TILI Automation

 Valves, the actuators that move them, and the electronic circuits that control them, are all subject to aging soon after they are installed. Valve seats wear from repeated seatings and from the liquid or gas that passes through them. A valve may be stroked up to tens of thousands of times a year, which causes screws to reposition, springs to weaken and mechanical linkage to loosen. Electronic components change value over time. All of that can produce valves that don’t fully open or close, close prematurely, or operate erratically. This “calibration drift” can result in improper regulation of the gas or liquid under the valve’s control. Functional Testing of Control Valve Positioners To keep valves operating properly, you need to periodically check electronic valve positioners. However, these checks need to be conducted quickly to minimize down time. If calibration drift is found, the valve positioner must also be recalibrated immediately. A good tool for this is source meter or a ...

 Pressure Differential Switch Calibration Test Equipment Required: Pneumatic Calibration Digital Multimeter Test Gauge Typical Test Set-up  Calibration Procedure a. Check and confirm instrument range as per specification. b. Hook-up instrument as per typical test set-up. For Switch Low 1) Apply the calibrating pressure above the reset value of the set pressure. 2) Slowly decrease the calibrating pressure and confirm switch contacts transfer from N.C. to N.O. (or vice versa). 3) Record the pressure where the switch contact transfer happened. 4) Increase the calibrating pressure until the switch resets (Multimeter continuity will change) and record the reset point. For Switch High 1) Gradually increase the calibrating pressure to the set pressure and confirm switch contact transfers from NC to NO (or vice versa). 2) Record the pressure where the switch contact transfer. 3) Decrease the calibrating pressure until the switch resets (Multimeter continuity will change) and record th...

 PRESSURE SAFETY/RELIEF VALVES FUNCTIONAL TESTING Test Equipment required :- Test Gauge Regulator Relief Valves Test Jig Typical Test Sel-up Functional Testing Procedure : a. Check and ensure instrument complies to datasheets. Check the relief/safety valve set point. b. Hook up pressure relief valve as per the typical test setup shown above. c. Check the manufacturer’s seal for setting. d. Hook-up N2 cylinder to the test manifold inlet. e. Adjust pressure via regulator. Gradually increase pressure until the pressure relief valve -pops”. Note reading on test gauge. f. Ensure the reset value is within the tolerance. Reset value shall be recorded. g. Items (e) ancl (f) popping and resetting should be carried out 3 times for confirmation. h. Leak test the PSV or RV at 90% of the set point I. DO NOT remove ‘Manufacturer’s seal or adjust setting. j. Compile all results in Inspection/Calibration Pressure Relief Valve’. Note: Any accumulated dust at the valve seat to be cleaned or flushed ...

 Pig Signalling Switches Functional Testing Test Equipment:- i.) Multimeter Typical Test Set-up Functional Testing Procedure a. Ensure pig detector is as per data sheets. Inspect for any physical damage. b. Prepare the instrument as per typical test set-up and confirm the vertical position on testing. c. Push on trigger assembly left and right. Confirm the switch contacts change status and mechanical indicator flag straight up. d. Tabulate all result in calibration check sheet.

 Sand Probe Functional Testing Test Equipment:- Gauges Pressure Regulator Hydraulic Pump  Typical Test Set.up Functional Testing Procedure : a. Check the manufacturer datasheet / instrument nameplate b. Hook-up instrument as per typical test set-up. c. Apply control pressure through inlet A and output B will show (control pressure) reading. d. Simulate probe pressure by injecting line pressure through Hydraulic Hand Pump D, reading at gauge B will drop, (block and bleed  concept) and gauge C will show (control pressure) reading. e. Tabulate all result in Calibration Check Sheets.

 SELF ACTUATED PRESSURE CONTROL VALVE FUNCTIONAL TESTING 1) Pressure Reducing Method Test Equipment Required :- Regulator Test Gauge Typical Test Set-up Functional Testing Procedure a. Check instrument data, check for pressure requirement. b. Check vendor’s specification sheet or instrument nameplate maximum allowable pressure. c. Hook-up instrument as typical test set-up. d. Open Valve A, note down pressure indication of the test gauge B as the set pressure. e. If the set pressure is not as per specification carry out as follows: Remove the cover of the set point adjustment screw Adjust the set point screw until the test gauge indicates the desired pressure. f. Records all results in Instrument Calibration Check sheets. 2) Back Pressure Regulator Method Test Equipment Required :- Regulator Test Gauge Typical Test Set-up Functional Testing Procedure a. Check instrument data, check for pressure requirement. b. Check vendor’s specification sheet or instrument nameplate maximum allowa...

 ELECTRIC MOTOR VALVE ACTUATOR FUNCTION TEST Test Equipment Required :- 415 Volt Supply Multimeter Clamp-on Meter Megger Tester Typical Test Set-up Functional Test Procedure a. Check motor spec as per datasheets. b. Check motor winding insulation resistance and record it. c. Hook-up instrument as per typical set-up. d. Confirm valve fail position (AFC/AFO). Switch on power supply and check voltage and phase sequence. e. Set the L-O-R selector (Mode Selection) to ‘LOCAL’ position. f. Press the ‘OPEN’ button and confirm the valves opens. Verify valve position indication. g. Check the limit switch for ‘OPEN’ position. Limit switches contact to be adjusted to actuated at around 95% of valve stroke. h. Press the ‘CLOSE’ button and confirm the valve doses. Verify valve position indication. i. Check the limit switch for ‘CLOSE’ position. Limit switches contact to be adjusted to activate at around 95% of valve stroke. j. Set the L-O-R selector  (Mode Selection) to ‘REMOTE position. k....