SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)

SAUDI ARAMCO INSPECTION CHECKLIST

Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)
PROJECT TITLE

SAIC NUMBER

SAIC-J-6501

WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

DATE APPROVED

1-Oct-05

QR NUMBER

INST

CONTRACTOR / SUBCONTRACTOR

EQPT CODE

SYSTEM ID.

PURCHASE ORDER NUMBER

PLANT NO.

EC / PMCC / MCC NO.

QUANTITY INSP.

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY

SAUDI ARAMCO TIP NUMBER

SAUDI ARAMCO ACTIVITY NUMBER

SAUDI ARAMCO INSPECTION LEVEL

CONTRACTOR INSPECTION LEVEL

ITEM
No.
A.

ACCEPTANCE CRITERIA

REFERENCE

Documentation Review

A1

The loop document / Package shall comprise of documents detailed

below:

SAEP-16 Sec.
4.1.11 and SAEP1636 Sec 5 &6

A2

Instrumentation Installation Record

SAEP-16 Sec.
4.1.11 and SAEP1636 Sec 5 &6

A3

Loop Check Punch list Form

A4

Loop Check Sheet

A5

Instrumentation Calibration Records

A6

Instrument Data Sheets

A7

Control Valve Pneumatic Hook-up (for complex valves only)

A8

Instrument Loop Diagrams

A9

Piping and Instrument Diagram

B.
B1
B2

SAEP-16 Sec.
4.1.11 and SAEP1636 Sec 5 &6
SAEP-16 Sec.
4.1.11 and SAEP1636 Sec 5 &6
SAEP-16 Sec.
4.1.11 and SAEP1636 Sec 5 &6
SAEP-16 Sec.
4.1.11 and SAEP1636 Sec 5 &6
SAEP-16 Sec.
4.1.11 and SAEP1636 Sec 5 &6
SAEP-16 Sec.
4.1.11 and SAEP1636 Sec 5 &6
SAEP-16 Sec.
4.1.11 and SAEP1636 Sec 5 &6

Pre- Loop Check

Ensure that actual field installation is completed in all aspects for the
concerned loops.
The installation Record sheets to be verified and formed as part of loop
folder

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.

Page 1 of 7

SAEP-16
Sec. 4.1.13
SAEP-16
Sec. 4.1.13
SAEP-16
Sec. 4.1.13
SAEP-16
Sec. 4.1.13

WORK PERMIT REQUIRED?

PASS

FAIL

N/A

RE-INSP DATE

SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)

SAUDI ARAMCO INSPECTION CHECKLIST

Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)
PROJECT TITLE

ITEM
No.

SAIC NUMBER

SAIC-J-6501
WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

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

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

B7

B8

C.

DCS loop checks may include verification of all PCS functions such as
database parameters, alarm initiations, trending, report generation,
graphics etc.
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
SAEP-16
Sec. 4.1.13

Testing Method

C1

Ensure that all loop diagrams, cause and effects charts and logic
diagrams are available prior to testing.

SAEP-1636
Sec 5 & 6

C2

During loop check the following items shall be generally be confirmed or

checked: C3 to C17

SAEP-1636
Sec 5 & 6

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

C4

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

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

C5

Page 2 of 7

DATE APPROVED

1-Oct-05

QR NUMBER

INST

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)

SAUDI ARAMCO INSPECTION CHECKLIST

Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)
PROJECT TITLE

ITEM
No.

C6

C7

C8

SAIC NUMBER

SAIC-J-6501
WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

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.

SAEP-1636
Sec 5 & 6

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

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

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.

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

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

DATE APPROVED

1-Oct-05

QR NUMBER

INST

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)

SAUDI ARAMCO INSPECTION CHECKLIST

Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)
PROJECT TITLE

SAIC NUMBER

SAIC-J-6501
WBS / BI / JO NUMBER

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

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

DATE APPROVED

1-Oct-05

QR NUMBER

INST

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)

SAUDI ARAMCO INSPECTION CHECKLIST

Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)
PROJECT TITLE

ITEM
No.

SAIC NUMBER

SAIC-J-6501
WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

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

MCC Loops
a) MCC loops shall be executed after motor solo run test.
C16 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 the
condition
be prepared
forcing
the applicable
d) Remove
controlshould
transformer
primarybyand
secondary
fuses forESD
the
applicable cubicle.
C17 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 from DCS / ESD / Field for start stop or trip as
REMARKS:

SAEP-1636
Sec 5 & 6

SAEP-1636
Sec 5 & 6

REFERENCE DOCUMENTS:
1. Schedule G -- Material, Tools and Equipment (Pro Forma MP-IK-LS Contract), July 1993
2. Schedule Q -- Quality Requirements (Pro Forma Contract), November 2003
3. SAES-J-901, Instrument Air Supply Systems, 30 June 2003
4. SAEP-16- Project Execution Guide for Process Automation Systems,31 May 2003
5. SAEP-1636 Installation and Checkout Plan , 28 February, 2005
6. SAEP-1638 Site Acceptance Test Plan, 30 April, 2002

Page 5 of 7

DATE APPROVED

1-Oct-05

QR NUMBER

INST

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)

SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)
PROJECT TITLE

ITEM
No.

DATE APPROVED

SAIC-J-6501
WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

1-Oct-05

QR NUMBER

INST

CONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

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
that the equipment, material, or services either meets appropriate designated standards or has been tested and found suitable for a specified
4. Labeled - Equipment or materials to which has been attached a label, symbol, or other identifying mark of an approved qualified organization
with product evaluation, that maintains periodic inspection of production of labeled equipment or materials, and by whose labeling the
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:

Name, Initials and Date:

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

Name, Initials and Date:

PID Representative

QC Inspector
Performed Inspection

Work / Rework May Proceed

Name, Initials and Date:

Name, Initials and Date:

QC Supervisor

Proponent and Others

Quality Record Approved:

Name, Sign and Date:

Name, Organization,
Initials and Date:

*Person Responsible for Completion of Quality Work / Test

Y = YES

Page 6 of 7

N = NO F = FAILED

SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)

SAIC NUMBER

SAUDI ARAMCO INSPECTION CHECKLIST

Instrumentation and Control Loop checking- Documentation
Review (Procedures and Packages)

SAIC-J-6501

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 ( 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

YES NO N/A
RESET

GAS DETECTOR NO.

YES NO N/A
ON

BY PASS

OFF

ON / START

RUNNING

OFF / STOP

STOPPED

OPEN

OPEN

CLOSE

CLOSE

STOP

CMDIS

INPUT
OUTPUT
(PPM/LEL)

SIMULATION RESULTS
TAG NO. :

VALVE TAG NO.: SWITCH TAG NO. :

PROCESS INPUT RANGE :

VALVE
PROCESS
OUTPUT
INPUT %
INPUT %
INPUT TO DCS
TRAVEL

25

25

50

50

75

75

100

100

75

75

50

50

25

25

SWITCH SET POINT :

SWITCH FUNCTION

RESULT

SWITCH ACTIVATES AT
SWITCH ACTION AT SET POINT

SWITCH RESET AT

Page 7 of 7

DATE APPROVED

1-Oct-05

QR NUMBER

INST