PETRONAS TECHNICAL STANDARDS

INSPECTION AND FUNCTIONAL TESTING OF

INSTRUMENTS

PTS 14.10.07
June 2017

© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored in
a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.
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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 5
1.1 SCOPE .............................................................................................................................. 5
1.2 GLOSSARY OF TERM ........................................................................................................ 5
1.3 SUMMARY OF CHANGES ................................................................................................. 6
2.0 QUALITY PLAN ....................................................................................................... 7
2.1 GENERAL ......................................................................................................................... 7
2.2 QUALITY PLAN REQUIREMENT ........................................................................................ 7
3.0 FACTORY ACCEPTANCE TEST (FAT) ......................................................................... 8
3.1 GENERAL ......................................................................................................................... 8
3.2 FACTORY ACCEPTANCE TEST REQUIREMENT ................................................................. 8
4.0 RECEIVING OF INSTRUMENTS AND MATERIALS .................................................... 10
4.1 GENERAL ....................................................................................................................... 10
4.2 WAREHOUSE VERIFICATION TEST ................................................................................. 10
5.0 WORKSHOP EQUIPMENT ..................................................................................... 12
5.1 GENERAL ....................................................................................................................... 12
5.2 TRACEABILITY OF EQUIPMENT CALIBRATIONS ............................................................. 12
5.3 CALIBRATION AND STANDARD MATERIALS .................................................................. 13
6.0 FIELD INSTALLATION CHECK ................................................................................. 14
6.1 GENERAL ....................................................................................................................... 14
6.2 SCOPE AND PROCEDURES ............................................................................................. 14
7.0 SYSTEM INTEGRATION TEST (SIT) ......................................................................... 16
7.1 GENERAL ....................................................................................................................... 16
7.2 SYSTEM INTEGRATION TEST REQUIREMENT ................................................................ 16
8.0 FUNCTION CHECK ................................................................................................ 17
8.1 GENERAL ....................................................................................................................... 17
8.2 FUNCTION CHECK REQUIREMENT ................................................................................ 17
9.0 SITE ACCEPTANCE TEST (SAT) ............................................................................... 18
9.1 GENERAL ....................................................................................................................... 18
9.2 SITE ACCEPTANCE TEST REQUIREMENT........................................................................ 18
10.0 BIBLIOGRAPHY .................................................................................................... 19
APPENDIX 1: TYPICAL ACTIVITIES TO BE CARRIED OUT DURING CONSTRUCTION. ............ 20
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APPENDIX 2: TYPICAL EQUIPMENT AND TOOLS OF AN INSTRUMENT WORKSHOP ........... 21

APPENDIX 3: EXAMPLES OF FIELD INSTALLATION CHECK ITEMS....................................... 22
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1.0 INTRODUCTION

This PTS provides the minimum technical requirements for testing and inspection of
instruments to ensure the reliability of the installed instruments.

This PTS was developed to ensure safe and reliable operations of instruments and systems in
PETRONAS assets based on PETRONAS lessons learnt and best practices.

1.1 SCOPE

This PTS specifies the requirements for the inspection and functional testing of instruments
from before the FAT until the SAT. This includes the general guideline and requirement of a
Quality Plan, Factory Acceptance Test (FAT), receiving of instruments and materials, workshop
equipment, field installation check, System Integration Test, Site Acceptance Test (SAT) and
function check.

1.2 GLOSSARY OF TERM

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS Requirements, General Definition of Terms, Abbreviations & Reading Guide
PTS 00.01.03 for General Definition of Terms & Abbreviations.

1.2.2 Specific Definition of Terms

No Term Definition

1 Commissioning and Start-up Operational activation of instruments and systems in

Activities line with required operating conditions. It includes
handing over the instruments and systems for
continued use to the operating and maintenance
departments.

2 Control Room Equipment All instruments and instrument systems located in

control and auxiliary rooms and field auxiliary rooms.

3 Field Inspection Verification of field instruments condition,

installation and setup in accordance to requirement.

4 Function Check Check for correct operation of the instruments,

systems and subsystems, in preparation for start-up
activities.

5 In-situ Calibration/Testing On-site calibration/testing of instrumentation using

portable test equipment.

6 Inspection of Instruments Carrying out all procedures needed to check that

instruments and systems conform to requirements.
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No Term Definition

7 Quality Measurement Instruments Industrial instruments which continuously monitor

the physical and chemical properties of fluids in
process and auxiliary plants. They may be installed in
analyser houses or mounted locally in the plant.

8 System Integration Test Verifying all system hardware and software

configuration, including the functionality of the
communication link between the various systems,
HMI graphics, logic and sequences against the design
documentations and specifications.
Table 1.1: Specific Definition of Terms

1.2.3 Specific Abbreviations

No Abbreviation Description

1 CPU Central Processing Unit

2 IPS Instrumented Protective System

3 MCS Master Control System

4 PLC Programmable Logic Controller

5 QMI Quality Measurement Instruments

6 SAT Site Acceptance Test

7 SIT System Integration Test

Table 1.2: Specific Abbreviations

1.3 SUMMARY OF CHANGES

This PTS 14.10.07 (June 2017) replaces PTS 14.10.07 (June 2014).
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2.0 QUALITY PLAN

2.1 GENERAL

2.1.1 A comprehensive Quality Plan shall be prepared in accordance with ISO 9001 or equivalent
before commencement of any testing and inspection activity. The Quality Plan describes the
quality documents (i.e. procedures, specifications, standards, acceptance criteria, and work
instructions) to be used in the dedicated organization to assure quality in each activity. All
documents and drawings that are used shall be listed and properly controlled.

2.1.2 The ISO 9001 or equivalent quality plan of the instrument vendors shall be taken into account
in the preparation of The Quality Plan. Generally the test and inspection results of the
individual instruments can be obtained from the instrument vendors and are traceable at any
time through the Quality Plan. Certificates and documents required for the functioning and
commissioning of the instruments shall be supplied with the instruments.

2.1.3 Changes during the course of activities shall be handled according to the agreed change
procedure.

2.1.4 The organization and reporting hierarchy of all personnel involved in testing and inspecting
shall be included in the Quality Plan.

2.2 QUALITY PLAN REQUIREMENT

2.2.1 Each activity shall be planned and reviewed before the particular instrumentation is operated,
especially activities that interface with other disciplines that carry out radiography
inspections, pressure tests and flushing. Time schedule, checklists, test plan and progress
reporting shall be prepared and agreed.

2.2.2 Inspection of instruments requiring hazardous area protection certification shall follow the
guidelines detailed in PTS 13.40.01 and PTS 13.41.01.

2.2.3 A complete list of inspection and testing requirements shall be made available. The list shall
be completed, reviewed and agreed to ensure that all parties involved are aware of the agreed
activities.

Appendix shows a list of typical activities to be carried out during construction as example.
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3.0 FACTORY ACCEPTANCE TEST (FAT)

3.1 GENERAL

3.1.1 The purpose of a factory inspection and factory test is to check whether the instruments and
instrument systems to be supplied comply with the requirement stated in the purchase order.

3.2 FACTORY ACCEPTANCE TEST REQUIREMENT

3.2.1 An FAT procedure shall be agreed in accordance to the Quality Plan. The procedure shall
indicate requirements for the factory inspection/test including instructions for testing and
inspection activity, acceptance criteria, witnessing parties, approving authorities, etc.

3.2.2 Prior to commencing factory inspection/test attended by witnessing parties, an internal test
shall be carried out to verify the instruments or instrument systems to be supplied if specified
in Quality Plan. The internal test report shall be submitted for review/endorsement before
commencing factory inspection/test.

3.2.3 A complete list of instruments and systems to be inspected in the FAT shall be made available.

3.2.4 The FAT shall be carried out by contractor’s qualified instrument inspector.

3.2.5 The inspector shall make available and follow strictly the agreed inspection procedure.

3.2.6 The FAT shall include visual checking of instrument and system hardware such as their physical
condition, paint work, tagging, marking, etc.

3.2.7 For systems such as the DCS and PLC, the FAT shall cover all input and output points from the
incoming terminal blocks to the outgoing terminal blocks of the marshalling cabinets. This
includes the physical hardware connections and the software configurations.

3.2.8 All equipment used for the calibration of instrument shall be calibrated and traceable to
internal standards. Valid calibration certificates shall be made available prior to the inspection.

3.2.9 The inspector shall use test procedures and inspection sheets for all items. Whenever
available, manufacturers’ procedures and instructions shall be used.

3.2.10 FAT for package units shall conform to PTS 14.10.03.

3.2.11 FAT for on-off and safeguarding valve shall follow the guidelines detailed in PTS 14.10.01.

3.2.12 FAT for control valve shall follow the guidelines detailed in PTS 14.10.04.

3.2.13 FAT for level transmitter with level chamber (e.g. guided wave radar, displacer, etc.), control
valve, on-off and safeguarding valves shall include painting quality check.

3.2.14 FAT for analyser shall follow the guidelines detailed in PTS 14.30.05.

3.2.15 Final calibration of analyser systems shall be carried out during commissioning, prior to the
start-up of the process plant.
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3.2.16 The test plan for DCS and IPS shall be prepared by the manufacturer and agreed by approving
parties. The test procedure (including checklists) shall be designed specifically for the project.
Performance reports shall be generated.

3.2.17 FAT for DCS shall follow the guidelines detailed in PTS 14.11.04.

3.2.18 FAT for IPS shall follow the guidelines detailed in PTS 14.12.12.
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4.0 RECEIVING OF INSTRUMENTS AND MATERIALS

4.1 GENERAL

4.1.1 All received instruments and materials shall be inspected immediately upon arriving at the
warehouse or receiving area at site by a qualified instrument inspector or technician.

4.1.2 Material certifications such as Hazardous Area Protection certificate and calibration
certificates shall be checked and compiled as part of receiving requirements.

4.1.3 The inspection result, together with the details of acceptance/rejection date and inspector’s
name, shall be documented.

4.1.4 Instrument and material not meeting the requirements and specification as stated in the
purchase order or delivery order shall be rejected and kept aside for further action according
to a non-compliance procedure.

4.1.5 Instrument and material goods with damaged packaging shall be set aside for further
investigation to determine if there are damages to the instrument and material before any
decision being made either to accept or reject them.

4.1.6 All protective covers and wrapping shall be reinstated after inspection.

4.2 WAREHOUSE VERIFICATION TEST

4.2.1 All incoming instrument devices shall be tested and verified to ensure it is healthy and
functional. Any exception for test shall be agreed by approving authority.

4.2.2 The requirement of vendor presence during warehouse verification test shall be agreed in the
Quality Plan.

4.2.3 Verification test of received instruments shall be done in a warehouse that is equipped with
proper test bench completed with stable utilities (i.e. power supply, instrument air, etc.).
Otherwise verification test may be done in alternative location that has proper testing
facilities and utilities (e.g. instrument workshop, etc.) and shall be agreed by approving
authorities.

4.2.4 Prior to commencing warehouse verification test, all temporary locking mechanism installed
on instruments (e.g. gauge needle stopper, etc.) for protection during transportation shall be
removed. The locking mechanism shall be reinstated after completion of verification test if
required for further preservation.

4.2.5 Instruments shall be energized using stable power supply to ensure functioning upon power
up.

4.2.6 Any verification test carried out on the instrument devices shall be executed by a qualified
instrument technician.
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4.2.7 Any verification test for control valves and safeguarding valves shall use dry and clean (oil free)
instrument air or nitrogen from bottles, in addition to portable instrument calibrators to
stroke the valve from full open position to full close position and vice versa. This is to ensure
that the valves are not damaged or defected during the shipment, which may not be visible
from the physical inspection.
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5.0 WORKSHOP EQUIPMENT

5.1 GENERAL

5.1.1 The instrument workshop shall be adequately equipped with equipment and tools for the
repair and calibration work. This shall include utilities such as electrical power supply, water,
as well as dry and clean compressed air.

5.1.2 The list of all equipment and tools in the instrument workshop shall be included in the Quality
Plan.

5.1.3 The units of measurement of the equipment shall be in SI units unless it is project specific and
shall be agreed by approving authority.

5.1.4 The accuracy of test and calibration equipment shall be at least twice as good as the
manufacturer's stated accuracy of the instrument(s) to be tested.

5.1.5 Test bunker shall be provided for hydrotest facilities for valves as part of the safety
requirement.

Appendix shows a list of typical equipment and tools of an instrument workshop.

5.2 TRACEABILITY OF EQUIPMENT CALIBRATIONS

5.2.1 All calibration certificates for instruments and instrument systems including those of
equipment packages shall be checked and documented in accordance with the Quality Plan.

5.2.2 A complete list of instruments requiring calibration shall be agreed.

5.2.3 All calibration equipment shall be provided with a calibration certificate traceable to a primary
standard certified by an accredited laboratory which is recognized and awarded by a national
or international standards body.

5.2.4 Field test equipment (including portable equipment) shall be tested against calibration
standards at predetermined intervals in accordance with ISO 10012 and as agreed by
approving authority.

5.2.5 All traceability documents, such as the calibration certificates of individual instruments shall
be documented and controlled according to the quality management system being used.

5.2.6 The method of calibration shall be in accordance with the manufacturer's instructions and can
often be found in the equipment's instruction manual.
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5.3 CALIBRATION AND STANDARD MATERIALS

5.3.1 When QMIs are calibrated, the various calibration gases, liquids etc. shall be formulated to
reflect the concentrations expected in the process streams under normal operating
conditions. The quality of the calibration materials shall conform to the agreed requirements
as indicated by the supplier of the analyser and approving authority. All calibration certificates
shall indicate the due date for re-calibration or re-certification.

5.3.2 The certificate of gravimetrically prepared calibration materials shall be derived from the
"Certificate of Preparation" (weighing procedures) and not from post-preparation analyses
and subsequent "Certificate of Analysis". Other calibration materials shall be issued with a
"Certificate of Analysis".

5.3.3 Gravimetrically prepared calibration materials shall be used when maximum accuracy is
required of on-line analysers that measure composition. For checking and testing (e.g.
repeatability test), either a traceable or a secondary standard shall be used.

5.3.4 The site’s Laboratory personnel shall be the custodian to supervise the calibration materials
after they been delivered and installed at site. It is the responsibility of the custodian to ensure
that the installed calibration materials remain certified for continued use. Prior to site hand
over, calibration materials shall remain in the hands of the supplying party.
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6.0 FIELD INSTALLATION CHECK

6.1 GENERAL

The purpose of field installation check is to ensure that what has been installed will work as
intended and can subsequently be maintained. All installations shall be validated to conform
to approved documents.

6.2 SCOPE AND PROCEDURES

6.2.1 Prior to field installation check, the latest construction documents shall be made available.
These construction documents shall be used as primary documents to verify installations and
hook-ups. Any changes to these documents shall be governed by the Management of Change
procedure.

6.2.2 Field installation check shall be done on all instruments and no random check is allowed.
Approving authority shall be informed on any inspection activity to be done including planning
and scheduling of the activity. Instruments fitted at the factory (pre-fabricated units) may be
visually inspected provided the relevant factory inspection certificates are available.

Appendix shows examples of field installation check items.

6.2.3 Inspection sheets and verification forms shall be used to record inspection findings. If an
instrument database is being used at site or on the project then the inspection and test results
shall be stored in it. The same database shall be transferred to the Instrument Maintenance
Management System. The database shall also be utilized to produce progress reports.

6.2.4 Pressure testing shall be carried out on the installed instrument and analyser impulse and
transport lines.

6.2.5 Leak testing shall be carried out on all installed instrument signal tubing and fittings.

6.2.6 Testing of fire and gas detectors shall comply with the requirement stated in PTS 14.12.07.

6.2.7 All test and inspection activities shall be audited. The procedure for this shall be included in
the Quality Plan.

The following shall be agreed:

i. Work instructions and inspection sheets required for each item.

ii. Overall schedule and the detailed daily schedule.

iii. Relevant engineering and construction drawings as needed for inspection and
testing.

iv. Notification for inspection and testing.

v. Method for reporting the overall progress.

vi. Procedure for clearing the rejected items (punch list).

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vii. Procedure for handling changes.

viii. Procedure for handling non-conformance materials.

ix. Procedure to issue queries on the design.

6.2.8 As a general rule, sensors of gas detector systems shall remain powered-up once installed.
Hence, it shall only be installed during commissioning. If there is need to power down the
sensor after installation, it shall be carried out with proper procedure as per manufacturer’s
manual or instruction.

6.2.9 Aspirated, ultra-sensitive smoke detection systems are very susceptible to air-borne dust.
Commissioning of the systems should therefore be done as late as possible to allow the dust
in newly constructed buildings to settle down.

6.2.10 Polyethylene fire-detection tubing shall be installed only after paintwork has been completed
so as to avoid chemical attack of the tubing.

6.2.11 Valve shall be installed only after all the piping has been purged completely so as to ensure
there is no any debris left in the piping that might damage the valve internal and trim.
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7.0 SYSTEM INTEGRATION TEST (SIT)

7.1 GENERAL

7.1.1 A system integration test shall be conducted to ensure the main control system is able to
integrate seamlessly with its subsystem such as PLC, machinery control system and 3 rd party
control system. The test shall include the functionality of the communication link between the
various systems, the communication traffic loading, system’s CPU loading, critical alarm
setting and relevant logic.

7.1.2 The complete list of main control systems that require system integration test shall be agreed
in Quality Plan. Examples of such systems are Distributed Control System (DCS), Master
Control System (MCS), asset performance monitoring system, etc.

7.2 SYSTEM INTEGRATION TEST REQUIREMENT

7.2.1 An SIT procedure shall be agreed in accordance to the Quality Plan. The procedure shall
indicate requirements for the test including instructions of the activity, acceptance criteria,
witnessing parties, supporting vendors, approving authorities, etc.

7.2.2 Prior to commencing SIT, FAT of all relevant subsystems shall be completed.

7.2.3 The internal functions of each instrument system shall be tested live (i.e. with power-on). This
shall include complete testing of all communications between systems.

7.2.4 The system integration test shall include all aspects of the instrument system or tag being
tested. This shall include:

i. All associated DCS functions, displays and reports.

ii. All associated IPF functions, displays and reports.

iii. All associated interfaces.

7.2.5 The system integration test shall verify all entities or items that are internal to all systems.
This shall include Numeric, Timers, Flags, Matrices and Parameters.

Note: Any instrument signals contained within the buildings or systems contained within the building shall be tested and
commissioned only once. These signals shall include system alarms, cabinet alarms, fire detectors, manual call points,
smoke detectors, HVAC systems, earth fault detection devices and shall be witnessed in accordance with the Quality
Plan.
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8.0 FUNCTION CHECK

8.1 GENERAL

The aim is to verify the installation against the design's functional purpose. Instrument
documentation such as loop sheets, data sheets and software block diagrams shall be used.
The check is to ensure that all components are connected and functioning correctly (from the
wet-end of measurement, through control schemes to operators' displays and out to the
actuated media). The performance of all the instrument system’s features shall be functionally
verified.

8.2 FUNCTION CHECK REQUIREMENT

8.2.1 Function check shall be carried out for each instrument, tag or instrument system after field
installation check has been completed and accepted.

8.2.2 Once the function check has been completed, any subsequent change to the tag, instrument
or system would require the check to be repeated. The test results shall be recorded. The
Management of Change procedure shall be strictly adhered to.

8.2.3 The test shall not be used for calibrating instruments or systems. Adjustments shall be avoided
except when in-situ calibration is necessary.

8.2.4 Testing of analysers and analyser systems shall take place only when:

i. the required utilities are available, operational and correctly set;

ii. an analyser house has been commissioned including its systems, HVAC,
safeguarding, electrical system and sample disposal system.

8.2.5 Analysers systems should remain powered-up upon initial calibration and shall remain
isolated from the process until normal operating condition is achieved.
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9.0 SITE ACCEPTANCE TEST (SAT)

9.1 GENERAL

9.1.1 The objective of site acceptance test is to verify that the installed instrument system is
functioning as per specification and in actual site conditions. SAT is normally marked as a
critical milestone in contractual agreement to indicate completion of project’s technical
activities, to signify handover of equipment from project phase to operation phase, and as
pre-requisite for major progress payment.
SAT is normally applicable to systems (e.g. DCS, PLC, machinery monitoring and control
system, etc.).

9.2 SITE ACCEPTANCE TEST REQUIREMENT

9.2.1 An SAT procedure shall be agreed in accordance to the Quality Plan. The procedure shall
indicate requirements for the inspection/test including instructions for testing and inspection
activity, acceptance criteria, witnessing parties, approving authorities, etc.

9.2.2 SAT shall include repeating test and inspection activities done during FAT with agreed
test/inspection coverage. This is to verify equipment condition as per that of FAT’s.

9.2.3 SIT can be carried out as part of SAT.

9.2.4 At the completion of SAT, all checklists shall be signed off and accepted by approving
authorities. Final acceptance of SAT results may include successful completion of performance
test run of facilities/plant/main equipment.
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10.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:

PETRONAS STANDARDS
Index to PTS PTS 00.01.01
PTS Requirements, General Definition of Terms, Abbreviations & PTS 00.01.03
Reading Guide
Ex Electrical Equipment Inspection & Maintenance Guidelines PTS 13.40.01
(Ex IMG)
Ex Management Assessment Guidelines (Ex MAG) PTS 13.41.01
Shutdown & Blowdown Valves Sizing, Selection and PTS 14.10.01
Specification
Instrumentation for Equipment Packages PTS 14.10.03
Control Valves : Selection, Sizing and Specification PTS 14.10.04
DCS Engineering Specifications PTS 14.11.04
Design, Installation, Maintenance of Fire and Gas Detection PTS 14.12.07
System
Instrumented Protective System PTS 14.12.12
Acceptance Test of Analyser and Associated Sampling PTS 14.30.05
System

INTERNATIONAL STANDARDS
Quality management system - Requirements ISO 9001:2015
Measurement Management Systems – Requirements for ISO 10012:2003
Measurement Processes and Measuring Equipment
Issued by:
International Organisation for Standardization
1, Rue de Varembé
CH-1211 Geneva 20
Switzerland
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APPENDIX 1: TYPICAL ACTIVITIES TO BE CARRIED OUT DURING CONSTRUCTION.

No. Activities

1 Cable trench inspection.

2 Underground cable inspection (to be inspected before back-filling).

3 Cable insulation test (megger test).

4 Inspection of in-line instruments e.g. orifice plate dimensions.

5 Impulse-line pressure testing (including the seal pot).

6 Point-to-point wiring checks.

7 Earthing integrity tests.

8 Field junction box inspection.

9 Instrument cabinet inspection.

10 Check on the straight length requirements for flow meters.

11 Instrument accessibility (including stanchion pipe inspection).

Inspection of process connections, including QMI sample take off and return
12
arrangements.
Ensuring that welding activities shall not affect the electronic instruments already
13
installed.
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APPENDIX 2: TYPICAL EQUIPMENT AND TOOLS OF AN INSTRUMENT WORKSHOP

No Test equipment

1 Bench top unit.

2 Panel with adjustable air supply.

3 Plug and socket panel.

4 Stabilised power supply.

5 Analogue precision gauges.

6 Digital pneumatic pressure calibrators.

7 Digital multimeters.

8 Digital temperature calibrators.

9 Portable manually operated hydraulic pumps (bucket pumps).

10 High and low pressure, hand-help pressure pumps.

11 Vacuum pumps (manually operated).

12 Dead weight tester.

13 Thermostatically controlled temperature bath.

14 Sets of standard (precision) mercury-in-glass thermometers.

15 Decade resistance box.

16 Milliamp injector.

17 Temperature loop calibrator.

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APPENDIX 3: EXAMPLES OF FIELD INSTALLATION CHECK ITEMS

1. UNDERGROUND CABLE INSTALLATION

Trench Inspection
This inspection is required to ensure that, prior to pulling cables, the trench preparation
is complete and in accordance with the specification and route drawings.

Cable Laying
This inspection is required to ensure that cables have been laid and identified in
accordance with the specification and route. This inspection is required for each layer of
cables within a trench. Cable ends shall be protected from moisture ingress.

Glanding and Termination

This inspection is required to ensure that the cables have been glanded and terminated in
accordance with the specification and termination drawings. Care shall be taken to ensure
that the field cabling is not energised by the instrument systems. The field
termination/isolation (knife terminals) shall be opened and clearly labelled.

Cable Testing
Megger test of underground cables should be carried out after laying, trench backfilling,
glanding and termination have been completed for the cable and prior to paving.

2. ABOVEGROUND CABLE INSTALLATION

Cable Supporting Infrastructure

This inspection is required to ensure that, prior to cable pulling activity, the cable
supporting infrastructure is complete and in accordance with the specification and route.

Cable Laying
This inspection is required to ensure that the cables are correctly installed to their final
destination. Cable ends shall be protected from moisture ingress.

Glanding and Termination

This inspection is required to ensure that the cables have been glanded and terminated in
accordance with the specification and terminal drawings.

Testing
Testing of above-ground cables should be carried out after laying, glanding and
termination activities have been completed.

3. INSTRUMENT AIR SUB HEADER

This inspection is required to ensure that the instrument air subheader supports and
infrastructure are complete and in accordance with the specification and agreed route.

A procedure shall be developed and agreed for cleaning and leak testing the instrument
subheaders. These tests should be carried out for each take-off from the main header.
 PTS 14.10.07
INSPECTION AND FUNCTIONAL TESTING OF INSTRUMENTS June 2017
Page 23 of 23

The test procedure for the secure air system shall verify that the requirements of the
specification are met with regard to the number of operations for the associated
equipment.

4. INSTRUMENTS AND INSTRUMENT PANEL

Impulse/Sample Lines
This inspection is required to ensure that instrument impulse lines have been installed in
accordance with the specification and drawings. Testing should be carried out at a
minimum of the relief pressure of the associated system unless otherwise agreed with the
approving authority.

Cabling
This inspection is required to ensure that the cables have been glanded and terminated in
accordance with the specification and termination drawings.

5. CABINET AND SYSTEM INSTALLATION

A full inspection of instrument system cabinets shall be carried out to assess any transport
damage from transportation prior to installation. Approving authority shall be informed
on any defect found during this inspection; details of the defect shall be reported in the
delivery notes of the equipment as well as to the supplying party.