Method Statement Instrument Loop Checking Qa 00 057_b

UNCONTROLLED COPY

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 PROCEDURE

Rev. B

Date: 23-07-2017 Sheet 2 of 10

INDEX INDEX ................................................................................................................................................................. 2 AMENDMENTS AND REVISIONS .................................................................................................................... 3 1.

SCOPE OF DOCUMENT............................................................................................................................ 4

2.

DEFINITIONS, ABBREVIATIONS AND ACRONYMNS ............................................................................ 4

3.

2.1

DEFINITIONS AND ABBREVIATIONS .............................................................................................. 4

2.2

ACRONYMS ....................................................................................................................................... 4

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

6.

7.

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

DOCUMENTATION .................................................................................................................................... 9 6.1

SAUDI ARAMCO TEST REPORTS ................................................................................................... 9

6.2

PRECOMMISSIONING FORMS ......................................................................................................... 9

ATTACHED LOOP PACKAGE CONTENTS SAMPLE FORMAT ..........................................................10

UNCONTROLLED COPY

This document is CONFIDENTIAL and the sole property SAIPEM/SNAMPROGETTI/STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those for which it was 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 PROCEDURE

Rev. B

Date: 23-07-2017 Sheet 3 of 10

AMENDMENTS AND REVISIONS Amendment and revision

Date

Page

Description

Contractor Rep.

X1

15-09-2016

All

Issued for Inter Disciplinary Check (IDC)

PB

A

03-04-2017

All

Issued for Approval

PB

B

23-07-2017

All

Re-Issued for Approval COMPANY comments are incorporated as per Transmittal FD/T-5575/17

PB

UNCONTROLLED COPY

This document is CONFIDENTIAL and the sole property SAIPEM/SNAMPROGETTI/STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those for which it was 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 PROCEDURE

Rev. B

Date: 23-07-2017 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 CONTRACTOR SUBCONTRACTOR CERTIFYING AUTHORITY PROJECT SUPPLIER / VENDOR 2.2

Saudi Arabian Oil Company (Aramco) Consortium (“STAR” and “Snamprogetti Saudi Arabia”) All organizations selected and awarded by CONTRACTOR to supply a 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 the WORK. “Maintain Potential Facilities Long Term Agreement Agency supplying the material as specified and required by the contractor

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 Systems) Test Report

ICSS TR

UNCONTROLLED COPY

This document is CONFIDENTIAL and the sole property SAIPEM/SNAMPROGETTI/STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those for which it was 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 PROCEDURE

Rev. B

Date: 23-07-2017 Sheet 5 of 10

RTD

A set of measuring / control instruments including intermediate junction boxes, marshalling cabinets, control systems (hardware and software), 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 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. Resistance Temperature detector.

MCC

Motor Control Centre

MOV

Motor Operated valve

PSD

Process Shut Down

SDV

Shut Down Valve

Loop

Loop Diagram

3.

REFERENCE RULES, CODES AND STANDARDS

3.1

CODES AND STANDARDS

Document Number ISO 9001:2008 ISA IEC ANSI NEMA NFPA 70 - 2008 SAES-J-002 SAES-J-100 SAES-J-200 SAES-J-300 SAES-J-400 SAES-J-700 SAES–J-601 SAES-J-902 SAES-P-111 3.2

Title Quality management system – Requirements International society of Automation International Electro-Technical Commission American National Standards Institute National Electrical Manufacturers Association National Fire Protection Code (NEC) Technically Acceptable instruments Process Flow metering Pressure Level Temperature Control Valves Emergency shutdown and isolation systems. Electrical System for Instrumentation Grounding

COMPANY DOCUMENTS

Document Number CRPO’ DE-119890

Title Scope of work standards Instrument and Control System Installation

UNCONTROLLED COPY

This document is CONFIDENTIAL and the sole property SAIPEM/SNAMPROGETTI/STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those for which it was 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 PROCEDURE

Rev. B

Date: 23-07-2017 Sheet 6 of 10

DE-119957 DE-119885 DE-930526 SATIP; SAIC & SATR Schedule “Q” 3.3

Procedure for Diving Safety Requirements Procedure for Quality Assurance and Quality Control Mechanical Completion Check List and Performance Acceptance and Testing Saudi Aramco ITPs ; Checklists & Test Reports Quality Requirements

CONTRACTOR DOCUMENTS

Document Number 00-C-C-00-ST-P-QA-00-049

4.

Title Procedure for field Instruments Calibration Verification

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.

UNCONTROLLED COPY

This document is CONFIDENTIAL and the sole property SAIPEM/SNAMPROGETTI/STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those for which it was 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 PROCEDURE

Rev. B

Date: 23-07-2017 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.

UNCONTROLLED COPY

This document is CONFIDENTIAL and the sole property SAIPEM/SNAMPROGETTI/STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those for which it was 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 PROCEDURE

Rev. B

Date: 23-07-2017 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

UNCONTROLLED COPY

This document is CONFIDENTIAL and the sole property SAIPEM/SNAMPROGETTI/STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those for which it was 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 PROCEDURE

Rev. B

Date: 23-07-2017 Sheet 9 of 10

6.

•

Analog Output from ICSS

•

Digital Output from ICSS

•

Fire and Gas Systems

•

Motor Control Centre

•

Vibration / Condition Monitoring Systems

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) 6.2

Instrumentation materials manufacturer instructions.

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

UNCONTROLLED COPY

This document is CONFIDENTIAL and the sole property SAIPEM/SNAMPROGETTI/STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those for which it was 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 PROCEDURE

Rev. B

Date: 23-07-2017 Sheet 10 of 10

7.

ATTACHED LOOP PACKAGE CONTENTS SAMPLE FORMAT

UNCONTROLLED COPY

This document is CONFIDENTIAL and the sole property SAIPEM/SNAMPROGETTI/STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those for which it was prepared.