FAIL N/A

Vendor Manuals
and test
procedures
Vendor Manuals
and test
procedures
Vendor Manuals
and test
procedures
RE-TEST DATE
A Works Inspection
The pressure shall be reduced in 25% steps as in A 7( above) again
noting the corresponding spindle position.
Vendor Manuals
and test
procedures
A11
The control valve shall be checked to ensure the correct action on air
failure.
Vendor Manuals
and test
procedures
A10
The control valve shall be re-stroked as in Items A 7 and A 8 (above)
simulating an input to the valve positioner in steps of 25% of range. The
positioner output shall be adjusted to obtain the correct spindle position.
Vendor Manuals
and test
procedures
A 7
The valve diaphragm shall be loaded with rising actuating pressure
equivalent to 0, 25, 50, 75 and 100% of the valve storke noting the
corresponding positions of the spindle on the position indicator. The
diaphragm pressure shall be increased to 110% to ensure the spindle is
fully raised.
Vendor Manuals
and test
procedures
A6 Calibration shall take place before installation.
ITEM
No.
TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE PASS
The position of the spindle shall be checked to ensure that pressures
applied to the diaphragm compare to those specified in the "bench set"
condition. The spring shall be adjusted to attain the correct starting
points.
A1 Ensure that actual field installation is completed in all aspects .
SAEP-16
Sec. 4.1.13
Vendor Manuals
and test
procedures
A2
A3
Ensure the following:
a) The Valve trim is correct
b) The valve action is correct i.e. air to open /close.
c) Where specified a valve positioner is fitted.
d) Lubricators are installed and charged with the correct lubricant.
Vendor Manuals
and test
procedures
A4
The installation Record sheets to be verified and formed as part of loop
folder
A5
A8
The valve should take up the same position, within 5% in both stroking
directions. If these limits are not met the actuator should be checked for
suction and adjustments made in accordance with the manufacturer's
instructions.
A9
Where control valves have positioners fitted, the control valve shall be
further calibrated with the positioner "On-Line". The positioner shall be
checked to ensure the correct "action" prior to stroking the valve.
Vendor Manuals
and test
procedures
A8
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
1-Oct-05 INST
WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
SATR-J-6512
PLANT NO. EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID.
LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.
TRAVEL TIME
SAUDI ARAMCO USE ONLY
SCHEDULED TEST DATE & TIME ACTUAL TEST DATE & TIME QUANTITY INSP. MH's SPENT
SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?
SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL
Instrument Loop-Outputs-Hydraulic /Pneumatic Control
Valve Test
PROJ ECT TITLE
Initial checking of the valve shall be carried out with the positioner in "By-
pass" mode.
Vendor Manuals
and test
procedures
SAUDI ARAMCO TIP NUMBER
Page 1 of 5
NOTES:
Manufacture's special Test Procedures if any, to be confirmed and verified apart from the following:
POSITIONER PROCEDURE
(a) When control valve bench setting is complete reconnect positioner and all air supplies and control signals (3-15 psi or 4-20 mA) tubing.
(b) 1) For a Smart or electronic positioner connect a 4-20 mA signal.
2) For a pneumatic positioner connect an appropriate air supply and connect with Test
Gauge.
(c) The action of the positioner will be checked against specifications(Direct/Reverse) and connected where necessary.
(d) The valve is then stroked but this time the signal goes through the positioner and any adjustments to be made will be done on the
positioner with reference to the positioner manufacturers instructions.
(e) The time for stroking the valve is then recorded where applicable.
(f) Other devices such as lock up ,SOV, Limit switches and all other ancillary devices will also be checked during this procedure
(g) Perform all other inspection tests that are required by the calibration sheet
(h) After this is completed turn off power supply. Disconnect all wiring and replace cover tightly.
(i) All connections are to be sealed to prevent ingress of solid particles or moisture.
(j) The Valve and the positioner will then be tagged as calibrated with a blue calibration label.
(k) Sign off calibration sheet.
(l) Instrument calibrations will be repeated where necessary during pre-commissioning or at any other stage where deficiencies are to be rectified
14. Test Procedure - Control Valve Test
5. SAEP-1636 Installation and Checkout Plan , 28 February, 2005
6. SAEP-1638 Site Acceptance Test Plan, 30 April, 2002
1. Schedule G -- Material, Tools and Equipment (Pro Forma MP-IK-LS Contract), J uly 1993
2. Schedule Q Attachment IV, Control of Monitoring and measuring devices Sec 6 & 7. (Pro Forma Contract), November 2003
3. SAES-J -700, Control Valves, 31 August 2004
4. SAEP-16- Project Execution Guide for Process Automation Systems,31 May 2003
ITEM
No.
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE
Attachment 1-: Control Valve Pre-Calibration Inspection
8. 34-SAMSS Electric Motor Operated Valve Actuators, 31 December , 2003
Manufacturer's test routines to be followed and calibration's to be be confirmed within tolerance limits:

(a) Valve will be checked against specifications.
(b) The Valve will be checked in the installed position using applicable method.
(c) The air signal and a Certified test Gauge shall be tee in to the actuator of the Control valve. Where a positioner is present it shall be by-passed for
this bench-setting
(d) Bench setting of the Control Valve shall be carried out according to Manufacturers recommendation.
(e) The valve is stroked through positions 0 and 100 % and the corresponding adjustments are made where necessary and indication noted. If
necessary adjust the valve/ diaphragm stop to meet the distance indicated on the specification sheet.
(f) Note Reverse action in the remarks section of the calibration sheet.
(g) Where required the stroking time is noted and recorded.
(h) Air failure action is checked and recorded.
(i) Where limit switches are present these are checked during this procedure.
(j) When all tests are completed reconnect positioner if one is present.
PASS FAIL N/A RE-TEST DATE
27. REFERENCE DOCUMENTS
Attachment 2 -- CONTROL VALVES CALIBRATION AND LEAKAGE TEST
7 34-SAMSS-711, Control Valves -General Services, 31 March 2003
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
Instrument Loop-Outputs-Hydraulic /Pneumatic Control
Valve Test
SATR-J-6512 1-Oct-05 INST
A12
Control valves shall open fully when they are subjected to an input signal
to open greater than 99 % and close fully when the input signal to close
is less than 1 %.
Vendor Manuals
and test
procedures
Attachments:
A13
The results shall be recorded on Form (Attachment -2) and the valve
colour coded.
Vendor Manuals
and test
procedures
Page 2 of 5
ITEM
No.
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
Instrument Loop-Outputs-Hydraulic /Pneumatic Control
Valve Test
SATR-J-6512 1-Oct-05 INST
4. Labeled - Equipment or materials to which has been attached a label, symbol, or other identifying mark of an approved qualified organization
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
Work Verified
Saudi Aramco
with product evaluation, that maintains periodic inspection of production of labeled equipment or materials, and by whose labeling the
PMT Representative
T&I Witnessed QC Record Reviewed
Technician Performing Test*
Name, Title, Department,
Company, Initials and
Date:
Test Performed Successfully and Results are Acceptable:
QC Supervisor Proponent and Others
Contractor / Third-Party
1. Approved - Acceptable to the authority having jurisdiction (i.e., Saudi Aramco ID).
QC Inspector PID Representative
Name, Initials and Date:
QC Record Reviewed
Name, Sign and Date:
Quality Record Approved:
Name, Organization,
Initials and Date:
T&I Witnessed QC Record Reviewed
Work Verified
indicates compliance with appropriate standards or performance in a specified manner.
Work Verified
Y =YES N =NO F =FAILED *Person Responsible for Implementation of Test and Analysis of Results
Name, Initials and Date:
Witnessed Test Work / Rework May Proceed
Name, Initials and Date:
T&I Witnessed
Page 3 of 5
Solenoid Valve Correct
Pneumatic / Electric Connections correct
General Condition Correct
Signal Range Correct
Air Failure status Correct
Body Material Correct
Filter Regulator Correct
Volume Tank Correct
Shipping toppers removed and reinstalled after calibration wherever applicable
Limit Switches Correct
calibration test Equipment S.No Spring Rating Calibration expiry date
PURCHASE ORDER NUMBER Data Sheet No
CONTROL VALVES PRE- CALIBRATION INSPECTION
EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.
Technician Performing Test* PMT Representative
Manufacturer
Description
Calibration Inspection Remarks
Item No
S.No
Contractor / Third-Party Saudi Aramco
By-Pass Correct
Lubricators installed and changed
Actuator correct
Positioner Correct
PASS FAIL N/A RE-INSP DATE
QC Inspector PID Representative
Tag number Correct
QC Record Reviewed
INST
Attachment 1-: Control Valve Pre-Calibration Inspection
Instrument Loop-Outputs-Hydraulic /Pneumatic Control
Valve Test
SATR-J-6512 1-Oct-05
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
Name, Title, Department,
Company, Initials and
Date:
Test Performed Successfully and Results are Acceptable:
Name, Initials and Date:
T&I Witnessed Work Verified
Page 4 of 5
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
INST
Attachment 2 -- CONTROL VALVES CALIBRATION AND LEAKAGE TEST
Instrument Loop-Outputs-Hydraulic /Pneumatic Control
Valve Test
SATR-J-6512 1-Oct-05
0%
25%
50%
75%
75%
100%
50%
25%
PASS
0%
FAIL N/A RE-INSP DATE
calibration test Equipment S.No Spring Rating
Calibration Inspection Remarks
% INPUT
BAR /mA
BYPASS NORMAL
VALVE POSITION
BYPASS NORMAL
S.No PURCHASE ORDER NUMBER Data Sheet No
CONTROL VALVES CALIBRATION AND LEAKAGE TEST
PLANT NO. EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID.
Calibration expiry date
Manufacturer
LEAKAGE TEST TEST EQUIPMENT
VE
LEAKAGE
TEST
TEST MEDIUM TEST PRESSURE
MAX. LEAKAGE
RATE
ACTUAL LEAKAGE
RATE
PASS FAIL N/A RE-INSP DATE
Saudi Aramco
Technician Performing Test* PMT Representative
QC Inspector PID Representative
Name, Title, Department,
Company, Initials and
Date:
Test Performed Successfully and Results are Acceptable:
Name, Initials and Date:
T&I Witnessed QC Record Reviewed Work Verified
Contractor / Third-Party
Page 5 of 5