Calibration & Loop Checking

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 Outline

Loop
Calibration Checking

Common Calibration of
terms used Calibration of Calibration of Pressure & Calibration of
Pre-
Definition Temperature Temperature Control Definition Contents of Process
in DP requisite Loop Folders Variables
calibration Element Transmitter Valve
Transmitter

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Calibration

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Definition
To calibrate an instrument means to check and adjust(if necessary) its response so
the output accurately corresponds to the input throughout the specified range.
Why Calibrate an instrument:
As instruments age, they loose stability and drift from there ideal specifications
even though they may appear to be okay physically. Calibration assures that the
instrument continually meets the specification.
How often should we calibrate:
The frequency of recalibration will vary with the type of instrument and the
prevailing conditions where the instrument is installed. However, as a rule,
instruments should be calibrated once a year. But in critical applications the
frequency will be much greater.

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 Common terms used in Instrument Calibration
Span:
Span=Upper range value(URV)-Lower range value(LRV)
mA in Linear
(% x Span in mA)+4
mA O/P in Square Root
(Sqrt of %) x 16+4 % I/P % Sqrt O/P mA (Sqrt)
% Output in Square root 0 0 4
(Sqrt of %) x 100 = % O/P 25 50 12
I/P Pressure 50 70.7 15.31
(Span x % )+ LRV 75 86.6 17.86
100 100 20

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Ranging:
Suppose we want to use pressure transmitter to measure pressure in the range of
(0 ~100 ) bar to give an output of (4-20) mA. To range this transmitter, we simply
set at:
0 bar=4mA
100 bar=20mA
Re-ranging:
Suppose we want to re-range the above transmitter now to measure pressure in the
range of (50~150) bar. To re-range, we simply set as:
50 bar=4mA
150 bar=20mA

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Five Point Calibration:
When calibrating an instrument, as a general rule, the instrument data points
should include readings taken at 0%,25%,50%,75% and 100% for rising and
falling. This is known as five point calibration.
Field Calibration:
In field calibration, the instrument is not removed from process. Field
Calibration allows field instrument to be calibrated at true process and
ambient conditions.
Bench Calibration:
It is a process in which instrument is calibrated at calibration bench using
different calibrators to simulate process variables.

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 Calibration of Temperature Element
Temperature Element is calibrated by using temperature bath by simply setting the type
of sensor and the calibration range.

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 Calibration of Temperature Transmitter
Calibration of temperature transmitter is performed by simulating
temperature from Multifunction calibrator or Decade Resistance Box (in
case of RTD) as shown in the next slide.
Before calibration, transmitter has to be configured for sensor type. Tag
number and range has to be assigned. Temporary physical address need to
assigned in case of FF transmitter.
Equipment Needed:
 Digital Multi Meter(DMM)
 Multifunction Calibrator or Decade Resistance Box
 Hart communicator
 24Vdc Power supply
 FF segment protector(for FF transmitter)
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Calibration of Temperature Transmitter

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 Calibration of Pressure Transmitter
Calibration of pressure transmitter is performed by applying pressure to the
transmitter using different kind of calibrators as shown in the next slide.
Before calibration, Tag number and range has to be assigned. Linearity type
need to be set. Temporary physical address need to assigned in case of FF
transmitter.
Calibration of DP type transmitters almost has the same procedure. DP
transmitters are used to measure Level and Flow as well
Equipment Needed:
 Digital Multi Meter(DMM)
 Pressure Calibrator
 Hart communicator
 24Vdc Power supply
 FF segment protector(for FF transmitter)
 Appropriate Tube and fittings
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Calibration of Pressure & Differential Pressure
Transmitter

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 Calibration of Control Valve
To Calibrate a control valve we need to complete device setup first
Following parameters need to be configured
 Relay Type
 Actuator Model
 Actuator Size
 Valve position at Zero power condition
 Travel
Once we have finished setting up the mentioned parameters using Hart
Communicator.
We have to go Transducer Block>Configure>Calibration or we can go to valvelink
mobile which will demonstrated in the upcoming video.
Where we will select Auto Calibration and follow the on screen prompts to
complete.
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Loop Checking

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 Definition
The Loop checking is defined as pre-Commissioning
activity for operational test / communication between
field to DCS by simulating process input using
different kind of simulators actual / virtual
from respective field instrument and cross check its
response on DCS/PLC system.

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 Prerequisite
SAT of DCS/ESD shall be completed
Total IO's shall be divided into loops
Loop Folder shall be prepared and approved from PMT/Client
Loop Check Procedure shall be prepared and approved from
PMT/Client.
Loop check shall be carried out with Handheld communicator /
Calibrators depending on the type for both HART and FF Devices
The checks shall be witnessed, loop folder documents shall be signed
by DCS contractor, EPC contractor and Client’s O&M team.

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 Contents of Loop Folders
 RFI Status
 Loop Check Cover Sheet
 Loop Check Record Sheet
 Instrument Index
 Instrument Loop diagram
 P&ID
 Instrument Specification Sheet /Data Sheet
 Instrument Installation detail / Hook-Up
 Instrument Location Plan
 Calibration Sheet
 Punch list
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 P&ID
Piping and Instrumentation
Diagram

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Tag Descriptors

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Tag Numbers

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Instrument Location

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Instrument Type & Location

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Piping & Connection Symbol

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Reading P&ID

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 ISS
Instrument Specification Sheet / Data
Sheet

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Instrument Data Sheet or Instrument Specification Sheet is a
document containing specification and information of an instrument
device. It specifies general information of instrument such as tag
number identification, service description, location (line
number/equipment number), P&ID number or drawing number
reference, process data (if applicable), calibrated range (if applicable),
material, performance details (such as accuracy, linearity – if
applicable), hazardous certification (for electrical device), accessories
required, etc. The details of information in data sheet may differ
among each types of instrument such as transmitter, switch, gauge,
control valves.

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 ILD
Instrument Loop Diagram

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Instrument Loop Diagram represents detailed drawing
showing a connection from one point to control system. It
could be connection between:
Field instrument to control system (or vice versa)
Signal from Control Panel to control system (or vice versa)
Signal from MCC to control system (or vice versa)
Signal form one control system to another system

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Instrument Installation Detail / Hook Up

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 Instrument installation Detail or Hook-up is a detailed drawing
showing typical installation of instrument in a correct manner so that
instrument operates properly (gives accurate indication and prevent
any issued which could potentially affect the measurement such as
liquid trap in gas impulse line).
Hook-up drawing indicates tubing slopes, position of instrument in
reference to process tapping point, scope break between instrument
vs piping.
Hook-up drawing also gives information the requirement of bulk
material for each installation. It also details its specification (size, type
and material) and the quantity.

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 Types of hook-up drawing
Process Hook-Up
This hook-up drawing contains typical installations for instrument
which connects to the process
Pneumatic Hook-Up
This hook-up drawing contains typical installations for instrument
which requires instrument air such as control valve, On/Off Valves.

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Instrument Location Plan or Instrument Layout

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Instrument Layout is also known as instrument location plan. This drawing
shows the exact position of each instruments with reference to plant layout. The
drawing shall detail:
 The point indication of instrument position and its mounting stand where
instrument to be mounted and process tap location. Often the tap location and
the instrument is separated quite distant. In some project, it is not mandatory
to show the process tap location.
 Elevation information of instrument (and its mounting stand) and process tap.
 Junction box location including its elevation.
 Instrument Air Manifold location including its elevation.

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Instrument Index

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Instrument index is a document containing list of instrument devices
within a plant. Instrument index shall include tag number of all
physical instruments (e.g. field instrument, physical alarm and
indicator) and pseudo instruments which commonly named “soft tag”
(e.g. DCS indication, alarm, controller).
Instrument index shall be created at the beginning of project and
considered as a live document which should be kept updated even
though the plant has been operated. Instrument index shall be revised
if there is any plant or system modification which impact to additional,
removal, or resetting of instrument.

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In instrument index document, the following information should be stated but not limited
to:
 Tag number
 Loop Number
 Type of Instrument
 Location
 Service description
 P&ID Number
 Line number or equipment number
 I/O Type
 Control System
 Range or set point along with engineering unit used
 Applicable reference Document (Instrument Data Sheet Number, Hook-up
Drawing Number , Instrument Layout Number, Loop Drawing Number)
 Package Number
 Manufacturer
 Model Number
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 Process Variables
We have four basic process variables and loop check is
executed for different instruments including valves and
transmitters related to these variables
Flow
Temperature
Level
Pressure

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 Flow
 Differential Pressure Flow Meter
 Coriolis Flow Meter
 Vortex Flow Meter
 Electromagnetic Flow meter
 Ultrasonic Flow Meter

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 Loop Test Procedure for DP Transmitter
Loop test for this type of transmitter is performed by applying actual pressure using
different types of calibrators & Pumps depending on the range of the transmitter

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 Loop Test Procedure
 All the Transmitters discussed above are special type of instruments for
which loop check is completed by performing simulation from Hart
Communicator
 For differential pressure transmitters, actual pressure is applied using
different kind of Pressure Calibrators and Pumps depending on the range
of the transmitter.

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General Simulation Steps

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 Temperature
For Temperature Measurements
 Resistance Temperature detectors (RTD)
 Thermocouple
are the most widely used technologies in industrial applications

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 RTD
 An RTD (resistance temperature detector) is a temperature sensor that
operates on the measurement principle that a material’s electrical
resistance changes with temperature.

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LEAD WIRE CONFIGURATION OF RTD
The general lead wire configuration for industrial RTD probes is three-wire
configuration. There is also two-wire type. However, the resistance value on lead
wire is added directly on a measurement, and the error is bigger than three-wire
type. Three-wire configuration, which is widely applied for industrial applications,
can offset the error and enable a precise measurement. In case more precise
measurement requires, four-wire configuration is applied.

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 Thermocouple
A Thermocouple is a sensor used to
measure temperature. Thermocouples
consist of two wire legs made from
different metals. The wires legs are welded
together at one end, creating a junction.
This junction is where the temperature is
measured. When the junction experiences
a change in temperature, a voltage is
created. The voltage can then be
interpreted using thermocouple reference
tables to calculate the temperature.
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Thermocouple Types

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 Loop Test Procedure
For Loop Test ohms are applied by using Decade Resistance Box in case of
RTD or temperature can be applied directly by using Multifunction
Calibrators like JOFRA ASC 300

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Simulation of a Thermocouple

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 Level
For Level measurement different type of transmitters are being used in the
modern industry
 Guided Wave Radar
 Magnetic Level Transmitter
 DP Type Level Transmitter

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GWR

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Commissioning of GWR

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 Magnetic Level Transmitter
Inside the probe tube there is a rigid wire made of magnetostrictive material. The sensor
circuitry emits pulses of current through the wire, generating a circular magnetic field. The
level transmitter is a magnet, which is integrated into the float. Its magnetic field
magnetizes the wire axially. Since the two magnetic fields are superimposed, around the
float magnet a torsion wave is generated which runs in both directions along the wire. One
wave runs directly to the probe head while the other is reflected at the bottom of the
probe tube. The time is measured between emission of the current pulse and arrival of the
wave at the probe head. The position of the float is determined on the basis of the transit
times.

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 Loop Test Procedure
 Loop Test for GWR is executed by performing simulation with
HART Communicator following the same simulation steps that are
discussed earlier.
 Loop Test for Magnetic Type LT is performed by moving a magnet
along with the rod which contains magnetostrictive wire or it can be
performed by simulation only depending on the Client’s O&M team
requirement.

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 Loop Test Procedure(DP Type LT)
 Loop Test for this type is executed by applying actual pressure to the High Side
Capillary
 One Important thing which must be considered is that the transducer scale of
the transmitter has to be re-ranged in order to adjust for mounting positions of
the capillary.

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 Loop Test Procedure(DP Type LT)
For example we have DP Type LT having calibration range of 0-100
mbar
And we are getting valve in AI block as 250mbar So our
 Transducer scale range at 0%=0+250=250mbar
 Transducer scale range at 100%=250+100=350mbar

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Loop Test Procedure for Pressure Transmitters
As discussed earlier loop test for Pressure transmitter in most of the cases is
carried out by applying actual pressure to the transmitter
Somewhere it is performed only by simulation depending on the type of the
transmitter.

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Vibration Monitoring System(VMS)

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 Introduction to Vibration
Vibration is an important part of any plant. It is the dynamic motion of machine
components. The vibration measurement is the measurement of the mechanical
vibration relative to a known reference. The rotor seals, bearings housing and
machine cases are the mechanical components that are of most concern. Accurately
measuring and monitoring the vibration of these components will describe the
mechanical condition of the machine.
 The principle that the vibration probes work is the change of one form of
energy into another form. For example, the mechanical vibration of the rotor
will be sense by the probes and then this mechanical energy will be changed into
electrical energy sent as a signal.

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 Types of Vibration
Radial Vibration
Axial or Thrust Vibration
Keyphasor
Siesmic Vibration

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 Radial Vibration
The Radial vibration is measured by the method of installing two 8mm
proximity probes located on the shaft with a gab distance and 90 degree
difference between them.
The gap voltage is adjusted to -10Vdc.

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 Axial or Thrust Vibration
It is the axial position of the rotor with respect to the thrust bearing or some fixed
reference. It uses two 11mm proximity probes (14mm). They should be installed in
front of the thrust bearing cooler not more than 6 inches.

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 Key Phasor
The Key Phasor probe is used to measure the speed. It uses 8mm proximity
probe located on shaft area witch has notch or projection.
It adjusted to –10vdc considering the notch place.

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 Loop Test Procedure
 Loop Test for all these types of Vibration is performed by using
Wobulator TK-3e

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 Siesmic Vibration
The casing vibration probes (Velomiters) are used on most equipment protected by
vibration system. They are used to measure the vibration on the body. The probes
are installed on the case of the machine or on the bearing case.
The casing vibration probes (Velomiters) are installed on the body of the machine
by the method of tightening the probe only without any gab voltage.

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 Loop Test Procedure
 Loop test for Velomitor is performed by using Portable Shaker Vibrator
shown below

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Control Valves

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Parts of Control Valves

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 Loop Test Procedure for Control Valve
 Control Valve should be calibrated first before it can be loop tested.
 Temporary air is to be used if plant air is not yet operational
 By using Analog Output(AO) function block from hart communicator, we can
stroke the valve from 0 to 100 %
 In other case, operator can give manipulated variable command manually bypassing
the controller and corresponding valve movement can be checked and verified in
the field.

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 Loop Test Procedure for Control Valve
As you can see in faceplate shown below taken from ABB IT 800xA. Operator
can enter MV in the Man tab and check feedback in the AO faceplate
mentioned as RB (Readback) value.

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 On/Off Valves
 Like the name suggests, on/off valves are
designed to shutoff and to open fully with
no ability to regulate effectively through
the range of travel.
 Although the functioning of an on/off
valve is simpler than a control valve,
providing for highly reliable and repeatable
tight shutoff can be equally challenging.
Shutoff valves often provide a safety
function as they are called to stop flow
quickly and positively as in a gas service
shutoff valve or a heat activated shutoff
valve.
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 Loop Test Procedure for On/Off valves
 Basically On/Off uses a solenoid to pass the air to the actuator. Solenoid
needs 24Vdc to energize and pass the air through it.
 This 24Vdc is fed in the form of a Digital output (DO) signal from the
BPCS.
 For Feedback On/Off valve uses a limit switch which sends the Digital
Input (DI) to the allocated I/O channel in the BPCS.
 Operator can give DO command from the corresponding faceplate and
verify the feedback at the same faceplate and in the graphics.
 Temporary air is used for the execution of loop test if the Plant air is not
yet operational.

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THANK YOU

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