Sabp Z 019

Best Practice
SABP-Z-019 10 November 2014

Process Automation System Condition Assessment Survey
Document Responsibility: Process Control Standards Committee
Saudi Aramco DeskTop Standards

Table of Contents
1 Introduction……………………………………..……….. 2
2 Scope…………………………………………………..… 2
3 Conflicts with Mandatory Standards………………...... 2
4 References……………………………………………..... 3
5 Abbreviations…………………………………………..... 4
6 Definitions……………………………………………..… 4
7 Roles and Responsibilities…………………………..… 6
8 Site Survey Instructions………………………………... 8
9 Interview of Operations & Engineering Personnel.… 17
10 PAS Condition Assessment Survey Report………… 17
11 Field Survey Status Monitoring………………………. 18
Appendix A – Panel List…………………………………… 20

Appendix B – UPS Survey………………………………… 21
Appendix C – Minimum PCAST Deliverable List……….. 22
Appendix D – Document & Drawing Register…………… 24
Appendix E – IO Database Structure and Fields……….. 25
Appendix F – Status Report…………..…………………... 28
Previous Issue: New Next Planned Update: TBD

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Primary contacts: David Northup at +966-013-8809487, and Paul Mevec at +966-013-8809203
Copyright©Saudi Aramco 2014. All rights reserved.

Document Responsibility: Process Control Standards Committee SABP-Z-019
Issue Date: 10 November 2014
Next Planned Update: TBD Process Automation System Condition Assessment Survey
1 Introduction
Saudi Aramco executes large, complex brownfield process automation system (PAS)
upgrade and migration projects. It is critical to have complete and field verified PAS
documentation and performance data to ensure the correct project alternatives are
identified during FEL 2 so that the optimal PAS alternative is selected prior to
development of the project proposal during FEL 3.
Identification of the correct project alternatives during FEL 2 will ensure reduced
project costs and schedule due to the elimination of project re-scoping during the
project proposal phase. Likewise, correct development of the engineering design during
project proposal, FEL 3, will reduce project costs and schedule due to elimination of
late scope changes during detailed design, construction and commissioning.
2 Scope
The scope of this document is to:

 Define a systematic site survey method to identify, verify and organize accurate
documentation and performance data on existing process automation systems being
considered for migration, upgrade or replacement.
 PAS Condition Assessment Survey Team (PCAST) to identify engineering,
configuration and performance gaps in existing PAS to help the Integrated Project
Team (IPT) decide if these issues will be included in the project scope or are to be
corrected by the facility. Work identified for correction by the facility and deemed
critical to start-up, should be completed prior to commissioning.
 Define a process to conduct and document interviews with facility personnel to
identify operational or maintenance concerns related to the existing PAS.
 Define deliverables for a PAS Condition Assessment Survey.
 Define Roles and Responsibilities for the work outlined in this document.
3 Conflicts with Mandatory Standards
In the event of a conflict between this Best Practice and Mandatory Saudi Aramco
Engineering Requirements (MSAER), the Mandatory Saudi Aramco Engineering
Requirements shall govern.
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4 References
Specific sections of the documents listed below are referenced within the body of this
standard. Where specific sections are not referenced the entire referenced document
shall apply.
 Saudi Aramco Engineering Procedure

SAEP-99 Process Automation Networks and Systems Security
 Saudi Aramco Engineering Standards

SAES-J-601 Emergency Shutdown and Isolation Systems
SAES-J-602 Burner Management, Combustion and Waterside Control
Systems for Watertube Boilers
SAES-J-603 Process Heater Safety System
SAES-J-901 Instrument Air Supply Systems
SAES-Z-001 Process Control Systems
SAES-Z-004 Supervisory Control and Data Acquisition (SCADA)
System
SAES-Z-010 Process Automation Networks
 Saudi Aramco Materials System Specifications

23-SAMSS-010 Distributed Control Systems
23-SAMSS-020 Supervisory Control and Data Acquisition (SCADA)
Systems
23-SAMSS-030 Remote Terminal Unit
23-SAMSS-050 Terminal Management Systems
34-SAMSS-621 ESD Systems - Hard-Wired - Solid-State
(Nonprogrammable)
34-SAMSS-622 ESD Systems - Electromagnetic Relay
34-SAMSS-623 Programmable Controller Based ESD Systems
34-SAMSS-820 Instrument Control Cabinet - Indoor
34-SAMSS-821 Instrument Control Cabinet - Outdoor
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5 Abbreviations
DCS Distributed Control System
E&PM Engineering & Project Management
ESD Emergency Shutdown System
FEL Front End Loading
IO Input/output
IPL Independent Protection Layer
IPT Integrated Project Team
MSAER Mandatory Saudi Aramco Engineering Requirements
PAS Process Automation System
PCASR PAS Condition Assessment Survey Report
PCAST PAS Condition Assessment Survey Team
PCS Process Control System
PMT Project Management Team
P&ID Process and Instrumentation Diagram
SIF Safety Integrity Function
SIL Safety Integrity Level
SME Subject Matter Expert
SRS Safety Requirement Specification
6 Definitions
Distributed Control System (DCS): A process control system that is composed of

distinct modules. These modules may be physically and functionally distributed over
the plant area. The distributed control system contains all the modules and associated
software required to accomplish the regulatory control and monitoring of a process
plant, excluding field instruments, remote terminal units, auxiliary control systems and
Plant information systems.
Front End Loading Process: Front End Loading is the project delivery system that
provides reference and directions to the Integrated Project Teams and all the involved
Functions in project development, from the early/initial phase up to execution and hand
over to operations, thereby enhancing the value of company projects to all stakeholders.
The following diagram illustrates this Process:
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Hardware: Physical components used within a Process Control System such as:
Controllers, IO cards, power supplies, network devices, workstations and servers.
Integrated Project Team: A team composed of appointed members from different

functions who work in an integrated manner and have clear roles, responsibilities and
accountabilities. The chart below provides the minimum members of the IPT:
Operating System: Software that runs on a computer for the purpose of managing
computer hardware and providing common services for the execution of application
software.
Panel: Is defined as any system cabinet, FTA cabinet, marshalling cabinet, enclosure
or junction box installed in a facility.
PAS Condition Assessment Survey Team: The team of engineers responsible to

conduct the condition assessment survey of existing PAS equipment and
documentation. This team shall verify the accuracy of existing project documentation,
create missing documentation, record PAS performance data and identify PAS
performance gaps to be addressed by the project or assigned to the facility for
resolution. This team may be comprised of FPD, operations organization, P&CSD,
PMT as well as contractor’s engineering, PAS specialists and third party consultants as
required. Assessment survey team may be the IPT or a dedicated team.
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Project Management Team: The team assigned the responsibility of managing the
project. An E&PM organization or the operating organization may serve as the PMT.
For projects classified by FPD as “engineered”, P&CSD decides on the organization
responsible for the project management. For “non-engineered” projects, the proponent
organization decides whether to take the responsibility or make a request that this
function be performed by an E&PM organization.
Operating Organization: The organization responsible for operating the facility.
Process Control System: The integrated system which is used to automate, monitor
and/or control an operating facility (e.g., plant process units). The PAS consists of
operating area Distributed Control Systems and their related auxiliary systems which
are connected together at the Process Control Network and Process Automation
Network level to form a single integrated system.
Software: Software shall be considered operating systems, applications, programming

code, computer instructions or data that can be stored electronically.
Verify: The process of comparing drawings or documents with the physical PAS
hardware and software at the actual operating facility. Verification of logic and
configuration may be done remotely provided copies of the latest applications have
been obtained.
7 Roles and Responsibilities
7.1 IPT
The IPT is responsible for:
7.1.1 Creating a project specific list of deliverables based on the general list
of deliverables provided in Appendix C for each survey. The IPT to
provide the proposed list of deliverables to the PCAST before the field
verification work is started.
7.1.2 Provide general oversight of work throughout execution.
7.1.3 Timely answers to questions and requests for clarification or detailed

direction that may come from the PCAST.
7.1.4 Coordinating status meetings and reviews of the work in progress to

ensure that the deliverables are on schedule.
7.1.5 Reviewing the final PCASR for completeness with support from PASU
and FPD SMEs.
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7.2 P&CSD
P&CSD to be responsible for review of the final PCASR.
7.3 FPD
FPD to be responsible for review of the final PCASR.
7.4 PCAST
PCAST to be responsible for:
7.4.1 Adhering to Saudi Aramco safety rules as well as the rules, regulations,
permitting and work processes of the facility being surveyed.
7.4.2 Regularly forecasting and reporting its progress, problems and

schedule to the IPT.
7.4.3 Locating and creating an electronic file and one master paper copy of
the relevant project PAS documentation.
7.4.4 Documenting all identified drawings in the document register and

provides an electronic Document Register as shown in Appendix D, as
part of the PCASR.
7.4.5 Verifying and marking up the identified documents to accurately

reflect the actual installation.
7.4.6 Creating hand sketches for any items for which no drawing can be found.
7.4.7 Initialing and dating in the lower left corner any document surveyed or
sketch created regardless of whether or not it was marked up per
survey findings.
7.4.8 Verifying and updating documents associated with the PAS to be

replaced or upgraded and its associated infrastructure. The PCAST is
not responsible for performing an “as-built” of non-automation system
content.
7.4.9 Scanning all verified documents utilized by the PCAST
7.4.10 Engaging facility process control engineer and network administrator

support to obtain required system documentation and information.
7.4.11 Engaging the services of vendor or specialty contractor to perform

PAS performance related activities.
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7.4.12 Identifying any site conditions that might affect project construction
and cutover.
7.4.13 Preparing a PCASR containing all site survey documentation and

recommendations.
7.4.14 Providing the IPT with the verified data and supporting documentation
required to assess the current condition of existing PAS, identify and
evaluate project alternatives and define the correct project scope during
FEL 2.
7.5 Operating Organization
Operating Organization to be responsible for:
7.5.1 Providing Process Control Engineer and Network Administrator to

support PCAST with PAS assessment survey.
7.5.2 Participating in interviews with PCAST to obtain plant personnel

system and process specific experience.
7.5.3 Reviewing PCASR
7.5.4 Ensuring that identified PAS performance gaps critical to startup is

rectified prior to project commissioning.
7.6 PAS Vendor
PAS Vendor to be responsible for providing support to the PCAST team to

obtain PAS performance data.
8 Site Survey Instructions
8.1 Field Instrumentation Site Survey Scope
The following documentation to be field verified as part of the Site Survey:
8.1.1 Hazardous Area Classification Drawings
8.1.2 Instrument Points and Line Drawings
8.1.3 Cable Schedules
8.1.4 Field Panels, Enclosures, Junction Boxes Drawings

 Verify and record information such as name, panel location, cable
numbers, terminal strip numbers, and equipment/tagnames of
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internal elements (i.e., relays, intrinsic safety barriers, etc.) on

drawings as shown in Appendix A
 Make note of the wiring termination types used inside the panels
such as screwed, spring clamp, ring lug, etc.
 Verify and record the type of panel (NEMA classification), and a
general assessment of the condition of the panel and contents.
 Verify and record if the panel is equipped with purging on the
panel drawings or sketches. The type of purging (X, Y, Z), the gas
used for purging and whether or not the purging system has
alarming or automatic power cutoff should be recorded.
 Verify segregation of DCS and ESD field instruments, junction
boxes and cabling.
 Make note of spare cable entries or space for additional panel
penetrations.
 Make note of the state of wiring, terminal blocks, cables, cable
entry and note any conditions that may affect expansion or reuse of
the equipment.
8.1.5 Instrument Installation Details

 Locate the latest versions of detail drawings for field
instrumentation and valves and make copies
 Verify and record the field installation such as configuration of
tubing, solenoids, actuators, etc.
 Record the manufacturer and model number of all instrumentation
and valves.
 Record instrument information in existing IO database; if none
exists create a new IO database based on Appendix E.
8.2 PAS System Site Survey Scope
The following documentation to be field verified as part of the condition

assessment survey:
8.2.1 P&IDs
 Redline P&IDs to depict field instruments and control strategies
associated with the PAS project scope. Piping and vessel updates
to the drawings are outside of the PAS project scope.
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 The applicable instrument tag, specification data and P&ID

drawing number is to be input into the IO Database for each
instrument. If an IO database does not exist create a new one based
on see Appendix E.
8.2.2 SIL Assessment and Verification

 Obtain a copy of any SIL Assessment Study performed at the facility
 Obtain a copy of any SIL Verification Report for the affected plant
 Obtain ESD test records for the affected plant
 Obtain a list of DCS IPLs
 Obtain a copy of SRS for existing ESD
8.2.3 Shutdown Hierarchy Drawing
Verify against PAS configuration and other logic documentation and

redline as required.
8.2.4 Cause and Effects

8.2.5 Logic Drawings

8.2.6 Control Narratives

8.2.7 Alarm System

 Obtain a copy of any Alarm Rationalization Study
 Obtain alarm and event logs
 Identify bad actors or problem loops
8.2.8 PAS Installed Base

 Obtain the latest copy of the PAS installed base database from the
proponent
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 Verify and update the PAS installed base database

 Verify and update installed PAS Servers, Operator Consoles and
Engineering Workstations hardware, operating system and
application version in the PAS installed base database
 Provide the updated version of the PAS installed base to Proponent
for upload to the PA LCM ShareK website.
8.2.9 Control System Block Diagrams
Verify that the block diagrams represent the installed PAS equipment
and their interconnections to field equipment and other PAS.
8.2.10 System Architecture Diagrams
Verify system architecture drawing reflects the installed PAS.
8.2.11 Process Automation System Network Diagrams

 Visually inspect each PAS node, switches and routers and record
the IP address, subnet mask, default gateway, link speed, duplex
and firmware revision.
 Inspect and record each communication cable rating such as CAT 5,
CAT 5E, CAT 6, etc.
 Save running router and switch configuration. Identify any
potential configuration optimization.
 Inspect all network cables and cable connectors. Record information
on their condition such as broken connectors, kinked cables, etc…
 Verify existing network software configuration against vendor
design recommendations
 Measure and record router and switch
- Network traffic loading
- Hardware CPU loading
- Number of Network Traffic Collisions on each port
- Fault and event log review
- Network generated error reports
 Perform detailed network diagnostics for sites experiencing router
and switch issues
 Conduct a security assessment based on SAEP-99
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 Document network spare capacity to support project requirements
8.2.12 PAS Configuration Backups

 Obtain a backup of the following PAS configuration:
- PAS Controller
- PAS IO
- PAS Graphics
- PAS workstation configuration files
- PAS Server Files
 Obtain a hard disk image of all PAS servers and workstations
8.2.13 Marshalling Cabinets

 Verify and record information such as panel name, panel location,
equipment and tagnames in Panel List, Appendix A
 Verify cabinet layout and components against available drawings
 Inspect integrity of existing termination assemblies. Note any
damage to terminal blocks or wiring.
 Record termination block, and Wire duct spare capacity
 Measure and record spare capacity for additional field and
interconnect cables
 Make note of any wiring, terminal blocks, cables, cable entry,
building penetration, field cable tray or other conditions that may
affect expansion or reuse of the marshaling cabinet
8.2.14 PAS Cabinets

 Verify and record information such as Name, panel location, cable
and equipment/tagnames in Panel List, Appendix A
 Verify cabinet layout and components against available drawings
 Record cabinet number and location
 Inspect integrity of existing termination assemblies. Note any
damage to terminal blocks or wiring.
 Record termination block, and Wire duct spare capacity
 Measure and record spare capacity for additional field and
interconnect cables
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 Make note of any wiring, terminal blocks, cables, cable entry or

any other conditions that may affect expansion or reuse of the PAS
cabinets
8.2.15 PAS Controller and IO Modules

 Visually inspect all PAS controller and IO modules and record any
error messages on the physical hardware, on a cabinet basis.
 Record controller and IO Firmware revisions
 Record system controller and IO Module diagnostic errors from
engineering workstation
 Controller Performance
- Record controller memory spare capacity
- Record execution time spare capacity
 Measure and record controller and IO power supply voltage and
amps.
 Measure and record power supply output quality.
 Document rated capacity of all power supplies.
 Termination Assemblies
- Inspect integrity of existing termination assemblies.
Record cabinet number and location with a description of
damaged termination assembly.
- Record termination assembly spare capacity
- Record Wire duct spare capacity for additional field and
interconnect cables
 Gather any Vendor knowledge articles related to the installed
system that may address mandatory or recommended upgrades,
repairs, etc.
 Make note of any conditions that may affect expansion or reuse of
the PAS cabinets.
8.2.16 Interfaces
 Verify all PAS to PAS interfaces have been identified
 Verify all PAS to external system interfaces, such as local control
panels, have been identified
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 Verify and record interface Protocols

 Verify and record the quantity and type of data for each interface
 Identify any communication upgrades required to interface existing
PAS systems to new PAS components. Confirm data transmission
to external system will not be interrupted during cutover to new
system
 Measure and record the actual update time of all interfaces through
visual verification of value change on an operator console
 Record the actual interface configuration of all communication
devices
 Inspect and redline network drawings to reflect the field installation
and node numbers for interfaces.
8.2.17 Motor Controls

 Verify PAS interface to existing MCC drawings and verify against
logic documentation.
 Verify where interposing relays are utilized
 Verify where sequence logic is performed with relay logic
8.2.18 Loop Drawings
Verify the wire tags at each termination point on the loop's wiring.
If the existing loop drawing does not indicate wire tag names, then the
survey team should write “NWT” (No Wire Tag) for that wire at the
termination point on the drawing.
8.2.19 IO Database
For each instrument of the affected PAS, enter IO data into a database
based on the format shown in Appendix E.
8.2.20 Control System Performance

 Identify number of loops in manual
 Document number and causes of controllers out of service
 Identify number and types of IO card and channel faults
 Identify faulty instruments that are reading bad quality during
normal operation.
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8.2.21 Control, PIB and Rack Rooms

 Redline layout drawings to reflect equipment location
 Document free space in system cabinets for new PAS equipment
 Document free space for new system and marshalling cabinets
 Measure and record control room lighting level
 Verify spare marshalling capacity available for new instruments
 Verify cable tray loading and spare space for additional cabling
 Verify Control Room, PIB and Rack rooms are adequately
pressurized and temperature/humidity controls work
 Verify HVAC capacity
 Measure and record Control Room and PIB actual heat loads
 Identify and record PAS cabinets that do not meet existing SA
standards
 Make note of any space limitation or constructability issues that
may affect expansion or reuse of the PIB such as underfloor cable
space, cable tray spare capacity and fire & gas detection.
8.2.22 PAS Servers, Operator Consoles and Engineering Workstations

 Verify console arrangement drawings
 Record the following for each server, console and workstation:
- Operating system version
- Operating system patch version
- Anti-virus patch engine and signature version
- Vendor application version
- CPU capacity
- CPU utilization
- Memory capacity
- Memory utilization
- Hard disk size
- Hard disk space used
- Network card rating
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- Network card utilization

- USB ports enabled and disabled
- Event logs
8.2.23 Grounding
 Verify all cabinet components (doors, panels, etc.) are grounded
per the drawings
 Verify all system ground wires are terminated to the proper ground
points per the drawings
 Verify all system ground wire terminations are corrosion free
 Measure and record the resistance from cabinet components
(such as doors, FTAs, power supplies, etc.) to the AC or Master
Reference ground points in the cabinet.
 Measure and record the resistance from the cabinet grounds to the
building ground
 Measure and record the resistance from the building ground to the
master ground reference
 Perform detailed grounding test for sites experiencing power and
ground issues
8.2.24 UPS & Power Distribution Panels

 Inspect all existing UPS equipment cabinets and document their
specifications per Appendix B.
- Make and model number of the UPS
- Power rating
- Battery type
- How many minutes of battery back-up
- Spare capacity
- The primary and alternate power feeds
- Record the panel or equipment numbers of the downstream
power distribution panels powered by it.
- Review all Maintenance performed on the UPS and identify
recurring maintenance and operational issues
 Verify single line drawings
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 Verify UPS power distribution panel drawings. The following to

be recorded at minimum:
- Circuit assignments
- Breaker ratings
- Spare installed breakers and their ratings
- Spare spaces
 Assess the integrity of UPS, i.e., battery condition, static switch, etc.
 Verify spare capacity of power and circuits for new PAS equipment
 Verify that there is physically independent primary and secondary
power distribution panels feed by the UPS.
 Verify that all wiring and circuit breakers are rated for the existing
load.
 Verify UPS meets redundancy requirements of SAES-Z-001.
8.2.25 Standards and Material Specifications
Note any deviations from the following applicable engineering

standards: SAES-J-601, SAES-J-602, SAES-J-603, SAES-J-901,
SAES-Z-001, SAES-Z-004, SAES-Z-010, 23-SAMSS-010,
23-SAMSS-020, 23-SAMSS-030, 23-SAMSS-050, 34-SAMSS-621,
34-SAMSS-622, 34-SAMSS-623, 34-SAMSS-820 and 34-SAMSS-821.
9 Interview of Operations and Engineering Personnel
9.1 PCAST will meet with and interview various members of the facility
management, operators, engineers, maintenance technicians, etc. The purpose
of these interviews is to learn information regarding operational, maintenance
and system integrity concerns that may not have been identified in the
documentation verification process.
9.2 The PCAST members who meet with or interview operations personnel are to
formally document those meetings. Locate and include any documentation to
support concerns that may impact the project.
10 PAS Condition Assessment Survey Report
PCAST to prepare a formal condition survey report with the following section at a
minimum:
General – Describes the scope of the survey
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Survey Result – This section presents the Document Index which identifies all
information considered. For each element of the Site Survey Instructions, from Section 7
of this Best Practice document, the following information should be provided.
 Summary of work performed
 Location in report of verified drawings
 Documentation and records of all requested information such as controller loading,
network performance, etc.
 Write-ups on general health of system, terminals, field wire with reference to
standards on signal segregation, marshalling, spares capacities, etc.
Concerns – This section to address any concerns that may affect project alternative
identification and evaluation or project execution, such as,
 Concerns with implementing new ESD into existing system and wiring
 Concerns with PIB, CR or cabinet space that may affect migration, upgrade or
replacement. Suggest alternatives to make the construction/cutover easier
 Concerns with DCS/ESD segregation
 Concerns with existing reliability and existing PAS gaps
 Concerns with alarms and bad actors
 Concerns with risk area segregation or redundancy
Interview Findings – This section to document the findings of the facility interviews
and highlight any issues that may affect project alternative analysis and selection,
Recommendations – This section to detail any recommendations on alternatives to be

considered along with any potential risks and construction issues to be considered
during project alternative analysis,
Electronic/Scanned Copies of Documents - Each drawing and document of the survey

is to be scanned and made into a high resolution, full color electronic file. The files
should be given file names which include the description of the drawing as well as the
drawing number. Electronic files are to be attached to the PCASR.
11 Field Survey Status Monitoring
The PCAST leadership will be responsible for issuing a status report on the survey
progress.
The status report should include a brief section with a bullet list of activities worked on
during the reporting period.
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The report should include a brief section with a bullet list of activities planned to be
worked on during the next reporting period.
The report should include a brief section with a description of what problems exist that
might hinder upcoming work activities (i.e., survey team staffing issues, access to
facility areas or equipment, vendor support, availability of key facilities personnel, etc.).
The report should state the man hours spent during the current reporting period by the
PCAST.
The report should state the man hours that are estimated to be expended during the next
reporting period by the PCAST.
The report should include a brief section with the man hours estimated to complete the
remaining activities of the work package.
The report should include a brief section with an approximate date when the PCAST
will complete the work package.
An example status report is shown in Appendix F.
Revision Summary
10 November 2014 New Saudi Aramco Best Practice.
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Appendix A – Panel List
Field Title Field Description
Administration Area Refining, SAOO, NAOO, etc.
Facility Name of facility
Panel Tag Number The equipment tag number of the panel.
Panel NEMA Rating The NEMA rating of the panel.

 Type of purging, if any.
 Enter: “None” if the panel is not purged;
 Enter “X” if the panel has type X purging (purge results in change of
classification from Class 1, Division 1 to Non-Classified, loss of purge
results in automatic cutoff of electrical power to panel);
 Enter “Y” if the panel has type Y purging (purge results in change of
Purging classification from Class 1, Division 1 to Class 1, Division II, loss of purge
results in alarm only);
 Enter “Z” if the panel has type Z purging (purge results in change of
classification from Class 1, Division 2 to Non-Classified, loss of purge
results in alarm only).
 Enter “Other” if the panel has purge air or gas to it, but has no form of
alarm or power cut-off on loss of purge.
Panel Service A brief description of the panel's service type - “lighting power”, “UPS power
Description distribution”, “analog IO JB”, “safety shutdown relays”, DCS, etc.
The panel equipment arrangement drawing for this panel. If the panel does
Panel Arrangement
not have a schedule drawing, then please indicate so by entering “None” in
Drawing
this field.
The hazardous area classification drawing that the panel is located in/on.
Area Class DWG If the panel is not already shown on this drawing, then the drawing should be
marked up by hand to indicate the panel's location.
The location plot plan drawing or PIB/CR layout drawing that the panel is
Location Plan DWG located in/on. If the panel is not already shown on this drawing, then the
drawing should be marked up by hand to indicate the panel's location.
The name of the Field Survey Team member who performed the survey for
Survey and Mark Up
this panel. Each survey team member is to initial and date the bottom left
Person
corner of each drawing in the survey.
Enter the date that the panel was surveyed and marked up. Each survey team
Date Surveyed
member is to initial and date the bottom left corner of each drawing in the
and Marked Up
survey, regardless of whether it was marked up or not.
This is a general comment field for anything unusual to be noted about the
Comments
panel.
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Appendix B – UPS Survey
Administration Area SAOO
Facility Facility name
UPS Cabinet Number The equipment tag number of the UPS cabinet.
UPS Manufacturer The manufacturer of the UPS, not the model number.
UPS Model The model number of the UPS, not the manufacturer.
Power Rating The kVA rating of the UPS.
Battery Type The type of batteries for this UPS (lead acid, sealed, etc.)
Identify how many minutes of battery back-up time the current installation
Battery Back UpTime
is equipped for.
The existing spare capacity of the UPS, defined as the rated capacity less
the meter reading at the time the survey was made, less the power draw
of any equipment that is offline at the time of the survey if that equipment
Spare Capacity is normally drawing power from the UPS. This determination requires that
the field survey team member carefully research all downstream devices
and panels of the UPS and interview maintenance and operations
personnel for related information.
Primary Power Source Specifically identify the primary root power source for this UPS.
Specifically identify the alternate root power source for this UPS.
Alternate Power Source Be advised that a second cable run from the same root power source is
still the same power source…
Identify, by panel name and number, all downstream power distribution
Downstream Panels
panels for this UPS.
Survey and Mark Up The name of the Field Survey Team member who performed the survey
Person for this UPS.
Enter the date that the panel was surveyed and marked up. Each survey
Date Surveyed and
team member is to initial and date the bottom left corner of each related
Marked Up
drawing in the survey, regardless of whether it was marked up or not.
This is a general comment field for anything unusual to be noted about the
Comments
panel.
Page 21 of 29
Appendix C – Minimum PCAST Deliverable List
In Scope
Item Reference Deliverable
(Y/N)
1 7.1.1 Hazardous Area Classification Dwg.
2 7.1.2 Instrument Point and Line Dwg.
3 7.1.3 Cable Schedule
4 7.1.4 Field Panel Survey
5 7.1.5 Instrument Installation Dwg.
6 7.1.5 Instrument Data
7 7.2.1 P&IDs
8 7.2.2 SIL Assessment Report
9 7.2.2 SIL Verification Report
10 7.2.2 ESD Test Records
11 7.2.2 DCS IPLs
12 7.2.2 SRS
13 7.2.3 Shutdown Hierarchy
14 7.2.4 Cause and Effect
15 7.2.5 Logic Drawings
16 7.2.6 Control Narratives
17 7.2.7 Alarm Rationalization Study
18 7.2.7 Alarm System Performance Data
19 7.2.8 PAS Installed Base
20 7.2.10 Control System Block Diagram
21 7.2.11 System Network Diagrams
22 7.2.11 System Network Performance
23 7.2.12 PAS Configuration Backups
24 7.2.13 Marshalling Cabinet Survey
25 7.2.14 PAS Cabinet Survey
26 7.2.15 PAS Controller and IO Module Survey
Page 22 of 29
In Scope
Item Reference Deliverable
(Y/N)
27 7.2.15 PAS Controller Performance Assessment
28 7.2.16 PAS Interface Survey
29 7.2.17 PAS MCC Interface Survey
30 7.2.18 Loop Dwgs.
31 7.2.19 IO Database
32 7.2.20 Overall Control System Performance
33 7.2.21 PIB/CR Layout Dwgs.
34 7.2.21 PIB/CR Auxiliary Systems Survey
35 7.2.23 Console Arrangement Dwgs.
36 7.2.23 Server/Op Console Survey
37 7.2.23 Server/Op Console Performance
38 7.2.24 Grounding Survey
39 7.2.24 Grounding Data
40 7.2.25 UPS Survey
41 8.0 Operations Engineering and Maintenance Interviews
42 10 Condition Assessment Survey Report
Page 23 of 29
Appendix D – Document and Drawing Register
The type of drawing document - P&ID, Plot Plan, Hazardous Area

Document Type
Classification, Motor Schematic, Loop Drawing, etc.
The drawing control number for the record or document. If the drawing or
document does not have a unique control number, then the survey team
Document Number
should assign one to it and hand write it near the title block or on the first page
of a multiple page document.
Revision Number The revision number as shown in the drawing or document.
The sheet number as shown on a multi-sheet drawing. In the event that a

multi sheet drawing does not have individual sheet numbers assigned as part
Sheet Number
of the drawing, and then the survey team should hand mark the sheet numbers
on the drawings and include them in this database.
The Drawing Title as it appears in the title block for the drawing or document.
Document Title Please capitalize the first letter of each word in the title. Do not use all capitals
when entering any drawing titles.
The hard copy or electronic file type for the master/original drawing or
Original Format
document- sepia, blue line, AutoCAD file, TIF file, etc…
Document Size The drawing size for the original/master drawing or document.
Date Surveyed and The date that the drawing or document was surveyed and marked-up or
Marked Up verified to be accurate.
Survey and
The name of the person who surveyed this drawing or document.
Mark Up Person
Survey and
The office or cell phone number of the person who surveyed this drawing or
Mark Up Person
document.
Contact Number
Comments Any pertinent comments regarding this drawing or document.
Page 24 of 29
Appendix E – IO Database Structure and Fields
Data Group Data Field Description
General Tagname The IO Point's tagname.
General Signal Type AI, AO, DI, DO, TC, RTD, Pulse, Pneumatic, etc.
General Signal Level 4-20 mA, 24 VDC, 120 VAC, mV, 3-15 psig, etc.
General Power Type 24 VDC, 120 VAC, etc.
General Power Source DCS, UPS Panel, etc.
General Function PCS, Safety, RTU
General System Mfg. Honeywell, Emerson, Invensys, Yokogawa, Bentley Nevada, CCC, etc.
General System Model C300, 3300, M1 RTU, etc.
General System Description Process unit of function
Location Administration Area SAOO
Location Facility Facility name
The drawing number of the plot plan on which the instrument or piece of
Documentation Plot Plan
equipment is located.
The drawing number of the instrument location plan on which the
Documentation Location Plan
instrument or piece of equipment is located.
The drawing number of the hazardous area classification drawing on which
Documentation Area Class
the instrument or piece of equipment is located.
The drawing number of the P&ID on which the instrument or piece of
Documentation P&ID
equipment is located.
The drawing number of the C&E which references the instrument of this
Documentation C&E
record.
Documentation Narrative The drawing number of the narrative for the IO point of the record.
Documentation Loop The drawing number of the loop drawing for the IO point of the record.
The basic type of field instrument or device. For example: XMTR for any
Field Device Type
type of transmitter, I/P, Valve, Positioner, Relay, etc.
Field Device Mfg. The manufacturer but not the model number of the field device.
Field Device Vlv Fail Position The valve's fail position either “Open” or “Closed”.
Field Device Model The model number, not the manufacturer of the field device.
Whether or not the field instrument has a manifolds, and if so - the number
Field Device Manifold
of valves in that manifold. “None” if there is no manifold.
Does the instrument have heat tracing and if so, what type? “None”,
Field Device Tracing
“Steam” or “Electric”
The cable name of the cable entering into the box or enclosure (JB#1) from
Field Wiring Cbl1 In
the field side of the box or enclosure.
Page 25 of 29
The equipment tag or number for the junction box, panel or enclosure into
Field Wiring JB1 #
which Cbl1 In enters.
The terminal strip on which is landed the wires for the instrument or IO
Field Wiring JB1 TS
point which is the subject of this record.
The terminal block on which is landed a wire for the instrument or IO point
of the record. Append a “+”, “-” or “S” to the block number to designate
positive, negative or shield for general instruments (i.e., “21+” to indicate
Field Wiring JB1 TB1
the positive wire lands on TB21). Enter the color and, if applicable,
“+”, “-”, “G” (for ground) for other wiring configurations (triads,
non-paired conductors, etc.).
positive, negative or shield for general instruments (i.e., “22-” to indicate
the negative wire lands on TB22). Enter the color and, if applicable,
of the record. Append a “+”, “-” or “s” to the block number to designate
positive, negative or shield for general instruments (i.e. “23s” to indicate
the shield wire lands on TB23). Enter the color and, if applicable,
The cable name of the cable leaving the box or enclosure and heading
Field Wiring Cbl Out
towards the control system equipment.
These fields are basically the same as those just described, but are only
applicable if there is more than one enclosure between the field device and
Field Wiring Cbl In the controller. The #1 set of fields are for the enclosure and cables nearest
to the field device. Each sequentially numbered set of fields is for the next
enclosure heading to the marshalling cabinet or control systems equipment.
Field Wiring JB2 #
Field Wiring JB2 TS
Field Wiring JB2 Cbl Out

The cable name of the cable entering into the marshalling cabinet, usually
Marshalling
MCab1 Cbl In from the field, but it could also be from another marshalling cabinet or
Cabinet
elsewhere in the IO Room.
Marshalling The equipment tag or number for the marshalling cabinet into which Cbl1 In
MCab1
Cabinet enters.
Marshalling The terminal strip on which is landed the wires for the instrument or IO
MCab1TS1
Cabinet point which is the subject of this record.
Marshalling MCab1TS1TB1 The terminal block on which is landed a wire for the instrument or IO point
Page 26 of 29

Cabinet of the record. Append a “+”, “-” or “S” to the block number to designate
positive, negative or shield for general instruments (i.e. “21+” to indicate
the positive wire lands on TB21). Enter the color and, if applicable,
Marshalling positive, negative or shield for general instruments (i.e. “22-” to indicate
MCab1TS1TB2
Cabinet the negative wire lands on TB22). Enter the color and, if applicable,
of the record. Append a “+”, “-” or “s” to the block number to designate
Marshalling positive, negative or shield for general instruments (i.e. “23s” to indicate
MCab1TS1TB3
Cabinet the shield wire lands on TB23). Enter the color and, if applicable,
The cable name of the cable exiting out of the marshalling cabinet, usually
Marshalling
MCab1CblOut to the control system cabinet, but it could also be to another marshalling
Cabinet
cabinet or elsewhere in the IO Room.
These fields are basically the same as those just described, but are only
Marshalling applicable if there is more than one marshalling cabinet through which the
MCab2Cbl In
Cabinet instrument is wired to reach the controller system cabinet. The #1 set of
fields are for the marshalling cabinet and cables nearest to the field device.
Marshalling
MCab2
Cabinet
Marshalling
MCab2TS1
Cabinet
Marshalling
MCab2TS1TB1
Cabinet
Marshalling
MCab2TS1TB2
Cabinet
Marshalling
MCab2TS1TB3
Cabinet
Marshalling
MCab2 Cbl Out
Cabinet
This field is for the information regarding the Remote IO or chassis for
System Cabinet Drop
systems that utilize such. Enter “none' if it does not apply.
The cable tag of the cable entering into the system cabinet, either from the
System Cabinet Cable
marshalling cabinet from a junction box or panel outside the control room.
The equipment tag or number for the system cabinet into which the IO
System Cabinet SCab
point's signal transmits.
System Cabinet Rack The rack number for the module of the IO point.
System Cabinet Module Type The module type for the IO point.
System Cabinet Module # The module number for the IO point.
System Cabinet Slot # The slot or point number on the IO card for the IO point.
Page 27 of 29
Appendix F – Status Report
The following is an example of what will be required for a status report each reporting period
from the PCAST. The intent is to provide only a brief, outline or bullet list of descriptions for
the required information.
****************************************************************************
A. Activities Worked On This Reporting Period
1. Completed pulling drawings for Plot Plans, Hazardous Area Classifications and local
field panels.
2. Continued pulling drawings from iPlant and facility files for junction boxes, motor
schematics, installation details and loop drawings.
3. Began surveying of local field panels and instrument installations.
B. Activities To Be Worked On Next Reporting Period
1. Complete pulling drawings for junction boxes and motor schematics.
2. Continue pulling loop drawings.
3. Begin interviewing location personnel.
4. Continue surveying of local field panels and instrument installations.
C. Problems And Potential Problems
 Previously unscheduled shutdown now planned for next week. Access to equipment
and key operations personnel will be limited.
D. Non Man Hour Costs Incurred This Reporting Period
 If any.
E. Man Hours Spent This Reporting Period
 Three persons working 40 hours/week and two persons working 20 hours/week for an
estimated total of 320 man hours over the next two week reporting period.
F. Non Man Hour Costs Estimated To Be Incurred Next Reporting Period
 None.
G. Man Hours Estimated To Be Expended Next Reporting Period
 Three persons working 20 hours/week for an estimated total of 120 man hours over
the next two week reporting period.
Page 28 of 29
H. Man Hours Estimated To Yet Be Expended To Complete Remaining Work

 Current estimate is 460 man hours work needed to complete work package.
I. Estimated Date When Work Will Be Completed
 Mid November 2008
Page 29 of 29

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SABP-Z-019 10 November 2014

Saudi Aramco DeskTop Standards

Appendix A – Panel List…………………………………… 20

Previous Issue: New Next Planned Update: TBD

Copyright©Saudi Aramco 2014. All rights reserved.

The scope of this document is to:

3 Conflicts with Mandatory Standards

 Saudi Aramco Engineering Procedure

 Saudi Aramco Engineering Standards

 Saudi Aramco Materials System Specifications

Distributed Control System (DCS): A process control system that is composed of

Integrated Project Team: A team composed of appointed members from different

PAS Condition Assessment Survey Team: The team of engineers responsible to

Operating Organization: The organization responsible for operating the facility.

Software: Software shall be considered operating systems, applications, programming

7 Roles and Responsibilities

The IPT is responsible for:

7.1.2 Provide general oversight of work throughout execution.

7.1.3 Timely answers to questions and requests for clarification or detailed

7.1.4 Coordinating status meetings and reviews of the work in progress to

P&CSD to be responsible for review of the final PCASR.

FPD to be responsible for review of the final PCASR.

PCAST to be responsible for:

7.4.2 Regularly forecasting and reporting its progress, problems and

7.4.4 Documenting all identified drawings in the document register and

7.4.5 Verifying and marking up the identified documents to accurately

7.4.8 Verifying and updating documents associated with the PAS to be

7.4.9 Scanning all verified documents utilized by the PCAST

7.4.10 Engaging facility process control engineer and network administrator

7.4.11 Engaging the services of vendor or specialty contractor to perform

7.4.13 Preparing a PCASR containing all site survey documentation and

7.5 Operating Organization

Operating Organization to be responsible for:

7.5.1 Providing Process Control Engineer and Network Administrator to

7.5.2 Participating in interviews with PCAST to obtain plant personnel

7.5.3 Reviewing PCASR

7.5.4 Ensuring that identified PAS performance gaps critical to startup is

7.6 PAS Vendor

PAS Vendor to be responsible for providing support to the PCAST team to

8 Site Survey Instructions

8.1 Field Instrumentation Site Survey Scope

The following documentation to be field verified as part of the Site Survey:

8.1.1 Hazardous Area Classification Drawings

8.1.2 Instrument Points and Line Drawings

8.1.3 Cable Schedules

8.1.4 Field Panels, Enclosures, Junction Boxes Drawings

internal elements (i.e., relays, intrinsic safety barriers, etc.) on

8.1.5 Instrument Installation Details

8.2 PAS System Site Survey Scope

The following documentation to be field verified as part of the condition

 The applicable instrument tag, specification data and P&ID

8.2.2 SIL Assessment and Verification

8.2.3 Shutdown Hierarchy Drawing

Verify against PAS configuration and other logic documentation and

8.2.4 Cause and Effects

Verify against PAS configuration and other logic documentation and

8.2.5 Logic Drawings

Verify against PAS configuration and other logic documentation and

8.2.6 Control Narratives

Verify against PAS configuration and other logic documentation and

8.2.7 Alarm System

8.2.8 PAS Installed Base