What is Loop checking:

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

checking is the final process before the commissioning of the processing system. Loop ch
ecking is the process that confirms the components wired correctly and also helps to ensur
e that the system is functioning as designed.The loop checking checks the connection bet
ween each component in the control loop. A control loop consists of transmitter/sensor, pr
ocess controller, final control element.Before start, the loop check include, first list the num
ber 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 si
gnal 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 t
he circuit protection devices to operate and maintain the integrity of the cable if there is a f
ault 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 th
e 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 resista
nce 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 fix
ed equipment circuits.
Insulation resistance test:
The insulation resistance tests to ensure there is no current flow between conductor and gr
ound or insulation surface. If there is no current flow the wire could prevent electric shock h
azards, 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 an
d 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 separ
ately to ensure that the insulation resistance of both the circuit and the appliances complie
s 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 i
n 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 oh
ms
Confirm the switching of the active conductors using an ohm meter with the long cable con
nected 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 oth
er terminal.
With the MEN link in place, confirm the polarity of the sockets using a 10Ώ resistor and an o
hm meter. Connect the 10Ώ resistor between the active circuit conductor and the neutral bu
s, then connect the multimeter cable to the ground terminal and the second cable to the act
ive 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 Ch
eck 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 Distributiv
e Control System Controller. (e.g. Current Loop, Multiple device Bus Communication Protoc
ol, 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 de
vice analog and engineering units.

The HMI of the DCS Controller accurately displays the engineering unit response to the sign
al 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 recei
ved 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 prope
rly 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 Distributiv
e Control System Controller. (e.g. Current Loop, Multiple device Bus Communication Protoc
ol, etc.

The Field control device responds appropriately to the corrective signal received from the D
CS 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 Contro
ller and displayed on the HMI.

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

It is not the focus of the Loop Check to correct any deficiencies found. Full information con
cerning 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: Loc
ational 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 et
c.

Loop availability can prevent this. If at all possible, Loop availability should be planned to ac
commodate Locational Grouping)

Each loop is assigned a separate unique folder.

Each Loop Folder is populated with either a comprehensive Loop Sheet, and/or individual el
ements, 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 L
oop 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 Cons
ole Engineer can confirm alarm action.

(NOTE: Common is a 0% 25% 50% 75% 100% Check. This was originally necessary to confir
m 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 Diffe
rential Flow Transmitter to be placed in service after check out, the three valve manifold wo
uld 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 C
ontrol Algorithm faceplate and by placing the control mode (PID Controller) to Auto, determ
ine that the output action is appropriate.

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

If pneumatic, the Field Technician opens the air source checking for proper pressure adjust
ment 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 obse
rves the action of the valve.

Jointly, the Field Technician and the Console Engineer determine if the resultant action is a
ppropriate for the control signal sent and the previously determined action of the control al
gorithm.
Where present, the Console Engineer observes any feedback from the valve to be in agree
ment 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 specifica
tion details and good installation practice.

Either by Signal Impression, manual toggling, or conductor manipulation, the Field Technici
an 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 phy
sical state as impressed on the device by the Field Technician.

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

If no deficiencies were noted during the Loop Check, the Loop Folder is placed in the Compl
eted 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 Engi
neer.

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, va
lves, vibration, DCS loop, switchgear loop and ramaining pressure and level types instrumen
ts.

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 Instrum
ent Supervisor prior to use. Calibration equipment shall comply with the Saudi Aramco Stan
dards 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 D
C 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 (Ha
nd 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 a
pplicable.
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 usin
g 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 w
orks including pressure test. In some case loop test can be executed without impulse tubin
g 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 D
C
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 re
sults 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 o
f 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 calibrati
on 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 th
e internal air supply piping.
xiii. In case of air piping is not installed and tested then this exception item to be mention
ed 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 valv
e, 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 va
lve 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 ai
r 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 mentione
d 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 conditio
n should be prepared by forcing the applicable ESD points on ladder on logic and sam
e 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 s
top.
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 th
e status in the DCS / ESD. However, ESD switch case actual pressure simulat
ion 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 t
he 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 H
2S 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 /D
CS range, by using decade resistance box or any other resistance simulator at the RTD ter
minal head.
iii. Verify the corresponding reading in the DCS / integral indicator of transmitter and remo
te 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 temper
ature at integral indicator of temperature transmitter and in DCS. Special consideration sha
ll be given to electrical connection of the RTD.
vi. During loop checking, If the instrument is not accurate re –calibration should be done i
n 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 / DC
S range, by using “mv” source (simulator) at the thermocouple terminal head.
iii. Verify the corresponding reading in the DCS / integral indicator of transmitter and remo
te 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 temper
ature at integral indicator of temperature transmitter and at remote indicator if applicable t
o 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 l
eads at proximitors terminals for check gap voltages.(If applicable).
iv. Adjust the probe at approximately (-10Vdc) gap voltages and reset VMS rack.( If pplica
ble)
v. Simulate the signal by wobulator 0%, 50% and 100% of the range and verify the corresp
onding 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 norm
al 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 MC
C/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/S
WR unit breakers.
xi. Removal of the pad lock on the breakers required permission from Electrical Mechanic
al 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 Instrumenta
tion Types of loops Types of signals DCS PLC & ESD system Alarms Generally used terms i
n instrumentation legends Temp vs mv tables for all kinds of thermocouples Test equipme
nt & 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 SYST
EM. 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 contrac
tors are operational and within applicable standards and manufacturer’s tolerances and tha
t 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 testin

g 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 be
tween (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 o
peration of equipment by means of the plant wide Distributed Control System (DCS), ESD, F
GS 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 conn
ector
The complete instrument loop shall be tested as one system, and when necessary adjust
ment 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 stam
ped 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/checkin
g 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 T
echnician) 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, esp
ecially 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 bee
n satisfactory closed out.
Factory Acceptance Test (FAT) of DCS, ESD, FGS Systems and all other control panels as
sociated with mechanical and other packages have been successfully concluded.
The appropriate pre-installation instrument calibration/testing has been completed, recor
ded on the Instrument Calibration Record and witnessed/accepted by Owner Representativ
e.
All punch items are completed. All required documentation drawings are assembled withi
n 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, ins
trument air piping, mounting details and Instrument drawings. All cabling and wiring has be
en 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 bo
xes must be maintained.
Safety belts will be required in some other areas where the instruments are mounted on hi
gh elevations.
Observed proper polarity connections for electronic instruments and any other instrument
s requiring separate supply.

COMMUNICATION REQUIREMENTS

During early commissioning or pre commissioning activities like flushing and blowing it mu
st be ensured that the (operational) commissioning crew is fully equipped with means of co
mmunication.

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 un
der 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 th

e 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 un
der 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 suc
h 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 un
der 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 D
CS 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 closin
g of control valve. Check the fail-safe position of the valve after completing the test by rem
oving 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 un
der 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 closin
g of control valve. Check the fail-safe position of the valve after completing the test by rem
oving 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 un
der 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 closin
g of control valve. Check the fail-safe position of the valve after completing the test by rem
oving 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 un
der 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 t
able. While in RTD input, connect the decade resistor box in place of RTD and obtain the res
istance values corresponding to 0%, 25%, 50%, 75% and 100% of the span and use the obtai
ned 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 ti
ght closing of control valve. Check the fail-safe position of the valve after completing the te
st by removing the air supply to the valve.
Reassemble the temperature element to the original position

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