What is Loop checking:

The Loop checking is defined as pre-Commissioning activity which is initiated after installation of
instruments in the field and carry out the instrument loop checks between installed field instrument and
respective control system i.e. PLC or DCS.

checking is the final process before the commissioning of the processing system. Loop checking is the
process that confirms the components wired correctly and also helps to ensure that the system is
functioning as designed.The loop checking checks the connection between each component in the control
loop. A control loop consists of transmitter/sensor, process controller, final control element.Before start,
the loop check include, first list the number of loops, test actions, the procedure for documenting the
check and plan should specify the type and characterization of signal. For example, differential flow
meter generates a signal that has a square root relationship between flow rate and differential pressure.

Loop testing procedure:

For loop checking the test to be carried out while there is no electric connection otherwise, the circuit to
be tested should be isolated from the electric supply.

Earthing and Continuity test:

Earth resistance tests are required to confirm that the installed earthing system will cause the circuit
protection devices to operate and maintain the integrity of the cable if there is a fault between the active
parts and the exposed conductive parts.

The resistance from any point of the electric installation should be earthed. The resistance from the
earthing electrode to the point where the main earthing conductor is connected to the neutral conductor of
the supply system shall not exceed 5 ohms.

Ensure that the electricity supply has been disconnected

Connect an insulated copper conductor of suitable length(long lead) to one terminal of the ohm meter.
Connect a standard length test lead to the other terminal of the ohm metre(short lead
Connect the two leads together and zero the multimeter or if this is not possible. Record the resistance of
the test lead
Main earth conductor:

Connect the short lead to the earth electrode and measure the earth resistance of the main earthing
conductor
The resistance shall not exceed 5 ohms for the main earthing conductor
Earth continuity test:

Using the long lead and zeroed meter, measure for each circuit, the earth conductor resistance from the
circuit extremity to the switchboard.
To confirm the measured values are less than those values as provided by table
This test is applicable to all circuits, including socket outlets circuit, lighting circuits and fixed equipment
circuits.
Insulation resistance test:
The insulation resistance tests to ensure there is no current flow between conductor and ground or
insulation surface. If there is no current flow the wire could prevent electric shock hazards, fire hazards
and equipment damage.

Test procedure:
Ensure all protective device in the circuit is switched ON.
Set the insulation tester to megaohms
Connect an insulation tester cable to the main earth bar and the other cable to the active and neutral
connected together. Do not perform tests between assets and neutrals.
Measure the insulation resistance of the total installation, if the resistance is greater than 1 megaohm then
the normal to work.
If resistance is less than 1 megaohm disconnect the appliances. Then test the circuit separately to ensure
that the insulation resistance of both the circuit and the appliances complies with the following
Not containing a heating element- is not less than1 mega ohm or
Containing a heating element-is not less than 0.01 mega ohm
Polarity test:
Polarity tests are carried out to ensure that the correct connection of the active, neutral and ground
conductors to the electrical equipment ensures that the switches are not installed in neutral conductors.

Test procedure:

Isolate the active conductors by turning the main switch OFF and tagging
Confirm the consumer and sub main cables by simply testing from the point of distribution board to the
main switch board using an ohm meter and long test loads. Test result= 0 ohms
Confirm the switching of the active conductors using an ohm meter with the long cable connected to the
active conductor on the board and the short wire connected to the terminals of the switch as follows
Switch ON = 0Ώ for both terminals, Switch OFF = 0Ώ for one terminal and infinite for the other terminal.
With the MEN link in place, confirm the polarity of the sockets using a 10Ώ resistor and an ohm meter.
Connect the 10Ώ resistor between the active circuit conductor and the neutral bus, then connect the
multimeter cable to the ground terminal and the second cable to the active terminal. Test the resistance
value for.
Fault loop impedance test:
This test is performed to confirm that the impedance value of the fault loop of each circuit will be low
enough to guarantee the operation of the protection device during a fault.

Test procedure

Energize all circuits

Using the fault loop impedance meter, proceed to the equipment to be tested and measure the impedance
of the ground loop at this point. Repeat for other elements in the circuit
The measured value must be less than the maximum values as in the Wiring Rules
If an RCD works during the test, the results of the test can be considered satisfactory.

Loop Check :
An operational check of the field, controller and HMI elements of a control loop. A Loop Check is
intended to ensure the integrity of the following.

The field sensing device is properly installed in accordance with engineering specifications.

The field sensing device is calibrated in accordance with engineering specifications.

The field sensing device is properly connected to it’s communication path to the Distributive Control
System Controller. (e.g. Current Loop, Multiple device Bus Communication Protocol, etc.)

The field sensing device develops and transmits a proper analogous signal in response to a variable
impressed upon it or a simulation command issued to it.

The corresponding logic in the DCS Controller is ranged accordingly for the field sensing device analog
and engineering units.

The HMI of the DCS Controller accurately displays the engineering unit response to the signal of the field
sensing device.

Alarm points are properly entered into the logic of the DCS Controller and the HMI displays and logs
these appropriately as they are reached.

Where control functionality is required, that the signal from the field sensing device is received by the
control algorithm and generates the appropriate corrective output signal.

If present, the field control device, (e.g. Control Valve, Variable Speed Control etc.), is properly installed
in accordance with engineering specifications.

The field control device is calibrated in accordance with engineering specifications.

The field sensing device is properly connected to it’s communication path to the Distributive Control
System Controller. (e.g. Current Loop, Multiple device Bus Communication Protocol, etc.

The Field control device responds appropriately to the corrective signal received from the DCS Controller
and that this action is appropriate to the desire process variable.

Where specified, the response action of the valve is correctly transmitted to the DCS Controller and
displayed on the HMI.

SUMMARY
The Loop Check is intended to locate and identify deficiencies in the Field/Controller/HMI interface. This
includes, but is not limited to, wiring and cabling issues, engineering issues and mechanical installation
issues.

It is not the focus of the Loop Check to correct any deficiencies found. Full information concerning the
deficiency is captured and passed on to the appropriate parties for correction. Minor corrections can be
accepted, but this should be limited in scope.

Procedure:
A list of Loops is collected and identified by Tag Number.

Loops are grouped by Location, Availability, System, Equipment or other criteria. (Note: Locational
Grouping of Loops results in the most efficient execution of Loop Check.

The field team can be routed in a logical geographical progression of one device to another adjacent
device without time loss for accessing different floors, buildings, plant sections etc.
Loop availability can prevent this. If at all possible, Loop availability should be planned to accommodate
Locational Grouping)

Each loop is assigned a separate unique folder.

Each Loop Folder is populated with either a comprehensive Loop Sheet, and/or individual elements,
consisting of the following

Field Device Tag Number

Field Device Parameters
Calibrated Zero Process Value and corresponding Analog (common 4 ma)

Calibrated Full Process Value and corresponding Analog (common 20ma)

Action
Field Device Accessory List (e.g. Transmitter 3 Valve manifold, Valve Pneumatic Latch etc.)

Field Device Physical Location

Field Device instructions as appropriate

Field Device Wiring connection data. (Terminals, polarity)

Wiring Routing information (e.g. Junction Boxes, Terminals etc)

DCS I/O Marshalling Information, (Cabinet,Terminals, Polarity)

DCS I/O Card or Module information.

DCS Parameters

Ranges
Alarm points
DCS HMI Graphics assignments
From the Pending Loops file, the Console Engineer and the Field Technician draw the Loop Folders to be
checked in that time period.

The Console Engineer (or Operator) and the Field Technician review the contents of each Loop Folder in
the group to be checked, comparing parameters for parity and completeness of data.

A sequence of Check is agreed to the following

The Console Engineer prepares his record keeping tool, tracker, for the loops to be checked in the agreed
upon sequence.

The Field Technician evaluates the test equipment to be used, collects same and proceeds to the first
device to be checked.

The Field Technician communicates to the Console Engineer the Tag of the device he is at
The Console Engineer calls up the appropriate I/O channel

The Console Engineer calls up the appropriate HMI graphic or graphics

Transmitters
The Field Technician reviews the installation and process connections to ensure they are in accordance
with the specification details and good installation practice.

Either by impressed signal, (“Pump Up”) or Communicator command, the Field Technician drives the
transmitter output signal through it’s range. Slowing at Alarm Points so the Console Engineer can
confirm alarm action.

(NOTE: Common is a 0% 25% 50% 75% 100% Check. This was originally necessary to confirm the
linearity of earlier Pneumatic and ElectroMechanical devices, it no longer is as critical and becomes a
matter of agreed upon preference.)

Any wiring and/or piping disturbed to accomplish signal impression is restored.

The Field Technician confirms the process connection line up is as desired. (e.g. For a Differential Flow
Transmitter to be placed in service after check out, the three valve manifold would have the balance
closed and the process ports open)

Control Loops
While the transmitter signal impression is occurring, the Console Engineer will call up the Control
Algorithm faceplate and by placing the control mode (PID Controller) to Auto, determine that the output
action is appropriate.

Control Valves
The Field Technician reviews the installation to ensure it is in accordance with the specification details
and good installation practice.

If pneumatic, the Field Technician opens the air source checking for proper pressure adjustment and air
quality.

If electric, the Field Technician energizes the proper breaker.

The Console Engineer adjusts the output signal to the valve while the Field Technician observes the
action of the valve.

Jointly, the Field Technician and the Console Engineer determine if the resultant action is appropriate for
the control signal sent and the previously determined action of the control algorithm.

Where present, the Console Engineer observes any feedback from the valve to be in agreement with the
reported position of the valve action by the Field Technician.

Any accessories to the valve are checked for proper action.

We suggest you to check out the below articles on loop checks

Basics of Loop Checks
Instruments Loop Checks
Switches
The Field Technician reviews the installation to ensure it is in accordance with the specification details
and good installation practice.

Either by Signal Impression, manual toggling, or conductor manipulation, the Field Technician causes a
change in state of the field device signal.a

The Console Engineer observes the indication of the signal to be in agreement with the physical state as
impressed on the device by the Field Technician.

The Console Engineer records the results of the results of the signal impression, alarm points, ranges,
valve actions, etc.

If no deficiencies were noted during the Loop Check, the Loop Folder is placed in the Completed Loops
File. At this point, the client signs for the Loop as being complete.?ll
The resolution team draws Kick Back forms from the Active Kick Back file.

Each time the deficiency is addressed, the Kick Back form is submitted to the Console Engineer.

The Kick Back shall include

Date
Resolving Party
Thorough description of the corrective actions taken
Recommendations for further actions
Responsible party assigned to further actions
When the deficiency is corrected, the Kick Back form is submitted to the Console Engineer.

The Completed Kick Back shall include

Date
Loop checking procedure of Instruments
This article is about the loop checking procedure of all instruments like flow transmitter, valves,
vibration, DCS loop, switchgear loop and ramaining pressure and level types instruments.

Loop checking procedure of Instruments

LIST OF TOOLS AND EQUIPMENT IN LOOP CHECKING
Tools and equipment needed should be in good condition and must be checked by Instrument Supervisor
prior to use. Calibration equipment shall comply with the Saudi Aramco Standards requirements and
provided with calibration certificate to support the readings of the calibrating equipment these includes
but not
limited to:

HART Communicator
Dead Weight Tester
Air Compressor
MC5 FF Multifunction Calibratorll
Test Gauges with Ranges per Specification
Absolute Pressure Gauge
Portable 120Vac, 60Hz Gasoline Powered Generator
Pulse/Frequency Generator
DC Power Supply Regulated 24Vdc Variable
Nitrogen Tank w/ High Pressure Regulator
Thermo Bath
Hydrostatic Test Pump
Set of Precision Weights
Digital Thermometer
Glass Thermometer
Potentiometer
Portable Pressure Calibrator (DRUCK)
Process Calibrator
Advanced Temperature Calibrator
RTD Conversion Chart
Circuit Tester
Decade Resistance Box
Digital Manometer (Mercury or Water Manometer)
Mercury and Water Manometer
Hand Pump
Hygrometer (Humidity Tester)
Air Regulator
Pneumatic Comparator
Vacuum Pump
Oscilloscope
Radio Communication Equipment (intrinsically safe as per approved)
Multi meter
Test Bench with clean, dry and oil free instrument air
Set of Tools, Hose & Fittings
Stop Watch
Millivolt/Temperature conversion chart
TK-3 (for checking of vibration element)
Spirit Level
BEAMEX MC5 Calibrator
Others,if any
All tools utilized in a classified area should be intrinsically safe and suitable for hazardous
areas.Resolving Party
Thorough description of the corrective actions taken

OP CHECKING PROCEDURE OF FF and Conventional Transmitter (Flow/Level/Pressure)

For FF device commission FF segment prior to loop testing by measuring resistance and DC voltage of
segment conductor if all devices are connected otherwise only resistance will be recorded and voltage will
be measured after all devices are connected and compare the result with FF segment checkout forms.
Check and verify the DCS configuration for applicable points. Reference drawings will be P&ID and
ISS.
Apply the pressure for all (Analog / Digital) smart transmitters by using test equipment (Hand Pump) for
0%, 25%, 50%, 75% and 100% simulation to check the transmitter response at DCS. This method shall
be used for all smart
transmitters.
Verify the corresponding reading in the DCS / Integral indicator and at remote indicator if applicable.
For non-smart transmitters case Hand Pump shall be used for simulation or when required (4-20mA) ma
source to be used for simulation purpose instead of hand pump.
Alarms function (in DCS) shall be checked by simulating / verifying the required signal using
communicator or hand pump using latest P&ID.
For displacement type LT Hydraulic pump will be used with hosepipe and transparent tube with liquid
(water).
Normally Transmitter loop test should be performed after completion of the impulse line works including
pressure test. In some case loop test can be executed without impulse tubing being connected if piping is
not completed.
In case of impulse line not installed and tested then this exception item to be mentioned in the loop test
exception log sheet prior to signing the loop folder.

LOOP CHECKING PROCEDURE FF and Conventional Control Valves Loops

For FF device commission FF segment prior to loop testing by measuring resistance and DC
voltage of segment conductor if all devices are connected otherwise only resistance will be recorded and
voltage will be measured after all devices are connected and compare the results with FF segment
checkout form.
Check and verify the DCS configuration for applicable points. Reference drawings are to be P&ID and
ISS.
iii. If any logic / interlocking are involved in applicable loop. Energize the solenoid valve by forcing the
applicable ESD points on functional logic and same procedure to be carried out for DCS logic.
iv. If instrument air supply is not available then, dry and clean air or nitrogen shall be used.
v. Apply the command from DCS for 0%, 25%, 50%, 75%, 100% and monitor the response of the valve
from the field.
Verify the corresponding valve position.
vii. Verify the controller action.
viii. Verify the control valve action on increase signal.
ix. Verify the control valve action on air supply failure.
x. Verify the control valve max / min travel stopper setting if applicable.
xi. Check the hand wheel manual operation / function if applicable. Auto/ manual calibration is
applicable.
xii. Normally control valve loop test should be performed after completion of the external air supply
piping works. In some cases when required, loop test can be executed without the internal air supply
piping.
xiii. In case of air piping is not installed and tested then this exception item to be mentioned in the loop
test exception log sheet prior to signing the loop folder.
xiv. Loop will be installed only and signed after the clearance of the punch list.
LOOP CHECKING PROCEDURE On / Off Valves Loops
Valve response time shall be recorded in loop record sheet.
ii. Check and verify the DCS / ESD configuration for applicable points.
iii. If any ESD logic / interlocking are involved in applicable loop to energized solenoid valve, should
be prepared ESD points on functional logic and same procedure to be carried out for DCS logic.
iv. If instrument air supply is not available then connect nitrogen cylinder. In big size of valve cases,
big volume of
nitrogen will be required then in that case on/off valves function test will be executed upon air supply
availability.
v. Apply the command from DCS / field for open and close as applicable.
vi. Verifying the corresponding valves position in DCS and field.
vii. Verify the partial stroke function test of “ZV”.
viii. Verify the valve action on air supply failure.
ix. Check the hand wheel / hand jack manual operation / function as applicable.
x. Normally On/Off valve loop test should be performed after completion of the external air supply
piping works. In some cases when required, loop test can be executed without air.
xi. In case of air piping is not installed and tested then this exception item to be mentioned in the loop
test exception log sheet prior to signing the loop folder.
xii. Loop will be initiated only and signed after the clearance of the punch list.
LOOP CHECKING PROCEDURE MOV’s Loop
i. Check and verify DCS configuration for applicable points.
ii. Valve response time shall be recorded in the loop record sheet against ISS.

iii. If any ESD logic / interlocking are involved in applicable loop, then first normal condition should be
prepared by forcing the applicable ESD points on ladder on logic and same procedure to be carried
out for DCS logic.

iv. Check and verify the logic / remote switch function.

v. Stroke the MOV from DCS and field on applicable commands such as open, close and stop.
vi. Verify the status of the MOV at DCS and field.
vii. Check the hand wheel manual operation and function if applicable.

LOOP CHECKING PROCEDURE Switches Loops (Flow, Level, Pressure, Temperature)

i. Check and verify the DCS / ESD configuration for applicable points.
ii. Simulate the contact operation (Make / Break) at the switch terminal block and verify the status in
the DCS / ESD. However, ESD switch case actual pressure simulation to be provided with
hand pump.
iii. ESD hand switches, Start / Stop, Open / Close shall be checked by operating the switch mechanism.

LOOP CHECKING PROCEDURE Hand Switch loops

i. Power up loop, check contact status as expected.
ii. Check and verify the DCS/SIS configuration for applicable loop.
iii. Hand switches (Including SIS), Start / Stop, Open/Close shall be checked by operating the switch
mechanism for both hardware & software switches.
iv. Complete QC documentation and sign off after clearance of punch list items.

LOOP CHECKING PROCEDURE Gas Detectors / Beacon / Horns

Check and verify the DCS / ESD configuration for applicable points.
ii. Proceed the verification of gas detector by introducing the applicable sample gas for H2S and LEL.
iii. If no calibration gas available on the time of testing hart communicator or test magnet provided by
vendor will be used to perform the linearity check and the exception log will be maintained.
iv. Check the beacon status at high alarm condition.
v. Check the horn status at high alarm condition.
vi. In gas detector process, zero will be confirmed using span gas or zero gas or any other means before
applying / tuning the actual zero.
Please check also: TEMPERATURE TRANSMITTER EXPLANATION & COMPARISON
BETWEEN RTD AND THERMOCOUPLE
LOOP CHECKING PROCEDURE RTD /Temperature Transmitter Loops
Check and verify the DCS / ESD configuration for applicable points.
ii. Simulate resistance equivalent to the 0%, 25%, 50%, 75% and 100% of the transmitter /DCS range,
by using decade resistance box or any other resistance simulator at the RTD terminal head.
iii. Verify the corresponding reading in the DCS / integral indicator of transmitter and remote indicator
if applicable.
Alarm functions (in DCS) to be checked by simulating / varying the required signals.
v. Normalize all the connections prior to closing the terminal and confirm ambient temperature at
integral indicator of temperature transmitter and in DCS. Special consideration shall be given to
electrical connection of the RTD.
vi. During loop checking, If the instrument is not accurate re –calibration should be done in calibration
shop. Zeroing is not allowed.
LOOP CHECKING PROCEDURE Thermocouple / Temperature Transmitter Loops
Check and verify the DCS configuration for applicable points.
ii. Simulate millivolt equivalent to the 0%, 25%, 50%, 75% and 100% of the transmitter / DCS range,
by using “mv” source (simulator) at the thermocouple terminal head.
iii. Verify the corresponding reading in the DCS / integral indicator of transmitter and remote indicator
if applicable.
iv. Alarm functions (in DCS) to be checked by simulating / varying the required signals.
v. Normalize all the connections prior to closing the terminal and confirm ambient temperature at
integral indicator of temperature transmitter and at remote indicator if applicable to DCS.
Please check also: Basic Concept of Vibration Monitoring System
LOOP CHECKING PROCEDURE Vibration Loops (with Proximitors)
Check and verify the VMS / DCS configuration for applicable points.
ii. Connect a spare probe to extension cable of applicable proximitors.( If applicable)
iii. Insert the probe into the TK-3 wobulator (Bently Nevada) and connect the Multi meter leads at
proximitors terminals for check gap voltages.(If applicable).
iv. Adjust the probe at approximately (-10Vdc) gap voltages and reset VMS rack.( If pplicable)
v. Simulate the signal by wobulator 0%, 50% and 100% of the range and verify the corresponding
reading at VMS / DCS.( If applicable)
vi. Verify the response of the high and high alarms at VMS / DCS as per P&ID.
vii. Normalize the connection of extension cables. (If applicable)
viii. Actual probe gap voltage shall be adjusted to -10Vdc and check the point shows normal in VMS /
DCS after VMS rack reset.( If applicable)
Please check also: What is MCC? How Motor Control Centre Works?
LOOP CHECKING PROCEDURE MCC / SWR Loops
Check the Power Transmitter linearity on each cubicle wherever applicable VSD commands i.e. AO/AI
Shall be included, and the Testing requirements if no test position available.
ii. Check and verify the DCS configuration for applicable points.
iii. If ESD logic / interlocking are involved in applicable loop, by forcing the applicable ESD points on
ladder logic, same procedure to be carried out for DCS logic.
iv. Remove the control power transformer primary and secondary fuses for applicable MCC/SWR units
(check / confirm if MCC/SWR unit is on test position by electrical).
v. Apply 120Vac power (external power from building outlet) on the secondary fuses load side to
energize the control circuit.
vi. Apply the command from DCS / ESD Field for start, stop or trip as applicable.
vii. Verify the running / stop or trip status in DCS / Field / Sub Station as applicable.
viii. Check and verify the local / remote switch function if applicable.
ix. After completion of the applicable loop check, the fuses should be returned on the
control transformer.
All the above mentioned steps can be carried out with removing the pad lock on the MCC/SWR unit
breakers.
xi. Removal of the pad lock on the breakers required permission from Electrical Mechanical section.

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Instrumentation Loop Test Loop Checking

instrumentation loops
Instrumentation Test Procedure - Instrumentation Loops
Introduction to Loop Checking of Instrumentation - Loop Checking Preparation
Introduction to Loop Checking of Instrumentation - Loop Checking Preparation Instrumentation Types of
loops Types of signals DCS PLC & ESD system Alarms Generally used terms in instrumentation legends
Temp vs mv tables for all kinds of thermocouples Test equipment & tools Tools required for loop
checking work Test Equipments…

Tags:Instrumentation Calibration
Reference
Introduction to instrument third edition

Instrumentation Loop Test Loop Checking

Instrumentation Loop Test Loop Checking. TYPES OF LOOPS. OPEN LOOP CONTROL SYSTEM.
CLOSE LOOP CONTROL SYSTEM. LOOP FOLDER CONTENTS. FLOW LOOP.

Instrumentation Loop Test Loop Checking

 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

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.

 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.

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.

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).
 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.)

OPEN LOOP CONTROL SYSTEM

OPEN LOOP CONTROL SYSTEM

CLOSE LOOP CONTROL SYSTEM

CLOSE LOOP CONTROL SYSTEM

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

GENERAL REQUIREMENTS

 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.
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.

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.

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 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
INSTALLATIONPUNCH LIST SHEET
Record of all items found during loop physical inspection and testing
CALIBRATION RECORDS
INSTRUMENT SPECIFICATION & CALCULATION SHEETS

INSTALLATION INSPECTION RECORD

Instrument Calibration is complete and verified.
Cable continuity and meggertest 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

ANALOG LOOP FLOW TRANSMITTER

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

 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
loop test

loop checking

FLOW LOOP
FLOW LOOP

 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
PRESSURE LOOP

 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
LEVEL LOOP

 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
TEMPERATURE LOOP

 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.

 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

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I.M.D level-4 extension

Final exam(50%)
Parts 1
Choose the best answers from the following choice (A,B,C,D)(20 marks)
1------is defined as pre-Commissioning activity which is initiated after installation of instruments in the
field and carry out the instrument loop checks between installed field instrument and respective control
system i.e. PLC or DCS.
A the loopchecking B conduct loop C testing D all
2-----it has no feedback
A,openloop B,closedloop C, shortcircuit D,None
3----it has feedback
A,openloop B, closedloop C,shortcircuit D,None
4,Verify the ferruling of the wiring on the field device,field junction box.
A,leveloop B temperature loop C,pressure loop D,simpleloop
5,while the transmitter signal impression is occuring in console engineer will call up the control algorithm
faceplate and by placing the control mode.
A,control loop B, control valves C,transmitter D all

Parts 2
Say true if the statement is correct false if the statement is incorrect(10 marks)
1,checking is the final process before the commissioning of the processing system.
2,Do not perform tests between assets and neutrals.
3,The loop checking checks the connection between each component in the control loop.
4,if resistance is than, mega-ohm- disconnect the appliances.
5,The fielding sensing device is properly installed in accordance with engineering specification.

Part3 workout(20 marks)

1.List the types of loopcheck?
2.Explain briefly the control loop valves
3.what is loop check procedure
4.Define the control loop,pressureloop,transmitterm and temperature loop check.