4-Construction QA QC-Instrumentation & Control

Construction QA/QC
Instrumentation and Control Systems
Rev. No. Rev. Date Description of Revision Revised by Approval

00 21/April/2016 New KIA
PROPRIETARY & CONFIDENTIAL

This document and the information contained herein is E2C proprietary know-how. This document or any part
therefore should not be reproduced stored in a retrieval system or transmitted by any means, electronic or
otherwise, or divulged without permission of E2C.
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INSTRUMENTATION AND CONTROL SYSTEMS DATE: April 21, 2016
TABLE OF CONTENTS
1. General ............................................................................................................................. 3
2. Acronyms.................................................................................................................... 4
3. Unpacking Inspection ................................................................................................. 4
4. Bench Test .................................................................................................................. 5
5. Inspection Prior to Installation ................................................................................... 6
6. Inspection after Installation ........................................................................................ 8
7. Power and Air Supply Checks .................................................................................... 9
8. Field Check and Calibration ....................................................................................... 11
9. Loop Test .................................................................................................................... 11
10. Line Up for Pre-Commissioning ............................................................................ 13
11. Loop Check Guidelines .......................................................................................... 33
TABLE
I Overall Plan for Inspection Test and Preparation or Recommissioning 15

for Instrumentation at site
II Unpacking Inspection 17
III Procedure Outline for Beach Test 18
IV Inspection Prior to Installation 21
V Inspection after Installation 24
VI Outline Procedure for Loop Test 26
VII Line-up for Pre-Commissioning 28
VIII Apparatus and Instrument for Calibration and Test 31
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1. General
1.1 This specification covers the basic test and inspection requirements for instrumentation.
Based on this specification, the construction contractor will prepare detailed inspection
procedure for instrumentation. The tests and inspection for instrument installation works,
vibrating monitoring system, analyzers, DCS, PLC and computer systems are not covered by
this specification. Test and inspection procedure for such items will be prepared by relevant
vendors.
1.2 Instruments undergo various tests during manufacturing, before installation and after
installation.
The overall instrument inspection plans are shown on attached Table I "Overall Plan for
Inspection, test and Preparation of Pre-commissioning of Instrumentation at Site".
1.3 Applicable documents

Reference is made in this specification to the following documents. The latest issues,
amendments, and supplements to these documents shall apply unless otherwise indicated.
Client Engineering Standards

Instrument Quality Assurance
1.4 Application
Sub-contractor or vendor shall submit an application for inspection of specified items to
contractor a day before the inspection date.
After checking, contractor shall submit the application for inspection to Client for the items
specified in this specification.
1.5 Witness inspection

Contractor and/or Client shall witness all tests and inspections.
Refer to Appendix-1 of SITE INSPECTION/TEST for items requiring presence of witness.
Construction contractor of Vendor shall record the inspection and test results and obtain the
signature of acceptance from Client and contractor on the inspection form.
1.6 The main apparatus and instruments for tests and inspection are shown in Table IX:
(Apparatus and instrument for tests and inspection).
The quantities and other materials shall be finalized by the subcontractor or Vendor according
to the project requirements. All test equipment must carry valid inspection certificate from a
recognized agency.
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2. Acronyms
BT Bench Test
UI Unpacking Instruction
PI Prior to Installation
SIS Safety Instrumented System
AI After Installation
SWB Switchboard
LT Loop Test
LU Line-Up
CMC Construction Management Contactor
3. Unpacking Inspection
3.1 General
All instruments, DCS equipment, miscellaneous equipment and other vendor supplied
equipment shall be checked in accordance with specifications and vendor's drawings for the
following items, on unpacking:
a. Damages caused by vibration, impacts, permeation of moisture, rain water, etc, during
transportation.
b. Name plates, Tag No., Service, Range
c. Accessories to be assembled
d. Disassembled accessories
e. Quantity
3.2 Unpacking inspection of instruments
Following instruments shall be inspected in accordance with attached Table II (Unpacking
Inspection):
Instrument Inspection No.
Orifice Plate UI-F1
Orifice Flange UI-F2
Meter Run UI-F3
Venturi Tube UI-F4
Pilot Tube(Annubar) UI-F5
Rotameter UI-F6
Positive Displacement Meter UI-F7
Tank Gauge (Mechanical) UI-L1
Level Gauge UI-L2
Thermocouple, RTD UI-T1
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Thermometer UI-T2
PCV (Regulator) UI-V1
Restriction Orifice UI-X1
3.3 Record
Results of inspection shall be recorded on "Inspection Record for Unpacking" (Appendix-2)
4. Bench Test
4.1 General
4.1.1 Bench test and calibration shall be undertaken at the site work shop after finishing the
unpacking inspection.
4.1.2 All scales shall be checked for range and graduations in accordance with specifications
and nameplate data.
4.2 Instruments to be tested and procedure outline

4.2.1 Following instruments shall be tested in accordance with attached Table III (Procedure
Outline for Bench Test):
Instrument Test No.

Differential Pressure Transmitter BT-F1
Turbine Meter BT-F2
Flow Switch BT-F3
Displacer Type Level Instrument BT-L1
Capacitance Type Level Instrument BT-L2
Tank Gauging System BT-L3
Pressure Transmitter BT-P1
Pressure Switch BT-P2
Pressure Gauge BT-P3
Draft Gauge BT-P4
Differential Pressure Gauge BT-P5
Temperature Transmitter BT-T1
Temperature Instrument (Filled System) BT-T2
Temperature Switch BT-T3
Control Valve BT-V1
Vibration Monitors BT-X1
Output Gauge (Electric) BT-X2
Detail Procedure for bench shall be prepared by the sub-contractor.
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4.2.2 As the performance tests of instruments are to be held at the manufacturer's shop,
emphasis shall be placed upon zero-point checks and/or span checks of the transmitters,
receiving instruments, etc. rather than indicating accuracy tests of the instruments against the
process variable.
4.2.3 Prior to bench test, it is necessary to confirm if the air source and/or power source
instruments are normal.
4.3 Record.
Results of tests shall be recorded on "INSPECTION RECORD FOR BENCH TEST
(INSTRUMENT) (APPENDIX-4)" and "INSPECTION RECORD FOR BENCH TEST
(VALVE) (APPENDIX-3)
5. Inspection Prior to Installation

5.1 General
The inline instruments and instruments mounted on equipment shall be checked prior to
installation.
5.2 Instrument to be inspected
Following instruments shall be inspected in accordance with attached Table IV (Procedure
outline for Inspection Prior to Installation):
Orifice Plate PI-F1
Orifice Flange PI-F2
Meter Run PI-F3
Venturi Tube PI-F4
Pilot Tube (Annuba) PI-F5
Rotameter PI-F6
Turbine Meter PI-F7
Positive Displacement Meter PI-F8
Orifice Flange PI-F9
Capacitance Type Level Instrument PI-L1
Tank Gauging System (Electric) PI-L2
Tank Gauge (Mechanical) PI-L3
Level Gauge PI-L4
Thermocouple, RTD PI-T1
Thermometer PI-T2
Control Valve PI-V1
On-off Valve PI-V2
PCV (Regulator) PI-V3
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Density Meter PI-A1

Restriction Orifice (FO) PI-X1
Vibration Monitors PI-X2
5.3 Record
Results of test shall be recorded on "Inspection Record for Instruments, Prior to Installation
(Appendix-5)
5.3.1 Installations of Level Instruments should be designed for the extreme environmental
conditions of Saudi Arabia and unique operating conditions.
5.3.1.1 Instruments should never be mounted any closer to grade than 1400 mm (4.5 ft).
General site conditions shall be as per Client document BEDD. Site specific exceptions to
BEDD shall be conveyed to contractor.
Level instruments such as level sight glasses and indicators frequently require observation
during manual operation of the level control valve. Therefore, a local level indicator should be
observable at the control valve lever or the level sight glasses should be installed to be visible
from the manual station of the control valve.
5.3.1.2 Displacer type instruments should always be installed in a manner to permit removal
without disconnecting major process piping. External chambers should be installed in a
manner to permit removal of the float without removing the chamber from the process piping.
Block and drain valves must be provided to permit chamber draining for cleaning and
instrument calibration. Open drains can be provided for all hydrocarbons and other hazardous
fluids. Displacer instruments should never be considered for vessels which are subject to high
vibration.
5.3.1.3 Direct flange mounting transmitters are preferred for installations which have a 2-inch
pipe nozzle or larger and which require a differential pressure transmitter regardless of solid
content. However, it should be remembered that the solids can form in the nozzle next to the
diaphragm in the same manner that they develop in a standard diaphragm cavity.
Differential pressure transmitters should not be installed in a service where the measured
liquid specific gravity will vary widely and often. For example, a vessel is used for oil at a
S.G. of 0.8 and salt water at a S.G. of 1.0; when in oil service, a transmitter calibrated for
water would actually contain 3.6 meters of oil when indicating 3 meters of level. Also,
differential pressure transmitters work best on clean fluids which are fairly constant in specific
gravity, temperature.
5.3.2 Installation. In pressure measurement and control systems the means by which the
instrument interfaces with the process is a prime consideration to achieve reliable operation.
The measuring device must come in physical contact with the process, but in some instances
special precautions must be exercised to prevent damage to the pressure element/ The process
temperature may be above the design limits of the instrument or the process medium may be
corrosive. Mechanical vibration or process pressure pulsation can also be detrimental to the
instrument's reliability by causing excessive wear and mechanical shock to the element and
other moving parts. Insulation and bleed valves, seals and purges, temperature insulation and
heat tracing should be considered to maintain instrument reliability.
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5.3.2.1 Location. All Field devices shall be mounted as close to the process connection as
practical, consistent with required accessibility and visibility, and not be subject to vibration.
For maintenance purposes all locally mounted instruments shall be readily accessible from
grade, platform, fixed walkway, or fixed ladder.
Where several instruments are installed within a small area, consideration shall be given to
mounting them on a common panel, and providing a sunshade to avoid calibration drift.
5.3.2.2 Elevation. Instruments and impulse lines in gas service shall be free of liquid, and D/P
instruments shall be mounted below the process connection. For liquid and vapor service the
lines shall be liquid full, and D/P instruments shall be mounted below the process connection.
Impulse lines shall be free of air pockets and liquid traps. For pressure service at elevated
locations, instruments may be located remote from, and below, the pressure tap.
5.3.2.3 Gauges. Pressure and D/P gauges shall not be mounted on instrument piping or
standpipes. Gauge supports shall be designed so that safety disc inserts or blowout backs are
not covered. Field gauges shall not be painted. To facilitate easy reading, gauge dials shall
face the point from which corrective action will be taken.
5.3.2.4 Switches. Pressure and D/P switches shall be mounted on a tee with a direct connected
process pressure or D/P gauge and two isolation valves to permit testing of the pressure and
D/P switches shall prevent accumulation of liquids in the sensing element to avoid corrosion
in sour (gas or vapor) service.
If the switch is used in SIS service, the switch shall have its own direct connection to the
vessel, process piping, or equipment and shall not be combined with another loop.
6. Inspection after Installation

6.1 General
The inspection shall be undertaken after final installation of instruments. It shall be confirmed
that all instruments are installed at the proper place.
6.2 Inspection Items for each Instruments

Following instruments shall be inspected in according with Table V ‘Inspection after
Installation’.
Instrument Inspection No.
Orifice Plate AI-F1
Meter Run AI-F2
Venturi Tube AI-F3
Pilot Tube (Annubar) AI-F4
Rotameter AI-F5
Turbine Meter AI-F6
Positive Displacement Meter AI-F7
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Flow Switch AI-F8

Tank Gauge System (Electric) AI-L1
Tank Gauge (Mechanical) AI-L2
Level Gauge AI-L3
Capacitance Type Level Instrument AI-L4
Thermometer AI-T1
Control Valve AI-V1
On-off Valve AI-V2
PCV (Regulator) AI-V3
Density Meter AI-A1
Restriction Orifice AI-X1
Vibration Monitors AI-X2
The terminal and indicator direction of transmitters and switches shall be checked during
inspection for instrument installation works.
6.3 Record
Results of test shall be recorded on "Inspection Record for Instruments after Installation
(Appendix-6).
7. Power and Air Supply Checks

Prior to starting of field check and calibration of instruments, the following systems operation
shall be confirmed.
7.1 Electric Power Source

Checking power supply from switchboards (SWB) to users:
Test to be required as follows:
a. If power can be switched off at SWB

b. If power can be switched off at instrument.
For both tests, switching off power has to be confirmed by measuring instruments.
7.1.1 DC 24V power system. Duties of the instrument inspector shall come after connection of
cables to SWB. Then, instrument inspection shall ask the electrical inspector for check of the
following items:
a. If the electric power source system energizes normally
b. If the voltage is normal
c. If the insulation is normal
d. If the terminals have been tightened.
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9 INSTRUMENTATION AND CONTROL SYSTEMS DATE: April 21, 2016
In this case, main switch of DC 24V instrument power source unit shall be cut off.
His other duties are checking, measuring and confirming DC 24V instrument power system
with electrical inspector, as follows:
a. If converter/invertor system is normal

b. If the right voltage is supplied
c. If the take-over system is functioning, normally
d. If the back-up time of each battery is more than holding up time
Refer to ‘Vendor's instruction manual’.
Note: Dummy load may be considered for this test. In this case, main switch of SWB shall be
cut off.
9.1.2 AC 120V power system (UPS). The same checks are to be carried out which were
carried out with DC 24V system:
a. If the converter/invertor system is normal

b. If switching system is orderly
c. If rotary converter is normal
d. If the right voltage is supplied
e. If the back-up time of each battery is more than 30 minutes
Refer to ‘Vendor instruction manual’.
9.1.3 AC 120V (Normal Power)
a. If the right voltage is supplied

b. If opening and closing operation of main switches are orderly
c. If the terminals have been tightened
d. If the opening and closing operation of main switches are orderly
e. If the rating of fuse is correct
f. If the fuse is not disconnected
9.1.4 Supply of electric power. The electric power source shall be energized after the checks
and confirmation in para 7.1 have been completed.
9.1.5 Testing power source. These tests have to be done in cooperation with the electrical
inspector. The following tests shall be done as a minimum:
a. Changing over from one feeder to another

b. Checking back-up systems for vital power supply.
c. Changing to back-up batteries for DC 24V.
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11 INSTRUMENTATION AND CONTROL SYSTEMS DATE: April 21, 2016
a. Changing to rotary-converter back-up supply for AC 120V (UPS)

Note: During these test, instrumentation systems such as DCS, computer shall be in operation
and the operation shall be kept without any interruption.
7.2 Instrument Air Supply

Upon completion of tests and inspection for construction works of instrument air supply piping
group and instrument air supply tubing by instrumentation group, the required supply air
pressure of each kind of instrument shall be conformed and setting of the pressure regulator
(air set) shall be made.
The set pressure shall be 140 kPag for general instruments, unless specified otherwise.
8. Field Check and Calibration

8.1 Outline of Field Check and Calibration
Check and calibration for the following instruments shall be carried out in accordance with
Vendor's standard procedure.
a. DCS Operator Console

b. DCS Cabinet
c. Other Console Panel
d. SIS, PLC & Monitor Switch Cabinet
e. Interlock Relay Cabinet
f. Machinery Monitoring System
g. Power Distribution Panel
h. Marshalling Cabinet
i. Analyzer Systems
8.2 Record
Results of check and calibration shall be recorded on Vendor's Standard Format.
9. Loop Test
9.1 General
9.1.1 After each component of a loop has been calibrated individually, an operational test of
the loop shall be carried out.
9.1.2 Loop tests are categorized as follows:

LOOP TEST A: Loop tests between Marshalling cabinets and DCS, SIS and interlock
Systems (Inside Control Room)
LOOP TEST B: Loop tests between marshalling cabinets and field transmitters.
LOOP TEST C: Loop test between DCS and field instrument (e.g. transmitter, switch,
control valve, on off valve) except local gauges.
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LOOP TEST D: Complete loop test for control loop between transmitter and final control
element such as control valves, through DCS.
LOOP TEST E: Complete loop test for SIS, interlock and sequence system between field
instrument (e.g. transmitter, switch) and final control element such as on-off valve, through
PLC relay circuit and MCC relay circuit.
9.1.2.1 Loop Test A and Loop Test B will be carried out separately for all loops.
9.1.2.2 Loop Test C is performed for all loops after the completion of Loop Test A and B.
9.1.2.3 It is permitted that Loop Test C represent Loop Test A and B in certain cases.
9.1.2.4 Loop Test D and E are performed after completion of Loop Test C.
9.2 Outline of Loop Test for Each Loop

9.2.1 The loop test for following instruments and loops shall be carried out in accordance with
the attached Table VI "Procedure Outline for Loop Test".
LOOP TEST
INSTRUMENT OF LOOP TEST NO.
CATEGOR
Y C D/P Transmitter LT-F1
C Turbine Meter LT-F2
C Flow Switches LT-F3
C Displacer Type Level Instrument LT-L1
C Capacitance Type Level Instrument LT-L2
C Tank Gauging System (Electric) LT-L3
C Pressure Transmitter LT-P1
C Pressure Switch LT-P2
C Temperature Transmitter LT-T1
C Thermocouple, Resistance Bulb LT-T2
C Temperature Switches LT-T3
C Control Valve LT-V1
C On-Off Valve LT-V2
C Analyzers *1
C Vibral Monitoring System *1
D Control Loop LT-d
E SIS, Interlock and Sequence Loop LT-E
*1 Comply with Vendor's standard procedures.
9.2.2 Alarm point shall be checked during TEST C.
9.3 Loop Test Preparation by Construction Contractor

The construction contractor will assemble loop test teams for carrying out loop tests. The
teams will comprise of capable instrument technicians and lead by contractor’s instrument
inspectors/supervisors. The construction contractor will prepare a methodology for carrying
out loop tests expeditiously with this end in view. Construction contractor will prepare a
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detailed procedure which will comprise description of steps that are needed to carry out loop
test.
9.4 Record
Results of test shall be recorded on the following formats:
Test Record for Loop Check

(Common Loop) Appendix-7
Test Record for Loop Check
(Complicated Loop) Appendix-8
Test Record for Interlocking and
Sequence System. Appendix-9
10. Line Up for Pre-Commissioning
10.1 General
10.1.1 Preparation prior to pre-commissioning. The order to start up a plant will begin from
setting up utilities and common facilities. Then, a series of process of operations, such as
mechanical running, water operation, cold oil run, hot oil run, etc., will come. Prior to
these operations, the following work shall be completed:
Confirmation of valve condition for instrument.
Isolation valve, Block valve : Close

Vent valve, Drain valve : Close
Equalizing valve : Open
10.1.2 Pre-commissioning of instruments. The instrument inspector shall fully communicate
with the operation representative and machinery inspector during pre-commissioning of
instruments.
10.1.3 Following instruments shall be prepared in accordance with Table VII ‘Line-up for Pre-
commissioning’:
Instrument Work No.
DCS LU-C1
PLC
Sequence and Interlock System LU-C2
Differential Pressure Transmitter LU-F1
Rotameter LU-F2
Turbine Meter LU-F3
Positive Displacement Flow Meter LU-F4
Displacer Type Level Instrument LU-L1
Tank Gauge (Mechanical) LU-L2
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Pressure Transmitter LU-P1

Pressure Switch LU-P2
Pressure Gauge LU-P3
Thermocouple, RTD LU-T1
Control Valve LU-V1
On-Off Valve LU-V2
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TABLE I
Overall Plan for Inspection Test and Preparation or Recommissioning for
Instrumentation at Site
INSPECTION BENCH INSPECTION INSPECTION FIELE LOOP LINE UP TIME FOR FLUSHING PRESSURE REMARK
ON TEST PRIOR TO AFTER CHECK & TEST FOR INSTALLA TEST
UNPACKING INSTALLATION INSTALLATION CALIBRATI RECOMMIS TION ISOLATION
ON SIONING
OPERATION
REMOVE ISOLATION
DCS OPERATOR MF A
CONSOLE
DCS CABINET MF A
OTHER CONSOLE MF A
PANEL
PLC MF A
SIS, PLC & MF A
MONITOR
SWITCH CABINET
INTERLOCK MF A
RELAY CABINET
PSA PLC CABINET MF A
POWER MF A
DISTRIBUTION
PANEL
MARSHALLING MF A
CABINET
MISCELLANEOUS MF A
CABINET
VIBRATION MF
MONITORING
SYSTEM
ORIFICE PLACE UI-F1 P1-F1 AI-F1 F

ORIFICE FLG'S UI-F2 P1-F9 R
METER RUN UI-F3 P1-F2 AI-F2 R Y*1
VENTURI TUBES, UI-F4 P1-F3 G Y*1
ASME FLOW
NOZZLES
ANNUBAR, PITOT UI-F5 P1-F4 AI-F3 G Y*1
TUBES
D/P BT-F1 AI-F4 LT-F LU-F1 R Y Y*11,*13
TRANSMITTERS 1
ROTAMETERS UI-F6 P1-F5 AI-F5 LU-F2 R Y
TURBINE METERS BT-F2 P1-F6 AI-F6 LT-F LU-F3 R Y
2
POSITIVE DISPL. UI-F7 P1-F7 AI-F7 LU-F4 R Y
METERS
FLOW SWITCHES BT-F3 P1-F8 AI-F8 LT-F R Y*1 Y
3
DISPLACER TYPE BT-L1 PI-L1 LT-L LU-L1 R

LEVEL 1
INSTRUMENT
CAPACITANCE BT-L2 PI-L2 AI-L4 LT-L R
TYPE LEVEL 2
INSTRUMENT
TANK GAUGING BT-L3 PI-L3 AI-L1 LT-L R
SYSTEM 3
(ELECTRIC)
TANK GAUGE PI-L4 AI-L2 LU-L2 R
(MECHANICAL) UI-L1
LEVEL GAUGES UI-L2 PI-L5 AI-L3 R
Contd...
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TABLE I (CONTD.)
PRESSURE TRANSMITTER BT-P1 LT-P1 LU-P1 R Y*13
PRESSURE SWITCHES BT-P2 LT-P LU-P2 R Y*13
2
PRESSURE GAUGES BT-P3 LU-P3 R Y*13
DRAFT GAUGES BT-P AI-P1 R
D/P GAUGES BT-P5 R Y*12
TEMPERATURE BT-T1 LT-T R

TRANSMITTERS 1
THERMOCOUPLES RID'S UI-T1 PI-T1 LT-T LU-T1 R
2
TEMP. INSTRUMENTS BT-T2 R
(FILLED SYSTEM)
THERMOMETERS UI-T2 PI-T2 AI-T1 R
TEMP. SWITCHES BT-T3 LT-T R
3
CONTROL VALVE, I/P BT-V1 PI-V1 AI-V1 LT-V LU-V1 R Y*1

POSITIONER 1
ON-OFF VALVE BT-V2 PI-V2 AI-V2 LT-V LU-V2 R Y*1
2
PCV (REGULATORS) UI-V1 PI-V3 AI-V3 R Y*1 Y*12
GAS CHROMATOGRAPH MF MF R Y*12

SAMPLE CONDITIONING R Y*12
UNIT
DENSITY METER PI-A1 AI-A1 MF MF R Y*1
PH ANALYZER MF MF R Y
CONDUCTIVITY MF MF R Y
ANALYZER
VISCOSITY METER MF MF R Y
HES MF MF R
MONITORS.COMBUSTIBLE
GAS MONITORS
ANALLYZERS (EXCEPT MF MF R Y*12
FOR ABOVE ANALYSERS)
VIBRATION MONITORS BT-X1 PI-X2 AI-X2 R

OUTPUT GAUGE (E) BT-X2 R
RO(RESTRICTION ORIFICE) UI-X1 PI-X1 AI--X1 R Y*1
LOCAL PANEL
CONTROL LOOP LT-D
SIS.INTERLOCK SEQUENCE LT-E
SYSTEM
*1 : To be removed when installed before flushing operation

*2 : To be removed the instrument with no block valve
*11 : Equalizing valve to be opened
*12 : Drain or vent valve to be opened. Isolation valve to be closed.
*13 : Instruments which the rated pressure is under the test pressure and have not the drain or vent valve
shall be removed.
A : After available control room and HVAC
F : After flushing operation
G : After flushing operation in principle
MF : Performed by vendor’s standard procedure
R : When installation condition is settled.
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TABLE II
Unpacking Inspection
INSPECTION# ITEM
UI-F1 Orifice Plate
1) Orifice plates integrated in meter runs shall be removed prior to the unpacking
inspection.
2) The stamped date on orifice tabs shall be checked in accordance with
specifications and vendor's drawings
UI-F2 Orifice Flange
1) The stamped date on flanges shall be checked in accordance with specifications
and vendor's drawings.
2) Bolts and nuts, jack screws and gaskets shall be confirmed.
UI-F3 Meter Run
1) The stamped data on meter runs shall be checked in accordance with
specifications and vendor's drawings.
UI-F4 Venturi Tube
Same as UI-F3
UI-F5 Annubar, Pilot Tube
The stamped data on the elements and nameplates shall be checked in accordance
with specifications and vendor's drawings.
UI-F6 Rotameter
1) Same as UI-F5
2) Scales shall be checked
UI-F7 Positive Displacement Meters
Same as UI-F6
UI-L1 Tank Gauge (Mechanical)
1) Same as UI-F6
2) Accessories shall be confirmed in accordance with specifications and vendor's
drawings.
UI -L2 Level Gauge
Same as UI-F5
UI-T1 Thermocouple, RTD
Same as UI-F5
UI-T2 Thermometer
Same as UF-F6
UI-V1 PCV (Regulator)
1. Same as UI-F5
2. Face to face length shall be checked
UI-X1 Restriction Orifice
The stamped data on orifice tabs shall be checked in accordance with
specifications and vendor’s drawings.
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TABLE III
Procedure Outline for Bench Test
TEST #. PROCEDURE OUTLINE

BT-F1 Differential Pressure Transmitter
The transmitters shall be calibrated against standard water or mercury column manometer
at zero, 50% and 100% of span prior to installation. A precision calibration meter shall be
used to check the transmitted signal.
BT-F2 Turbine Meter
1) The movement of sensor rotors shall be checked by the finger.
2) The characteristic converters shall be confirmed using a pulse-synthesizer.
BT-F3 Flow Switch
The switch action shall be checked by moving the paddle or float.
BT-L1 Displacer Type Level Instrument
1) The instruments shall be calibrated by filling the chamber with clean water and using
clear plastic tubing connected at the bottom drain as a gauge glass.
Check calibration at zero, 50% and 100% of span. Generally, these test liquid are
different in specific gravity from the liquid at the operational stage, special care must be
taken.
(100% output at range density of liquid
density of water mmH2o)
As for details, refer to vendor's instruction manual.
As for instrument which is water free, use some other liquid suitable for the instrument.
After operation, make blows and open the drain valve in order to remove any scale
2) Internal displacement type level instruments shall be bench calibrated with the help of
weights simulating at zero, 50% and 100% of span.
Interface level may be calibrated with water as follows:

(100% output at range density of heavy liquid
(100% output at range density of light liquid
If full range cannot be checked, because density of liquid density of water, max. value
of water shall be checked.
BT-L2 Capacitance Type Level Instrument
The instrument shall be put into water, filled in a metallic bucket, and it's response noted.
As for details, refer to the vendor's instruction manual.

BT-L3 Tank Gauging System
The dimension or length of the float and wire shall be checked in accordance with vendor's
drawing.
Page 18 of 34
CONSTRUCTION QA/QC
TABLE III (CONTD.)
BT-P1 Pressure Transmitter

The instruments shall be calibrated at zero, 50% and 100% of range using a dead weight
tester or similar equipment prior to installation.
BT-P2 Pressure Switch
The instruments shall be calibrated with a precision calibration gauge or manometer
using dry air or nitrogen as a source of pressure if receiver type, or dead weight tester if
direct connected process and set at a proper value and action.
BT-P3 Pressure Gauge
The needle shall be adjusted at zero point.
BT-P4 Draft Gauge
Same as bourdon type pressure gauge (BT-P3).
BT-P5 Differential Pressure Gauge
The instruments shall be checked against standard water or mercury at zero, 50% and
100%.
A precision calibration gauge shall be used to check.

BT-T1 Temperature Transmitter
1) The temperature transmitters for thermocouple shall be calibrated at zero, 50% and
100% of range using DC voltage standard.
A precision calibration meter shall be used to check the transmitted signal.

2) The temperature transmitters for resistance bulbs shall be calibrated at zero, 50% and
100% of range using a precision resistance.
BT-T2 Temperature Instrument (Filled system)
The instruments shall be calibrated at zero, 50% and 100% of range during a controlled
temperature bath.
BT-T3 Temperature Switch
The instrument shall be calibrated at zero, 50% and 100% of range using a controlled
temperature bath and set and tested at the proper value.
BT-V1 Control Valve
1) The control valves shall be set at the installed condition using a chain block or pulley.
2) All diaphragm or piston operated control valves shall be pneumatically stroked using
a pressure regulator and test gauge.
Following items shall be checked and calibrated.
Valve action
Travel indicator
Positioner calibration
Stroking time (for specified value)
Limit switch function
3) Accessories such as regulator, hand wheel, booster relay, lock-up valve, etc. shall be
operationally checked.
Page 19 of 34
CONSTRUCTION QA/QC
TABLE III (CONTD.)
4) The control valves with a solenoid valve shall be checked for the following items
using a DC power supply unit.
Action
Air failure position of the control valve.
BT-V2 On off valve
1) The on-off valve shall be set at the installed position using a chain block or pulley
.
2) All diaphragm or piston operated or piston operated on-off valve shall be operated
using a pressure regulator, test gauge, DC power supply unit, etc. Following items
shall be checked and calibrated.
On-off valve action
Solenoid valve action
Stroking time
Limit switch function
Air and electrical failure position.
3) All accessories such as air set, handwheel, booster relay, lock up valve etc. shall be
operationally checked.
BT-X1 Vibration Monitors
1) The sensors shall be installed on the vibration generator.
2) The output signal of sensor shall be measured using the vibration generator.
BT-X2 Output Gauge
1) Receiver type local indicators shall be calibrated at zero, 50% and 100% of range
using a standard current generator.
2) Receiver type pressure gauges shall be calibrated using a precision calibration

gauge or manometer at zero, 50% and 100% of range.
Page 20 of 34
CONSTRUCTION QA/QC
TABLE IV
Inspection Prior to Installation
P1-F1 Orifice Plate

1) Orifice plates shall be checked for the following items using a vernier or
micrometer.
Outside diameter
Bore diameter
Plate thickness
Stamped data on tab
Flow direction (stamped on upstream side)
Flatness
2) Just prior to installation, following items shall be checked and confirmed.
Tag No.
Flatness
Freedom from adhesive materials
Edge Squareness
Flow direction
Specification of gaskets
Cleanness
PI-F2 Meter Run

1) Meter Runs shall be checked for the following items using a vernier or conved rule.
face to face length

Inside diameter
Tag No.
No damage
Cleanness
PI-F3 Venturi tube

Same as meter run
PI-F4 Annubar, Pilot Tube

Following items shall be confirmed just prior to installation.
Tag No.
No damage
Flow direction
Insertion length
Contd..
Page 21 of 34
CONSTRUCTION QA/QC
TABLE IV (CONTD)
PI-F5 Rotameter
1) Rotameters in which the float is not visible shall be checked for action by manually
positioning the float.
2) Just prior to installation, rotameters shall be checked that all shipping stops have
been removed and the proper float is correctly installed, and that the float moves
freely.
Cleanness shall be checked.
PI-F6 Turbine Meter
Just prior to installation, following items shall be checked.
Tag No.
No Damage
Flow Direction
Cleanness
PI-F7 Positive Displacement Flow Meter.
Positive displacement meters shall be checked for mechanical operability.
PI-F8 Flow Switch
Same as PI-F6
PI-F9 ORIFICE FLANGE
1) Orifice flanges shall be checked for the following items using a vernier or
micrometer.
Outside diameter
Inside diameter
Flange thickness
Orifice taps size and orientation
Stamped data on flange
Tag No.
Freedom from adhesive materials
Cleanness
PI-L1 Displacer Type Level Instrument
1) Stiffeners shall be removed just prior to installation.
2) Direction of indicators or transmitters shall be confirmed when they are mounted.
PI-L2 Capacitance Type Level Instrument
Direction of transmitters shall be confirmed when they are mounted on the equipment.
PI-L3 Tank Gauge System (Electric)
Following items shall be verified using a vernier, convex rule or measuring tape.
Float
Wire Length
Contd..
Page 22 of 34
CONSTRUCTION QA/QC
TABLE IV (CONTD.)
PI-L4 Tank Gauge System (Mechanical)

Same as PI-L3
PI-L5 Level Gauge

The center to center length shall be checked in accordance with specifications and
vendor's drawing.
PI-T1 Thermowell for thermocouple and RTD
1) The dial pointer shall be adjusted to the ambient temperature.
2) All wells shall be checked for the following dimension using a vernier caliper
and/or micrometer.
Insertion length
Outside diameter
PI-T2 Thermometer and Thermowell
1) The dial pointer shall be adjusted to the ambient temperature.
2) All wells shall be checked for the following dimension using a vernier caliper
and/or micrometer.
Insertion length
Outside diameter
PI-V1 Control Valve
Visual Inspection of valve body inside and confirmation of flow direction shall be
done just prior to installation.
PI-V2 On-off valve
Same as PI-V1.
PI-V3 PCV (Regulator)
Same as PI-V1.
PI-A1 Density Analyzer
1) Density meters shall be checked for the following items using a vernier or convex
rule.
face to face length (for liquid density meter)
Inside diameter (for liquid density meter)
Tag No.
No damage
Cleanness
PI-X1 Restriction Orifice
Same as PI-F1.
PI-X2 Vibration Monitors
Following items shall be checked and confirmed:
Tag No
No damage
Cleanness
Page 23 of 34
CONSTRUCTION QA/QC
TABLE V
Inspection after Installation
AI-F1 Orifice Plate

Following items shall be checked.
Tag No.
Flow Direction
AI-F2 Meter Run
Same as AI-F1
AI-F3 Venturi Tube
Same as AI-F1
AI-F4 Annubar, Pilot tube
Same as AI-F1
AI-F5 Rotameter
Following items shall be checked
Tag No.
Indicator direction
AI-F6 Turbine Meter
Same as AI-F1
AI-F7 Positive Displacement Meter
Following items shall be checked
Tag No
Flow Direction
Indicator direction
AI-F8 Flow Switches
Same as AI-F1.
A-L1 Tank Gauge System
Following items shall be confirmed:
Guide wires are properly installed.

The float and float wire are property installed and move smoothly in raising the float
mechanically.
Zero point.
AI-L2 Tank Gauge (Mechanical)
Same as AI-Ll1
AI-L3 Level Gauge
The direction of indication shall be checked.
Contd..
Page 24 of 34
CONSTRUCTION QA/QC
TABLE V (CONTD.)
AI-L4 Capacitance Type Level Instrument

Sensor and transmitter are properly installed.

AI-P1 Pressure Gauge
Same as AI-L3
AI-T1 Thermometer
Same as AI-L3
AI-V1 Control Valve
Tag No.
Flow direction
Valve position
AI-V2 On-Off Valve
Same as AI-V1
AI-V3 PCV (Regulator)
Same as AI-F1
AI-A1 Density Meter
Same as AI-F1
AI-X1 Restriction Orifice
Tag No. shall be confirmed.
AI-X2 Vibration Monitors
Following items shall be checked:
Devices are installed according to vendor's instruction.
Page 25 of 34
CONSTRUCTION QA/QC
TABLE VI
Outline Procedure for Loop Test
LT-F1 Differential Pressure Transmitter

1) Zero, 50%, 100% of full scale shall be verified on DCS at the same time.
2) Hard wired alarms for the loop shall be confirmed at the annunciator console at the
same time.
LT-F2 Turbine Meter
1) Simulated signal of zero, 50%, 100% of full scale shall be verified on DCS.
LT-F3 Flow Switch
Alarms on the DCS or the annunciator console shall be confirmed by giving open or close
signals at the terminal of the instruments
Tripping circuit contact shall be confirmed on MCC panel or the final control element at
the same time.
LT-L1 Displacer Type Level Instrument
1) The loops shall be tested using a portable milliampere simulator connected to the
terminal of the instrument.
2) Zero, 50%, 100% of full scale shall be verified on DCS at the time.
3) Hard wired alarms for the loop shall be confirmed on the annunciator console at the
same time.
4) MCC relay contact shall be confirmed in MCC panel at the same time.
LT-L2 Capacitance Type Level Instrument
Same as LT-L1
LT-L3 Tank Gauge System (Electric)
Zero point shall be verified on DCS raising the float electrically.
LT-P1 Pressure Transmitter
Same as LI-F1
LT-P2 Pressure Switches
Same as LT-F3.
LT-T1 Temperature Transmitter
Same as LT-L1
LT-T2 Thermocouple, RTD
1) Thermocouple loops shall be tested using a portable millivolt simulator connected to
the terminal of the element.
RTD loops be tested using a resistance simulator connected to the terminal of the
element.
2) Zero, 50%, 100% of full scale shall be verified on DCS at the same time.
3) Alarms for the loop shall be confirmed on the annunciator console at the same time.
LT-T3 Temperature Switch
Same as LT-F3
Contd..
Page 26 of 34
CONSTRUCTION QA/QC
TABLE VI (CONTD.)
LT-V1 Control Valve

1) Following items shall be verified by giving signal from DCS.
Valve action (smooth)
Travel (0%, 50%, 100%)
Limit switch action
(to be confirmed on DCS if it works at the specified traveling scale)
If the control valve has a solenoid valve and the test is impossible, this test
may be performed at the same time of the operational confirmation of
interlock system or sequence system.
LT-V2 On-Off valve
1) Following items shall be verified by giving signal from DCS, PLC and
Interlock system.
Valve action (Smooth)

Solenoid valve action
Limit Switch action
Air and electrical failure position.
LT-D Complete Loop Test for Control Loop
Each control loop must be operated to simulate actual operation from the
transmitter to final control element by giving simulated signals. Following items
shall be checked according to the system specifications.
Control action (direct/reverse)

Control valve action (Open/Close)
Control valve air failure position
LT-E Complete Loop Test for SIS, Interlock and Sequence control System.
1) "Confirmation Test Procedure" shall be prepared.
The system shall be tested in accordance with this procedure.
2) Input signals coming to the system shall be simulated from field and the
operational confirmation shall be made at the final output end.
If the operational confirmation of a non SIS instrumentation loop has already

been done and an input to SIS, interlock and sequence system is duplicate to
alarm system, it is permissible to check input to system without operational
confirmation from local instruments. In such a case, the simulated signal may
be sent from the marshalling cabinet terminals. However, SIS sequences shall
be checked completely.
3) The stroking time of the on-off valve shall be measured using a stop watch,
where such time is specified.
Page 27 of 34
CONSTRUCTION QA/QC
TABLE VII
Line-up for Pre-commissioning
LU-C1 Controller
For setting the PID parameter of controllers, keep the sensitivity dull at the start-up of
operation. Rough values of the PID parameter shall be incorporated in data base by DCS
vendor.
LU-F1 Differential Transmitter
1) Preparation prior to pre-commissioning
a) Filling of seal liquids
Sealing liquids shall be filled into pots for the instruments with seal pots.
It is desirable that sealing liquids will be slowly filled by hand type pump
patting the impulse piping.
b) Confirmation of valve condition
Following condition shall be confirmed:

Equalizing valve : Open
Take-off valve : Shut
2) Start-up of instruments
After the zero adjustment is verified, open the take-off valve and close the equalizing
valve and check if the signal output of transmitter is realistic.
For the instruments with sealing pots and remote seal type instrument, the
suppression shall be adjusted.
LU-F2 Rotameter
1) Preparation prior to pre-commissioning.
The block valve shall be closed.
When the instrument operates, the block valve shall be slowly opened.
LU-F3 Turbine Meter
When the instrument operates, the block valve shall be slowly opened and air/gas
shall be vented. At the same time the upstream valve shall be slowly opened.
LU-F4 Positive Displacement Flow Meter
Same as LU-F3
LU-L1 Displacer Type Level Instrument
The take-off valves of the equipment shall be closed.

Contd..
Page 28 of 34
CONSTRUCTION QA/QC
TABLE VII (CONTD.)
First, open the upper take-off valve, and then open the lower take-off valve.
Don’t give any impact to the float.
Check output against level gauge.

LU-L2 Tank Gauge (Mechanical)
Sealing liquids shall be filled for the instrument with sealing apparatus prior to pre-
commissioning.
LU-P1 Pressure Transmitter
The take-off valve shall be closed.

a) When the instrument operates, the take-off valve shall be slowly opened.
b) Check the zero point using vent or drain valve/plug.
LU-P2 Pressure Switch

The take-off valve shall be slowly opened.

LU-P3 Pressure Gauge
1) Preparation prior to Pre-commissioning

a) The take-off valve shall be slowly opened.
b) Attention shall be paid to protect pressure element (Bourdon tube) from
damage.
c) Check the zero point using the vent or drain valve plug.
d) The take-off valve of pressure gauges located at the place where pulsation is
big, such as pressure gauge for discharge of pump may have reduced openings
at the entrance and the openings shall be checked against proper function at
start-up.
LU-T1 Thermocouple and RTD
Prior to pre-commissioning, confirm the measurement value against ambient
temperature to check the connection of wire after loop tests.
Page 29 of 34
CONSTRUCTION QA/QC
TABLE VII (CONTD.)
LU-V1 Control valve

The block valves shall be closed.
Control valves shall be closed with mutual operation from DCS.

2) Start-up
The block valves shall be slowly opened.
After start-up, if a gland leakage is found, tighten the gland.

LU-V2 On-Off Valve
a) The block valves shall be closed.
b) When the instrument inspector makes the operational confirmation of the control
circuit of a motor and so on, the load shall be removed beforehand.
The instrument inspector shall communicate with electrical inspector, and check
the control circuit before making energized and circuit tests.
Page 30 of 34
CONSTRUCTION QA/QC
TABLE VIII
Apparatus & Instrument for Calibration and Test
ITEM SPECIFICATION ITEM SPECIFICATION

Nitrogen Cylinder 0.7 M3 Venier Caliper Range 300mm
High Pressure 250/150k Venier Caliper Range 100mm
Regulator
Digital Manometer 500mmmh2o-200kg/cm2 6 Outside Micrometer Range 0-25mm
Set
Precision Type Pressure -1 – 250 Kg/cm2 10set Outside Micrometer Range 25-50mm
Gauge
Bench Type Dead- 0 - 300 Bar Inside Micrometer Range 5-30 Mm
weight Tester
Standard Dead-weight 0-500 Kg/cm2 Inside Micrometer Range 25-50mm
Tester
Water Column 0-1500 Mmh2o Dial Gauge Range 30,10,5,2mm
Manometer
Potable Hand Pump -600mmhg - 7kg/cm Dew Point Meter -60 - 0 C
Very Low Pressure 0-300 Mm H2o Sound Level Meter 31.5 - 8000 Hz/30 - 130
Meter Db
Vacuum Pump 1 Torr Tachometer 60 - 19999 Rpm
Regulator 7 Kg/cm2 Vibration Generator
Oil Separator Potable Telephone
Air Compressor 2.2kw 8-9bar 245/min. Transceiver
Low Temperature Bath -35 – 50 C Oiler Oil Pitcher
Temperature Water Amb - 100 C Bench Grinder Sheel Size: 305*25.4mm
Bath
Temperature Oil Bath 100 – 250 C Cord Reel Cable 30 M
Sand Bath Amb - 500 C Pipe Wrench 1/8 - 2 Inch
Electric Bath Amb - 1000 C Monkey Wrench Max. Opening 24mm
Digital Thermometer -50 - 99.9 C Spanner
Digital Thermometer -50 – 600 - 3000 C Offset Wrench
Standard Glass -56 – 350 C 8 Pcs Socket Wrench Size 1.4 - 10mm
Thermometer
Pyrometer -50 - 1000/600 - 3000 C Hexagonal Erench
Cold Junction Box K,e,j,t Pipe Bendor 6,6,10,12,16mm
Potable Temperature 1,10,100 O Tap Wrench 6,10,12mm
Calibrator
Silicon Oil 204l*2 For 150,300 C Hand Vice
Decade Resistance Box 0.1 – 111.111 Ohm Cutter Plier 150mm
Standard Resister 1,10,100 O Cable Joint Plier
Side Resistor 0 - 6a/00 - 100v Wire Stripper
Contd..
Page 31 of 34
CONSTRUCTION QA/QC
TABLE VIII (CONTD.)
ITEM SPECIFICATION ITEM SPECIFICATION

Digital Multimeter Yew: Model 2506a-21 Hammer 1.1 Kg
Dc Voltage/current Yew: Model 2554 Wooden Hammer 48 Mm
Standard
Dc Power Supply 0-35v / 0-10a Center Punch 100 Mm
Insulation Tester 500v/1000 Meg-ohm File Set Flat, Round, Half Round
Tester Standard Vice 180,200 Mm
Potable Type 4-20 Maa, 1-5v, T/c Rtd Chain Block 2 Ton Houusting 3.0 M
Calibrator
Oscilloscope Pulley 1.5 Ton Wire 20 M
Pulse Synthesizer 0.0001-299.999 Khz Spling Wire 16mm 5 M
Capacitance Box 40 Pf-1.2 Uf 5 Dial Plier 175 Mm
Stroboscope 100 - 12000 Rpm Cutter Nipper 150 Mm
Universal Counter 1 Mhz - 50 Mhz Radio Plier 150mm
X-y Recorder 250mm Width 0.5 - 5 Electrician Knife Standard
V/cm
Transformer Screw Driver
Soap Film Meter 0-10l Max Ele' Soldering Iron 80w
Dc 17 Range Volt- Solder With Paste 1.6 Mm
ameter
Function Generator Burring Reamer 1/2 - 11/4 Inch
Stop Watch Tube Cutter 1/8 - 1-1/8 Inch
Measuring Tape Length 50mm Potable Generator
Convex Rule Length 7.5 Mm Work Bench With Vice 1500*750*740mm
Spring Type Weigher Oil Jack 4 Ton
Standard Weight Tool Set For Electronics Yew: Model 6925-2000
Humidity Meter Tool Set For Pneumatic Yew: Model 6925-1000
Mercury Type Tool Set For Mechanics Maeda: Model 700a/700s
Thermometer
Lelel 300 Mm
Surface Plate
Page 32 of 34
CONSTRUCTION QA/QC
11. Loop Check Guidelines

11.1 Loop check shall be thorough and accurate to verify the following:
a. Correct wiring (continuity)

b. Correct instrument operation and calibration (transmitter, valve, relay, etc.)
c. Compatibility between different instruments in a loop (range, power/signal source,
etc).
d. Correct indication and operation of a loop in DCS (indication, control action, alarms,
square root, etc)
e. Loop check shall be carried out in such a way to attain the above objectives.
11.2 Base Data
The main documents which shall be used as a design base for loop check are as follows:
a. For DCS loops: P&IDs, Instrument Data Sheets, Loop drawings.

b. For SIS/Interlock systems: P&IDs, Logic drawings and loop diagrams.
c. For local loops/instruments: P&IDs, Instrument data sheets.
Reference and support documents include instrument data sheets, sequence of wiring
drawings, connection lists, ladder diagrams for PLCs and cabinet internal connection
diagrams.
11.3 Checklist
Latest P&IDs defined for each turnover package shall be used as a checklist for the loop test
(There is no other complete list of loops for each turnover package). Yellow off or other
means of mark-ups shall be used to ensure all loops in a package are signed off before it is
turned over.
11.4 Schedule and Progress Reporting

A schedule for the entire loop check activity shall be established based on the turnover date
and the volume of each package. This schedule will be adjusted based on actual completion of
construction activities.
11.5 Loop Check Team

Loop check team shall be well prepared, well organized and be familiar with loop test
procedure approved by Client. Team members who cannot demonstrate their ability or cannot
work as a team will be rejected. Each team shall have a leader (Senior Technician) who can
command and control team members, is familiar with the equipment involved, can read and
understand design drawings and loop check objectives, know what to check or expect and how
to organize for a complete and effective loop test. The team leader shall be given time to
study the loops in advance and ensure that all data are available and loop check
documentation is complete.
Page 33 of 34
CONSTRUCTION QA/QC
11.6 Loop Check Documentation

The record/sign off sheet shall have the following data as a minimum:
a. P&ID and Loop drawing (or logic diagrams) number.

b. Loop number (or interlock/SIS number).
c. Loop number shall usually be the transmitter tag No. or tag No. of main component in
the loop (i.e. HS-1123).
d. All DCS Tag No. in the same loop (ie. indication, alarm, etc.) together with test results.
Analog indication shall be recorded (as seen) in Engineering Unit, Alarm shall be noted
DCS or annunciator alarm with tag No.
e. Tag numbers of all components in the same loop with test results recorded clearly with
inputs and outputs
f. Tag numbers of all inputs and outputs for each SIS/Interlock.
11.7 Documentation Mark-ups
All documents used for loop check shall be marked with correct information in case
discrepancies are found. A copy of the mark-up documents shall be forwarded to CMC at the
end of each loop check day.
11.8 Sign off Procedure

Each loop shall be checked entirely before it is accepted and signed off. The test record sheet
shall be filled out completely at the end of each loop test and handed over to Client
inspectors for sign off.
11.9 Loop Check Tagging

After successful completion of a loop, a green loop check tag shall be attached to the field
instruments in the loop.
A green tag shall also be affixed to the terminals inside the field junction box for the accepted
loops (small stickers can be used). Disconnection of wires on these green tagged terminals
shall be witnessed by Client inspectors. This green tag is not required if the junction box has
been completed, inspected and accepted by Client prior to loop test activity.
11.10 Problem Reporting

When the loop test team encounters a problem and the source of error has been determined by
the Troubleshoot Team as a result of work by others, a Field Mismatch Report shall be
initiated in accordance with contractual procedure. Once the mismatch report is approved,
Instrument Contractor shall proceed with the correction work.
Page 34 of 34

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Construction QA/QC

Instrumentation and Control Systems

Rev. No. Rev. Date Description of Revision Revised by Approval

PROPRIETARY & CONFIDENTIAL

I Overall Plan for Inspection Test and Preparation or Recommissioning 15

III Procedure Outline for Beach Test 18

IV Inspection Prior to Installation 21

V Inspection after Installation 24

VI Outline Procedure for Loop Test 26

VII Line-up for Pre-Commissioning 28

VIII Apparatus and Instrument for Calibration and Test 31

1.3 Applicable documents

Client Engineering Standards

1.5 Witness inspection

Refer to Appendix-1 of SITE INSPECTION/TEST for items requiring presence of witness.

4.2 Instruments to be tested and procedure outline

Instrument Test No.

5. Inspection Prior to Installation

Density Meter PI-A1

6. Inspection after Installation

6.2 Inspection Items for each Instruments

Flow Switch AI-F8

7. Power and Air Supply Checks

7.1 Electric Power Source

Test to be required as follows:

a. If power can be switched off at SWB

a. If converter/invertor system is normal

a. If the converter/invertor system is normal

9.1.3 AC 120V (Normal Power)

a. If the right voltage is supplied

a. Changing over from one feeder to another

a. Changing to rotary-converter back-up supply for AC 120V (UPS)

7.2 Instrument Air Supply

8. Field Check and Calibration

a. DCS Operator Console

9.1.2 Loop tests are categorized as follows:

9.2 Outline of Loop Test for Each Loop

9.2.2 Alarm point shall be checked during TEST C.

9.3 Loop Test Preparation by Construction Contractor

Test Record for Loop Check

Confirmation of valve condition for instrument.

Isolation valve, Block valve : Close

Pressure Transmitter LU-P1

ORIFICE PLACE UI-F1 P1-F1 AI-F1 F

DISPLACER TYPE BT-L1 PI-L1 LT-L LU-L1 R

TEMPERATURE BT-T1 LT-T R

CONTROL VALVE, I/P BT-V1 PI-V1 AI-V1 LT-V LU-V1 R Y*1

GAS CHROMATOGRAPH MF MF R Y*12

VIBRATION MONITORS BT-X1 PI-X2 AI-X2 R

*1 : To be removed when installed before flushing operation

TEST #. PROCEDURE OUTLINE

Interface level may be calibrated with water as follows:

As for details, refer to the vendor's instruction manual.

TABLE III (CONTD.)

BT-P1 Pressure Transmitter

A precision calibration gauge shall be used to check.

A precision calibration meter shall be used to check the transmitted signal.

TABLE III (CONTD.)

2) Receiver type pressure gauges shall be calibrated using a precision calibration

P1-F1 Orifice Plate

2) Just prior to installation, following items shall be checked and confirmed.

PI-F2 Meter Run

face to face length