Loop-check instrumentation and control loops

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Notes Format of Learner’s Guide

Course: Instrumentation and Control Servicing NCIII
Unit of competency: Loop-Check Instrumentation and Control Loops
Loop-Check Instrumentation and Control Loops
Module: At the end of the session, learners should be able to:
Learning outcomes:

Duration: 1. Interpret work instruction for loop checking.
Situating Learning: 2. Identify the PPE and OHS policies and procedures required for

the loop-checking job.
3. Identify tools, equipment testing devices and materials needed

for loop-checking.
4. Conduct loop-checking.
5. Test the loop that were checked
40 hours

You were an Instrument Technician in ICC (Industrial Controls Corpora-
tion) and currently a sub-contractor in SAFI (Southeast Asia Food Inc)
one of the leading manufacturer in food and beverage industry in the
Philippines. You were assigned there as IT for Instrument Maintenance
contract. By the end of the month there would be an internal audit, one
of the main concern of the Engineering Officer is the communication
between instruments in different process such as flow, pressure, tem-
perature and level. Any small discrepancy in the signals being send by
instruments in a loop may greatly affect the finish product of different
areas such as liver sauce (Mang Tomas), soy sauce (Datu Puti Toyo),
and Vinegar (Datu Puti Suka) which is very critical to them that is being
examine by the auditors. Your task is to check whether each instrument
(e.g. sensors, transmitters, transducers, controllers and valves) in a
control loop receives and generate the standard signal needed for con-
trol loop to run in line with the company’s Standard Operating Proce-
dures.

The following tasks are given to you by the Engineering officer.

1.) Identify parameters to be check in each instruments ( e.g. power
supply,input,output,span and tolerance)
2.) Conduct loop check by simulating signals in instruments control loop
using standard equipment device or calibrators.
3.) Test analog and digital signals in field and control station to verify
the functionality of the entire loop being checked.

You must produce a complete loop check report including your proposal
for possible action and recommendation if there’s any.
Upon completion of the job your company will be evaluated according to
the work order you accomplished and a good performance will lead to
extension of the contract and 10% increase when target quota is met.

Pedagogical Training in Instructional Design & Delivery for TVET Page 1
© 2010, Institute of Technical Education, Singapore

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Assessment Criteria: LO1:
1. Communication skills to interpret work instructions are de-
fined and demonstrated according to the established proce-
dures
2. Work signs, symbols and conventions are defined and ex-
plained according to the set standards
3. Work instructions and procedures are demonstrated accord-
ing to the set standards

LO2:
1. Materials needed for loop-checking are identified and pre-
pared according to the work instructions
2. Tools and equipment types and functions needed for loop-
checking are identified and demonstrated according to set
standards
3. Testing devices and instruments operations needed for loop-
checking are explained and demonstrated according to in-
struction manual
4. Personal protective equipment are used in accordance with
the Occupational Health and Safety guidelines and policies

LO3:
1. Personal Protective Equipment (PPE) needed for loop-
checking are identified and prepared according to the work
instructions
2. Use of PPE needed for loop-checking are demonstrated ac-
cording to the set standards
3. Occupational and Health Safety (OHS) needed for loop-
checking are identified and explained according to the work
instructions
4. OHS procedures and policies needed for installation are
demonstrated according to the set standards

LO4:

1. Appropriate personal protective clothing is used in line with
standard operating procedures.

2. Devices’ defects are diagnosed using specified testing pro-
cedures from manufacturer’s manual.

3. Defect/s and fault/s on the devices & loops are identified and
reported in line with standard operating procedures.

4. Contingency measures are managed and implemented in
accordance with established procedures.

LO5:
1. Instrumentation & Control loops are tested to ensure safe
operation.
2. Unplanned events or conditions are responded to in accord-
ance with established procedures
3. Report is prepared/completed according to company proce-
dures.

Pedagogical Training in Instructional Design & Delivery for TVET Page 2
© 2010, Institute of Technical Education, Singapore

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Learning chunk Performance Criteria Learning Activities Learning docu-
(Brief description of ments
Sub-task 1: -Loop checking is strategies, sequence of
planned and pre- lesson, evaluation) (Documents refer-
PLAN & PREPARE pared in line with the 1.1. Identify Different enced by each
for LOOP CHECKING job requirements. Technical Drawing use
-Read & Interpret - Loop checking pa- In Loop Checking job. learning activity)
Work Instruction rameters are identi- 1.2.Read and interpret -Information Sheet
for Loop Checking. fied from appropriate 1.1.1- Instrumentation
documentation Different Technical Symbol and Terminolo-
Sub-task 1: and/or requirements drawings use in gy
- Instrumentation Loop checking job. -Worksheet 1.1.2
PLAN & PREPARE and control loops to Identify Different ISA
for LOOP CHECK- be loop-checked are 2.1. Identify correct Symbol and Terminolo-
ING identified from the Personal Protective gy
-Identify PPE and Job/Service Order or Equipment in line with -Information Sheet
OHS Policies instructions standard operating 1.2.1- Loop Check
- Instrumentation procedures. Technical Drawings
and Control stand- 2.2. Identify OHS Poli- -Worksheet 1.2.2-
ards are followed in cies and Procedures Read and Interpret In-
line with the job re- strumentation drawing
quirements
- Appropriate per- - Information Sheet
sonal protective 2.1.1- Different
equipment is used in Types and Application
line with standard of PPE use in loop
operating proce- checking job.
dures. -Worksheet 2.1.2-
-OHS policies and Identify PPE to be use
procedures are fol- given a work condition
lowed in line with job -Activity 2.1.3.- Prac-
requirements. tice Proper Wearing of
PPE
-Information Sheet
2.1.4- Importance,
Benefits and Limitation
of using PPE.
- Worksheet 2.1.5-
Enumerate Importance
and Limitation of Using
PPE’s
-Information Sheet
2.2.1- OHS Policies and
Procedures.
- Worksheet 2.2.2-
List all OHS policies
and Procedures

Pedagogical Training in Instructional Design & Delivery for TVET Page 3
© 2010, Institute of Technical Education, Singapore

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Learning chunk Performance Criteria Learning Activities Learning docu-
(Brief description of ments
Sub-Task 1: -Tools, equipment strategies, sequence of
and testing devices lesson, evaluation) (Documents refer-
PLAN & PREPARE needed for loop enced by each
for LOOP CHECK- checking are ob- 3.1-Identify tools and
ING tained and checked equipment testing de- learning activity)
3-Identify Tools & for correct operation vices us in loop check- - Information Sheet
Equipment Testing De- and safety ing job 3.1.1- Different Tools
vices and Equipment Testing
-Devices’ defects are 3.2- Configuration of Devices use in loop
Sub-Task 2: diagnosed using Equipment Testing De- checking job
CONDUCT LOOP specified testing pro- vices. - Worksheet 3.1.2-
CHECKING cedures from manu- Categorize Tools and
facturer’s manual 4.1-Explain guidelines Equipment Testing De-
Conduct Loop Check- - Defect/s and for loop checking in vices
ing in Control Loop fault/s on the devic- control loop system. - Information Sheet
System.Sub-task 3: es & loops are identi- 4.2-Explain common 3.2.1- Equipment Test-
TEST THE LOOP fied and reported in encountered devices ing Device Data Sheet
THAT WERE line with standard defects -Operation Sheet
CHECKED operating proce- 4.3- Explain proce- 3.2.2- Configure
dures. dures of contingency Equipment Testing De-
-Contingency measures in loop vices
measures are man- checking -Information sheet
aged and imple- 4.4-Familiarization on 4.1.1- Guidelines &
mented in accord- instrument specifica- Procedures for Loop
ance with established tion Checking in Control
procedures Loop System
5.1-Explain procedures -Worksheet 4.1.2-
-Instrumentation & to test the loop that Enumerate Guidelines
Control loops are were checked. & Procedures on Loop
tested to ensure safe 5.2-Conduct testing Checking
operation. procedures. -Information sheet
-Unplanned events or 4.2.1-Common
conditions are re- Devices Defects.
sponded to in ac- -Information Sheet
4.3.1- Procedures of
Contingency Measures
in Loop Checking
-Worksheet 4.3.2-
Enumerate Procedures
of Contingency
Measures in Loop
Checking & Devices
Defects
-Information Sheet
4.4.1- Instruments
specification
- Job Sheet 4.4.2-
Conduct Loop Checking
in Control Loop System
-Information Sheet
5.1.1-Testing Proce-
dures in Loop Checking

-Operation Sheet
5.2.1-Conduct Testing
Procedures

Pedagogical Training in Instructional Design & Delivery for TVET Page 4
© 2010, Institute of Technical Education, Singapore

DLM 03 Developing print-based Learner’s Guide including all related documents
Notes Format of Learner’s Guide

Learning chunk Performance Criteria Learning Activities Learning docu-
(Brief description of ments
cordance with estab- strategies, sequence of
lished procedures lesson, evaluation) (Documents refer-
-Report is pre- enced by each
pared/completed 5.3-Completion of re-
according to compa- port and documents for learning activity)
ny procedures. the whole loop check- -Information Sheet
ing job. 5.3.1- Sample of In-
strument Loop Check
Sheet

-Work Sheet 5.3.2- Fill
-up Loop Check Sheet

Pedagogical Training in Instructional Design & Delivery for TVET Page 5
© 2010, Institute of Technical Education, Singapore

Information Sheet 1.1.1: INSTRUMENTATION SYMBOLS & TERMINOLOGY

Learning outcomes:
1 Interpret work instruction for loop checking.
Learning Activity:
1.1 Identify different technical drawing use in loop checking job.

I. Definition of Terms:

 Process – defined as systematic series of actions directed to a specific end result, also referred as to the
equipment that performs series of task.

 Process Instrumentation – it is the application of measuring and controlling devices to an
object, or a combination of objects (a system) for the purpose of controlling varying physical or chemical
quantities within specific limitations.

 Instrument – a physical device replacing or extending the perceptual, communicative, manipulative, or
intellectual abilities of man.

 Primary Element – component that measures the process and transmit signal proportional to process condition
to controller.

 Controller - decision making of the system
 Final Control Element - directly regulates the flow of energy or material to the process.
 Transmitter- sense the actual value of a system and transforms the value to a standardized signal

4-20mA is common for analog sigals-as input to control system.
 Automatic Control – is used to describe a control situation in which process variables are manipulated to bring

about a balance between supply and demand on the process.
 Process Variable- the actual value in control loop, temperature,flow,level,pressure,ph etc.
 Set Point- desired value of the process variable.
 Error- in a control loop the error=set point-process value.
 Closed Loop- controller in automatic mode.
 Analog Signal- like voltage or electric current signal, representing temperature, pressure, level etc. Usually the

electrical current signal is of magnitude 4-20 mA where 4 mA is the minimum point of span and 20 mA is the
maximum point of span.
 Digital Signal- a discrete value at which an action is performed. A digital signal is a binary signal with two
distinct states - 1 or 0, often used as an on - off indication.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 1

Information Sheet 1.1.1: INSTRUMENTATION SYMBOLS & TERMINOLOGY
II. General Instrument Bubble Symbols (Instrument Location)

III. Line Symbols

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 2

Information Sheet 1.1.1: INSTRUMENTATION SYMBOLS & TERMINOLOGY

IV. Read Instrument Identification

ISA Instrumentation Code in Process Control System

Process Variable Symbol Type of Instrument Symbol

Analyses A Alarm A

Burner B Users Choice B

Combustion B Controller C

Users Choice C Control valve CV

Users Choice D Trap CV

Voltage V Sensor (primary element) E

Flow Rate F Rupture disc E

Users Choice G Sight or gage glass G

Current (electric) I Monitor G

Power J Indicator I

Time K Control Station K

Level L Light (pilot/operation) L

Users Choice M Users Choice N

Users Choice N Flow Resistance Orifice O
Users Choice
Pressure / Vacuum O Test point (sample point) P

Radiation P Recorder R
Speed (or Frequency)
R Switch S
Temperature
Multivariable S Transmitter T

Vibration T Multifunction U
Weight (force)
U Valve/Damper V
Unclassified
V Well W
Event
W Unclassified X
Position, dimension
X Relay Y

Y Driver Z

Z Actuator Z

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 3

Information Sheet 1.1.1: INSTRUMENTATION SYMBOLS & TERMINOLOGY

IV.I. DESCRIPTION:

1.) First Letter- Indicates a measured or initiating variable, or a modifier, such as Current (I), Speed (S) or Flow (F).
Measured or Initiating Variable.

 A - Analysis
 B - Burner, combustion
 C - User's choice
 D - User's choice
 E - Voltage
 F - Flow rate
 G- User's choice
 H - Hand
 I - Current (electrical)
 J - Power
 K - Time, time schedule
 L - Level
 M- User's choice
 N- User's choice
 O- User's choice
 P - Pressure, vacuum
 Q - Quantity
 R - Radiation
 S - Speed, frequency
 T - Temperature
 U - Multivariable
 V - Vibration, mechanical analyses
 W - Weight, force
 X - Unclassified
 Y - Event, state or presence
 Z - Position, dimension

1.1) Modifier

 D - Differential
 F - Ration (fraction)
 J - Scan
 K - Time rate of change
 M - Momentary
 Q - Integrate, totalizer
 S - Safety
 X - X-axis
 Y - Y-axis
 Z - Z-axis

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 4

Information Sheet 1.1.1: INSTRUMENTATION SYMBOLS & TERMINOLOGY

2.) Second or Succeeding Letters- Indicates readout or passive function, output function or a modifier function.
Readout or Passive Function

 A - Alarm
 B - User's choice
 E - Sensor (primary element)
 G- Glass, viewing device
 I - Indication
 L - Light
 N- User's choice
 O- Orifice, restriction
 P - Point (test connection)
 R - Record
 U - Multifunction
 W - Well
 X – Unclassified

2.1) Output Function

 B - User's choice
 C - Control
 K - Control Station
 N- User's choice
 S - Switch
 T - Transmit
 U - Multifunction
 V - Valve, damper, louver
 X - Unclassified
 Y - Relay, compute, convert
 Z - Driver, actuator

2.2) Modifier Function

 B - User's choice
 H - High
 L - Low
 M - Middle, intermediate
 N- User's choice
 U - Multifunction
 X – Unclassified

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 5

Information Sheet 1.1.1: INSTRUMENTATION SYMBOLS & TERMINOLOGY

Examples - P&ID codes
1.) Flowmeter - Indicating
 FI 001
2.) Temperature - Transmitter
 TT 001
3.) Control Valve
 FV 001
4.) Position Switch - High Level
 ZSH 00

_____________________________________________________________________________________________

Reference:
Book
Kuphaldt, Tony R., Lesson in Industrial Instrumentation, Creative Commons Attribution License, version 3.0.
Website
http://www.isa.org

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 6

Worksheet 1.1.2 : INSTRUMENTATION SYMBOLS & TERMINOLOGY

Learning outcomes:
1. Interpret work instruction for loop checking.
Learning Activity:
1.1 Identify different technical drawing use in loop checking job.

Instruction:

1. Read each question carefully. Fill in the correct answer on the blank provided.
2. Passing Score is 80%.

I. Instrumentation Terminology

1. _______________ defined as systematic series of actions directed to a specific end result, also
referred as to the equipment that performs series of task.

2. _______________ it is the application of measuring and controlling devices to an object, or a combination of
objects (a system) for the purpose of controlling varying physical or chemical quantities within specific
limitations.

3. _______________ a physical device replacing or extending the perceptual, communicative, manipulative, or
intellectual abilities of man.

4. _______________ component that measures the process and transmit signal proportional to
process condition to controller.

5. _______________ decision making of the system
6. _______________ directly regulates the flow of energy or material to the process.
7. _______________ sense the actual value of a system and transforms the value to a standardized signal

4-20mA is common for analog signals-as input to control system.
8. _______________ is used to describe a control situation in which process variables are manipulated to

bring about a balance between supply and demand on the process.
9. _______________ the actual value in control loop, temperature, flow, level, pressure, ph, etc.
10. _______________ desired value of the process variable.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Develop Date: Revised Page #

CONTROL LOOPS 1

Worksheet 1.1.2 : INSTRUMENTATION SYMBOLS & TERMINOLOGY

II. Instrumentation Symbols

1. This symbol refers to _____________________.
2. This line is a _______________________.
3. This symbol
4. This line refers to _________________________.
5. This symbol is a _________________________.

refers to _______________________.

III. Read Instrument Identification

1. ___________________________
2. ____________________________
3. ______________________________

4. _____________________________

5. ________________________________

Code No. LOOP CHECK INSTRUMENTATION AND Date: Develop Date: Revised Page #

CONTROL LOOPS 2

Information Sheet 1.2.1: LOOP CHECK TECHNICAL DRAWINGS

Learning outcomes:
1 Interpret work instruction for loop checking.
Learning Activity:
1.2 Read and interpret different technical drawings use in loop checking job.

I. INTRODUCTION

“At the highest level, the instrument technician is interested in the
interconnections of vessels, pipes and flow paths of process fluids. The proper form of
diagram to represent the ”big picture” of a process is called a Process Flow Diagram.
Individual instruments are sparsely represented in PFD, because the focus of the
diagram is the process itself. “

“At the lowest level, the instrument technician is interested in the
interconnections of individual instruments, including all the wire numbers, terminal
numbers, cable types, instrument calibration ranges etc. The proper form of diagram for
this level of the detail is called Loop Diagram. Here, the process vessels and piping are
sparsely represented, because the focus of the diagram is the instruments themselves.”

“Process and Instrumentation Diagrams (P&ID’s) lie somewhere in the middle
between process flow diagrams and loop diagrams. A P&ID shows the layout of all
relevant process vessels, pipes, and machinery, but with instruments superimposed on
the diagram showing what gets measured and what gets controlled.”

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 1

Information Sheet 1.2.1: LOOP CHECK TECHNICAL DRAWINGS
II. SAMPLE DIAGRAMS
I.1. Process Flow Diagram of Compressor Control System

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 2

Information Sheet 1.2.1: LOOP CHECK TECHNICAL DRAWINGS
I.2. Process and Instruments Diagram of Evaporator Process

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 3

Information Sheet 1.2.1: LOOP CHECK TECHNICAL DRAWINGS
I.3. Loop Diagram of Compressor Surge Control System

______________________________________________________________________

Reference:
Book
Kuphaldt, Tony R., Lesson in Industrial Instrumentation, Creative Commons Attribution License, version 3.0.
Website
http://www.isa.org

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 4

Worksheet 1.1.2 : READ & INTERPRET INSTRUMENTATION DRAWING

Learning outcomes:
1. Interpret work instruction for loop checking.
Learning Activity:
1.2 Read and interpret different technical drawings use in loop checking job.

Instruction:

1.) Identify what kind of instrumentation drawing and complete the table below.
2.) 0ne (1) point for each correct answer.
3.) Passing score is 80%.

1.) _________________________

INSTRUEMENT INSTRUMENT STD. INPUT SIGNAL STD. OUTPUT LOCATION
No. TAG No./ID DESCRIPTION SIGNAL

1
2
3
4
5
6
7
8

Code No. LOOP CHECK INSTRUMENTATION AND Date: Develop Date: Revised Page #

CONTROL LOOPS 1

Worksheet 1.1.2 : READ & INTERPRET INSTRUMENTATION DRAWING
2.) __________________________

INSTRUEMENT INSTRUMENT INPUT CAL. OUTPUT CAL LOCATION
No. TAG No./ID DESCRIPTION

1
2
3
4
5
6
7

Code No. LOOP CHECK INSTRUMENTATION AND Date: Develop Date: Revised Page #

CONTROL LOOPS 2

Information Sheet 2.1.1 : DIFFERENT TYPES & APPLICATION OF PPE

Learning outcomes:

2. Identify the PPE and OHS policies and procedures required for the loop-checking job.

Learning Activity:

2.1 Identify correct Personal Protective Equipment in line with standard operating procedures.

I. WHAT IS PERSONAL PROTECTIVE EQUIPMENT (PPE)?

Personal protective equipment, or PPE, is designed to protect employees from serious workplace injuries or
illnesses resulting from contact with chemical, radiological, physical, electrical, mechanical, or other workplace
hazards (OSHA). Besides face shields, safety glasses, hard hats, and safety shoes, PPE includes a variety of
devices and garments such as goggles, coveralls, gloves, vests, earplugs, and respirators.

II. DIFFERENT TYPES OF PPE

1.) OCCUPATIONAL FOOT PROTECTION
Safety-toe footwear for employees shall meet the requirements and
specifications in American National, Standard for Men's Safety-Toe
Footwear, ANSI Z41.1-1967

2.) HEAD PROTECTION
Employees working in areas where there is a possible danger of head
injury from impact, or from falling or flying objects, or from electrical shock
and burns shall be protected by protective helmets. Helmets for the
protection of employees against impact and penetration of falling and
flying objects shall meet the specifications contained in American National
Standards Institute, ANSI Z89.1-1969, Safety Requirements for Industrial
Head Protection. Helmets for the head protection of employees exposed
to high voltage electrical shock and burns shall meet the specifications
contained in American National Standards Institute, ANSI Z89.2-1971.

3.) HEARING PROTECTION
Wherever it is not feasible to reduce the noise levels or duration of
exposures to those specified in Table D-2, Permissible Noise Exposures,
ear protective devices shall be provided and used. Hearing protective
devices inserted in the ear shall be fitted or determined individually by
competent persons. Plain cotton is not an acceptable protective device.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
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Information Sheet 2.1.1 : DIFFERENT TYPES & APPLICATION OF PPE

4.) EYES AND FACE PROTECTION
Employees shall be provided with eye and face protection equipment
when machines or operations present potential eye or face injury from
physical, chemical, or radiation agents. Eye and face protection
equipment required by this section shall meet the requirements specified
in American National Standards Institute, ANSI Z87.1-1968, Practice for
Occupational and Educational Eye and Face Protection. Employees
whose vision requires the use of corrective lenses in spectacles, when
required by this regulation to wear eye protection, shall be protected by
goggles or spectacles of one of the following types:
 Spectacles whose protective lenses provide optical correction;
 Goggles that can be worn over corrective spectacles without
disturbing the adjustment of the spectacles; or
 Goggles that incorporate corrective lenses mounted behind the
protective lenses.
Face and eye protection equipment shall be kept clean and in good repair.
The use of this type equipment with structural or optical defects shall be
prohibited. Protectors shall meet the following minimum requirements:
 Provide adequate protection against the particular hazards for which
they are designed
 Be reasonably comfortable when worn under the designated
conditions
 Fit snugly and not unduly interfere with the movements of the wearer
 Be durable
 Be capable of being disinfected
 Be easily cleanable
Every protector shall be distinctly marked to facilitate identification only of
the manufacturer. When limitations or precautions are indicated by the
manufacturer, they shall be transmitted to the user and care taken to see
that such limitations and precautions are strictly observed.

5.) SAFETY BELTS, LIFELINES, AND LANYARDS

Lifelines, safety belts, and lanyards shall be used only for employee
safeguarding. Any lifeline, safety belt, or lanyard actually subjected to in-
service loading, as distinguished from static load testing, shall be
immediately removed from service and shall not be used again for employee
safeguarding. Lifelines shall be secured above the point of operation to an
anchorage or structural member capable of supporting a minimum dead
weight of 5,400 pounds. Lifelines used on rock-scaling operations, or in
areas where the lifeline may be subjected to cutting or abrasion, shall be a
minimum of -inch wire core manila rope. For all other lifeline applications, a
minimum of ¾-inch manila or equivalent, with a minimum breaking strength
of 5,400 pounds, shall be used. Safety belt lanyard shall be a minimum of ½-
inch nylon, or equivalent, with a maximum length to provide for a fall of no
greater than 6 feet. The rope shall have a nominal breaking strength of
5,400 pounds.

6.) RESPIRATORY PROTECTION

Protects users by removing harmful materials that may enter the
body via the lungs. Inhalation is one of the quickest, most efficient
ways to introduce lethal levels of hazardous materials into the body.
On October 5, 1998, OSHA's revised Respiratory Protection Standard
took effect. It replaces the standards adopted in 1971 (29 CFR 1910.134
and 29 CFR 1926.103), and it applies to general industry.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 2

Information Sheet 2.1.1 : DIFFERENT TYPES & APPLICATION OF PPE

III. APPLICATION

Protective equipment, including personal protective equipment for eyes, face, head, and extremities,
protective clothing, respiratory devices, and protective shields and barriers, shall be provided, used, and maintained
in a sanitary and reliable condition wherever it is necessary by reason of hazards of processes or environment,
chemical hazards, radiological hazards, or mechanical irritants encountered in a manner capable of causing injury or
impairment in the function of any part of the body through absorption, inhalation or physical contact.

IV. TRAINING

 Make sure anyone using PPE is aware of why it is needed, when it is to beused, repaired or replaced and
its limitations.

 Train and instruct people how to use it properly and make sure they are doing this.
 Because PPE is the last resort after other methods of protection have beenconsidered, it is important that

user’s wear it all the time they are exposed tothe risk. Never allow exemptions for those jobs which take
‘just a few minutes’.
 Check regularly that PPE is being used and investigate fully any reasons why itis not. Safety signs can be
useful reminders to wear PPE.

V. MAINTENANCE

 Looked after and properly stored when it is not being used, for example in a dry, clean cupboard, or in the
case of smaller items, such as eye protection, in a box or case;

 Kept clean and in good repair follow the manufacturer’s maintenanceschedule (including recommended
replacement periods and shelf lives). Simplemaintenance can be carried out by the trained wearer, but
more intricate repairs should only be done by specialists.

NOTE: Make sure suitable replacement PPE is always readily available.

VI. CE MARKING

Ensure any PPE you buy is ‘CE’ marked and complies with the requirements of the Personal Protective
Equipment Regulations 2002. The CE marking signifies that thePPE satisfies certain basic safety requirements and
in some cases will have been tested and certified by an independent body.Personal Protective Equipment at Work
Regulations 1992

______________________________________________________________________

Reference:
Website
www.osha.gov
www.hsebooks.co.uk

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 3

Worksheet 2.1.2 : DIFFERENT TYPES & APPLICATION OF PPE
Learning outcomes:
2. Identify the PPE and OHS policies and procedures required for the loop-checking job.
Learning Activity:
2.1 Identify correct Personal Protective Equipment in line with standard operating procedures.

Instruction:
1. This a short answer question type. Read each question carefully.
2. Do not write on this test paper, separate answer sheet will be provided.
2. Passing Score is 80%.

Questions:
1.) What is Personal Protective Equipment (PPE)? (2 pts)
2.) Give examples of PPE that can be use in loop checking job and define each. (2 pts/each)
3.) Write a paragraph explaining when and why the following PPE that you mentioned on question no. 3

should be used. (5 pts)
4.) Give one maintenance tip on keeping your PPE. (2 pts)
5.) Why is CE MARKING important? (3 pts)

Code No. LOOP CHECK INSTRUMENTATION AND Date: Develop Date: Revised Page #

CONTROL LOOPS 1

Information Sheet 2.1.4 : IMPORTANCE, BENEFITS & LIMITATION OF USING PPE

Learning outcomes:
2. Identify the PPE and OHS policies and procedures required for the loop-checking job.
Learning Activity:
2.1 Identify correct Personal Protective Equipment in line with standard operating procedures.

I. WHEN IS PPE NEEDED?

When hazards cannot be eliminated through engineering and /or administrative controls, PPE
must be used to protect the eyes, face, head, feet, hands, arms, body, ears, and lungs. Here is the list of
hazard that worker may encounter in workplace.

A.) Impact hazards
– Falling objects or potential for dropping objects.

B.) Penetration Hazards
– Objects or machinery that may cause punctures, cuts, or abrasions.

C.) Compression Hazards
– Machinery/heavy objects that may roll over and crush or pinch feet.

D.) Chemical Hazards
– Chemical exposures from inhalation or contact with the skin and eyes.

E.) Heat Hazards
– Hot work areas and sources of high temperature that could result in burns, eye injury, or
ignition of PPE.

F.) Harmful Dust
– Dust from sandblasting, sawing, grinding, or other generation of airborne dust.

G.) Optical Radiation
– Sources of light radiation (welding, cutting, lasers, high intensity lights).

H.) Biological Hazards
– Exposures to blood or other body fluids, mold, or other biological exposures.

I.) Noise Hazards
– Excessive noise (louder than a hair dryer).

J.) Electrical Hazards
– Potential to come in contact on high voltage equipment or power supply.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 1

Information Sheet 2.1.4 : IMPORTANCE, BENEFITS & LIMITATION OF USING PPE

II. Personal Protective Equipment (Benefits & Limitations)
It is widely recognized that the risk of exposure should be addressed through administrative, and

engineering controls, work practices and training. It is equally recognized that these controls may not
prove to be adequate in situations where the risk could not be completely minimized, or in the event of an
unplanned exposure. Thus the use of personal protective equipment (PPE) becomes last line of defense
against exposure.

The benefits gained by wearing PPE are:

 possible prevention of exposure,
 potentially minimizing the risk should an exposure occur, and
 compliments existing controls to enhance personal protection.

It is also important to recognize the limitations associated with PPE:

 PPE only protects the individual wearing it, not anyone else in the workplace, discrepancy
between theoretical and actual levels of protection provided exists (the latter is difficult to assess).

 PPE is only effective if correctly selected, fitted, used, and cared for, and the individual is trained,
and the choice of PPE may compromise mobility, visibility, communication etc.

_____________________________________________________________________________ _______

Reference:
Website
http://www.uottawa.ca
http://www.osh.gov

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 2

Worksheet 2.1.5 : IMPORTANCE, BENEFITS & LIMITATION OF USING PPE
Learning outcomes:
2. Identify the PPE and OHS policies and procedures required for the loop-checking job.
Learning Activity:
2.1 Identify correct Personal Protective Equipment in line with standard operating procedures.

Instruction:
1. This a short answer question type. Read each question carefully.
2. Do not write on this test paper, separate answer sheet will be provided.
2. Passing Score is 80%.

Questions:
1.) When is PPE needed? (5 pts)
2.) Give atleast five (5) possible hazard in loop checking job and explain each. (2 pts/each)
3.) List down the benefits of using PPE. (2 pts/each)
4.) Enumerate limitation of using PPE. (2 pts/each)

Code No. LOOP CHECK INSTRUMENTATION AND Date: Develop Date: Revised Page #

CONTROL LOOPS 1

Information Sheet 2.2.1 : OHS POLICIES AND PROCEDURES

Learning outcomes:
2. Identify the PPE and OHS policies and procedures required for the loop-checking job.
Learning Activity:
2.2 Identify OHS Policies and Procedures

I. WHAT IS OHSAS 18001?
Internationally recognized model for Occupational Health and Safety Assessment Series (OHSAS) for
management systems.Enable organizations to control their OH&S risks and improve their performance.
Specification is intended to address occupational health and safety rather than product and services
safety.

II. WHY WAS OHSAS DEVELOPED?
In response to urgent customer demand for a recognizable occupational health and safety
management system standard and need for health and safety management system that could be
audited and certified.

III. OH&S MANAGEMENT SYSTEM ELEMENT

1. General requirements
2. OH&S policy & commitment

1. Clearly states overall OH&S objectives
2. Authorised by top management
3. Appropriate to nature & scale of OH&S risks
4. Documented, implemented, and maintained
5. Communicated to all employees
6. Available to interested parties
7. Reviewed periodically
8. Improve health & safety performance*
9. Continual improvement
10. “at least” comply with current applicable
11. OH&S legislation and other requirements

3. Planning
4. Implementation and Operation
5. Management Review

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 1

Worksheet 2.2.2: OHS POLICIES AND PROCEDURES
Learning outcomes:
2. Identify the PPE and OHS policies and procedures required for the loop-checking job.
Learning Activity:
2.2 Identify OHS Policies and Procedures.

Instruction:
1. This a short answer question type. Read each question carefully.
2. Do not write on this test paper, separate answer sheet will be provided.
2. Passing Score is 80%.

Questions:
1.) Explain OSHAS 18001? (5 pts)
2.) Why was it developed? (3 pts)
3.) Enumerate the OH&S Management System Elements. (2 pts/each)
4.) List down OHS Policy and Commitments. (2 pts/each)

Code No. LOOP CHECK INSTRUMENTATION AND Date: Develop Date: Revised Page #

CONTROL LOOPS 1

Information Sheet 3.1.1 : DIFFERENT TOOLS AND EQUIPMENT TESTING DEVICE
Learning outcomes:
3. Identify tools, equipment testing devices and materials needed for loop-checking.
Learning Activity:
3.1 Identify tools and equipment testing devices us in loop checking job.
I. ELECTRICAL HANDTOOLS

1.) Srewdrivers
- the most common tools used for securing various styles of screws used on
electrical/electronic equipment. They are available in a wide variety on handles,
shank lengths, shapes, and driver styles. The most common driver styles used
in electronics are the standard (blade), Phillips, and Hexagonal (Allen).

2.) Jewelers Screwdriver
- Sets may be used for small and delicate work.

3.) Power Screwdriver
- May be used for the removal or insertion of large numbers of screws during
service assembly.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 1

Information Sheet 3.1.1 : DIFFERENT TOOLS AND EQUIPMENT TESTING DEVICE

4.) Wrenches
- Used for large nuts found on some potentiometers, switches, and binding posts
where the correct size nut driver is not available or accessibility does not allow
for its use. Box-end, open-end, and adjustable are the most common types
used for electrical/electronic service and assembly.

5.) Pliers
- Two types commonly used in electrical/electronic service and assembly are the
long nose and slip-joint pliers.

6.) Wire Strippers
- Used to removed insulation from wires, to prepare the wire for electrical
connection during assembly or service of electronic equipment. The most
popoular wire stripper is the “Miller Stripper”. This stripper contains a single
slot adjustment within the handle to allow for different gauges of wire. To
minimize the damage to conductors , be sure to set the tool for the proper
gauge wire, and hold it perpendicular to the wire when pulling off the insulation.
Do not use the stripper as a wire cutter, as it will put the cutting edges out
alignment, making the stripper useless.

7.) Diagonal Cutters
- Used to removed the excess wire length along with the accumulation of solder
that usually builds up on the wire after soldering operation. The size of the
diagonal cutter determines the AWG gauge that it will be capable of cutting.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 2

Information Sheet 3.1.1 : DIFFERENT TOOLS AND EQUIPMENT TESTING DEVICE

II. Hand Tool Guidelines

1) Know the purpose of each tool you use, and use each for the specific task it was
designed to do.

2) Never use any tool - hand or power tool unless you are trained to do so and are
familiar with its use.

3) If you have a question about hand tool usage - ask your supervisor.
4) Inspect tools before each use and repair or replace if worn or damaged.
5) Clean tools after every use.
6) Keep cutting edges sharp.
7) Never test a cutting edge with your fingers - test on a scrap material instead.
8) Select the right size tool for the job - don't use cheater bars.
9) When working on ladders or scaffolding, be sure that you your tools are secure. A

falling tool can seriously injure a co-worker or bystander.
10) Carry tools correctly - never put sharp or pointed tools in your pockets.
11) When hand-carrying sharp tools, point cutting edges away from you, toward the

ground or cover the sharp edges.
12) Wear Personal Protective Equipment (PPE) such as safety glasses, safety goggles,

face shields, gloves and proper clothing as appropriate.

____________________________________________________________________________

Reference:
Website
http://www.electricianeducation.com

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 3

Worksheet 3.1.2: DIFFERENT TOOLS AND EQUIPMENT TESTING DEVICE
Learning outcomes:
3. Identify tools, equipment testing devices and materials needed for loop-checking.
Learning Activity:
3.1 Identify tools and equipment testing devices us in loop checking job.

Instruction:
1. Read each question carefully.
2. Do not write on this test paper, separate answer sheet will be provided.
2. Passing Score is 80%.

Questions:
1.) Given the following image of hand tools use in loop checking identify and define each. (3 pts/each)

a.) b.) c.)

d.) e.)
2.) Enumerate the Hand Tools Guidelines. (2 pts/each)

Code No. LOOP CHECK INSTRUMENTATION AND Date: Develop Date: Revised Page #

CONTROL LOOPS 1

Information Sheet 3.2.1 : EQUIPMENT TESTING DEVICE DATA SHEET

Learning outcomes:
3. Identify tools, equipment testing devices and materials needed for loop-checking.
Learning Activity:
3.2 Configuration of Equipment Testing Devices.

I. INSTRUMENT TESTING DEVICES DATA SHEET

CALIBRATOR NAME: mAcal Milliamp Calibrator
MANUFACTURER:
DESCRIPTION: Ametek (Jofra)

The mAcal Milliamp Calibrator is an
economical and easy-to-use calibration
device for sourcing and measuring mA
signals.The instrument is designed
specifically for 2-wire transmitter loops
with 4 to 20 mA signals.

Figure 1: Jofra mAcal

Sources and measures current TECHNICAL SPECIFICATION
Stable source
High resolution Allows for calibration of transmitters in a two-wire loop
% of full scale reading
Timesaving features Internal 24 VDC supply for consistent
loop power
Large display Read to 0.001 mA in the measurement
mode
Displays a percentage to provide for easy analysis of results

Fast one-key-one-function access to the features such as the step
function or loop supply power

Includes large numbers for unit reading, a percentage display, and
dedicated icons for calibrator status including a low battery indicator

Traceable calibration For your confidence, the unit is supplied with a calibration certificate that
is fully traceable to a national standards lab such as NIST or NPL

Complete marine program Part of a complete program of marine
approved temperature, pressure and signal calibrators; including
temperature sensors

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 1

Information Sheet 3.2.1 : EQUIPMENT TESTING DEVICE DATA SHEET
KEYS FUNCTION

Reference:
www.ametekcalibration.com
www.jofra.com

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 2

Operation Sheet 3.2.2 : CONFIGURE EQUIPMENT TESTING DEVICE (CALIBRATOR)

Learning outcomes:
3. Identify tools, equipment testing devices and materials needed for loop-checking.
Learning Activity:
3.2 Configuration of Equipment Testing Devices.

1. Turn on the calibrator by pressing ON/OFF keypad.

2. Switch between external and internal loop power supply by pressing PWR keypad.
NOTE: For external power loop supply, the +24Vdc of the current loop is generated by the
external power supply while for internal power loop supply, the +24Vdc of the current
loop is generated by the mAcal itself.

3. Press FUNC to allow changes from measuring and sourcing function of the calibrator.

3.1. Current Measurement
1. Press FUNC key and select MEASUREMENT mA. The range for current
measurement is limited to 0 to 24mA.
2. Connect in series the red test lead to the positive potential of the loop/instrument
being measured and the black test lead to negative potential.
3. Read the digital display.

3.2. Voltage Measurement
1. Press FUNC key and select MEASUREMENT Volt. The range for voltage
measurement is limited to 0 to +45Vdc.
2. Connect in parallel the red test lead to the positive potential of the loop/instrument
being measured and the black test lead to negative potential.
3. Read the digital display.

3.3. Current Sourcing
1. Press FUNC key and select Source mA. The range for current sourcing is limited to
0 to 24mA.
2. Connect the red test lead to the positive potential of the loop/instrument being
supplied and the black test lead to negative potential.
3. Press the arrow UP/DOWN to increase or decrease the entered value.

NOTE: Be aware on polarity connection, wrong polarity connection may cause short circuit or
may damage the instrument as well as the calibrator.

4. Press mA / % keypad to alternate change between the read-out of mA or percent value.

Code No. LOOP CHECK INSTRUMENTATION Date: Developed Date: Revised Page #
AND CONTROL LOOPS

Information Sheet 4.1.1 : LOOP CHECKING GUIDELINES AND PROCEDURES

Learning outcomes:
4. Conduct loop-checking
Learning Activity:
4.1 Explain guidelines for loop checking in control loop system.

I. Guidelines on Instrument Loop Checking

1.) Review P&ID drawings for location and piping instructions.
2.) Review device instructions for proper location, mounting, and piping.
3.) Verify field device is physically located in the correct location per the P&ID. Verify that a

permanent tag label is securely attached to the device that clearly indicates the assigned
loop tag number.
4.) Verify field device is correctly connected by performing the following inspections:

a.) Physical-Properly mounted an oriented as designed, ensure close-
coupled connection s are securely fastened; pipe stands are structurally sound.

b.) Mechanical- Sensing lines, and other process connections are properly installed,
connected and verified per instrument design specification.

c.) Electrical- Conduit runs are properly connected; seal drains are installed correctly, etc.
5.) Verify the input or output signal is within the device’s normal operating range.
6.) Verify that any special/custom device characteristics required are present (example: custom gas

curves, special construction materials, etc.)
7.) Measure and adjust associated air and electrical power supplies.
8.) Measure loop impedance by disconnecting the signal wiring at both the transmitter and rack room

ends, shorting the signal wiring at the transmitter and measuring the loop resistance with an
ohmmeter at the termination panel end. This process typically takes two technicians with two-way
radios for communication.
9.) With an ohmmeter, verify there are no shorts to ground in the signal wiring by checking the wiring to
ground while the wiring is still disconnected. This process typically takes two technicians with two-
way radios for communication.
10.) Verify proper wiring polarity.
11.) Connect the wiring to the transmitter in the field and in the rack room.
12.) Verify that all field wiring is properly labelled per the instrument loop diagram. This includes all

terminations per the instrument loop diagram.
13.) Verification that all instrumentation wiring is mechanically sound by performing a physical “Tug

Test” of the wires.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 1

Information Sheet 4.1.1 : LOOP CHECKING GUIDELINES AND PROCEDURES

14.) Verify that the field device enclosure is closed, all temporary shipping stops removed, and the
device is mechanically fit for service as defined above and in the device instruction manual.

15.) Apply power to device.

II. PROCEDURES ON LOOP CHECKING
A.) FLOW LOOP

1.) Simulate appropriate input signal.

TRANSMITTER TYPE INPUT SOURCE
Differential Type Pneumatic Calibrator
Turbine Meter Type Pulse Generator
Miscellaneous Type As per vendor’s instruction

2.) Check and supply proper instrument air and/or electrical power to the system to
be tested.

3.) Inject input signal 10%, 50% and 90% of full scale and check all corresponding
instruments at each input value.

4.) If the flow loop consist with control valve and controller. adjust the controller output
manually 0,25,75 and 100% of valve operating signal and check valve stroke. Check
tight closing of control valve, if necessary.

5.) Reassemble the impulse piping or turbine meter and complete loop check sheet.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 2

Information Sheet 4.1.1 : LOOP CHECKING GUIDELINES AND PROCEDURES

B.) PRESSURE/VACUUM LOOP
1.) Simulate appropriate input signal.

TRANSMITTER TYPE INPUT SOURCE
Low Pressure
Medium/High Pressure Pneumatic Calibrator
Vacuum
Vacuum (D/P Cell Type) Dead Weight Tester or Hydro Pump

Vacuum Pump w/ Manometer or Vacuum
Gauge
Pneumatic Calibrator

2.) Check and supply proper instrument air and/or electrical power to the system to
be tested.

3.) Inject input signal 10%, 50% and 90% of full scale and check all corresponding
instruments at each input value.

4.) If the pressure loop consist with control valve and controller. adjust the controller
output manually 0,25,75 and 100% of valve operating signal and check valve stroke.
Check tight closing of control valve, if necessary.

5.) Reassemble the impulse piping and complete loop check sheet.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 3

Information Sheet 4.1.1 : LOOP CHECKING GUIDELINES AND PROCEDURES

C.) LEVEL LOOP
1.) Simulate appropriate input signal.

TRANSMITTER TYPE INPUT SOURCE
Differential Pressure Pneumatic Calibrator
Displacer or Float Type Water Simulation Set
Miscellaneous Type As per vendor’s instruction

2.) Check and supply proper instrument air and/or electrical power to the system to
be tested.

3.) Inject input signal 10%, 50% and 90% of full scale and check all corresponding
instruments at each input value. For displacer type level transmitter the input
signal of water level should be compensated.

4.) If the level loop consist with control valve and controller. adjust the controller output
manually 0,25,75 and 100% of valve operating signal and check valve stroke. Check
tight closing of control valve, if necessary.

5.) Reassemble the impulse piping and transmitter body to original condition and complete
loop check sheet.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 4

Information Sheet 4.1.1 : LOOP CHECKING GUIDELINES AND PROCEDURES

D.) TEMPERATURE LOOP
1.) Simulate appropriate input signal.

MEASURING ELEMENTTYPE INPUT SOURCE

Thermocouple Type Accurate millivolt Generator

RTD (Resistance Temperature Detector) Decade Resistance Box

Bulb Type Oil Bath
Miscellaneous Type As per vendor’s instruction

2.) Check and supply proper instrument air and/or electrical power to the system to
be tested.

3.) Inject input signal 10%, 50% and 90% of full scale and check all corresponding
instruments at each input value. If the system is equipped w/ burn out function,
check it by opening the temperature element circuit while observing the output.

4.) If the temperature loop consist with control valve and controller. adjust the controller
output manually 0,25,75 and 100% of valve operating signal and check valve stroke.
Check tight closing of control valve, if necessary.

5.) Reassemble the temperature element to the original condition and complete loop check
sheet.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 5

Information Sheet 4.2.1 : COMMON DEVICES DEFECTS

Learning outcomes:
4. Conduct loop-checking
Learning Activity:
4.2 Explain common devices defects

COMMON DEVICES DEFECTS

A.) Actuator System
• Excessive valve deadband
• Improperly sized control valve
• Valve packing is tightened too much
• Improperly tuned valve positioner

B.) Sensor System
• Transmitter
– Improperly calibrated
– Excessive signal filtering
• Temperature sensor
– Off calibration
– Improperly located thermowell
– Buildup of material on the thermowell
• Pressure
– Plugged line to pressure sensor
• Flow indicator
– Plugged line to differential pressure sensor
• Level indicator
– Plugged line to differential pressure sensor

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 1

Information Sheet 4.3.1 : CONTINGENCY MEASURES IN LOOP CHECKING

Learning outcomes:
4. Conduct loop-checking
Learning Activity:
4.3 Identify contingency measures in unexpected condition.

I. PROCEDURE OF CONTINGENCY MEASURES IN LOOP CHECKING

Often the first indication of a control loop problem comes from the operator:
“I think we have a bad valve” or “this loop isn’t responding the way it used to.” In either
case, it’s the technician’s signal to begin troubleshooting.

A.) Tracing the control loop problem

Step 1: The first step is to measure the 4-20 mA signals, either by breaking the loop
connecting in series with a current loop calibrator and verifying the loop current
value. If the loop current measured is not as expected, there are three likely
causes: broken/disconnected/shorted wires, a bad loop power supply, or faulty
instrumentation.

Step 2: If no problem is found in the wires, use current loop calibrator to check the loop
power supply. If the power supply shows no output, use the 24 V loop power
function of the meter to substitute for it; if the loop then works properly the source
of the problem is obvious.

Step 3: If the wiring and the power supply both check out, it’s time to check the transmitter.
If you have a loop calibrator, process calibrator or multi-function clamp-on meter, use
its mA simulate mode to substitute for the transmitter. If the loop performs as requested,
the problem lies with the transmitter, if not, it is elsewhere.

Step 4: If a final control element (valve positioner, etc.) is suspected, use the mA source/
simulate mode on the current loop calibrator to feed a signal into it while watching
the local indicator for a response.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 1

Information Sheet 4.4.1 : INSTRUMENT DATA SHEET

Learning outcomes:
4. Conduct loop-checking
Learning Activity:
4.4 Familiarize on instrument specification.

SAMPLE INSTRUMENT DATA SHEET

FLOW METER
CORIOLIS

Client: REV. DESCRIPTION BY DATE SHT: 16
Project: 0 Issue
OCT 30
Doc No. ISS-001
2009 BY:

CHECKED:

APPROVED:

1. Function: Indicate, Transmit

2. Type: Flow Coriolis 10 Process Temp 20 to 80 deg c
3. Accuracy: Density 0.10% of Rate Range: 800 to 1500 kg/m3
0.0005 g/cc 10. Process Density Range: 1" Flange
3. Housing Material: 10. Procees Conn:
Transmitter Vendor 11. Electrical Vendor Std
Connection: NEMA 4X
Sensor 316 SST 12. Protection Rating: Siemens, E&H, Micro
6. Transmitter Mounting: Remote Motion
7. Output 1 x Frequency 13. Manufacturer : Vendor
8. Power Supply: 24VDC 14. Model :
9. Output 1 x Frequency
1 x 4-20
mA

OPERATING

REV. TAG PIPELINE SIZE FLOW MEDIUM FLOWRATE PRES. LINE NUMBER
NUMBER
HLPCB M3/HR kPa
MINERAL OIL
0 FIQT-0114 25 MINERAL OIL 0-1.5 250 1.04-PCBH-25-CFT-HC
0 FIQT-0115 25 0-1.5 250 1.07-CO-25-CFT
0 FIQT-0208 25 PCBL 0-1.5 250 2.01-Mor-25-CFT-HC
0 FIQT-0608 25 0-4 250 6.09-PCBL-25-CFT

NOTES: Flow switch shall be installed with 5D upstream and downstream straight pipe run allowance
1 Seal material shall be Viton
2

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 1

Information Sheet 4.4.1 : INSTRUMENT DATA SHEET

PRESSURE/VACUUM GAUGES

Client: REV. DESCRIPTION DATE BY: SHT:
Project: 0 Issue
OCT 30 2009 BY:
Doc. No. ISS-001
CHECKED:

APPROVED:

1. Type Direct Reading 12. Pressure Element Bourdon
Local 13. Element Material 316 SS
2. Mounting 100 mm minimum size 14. Socket Material 316 SS
Phenol 15. Connection - NPT 1/2 inch
3. Dial Diameter Screwed 16. Movement
Stainless Steel
4. Case & Cover Back 17. Diaphragm Seal
Glass Type YES
5. Ring Direct Flange
6. Blow-out Dry Material Diaphragm
Protection 316L SST
0.50% Seal Chamber Material
7. Lens WAAREE or equiv Fill Fluid 316 SST
8. Movement (BY VENDOR) Process Conn
Damping 18. Temperature Rating (See note 2)
9. Nom. Accuracy 300 deg C
Req.

10. Manufacturer

11. Model Number

REV. TAG No. RANGE OPERATING MEDIUM DENSITY SERVICE
(MPas) PRESSURE
0 PG-0102 GO (GAS OIL) kg/m3
0 PG-0104 0.3 (MPas) QRM (REACTION MIXTURE)
0 PG-0201 130 1R01 Reactor
0 PG-0206 0.3 0.2 NaD (Sodium Dispersion) 1.10-RM-25-
0 PG-0501 0.3 NaD (Sodium Dispersion) 130
0 PG-0502 0.6 0.02 902 CFT-PP
0 PG-0504 0.2 PCBH (HI Level PCB) 902
0 PG-0506 0.3 0.2 PCEu (Perchloroethylene) 2A01
0 PG-0507 PCEu (Perchloroethylene) 1500
0 PG-0602 0.3 0.15 PCEg (Perchloroethylene-gas) 2A02
0 PG-0603 1620 5.02-PCBH-
0 PG-0605 0.3 0.15 AIr + PCEg
0 PG-0605A 0.01 PCEu (Perchloroethylene) 1620 25-CFT
0 PG-0606 1.01 ATM 1.2 5.07-PCEu-
0.6 ATM PCBH (Hi Level PCB) 1.2
ATM PCEr (Perchloroethylene) 1620 50-CFT
0.3 0.6 PCEu (Perchloroethylene) 5.10-PCEu-
PCEr (Perchloroethylene) 1500
0.3 0.15 50-CFT
1620
0.3 0.15 5.2
0.6 1620
0.15 1620 5.21
0.6
6G01
6.03-PCBH-
25-CFT-PP
6.07-PCEr-

25-CFT
6.08-PCEr-

25-CFT

6H01

NOTES:

1. Reaction Mixture comprise of PCB, Mineral oil, Sodium, Water, Gas Oil (GO) is the reaction vapor
2. Connection for PG-0102 is DN 80. 1/2 NPT for PG-0104. DN 40 for PG-0201 & 0206, 1/2" NPT for PG-0501,

PG-0502. PG-0504, PG-0507; 1/2" NPT for PG-0602, PG-0603, PG-0605, PG-0605A, PG-0606

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 2

Information Sheet 4.4.1 : INSTRUMENT DATA SHEET

PRESSURE SWITCH

Client: REV. DESCRIPTION DATE BY: SHT:
Project: Issue OCT 30 BY:

2009

CHECKED:

Doc. No. ISS-001-PS APPROVED:

1. Function: Switch 8. Process Operating Pressure: 0.25 Mpa
2. Type: 9. Process Operating Temp.: 20 Deg. C
Diaphragm
3. Housing Mat'l: Epoxy coated die cast 10.Electrical Certification: Standard
4. Process aluminum
Connection: 11. Electrical Connection: Standard
5. Wetted Material: 1/4 inch NPT 12. Protection Rating: NEMA 4X
6. Form: 13. Manuufacturer : UE or equivalent
316 SST
7. Rating: 14. Model : 400 Series
D.P.D.T. 15. Application : Nitrogen Supply
15A 115/230
VAC

REV. TAG No. RANGE OPERATIN MEDIUM DENSITY SERVICE
0 PS-1001 (MPas) G NITROGEN kg/m3 10.02
1.185
0.6 PRESSURE
(MPas)
0.25

NOTES:

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 3

Information Sheet 4.4.1 : INSTRUMENT DATA SHEET

TEMPERATURE TRANMITTER

Client: REV. DESCRIPTION BY DATE SHT:
0 Issue
Project: Doc. No. OCT 30 BY:
2009 CHECKED:
A. TRANSMITTER Transmit APPROVED:
1. Function (See Sensor Head Type) ISS-001
2. Case 3 WIRE PT 100 RTD
Sensor Head Mounted B. TEMPERATURE Form B, SST, screw cover
3. Mounting IP 54 SENSOR 316SS,not > 6mm dia.
24 VDC (Loop powered)
4. Enclosure Class 13. Element Vendor
5. Power Supply
6. 14. Head Type MINCO
Output
7. Electrical Cert. 15. Sheath
8. Electrical Conn. 16. Electrical
9. Conn.
Service 17.
10. Transmitter Type Manufacturer

11. Manufacturer 4 ~ 20 mA plus HART C. THERMOWELL
12.Model Number FM Approved
1/2"NPT

See table below 18. Material

Universal TC/RTD Input 316L SST
Siemens or
equiv
TH 300

REV. TAG ADJUSTMENT WELL INSERTION SERVICE
NUMBER RANGE CONNECTION LENGHT
0 (ºC) (inches) 1R01
0 TT-0105 DN 40 2H02
0 TT-0222 0 to 200 DN 25 6 4E01
0 TT-0401 0 to 200 DN 25 6 4E02
0 TT-0403 0 to 50 DN 25 3 5.22-PCEg-150-CFT-HC
0 TT-0563 0 to 50 DN 25 3 7.18-PCEu-20-CFT
0 TT-0609 0 to 200 3 6G01 Steam Jacket
0 TT-0604 0 to 200 1/2 1/2 6.05-PCEr-50-CFT
0 TT-0621 0 to 200 DN 50 60 6H01
0 TT-0622 0 to 200 1/2 7.12-Mor-80-CFT
TT-0747 0 to 200 1/2 8
0 TT0714 (TI- 0 to 50 DN 40 3 7.43-GLr-75-CFT-CC
0 11.9-GLr-50-CFT-CC
0 0714) 0 to 200 1/2 3 11.10-GLr-50-CFT-CC
0 TI-1104R 0-100 1 1/2 11.11-GLr-50-CFT-CC
0 TI-1105R 0-100 1/2 1 1/2 11.12-GLr-75-CFT-CC
TI-1106R 0-100 1/2 1 1/2
0 TI-1107R 0-100 1/2 1 1/2 11Z01 Chiller
0 TT-1102 1/2 11.07-GLS-50-CFT-CC
0 0-100 1/2 3 11.05-GLs-50-CFT-CC
0 (1101) 0-100 1 1/2 11.03-GLs-50-CFT-CC
0 TI-1104S 0-100 1/2 1 1/2 11.01-GLs-75-CFT-CC
TI-1105S 0-100 1/2 1 1/2
TI-1106S 0-100 1/2 1 1/2
TI-1107S 1/2
1/2

Note:
1. Final dimensions of the insertion length and stem length are subject to verification upon availability of tank nozzle details.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #
CONTROL LOOPS 4

Job Sheet 4.4.2 : CONDUCT LOOP CHECKING

Learning outcomes:
4. Conduct Loop Checking
Learning Activity:
4.4 Conduct Loop Checking in Control Loop System.

Equipment / Resources:
 Level Control Loop Training Kit
 Flow Control Loop Training Kit
 Pressure Control Loop Training Kit
 Temperature Control Loop Training Kit
 Pressure Calibrator
 Electronic Calibrator
 Dry Block Calibrator
 Multi Tester
 Electrical Hand Tools

At the end of these learning activities you should be able to conduct loop checking and
complete loop check sheet/report.

I. Using the given equipment/materials perform loop check on the given instrument loop
diagram for level, flow, pressure and temperature.

1. Pressure Transmitter

Diagram 1: Loop Diagram of D/P Transmitter

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #

CONTROL LOOPS 1

Job Sheet 4.4.2 : CONDUCT LOOP CHECKING
2. Magnetic Flow Meter

Diagram 2: Loop Diagram of Magnetic Flow Meter
3. Switches

Diagram 3: Loop Diagram of Flow & Level Switches

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #

CONTROL LOOPS 2

Job Sheet 4.4.2 : CONDUCT LOOP CHECKING
4. Valve

Diagram 4: Loop Diagram of On-Off Valve

II. Complete the Loop Check Sheet Report by filling-up the necessary information.

Warning: Always keep in mind SAFETY FIRST! You may be working on HIGH VOLTAGE SOURCE
& HIGH PRESSURE SUPPLY.

Code No. LOOP CHECK INSTRUMENTATION AND Date: Developed Date: Revised Page #

CONTROL LOOPS 3

Worksheet 4.4.2 : CONTINGENCY MEASURES IN LOOP CHECKING
Learning outcomes:
4. Conduct loop-checking
Learning Activity:
4.3 Identify contingency measures in unexpected condition.

Instruction:
1. This a short answer question type. Read each question carefully.
2. Do not write on this test paper, separate answer sheet will be provided.
2. Passing Score is 80%.

Questions:
1.) Enumerate the step by step procedure of contingency measure in loop checking. (5 pts)
2.) List the equipment testing device (calibrator) used in this procedures. (2 pts/each)
3.) Recalling back that there are common devices defects that technician might encounter while

conducting loop check, list down some that you know. (3 pts/each)

Code No. LOOP CHECK INSTRUMENTATION AND Date: Develop Date: Revised Page #

CONTROL LOOPS 1