Calibration, Installation & Commissioning of Instrumentation

It is so important for any Engineer deal with industry facility to understand the phases of project life cycle 

Project life cycle  of Process Field Instrumentation

1 Planning

2 -Design

3- Installation

4 -Pre- Commissioning

5- commissioning

6-Startup

7- Initial Operation

8 - Maintenance

Planning With out planning you will not be able to carry out a plant safely and in time

Which items you have to plane for fast , safe and successful plant execution 

•Risk assessment (•Safety is the first priority during any process eg. "HAZOP" (Hazard and operability analysis ) It is to identify and assess risk)

•Completion priority

•Documents

•Manpower

•Tools

Design

•Design basis

•"P&ID" design

Installation

•Initially, Instrumentation Engineers and supervisors mark the :

1.location of Instruments.

2.Junction boxes.

3.Identify cable routing.

• Locations will be marked on nearby structures, vessels, etc.

•Civil foundations, structural, mechanical static equipment will be installed first.

•Based on the work front available to install Instruments, the Instrumentation team will start their activities.

Pre- Commissioning

• Confirm calibration settings , ranges

Calibration is adjustment to ensure that the instrument give accurate reading.

Its done by comparing the readings on an instrument with reference one.

• Cold and Hot loop check

  • Cold loop testing is done without powering up, ie the wiring integrity is tested through loop resistance and continuity check.

  • Hot loop test is done by simulation of the automation controller (PLC, DCS) and the I/O, Functions etc. are tested.

• Stand alone tests confirm no damage after installation

  • FAT Factory acceptance testing (manufactory) is simply a test for a newly manufactured control system that takes place at your factory or your workshop before you ship the control panel to the customer.

  • SAT Site acceptance testing (vendor or commissioning team)

  • SIT Site integration testing (confirm equipment functions as a system)

  
  

  Commissioning

• Usually it is the phase when design process fluids are introduced to the systems and sub system

• Cold commissioning

  •Dry commissioning : tests and procedures without fluids yet introduced to the plant

  •Example activities : Interlock and emergency shut-down tests

  •Control system sequence checks

  •Wet commissioning : tests and procedures with safe fluid (water or solvent) has been introduced into the systems and sub-systems

  •Example activities “running pumps with closed loops”

• Hot Commissioning "Live commissioning"

  •Design process fluids are introduced to the systems and sub-systems

  •Example activities “running pumps with closed loops”

Startup The phase in a project where the entire plant (all systems and sub-systems) are taken into operation, Process fluids are introduced and process conditions are established with the intent of making products

Initial operation The entire plant is running in continuous operation, fine-tuned and prepared for the performance test.

Maintenance

•Preventive Maintenance

•Corrective Maintenance

•PREDICTIVE Maintenance

•EMERGENCY Maintenance

•RENOVATION Maintenance

I hope you will enjoy learning.