PROCEDURE ELECTRICAL

& INSTRUMENT DEPARTEMENT

CALIBRATION PROCEDURE

PT. ASUKA ENGINEERING INDONESIA

PT. INTI KARYA PERSADA TEHNIK

CALIBRATION PROCEDURE
 PROCEDURE ELECTRICAL
& INSTRUMENT DEPARTEMENT

CALIBRATION PROCEDURE
1 Purpose
The purpose of this document is to describe the calibration process and required tools, drawing, material
inprovision Field Instrument at IKPT, this procedure shall be applied calibration
and ensure that each instrument is functionally correct and correctly calibrated

2 Scope Of Work
The scope of work shall be covered all calibration level switch, pressure switch, flow meter
temp switch, transmitter, etc

3 Responsibilities
3.1 Instrument Leader
Ensure relevant permits are raised and received prior to commencement of work with full
compliance by all instrument foreman, technician, and labour regarding excutions of work
in accordance with the IKPT project requirments and specification. Confirm the anailability
of the material, tools, equipment personnel who will carry out work

3.2 Instrument Engineers

Provide technical support to the instrument group, provide, latest revision of drawing
procedure, material specfications, standart and technical specifications

3.3 Safety
ensure that personal comply with all safety rulles and requipments in the conduts of all
instrument equipment installation activities performed in the project

4 Technical requirement
4,1 Tools calibration
a_ Digital multi-meter
b. DC standard voltage and current generator
c. Standard resistance box and thermocouple
d. Hand Held Communicator for Smart Transmitters and Smart
e. Hand pum
f. Pressure gauge / digital pressure gauge
g. Precision air regulator
h. Compressor / Nitrogen with air pressure
i. Connector, Tubing of various sizes
j. Others, if any

4,2 Instrument to be Calibrated

a. Control Valve
b. On / Off Valve
c. pressure switch
d. Pressure Transmitter
e. Differential pressure transmitter
f. Temperature Transmitter (TC and RTD)
g. Mass Flow Meter
h. Level Transmitter
i. Pressure Gauge
j. Temperature Gauge
k. Others, if any
 PROCEDURE ELECTRICAL
& INSTRUMENT DEPARTEMENT

CALIBRATION PROCEDURE

5 CALIBRATION, DIAGNOSTIC AND VISUAL CHECK PROCEDUR

Basically, calibration shall be witnessed by Owner. Contractor shall notify for the request of
witness in advance. Should any of the tests not be witnessed, Contractor can precede the test by
themselves under the confirmation of Owner's acceptance.
5,1 Control valve
5.1.1 Where specified on the Vendor's specification sheet, confirm that the material
conform to spesification,size or rating, connection type, data plate or tag plate, cable
or wiring in place and no mechanical damage.
5.1.2 Where the valve has FP positioner or E/P positioner (smart) , input the simulated
signal to the UP positioner using the "DC Standard Current Generator" or Hand held
communicator, respectively.
5.1.3 Where a valve positioner is mounted on the control valve, the stroke test shall he
performed with the positioner fitted at storage area. In this case, the supply air to be
connected to the air filter regulator mounted on the valve.
5.1.4 Before starting the stroke test, leakage test for actuator and fittings to be performed by
applying snoop from swagelok.
5.1.5 Increase the air signal pressure to load the actuator, and check the plug stem strokes at
full closing ( or full opening ) 25% opening, 50% opening, 75% opening and full
opening (or full closing) using the travel indicator mounted on the valve. Then,
decrease the air signal and check the plug stem strokes at full opening (or full
closing), 75% opening, 50% opening, 25% opening and full closing (or full opening).
Where necessary, adjust the spring tension or a positioner to obtain the correct "start
point" and "range". In case of limit switch, solenoid valve and/or booster relay are
mounted on the valve, check the action of them together with the stroke test.
5.1.6 The air failure action shall be confirmed by disconnecting either the loss of supply air
or signal function test of lock-up valve shall be performed together with this test.
5.1.7 The stroke time between full closing and full opening to be checked and confirm
which meet the specified time in the data sheets.( Note : Stroke time was specified
only which have process requirements) record stroke time.
5.1.8 Seat leakage test will not be performed unless the valve is dismantled for repair by
sheat damage.

5,2 On / Off valve ( Shut off Valve )

5.2.1 Where specified on the Vendor's specification sheet, confirm that the material
conform to spesification.size or rating, connection type, data plate or tag plate, cable
or wiring in place and no mechanical damage.
5.2.2 Connect air supply to the actuator via filter-regulator mounted on the valve,
5.2.3 Supply electric power to the solenoid valve.
5.2.4 Connect a circuit tester to the output terminals of the limit switch. if limit switch is specified
5.2.5 Before starting the stroke test, leakage test for actuator and fittings to be performed by
applying shoap solution from swagelok.
5.2.6 Check the valve action by means of making or breaking of power supply to the
solenoid valve. Also check the action of the limit switch, if applicable.
5.2.7 Check the valve action on air failure, if specified in the specification
5.2.8 Check the stroke time between full closing and full opening and confirm which meet
the specified time in the specification.
have process requirements). Record stroke time.
5.2.9 Seat leakage test will not he performed unless the valve is dismantled for repair by
seat damage.
 PROCEDURE ELECTRICAL
& INSTRUMENT DEPARTEMENT

CALIBRATION PROCEDURE

5,3 Pressure switch

5.3.1 Obtain the required actuating pressure by means of the dead weight tester, a variable
air supply or a hand-operated air pump.
5.3.2 Connect a circuit tester to the output terminals.
5.3.3 Where using an air supply or a hand-operated air pump, the actuating pressure shall
be connected to the instrument's process connection via a tee piece. One leg of the tee
connected to the actuating pressure shall have block valve and vent valve. The other
leg of the tee shall be connected to a precision pressure gauge.
5.3.4 With opening the block valve and the closing the vent valve, apply an actuating
pressure of approximately full range. Close block valve and check system for leaks.
When no fall-off pressure is observed, i.e. no leaks then proceed as follows.
5.3.5 Increase the actuating pressure up to the setting pressure ( for high or high high
alarm/trip) or the resetting pressure (for low or low-low alarm/trip). and record the
reaction of the switch at the setting/resetting pressures using the circuit tester.
Decrease actuating pressure down to the resetting pressure (for high or high-high
alarm/trip) or setting pressures
reaction or the switch at the resetting/setting pressures.
5.3.6 Where necessary, step (5) shall be repeated, and appropriate adjustment shall be made
until the required set/reset points are obtained considering the individual headband.

5,4 Pressure Transmitter

5.4.1 Obtain the required actuating pressure by means of the dead weight tester, a variable
air supply or a hand-operated air pump.
5.4.2 Connect a circuit tester to the output terminals.Connect hand held communicator to
input terminal if smart transmitter.
5.4.3 Reading in circuit/ multi tester should be 4,0 mA or in hand held communicator 0
pressure. Otherwise you can zeroing via adjustment screw, in hand held
communicator just zero trim or lower trim.
5.4.4 Where using an air supply or a hand-operated air pump, the actuating pressure shall
be connected to the instrument's process connection via a tee piece. One leg of the tee
connected to the actuating pressure shall have block valve and vent valve. The other
leg of the tee shall be connected to a precision pressure gauge.
5.4.5 With opening the block valve and the closing the vent valve, apply an actuating
pressure of approximately full range. Close block valve and check system for leaks.
When no fall-off pressure is observed, i.e. no leaks then proceed as follows.
5.4.6 Increase the actuating pressure up to the upper range pressure. Reading in circuit/
multi tester should be 20,0 mA or in hand held communicator upper range pressure.
Otherwise you can adjust via adjustment screw, in hand held communicator just upper
trim.
5.4.7 Where necessary, step (5) shall be repeated, and appropriate adjustment shall be made
until the required.

5.5 Diffrential Pressure Transmitter

Calibration step is equal to the pressure transmitter only in high pressure connection

5,6 Temperature Transmitter

All transmitters shall be checked Tag / Range / standart diagnostic to inject 24 VDC
for communication by Hand Held Communicator. Ambient temperature shall be
confirmed for the integrated type temperature transmitter.

5,7 Mas flow meter

The following instruments are also In-situ calibration by vendor's standard procedure.
Visual check and diagnostic shall be performed to confirm no damage before installation.
 PROCEDURE ELECTRICAL
& INSTRUMENT DEPARTEMENT

CALIBRATION PROCEDURE

5,8 Level Transmitter

See step 5.3 calibration step is equal to the pressure transmitter only in high
pressureconnection ( Dp type).

5,9 Pressure Gauge

Visual check to confirm no damage, right tag number and range.

5,10 Temperature Gauge

Visual check to confirm no damage, right tag number, range and show ambient temp

General Note
a. Any adjustment for instrument shall be done in accordance with the manufacturer's
intructions, if necessary.

b. Visual check shall be performed on all instruments, before starting the procedure, to
ensure that they are not damaged or incorrectly assembled.

c. Each instrument nameplate shall be checked with the latest version of individual project
specifications and/or Vendor's specifications to confirm correct tagging.
d. All support and stuffing for shipping shall be removed from the instruments before starting the procedure

6 HSE Task Analisys and Johan

The HSE focused task analisys has identified the following risks / hazards associated with this work
and a set job hazard analysis ( johan ) forms will be prepared for each / hazard see johan doc

Safety precaution:
a. Make sure the PPE is use Correctly
b. Make sure all equipment before using it in good condition and has passed inspection.
c. Ensure all employees who work above the level attended training working at heigth.
d. Use acces up and down and work, with scaffolding that has been in the inspection.
e. Ensure full body harness is hung acces strong and above the head.
f. In the work place should be displayed safety sign.
g. Barricade the work place.
h. Fit to work for working at height location.

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