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Saudi Aramco Inspection Checklist: Electronic Control Systems - PLC - Material Receiving SAIC-J-6803 24-Jul-18 Inst
Saudi Aramco Inspection Checklist: Electronic Control Systems - PLC - Material Receiving SAIC-J-6803 24-Jul-18 Inst
00 30-Jun-18
SAIC NUMBER DATE APPROVED QR NUMBER
SAUDI ARAMCO INSPECTION CHECKLIST
Electronic Control Systems - PLC - Material Receiving SAIC-J-6803 24-Jul-18 INST
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR
EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.
LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.
SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME
SAUDI ARAMCO USE ONLY
SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
Schedule G
A3 New and Unused - Instrumentation materials shall be new and unused.
Sec. 2.1
Verify that the contractor or it's Saudi Aramco approved third party
Schedule Q
inspector performed the quality activities at the supplier and sub-supplier
A8 Att. III
locations as required by the inspection level assigned for the materials
Sec. 3.2
and equipment identified in SAEP-1150 Inspection Requirements.
System Support:
DCS vendor shall guarantee support of all hardware, firmware and
software associated with the controller and I/O subsystems and any
23-SAMSS-010
A10 proprietary communications equipment for a period of ten (10) years from
Sec. 6.4.1
the hardware freeze date. Support shall include spare parts and technical
support. This support shall not be contingent on the customer upgrading
to later releases of software or hardware.
Inspection:
Items manufactured to this Specification are subject to the minimum 34-SAMSS-623
A15
Inspection Requirements as specified in Saudi Aramco Inspection Sec. 18
Requirement Form 175-344000.
Non-Material Requirements:
34-SAMSS-623
A16 The supplier shall provide non-material items as shown on Form NMR-
Sec. 18
7907.
Environmental Conditions:
All cabinet equipment and wiring shall be designed for continuous 34-SAMSS-820
B3
operation at 50 °C, and relative humidity 80% maximum (non-condensing) Sec. 5.2
and 20% minimum.
The selected CPU operating mode (Program, Run, Lock/Unlock), shall be 34-SAMSS-623
B7
visually indicated on the front of the CPU module. Sec. 8.2.4
I/O module types, quantities and respective signal levels shall be as 34-SAMSS-623
B9
indicated on attached ISS sheet. Sec.8.4.3
I/O modules shall be capable of being inserted into or removed from their
34-SAMSS-623
B10 rack without disturbing external wiring. Field I/O wiring shall be connected
Sec.8.4.4
to the I/O rack, via integral screw type terminals.
It shall be possible to mix all types of I/O modules in any given rack, 34-SAMSS-623
B11
irrespective of their voltage levels. Sec.8.4.5
All discrete I/O modules shall include local status indicators to monitor the
34-SAMSS-623
B12 status of each input and output. All analog modules shall include a local
Sec.8.4.7
status indicator to monitor the status of the module.
34-SAMSS-623
B13 All discrete I/O circuits shall be isolated from logic or processor circuitry.
Sec.8.4.8
All input and output points shall be individually fused or employ current
limiting circuitry, e.g., in the case of module "self powered" I/O. Fuses
34-SAMSS-623
B15 shall be located on an external termination panel, fused terminal strip or in
Sec.8.4.2
a location readily accessible for maintenance. Removal of I/O modules
shall not be necessary to accomplish fuse replacement.
Fuse ampacity ratings must be sized for the maximum expected load at
34-SAMSS-623
B16 the maximum operating temperature of the system, but not to exceed the
Sec.8.4.2
I/O module rating.
If remote I/O is selected, Vendor shall confirm, in writing, that the selected 34-SAMSS-623
B17
communications cable(s) meet the communications driver specification. Sec. 8.5.2
Incoming power to the PLC system will be from Saudi Aramco supplied 34-SAMSS-623
C2
120 VAC power sources, which are over-current protected. Sec8.7.1
Protection:
Each power supply shall have its own internal fuse/circuit breaker
protection on the incoming line side. Fuses or circuit breakers shall be 34-SAMSS-623
C5
capable of being replaced or reset, without removal of the power supply or Sec.8.7.5
disconnecting any wiring terminations. Output protection shall be provided
by current-limiting circuitry.
Power Restoration:
The PLC system shall be designed such that, such that output modules
34-SAMSS-623
C6 de-energize when primary UPS power is cycled to the ESD system (i.e.,
Sec.8.7.7.1
applied, removed, or restored to the CPU or I/O
modules).
Communications Interface:
The controller shall as a minimum, support multiple EIA/RS-232 EIA/RS-
422, EIA/RS-485, or ANSI/IEEE 802.3 ports for
communicating with external devices such as a DCS, host
34-SAMSS-623
C7 computer, local area network gateway, program development
Sec.8.6.2.1
station, or printer. Acceptable data communications protocols
include Modbus/RTU, TCP/IP, and OPC - (Object linking and
embedding for Process Control). Specific porting requirements
will be identified on the ISS
Identification:
Each type of PLC module shall be uniquely identified by a type number,
34-SAMSS-623
C8 serial number and a revision or some other production lot identification
Sec. 16
code. In addition, each PLC Module shall clearly indicate the designed
field signal range, type and service; e.g., 120 VAC Digital Output, etc.
Indoor PLC cabinet construction and wiring shall comply with the
34-SAMSS-623
C9 requirements of 34-SAMSS-820 "Instrumentation Control Cabinets except
Sec. 3.2
as may be superseded within this specification.
Wire Specifications:
General 120/230 VAC power wiring shall be minimum 14 AWG stranded, 34-SAMSS-820
D2
copper, UL listed and PVC or XLPE insulated . Wire insulation shall be Sec. 6.7.3.1
rated for 600 volts, 75°C, minimum.
Wire Specifications:
Electronic signal wire shall be UL listed, stranded copper, minimum size
18 AWG, 300 V for single conductors or a minimum 20 AWG, 300 V for
multicore cable (assuming Class-2 circuits per NEC). Wire insulation shall 34-SAMSS-820
D3
be XLPE PVC, or PTFE, with a minimum temperature rating of 75°C. Sec. 6.7.3.2
Special electronic signal wires shall be as described in the Purchase
Order.
Wiring Methods:
The following are exempted from the above rule:
Wiring for millivolt, micro amp, pulse and frequency signals under 1 Volt
34-SAMSS-820
D5 such as thermocouples, resistance temperature detectors (RTD), vibration
Sec. 6.7.6
elements, analyzer elements, thermistor elements and transmitters with
pulse outputs shall be directly connected to the I/O unless otherwise
specified in the Purchase Order.
Wiring Methods:
Exposed electrical connections with voltages greater than nominal 48 34-SAMSS-820
D6
volts AC/DC shall be shrouded by transparent, removable, insulating Sec. 6.7.4.1
plastic covers (or equivalent).
Terminal strip spacing shall allow ample room for plastic wire ducts
and permit lacing of cables, and fanning of individual wires to
termination points. Each terminal strip shall be labeled above or below
34-SAMSS-820
D8 with the terminal strip number, as shown on wiring diagrams.
Sec. 6.7.7.2
Terminals for similar (AC or DC) current service shall be grouped
together and physically separated from terminals for different service by
means of dividers, separate mounting rails or separate enclosures.
Standoffs for terminal strips are preferred to bring the terminal blocks
forward to be flush with the top of the plastic wire duct. This wiring method 34-SAMSS-820
D9
assures that all wires can be accessed without interference from other Sec. 6.7.7.3
wires as the wire duct is filled.
The maximum conduit/plastic wire duct fill (including spare capacity) shall 34-SAMSS-820
D14
not exceed the heat requirements of NFPA 70 Section 300.17. Sec. 6.7.9.3
In addition to the above, the maximum plastic wire duct fill (including 34-SAMSS-820
D15
spare capacity) shall not exceed 75% of its depth. Sec. 6.7.9.4
Where space limitations preclude the use of plastic wire ducts, wiring shall
be neatly loomed and secured with plastic spiral wrapping or tie-wraps 34-SAMSS-820
D17
and anchors. Wiring between movable parts such as doors shall be Sec. 6.7.9.6
installed in flexible hoses.
34-SAMSS-820
D18 Loomed wiring shall not be installed near sharp-edged surfaces.
Sec. 6.7.9.7
Wiring shall not be threaded through undressed access holes. Glands or 34-SAMSS-820
D19
protective grommets shall be used. Sec. 6.7.9.8
34-SAMSS-820
D21 Wire ducts for ESD wiring shall not contain any other types of wiring.
Sec. 6.7.11.1
Wire Color Coding:
34-SAMSS-820
D22
Sec. 6.7.11.2
Cables with connector plugs shall be tagged at each end. Each cable tag
shall have two labels. The first label (closest to the plug connector) shall
34-SAMSS-820
D23 identify the device and socket to which the plug is to be connected. The
Sec. 6.7.11.2
second label shall identify the device and socket to which the opposite
end of the cable is connected.
I/O and interconnecting wiring shall be tagged at each end with two
identification tags (or the two may be combined into one tag with sufficient
separation between wire numbers). The first tag (closest to the end of the 34-SAMSS-820
D24
wire) shall identify the terminal number to which the wire is physically Sec. 6.7.11.3
connected. The second tag shall identify the terminal number to which the
opposite end of the wire is connected.
The disconnect levers for fused terminals and knife-switch terminals shall 34-SAMSS-820
E5
be hinged. Sec. 7.8.5
Wires terminated on these terminal blocks shall not have the bare ends
coated with or dipped in solder ("tinned"). However, termination of wiring
34-SAMSS-820
E6 which has individual strands of the copper conductor tinned during
Sec. 7.8.6
manufacture (typical of shield drain wires or for corrosion protection) is
acceptable.
Direct termination of the bare wire end is acceptable. The terminal block
must be suited for the wire size. The use of crimp-on ferrules shall follow
the manufacturer's guidelines and the following:
a) One or two wire ferule is acceptable. (The use of ferrules to daisy chain 34-SAMSS-820
E7
is not acceptable). Sec. 7.8.7
b) Only one ferrule shall be connected to each side of a single terminal
block.
c) Ferrules shall be provided with plastic insulating collars.
Vendor standard cables shall be designed and installed in such a way as SAES-Z-001 Sec.
E10
to allow cable disconnection in order to service the equipment. 16.2.4
Nameplates:
All Cabinets shall have a nameplate permanently attached indicating the SAES-Z-001 Sec.
E11
service description. Nameplates shall comply with the relevant sections of 16.1.2
34-SAMSS-820 specific to Nameplates.
Nameplates:
34-SAMSS-820
E12 Cabinets designed for both front and rear entry shall have a nameplate
Sec.6.5.6
attached to both the front and back.
Nameplates:
All push buttons, switches, lamps and other console mounted devices SAES-Z-001 Sec.
E13
shall have a nameplate permanently attached indicating the service 10.1.7
description.
Grounding:
Both safety ground and instrumentation circuit ground must conform to
34-SAMSS-820
E14 NEC, Article 250. Grounding system recommendations and requirements
Sec. 6.7.18.1
provided by manufacturers of instrumentation and control systems (e.g.,
Distributed Control Systems) shall be followed.
Grounding:
34-SAMSS-820
E15 Separate, electrically isolated grounding bars shall be provided, as
Sec. 6.7.18.2
required.
Grounding:
All ground buses shall be made of a solid copper measuring the following
34-SAMSS-820
E16 nominal dimensions 5mm x 40 mm x (y length), suitably drilled and tapped
Sec. 6.7.18.3
for screw terminals and wire lugs, or fitted with screw-type compression
lugs.
Grounding:
34-SAMSS-820
E17 The preferred location of the ground bus bars is at the bottom of the
Sec. 6.7.18.4
cabinet.
Grounding:
A No. 2 AWG screw-type compression lug shall be provided on both end 34-SAMSS-820
E18
of each ground bar for interconnection with the Master Instrument Ground Sec. 6.7.18.5
or Master Safety Ground.
Grounding:
"INSTRUMENT CIRCUIT GROUND" for connecting cable and wire
shields and DC Common. Interconnections between shield consolidation 34-SAMSS-820
E20
points and the bus bar shall be minimum 12 AWG copper wire, green or Sec. 6.7.18.6
green with yellow tracer insulation. This bus bar shall be electrically
insulated from the cabinet structure.
Grounding:
When provided, AC power receptacle outlets shall be grounded using 34-SAMSS-820
E21
ground wire terminated on the receptacle grounding terminal. (e.g., A Sec. 6.7.18.7
receptacle utilizing the faceplate as a ground path is not permitted.)
Incandescent lamps shall have a guard to help protect the lamp from
34-SAMSS-820
E24 accidental breakage. Fluorescent lamps shall have clear plastic sleeve
Sec. 6.7.19.3
guards to help contain broken glass in case of an accident.
The cabinets and its integral parts shall be protected against corrosion
and operational failure due to wind-borne sea water spray and the
accumulation of wetted salt (NaCl), if it is located at:
a) Outdoor offshore locations, or 34-SAMSS-820
F3
b) Outdoor onshore locations within one kilometer from the shoreline of Sec. 5.2.2.3
the Arabian Gulf; all of the Ras Tanura Refinery and Terminal; and within
three kilometers from the shoreline of the Red Sea.
Conduit Entry: The entry (on non-explosion proof cabinets) shall have a
34-SAMSS-820
F10 removable blank gland plate as specified in the Purchase Order for
Sec. 7.2.3.1
Buyer's conduit entry.
Elevated outdoor control cabinets shall normally have conduit entry from 34-SAMSS-820
F11
the bottom. Sec. 7.2.3.2
Fans with suitable filters and louvers may be used within control cabinets
to assist in heat removal. This can be achieved by installing a filter fan at
the air inlet (typically at the bottom of the cabinet door) to blow cool air
34-SAMSS-820
F19 into the cabinet or by installing an exhaust filter fan at the air outlet
Sec. 6.3.3
(typically at the upper section of the door) to draw hot air out of the
cabinet. The fan filter shall be easily accessible for maintenance or
replacement without dismantling the fan assembly.
Cabinet cooling fans shall be sized to handle 20% more air flow by
volume than the amount taken credit for in the heat dissipation calculation.
34-SAMSS-820
F20 Commentary Note:
Sec. 6.3.5
As an example, if the heat dissipation calculation considers the air volume
of the fan to be 150 CFM, fans should be sized to deliver 180 CFM.
Where two or more front sections are required for a Control Panel, the 34-SAMSS-820
F23
interior shall be an open-frame construction. Sec. 6.3.8
34-SAMSS-820
F25 Each cabinet shall be provided with removable lifting rings.
Sec. 6.3.10
Cabinets intended for marshalling may have front and rear access and
shall be designed per paragraph 5.2. The distance from the front surface
34-SAMSS-820
F27 to the surface of rear terminal blocks, shall not be more than 400 mm
Sec. 6.3.12
deep to provide for safe access. The cable entry to the marshalling
cabinet shall be through the bottom.
When front and rear accesses are provided for control cabinets, each
section shall have its own full size mounting plate. Cable routing shall be
34-SAMSS-820
F30 tightly secured either on the sides and/or through properly dressed holes.
Sec. 6.3.15
Wiring shall not be threaded through undressed access holes. Glands or
protective grommets shall be used.
All doors shall be provided with integral lockable door handles with the 34-SAMSS-820
F31
same lock and key combination, unless otherwise specified on the ISS. Sec. 6.3.16
Equipment that are installed within cabinets or panels and are normally
used by the operator shall be readable and operable with the operator in a 34-SAMSS-820
F32
standing position. Sec. 6.3.17
The inside of each door shall be equipped with a pocket suitable for 34-SAMSS-820
F33 holding A4 documents and/or cabinet drawings. Sec. 6.3.18
Cabinets intended for bottom cable entry shall be provided with a gland
plate at the bottom of the cabinet. 34-SAMSS-820
F34
Sec. 6.3.19
All cabinets intended for outdoor applications shall be certified by one of
the approved IECEx certifying bodies. Certification shall also include
Ingress Protection (IP rating) per IEC 60529.
Commentary Note:
34-SAMSS-820
F35 For IP rating certification, a vendor would submit a sample to certifying
Sec. 7.1.3
agency and they will issue a compliance certificate and then the
manufacturer can mass produce that commodity as long as they adhere
to the specification of the type tested item. Only one certificate per type is
needed for all current and succeeding projects.
REMARKS:
REFERENCE DOCUMENTS:
1. Schedule G - Material, Tools and Equipment (Pro Forma MP-IK-LS Contract),
2. Schedule Q - Quality Requirements (Pro Forma Contract)
3. NFPA 70 - National Electrical Code 2017
4. 23-SAMSS-010 - Distributed Control Systems, 24 December 2017
5. 34-SAMSS-820 - Instrument Control Cabinets 13 July 2016
6. SAEP-385 - Preservation of Project Materials and Equipment - 25 October 2017
7. SAES-Z-001 - Process Control System - 20 December 2017
ATTACHMENTS:
NOTES:
1. Approved - Acceptable to the authority having jurisdiction (i.e., Saudi Aramco ID).
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 states
that the equipment, material or services either meets appropriate designated standards or has been tested and found suitable for a specified purpose.
4. Labeled - Equipment or materials to which has been attached a label, symbol or other identifying mark of an approved qualified organization
concerned with product evaluation, that maintains periodic inspection of production of labeled equipment or materials, and by whose labeling the
manufacturer indicates compliance with appropriate standards or performance in a specified manner.