Instrument Field Engineering: Prepared By: M.P.ALAM

INSTRUMENT FIELD ENGINEERING
Prepared By: M.P.ALAM

TITLE TABLE OF CONTENTS PAGE 1 OF 98
FIELD ENGINEERING HANDBOOK
1 GENERAL
1.1 Purpose
1.2 Scope
1.3 Responsibility
1.4 Reference
1.5 Testing Equipment
2 FIELD SUPERVISION
2.1 Instrument Calibration
2.2 Field Revision Work
2.3 Material Control
2.4 Vendor Supervision
3 INSTALLATION CHECK
3.1 Field Installation Check
3.2 Punchlist Preparation
3.3 Installation Check Sheet and Pre-installation Calibration Sheet
4 TESTING AND FUNCTION CHECK PROCEDURE

4.1 General
4.2 Instrumentation Pressure Test
4.3 Safety/Relief Valves
4.4 Instrument Loop Check
4.5 Testing and Function Check Sheet
5 TROUBLE SHOOTING
5.1 Control Valve
5.2 Field transmitter
□ CONTROLLED CONTROL NO.

□ UNCONTROLLED REGISTERED DATE 200 . . .
PREPARED REVIEWED REVIEWED REVIEWED APPROVAL
GROUP
SIGNATURE
DATE 200 . . . 200 . . . 200 . . . 200 . . . 200 . . .
TITLE 1. GENERAL PAGE 2 OF 98
1.1 PURPOSE
The purpose of this Field Engineering Handbook is to establish the basic requirements for the controlling,
field inspection and testing of instrument work in job site during construction.
1.2 SCOPE
This handbook is for instrument field engineer to ensure that instrumentation work (consistiong of material
storage, calibration, installation, testing and all appropriate records) is completed in accordance with
the requirements of the applicable codes, specifications and drawings.
1.3 RESPONSIBILITY
1.3.1 Responsibility for field instrumentation work shall be drawing issue for field revision work,
arrangement of supervision work for the specific items, and installation check.
1.3.2 The site supervisor shall be assigned to monitor instrument construction activities and witness tests
thereof to ensure compliance to specifications and drawings.
1.3.3 Quality control shall be advised on all engineering phases of the work by the assigned instrument
engineer and/or instrument supervisor.
1.3.4 As required and requested by the material control department, quality control shall assist in
the receiving inspection of instrumentation material and also monitor storage conditions to
ensure compliance to all requirement pertaining thereto.
1.3.5 Instrument engineer shall provide technical direction and guidance in all matters relative to
interpretation of codes, specifications, drawing and special procedure.
1.3.6. Instrument engineer shall establish procedures and modify existing one pertaining to calibration,
bench testing and final testing to ensure compliance with reference spec.
1.4 REFERENCES
· ANSI - American National Standards Institute.
· API - American Petroleum Institute.
· ISA - Instrument Society of America
· Applied Instrumentation in the Process Industries, Volume I, II and III
W.G. Andrew, Gulf Publishing Company.
· Instrument Engineers'Handbook, Volume I, II and III
B.G. Liptak, Chilton Book Company.
TITLE 1. GENERAL PAGE 3 OF 98
1.5 TESTING EQUIPMENT

The list of testing equipments shall be submitted to the engineer.
The testing equipments shall have a standard of accuracy better than the manufacturer's stated accuracy
for the instrument to be tested.
The following test equipments are normally required ;
1.5.1 Protable DC Voltage/Ampere Standard.

1.5.2 DC V/A Standard
1.5.3 Process Instrument Calibrator.
1.5.4 Portable DC Potentiometer.
1.5.5 Digital Manometers.
1.5.6 Pneumatic Pressure Standard.
1.5.7 Precision Pneumatic Calibrator.
1.5.8 Adjustable Pressurizer.
1.5.9 Pneumatic Test Kit.
1.5.10 Portable Dead Weight Tester.
1.5.11 Hydrostatic Pressure Pump.
1.5.12 Standard Pressure Gauge.
1.5.13 Temperature Testing Bath.
1.5.14 Digital Thermometer.
1.5.15 Glass Thermometer.
1.5.16 Decade Resistance Box.
1.5.17 Vibration Calibrator.
1.5.18 Portable Standard DC V/A Meter.
1.5.19 Digital Multimeter.
1.5.20 Electronic Circuit Tester.
1.5.21 Digital Pulse/Frequency Counter.
1.5.22 Sweep Generator (Sine, Triangle and Pulse Wave).
1.5.23 Portable Telephone
1.5.24 Walkie-Talkie Radio
TITLE 2.1 INSTRUMENT CALIBRATION PAGE 4 OF 98
- CONTENTS -
2.1.1 General
2.1.2 Differential Pressure Type

(1) Element Inspection
(2) Differential Pressure Indicator (PdI)
(3) PdIS and PdS
(4) Differential Pressure Transmitter
2.1.3 Turbine Meter Type

(1) Turbine Meter Inspection
(2) Transmitter / Indicator
2.1.4 Pressure Transmitter
2.1.5 Vacuum Transmittter
2.1.6 Pressure Switch
2.1.7 Displacement Type Level Transmitter

(1) Normal Level
(2) Interface Level
2.1.8 Air Purge Type Level Transmitter (Bubbler Type)
2.1.9 Level Switch
2.1.10 Bulb Type Temperature Transmitter
2.1.11 Temperature Switch
2.1.12 Thermocouple Type Temperature Transmitter

(MV/EMF to voltage/Current/Air Converter)
2.1.13 Resistance Temperature Detector Type Temperature Transmitter

(Resistance to voltage/current/Air Converter)
2.1.14 Vibration Monitor (Proximity Type)

(1) Proximitor Tuning Check
(2) Monitor Calibration
(3) Probe Installation
(4) Axial Displacement monitor
(5) Axial Probe Installation
2.1.15 Speedometer (Pick-up Coil Type)
2.1.16 Converter
(1) Current to Air Converter
(2) Air to Current Converter
(3) Voltage to Current Converter
(4) Current to Voltage/Current Converter
(5) Pulse Rate to Voltage/Current Converter
(6) Voltage/Current to Pulse Rate Converter (Integrator)
2.1.17 Computing/Signal Conditioning Relay

(1) General Procedure
(2) Multiplier/Divider
(3) Adder/Subtracter
(4) Scaler/Biaser
(5) Signal Selector
(6) Signal Isolator
(7) Signal Characterizer (Function Generator)
(8) Signal Limiter
(9) Square Root Extracter
(10) Signal Reverser
(11) Alarm Switching Module
2.1.18 Controller
(1) Input (Process Variable) Calibration
(2) Set Point Calibration (Alignment) - Manual Set
(3) Remote set (Cascade Control)
(4) Output Meter and Manual Output Control Unit
(5) Control Action Check
(6) Gap Action (on-off Control)
(7) Special Function Check/Calibration
2.1.19 Manual Station

2.1.20 Ratio Station
2.1.21 Recorder/Indicator
2.1.22 Control Valve

(1) Diaphragm Actuator
(2) Other Type Actuator
(3) Positioner (Stroke Check)
(4) Supply Failure Action
2.1.23 Motion Transmitter
2.1.24 Analyzer and Miscellaneous Instrument

2.1.1 General
(1) The purpose of instrument calibration procedure is ensure that each instrument has been
supplied in accordance with specifications, is functionally correct and is in working order.
(2) The calibrations shall be performed in accordance with this procedure and any adjustments
being made shall be in accordance with the engineering data sheet.
(3) All shipping stops shall be miscellaneous components such as charts, mercury and oil
shall be in accordance with the engineering data sheet.
(4) No tests shall be carried out on electronic instrument until an adequate warm-up
period has elapsed.
(5) The approval of the instrument engineer shall be obtained in writing before any
non-standard modification or adjustments made.
(6) Upon completion, Pre-installation Calibration Sheet shall be completed with signatures
and distributed as indicated on the sheet.
(7) The calibrated instrument shall be identified with appropriate identification tag.
(8) Visual inspection shall be made prior to any calibration/adjustment process and the results are
to be recorded on each Pre-installation Calibration Sheet to ensure the identification,
physical condition and accord with specification. Any off-spec. item must be reported to
instrument engineer for resolution.
(9) The acceptable error limit to each instrument depend on process requirement and
instrument's accuracy which stated by manufacturer.
If the above condition is not specified, the following table of expected error limits of
commercially available instruments may be utilized as a guide.
Expected Error Limits of Commercially Available Instruments

Flow :
Measuring Elements Total Error Measuring Elements Total Error
Concentric orifice ±½-1 % Magnetic resonance ±½ %
Segmental orifice ±2½ % Parshall flume ±2-3 %
Eccentric orifice ±2 % V-notch weir ±2-4 %
Quadrant edged orifice ±1 % Trapezoidal weir ±4 %
Integral wedge ±3 % Hot wire (anemometer) ±2 %
Segmental wedge ±1 % Thermal (displaced T/C's) ±½-1 %
Elbow taps ±5-10 % Target (disc) ±½ %
Vortex shedding body ±½ % Target (with strain elements) ±½-3 %
Swirl body ±¾-1 % Material accelerator (dry solids) ±½ %
Pitot tube ±½-1½ % Nutating disc meter ±1-2 %
Pitot venturi ±½-5 % Oscillating piston meter ±¼-½ %
Venturi tube ±¼-3 % Lobed rotor meter ±¼ %
Dall tube ±1 % Encased turbine meter ±3 %
Flow nozzle ±1-1½ % Reciprocating piston meter ±1 %
Turbine tube ±¼-½ % Rotating gear meter ±½ %
Propeller ±2 % Reciprocating piston pump ±1 %
Rotameter ±½-2 % Diaphragm pump ±1 %
Rotameter ((Purge)
g ) ±5-10 % Peristalic ppumpp ((roller)) ±1 %
Magnetic ±½-1 %
Level :
Gauge glass ±.02 inch Conductivity probe ±½ %
Bubbler ±1 % Nuclear ±1-2 %
Differential pressure ±½-2 % Manometer ±1 %
Displacer ±1-3 % Capacitance (continuous) ±1 %
Float and tap ±1-2 % Capacitance (switch) ±2-3 %
Float and pointer ±1 % Diaphragm switch within diaphragm
Diaphragm transmitter ±¼-2 % diameter
Ultrasonic ±3 % Vibrating probe or paddle ±.25 inch
Cable and drum ±.2 inch Rotating paddle within paddle
RF probe ±1½ % diameter
Pressure :
Bourdon ±.1-2 % Piezoelectric ±1 %
Bellows transmitter ±½ % Dead weight ±.01-.1 %
Bellows/indicator ±2 % Manometer ±.02-1 %
Diaphragm ±½-1¼ % McLeod Gauge (vacuum) ±1 %
Strain gauge ±.1-2 % Thermal transfer (vacuum) ±10-20 %
Variable impedance ±¼-½ %
Capacitance ±.1-2 %
Temperature :
Glass thermometers ±¼-½ % Manual optical pyrometer ±½-1 %
Thermocouples ±¼-5 % Radiation pyrometer ±½-1 %
Resistance detectors ±.2-.5 % Infrared pyrometer ±½-2 %
Thermistors ±½ % Color pencils, paint, etc. ±1 %
Filled systems ±½-1 % Acoustic thermometer ±2 %
Bimetallic ±½-2 % Quartz crystal ±.05 %
Weight :
Mechanical Lever ±.1-.5 % Spring Balance ±.1-.5 %
Load Cells ±.1-.5 %
Analyzers:
Device Total Error Device Total Error
Viscosity
Ultrasonic ±2 % Gas chromatograph ±½-1 %
Vibrating reed ±1 % Infrared ±1 %
1-float ±4 % pH ±.005-.05 pH units
2-float ±2-4 % Moisture ±2-5 %
Combustion ±2 % Conductivity ±½-3 %
Refractometer ±.006-.01 % Specific gravity
Oxygen ±3 % Mechanical weighing ±1 %
Dissolved oxygen ±1-5 % Vibrating tube or paddle ±1 %
Sulfur dioxide ±5 % Sonic ±.01 %
Total hydrocarbon ±2-10 % Density
Total organic carbon ±2-10 % Vibrating tube ±1 %
Carbon Dioxide ±½ % Radiation ±1 %
Chlorine ±5 % Turbidity ±2-5 %
Sodium ±5 %
No2, No±No2 ±10 %
Miscellaneous :
Device Total Error Device Total Error
Converters Velocimeter ±.01-½ %
Current-current ±½-1 % Vibration ±5 %
Current-pneumatic ±¼-½ % Torque transmeters ±½-1 %
Pneumatic-current ±¼-½ % Accelerometer (strain gauge type) ±¼-1 %
Resistance-current ±½ % Electronic indicator ±1-3 %
Voltage-current ±½ % (D'Arsonval type)
Voltage-Pneumatic ±½ % Electronic indicator ±.01-.5 %
ORP transmitters ±¼-½ % (digital readout)
Speed transmitters ±½ %
2.1.2 Differential Pressure Type

(1) Element Inspection
(1.1) Check identification.
(1.1.1) Check indentification.
(1.1.2) Check specification.
(1.1.3) Check Dimensions as follows ;

a. Outside diameter
b. Thickness
c. Edge type
d. Vent hold and drain hole
e. Surface finish
f. Tongue condition
g. Inside diameters with 120˚ rotation
Fig. 2. 1. 2-1 Orifice Plates
(1.2) Flow Nozzle

(1.2.1) Check identification.

a. Outside diameter
b. Thickness
c. Nozzle type
d. Inside diameters with 120˚ rotation
Fig. 2. 1. 2-2 Flow Nozzle

(1.3) Venturi Tube
(1.3.1) Check identification.

a. Inside diameter of entrance
b. Overal length
c. Tap to tap distance
d. Inside diameters of middle section with 120˚ rotation
Fig. 2. 1. 2-3 Venturi Tube

(2) Differential Pressure Indicator (PdI)

Step 1 : Hook up testing equipments as per Fig. 2.1.2-4 below ;
Fig. 2. 1. 2-4 Differential Pressure Indicator

Step 2 : Vent low side.
Step 3 : When no pressure is applied to the high side, the indicator should indicates zero.
If not, reset zero adjusting screw until the indication read zero.
Step 4 : Increase input signal to full range (100%) as shown in the specification sheet.
The indication should read full scale (100%). If not, adjust span adjustment.
Step 5 : Recheck zero after span adjustment. Repeat until both are correct.
Step 6 : Check indication for 0,25,75 and 100% of range with signal rising and falling.
Every indication shall be within error limit. If not, adjust linearity adjustment and repeat
step 3 to 6 until every indication corresponds with input signal within acceptable error.
(3) Differential Pressure Indicating Switch (PdIS) and Differential pressure Switch (PdS)
Step 1 : Determine set point and action of switching.
Example : 5 PSID-High, 20PSID-Low etc.
Step 2 : For PdIS, calibrate indicating function as per 2.1.2 (2).
Fig. 2. 1. 2-5 PdIS or PdS


Step 5 : Check switching action with simulating input signal rising for high
differential pressure service and falling for low. Check dead band.
Step 6 : When error found, adjust set point adjustment and repeat until desired value obtained.
(4) Differential Pressure Transmitter

Step 1 : Hook up testing equipments as per Fig. 2.1.2-6 Below
Fig. 2. 1. 2-6 Diffferential Pressure Transmitter

Step 3 : When no pressure is applied to the high side, the transmitter output should be 0% of
output range. If it is not, adjust zero adjustment until the output indicates 0%
The transmitter output should be 100% of its range. If not, adjust span adjustment.
Step 6 : Check output for 0,25,75 and 100% of range with signal rising and falling.
Step 7 : Every output reading shall be within error limit. If not, adjust linearity adjustment and
repeat step 3 to 7 until every output reading corresponds with input signal within
acceptable error limit.
Step 8 : If the instrument equiped with high/low range limit mechanism, adjust it to meet
proper requirement.
2.1.3 Turbine Meter Type

(1) Turbine Meter Inspection.
(1.1) Check identification.
(1.2) Check specification.
(1.3) Check probe conditions as follows ;

a. Physical conditions.
b. Probe insulation.
c. Probe resistance.
(1.4) Check rotor assembly.

a. Shipping stop.
b. Mechanical condition.
(2) Transmitter / Indicator

Step 1 : Determine pulse rate from turbine meter manufacturer's data sheet.
Example : 16 pulse/ Gallon, 40 pulse/ litter, etc.
Step 2 : Calsurate pulse per second and pulse duration at 0,10,25,50,75 and 100% of flow which
indicated in instrument specification.
Example ; Full range of transmitter/indicator : 300 GPM.
Pulse rate : 16 pulse/gallon.
300 GPM ÷ 60 = 5 Gallon/Sec.
16 Pulse/Gallon x 5 Gallon/Sec = 80 Pulse/Sec.
1/80 = 0.0125 Sec. (Pulse duration)
%Flow Puse/Sec. Pulse duration

100% 80 Hz 0.01250 Sec
75% 60 Hz 0.01667 Sec
50% 40 Hz 0.02500 Sec
25% 20 Hz 0.05000 Sec
10% 8 Hz 0.12500 Sec
0% 0 Hz ∞
Fig. 2. 1. 3-1 F.T.for Turbine Flowmeter

Step 4 : If the transmitter equiped with temperature and/or pressure compensating function,
obtain corresponding formular and factors which are to be calibrated,
In this case hook up testing equipments as per Fig. 2.1.3-2 below ;
Fig. 2. 1. 3-2 Transmitter with Temperature/Pressure Compensation

Step 5 : When on pulse injected to input terminal, the output shall be 0% of output range,
and if the transmitter equiped with indicator and/or totalizer, the indicator shall indicate
zero and the totalizer shall not run. If not, adjust individual zero adjustment so that
proper output/indication obtained.
Step 6 : If the instrument equiped with temperature/pressure compensation function, check and
calibrate their measuring function independently.
Simulate temperature/pressure signal as a base condition.
Step 7 : Inject 100% of pulse signal to input terminal and check output/indication.
If any error is found, correct them with proper adjustment.
Step 8 : Recheck zero and repeat until both are correct.
Step 9 : Check output/indication for 10,25,50 and 75% of range with signal rising and falling.
Every output reading should be within error limit. If not, adjust linearity adjustment and
repeat step 5 to 9 until every reading corresponds with input signal within acceptable error limit.
Step 10 : If the instrument equiped with temperature compensating function, simulate temperature
change and check output/indication at 0,25,50,75 and 100% of flow.
If output/indication does not properly correspond with temperature change, adjust
compensation factors with proper adjustment until every output/indication corresponds
input pulse and temperature within acceptable error limit.
Step 11 : If the instrument equiped with pressure compensating function, simulate pressure
change and check output/indication 0,25,75 and 100% of flow and temperature.
If the output/indication do not properly correspond with pressure change, adjust
compensation factors with proper adjustment until the output/indication correspond input
pulse, temperature and pressure within acceptable error limit.
2.1.4 Pressure Transmitter

Fig. 2. 1. 4-1 Pressure Transmitter

Step 2 : When no pressure is applied to the instrument, the output of transmitter should be 0%
of its range. If it is not, adjust zero adjustment until the output indicates 0% of its range.
The transmitter output should be 100% of its range. If not, adjust span adjustment.
Step 5 : Check output for 0,25,75 and 100% of range with signal rising and falling.
Step 6 : Every output reading shall be within error limit. If not, adjust linearity adjustment and repeat
step 2 to 6 until every output reading correspond with input signal within acceptable error limit.
2.1.5 Vacuum Transmitter

Step 1 : Determine input and output range from the instrument specification/data sheet.
Step 2: Hook up testing equipments as per Fig. 2.1.5-1 below ;
Fig. 2. 1. 5-1 Signaling for Vacuum Transmitter

Step 3 : When 0% of input signal is applied to the instrument, the output of transmitter should be
0% of its range. If not, adjust zero adjustment unil the output indicate 0% of its range.
Step 4 : Increase input signal to 100% of its range and read output.
The output should be 100% of its range. If not, adjust span adjustment.
Step 5 : Recheck zero after span adjustment.

Repeat until both are correct.
Step 6 : Check output for 0,25,75 and 100%of range with signal rising and falling.
Step 7 : Every output reading shall be within error limit.

If not, adjust linearity adjustment and repeat step 3 to 7 until every output reading
correspond with input signal within acceptable error limit.
2.1.6 Pressure Switch

Step 1 : Determine set point and action of switching from the instrument Specification/data sheet.
Example : 25 PSIG (Low), 5 PSIG (High), etc.
Fig. 2. 1. 6-1 Pressure Switch

Step 3 : Check switching action with simulating input signal rising for high pressure service and
falling for low. Check dead band.
Step 4 : When error is found, adjust set point adjustment and repeat until desired value obtained.
2.1.7 Displacement type leel transmitter

(1) Normal Level
Step 1 : Determine the operating range and specific gravity of operating fluid from the instrument
specification/data sheet.
Step 2 : Support the transmitter on a test stand firmly and vertically.

Step 3 : Connect water (calibrating fluid) line and clear vinyl hose and other testing equipments
as per the Fig.2.1.7-1 below ;
Fig. 2. 1. 7-1 Displacement Type Level Transmitter

Step 4 : Calculate calibration range which converted into water (Calibrating liquid) level as follows ;
⊙ Spen = Operating Range x Specific Gravity of Operating Fluid
⊙ Zero = Reference level
Step 5 : Mark zero and span on the transmitter body and divide into four section evenly so that they
represent 0,25,50,75 and 100% of calibrating range.
Fig. 2. 1. 7-2 Normal Lvel

Step 6 : Inject water to the transmitter upto zero level and adjust zero adjustment until 0% of output obta
Step 7 : Inject water upto 100% of calibrating level and read the output.
The output should be 100% of its range. If not, adjust span adjustment.
Step 8 : Recheck zero after span adjustment and repeat step 6 to 8 until 0% of output obtained.
Step 9 : Check output for 0,25,75 and 100% of range with level rising and falling.
step 6 to 10 until every output corresponds with level signal within acceptable error limit.
(2) Insterface Level

Step 1 : Determine the operating range and specific gravity of operating fluids, upper and lower,
from the instrment specification/data sheet.
Step 2 : Perform the step 2 and 3 of normal level transmitter on chapter 2.1.7
Step 3 : Calculate calibration range which converted into water (Calibrating liquid) level as follows ;
⊙ Spen = Operating Range x (lower Fluid's S.G.-Upper Fluid's S.G.)
⊙ Zero = Reference level + Operating Range x Upper Fluid's S.G.
Where : S.G. = Specific Gravity
Step 4 : Mark zero and span on the transmitter body and divide into four section evenly so that they
represent 0,25,50,75 and 100% of calibrating range.
Fig. 2. 1. 7-3 Interface Level

Step 5 : Perform the step 6 through 10 of normal level transmitter on chapter 2.1.7(1).
2.1.8 Air Purge Type Level Transmitter (Bubbler Type)

Step 1 : Determine operating range and specific gravity of the process fluid from specification/data shee
Step 2 : Calculate pressure range using formula below ;

Pressure Range = Operating Range x Specific Gravity
Fig. 2. 1. 8-1 Air Purge Type Level Transmitter

Step 3 : Calibrate the level transmitter as a differntial pressure transmitter per the chapter 2.1.2(4).
NOTE : If the purging system occupy liquid for purging fluid, a special installation method shall be used
and a zero adjustment shall be performed with operating condition to eliminate error due to
pressure drop on the purging system piping.
2.1.9 Level Switch

Step 1 : Support the level switch on a test stand vertically.
Step 2 : Hook up testing equipment as per Fig. 2.1.9-1 follows ;

Fig. 2. 1. 9-1 Level Switch

Step 3 : Check switching action with ohm meter (multimeter) while simulating level condition.
Actual operating fluid is preferred for the testing fluid, if the fluid is not handy, similar
characteristic (specific gravity or conductivity) fluid, shall be used.
If both of fluids are not handy, sweet water can be used as a testing fluid.
In this case, great care shall be considered to prevent malfunction.
Step 4 : Mark switching level on level switch so that the mark can be used as a reference
during field installation.
2.1.10 Bulb Type Temperature Transmitter

Step 1 : Determine the temperature range and output range from specification/data sheet.
Step 2 : Hook up testing equipments as per Fig.2.1.10-1 below ;

Fig. 2. 1. 10-1 Temperature Transmitter

Step 3 : Record ambient temperature (Calibration room temp.)
Step 4 : Simulate temperature change and check output.

Every output shall be read with sufficient stabilizing time.
Step 5 : Compare output against input and adjust zero and span until both are correct.
Normally three point calibration is acceptable.
Step 6 : If ambient temperature effect is to be checked, change ambient temperature of the

instrument and check output change.
2.1.11 Temperature Switch

Step 1 : Determine set point and action of swiching from the instrument specification/data sheet.
Example : 40。F falling (Low), 90。C rising (High). etc.
Step 2 : Hook up testing equipments as per fig.2.1.11-1 follows ;

Fig. 2. 1. 11-1 Temperature Switch

Step 3 : Check switching action with simulating temperature rising for high temperature service
and falling for low. Check dead band.
Step 4 : When error found, adjust set point adjustment and repeat until desired value obtained.
2.1.12 Thermocouple Type Temperature Transmitter

(MV/EMF to Voltage/Current/Air Converter)
Step 1 : Determine mV value at 0,25,75 and 100% of temperature range from temperature
conversion table.
Fig. 2. 1. 12-1 Thermocouple Type Temperature Transmitter

Step 3 : If the transmitter equped with type and/or range changing jumpers or switches,
put them on proper position.
Step 4 : Measure ambient temperature and determine mV value from the conversion table.
(See Appendix 4.)
Step 5 : Calculate calibration value at each calibration point using the formula below ;
mVcal. = mVoper. - mVamb.
Where
mVcal. = millivolt value of calibration
mVoper. = millivolt value of operating temperature
mVamb. = millivolt value of ambient temperature
Step 6 : Simulate 0% of calibration signal and check output. The output should be 0% of its range.
If not, adjust zero adjustment until correct value obtained.
Step 7 : Simulate 100% of calibration signal and check output.

Adjust span adjustment when error found.
Step 8 : Recheck zero after span adjustment and repeat step 7 to 9 until both are correct.
Step 9 : Check output at 0,5,75 and 100% of input range with signal rising and falling.
Every output reading shall be within error limit. If not, adjust linearity adjustment and repeat
step 7 to 10 until every output reading correspond with input signal within acceptable error limit
Step 10 : If ambient temperature effect is to be checked, change ambient temperature of the

instrument and check output change.
Step 11 : If the instrument equiped with burn-out option, check this function by opening the input
terminal and check output changing. When improper burn-out action observed, correct it
by changing jump or switching in accordance with the manufacturer's instruction.
2.1.13 Resistance Temperature Detector Type Temperature Transmitter

( Resistance to Voltage/Current/Air Converter )
Step 1 : Determine R.T.D. (Resistance Temperature Detector) type and operating temperature
convertion table.
Step 2 : Determine Resistance value at 0,25,75 and 100% of input range from temperature conversion ta
(See Appendix 4.)
Fig. 2. 1. 13-1 R.T.D. Type Temperature Transmitter

Step 4 : Simulate 0% of input signal by adjusting decade resistnace box and chek output.
Adjust zero adjustment until 0% of output obtained.
Step 5 : Increase input signal upto 100% of its range and check output.
The output shall be 100% of its range. If not, adjust span adjustment.
Step 6 : Recheck zero after span adjustment and repeat until both are correct.
Step 7 : Check output for 0,25,75 and 100% of range with signal rising ad falling.
step 4 to 8 until every output reading corresponds with input signal within acceptable error limit.
2.1.14 Vibration Monitor (Proximity Type)
Fig. 2. 1. 14-1 System Configuration

(1) Proximiter Tuning Check
Step 1 : Check every instruments and accessories against its specification/data sheet.
Step 2 : Hook up testing equipnent as per Fig.2.1.14-2 below ;
Fig. 2. 1. 14-2 Proximiter Tuning Check

Step 3 : Install probe on spindle micrometer so that the scale indicates 0 (zero) when micrometer's head
plate and probe butt each other.
Step 4 : Adjust micrometer upto manufacturer's referance gap and tune proximiter so that the DC㎂
meter indicates maximum.
NOTE : Some of manufactuers calibrate the proximiter in their factory.In this case,
the proximiter shall not be adjusted.
Step 5 : Compare the maximum reading and the value specified by the manufacturer.
Both values should be same or reasonably close. If not, the proximiter shall be replaced.
Step 6 : Tune proximiter in accordance with manufacturer's instruction.

Example : - Indicon Company -
Adjust tuning screw with adjusting gap until maximum reading reach to 21㎂ on
D.C. ㎂ by adjusting tuning screw clockwise.
Then reduce the reading upto 20㎂ by adjusting tuning screw clockwise.
(2) Monitor Calibration

(2.1) Gap mode Calibration
Step 1 : Check and calibrate the monitoring indicator on monitor unit with suitable method.
Step 2 : Hook-up testing equipments as per the Fig.2.1.14-2, chapter 2.1.14(1).
Step 3 : Put monitoring indicator on gap mode by pressing push button or switching toggle switch.
Step 4 : Adjust gap by adjusting micrometer upto 10% of range and check monitor indication.
Adjust zero when error exist.
Step 5 : Adjust gap 90% of range and check monitor indication.

Adjust span when error exist and repeat step 4 and 5 until both are correct.
Step 6 : Check monitor indication at 10,25,50,75 and 90% of gap.

Every indication shall be within error limit. If not, check linearity in accordance with
manufacturer's manual.
(2.2) Vibration Mode Check

Fig. 2. 1. 14-3
Step 2 : Read maximum indication variance on dial gauge while turning WOBBLE PLATE
manually and adjust the PROBE HOLDER ARM so that the maximum indication reach to
calibration points such as 0,25,50,75 and 100% of vibration range.
Step 3 : At each calibration point, lock the PROBE HOLDER ARM and replace dial gauge with
probe as per the Fig.2.1.14-4 below ;
Fig. 2. 1. 14-4
Step 4 : Adjust the average gap upto reference value of the instrument while observing the
monitoring indicator and lock the probe.
Step 5 : Put the monitoring indicator on vibration mode and rotate WOBBLE PLATE by energizing
motor and read the vibration indication and output signal.
Step 6 : Perform step 2 to 5 on each individual calibration point.
Step 7 : Every indication and output reading should be within error limit.
If not, recheck proximiter and monitor unit and repeat until desird accuracy obtained.
(2.3) Special Note

(2.3.1) If the materal of testing equipment (Spindle plate and wobble plate) differ from
actual material which is to be measured, the special error compensation shall be
considered by one of the following methods.
⊙ Change testing spindle plate and wobble plate with same material to be measured.
⊙ Consider characteristic compensation by comparing material character
which normally presented by manufacturer of vibration monitoring system.
(2.3.2) If the instrument equiped with two point (X-Y) monitoring system, each measuring
circuit shall be checked and/or calibrated individually.
Fig. 2. 1. 14-5 2 Point(x-y) Vibration Monitoring System

(2.4) Alarm and Shutdown System Set-up
If the monitoring unit equiped with alarm and/or shutdown function, the set points
shall be calibrated as follow ;
Step 1 : Put monitoring indicator on alarm set point mode by pressing push button or switching toggle sw
Step 2 : Adjust alarm set point adjustment until the monitoring indicator indicates desired value.
Step 3 : Put monitoring indicator on shutdown set point mode.
Step 4 : Adjust alarm set point adjustment until the monitoring indicator indicates desird value.
Step 5 : Hook up testing equipments as per the Fig.2.1.14-4 in 2.1.14(2.2).
Step 6 : Adjust the average gap upto reference value and put monitoring indicator on vibration mode.
Step 7 : Rotate wobble plate by energizing motor and simulate vibration by adjusting probe holder
arm to activate the alarm and/or shutdown function.
Step 8 : Check activating value on monitoring indicator while increasing the vibration slowly with
observing alarm and/or shutdown outputs which normally include indicating lamps and contact
outputs. Special care shall be taken when the instrument ha a time delay function.
Step 9 : Check reset function by pressing the reset button, which normally provided on power supply un
and the external reset button which connected on external reset terminal.
(3) Probe Installation
Step 1 : The machine or measuring subject shall be mechanically stop condition and whole vibration
monitoring system shall be calibrated before probe installation.
Step 2 : Put monitoring indicator on gap mode.
Step 3 : Tighten every threaded parts of probe housing. (Refer Fig.2.1.14-6)
Fig. 2. 1. 14-6 Probe Installation

Step 4 : Insert probe into measuring point until the monitoring indicator indicate reference gap.
Step 5 : Lock the probe with lock nut.
Step 6 : Insulate connector with non-adhesive tape such as teflon tape.
(4) Axial Displacement monitor
Fig. 2. 1. 14-7 System Configuration

(4.1) Proximiter tuning check.

Execute proximiter tuning check procedure as per chapter 2.1.14 (1).
(4.2) Gap mode calibration

Execute gap mode calibration procedure as per chapter 2.1.14 (2.1).
(4.3) Alarm and shutdown system set up.

If the monitoring unit equiped with alarm and/or shut down function.
the set points for the alarm and/or the shutdown shall be calibrated as follows ;
Step 1 : Put monitoring indicator on positive alarm mode and adjust positive alarm set point until
the desired value indicated.
Step 2 : Adjust the set points of negative alarm, positive shutdown and negative shutdown with same wa
Step 3 : Hook up testing equipment as per the Fig.2.1.14-2 in chapter 2.1.14(1).
Step 4 : Adjust spindle micrometer and check alarm and/or shutdown function.
Step 5 : Every actual activating value shall be same as adjusted value described step 1 and 2.
If not, recheck proximitor and monitor unit.
(5) Axial probe Installation

Step 1 : Hook up dial gauge as per Fig.2.1.14-8. below ;
Fig. 2. 1. 14-8 Measuring Total Movement

Step 2 : Push and pull the measuring subject with sufficient force (use hydro jack if required) until
the dial gauge stop the reading at both ends and read the maximum variance
(total movement of measuring subject). Record the reading for future reference.
Step 3 : Position the measuring subject to its mid-position (See note below) which determined from step
NOTE : If the manufacturer of the equipment specify the measuring reference point,
position the measuring subject to the recommended point. The indication and
alarm/shutdown set points are to be determined with this reference point.
Step 4 : Put monitoring indicator on gap mode.
Step 5 : Tighten every threaded parts of probe housing. (Refer to Fig.2.1.14-6, Chapter 2.1.14(3)).
Step 6 : Insert probe into measuring point until the monitoring indicator indicates reference gap.
Step 7 : Lock the probe with lock nut.
Step 8 : Insulate connector with non-adhesive tape such as teflon tape.
2.1.15 Speedometer (Pick up coil type)

Fig. 2. 1. 15-1 Speedometer

Step 2 : Determine the maximum r.p.m. (revolution per minute) of the instrument and calculate
maximum input frequency.
Fig. 2. 1. 15-2
Step 3 : When no pulse injected to input terminal, the output shall be 0% of its range and,
if the speedometer equiped with indicator, the indication shall be zero.
If it is not, adjust zero until proper output/indication obtained.
Step 4: Inject 100% of pulse signal to input terminal and check output/indication.
Adjust span when error found.
Step 5 : Rechek zero and repeat until both are correct.
Step 6 : Check output/indication for 0,25,75 and 100% of range.
Step 7 : Every output reading shall be within error limit.

If not, adjust linearity adjustment and repeat step 3 to 7 until every output/indication
corresponds with input signal within acceptable error limit.
2.1.16 Converter
(1) Current to Air Converter
Step 1 : Hook up teating equipments as per Fig.2.1.16-1 below ;
Fig. 2. 1. 16-1 I/P Converter

Step 2 : Inject 0% of input signal and check output.
Adjust zero when error found.

Adjust span when the output deviates more than error limit from 100% of its range.
Step 4 : Recheck zero after span adjustment and repeat step 2 to 4 until both are correct.
Step 5 : Simulate input signal 0,25,75 and 100% and check output with input rising and falling.
Every output reading shall be within error limit. If not, adjust linearity and repeat step 2 to 5
until desired input-output character obtained.
(2) Air to Current Converter

Step 1 : Hook up testing equipment as per Fig.2.1.16-2 below ;
Fig. 2. 1. 16-2 P/I Converter

Step 2 : Perform step 2 to 5 on chapter 2.1.16(1).
(3) Voltage to Current Converter

Fig. 2. 1. 16-3 V/I Converter

(4) Current to voltage converter

Fig. 2. 1. 16-4 I/V Converter

(5) Pulse Rate to Voltage/Current Converter

Fig. 2. 1. 16-5 Pulse Rate / V or I Converter

(6) Voltage/Current to Pulse Rate Converter (Integrator)

Step 1 : Hook up testing quipments as per Fig.2.1.16-6 below ;
Fig. 2. 1. 16-6 V or I/Pulse Rate Converter

2.1.17 Computing/Signal onditioning Relay

(1) General Procedure
(1.1) Before any calibration or set up proceed the correct function shall be selected in accordance
with manufacturer's instruction.
(1.2) Great care shall be taken to choose the input and output type (current, voltage, pulse rate,
logic, contact closure, etc.) to prevent damage.
(1.3) In case of complex computation, it is preferred to prepare calibration table which is helpful to
find output value at various input condition.
(1.4) In general, hook up testing equipments as per Fig.2.1.17-1

below for the relay of single input/output type.
Fig. 2. 1. 17-1 Single input/output type Relay

(2) Multiplier / Divider
Step 1 : Select proper funcitional equation by changing jumpers, arranging input/output or switching
selector switches to conform instrument specification.
General Equations ;
⊙ 0 = I1 x I2 , 0 = K0[K1(I1-Z) + B1] [K2(I2-Z) + B2]/S ±B0
⊙ 0 = I1 / I2 , 0 = K0[K1(I1-Z) + B1]/[K2(I2-Z) + B2]xS ±B0
⊙ 0 = I1 , 0 = K0 [K1(I1-Z) + B1] x S ±B0
⊙ 0 = (I1) , 0 = K0[K1(I1-Z) + B1] /S ±B0
2 2
⊙ 0 = I1 x I2 x I3 , 0 = K0[K1(I1-Z) + B1] [K2(I2-Z) + B2]/[K3 (I3-Z)+B3]±B0

⊙ 0 = (I1)2 / I2, 0 = K0[K1(I1-Z) + B1]2/[K2(I2-Z) + B2]±B0
⊙ 0 = I1 x I2 , 0 = K0 [K1(I1-Z + B1] [K2(I2-Z) + B2]±B0
Where ; I1 ~ I3 = Inputs
0 = Ouput
K0 ~ K3 = Ratio factor
B0 ~B3 = Bias
Z = Zero value
S =Signal span
Step 2 : Determine every ratio/bias factors by comparing specification and corresponding equation.
Prepare calibration table.
Fig. 2. 1. 17-2 Multiplier/Divider

Step 4 : Calibrate each factor in accordance with the calibration table and the manufacturer's instruction
(3) Adder / Subtracter

Step 1 : Select proper functional equation by changing jumpers, arranging inputs/output or switching
selector switches to conform instrument specification.
General Equations ;
⊙ 0 = I1 ± I2 , 0 = K1(I1-Z) ± K2(I2-Z)±B
⊙ 0 = I1 ± I2 ± I3 , 0 = K1(I1-Z) ± K2(I2-Z) ± K3(I3-Z)±B
⊙ 0 = I1 ± I2 ± I3 ± I4 , 0 = K1(I1-Z) ± K2(I2-Z) ± K3(I3-Z) ± K4(I4-Z)/B0
Where ; I1 ~ I4 = Inputs
0 = Ouput
K0 ~ K4 = Ratio facror
B ~ B0 = Bias
Z = Zero value
Step 2 : Determine every ratio/bias factors by comparing specification and corresponding equation.
Fig. 2. 1. 17-3 Adder / Subtracter

(4) Scaler / Biaser

Step 1 : Determine ration and bias factors by comparing specification and corresponding equation.
General Equation ;
⊙ 0 = K(I) ± B, 0 = K(I-Z) ± B + Z
Where ; I = Input
0 = Output
K = Ratio factor (Scale)
B = Bias
Z = Zero value
Step 2 : Hook up testing equipments as per the Fig.2.1.17-1 on general procedure of computing relay
chapter 2.1.17(1.4).
(5) Signal Selector

The signal selector is used to select the highest or the lowest out of 2 or 2 to 4 input signals
and produce an output equal to the input selected.
Step 1 : Hook up testing equipments as per Fig.2.1.17-4 follows ;

Fig. 2. 1. 17-4 Signal Selector

Step 2 : Select proper function - high or low selecting - by changing jumper or switcing
function selecting switch.
Step 3 : Simulate various input signal condition and check output.

Adjust proper adjustment, if required, in accordance with the manufacturer's instruction.
(6) Signal Isolator

The signal isolator accepts an input and converts into isolated output signal.
Step 1 : Hook up testing equipments as per the Fig.2.1.17-1 on general procedure of computing
relay chapter 2.1.17(1.4).
Step 2 : Inject various input signal and check output.

The output and input should be same or same percentage value when the
output transformed.
Step 3 : Adjust zero and span adjustment until the output corresponds with input within
acceptable error limit.
(7) Signal Characterizer (Function Generator)

The signal characterizer (function generator) converts an input signal into an output signal with
arbitrary characteristics such as concavity shape, convexity shape and s-shape, etc.
Step 1 : Check instrument specification and determine break points and ratio value which most conform
to desired character.
Fig. 2. 1. 17-5
Step 2 : Prepare calibration table.
Step 3 : Hook up testing equipments as per the Fig.2.1.17-1 on general procedure of computing relay,
chapter 2.1.17(1.4).
Step 4 : Inject various input signal and check output.

Adjust proper adjustment, if required, until the optimum character obtained.
(8) Signal Limiter

The signal limiter limits an output signal at the preset value when an input signal exceeds the value.
Step 1 : Determine the limiting value, both high and low, from the instrument specification.
Fig. 2. 1. 17-6
Step 2 : Hook up testing equipments as per the Fig.2.1.17-1 on general procedure of computing relay,
chapter 2.1.17(1.4).
Step 3 : Simulate input signal and check the output limiting function and adjust low and high
set point (limiting value) until the desired values obtained.
(9) Square Root Extracter

Fig. 2. 1. 17-7 Square Root Extracter

Step 2 : If the instrument equiped with low range drop-out function, adjust it to minimum so that
the output do not affect with it.
Step 3 : inject input signal 6.25% of its range and check output.
The output should be 25% od output signal range.
If not, adjust zero adjustment until the error eliminated.
Step 4 : Inject input signal 100% of its range and check output.
The output should be 100%.
If not, adjust span and recheck zero and repert until both are correct.

The output should be 50% of its range.
If not, adjust linearity and repeat step 3 to 5 until desired character obtained.
General equation ;
Output(%) = Input (%)
Output = Input - ZERO input x SPANoutput + ZEROoutput
SPANinput
Step 6 : Inject various input signal and check output readings.

The difference between output reading and calculated value should be less than error
limit from 10% through 100% of output range.
Step 7 : The error may be increased when the output is less than 10% (or input is less than 1%).
Therefore, the drop-out function might be required to eliminate this unaccurate output.
Fig. 2. 1. 17-8
Step 8 : If the instrument equiped with drop-out function, adjust it to desired value.
(10) Signal Reverser

The Signal reverser accepts an input signal and reverses it into an output signal.
Step 1 : General equation ;

Output(%) = 1 - Input(%)
Output = (SPAN + 2 x Z) - INPUT Z : Zero Value
Step 2 : Hook up testing equipments on general procedure of computing relay chapter 2.1.17(1.4).
Step 3 : Inject input signal and check output.

Adjust proper adjustment until the output corresponds input within error limit through entire rang
(11) Alarm Switching Module

(11.1) The alarm switching module compares an input signal with an internal setpoint, and an alarm
signal is generated as the input signal exceeds the preset value.
(11.2) The deviation alarm switching module initiates an alarm signal when a deviation between two
input signals exceeds a preset value.
(11.3) The rate monitor alarm switching module generates an alarm signal as the rate of change
in the input signal exceeds the preset rate.
Fig. 2. 1. 17-9a Alarm Switching Module Fig. 2. 1. 17-9b Deviation Alarm
Fig. 2. 1. 17-9c Rate Monitoring Alarm

Fig. 2. 1. 17-10a Alarm Switching Module
Fig. 2. 1. 17-10b Deviation Alarm Switching Module
Fig. 2. 1. 17-10c Rate Monitor Alarm Switching Module

Step 2 : Select proper function, high or low, by changing jumpers, switching function selecting
switch or arranging input/output.
Step 3 : Select proper input/output type if required.

Input type : Current/Voltage signal, pneumatic signal, etc.
Output type : Normal open/close contact, logic output, open collector output, etc.
Step 4 : Check setpoint with increasing signal for high alarm service and decreasing for low
while observing output.
Step 5 : Check dead band with resetting alarm action.
Step 6 : Adjust setpoint and dead band, repeat step 4 to 6 until desired switching action obtained.
2.1.18 Controller
(1) Input (Process Variable) Calibration
Fig. 2. 1. 18-1 Input Calibration of Controller

Step 2 : Inject input signal 0,25,75 and 100% of signal range and adjust input (P.V.) zero and
span adjustment so that the indication works properly.
(2) Set Point Calibration (Alignment) - Manual Set

This procedure does not applicate to gap action controller. Refer chapter 2.1.18(6) for the
gap action controller.
Fig. 2. 1. 18-2 Set Point Calibration of Controller

Step 2 : Put anto-manual selector on automatic position and set controller action, direct or reverse,
to the actual servicing direction.
Step 3 : Adjust gain(Proportional band), integral (reset) and derivative (rate) as follows ;
⊙ Gain = 1 or proportional Band = 100%
⊙ Integral (reset time) = medium value.
⊙ Derivative (rate time) = minimum value.
Step 4 : Inject 50% of input signal and adjust set point knob so that the output indicates as follows ;
⊙ P mode : 50% of output range
⊙ PI or PID mode : Stop between 40 and 60% of output range.
Step 5 : Read setpoint indication and compare with input signal. If the difference between input and
set point indication is greater than 2% of scale, adjust set point zero adjustment and
repeat step 4 and 5 until the difference eliminated.
Step 6 : Inject 90% of input signal and adjust set point adjustment so that the output indicates 50% of
scale for P-mode controller and stop between 40 and 60% of scale for PI and PDI mode.
Step 7 : Read setpoint indication and compare with input signal. If he difference is greater than 2% of
scale, adjust setpoint span adjustment and repeat step 4 to 7 until both are correct.
Step 8 : Inject 10% of input signal and check set point indication same way as step 4 and step 6.
Step 9 : If the difference is greater than 2% of scale, adjust set point linearity adjustment and
repeat step 4 to 9 until all of three point check outs are correct within 2%.
Step 10 : If the instrument equiped with control unit alignment adjustment, adjust it as follow.
⊙ Increase gain upto 5(Proportional band 20%) and check set point according to step 4.
⊙ Read setpoint indication and compare with input signal.
⊙ If the difference is greater than 2% of scale, adjust control unit alignment and repeat
step 4 to 10 until the proper alignment obtained.
(3) Remote Set (Cascade Control)

Fig. 2. 1. 18-3 Remote Set of Controller

Step 2 : Put the controller mode on cascade position (remote set point)
Step 3 : Inject remote set signal 0,25,75 and 100% of its range and adjust setpoint indications zero and
span adjustment so that the indication of remote set works properly.
NOTE : The set point indication zero and span adjustment are different from set
point zero and span which described on manual set point calibration.
Step 4 : Align control unit as per manual set point calibration step 3 to 10, chapter 2.1.18(2).
(4) Output Meter and Manual Output Control Unit

Step 1 : Hook up testing equipment a per Fig.2.1.18-4 below ;
Fig. 2. 1. 18-4 Output Meter/Manual Output Control Unit

Step 2 : Put auto-manual selector on manual position.
Step 3 : Adjust manual output adjusting knob and check output at 0,25,75 and 100% and minimum/
maximum value.
Step 4 : Compare integal output meter/gauge and external testing meter/gauge reading.
Adjust output meter/gauge when error found.
(5) Control Action Check

This control action check procedure is another applicable method to align control unit when
the controller equiped with integral(reset) action such as PI and PID mode.
Therefore, this method is not applicable to P, PD or gap action mode.
Fig. 2. 1. 18-5a Manual-Set Type

Fig. 2. 1. 18-5b Remote-Set(Cascade Control) Type

Step 2 : Put the controller action on reverse position (i.e., input increase-output decrease).
Step 3 : Adjust gain (proportional band), integral (reset) and derivative (rate) as follows ;
⊙ Gain(Proportional band) = 1 - 1.5 (70 - 100%)
⊙ Integral (reset time) = medium
⊙ Derivative (rate time) = medium
Step 4 : Adjust set point by adjusting set point knob (manyal set) or set point signal (remote set).
Step 5 : The input indicator should be followed up to set point within 2% of scale through entire scale
range. If not, proper adjustment shall be executed to eliminate the error.
(6) Gap Action (On-Off Control)

Step 1 : Hook up testing equipments as per the Fig.2.1.18-2 on set point calibration, chapter 2.1.18(2).
Step 2 : Determine action and acting points from the instrument specification sheet and/or P. & I.D.
Fig. 2. 1. 18-6
Step 3 : Put control action (direct or reverse) to proper position as determined from step 2.
Step 4 : Simulate input signal and check the gap action.

Adjust gap width and zero shifting to suit the specification and process condition.
Step 5 : If the instrument equiped with set point and gap width indications, it shall be calibrated
with proper adjustment.
(7) Special Function Check/Calibration

If the controller equiped with special function such as override, anti-reset windup, alarm,
batch control, output limiting and programmable function, it shall be checked and/or calibrated
in accordance with manufacturer's instruction.
2.1.19 Manual Station

Fig. 2. 1. 19-1 Manual Station

Step 2 : Inject input signal 0,25,75 and 100% of signal range and adjust input indicator zero
and span adjustment so that the indication works properly.
Step 3 : Put the selector switch on auto position and check output and output meter.
The output should be same as input signal.
Step 4 : Put the selector switch on manual position and adjust output adjusting knob from zero to full sc
The output should be close to the indication of manual output.
If not, adjust zero and span until proper output obtained.
2.1.20 Ratio Station

Fig. 2. 1. 20-1 Ratio Station

Step 2 : Inject input signal 0,25,75 and 100% of range and calibrate input indicator.
Step 3 : Set bias adjusting knob to zero and inject 0% of input signal.
Step 4 : Check output while adjusting ratio from minimum through maximum.
The output should stay at 0% of output range. If not, adjust bias zero and ratio zero
adjustment until the output stay 0% of its range while changing ratio.
Step 5 : Set bias adjusting knob to zero and inject various input signal.
Check output while edjusting ratio.
The output should be same as calculated value using formula below ;
Input - ZERO input
Output = x Ratio x SPANoutput + ZERO output
SPAN input
Step 6 : If the ouput dose not correspond properly, adjust ratio span adjustment and repeat
step 3 to 6 until the output correspond within error limit.
Step 7 : If the instrument equiped with bias indicating scale, calibrate it as injecting various input
and comparing output with calculated value using formula below ;
Output(%) = Input(%) x Ratio ± Bias(%)
Input - ZERO input
Output = x Ratio x SPANoutput + ZERO output ± Bias
SPAN input
Step 8 : Check output meter and calibrate it when error found.

2.1.21 Recorder / Indicator

Step 1 : Hook up testing equipment as per Fig.2.1.21-1 below ;
Fig. 2. 1. 21 Recorder/Indicator
Step 2 : Inject 0% signal and adjust zero adjustment.
Step 3 : Inject 100% signal and adjust span adjustment. Repeat step 2 and 3 until both are correct.
Step 4 : Inject 25% and 75% of input signal and check indication with signal rising and falling.
Every indication should be within error limit.
If not, adjust linearity and repeat step 2 to 4 until the instrument works properly.
Step 5 : If the instrument equiped with low and high over range stopping mechanism, adjust it properly.
Step 6 : For recorder, check inking system and chart driving mechanism.
2.1.22 Control Valve

(1) Diaphragm Actuator ; Spring Adjustment (Bench Set)
Step 1 : The diaphragm actuator shall be checked following items ;
⊙ Size and type
⊙ Stroke range
⊙ Spring range
Step 2 : hook up testing equipments as per Fig. 2.1.22-1 below ;
Fig. 2. 1. 22-1 Diaphragm Actuator

Step 3 : Adjust pneumatic signal so that the valve close slowly, and stop when the valve fully closed.
Step 4 : Read the pneumatic signal value and compare it with the actuator's range.
If the difference is greater than 2%, adjust spring adjusting nut and repeat step 3 and 4 until
the desired value obtained.
If the desired value cannot obtain with spring adjustment, change stem length by adjusting
connector assembly and repeat step 3 and 4.
Step 5 : Adjust pneumatic signal so that the valve open slowly, and stop when the valve fully opened.
Step 6 : Read the pneumatic signal value and compare it with the actuator's range.
If the difference is greater than 15%, change spring and recheck closing and opening.
Step 7 : Adjust position indicator scale so that the indication works correctly
Step 8 : Inject pneumatic signal 0,25,75 and 100% of its range and read valve position
with signal rising and falling.
(2) Other Type Actuator

The actuators other than diaphragm type shall be checked following items before the stroke check
(positioner calibration).
(2.1) Piston Type Actuator

(2.1.1) Size and Type
(2.1.2) Stroke range
(2.1.3) Leakage
(2.2) Electro-hydraulic Actuator

(2.2.1) Cleanness of hydraulic fluid.
(2.2.2) Quantity of hydraulic fluid.
(2.2.3) Leakage
(2.2.4) Power requirement
(2.2.5) Electrical insulation of motor and associated electrical parts.
(2.3) Electric Actuator

(2.3.1) Electrical insulation of motor and other electrical parts
(2.3.2) Limit switches and/or torque limit switches.
(2.3.3) Positioner assembly.
(2.3.4) Power requirement
(3) Positioner (Stroke Check)

Step 1 : Determine signal range and characteristic curve through full stroke of valve.
Select proper travel character cam if provided.
Step 2 : Connect power supply and/or air supply to the positioner and actuator
Step 3 : Connect proper input signal sorce to the positioner.
Step 4 : Adjust input signal so that the valve close slowly, and stop when the valve fully closed.
Step 5 : Read the input signal and adjust zero adjustment when error found.
Repeat step 4 and 5 until the valve corresponds with closing signal within error limit.
Step 6 : Adjust input signal so that the valve open slowly, and stop when the valve fully opened.
Step 7 : Read the input signal and adjust span adjustment when error found.
Repeat step 4 to 7 until the valve corresponds with closing and opening signal within error limit.
Step 8 : Inject signal 0,25,75 and 100% of its range and read valve position with signal rising and falling
Step 9 : Analyze the stroke characteristic curve and figure out the reproducibility which includes
deadband and hysteresis.
Step 10 : If the character or the reproducibility are not acceptable, check feel back can style
and/or mechanical condition of all moving parts and correct deficiency if exist.
Repeat step 4 to 10 until desired character obtained.
(4) Valve Action on Supply Failure

(4.1) The action of valve on supply failure shall be checked with appropriate method.
(4.2) If the control valve equiped with special accessories for the action of supply failure,
the functional check and/or calibration shall be executed for them.
2.1.23 Motion Transmitter
Fig. 2. 1. 23-1 Motion Transmitter

Step 2 : Determine the mechanical movement range and direction with comparing
output range and direction.
Step 3 : Simulate 0% input, i.e., simulate mechanical movement which is the position input to
produce 0% output.
Step 4 : Check output and adjust zero adjustment when error found.
Step 5 : Simulate 100% input and check output.

Adjust span adjustment when the output deviates more then error limit from 100% of its range.
Step 6 : Recheck zero and repeat step 3 to 6 until both are correct.
Step 7 : Simulate 25 and 75% of input and check output.

Every output reading shall be within error limit. If not, adjust linearity and repeat
step 3 to 7 until the proper input-output character obtained.
2.1.24 Analyzer and Miscellaneous Instrument

(1) The analyzer and its sampling system shall be checked and/or calibrated in accordance
with manufacturer's instruction.
(2) The miscellaneous type of instrument which is not described in this Q.C. procedure such as
thermal flowmeter, magnetic flowmeter, targetmeter type flowmeter, ultrasonic instrument,
radiographic type instrument and infrared type instrument,etc. shall be checked and/or
calibrated in accorance with each manufacturer's instruction.
TITLE 2.2 FIELD REVISION WORK PAGE 57 OF 98
2.2.1 Drawing Revision

Field engineer shall be responsible for updating site revised design data on the master drawing
in site in order to control the latest data during the construction stage.
Field engineer has to issue "Field change notice"(FCN) for the instruction of the revision
work to the construcion contractor.
Additional material and reason to change shall be specified on FCN including the revised
drawing for construction work.
Before issue of FCN, field engineer should confirm the site situation whether the relevant
work already has been done or not in order to follow up the cost impact due to the revision work.
TITLE 2.3 MATERIAL CONTROL PAGE 58 OF 98
Field engineer should check the contruction material including field instrument when a
instrument or bulk material is delivered to job site.
The delivered material shall be checked with purchase order and vendor print.
Typical material can be checked by random sampling as partial.
When field engneer has found something wrong with delivered material, that should be
informed to material controller.
Field engineer also has to monitor the delivery date comparing with delivery schedule which prepared
by procurement group.
If there is any delayed item as per the schedule, field engineer shall notify the delayed item
to procurement manager for expediting material delivery.
TITLE 2.4 VENDOR SUPERVISION PAGE 59 OF 98
Field engineer has to consider vendor supervision schedule according to construction

schedule and actual progress. Mostly, the following items shall be required to arrange
the vendor supervisor.
1. DCS
2. ANALYZER
3. TMR
4. NUCLEAR INSTRUMENT
5. METERING SYSTEM
6. MECHINERY PACKAGE (COMP'R, etc.)
Field engineer should confirm the following work to arrange a supervisor schedule.
1 DCS
- UPS power for DCS to be available
- System interconnection cable to be connected between each DCS system cabinet.
- Grounding wire to be connected.
2 ANALYZER
- Utility line to be available
- Power in shelter to be available
- Standard gas and carrier gas to be available.
3 TMR
- UPS power for TMR to be available.
- System interconnection cable to be connected.
4 NUCLEAR INSTRUMENT.
- Power supply for instr.
- Mounting of nuclear instr. to be same as drawing.
5 METERING STATION
- Service material to be available.
- Flow computer cabinet to be installed.
- Power to be available for flow computer cabinet.
- Prover to be available.
- Interface cable between metering skid and flow computer to be completed.
TITLE 3.1 FIELD INSTALLATION CHECK PAGE 60 OF 98
The instrument supervisior shall check physical condition of all instrument installations to ascertain
that the installations agree with instrumentation drawing and requirement.
The following field inspection check guide represent a list of basic items which should be
checked as the instrumentation work progresses prior to testing the system.
The details are described on individual installation check sheet, chapter 3.3.
3.1.1 Field Mounted Instrument
3.1.2 Instrument Piping/Tubing System
3.1.3 Control Panel or Equipment
3.1.4 Control Valve

TITLE 3.2 PUNCH LIST PREPARATION PAGE 61 OF 98
The following is an outline of the punch list to be established and used in the completion of
construction for individual testing of system.
3.2.1 The instrument supervisor of higher authority is responsible to establish the punchlist.
3.2.2 The punch lists will be established by reviewing the P. & I.D., Piping isometric drawing,
instrument list and the hydrostatic testing scope of equipments, valve, pipe, instrument, etc.,
and reviewing the actual field installation in detail.
The punch list preparation will start at the beginning of the testing phase.
3.2.3 The punch lists are to be included all the items which are not complete whether they are
construction, engineering or material deficiencies.
Engineering and procurement items shall include the identification of correspondence, vendor names,
status and latest delivery information.
3.2.4 The instrument supervisor shall review his punch list with piping engineer who will add any piping
items before distribution to responsible craft supervision.
3.2.5 Instrument engineer is responsible for correcting the engineering and material deficiencies.
Construction deficiencies will be corrected by field supervision.
As items are completed, supervision is to advise the instrument supervisor with a marked up
copy of the punch list.
The instrument supervisior will then reinspect the deficiency and delete the item.
3.2.6 The punch list will be updated every week.

If no now engineering or material deficiencies arise, the distribution will be confined to the jobsite.
3.3 INSTALLATION CHECK SHEET AND
TITLE PRE-INSTALLATION CAALIBRATION SHEET PAGE 62 OF 98
3.3.1 Field Installation Check Sheet

(1) Field Mounted instrument : I-331-01
(2) Instrument Piping/Tubing System : I-331-02
(3) Control Panel or Equipment : I-331-03
(4) Control Valve : I-331-04
3.3.2 Instrument Pre-installation Calibration Sheet

(1) Instrument Pre-installation Cablibration Record Sheet : I-332-11
TITLE FIELD MOUNTED INSTRUMENT PAGE 63 OF 98
INSTALLATION CHECK SHEET
PROJECT : CLIENT : JOB NO. :
AREA/LOCATION : REF. DWG. :
DESCRIPTION :
CHECK
ITEM TO CHECK / INSPECTION
(SIGNATURE/DATE)
1. Instrument damage during or after installation.
2. Nameplate and compare with instrument data sheet.
3. Tag fastened securely.
4. Accessibility and visibility of instructions and indication.
5. Accordance with appropriate drawings, standards and spec.
6. Lubrication of all removable parts such as cover, cap, etc.
7. Adequate protection from moisture, corrosive vapor, dust and freezing.
8. Proper action of controller,i,e., direct or reverse.
9. Support of instruments and related piping to insure min. vib.
10. Painting of instrument surfaces requiring corrosion resistance.
11. Seal weld of thermowell requiring socket weld.
12. Instrument mounted securely and neatly.
13. Instrument mounting stanchion properly supported and painted.
14. Proper leveling of instrument.
15. The condition of name plates and sight glasses.
16. Are all instruments free from access ways?
17. Is the flow element comply with flow direction?
REMARKS :
DISTRIBUTION SIGNATURE
Contractor / Original CHECKED by : DATE :

ACCEPTED by : DATE :
Owner / Copy WITNESSED by : DATE :
TITLE INSTRUMENT PIPING/TUBING SYSTEM PAGE 64 OF 98
DESCRIPTION :
CHECK
(SIGNATURE/DATE)
1. Are instrument piping to process in correct location?
2. Accordance with appropriate drawings, standards and spec.
3. Proper continuity of high and low pressure connections.
4. Seal pot requirements of flow meter and its support.
5. The piping/tubing installed in an orderly manner.
6. Proper support of piping/tubing.
7. Are tubing unions accessible for maintenance?
8. Is tubing routed so as not to impede access to instrument/valve?
9. Are all piping/tubing thoroughly cleaned?
10. Is the blow(vent) or drain piping installed up to safe location?
11. Proper slope of piping/tubing.
12. Are all support and its fittings painted/lubricated?
13. Is the pressure regulator set properly?
REMARKS :

CONTROL PANEL OR EQUIPMENT
TITLE INSTALLATION CHECK SHEET PAGE 65 OF 98
DESCRIPTION :
CHECK
(SIGNATURE/DATE)
1. Instrument panel damage during or after installation.
2. Proper location of instrument per the appropriate drawings,
standards and specification.
3. Name plates and instrument tags installed properly.
4. Is the panel located within tolerance?
5. Is the panel leveled properly?
6. Are the panels stand in a row?
7. Is touch-up painting carried out?
8. Is the panel supported to base properly?
9. Are all lamps installed with correct size and ratings?
10. Proper grounding of panels.
11. Is the air header connected to the air supplier properly?
12. Are the tubings installed in an orderly manner and supported?
13. Tagging or color code of tubing connectiond
14. Do all tubing/wiring maintain accessibility of instruments?
15. Proper identification of all electrical wirings.
16. Cleanness of panel or equipment.
REMARKS :

CONTROL VALVE
TITLE PAGE 66 OF 98
DESCRIPTION :
CHECK
(SIGNATURE/DATE)
1. Are the indication gauges and valve position indicator located for easy
observation by operator?
2. Is the inside of valve body cleaned before installed?
3. Are sufficient clearance and accessibility provided for removal,
service and manual operation?
4. Control valve damage during or after installation.
5. Are all control valve accessories such as valve positioner electro-pneumatic
transducer, handwheel, air booster, trip valve, volume tank, air filter/regulator,
position transmitter and associated tubings installed properly per the drawing,
standard and specification?
6. Are the valve body and actuator painted properly?
7. Are all links connected properly and sufficient clearance provided?
8. Is valve inlet and outlet comply with flow direction?
REMARKS :

INSTRUMENT PRE-INSTALLATION
TITLE PAGE 67 OF 98
CALIBRATION RECORD SHEET
INSTRUMENT TAG NUMBER : SERVICE :
MANUFACTURER : MODEL/TYPE NO. :
SPEC./DATA SHEET NO. : SERIAL NO. :
MEET SPECIFICATION/DATA SHEET. YES □ NO □ REASON :
PHYSICAL CONDITION. GOOD □ DAMAGED □
DAMAGED ITEM :
INPUT RANGE : UNIT :

OUTPUT RANGE : UNIT :
INDICATOR/RECORDER SCALE :
SUPPLY SETTING. ELECT. □ AIR □ SET AT : UNIT :
LIST OF ANCILLARY EQUIPMENT :

CALIBRATION ROOM TEMP. : ℃, CALIBRATION DATE : ( ) UNIT
OUTPUT READING ( )
INPUT ( ) DESIRED OUTPUT REMARK
RISING FALLING
0%
25%
75%
100%
SWITCH SETTING : SWITCH SET WITH INPUT SIGNAL-RISING □ , FALLING □

DESIRED SET POINT : UNIT : , % OF INPUT
ACTUAL SET POINT : UNIT : , % OF INPUT
RESET POINT : UNIT : , DEAD BAND :
CONTROL UNIT : ACTION-DIRECT □ , REVERSE □ , SET POINT-MANUAL □ , REMOTE □

CONTROL MODE-PROPORTIONAL □ , INTEGRAL □ , DERIVATIVE □ ,
ON-OFF □ , IS SET POINT ALIGNMENT DONE? YES □ NO □
ARE OUTPUT METER AND MANUAL OUTPUT UNIT CHECKED? YES □ NO □
REMARKS :

TITLE 4.1 GENERAL PAGE 68 OF 98
4.1.1 All testing and function check shall be executed with appropriate documentation and witnessed
by client and/or consultant.
4.1.2 Discrepant items which arise during the testing or function check should be listed and
corrected as a punch list item.
4.1.3 Instrument piping pressure test should be executed by proper method as follows ;
(1) Impulse piping/tubing : Chapter 4.2.1.
(2) Signal transmission tubing : Chapter 4.2.2.
(3) Air supply piping : Chapter 4.2.3.
4.1.4 The method and policy of witness for the safety/relief valves are to be discussed between
client and contractor prior to check and/or test.
4.1.5 Special tests or adjustments which require costly test equipment and a high degree of technical
skill may be performed by vendor representative, under contract wherever they are available.
4.1.6 All proposed testing will be informed at least 24 hours in advance by contractor in notification.
(form No. G-1000-01)
4.1.7 The testing will be informed by client in writing, at least 24 hours in advance, the extent and duration
of all proposed test, indicating areas that will come under restricted access conditions.
TITLE 4.2 INSTRUMENTATION PRESSURE TEST PAGE 69 OF 98
4.2.1 Impulse piping/Tubing

(1) General
All the pressure/vacuum lead piping (impulse piping/tubing) which connect a instrument to
process should be pneumatically tested for tightness.
The test fluid should be clean air or nitrogen gas.
(2) Testing Pressure

Impulse piping/tubing shall be tested at 110% of the design pressure.
(3) Test Preparations

(3.1) Before commencing the pressure test for the differential pressure instruments,
close block valves at the process and open the bypass valve and block valves at the instrument.
(3.2) Close block valve at the provess for pressure instruments.
(3.3) If the differential type level instrument is not equiped with bypass line, close block valves
at the vessel and add temporary bypass line between the high pressure and low pressure
sides to prevent excess differential pressure at the instrument.
(3.4) All joint, including welds, are to be left uninsulated and exposed for examination during the test.
(3.5) Vacuum service lines shall be tested at minimum pressure of 20 PSIG unless limited.
(3.6) Analyzer unit shall be disconnected before pressure testing of sampling lines.
(4) Testing Sequence

Step 1 : Prepare piping to be tested as indicated in chapter 4.2.1(3), test prparation.
Step 2 : Connect the test assembly to the impulse piping/tubing.
Step 3 : Inject preliminary test pressure upto 20 PSIG.
Step 4 : Locate major leaks and correct them.
Step 5 : Increase testing pressure gradually in steps with providing sufficient time to allow
the piping equalize the strains during test.
Step 6 : The pressure is to be reached the testing pressure which determined on chapter 4.2.1(2).
Step 7 : The test pressure shall be maintained for a sufficient time to determine if there are
any leaks, but not less than 10 minutes.
Step 8 : Accurate records shall be maintained for all the lines tested on the form No. I-405-01
4.2.2 Signal Transmission Tubing

(1) General
All of the control and signal transmission tubings shall be tested pneumatically prior to final loop check.
Testing medium shall be instrument air or nitrogen gas.
(2) Testing Pressure

The signal transmission tubing shall be tested at maximum pressure of the signal range, i.e.,
15 PSIG for 3 to 15 PSIG signal range.
(3) Test Preparations

(3.1) Establish the identity of each component of a given control loop and its conformance to
design specification.
(3.2) Blow air lines clean.
(3.3) Identify positively the air circuit from air supply valve through instrument to air-operated
element by setting instrument to deliver air and observing air leakage at the disconnected
air line at the air-operated element.
(3.4) Before any test of pneumatic line, instruments which would consume air from the line must be
disconnected and the line be blocked at the point of disconnection.
(4) Testing Sequence

Step 1 : Disconnect air consuming pilots from the section of tubing to be tested.
Step 2 : Connect the bubbler unit to the open end of the line to be tested.
(Refer to Fig.4.2.2-1)
Fig. 4. 2. 2-1 Bubble Test Pot

Step 3 : Close all three valves - A,B and C.
Step 4 : Open the air supply valve and adjust regulator so that the pressure reach to testing pressure.
Step 5 : Open the valve A and allow the line to be fully pressurized.
Step 6 : Close valve A and open valve B and C.
Step 7 : Observe the bubbler unit.

A leak on the line will cause bubbles to appear in the unit.
Step 8 : Determine the source of the leak and correct it.
Step 9 : The line shall be considered acceptable when the bubbles are slowed to a rate
of no more than three per minute.
Step 10 : It must be stressed that air supply pressure to the bubble unit must be stable.
Step 11 : Accurate records shall be maintained for all the lines tested on the from No. I-405-02.
3.2.3 Air Supply Piping

(1) General
All instrument air subheaders and branch systems shall be subject to leak and pressure testing.
Main instrument air piping shall be pressure-tested by piping group.
The test medium for these tests shall be clean, oil free air. A portable compressor may be
used with dry alumina filter for this purpose, however, main instrument air compressor
shall be used if it is available.
(2) Testing Procedure

Step 1 : Operate the system instrument air compressor.
Step 2 : Put drain traps and air dryer into operation, and check quality of instrument air at
the down-stream of air dryers.
Step 3 : Test pressure shall be the maximum operation pressure of the instrument air supply
piping system.
Step 4 : Open the end of air supply pipe at the nearest union or coupling from the instruments and
blow air pipes clean removing all the foreign object and drain trapped inside pipes.
Step 5 : After blowing is finished, reconnect all the supply piping to the instruments.
Step 6 : Apply soap solution around all the possible source of leaks (union, coupling, etc.).
Step 7 : Check for leaks observing bubbles.

Step 8 : Mark on the leak points and depressurized the leaking section of the air supply
piping for maintenance.
Step 9 : Repeat above steps throughout the piping system.
Step 10 : Accurate recrds shall be maintained for all the line tested on the form No. I-405-03.
TITLE 4.3 SAFETY/RELIEF VALVES PAGE 73 OF 98
4.3.1 Scope
This procedure covers a pneumatic relief and leakage test of spring loaded relief valves,
pilot operated relief valves, vacuum relief valves and safety valves.
4.3.2 Test Preparation

(1) Pressure gauge used for testing shall be calibrated plus or minus one percent.
(2) Test medium used for pressure relief valves shall be nitrogen gas or compressed air
and free of any solids.
(3) Vacuum producing device shall be used for inbreathing relief valves.
(4) All piping used shall be purged to ensure there are no solids.
(5) Valves shall be cleaned of sand and dirt on exposed surfaces before testing.
(6) All data on valve nameplate shall be checked against design data sheets before testing.
(7) During testing all personnel not directly involved shall be cleared from the immediate area.
(8) Personnel involved in testing will wear ear plugs to protect ears from the popping noise.
(9) The outlet of the valve to be tested shall be placed to the opposite side of the operator.
4.3.3 Pneumatic Pop Test for Thermal Relief Valves and Full Lift Test for all PSVs using Test Stand.
(1) The valve shall be calibrated by poping pneumatically at the cold differential test pressure
(factory set pressure) listed on data sheets.
(2) The valve will be preinstalled on the test bench in accordance with the size of the valve,
and the test gauge shall be selected and installed after considering the range of the
specified test pressure.
(3) The pressure source shall be connected to the test bench and the pressure shall be gradually
increased to the set pressure of the valve as stated on valve data sheet by a throttling valve.
(4) When poping, the test gauge shall be checked whether in accordance with the set pressure or not.
In case the test pressure is above or under the specified set pressure, spring adjusting nut
shall be adjusted according to the Vendor's instruction.
(5) After adjusting, retest the valve and read the popping pressure and reset pressure.
(6) The testing shall be stopped and the valve readjusted when popping is not carried out at
the set pressure.
4.3.4 Leakage Test for Spring Loaded Relief Valves

(1) The relief valve seat tightness shall be bubble tested immediately after the pop test.
(2) Commercial seat tightness of safety/relief valves with metal-to-metal seats. (API Standard No.527)
(2.1) Scope
The maximum acceptable leakage rates are defined for commercial safety/relief valves with
metal-to-metal seats for set pressures up to 6000 pounds per square inch gage (41 megapascals).
If greater tightness is required, it can be supplied but must be specified on the purchase
order or inquiry.
(2.2) Test Apparatus
Fig. 4. 3. 4-1 Leakage Test Fixture

A typical test arrangement for determining seat tightness for safety/relief valves is shown in
Fig.4.3.4-1. Leakage measurement shall be made with use of a 5/16 inch (7.9mm) OD tubing
with 0.035 inch (0.89mm) wall. The tube end shall be cut square and smooth.
It shall be parallel to and 1/2 inch (12.7mm) below the surface of the water.
NOTE : The cover plate should be fitted with a suitable device to relieve body pressure in
case of accidental popping of the valve.
(2.3) Procedure
With the valve mounted vertically, as shown in Figure 4.3.4-1, the leakage rate in bubbles
per minute shall be determined with pressure at the safety/relief valve inlet held at 90
percent of the set pressure immediately after popping.
For valves set at 50 pounds per square inch gage (354 kilopascals) or below,
the pressure shall be held at 5 pounds per square inch gage (35 kilopascls) below the set
pressure immediately after popping. The test pressure shall be applied for a minimum of
1 minute for valves of inlet sizes through 2 inch (50.8 milli meters);
2 minutes for sizes 2 1/2, 3, and 4 inch (63.5, 76.2 and 101.6 millimeters);
and 5 minutes for sizes 6 inch and 8 inch (152.4 and 203.2 millimeters).
Air at approximately atmospheric temperature shall be used as the pressure medium.
(2.4) Tightness Standard

The leakage rate in bubbles per minutes shall not exceed the numbers listed in Table 1 for
set pressures to 1000 pounds per square inch gage (6.9 megapascals) or figure 3.3.4-2 for
set pressures over 1000 pounds per square inch gage (6.9 megapascals).
Table 1 - Leakagee Rates for Safety/Relief Valves for Set Pressures to 1000 Pounds
per Square inch Gage (6.9 Megapascals)
Approximate Leakage Rate
Type of Manufactuer's Maximum Leakage Rate (Standard Cubic Feet (Standard Cubic
Valve Orifice Size (Bubbles per Minute) Per 24 Hour) meter Per 24 Hour)
Convention F and smaller 40 0.6 0.017
al G and larger 20 0.3 0.085
Balanced F and smaller 50 0.75 0.021
bellows G and larger 30 0.45 0.031
Table 2 - Standard Orifice Sizes

EFFECTIVE ORIFICE EFFECTIVE ORIFICE
ORIFICE AREA DESIGNATION ORIFICE AREA DESIGNATION
0.110 SQ.IN. D 2.853 SQ.IN. L
0.196 SQ.IN. E 3.60 SQ.IN. M
0.307 SQ.IN. F 4.340 SQ.IN. N
.507 SQ.IN. G 6.380 SQ.IN. P
0.785 SQ.IN. H 11.050 SQ.IN. Q
1.287 SQ.IN. J 16.0 SQ.IN. R
1.838 SQ.IN. K 26.0 SQ.IN. T
Fig. 4. 3. 4-2 Maximum Seat Leakage Rate, Bubbles Per Minute
4.3.5 Pilot Operated Relief Valves

Because the many types of pilot-operated valves are available, it is impractical to set forth
the various instructions in this procedure.
Therefore, manufacturer's recommendations should be consulted and followed carefully.
The following testing procedure for one of the pilot operated valves should be read as a guidance only.
(1) Procedure for Pilot Only

The following procedure shall be utilized in testing the pilot valve without the main valve attached.
Step 1 : Install the pilot valve on the test fixture, per Figure 4.3.5-1 for pressure plots,
on Figure 4.3.5-3 for vacuum pilots. The "Dome" port is connected to a pressure gauge
to indicate the degree of pressure change achieved while the pilot valve is venting.
On vacuum valves only, apply a positive pressure equal to the positive reciprocal value of
the vacuum set pressure.
Step 2 : Adjust the pressure adjusting bolt to obtain the correct set pressure.
Clockwise rotation increases the relief pressure.
NOTE : Set pressure (actuation) of vacuum pilots is evidenced by the rapid change of
dome pressure from atmospheric (zero gauge) to accumulator pressure.
Tighten the locknut after adjustment is completed.

Step 3 : Adjust the blowdown adjusting screw to obtain the desired reseat pressure. Clockwise rotation
will lengthen the blowdown. Tighten the locknut sfter adjustment is completed. A small
interaction between set pressure and blowdown may occur. If so, readjust the set pressure.
NOTE : The reseat value of the complete valve (pilot pluse main valve) with internal pressure
pickup will be approximately 2% less than the reseat value of the pilot only on snap
action pilots due to the loss in the dipper tube (total pressure pickup).
Step 4 : Cycle the pilot valve a minimum of five times to assure that it is relieving and reseating
consistently. Increase the pressure very slowly in order to obtain an accurate reading of
the cracking and relieving pressure and to expose any erratic performance.
NOTE : Cracking pressure on vacuum pilots is that pressure at which the initial dome
pressure change is noted.
Step 5 : Flow the pilot valve at set pressure to obtain the dome pressure reading.
For modulating pilots, dome pressure shall be read with the inlet at 110% of set pressure.
Steps 1 through 4 shall be completed before step 5 is undertaken.
(2) Procedure for Complete Valve Assembly

Connect the main valve inlet to a pressure source as shown in Figure 4.3.5-2 for
pressure relief valves and Figure 4.3.5-4 for vacuum relief valves.
(3) Leakage Check

(3.1) Presure relief valves
Increase the inlet pressure to 90% of the set pressure. Check for leakage at the cap seal,
casting pilot support pipe and supply tube and other applicable connections using soap
solutions and at the main valve seat in accordance with Figre 4.3.5-6.
No visible leakage shall occur in one minute.
(3.2) Vacuum relief valves

Valves equipped with vacuum pilots shall be leak tested per chapter 4.3.5(3.1) on positive
pressure with the set pressure equal to the reciprocal of the vacuum set pressure.
Valves with weighted diaphragms shall be tested for leakage at 50% of their weighted set.
(3.3) If the pilot internal leak test required, the test shall be performed in accordance with Fig. 4.3.5-5.
Fig. 4. 3. 5-1 Pilot Test Fixture

Fig. 4. 3. 5-2 Asssembly Checkout Fixture
Fig. 4. 3. 5-3 ilot Test Fixture (Vac.)
Fig. 4. 3. 5-4 Assembly Checkout Fixture (Vac.)

Fig. 4. 3. 5-5 Pilot Internal Leakage Test
Fig. 4. 3. 5-6 Main Valve Seat Leakage Test

4.3.6 Calibration Record and Valve Storage
(1) All tests should be witnessed by and subject to the approval of the client.
(2) The test record should be completed by contractor.
(3) Lead seals will be attached by the client after completion of test.
(4) All valves are to be stored in an upright position with inlet and outlet flange covered
(5) All valves which ready for installation shall have proper identification.
(6) The form No. I-405-04 should be used for test record.
TITLE 4.4 INSTRUMENT LOOP CHECK PAGE 80 OF 98
4.4.1 General
This procedure shall cover the requirements for the quality control of instrument loop check.
The loop check should be witnessed by client and all results of check shall be recorded on
loop check sheet, I-405-11.
The purpose of loop check is to prove the installed instrumentation functions and fit
condition for commissioning.
When the loop related with multiplexer unit, the entire loop should be checked following
vendor's instructions.
The procedure to be adopted in carrying out loop check is detailed following, but in general
the complete instrument loop shall be tested as one system, and where necessary,
adjustments shall be made for calibration.
All of associated instrumentation such as alarms, trips, data logger, indicating lights and
push buttons shall be checked during loop check.
During loop check, the power supply for correct identification of loop power switch, circuit
breakers or fused isolating switches are to be checked.
4.4.2 Testing for electrical cables and wires

Prior to loop check, the electrical cables and wires are to be tested as follows ;
(1) Continuity test
The continuity test should be performed from source of supply through utilization equipment
for each circuit. This shall also include instrument analog signal cable, thermocouple
compensation wire, switched signal cable and special cable and wire.
(2) Insulation resistance test (Megger test)

The insulation resistance test for each electrical cable or wire shall be performed as per
electrical quality control procedure.
4.4.3 Loop Check

(1) Flow Loop
Step 1 : Simulate appropriate input signal as follows ;
Transmitter Type Input Source

Differential Pressure Type Pneumatic Calibrator
Turbine Meter Type Pulse Generator
Miscellaneous Type As per Vendor's Instruction
Fig. 4. 4. 3-1 Typical Flow Loop

Step 2 : Check and supply proper instrument air and/or electrical power to the system to be tested.
Step 3 : Inject input signal 10%, 50% and 90% of full scale and check all corresponding
instruments at each input value.
Step 4 : If the flow loop consist with control valve and controller. adjust the controller
output manually 0,25,75 and 100% of valve operating signal and check valve stroke.
Check tight closing of control valve, if necessary.
Step 5 : Reassemble the impulse piping or turbine meter and complete loop check sheet I-405-11.
(2) Pressure / Vacuum Loop


Low Pressure Pneumatic Calibrator
Medium/High Pressure Dead Weight Tester or Hydro Pump
Vacuum Vacuum Pump With Manometer
or Vacuum Gauge
Vacuum (D/P Cell Type) Pneumatic Calibrator
Fig. 4. 4. 3-2 Typical Pressure Loop

Step 4 : If the pressure/vacuum loop consist with control valve and controller adjust the controller
Step 5 : Reassemble the impulse piping and complete loop check sheet I-405-11.
(3) Level Loop


Differential Pressure Pneumatic Calibrator
Displacer or Float Type Water Simulation Set
Fig. 4. 4. 3-3a Typical Displacer Type Level Loop

Fig. 4. 4. 3-3b Typical D/P Cell Type Level Loop

Step 2 : Check and supply proper instrument air and/or electrical power to the system
to be tested.
For displacer type level transmitter the input signal of water level should be
compensated as per the chaper 2.1.7, I-0203.
Step 4 : If the level loop consist with control valve and controller, adjust the controller output
manually 0,25,75 and 100% of valve operating signal and check valve stroke.
Step 5 : Reassemble the impulse piping or transmitter body to original condition and complete
Loop Check Sheet I-405-11.
(4) Temperatur Loop

Measuring Element Type Input Source

Thermocouple Type Accurate millivolt Generator
RTD (Resistance Decade Resistance Box
Temperature Detector) Type
Bulb Type Oil Bath
Fig. 4. 4. 3-4a Typical thermocouple type temperature loop
Fig. 4. 4. 3-4bTypical R.T.D type temperature loop
Fig. 4. 4. 3-4c Typical Bulb Type Pneumatic Temperature loop

Step 3 : Inject input signal 10%,50% and 90% of full scale and check all corresponding
instrument at each input value. If the system equiped with burn out function,
check it by opening the temperature element circuit while observing the output.
Step 4 : If the temperature loop consist with control valve and controller, adjust the controller
Step 5 : Reassemble the temperature element to the original condition and complete
Loop check sheet. I-405-11.
(5) Vibration/Axial Displacement Monitor Loop

Upon completion of mechanical installation, the loop checking for the vibration and axial
displacement monitoring system shall be carried out as per chapter 2.1.14, I-0203.
(6) Speedometer Loop

Upon completion of mechanical installation, the loop checking for the speed monitoring
system shall be carried out as per chapter 2.1.15, I-0203.
(7) Switching Loop

Switch Type Input Simulating Method

PdIS or PdS As per chapter 2.1.2(3), I-0203
Pressure Switch As per chapter 2.1.6, I-0203
Level Switch As per chapter 2.1.9, I-0203
Temperature Switch As per chapter 2.1.11, I-0203
Electronic Alarm As per chapter 2.1.17(11), I-0203
Switching Module
NOTE : Where the method described above is impractical and the switching function is proved
by other means, the alternate method such as manual actuation of switching mechanism
may be used.
Step 2 : Actuate switching action and check all related system such as alarm, trip, trip signal,
indicating lamp, etc.
Step 3 : Reassemble the switching mechanism to its original installation and complete
loop check sheet I-405-11.
(8) Analyzer and Miscellaneous Instrument Loop

The analyzer and miscellaneous instrument loop shall be checked as per Vendor's instruction.
If special technics required to check out the specific instrumentation, the Vendor
representative or the specially trained technician shall be attended.
TITLE 4.5 TESTING AND FUNCTION CHECK SHEET PAGE 86 OF 98
4.5.1 INSTRUMENT PRESSURE TEST SHEET I - 405 - 01

IMPULSE PIPING / TUBING

SIGNAL TRANSMISSION TUBING

AIR SUPPLY PIPING
4.5.4 SAFETY / RELIEF VALVE I - 405 - 04

TEST RECORD SHEET
4.5.5 INSTRUMENT INSTALLATION I - 405 - 11

LOOP CHECK SHEET
4.5.6 REQUEST FOR INSPECTION / TEST G - 1000 - 01

INSTRUMENT PRESSURE TEST SHEET
TITLE IMPULSE PIPING / TUBING PAGE 87 OF 98
INSTRUMENT PROCESS SERVICE TEST TESTING

RESULT REMARKS
TAG NO. PIPE/EQUIP. PRESSURE PRESSURE DURATION
REMARKS :
Contractor / Original TESTED by : DATE :

INSTRUMENT PRESSURE TEST SHEET
TITLE PAGE 88 OF 98
SIGNAL TRANSMISSION TUBING
SIGNAL TEST BUBBLES

FROM TO RESULT REMARKS
RANGE PRESSURE PER MIN.
REMARKS :

TITLE INSTRUMENT PRESSURE TEST SHEET PAGE 89 OF 98
AIR SUPPLY PIPING
LINE TEST
FROM TO RESULT REMARKS
SIZE PRESSURE
REMARKS :

TITLE SAFETY/RELIEF VALVE PAGE 90 OF 98
TEST RECORD SHEET
SAFETY/RELIEF VALVE SPEC./DATA SHEET NO. : MODEL/TYPE NO. :

TAG NO. : MANUFACTURER : SERIAL NO. :
SERVICE : TEST DATE :
MEET SPECIFICATION/DATA SHEET. YES □ NO □ REASON :
PHYSICAL CONDITION. GOOD □ DAMAGED □
DAMAGED ITEM :
BODY MATERIAL : SPRING RANGE :

SPRING MATERIAL : SPRING NUMBER :
TRIM MATERIAL : SIZE (INLET X OUTLET) :
SPECIFIED COLD SET PRESSURE : UNIT :

POPPING TEST
POPPING PRESSURE RESET PRESSURE REMARKS
BEFORE ADJUST
AFTER ADJUST
TIGHTNESS TEST (LEAKAGE CHECK) UNIT : BUBBLES/MIN.
TESTING MAX. ALLOWABLE ACTUAL RESULT REMARKS
PRESSURE LEAKAGE RATE LEAKAGE RATE
PILOT VALVE TEST

REQUIRED ACTUAL RESULT REMARKS
SET PRESSURE SET PRESSURE
REMARKS :
SEALED AFTER TEST YES □ NO □

TITLE INSTRUMENT INSTALLATION PAGE 91 OF 98
LOOP CHECK SHEET
LOOP NO. : SERVICE :
LOOP DWG. NO. : P. & I.D. NO. : DATA :
MEASURING ELEMENT CONTROL VALVES
INSTALLED CORRECTLY INSTALLED & LOCATION CORRECT
LOCATION CORRECT TYPE & SIZE CORRECT
ISOLATING VALVES CORRECT STROKE TESTED
MATERIAL CORRECT LIMIT SWITCH CORRECTLY SET
ORIFICE TAPS ORIENTATION CORRECT POSITIONER CHECKED
IMPULSE CONNECTIONS I/P TRANSDUCER CHECKED
CORRECT TO HOOK-UP TRANSMISSION-ELECTRONIC
MATERIAL CORRECT LINES VISUALLY INSPECTED,
PRESSURE TESTED BLOWN CLEAR & LEAK TESTED
WEATHER PROTECTED TRANSMISSION-ELECTRONIC
INSTRUMENT-FIELD CONTINUITY CHECKED
INSTALLED CORRECTLY I.R. CORE TO CORE CHECKED
WEATHER PROTECTED I.R. CORE TO EARTH CHECKED
POWER SUPPLY CORRECT LOOP IMPEDANCE CHECKED
AIR SUPPLY CORRECT EARTH BONDING CHECKED
INSTRUMENT PANEL
INSTRUMENT-PANEL ZENER BARRIER DEVICES CORRECT
INSTALLED CORRECTLY T/C OR R.T.D.
CHART, INDICATOR CORRECT INSTALLED CORRECTLY
ALARM SWITCH CORRECT CONTINUITY CHECKED
POWER SUPPLY CORRECT LOOP IMPEDANCE CHECKED
AIR SUPPLY CORRECT CABLE TO SPECIFICATION
AIR SUPPLIES
VISUALLY INSPECTED, BLOWN CLEAR & LEAK TESTED
CORRECTLY CONNECTED TO HOOK-UP DRAWING
CONTROLLER ACTION : DIRECT □ REVERSE □
SUPPORTS CHECKED TAGGING CORRECT
GENERAL
TRANSMITTER OUTPUT TO RELEVANT ITEMS OF LOOP CHECKED
CONTROLLED OUTPUT TO RELEVANT ITEMS OF LOOP CHECKED
LOOP TEST Tx. INPUT Tx. OUTPUT LOCAL INST. PANEL INST. REMARKS
10%
50%
90%
REMARKS :

TITLE REQUEST FOR INSPECTION / TEST PAGE 92 OF 98
TO : REQ. NO. :
DATA :
FROM : TIME :
I/We give you 24 hours notification that the following work will be ready for inspection/test.
Subject :
Area/Location :
Description of work completed
Time ready for inspection / test

Date : Time :
It is intended to proceed with work

Date : Time :
Contractor / Original FIELD SUPERVISOR : DATE :

Owner / Copy Q.C. SUPERVISOR : DATE :
TITLE 5.1 CONTROL VALVE MAINTENANCE PAGE 93 OF 98
5.1.1 Replacing Actuator Diaphragm

After isolating the valve from all pressure, relieve all spring compression in the main spring,
if possible. (On some spring and diaphragm actuators for use on rotary-shaft valve bodies.
spring compression is not externally adjustable. Initial spring compression is set at the
factory and does not need to be released in order to change the diaphragm.)
Remove the upper diaphragm case. On direct-acting actuators, the diaphragm can be lifted
out and replaced with a new one. On reverse-acting actuators, the diaphragm head
assembly must be dismantled to change the diaphragm.
Most pneumatic spring-and-diaphragm actuators utilize a molded diapragm for control valve service.
The molded diaphragm facilitates installation, provides a relatively uniform effective area
throughout the valve's travel range, ad permits greater travel than could be possible if a flat-sheet
diaphragm were used. If a flat-sheet diaphragm is used in an emergency repair situation,
it should be replaced with a molde diaphragm as soon as possible.
When re-assembling the diaphragm case, tighten the cap screws around the perimeter of
the case firmly and evenly to prevent leakage.
5.1.2 Replacing Stem Packing

Bonnet packing, which provides the pressure seal around the stem of a globe-style or
angle-style valve body, may need to be replaced if leakage develops around the stem,
or if the valve is completely disassembled for other maintenace or inspection.
Before starting to remove packing nuts, make sure there is no pressure in the valve body.
If the packing is of the split ring variety, it can be removed (with considerable difficulty) without
removing the actuator by digging it out of the packing box with a narrow, sharp tool.
This is not recommended, because the wall of the packing box or the stem could easily be scratched,
thereby causing leakage when the new packing was installed.
Don't try to blow out the old packing rings by applying pressure to the lubricator hole in the bonnet.
This can be dangerous and frequently doesn't work very well anyway. (Many packing
arrangements have about half of the ring below the lubricator opening.)
The approved method is to :

1. Separate the valve stem andactuator stem connection.
2. Remove the actuator from the valve body.
3. Remove the bonnet and pull out the valve plug and stem.
4. Insert a rod (preferably slightly larger than the stem) through the bottom of the packing box
and push or drive the old packing out the top of the bonnet.
(Don't use the valve plug stem because the threads could be damaged in the process.)
5. Clean the packing box. Inspect the stem for scratches or imperfections that could
damage new packing.
6. Check the valve plug, seat ring, and trim parts as appropriate.
7. Re-assemble the valve body and put the bonnet in position.
8. Tighten body/bonnet bolting in sequence.
9. Slide new packing parts over the stem in proper sequence, being careful that the stem
threads do not damage the packing rings.
10. Install the packing follower, flange, and packing nuts.
11. For spring-loaded TFE V-ring packing, tighten the packing nuts as far as they will go.
For other varieties, tighten in service only enough to prevent leakage.
12. Replace and tighten the actuator onto the body. Position and tighten the stem
connector to provide desired valve plu travel.
5.1.3 Replacing Threaded Seat Rings

Many conventional sliding-stem control valves use threaded-in seat rings.
Severe service conditions can cause damage to the seat ring(s) so that the valve does
not shut off satisfactorily. In that event, replacement of the seat ring(s) will be necessary.
Before trying to remove the seat ring(s), check to see if the ring has been tack-welded to
the valve body. If so, cut away the weld and apply penetrating oil to the seat ring threads
before trying to remove the ring. The following procedure for seat ring removal assumes
that a seat ring puller, such as that shown in Figure 5-4, is being used. If a puller is not
available, a lathe or boring mill may be used to remove the ring(s).
1. Place the proper size seat lug bar across the seat ring so that the bar contacts the seat
lugs as shown.
2. Insert drive wrench and place enough spacer rings over the wrench so that the hold
down clamp will rest about 1/4-inch above the body flange.
Slip hold-down clamp onto drive wrench and secure the clamp to the body with two cap
screws (or hex nuts for steel bodies) from the bonnet.
Do not tighten cap screws or nuts.
3. Use turning bar to unscrew the seat ring. Stuck seat rings may require additional force
on the turning bar. Slip a 3-to 5-foot length of pipe over one end of the turning bar, and while
applying a steady force, hit the other end of the bar with a heavy hammer to break the ring loose.
In addition, a large pipe wrench can used on the drive wrench near the hold-down clamp.
4. After the seat ring is loose, alternately unscrew the flange bolts (or nuts) on the hold-down clamp
and continue to unscrew seat ring.
5. Before installing new ring(s), thoroughly clean threads in the body port(s).
Apply pipe compound to the threads of the new seat ring(s).
NOTE : On double-port bodies, one of the seat rings is smaller than the other. On direct-acting valves
(push-down-to-close action), install the smaller ring in the body port farther from the bonnet
before installing the larger ring. On reverse-acting valves (push-down-to-open action),
install the smaller ring in the body port closer to the bonnet before installing the larger ring.
Screw the ring(s) into the body. Use the seat ring puller, lathe,or boring mill to tighten seat
ring in the body. Remove all excess piping compound after tightening.
The seat ring can be spot welded in place to ensure that it does not loosen.
6. Reassemble the Valve
5.1.4 Grinding Metal Seats

A certain amount of leakage should be expected with metal-to-metal seating in any globe-style valve body.
If the leakage becomes excessive, however, the condition of the seating surfaces of the valve plug and
seat ring can be improved by grinding. Large nicks should be machined out rather than ground out.
Many grinding compounds are available commercially. Use one of good quality or make your
own with a mixture of 600-grit silicon carbide compound and solidified vegetable oil.
White lead should be applied to the seat to prevent excessive cutting or tearing during grinding.
In cage-style constructions the bonnet or bottom flange must be bolted to the body with the gaskets
in place during the grinding procedure to position the cage and seat ring properly and to help align
the valve plug with the seat ring. A simple grinding tool can be made from a piece of strap iron
locked to the valve pluge stem with nuts.
On double-port bodies, the top ring normally grinds faster tha the bottom ring.
Under these conditions, continue to use grinding compound and white lead on the bottom ring,
but use only a polishing compound (rottenstone and oil) on the ring. If either of the ports continues
to leak, use more grinding compound on the seat ring that is not leaking and polishing compound
on the other ring. This procedure grinds down the seat ring that is not leaking until both seats touch
at the same time. Never leave one seat ring dry while grinding the other.
After grinding, remove bonnet or bottom flange, clean seating surfaces, and test for shutoff.
Repeat grinding procedure if leakage is still excessive.
5.1.5 Lubricating Control Valve Packing

A lubricator or lubricator/isolating valve (as shown in Figure 5-5) is required for semi-metallic
packing and is recommended for graphited asbestos and TFE-impregnated asbestos packing .
The lubricator or lubricator/isolating valve combination should be installed on the side of
the valve bonnet, replacing the pipe plug used with packing types not rquiring lubrication. Use Dow
Corning X-2 lubricant or equivalent for standard service up to 450℉(232℃) and Hooker Chemical
Corporation Fluorolube lubricant or equivalent for chemical chemical service up to 300℉(149℃).
With lubricator, isolating valve, and pipe nipple (if used) completely filled with lubricant and
installed on bonnet, open isolating valve (if used) and rotate lubricator bolt a full turn clokwise
to force lubrcant into the packing box. Close the isolating valve after each lubrication.
5.1.6 Adjsting Travel and Connecting Stem

Sliding-Stem Control Valves
Part names used throughout the following section are shown in Figure 5-6. The procedure is
appropriate for slidingstem valves with either spring-and-diaphragm or piston actuators.
When performing the travel adjustment procedure, be careful to avoid damaging the valve plug stem.
Scratches on the stem can lead to packing leakage. If the unit includes a bellows seal bonnet,
the stem must not be rotate or the bellows will be damaged. On all other units, the stem may be
rotte for minor travel adjustment, but the valve plug should not be in contact with the seat
ring during rotation of the stem.
1. Assemble the body and mount the actuator. Screw the stem locknuts onto the valve plug
stem and set the travel indicator disc on the locknuts with the "cupped" portion downward.
Leave enough threads exposed above the disc for the stem connector.
2. Be sure the actuator stem is in the position that equates with the "closed" valve plug
position-flly "down" for push-down-to-close valve styles; fully "up"for push-down-to-open valve styles.
To achieve this condition, it will often be necessary to pressure load the actuator to
properly position the stem.
3. Move the valve plug to the "closed" position, contacting the seat ring.
4. Change actuator loading pressure in oder to move the actuator stem 1/8-inch.
Install the stem connector, clamping the actuator stem to the valve plug stem.
5. Cycle the actuator to check availablity of desired otal travel and that the valve plug sats
before the actuator contacts the upper travel stop. Minor adjustments in total travel can be made,
if necessary, by loosening the stem connector slightly, tightening the locknuts together, and screwing
the stem either into or out of the stem connector by means of a wrench on the locknuts.
If overall travel increase is desired, the increase must be less than the 1/8-inch the
actuator rod was moved in step 4 above, or the valve will not shut off.
6. If the total travel is adequate, tighten the stem connector secuely, lock the travel indicator disc
against the connector with the locknuts, and adjust the indicator plate on the yoke to show
valve plug poisition.
7. Provide a gauge to measure the pressure to the actuator. Make a final adjustment on the
actuator or its positioner to set the starting point of valve travel and to obtain full travel for
the desired instrument range.
Rotary-Shaft Control Valves

As shown in Figures 5-7 and 5-8, there are a variety of actuator mounting styles and
position possible with rotary-shaft control valve bodies. Specific adjustment procedures vary depending
on whether desired valve action is push-down-toclose or push-down-to-close or push-down-to-open.
The connecting linkage between the actuator and the valve body normally includes a lever
which is attached to the valve shaft by means of a key and keyway slot or by mating
multiple cut splines on the lever and shaft. A rod end bearing and turnbuckle usually
connect the lever to th actuator stem. The valve shaft and disc or V-notched ball are
stamped with indicating marks to show proper orientation for mating splines.
Similar indicating marks are used to show shaft and lever orientation. Fine adjustment is
accomplished by lengthening or shortening the turnbuckle to achieve full disc or V-notch
ball closure at 0o indicated rotation.
For disc-style rotary vaalves, fine travel ajustment should be performed with the valve body
out of the pipline so that measurements can be made as suggested in Figure 5-9.
Refer to the manufacturer's instruction manuals for specific adjustment details for the
body and actuator being used.
TITLE 5.2 FIELD TRANSMITTER PAGE 98 OF 98
Milliamp Reading is Zero · Check if Power Polarity is Reversed

· Verify Voltage Across Terminals (should be10 to 55 V dc)
· Check for Bad Diode in Terminal Block
· Replace Transmitter Terminal Block
Transmitter not Communicating · Check Power Supply Voltage at Transmitter (Minimum 10.5 V)
with Communicator · Check Load Resistance (250 Ωminimum)
· Check if Unit is Addressed Properly
· Replace Electronics Board
Milliamp Reading is Low or High · Ckeck Pressure Valtable Reading for Saturation
· Check if Output is in Alarm Condition
· Perform 4~20mA Output Trim
· Replace Electronics Board
No Response to · Check Test Equipment
Changes in Applied Pressure · Check Impulse Piping for Blockage
· Check for Disabled Span Adjustment
· Check Transmitter Security Jumper
· Verify Calibration Settings (4 and 20mA Points)
· Replace Sensor Module
Pressure Variable Reading is · Check Impulse Piping for Blockage
Low or High · Check Test Equipment
· Perform Full Sensor Trim
Pressure Variable Reading is Erratic · Check Impulse Piping for Blockage
· Check Damping
· Check for EMF Interference

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INSTRUMENT FIELD ENGINEERING

Prepared By: M.P.ALAM

FIELD ENGINEERING HANDBOOK

4 TESTING AND FUNCTION CHECK PROCEDURE

□ CONTROLLED CONTROL NO.

1.5 TESTING EQUIPMENT

1.5.1 Protable DC Voltage/Ampere Standard.

2.1.2 Differential Pressure Type

2.1.3 Turbine Meter Type

2.1.4 Pressure Transmitter

2.1.5 Vacuum Transmittter

2.1.6 Pressure Switch

2.1.7 Displacement Type Level Transmitter

2.1.8 Air Purge Type Level Transmitter (Bubbler Type)

2.1.9 Level Switch

2.1.10 Bulb Type Temperature Transmitter

2.1.11 Temperature Switch

2.1.12 Thermocouple Type Temperature Transmitter

2.1.13 Resistance Temperature Detector Type Temperature Transmitter

2.1.14 Vibration Monitor (Proximity Type)

2.1.15 Speedometer (Pick-up Coil Type)

2.1.17 Computing/Signal Conditioning Relay

2.1.19 Manual Station

2.1.20 Ratio Station

2.1.22 Control Valve

2.1.23 Motion Transmitter

2.1.24 Analyzer and Miscellaneous Instrument

Expected Error Limits of Commercially Available Instruments

2.1.2 Differential Pressure Type

(1.1.2) Check specification.

(1.1.3) Check Dimensions as follows ;

Fig. 2. 1. 2-1 Orifice Plates

(1.2) Flow Nozzle

(1.2.2) Check specification.

(1.2.3) Check Dimensions as follows ;

Fig. 2. 1. 2-2 Flow Nozzle

(1.3.2) Check specification.

(1.3.3) Check Dimensions as follows ;

Fig. 2. 1. 2-3 Venturi Tube

(2) Differential Pressure Indicator (PdI)

Fig. 2. 1. 2-4 Differential Pressure Indicator

Step 2 : For PdIS, calibrate indicating function as per 2.1.2 (2).

Step 3 : Hook up testing equipments as per Fig. 2.1.2-5 below ;

Fig. 2. 1. 2-5 PdIS or PdS

Step 4 : Vent low side.

(4) Differential Pressure Transmitter

Fig. 2. 1. 2-6 Diffferential Pressure Transmitter

2.1.3 Turbine Meter Type

(1.2) Check specification.

(1.3) Check probe conditions as follows ;

(1.4) Check rotor assembly.

(2) Transmitter / Indicator

%Flow Puse/Sec. Pulse duration

Step 3 : Hook up testing equipments as per Fig. 2.1.3-1 below ;

Fig. 2. 1. 3-1 F.T.for Turbine Flowmeter

Fig. 2. 1. 3-2 Transmitter with Temperature/Pressure Compensation

Step 8 : Recheck zero and repeat until both are correct.