A9 Piping and Instrument Diagram

SAEP-16 Sec.
4.1.11 and SAEP-
1636 Sec 5 &6
SAEP-16 Sec.
4.1.11 and SAEP-
1636 Sec 5 &6
SAEP-16 Sec.
4.1.11 and SAEP-
1636 Sec 5 &6
A4 Loop Check Sheet
SAEP-16 Sec.
4.1.11 and SAEP-
1636 Sec 5 &6
EC / PMCC / MCC NO. REV. NO. PURCHASE ORDER NUMBER
CONTRACTOR INSPECTION LEVEL
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER
RE-INSP DATE
ITEM
No.
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A
TRAVEL TIME QUANTITY INSP.
WORK PERMIT REQUIRED?
ACTUAL INSPECTION DATE & TIME
SAUDI ARAMCO USE ONLY
MH's SPENT SCHEDULED INSPECTION DATE & TIME
SAUDI ARAMCO INSPECTION LEVEL
LAYOUT DRAWING NUMBER
PLANT NO. EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID.
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)
SAIC-J-6501 1-Oct-05 INST
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO INSPECTION CHECKLIST
SAIC NUMBER DATE APPROVED QR NUMBER
A2 Instrumentation Installation Record
A3 Loop Check Punch list Form
A. Documentation Review
A1
SAEP-16 Sec.
4.1.11 and SAEP-
1636 Sec 5 &6
The loop document / Package shall comprise of documents detailed
below:
SAEP-16 Sec.
4.1.11 and SAEP-
1636 Sec 5 &6
SAEP-16
Sec. 4.1.13
SAEP-16
Sec. 4.1.13
SAEP-16
Sec. 4.1.13
B1
Ensure that actual field installation is completed in all aspects for the
concerned loops.
SAEP-16
Sec. 4.1.13
B3 Ensure that all individual loop components have been calibrated
B4
Aramco Inspection / Proponent , Contractor QC signatures to be verified
on installation inspection as well as test / calibration sheets.
A6 Instrument Data Sheets
B2
The installation Record sheets to be verified and formed as part of loop
folder
A8 Instrument Loop Diagrams
B. Pre- Loop Check
A5 Instrumentation Calibration Records
SAEP-16 Sec.
4.1.11 and SAEP-
1636 Sec 5 &6
A7 Control Valve Pneumatic Hook-up (for complex valves only)
SAEP-16 Sec.
4.1.11 and SAEP-
1636 Sec 5 &6
SAEP-16 Sec.
4.1.11 and SAEP-
1636 Sec 5 &6
Page 1 of 7
B6
The loop testing shall be performed from the field instrument through to
the DCS maintenance consoles and associated systems located either
at the CCR or PIB control rooms.
SAEP-16
Sec. 4.1.13
C5
SAEP-1636
Sec 5 & 6
B8
B7
C4
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO INSPECTION CHECKLIST
SAIC NUMBER DATE APPROVED QR NUMBER
PASS FAIL
ITEM
No.
CONTRACTOR / SUBCONTRACTOR
Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)
SAIC-J-6501 1-Oct-05 INST
PROJ ECT TITLE WBS / BI / J O NUMBER
ACCEPTANCE CRITERIA REFERENCE N/A RE-INSP DATE
B5
The completed instrument loop shall be tested as one system, and
where necessary adjustments shall be made to the calibrations.
SAEP-16
Sec. 4.1.13
C1
Ensure that all loop diagrams, cause and effects charts and logic
diagrams are available prior to testing.
C2
During loop check the following items shall be generally be confirmed or
checked: C3 to C17
SAEP-1636
Sec 5 & 6
DCS loop checks may include verification of all PCS functions such as
database parameters, alarm initiations, trending, report generation,
graphics etc.
SAEP-16
Sec. 4.1.13
After successful completion of each loop check the individual loop
components shall be marked with a colored label bearing the date of the
loop check and the initials of the witnessing party.
The color code shall be : RED- Loop Check Complete.
SAEP-16
Sec. 4.1.13
C3
In the control room:
1. Indication and output signal level on the PCS CRT console
2. Function of flow counter
3. Action of Controller of PCS
4. Function of alarm display
5. Function of all other components such as computing devices, limiting
devices, low / high signal selectors, etc.
SAEP-1636
Sec 5 & 6
Transmitters Loops (Flow/Level/pressure):
a) Check and verify the DCS Configuration for applicable points.
b) Verify the transmitter set (Calibration) range as per latest ISS, by
using Foxcom (HHT) communicator for Foxboro Transmitters / HART for
Rosemount Transmitters or in DCS as applicable
c) Apply the pressure for digital smart transmitters by using test
equipment (Hand Pump) for 50% simulation to check the transmitter
response at DCS. This method shall be used for digital smart
transmitters case only.
d) Confirm / Verify the corresponding reading in the DCS / Integral
indicator and at remote indicator if applicable.
e) However, for analog Foxboro smart transmitters case Foxcom (HHT)
communicator shall be used for simulation purpose instead of hand
pump.
SAEP-1636
Sec 5 & 6
In The Field:
1. Action control valves with positioners, stroke may be checked with
stroke indicator and output signal from positioner shall be checked.
2. Control Valve stroke time shall be less than maximum time or larger
than the minimum time specified in the specification sheet.
3. Range of Transmitters and local controllers.
4. Indication of remote mounted output indicators.
SAEP-1636
Sec 5 & 6
C. Testing Method
Page 2 of 7
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO INSPECTION CHECKLIST
SAIC NUMBER DATE APPROVED QR NUMBER
PASS FAIL
ITEM
No.
CONTRACTOR / SUBCONTRACTOR
Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)
SAIC-J-6501 1-Oct-05 INST
PROJ ECT TITLE WBS / BI / J O NUMBER
ACCEPTANCE CRITERIA REFERENCE N/A RE-INSP DATE
C6
SAEP-1636
Sec 5 & 6
SAEP-1636
Sec 5 & 6
C7
Control Valves Loops:
a) Check and verify the DCS Configuration for applicable points.
b) If any ESD logic / inter locking are involved in applicable loop for
energize the solenoid valve, then first normal condition should be
prepared by forcing the applicable ESD points on ladder logic and same
procedure to be carried out for DCS logic.
c) If instrument air supply is not available then connect nitrogen cylinder.
d) Apply the Command from DCS for 0%, 50% and 100%
e) Verify the corresponding valve position.
f) Verify the controller action.
SAEP-1636
Sec 5 & 6
d) Apply the Command from DCS / field for open and close.
e) Verify the corresponding valve position in DCS / Field as applicable.
f) Verify the partial stroke function test of ZV.
g) Verify the valve action on air supply failure.
h) Verify the valve action on control signal failure.
i) Check the hand wheel / hand jack manual operation / function as
applicable.
j) On off valve loop test should be performed after completion of the air
piping works.
SAEP-1636
Sec 5 & 6
ON / OFF Valves Loops:
a) Check and verify the DCS Configuration for applicable points.
b) If any ESD logic / Inter locking are involved in applicable loop to
energize the solenoid valve, then first normal condition should be
prepared by forcing the applicable ESD points on ladder logic and same
procedure to be carried out for DCS logic.
c) If instrument air supply is not available then connect nitrogen cylinder.
In big size of valve cases, big volume of Nitrogen will be required then in
that case on off valves function test will be executed upon air supply
availability.
g) Verify the control valve action on increase signal.
h) Verify the control valve action on air supply failure.
i) Verify the control valve Max / Min travel stopper setting if applicable.
j) Check the hand wheel manual operation / function if applicable.
k) Control valve loop test should be performed after completion of the air
piping works
SAEP-1636
Sec 5 & 6
f) For Rosemount smart transmitters case (HART) communicator shall
be used for simulation purpose instead of hand pump.
g) For Non- smart transmitters case (4~20 mA) source to be used for
simulation purpose instead of hand pump.
h) Alarms function (in DCS) shall be checked by Simulating /Verifying the
required signal.
i) Transmitter loop test should be performed after completion of the
impulse line works including pressure test.
C8
MOVs Loops:
a) Check and verify the DCS configuration for applicable points.
b) If any ESD logic / inter locking are involved in applicable loop, then
first normal condition should be prepared by forcing the applicable ESD
points on ladder logic and same procedure to be carried out for DCS
logic.
c) Check and verify the local / remote switch function.
d) Stroke the MOV from DCS / field on applicable commands such as
Open / Close and stop.
e) Verify the status of the MOV at DCS / Field.
f) Check the hand wheel manual operation / function if applicable.
SAEP-1636
Sec 5 & 6
Page 3 of 7
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO INSPECTION CHECKLIST
SAIC NUMBER DATE APPROVED QR NUMBER
PASS FAIL
ITEM
No.
CONTRACTOR / SUBCONTRACTOR
Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)
SAIC-J-6501 1-Oct-05 INST
PROJ ECT TITLE WBS / BI / J O NUMBER
ACCEPTANCE CRITERIA REFERENCE N/A RE-INSP DATE
C9
Switches Loops:
a) Check and verify the DCS configuration for applicable points.
b) Simulate the contact operation (Make/Break) at the switch terminal
block and verify the status in the DCS/ESD. However, ESD switch case
actual pressure simulation to be provided.
c) ESD hand switches, Start / Stop, Open / Close hand switches shall be
checked by operating the switch mechanism.
SAEP-1636
Sec 5 & 6
C10
Gas Detectors / Beacons / Horns:
a) Check and verify the DCS configuration for applicable points.
b) Proceed the calibration of gas detector by introducing the applicable
gas for H2S and LEL.
c) Apply the magnet for 0% and verify the status at gas detector display /
DCS.
d) Apply 50% and 100% for the H2S gas detector and verify the status at
gas detector display / DCS.
e) Apply the gas 50% only for LEL gas detector and verify the status at
gas detector display / DCS.
f) Check the Beacon status at high alarm condition.
g) Check the Horn status at high, high alarm condition.
SAEP-1636
Sec 5 & 6
C11
RTD / Temperature Transmitter Loops
a) Check and verify the DCS configuration for applicable points.
b) Verify the temperature transmitter set (calibration) range as per latest
ISS.
c) Simulate resistance equivalent to the 50% of the transmitter / DCS
range, by using decade resistance box or any other resistance simulator
at the RTD terminal head.
d) Verify the corresponding reading in the DCS / integral indicator of
transmitter and remote indicator if applicable.
e) Alarms functions (in DCS) to be checked by simulating / varying the
required signal.
f) Normalize all the connections prior to closing the terminal head and
confirm ambient temperature at integral indicator of temperature
transmitter and in DCS.
SAEP-1636
Sec 5 & 6
C12
Thermocouple / Temperature Transmitter Loops:
a) Check and verify the DCS configuration for applicable points.
b) Verify the temperature transmitter set (calibration) range as per latest
ISS.
c) Simulate the MV equivalent to the 50% of the transmitter / DCS
range by using MV source (simulator) at the thermocouple terminal head.
d) Verify the corresponding reading in the DCS/Integral indicator of
transmitter and at remote indicator if applicable.
e) Check the burn out features by disconnecting the wires if applicable.
f) Alarms functions (in DCS) shall be checked by simulating / varying the
required signal.
g) Normalize all the connection prior to closing the terminal head and
confirm ambient temperature at integral indicator of transmitter and at
remote indicator if applicable / DCS.
SAEP-1636
Sec 5 & 6
Page 4 of 7
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO INSPECTION CHECKLIST
SAIC NUMBER DATE APPROVED QR NUMBER
PASS FAIL
ITEM
No.
CONTRACTOR / SUBCONTRACTOR
Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)
SAIC-J-6501 1-Oct-05 INST
PROJ ECT TITLE WBS / BI / J O NUMBER
ACCEPTANCE CRITERIA REFERENCE N/A RE-INSP DATE
3. SAES-J -901, Instrument Air Supply Systems, 30 J une 2003
1. Schedule G -- Material, Tools and Equipment (Pro Forma MP-IK-LS Contract), J uly 1993
5. SAEP-1636 Installation and Checkout Plan , 28 February, 2005
6. SAEP-1638 Site Acceptance Test Plan, 30 April, 2002
2. Schedule Q -- Quality Requirements (Pro Forma Contract), November 2003
REFERENCE DOCUMENTS:
REMARKS:
4. SAEP-16- Project Execution Guide for Process Automation Systems,31 May 2003
C13
Vibration Loops (with proximitors)
a) Check and verify the VMS / DCS configuration for applicable points.
b) Connect a spare probe to extension cable of applicable proximitors.
c) Insert the probe into the TK-3 Wobulator (Bentley Nevada) and
connect the Multimeter leads at Proximitors terminals for check the gap
voltages.
d) Adjust the probe at approximately (-10 VDC) gap voltages.
e) Simulate the signal by Wobulator 0%, 50% and 100% of the range
and verify the corresponding reading at VMS / DCS.
f) Verify the response of the high and high, high alarms at VMS / DCS.
g) Normalized the connection of extension cables.
h) Actual probe gap voltage shall be adjusted at the final stage, prior to
commissioning / start up.
SAEP-1636
Sec 5 & 6
C14
Velocity Seismo Probe Loops
a) Check and verify the VMS/DCS configuration for applicable points.
b) Create the vibration by using wooden hammer (Carefully wooden
hammer shall be hit slowly on the probe housing. If cannot get the
required values then disconnect / remove the probe and shake well
probe by hand (create the vibration to achieved the high and high, high
alarms points.
c) Verify the response reading at VMS / DCS.
d) Verify the response of the high and high, high alarms at VMS / DCS.
e) Normalize all the connections.
SAEP-1636
Sec 5 & 6
C15
FFVMS Loops (Trend Master 2000)
a) Check and verify the FFVMS / DCS configuration for applicable points.
b) Create the vibration by using steel hammer (Carefully steel hammer
shall be hit near to the probe.
c) Verify the response reading at FFVMS / DCS.
d) Verify the response of the high and high, high alarms at FFVMS / DCS
SAEP-1636
Sec 5 & 6
C16
MCC Loops
a) MCC loops shall be executed after motor solo run test.
b) Check and verify the DCS configuration for applicable points.
c) If any ESD logic / inter locking are involved in applicable loop, then
first normal condition should be prepared by forcing the applicable ESD
SAEP-1636
Sec 5 & 6
C17
d) Remove the control transformer primary and secondary fuses for the
applicable cubicle.
e) Apply 120 VAC power (external power from building outlet) on the
secondary fuses load side to energize the control circuit.
f) Apply the Command fromDCS / ESD/ Field for start stop or trip as
SAEP-1636
Sec 5 & 6
Page 5 of 7
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO INSPECTION CHECKLIST
SAIC NUMBER DATE APPROVED QR NUMBER
PASS FAIL
ITEM
No.
CONTRACTOR / SUBCONTRACTOR
Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)
SAIC-J-6501 1-Oct-05 INST
PROJ ECT TITLE WBS / BI / J O NUMBER
ACCEPTANCE CRITERIA REFERENCE N/A RE-INSP DATE
Name, Sign and Date:
Quality Record Approved:
Name, Organization,
Initials and Date:
Proponent and Others QC Supervisor
T&I Witnessed QC Record Reviewed
Name, Initials and Date:
Work Verified QC Record Reviewed T&I Witnessed
*Person Responsible for Completion of Quality Work / Test Y =YES N =NO F =FAILED
1. Approved - Acceptable to the authority having jurisdiction (i.e., Saudi Aramco ID).
QC Inspector
Work Verified
Name, Initials and Date:
Performed Inspection Work / Rework May Proceed
PID Representative
ATTACHMENTS:
Contractor / Third-Party Saudi Aramco
indicates compliance with appropriate standards or performance in a specified manner.
with product evaluation, that maintains periodic inspection of production of labeled equipment or materials, and by whose labeling the
3. Listed - Equipment and materials included in a list published by an approved qualified organization concerned with evaluation of products
that the equipment, material, or services either meets appropriate designated standards or has been tested and found suitable for a specified
NOTES:
2. Identified - Recognizable as suitable for the specific application by a qualified testing laboratory (i.e., listing and/or labeling).
4. Labeled - Equipment or materials to which has been attached a label, symbol, or other identifying mark of an approved qualified organization
or services, that maintains periodic inspection of production of listed equipment or materials or periodic evaluation of services, and whose listing
1. Attachment 1 -Instrument Loop Check Sheet And Pre Loop Check Sheet
Work Verified
Construction Representative* PMT Representative
Name, Initials and Date:
Work is Complete and Ready for Inspection:
Name, Initials and Date:
T&I Witnessed QC Record Reviewed
Page 6 of 7
Unit No.: System No.: Loop No. Loop Dwg. No.:
DCS INSPECTION PERFORMED
POINTING TAG YES NO N/A
POINT DESCRIPTION YES NO N/A
POINT CONFIGURATION YES NO N/A
POINT RANGE ( YES NO N/A
INPUT / OUTPUT FUNCTION YES NO N/A
CONTROLLER ACTION ( YES NO N/A
SCHEM. & ASSOCIATED GRAPHICS ( YES NO N/A
ALARM (LL) YES NO N/A
ALARM (L) YES NO N/A
ALARM (HH) YES NO N/A
ALARM (H) YES NO N/A
DCS / FIELD INSPECTION PERFORMED
MOTOR CONTROLS / SWITCHES / MOV'S / AOV'S GAS DETECTOR
RESET ON
ON / START RUNNING
OFF / STOP STOPPED
OPEN
CLOSE
STOP
SIMULATION RESULTS
TAG NO. : VALVE TAG NO.: SWITCH TAG NO. :
PROCESS INPUT RANGE : SWITCH SET POINT :
SWITCH ACTIVATES AT
SWITCH ACTION AT SET POINT
SWITCH RESET AT
INPUT TO DCS TRAVEL
OFF
OPEN
CLOSE
CMDIS
BY PASS
N/A YES
25 25
0 0
75 75
50 50
75 75
100 100
25 25
50 50
0 0
INPUT %
INPUT
OUTPUT
(PPM/LEL)
VALVE
SWITCH FUNCTION RESULT
NO
INPUT %
PROCESS OUTPUT
1-Oct-05 INST
NO N/A
GAS DETECTOR NO.
Attachment 1- INSTRUMENT LOOP CHECK SHEET
YES
COMMANDS INDICATION
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO INSPECTION CHECKLIST
SAIC NUMBER DATE APPROVED QR NUMBER
Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)
SAIC-J-6501
Page 7 of 7