PAGE
1 of 21
CONSTRUCTION PROCEDURE FOR
CALIBRATION WORKS
3X330 MW POWER PLANT PROJECT
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 2 of 21 01
INDRAMAYU- WEST JAVA.
DOCUMENT NO : P-T3109-EI-016
ORIGINATED BY REVIEWED BY APPROVED BY DISTRIBUTION
- SDCC : Original
- CNEEC : Copy
- All Dept. : Copy
Sigit I. M. Arifin Iman P. Agus S.
ISSUED EFFECTIVE
REV. NO BRIEF OF REVISION
DATE DATE
01 27/03/09 27/03/09
- Page 5~14 of 21 with sign :
- Approval of HIERAC attachment by HSE Truba
TABLE OF CONTENT
NO DESCRIPTION PAGES
1 TITLE 3
2 SCOPE 3
3 OBJECTIVE 3
4 REFERENCE 3
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 3 of 21 01
5 RESPONSIBILITY 3
6 WORK PROCEDURE 4
6.1 GENERAL 4
6.2 RISK ANALYSIS 4
6.3 PREPARATION OF WORKS 4
6.4 MATERIAL 5
6.5 CALIBRATION – GENERAL NOTES 5
6.6 CALIBRATION PROCEDURES 6
6.6.1 PRESSURE INSTRUMENT 6
6.6.2 TEMPERATURE INSTRUMENT 10
6.6.3 LEVEL INSTRUMENT 13
6.6.4 FLOW INSTRUMENT 17
6.6.5 CONTROL VALVE 18
6.6.6 SAFETY VALVE 19
6.6.7 SHUTDOWN VALVE 19
Attachment HSE Aspects Identification, Risk Assessment
21
and Risk Control
1. TITLE
Procedure for Calibration Works
2. SCOPE
This procedure is to describe the minimum requirements for Calibration
Works which is of prime importance for the personnel safety and system
availability.
3. OBJECTIVE
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 4 of 21 01
This is to assure that the requirements of Calibration works are meets the
codes requirements and contract specifications. To make sure, the works
are carried out in acceptable workmanship and follow the requirements in
the quality manual.
4. REFERENCE
4.1 Project Quality Plan/ PQP (Q-T3109-119)
4.2 Contract Document (CT3109-703)
4.3 Construction Drawing (F744S-K-index)
4.4 P-HSE-001- Management and Implementation of HSEMS
4.5 W-HSE-001- Project HSE Management System Plan
5. RESPONSIBILITY
5.1 The Instrument Engineer at site shall be responsible for the planning
scheduling and coordination, record and monitor progress of
calibration works. To guide the supervisors in the field in terms of
engineering and technical problems.
5.2 The Instrument Superintendent shall be responsible for the daily
construction activities to coordinate with Area Supervisors and
support The Supervisors in terms of technical matters.
5.3 The Instrument Supervisors shall be responsible to the respective
superintendents and carry out the direct field activities through the
skilled and unskilled workers according to the installation procedures
and drawings and applicable procedures for calibration works.
6. WORK PROCEDURE
6.1 GENERAL
1. The calibration works shall be executed according to the relevant
drawings and documents specified in paragraph 4.0.
2. The work shall be done according to good workmanship and by
using the suitable tools and material as stated in the construction
drawings, approve documents, and procedures and it shall be
studied before carry out any instrument works.
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 5 of 21 01
3. Field Engineers will ensure that they are in possession of the
following documents, prior to the commencement of the works:
4. Safety and Sanitation.
Full care and pre-caution shall be given by the field management
for the safety and sanitation of workman in the field to prevent
accidents during execution of the works.
6.2 RISK ANALYSIS
6.2.1 Check equipment condition before calibration
6.2.2 Check calibration tools and accessories condition like no
leakage voltage
6.2.3 Check calibration room condition should free from dust, rust
and dirt with temperature kept on 25 degC.
6.2.4 Please see attachment for HSE Aspects, Identification, Risk
Assessment and Risk Control.
6.2.5 Perform house keeping after job completion.
6.3 PREPARATION OF WORK
Prior to commencement of Calibration work, Instrument Engineer will
ensure the correct drawings are available to the field force. Instrument
Engineer will, after consultation with the Certification Documents,
establish any special requirements which may need to be fulfilled
during calibration works. He will ensure the Construction Department
are fully aware of these needs.
6.4 MATERIAL
Each items of equipment to be calibrated shall be Inspected to check
that it's data agrees with the Specification.
6.5 CALIBRATION – GENERAL NOTES
6.5.1 Any adjustments for instruments shall be in accordance with
the manufacturer’s instruction
6.5.2 Visual check shall be performed on all instruments, before
starting the procedure, to ensure that they are not damaged or
correctly assembled.
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 6 of 21 01
6.5.3 Each instrument name plate shall check with the latest version
of individual specifications to confirm correct tagging, range,
accessories, function, etc.
6.5.4 All support and stuffing for shipping shall be removed the
instruments before starting the procedure.
6.5.5 Sufficient warm up period to be taken for electronic instruments
before conducting the functional test
6.5.6 Upon completion of the work shop test, all connections and
entries shall be sealed to prevent subsequent ingress of
moisture and dirt.
6.5.7 If hydraulic pressure test is performed, inside of the instrument
shall be blown up using instrument air after completion of the
work shop test.
6.5.8 Tag mark after calibrated (including tag no., required range,
calibration person, date)
6.5.9 Equipment List & I/O list should be checked for range, function,
etc.
6.5.10 Pay attention to the storage requirement (air conditioned,
separation between before and after calibrated, identification
label, dust & tidy, etc)
6.5.11 The test equipment having the standard accuracy shall be
better than the instrument which to be tested. The test
equipment shall be calibrated every 6 months or yearly, and
the calibration record shall be kept.
6.5.12 In general, instrument workshop test/ calibration shall be
witnessed by owner. Contractor shall notice for the request of
witness in advance. Should any of the test not be witnessed.
Contractor can proceed the test by themselves under the
confirmation of owner’s acceptance
6.6 CALIBRATION PROCEDURE
6.6.1 PRESSURE INSTRUMENT
6.6.1.1 Pressure Indicators
List of testing instruments required:
a) Dead weight tester
b) Standard Test Gauge
Procedure :
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 7 of 21 01
Typical test set-up :
a) Zero adjust the mechanical zero adjusting screw
b) Apply calibrating pressure equal to upper range of the
pressure indicator and adjust as necessary so that the
indicated pressure is equal to that of the standard test gauge
+/- 1% of the FSV
c) Apply calibrating pressure equal to 0, 25%,50 %,
75%,and 100% of the pressure indicator range and observe
the indicated pressure equal to that of the standard test gauge
+/- 1% of the FSV
c) Repeat step (b) to (c) until the specified error is obtained
d) Calibration report will be provided by Truba-QC with
approval from CNEEC
6.6.1.2 Pressure Transmitter
List of testing instruments required:
a) Digital pneumatic calibration or digital pressure standard
with digital manometer.
b) Digital multi meter.
c) Dead weight tester.
d) Portable hand Pump (for low range).
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 8 of 21 01
e) Constant current source
Procedure :
Typical test set-up :
a) Check pressure range of the pressure transmitter form
specification.
b) Make zero and span adjustments as per designer’s
requirement.
c) Apply 0, 25%,50 %, 75%,and 100% of the full span of
the transmitter. Observe corresponding outputs shall be 4, 8,
12, 16 and 20 mA respectively.
d) Repeat calibration 2 times up and down after
adjustments. Accuracy at all points should be within
manufacturer's specified accuracy.
e) Calibration report will be provided by Truba-QC with
approval from CNEEC
6.6.1.3 Differential Pressure Transmitter
List of testing instruments required :
a) Digital pneumatic calibrator or digital pressure standard
with digital manometer.
b) Digital multi meter.
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 9 of 21 01
c) Deadweight tester.
d) Portable hand Pump.
e) Constant current source.
Procedure :
Typical test set-up :
a) check differential pressure range of the DP cell from
specification.
b) Make zero and span adjustments as per designer’s
requirement.
c) Apply 0, 25%,50%,75% and 100% differential to the HP
site, while the LP side of the below is to the vented to
atmosphere. Observe corresponding outputs. For electronic
transmitters output shall be 4, 8, 12, 16 and 20 mA
respectively.
d) Repeat calibration 2 times up and down after all
adjustments. Accuracy at all points should be within
manufacturer’s specified accuracy.
e) For D/P cells with manifold valve apply air-nitrogen
pressure equal to 100o% of the delta P directly to the H/P side
with equalizing valve closed. Lock-in the applied pressure.
Observe any fall of pressure which is indicative of leakage in
the equalizing valve.
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 10 of 21 01
f) Calibration report will be provided by Truba-QC with
approval from CNEEC
6.6.1.4 Pressure Switches
List of instruments required:
a) Deadweight tester.
b) Precision pressure standard gauge( optional).
c) Digital pressure standard and hand pump ( alternative).
Procedure :
Typical test set up :
a) Check pressure setting of switch from the Specification.
b) Apply pressure to the desired pressure by dead weight
tester or portable pneumatic calibrator.
c) Check the contact operation with multi meter. Open to
close or vice versa.
d) lf switch action is not correct, adjust to operate at the
desired point then sealing the adjust point
e) Raise or lower the pressure to check differential of
operation.
f) Calibration report will be provided by Truba-QC with
approval from CNEEC
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 11 of 21 01
6.6.2 TEMPERATURE INSTRUMENT
6.6.2.1 Temperature RTD Type
List of testing instruments required:
a) Batch Temperature Calibrator
b) Resistance Digital Meter
Procedure :
Typical test set-up :
a) Insert the RTD to the temperature Batch
b) Increase the temperature as operating range for 0,
25%,50 %, 75%,and 100% of the temperature RTD range.
c) Observe the indicated temperature equal to that of the
standard +/- 0.15% of the FSV
d) Calibration report will be provided by Truba-QC with
approval from CNEEC
6.6.2.2 Temperature TC- Type
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 12 of 21 01
List of testing instruments required:
a) Batch Temperature Calibrator
b) mV Digital Meter
Procedure :
Typical test set-up :
a) Insert the TC to the temperature Batch
b) Increase the temperature as operating range for 0,
25%,50 %, 75%,and 100% of the temperature TC range.
c) Observe the indicated temperature equal to that of the
standard +/- 0.4% of the FSV
d) Calibration report will be provided by Truba-QC with
approval from CNEEC
6.6.2.3 Temperature Switches
This calibration procedure covers filled system type
temperature switch.
List of instruments required:
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 13 of 21 01
a) Temperature Calibrator.
b) Multi meter.
c) Digital thermometer.
d) Hand tools.
Procedure :
Typical test set up :
a) Check temperature setting of switch from the
Specification.
b) Raise the temperature of the Temperature Calibrator to
the desire temperature with the bulb fully insert done it.
c) Adjust the switch to operate at the desire point. Check
the contact operation with multi meter. Open to close or vice
versa, then sealing the adjust point.
d) Raise or lower the temperature to check differential of
operation.
e) Calibration report will be provided by Truba-QC with
approval from CNEEC
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 14 of 21 01
6.6.3 LEVEL INSTRUMENT
6.6.3.1 Displacement Type Level Transmitter
This calibration procedure covers all displacement type level
transmitter and level switches.
List of testing instruments required:
a) Wallace & Tiernan.
b) Digital multimeter.
c) Tubing set up as required.
d) Constant current source.
Procedure :
Typical test set up :
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 15 of 21 01
a) Check calibration procedure with water (Sp Gr = 1.0)
per vendor's instruction manual.
b) Put air supply and admit water into the chamber.
c) Make zero and span adjustment as required to keep the
output within specified limit of accuracy.
d) Check transmitter output at 0, 25%,50 %,75% and
100% water level corresponding to the full range. Measure
water level in the transparent polyethylene tube.
e) In case of controller, check alignment of controller as
per manufacturer's instruction.
f) Repeat calibration once up and down after adjustment
water level can be decreased by draining water slowly through
the drain.
g) In case of levels switch make Sp Gr correction of water
and calculated desired level of operation with water.
h) Check operation of the switch contact at the operating
level with multi meter.
i) Check deferential of operation by increasing or
decreasing water level as required.
j) Calibration report will be provided by Truba-QC with
approval from CNEEC
6.6.3.2 Magnetic Float Type Level Instrument
Typical Loop :
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
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a) Provide testing equipment and prepare above testing
loop
b) Stand level instruments in a vertical, upright position
c) Obtain the required simulating level by connect water
supply to the bottom of level instrument. Calculate the
actual level refer to water with Sp Gr 1.0 if the process
were not water
d) Open water supply valve slowly and close drain valve,
apply simulating level of approximately full range.
Record water height reading on the clear plastic tubing
e) Close supply valve and open drain valve slowly until
output indication on digital multimeter is 4mA and on
indicator is zero. Record water height reading.
f) Apply simulating level as steps d) and e) to
approximately 0, 25, 50, 75, 100 % of the instrument
range or span in both increase and decrease direction.
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 17 of 21 01
Record corresponding output signal indicated by
Multimeter
g) Repeat simulating level as steps e) thru f). Relevant
adjustments shall be made (if any) until the specified
error is obtained.
h) Calibration report will be provided by Truba-QC with
approval from CNEEC
6.6.3.3 Level Switch Float Type
Typical Loop :
a) Level switches shall be tested using the same operating
methods as the one fro the transmitter on the same
procedure. However, ohmmeter or buzzer shall carry
out output measurements in order to check a contact
moving points.
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 18 of 21 01
b) Set a switch to the setting point given on the data sheet
and ensure that it makes or brakes on increasing or
decreasing level required. Record the reading
c) The above steps a) and b) shall be repeated and
relevant adjustment shall be made until the overall
percentage error repeatability does not exceed a
specified value notified by manufacturer.
d) Calibration report will be provided by Truba-QC with
approval from CNEEC
6.6.4 FLOW INSTRUMENT
6.6.4.1 Flow Transmitter- DP Cell Type
Typical test set up :
a) Apply a calibration pressure equal to lower range of the
transmitter and adjust zero for 4mA output
b) Apply a calibrating pressure equal to upper range of
transmitter and adjust span for 20mA output
c) Return to step a) and check for 4mA output. Repeat steps
a) and b) until 4~20 mA output is achieved without having
to adjust the zero span
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 19 of 21 01
d) Apply a calibrating pressure equal to 50% of FSV and
check for linierity. If error exist, refer to manufacturer’s
instruction for linierity adjustment
e) Repeat a) to d) as required
f) Calibration report will be provided by Truba-QC with
approval from CNEEC
6.6.5 Control valves
List of testing instruments required.
a) Digital pneumatic calibrator or digital pressure standard
with digital manometer.
b) Digital multi meter
c) Hand tools.
d) Air filter regulator.
e) Constant current source.
f) Wallace& Tiernan.
Procedure :
a) Check positioner and l/P converter operating pressure
and unsure correct supply.
b) Check valve action( A.F.O o r A.F C) from Specification.
c) Apply 0, 25%,50%,75% and 100% of input control signal
and observe corresponding valve travel.
d) Check valve action on air failure by reducing positioner
supply pressure to zero.
e) Calibration report will be provided by Truba-QC with
approval from CNEEC
6.6.6 Safety valve
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 20 of 21 01
Procedure :
a) Check pressure of safety valve from Specification.
b) Apply pressure to the desired pressure by throttling
valve in N2 cylinder. For gas system installation. Hydraulic fluid
for liquid system installation.
c) Observe safety valve popping action.
d) Raise or lower the nitrogen pressure to check
differential of operation.
e) Do not attempt o remove" Manufacturer Seal".
f) Calibration report will be provided by Truba-QC with
approval from CNEEC
6.6.7 Shutdown Valves
This calibration procedure covers all remote operated on/off
valves for shutdown blow down, vent or any other purposes.
a) Check valve action( air to open or close) from
Specification or flow diagram.
b) Check operation of solenoid and/or pilot valve.
c) Stroke the valve by operating the solenoid/pilot, which
controls air to the actuator. Check and adjust valve stoke
stopper and position indicator to proper position, if not already
present by Manufacturer prior to valve entering service.
d) Repeat operation for close position of valve and adjust
close limit switch.
e) Time the operation for close position of valve, record
open and close time. Adjust f low restricted if necessary.
DOCUMENT NO. :
P-T3109-EI-016
CONSTRUCTION PROCEDURE FOR ISSUED DATE :
CALIBRATION WORKS 27-03-2009
UNIT ISSUING : APPROVED BY : PAGE REVISION
E & I Dept Site Manager 21 of 21 01
f) Calibration report will be provided by Truba-QC with
approval from CNEEC
