WORK INSTRUCTION INSTRUMENT

ELECTRICAL & INSTRUMENT DEPARTMENT

DOCUMENT CODE IFE-WI-IMS-001 REV. # 01 REV. DATE 01/07/2019 PAGE 1 of 2

TITLE: CALIBRATION OF CONTROL VALVES (INSTRUMENT WORKSHOP)

1.0 SCOPE & OBJECTIVE:

To define the work instructions for calibration of control valves in instrument workshop.

2.0 TOOL(S) / TEST EQUIPMENT(S) REQUIRED:

2.1 Test Bench for Control Valve / Pressure Safety Valve calibration.
2.2 Current / HART / pneumatic source for control valve calibration.
2.3 Tools required for calibration purposes.
2.4 Standard Tool Kit.

3.0 STEP(S):

3.1 Job Preparation:

3.1.1 Get work permit and read it carefully (if applicable).
3.1.2 Raise SAP Notification N7 (Maintenance Assistance) for Mechanical Department to Dismantle
and shift Control Valve to Workshop
3.1.3 Conduct safety talk regarding any potential hazard.
3.1.4 Discuss job details before starting the job.
3.1.5 Observe wind direction (for plant area only) and check working condition.
3.1.6 Use complete PPEs as per job requirement.
3.1.7 Open work permit and exchange copies (if applicable).
3.1.8 Display hard copy of work permit at prominent location (if applicable).

3.2 Physical Condition of Control Valve:

3.2.1 Check the physical condition of Control Valve once it has been transported to instrument
workshop. In this regard following checks are to be made;
a- Any visible signs of damage found.
b- Any signs / marks of corrosion / erosion etc found.
c- Check if indicator is in correct position (as per valve action).

ROUTE PREPARED BY REVIEWED BY APPROVED BY REFERENCE

Name FARHAN AHMED MUHAMMAD QMS :
SHABIR MEMON
MAZARI AMJAD
HSE :
Date
Design/Sign. Section Unit Department
Manager Manager Manager
 WORK INSTRUCTION INSTRUMENT
ELECTRICAL & INSTRUMENT DEPARTMENT

DOCUMENT CODE IFE-WI-IMS-001 REV. # 01 REV. DATE 01/07/2019 PAGE 2 of 2

3.3 Checking of As-Found Calibration:

3.3.1 As found checking of valve calibration to be done. In this regard following steps are to be taken;
a- Blow air through inlet / outlet flanges for removal of any particles.
b- Install valve on test bench and clamp it properly.
c- Perform leak test of the valve (if required). Apply the valve required pressure at inlet of the
valve and check the passing of the valve.
d- Confirming the actuator bench set of the valve.

3.4 Calibration of Control Valve:

3.4.1 If the control valve is passing / not operating following steps are performed for overhauling /
calibration of a control valve;
a- Dismantle the control valve.
b- Physically inspect the trim and actuator parts.
c- Damaged parts are repaired or replaced.
d- Assembling of control valve and confirming its actuator bench set.
e- Perform leak test as per requirement.
f- Calibrate the control valve with its positioner using pneumatic / HART.
g- Painting of valve is done if required.
h- Transport the valve to the area.
i- Perform stroke test from DCS / PLC.

3.5 Job completion:

3.5.1 Perform housekeeping after completion of job.
3.5.2 Close work permit and exchange copies (if applicable).

4.0 SPECIAL INSTRUCTION(S):

4.1 Use 2 or 3 long stud’s bolts for diaphragm case in order to release the spring tension from
diaphragm.
4.2 Do not touch Plug / seat when final calibration of control valves is in progress.

ROUTE PREPARED BY REVIEWED BY APPROVED BY REFERENCE

Name FARHAN AHMED MUHAMMAD QMS :
SHABIR MEMON
MAZARI AMJAD
HSE :
Date
Design/Sign. Section Unit Department
Manager Manager Manager