B Installation Inspection

A5
CONTRACTOR personnel performing test and calibrations shall be trained
per applicable international or manufacturer requirements.
Schedule Q,
Att. IV, Sec.6.2
A6
Contractor to produce test results / certification that the pyrometers were
standardized against other optical pyrometers that have been calibrated
by the National Bureau of Standards.
A4
CONTRACTOR shall provide backup equipment when the primary
equipment is being calibrated or tested.
Schedule Q,
Att. IV, Sec.6.1.
A2
The CONTRACTOR shall identify, maintain, control, adjust, and calibrate all
tools, gauges, instruments and other measuring and testing devices used
for controlling quality.
A3
Calibration shall be performed at established periods as specified in
the most stringent of SAUDI ARAMCO standards, other applicable
standards, or manufacturer recommendations; if no standards apply,
the calibration cycle shall not exceed six months.
Schedule Q,
Att. IV, Sec.6.1.
A1
Specific tools and equipment shall be identified to make and perform tests
in the field with instructions for their use, calibration, and storage.
Schedule Q,
Att. IV, Sec.6.1.
Schedule Q,
Att. IV, Sec.6.1.
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED
SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL
TRAVEL TIME
SAUDI ARAMCO USE ONLY
SCHEDULED TEST DATE & TIME ACTUAL TEST DATE & TIME QUANTITY INSP. MH's SPENT
LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.
EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID.
WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
SATR-J-6406 1-Oct-05 INST
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
RE-TEST
DATE
ITEM
No.
TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE PASS
A Certification
Temperature -Transmitter T/C type-Functional Check / Testing,
and Certification
PROJ ECT TITLE
FAIL N/A
PLANT NO.
SAES-J -400,
Sec. 3.2
B1
All temperature sensing elements shall be installed in thermowells.
Exceptions: Sensors for bearing, motor winding, furnace, skin or surface
temperature measurement, ambient air, electronic equipment cabinets.
(However, a mechanical protection sleeve shall be considered for the
sensors in the area where there is possibility of damage such as pump
bearings.).
SAES-J -400,
Sec.5.1
B2
All temperature instruments, connections, and primary elements shall be
located to provide safe access for installation and maintenance.
SAES-J -400,
Sec.4.3.1
B3
Instrumentation requiring frequent access, such as local controllers, shall
be located no more than 1.5 meters above grade or permanent platform.
Instruments requiring limited access, such as temperature transmitters,
shall be no more than 3 meters above grade or permanent platform, and be
accessible by ladder or mobile platform.
SAES-J -400,
Sec.4.3.2
B4
When process temperatures are less than 535C and pressure-temperature
design conditions do not require an ANSI Class 900 or higher flange,
threaded or flanged thermowells may be used. If process temperatures
exceed 535C or the pressure-temperature design conditions require an
ANSI Class 900 or greater flange, flanged thermowells shall be used.
SAES-J -400,
Sec.5.2.1
Page 1 of 10
Temperature -Transmitter T/C type-Functional Check /
Testing, and Certification
SATR-J-6406 1-Oct-05 INST
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
PASS FAIL N/A RE-TEST DATE
ITEM
No.
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE
B5
Weld-in thermowells shall only be used when ASME or Saudi Aramco
standards or specifications require welded connections.
SAES-J -400,
Sec.5.2.2
B6 Thermowells shall be tapered and machined from barstock material.
SAES-J -400,
Sec.5.2.3
B7
Thermowells shall be 316 stainless steel unless alternative metallurgy is
specified or dictated by process conditions. Alternative metallurgy shall
be approved by the Materials Engineering Unit of CSD
SAES-J -400,
Sec.5.2.4
B8
Threaded thermowells shall be constructed and installed in accordance
with Standard Drawing AB-036019.(Attachment 2 of 4)
Commentary Note: Threaded thermowells with -inch MNPT process
connections shall be used only when required to replace existing -inch
thermowells.
SAES-J -400,
Sec.5.2.5
B9
Flanged thermowells shall be furnished with ASME B16.5 flanges.
Flanged thermowells shall be constructed and installed in accordance
with Process Industry Practice PCFTE000 Temperature Measurement
Fabrication Details, Drawing PCFTE102. Flange size shall be 1- inch
minimum 300 #RF. See attachment 3
SAES-J -400,
Sec.5.2.6
B10
Standard thermowell bore selection for Threaded and Flanged
thermowells is 0.260 inch. The thermowell bore may be increased to
0.385 inch where required (e.g. filled systems). For the flanged
thermowell the tip diameter shall then be increased to 0.75 inc
SAES-J -400,
Sec.5.2.7
B11
Insertion Length
Initial insertion length "U" for threaded thermowells in process piping
shall be per Standard Drawing AB-036019. Attachment 2 of 4
SAES-J -400,
Sec.5.2.8.1
B12
Initial insertion length "U" for flanged thermowells in process piping shall
be per Process Industry Practice PCFTE000 Temperature Measurement
Fabrication Details, Drawing PCFTE102.
Commentary Note: The final selection may be shorter based on wake
frequency calculations as detailed in Paragraph thermowell vibration and
stress. Attachment 2 & 4
SAES-J -400,
Sec.5.2.8.2
B13
For process vessels and columns, the maximum insertion length shall be
600 mm (24 inches).
Exception:
For Catalyst Bed and other similar temperature profile measurements,
extended thermowells are allowed. Extended thermowells shall be in a
vertical orientation if feasible or supported such that vibration/gravity/
flow effects shall not cause fatigue or deformation failure of the
thermowell.
SAES-J -400,
Sec.5.2.9
B14
Thermowell Vibration and Stress
Natural frequency and wake frequency calculations shall be performed
on each thermowell application, per ASME PTC 19.3.
If the calculated wake frequency is equal to or greater than 80% of the
thermo well's natural frequency, the next shorter standard size well shall
be specified until the calculated wake frequency falls below 80% of the
natural frequency. Standard U-lengths should be chosen whenever
possible.
SAES-J -400,
Sec.5.3.1.
Page 2 of 10
Temperature -Transmitter T/C type-Functional Check /
Testing, and Certification
SATR-J-6406 1-Oct-05 INST
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
PASS FAIL N/A RE-TEST DATE
ITEM
No.
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE
C Calibration Record / Test Equipment model :
Test Equipments Serial number:
a) Smart Field Communicator (SFC)
b) Millivolt generator
c) Digital Multimeter
d) Supply Unit
e) 250 Ohms Resistor
C1
General Test Routines D
B15
For Flanged Thermowells, where the calculated U-length ends up being
too short for good heat transfer, modifications to the thermowell design
may be made such as:
a) A thermowell collar or special flange weldolet may be used to tightly
hold the thermowell to the flange near the pipe wall, thus effectively
reducing the calculation U-length, or;
b) External dimensions such as root and tip diameter may be increased
to lower the wake frequency and increase the resonant frequency.
SAES-J -400,
Sec.5.3.2
C Calibration Inspection
B16
Maximum process pressure and static stress calculations shall be
performed on each thermowell application, per ASME PTC 19.3.
Commentary Note: Pressure and static stress effects may combine with
wake frequency vibration to cause failure of thermowells.
SAES-J -400,
Sec.5.3.3
C1 Instrument checked against data sheet and Attachment 1
Schedule Q,
Att. IV, Sec.6.1.
C2 General conditions satisfactory
Schedule Q,
Att. IV, Sec.6.1.
C3 Instrument checked for damage
Schedule Q,
Att. IV, Sec.6.1.
C4 Tag number
Schedule Q,
Att. IV, Sec.6.1.
C5 Line Size
Schedule Q,
Att. IV, Sec.6.1.
C6 Line number
Schedule Q,
Att. IV, Sec.6.1.
C7 Material
Schedule Q,
Att. IV, Sec.6.1.
Page 3 of 10
Temperature -Transmitter T/C type-Functional Check /
Testing, and Certification
SATR-J-6406 1-Oct-05 INST
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
PASS FAIL N/A RE-TEST DATE
ITEM
No.
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE
1. Instruments shall be calibrated in a clean , dry, and air conditioned test and calibration workshop.
2. Test Instruments for Calibration shall be split in to two categories- Primary & secondary.
3. Primary instruments shall be high precision instruments and have valid calibration certificates traceable to a National Standards
laboratory.
4. The instruments shall be Calibrated every 6 months and the certificate retained in the workshop available for the Clients Inspection.
5.Primary instruments shall remain in the calibration workshop and shall not be removed to site.
6.Secondary instruments of lesser precision shall be calibrated by the Primary Instruments and shall be used for calibration works both with
in
the workshop and in the field.
7. Prior to calibration, the instruments shall be inspected to ensure that there is no physical damage. The instrument shall be identified by
Tag
No. and checked against data sheet, manufacturer, correct model, range, span and connection size .
8. All instruments must have a Calibration Certificate which is held in a file in the Instrumentation Work shop and is available for inspection o
request.
9. Field Instruments when not held in the Calibration workshop must be signed out /signed in on a Daily basis. This task to be done using a Lo
book system. The Log book to be made available for inspection on request.
10.All instruments used for Testing on project,on Arrival in to the Instrument Work shop must be logged in to a controlled log book of
instruments to be used on project. The Log book to be made available for inspection on request.
11.Instruments used daily for Testing on site to be entered on a daily log sheet .One copy to be kept in the Instrumentation work shop and on
copy to be placed in the instrumentation R.F.I box.
Test Procedures
D1
E
E1
F1
F
(a) Check Temperature transmitter against Data sheet.
(b) Connect as per attached hook-up drawing.
(c) Ensure that all polarities are correct and all connections are tight. Connect SFC, red wire to positive, black to negative.
(d) Switch on power supply and SFC unit.
(e) When the SFC is communicating , check that the ID of the transmitter is correct .
(f) If the output of the Transmitter is analog format proceed with calibration.
(g) If the output of the transmitter is digital format, change the format to analog using the SFC and as per the operations manual.
(h) When the output has been changed to analog proceed with calibration.
(i) Using T/C Tables, inject 0% input with millivolt generator and note that the output should be 4 mA, on the Multimeter.
(j) Inject 25,50,75,& 100 % of the range to the Transmitter and note that the output should
be 8mA,12mA,16mA and 20mA respectively.
(k) Then proceed in the reverse direction from 100% to 0%.
(l) If the error is greater than the allowable tolerance, inject 0% to the input of the transmitter and using the SFC and the operations
manual,adjust transmitter until output reads 4 mA
(m) Inject then 100% input and adjust accordingly the output should equal to 20 mA or 100%.
(n) Repeat steps (l) and (m) until accuracy is with in required tolerances.
(o) When accuracy is with in required tolerances repeat steps (i),(j) (k) and record the reading on the calibration certificte.
(p) For those transmitters are digital formatted, change back from analog to digital format using the SFC with reference to operators manual.
(q) After the calibration is completed turn off power supply.
(r) Disconnect all wiring and replace cover tightly.
(s) Then place calibration Tag, which shall be a blue colour on transmitter
(t) Sign off calibration sheet
(u) Instrument calibrations will be repeated where necessary during pre-commissioning or at any other stage where deficiencies are to be
rectified.
G - Tabulate the pass/fail criteria here (include range, limits, and units of measurement)
Test Variables
Manufacture's Test Variables if any to be highlighted including the
following:
F1 The temperature indicators / thermometers, 0% equal to the ambient
temperature of the room.
F2.The manufacturers instructions regarding adjustment, preservations,
accuracy to be adhered to.
Page 4 of 10
Temperature -Transmitter T/C type-Functional Check /
Testing, and Certification
SATR-J-6406 1-Oct-05 INST
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
PASS FAIL N/A RE-TEST DATE
ITEM
No.
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE
1. Schedule G -- Material, Tools and Equipment (Pro Forma MP-IK-LS Contract), J uly 1993
2. Schedule Q -- Quality Requirements (Pro Forma Contract), November 2003
Hystersis at 110%
Specific gravity setting (For liquid interface level measurement)
After successful completion of each calibration, the instrument shall be marked with a colored label bearing date of the calibration and the initials of
the witnessing party The color code shall be as follows:
Blue- Pre Calibration Tested.
Yellow - Installed & Pressure Tested.
Green- cables or tubing tested.
Red- Loop Check completed.
REFERENCE DOCUMENTS:
Resistance
0%
25%
Simulated Input Out Put
H. RESULTS
ITEM
No.
TEST RESULTS ACCEPTANCE CRITERIA PASS FAIL N/A RE-INSP DATE
75%
25%
50%
100%
0%
I. CONCLUSIONS
Ambient:
Insulation Resistance
Notes: a. Indicate in 1 report all instruments of a skid tested and passed .
b. Rejected items should be listed in another report, unless they were corrected
within the calibration period.
c. Instruments repaired shall be indicated "Repaired and Accepted" in the test report.
5. ASME PTC 19.3 -1974, Part 3, Temperature Measurement- Instruments and Apparatus, Supplement to ASME Performance test codes
REMARKS:
3. SAES-J -400, Temperature, 31 May, 2004
4. ISA-MC96.1-1982 Temperature Measurement Thermo couples
Error
75%
Input %
Page 5 of 10
Temperature -Transmitter T/C type-Functional Check /
Testing, and Certification
SATR-J-6406 1-Oct-05 INST
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
PASS FAIL N/A RE-TEST DATE
ITEM
No.
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE
Y =YES N =NO F =FAILED *Person Responsible for Implementation of Test and Analysis of Results
QC Record Reviewed Work Verified
Name, Sign and Date:
Quality Record Approved:
Name, Organization,
Initials and Date:
T&I Witnessed
QC Supervisor Proponent and Others
Name, Initials and Date:
Witnessed Test
or services, that maintains periodic inspection of production of listed equipment or materials or periodic evaluation of services, and whose listing
that the equipment, material, or services either meets appropriate designated standards or has been tested and found suitable for a specified
Work Verified T&I Witnessed QC Record Reviewed
QC Inspector PID Representative
indicates compliance with appropriate standards or performance in a specified manner.
Technician Performing Test*
Name, Title, Department,
Company, Initials and
Date:
1. Approved - Acceptable to the authority having jurisdiction (i.e., Saudi Aramco ID).
2. Identified - Recognizable as suitable for the specific application by a qualified testing laboratory (i.e., listing and/or labeling).
3. Listed - Equipment and materials included in a list published by an approved qualified organization concerned with evaluation of products
ATTACHMENTS:
Attachment 3 Threaded thermowells-Practice PCFTE000 Temperature Measurement Fabrication Details, Drawing PCFTE102.
NOTES:
6. SAMA RC 21-4-1966 Scientific Apparatus Makers Association, Temperature- Resistance Values for Resistance Thermometer elements for
Platinum, Nickel and Copper.
Attachment 2 Threaded thermowells -Standard Drawing AB-036019
Test Performed Successfully and Results are Acceptable:
Name, Initials and Date:
5. Remarks: -1. Table G to be modified based on usage.
2. Exergen models are used as example. The product has to be approved by CSD and proponent.
Contractor / Third-Party
QC Record Reviewed
Work / Rework May Proceed
Name, Initials and Date:
4. Labeled - Equipment or materials to which has been attached a label, symbol, or other identifying mark of an approved qualified organization
Work Verified
Saudi Aramco
with product evaluation, that maintains periodic inspection of production of labeled equipment or materials, and by whose labeling the
f
PMT Representative
T&I Witnessed
Attachment 4 Temperature Instrument Installation- PCCFTE001
Attachment 1 Instrument Installation Check List
Page 6 of 10
Contractor / Third-Party Saudi Aramco
Technician Performing Test* PMT Representative
4.3 Check connection terminations with instrument for tightness
4.1 Check electrical installation with respect to conduits, glands, seals, are correct
4 Cabling / Signal / Conduit
4.4 Instrument installation pressure tested as required
4.2 Core and cable tagging are meggered and checked
3.9 Pressure Test of impulse tubing
3.8 Leak Test done
3.6 Tubing slope Checked
3.7 Verify Tubing connection to HP & LP sides
3.5 Vent and drain / manifold installed
3.1 Steam tracing and insulation as per hook up
3.4 Isolation and equalization valves / manifold installed
3.3 Seal fitting installed and Filled
2.6 Sunshade installed
3.1 Material used according to specification
3 Impulse Tubing
2.7 Stand and Support Secure
Temperature -Transmitter T/C type-Functional Check /
Testing, and Certification
INST
PASS FAIL N/A Remarks
SAUDI ARAMCO ID/PID - 4/14/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
SATR-J-6406 1-Oct-05
Attachment 1 Instrument Installation Check List
Instrument Installation
Instrument Calibrated prior to installation and documentation checked 2.1
2.2 Instrument mounted in accordance with hook up drawing.
Deburred , Primed and Painted
1.3
Stand and Support Secure
Instrument location as per IPL Drawing
Access is unobstructed and clear for maintenance
Stand earthed
1.2
2
2.5 Elevation correct relative to process tapping
2.3
1.6
1.5
1.4
2.4 Instrument securely installed on stand
Check instrument is correct in accordance with ISS / P & ID
Attachment 1 Instrument Installation Check List
Project: --------------------------------------------------------------------------------------------------------- Plant Area--------------------------------------
Location :---------------------------------------------------------------------------------
Unit No: -------------------------------------------------------------Tag No:----------------------------------------------Manufacturer------------------ -----------------------
Specification Sheet No:---------------------------------------------------Serial No----------------------- System Plant No------------------------------
Instrument Stand / Supports
Fabrication of Stand as per drawing
ITEMS TO CHECK
ITEM
No.
1
1.1
QC Inspector PID Representative
Name, Title, Department,
Company, Initials and
Date:
Test Performed Successfully and Results are Acceptable:
Name, Initials and Date:
T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date:
Witnessed Test Work / Rework May Proceed
Name, Initials and Date:
Work Verified
T&I Witnessed QC Record Reviewed Work Verified
*Person Responsible for Implementation of Test and Analysis of Results Y =YES N =NO F =FAILED
QC Supervisor Proponent and Others
Name, Sign and Date:
Quality Record Approved:
Name, Organization,
Initials and Date:
T&I Witnessed QC Record Reviewed
Page 7 of 10
SAUDI ARAMCO ID/PID - 4/14/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO INSPECTION CHECKLIST
SAIC NUMBER DATE APPROVED QR NUMBER
SATR-J-6406 1-Oct-05
Attachment 2 Threaded thermowells -Standard Drawing AB-036019
Temperature -Transmitter T/C type-Functional Check /
Testing, and Certification
INST
Page 8 of 10
SATR-J-6406 1-Oct-05
Attachment 3 Flanged thermowells-Practice PCFTE000 Temperature Measurement Fabrication
Temperature -Transmitter T/C type-Functional Check /
Testing, and Certification
INST
SAUDI ARAMCO ID/PID - 4/14/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO INSPECTION CHECKLIST
SAIC NUMBER DATE APPROVED QR NUMBER
Page 9 of 10
SATR-J-6406 1-Oct-05
Attachment 4 Temperature Instrument Installation- PCCFTE001
Temperature -Transmitter T/C type-Functional Check /
Testing, and Certification
INST
SAUDI ARAMCO ID/PID - 4/14/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO INSPECTION CHECKLIST
SAIC NUMBER DATE APPROVED QR NUMBER
Page 10 of 10