仪表回路检查方案 Loop Check Scheme
1. 编制说明
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本方案适用于上海工业气体公司合成气装置2期扩建项目仪表工程，包括回路检查的各项规定及相应要求。同时列出回路检查的方法及标准，在回路检查过程主要负责现场模拟信号及接点信号的输入工作，DCS操作站上操作主要由厂家及现场操作人员负责；同时要求有其他相关专业的协调与配合。
This Scheme is apply to Hyco II Instrument Project of Shanghai Industrial Gas Company, including loop check specifications and relevant requirements. The loop check method and standard have been listed. During the loop check, we are only responsible the local analog signal and point signal input. DCS operating station is mainly responsible by vendor and site operators; at the same time, it is requested coordinate and cooperate from other specialties.
2. 编制依据
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GB50093 2002《自动化仪表工程施工及验收规范》
GB50093 2002《Automation Instrument Engineering Construction and Acceptance Specifications》 SH3521-2007 《石油化工仪表施工规程》
SH3521-2007《Petrochemical Instrument Construction Regulations》 SH3503-2007 《石油化工建设工程项目交工技术文件规定》
SH3503-2007《Petrochemical Construction Project Hand Over Technical and Document Rules》 GB50168-2006 《电缆线路施工及验收规范》
GB50168-2006《Cable Run Construction and Acceptance Specification》 SY4031-93 《石油建设工程质量检验评定标准自动化仪表安装工程》
SY4031-93《Petrochemical Engineering Quality Inspection Assessment Standard Automation Instrument Installation
project》
GB50131-2007《自动化仪表工程施工质量验收规范》
GB50131-2007《Automation Instrument Project Construction Quality Acceptance Specification》 SH3543-2007 石油化工建设工程项目施工过程技术文件规定(通用电气仪表)
SH3543-2007 Petrochemical Construction Project Construction Process Technical Document Specification (General
Electric/Instrument)
69817-01-0850001 鲁奇规范 《仪表通用规范》
69817-01-0850001 Lurgi Specification《General Instrument Specification》
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69817-01-0850071 鲁奇规范 《回路检查工程规定》
69817-01-0850071 Lurgi Specification《Loop Check Project Specification》
3．回路检查的一般规定
General provision on Loop Check
3.1 回路检查应在系统投入运行前进行，试验前系统应具备下列条件：
Loop check should be carried out before the system put into operation, the following conditions should be
available.
3.1.1回路检查文件夹已准备完整，符合规范要求；
Loop check document folder have been prepared and fulfilled specification requirements; 3.1.2 回路中的仪表设备、装置和仪表线路、仪表管道应安装完毕；
The instruments, devices and instrument line, instrument pipeline in the loop should be completely installed; 3.1.3 仪表配线和配管经检查确认正确完整，配件附件齐全；符合试验要求；
Instrument wiring and piping should be checked and confirmed completely, fittings and accessory is complete
in accordance with test requirements;
3.1.4 回路中的电源、气源已能正常供给并符合仪表运行的要求；
Power and gas resource in the loop should be supplied normally and in accordance with operating requirement; 3.1.5气源管道经吹扫、气密性试验合格，已通入压力稳定的仪表空气；
Air source pipeline has been purged and air test qualified, instrument air with stable pressure has been put into
the system;
3.1.6电气回路已进行校线及绝缘检查，接线正确、端子牢固、接触良好、标识正确；
Electric loop has been tested, insulation checked , wiring correct, terminal fastness, contact in good condition,
proper label;
3.2 参加系统试验的施工人员应熟悉图纸及仪表系统工作原理，并具有熟练的调试技术。
Constructors involve with the system test should familiar with the drawing and instrument system
operating principle and with skill debugging technical.
3.3 回路检查应根据现场情况和回路的复杂程度，按回路位号和信号类型合理安排，回路试验应做好相应的试验记录；
Loop check should be reasonably arranged according to site condition and loop complexity level, and loop position number and signal type. Loop check should be recorded accordingly;
3.4 仪表试验用的标准仪器仪表应具备有效的计量检定合格证，其基本误差的绝对值不超过被校准仪表基本误差绝对值的1/3;
The standard instrument using in instrument test should equipped with measure calibration certification, the absolute intrinsic error data should not over than 1/3 to the instrument to be tested;
3.5 仪表校试验的条件、项目、方法应符合产品技术文件的规定和设计文件要求；
The instrument test condition、item、method should be accordance with product technical specification
and design requirements;
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4. 回路检查的方法及要求
Loop Test Method and Requirement
4.1 回路检查文件夹的准备： Loop check folder prepare:
4.1.1 仪表数据表、回路接线图、Hook-up图；
Instrument data sheet、loop wiring drawing、Kook-up drawing; 4.1.2 Vendor提供的仪表标定数据表及部分阀门的HOOK-UO图；
Instrument rating data table provided by Vendor and part of valve Hook-up drawing; 4.1.3 仪表设备安装检查记录： Instrument installation check report; 4.1.4 模拟量输入回路的试验报；
Analog quantity input loop test report; 4.1.5 模拟量输出回路试验报告； Analog quantity output test report;
4.1.6 仪表导压管/气源管检查（泄漏及气密性检测）报告；
Instrument guide piping/air source test report(leakage test and air tightness test );
4.1.7 开关量仪表输入/输出检查，主要检查现场自控阀的动作是否到位、操作站上的反馈信号是否正确； Switch value input/output check, to check local automation valve act in place or not、feed back signal in
operation station is correct or not; 4.2 仪表安装检查：
Instrument installation check:
4.2.1 根据HOOK-UP图检查现场仪表管、线路安装是否正确完整，并符合相关规范及规定。
Inspect site instrument piping、line installation is correct and complete according to Hook-up drawing, fulfill
with relevant specification and rule. 4.2.2 仪表管路应有泄漏试验并符合要求；（同管道专业一起做泄漏试验）
Leakage test should be done on instrument piping and fulfill with requirement (leakage test together with
piping specialty);
4.2.3仪表线路应做绝缘测试符合规范要求：
Insulation test should be done in instrument line and fulfill to specification requirement;
4.2.3.1 核对电缆规格、型号是否符合设计文件规定及进行导通检查，并用兆欧表测量其绝缘电阻，其电阻值
不应小于5MΩ。
Verify cable specification and type, if they are fulfill design document rule, carry out breakover check, check
insulation resistance value with megameter, the resistance value should not be smaller than 5MΩ.
4.2.3.2 线路敷设完毕，应进行校线和标号；
After completed cable pulling, line should be checked tagged; 4.21.3.3 电缆与端子连接整齐、牢固，导电良好；并进行单端接地；
Cable connecting with terminal should be in order、fastness, conductivity in good condition; single-end
earthed;
4.2.4仪表管、线路的位号标识应清晰、方便检查，固定应牢固；
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Instrument piping and line position tagging should be clearness, easy to be check, firmly fixed;
4.3 回路试验时，仪表校准点不应少于3点；
For the instrument test, instrument calibration point should not be less that 3 points;
4.4 检测回路的试验应符合下列要求：
Loop test should fulfill with the following requirement:
4.4.1 在检测回路的信号输入端输入模拟被测变量的标准信号，回路的显示仪表部分的示值误差不应超过回路
身内各仪表允许基本误差平方和的平方根值；
Input the standard measured variable analog signal to be tested in signal input terminal in the loop, the error
indication in loop indication should not be bigger than the allowance intrinsic error square and square root of all instruments in the loop;
4.4.2 温度检测回路可在检测元件的输出端（温变的输出端）输入相应的模拟信号；热电阻及热电偶的检查可
现场利用万用表进行；
Temperature loop can input relevant analog signal in test element output terminal( temperature output terminal);
thermal resistance and thermocouple can be done by using multimeter on site;
4.5 控制回路的试验应符合下列要求：
Test for control loop should fulfill the following requirement:
4.5.1 控制器和执行器的作用方向应符合设计规定；
Controller and actuator acting direction should fulfill design specification;
4.5.2 通过DCS系统操作站的输出向执行器发送控制信号，检查执行器执行机构在全行程范围内的动作方向
和位置是否正确；
Send control signal to actuator from DCS operation station, to check actuator action direction and position
correct or not in full length of distance travel.
4.5.3 当操作站上有执行器的开度和起点、终点信号显示时，应同时进行检查和试验；
When all opening and start point、finished point indicating on actuator in operation station, check and test
should be done at the same time; 4.6 报警系统的试验应符合下列要求：
Alarm system test should fulfill the following requirement:
4.6.1 在报警回路的信号发生端模拟输入信号，检查报警灯光、音响和屏幕显示应正确；
Input analog signal to signal generator terminal in alarm loop, to check alarm light、sound and panel display
should be correct;
4.6.2 报警的消音、复位和记录功能应正确。
Alarm sound acknowledge、 reset and record function should be correct.
5. 回路检查的工器具准备： Loop check preparation:
回路检查所使用仪表、仪器应在检验周期内，其精度应符合规范及设计规定。主要设备如下：
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The instrument and apparatus to be used in loop check should within the checkout period, the precision should fulfill specification and design rule. The main apparatus are as follow: 序号 No. 1 2 3 4 5 6 7 设备名称 Mane 数字万用表 Digital multimeter 兆欧表 Megameter 数字兆欧表 Digital megameter 现场校验仪 Site checker 24V DC电源 24V dc power 手操器 Hand operator 精密电阻箱 Precision resistance box 规格 specification ZC25-4A HC-982 APS3003S Hart 475/375 单位 unit 块 piece 块 piece 块 piece 块 piece 块 piece 块 piece 块 piece 数量 Quantity 2 1 1 1 1 1 1
6.安全保证措施
Security precautions
6.1严肃认真执行安全技术文件规定和要求，针对工程特点，作好安全教育和安全技术交底，牢固树立“安全第一，预防为主”的思想。
Be strict and conscientious in execute safety specification and requirement, safety education and safety technical hand over according to project feature, firmly build safety first and prevent priority.
6.2各项施工工作和施工活动必须有各项合格经过批准的程序后方可进行。特别是有特殊要求，特殊区域和 有毒有害物质和区域工作。
Before any construction and activities to be carry out, approved procedure should be passed. Especially for special area and harmful material and area.
6.3参加施工人员，必须遵守个人防护用品的佩戴要求。高空作业者必须经健康检查并被准许进行高空作业，登高超过1.8m的高空作业者必须系安全带，安全带要求有缓冲装置，有两条带自锁挂钩的挂绳。
The test personnel should follow the requirement to wear protective equipment. Working in the high level should through health examined and approved. If the working level above than 1.8m, the worker should wear safety belt with buffer device and two hook with self-lock.
6.4严禁设备和施工人员带病工作。使用各种器具，严格按其规程进行。
Equipment with defected and worker with illness is not allowed. All equipment to be used should follow the specification.
6.5施工现场严禁吸烟，施工需用的易燃易爆物品，用完后立即送回到保管地点。
Smoking is not allowed on site, flammable and explosives should back to storage after use.
6.6与工艺介质相连的仪表，安装后必须关死根部阀，打开平衡阀，防止管内压力窜入仪表，造成仪表单向受压或过压损坏仪表。仪表投入运行时一定要按操作顺序进行，以免损坏仪表。
Instrument connect to process media, root valve should be closed after installed, open the balance valve to avoid
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the pressure get into the instrument, and cause the instrument over pressure or damage. To avoid instrument damage, the operation procedure should be followed before put into operation. 6.7各种仪表（器）、机具在送电前，仔细检查电源接线是否正确。
Carefully check power connection is correct or not before energize any instruments.
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