AUTOMATED LOOP CHECKING FOR

INSTRUMENTATION SYSTEMS
By ABDULRAHMAN NASSER ALGHAMDI
Abstract
This technical paper addresses the significant challenges associated with instrument loop
checking in large-scale mega-projects, where thousands of loops must be verified within tight
schedules. Achieving high accuracy and efficiency is crucial to meeting critical milestones without
compromising quality. The paper introduces an innovative strategy that leverages a cutting-edge
technology, newly implemented in Saudi Aramco projects in collaboration with Yokogawa. This
approach not only reduces the time required for loop checking but also enhances precision,
ensuring that project timelines and quality standards are maintained. Through a detailed case
study, the paper compares traditional methods with this novel approach, providing practical
insights and actionable recommendations for project managers and engineers. Ultimately, this
work serves as a valuable resource for professionals involved in similar high-stakes projects,
offering guidance that contributes to the successful and economically impactful execution of
such ventures.

In addition to presenting the technical aspects and benefits of the new technology, this paper
also delves into the collaborative processes between Saudi Aramco and Yokogawa that were
critical in driving the successful implementation of this solution. It highlights the importance of
cross-disciplinary teamwork and the integration of advanced automation tools in overcoming
the logistical and operational challenges inherent in mega-projects. The paper also discusses
the lessons learned during the implementation phase, including risk management strategies and
the adaptation of best practices from previous projects. By examining these elements, the paper
provides a comprehensive overview of how innovative technologies, when effectively integrated
into large-scale projects, can transform traditional workflows, leading to significant time and
cost savings, as well as improved project outcomes.

Keywords: Instrumentation, Loop Check, Auto loop check, Gas Plant, PRM-CSP, Mega Project,
Schedule

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1.Introduction 1.1 History of Logical Programing
(Instrumentation)
In large-scale projects, particularly those
involving complex industrial plants, the Robinson's landmark paper, published in
process of loop checking can be a monumental 1965, marked a significant milestone in the
task, often requiring several months and field of automated reasoning by introducing
thousands of man-hours to complete. This is the resolution rule. Resolution, a powerful
primarily because, in conventional practice, inference rule, is particularly well-suited
the loop check process is typically conducted for automation within computer systems,
after the completion of critical preliminary laying the groundwork for advancements in
tasks, such as piping hydrotests and the logic-based computation [1].
alignment and installation of equipment. The
sheer scale of such projects introduces a In the early 1970s, the field of logic
variety of challenges, including issues related programming emerged as a direct extension
to communication across vast distances, of earlier research in automatic theorem
the logistical difficulties of operating at proving and artificial intelligence. This period
varying elevations, and the potential for saw pioneering contributions from several
miscommunication among teams. These key figures, with Kowalski and Colmerauer
factors can significantly impact the efficiency receiving most of the credit for the formal
and accuracy of loop checking, making it a introduction of logic programming. Their
critical area of focus in project execution. work built upon the foundational ideas of
predecessors like Green and Hayes, whose
Before delving deeper into the complexities contributions to the development of logical
and strategies associated with loop checking, systems also deserve recognition [2].
it is essential to understand the pivotal role
that instrumentation and control systems By 1972, Kowalski and Colmerauer had
play in plant operations. These systems are developed the groundbreaking idea that
integral to the plant’s safety, monitoring, logic could be harnessed as a programming
and regulation of critical process parameters language. This realization transformed logic
such as temperature, pressure, flow, level, from a purely theoretical discipline into a
and quality. By providing real-time data on practical tool for programming, enabling the
these variables, instrumentation and control creation of programs that could perform
systems provides several safety layers in complex reasoning tasks. The introduction
addition to empowering operators to make of logic programming not only expanded the
informed decisions, enabling them to maintain capabilities of artificial intelligence but also
optimal operating conditions and prevent influenced the design and implementation
potential disruptions. of future programming languages, laying the
foundation for developments in fields such as
The accuracy and reliability of these systems expert systems, natural language processing,
are paramount, as they directly influence the and more [2].
safety, efficiency, and overall performance
of the plant. Therefore, ensuring that all 1.2 Programmed Control System
instrument loops are thoroughly checked (PCS)
and validated is not merely a procedural
necessity but a fundamental requirement for The Process Control System (PCS) is a critical
the successful operation of any industrial component in the management and operation
facility. of industrial plants, and it is typically divided
into two primary subsystems: Distributed
Control System (DCS) and Emergency
Shutdown System (ESD).

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The DCS is responsible for the continuous By integrating these comprehensive safety
monitoring and control of process-related measures, the PCS ensures both operational
systems under normal operating conditions. efficiency under normal conditions and robust
It manages the distribution of tasks across protection in the face of potential hazards.
various sections of the gas plant, ensuring
that processes run smoothly, efficiently, and
in accordance with predefined parameters. 2. Loop Check
The DCS plays a vital role in optimizing plant
performance, maintaining process stability, Loop Testing is a critical software testing
and ensuring the safe production of gas by technique that specifically targets the
adjusting variables like pressure, temperature, validation of loop constructs within a program.
and flow rates in real-time. As an integral part of Control Structure
Testing, which also includes path testing,
On the other hand, the ESD system is designed data validation testing, and condition testing,
to act in response to unsafe or abnormal Loop Testing ensures that loops function as
conditions that could potentially endanger intended under various conditions. This type of
the plant, personnel, or the environment. As testing is essential for verifying the correctness
the DCS is considered as the first layer of and performance of iterative processes within
protection, the ESD comes after as the second software, particularly in systems where loops
layer of protection in case the DCS couldn’t play a key role in decision-making and control.
control the readings within the normal or
acceptable range. The ESD is programmed
with various safety protocols to execute In the context of industrial automation and
immediate protective actions when certain risk process control, loop testing is a vital step in
thresholds are crossed. These actions include the final phase before the commissioning of
implementing the single failure criterion, which a Process Control System (PCS). This phase,
ensures that no single point of failure can known as loop check, involves a comprehensive
compromise the system's safety functions. verification process to confirm that all
Additionally, the ESD incorporates redundancy, components within the control loops are
ensuring that multiple backup systems are in correctly wired and functioning as designed.
place to maintain operational integrity even if The primary objective of loop checking is
primary components fail [3][4]. to ensure the integrity and reliability of the
control system by meticulously inspecting the
Other key features of the ESD include connections and interactions between each
independence and diversity, which prevent element in the loop.
common mode failures by using different
technologies or methods to achieve the same
safety goal. The system is also designed with A control loop typically comprises of three
fail-safety in mind, meaning that it defaults main components: the transmitter or sensor,
to a safe state in the event of a malfunction. the process controller, and the final control
element. The transmitter or sensor detects
Moreover, the ESD provides Sequence of Event the process variable, such as temperature,
(SOE) in order to identify the first cause of pressure, level, or flow, and sends this data
trip during any investigations. Furthermore, to the process controller. The controller
the ESD can be manually initiated if automatic then processes this information and makes
systems fail to respond, ensuring that decisions based on the predefined control
operators have the ability to intervene directly. strategy, sending appropriate commands to
The system is also tasked with identifying the final control element, which could be a
and executing the appropriate protective valve, motor, or other actuator, to adjust the
actions tailored to specific emergencies, and process accordingly [5].
all equipment used in the ESD is rigorously
qualified to meet the highest safety standards.

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During the loop check, each of these 2.1 Conventional Loop Check
components is tested in unison to verify that
the signals are accurately transmitted and Conducting a conventional loop check involves
received, that the control logic is correctly a lengthy and time-consuming procedure for
implemented, and that the final control each loop. Loop testing requires a coordinated
element responds appropriately to the effort between two crews: one stationed in
controller's commands. This process not only the field and the other in the PCS (Process
Control System) room, where the marshalling
ensures that the control loop is functioning as and system cabinets are located. Constant
intended but also helps identify and rectify any communication between the field crew and
wiring errors, calibration issues, or component the PCS room crew is essential during device
failures before the system is fully operational. commissioning, necessitating reliable remote
Additionally, the loop check ensures that communication systems that are appropriate
process parameters and their corresponding for the site's area classification [5].
alarms are accurately verified for the DCS
operator. Each loop must be tested thoroughly, starting
from the field signal input and extending to the
By rigorously conducting loop checks, receiving instrument. This testing is conducted
engineers can ensure the PCS operates reliably using specialized tools such as a manual hand
and safely, minimizing the risk of malfunctions pump, temperature calibrator, shaker table,
that could lead to operational inefficiencies, and communicator. The communicator, in
safety hazards, or costly downtime. particular, is crucial for troubleshooting and
configuring all instrument parameters For
loops involving controllers, the output from the
controller must also be verified through the
final control element. This ensures the entire
loop is functioning correctly.

Loops are identified and organized by tag

number, and then grouped based on various
criteria such as location, system, elevation,
equipment, accessibility, or availability.
However, when field instrument installation
and cable termination are still ongoing, the
field team may need to conduct loop checks
and tests in a non-sequential order. This
Loop Check Synopsis, Figure.1 approach, while necessary at times, can
be highly inefficient and time-consuming,
Before commencing the loop check, it is especially when dealing with a large number
essential to complete several preliminary of loops, as in this case, which could extend
steps, including the review of marshalling the process to over six months.
terminations, JB (junction box) terminations,
field installation checks, PCS (Process Efficient resource management is crucial to
Control System), wiring continuity test, increasing productivity. Each team should
configuration reviews, site acceptance tests include QC personnel, a site engineer, a
(SAT), and pre-loop testing. Once these tasks foreman, an instrument calibrator, and
are completed, the loop check can begin. helpers or laborers. Additionally, the team
must be equipped with the necessary tools
and equipment to carry out the loop checks
effectively.

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2.2 Auto-Loop Check
(Unconventional)
Automated loop checking can be facilitated
by software solutions from various vendors.
In this case, the software used is the
Plant Resource Manager Commissioning
Support Package (PRM-CSP) developed by
Yokogawa. The PRM-CSP is a powerful tool
designed to streamline the loop checking
process by automating critical tasks such as
connectivity verification, range checking, data
validation, and verifying the final element’s
source availability, either instrument air for
air-operated valves or electricity for the
motor operated valves (MOV). This software General Start-Up Procedure, Figure.2 [7]
is particularly effective for both Foundation
Fieldbus and HART devices, making it an Utilizing PRM-CSP significantly reduces the
invaluable asset during plant startup or commissioning time for field devices while
maintenance phases. enhancing their overall reliability. Additionally,
it improves the quality and consistency of the
commissioning process, ensuring that field
By leveraging PRM-CSP, engineers can perform devices are configured and validated to the
comprehensive loop checks more efficiently, highest standards.
ensuring that all devices are properly
connected, configured, and functioning within PRM-CSP is designed to streamline the
specified parameters. The software reduces commissioning process by automatically
the need for manual intervention, minimizing generating tasks based on the available device
human error and significantly cutting down data and the selected task templates within
the time required for loop testing. Additionally, the software. This automation ensures that
PRM-CSP provides detailed reports and each device is subjected to the appropriate
diagnostics that facilitate quick identification checks and procedures, tailored to its specific
and resolution of any issues, thereby requirements. During the execution of these
enhancing the overall reliability and safety of tasks, PRM-CSP continuously monitors the
the plant's instrumentation systems [6][7]. status and progress, providing real-time
updates to the commissioning team [7].

This automated approach not only improves Upon completion of the commissioning
productivity but also contributes to tasks, PRM-CSP automatically generates
maintaining high standards of quality and detailed work reports. These reports offer
consistency throughout the commissioning valuable insights into the commissioning
process. As a result, PRM-CSP plays a crucial process, highlighting any issues encountered
role in ensuring a smooth and successful plant and the actions taken to resolve them.
startup, as well as in ongoing maintenance This comprehensive documentation not
activities. only supports quality assurance efforts but
also serves as a reliable record for future
maintenance and audits.

Integrating PRM-CSP into the commissioning

workflow enables teams to achieve faster,
more reliable, and higher-quality outcomes,
significantly contributing to the successful
and efficient startup of the plant.

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2.2.1 Execution 2.2.2 Reports
PRM-CSP can be conducted in two distinct PRM-CSP also features automated work report
modes: Step-by-Step (Semi-Auto) and generation, including loop check results, with
Continuous (Full-Auto), each offering different the capability to produce three different types
levels of control and automation tailored to of reports:
the needs of the user.

2.2.2.1 Task Summary Report

2.2.1.1 Step-by-Step Mode
(Semi-Auto) Contains details about the tasks that are in
the selected folder, and the devices that are
This mode allows the user to manually associated with these tasks.
advance through each step of the loop
checking process. It provides a higher 2.2.2.2 Device Summary Report
degree of control, enabling the user to
carefully review and confirm each task Contains details about the devices that are in
before proceeding to the next. This mode a selected device folder, and the tasks that are
is particularly useful in situations where associated with these devices.
precision and careful verification are
paramount, as it allows for a more deliberate 2.2.2.3 Task Detail Report
and thorough approach to loop checking.
Contains execution details about a selected
task or the tasks that are in a selected folder,
2.2.1.2 Continuous Mode (Full-Auto) including specific check function details.

In this mode, the system automatically

progresses through the entire loop checking
sequence without requiring manual
intervention. Tasks are executed in a
continuous flow, with the user monitoring the
progress in real-time. Continuous mode is
designed for efficiency, significantly reducing
the time required to complete the loop check
while maintaining high levels of accuracy. This
mode is ideal for large-scale projects where
time is a critical factor, allowing for rapid Report Samples, Figure.3
completion of loop checks across multiple
devices or systems.

3.Implementation
By offering these two modes, PRM-CSP
provides flexibility in how loop checks are The implementation of PRM-CSP is not
conducted, catering to both detailed, hands-on universally applicable to all types of loops.
approaches as well as streamlined, automated The table below highlights the specific
workflows. This versatility ensures that the loops for which PRM-CSP can be effectively
system can be adapted to various project utilized. These loops are selected based
needs, whether the focus is on meticulous, on their compatibility with the system’s
step-by-step verification or on achieving capabilities and the benefits PRM-CSP offers
swift, comprehensive testing across large in terms of efficiency, accuracy, and ease of
installations. commissioning.

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 By focusing on FF and HART loops within
PRM-CSP DCS, and HART loops within ESD, PRM-CSP
System Total Loops Percentage
Applicable optimizes the loop checking process for
DCS 9522 3948 41.5% the most advanced and widely used digital
ESD 3578 1375 38.4% communication standards, while recognizing
Total 13100 5323 40.6% the limitations of the system when applied to
other loop types.

4.Case Study
Applicable Loops for PRM-CSP, Table.1
As a case study highlights the efficiency of
using the PRM-CSP tool for loop checking
in comparison to conventional methods. In
this case study, a conventional loop check
was conducted on a pressure transmitter.
The process involved testing the readings for
both the system side and the field indicator
by gradually increasing the pressure in 500
psi increments until reaching 2000 psi. This
method consumed approximately one hour (60
minutes) to complete it using the conventional
loop check Process with Pressure Increments
500 psi with total pressure range 0 psi to 2000
psi.

Applicable Loops for PRM-CSP, Chart .1 In contrast, an automated loop check was
conducted on the same pressure transmitter
using the PRM-CSP tool. The process
significantly reduced the time required,
For the DCS system, PRM-CSP is applicable completing the loop check for one transmitter
exclusively to Foundation Fieldbus (FF) and in 1 minute. Furthermore, the tool automatically
HART loops. These digital communication generated reports, enhancing efficiency and
protocols are fully supported by PRM-CSP, documentation accuracy.
allowing for automated loop checking,
data validation, and enhanced diagnostics. Automated loop check using PRM-CSP is 60
However, DCS loops that utilize conventional times faster than the conventional method,
wiring, Discrete Input/Output (DI/DO) drastically reducing the time required from
signals, and wireless communication are not 1 hour to just one minutes for a transmitter.
compatible with PRM-CSP and therefore Additionally, the automation of report
cannot be automated using this tool. generation further streamlines the process,
providing significant operational advantages
in large-scale projects. This comparison
Similarly, for the ESD system, PRM-CSP is effectively demonstrates the time-saving
applicable only to HART loops. The software benefits and added value of using automated
is designed to automate the testing and systems like PRM-CSP in complex and
verification of HART-enabled devices within large-scale projects.
the ESD framework, ensuring high levels of
reliability and safety. Other loop types within
the ESD, such as conventional or DI/DO loops,
are not supported by PRM-CSP, necessitating
manual verification methods for these
systems.

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5.Compression The PRM Commissioning Support Package
(PRM-CSP), an example of automatic loop
Overall, PRM-CSP offers several key check, from Yokogawa significantly enhances
advantages, including streamlined the loop checking process by automating key
pre-inspection processes for loops, optimized tasks such as connectivity verification, range
utilization of human resources in the field, checking, and data validation, particularly for
and enhanced reliability of testing results, Foundation Fieldbus and HART devices.
as attached in Appendix A. By minimizing
unnecessary time expenditures and reducing Moreover, PRM-CSP offers several
strategic advantages, including streamlined
potential risk points, PRM-CSP not only pre-inspection processes, optimized use of
improves the efficiency of loop checks human resources in the field, and increased
but also enhances the overall safety and reliability of testing outcomes. By reducing
effectiveness of operations. Additionally, unnecessary time expenditures and mitigating
the system's ability to generate accurate potential risk points, PRM-CSP not only
and comprehensive reports further improves improves the efficiency of loop checks but also
the reliability of documentation, ensuring bolsters the overall safety and effectiveness
better availability and traceability of data of plant operations. The system's capacity
throughout the loop checking process. to automatically generate accurate and
comprehensive reports further enhances the
The chart below provides a clear comparison, reliability of documentation, ensuring better
illustrating the substantial benefits of data availability and traceability throughout
PRM-CSP in terms of minimized schedule the loop checking process.
impact.
Overall, integrating PRM-CSP into the
commissioning workflow represents a pivotal
advancement in managing the complexities
of large-scale industrial projects, ultimately
contributing to more successful, efficient, and
safe plant startups and maintenance activities.

Duration Compression, Chart .2

6.Conclusions
In conclusion, the complexity and scale of
loop checking in large-scale industrial projects
highlight the critical need for efficient and
reliable processes. Instrumentation and
control systems are fundamental to plant
operations, and their accuracy directly impacts
safety, efficiency, and overall performance.

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References
[1] Robinson, J. A. (1965). A Machine-Oriented
Logic Based on the Resolution Principle.
Journal of the ACM, 12(1), 23-41.
doi:10.1145/321250.321253

[2] Colmerauer, A., Roussel, P. (1996). The Birth

of Prolog. In K. R. Apt (Ed.), Handbook of Logic
in Artificial Intelligence and Logic Programming
(Vol. 5, pp. 3-36). Oxford University Press.

[3] Lipták, B. G. (2003). Instrument Engineers'

Handbook, Volume Two: Process Control and
Optimization (4th ed.). CRC Press.

[4] Considine, D. M. (1993). Process/Industrial

Instruments and Controls Handbook (5th ed.).
McGraw-Hill.

[5] Pressman, R. S. (2014). Software

Engineering: A Practitioner's Approach (8th
ed.). McGraw-Hill Education.

[6] Yokogawa Electric Corporation. (2016). PRM

Commissioning Support Package (PRM-CSP)
User Guide. Yokogawa Electric Corporation.

[7] Yokogawa Electric Corporation. (2018).

Field Digital Solutions: PRM – Plant Resource
Manager. Retrieved from Yokogawa Official
Website.

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Compression Table

Function Conventional Unconventional

There is no need to disconnect the field
Confirm the property It is necessary to disconnect
devices. Verification can be done using
and physical location the field devices to perform
HART/FF commands;
and connection of field verification;
1.Utilize the SQUAWK command to send
devices 1.Disconnect the cable from the
a signal from the DCS TAG.
field device and check for an open
2.Verify the SQUAWK signal on the LCD
circuit on the corresponding DCS
of the field devices directly in the field.
TAG.
3.If the device does not support the
SQUAWK command, use the simulate
mode to set data to the device and
verify the value displayed on the LCD in
the field.

Although AI/AO parameter checking

Verify the Performance Performance and precision
remains necessary, PRM-CSP streamlines
and Precision of Field are confirmed manually by
the process by allowing loop checks
Devices in Loops coordinating between the control
to be conducted more efficiently.
room and field operators, often
Devices can be grouped into tasks,
using walkie-talkies to check
enabling sequential (batch) execution
AI/AO parameters.
when verifying multiple field devices
consecutively.

Connectivity Check The connection between the

This verification is integrated into
marshalling cabinet and the field
the loop check process and can be
device must be manually verified
conducted simultaneously.
before starting the loop check.

Sending Signals for The Field Engineer must manually

Once connectivity is verified, the Field
Testing send a signal from the field device
using a communicator each time a Engineer no longer needs to send a signal
check is performed. manually for each subsequent check.

Values are automatically recorded with

Measurement Values Source and measurement values
voiced by field side tester. high accuracy in PRM-CSP.

Field Crew Moving The field crew must physically

move to each field instrument for The field crew does not need to move to
every check. each instrument for every check.

Can operate with minimal impact from

Environments Operations are limited by
environmental conditions.
Condition environmental conditions such as
weather, time, and other factors.

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Reporting Manual documentation is required Reports are automatically generated by
for reporting purposes. the system.

Re-testing Requires additional time in the Minimizes the impact on the schedule
schedule for re-testing when re-testing is necessary.

Manpower A crew of 25 people is required A crew of 2 people are required

Time Consuming A duration of 300 days for all A duration of 40 days is enough for all
required loops loop to be checked including the loops
that will not be tested using auto- loop
checking

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