ENGINEERING GUIDE

ECA / EUSA

EG 15-14-1.1
Page 1 of 3 Rev. 0 June 1999

Inspection and Testing of Instruments

(This practice is appropriate for attachment to Inquiry or Purchase Document)

SCOPE
I I 1.1 1.2 This guide covers inspection and testing of instruments at the Owner's plant. An asterisk () indicates that a decision by the Owner is required, additional information is to be furnished by the Owner, information for approval is to be supplied by vendor, or approval by Owner is required.

SUMMARY OF ADDITIONAL REQUIREMENTS

I 2.1 Table 1 lists the documents that shall be used with this guide. TABLE 1
PRACTICES IP 3-6-1 IP 3-9-1 IP 3-19-1 EG 15-6-1.1 IP 15-10-1 EG 15-14-1.2 IP 18-12-1 Piping for Instruments Winterizing and Protection Against Ambient Temperatures Piping Erection, Testing, Flushing, and Cleaning Instrumentation, Field Installation Instrument Transmission Systems Instrument Calibration Positive Materials Identification

INSPECTION AND TESTING

R R R 3.1 3.2 3.3 Testing and checking of instrumentation and alarms should be conducted prior to unit startup. All components of the instrument systems shall be inspected for proper mounting, tagging, and installation as specified by EG 15-6-1.1. Inspection shall be made to ensure that control valves, orifice plates, flow nozzles, turbine meters, and other in-line devices are removed from the line before process piping is flushed and are reinstalled after flushing (see IP 3-19-1). The following items shall be inspected to ensure they are free from paint or other coatings after the unit has been painted: a. Vents b. c. d. e. O R R 3.5 3.6 3.7 Breathers Drains Glass Nameplates

3.4

f. Moving parts, such as valve stems and shafts Instruments shall be calibrated in accordance with EG 15-14-1.2. Alloy pressure-containing instrument housings and valves in alloy piping systems shall be identified as required in IP 18-12-1. Thermowells shall be inspected periodically for corrosion, erosion, connection integrity, and type of material. Thermowells in pipes up to 6 or 8 in. can generally be inspected by radiography. Longer thermowells and thermowells in vessels shall be inspected during downtimes.

EQUIPMENT CHECKOUT
I 4.1 Equipment checkout shall be done in accordance with the procedures listed below and any deficiencies corrected.

CONTROL VALVES R O 4.2 4.3 Control valves shall be checked for their action on air failure. This check shall include the field observation of the position indicator when the air pressure on the diaphragm is zero psig. Control valves and valve positioners shall be checked for proper operation.

ECA / EUSA Regional Engineering Guide

EG 15-14-1.1
Page 2 of 3 Rev. 0 June 1999

ENGINEERING GUIDE Inspection and Testing of Instruments

(This practice is appropriate for attachment to Inquiry or Purchase Document)

ECA / EUSA

O R O

4.4 4.5 4.6

Control valves shall be checked to ensure that they are installed correctly with respect to process flow direction. Control valves that have bottom head flanges with a drain tap shall be checked to ensure that a bar stock pipe plug has been installed. Indicators associated with the control loop valves shall be checked to ensure that they are installed such that they are readable from the control valve by-pass.

FLOW METER INSTALLATIONS R O O R O O

4.7 4.8 4.9 4.10 4.11 4.12

An orifice meter inspection report shall be filled out for each orifice meter prior to installation of the orifice plate. Results shall be reported to the Owner's Engineer who will accept or reject the plate. Orifice plates shall be checked for proper installation with respect to process flow direction. Orifice flange taps shall be checked to be sure they are not plugged. Prior to installation of meter run, drillthrough holes in orifice fitting shall be checked for freedom from burrs and for smoothness. Orifice flanges shall be checked to ensure that flange plugs opposite the orifice taps have been made from bar stock and have been seal-welded. Meter leads are to be checked to see that the upstream orifice tap is connected to the high side of the meter and the downstream orifice tap is connected to the low side of the meter. Flow meters, other than orifice meters, shall be inspected and tested in accordance with requirements provided by the Owner's Engineer.

LEVEL INSTRUMENTS O 4.13 Chamber-type displacer and ball float level instruments are to be shop checked for correct response by using water. Final field calibration must be done using the process fluid. Note that closed piping systems are required for calibration when the process fluid is a low-flash or toxic material. Level instruments, other than displacer-type and ball floats, shall be inspected and tested in accordance with requirements provided by the Owner's Engineer.

4.14

ALARMS R R 4.15 4.16 Alarm switches and trips shall be set according to the requirements of the instrument schedules or specifications. Alarms associated with major pieces of equipment (gas turbines, compressors, etc.) shall be set according to manufacturer's instructions. The trip points shall be documented and submitted to the Owner's Engineer.

AIR SUPPLY PIPING O R R 4.17 4.18 4.19 Air supply piping shall be checked to ensure that individual instruments and/or control valves can be removed from service without shutting off air to additional instruments and/or control valves. Instrument air headers shall not be left open to atmosphere during construction. All gate valves shall be closed and open ends capped to preclude entry of foreign material and rain to prevent internal corrosion. During commissioning of the instrument air distribution system, but before instrument devices are connected, all headers shall be blown down in sequence starting at the source. Flushing of instrument air headers and lines with any liquid is not permitted.

TEMPERATURE INSTRUMENTS O O 4.20 4.21 Each pair of thermocouple wires and their shields shall be checked for proper type, identification, continuity, grounding, and polarity. Identification shall be in accordance with IP 15-10-1. Temperature instruments shall be checked to ensure they have proper action upon thermocouple burnout.

RECORDERS, INDICATORS, AND CONTROLLERS O O O 4.22 4.23 4.24 Instruments shall be checked for proper scale and/or chart range. Chart drive mechanism shall be checked for proper operation. All auxiliary hardware, such as power supplies, slave transmission systems, etc., shall be checked for proper operation.

ECA / EUSA Regional Engineering Guide

ENGINEERING GUIDE
ECA / EUSA

EG 15-14-1.1
Page 3 of 3 Rev. 0 June 1999

Inspection and Testing of Instruments

(This practice is appropriate for attachment to Inquiry or Purchase Document)

INSTRUMENT LOOPS O 4.25 The operability of each loop shall be functionally checked to the fullest extent possible prior to unit start-up. All loops shall be checked completely through to the control system to confirm units, range, control action and alarms. The following initial settings shall be put into the controllers. The proportional and reset modes of control shall be set at mid-range, and the derivative mode shall be set at the wide-open position (no derivative). Control loops shall be checked for correct action by stroking control valves from the controller in both automatic and manual modes. A complete functional check of all alarms and protective systems shall be made.

O O R

4.26 4.27 4.28

PROGRAMMABLE CONTROLLERS / MICROCOMPUTER SYSTEMS O

4.29

Instrument systems employing Programmable Devices shall be tested to Owner's Engineer's testing specification prior to field start-up.

MISCELLANEOUS O R M

4.30 4.31 4.32

Contractor shall put proper sealing fluid in all meters that require sealing. Owner's Engineer will specify the proper sealing fluid. Instruments shall be inspected to ensure winterizing is in accordance with IP 3-9-1. Contractor shall check to make sure instruments may be removed from service without damaging heat tracing. Each instrument shall be inspected to ensure that it is accessible for maintenance in accordance with IP 3-6-1.

PIPING AND WIRING TESTS

PIPING TESTS O O O O 5.1 5.2 5.3 5.4 Instruments shall be disconnected during pressure testing of process piping and vessels. Pressure testing of instrument lead lines shall be in accordance with IP 3-19-1. All instrument equipment items shall be disconnected from the instrument air supply piping system prior to testing the instrument air supply piping system. Instrument air supply piping and pneumatic transmission system tubing shall be tested in accordance with IP 3-19-1. Leak testing of instrument piping connections shall be made prior to installation of heat tracing and insulation.

WIRING TEST O 5.5 All instrument electrical wiring shall be tested in accordance with IP 15-10-1.

6/99

Revision Memo Revision 0 - Original Issue of Engineering Guide

Exxon Chemical Americas, Exxon Company, USA, 1999

ECA / EUSA Regional Engineering Guide