11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

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Home » How to Do Loop Checks During Plant Pre-

Commissioning

Basics Control Systems

How to Do Loop
Checks During
Plant Pre-
Commissioning

‫ﻋﺎﻣ ًﺎ ﻣﻦ اﻟﺨﺒﺮة‬

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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

How to Do Logic Checks During Plant Pre-

Basic Industrial
Guide X lines to be
Networking and Wireless Interview
X

Commissioning…
followed
Questions…
during DCS Loop
Basic Guidelines to be followed during Logic Checks Checks
B ASI CS PLC TUT ORI ALS

Refer the below industrial networking and wireless

(Follow Cause & Effect, Control Narrative, P&ID and interview questions with answers. Industrial
Latest Alarm & Trip Schedule): 1. … (Follow Networking
P&ID and Instrument
& Wireless InterviewIndex):
Questions Industri…

1. Location of the instrument Tag no. to be

checked (As per P&ID)

2. Tag number & Description of the Tag to

be checked.

(For Ex: Flash drum level or Instrument air

header pressure or Hot oil heater inlet
Temp or HP Fuel gas inlet flow)

3. Range & Alarm values for that Particular

instrument to be noted. (As per Instrument
index or IO List)

4. Unit of that particular tag both in DCS &

Field also to be verified.

(Level: m, %, Flow: m3/hr or Nm3/hr or

Sm3/hr
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assume Pressure:
you're barg
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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

mm/yr,
X Temperature: “C, Control valves: X
How to Do Logic Checks During Plant Pre- Industrial Networking and Wireless Interview 
Commissioning… arrow for Fail Open or Fail Close types)
Questions…
B ASI CS PLC TUT ORI ALS

Basic Guidelines to be followed during Logic Checks 5. For All

ReferTransmitters,
the below industrialthe checks
networking and to be
wireless
(Follow Cause & Effect, Control Narrative, P&ID and interview questions with answers. Industrial
Latest Alarm & Trip Schedule): 1. …
done forNetworking
0%, 50%& & 100% of the total range.
Wireless Interview Questions Industri…

6. If the Flow Transmitters is of DP type,

checks to be as follows: For Eg. For
Transmitter Range: 0 to 100 m3/hr & DP
Range: 0 to 500 mbar, 0% (0 mbar) = 0
m3/hr; 25% (125 mbar) = 50 m3/hr;  50%
(250 mbar) = 70.7 m3/hr; 75% (375 mbar) =
86.6 m3/hr; 100% (500 mbar) = 100 m3/hr

7. All Level Transmitters to be checked only

with water. If they are not using water
(except vessel mounted Radar Transmitter),
report in DPR that LIT was checked with mA
& to be checked with water again.

8. For DCS Transmitters, normal checks,

Alarm values & its recovery values to
be checked by simulating from field.

9. If Instrument Index & Data Sheet Ranges

are not matching, please record in your DPR

10. For all Alarm values simulation, check

for alarm in Current Alarm Manager (CAM).
When an Alarm comes, it has to blink in
graphics in Red, if we accept it will become
static.

11. For ESD Transmitters, Alarm values, LL

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or HH or either & SC (Short Circuit), OC

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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

(Open
X Circuit) to be checked by simulating X
How to Do Logic Checks During Plant Pre- Industrial Networking and Wireless Interview 
Commissioning… from field.
Questions…
B ASI CS PLC TUT ORI ALS

Basic Guidelines to be followed during Logic Checks 12. Alarm description

Refer to benetworking
the below industrial checkedand
(For Ex:
wireless
(Follow Cause & Effect, Control Narrative, P&ID and interview questions with answers. Industrial
IA header pressure low or Hot oil heater all
Latest Alarm & Trip Schedule): 1. … Networking & Wireless Interview Questions Industri…
temp. High or HP fuel gas inlet flow low)

13. Color of the Display in Graphics also

required to verify.

14. For Control valves, the stroke checks to

be done for 0%,25%.50%, 75%, 100%, 75%,
50%, 25% & 0%.

The valve openings actually in Field to be

confirmed from Person on Field & Recorded
in Loop checks report.

For Checking Fail Open type, Close the

valve, isolate the instrument air supply &
reduce the air pressure by bleeding off (the
Control Valve should open & opening in
DCS & Field should match).

For Checking Fail Close type, open the valve

50%, isolate the instrument air supply &
reduce the air pressure by bleeding off, (the
Control Valve should close). Color change
also to be checked.

15. Manual & Auto change over from Face

plate Controllers to be checked & control
valve moving  action, in case of Control
valves.
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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

(Direct
X & Reverse action of Controllers as X
How to Do Logic Checks During Plant Pre- Industrial Networking and Wireless Interview 
Commissioning… per control narrative also to be verified).
Questions…
B ASI CS Some ofPLCthe controllers,
TUT ORI ALS we have seen
Basic Guidelines to be followed during Logic Checks Refer the below industrial networking and wireless
(Follow Cause & Effect, Control Narrative, P&ID and
Action given in Control narrative is wrong.
interview questions with answers. Industrial
Latest Alarm & Trip Schedule): 1. … Please identify &&report
Networking Wirelessin DPR. Questions Industri…
Interview

16. Check Control Valves, XV’s, SDV’s, BDV’s

either permanent instrument air tubing is
connected or not. If not,  don’t check that
valves. BDV’s, few SDV’s, few XV’s, few PCV’s
has Volume Bottle. Ensure Volume bottle is
connected or not as per design. Otherwise
report in your DPR.

17. During  SDV Loop Checks:  Open, Close,

Fail Open, Fail Close, reset, PST & mismatch
alarm to be checked.  Color change in
Graphics & Face plate for SDV’s to be
checked while open & close operation.

Also Read : Basics of Loop Checks

Ensure the following

a. Valve Open & Close (Color change in Face

plate & Graphics & Field position). For
Open, we should get ZSO alarm & for Close,
we should get ZSC alarm. (ZSO & ZSC also
refers as ZSH/ZSL or may change from
company to company)

b. SOV energise & de-energise (Color

change in Face plate & Graphics). For SOV
command,
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withSDY
this, or
but SDC alarm
you can opt-out

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Accept given a d k h J %
for Close Command).
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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

c.X For Reset alarm, we should get HS-XXX X

How to Do Logic Checks During Plant Pre- Industrial Networking and Wireless Interview 
Commissioning… alarm. Questions…
B ASI CS PLC TUT ORI ALS

Basic Guidelines to be followed during Logic Checks d. For PST

Refer (Partial Stroke networking
the below industrial Test), weandshould
wireless
(Follow Cause & Effect, Control Narrative, P&ID and interview questions with answers. Industrial
get ZY-XXXX alarm.
Latest Alarm & Trip Schedule): 1. … Networking & Wireless Interview Questions Industri…

c. Time taken for Open & Close in Field,

after the signal given, to be checked. (Check
as per Data sheet, it is operating or not) &
note in your DPR if it takes more than 20
sec for close.

d. Fail Position of SDV’s: Fail close, Fail Open

or Fail Last as per P&ID & data sheet in
Field. e. If your get mismatch alarm, report
in your DPR.

e. Some of the SDV’s are Fail last (meaning it

will remain in last position). It is also to be
checked by cutting of air & SOV power
supply.

f. Some SDV’s has DCS Hand Switch

(particularly MEG area, from DCS Hand
Switch operation from DCS to be checked).
Open & close timings to be also checked. If
it is more than given in datasheet, please
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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

g.
X Some of the SDV’s (MEG) has Volume X
How to Do Logic Checks During Plant Pre- 
Industrial Networking and Wireless Interview
Commissioning… Bottle. ItQuestions…
is also to be checked. If not, report
B ASI CS in your  DPR.  Please
PLC TUT ORI ALS write in your DPR –
Basic Guidelines to be followed during Logic Checks Refer the below industrial networking and wireless
(Follow Cause & Effect, Control Narrative, P&ID and
what are all we checked during
interview questions with answers. Industrial
Latest Alarm & Trip Schedule): 1. … SDV/XV/BDV/MOV loop Interview
Networking & Wireless checks:  like Open,
Questions Industri…

Close, SOV close command, Field Reset, PST

alarm checked. (If it has checked  & we got
alarm).

18. During  BDV Loop Checks:  Open, Close,

Fail last condition, Operation from Volume
Bottle also to be checked.  Color change in
Graphics & Face plate for SDV’s to be
checked while open / close operation.

Ensure the following

a. Valve Open & Close (Color change in Face

plate & Graphics & Field position). For
Open, we should get ZSO alarm & for Close,
we should get ZSC alarm.

b. SOV energise & de-energise (Color

change in Face plate & Graphics). For SOV
command, we  should get BDY1 for Open
Command.

c. Fail Last Position. (After opening the

valve, isolate air & isolate power supply to
SOV, the valve should be in open condition
(i.e.) last position)

19. During MOV Loop Checks:

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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

a)
X Get Clearance from Respective Team X
How to Do Logic Checks During Plant Pre- Industrial Networking and Wireless Interview 
Commissioning… Lead. Questions…
B ASI CS PLC TUT ORI ALS

Basic Guidelines to be followed during Logic Checks b) Ensure

Referthe valve
the below is smoothly
industrial networkingoperated
and wireless
(Follow Cause & Effect, Control Narrative, P&ID and interview questions with answers. Industrial
Latest Alarm & Trip Schedule): 1. …
(Full Open & Close) with Hand Wheel. (To
Networking & Wireless Interview Questions Industri…
engage the Hand wheel, depress the Hand
lever & turn the Hand wheel to engage the
clutch. Operate one turn & then release the
lever).

c) After ensuring it is operated freely, Give

Clearance for loop checks.

d) Put the corresponding switch in “IN

CIRCUIT” position in Field.

e) Then turn the selector switch provided in

MOV in “Local” mode & then fully operate
using the Open/Close switch provided in
MOV. Check for smooth operation. If any
Jerky/abnormal operation found, stop
checking.

f) Check for color change in MOV face plate

& graphics during Open/Close operation.

g) Check for alarms for Open/Close (ZI-XXXX

alarm)

h) Finally keep MOV in open condition (say,

20 or 30%) & then using Hand wheel
operate the  MOV. It should Open / Close
irrespective of the Power Supply.

i) Some
This website uses cookies to improve your experience. MOV’s you're
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opened from
this, but you can DCS
opt-out
$ if you wish. (see P&IDRead
Accept forMore a d k h J %
Hand switch). Turn the
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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

selector
X switch in MOV to “Remote Mode”, X
How to Do Logic Checks During Plant Pre- Industrial Networking and Wireless Interview 
Commissioning… then operate from DCS – Full Open/Close.
Questions…
B ASI CS PLC TUT ORI ALS

Basic Guidelines to be followed during Logic Checks j) If anyRefer

abnormalities found
the below industrial in Graphics,
networking and wireless
(Follow Cause & Effect, Control Narrative, P&ID and interview questions with answers. Industrial
Latest Alarm & Trip Schedule): 1. …
Faceplate or Field like Mismatch, Battery
Networking & Wireless Interview Questions Industri…
Low, Device  Alarm, Jerky Operation, not
operating when power supply is ON etc.
report in your DPR.

k) Don’t forget to check the Hand wheel

Operation when power supply is “ON”.

20. Please guide Field Engineer and get feed

back from them while loop checking for
deviations.

21. It is the DCS Engineer responsibility to

get the Field Engineer to do all checks & get
Punch Points from Field. During Valve
Checks, Field Person is necessary.

22. If there is any deviation from the above,

please write your observations in Loop Test
Report & DPR.

NOTE: Mark in P&ID daily after loop check is

completed. It will be useful for tracing the
balance loops.

Also Read : Field Instruments Loop

Checks Procedure

Guide lines to be followed in

Field during DCS Field Loop
Checks (with P&ID):
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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

1.
X Location of the instruments (As per X
How to Do Logic Checks During Plant Pre- Industrial Networking and Wireless Interview 
Commissioning… P&ID). Questions…
B ASI CS PLC TUT ORI ALS

Basic Guidelines to be followed during Logic Checks 2. Position of below

Refer the thatindustrial
instrument inand
networking field &
wireless
(Follow Cause & Effect, Control Narrative, P&ID and interview questions with answers. Industrial
Latest Alarm & Trip Schedule): 1. …
Canopy Networking
for that& Wireless
instrument. (Viewing the
Interview Questions Industri…
display, isolation valve accessibility – should
not be difficult, direction of control valve,
Color & instrument tubing for Fail close –
Green color / Fail open – Red color, Flow
transmitters – HP & LP impulse tube
tapings)

3. Flow Orifice Tapping : For Liquid Service –

it should be from bottom (45 Deg C both
sides) &  transmitter should be fixed below
the tap-off point; For Gas Service – it should
be from bottom (45  Deg C both sides) &
transmitter should be fixed above the tap-
off point.

4. Pressure Transmitter Tapping: For Gas

Service- It should be above the tap-off
point; For Liquid  Service – It should be
above the tap-off point.

5. Name plate of that instrument (Should

match with P&ID and DCS).

6. Display of the readings with parameters

on that Transmitter. (Should be clear &
check for any damage).

7. Unit of that particular tag – Should match

with We'll
This website uses cookies to improve your experience. DCS.assume
(Level: %, Flow:
you're ok withm3/hr
this, but or
youNm3/hr
can opt-out
$ if you wish. orAccept
Sm3/hr Read
or Kg/hr, a d k h J %
More Pressure: barg or bara

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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

or
X mmwc, Corrosion: mm/yr, Temperature: X
How to Do Logic Checks During Plant Pre- Industrial Networking and Wireless Interview 
Commissioning… °C). Questions…
B ASI CS PLC TUT ORI ALS

Basic Guidelines to be followed during Logic Checks 8. For Transmitters, the checks
Refer the below industrial will and
networking be wireless
done
(Follow Cause & Effect, Control Narrative, P&ID and interview questions with answers. Industrial
Latest Alarm & Trip Schedule): 1. …
for 0%, Networking
50% & 100% of the total range. The
& Wireless Interview Questions Industri…
readings displayed to be counter checked
with the person on DCS.

9. For Control valves, the stroke checks will

be done for 0%, 25%. 50%, 75%, 100%, 75%,
50%, 25% & 0%. The valve openings actually
in Field to be informed to the Person on
DCS.

10. If there is any deviation from the above,

please note & inform your observations to
the Person in Control Room, so that he will
write in Loop Test Report & DPR.

Also Share any other Points if we missed

in the above mentioned list via
comments section

Also Read: Guidelines for Logic Checks

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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

How to Do Logic Checks During Plant Pre-

X
a Facebook d Twitter k
LinkedIn
Industrial Networking and Wireless Interview  X

Commissioning…
B ASI CS
h Questions…
Pinterest vEmail
PLC TUT ORI ALS
J
WhatsApp

Basic Guidelines to be followed during Logic Checks Refer the below industrial networking and wireless
(Follow Cause & Effect, Control Narrative, P&ID and interview questions with answers. Industrial
Latest Alarm & Trip Schedule): 1. … Networking & Wireless Interview Questions Industri…

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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

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14 COMMENTS
junaid REPLY

 March 9, 2016 at 7:14 am

Dear Sir,

Thank you very much for updating

valuable knowledge but please provide
one PDF file save option to download the
soft copy. Here there is no option of
downloading or copying the paragraph
please help, only print & email option is
available.
print option showing the only hard copy
of print no soft copy option available in
print.

Badri REPLY

 March 12, 2016 at 5:07 am

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Respected Sir,
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I’m Veerabhadra Gouda BE
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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

X instrumentation Engineer working in JSW X

How to Do Logic Checks During Plant Pre- Industrial Networking and Wireless Interview
Steel in Bellary & I’m Big Fan Of U , U R

Commissioning… Questions…
My Guru, I’m Waiting 4 Such A Person
B ASI CS PLC TUT ORI ALS
Like U Thanks Bharadwaj Garu..
Basic Guidelines to be followed during Logic Checks Refer the below industrial networking and wireless
(Follow Cause & Effect, Control Narrative, P&ID and interview questions with answers. Industrial
Latest Alarm & Trip Schedule): 1. … Networking & Wireless Interview Questions Industri…
ko REPLY

 March 17, 2016 at 2:42 am

this theoretical basic ok but also put

same job video

SK REPLY

 May 9, 2016 at 5:53 pm

Such a wonderful article for loop check

starters.
Good job author…Keep up the Excellent
Job….

Nishil parmar REPLY

 June 5, 2016 at 9:27 am

Thank you for sharing your valuable

knowledge

Kristine REPLY

 July 21, 2016 at 9:26 am

very useful info …. thank you so much for

sharing the knowledge … its all summary
and refresher to my college years and
years of experience in industry … also
serve as guidelines

Rajkumar Kannan REPLY

 September 11, 2016 at 5:42 am

Amazing information. Practical dos and

donts…you're
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pre-commissioning….
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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

X X
How to Do Logic Checks During Plant Pre- Fanish Networking and Wireless Interview
Industrial REPLY 
Commissioning… Questions…
 December 17, 2016 at 11:57 am
B ASI CS PLC TUT ORI ALS

Basic Guidelines to be followed during Logic Checks

A very forum
Refer the below industrial networking and wireless
(Follow Cause & Effect, Control Narrative, P&ID and interview questions with answers. Industrial
Latest Alarm & Trip Schedule): 1. … Thanks for
Networking sharingInterview Questions Industri…
& Wireless

greater giving greater living

Stephan REPLY

 December 20, 2016 at 9:06 pm

Wow, a lot of mistakes are in here. How

can you state that 500mbar equals any
flow without checking the actual flow
element.
Level checks should be done with the
correct liquid. Diesel for example.
For valves it is crucial to know what the
actual response is instead of 25% steps.
Does it overshoot? Hunt? Takes for ever
to get there?

ELIAS MUSA REPLY

 December 25, 2016 at 1:21 pm

There are times when the alarm and

shutdown level is simulated by injected
signal eg 4 to 20 mA current, where it is
not possible to use actual fluid.

Jerome Stephen REPLY

 December 26, 2016 at 10:36 am

These information are extremely rich and

I really want to thank the author for this
details information.
please I want to beg if it is possible we
get thisyou're
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this, . you can opt-out

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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

X
m.k REPLY
X
How to Do Logic Checks During Plant Pre- Industrial
 JanuaryNetworking
19, 2018 at 9:13and

pm Wireless Interview
Commissioning… Questions…
B ASI CS dear
PLC sir
TUT ORI ALS

Basic Guidelines to be followed during Logic Checks it isthe

Refer a great
belowjob ,thanks
industrial a lot for and
networking yourwireless
(Follow Cause & Effect, Control Narrative, P&ID and interview questions with answers. Industrial
efforts
Latest Alarm & Trip Schedule): 1. … Networking & Wireless Interview Questions Industri…

Ramin Osmanov REPLY

 January 30, 2018 at 7:54 am

4. Pressure transmitter tapping: For

Liquid Service- It should be above the
tap-off point.
I think You should change above to
below

Anandraj REPLY

 June 17, 2018 at 8:02 pm

Bro kindly tell me that,what is DPR in ur

Article..

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11/11/2019 How to Do Loop Checks During Plant Pre-Commissioning

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How to Do Logic Checks During Plant Pre- Industrial Networking and Wireless Interview 
Commissioning… Questions…
B ASI CS PLC TUT ORI ALS

‫ﻓﺮوﻗﺎت ﺳﻌﺮﻳﺔ‬
Basic Guidelines to be followed during Logic Checks Refer the below industrial networking and wireless
(Follow Cause & Effect, Control Narrative, P&ID and interview questions with answers. Industrial

‫ﻣﻨﺨﻔﻀﺔ‬
Latest Alarm & Trip Schedule): 1. … Networking & Wireless Interview Questions Industri…

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