Saudi Aramco Inspection Checklist

SAUDI ARAMCO ID/PIEU-24-July-2018 - REV.2018.06.00 (Standards Cutoff - June 30,2018) Rev.2018.06.
00 30-Jun-18
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Instrumentation and Control Loop checking - Documentation
SAIC-J-6501 24-Jul-18 INST
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 INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
A Documentation Review
SAEP-16
Sec.5.1.12 &
A1 The loop document/Package shall comprise of documents detailed below:
SAEP-1636
Appendix 1
SAEP-16
Sec.5.1.12 &
A2 Instrumentation Installation Record
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.5.1.12 &
A3 Loop Check Punchlist Form
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.5.1.12 &
A4 Loop Check Sheet
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.5.1.12 &
A5 Instrumentation Calibration Records
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.5.1.12 &
A6 Instrument Data Sheets
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.5.1.12 &
A7 Control Valve Pneumatic Hook-up (for complex valves only)
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.5.1.12 &
A8 Instrument Loop Diagrams
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.5.1.12 &
A9 Instrumentation Points and Lines
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.5.1.12 &
A10 Instrumentation Hook up Drawings
SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.4.1.12 &
A11 Instrument Cables Test Reports
SAEP-1636
App.1 Sec.5&6
Saudi Aramco: Company General Use

SAUDI ARAMCO ID/PIEU-24-July-2018 - REV.2018.06.00 (Standards Cutoff - June 30,2018) Rev.2018.06.00 30-Jun-18
ITEM
No.
SAEP-16
Instrument Pressure Test Reports (Process Impulse / Air supply line / Sec.5.1.12 &
A12
Pneumatic signal tubing) SAEP-1636
App.1 Sec.5&6
SAEP-16
Sec.5.1.12 &
A13 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.5.1.14 &
B1
concerned loops. SAEP-1636
App.1 Sec.5.5
SAEP-16
The installation record sheets to be verified and formed as part of loop Sec.5.1.14 &
B2
folder. SAEP-1636
App.1 Sec.6
SAEP-16
Sec.5.1.14 &
B3 Ensure that all individual loop components have been calibrated.
SAEP-1636 App.1
Sec.5.5&6
SAEP-16
Aramco Inspection/Proponent, Contractor QC signatures to be verified on Sec.5.1.14 &
B4
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.5.1.14 &
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 to the DCS
Sec.5.1.14 &
B6 maintenance consoles and associated systems located either at the CCR
SAEP-1636
or PIB control rooms.
App.1 Sec.5
SAEP-16
DCS loop checks may include verification of all PCS functions such as
Sec.5.1.14 &
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 and marked with a colored label bearing the date of loop Sec.5.1.14 &
B8
check and initials of witnessing party. SAEP-1636
The color code shall be: RED - Loop Check Complete. App.1 Sec.5

ITEM
No.
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 confirmed or checked: C3 SAEP-1636
C2
to C16. 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.
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
communicator for HART and Foundation Field Bus Transmitters or in
DCS as applicable
c) Apply pressure for digital smart transmitters by using test equipment
(Hand Pump) for 50% simulation to check transmitter response at DCS.
This method shall be used for digital smart transmitters only.
d) Confirm/verify the corresponding reading in the DCS / Integral indicator
and at remote indicator, if applicable.
e) For analogue transmitters, communicator shall be used for simulation SAEP-1636
C5
along with hand pump. App.1 Sec.5&6
f) For Foundation Field Bus transmitters, FF/HART communicator shall
be used for simulation . Hand pumps may be used.
g) For Non-smart transmitters, 4~20 mA source to be used for simulation
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. In case of an exception it
needs to be mentioned in the approved Loop check procedure and
agreed by the proponent and Inspection .

ITEM
No.
Control Valves Loops:

b) If any ESD logic or inter-locking are involved in applicable loop to
energize a solenoid valve, in normal condition, force the applicable ESD
points on ladder logic. The same procedure to be carried out for DCS
logic.
c) If instrument air supply is not available, use a nitrogen.
d) Apply a 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 increasing 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 hand wheel manual operation/function, if applicable.
k) Control valve loop test should be performed after completion of the air
piping works.
ON/OFF Valves Loops:

b) If any ESD logic or Inter locking are involved in applicable loop to
energize a solenoid valve, in normal condition, force the applicable ESD
points on ladder logic. The same procedure to be carried out for DCS
logic.
c) If instrument air supply is not available, use a nitrogen. Larger sizes of
valves require a larger volume of nitrogen.
d) Apply a command from DCS and Field for opening and closing the SAEP-1636
C7
valve. App.1 Sec.5&6
e) Verify the corresponding valve position in DCS and 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 hand wheel and 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 or Inter locking are involved in applicable loop, in
normal condition, force the applicable ESD points on ladder logic. The
SAEP-1636
C8 same procedure to be carried out for DCS logic.
App.1 Sec.5&6
c) Check and verify local/remote switch function.
d) Stroke the MOV from DCS and Field - Open, Close and Stop.
e) Verify the status of the MOV at DCS and Field.
f) Check hand wheel manual operation/function if applicable.

ITEM
No.
Switches Loops:
b) Simulate the contact operation (Make/Break) at the switch terminal
SAEP-1636
C9 block and verify the status in the DCS/ESD. For ESD switch,actual
App.1 Sec.5&6
pressure simulation to be provided.
c) For ESD hand switches, Start/Stop and Open/Close switches shall be
checked by operating the switch mechanism.
Gas Detectors/Beacons/Horns:
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
and in 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 and in DCS.
e) Apply 50% gas for LEL gas detector and verify the status at gas
detector display and in DCS.
f) Check Beacon status at High Alarm condition.
g) Check Horn status at High-High Alarm condition.
RTD Temperature Transmitter Loops:

b) Verify temperature transmitter set (calibration) range per ISS.
c) Simulate resistance equivalent to 50% of the transmitter 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 the
App.1 Sec.5&6
transmitter and at remote indicator, if applicable.
e) Alarms functions in DCS to be checked by simulating and varying the
required signal.
f) Normalize all connections prior to closing the terminal head and confirm
ambient temperature at integral indicator of the temperature transmitter
and in DCS.

ITEM
No.
Thermocouple Temperature Transmitter Loops:

b) Verify temperature transmitter set (calibration) range per ISS.
c) Simulate “MV” equivalent to 50% of the transmitter range by using MV
source (simulator) at the thermocouple terminal head.
d) Verify the corresponding reading in the DCS, Integral indicator of the
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 and varying the
required signal.
g) Normalize all connection prior to closing the terminal head and confirm
ambient temperature at integral indicator of the transmitter, in DCS and at
remote indicator, if applicable.
Vibration Loops (with proximitors):

a) Check and verify 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 to check the gap voltages.
d) Adjust the probe at approximately (-10 VDC) gap voltage. SAEP-1636
C13
e) Simulate a signal using a Wobulator at 0%, 50% and 100% of the range App.1 Sec.5&6
and verify the corresponding reading at VMS/DCS.
f) Verify the response of the High and High-High Alarm 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 VMS/DCS configuration for applicable points.
b) Create a vibration using a wooden hammer. Carefully and slowly hit the
probe housing by a wooden hammer. If the required values cannot be
SAEP-1636
C14 achieved, disconnect/remove the probe and shake well by hand. Create a
Sec.5&6
vibration to achieved a High and High-High Alarm points.
c) Verify the response reading at VMS/DCS.
d) Verify the response of the High and High-High Alarm at VMS/DCS.
e) Normalize all the connections.
FFVMS Loops (Trend Master 2000):

a) Check and verify the FFVMS/DCS configuration for applicable points.
b) Create a vibration using a steel hammer. Carefully hit near the probe by SAEP-1636
C15
a steel hammer. Sec.5&6
c) Verify the response reading at FFVMS/DCS.
d) Verify the response of the High and High-High Alarm at FFVMS/DCS.

ITEM
No.
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 or Inter locking are involved in applicable loop, in
normal condition, force the applicable ESD points on ladder logic. The
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.
f) Apply a Command from DCS/ESD/Field for Start, Stop or Trip, as SAEP-1636
C16
applicable. Sec.5&6
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, 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.
k) Removal of the lock on the breakers requires permission from Electrical
section.
REMARKS:
REFERENCE DOCUMENTS:
4. SAEP-16 - Project Execution Guide for Process Automation Systems, 14 March 2017
5. SAEP-1636 - Installation and Checkout Plan, 16 October 2017
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.

ITEM
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

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. & ASSOC. 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 :

PROCESS OUTPUT 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
100 100
75 75
50 50
25 25
0 0

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


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SAUDI ARAMCO ID/PIEU-24-July-2018 - REV.2018.06.00 (Standards Cutoff - June 30,2018) Rev.2018.06.

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

Saudi Aramco: Company General Use

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

Saudi Aramco: Company General Use

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

In the control room:

Transmitters Loops (Flow/Level/pressure):

Saudi Aramco: Company General Use

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

Control Valves Loops:

ON/OFF Valves Loops:

Saudi Aramco: Company General Use

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

RTD Temperature Transmitter Loops:

Saudi Aramco: Company General Use

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

Thermocouple Temperature Transmitter Loops:

Vibration Loops (with proximitors):

Velocity Seismo Probe Loops:

FFVMS Loops (Trend Master 2000):

Saudi Aramco: Company General Use

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

Saudi Aramco: Company General Use

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

Contractor / Third-Party Saudi Aramco

QC Inspector PID Representative

QC Supervisor Proponent and Others

*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED

Saudi Aramco: Company General Use

Unit No.: System No.: Loop No. Loop Dwg. No.:

DCS INSPECTION PERFORMED

POINTING TAG YES NO N/A

DCS/FIELD INSPECTION PERFORMED

MOTOR CONTROLS/SWITCHES/MOV'S/AOV'S GAS DETECTOR

COMMANDS INDICATION GAS DETECTOR NO.:

TAG NO. : VALVE TAG NO.: SWITCH TAG NO. :

PROCESS INPUT RANGE : SWITCH SET POINT :

Saudi Aramco: Company General Use

LOOP CONTINUITY CHECK SHEET (PRE-LOOP CHECK)

Manufacturer S.No LOOP DRAWING NO Data Sheet No

CONTINUITY CHECK SHEET

Calibration Inspection Remarks

FROM TO CHECKS PER SECTION

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

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