Monday, December 5, 2016

METHOD STATEMENT FOR PRESSURE GAUGE AND RELIEF VALVE CALIBRATION

TABLE OF CONTENTS


1........... SCOPE.. 3
2........... PURPOSE.. 3
3........... REFERENCES.. 3
4........... DEFINITION.. 3
5........... RESPONSIBILITIES.. 4
6........... PROCEDURE.. 4
7........... ATTACHMENTS.. 8
      1.            SCOPE
This procedure sets out the requirement, principle & responsibilities for the calibration of pressure gauges and pressure relief valve to be utilized in the hydro testing and pneumatic testing of fabricated and erected piping system in accordance with ARAMCO specification for package 4 and ISO 10012-2003 requirements.

2.    PURPOSE


The purpose of this procedure is to provide guidelines for the calibration of pressure gauges and pressure relief valves and determine individual setting such as pressure test and range are correct and within allowable tolerance for their safe efficient operation.

3.    REFERENCES


SAES-A-004                    General Requirements for Pressure Testing
(Paragraph 7.1.5)

SAES-L-150                     Pressure Testing of Plant Piping and Pipeline

API-576                            Inspection of Pressure Relieving Device

ASME B 31.3                   Process Piping

ISO-10012-2003              Quality assurance Requirement for Measuring Equipment

Contract Schedule “ Q “ attachment IV, chapter 4 section 6.2

4.    DEFINITION


4.1  Calibration

            The set of operations which will establish under specified conditions, the relationship between values indicated by measuring instrument and the corresponding value of a quantity by a reference standard.

4.2          Testing

            The operation of proving an items ability, to meet specified criteria by subjecting it to simulated operational conditions, to verify its conformance and accuracy

4.3          Calibration and Test facility

            A location where permanent calibration and testing laboratory, A portable unit prepared specifically for the purpose of completing calibration and testing at premises or site location



5.    RESPONSIBILITIES


QA/QC Manager

Responsible for maintaining the calibration record to assure re-calibration on schedule to provide documentation of calibration, QA/QC manager has the overall responsibility for the quality aspect associate with any calibration and test activities conducted throughout the project.

QC Instrument Inspector

Responsible to report all quality aspects associated with the calibration and testing to QA/QC manager, He shall be responsible for all required action and activities during the calibration and test equipment. He shall maintain a library of procedure, work instruction and any required reference documents to provide direction and guidance during calibration.

Instrument Technician

Responsible to conduct calibration and testing of equipment as per procedure and reference standard, He shall report and take their direction from QC Instrument Inspector and under his direction. Shall complete required calibration and test in accordance with documented requirement, report and report on the findings


6.    PROCEDURE


6.1          Calibration and Test Facilities

6.1.1      The following general equipment and documents shall be available as a minimum requirement for any operational activity.

a)    Appropriate work benches and shelves or rack for the instrument being inspected, repaired, calibrated and stored.

b)    Temperature/ Humidity controlled atmosphere with a relatively dust-free environment. Restriction shall be placed on vibration or electromagnetic disturbance to an extent that permissible level shall no effect the calibration and testing activity.

c)    A complete set of relevant hand tools and aids.

d)    A full of set of inspection, measuring and test equipment, calibrated by an approved authority/ third party laboratory to the required accuracy and shall be traceable to a known international standard. This shall be classed as the reference or a master instrument.

e)    A copy of the calibration data sheet for each referenced instrument.

f)     Relevant instrument operating and repair manuals, where specifically referenced.

6.1.2      A separate safe and secure area will be established for high pressure and relief valve testing equipped as a hydrostatic and pneumatic test facility with the required volume manifolds and ancillary equipment.

6.1.3      All calibration and test equipment will be suitable for its intended use and will be certified for that specific use. As a general rule volume manifolds will be manufactured in accordance with ASME B 31.3 or relevant applicable codes. Fluid manifolds will be tested at 1.5 times the maximum required manifolds for air testing 1.1 times maximum operating pressure. The maximum test operating pressure must be identified in white paint lettering of maximum of 1” in height in a prominent place on the manhole. All volume manifolds will have a suitable safety relief valve fitted set to the maximum operating pressure.

6.2          Calibration

6.2.1      Before any calibration or test is undertaken reference instruments or equipment shall be checked for conformity and calibration validity. Only instruments specifically identified on the measuring and test equipment calibration log sheet shall be used by ARAMCO.

6.2.2      Calibration shall only be performed by suitably qualified and experienced personnel who have been assigned to the work by the facility.

6.2.3      Only approved testing medium: i.e., potable water shall be used.

6.2.4      Unless identified with current calibration sticker, all items or equipment will be considered out of calibration.

6.2.5      All items returned for calibration will immediately have any previous stickers removed and the items places in a holding area and fitted with an identification tag.

6.2.6      All items checked with reference equipment which are subsequently found to be inaccurate shall be regarded as non-conforming, until they are re-examined or tested with equipment of proven accuracy. At this reason absolute traceability is essential so that equipment can be recalled.

6.2.7      Where an instrument or items of equipments is found to have initial readings excessively high or low during calibration, a query shall be raised with CONTRACTOR/ ARAMCO to enable them to re-check any on site readings taken with that instrument.

6.2.8      After calibration or test the adjustment point (s) of any instrument or equipment shall be sealed to prevent any unauthorized access.

6.2.9      A calibration label shall be fixed to each calibrated instrument, if the item is too small for the label to be affixed then it shall fixed to its box or container if traceability can be assured. The label shall indicate the instrument serial number. Date calibrated and due date of next calibration.

6.2.10   A calibration test report and certificate shall be completed for each calibration and test performed and shall indicate the following:

a)    The instrument serial no.

b)    Instrument reading

c)    Reading as received

d)    Reading after adjustment

e)    Calibration date and next calibration due date

f)     Date

6.3 Inspection and Witness

Prior to any calibration activities, the RFI shall be raised by the QA/ QC inspector to witness the calibration of Pressure Relief valve and Pressure Gauges.

6.4          Calibration of Instruments

6.4.1      Pressure Gauges

l The pressure gages shall be calibrated by a dead weight tester shall be at +/- 2% tolerance.

l Align equipment at zero.

l Apply actuating pressure full range and lock-in signal pressure check system for leaks, then reset to zero.

l Apply actuating pressure of 25, 50, 75 and 100% of range and record in calibration data sheet.

l Reduce actuating pressure 75, 50, 25 and 0% of range and record in calibration data sheet.

l When necessary adjustment according to manufacturers shall be made until the quoted accuracy in obtained.

l After successful calibration, the pressure gauges stickers shall put in the place and specified the serial number, date of calibration, due for calibration and initial of instrument technician.

l All pressure gauges shall be (1) month validity after calibration as per SAES-A-004 standard.

6.4.2     Pressure Relief Valve

l Prior to testing, the pressure relief valves shall be subject to a thorough visual inspection for any obvious surface damage.

l The valves shall be mounted on test rig.

l Test gauges used for checking the set value shall be at +-1%.

l The pressure of the test medium shall be increased gradually until valve lifts at the cold set pressure specified on the data sheet.

l The result shall be recorded (see attached calibration data sheet)

l After successful testing of the cold set pressure, the valve shall be subject to a seat tightness test.

l The applied pressure of the testing medium shall increase gradually to 90% of the “cold set pressure”.

l The result shall be recorded on calibration data sheet.

l Acceptance criteria-For a valve with a metal seat, the leakage rate in bubbles per minute shall not exceed 50% of the appropriate value in API 576 table1. For soft-seated valve, there shall be no leakage for 1 minute (0 bubbles per minute).

l All Pressure Relief Valves shall have one (1) week validity after the calibration per SAES-L-150 standard.

6.4.3      Testing Manifold

l Will be performed by third party.

6.5          Calibration Record & Status

6.5.1      Calibration and testing operation on instrument or equipment shall be recorded and maintained on a calibration log. This wherever possible, should be a computerized format.

6.5.2      Newly purchased calibrated items shall be included in the calibration and test log. These shall be substantiated by relevant manufacturers calibration certificates, which shall be clearly identify calibration and due date.

6.5.3      The calibration and test log shall be maintained to provide traceability and status of all instruments and equipment including, but not limited to those distributed or allocated projects the fabrication shop or outside customers.

6.5.4      An instrument status report shall be issued for any test instrument/ equipment that has failed performance test conducted. Any defects or deviation of the instrument on its specified tolerance shall be indicated ion this report.

6.5.5      Any instrument that has not been returned by the calibration due date will result in a non-conformance report being issued. The above does not apply to where a site mobile laboratory has been established apart from the requirements for the reference or mater instruments, or equipment.

6.5.6      CONTRACTOR reference instrument shall themselves require periodic calibration in accordance with the manufacturer’s instructions and all reference instruments shall be calibrated to a prescribed tolerance, which shall in all cases be higher than the requirement for which they are to be used.

6.5.7      All calibration report for reference instruments shall identify all recorded deviations prior to adjustment. On return to CONTRACTOR the QA/ QC manager shall review these records to evaluate whether recorded deviations will impact the validity of tests on instruments or equipment previously conducted with the particular item. Where the impact is considered to be detrimental items shall be recalled for verification.

6.6          Handling and Storage

6.6.1      All instrument and equipment for calibration and testing shall be checked on receipt for damage and deficiency, any item found to be defective or incomplete at this stage, or during subsequent calibration, or testing shall be reported to the originator and their disposition agreed before any further action.

6.6.2      Instruments or equipment once certified as being a current calibrated or tested condition must be in handled with care and protected from any impact, vibration or electromagnetic disturbance that could affect the accuracy of the instrument.

6.6.3      Calibrated or test instrument and equipment shall be stored in a vibration, impact and dust free environment. Away from direct sunlight and sudden change in temperature.


7.                ATTACHMENTS


l Attachment 1 – Calibration Data Sheet (Pressure gauge)

l Attachment 2 – Calibration Data Sheet (pressure Relief valve)

l Attachment 3 – Calibration Sticker

l Attachment 4 - measuring and Test Instrument calibration Log Sheet

l Attachment 5 – Job Safety Analysis










l ATTACHMENT 1


Calibration DATA SHEET

PRESSURE GAUGE
                            Cert. No.:
Manufacture:
Tag Number :
Model Type:
Calibration Data:
Serial Number:
Calibrated By:
Set pressure:
Witnessed By:

Percent
Desired Value (PSI)
Actual Value (PSI)
Error

Rising/ Decreasing
Rising/ Decreasing

0%



25%



50%



75%



100%



75%



50%



25%



0%




CALIBRATION DEVICED DATA
Description
Dead Weight Tester
Manufacture

Model

Serial Number

Control Number

Last calibration

REMARKS



l ATTACHMENT 2


CALIBRATION DATA SHEET


PRESSURE GAUGE
                            Cert. No.:
Manufacture:
Tag Number :
Model Type:
Calibration Data:
Serial Number:
Calibrated By:
Set pressure:
Witnessed By:

CALIBRATION RESULT
Number of Trials
Set pressure(psig)
Error %
Reset Pressure (psig)
1




2




3





CALIBRATION DEVICE DATA

Description
Pressure test Gauge
Dead Weight Tester
Precision pressure Calibration
Manufacturer




Model




Serial No.




Control No.




Last Calibration




REMARKS









l  ATTACHMENT 3





CALIBRATION LABEL/ STICKER FOR
PRESSURE GAUGE





PG SR NO.:
CAL. DATE:
DUE DATE:
CAL BY:

Actual Size : 2cm x 4cm




CALIBRATION LABEL/ STICKER FOR
PRESSURE RELIEF VALVE





PSV SR NO.:
CAL. DATE:                         DUE DATE:
SET PRESSURE:
CAL BY:


Actual Size: 2cm x 4cm

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