JASA MAINTENANCE SURFACE FACILITIES DI SPG MERBAU

DAN METERING STATION PAGAR DEWA PT PERTAMINA

ZONA 4 FIELD PRABUMULIH
Document No.
Date :
SA10038030A Rev.0
14 October 2024

S TANDARD OPE RAT ING PR OC ED UR E

( S OP )

I NST R UMENT I NST AL LATI ON PR OC ED URE

0 8 March 2022 - ISSUED FOR APPROVAL SN ARH MFG

REV ISSUE DATE EXPIRED DATE ISSUE PURPOSE PRE’D CHE’K APP’D

CONTRACTOR

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1.0 TITLE

Procedure for Instrumentation Installation Works

2.0 SCOPE

This procedure is to describe the general requirements for the instrument

materials receiving, storing, installation, calibration and testing, inspection and
pre-commissioning of instrument installation works.

The specification given are adequate for the majority of applications. However, for
unusual situation, such as very high temperatures and/or pressure, corrosive
conditions etc,. alternate procedure may be required.

3.0 OBJECTIVE

This is to assure that the installation of instruments and devices are done as per
the specification requirements, drawings and applicable codes. To make sure that
all the works are satisfactorily done, tested and accepted according to contract
specifications.

4.0 REFERENCE

4.1 Applicable Manufacturers Manuals

4.2 Technical Specifications and Construction Drawing
4.3 Standards, codes and recommended practices
4.4 National Electric Code ( NEC)
4.5 National Electric Manufacturers Association
4.6 National Fire Protection Association

5.0 RESPONSIBILITY

5.1 The Instrument Engineer at site shall be responsible for the planning
scheduling and coordination, record and monitor progress of
instrumentation works. To guide the supervisors in the field in terms of
engineering and technical problems.

5.2 The Instrument Superintendent shall be responsible for the daily

construction activities to coordinate with Area Supervisors and support The
Supervisors in terms of technical matters.

5.3 The Instrument Supervisors shall be responsible to the respective

superintendent and carry out the direct field activities through the skilled

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and unskilled workers according to the installation procedures and

drawings.

6.0 WORK PROCEDURE

6.1 GENERAL

6.1.1 Field Engineers will ensure that they are in possession of the
following documents, prior to the commencement of construction
activities:

• Applicable Engineer’s specifications (Data Sheets)/Instrument

Index
• Applicable Owner specifications
• Vendor’s/Manufacturer’s installation instructions
• Applicable Engineer’s installation drawings/ the last revision of
construction drawing
• Applicable purchase orders

6.1.2 The work shall be done according to good workmanship by using the
suitable tools and material as stated in the construction drawing and
procedures and it should be studied before carry out any
Instrumentation works.

6.1.3 Form reports which will be in the possession of Field Engineers and
which will be completed during the major construction activities
include:

• Instrument Calibration Sheets

• Instrument Check Lists
• Instrument Loop Check Report

6.1.4 Safety and Sanitation

Full care and pre-caution shall be given by the field management for
the safety and sanitation of workman in the field to prevent accidents
during execution of the works.

6.2 RECEIVING, HANDLING, STORAGE and DELIVERY

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6.2.1 When receiving the instrument materials and before delivered to the
field it will be subjected to the following inspections by warehousing:

a) Instruments received will be uncrated and checked against the

packing slip.

b) Instruments will be visually inspected for any signs of damage as

they are uncrated or unpacked.

c) The quantity of instruments shipped will be checked to confirm

that it corresponds to the quantity indicated in the purchase
order.

d) The model, style or type of instrument received will be checked

to confirm that it corresponds to the exact model, style or type of
instrument stated in the purchase order and instrument
specification sheet.

6.2.2 Instrument materials shall be handled with care to ensure against

mechanical and moisture damage.

6.2.3 Instrumentation will be stored in accordance with the following

guidelines:

a) Instrument connections whether small, as on transmitters,

gauges, etc. or larger, as on flanged control valves, will be
adequately protected by temporary closures.

b) Instrument cases will be taped closed and covered.

c) Manufacturers Identification nameplates, glasses or plastic

extensions will be covered by masking tape r equivalent.

d) Small items such as pressure gauges and bimetal thermometers

will be left intact and stored in original containers.

e) Exposed stems of control valves will be covered with a protective

material.

f) Shipping stops will be left in place

g) All instruments will be store in a clean, dry location.

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6.3 INSTRUMENT CALIBRATION

All instrument devices which are connected to a measurement and control

loop plus process alarm and shutdown switches will be calibrated prior to
installation and will be subjected to the following inspections:

a) Transmitter will be inspected for zero, span and linearity throughout its
range.

b) Local controllers will be inspected for zero, span and linearity

throughout its range.

c) Local controllers will be inspected for proper operation of gain or

proportional band.

d) Control valves will(AOV, Choke Valve, MV and SV) be stroked and

start-point checked.

e) All process switches (e.g. pressure) will be verified for correct activation
point.

As each instrument is calibrated, the appropriate calibration sheet shall be

completed.

6.4 INSTRUMENT INSTALLATION

All field devices on the Instrument check list shall be marked with a “tic”
under each applicable item for every category on the list and non
applicable items shall be marked “N/A”. An item shall be checked off only
when the inspector is satisfied that the installation meets the criteria listed
below. Items failing to satisfy this criteria shall be noted on a “punch list” for
the contractor to rectify.

6.4.1 Mounting Stands/Brackets

i. Fabrication

• Installation of the stand or bracket is complete with all the

required parts and pieces.
• All part and pieces are assembled properly and are true and
square.
• The dimensions of the stand or bracket are in accordance
with the associated Mounting holes are the correct size and

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neatly drilled in the proper locations with burrs removed.

Holes made using a cutting torch are not acceptable.
• The finishing is smooth with no sharp or jagged edges or
gouges.
• Welds are professionally done with all slag and spatter
removed and any imperfections or excess weld material
ground down.

ii. Location

• The stand or bracket is in the correct geographical location

from a process requirement point of view i.e.- as per location
drawing or MPI engineers instruction.
• It is mounted at the correct right.
• It is location and oriented properly so as to allow correct
installation of the instrument, providing free and easy access
to all connections, covers, adjustments, etc.
• It is attached to a solid structure that will not be subject to
excess vibration.
• It does not block off any access way or seriously interfere with
maintenance access to other equipment.
• It is not in the path of any normal process overflows or spills.

iii. Installation

• The stand or bracket is family secured to the structure to

which it is attached using the correct fasteners. All required
fasteners are in place and properly tightened. Any welds use
for attachment are professionally done with all slag and
spatter removed and any imperfections or excess weld
material ground down.

• It is plumb and level.

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• Stands mounted on concrete floors are properly grouted.

Grouting is neatly finished and at the correct height as per the
typical installation drawings.

iv. Painting

• The surface of the stand or bracket has been properly

prepared in regards to removal of oil film residue, rust, etc.

• It has been primary and painted in accordance with the

project painting specifications(EMEP MP35-P-01) using the
correct products (type and color) and applying the proper
thickness. The finish is smooth and free of runs and other
gross imperfections.

• Any damage to the stand, bracket or mounting structure due

to handling, installation. Etc., has been repaired and the
painting touched up using the correct color.

6.4.2 Field Transmitters & Devices/Primary Elements/Control valve(AOV, Choke

Valve and Control Valve) & Final Control Elements

i. Location

• The instrument is in the correct geographical location from a

process requirement point of view i.e.- as per location
drawing or MPI engineers instruction.

• It is mounted at the correct elevation to satisfy the process

control application for which it is intended e.g.- below the
process tap for liquids and steam above the process tap for
gasses.

• It is located and oriented properly so as to allow free and

easy access to all connections, covers, adjustments, etc.

• Transmitters are mounted as close as practical to their

associated process tapping points or primary elements,
considering access requirements and interconnecting impulse
tubing or wiring.

ii. Installation

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• Inline devices are mounted correctly for flow direction,

orientation on the pipe line etc.

• The instrument is securely attached to it’s mounting device

with the proper fasteners and is not subject to excess
vibration.

• It does not block any access ways or seriously interfere with

maintenance access to other equipment.

• It is not subject to mechanical damage from any obvious

sources in it’s general vicinity.

• It is not in the path of any normal process overflows or spills.

• It is tagged with proper identification.

• It is access cover(s) are securely fastened.

• Any required services such as instrument air, 220 VAC

power, purge or cooling water, etc. are properly installed and
connected.

• Any unused connections on instruments are properly

plugged.

• All threaded vent connections on instruments have short

lengths of tubing or hose connected to them, venting
downward.

iii. Cabling / Wiring

• Cables and wires are properly dressed to the correct length.

• The correct size and type of wiring lugs are used and they are
firmly and properly attached to the wires.

• The correct size and type of cable gland is used and it is

properly tightened in the housing and around the cable.

• Wiring is correctly terminated and terminal screws are firmly

tightened.

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• Unused wires are cut short and neatly taped back.

• Unconnected shields (e.g.- on signal cables at transmitters

are clipped back flush with the cable’s outer sheath).

• A short excess length of cable between the device and the

cable conduit is neatly coiled and tie-rapped in place.

• Cables are properly secured in cable trays using tie-raps to

prevent sagging or shifting.

• Cables are identified with the correct tags using the proper
markers.

iv. Conduit / Tray

• Conduit and tray are routed using the most direct practical
path, between it’s terminal points, that generally follows
structural members and/or equipment where possible.

• It is plumb and level and runs in the horizontal and vertical

planes only.

• It does not run at odd angles to structural members or

equipment.

• It does not block any access ways or seriously interfere with

maintenance access to other equipment.

• It is not subject to mechanical damage from any obvious

sources in it’s general vicinity.

• It is attached to a solid structure that will not be subject to

excess vibration.

• It is not in the path of any normal process overflows or spills.

• It is sufficiently supported and clamped to provide a rigid

installation that cannot be easily bent or shifted out of
position. Supports are properly painted, including touch up
after installation.
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• It is of the correct size for the cable(s) it holds.

• It is not crooked, bent or otherwise damaged.

• Conduit ends are oriented downward or horizontal, not

upward.

• Conduit clamps are of the correct size and are firmly

tightened.

• Conduit terminates within about 30 cm of the instrument were

practical and within a few centimeters of the cable tray.
Multiple conduits terminating at the same location run parallel
and in the same plane wherever possible and terminate with
their ends square or evenly staggered to each other.

• Conduit bends are neat and properly made using the correct
bending tools for the job.

• Conduit ends are neatly threaded and fitted with a plastic

bushing to protect the cable from cuts and wear.

• Conduit fittings are firmly tightened onto properly prepared

threads. Couplings are used only to join a full conduit length
to a shorter one, two or more short lengths are not to be
joined together.

v. Impulse Tubing / Piping

• Impulse tubing or piping is routed using the most direct

practical path between the process tap and the instrument.

• It has a minimum 1 in 10 slope on horizontal runs (towards

the instrument for liquid and steam, towards the process for
gasses).

• It does not block any access ways or seriously interfere with

maintenance access to other equipment.

• It is not subject to mechanical damage from any obvious

sources in it is general vicinity.

• It is not in the path of any normal process overflows or spills.

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• It is sufficiently supported and clamped to provide a rigid

installation that cannot be easily bent or shifted out of
position. Supports are properly painted, including touch up
after installation. Clamps are of the correct size and are firmly
tightened.

• It supports are attached to a solid structure, where practical,

that will not be subject to excess vibration. There is, however,
enough distance as well as the proper geometry between the
process tap and the first rigid supports to allow for any
anticipated repositioning of a tap connected to a pipe line or
other equipment which is subject to movement under
operating conditions. If process tap movement is excessive
(e.g.- on lower regions of large boilers) a flexible section may
be required in the impulse line.

• It is not crooked, bent or otherwise damaged.

• It is of the correct material, diameter and wall thickness to

satisfy the requirement of the process as well as any
applicable standards.

• Pairs or multiple impulse tubes or pipes are run parallel and in

close proximity to each other but they do not cross each
other.

• On D/P transmitters the impulse lines are connected to the

correct High and Low pressure ports.

• Fittings are of the correct type and size and are properly
tightened.

• Unions/couplings are generally only used when the run

exceed the standard manufactured length of tubing/piping.

• Tubing bends are neat and properly made using the correct
bending tools for the job.

vi. Air Supply Tubing and Branch Piping

• Air supply tubing and branch piping is routed using the most
direct practical path, between it is terminal points, that

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generally follows structure members and/or equipment where

possible.

• It is plumb and level and runs in the horizontal and vertical

planes only.

• It does not run at odd angles to structural members or

equipment.

• It is not block any access ways seriously interfere with

maintenance access to other equipment.

• It is not subject to mechanical damage from any obvious

sources in it is general vicinity.

• It attached to a solid structure that will not be subject to

excess vibration.

• It is not in the path of any normal process overflows or spills.

• It is sufficiently supported and clamped to provide a rigid

installation that cannot be easily bent or shifted out of
position. Supports are properly painted, including touch up
after installation. Clamps are of the correct size and are firmly
tightened.

• It is of the correct size for the number of devices it is

supplying (see applicable standards).

• It is not crooked, bent or otherwise damaged.

• It has a ½” stainless steel ball isolation valve in close

proximity to each device it is supplying. The supplied device
is connected to the isolation valve with flexible, reinforced
rubber hose and push on hose connector or to the stainless
steel multiple air manifold pipe with the isolation valves (one
manifold for five up to ten ways of air line). At least one of the
connectors is of the swivel type and the hose/tube has extra
length to provide slack.

6.4.3 Junction Boxes

i. Location

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• The junction box is in the correct geographical location, i.e.-

as per location drawing or MPI engineers instruction.

• It is mounted at the correct height.

• It is located and oriented properly so as to allow free and

easy access to it.

ii. Installation

• The junction box is attached to a solid structure that will not

be subject to excess vibration.

• It is firmly secured to the structure using the correct brackets

and fasteners. All required fasteners are in place and properly
tightened.

• It is plumb and level.

• It does not block any access ways or seriously interfere with

maintenance access to other equipment.

• It is not subject to mechanical damage from any obvious

sources in it is general vicinity.

• It is not in the path of any normal process overflows or spills.

• It is tagged with proper identification.

• It is access door is properly closed and latched.

iii. Cabling/Wiring

• Cable and wires are properly dressed to the correct length.

• The correct size and type wiring ferrules are used and they
are firmly and properly attached to the wires.

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• The correct size and type of cable gland(c/w heat shrink

shroud) are used and they are properly tightened in the
junction box and around the cables.

• All cables enter and leave field junction boxes from the
bottom, or sides when necessary, but not from the top.

• Wiring is correctly terminated and terminal screws are firmly

tightened.

• All spare multi-pair wires are terminated.

• Internal junction box wiring is properly routed through the

appropriate cable ducts.

• Spare cable glands and/ or entry holes are properly plugged.

• Cables are properly supported in cable trays and secured
using tie-wraps to prevent sagging or shifting.

• Cables are identified at the required places with the correct

tags using the proper markers.

6.4.4 General Installation.

• The overall installation appears neatly installed and is

functionally correct.
• There is no apparent damage to any the components.
• The entire installation is clean and all touch up painting is
completed.
• There is no construction debris left in the vicinity.

6.5 LOOP CHECK

6.5.1 General

The purpose of the loop check is to:

i. Confirm that all instrumentation field devices are properly

connected, in accordance with the engineering drawings, to their

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associated components and/or to the DCS (or other

control/monitoring systems).
ii. Prepare the loop for operation by turning on the necessary
services (power, air, etc.) and opening process isolation valves
as required.
iii. Prove the functionality and operational readiness of the
individual loop components and the loop as a whole.

6.5.2 Organization

An instrument engineer will coordinate the loop check out team’s

activities with the requirements of the MPI lead engineer. He will
plan and assign the work, monitor and report the progress, organize
the documentation, assist with problems and ensure punch list items
are dealt with.

Each loop check out team will consist of three members:

i. A DCS engineers, who will be stationed at the DCS console in

the control room.
ii. An instrument technician who will be located in the field.
iii. An instrument or DCS technician who will be located in the DCS
rack room.

Other personnel such as the QA/QC & Construction field engineer

may observe the check out procedures. They will not, however,
participate in the check out activities unless specifically authorized to
do so by the MPI lead engineer.

Assistance (if any) in the loop checks is dependent upon prior

contractual agreement of manpower levels to be supplied for
this purpose.

6.5.3 Communications

Three portable radios will be assigned to each check out team. One
in the control room, one in the rack room one in the field. Each
team’s set of three radios shall operate on a frequency independent
from other check out teams. Each radio shall have it’s own spare
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battery pack and charger stand. Communications will normally be

carried out in the English language unless otherwise authorized by
the commissioning manager.

6.5.4 Documentation

All check out activities will be documented in order to monitor

progress, identify problems and provide a permanent record of the
check out work.

Documents to be used by the check out teams will include:

i. Loop/instrument lists prepared by the instrument engineer

based on the commissioning manager’s schedule and
equipment requirements.
ii. Loop diagrams
iii. Junction box lay outs
iv. Punch lists
v. Modification of DCS existing will be done by Yokogawa
technician.

Control system will consist of :

Phase B
- YS – 170 + FA – M3 + DAQ Panel

SLS - D
- FA – M3 + DAQ

SLS – A
- DCS existing
- PFCD existing

For further information see Yokogawa’s detail drawing.

Other document such as flow sheets, location drawings, cable

schedules, vendor manuals, etc. may be used for reference but will
not be used to record check out activities.

Successfully checked out components and loops will be marked up

with a “highlighter” marking pen on the appropriate documents. Any
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deficiencies will not be “highlighted”, instead they will be placed on

the punch list.

6.5.5 Preparations

A daily check out plan will be prepared for each team by the
instrument engineer(s).
This plan will be based on the requirements of the commissioning
schedule and all document necessary to execute the work shall be
prepared in advance.

Before starting each day’s work the check out teams will attend a
short meeting with the engineer for distribution of the appropriate
documentation and to discuss the planned activities.

Another short meeting will be held at the end of each day for
collection of the documentation and to discuss the day’s work.

6.5.6 Methods

i. The field instrument technician will normally select the order of

the field devices to be checked, typically based on their
geographic location and junction box assignment. He will then
perform the required test procedure in conjunction with the other
team members, as directed by the DCS engineer.

ii. The field instrument technician will prepare the devices for
check out as required and secure the devices as necessary
after the check out is complete.
e.g. Remove covers, check wiring, turn on air and/or power
supplies, open process taps, disconnect signals, connect
test equipment, perform test procedures, reconnect signals
and wiring, reinstall covers, etc.

iii. The DCS engineer will direct the actual testing activities once
the field device has been prepared. He will operate the DCS as
required and perform any special manipulations such as
bypassing interlocks or forcing outputs when necessary to
execute a particular test(Yokogawa scope).

iv. The instrument/DCS technician will perform any activities at the

DCS cross connection cabinets and equipment racks that are
required to execute the testing(Yokogawa scope).

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v. Punch lists items will be issued to the contractor(s), or others as

appropriate, for immediate action. Affected devices and/or loop will be
added to future check out lists for re-testing after the deficiencies have
been rectified.

6.5.7 Procedures

i. All connections shall be verified as correct before electrical

power, air supplies are processes are applied to field devices.

ii. Identification tags for all devices, junction box, cables, etc. shall
be verified as being in place and correct.

iii. Wherever possible, the actual field device shall be manipulated

to generate a full range of signals to the DCS. Where not
possible, test equipment shall be connected at the device to
simulate signals to the DCS.

iv. DCS indications must correspond to the signals sent from the
field devices. Engineering units, zero and full scale values,
linear, compensations, integrate, graphic dynamics, state
descriptors etc. in both the field devices and the DCS must be in
concordance with each other as well as with the engineering
documentation.

v. When the testing of a device has been completed it’s present

indication on the DCS shall be confirmed as being sensible (e.g.
– Typically temperature transmitters would indicate ambient
while pressures, levels, and flows would indicate zero and a
closed on/off valve’s dynamic graphic symbol would be colored
red.

vi. Signal shall be sent to and from the DCS to confirm correct
connectivity and functionality only. Activities such as calibrating
field devices, programming the DCS, modifying control strategic,
changing graphics etc. are to be avoided during loop checking.

vii. Only small repairs and corrections that can be made quickly
(within a few minutes) shall be done by the check out team (e.g.
– changing wires from N.O. to N.C. contacts on switches,
reversing signal polarities, etc.). More extensive changes should
be noted on the punch list for later action by others.

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viii. The check out team must, however, troubleshoot all problems
until the cause of the fault is determined. Any problems or
deficiencies placed on the punch list must be accompanied by a
description of the corrective action to be taken.

ix. Control valves and other final control elements shall have their
power or air supplies turned on and they shall be fully stroked
from 0 % to 100 % via the DCS. Correct control action in
automatic mode shall be verified if possible.

x. Limit switches shall be checked with their actuators in the

appropriate position. Jumper of switches shall only be done
when it is impossible to move the actuator. As a general rule all
discrete switches should be wired such that the contacts to the
DCS are closed when the device is in it is “satisfied” or “normal
operating” position. Exceptions to this rule may exist within
various vendor supplied logic systems and should be observed
as required.

xi. After a loop check has been successfully completed power and
air shall remain turned on to the field devices and process
connections shall remain open, unless specific instructions to
the contrary have been given by an authorized person.

7.0 ATTACHMENT :

7.1 Form of Calibration for ON-OFF VALVE (Form No. I – 05)

7.2 Form of Calibration for Control Valve (Form No. I – 06)
7.3 Form of Pneumatic Device Basic Inspection (Form No. I – 07)
7.4 Form of Calibration for Valve (Form No. I – 08)
7.5 Form of Calibration for Switches (Form No. I – 09)
7.6 Form of Calibration for Transmitter (Form No. I – 10)
7.7 Form of Calibration for Pressure Gauge (Form No. I – 12)
7.8 Form of Instrument Loop Check (Form No. I – 04)
7.9 Form of Field Device Installation Record (Form No. I - 02)
7.10 Form of Leak Test Report(Form No. I – 18)
7.11 Form of Instrument Punch List Report (Form No. I – 14)

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