TABLE OF CONTENTS
1........... SCOPE
2........... PURPOSE
3........... REFERENCES
4........... DEFINITION
5........... RESPONSIBILITIES
6........... PROCEDURE
7........... ATTACHMENTS
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
No comments:
Post a Comment