SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Instrumentation and Control Loop checking -
SAIC-J-6501 15-Dec-09 INST
Documentation Review (Procedures and Packages)
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.
LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.
SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?
SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
A Documentation Review
SAEP-16
The loop document / Package shall comprise of documents detailed Sec.4.1.12 &
A1
below: SAEP-1636
Appendix 1
SAEP-16
Sec.4.1.12 &
A2 Instrumentation Installation Record
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.4.1.12 &
A3 Loop Check Punch list Form
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.4.1.12 &
A4 Loop Check Sheet
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.4.1.12 &
A5 Instrumentation Calibration Records
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.4.1.12 &
A6 Instrument Data Sheets
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.4.1.12 &
A7 Control Valve Pneumatic Hook-up (for complex valves only)
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.4.1.12 &
A8 Instrument Loop Diagrams
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.4.1.12 &
A9 Piping and Instrument Diagram
SAEP-1636
App.1 Sec.5&6
B Pre- Loop Check
SAEP-16
Ensure that actual field installation is completed in all aspects for the Sec.4.1.14 &
B1
concerned loops. SAEP-1636
App.1 Sec.5.5
Page 1 of 11
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Instrumentation and Control Loop checking -
SAIC-J-6501 15-Dec-09 INST
Documentation Review (Procedures and Packages)
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.
LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.
SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?
SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
SAEP-16
The installation Record sheets to be verified and formed as part of loop Sec.4.1.14 &
B2
folder SAEP-1636
App.1 Sec.6
Page 2 of 11
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Instrumentation and Control Loop checking -
SAIC-J-6501 15-Dec-09 INST
Documentation Review (Procedures and Packages)
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
SAEP-16
Sec.4.1.14 &
B3 Ensure that all individual loop components have been calibrated SAEP-1636
App.1
Sec.5.5&6.6
SAEP-16
Aramco Inspection / Proponent , Contractor QC signatures to be verified Sec.4.1.14 &
B4
on installation inspection as well as test / calibration sheets. SAEP-1636
App.1 Sec.6.4
SAEP-16
The completed instrument loop shall be tested as one system, and where Sec.4.1.14 &
B5
necessary adjustments shall be made to the calibrations. SAEP-1636
App.1 Sec.5
SAEP-16
The loop testing shall be performed from the field instrument through to
Sec.4.1.14 &
B6 the DCS maintenance consoles and associated systems located either at
SAEP-1636
the CCR or PIB control rooms.
App.1 Sec.5
SAEP-16
DCS loop checks may include verification of all PCS functions such as
Sec.4.1.14 &
B7 database parameters, alarm initiations, trending, report generation,
SAEP-1636
graphics etc.
App.1 Sec.5
After successful completion of each loop check the individual loop SAEP-16
components shall be marked with a colored label bearing the date of the Sec.4.1.14 &
B8
loop check and the initials of the witnessing party. SAEP-1636
The color code shall be : RED- Loop Check Complete. App.1 Sec.5
C Testing Method
Ensure that all loop diagrams, cause and effects charts and logic SAEP-1636
C1
diagrams are available prior to testing. App.1 Sec.5&6
During loop check the following items shall be generally be confirmed or SAEP-1636
C2
checked: C3 to C17 App.1 Sec.5&6
In the control room:
1. Indication and output signal level on the PCS CRT console
2. Function of flow counter
SAEP-1636
C3 3. Action of Controller of PCS
App.1 Sec.5&6
4. Function of alarm display
5. Function of all other components such as computing devices, limiting
devices, low / high signal selectors, etc.
In The Field:
1. Action control valves with positioners, stroke may be checked with
stroke indicator and output signal from positioner shall be checked.
SAEP-1636
C4 2. Control Valve stroke time shall be less than maximum time or larger
App.1 Sec.5&6
than the minimum time specified in the specification sheet.
3. Range of Transmitters and local controllers.
4. Indication of remote mounted output indicators.
Page 3 of 11
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Instrumentation and Control Loop checking -
SAIC-J-6501 15-Dec-09 INST
Documentation Review (Procedures and Packages)
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
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. SAEP-1636
C5
e) However, for analog Foxboro smart transmitters case Foxcom (HHT) App.1 Sec.5&6
communicator shall be used for simulation purpose instead of hand
pump.
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.
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% SAEP-1636
C6
e) Verify the corresponding valve position. App.1 Sec.5&6
f) Verify the controller action.
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
Page 4 of 11
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Instrumentation and Control Loop checking -
SAIC-J-6501 15-Dec-09 INST
Documentation Review (Procedures and Packages)
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
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
SAEP-1636
C7 availability.
App.1 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.
MOV’s 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
SAEP-1636
C8 logic.
App.1 Sec.5&6
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.
Switches Loops:
a) Check and verify the DCS configuration for applicable points.
b) Simulate the contact operation (Make/Break) at the switch terminal
SAEP-1636
C9 block and verify the status in the DCS/ESD. However, ESD switch case
App.1 Sec.5&6
actual pressure simulation to be provided.
c) ESD hand switches, Start / Stop, Open / Close hand switches shall be
checked by operating the switch mechanism.
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. SAEP-1636
C10
d) Apply 50% and 100% for the H2S gas detector and verify the status at App.1 Sec.5&6
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.
Page 5 of 11
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Instrumentation and Control Loop checking -
SAIC-J-6501 15-Dec-09 INST
Documentation Review (Procedures and Packages)
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
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. SAEP-1636
C11
d) Verify the corresponding reading in the DCS / integral indicator of App.1 Sec.5&6
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.
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 SAEP-1636
C12
transmitter and at remote indicator if applicable. App.1 Sec.5&6
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.
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.
SAEP-1636
C13 d) Adjust the probe at approximately (-10 VDC) gap voltages.
App.1 Sec.5&6
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.
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 SAEP-1636
C14
probe by hand (create the vibration to achieved the high and high, high Sec.5&6
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.
Page 6 of 11
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Instrumentation and Control Loop checking -
SAIC-J-6501 15-Dec-09 INST
Documentation Review (Procedures and Packages)
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
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 SAEP-1636
C15
shall be hit near to the probe. Sec.5&6
c) Verify the response reading at FFVMS / DCS.
d) Verify the response of the high and high, high alarms at FFVMS / DCS
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
points on ladder logic and same procedure to be carried out for DCS
logic.
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.
SAEP-1636
C16 f) Apply the Command from DCS / ESD / Field for start, stop or trip as
Sec.5&6
applicable.
g) Verify the running / stop or trip status in DCS / Field / Sub Station as
applicable.
h) Check and verify the local / remote switch function if applicable.
i) After completion of the applicable loop check, the fuses should be
returned on the control transformer.
j) All the above-mentioned steps can be carried out without removing the
pad lock on the MCC unit breakers, if possible.
k) Removal of the lock on the breakers requires permission from
Electrical section.
REMARKS:
REFERENCE DOCUMENTS:
1. Schedule G - Material, Tools and Equipment (Pro Forma MP-IK-LS Contract), March 2006
2. Schedule Q - Quality Requirements (Pro Forma Contract), November 2003, Febraury 2008
3. SAES-J-901 - Instrument Air Supply Systems, June 2003
4. SAEP-16 - Project Execution Guide for Process Automation Systems, November 2007
5. SAEP-1636 - Installation and Checkout Plan , September 2007
6. SAEP-1638 - Site Acceptance Test Plan, September 2007
ATTACHMENTS:
1. Attachment 1: Instrument Loop Check Sheet And Pre Loop Check Sheet
NOTES:
1. Approved - Acceptable to the authority having jurisdiction (i.e., Saudi Aramco ID).
2. Identified - Recognizable as suitable for the specific application by a qualified testing laboratory (i.e., listing and/or labeling).
3. Listed - Equipment and materials included in a list published by an approved qualified organization concerned with evaluation of products or
services, that maintains periodic inspection of production of listed equipment or materials or periodic evaluation of services, and whose listing states
that the equipment, material, or services either meets appropriate designated standards or has been tested and found suitable for a specified purpose.
Page 7 of 11
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Instrumentation and Control Loop checking -
SAIC-J-6501 15-Dec-09 INST
Documentation Review (Procedures and Packages)
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
4. Labeled - Equipment or materials to which has been attached a label, symbol, or other identifying mark of an approved qualified organization
concerned with product evaluation, that maintains periodic inspection of production of labeled equipment or materials, and by whose labeling the
manufacturer indicates compliance with appropriate standards or performance in a specified manner.
Contractor / Third-Party Saudi Aramco
Construction Representative* PMT Representative
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:
QC Inspector PID Representative
Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:
QC Supervisor Proponent and Others
Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Sign and Date:
Initials and Date:
*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED
Page 8 of 11
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Instrumentation and Control Loop checking -
SAIC-J-6501 15-Dec-09 INST
Documentation Review (Procedures and Packages)
Attachment 1: Instrument Loop Check Sheet
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 (NO.
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
COMMANDS INDICATION GAS DETECTOR NO.:
YES NO N/A YES NO N/A
RESET ON INPUT
OUTPUT
BY PASS OFF (PPM/LEL)
ON / START RUNNING
OFF / STOP STOPPED
OPEN OPEN
CLOSE CLOSE
STOP CMDIS
SIMULATION RESULTS
TAG NO. : VALVE TAG NO.: SWITCH TAG NO. :
PROCESS INPUT RANGE : SWITCH SET POINT :
PROCESSOUTPUT VALVE SWITCH FUNCTION RESULT
INPUT % INPUT %
INPUT TO DCS TRAVEL SWITCH ACTIVATES AT
0 0 SWITCH ACTION AT SET POINT
25 25 SWITCH RESET AT
50 50
75 75
### ###
75 75
50 50
25 25
0 0
Page 9 of 11
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Instrumentation and Control Loop checking -
SAIC-J-6501 15-Dec-09 INST
Documentation Review (Procedures and Packages)
Attachment 1: Instrument Loop Check Sheet
LOOP CONTINUITY CHECK SHEET (PRE-LOOP CHECK)
SYSTEM NO LOOP NO EQPT CODE SYSTEM ID. PLANT NO.
Manufacturer S.No LOOP DRAWING NO Data Sheet No
CONTINUITY CHECK SHEET
Calibration Inspection Remarks
FROM TO CHECKS PER SECTION
CABLE No RE-INSP DATE
ITEM No Area TAG/ ITEM NO AREA Cont.Test Termination
Page 10 of 11
SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008) REV 3 30-Jun-08
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Instrumentation and Control Loop checking -
SAIC-J-6501 15-Dec-09 INST
Documentation Review (Procedures and Packages)
Attachment 1: Instrument Loop Check Sheet
Page 11 of 11
