Instrument Loop Testing Procedure-1 [PDF]

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Project Title: APN-E/F New Field Development Project STC # 0558



Document Number: BCON-J-PRC-0003



Author Org: CONSTRUCTION ENGINEERING



Validation : 2 Years Expired Date: 24-05-2013



APN-E/F NEW FIELD DEVELOPMENT PROJECT



INSTRUMENT LOOP TESTING PROCEDURE



Approval Sheet Name



Title



Date



Signature



Revision Status EPCI PT SI , PT PLI & PLL Consortium



Rev



Issue Date



Sub-Contractor PT. Bakrie Construction



B



24-05-2011



Prepared by



Checked by



Approved by



APP



TAS/MHR



AL/FA



CTR Approved By



REVISION LOG SHEET



Issue Purpose



IFR



Owner Signature



PHE ONWJ Ltd.



INSTRUMENT LOOP TESTING PROCEDURE



Document Number: BCON-J-PRC-0003 Document Title Revision



: INSTRUMENT LOOP TESTING PROCEDURE :B



Page



DATE



All



24 May 2011



DESCRIPTION OF CHANGE Re-Submit Due to Changing on document numbering system



PHE ONWJ Ltd.



INSTRUMENT LOOP TESTING PROCEDURE



TABLE OF CONTENTS



1. GENERAL .......................................................................................................................... 4 1.1. Scope............................................................................................................................. 4 1.2. References..................................................................................................................... 4 1.3. Terminology.................................................................................................................. 4 2. COMMON PROCEDURE................................................................................................. 5



3. GENERAL LOOP TEST PROCEDURE......................................................................... 6



4. DETAILED LOOP TEST PROCEDURE........................................................................ 7 5. SEQUENCE TEST.............................................................................................................. 8 6. ATTACHMENTS................................................................................................................ 9



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INSTRUMENT LOOP TESTING PROCEDURE



1. GENERAL 1.1. Scope This procedure covers the general requirements for the acceptance of instrument loop/sequence testing before/after installation and prior to the commissioning work. The procedure is the final non-operational checking for instrumentation acceptance to ensure that a combination of one or more interconnected instruments can measure and /or control a process variable correctly and ready to be operated. 1.2. References 1.2.1. Related Procedures The related Engineering Procedures to supplement this procedure are as follows: - MIKE-J-SPE-0001. General Instrument Specification. - MIKE-J-SPE-0002. Instrument Installation and Test Specification. - MIKE-J-SPE-0003. Specification Fire & Gas Detector. - MIKE-J-PHI-0002. Emergency Shutdown Philosophy. - MIKE-J-PHI-0003. Fire & Gas Detection and Protection Philosophy. 1.2.2. Code and Standards ANSI C96.1 1.3. Terminology In this specification, the following words and terms shall have the meanings hereby assigned to them, unless noted otherwise. 1.3.1. Company PT. Pertamina Hulu Energy, as the ultimate user and owner, and the authorized representative. 1.3.2. Contractor PT. Punj Llyod Indonesia was responsible for the detailed engineering design, material and equipment procurement. 1.3.3. Sub Contractor PT. Bakrie Construction was refers to the contractor selected which is responsible for the Shop drawing and construction as specified in Contract Scope of Work or Work Order. 1.3.4. Loop Test The loop test is a non-operational checking for instrument or control system before the sequence test and after the construction test (pressure test, continuity test, megger test, high potential test, calibration test, and function test). The scope of loop test is to check the looping system with referring to the loop drawing or loop diagram. This test can conducted using dummy signal or actual signal input and output. This is depending on the critical/non-critical loop and the project necessary. All the loops shall be tested by feeding actual inputs to the transmitter such as pressure, by pressure pump. Resistance Decade box for RTD, filling water in displacer water for level transmitter



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INSTRUMENT LOOP TESTING PROCEDURE



1.3.5. Sequence Test The sequence test is a non-operational checking for logic system for instrument or control system before commissioning/start up. The scope of sequence test is to check the logic system with referring to the logic diagram document. The sequence test can conducted using dummy signal or actual signal input and output. This is depending on the critical/non-critical loop and the project necessary. 1.4. Conflicting Requirements Should conflicts exist between this specification and other documents, the following order of precedence shall govern: - Scope of Work - Data Sheets. - This Specification - Other Company Specifications - Other Referenced Publications - Approved for Construction Drawings 2. COMMON PROCEDURE 2.1.



Before the loop test or sequence test is conducted, all instruments related shall be calibrated, this can be seen from the instrument label and documentation. The final loop test shall be performed to ensure that the installed instrumentations are functionally correct. Each transmitter and switch should not be recalibrated during the loop test, since all transmitter and switches are installed after finished the workshop calibration.



2.2.



When performing tests, two groups will be required, one in the field and other in the control equipment. The sub-contractor is required to provide proper communication for all involved in test verification, i.e. field radios or walkie talkies approved by appropriate Indonesian radio frequency Government agency.



2.3.



Adequate skilled manpower and technically/ organizationally skilled supervision is required to provide proper test and meet the time schedule of the job. In most instances Company and/or Contractor representative will witness the entire test and countersign the test report. Should any of the tests not be witnessed, Sub-Contractor can proceed the test by themselves under the confirmation of Contractor’s and/or Company’s acceptance.



2.4.



Associated alarms and trip actions of MCS and/or board-mounted instruments shall be checked during the loop test. When particular loops ties into MCS system, a technician may be required in the MCS area for troubleshooting.



2.5.



Where interlock inputs have already been proven during loop tests, these inputs may be by passed. One of the inputs to a given interlock will be tested to prove entire loop. All other inputs shall be proven at the sequence test.



2.6.



Where interlock inputs and/or outputs are associated with electrical equipment such as motors for pumps, compressors and valves, the sequence test shall be carried out in conjunction with the mechanical and electrical discipline to insure protection to equipment.



2.7.



Tests are essentially functional and if an inoperative or badly calibrated or otherwise unsatisfactory test result is encountered, all results for that loop should be considered null and void. The relevant earlier tests shall be repeated, as necessary, after rework, replacement or repair. The test shall then be completely repeated for that particular loop.



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INSTRUMENT LOOP TESTING PROCEDURE



3. GENERAL LOOP TEST PROCEDURE 3.1.



Prior to performing loop verification, check the entire loop per loop diagram to ensure all wires and tubing are connected. Check for proper voltages and set instrument air pressure to the recommended manufacturer’s requirements.



3.2.



For electronic loops, check polarities and measure loop impedance, where necessary.



3.3.



For Resistance Temperature Detector (RTD) loops, check the function of all instruments and control valve in the loop by connecting the appropriate resistance (120 ohm for Nickel. 100 ohm for Platinum) at the terminal heads, and visually check the correct connections when close the terminal heads.



3.4.



Connect a precision known source to the primary field transmitter. A simulation of the measured variable is applied to the transmitter for zero, mid scale and full scale reading, according to the manufacturer’s recommended instructions. Observe on the MCS system’s, that the indication shows as being simulated. Also observe on the MMI (Man Machine Interface) screens on the PC. It must indicate proper actions on Display and Alarm Screens.



3.5.



Control Loop Place the controller in the manual mode and simulate a process variable signal from 0%, 25%, 50%, 75% and 100% of scale and observe on the monitor that the process variable indication shows as simulated signals. Return process variable to 0%, put the controller in the automatic mode, place P.B. at 100%, reset time and derivative to minimum setting with set point at 50% and ensure that controller is in direct action. Simulate process variable signal 0%, 25%, 50%, 75% and 100%, observe and record all findings.



3.6.



Switches Activate loops, make and/or break each set of contacts and ensure that all devices respond accordingly. Observe and record all findings.



3.7.



Analytical and special installation shall be checked according to manufacturer’s instruction and/or by agreement with Company and/or Contractor.



3.8.



During loop testing, the following items shall generally be confirmed or checked: 3.8.1. In MCS area or at the local panel - Indication for input and output signals on MCS or board mounted instruments. - Function of controllers of MCS or conventional instruments - Indication of trend recorders associated with MCS - Function of annunciators on MCS - Function of flow counters 3.8.2. In the field Action of control valve including associated accessories such as solenoid valves, limit switches, etc. - Range of transmitter - Indication of remote mounted output gauges. - Timing to open/ close large valves greater than 6”.



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INSTRUMENT LOOP TESTING PROCEDURE



4. DETAILED LOOP TEST PROCEDURE 4.1.



Pressure Loop Test The pressure transmitter is to be tested by carrying out loop checks on the choke valve production well and drain system. 4.1.1. Apply air or hydraulic pressure to each pressure transmitter loop and charge to 0%, 25%, 50%, 75%, and 100% of pressure transmitter capacity. 4.1.2. Verify response of Pressure Alarm High/Low at MCS cabinet monitor, and check response of pressure control valve and pressure safety valve status at field area and MCS cabinet. Discharge the Pressure transmitter after finished the test. 4.1.3. Observed and Recorded all finding to loop test sheet, and confirmed the result to contractor and/or company for approval.



4.2. Level Loop Test The level transmitter is to be tested by carrying out loop checks on the chemical injection system. 4.2.1. Apply water to tank/vessel that level transmitter stand on it, and charge to 0%, 25%, 50%, 75%, and 100% of tank/vessel capacity. 4.2.2. Verify response of Level Alarm High/Low at MCS cabinet monitor, and check response of Control Valve status at field area and MCS cabinet. Discharge the tank/vessel after finished the test. 4.2.3. Observed and Recorded all finding to loop test sheet, and confirmed the result to contractor and/or company for approval. 4.3. Temperature Loop Test. The temperature transmitter is to be tested by carrying out loop checks on the Production Manifold system. 4.3.1. Apply resistance 0-700 Ω to input of temperature transmitter loop, and charge to 0%, 25%, 50%, 75%, and 100% of 0-700 Ω. 4.3.2. Verify response of Flow Alarm High/Low at MCS cabinet monitor, and check response of corrosion inhibitor status at field area and MCS cabinet. Re-connect the temperature transmitter wire after finished the test. 4.3.3. Observed and Recorded all finding to loop test sheet, and confirmed the result to contractor and/or company for approval. 4.4. Flow Loop Test The flow transmitter is to be tested by carrying out loop checks on the production manifold system. 4.4.1. Apply air to orifice of flow transmitter, and charge to 0%, 25%, 50%, 75%, and 100% of flow capacity. 4.4.2. Verify response of Flow Alarm High/Low at MCS cabinet monitor, and check response of Control Valve status at field area and MCS cabinet. Discharge the flow transmitter after finished the test. 4.4.3. Observed and Recorded all finding to loop test sheet, and confirmed the result to company for approval. /conversion/tmp/activity_task_scratch/543867876.doc



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INSTRUMENT LOOP TESTING PROCEDURE



5. SEQUENCE TEST 5.1.



Prior to sequence test, Sub-Contractor will request Contractor and/or Company (2 months in advance) to approve sequence and timing flow diagram provided by Sub-Contractor. This approval is to ensure that there will be no change in sequence test during commissioning.



5.2.



Complete interlock system shall be checked for correct sequence of operation and all interlock systems shall be checked for “fail safe” operation.



.5.3. Where interlock inputs and/or outputs are associated with electrical equipment, such as motors for pump, compressors and, valves, the sequence test shall be carried out in conjunction with the related section engineer. 5.4.



Start-up bypass and maintenance override switches shall generally be “OFF” prior to sequence.



5.5.



For inputs devices, signal Photovoltaic Array output will be required to provide analog signal or pulse in lieu of transmitters signals. Contact activation will be required to make and/or break manually to provide discrete signal. Function check will not be necessary, since it should be finished during loop test.



5.6.



For output devices, pushing manual trip buttons or making various input combination including emergency conditions will be required to check and ensure that the control system provide output states correctly. At the same time, feed back signal shall be checked, where necessary.



5.7.



For remote pneumatic or motor operated valve, manual switches or MCS operation keyboard switches shall be on and/or off to check the valve operation. It shall be switched to remote position prior to test. See fig.1 below. TYPICAL INSTRUMENT CONTROL LOOP



MCS



CONTROL PANEL FIELD MULTICORE CABLES



J/B



J/B



FIELD JUNCTION BOXES INSTRUMENT CABLES CONTROL VALVE



TX



TRANSMITTER



SENSING ELEMENT Fig.1. Sample Typical Instrument Control Loop /conversion/tmp/activity_task_scratch/543867876.doc



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INSTRUMENT LOOP TESTING PROCEDURE



9. ATTACHMENTS



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