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Maintain Potential Facilities Offshore

Long Term Agreement
Contract No.6600035841 (OOK) /
6600035823 (IK)

Doc. No. 00-C-C-00-ST-P-QA-00-057

INSTRUMENT LOOP CHECKING
Rev. B Date: 23-07-2017
PROCEDURE
Sheet 2 of 10

INDEX
INDEX ................................................................................................................................................................. 2
AMENDMENTS AND REVISIONS .................................................................................................................... 3
1. SCOPE OF DOCUMENT............................................................................................................................ 4
2. DEFINITIONS, ABBREVIATIONS AND ACRONYMNS ............................................................................ 4
2.1 DEFINITIONS AND ABBREVIATIONS .............................................................................................. 4
2.2 ACRONYMS ....................................................................................................................................... 4
3. REFERENCE RULES, CODES AND STANDARDS ................................................................................. 5
3.1 CODES AND STANDARDS ............................................................................................................... 5
3.2 COMPANY DOCUMENTS .................................................................................................................. 5
3.3 CONTRACTOR DOCUMENTS .......................................................................................................... 6
4. RESPONSIBILITIES ................................................................................................................................... 6
5. PROCEDURE DESCRIPTION ................................................................................................................... 6
5.1 GENERAL REQUIREMENTS............................................................................................................. 6
5.2 LIST OF EQUIPMENTS ...................................................................................................................... 6
5.3 DRAWINGS AND DOCUMENTS ....................................................................................................... 7
5.4 HSE ..................................................................................................................................................... 7
5.5 PRELIMINARY CHECKS ................................................................................................................... 7
5.6 LOOP PROCEDURE .......................................................................................................................... 8
6. DOCUMENTATION .................................................................................................................................... 9
6.1 SAUDI ARAMCO TEST REPORTS ................................................................................................... 9
6.2 PRECOMMISSIONING FORMS ......................................................................................................... 9
7. ATTACHED LOOP PACKAGE CONTENTS SAMPLE FORMAT ..........................................................10

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prepared.
 Maintain Potential Facilities Offshore
Long Term Agreement
Contract No.6600035841 (OOK) /
6600035823 (IK)

Doc. No. 00-C-C-00-ST-P-QA-00-057

INSTRUMENT LOOP CHECKING
Rev. B Date: 23-07-2017
PROCEDURE
Sheet 3 of 10

AMENDMENTS AND REVISIONS

Amendment Contractor
Date Page Description
and revision Rep.

X1 15-09-2016 All Issued for Inter Disciplinary Check (IDC) PB

A 03-04-2017 All Issued for Approval PB

Re-Issued for Approval

B 23-07-2017 All PB
COMPANY comments are incorporated as per Transmittal FD/T-5575/17

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 Maintain Potential Facilities Offshore
Long Term Agreement
Contract No.6600035841 (OOK) /
6600035823 (IK)

Doc. No. 00-C-C-00-ST-P-QA-00-057

INSTRUMENT LOOP CHECKING
Rev. B Date: 23-07-2017
PROCEDURE
Sheet 4 of 10

1. SCOPE OF DOCUMENT
Loop checking ensures that all instrument components in a loop function correctly and accurately as per
Engineering documents / drawings. The purpose of this document is to explain the preliminary requirements that
should be followed before commencing loop checking activities and the generic procedures for loop checking of
field instrumentation. Project specific procedure shall be prepared based on vendor recommendation, site
condition and project specification.
This procedure serves as guideline to define the method of Instrument Loop Checking in achieving the quality
requirement for Saudi Aramco Projects in STAR Yard.

2. DEFINITIONS, ABBREVIATIONS AND ACRONYMNS

2.1 DEFINITIONS AND ABBREVIATIONS

COMPANY Saudi Arabian Oil Company (Aramco)

CONTRACTOR Consortium (“STAR” and “Snamprogetti Saudi Arabia”)
All organizations selected and awarded by CONTRACTOR to supply a
SUBCONTRACTOR certain Project materials or equipment or whom a part of the WORK has been
subcontracted
The authority entrusted by COMPANY for the certification “fit for purpose” of
CERTIFYING AUTHORITY
the WORK.
PROJECT “Maintain Potential Facilities Long Term Agreement
SUPPLIER / VENDOR Agency supplying the material as specified and required by the contractor

2.2 ACRONYMS

PQM Project Quality Manager

AI Analogue Input
AO Analogue Output
CCR Central Control Room
CMS Condition Monitoring Systems
DI Digital Input
DO Digital Output
DCS Distributed Control System
ESD Emergency Shut Down
F&G Fire and Gas
HMI Human Machine Interface
I/O Input/ Output
Integrated Control Safety System (Integrating PCS / PSD / ESD / F&G
ICSS
Systems)
TR Test Report

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 Maintain Potential Facilities Offshore
Long Term Agreement
Contract No.6600035841 (OOK) /
6600035823 (IK)

Doc. No. 00-C-C-00-ST-P-QA-00-057

INSTRUMENT LOOP CHECKING
Rev. B Date: 23-07-2017
PROCEDURE
Sheet 5 of 10

A set of measuring / control instruments including intermediate junction

boxes, marshalling cabinets, control systems (hardware and software),
Loop
cables, air supply components, tubing, designed to work together for the
performance of a measurement / control function.
A Loop diagram depicts the signal flow from the measuring / final control
element, intermediate junction boxes, marshalling cabinets up to the Operator
Loop Diagram Display Stations in the Control Room. It typically depicts details of
termination, cables, Junction Boxes, Marshalling / system cabinets /
Interposing Relay Panels and Operator Display stations.
RTD Resistance Temperature detector.
MCC Motor Control Centre
MOV Motor Operated valve
PSD Process Shut Down
SDV Shut Down Valve

3. REFERENCE RULES, CODES AND STANDARDS

3.1 CODES AND STANDARDS

Document Number Title

ISO 9001:2008 Quality management system – Requirements
ISA International society of Automation
IEC International Electro-Technical Commission
ANSI American National Standards Institute
NEMA National Electrical Manufacturers Association
NFPA 70 - 2008 National Fire Protection Code (NEC)
SAES-J-002 Technically Acceptable instruments
SAES-J-100 Process Flow metering
SAES-J-200 Pressure
SAES-J-300 Level
SAES-J-400 Temperature
SAES-J-700 Control Valves
SAES–J-601 Emergency shutdown and isolation systems.
SAES-J-902 Electrical System for Instrumentation
SAES-P-111 Grounding

3.2 COMPANY DOCUMENTS

Document Number Title

CRPO’ Scope of work standards
DE-119890 Instrument and Control System Installation

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 Maintain Potential Facilities Offshore
Long Term Agreement
Contract No.6600035841 (OOK) /
6600035823 (IK)

Doc. No. 00-C-C-00-ST-P-QA-00-057

INSTRUMENT LOOP CHECKING
Rev. B Date: 23-07-2017
PROCEDURE
Sheet 6 of 10

DE-119957 Procedure for Diving Safety Requirements

DE-119885 Procedure for Quality Assurance and Quality Control
Mechanical Completion Check List and Performance Acceptance and
DE-930526
Testing
SATIP; SAIC & SATR Saudi Aramco ITPs ; Checklists & Test Reports
Schedule “Q” Quality Requirements

3.3 CONTRACTOR DOCUMENTS

Document Number Title

00-C-C-00-ST-P-QA-00-049 Procedure for field Instruments Calibration Verification

4. RESPONSIBILITIES
Loop checking will be carried out by a designated instrumentation team in conjunction with site responsible
contractor personnel and witnessed by QC inspector and Company representative.

5. PROCEDURE DESCRIPTION

5.1 GENERAL REQUIREMENTS

The Material Supervisor shall ensure that all equipments are properly inspected, handled, stored and
transported in accordance with applicable quality procedures define in this manual. Any discrepancies found
shall be recorded in accordance "Control of Non -Conformities".
Three technicians are required per team to carry out the hot loop check. The field technician simulates the milli
volt / milliamp / contact signal in the field and the control room operator / technician confirms receipt of the signal
on the HMI. The signal received shall be checked & confirmed for accuracy with the signal transmitted. Two
technicians are required per team to carry out cold loop checks. They shall troubleshoot problems if any arising
during loop checking. All technicians’ reports to instrumentation commissioning engineer, vendor assistance
shall be taken wherever required.
Loop check shall be carried out by experienced qualified technicians supported by craftsman under the
supervision of Precom Engineer/ Precom supervisor.
The tests shall be recorded as defined herein and witnessed by Saudi Aramco Inspection Unit representative in
accordance with contract procedures.

Loops with punch items shall be return to the construction for rectification, closeout and handover to QC.

5.2 LIST OF EQUIPMENTS

All calibrators utilized for loop checking shall be certified with traceability to a Saudi Aramco standard as per the
project specification. Calibration certificates shall be available for inspection in the instrument calibration
workshop.
All test equipment used during a loop test shall have stickers containing the serial number, date of calibration
and date of expiry of calibration.

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 Maintain Potential Facilities Offshore
Long Term Agreement
Contract No.6600035841 (OOK) /
6600035823 (IK)

Doc. No. 00-C-C-00-ST-P-QA-00-057

INSTRUMENT LOOP CHECKING
Rev. B Date: 23-07-2017
PROCEDURE
Sheet 7 of 10

Calibration cycle of all test equipment shall not exceed six (6) months as per schedule Q, Attachment IV, para
6.1.
Contractor shall provide backup equipment when primary equipment is being calibrated or tested as per
schedule Q Attachment IV, para 6.1.
Note: Test instruments shall be suitable for the Electrical Area classification, if the loop checking is being done in
a hazardous area or an operational facility.

5.3 DRAWINGS AND DOCUMENTS

The documents and drawings for loop checking include P&IDs, loop diagrams, instrument datasheets, wiring
diagrams, cable termination details, instrument hook-up drawings, power supply distribution drawings, calibration
certificates and in some cases, package vendor’s specifications, termination schedules and other detailed
drawings. Ensure that all the above documents shall be “Approved for Construction” and of the latest revision as
per the project document schedule. Field engineer is responsible for the approved red mark-up drawings and
datasheets.

5.4 HSE
• Ensure suitable work permit is obtained before commencing loop check activities.
• Ensure good house keeping during loop checking which may run concurrently with construction activities in
the adjacent areas.
• Possibility of any unsafe situation due to maloperation during loop checking shall be communicated to all
concerned personnel in the vicinity. Incase the loop checking is being done in an existing plant which is
operating special care is to be taken and the Instruments / devices used shall be suitable for the area
classification and necessary certification to that effect shall be available .
• During initial commissioning of the equipment for each system, the limits of the equipment shall be defined
and communicated to all the involved personnel.

5.5 PRELIMINARY CHECKS

• Prior to loop checking the following points are required to be checked.
• Ensure proper fuse / breaker rating of power distribution to the system / Marshalling cabinets.
• Confirm proper Safety Grounding, Instrument Grounding, Screen /Drain Grounding as per the Project
Specification.
• Ensure the loop folder pack containing the latest revisions of P&ID, loop diagram, instrument data sheets,
Instrument layout and Fire & Gas layout drawings, etc are ready.
• Ensure each loop check team has a minimum of two sets of Radios for the communication between field and
CCR personnel.
• Carry out COLD loop checks (without power) / Continuity checks for all cables from the field instrument side
to the marshalling cabinets.
• A preliminary physical check of the instrument shall be carried out for proper instrument identification,
installation and housekeeping.
• A physical check of all intermediate junction boxes, between the field and Marshalling Panels should be
carried out to confirm termination accuracy, ferrule accuracy and housekeeping prior to loop check.

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 Maintain Potential Facilities Offshore
Long Term Agreement
Contract No.6600035841 (OOK) /
6600035823 (IK)

Doc. No. 00-C-C-00-ST-P-QA-00-057

INSTRUMENT LOOP CHECKING
Rev. B Date: 23-07-2017
PROCEDURE
Sheet 8 of 10

• Instrument installation and process orientation shall be verified using the P&ID. Ensure that all the
instruments are mounted correctly and are accessible for observing, adjusting, setting etc. and the relevant
ITR is attached to the loop folder.
• Ensure that all field measuring instruments and analog output devices are calibrated prior to installation in
the field and the relevant ITR is attached to the loop folder.

5.6 LOOP PROCEDURE

• Loop Checks shall test all the field inputs and outputs associated with the various process and utility systems
to and from the ICSS, MCC and package control panels.
• Loop testing shall not be carried out until an instrument has had an adequate warm up period. Certain
instruments such as analyzers or some F&G detectors may need to be energized prior to testing for a longer
period. This length of time should be as recommended by the manufacturer.
• Testing of each input loop shall be from the primary sensing device through the marshalling / system panels
to the displays on the operator console. Testing of each output loop shall be from the operator console
display through the system / marshalling panels to the final field device.
• Loop testing shall prove the correctness of ranges, limits, alarm points, engineering units, trip settings and
displays.
• When all the preliminary checks are done and the loop is ready for testing, the knife edge switches located
on terminal blocks in the appropriate marshalling panel, for all devices on the loop to be tested is closed.
• The instrument zero should be checked prior to starting loop checking, at the instrument and at the ICSS. If
appropriate, the final control element’s (i.e. control valve, shutdown valve etc) failed position (open, close or
last position) should also be checked prior to starting loop checking.
• The process variable (PV) shall be changed for each instrument, and the readings are confirmed on the
ICSS. The Final Control Element (control valve) is then checked to confirm the valve opening / closing, in the
correct direction, and proportional (for direct acting) to the process change.
• For I/Os connected to the ESD system, it is not necessary to test Cause and Effects since these will be
tested during Functional Logic Checks / System commissioning.
• In case of serial link / modbus communication between PCS, CMS, ESD, PLC and vendor skid package
control systems, the status change / value is to be confirmed simultaneously for all systems connected on
the same network.
• During the course of loop check any loose cables removed from terminals shall be reconnected to terminals
wherever applicable and temporary jumpers / software forces (if any) should be removed.
• All interfaces between Electrical equipment and Instrumentation devices shall be tested jointly with the
Electrical Commissioning team.
• Any changes made during loop checking shall be red marked on the relevant drawings in the loop folder
pack and in the master file for preparing As-Built.
• The knife edge switches for all the devices, for which loop checking is completed, should be kept in closed
position. If the knife edge switch has to be opened for any reason after completing the loop checking, it
should be duly recorded either by logging on a dedicated log list or by creating a punch list item.
The Loop Checking is broadly divided under the following input / output categories.
• Analog Input to ICSS
• Digital Input to ICSS

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 Maintain Potential Facilities Offshore
Long Term Agreement
Contract No.6600035841 (OOK) /
6600035823 (IK)

Doc. No. 00-C-C-00-ST-P-QA-00-057

INSTRUMENT LOOP CHECKING
Rev. B Date: 23-07-2017
PROCEDURE
Sheet 9 of 10

• Analog Output from ICSS

• Digital Output from ICSS
• Fire and Gas Systems
• Motor Control Centre
• Vibration / Condition Monitoring Systems

6. DOCUMENTATION
Completed instrument loop checking as one complete system and its results need to be documented using
Saudi Aramco Test Report and Precom forms as follows.

6.1 SAUDI ARAMCO TEST REPORTS

a) Saudi Aramco Test Report (SATR-J-6501) : Transmitter Circuit Test
b) Saudi Aramco Test Report (SATR-J-6506) : CT/PT Circuit Test
c) Saudi Aramco Test Report (SATR-J-6511) : Motor Operated Valve Test
d) Saudi Aramco Test Report (SATR-J-6512) : Hydraulic/Pneumatic control Valve Test
e) Saudi Aramco Test Report (SATR-J-6501) : Transmitter Circuit Test
f) Saudi Aramco Test Report (SATR-J-6513) : Variable/Fixed speed Motor test
g) Saudi Aramco Test Report (SATR-J-6514) : I/O Control Lop Test
h) Saudi Aramco Typical Inspection plan (SATIP-J-900-01, Rev.1) : Instrumentation control loop checking
i) Instrumentation materials manufacturer instructions.

6.2 PRECOMMISSIONING FORMS

j) Saudi Aramco Recommissioning form (J-014) : Loop check cover sheet
k) Saudi Aramco Recommissioning form (J-013) : Installation Inspection
l) Saudi Aramco Recommissioning form (J-006) : Control valves
m) Saudi Aramco Recommissioning form (J-015) : Instrument and control cables
n) Saudi Aramco Recommissioning form (J-040) : Low voltage cables
o) Saudi Aramco Recommissioning form (J-018) : H2S Monitoring system

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 Maintain Potential Facilities Offshore
Long Term Agreement
Contract No.6600035841 (OOK) /
6600035823 (IK)

Doc. No. 00-C-C-00-ST-P-QA-00-057

INSTRUMENT LOOP CHECKING
Rev. B Date: 23-07-2017
PROCEDURE
Sheet 10 of 10

7. ATTACHED LOOP PACKAGE CONTENTS SAMPLE FORMAT

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