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KUWAIT OIL COMPANY (K.S.C.)

Engineering Group

Specificstion Number
015-JH-1910
Mechanical Completion of Instrument Systems

1 5 DEC 94 ISSUED AS KOC ENG GROUP SPEC

0 7 MAR 93 ISSUED FOR INVITATION TO BID

Rev Date Revision BY Chkd Section PE Client

 Project Number Specification Number Rev Date Sheet

EF719 1 4 01 5-JH-1910 0 5 Dec 94 2 o f 15

CONTENTS I

1.0 SCOPE ............................................... 3

2.0 NATIONAL CODES AND ENGINEERING GROUP SPECIFICATIONS ....... 3

3.0 SERVICE CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.0 BASIC ENGINEERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.1 Construction Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 . 2 Quarantine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 . 3 Defined Test Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 . 4 Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.5 Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5.0 CONSTRUCTION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5.1 Mechanical Completion Checklists . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2 Manufacturer and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6 . 0 PERFORMANCE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 Mechanical Completion Test Equipment . . . . . . . . . . . . . . . . . . . . . 8
6 . 2 Documentation Record of Completion Tests . . . . . . . . . . . . . . . . . . 9
6 . 3 Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.4 Completion Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.5 Witnessed Mechanical Completion Testing . . . . . . . . . . . . . . . . . . . 1 3
1.0 SCOPE

1.1 This specification details the minimum requirements for mechanical

completion of instrument systems. It is the Contractor's responsibility to
ensure that the complete system is inspected and tested throughout all stages
to ensure a smooth and trouble-free startup of the plant, free from danger to
the operations personnel and without damage or excessive wear to any of the
instruments or systems.

1.2 The plant instrumentation shall fully comply with all relevant contractual
requirements specified in the Scope of Work and Technical Specification of
the Contract.

2.0 NATIONAL CODES AND ENGINEERING GROUP SPECIFICATIONS

2.1 Instruments, systems, equipment and testing shall conform in design, supply,
materials and performance, except where otherwise specified, with the
current issue and amendments of the applicable codes and standards
prevailing on the effective date of the Contract.

2.1.1 A non-inclusive listing of applicable codes and standards is to be

found in the Engineering Group Specification entitled "lnstrument
Engineering Basic Data" (Number 015-JH-1901).

2.1.2 Engineering Group Specifications

All equipment and accessories covered by this specification shall

comply with relevant Engineering Group Specifications of which the
following are specifically referenced in this specification:

01 5-AH-1001 Basic Design Criteria

01 5-AH-1002 International Codes and Standards

015-JH-1901 Instrument Engineering Basic Data

2.2 Compliance with this specification shall not relieve the Contractor of its
responsibility to supply equipment suited to meet the specified service
conditions and applicable regulations.

2.3 Where conflicts exist between this specification and other Drawings,
standards, codes and specifications, the most stringent shall be applied.

3.0 SERVICE CONDITIONS

3.1 The equipment shall be suitable for continuous operation at a desert location
under high ambient temperatures and humidity. The atmosphere at the
Facility is generally dusty and corrosive and may contain traces of hydrogen
sulphide.
 Project Number Specification Number Rev Date Sheet

EF71914 015-JH-1910 0 5 Dec 94 4 o f 15

3.2 The plant instrumentation systems shall in all respects be suitable for
continuous operation in the service conditions stated in the Engineering Group
Specification entitled "Basic Design Criteria" (Number 015-AH-1001).

4.0 BASIC ENGINEERING INFORMATION

4.1 Construction Drawings

Before commencing mechanical completion inspection and testing, the

construction records shall be reviewed against the Facility pipe work and
instrument systems to ensure that all necessary requirements have been met,
and that the Drawings have been revised in accordance with modifications
made during construction, re-issued and approved by the Company.

4.2 Quarantine

lnstruments or systems in any incomplete areas of the plant, or

those with known faults, shall be fully identified and documented
and recorded in a Quarantine Register. Where possible, the affected
areas of the plant shall be marked by warning labels or other durable
markings, of a type approved by the Company.

lnstruments or systems found defective during testing, and not

rectified during the immediate course of the test, shall also be
placed in the Quarantine Register. This may be effected by use of
a copy of the affected failed test record sheet.

Any instruments or instrument systems designated as quarantined

shall be tested or retested, and until the tests are satisfactory,
cannot be removed from the Quarantine Register.

Items in the Quarantine Register cannot be used for later stages of

the mechanical completion testing structure as described in this
specification. Mechanical Completion cannot be achieved while
there are any items on the quarantine list.

4.3 Defined Test Areas

Testing shall be conducted systematically in defined areas, on dedicated

equipment or equipment groups or on other types of system where the limits
can be clearly identified. The Contractor shall adopt procedures which avoid
parts of the system being missed from the testing schedule.

4.4 Warnina Labels

4.4.1 Warning labels from other disciplines on any equipment or pipework

affecting parts of the system to be tested shall be noted and
followed. Where applicable they shall be cause to quarantine the
affected parts of instrument systems.
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4.4.2 Instruments or systems creating restrictions on the test methods

that can safely be adopted, eg. low-energy systems, fragile
instruments etc. shall be identified and the instruments, etc. shall be
identified, and the instrument/junction boxes labelled to avoid
accidental damage during the testing.

4.5 Test Procedure*

4.5.1 The various categories of loops, systems, hook-ups etc. that

constitute the complete system shall be identified and suitable test
procedures and schedules developed for each separate type. These
shall be submitted to Company for written approval before
proceeding. Company authorisation shall not limit in any way
Contractors responsibility in the testing, or in any additional testing
that may prove necessary.

4.5.2 The test procedures shall be arranged to clearly demonstrate the

integrity and operability of the system without overloading any of
the components. Each procedure shall be accompanied by a check-
list. The lists shall not be of a general nature but shall be specific to
an item e.g., an instrument, unique loop or system. More than one
item can be on a sheet providing clarity is not affected.

4.5.3 Company may wish to witness part or all of the testing and will
advise requirements to Contractor's as part of the document review,
or on the review of the Contractor's submitted quality (test and
inspection) plan, which shall be submitted for approval 3 months
before testing is scheduled to start.

5.0 CONSTRUCTION REQUIREMENTS

5.1 Mechanical Com~letionChecklists

Apart from the tests for specific items covered by the test procedures, the
construction requirements for the plant in general shall be verified and
confirmed on checklists. These lists shall be prepared by Contractor for all
systems and shall typically include:

5.1.1 For All Types of Equipment

a. Standard and finish of components and assemblies, including

supporting structures and paint work.

b. Overall dimensions, installation methods and construction are in

accordance with approved Drawings.

c. Frameworks are sufficiently rigid to support all equipment and

systems (including "future" spare capacity), without distortion.
 Project Number Specification Number Rev Date Sheet

Q KOC ~ ~ 7 114 9 015-JH-1910 0 5 Dec 94 6 o f 15

d. Individual devices are accessible for adjustment and/or

maintenance without removal of trunking, wiring, supports and
other instruments.

e. Equipment generating heat is suitably located for cooling (and

cooling provided if necessary).

f. Cabling and other items are suitably protected from the direct
sun.

g. Gland entries are not at the top of enclosures.

h. Shutdown instruments colour coded.

i. Tags, nameplates and warning labels have all been fitted

according to the national and local laws and the Engineering
Group Specifications.

j. Terminals and cabling segregated and protected to meet the

most stringent requirement of the hazardous area, electrical
safety and the Engineering Group Specification.

k. Terminals and junction boxes correctly identified.

I. Adequate spare capacity provided in wiring and traywork,

junction boxes, trenches and ducts, etc. in accordance with the
Engineering Group specification entitled "Instrument Installation"
(Number 01 5-JH-1908).

m. Earthing completed in accordance with the Engineering Group

Specification.

Field Supporting of Instruments

a. Adequate mounting, tightness of bolting.

b. Adequate sun shielding and other necessary protection.

c. Accessibility for servicing, venting and draining, correct tagging

and labelling.

d. Correct orientation and direction for ease of reading by the

operator.

Pneumatic System

a. Completeness and freedom from damage.

b. Tightness of all connections.

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EF719 14 015-JH-1910 0 5 Dec 94 7 0 f 15

c. Neatness of the runs, access to equipment, flexibility and

adequate supporting.

d. Airsets etc. independently supported.

e. Airset spring range adequate for instrument and set correctly.

f. Adequate low point drainage.

g. Tag number on the air supply isolation valve agrees with the
served instrument.

h. All valves operable, free from finger traps and accessible.

i. Main header valves on shutdown service painted red and locked -

open.

j. PVC sheaths of copper piping properly terminated within the

O-ring seals.

5.1.4 Direct Connected lnstruments

a. Thermowells, orifice plates, in line instruments, level instruments,

valves:

1. Assembly is in accordance with the Approved Manufacturer's

Drawings and instructions.

2. Complete and free from damage.

3. Correct gaskets and bolting used, tightening torque correct.

4. Direction of flow correct (includes checking of orifice plates

in vertical pipes, liquids near their flashing point shall flow
upward, gases near their condensing point shall flow
downward .)

5. lnstruments correctly orientated and concentric to pipe bore.

6. Clearance for removal and maintenance adequate.

7. Accessibility adequate for scale or readout, handwheel,

resets, labelling, gland connection etc. as applicable for the
instrument.

b. lnstruments connected via stainless steel tubing and compression

fittings, also direct-mounted pressure gauges.

1. Complete and free from damage.

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 Project Number Specification Number Rev Date Sheet

EF71914 01 5-JH-1910 0 5 Dec 94 8 o f 15

Correct materials used for the hook-up and certificates

available.

Instrument flange is of a suitable specification for the

process service, or equal to the line class flanges.

Correct gaskets and bolting used, tightening torque correct.

Installation is neat, accessible and free from pipe crimps due

to over bending.

Expansion allowance made between fixed components.

All joints tight, free from tape sealant or other compounds

unsuitable for the process conditions.

Disposal systems for hazardous vent and drain effluent are

provided in accordance with the effluent type and
temperature and pressure.

Self-venting and draining arrangements are in accordance

with the service and the characteristics of the fluid. Any
necessary fill legs, drip legs or balance legs etc. have been
provided.

5.2 Manufacturer and ADDlication

Every procedure checklist shall include a verification by the Contractor's

Inspecting Engineer that the item and its installation materials are suitable for
the application in which they are installed, regarding:

5.2.1 Supply by a Company-approved Manufacturer.

5.2.2 The rating of the instrument is in excess of the process conditions.

5.2.3 The whole assembly is suitable for the environmental conditions.

5.2.4 Other factors relevant to the individual application have been

adequately covered.

6.0 PERFORMANCE REQUIREMENTS

6.1 Mechanical Com~letionTest Eaui~ment

6.1 .I All test equipment shall conform to National or Local laws as

applicable.

6.1.2 As a minimum the equipment shall be to industrial standards and

shall have a current calibration certificate, not less than six months
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 Project Number Specification Number Rev Date Sheet

EF719 14 01 5-JH-1910 0 5 Dec 94 9 of 15

old. This period shall be shorter for fragile testing instruments. The
calibration certificate shall be available for verification and approval
by the Company during the tests.

6.2 Documentation Record of Comoletion Tests

6.2.1 All examination and testing shall be conducted in a structured way,

using the test procedures and checklists. Procedures proving to be
inadequate or unworkable shall be re-written by the Contractor and
re-approved by the Company.

All tests shall be reported on a document clearly identifying the

loop, component or system, shall state the object of the test and
the procedure being followed, and shall state the result and the
conclusion. The checklist shall be specific to the identified item, All
failed tests which cannot be rectified during the immediate testing
shall be a reason to quarantine the item. The item shall subsequently
be repaired and re-tested until successful, and the results of such
tests appended to the earlier report, so that there is a continual one
source traceability of the status of any item.

6.2.3 Where witnessing by Company has been requested for any item, the
Contractor must coordinate the testing to suit Company availability.
This Witnessing is not to be confused with the "Witnessed
Mechanical Completion Testing" noted later within this specification.

6.2.4 The Contractor shall take due note of those items marked as HOLD
points on the quality plan.

At the end of the successful completion testing, the procedures, checklists,

test instrument certificates and the results of all tests shall be collated in an
easily referenced manner and submitted to Company for approval.

6.4 Comoletion T e a

6.4.1 Blowdown and Leak Testing of Pneumatic Systems

After examination, each distribution system shall be blown down

with clean, dry, instrument quality air. After blowdown, the system
shall be left pressurised and a leak test conducted. When any initial
large leakages have been identified and rectified, an in-line visual
bubble indicator shall be installed. This item is usually installed as a
bypass to the closed main header isolation valve. All leaks shall be
identified and rectified until there are no bubbles passing through the
indicator over a one minute period. The test shall be conducted with
all instrument valves open and with the airsets correctly set.
Relieving instruments or airsets shall be isolated as far downstream
within the system as possible to enable the most complete system
test within practical limits.
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 Project Number Specification Number Rev Date Sheet

EF71914 015-JH-1910 0 5 Dec 94 10 of 15

6.4.2 Leak Testing of Process Connected lnstruments

a. After examination the system shall be leak tested, usually

between the closed line valve and the instrument or its manifold
valve, by applying pressure to the manifold valve test
connection. The fluid used shall be:

1. Compatible with the process fluid.

2. Non-corrosive to the process piping system and valves, non-

injurious to any seals or gaskets fitted.

3. Easily detectable at any leaks.

b. The test pressure used shall be selected at or above the

maximum applicable process pressure, but shall not be above the
rating of any component, instrument item or closed valve.

c. The Company shall be informed in the test procedure of the type

of test fluid proposed and the test pressure that has been
selected and its basis for selection. Written approval must be
received from Company before testing proceeds.

6.4.3 Field lnstruments Calibration

a. Field lnstruments calibration shall be carried out by a Company-

approved Contractor.

b. Following initial installation the process gauges, pressure

switches and transmitters are to be removed, bench tested and
calibrated and reinstalled correctly to the process piping
connections. The instrument is to be identified by a weatherproof
label with the test date, and adequate records are to be
maintained on calibration lists and certificates.

c. The calibration shall be witnessed and verified by the Company.

6.4.4 Local Pneumatic Loops

a. All pneumatic loops, including solenoid and I/P signal feeds to

valves, shall be checked by simulating the correct input
electronic or pneumatic signal and observing the correct
operation of the system, particularly:

1. Failure mode.

2. Direction of operation.

3. Smoothness of action.

4. Use of bypasses, manual controls, resets etc. as applicable.

d
 Project Number Specification Number Rev Date Sheet

EF71914 015-JH-1910 0 5 Dec 94 11 of 15

5. Speed of response.

6. Speed of closing (any special data sheet requirements to be

tested).

7. Operation of position switches, position transmitters etc.

b. Any discrepancy shall be rectified and retested before

commencing any of the tests utilising control room signals.

6.4.5 Electronic Loops

a. General Examination

The loops at this stage are not to be powered. However, the

power shall be available, isolated at the withdrawable fuses,
miniature circuit breakers (MCB) or similar. High-voltage circuit
testing procedures shall not be used for testing circuits involving
connected components. If high voltage test methods are
proposed, all instrument components are to be removed or
electrically isolated.

The checklist shall include:

Confirm hazardous area certification matches or exceeds the

actual area classification.

Check of hazardous area certificate against labelling and for

special provisions, eg., type of gland, temperature limits,
intrinsically Safe (IS) barriers etc.

Check gland and terminations are properly made off, sealed,

labelled and numbered.

Check voltage and polarity of the supply to each loop; the

supply is not to be connected to the loop.

With computer system isolated, the loop test shall be

conducted from the computer inputloutput (110)back to the
instrument terminations.

Check resistance of system grounding to plant earth.

Check continuity of screen to clean earth.

Check freedom of loop and screen cabling from earth faults.

Check correct fitting of any applicable end of line provisions

such as resistors, diodes etc. and that no unrecorded
modifications have been made to instruments or junction
boxes.
 Project Number Specification Number Rev Date Sheet

Q KK EF71914 0 1 5-JH-1910 0 5 Dec 9 4 12 of 15

b. Loop Checks Under Power

1. The serial link from I10 to Distributed Control System (DCS)

shall not be connected. At this stage, the field measurement
will not be displayed, and the outputs to the field shall be
injected at the disconnected DCS 110. The purpose is to
prove the operation of the field devices and any installed
barrier systems through to the 110, under power.

2. The system shall be powered one loop at a time and the

functions of each loop inputloutput checked. Field signal
simulation shall always approximate to actual conditions
whenever possible. For example, a pressure instrument,
pressure shall be applied at the instrument. An injected 4-20
mA signal shall not be used for simulation. Thermocouple
and Resistance Temperature Device (RTD) simulation shall be
by millivolt generator and decade resistance box,
respectively. Outputs shall be directed to the actual field
valve or other device to prove the correct operation.

6.4.6 Communications and Power Test

a. DCS Communication

1. This is a confirmation of the Factory Acceptance Test under

loop powered conditions.

When all I10 interfaces have been proved, the system shall
be powered down and the 110s connected to the DCS input
cards. The Contractor shall prove by simulation (from the
instrument in the field, wherever possible) the operation of
the control loops, alarm functions, line break and signal
viability functions, recording and printer functions, failure
modes, trending, paging up and down and updating, soft and
hardware redundancy and all other features of the system
and graphics configuration.

Since the functioning of the 110s has been proved, reversion

to signal and output simulation at the I10 interface is
permissible to aid faultfinding of the computer faceplate and
graphics functions. Where convenient, valve outputs can be
fed back as measured variable inputs through a software
delay. However, after all faultfinding, the complete system
shall be powered up and the full system check undertaken
with signals on all 110s in a simulated plant running mode.
The actions of the system under field signalloutput
conditions must be reconfirmed.
 I Project Number I Specification Number I Rev I Date ( Sheet
I
4. The functions of each loop, pages of alarms, printer
operation, trend storage etc. shall be listed on individual
checklists and a positive checking procedure adopted.
General statements are not acceptable.

b. Externally Interfaced Equipment

The functions of external devices such as package control

panels, analysers etc. shall be checked in the same fashion and
the control and data interfaces with the computer confirmed and
recorded on a checklist.

c. Signals from Non-Instrument Systems

Where complete checking of the system requires operation or

simulation of parts of the plant outside the Instrument scope,
e.g., starting of motors, operation of Motor Operated Valve
(MOV) etc., the Contractor shall organise joint testing procedures
with the other disciplines to enable comprehensive system
testing to be performed and recorded on the checklists.

d. Power Rating and Distribution

The total electrical load and power factor shall be measured for
the complete system and the various isolated subsystems. All
values shall be recorded and checked against the relevant
fuseIMCB. The fuses shall be checked that they are of the
correct rating for the service. It shall be confirmed that only the
correct sections of the plant are isolated when the fuseIMCB is
withdrawn, and that fuseIMCB failure on redundant items does
not cause loss of plant operations.

e. Tests shall be made to confirm that sections of the plant can be

brought on and off load without causing voltage changes in the
system to a level that affects the normal operation.

6.5 Witnessed Mechanical Com~letionTesting

6.5.1 Basis of the Test

a. When Contractor is fully satisfied that the system is operating to

specification, and the test report has been accepted by the
Company, the Contractor shall offer the complete system for the
Witnessed Mechanical Completion Test demonstration to the
Company. The Contractor shall supply all required test personnel,
suitable tools, equipment, test gear and all required sources of
power, air, water and other services at all levels t o perform the
test successfully.
 Project Number Specification Number Rev Date Sheet

EF7/9 14 015-JH-1910 0 5 Dec 94 14 of 15

b. During this test, all equipment shall be powered up and remain

powered throughout the test period. The equipment shall be
tested as a fully assembled package complete with all
communications systems and interconnections. Where a circuit
is incomplete for any reason or where temporary wiring is
installed, then Company agreement must be obtained and details
shall be recorded on a final action list. Checkouts shall include
proving of system interfaces (eg., to remote fire station) even if
the external equipment is outside Contractor's scope. Test
equipment shall be connected at field instrument terminals only
and not at any intermediate point. The demonstrations are to
verify that the system is fully operational and that any changes
in the state of inputs provides the correct response within the
system.

6.5.2 Drawings and Documents

The Contractor shall make available for use during the test two
complete copies of all relevant Drawings and documents. It is
preferred that one copy is in roll-file format for ease of access.
These shall include:

a. lnstrument schedule/list.

b. lnstrument data sheets.

c. Cable Schedule.

d. Loop diagram.

e. Loop schedules,

f. Control circuit diagrams.

g. Junction box termination schedules.

h. Functional configuration block diagrams for the DCS.

i. Parameter listings, e.g., DCS configuration datasheets, set point

schedules etc.

j. Ladder logic diagrams for the Programmable Logic Controller

(PLC) for ESD, SSLS, F&G.

6.5.3 Test Procedure

a. The Contractor shall have available Company-approved test

procedures for all functions. It is expected that these will be the
basic procedures used at the Factory Acceptance Test, refined
and amended in accordance with the Site conditions and results
 Project Number Specification Number Rev Date Sheet

EF719 14 015-JH-1910 0 5 Dec 94 15 of 15

of the Contractor's own testing previously specified.

b. Circuits shall generally be tested one at a time. However, where
cascade or interrelated loops are involved, these tests shall be
conducted as one complete system. Functional tests shall include
multi-loop devices such as data loggers or system interfaces, and
also ancillary devices such as printers, copiers and recorders.
Indicator and recorder circuits shall be checked by varying the
input and ensuring that the correct receiving device operates and
that no interaction occurs with other circuits.

6.5.4 Recording of Results

a. Operational faults discovered will generally be corrected during

the testing (together with amendment of the relevant documents)
and the final results only recorded on the checklists.

b. Equipment faults or breakdowns shall be recorded in detail on an

individual basis.

c. Incomplete sections, or systems requiring rework or improvement

shall be recorded on a final report for action and retesting as
necessary. A Quarantine List shall be prepared including all failed
systems and systems not tested for any reason. Final clearance
of the system shall not be given until a clean bill of health is
available and the Company is fully satisfied. The results of later
testing shall be appended to the base report so that a
continuous, easily traceable, single-source record of the complete
test is available.

d. The Contractor shall markup and retain one copy of all

documents for use in production of the final "as-built" document
submission.

6.5.5 Radio Frequency Interference Test

a. The system shall be checked for immunity to radio frequency

interference. Such tests shall be conducted using a portable 5-W
radio transmitter. With all cabinet doors closed, equipment shall
be unaffected when the transmitter is keyed at a proximity of not
closer than 1 metre. Trip amplifiers and alarm inputs shall be
powered and their inputs set close to their alarm setting.
Computer inputs are to be set close to their alarm points.

b. Since the tests are by their nature non-specific, various simulated

plant operations shall be conducted, page changes etc.
Observations shall be made in the plant and in the control room,
and any unexpected results shall be analysed to determine if
radio interference is the cause. The Contractor shall eliminate any
faults and retest to Company satisfaction.
d