DOCUMENT CODE

INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION PROCEDURE

RIC8952290

GE NuovoPignone-Electronically Approved Drawing-Checked: Menichini A., Approved: Arcioni M.-Internal DT-'N'

INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION
PROCEDURE

TITLE DOCUMENT CODE REVISION

INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION
PROCEDURE RIC8952290 3
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THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF NUOVO PIGNONE S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
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INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION PROCEDURE
RIC8952290

Contents
1 FOREWORD ............................................................................................................................................................................................... 3
2 MAIN ISSUES ............................................................................................................................................................................................. 4
2.1 REFERENCE DOCUMENTS................................................................................................................................................................ 4
2.2 REQUIRED INSTRUMENTS................................................................................................................................................................ 4
3 FUNCTIONAL CHECKS .......................................................................................................................................................................... 5
3.1 FUNCTIONAL CHECK OF SERVO VALVES & LVDT CONTROL LOOPS (with MKVI Control System) .................. 5
3.2 FUNCTIONAL CHECK OF 4÷20 mA PRESSURE TRANSMITTERS (including differential PT) ............................. 10
3.3 FUNCTIONAL CHECK OF TEMPERATURE LOOPS: 4÷20 mA TRANSMITTERS,
THERMOCOUPLES and RTD’s...................................................................................................................................................... 11
3.4 FUNCTIONAL CHECK OF 4÷20 mA LEVEL/FLOWMETER TRANSMITTERS ............................................................... 12
3.5 FUNCTIONAL CHECK OF ACCELEROMETER / VELOCIMETER SEISMIC PROBE ...................................................... 13
3.6 FUNCTIONAL CHECK OF DIGITAL INPUT ............................................................................................................................... 16
3.7 FUNCTIONAL CHECK OF ANALOG OUTPUT ......................................................................................................................... 18
3.8 FUNCTIONAL CHECK OF DIGITAL OUTPUT ........................................................................................................................... 19

TITLE: DOCUMENT CODE REVISION

INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION
PROCEDURE RIC8952290 3
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
ADDED RUSSIAN TRANSLATION N/A N
ORIGINAL JOB SIZE LANGUAGE
N/A 4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF NUOVO PIGNONE S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF NUOVO PIGNONE S.r.l. UNPUBLISHED WORK ©2014 NUOVO PIGNONE S.r.l. ALL RIGHTS RESERVED. 2/3
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INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION PROCEDURE
RIC8952290

1 FOREWORD
This documents aims to provide general directions for the functional loop test of the instruments / devices
installed on GE/NP equipments and the relevant control system(s).

Typically, a loop is composed by the following components:

o Instrument, that is a transducer that converts a physical process variable into an electrical analog
signal (4-20 mA), or digital (open/closed contact). This may also be an output device, such as an
actuator, a solenoid, etc converting an electric signal into a physical process variable.

o Electrical connection, that may include several terminal boards,

o Electronic data acquisition and control system, generally microprocessor based

o Control software

o Animated display system (HMI)

These loops shall be checked including, as much as possible, all the above components, meaning that the preferred
test method implies to simulate the physical process variable, verifying the reading on the animated display AND
the actions caused by the control software, such as alarms, trips, sequencing, etc.

Sometime, the entire loop may not be tested due to limited or impossible access to some portion of the loop itself,
for instance when an instrument is installed inside a sealed or assembled part of machinery. In this case, only the
portion that is available can be checked, injecting an electrical signal, equivalent to the instrument output, at the
first terminal board, closest to the instrument. The inaccessible portion of the loop must have been checked and
certified in the factory, at assembly. The correct functionality can also be confirmed at site comparing the output
of the instrument with the process variable measured elsewhere, using a verified loop.

The simulation of the instrument output can be also recommended when the process physical variable cannot be
changed or simulated or measured, or when this is unrealistic at site.

Loops including “Smart” instruments can be checked using a “Hart communicator”, when the physical variable cannot
be simulated.

Warning: In case a fully tested loop is altered in any way and for any reason, the loop check validity is void and it
shall be repeated, signing off again the relevant SQCL line. <2>

TITLE: DOCUMENT CODE REVISION

INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION
PROCEDURE RIC8952290 3
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ADDED RUSSIAN TRANSLATION N/A N
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THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF NUOVO PIGNONE S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF NUOVO PIGNONE S.r.l. UNPUBLISHED WORK ©2014 NUOVO PIGNONE S.r.l. ALL RIGHTS RESERVED. 3/4
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INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION PROCEDURE
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2 MAIN ISSUES

2.1 REFERENCE DOCUMENTS

 Instruments list
 UCP wiring diagram
 P&I Diagram
 Control System software
 Cause & Effects diagram

2.2 REQUIRED INSTRUMENTS

The following list is only for reference, as there may be alternative methods for simulation and measurement of
process variables / instruments output

 • Common tools (mm/inch)

 • Multimeter
 • Resistance box
 • Signal generator (i.e microcal)
 • Pressure simulator (pneumatic / hydraulic hand pump)
 • Calibrated pressure gauges
 • Thermostatic oven
 • Reference thermometers
 • Hart communicator

TITLE: DOCUMENT CODE REVISION

INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION
PROCEDURE RIC8952290 3
REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
ADDED RUSSIAN TRANSLATION N/A N
ORIGINAL JOB SIZE LANGUAGE
N/A 4 A
THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF NUOVO PIGNONE S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
WRITTEN PERMISSION OF NUOVO PIGNONE S.r.l. UNPUBLISHED WORK ©2014 NUOVO PIGNONE S.r.l. ALL RIGHTS RESERVED. 4/5
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INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION PROCEDURE
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3 FUNCTIONAL CHECKS
All installation requirements have been successfully completed, witnessed and signed-off, and the documents are
readily available for review if needed. It is also required that all instruments are loop-checked prior to each
functional test.

3.1 FUNCTIONAL CHECK OF SERVO VALVES & LVDT CONTROL LOOPS (with MKVI Control System)
 System pre-commissioning
1) Lube oil (L.O.) and hydraulic oil (H.O.) pressure available.
2) Continuity/ground check from TSVO to servo’s and LVDT.
Servo coil resistance should be 1 Kohm
Colors are: Red/White – Yellow/Green – Orange/Blue
LVDT resistance should be few tenths ohm
Colours are: Extc. Red/Black+Blu or Yellow
Fdbk Orange/Yellow or Blue
Open circuit to ground for all terminals.

3) Test the Trip Solenoid Valves (i.e. 20HD-1, 20FG-1, 20TV-1, etc.)
4) Keep the Trip Solenoid Valves energized.
5) With everything disconnected and both L.O. and H.O. in pressure, verify the devices moves to their
safety position:
 SRV closed
 GCV closed
 IGV closed
 TSNZ open

Note: If the device moves to the wrong direction, check the Moog valve Model number, the tubing connection and
the installation position (P is the inlet H.O. port). Otherwise is a mech. Bias problem (refer to Mech. Bias adjusting
procedure).

 LVDT Zero Setting

The LVDT excitation from Mark6 is 7Vac (RMS). The linearity of the Voltage Vs Position is ensured only when
the output is between 0.7 and 3.5 Vac, therefore with the device at safe position the LVDT should be
mechanical adjusted to have 0.7Vac (true RMS).
1) Verify that the Excitation Voltage (7Vac RMS from Mark6) is connected to the Red and Black wires.
Note: if a 5 wires LVDT type, the Yellow or the Blue one must be connected with Black, depending if
the LVDT stroke is inside or outside while on safe position. (i.e. on Gas Valve connect Blue with
Black).
2) With the device at safe position, mechanically adjust the LVDT stroke to have 0.7Vac on field TB (the
Voltage can drop trough barriers, not a problem).
 Servovalve polarity check
With L.O. and H.O. available.
1) Connect only one servo coil.

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2) On VSVO Card Points Force CalibEnabn for that Regulator to 1.

3) MASTER RESET
4) Open the Calibration Task from VSVO/Regulator (right click on the Regulator)

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5) Select Calibration ON.

6) Select “Min.End Position” and verify the Device is at the Safe position.
7) Select “Max.End Position” and verify the Device is at the opposite Safe position.
Note: if it’s working in the opposite way, remove H.O. pressure and invert the polarity connection at the field
TB, servovalve side. Repeat step 4 & 5.
8) Disconnect the 1st coil and follow the procedure with 2nd coil and then 3rd coil.
Note: at the end the loop connection should be as follow, refer to GEH-6421_2 , VSVO chapter (TSVO /
Moog):

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INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION
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ADDED RUSSIAN TRANSLATION N/A N
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THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF NUOVO PIGNONE S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
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INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION PROCEDURE
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 LVDT 0-100% range calibration

1) With all 3 servo coils connected put the Device to “Min End Position” and verify on Field it’s steady
at Safe position.
2) Click on “Fix1” button to fix the Voltage for that point.
3) Put device to “Max End Position” and verify on field.
4) Click on “Fix2” button to fix the Voltage for that point.
5) Select “Calibrate” to use the fixed values.
6) Repeat the step 1 to 5 a couple of time and verify that the result is consistent.
7) Click on the “Save” button to save the calibration parameters to the Flash memory.
8) Close Calibration task and Save the m6b file, to store the calibration.
 Regulator Gain and Bias setting
Note: the Moog Servovalve is supplied with a Mechanical Null Bias of 10% of nominal flow to port.
In this way, if no current is applied to the coils, the oil through that port will ensure the device to move to
the Safe position (as checked during Pre-commissioning).
The “RegNullBias” on Control system Regulator is to compensate the Mechanical Bias to have a lower error
between command and feedback.
1) Prepare a trend page with the following parameters related to the Regulator (from Card Points and
TSVO):
- Regulator Reference (FSROUT, CSRGVOUT, etc)
- Regulator Feedback (FSG, CSGV, etc)
- Regulator output (FAG, CAGV, etc)
2) From the Regulator Calibration task select “Verification” “Manual”.
3) Insert a value of 20% and “Send Manual”
4) Same with 50%, 80% and back to 50%.
5) Analyze the trend and if needed adjust the “RegGain” to have a fast response but without excessive
over-shut and maintaining a stable regulation while steady.
6) Leaving the device at 50%, adjust “RegNullBias” to reduce almost to zero the difference between
Command and Feedback.
Note: after each modification move the device few % up and down to avoid mechanical tolerance (black-lash)
influences on this calibration.
7) The RegNullBias should be equal to 0.8mA (8% of the maximum current of 10mA). For TMR the 8% is
split between the 3 cores = 2.67% (typically).
IMPORTANT: After any modification on VSVO parameters, perform a Download Configuration from that card (right
click on the card).

Servo Mechanical Bias adjustment (if required)

Note: The “RegNullBias” on Control system Regulator is to compensate the Mechanical Bias to have the lower
error between command and feedback.
If the Device doesn’t move to Safe position (whiteout current to the Servo) or if the RegBias needed is too high,
the Servo Mechanical Bias should be adjusted (or Moog replaced).
Even in this condition the LVDT Zero Setting, the ServoValve polarity check and the LVDT 0-100% range
calibration can be performed, but the necessary current to Servo will be higher, also to keep the Zero position.
After these steps are complete, before to Adjust Gain and Bias, follows these instruction:
8) Verify that the RegBias is for 0.8mA (2.67% on TMR).

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INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION
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ADDED RUSSIAN TRANSLATION N/A N
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THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF NUOVO PIGNONE S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
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INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION PROCEDURE
RIC8952290

9) In calibration mode give a Manual command of 50% (the feedback will be different).
10) On the servovalve adjust the Mechanical Bias screw, located on the side of the body:
- put the allen-key to hold the screw, then loose the nut
- adjust the screw to align the feedback to the 50% command
- tight the nut, keeping the screw, and verify the feedback remains at 50%.
Note: the screw is rotate
11) Move the Device up and down to verify that the difference between Command and Feedback remains
almost zero.
Note: if this procedure doesn’t fix the problem, replace the Moog valve.

 Final loop verification

After having completed the servo calibration procedure, proceed to the final loop verification and certification.
1) From the Regulator Calibration task select “Verification” “Manual”.
2) Insert a value of 0% and “Send Manual”
3) Measure servo physical position reference for Zero stroke
4) Repeat the previous step at 25%, 50%, 75% and 100%, recording and plotting each points in the loop
calibration test report)

 Acceptance criteria:
The max deviation between reference and actual position shall not exceed the value indicated in the Control
Specification (if existing). For reference, the acceptable limits may be +/- 1%, for linear strokes (SRV & GCV) and
+/- 1 Deg for angular positions (IGV and Nozzles).

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INSTRUMENTS FUNCTIONAL LOOP CHECK EXECUTION
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REVISION DESCRIPTION: PAGE MARKER SECURITY CODE
ADDED RUSSIAN TRANSLATION N/A N
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THIS DOCUMENT IS AND CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF NUOVO PIGNONE S.r.l. WHICH SHALL NOT BE USED OR DISCLOSED TO OTHERS, EXCEPT WITH THE SHEET
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