Pressure Transmitter Commissioning Checklist 

Step 1: Preliminary Inspection

Visual Inspection

• Inspect the transmitter for any visible damage, such as dents, cracks, or rust.
• Ensure that the casing is intact and all components are properly secured.

Verify Model and Specifications

• Confirm that the transmitter model and specs meet the application’s requirements.
• Check the nameplate for the model number, range, and serial number to guarantee compatibility.
• Verify the transmitter against the specification sheet or instrument data sheet to ensure it meets the required specifications.

Step 2: Preparation for Commissioning

Gather Necessary Tools and Equipment

• Collect all necessary calibration tools, such as a handheld communicator, pressure calibrator, and reference standards.
• Check that all calibration equipment is in good working order and was recently calibrated.

Safety Equipment

• Provide all personnel with proper PPE, such as hard hats, safety glasses, gloves, and flame-resistant clothes.

Documentation Review

• Consult the manufacturer’s technical manuals for installation, wiring, and calibration  instructions.
• Collect all required diagrams, including Instrument Loop Diagram, hook-up drawings, and instrument data sheet. Understanding the process context facilitates effective setup and calibration.

Clock here for How to read the data sheet of a pressure transmitter?

Step 3: Safety Measures

Hazard Assessment

• Conduct a detailed risk assessment for the commissioning area. Determine hazards such as high pressure, high temperatures, and potentially hazardous substances.

Implement Safety Protocols

• Ensure that all safety precautions, including emergency procedures, are implemented and conveyed to the entire team. Install safety barriers and signage as needed.

Lockout/Tagout Procedure

• Implement lockout/tagout measures to keep the transmitter and associated equipment apart from the process.
• Double-check that the equipment is de-energized and disconnected, and use suitable testing methods to ensure that no residual energy is present.

Click here for Basic Safety and General Consideration While Executing Calibration Process in process industries

Step 4: Collection of Documents

Pre-Commissioning Checklist

• Create a complete pre-commissioning checklist that includes visual inspections, wiring checks, calibration procedures, and safety measures.

Ensure Completeness

• Ensure that all required paperwork, including as technical manuals, process diagrams, and previous calibration records, is available on-site.

Calibration Records

• Review prior calibration records to assess the transmitter’s performance and discover any issues or adjustments.
• Collect the necessary setpoint and calibration information, including pressure ranges and span values.

Step 5: Verification of Installation

Mounting

• Ensure that the transmitter is mounted according to the manufacturer’s recommendations. It should be level, properly attached, and positioned to reduce vibration impacts.

Piping and Connections

• Make that all process and impulse lines are properly installed, with no kinks, sharp curves, or poor fittings.
• To discover leaks, conduct a visual inspection and employ leak detection fluid. Ensure that all seals and connections are tight and secure.
• Confirm the installation follows the process piping hookup and pneumatic piping hookup diagrams.
• Check that the transmitter piping is easily accessible and properly supported.
• Assess the environment to ensure there is no excess vibration, heat, or splash.
• Verify the installation includes required components such as siphons, over-range protection, seals, and snubbers.
• Confirm the instrument is traced or purged as required and that the system has been checked to standard.
• Ensure the system is cleaned for oxygen service, if applicable.

Click here for Step by Step Pressure Transmitter Installation Procedure

Step 6: Wiring and Voltage Checking

Wiring Connections

• Check all wiring connections to ensure they are properly terminated and labeled. Check for evidence of wear or damage.
• To avoid loose connections, ensure that all terminal screws are tightly fastened.
• Check wiring continuity and verify the polarity is correct.

Voltage Verification

• Use a multimeter to ensure that the transmitter is receiving the right voltage. Ensure that the power supply is stable and operates within the defined range.

Step 7: Loop Checking

Signal Loop Verification

• Inject a known signal into the loop and ensure that it is properly received by the control system.

Check Continuity

• Maintain the signal loop from the transmitter to the control system. Use a loop calibrator to check for breaks or faults.

Click here for Method Statement for Loop Checking of Pressure Transmitter Loop

Step 8: Commissioning of Pressure Transmitter

Zero and Span Calibration

• Apply zero pressure to the transmitter and modify its zero setting. Ensure that the output signal is accurate and stable at the zero point.
• In order to modify the span setting, apply a known pressure equivalent to the transmitter’s maximum range.

Linearity Check

• Apply pressure at numerous intermediate places along the range (e.g., 25%, 50%, and 75%) and record the results. Ensure that output is linear and within acceptable bounds.

Click here for HART transmitter calibration procedure – For pressure transmitter

Step 9: Field Calibration If Required

Zero Calibration

• Calibrate under actual operating circumstances, adjusting for variables like as temperature and pressure.

Signal Verification

• Check that the transmitter’s output signal matches the expected value under specific pressure conditions.

Damping Adjustment

• Set the appropriate damping level on the transmitter to stabilize the output signal and filter out process noise or pulsations, as required by the application.

Installation Check

• Ensure that impulse lines are correctly filled and clear of air pockets. To equalize the pressure in the impulse lines, open and close the equalization valve.

Compare Output Signals

• Compare the transmitter’s real output to the control system’s displayed value. Measure the mA output using a multimeter and compare it to the control room value.

Click here for Rangeability vs. Turndown Ratio and their Implications for Pressure Transmitter Selection

Response Time Verification

• Measure the transmitter’s response time to ensure it meets the requirements of the process. This may involve applying a step change in pressure and measuring the time for the output to reach 90% of the final value.

Step 10: Fail-Safe Function Check

Induce Failures

• To test fail-safe functions, simulate failure scenarios such as signal loss, power failure, or pressure anomalies.

System Response

• Check the control system’s response to failure conditions, including alarms and process shutdowns.

Step 11: Troubleshooting

Signal Drift

• Check for signal drift and recalibrate as necessary. Drift may be caused by environmental causes or component aging.

Blockages and Leaks

• Inspect the impulse lines for blockages or leaks and repair any that are discovered.

Diagnostic Software

• Use manufacturer-provided diagnostic software to discover and resolve faults.

Error Codes

• Use the manufacturer’s instructions to interpret and resolve any problem codes reported by the transmitter.

Click here for What are the major problems in a pressure transmitter and how to troubleshoot it?

Step 12: System Integration and Testing

• Check that the process control system’s pressure transmitter is correctly connected.
• Test system integration to guarantee the transmitter interacts successfully with other instrumentation and control systems.
• Once you’ve added the pressure transmitter, you should do a full system check to make sure that all of the parts work together.
• Under several running conditions, test the system to confirm dependability and performance.

Step 13: Reporting and Completion Process

Documentation

• Document all calibration and commissioning actions, such as settings, modifications, and measurements. Maintain detailed records for audits and future reference.
• Create a detailed final report that summarizes the commissioning process, findings, and suggestions.

Sign-Off

• Obtain approval from the appropriate personnel, ensuring that all stakeholders are satisfied with the commissioning procedure.
• Hand over the transmitter to the operations team along with any necessary documentation and instructions. Provide training as necessary.

Step 14: Environmental and Operational Conditions Monitoring

• Track the surrounding environmental factors to make sure the pressure transmitter runs within the permitted temperature, humidity, and vibration ranges.
• Install vibration dampeners or heat shields to guard the transmitter from unfavorable environmental conditions.
• Check the operational state of the process often to guarantee the pressure transmitter is operating as it should.

Step 15: Adhering to Standards and Regulations

Industry Standards

• Ensure compliance with industry standards such as ISA and IEC while adhering to best practices for instrumentation and control.

Regulatory Requirements

• Follow local regulatory regulations to ensure that all actions are safe and compliant. Maintain detailed documentation for audits and inspections.

Downloadable Pressure Transmitter Commissioning Excel Checklist

To help ensure proper commissioning, we have created an easy-to-use checklist in Excel format. Click the below link below to download.

What are the most common issues found during the commissioning of pressure transmitters ?

During the commissioning of pressure transmitters, some common issues often arise:

1. Transmitters can experience signal drift over time due to environmental factors or aging components. Regular recalibration and long-term stability monitoring are essential to detect and correct any drift.
2. Blockages or leaks in the impulse lines that connect the transmitter to the process can cause inaccurate pressure readings. It’s important to inspect these lines regularly and address any issues promptly.
3. Wiring problems, such as loose terminals or incorrect polarity, are common during commissioning. Ensuring that the transmitter receives the proper voltage and that all wiring connections are secure and correct is crucial.
4. Inaccurate pressure measurements can result from improper zero and span calibration or issues with linearity across the transmitter’s full operating range. Thorough calibration is essential to prevent these errors.
5. It’s vital to verify the transmitter’s fail-safe functions and test its response to potential failure scenarios, like signal loss or power failure. This helps ensure the safety and reliability of the pressure measurement system. Addressing these common issues during the commissioning process ensures accurate and reliable performance from pressure transmitters in process plants.

Click here for Factors that Influence the Accuracy of your Pressure Transmitter