meter  Millivolt measurement Model 2012,

YOKOGAWA Accuracy
+/-0.5% F.S.

(7) Potentiometer  Millivolt measurement Model 2727,

YOKOGAWA Accuracy
+/-0.5% F.S.

(8) Insulation tester  Insulation resistance check Model 3213 100 V /

20M250V / 50M 500V /
100M/ E33,
YOKOGAWA

(9) Multi-range A-V ohm  AC/DC voltage, DC current Model 3201,

meter resistance measurement YOKOGAWA

(10) Constant voltage  current power unit model 8414-63,

METRONIX

(11) Wheatstone bridge Model 2768,

YOKOGAWA

(12) Digital frequency counter Model TR-5115

YOKOGAWA

(14) Pulse generator Model PG-230 IWATSU,

50 MHz

642500738.doc
Page
 Doc. No. BPK-PROC-IC-002
PT. BAHARU PENTA
INSTRUMENT TESTING PROCEDURE Page No. 6 of 13
KENCANA Date February 10, 2010

5.2 PRESSURE

Equipment Name Application Preferable Model, Manufacturer,

and Specification (or Equivalent)
(1) Hydraulic Pump * Pressure generator (portable, Druck, Ametek,
manually operated)

(2) Hand-operated air pump * Low pressure generator (for Ametek, Druck
d/p low pressure instrument)

(3) Dead weight-tester * Pressure generator w/ Model PO. NAGANO KEIKI

Pressure range (portable type)
0-100 Kg/cm3g
0-200 Kg/cm2g

(4) Air filter regulator * Air pressure regulation set Fisher

(precision type)

(5) Digital manometer * W.C and/or pressure Model 2654, YOKOGAWA

measurement accuracy +/-0.2%

(6) Pressure gage * Up to 30 PSIG (2Kg/cm2) Model 2089, ASHCROFT Gage

measurement (for d/p and low accuracy +/- 0.15% F.S
pressure instrument)

(7) Pressure gage * Pressure measurement Model GP, ASHCROFT Gage

accuracy +/- 0.15% F.S.

5.3 TEMPERATURE

Dry Block Calibrator  Temperature Jofra-Ametek, Omega

measurement -00 - 1200 C

Thermometers  Glass thermometers

5.4 OTHERS
(1) Air compressor * Instrument air generator OIL- Model OLP-048, IWATA7.0
free, with mini-dryer And Kg/cm2g
filter
(2) Vacuum pump * For vacuum instrument Model VP-20, HITACHI,
760mmHg

6. INSTRUMENT RECEIVING INSPECTIONS

On arrival at jobsite, or as soon as is practicable, all instruments and equipment

shall be checked against the latest instrument lists or specification sheets to
confirm that the model number, options, accessories, etc, are correct. They shall

642500738.doc
Page
 Doc. No. BPK-PROC-IC-002
PT. BAHARU PENTA
INSTRUMENT TESTING PROCEDURE Page No. 7 of 13
KENCANA Date February 10, 2010

also be inspected for damaged or missing parts, incorrect assembly, etc, at the
warehouse, storage area or field test shop.

All orifice plates should be checked visually for:

(a) Smooth perfectly flat surface without scratching or bowing.

(b) A sharp non-reflecting edge on the upstream face where relevant, or a
radius on quadrant edge type orifices
(c) Correctly stamped identification and bore dimensions on face of tag
handle

Bore dimensions shall be measured and compared with stamped dimensions.

This inspection shall be done in the field test shop before installation. Orifice
plates should be installed after finishing the flushing of the process line.

7. FIELD SHOP TEST

The calibration of Smart Instrument shall be conducted in accordance with the

Vendor’s standard test procedure as a minimum.
The purpose of the tests is to check that data contained in the instruments is
correct and meets with the data sheet and specification.
The other instruments (non smart type) are to be tested according to appendix-3

8. INSTALLATION

8.1 Panels
 Installation shall be based on the details as shown in the drawings.
 Installed conditions on both horizontally and vertically.
 Outside appearance of the panels after the installation.

8.2 Measuring Instruments

 To ensure the installation position has already firmly synchronized
with its function, operation and maintenance
 Materials in accordance with the specifications.
 Angle in horizontal or vertical direction.
 Non-deficiency of any damage on installation appearance.

8.3 Ducts and Racks

 Structure and dimension as installed.

 Outside appearance of fixed sleeved portion in comparison with the
drawing.
 Absence of protrusion inside ducts and racks protrusion, if any, will
damage cable.
 Welding galvanized steel plate the worksite shall be in accordance
with the repair work requirements specified.
 Cover shall be firmly fixed

642500738.doc
Page
 Doc. No. BPK-PROC-IC-002
PT. BAHARU PENTA
INSTRUMENT TESTING PROCEDURE Page No. 8 of 13
KENCANA Date February 10, 2010

9. INSTRUMENT PRESSURE LEAD PIPING

9.1 Outside Appearance

Inspect the following items.
 Pipe structure in accordance to the drawing.
 Materials and dimensions thereof.
 Relative positions of pressure lead piping nozzle and measuring
instrument.
 Seal pots and condensed pots - whether in the horizontal position or in
the designated position.
 Inclination of pipes - whether installed in specified position.
 Connection between high pressure side and low pressure side of the
differential pressure gauge.

9.2 Pressure and airtight test.

 Two ways of inspection are provided:
 Airtight test shall be carried out after pressure test.
 Pressure test and airtight test are simultaneously carried out.
 As a rule, test shall be carried out by connecting pressure lead pipe to
measuring instrument.
 When the pressure exceeds the pressure allowed by the measuring
instrument, seat it as allowable by the measuring instrument.

Remark: This test can be carried out simultaneously with test for
corresponding equipment.

9.3 Pressure Test

 As a rule, test fluid shall be water. In case water has adverse effect on
pressure lead piping, light oil or gas shall be applied.
 Pressure to be applied
Fluid : 1.5 times of working pressure
Gas : 1.25 times of working pressure
 Pressure applied for test shall be released for five minutes.

9.4 Air tightness test

 Gas such as nitrogen or air shall be applied.
 Pressure shall be 1.0 time of the maximum working pressure.
 After the Air tightness test, check leakage on connected sections with
soap water with the pressure as it is.

9.5 Pressure and Air tightness, simultaneous test

 Gas such as nitrogen and air shall be applied for test.
 Test pressure shall be 1.25 times of the maximum working pressure.
 The Air tightness test pressure shall be kept for five minutes. Check
leakage on connecting sections with soap water.

Remark: In case gas is applied for test, care shall be taken not to
give pressure abruptly. Abrupt application of pressure
produces danger.

642500738.doc
Page
 Doc. No. BPK-PROC-IC-002
PT. BAHARU PENTA
INSTRUMENT TESTING PROCEDURE Page No. 9 of 13
KENCANA Date February 10, 2010

10. WIRING

10.1 Outside appearance

Confirm the followings;
 Piping system in accordance with drawing.
 Materials and dimensions there of.
 Connections to the measuring instruments.
 Wiring installation free from influence by the ambient temperature. Heat
insulating materials for equipment or process piping shall be avoided.
 Wiring installation free from thermal expansions of equipment or process
piping.
 Wiring installation free from influence from power wiring.
 Shielding structure in accordance with the specifications.
 Grounding in accordance with the specifications.

10.2 Continuity Test

Continuity test shall be carried out as follows:
 For testing purpose, apply low voltage instruments such as tester, buzzer
and telephones.
 Confirm continuity after disconnecting both terminals of wire and cable
from terminal board.
 Confirm identification of wiring and cabling in accordance with the
drawing.

10.3 Insulation resistance test

After the continuity test, carry out insulation resistance test.
 For testing purpose, Insulation Tester of over 100 V rating shall be
applied.
 Measure the insulation resistance of wires and cables that passed the
continuity test between cables and grounding in accordance with rating of
wires and cables after disconnecting terminals from the terminal board.
The tested value over the value as shown in the TABLE -1 would be
acceptable.

TABLE - 1

Insulation Resistance
Voltage in Electric Path
Value
In case voltage to ground is less than
150V (voltage between cable and
Under 300 V ground – grounding system voltage More than 0.1 Ohm
between cables – non grounding
system)
More than 0.2 M
In other cases
Ohm
More than 0.4 M
Over 300 V
Ohm

642500738.doc
Page
 Doc. No. BPK-PROC-IC-002
PT. BAHARU PENTA
INSTRUMENT TESTING PROCEDURE Page No. 10 of 13
KENCANA Date February 10, 2010

Note: This table is based on Japanese Electrical Facilities Technology

Standard. It is recommended that the insulation resistance values are
over 330 M Ohm in case of new construction work. If specially
designated, it shall be in accordance with the designation.

 After the test, earth wires and cables to release the electric potential.

10.4 Earth resistance test.

Test earth resistance with earthing resistance measures in the specified manner.
The value less than that specified in TABLE - 2 is acceptable. Less resistance
value is specified as in the case of intrinsically safe gas proof circuit.

TABLE 2

Classification by grounding Earthing resistance value

Grounding of equipment Less than 100 Ohm

Grounding of system Less than 10 Ohm

Shielded grounding Less than 10 Ohm

11. FIELD TEST

The calibration and test of the field instruments which cannot be conducted by
the field shop test shall be made at the designated field location after installation.
(Refer to appendix-3)

The functional checks on the following items will not be conducted prior to
commissioning. These will be checked after the process or standard sample
medium is introduced.

(1) Tachometer
(2) Process Analyzer Package
(3) Speed Indicators

11.1 System Test

This section applies to all instruments located in Control Rooms including

Distributed Control System (DCS), Programmable Logic Controllers (PLC), and
conventional instruments.

The testing and calibration of the aforementioned systems shall be carried out
before loop testing. It is intended that calibration should only be carried out if a
test reveals it is necessary. Before test and calibration, check that the designated

642500738.doc
Page
 Doc. No. BPK-PROC-IC-002
PT. BAHARU PENTA
INSTRUMENT TESTING PROCEDURE Page No. 11 of 13
KENCANA Date February 10, 2010

electrical power switch to a particular instrument is unique and correct to that

instrument. A Visual inspection shall be carried out on all of the instruments
prior to test and calibration.

11.2 Conventional Analogue Instruments

Prior to loop testing of the Instrumentation a complete check of the system will
be made including but not limited to continuity, insulation & calibration tests t
confirm that the internal and point to point wiring from the Control Room and
marshalling Cabinets to the field is correct.

(1) Indication Test

Indicators

 Apply a calibrated signal to drive the indicator/recorder to 0%, 50% and

100% of full range, observe and pen or pointer position corresponding to
each calibrated input both going up and down scale.
 Adjust linkage or appropriate mechanism if and as necessary to set span
correctly. Check the smoothness of the motor across the full range of the
recorder.
 Retain the graph print out for submission with the test report and ensure
the serial no. and any other relevant details are included with the chart
test record.

11.3 Distributed Control System (DCS) and Programmable Logic Controller

(PLC).

The tests for DCS and PLC shall be conducted in accordance with the vendor’s
standard test procedure to verify the completeness of total system function
including all equipment connected to data high way.
The test shall be conducted with the field wiring disconnected at the terminals in
the marshalling cabinets.
The test will be conducted mainly by the DCS, PLC Vendor’s supervisors with
the Subcontractor’s assistance.
Detailed Vendor’s standard test procedures will be submitted to Client for
review/approval prior to conducting any test.

12. LOOP TEST

(1) The loop and function checks shall be carried out with reference to
Appendix-3.
(2) Loop testing is the final check that the installed instrumentation system
functions correctly and satisfactorily. Upon completion of the loop testing the
instrumentation shall be made ready for commissioning. All calibration,
wherever carried out, and all aspects of field inspection and testing should be
satisfactorily completed before final loop tests are performed.

642500738.doc
Page
 Doc. No. BPK-PROC-IC-002
PT. BAHARU PENTA
INSTRUMENT TESTING PROCEDURE Page No. 12 of 13
KENCANA Date February 10, 2010

(3) Alarm and trip system monitor switches shall be set at the value unless
tested/calibrated during the system test. If incorporated in an instrument loop
they shall be checked by varying the actuating signals.
(4) During the course of the loop tests, the following verification or settings shall
be carried out to ensure that each instrument has been properly installed.

(a) Set up of instrument loops

Check that the designated air supply valve to a particular instrument is
unique to that instrument and set the pressure of its air regulator.
(b) Check and set the pressurizing or purging system.
(c) Carry out visual examination of in-line instruments, paying particular
attention to the direction of flow through the following :

- Orifice Plates, including Straight Pipe Runs

- Control Valves and Regulators
- Pressure taps of Differential Pressure Instruments
- Venturi
- Annubar Meter
- Corrosion Meter

13. APPENDIXES

The following appendixes shall form a part of this specification.

Appendix Title Refer to.

No.
1 Scope of Instrument Calibration Work Section 4
2 Instrumentation Test Report Subsection 2.2
3 Instrument Testing and Calibration Test Report Section 7.8 and 9

642500738.doc
Page
 Doc. No. BPK-PROC-IC-002
PT. BAHARU PENTA
INSTRUMENT TESTING PROCEDURE Page No. 13 of 13
KENCANA Date February 10, 2010

APPENDIX 1

Scope of Instrument Calibration Work

SCOPE OF WORK
VISUAL CALIBRATION INSTALLATION LOOP
NO INSTRUMENT TYPE CHECK TEST TEST CHECK
1 Pressure Transmitter Y Y Y Y
2 Level Transmitter Y Y Y Y
3 Flow Transmitter Y Y Y Y
4 Temperature Transmitter Y Y Y Y
5 O2 Analyzer Y Y Y Y
6 Speed Transmitter & Tachometer Y Y Y Y
7 Pressure Switch Y Y Y Y
8 Level Switch Y Y Y Y
9 Temperature Switch Y Y Y Y
10 Pressure Gauge Y Y Y N
11 Solenoid Valve Y N Y Y
12 Vibration Switch Y N Y Y

642500738.doc
Page