SAUDI ARAMCO TOTAL REFINING and

PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

SPECIAL WORKS PROCEDURE

FOR
INSTRUMENTATION WORKS EXECUTION
MRK-SWP-003/00
(Rev.00: October 2009)

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

DISCIPLINE: INSTRUMENTATION (Job Specific Work Procedure)

Title: Instrumentation Job Specific Work Procedure (MRK-

SWP-003)

1 Purpose

To ensure that the conduit, cable (above and underground) installation,

cable testing, grounding, cable termination and splicing, installation of
field and variable instruments, instrument support, stanchions,
equipments, pumps, MCCs, etc., Pre-commissioning and vendor
assistance for the commissioning processes of all electrical and
instrumentation installation works are done in accordance with the
required standards, specifications and contract scope of work and
drawings, etc.

2 Scope

This procedure serves to establish the requirements for the preparation

of checklist and to maintain records for instrumentation works, which
covers the installation, wiring, testing and commissioning, in accordance
with the scope of work, issued for construction (IFC) drawings, applicable
SATORP, national and international engineering standards and
specifications.

The purpose of this specification together with the referenced standards,

specifications and drawings is to define the quality aspects to be
considered during the installation processes.

3 Terms, Definitions & References

QA - Quality Assurance
QC - Quality Control
QAM - Quality Assurance Manager
QCM - Quality Control Manager
PC - Planning Control

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

4 References

 JERES-J-002: Regulated Vendors List for Instruments.

 JERES-J-003: Instrumentation-Basic Design Criteria.
 JERES-J-004: Instrumentation Symbols and Identification.
 JERES-J-100: Process Flow Metering.
 JERES-J-200: Pressure.
 JERES-J-300: Level.
 JERES-J-400: Temperature.
 JERES-J-601: Emergency Shutdown and Isolation Systems.
 JERES-J-604: Protective and Condition Monitoring Equipment for
Rotating Machinery.
 JERES-J_700:Control Valves.
 JERES-J-902: Electrical Systems for Instrumentation.
 ANSI/ISA-5.1: Instrumentation Symbols and Identification.

5 Responsibilities

5.1 The overall responsibility of all project execution activities is vested on

the Project Manager.

5.2 The project’s site safety officers assigned for the project shall be
responsible for the development, implementation and maintenance of
MRK's safety policy and plan throughout the project execution activities.
He shall coordinate with the Project Engineer and Site Foremen and
multicasts crew deployed under the project for its successful
implementation.

5.3 The Instrumentation QC Inspector (E & I) shall be responsible for the

overall implementation of this works procedure in liaison and
coordination with MRK's Planning Department through the project
Planner and sub contractors to ensure efficient execution of works in
accordance with the specification requirements through the QC
Supervisor, QC / QA Manager.

5.4 The QA / QC Manager and QC Discipline Inspectors (Instrumentation)

along with the QC Supervisors shall be responsible for conducting the
surveillance and inspection tasks of work defined herein and fro efficient
recording and reporting of the results as required.

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

5.5 The QA/QC Manager shall directly coordinate with the Project Manager
for the execution of all quality activities with the same level of authority.

5.6 The QA/QC Manager shall review all quality related documents, material
certificates and non conformances prior to taking any action.

5.7 The QA/ QC Manager and QC Supervisors shall review all Request for
Inspection (RFI) forms from various QC Discipline Inspectors and make a
summary report daily basis.

5.8 The Instrumentation Quality Control Inspector shall report to the QC

Supervisors and process the request for inspection for each and every
electrical and instrumentation activity which may require any inspection.

5.9 The Instrumentation QC Inspector shall carry out inspections and shall
release hold points by signing various quality records as a documentary
evidence of inspection conforming to specifications.

5.10 The site Foremen (Instrumentation) and safety officer shall jointly and
severely be responsible for the observance of all safety precautions
required by MRK's safety plan and wherever applicable to the
manufacturer’s safety indications.

5.11 The Instrumentation and Electrical QC Inspectors shall ensure that the
cable splicing and termination work is carried out as per manufacturer's
instructions. He shall be responsible for all documentations, test
reports, material certificates and non-conformance reports.

6 Safety

6.1 The assigned safety officer shall ensure that the work permit is obtained
prior to starting any work, if it is applicable.

6.2 Safety officer shall ensure that all personnel protective equipments (PPE)
are made available with all crafts as per the required standard and
specifications.

6.3 For higher voltage cable testing a person shall be stationed at any point
where the test item is accessible to unauthorized persons. Barriers shall
be erected and signs must be posted to be read as:

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

'Danger!! – High voltage cable test in progress, keep out'.

6.4 All Instrumentation and electrical cables and equipments ends shall be
guarded against accidental contact and shall be separated from all ends
or elements not subjected to testing.

7 Work Procedure

7.1 General

The quality plan for Instrumentation shall address all the prescriptions
related to the construction practice, particularly the installation,
interconnections and system integration issues.

• Instruments and impulse lines shall be protected against mechanical

damage.

• Pressure gauges and thermowells shall not be mounted directly on the

lines where vibration is likely to be present. If it couldn't be avoided,
then process of mitigating vibration shall be employed.

• All electronic instruments shall be protected from dripping and shall be

provided with steel type sun-shades and white paint furnished.

• Instruments shall be easily removable for servicing and draining, zero

and range check provisions shall also be provided.

7.2 Design of Instrumentation & Controls:

a) Instrument systems shall be designed for easy operation,

maximum simplicity and reliability and for minimum maintenance.
The instrumentation devices shall be designed according to the
applicable national and international codes and standards.

b) Signal and control wiring shall meet the requirements of JERES-J-

902.

c) The panels shall be designed as per the relevant IEC standards as

applicable indoor and outdoor services.

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

7.2.1 Design Conditions

Environmental conditions and utility conditions shall be considered

while selecting the instruments for suitability and operational efficiency.

7.2.2 Symbols

Standard instrumentation symbols shall be used in the in P&ID drawings

and legend shall be appended wherever applicable. Abbreviations specific
to the drawings shall also be appended accordingly for clarity and easy
reference. The symbols for Instrumentation shall be in accordance with
the standard ISA-S5.1 last edition. JIS Z8204 shall be used when not
found in the ISA-S5.1 last edition.

7.3 Identification of Instruments

• All instruments shall be assigned with unique tag numbers and a

cancelled instrument tag number shall not be reused to maintain proper
traceability.

• Each field and control room instruments shall have a name plate
showing the identification tag number, other instruments such as
switches, fuses, terminal strips and assorted accessories. The control
panels and cabinets shall be appropriately identified by means of
nameplates and/or tag numbers.

7.4 Instrumentation Equipments (Devices)

7.4.1 Temperature Instruments

Thermo-elements employed for monitoring temperature controllers or

shutdown temperature switches shall be placed in thermo wells installed
as close as possible to the primary elements of the monitored chain.

7.4.2 Pressure Instruments

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

The pressure gauges for steam services shall be equipped with siphon
tube. The takeoff point shall not be located near the pressure regulators,
valves etc., which tend to cause turbulence.

7.4.3 Flow Instruments

The orifice type flow meters shall not be installed on vertical piping, but
vertical orifice runs may be allowed, where necessary, on non-flushing
liquids, gas and steam

7.4.4 Level Instruments

• In general, level gauge glasses shall be located so that the mid-range

position of the instruments comes to the normal liquid level under the
design condition.

• The level gauge shall be installed so as to be accessible from the ground,

platform or ladder.

7.4.5 Analyzers

Excluded from those directly mounted on line, the process analyzers

shall generally be installed in preassembled cabinets, if required proper
ventilation shall be provided, however, keeping in view the climatic
conditions and in particular against sand storms.

7.4.6 Control Valves

The installation of control valves shall be as per the requirements of

JERES-J-700 and shall ensure proper accessibility from ground,
platform or ladder.

The connections of control valves shall conform to those of piping

specifications.

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

7.4.7 Panels, Cabinets & Control Consoles

Each unit shall be firmly and rigidly mounted in position at the

designated location. The connections required to be made inside
instrument enclosures shall be made under authorized and qualified
technicians and supervision only.

7.4.8 Process variable input –Analog signal

Process variable signals coming from field transmitters shall be

simulated as follows:

1) Flow Process Variables

Flow signal origination from different pressure type transmitters shall be

simulated by first disconnection and injecting instrument quality air into
the transmitters input line a precision pneumatic check box.

2) Flow signals originating from direct reading flow meters such as vortex
shedding meters shall be simulated by transmitter junction box and
injecting a 4-20 milliamp signal in the output leads.

The power output signal from the control room shall be verified and to be
present and correct at the transmitters.

7.4.9 Level process variables

1) Level signal originating from displacer type transmitters shall be

simulated by filling the displacer body with lube oil or distilled water as
applicable as per the requirements of JERES-J-300.

2) Level signal originating from different pressure transmitters shall be

simulated by first disconnecting the process line connections and
injecting instrument quality air into the transmitter input-line by means
of a precision pneumatic check box.

7.4.10 Pressure process variables

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

1) Pressure signal shall be simulated by first disconnecting the process line

connection and injecting a simulated process signal into the transmitter
input line using a hydraulic or precision pneumatic check box as
required by instrument range as per the requirements of JERES-J-200.

2) Pressure signals originating from different pressure type transmitter

shall be simulated by first disconnecting the process line connection and
injecting instrument quality air into the transmitter input line using a
precision pneumatic box.

7.4.11 Temperature process variables

1) Temperature signals originating from millivolt sources shall be simulated

by disconnecting the sensor leads at the thermocouple head and
injecting a millivolt signal into the output leads.

2) Temperature signals originating from RTD (Resistance Temperature

Detector)sources shall be simulated by disconnecting the sensor leads at
the RTD terminal head and connecting a variable resistance across
output lead.RTD shall comply with the requirements of JERES-J-400
Para 8.

3) Multiplexed temperature signal RTD’s thermocouples shall be checked by

first verifying the calibration of one input per multiplexer as described
below:

a) A point verification check will then be made disconnecting each

input in turn at the sensor to verify ambient temperature
indication on the control room display.

b) Where the transmitter has an integral transducer (i.e. Gould

transmitter) field simulation of the process signal may be
impractical and as such client witnessed bench calibration may be
done in lieu of field process simulation.

7.4.12 For the loop check a 4-20 milliamp signal shall be injected at the
transmitter attached junction box to verify the signal integrity.
Upon recognition, indication of ambient temperature shall be
verified.

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

7.4.13 The correct valves corresponding to the injected signal shall be

checked for five points (0, 25%, 50%, 75% and 100%) of the
instrument range on all devices displaying the particular variable.

7.4.14 Alarm states for the process variables shall be verified if specified
for the loop under check, including pre-alarm, alarm and return
from alarm values.

a) Interlocking & Shutdown Systems

• All interlocking and ESD systems, including package system shall

be checked for proper operation as and when required or
applicable as per the requirements of JERES-J-601 Para 5.

• Bypass systems shall be tested to include rack bypass switches

and light as well as common bypass alarm indication.

b) Miscellaneous Inputs

These are loops that will be verified with the assistance of a vendor
representative and include items such as analyzers and machinery protection
equipment.

c) Process Output

1) Motors

1.1 Proper control action shall be verified by witnessing motor

control operation, breaker shall be set to test position if
provided or electrically disconnected to prevent motor
operation.

1.2 Start/stop status display for each operating stage of the

motor shall be verified.

d) AOV’s and ZV’s

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

1. AOV’s and ZV’s shall be operated from the push buttons at control
room console where applicable and the local push buttons. ESD
interlocks of these valves shall be verified.

2. Correct control action shall be verified for all mode of operation.

3. All local and control room alarm indication shall be verified for
both operation and closed states, including ESD alarms and
bypass switches where applicable.

f) Local Loops

Local control loops shall be checked in a manner similar to the loops

described above. All indications shall be verified at the respective field
device. Each loop check shall be documented and compiled together
with the appropriate attachments/drawings and inspection records.

7.5 Fire Alarm System

This section includes the supply and installation of the fire alarm panel
and devices. The fire alarm initiating devices are associated with the
cabling and conduit installation, etc. The instillation processes shall be
in accordance with NEC, NFPA and local codes as shown in the
drawings.

• All references to manufacturer’s model numbers and other pertinent

information, such as; the features shall be submitted to SATORP for
approval prior to place any fire alarm material purchase order.

• All works performed and all material supplied under this section shall be
free from defects and will remain so for a period of at least one year from
the date of acceptance.

• The fire detection and alarm system shall be a complete, supervised

system, designed and installed in accordance with the requirements of
NFPA 72.

• Electrical substations shall have a fixed projected beam-type smoke

detection system. The location shall be in accordance with the

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

manufacturer's documented instructions, but shall include one projected

beam parallel to the ceiling and just above each row of switchgear or
motor control cabinets. These facilities shall have interior and exterior
audible and visual alarms.

• Inspection shall be conducted after final installation in accordance with

the approved drawings, specifications, codes and standards as reference.

7.6 Instrument Control Cables Modification

7.6.1 Wiring

Wiring shall be carried out as per the requirements of JERES-J-902

and shall be as follows:-

• Wire tagging and terminations shall be checked and "tug" tested (A tug
test involves physically stressing a wire termination to determine
whether it has been crimped and terminated properly. The intent is not
to break wiring or stress insulation but to test the integrity of the
termination).

• Splices shall not be permitted in wiring. When wiring must be extended,

connections shall be made via terminal blocks in a junction box installed
aboveground.

• Minimum spacing requirement between parallel runs will be maintained

as per JERES-J-902

• Analog current/voltage, discrete (on/off), thermocouple, ESD, load cell

and AC signals will be routed via separate, segregated cabling.

• Testing and commissioning shall be done in accordance with the special

procedures, vendors and/or manufactures instructions or supports and
shall be documented via MRK’s testing and pre-commissioning forms
and checklists as applicable.

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

7.7 TMR / BMS

Installation and connection of TMR/BMS and connection with UCN to

TMR and verification of communication shall be done by making all the
field parameters healthy condition from the field and by checking each
signal from the TMR/BMS and verifying the communication.

7.8 DCS / PLC

Installation and connection of TDC 3000 PLC cabinets and installation

connection of power cable and internal wiring for the marshalling
cabinets and check all the loops related to DCS and PLCs and serial
communication and check all the shutdown logics from DCS to field with
reference indication of PLC. All the loop diagrams and data shall be
checked and verified.

8 FIBER OPTIC CABLES INSTALALTION PROCEDURE

8.1 Cable Routing

The fiber optic cables (FOC) route for all new cables shall be approved by
SATORP prior to start the trenching and cabling works. Cable routing
shall be done in accordance with the requirements of JERES-T-624.

Following are the major cable installation method:

a) Underground (in conduit)

b) Buried (Direct buried, i.e. not in a conduit).

All buried and above ground cables route shall be marked in accordance
with SATORP standard drawing AA-036897. The maximum attenuation
of each fiber within cable when normalize to a length of 1 Km at wave
length=1.300NMshall be 0.5 db/KM or less at wave length = 1550NM
shall be 0.3db/KM or less as per table-4 of JERES-T-634.

8.2 Cable bending radius for fiber optics:

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

a) Shall be 10 times the cable diameter, when the cable is not under
tension as per the requirements of JERES-T-624 Para 5.1.10.
b) Shall be 20 times the cable diameter, when the cable is under tension as
per the requirement of JERES-T-624 Para 5.1.10.

c) Pulling tension on fiber optic cables shall not exceed 600 pounds as per
the requirement of JERES-T-624 Para 5.1.11.

d) Cable should be pulled in a straight line and never bend and wrapped.

8.3 Direct buried cables placement methods and safety requirement

Before plowing in fiber optic cables, it is recommended that, the route to

be pre ripped, so that the obstacles can be identified and removed and
the placing operation precautions during the installation and backfilling
shall be in accordance with the requirements of JERES-T-628 and
JERES-T-629.

8.4 Preparation for splices and other requirements

Before beginning the splicing operation:

• Secured the cables in an optical fiber splice organizer.

• Banned and ground all metallic members of the cables.

• The ground resistance should be 25 ohms or less to prevent fiber optic

damage handle buffer tubes.

• Splicing shall be done as per the requirements of JERES-T-632.

8.5 Testing & Inspection

a) End to end testing shall be carried out on all outside planned fiber optic
cables facilities.

b) Splice acceptance test.

c) On reel acceptance tests by the approved testing agency, reel test report
shall be submitted to SATORP PMT/PID for their review and record.

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

9 Pre-commissioning & Acceptance

9.1 All checks will be accepted only if the verification of correct responses or
resultant signal has been in existence during simulation or actuation
period.

9.2 The client witness and/or authorized representative shall issue final
acceptance of instrument loops being checked by signing-off on space
provided on the instrument loop check report form/checklist.

9.3 All devices not proper signal setting shall be-calibrated or adjusted
accordingly to the normal settings conditions. The defective and/or
damaged instruments and devices shall be replaced by calibrated and
tested units.

10 Records

1. All test records pertaining to this procedure shall be prepared by using

SATORP approved forms and sign-off for witnessing and approving party
obtained.

2. Copies of signed-off records of loop checks shall be issued to witnessing

and approving parties.

3. One or several copies of each record or reports shall be retained in

project file and should be made available upon request in the future.

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)

 SAUDI ARAMCO TOTAL REFINING and
PETROCHEMICAL COMPANY
Jubail Export Refinery Project
M. R. Al-Khathlan Contract No. 3000235436, Auxiliary Utilities (Package 5C)
CONSTRUCTION QUALITY PLAN

MRK/QAD/JER/PKG5C-CQP (Rev. 00: December 20 ‘09)