Professional Documents
Culture Documents
GP 30-90
Applicability Group
Date 10 June 2003
GP 30-90
BP GROUP
ENGINEERING TECHNICAL PRACTICES
10 June 2003 GP 30-90
Guidance on Practice for Commissioning of Instrument and Control Systems
Foreword
This is the first issue of Engineering Technical Practice (ETP) BP GP 30-90. This Guidance on
Practice (GP) is based on parts of heritage documents from the merged BP companies as follows:
Amoco
A CO-PCOM-GEN-E Commissioning—Pre-Commissioning—General—Engineering
Specification.
A CO-PCOM-GEN-G Commissioning, Pre-Commissioning—General Guide.
A PC-PCOM-IN-C Process Control, Checkout, and Pre-Commissioning—Instrumentation
Construction Specification.
ARCO
Standard 316 Instrument Calibration, Certification, and Commissioning.
Copyright 2003, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organization. None of the information
contained in this document shall be disclosed outside the recipient’s own organization
without the prior written permission of Manager, Standards, BP Group, unless the terms of
such agreement or contract expressly allow.
Table of Contents
Page
Foreword.......................................................................................................................................... 2
1. Scope...................................................................................................................................... 5
2. Normative references.............................................................................................................. 5
3. Symbols and abbreviations.....................................................................................................6
4. General................................................................................................................................... 6
5. Instrumentation receiving and storage....................................................................................7
5.1. General........................................................................................................................ 7
5.2. Electronic instruments..................................................................................................7
5.3. Pneumatic instruments.................................................................................................8
5.4. Local control panels.....................................................................................................8
5.5. Dial thermometers, pressure gauges, and gauge glasses............................................8
6. Documentation........................................................................................................................ 8
6.1. General........................................................................................................................ 8
6.2. Records........................................................................................................................ 9
7. Installation inspection............................................................................................................ 10
7.1. Prerequisites..............................................................................................................10
7.2. General...................................................................................................................... 10
7.3. Instrument inspection checks.....................................................................................10
7.4. Piping, conduit, cable, and tubing...............................................................................12
7.5. Control valves inspection checks...............................................................................13
7.6. Temperature instruments inspection checks...............................................................14
7.7. Flow instruments........................................................................................................14
7.8. Level instruments.......................................................................................................15
7.9. Pressure instruments.................................................................................................16
8. Loop check and system checkout.........................................................................................16
8.1. Prerequisites..............................................................................................................16
8.2. General...................................................................................................................... 16
8.3. Instrument calibration and checkout...........................................................................17
8.4. Systems checkout......................................................................................................26
8.5. Alarm system components.........................................................................................27
8.6. Logic system components..........................................................................................28
9. Commissioning completion...................................................................................................28
Annex A (Informative) Figure A1 - Commissioning control loops flowchart.....................................30
Annex A (Informative) Figure A2 - Commissioning field switches flowchart....................................31
Annex A (Informative) Figure A3 - Commissioning local gauges flowchart.....................................32
Annex B (Informative) Instrument installation loop check sheet......................................................33
List of Tables
1. Scope
This GP provides guidance on commissioning activities to include receiving and storage, installation
inspection, loop check, and system checkout of process controls and instrumentation.
2. Normative references
The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For dated references, subsequent amendments to, or
revisions of, any of these publications do not apply. However, parties to agreements based on this
technical practice are encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references, the latest edition of the normative
document referred to applies.
BP
GIS 30-401 Guidance on Industry Standard for Process Automation Systems (PAS).
GIS 30-402 Guidance on Industry Standard for Programmable Logic Controllers
(PLC).
GIS 30-451 Guidance on Industry Standard for Human Machine Interface.
GIS 30-801 Guidance on Industry Standard for Safety Instrumented Systems (SIS).
GIS 30-851 Guidance on Industry Standard for Fire and gas Detection.
GP 12-XX Guidance on Practice for Field Wiring.
GP 12-XX Guidance on Practice for Heat Tracing.
GP 30-01 Guidance on Practice for Temperature Instruments.
GP 30-05 Guidance on Practice for Pressure Instruments.
GP 30-10 Guidance on Practice for Non-Fiscal Flow Instruments (Class 2 & 3).
GP 30-15 Guidance on Practice for Level Instruments.
GP 30-20 Guidance on Practice for Miscellaneous Instruments.
GP 30-30 Guidance on Practice for Field Communication Buses.
GP 30-35 Guidance on Practice for Control Valves and Pressure Regulators.
GP 30-40 Guidance on Practice for Process Automation Systems (PAS).
GP 30-45 Guidance on Practice for Human Machine Interface.
GP 30-65 Guidance on Practice for Control Panels.
GP 30-70 Guidance on Practice for Commissioning of Instrument and Control
Systems.
GP 30-80 Guidance on Practice for Safety Instrumented Systems (SIS) –
Implementation.
GP 30-81 Guidance on Practice for Safety Instrumented Systems (SIS) –
Operations and Maintenance.
GP 30-85 Guidance on Practice for Fire and gas Detection.
GP 30-95 Guidance on Practice for Control Loop Tuning
GP 31-XX Guidance on Practice on Analysers
GP 64-XX Guidance on Practice for Fiscal Flow Instruments (Class 1)
I/E Instrument/Electrical.
I/P Current-to-pressure.
IS Intrinsic safety.
4. General
a. For all checkout and commissioning activities, safety shall be the primary concern and
responsibility of all involved personnel. It is required that all commissioning personnel be
qualified to perform their assigned activities.
b. Personnel involved in calibration and commissioning of instrument systems shall have
experience and verifiable training to included but not limited to the following:
1. Calibration of instruments being installed.
2. Use of compression fittings.
3. Installation/inspection of electrical equipment in hazardous areas.
c. Commissioning personnel shall review, be familiar with, and adhere to all relevant portions
of Health, Safety and Environmental (HSE) documents and procedures.
d. Prior to commencing any work, a Job Safety Analysis (JSA) or other equivalent, site
specific, procedure shall be conducted to confirm that persons involved are trained and
competent, ensure that appropriate Personal Protection Equipment (PPE) is worn, review
emergency response plans, and emphasize that each person is empowered to stop the work
if it is perceived to be unsafe.
e. If hazardous materials (chemicals, fluids, etc.) are part of the commissioning procedure,
Material Safety Data Sheets (MSDS) shall be reviewed by all involved personnel prior to
proceeding with any related commissioning activity.
f. BP personnel will witness selected pre-commissioning and commissioning activities, at the
discretion of BP.
g. This GP groups tasks by phases of the construction cycle. Some testing and verification
steps were combined to facilitate efficient workflow.
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Guidance on Practice for Commissioning of Instrument and Control Systems
h. The safe and efficient commissioning of any facility requires associated instrumentation to
be installed completely, checked for integrity and commissioned for use. The steps
involved in achieving this process should be clearly understood and followed.
i. Refer to Annex A for examples of checkout and pre-commissioning of instrument and
control systems.
j. Prior to initiating any checkout and/or commissioning activities, mechanical completion
checklists and other appropriate documents shall be reviewed and confirmed as complete
and all components are acceptable for subsequent commissioning efforts.
k. Defective instruments shall be replaced or repaired.
5.1. General
a. Upon receipt, instruments shall be checked for:
1. Compliance with purchase specifications.
2. Correct tagging.
3. Shipping damage.
4. Relevant documentation (installation and handling instructions).
b. After inspection, instruments shall be:
1. Replaced in their original factory boxes.
2. Correctly tagged.
3. Stored on shelves in a dry, enclosed area.
c. Pneumatic and electrical openings should be closed with proper plugs and screw caps
should be securely in place if storing instruments prior to installation.
d. Integrity of sealed protective covers shall be maintained during storage.
e. For instruments or control panels that have been pre-mounted on the machinery package
and cannot be stored in a dry, enclosed area, special arrangements should be made between
representatives from the Manufacturer and BP.
f. Removal and indoor storage of pre-mounted instruments and control panels may be
required if such devices cannot be protected from rain, humidity, temperature, or dusty
conditions.
6. Documentation
6.1. General
a. Pre-commissioning documentation shall be organized either by system or by area.
b. Commissioning activities shall be performed using the current edition of the following
project documents:
1. Loop diagrams. *
2. Piping and instrument diagrams (P&IDs). *
3. Instrument index.
4. Instrument data sheets and/or specifications. *
5. Instrument calculation sheets. *
6. Level transmitter URV and LRV calculations (if applicable). *
7. Orifice inspection records. *
8. Instrument design drawings.
a) Instrument location drawings.
b) Wiring diagrams.
c) Junction box drawings.
d) Cable schedules.
e) Instrument installation detail drawings.
f) Relevant motor schematics. *
g) Marshalling cabinet drawings.
h) Shutdown schematics (if applicable). *
i) Specialized documentation unique to specific loop types (for example, trip point
calculation for current switches, panel drawings, etc.). *
9. Instrument supplier data.
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6.2. Records
a. As each instrument is checked, calibrated, and commissioned, a certification record shall
be completed. These records shall include the following information:
1. Complete listing of calibration test equipment being used and acceptable tolerances.
2. Record of test equipment calibration checks that have been performed.
3. Readout or output values from the calibration.
4. Commissioning services performed.
5. Deficiencies noticed.
6. Concerns identified.
b. Factory certification shall be included for factory-calibrated instruments. These
instruments should be verified, but not recalibrated, in the field.
c. For each instrument loop, a separate document file shall be maintained. The following
items shall be included in the file:
1. As-built status of installation.
2. Calibration, testing, and final instrument loop certification of control system
components.
3. Subsystems provided for the facility.
d. A complete set of project drawings, marked up to reflect the as-built condition of all
instruments and subsystems, shall be required at the end of the project.
e. Changes to documents shall be recorded to show the “as-built” condition of the document.
The following colour-coded format should be used:
1. Additions shall be in red.
2. Deletions shall be in green
3. Comments should be in blue or grey.
7. Installation inspection
7.1. Prerequisites
a. Air headers, takeoff lines, and signal tubes shall be cleaned by blowing clean, dry air
before connecting to instrument components.
b. Before the installation of inline instrumentation components, process lines, tanks, and
pressure vessels shall be prepared as follows:
1. Cleaned.
2. Flushed.
3. Pressure-tested.
4. Blown down, if applicable.
5. Placed in service, if feasible.
7.2. General
a. Some installation inspection activities may be deferred and combined with system
checkout or loop check.
b. A mechanical completion documentation (including a punch list) shall be submitted to BP.
c. Inspection of local gauges shall be performed just before commissioning activities are
started.
d. Miscellaneous and special instruments shall be checked for correct installation in
accordance with manufacturer instructions and instrument specifications.
e. Instruments shall be isolated during initial field inspection as follows:
1. Signal and process valves shall be closed.
2. Instruments shall be electrically de-energized.
the instruments or systems are listed or approved for use in the specified electrical area
classification.
m. Case bolts, stem clamps, yoke lockouts, and travel indicators are tight and packing gland
bolts are torqued in accordance with Manufacturer instructions.
n. Low-temperature thread sealants have not been used in high temperature applications.
o. High point vents and drains have been provided, if required, and verified that they have
pipe plugs.
p. Air vents and exhaust ports have bug screens installed.
q. No physical damage, including paint damage or cracked glass, has occurred to the
equipment.
r. Unused instrument and electrical equipment are plugged with proper plugs.
s. For instruments and tubing that require heat tracing, installation inspection shall be
according to GP 12-XX and the following:
1. Verification of adequate coverage, arrangement, and accessibility.
2. Continuity testing of the heat tracing installation.
3. Heat limiting arrangement to prevent boiling in impulse lines and accelerated
corrosion.
7.4.1. General
a. Piping, conduit, cable, and tubing shall be inspected for proper support in accordance with
specified requirements.
b. Piping and tubing in instrument signal air service shall be tested in accordance with
ISA 7.0.01.
c. Tubing connections shall be tight and in accordance with Manufacturer specifications.
d. Tubing connectors (nuts, ferrules, and fittings) shall be from the same manufacturer and of
the same type.
e. Tubing and instruments shall be leak-tested and the inside diameter of tubing and piping
verified.
f. Leak test should consist of the following:
1. Apply the maximum input signal input pressure to the process connection.
2. Close the inlet and disconnect the pressure source.
3. Observe the gauge on the signal inlet and ensure there is no fall-off of pressure over a
given period.
4. If leaks are evident, these shall be eliminated and the test repeated.
g. Field mounted electrical instruments using conduit shall have seals installed with sealant
as specified.
disassembled for inspection. For each improperly made up fitting, an additional two
fittings shall be inspected by disassembly.
b. Inspection criteria for tubing compression fittings shall include:
1. Cleanliness.
2. Burrs or deep longitudinal scratches.
3. Square tube ends.
4. Galling of the ferrule or fitting seat.
5. Tubing is out of round from bends being located too close to the fitting.
6. Tube bottoms in fitting body.
7. Ferrule adequately biting the tube and back from the tube end.
8. Ferrule(s) fitted correct way round.
4. Ball checks.
5. Heat tracing.
6. Other accessories.
c. External float and displacer type level instruments shall be checked as follow:
1. The float chamber shall be blocked, drained, and vented during hydrostatic testing.
2. The operation shall be field checked mechanically by raising and lowering the
displacer with water.
3. The cage shall be checked to ensure it is plumb.
d. Internal float and displacer type level instruments shall be removed during hydrostatic
testing.
8.1. Prerequisites
a. The following shall be verified before loop check or system checkout:
1. All items are mechanically completed.
2. Installation inspection is completed.
3. Compliance with local requirements and regulations.
b. Pressure testing and blowing out of tubing runs shall be completed before initial
connection to instruments.
c. All documentation pertaining to the loop should be available as per section sub-clause
6.1.1.1.c
8.2. General
a. For loop checking, 24-hours notice should be given to BP. This advance notice allows the
following BP personnel to plan to attend the loop check:
1. Instrument/Electrical (I/E) representative, who is responsible for signing off on the
loop check sheet,
2. Operations representative.
b. The following procedure should be followed to ensure all elements in the loop are
checked:
1. Check each loop in accordance with the latest revision of the “approved for
construction” loop diagram.
2. As the loop check proceeds and elements are checked, highlight verified portions of
the loop drawing.
3. Complete the appropriate loop check documentation.
4. When a loop check is complete and signed off, place a green dot on all major
components. If any work that could affect the loop is subsequently performed, notify
instrument personnel to recheck the loop.
5. The loop check should include a test label, with tester’s initial and date for
traceability.
c. Discrepancies, errors, or deficiencies shall be corrected and rechecked.
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Guidance on Practice for Commissioning of Instrument and Control Systems
d. The sequence of loop certification shall be coordinated with area construction schedules.
e. Loops shall be checked as a complete system, from inputs to outputs.
f. Loop checks shall involve checking components in all positions and under all scenarios to
ensure they work correctly, both locally and from the process automation system (PAS).
g. If an impact to operations may occur, Operations shall be advised of the loop to be
checked. In such cases, the state of the input shall be verified before proceeding.
h. A functional loop check shall be made while all loop instruments are energized.
8.3.1. General
a. Factory calibrated instruments should be verified by corresponding certification.
b. Instruments that have been factory calibrated shall not be recalibrated in the field.
c. Calibrate in the field only if not already factory calibrated. If certified factory calibration is
found to be wrong, the Manufacturer should be notified and the instrument replaced. Do
not recalibrate onsite.
d. If the calibration check indicates that the instrument will operate within the manufacturer
stated accuracy, additional calibration shall not be required.
e. Calibration of instruments shall be reserved only for those devices that, upon checking, are
not within their specified operating range.
f. Calibration checks shall be documented.
g. Stickers with the following information shall be attached to instruments that have been
checked and calibrated:
1. Date and time of calibration verification.
2. Technician identification.
h. To verify, calibration checks should be performed as follows:
1. At a minimum of three calibration points (0%, 50%, and 100% of operating range), or
otherwise indicated.
2. For smart transmitters, use electronically simulated outputs.
3. For standard analogue transmitters, use simulated process variable inputs.
4. Check calibration from each field device through the PAS to each device that uses the
selected variable and any combination of devices that use the selected variable and
other variables.
i. Check loop components for:
1. Correct readout or response at each transmitter input level.
2. Correct action of the controller, positioner, and control valve.
3. Incorrect response or readout shall be reported for correction.
j. Instrument covers and enclosures that were removed for calibration shall be replaced.
k. Loop check personnel shall not change calibration or system ranges without BP approval.
l. Conflicting data encountered between calibration ranges of field devices and displayed or
configured ranges within the PAS shall be brought to BP’s attention for resolution.
m. Signals shall be simulated at the input of the end device as shown in Table 2 (for analogue
transmitters) and Table 3 (for switches).
n. Digital communications devices may be used to set smart transmitter output to the required
levels for loop checking.
o. Smart transmitters shall be operationally tested and digitally ranged.
p. Input devices should be checked as follows:
1. Read and confirm correct value(s), as appropriate, on the PAS, at the panel, and at the
marshalling cabinet (if the device is a relay input).
2. For signals that enter multiple locations [for example, surge control points and
programmable logic controller (PLC) points], values should be checked at all input
locations.
3. For PLC inputs, use a voltmeter or check the input card indication light.
4. For relays, use a voltmeter or visually check the relay state.
5. Check local indicators or other remote indicator readings.
q. If feasible, correct outputs should be verified as shown in Table 4.
r. Using loop drawings or shutdown schematics, input and output interaction should be
checked for action direction as follows:
1. For control loops, increasing or decreasing transmitter input should open or close the
control valve, as applicable.
2. For shutdowns, toggling the inputs should cause solenoid valves or other end devices
to open or close or be on or off, as applicable.
s. After input wiring has been confirmed to the shutdown panel, subsequent toggling of the
input may be accomplished by removing the appropriate fuses at the input termination
strip.
8.3.4. Switches
a. Instruments that are two-position devices should not be calibrated over their full range.
Only the trip point and dead band (reset point) should be checked.
b. Switches used in alarms, shutdown, or signal switching service shall be set to specified
values by applying a rising and falling signal.
c. Dead bands shall be checked to ensure they are within the Manufacturer published
tolerance.
e. Throttling butterfly valves are set for maximum travel restrictions in accordance with
specifications.
f. The following shall be completed and recorded:
1. Check valve failure action.
2. Set position indicator.
g. Operation of valve accessories shall be checked, including:
1. Handwheels.
2. Solenoid valves.
3. Limit switches.
4. Boosters.
5. Relays.
h. Handwheels shall be in neutral position before stroking valves.
i. Diaphragm and piston-operated control valves shall be pneumatically stroked using a
regulator and test gauge.
j. The following shall be verified to be in accordance with Manufacturer nameplate data and
job specifications (if applicable) and recorded:
1. Valve action.
2. Mechanical seating.
3. Spring range or bench setting shown on valve nameplate.
4. Valve travel (including bench set).
5. Valve failure position.
6. Actuator setting (either reverse or direct action) is in accordance with Manufacturer
specifications.
7. Limit switches indicate full open and close.
8. Solenoid valves bleed the actuator when energized or de-energized.
9. Boosters amplify the pneumatic signal in compliance with Manufacturer
specifications.
10. Handwheel, if provided, opens and closes the valve and in neutral position, permits
automatic control.
11. Relays, if provided, activate in accordance with Manufacturer specifications.
12. Rotary valve plugs seat properly and are operating in the proper quadrant.
13. Local valve position indicators are installed properly to match valve position.
k. If valve includes a volume booster bypass valve, the gain shall be set by backing out the
adjusting screw 1-1/2 to 2 turns from closed and shall be checked for stable operation.
l. I/P transducers that output to control valves shall be calibrated to be direct acting, with an
output range of 0,2-1,0 bar (g) (3-15 psig) or 0,4-2,0 bar (g) (6-30 psig) for a
corresponding input of 4 to 20 mA.
m. Valve positioners and other auxiliary devices (for example, limit switches, position
transmitters, and trip relays) shall be verified in accordance with nameplate data and
Manufacturer specifications.
n. Check valve for smoothness of operation (hysteresis and stiction) according to the
pertinent sections on control loop tuning, GP 30-95.
o. Manually operated valves (including skid mounted valves) shall be manually sequenced
and spindle rotation and integrity shall be verified.
g. For instruments with suspected calibration and/or calibration is deemed necessary the
following guidance should apply:
1. Thermal-filled system temperature instruments shall be calibrated as follows:
a) At three calibration points, minimum (0%, 50%, and 100% of operating range).
b) By immersing the sensing bulb in a precisely controlled and agitated
temperature bath that is continuously monitored with a precision thermometer.
2. Non-factory calibrated thermocouple transmitters and receivers shall be calibrated, if
required, as follows:
a) Apply upscale and downscale millivolt signals from a precision voltage source.
b) Verify and adjust upper and lower operating limits.
c) Recheck the three-point calibration.
3. Non-factory calibrated RTD transmitters and receivers shall be checked, if required,
as follows:
a) Use a precision decade resistance box.
b) Verify and adjust upper and lower operating limits.
c) Recheck the three-point calibration.
h. Temperature switches shall be checked and set in accordance with procedures in Table 5.
6. Magnetic meters.
7. Target meters.
e. Thru-flow type flow switches shall be mechanically checked only.
f. Differential pressure type flow switches shall be checked as follows:
1. Calibration shall be against a standard water column manometer or precision gauge.
2. Dead band of switches shall be verified against the Data Sheet.
1. Calibrate pressure switches using hydraulic tester, dead-weight tester, or precision air
regulator and an output gauge to set the required alarm and trip point.
2. Verify dead band of the switches against the Data Sheet.
d. If pressure gauge reading suspect, the manufacturer should be notified and the instrument
replaced.
e. For critical pressure gauges and/or as required by the BP engineer the following may
apply:
1. Bourdon tube type pressure gauges should be checked at 10%, 50%, and 90% of full
scale. If gauge varies more than ±1,0% from true reading at any of the three points,
gauge should be replaced and/or recalibrated.
2. Draft type instruments shall be bench calibrated using an inclined-tube manometer or
precision accuracy strain gauge at 0%, 50%, and 100% of range.
3. Receiver type pressure gauges should be field checked to verify calibration at three
points (0%, 50%, and 100% of span).
4. Diaphragm type draft gauges shall be field checked to verify calibration as follows:
a) Verify calibration at three points (0%, 50%, and 100% of span).
b) Use a water column or inclined tube manometer in accordance with
Manufacturer recommended procedure.
8.4.1. General
a. The complete functions tested during FAT should not be retested onsite.
b. Retesting or an acceptable subtest should be required only to verify proper installation and
integration with other systems onsite.
c. Additional requirements for specific systems shall be in accordance with the following:
1. GP 30-30 for fieldbuses.
2. GP 30--40/45 and GIS 30-401/402/451 for process automation systems.
3. GP 30-65 for local control panels.
4. GP 30-70 for vendor package equipment.
5. GP 30-80/81 and GIS 30-801 for safety instrumented systems (SIS)
6. GP 30-85 and GP 30-851 for fire and Gas (F&G) systems.
d. Control systems components shall be checked as follows:
1. Check dynamic variables on each graphic screen during loop checks and verify
readings are correct.
2. Verify commands from operator consoles and screens.
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8.4.2. Controllers
a. Ratio controllers shall be checked by feeding a known signal into the station and observing
the output for various set ratios.
b. Set control modes, set points, and tuning parameters.
c. If controller tunings are not known, refer to GP 30-95 for guidance on control loop tuning.
d. After loop checking, controllers shall be left in manual mode.
a. Electrical devices that are part of an interlock, shutdown, or auto start circuit shall be
checked as follows using a pre-developed test plan:
1. Devices shall be thoroughly checked as an integrated system for continuity and
operation.
2. Shutdown and interlock responses shall be checked against shutdown and interlock
logic diagrams.
b. Switching and shutdown systems shall be checked as follows:
1. Perform check from the originating device to the switching or shutdown function.
2. Verify the operation of each circuit using the latest issue of the designated
logic/ladder drawings.
3. Record changes to logic/ladder drawings and show on “as-built” logic/ladder
drawings.
4. Check PLC systems using Manufacturer-provided system test procedures.
c. Process-actuated switches and process transmitters shall be checked as follows:
1. Activate by simulating the process variable or by manual trip.
2. Perform functional test, without use of jumpers.
d. Each shutdown system shall be checked as follows:
1. Verify failsafe design philosophy.
2. Verify the correct state of each output on loss of power to the logic system and on loss
of power to the field devices.
9. Commissioning completion
13. Place instruments in service by opening or closing instrument shutoff valves and
equalizing valves in instrument manifolds.
14. Vent air from instrument sensing lines in liquid service.
15. Drain liquids from instrument sensing lines in gas service.
c. Instruments and loops shall remain powered or pressurized with switches and valves set in
accordance with the startup requirements.
d. Control and instrumentation is considered to be commissioned and ready for startup when:
1. Mechanical completion checklists are signed off as complete.
2. All loop checks and system checkout are signed off as complete.
3. All punch lists are signed off as complete.
4. All commissioning activities are signed off as complete and ready for startup.
Annex A
(Informative)
Figure A1 - Commissioning control loops flowchart
MAKE A PACKAGE
CONTROL LOOPS FOR EACH LOOP
START
WITH ALL
PERTINENT INFO
CHECK CONTROL
VALVE OPERATION
VERIFY FROM CONTROLLER
INSTRUMENT PER & VERIFY FAILURE
DATA SHEET/ MODE
SPECIFICATION
SIMULATE 50% PV
NO AT TRANSMITTER &
VERIFY SET CONTROLLER
CALIBRATE IN SHOP, CALIBRATION OUTPUT TO 50% IN
RECORD RESULTS, CERTIFICATION MANUAL MODE
COPY TO LOOP COPY TO LOOP
PACKAGE PACKAGE. DO NOT
RECALIBRATE PUT LOOP IN AUTO &
INCREASED
SIMULATED PV,
CHECK VALVE
INSTALL ACTION AND
INSTRUMENTS RECORD RESULTS
RECORD FINDINGS
REWORK TO
AND COPY TO LOOP
INSPECT IS LOOP NO CORRECT
PACKAGE
INSTALLATION PER SATISFACTORY? DEFICIENCIES
INSTALLATION & RETEST AS
DETAILS, RECORD REQUIRED
RESULTS & COPY TO VERIFY ALL PAS YES
LOOP PACKAGE INDICATIONS
ALARMS, PAS
GRAPHICS, ETC. SIGN OFF AS
COMPLETE
YES INSTALLATION &
SPECIFICATION
OK? ENSURE
SIMULATE PROCESS PAPERWORK IS
THREE POINTS COMPLETED &
NO
CHECK (0%. 50%, PROPERLY FILED IN
100%) LOOP
REWORK TO DOCUMENTATION
CORRECT PACKAGE
DEFICIENCIES
Annex A
(Informative)
Figure A2 - Commissioning field switches flowchart
VERIFY
INSTRUMENT PER
DATA SHEET/
SPECIFICATION
FACTORY YES
CALIBRATED?
NO
VERIFY
CALIBRATE IN SHOP, CALIBRATION
RECORD RESULTS, CERTIFICATION
COPY TO LOOP COPY TO LOOP
PACKAGE PACKAGE. DO NOT
RECALIBRATE
INSTALL
INSTRUMENTS
RECORD FINDINGS
AND COPY TO LOOP
PACKAGE
INSPECT
INSTALLATION PER
INSTALLATION
DETAILS, RECORD
RESULTS & COPY TO
VERIFY ALL
LOOP PACKAGE
INDICATIONS SIGN OFF AS
ALARMS ETC. COMPLETE
Annex A
(Informative)
Figure A3 - Commissioning local gauges flowchart
START
LOCAL INSTUMENT
(GAUGE,
THERMOMETER,
SIGHT GLASS)
VERIFY
INSTRUMENT
AGAINST DATA
SHEET/
SPECIFICATIONS
INSTALL
INSTRUMENTS PER
INSTALLATION
DETAIL
INSPECT
INSTALLATION PER
INSTALLATION
DETAILS, RECORD
RESULTS & COPY TO
LOOP PACKAGE
NO
REWORK TO
CORRECT
DEFICIENCIES
SIGN OFF AS
COMPLETE
END
Annex B
(Informative)
Instrument installation loop check sheet
HOA->OFF Watch HW command switches from START->STOP HOA->AUTO, verify doesn't restart Verify Vibration S/D