Vous êtes sur la page 1sur 6

FAIL N/A RE-TEST DATE

ITEM
No.
TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE PASS
SAUDI ARAMCO ID/PID - 3/01/05 - REV A (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
Motor Operated Valve- Bench Calibration, Testing,
Installation, Field calibration, and Certification
SATR-J-6701 1-Oct-05 INST
PLANT NO. EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID.
LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.
TRAVEL TIME
SAUDI ARAMCO USE ONLY
SCHEDULED TEST DATE & TIME ACTUAL TEST DATE & TIME QUANTITY INSP. MH's SPENT
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?
SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL
A Certification
A1
Specific tools and equipment shall be identified to make and perform
tests in the field with instructions for their use, calibration, and storage.
Schedule Q,
Att. IV, Sec.6.1.
A2
The CONTRACTOR shall identify, maintain, control, adjust, and calibrate
all tools, gauges, instruments and other measuring and testing devices
used for controlling quality.
Schedule Q,
Att. IV, Sec.6.1.
A3
Calibration shall be performed at established periods as specified in
the most stringent of SAUDI ARAMCO standards, other applicable
standards, or manufacturer recommendations; if no standards apply,
the calibration cycle shall not exceed six months.
Schedule Q,
Att. IV, Sec.6.1.
A4
CONTRACTOR shall provide backup equipment when the primary
equipment is being calibrated or tested.
Schedule Q,
Att. IV, Sec.6.1.
B Installation Inspection- Electrical requirements
B1
Verify or conform that the physical location of the actuator and its
certification meet the following standard: The actuator shall be certified
for installation in a Class I, Division 1, Group C & D or Zone 1 areas,
classified under NFPA 70, National Electrical Code (NEC) Article 500, or
Article 505. The actuator shall also be listed or labeled by any of the
following agencies: UL, FM, CSA. Alternatively, the actuator may be
European third-party certified with the full requirements of CENELEC EN
50018 Zone 1, and Zone 2. The actuator shall be water and dust-tight in
accordance with NEMA ICS 6 and NEMA 250 Type 4X or IEC 60529
Type IP65.
34-SAMSS-718
Sec. 5.3.1
B2
The motor shall be high-torque, low inertia, squirrel-cage type, designed
specifically for actuator duty. As a minimum, the motor shall be rated for
15 minutes continuous operation or S2-15 duty cycle per IEC 60034-1,
and shall be with Class F insulation. All other performance
characteristics shall conform to the requirements of NEMA MG 1. Motors
shall be rated for 3 phase, 460 VAC, 60 Hz power supply, unless
specified otherwise. Motor shall be capable of operating under maximum
specified loads with 10% voltage variation to the motor.
34-SAMSS-718
Sec. 5.3.2
B3
The motor shall be protected by a temperature element embedded within
the stator winding or by a current sensing overload relay in all three
phases to protect against cold stall and continuous overload.
Commentary Note: Disabling or bypassing the temperature element will
invalidate the actuator hazardous area enclosure certification.
34-SAMSS-718
Sec. 5.3.2.1
B4
The motor power supply shall be fitted with a phase rotation protection
device designed to present the motor with the correct phase rotation
regardless of possible incorrect power connections or to prevent the
application of power if the phase rotation is incorrect.
34-SAMSS-718
Sec. 5.3.2.2
A5
CONTRACTOR personnel performing test and calibrations shall be
trained per applicable international or manufacturer requirements.
Schedule Q,
Att. IV, Sec.6.2.
Page 1 of 6
C4
Position limit switches shall be set by the valve manufacturer during
mounting/assembling of actuator to the valve at the valves
manufacturer's shop.
34-SAMSS-718
Sec. 5.4.4
C3
When mechanical position limit switches are used for external indication,
the appropriate contacts shall open at their preset limits of travel. They
shall function identically when the actuator is operated by motor or hand
wheel.
34-SAMSS-718
Sec. 5.4.3
C2
Position limit switches shall be fully adjustable over the full range of valve
travel.
34-SAMSS-718
Sec. 5.4.2
C1
Local indication of valve position shall be by either one of the following
methods:
(a) An integral, mechanically linked, pointer and dial that continuously
show the valve position (0-100%).
(b) A digital valve position indicator that continuously shows the valve
position (0-100%), plus separate green and red LEDs to indicate valve
open (green) and closed (red) position.
34-SAMSS-718
Sec. 5.4.1
C Installation Inspection- Valve Position Limit Switches and Indication
B13
All conduit connections shall be made so as to assure grounding
continuity.
34-SAMSS-718
Sec. 5.3.8
B12
A minimum of three 1-inch NPT or larger conduit entries shall be
provided per ANSI B1.20.1.
34-SAMSS-718
Sec. 5.3.7
B11
An external stud with lug shall be provided to accommodate a grounding
conductor of 10 mm.
34-SAMSS-718
Sec. 5.3.6
B10
Power and control terminals shall be segregated. Vendor's internal wiring
identification shall be by permanently embossed wire markers of heat-
shrinkable slip-on type or equivalent permanent marking system.
External wires shall be terminated with ring type wire lugs. Suitable screw
type terminals shall be provided. Termination schedule for external
control and monitor connections shall be permanently fixed to the inside
of the terminal enclosure cover plate.
34-SAMSS-718
Sec. 5.3.5
B9
A three-position control mode selector switch shall be provided. The
switch shall provide two control modes, Local and Remote. In addition,
the switch shall provide a third position which inhibits local and remote
operation of the actuator. The switch shall be lockable in all three
positions. The switch positions shall be marked LOCAL; STOP (OFF);
REMOTE or by suitable symbols to clearly identify the function of each
switch position.
34-SAMSS-718
Sec. 5.3.4
B8
External control voltage shall be 24 VDC, 125 VDC or 120 VAC nominal
as specified in 8020-718-ENG.
34-SAMSS-718
Sec. 5.3.3.3
B7
Hardwired electromagnetic relays, if used, shall comply with Form 8020-
825-ENG. Dust proof relays may be used in double sealed enclosures.
34-SAMSS-718
Sec. 5.3.3.1
B6
Integral contactor control logic may be implemented with hardwired
electromagnetic relays or hardwired solid state logic or configurable solid
state logic.
34-SAMSS-718
Sec. 5.3.3
ITEM
No.
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE
B5
The motor shall be protected against loss of one or more motor power
supply phases by a phase protection device which shall prevent
actuation of the motor control contactors on loss of one or more power
supply phases.
34-SAMSS-718
Sec. 5.3.2.3
PASS FAIL N/A RE-TEST DATE
SAUDI ARAMCO ID/PID - 3/01/05 - REV A (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
Motor Operated Valve- Bench Calibration, Testing,
Installation, Field calibration, and Certification
SATR-J-6701 1-Oct-05 INST
Page 2 of 6
ITEM
No.
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
SAUDI ARAMCO ID/PID - 3/01/05 - REV A (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
Motor Operated Valve- Bench Calibration, Testing,
Installation, Field calibration, and Certification
SATR-J-6701 1-Oct-05 INST
E2
Remote Push Button and Status Lamp Connections for remote control
and monitoring devices shall be provided as follows:
a) Remote Open, Close and Stop push buttons.
b) Valve position indicator lamps.
c) Monitor relay to indicate that actuator is in local or remote control
mode.
34-SAMSS-718
Sec. 6.2
E Installation Inspection- Torque Switches and Monitors
E1
Wiring Diagrams: Unless stated otherwise in 8020-718-ENG the
actuator shall be wired to provide maintained travel with intermediate
stop and reverse operation. Instantaneous reverse may be considered
when actuators are wired for remote ESD actuation. Vendor standard
wiring diagrams shall be used to achieve the required functionality.
34-SAMSS-718
Sec. 6.1
D6
If an external setting tool is used for no intrusive configuration, it shall be
intrinsically safe and shall be certified for use in Class 1 Division 1 or
Zone 1 areas. In addition, the setting tool shall be weatherproof and
suitable for use in the ambient conditions specified in attachment 1 of
SAIC-J -6702. In microprocessor based actuators, access to actuator
configuration and adjustments shall be password protected.
34-SAMSS-718
Sec. 5.6.2
D5
Actuator Configuration: Actuators may be configured by inserting
hardwired links into pre configured hardwired control circuits or by
external no intrusive means or by setting dip switches in logic circuits.
34-SAMSS-718
Sec. 5.6.1
D4
For microprocessor based actuators, settings of electronic torque
switches shall be retained in nonvolatile memory.
34-SAMSS-718
Sec. 5.5.4
D3
Torque switches) shall be adjustable. The opening torque switch shall be
set at a minimum by the actuator manufacturer. The closing torque
switch shall be set by the actuator manufacturer in accordance with Form
8020-718-ENG except on actuators to be mounted on existing valves.
34-SAMSS-718
Sec. 5.5.3
D2
When mechanical switches are used, contacts shall open when the
torque setting is exceeded either in the opening or closing direction.
Direct cam driven micro switches are acceptable only for no critical
auxiliary/utility services.
34-SAMSS-718
Sec. 5.5.2
D1
Motor torque shall be sensed by a mechanical mechanism or inferred
from a measurement of motor current, speed, mechanical pressure or
magnetic flux.
34-SAMSS-718
Sec. 5.5.1
D Installation Inspection- Torque Switches and Monitors
C5
When electronic valve position monitors and limit switches are used,
valve position and switch settings shall be stored in nonvolatile memory.
It shall be possible to monitor and retain the valve position if the actuator
is manually operated while the main power supply is lost or isolated. In
addition, the actuator shall not require limit switch resetting or position re-
calibration after power supply is re-established. When backup batteries
are used for digital position transmitter, the battery life shall be at least
five years. In addition, the battery condition shall be monitored and
alarmed.
34-SAMSS-718
Sec. 5.4.5
Page 3 of 6
ITEM
No.
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
SAUDI ARAMCO ID/PID - 3/01/05 - REV A (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
Motor Operated Valve- Bench Calibration, Testing,
Installation, Field calibration, and Certification
SATR-J-6701 1-Oct-05 INST
F4 Pneumatic wiring connections correct
Schedule Q,
Att. IV, Sec.6.1.
F3 Instrument checked for damage
Schedule Q,
Att. IV, Sec.6.1.
F2 Tag number correct
Schedule Q,
Att. IV, Sec.6.1.
F1 Instrument checked against data sheet.
Schedule Q,
Att. IV, Sec.6.1.
F Calibration Inspection- Visual and Dimensional Checks
E11
Electronic control circuits shall be tested to confirm that the equipment
will operate properly when energized and subjected to an
electromagnetic field from a radiated source, in particular hand held
walkie talkies operating at 5 watts within the frequency range 68 MHz to
470 MHz. Test method shall be based on test method "c" and a severity
class of "II" from IEC 60255-22-3.
34-SAMSS-718
Sec. 7.4
E10
Actuators shall be factory tested by the vendor to verify rated output
torque, output speed, hand wheel operation, local control, control power
supply, closing direction, all customer inputs and outputs, operation of
motor winding temperature detector, and operation position indication &
LEDs. A report confirming successful completion of these factory tests
shall be submitted by the vendor.
34-SAMSS-718
Sec. 7.2
E9
The position comparator circuit shall include the capability for zero, span,
and dead band settings.
34-SAMSS-718
Sec. 5.5.6
E8
Any external or internal fuses that are necessary for the protection of the
actuator motor shall be supplied by the actuator vendor.
34-SAMSS-718
Sec. 6.5.5
E7
The vendor shall ensure that the modulating card can continuously
monitor the valve position with the actuator traveling at its full specified
speed.
34-SAMSS-718
Sec. 6.5.4
E6
Motor with Class H insulation shall be used when the application requires
600 starts/hour or higher.
34-SAMSS-718
Sec. 6.5.3
E5
The actuator motor duty cycle shall be suitable for modulating service
and shall be selected in accordance with IEC 60034-1. As a minimum,
duty cycle S4-25% shall be provided when the required start/hour equals
to or higher than 60 Starts/Hour. Higher cyclic duration factor ("ON" time
/ Cycle time) should be considered based on the valve size and/or how
dynamic the process is.
34-SAMSS-718
Sec. 6.5.2
E4
Digital Two-Wire Networks Digital Two-Wire Networks that enable
several actuators to be controlled and monitored from a single master
station may be used with prior written approval of the Supervisor,
Instrumentation Unit/P&CSD.
34-SAMSS-718
Sec. 6.4
E3
The following features shall be supplied if specified in 8020-718-ENG:
a) External remote emergency shutdown, close or open, as specified.
Emergency contact shall be normally closed, open on emergency. When
the actuator is specified for emergency isolation application, the ESD
contact shall have its dedicated "Common" pin connection terminal that
is independent from other "Common" pin connection used for control
signals. Commentary Note: The additional dedicated ESD "common"
terminal is not required if the actuator Open/Stop/Close contacts are
wired to the ESD system. Emergency shutdown shall override the control
mode selector switch when set to either Local or Remote control,
however emergency shutdown shall not override when the MOV is set to
the STOP (OFF) position:
b) Remote indication of motor output torque.
c) Remote indication of torque switch status.
d) Remote continuous linear position indicator. The position indication
shall be achieved by externally powered potentiometer or 4-20 mA
isolated signal proportional to valve position.
34-SAMSS-718
Sec. 6.3
Page 4 of 6
ITEM
No.
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
SAUDI ARAMCO ID/PID - 3/01/05 - REV A (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
Motor Operated Valve- Bench Calibration, Testing,
Installation, Field calibration, and Certification
SATR-J-6701 1-Oct-05 INST
Manufacture's Test Variables if any to be highlighted
M3 Cable terminations complete and checked
M1 Equipment undamaged.
M2 Earthing as per the detail drawing
M Completion Results
Motor winding to
Ground
L1 RESULTS
L2 Motor insulation Resistance (If applicable)
Resistance Meg.
Ohms
Temp Deg.
Celsius
Resistance Meg. Ohms Result acceptable Results Rejected
K4 Limit Switches checked and operating correctly YES NO
L Post installation checks
K2 MOV is in accordance with spec. sheet YES NO
K3 Valve stroke was checked and correct YES NO
K Test Report
K1
J Test Procedures
J 1
Manufacture's special Test Procedures if any, to be confirmed and verified including the following:
(a) Insure that the valve is correct according to instrument specification.
(b) Ensure that the valve is upright and supported prior to carrying out test.
(c) Ensure that no sand or foreign material is in the body of the valve.
(d) Using the Hand wheel, fully close and open the valve.
(e) Check all switches when valve stem is in the open and closed position.
(f) Disconnect all wiring and replace cover tightly
(g) Then place calibration tag, which shall be a blue colour, on valve.
(h) Sign off calibration sheet
(j) Instrument calibrations will be repeated where necessary during pre-commissioning or at any other stage where deficiencies are to be
rectified
Note- The Valve may be checked at its lay down location
During Pre-Commissioning the following tests will be performed
(a) The motor will be powered up and operation of motor will be confirmed.
(b) The hand, off, auto switch function is correct.
(c) In local control mode the open ,close and stop push button functionality will be checked.
(d) The valve will reach its closed position on the torque limit switch setting
(e) Position indication lamps will be checked for correct operation.
(f) Opening and closing time will be noted and recorded.
G2 General Test Routines
G3 Manufacturer's test routines to be followed and calibration's to be confirmed within tolerance limits
G1 Test Equipment serial numbers : (a) Digital multimeter
F12 Non conformity with spec if any
Schedule Q,
Att. IV, Sec.6.1.
F11 Instructional manuals
Schedule Q,
Att. IV, Sec.6.1.
F10 Mounting brackets
Schedule Q,
Att. IV, Sec.6.1.
F9 Accessories checked
Schedule Q,
Att. IV, Sec.6.1.
F8 Flow direction identification
Schedule Q,
Att. IV, Sec.6.1.
F7 Electrical wiring connections correct
Schedule Q,
Att. IV, Sec.6.1.
F6 Electrical Safety Execution identification
Schedule Q,
Att. IV, Sec.6.1.
F5
Shipping stoppers removed and reinstalled after calibration wherever
applicable
Schedule Q,
Att. IV, Sec.6.1.
Page 5 of 6
ITEM
No.
TEST RESULTS ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-TEST DATE
SAUDI ARAMCO ID/PID - 3/01/05 - REV A (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
Motor Operated Valve- Bench Calibration, Testing,
Installation, Field calibration, and Certification
SATR-J-6701 1-Oct-05 INST
N CONCLUSIONS
After successful completion of each calibration, the instrument shall be marked with a colored label bearing date of the calibration and the initials of
the witnessing party The color code shall be as follows:
Blue- Pre Calibration Tested.
Yellow - Installed & Pressure Tested.
Green- cables or tubing tested.
Red- Loop Check completed.
M9 Valve local indication checked OPEN CLOSE
M10 Valve remote indication checked OPEN CLOSE
M7 Valve Operating time
M8 Remote operation checked OPEN CLOSE
M5 Valve limit switch set OPEN CLOSE
M6 Valve Torque switch set OPEN CLOSE
M4 Valve moment free
4. Labeled - Equipment or materials to which has been attached a label, symbol, or other identifying mark of an approved qualified organization
Work Verified
Saudi Aramco
with product evaluation, that maintains periodic inspection of production of labeled equipment or materials, and by whose labeling the
PMT Representative
T&I Witnessed QC Record Reviewed
Name, Initials and Date:
Witnessed Test Work / Rework May Proceed
Name, Initials and Date:
QC Inspector PID Representative
indicates compliance with appropriate standards or performance in a specified manner.
Technician Performing Test*
Name, Title, Department,
Company, Initials and
Date:
Test Performed Successfully and Results are Acceptable:
Name, Initials and Date:
5. Remarks: -1. This check list is not applicable to electric valve actuators that are specially designed for well head surface safety valve
applications.
2. Table L to be changed based on usage.
Contractor / Third-Party
3. SAES-J -003-Instrumentation Basic Design, 31 May, 2004
REMARKS:
QC Record Reviewed
1. Schedule G -- Material, Tools and Equipment (Pro Forma MP-IK-LS Contract), J uly 1993
2. Schedule Q -- Quality Requirements (Pro Forma Contract), November 2003
NOTES:
4. SAES-J -700-Control Valves, 31 August, 2004
5. 34-SAMSS-711-Control Valves-General Services, 31 March, 2003
REFERENCE DOCUMENTS:
1. Approved - Acceptable to the authority having jurisdiction (i.e., Saudi Aramco ID).
6. 34-SAMSS-718- Electric Motor Operated Valve Actuators, 31 December,2003
2. Identified - Recognizable as suitable for the specific application by a qualified testing laboratory (i.e., listing and/or labeling).
3. Listed - Equipment and materials included in a list published by an approved qualified organization concerned with evaluation of products
or services, that maintains periodic inspection of production of listed equipment or materials or periodic evaluation of services, and whose listing
that the equipment, material, or services either meets appropriate designated standards or has been tested and found suitable for a specified
Work Verified
Work Verified
Name, Sign and Date:
Quality Record Approved:
Name, Organization,
Initials and Date:
T&I Witnessed
QC Supervisor Proponent and Others
T&I Witnessed
Y =YES N =NO F =FAILED *Person Responsible for Implementation of Test and Analysis of Results
QC Record Reviewed
Page 6 of 6