DEP SPECIFICATION

INSPECTION AND FUNCTIONAL TESTING OF

INSTRUMENTS
Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale

DEP 62.10.08.11-Gen.

February 2021

DESIGN AND ENGINEERING PRACTICE

DEM1

© 2021 Shell Group of companies

All rights reserved. No part of this document may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 2

PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the information
set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely respons ble for such use, including the quality
of their work and the attainment of the required design and engineering standards. In particular, for those requirements not
specifically covered, the Principal will typically expect them to follow those design and engineering practices that will achieve
at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without
detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of a
Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which
requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply
with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever
as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part
thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The benefit of
this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these companies,
that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not,
without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the DEPs
shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use,
including any copies which shall only be made by users with the express prior written consent of Shell GSI. The copyright of
DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell GSI may at any
time require information satisfactory to them in order to ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 3

TABLE OF CONTENTS
1. INTRODUCTION ...............................................................................................4
1.1 SCOPE ..............................................................................................................4
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY
CONSIDERATIONS...........................................................................................4
1.3 DEFINITIONS ....................................................................................................5
1.4 CROSS-REFERENCES ....................................................................................8
1.5 SUMMARY OF MAIN CHANGES......................................................................8
1.6 COMMENTS ON THIS DEP ..............................................................................8
1.7 DUAL UNITS......................................................................................................8
1.8 NON NORMATIVE TEXT (COMMENTARY) .....................................................9
2. GENERAL REQUIREMENTS..........................................................................10
3. PROCESS AUTOMATION SYSTEM FAT ......................................................10
3.1 GENERAL ........................................................................................................10
3.2 REVISION CONTROL .....................................................................................10
3.3 REMEDIATION ................................................................................................10
3.4 ALARMS AND ALERTS ..................................................................................10
3.5 SECURITY .......................................................................................................11
3.6 SYSTEM PERFORMANCE .............................................................................11
4. INTEGRATED FAT ..........................................................................................11
5. SITE ACCEPTANCE TESTING.......................................................................11
6. WORKSHOP, TOOLS AND TEST EQUIPMENT ............................................12
7. PRE-INSTALLATION INSPECTION................................................................12
7.1 GENERAL ........................................................................................................12
7.2 INSTRUMENT CALIBRATION ........................................................................12
8. POST-INSTALLATION INSPECTION .............................................................12
9. PRE-LOOP CHECK .........................................................................................13
10. LOOP CHECK .................................................................................................13
11. FULL FUNCTION TESTING ............................................................................14
12. HYDROTEST AND LINE FLUSHING SUPPORT ACTIVITIES ......................14
12.1 GENERAL ........................................................................................................14
12.2 DEVICES THAT REQUIRE ISOLATION/REMOVAL PRE-TEST ...................15
12.3 POST-HYDROTEST AND LINE FLUSHING ACTIVITIES ..............................15
13. PROCESS TUBING LEAK TEST ....................................................................15
14. PRE-START-UP ACTIVITIES..........................................................................15
15. REFERENCES ................................................................................................16

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 4

1. INTRODUCTION
1.1 SCOPE
This DEP specifies requirements and gives recommendations for inspection and testing of
instruments and systems. This DEP applies to new and modified instruments and systems,
before and after installation. It also covers requirements for storage and hydrotesting of
instrumentation systems in the field. It defines activities and requirements to confirm that
instrumentation conforms to the Principal's requirements and is installed and functioning
according to the approved engineering/construction drawings and data.
This DEP also addresses the development of a Quality Plan for instrumentation.
The following stages of activities are covered in this DEP:
o Factory Acceptance Test (FAT) and Site Acceptance Test (SAT);
o pre-installation inspection;
o post-installation inspection;
o pre-loop check;
o loop check;
o full function testing;
o hydrotest and line flushing support activities;
o process tubing leak test;
o pre-start-up activities.
This DEP contains mandatory requirements to mitigate process safety risks in accordance
with Design Engineering Manual (DEM) 1 - Application of Technical Standards.
This is a revision of the DEP of the same number dated February 2019; see (1.5) regarding
the changes.
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS
Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them. Any authorised access to DEPs does not for that reason constitute an
authorization to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to oil and gas production, gas handling, oil
refining, chemical processing, gasification, distribution and supply/marketing. This DEP may
also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process shall be implemented;
this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to the safety, environmental, economic and legal aspects. In all
cases, the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 5

1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The capitalised term SHALL [PS] indicates a process safety requirement.
The word should indicates a recommendation.
The word may indicates a permitted option.
1.3.2 Specific definitions
The following definitions are specific to this DEP.

Term Definition

Calibration Adjustment of an instrument's ZERO and SPAN by observing the changes

in its output caused by manual changes to its input. Both the input and
output signals are monitored with test equipment that is more accurate
than the instrument being calibrated. Calibration also includes setting
switch set points by using test equipment.

Calibration Testing of an instrument’s calibration during the pre-loop and loop check
Check processes. This is done with test equipment monitoring the instrument’s
inputs and outputs.

Commissioning, Putting into service the Foundation Fieldbus devices, and downloading the
Foundation offline configuration to these devices. Electronically, the device is placed
Fieldbus into service, and could still require operational activation as part of the
Process Commissioning and Startup.

Configuration Manual or bulk entry of engineered parameters or programs into a

microprocessor-based device (e.g., Foundation™ Fieldbus device).

Configuration Data transfer of engineered parameters or programs from an electronic file

Download into a microprocessor-based device (e.g., Configuring a Foundation™
Fieldbus or HART® device from a portable PC or DCS Data Management
System).

Equipment Single or combined units of equipment supplied by a Supplier which

Package include instrumentation or to which instrument requirements could apply.

Factory A set of predefined test procedures conducted at the

Acceptance Test Manufacturer/Supplier's works after the system has been assembled, and
(FAT) before the system is shipped to Principal’s site. The FAT is when the
system is demonstrated to meet the functional, integrity and performance
requirements. It is not the tests that the Manufacturer/Supplier is expected
to carry out prior to the visit by the Principal for the FAT.

Field Inspection Verifying that field instruments are installed and configured according to
the Principal's requirements.

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 6

Fieldbus Digital, two-way, multi-drop communication link among intelligent

measurement and control devices. It serves as a local area network (LAN)
for advanced process control, remote input/output and high speed factory
automation applications.

Fire and Gas The fire and gas system includes the following components:
System • Detectors (fire, smoke, flammable and toxic gas, acoustic leak);
• A logic solver;
• Panel(s);
• Human Machine Interface in a manned control centre, and where
appropriate a second HMI at mustering point (where mustering point is
in different location) or Emergency Response Centre if separate from
control centre;
• Direct outputs, such as fire suppressants, audible and visible alarms;
• Interfaces to other systems, e.g., SIS, DCS;
• FGS Engineering Station.

Function Test Simulation of the transmitter process variable input to demonstrate the
operation of the loop. Control valves are function tested in a similar manner
by manually moving the appropriate controller output and observing the
actual valve position. A function test is not a calibration check.

HART® The Highway Addressable Remote Transducer Protocol (HART) is a digital

industrial automation protocol and is considered a de-facto standard for
digital communications with 4-20 mA smart process instrumentation.

Human Machine The combination of software and hardware elements that determine the
Interface (HMI) nature of human interactions with equipment and people in the workplace
span of control through command inputs and data outputs. The HMI
includes both visual and audio interfaces.

Inputs and Inputs and Outputs to a system (e.g., package control system or integrated
Outputs (I/O) control system). Typical I/O types include 4–20 mA analog input/output,
24 VDC discrete input/output, and are to/from field instrumentation or other
systems.

Inspection of Verification that instruments and instrument systems comply with

Instruments requirements.

Instrument Asset DCS-based asset management system that facilitates configuration,

Management diagnostics and troubleshooting on Smart field devices.
System (IAMS)

Instrument Loop Several instruments that are pneumatically, electronically or software

connected to provide control, indication, alarm, or shutdown function.

Instrument PLC Systems, Instrumented Protective Systems, Tank Gauging Systems,

System or Complex Control Loops that contain more than one instrument loop.

Integrated A FAT that includes 3rd party systems not supplied by the
Factory Manufacturer/Supplier that hosts the FAT and that aims to demonstrate
Acceptance Test correct functioning of interfaces to these 3rd party systems.
(IFAT)

Loop Check Procedure used to demonstrate proper operation of an instrument loop for
formal acceptance of the loop by QA/QC.

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 7

PLC Programmable Logic Controller – a microprocessor based control system

that is customarily used to perform complex, discrete switching logic.

Pre-Loop Check Procedure used to identify/solve problems prior to the loop check.

Process Process Automation System – consisting of the process control system

Automation (DCS), SIS and FGS. Also known as Industrial Automation Control System
System (PAS) (IACS)

Process Operational activation of instruments and instrument systems under

Commissioning operating conditions. It often includes handing over the instruments and
and Start-up systems for continued use to the operating and maintenance departments.
Activities This activity also includes the tuning of control loops, seal liquid filling of
impulse lines, commissioning of Advanced Process Control (APC), surge
and condition monitoring applications and final adjustment of settings for all
items.

Redundancy Use of multiple elements or systems to perform the same function;

redundancy can be implemented by identical elements (identical
redundancy) or by diverse elements (diverse redundancy).

Safety Instrumented system used to implement one or more SIFs.

Instrumented (Ref. IEC 61511) A SIS is composed of any combination of sensors, logic
System (SIS) solvers, and final elements. It also includes communication and ancillary
equipment (e.g., cables, tubing, power supply, impulse lines, heat tracing).
A SIS can include software.
A SIS can include human action as part of a SIF (see ISA
TR84.00.04:2015, part 1).

Site Acceptance A set of predefined procedures conducted at a job site after the system has
Test (SAT) been reassembled, and sometimes with testing of modifications to the
software tested at FAT. For this document, SAT includes all system testing
and verification prior to start of loop check. Sometimes referred to as the
SIFT (Site Integration Functional Test).

Work Pack A group of post-FAT software and/or hardware changes organized into a
single package for purposes of identification, tracking and subsequent
implementation and testing after FAT is complete.

1.3.3 Abbreviations
The following abbreviations are specific to this DEP.

Term Definition

DCS Distributed Control System. Also referred to as BPCS (Basic Process Control
System).

SIF Safety Instrumented Function (previously referred to as IPF in Shell DEPs)

SIS Safety Instrumented System

SRS Safety Requirements Specification

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 8

1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets ( ). Other documents referenced by this DEP are listed in (15).
1.5 SUMMARY OF MAIN CHANGES
This DEP is a revision of the DEP of the same number dated February 2019. This is an
administrative update only to align the layout of this DEP to a new publishing application.
The February 2018 revision of this DEP represents the most recent major update, and the
following were the main non-editorial changes:

Section/Clause Change
All Extensive rewrite to remove guidance and re-focus on essential
clauses.
SHALL [PS] requirements have been removed where they
duplicate SHALL [PS] requirements in other DEPs.
Previous 4 Removed SHALL [PS] from 4.1.2, 4.1.3. SHALL [PS] for SAT
moved from old 4.3 to new section 5. Two other SHALL [PS] in
old 4.3 removed.
Previous 11 Eight SHALL [PS] requirements consolidated into four
requirements in new sections 10 and 11.
Previous 15 SHALL [PS] removed as no longer justified

1.6 COMMENTS ON THIS DEP

Comments on this DEP may be submitted to the Administrator using one of the following
options:

Shell DEPs Online Enter the Shell DEPs Online system at

(Users with access to https://www.shelldeps.com
Shell DEPs Online) Select a DEP and then go to the details screen for that
DEP.
Click on the “Give feedback” link, fill in the online form and
submit.
DEP Feedback System Enter comments directly in the DEP Feedback System
(Users with access to which is accessible from the Technical Standards Portal
http://sww.shell.com/standards.
Shell Wide Web)
Select “Submit DEP Feedback”, fill in the online form and
submit.
DEP Standard Form Use DEP Standard Form 00.00.05.80‑Gen. to record
(other users) feedback and email the form to the Administrator at
standards@shell.com.

Feedback that has been registered in the DEP Feedback System by using one of the above
options will be reviewed by the DEP Custodian for potential improvements to the DEP.
1.7 DUAL UNITS
This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When agreed
by the Principal, the indicated USC values/units may be used.

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 9

1.8 NON NORMATIVE TEXT (COMMENTARY)

Text shown in italic style in this DEP indicates text that is non-normative and is provided as
explanation or background information only.
Non-normative text is normally indented slightly to the right of the relevant DEP
clause.

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 10

2. GENERAL REQUIREMENTS
1. A Quality Plan for the inspection and functional testing of instruments shall be prepared
in accordance with ISO 9000, or equivalent.
3. PROCESS AUTOMATION SYSTEM FAT
3.1 GENERAL
SIS (including FGS) FAT requirements (covering hardware and application program) are
detailed in DEP 32.80.10.10-Gen., Section 8.
1. A factory acceptance test (FAT) plan shall be developed for the process automation
system (PAS) and subject to approval by the Principal.
2. System configuration and performance requirements shall be verified against design
documentation and standards.
3. All testing documents shall be signed off and dated once satisfactory operation is
demonstrated.
4. If alarm management software is installed, this shall be included in the FAT scope.
3.2 REVISION CONTROL
For software changes to cause and effect shutdown logic or trip set points, refer
DEP 32.80.10.10‑Gen., Section 8.
1. The Manufacturer/Supplier shall have a revision control process for revision approvals
and implementation tracking that includes maintaining backups of all application
software.
2. The revisions of all documents shall be recorded in the FAT test report.
3. Prior to every download of application program to a processor, regardless of whether
on-line or off-line changes are made, a backup shall be made of the existing application
program, including tuneable or variable parameters.
4. Tuneable parameters set in the running application software (e.g., alarm levels, PID
tuning) shall be daily backed-up.
3.3 REMEDIATION
1. The Manufacturer/Supplier shall have a remediation plan in place that includes
generation of a full and complete non-conformance report (NCR) for incomplete tests
or identified deficiencies.
a. The NCR list shall be maintained and updated as remedial actions are completed.
2. The Manufacturer/Supplier shall agree with the Principal the classifications for
deficiencies prior to the start of the testing.
3.4 ALARMS AND ALERTS
DEP 32.80.10.14‑Gen. details alarm system design and implementation requirements.
1. All alarm and alert configuration shall be tested to confirm it has been completed as per
design documentation and standards, including the following aspects:
a. Prioritization;
b. Grouping;
c. Filtering;
d. Suppression;
e. Audible tones;
f. Acknowledgement and silencing.

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 11

2. Proper alarm handling shall be demonstrated through simulation.

3.5 SECURITY
1. All process control domain security features shall be verified to confirm they are
correctly configured to meet the requirements of DEP 32.01.20.12‑Gen. and other
relevant design documentation.
3.6 SYSTEM PERFORMANCE
The system performance requirements are defined in the design documentation and
standards.
1. All aspects of system performance shall be verified and recorded on the complete
system, including the following:
a. Processor loading and free memory;
b. Network Loading (e.g., bandwidth utilization);
c. Execution time of tasks of all priorities;
d. HMI graphics call-up time;
e. Response time to commands from HMI;
f. Server loading and response time;
g. Alarm manager capacity and response time;
h. Historian loading and response time;
i. Time synchronization;
j. Alarm and alert synchronization of rebooted operator HMI stations;
k. Alarm or event time stamping from third party interfaces.
4. INTEGRATED FAT
1. An integrated FAT (IFAT) shall be performed to test the interfaces across the following:
a. DCS;
b. SIS;
c. IAMS;
d. other systems (e.g., electrical motor manager, rotating machine monitoring
systems, AMADAS, package units, flow computers);
e. field devices.
2. The interface between the systems shall be tested for the following:
a. functionality;
b. redundancy (if available);
c. fault diagnostics.
3. Interface and integration testing shall be performed with project application
configurations, databases and software.
5. SITE ACCEPTANCE TESTING
SIS (including FGS) SAT requirements are detailed in DEP 32.80.10.10-Gen., Section 10.
Additional, specific SAT requirements for F&G systems are detailed in
DEP 32.30.20.11-Gen.
1. Site Acceptance Testing (SAT) SHALL [PS] be conducted for Safety Instrumented
Systems (SIS) and for Fire and Gas Systems (FGS).

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 12

2. Application program modifications as defined by post-FAT work packs shall be tested

during SAT.
3. SAT scope shall include PAS power supplies (as supplied with the system), and
verification of correct functioning of redundancy between them.
4. Prior to commencement of the SAT, all hardware, software, and documentation punch
lists from FAT shall have been resolved and accepted by the Principal.
5. All configuration or interface to other systems that could not be tested at FAT, IFAT or
SAT shall be listed on a punch list for completion before the start of the loop check.
6. WORKSHOP, TOOLS AND TEST EQUIPMENT
1. All test equipment required to perform configuration, calibration, and loop checks of
instrumentation shall meet the following:
a. be calibrated in the units of measurement selected for the project;
b. be calibrated against maintained standard master test equipment;
c. be traceable to a primary standard certified by an accredited laboratory;
An accredited laboratory can be recognised by its certificate of accreditation
which is awarded by a national or international standards body.
d. have an accuracy of at least twice better than the required measurement accuracy
(e.g., “tolerance class” as defined in DEP 32.31.00.32‑Gen.) of the instrument to
be tested.
7. PRE-INSTALLATION INSPECTION
7.1 GENERAL
1. The Project Quality Assurance/Control system shall have a process in place that
oversees all of the following:
a. implementation of pre-installation inspection;
b. recording of the results;
c. tracking of corrective actions for discrepancies found during pre-installation
inspection, including authorised signatories.
2. A full inspection of instrument system cabinets shall be carried out prior to installation,
to assess any damage during transport.
7.2 INSTRUMENT CALIBRATION
Workshop or field calibration (verification and adjustment) is not normally required for smart
instruments.
1. Each instrument that is to be calibrated shall have its input simulated with a test
instrument.
2. The calibration of the first of each make and model of instrument shall be subject to
witnessing by the Principal’s QA Inspector.
8. POST-INSTALLATION INSPECTION
1. The latest revisions of all construction drawings and data, relevant DEPs and
procedures as specified in the agreed Quality Plan shall be utilised for inspection and
loop testing.
a. Any changes to these documents resulting from either the construction activity or
engineering design shall be controlled by a change procedure.
2. Every instrument shall be inspected (100% QC) post installation.

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 13

3. Post-installation inspection shall be done after the following:

a. instruments have been installed;
b. connections for process tubing, air supply tubing, and signal tubing have been
made;
c. conduit/wire has been installed/terminated.
4. Instruments and accessories shall be visually inspected for damage.
5. Transmitters shall be verified to be installed with the process isolation valves closed,
and instrument manifold valves and vent plugs open to isolate from the main process
line in preparation for piping hydrotest.
6. All instrument devices shall be verified to be installed and permanently tagged
according to the project specification, and in the correct process location.
7. Temporary shipping restraints, stops, and plugs shall be removed from instruments.
8. Glass components shall be cleaned.
9. Equipment racks shall be inspected to verify that they have been properly installed,
grounded, and tagged.
10. Tubing connections shall be connected and tightened in accordance with
recommendations of the tube fitting Manufacturer/Supplier.
11. Tubing that has scars (e.g., from a tube cutter or knife) shall be replaced.
12. Instrumentation on equipment packages shall be inspected.
13. Temporary protective covers shall be used at all instrument and control valve
connection openings (i.e., piping, tubing, and electrical) in the following cases:
a. after installation, but prior to hook-up;
b. whenever instrumentation is temporarily removed for construction activities.
Tape alone is not an acceptable temporary cover or seal.
14. Special identification techniques for selected instruments (e.g., red labels for SIF
components) shall be verified against the project specifications.
9. PRE-LOOP CHECK
1. A pre-loop check procedure shall be established describing the activities required to
make equipment ready for loop checking after completion of the post installation
inspection.
2. The pre-loop check procedure shall include the following:
a. instrument confiuguration and calibration;
b. Testing of the loop functionality of HART®, Fieldbus and communication with the
IAMS.
10. LOOP CHECK
1. A loop check shall demonstrate proper loop operation for formal acceptance of the
loop.
2. Loop checks shall be carried out on all loops, including Equipment Package instrument
loops.
3. Wiring terminations within a junction box shall be complete before any loops that have
signals going through that box are loop checked.
4. The loop check shall include the following:
a. verification that related device diagnostic data is healthy in the Instrument Asset
Mangement System (IAMS);

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 14

b. verification of proper switch contact action on loss of power.

5. The loop check SHALL [PS] functionally verify all components of the SIF against the
purchase specification and the Safety Requirements Specification (SRS).
This includes specific travel/stroke times as shown on the requisition/datasheet or
SRS.
The SRS is required by IEC 61511-1, see also section 5 of DEP 32.80.10.10‑Gen.
Loop components include all field instruments, control and actuated valves, plus any
other components necessary to achieve the loop function.
6. Loop tests shall be subject to witnessing by the Principal’s QA Inspectors.
7. Following completion of loop testing, any forces or overrides that were required to
implement the testing shall be removed or reset.
8. The write protection for smart transmitters connected to the SIS, where provided, shall
be reinstated at the end of the loop function test, to lock the transmitter for
configuration changes.
a. Refer to DEP 32.80.10.10‑Gen., clause 6.3.3.1, 6.
9. At the end of a successful loop check, copies of the loop acceptance punch list shall be
submitted to the Principal for record.
11. FULL FUNCTION TESTING
The requirements for end to end testing of SIFs are covered in DEP 32.80.10.10‑Gen.,
Section 10, which references IEC 61511-1, Section 15. This enables some credit to be
taken for FAT with respect to the SIS application program, and thus the logic pertaining to
each individual SIF. The requirements in this section are supplementary.
1. All SIFs SHALL [PS] be subject to full function testing, including the following:
a. simulate the process input at the sensors;
b. all potential combinations of voted sensors;
c. all final elements.
2. Where the final element of a SIF is a valve driven by solenoids or similar, all
combinations of voted solenoids shall be tested, each being shown at least once to
successfully move the final element to the safe state.
3. Fire and gas detection devices shall be loop tested through to the SIS inputs, including
a verification of correct operation of all voting logic (e.g., 1ooN per zone alarm, 2ooN
per zone trip).
4. The correct operation of each of the following SHALL [PS] be verified, via simulating
(e.g. with test gas or IR source) at the sensors, and verifying full operation of all final
elements:
a. confirmed fire or gas event, per fire zone and overall;
b. plant shutdown and depressuring functions, per fire zone and overall.
5. All input/output forces (including jumpers) and logic overrides SHALL [PS] be removed
at the end of the full function testing before handover to operations.
12. HYDROTEST AND LINE FLUSHING SUPPORT ACTIVITIES
12.1 GENERAL
If piping hydrotesting and line flushing have been completed prior to instrument installation,
the procedures in (12.2) are not required.
1. All instruments to be removed for piping hydrotesting/flushing shall be identified on a
register list.

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 15

a. These instruments shall be tagged “Must be Removed for Hydrotest/Flushing”

prior to installation.
2. Transmitter impulse tubing shall not be tested during piping hydrotests, but as part of
process tubing leak test (13).
12.2 DEVICES THAT REQUIRE ISOLATION/REMOVAL PRE-TEST
1. Prior to hydrotest/flushing all on-line transmitters shall have their root valves closed,
with instrument manifold valves and vent/drain connection open.
2. During line flushing, the following instruments shall not be installed:
a. valves with a noise control trim;
b. valves with a cavitation trim;
c. valves with a leakage class V or higher;
d. Vortex meters;
e. Coriolis meters;
f. all insertion type flow meters.
12.3 POST-HYDROTEST AND LINE FLUSHING ACTIVITIES
1. Instruments shall be returned to their pre-hydrotest condition once the piping hydrotest
and line flushing activities are completed.
2. When instruments are disconnected during piping hydrotest, then these instruments
shall be retested after reinstallation.
13. PROCESS TUBING LEAK TEST
For requirements for tubing leak testing see DEP 74.00.10.10‑Gen.
1. A leak test procedure for process tubing shall be prepared and agreed with the
Principal.
a. The leak test procedure shall be used to test for leaks in instrument steam tracing.
2. Impulse tubing test shall check tubing for leaks to atmosphere by soaping (snooping)
fittings.
3. The instrument portion of a pressure test shall include a complete soaping of the root
valve body that is under test pressure.
14. PRE-START-UP ACTIVITIES
1. The allocation of responsibilities for commissioning and start-up activities shall be
established early in the Execute phase.
2. When mechanical equipment is handed over for commissioning and for start-up, the
associated instrumentation shall be handed over at the same time.
3. Before handover for commissioning or start-up, all instrumentation punch list items
shall be complete.
4. When handing over for commissioning or start-up, instruments shall be left in the
following state:
a. DCS/PLC powered up;
b. Power on to field instruments;
c. Air supplies to instruments on;
d. Controllers in manual with the valves in the failed position;
e. Main (pipe) block valves, to instrument lead lines, closed.

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31
 DEP 62.10.08.11-Gen.
February 2021
Page 16

15. REFERENCES
In this DEP, reference is made to the following publications:
Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
SHELL STANDARDS

DEP 00.00.05.80-Gen. DEP feedback form

DEP 32.01.20.12-Gen. IACS security

DEP 32.30.20.11-Gen. Fire, gas and smoke detection systems

DEP 32.31.00.32-Gen. Instruments for measurement and control

DEP 32.80.10.10-Gen. Safety Instrumented Systems

DEP 32.80.10.14-Gen. Alarm management

DEP 74.00.10.10-Gen. Shop and field pressure testing of piping systems

DEM1 Shell HSSE & SP Control Framework, Design Engineering Manual

(DEM) 1 - Application of Technical Standards

INTERNATIONAL STANDARDS

IEC 61511 Functional safety – Safety instrumented systems for the process
industry Part 1: Framework, definitions, system, hardware and
software requirements; Part 2 Guidelines for the application; Part
3: Guidance for the determination of the required safety integrity
levels - First Edition

ISO 9000 Quality management - Fundamentals and vocabulary

This document has been supplied under license by Shell to:

Petroleum Development Oman Haitham.HM.Musalhi@pdo.co.om 07/09/2022 13:30:31