PREPARED BY

EO-EG TEAM
 TABLE OF CONTENTS

 PURPOSE
 SCOPE
 INTRODUCTION (DEFINITION)
 WHAT WE WILL DO IN LOOP CHECKING
 TYPES OF LOOPS
 RESPONSIBILITY MATRIX
 GENERAL TESTING REQUIREMENT
 LOOP TEST FLOW CHART
 LOOP TEST DOCUMENTATION & FOLDER CONTENTS
 LOOP TESTING METHODES AND PROCEDURE
 LOOP TESTING FORMS
 PURPOSE

The purpose of this document is to assure that all the

control loops installed by the contractors are
operational and within applicable standards and
manufacturer’s tolerances and that systems are
installed in accordance with design specifications.

With this method cost and time will be minimized

and safety integrity will be maintained.
 SCOPE

This technical report is an informative document

providing guidance on performing testing of control
loops.
It covers the functionality test of digital and analog
instruments and controllers used in all areas of the
plant.
Inspection of all parameters and instrument response
based on the checklist will depend on the approved
Inspection & Test Plan (ITP) of the construction.
 DEFINITIONS
 Loop – is defined as a combination of one or more instruments
arranged to measure and / or control a process variable i.e. form the
measuring device, including all components in between
(electrical/pneumatic)

 Loop Checking – is defined as the checking for correct operation of

all instrument systems and loops and the preparation of all
instrumentation for commissioning. This includes the operation of
equipment by means of the plant wide Distributed Control System
(DCS), ESD, FGS and correct operation of the associated graphics on
the Man Machine Interface (MMI).
 WHAT WE WILL DO IN LOOP CHECK
 Before execution, all test equipment shall be prepared and calibrated, the
necessary connector
 The complete instrument loop shall be tested as one system, and when
necessary adjustment shall be made
 Associated alarms and trip actions of PCIMS and/or board-mounted
instruments shall be checked.
 Based on the sequence, each loop will be checked from field devices, through
the process interface equipment and to the control room consoles via data
highway
 Signal will be generated from the field devices, and the test data will be filled
in, then stamped on the loop wiring diagrams under the supervision of client
with signature by both
 The loop interfaced with packaged local panel shall be loop tested by
simulating/checking signals at the interface terminal block directly.
 WHAT WE WILL DO IN LOOP CHECK

 Loop/Function test is divided by a two-group operation. One group to be in the

field (Field Technician) and the other group to be positioned in the control
room or front of local panel (Operator Station Technician).
Operator Station Technician Field Technician
- Before loop check, shall check the I/O - Shall confirm zero adjustment (if
card, power the loop and keep electrical possible). In case of mismatch of range
installation of adjacent loop/points on span, damage or unsuitable installation
the same card of field instrument, the problem should
be recorded in instrument punch list

- Will verify the PCIMS range with that of - Give signal simulation from the field
the field instrument at the CRT

- Will verify all inputs, and execute - Will verify outputs and check the valve
outputs as required to demonstrate the failure position
operation of the loop
 WHAT WE WILL DO IN LOOP CHECK
 Loop check also includes:
– Wiring integrity check in field and at control system

– HOOK-UP verification vs installation of Instrument

– Perform analog inputs 3-point check, 0%, 50%, 100%; or more if needed

– Perform analog output 4-point check, 0%, 25%, 75%, 100%

– Perform switch contact check

 After finishing loop/function test, the field instruments shall be

restored immediately, especially notes:
– Connector tightly as original

– If open air supply valve during loop/function test, close it when finished

– For D/P pressure type, 3 valve manifold closed

– Lead pipe valve restored

 TYPES OF LOOPS

There are two types of loops are in the field of instrumentation.

1. Open loop: It has no feed back.
2. Close loop :It has feed back.

In instrumentation a Close loop is consist of 3 basic Parts.

1. Input device (pressure ,level ,flow ,temperature transmitters)

2. Output device (Control valve)

3. Controller (DCS, PLC , etc.)

 TYPES OF LOOPS
OPEN LOOP CONTROL SYSTEM

PV DCS

SENSOR

TRANSMITTER
 TYPES OF LOOPS
CLOSE LOOP CONTROL SYSTEM
SP
CONTROLLER

PV OUTPUT

SENSOR CONTROL
VALVE

TRANSMITTER
LOOP CHECK TEAM RESPONSIBILITY MATRIX
To minimize overlaps and duplicate efforts, it is very important that the loop
check team be prepared and are aware of their responsibilities

Organization Responsibility

Inspection Responsible for the correctness of the installation in

accordance with approved construction drawings and
standards. Detailed responsibility is outlined in the
Installation Inspection Record
Operations Responsible for witnessing and accepting the field and control
room performance of the loop.

Maintenance Responsible for ensuring that the loop is acceptable from

maintenance point of view. Included are pressure tests, label
correctness, termination tightness, accessibility, conformance
with ILD, etc.
Engineering Overall responsibility including configuration, red-marking,
applications, function testing, modifications, documentation
review and final sign-off of the loop.
 GENERAL REQUIREMENTS

 PRE-REQUISITE
 Loop shall be termed ready for testing when all the construction
punch list items have been satisfactory closed out.
 Factory Acceptance Test (FAT) of DCS, ESD, FGS Systems and all
other control panels associated with mechanical and other packages
have been successfully concluded.
 The appropriate pre-installation instrument calibration/testing has
been completed, recorded on the Instrument Calibration Record and
witnessed/accepted by Owner Representative.
 All punch items are completed. All required documentation drawings
are assembled within each package.
 Loop checking shall be witnessed by QC Group in accordance with
approved ITP.
 GENERAL REQUIREMENTS

 The components within the loop have been installed in accordance with
process piping, instrument air piping, mounting details and Instrument
drawings. All cabling and wiring has been installed, tested and labeled,
recorded on the Cable Test Report and witnessed/accepted by Owner
Representative.
 GENERAL REQUIREMENTS
 TEST EQUIPMENT AND TOOLS
 Digital Multimeter
 Current / Voltage Standard Source Instruments
 Decade Resistor Box/Millivolt Generator
 HART Communicator
 Screw driver sets
 Allen wrench set
 Portable Pressure Calibrator
 Hand Pump
 Temperature Calibrator
 Other Relevant Tools
Test equipments must be calibrated and performing in rated accuracy.
 GENERAL REQUIREMENTS

 SAFETY AND PRECAUTIONS

 All parties involved in this activity must be familiar with applicable
safety practice.
 Wearing appropriate PPE’s and use of proper tools in opening the
instrument terminals boxes must be maintained.
 Safety belts will be required in some other areas where the
instruments are mounted on high elevations.
 Observed proper polarity connections for electronic instruments and
any other instruments requiring separate supply.

 COMMUNICATION REQUIREMENTS
 During early commissioning or pre commissioning activities like
flushing and blowing it must be ensured that the (operational)
commissioning crew is fully equipped with means of communication.
 LOOP TEST FLOW CHART
New System

Filling of Loop Test

Verify System Documents Sheets & Relevant
Documents

NO Provide YES
Documents
Documents
Ready
Loop Final Check
YES And Signature
Verify Folder Content
YES

Folder NO Complete
Ready Folder System
YES
Pre-Comm Complete

Perform Loop Check

NO Trouble
Loop Passed shooting

YES
 LOOP TEST DOCUMENTATION
PIPING AND INSTRUMENT DIAGRAM(P&ID)
CAUSE & EFFECT DRAWING
INSTRUMENT SPECIFICATION SHEET
INSTRUMENT HOOK-UP DIAGRAM
INSTRUMENT LOOP DIAGRAM
INSTRUMENT LOGIC DIAGRAM
INSTRUMENT LOCATION DRAWING
INSTRUMENT LOOP TESTING CHECK REPORT
INSTRUMENT LOOP AND TAG INDEX LIST
ESD BLOCK & LOGIC DIAGRAM
PUNCH LIST
 LOOP FOLDER CONTENTS

 TEST/COVER SHEET
 Area
 LOOP NUMBER
 SERVICE DESCRIPTION
 ASSOCIATED INSTRUMENT TAG
 PRE-WITNESS LOOP CHECK TO BE SIGNED BY CONTRACTOR QA/QC
 PACKAGE CHECKLIST WITH CONTRACTOR
INSTALLATION PUNCH LIST SHEET
 Record of all items found during loop physical inspection and testing
 CALIBRATION RECORDS
 INSTRUMENT SPECIFICATION & CALCULATION SHEETS
 LOOP FOLDER CONTENTS

 INSTALLATION INSPECTION RECORD

 Instrument Calibration is complete and verified.
 Cable continuity and megger test complete and verified.
 Instrument installation inspection record.
 Impulse piping tested.
 Instrument air tubing tested.
 Instrument power supply inspected correctly.
 Instrument direction of flow correctly.
 SIMPLE ANALOG LOOP FLOW TRANSMITTER

CONTROL
FIELD DCS ROOM
JUNCTION BOX
INSTRUMENT MARSHALLING
RACK TE-....
JB-......
MR-......
ANALOG INPUT
+
-
-
CS 3000

CONTROL
HART

PRESSURE
CALIBRATOR
 PROCEDURE
 Verify the feruling (tag) of the wiring on field device, Field junction box,
Marshalling panel/rack and DCS cabinet.
 Verify the Tag of Instrument on Operator Console.
 Verify the Power requirement of the instrument are correctly configured for the
device under test.
 Verify correct cable termination at both DCS termination points and Device
under test.
 Verify that HOOK-UP installation has been correct.
 Test the wiring termination by doing cold wire test or continuity test end to
end from Field device until Marshalling Panel.
 Apply Input Signal through Hand Pump to High Side of Transmitter with
0%,50% and 100% for Raising or Falling and observe reading on DCS Console.
OR
 Simulate the instrument by HART to increase or decrease the simulating to
0,50,100 % of the instrument range and check on DCS console.
 SIMPLE DIGITAL LOOP SWITCHES

CONTROL
DCS ROOM
FIELD MARSHALLING
JUNCTION BOX
INSTRUMENT RACK PSH-....
JB-...... MR-...... DIGITAL INPUT
+
-
-
CS 3000

CONTROL
MULTI
METER
 PROCEDURE
 Verify the ferruling (tag) of the wiring on field device, Field junction box,
Marshalling panel/rack and DCS cabinet.
 Verify the Tag of Instrument on Operator Console.
 Verify the Power requirement of the instrument are correctly configured for the
device under test.
 Verify correct cable termination at both DCS termination points and Device
under test.
 Verify that HOOK-UP installation has been correct.
 Test the wiring termination by doing cold wire test or continuity test end to
end from Field device until Marshalling Panel.
 Check Switch by simulating the signal by actuating the Switch “ON” and “OFF”
by hand or put jumper at switch terminal head.
 Check DCS alarms etc. Actuate the switching action and check all the related
system such as alarms,trip signal, indicating lamp etc.
 SIMPLE LOOP
FIELD CONTROL BUILDING

Junction Box MARSHALLING

Instrument Field Cable RACK

ANALOG I/P

CONTROL
ROOM
Process Hook Up DCS
Home Run Cable
& Cable Trays

Process Control System (PCS)

 CONTROL LOOP
FIELD CONTROL BUILDING

Junction Box MARSHALLING

Instrument Field Cable RACK

CONTROL
ANALOG I/P
ROOM
Process Hook Up Home Run Cable DCS
& Cable Trays

Instr. Air Header

Instr. Air Sub-header

ANALOG O/P
Home Run Cable
Instrument Tubing & Cable Trays
JB
Field Cable

Process Control System (PCS)

Instrument
 COMPLEX CONTROL LOOP
FIELD CONTROL BUILDING
MARSHALLING
JB RACK

CONTROL
ANALOG I/P
Indicator ROOM
DCS

Instr. Air Header DIGITAL I/P

LSO
Instr. Air Sub-header

DIGITAL I/P
LSC

I /P ANALOG O/P

DIGITAL O/P
SOV
FLOW LOOP

MARSHALLING
RACK CONTROL
ANALOG I/P ROOM
DCS

ANALOG O/P
 PROCEDURE
 Verify the ferruling (tag) of the wiring on field device, Field junction box,
Marshalling panel/rack and DCS cabinet.
 Verify the Tag of Instrument on Operator Console.
 Verify the Power requirement of the instrument are correctly configured for the
device under test.
 Verify correct cable termination at both DCS termination points and Device
under test.
 Verify that HOOK-UP installation has been correct.
 Test the wiring termination by doing cold wire test or continuity test end to
end from Field device until Marshalling Panel.
 Apply Input Signal through Hand Pump to High Side of Transmitter with
0%,50% and 100% for Raising or Falling and observe reading on DCS Console.
 Perform simulation using 0%,50%,and 100% of full scale and verify the
indication on the DCS Console and local indicator if provided.
 In case of flow loop is having control output element, manually set the output
to 0%, 25%,75% and 100% of the operating signal in the HMI. Check for the
valve stroke and tight closing of control valve. Check the fail-safe position of
the valve after completing the test by removing the air supply to the valve.
PRESSURE LOOP

MARSHALLING
RACK CONTROL
ANALOG I/P
ROOM
DCS

ANALOG O/P
 PROCEDURE
 Verify the ferruling (tag) of the wiring on field device, Field junction box,
Marshalling panel/rack and DCS cabinet.
 Verify the Tag of Instrument on Operator Console.
 Verify the Power requirement of the instrument are correctly configured for the
device under test.
 Verify correct cable termination at both DCS termination points and Device
under test.
 Verify that HOOK-UP installation has been correct.
 Test the wiring termination by doing cold wire test or continuity test end to
end from Field device until Marshalling Panel.
 Apply Input Signal through Hand Pump to High Side of Transmitter with
0%,50% and 100% for Raising or Falling and observe reading on DCS Console.
 Perform simulation using 0%, 50%, and 100% of full scale and verify the
indication on the DCS Console and local indicator if provided.
 In case of flow loop is having control output element, manually set the output
to 0%, 25%, 75% and 100% of the operating signal in the HMI. Check for the
valve stroke and tight closing of control valve. Check the fail-safe position of
the valve after completing the test by removing the air supply to the valve.
LEVEL LOOP

MARSHALLING
RACK CONTROL
ANALOG I/P ROOM
DCS

ANALOG O/P
 PROCEDURE
 Verify the ferruling (tag) of the wiring on field device, Field junction box,
Marshalling panel/rack and DCS cabinet.
 Verify the Tag of Instrument on Operator Console.
 Verify the Power requirement of the instrument are correctly configured for the
device under test.
 Verify correct cable termination at both DCS termination points and Device
under test.
 Verify that HOOK-UP installation has been correct.
 Test the wiring termination by doing cold wire test or continuity test end to
end from Field device until Marshalling Panel.
 Apply Input Signal through Hand Pump to High Side of Transmitter with
0%,50% and 100% for Raising or Falling and observe reading on DCS Console.
 Perform simulation using 0%, 50%, and 100% of full scale and verify the
indication on the DCS Console and local indicator if provided.
 In case of flow loop is having control output element, manually set the output
to 0%, 25%, 75% and 100% of the operating signal in the HMI. Check for the
valve stroke and tight closing of control valve. Check the fail-safe position of
the valve after completing the test by removing the air supply to the valve.
TEMPERATURE LOOP

MARSHALLING
RACK CONTROL
ANALOG I/P ROOM
DCS

ANALOG O/P
 PROCEDURE
 Verify the ferruling (tag) of the wiring on field device, Field junction box,
Marshalling panel/rack and DCS cabinet.
 Verify the Tag of Instrument on Operator Console.
 Verify the Power requirement of the instrument are correctly configured for the
device under test.
 Verify correct cable termination at both DCS termination points and Device
under test.
 Verify that HOOK-UP installation has been correct.
 Test the wiring termination by doing cold wire test or continuity test end to
end from Field device until Marshalling Panel.
 For thermocouple input, use a voltage source and deliver input signals
corresponding to 0%, 50%, and 100% of the input span of temperature
transmitter according to the standard table. While in RTD input, connect the
decade resistor box in place of RTD and obtain the resistance values
corresponding to 0%, 25%, 50%, 75% and 100% of the span and use the
obtained resistance as the input value.
 PROCEDURE
 Verify the indication in the DCS indicator and local indicator if provided.
 In case of temperature loop is having control output element, manually set the
output to 0%, 25%, 75% and 100% of the operating signal in the HMI. Check
for the valve stroke and tight closing of control valve. Check the fail-safe
position of the valve after completing the test by removing the air supply to the
valve.
 Reassemble the temperature element to the original position
 LOOP TEST FORMS

LOOP TEST SHEET FOR INSTRUMENTS BY EPC

(CTCI)

LOOP TEST SHEET FOR INSTRUMENT BY EO-EG

TEAM
 LOOP TEST FORMS

LOOP TEST SHEET FOR TRANMITTER

LOOP TEST SHEET FOR CONTROL VALVE

LOOP TEST SHEET FOR SWITCHES

LOOP TEST SHEET FOR RTD OR T/C