Contractor Commissioning Procedure

ACTIVITE AVAL DIVISION RAFFINAGE RAFFINERIE D’ARZEW

DOC. NO.: HD-2208-00-PP-45-00-0906 JOB NO. : 2008117

COMMISSIONING PROCEDURE

PROJECT

: ARZEW REFINERY REHABILITATION AND ADAPTATION PROJECT (ARZEW)

PROJECT NO. : DEV-Z-22-08 LOCATION

: ARZEW, ALGERIA

COMPANY

: SONATRACH

IFC

0 REV.

Nov.20.2011 DATE

Issue For Construction

D. J. Lee

C. S. Jeon

S. J. Hur

DESCRIPTION

PREPARED

CHECKED

APPROVED

Company APPROVED

Doc. No. Job No. Rev. No. Page


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REVISION LOG REVISED PAGE

REVISION DESCRIPTION

REV. NO.

REV. DATE

A

Dec.06,2010

Issue for Approval

0

Nov.20.2011

Issue for Construction



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TABLE OF CONTENTS 1. General ..................................................................................................................... 1 1.1

Purpose ............................................................................................................................... 1

1.2

Scope .................................................................................................................................. 1

2. Commissioning Organization ................................................................................. 1 2.1

Commissioning Team .......................................................................................................... 1

2.2

Organization Chart .............................................................................................................. 2

3. Commissioning execution activities...................................................................... 3 3.1

Preamble ............................................................................................................................. 3

3.2

General requirements .......................................................................................................... 3

3.2.1 Definitions ............................................................................................................................ 3 3.3

Scope of Work ..................................................................................................................... 5

3.4

Responsibilities .................................................................................................................... 8

4. Preliminary Checks ............................................................................................... 11 4.1

Introduction ........................................................................................................................ 11

4.2

Operators Preliminary Checks ........................................................................................... 12

4.3

Mechanical Preliminary Checks ........................................................................................ 18

4.4

Electrical Preliminary Checks ............................................................................................ 19

4.5

Instrument Preliminary Checks .......................................................................................... 21

4.6

Reports .............................................................................................................................. 21

5. Functional Tests .................................................................................................... 23 5.1

Introduction ........................................................................................................................ 23

5.2

Electrical Functional Testing .............................................................................................. 25

5.3

Instrument Functional Testing ........................................................................................... 31

5.4

LOGIC TEST PROCEDURE ............................................................................................. 42

6. Pre-start up activities ............................................................................................ 43 6.1

Introduction ........................................................................................................................ 43

6.2

Catalyst loading of vessels ................................................................................................ 44

6.3

Inertness Procedure .......................................................................................................... 46

7. Operational tests ................................................................................................... 48 7.1

Introduction ........................................................................................................................ 48



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7.2

Scope of test...................................................................................................................... 49

7.3

Procedures format ............................................................................................................. 54

7.4

Typical report forms ........................................................................................................... 56

APPENDIX 1. ELECTRICAL FUNCTIONAL TEST SHEET 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

EMERGENCY GENERATOR UPS SYSTEM DC SYSTEM HV SWITCHBOARD LV SWITCHBOARD – Sheet 1 LV SWITCHBOARD – Sheet 2 EMERGENCY LOAD CENTER – Sheet 1 EMERGENCY LOAD CENTER – Sheet 2 HV TRANSFORMER LV TRANSFORMER HV MOTOR – Sheet 1 HV MOTOR – Sheet 1 LV MOTOR – Sheet 1 LV MOTOR – Sheet 2 ELECTRICAL HEATER MISCELLANEOUS USER LIGHTING AND SMALL POWER EARTHING LOOP ECS DISPLAY LOGIC

APPENDIX 2. INSTRUMENT FUNCTIONAL TEST SHEET 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.

PROCESS CONTROL LOOP DCS PROCESS CONTROL LOOP LOCAL PROCESS CONTROL LOOP PCS PROCESS OPEN / CLOSED LOOP DCS F & G DIGITAL LOOP ESD DIGITAL LOOP ESD ANALOG LOOP GAS DETECTOR XV / HV MOV DATA COMMUNICATION LINK SINGLE MACHINE CONTROL LOGIC SELECTIVE OPERATION CONTROL LOGIC F & G LOGIC F & G DISPLAY ESD LOGIC ESD DISPLAY PROCESS DISPLAY RELIEF VALVE EARTHING SEGREGATION



APPENDIX 3. PRE-STARTUP ACTIVITIES 40.

CATALYST & CHEMICALS LOADING REPORT

41.

INERTING REPORT

42.

LEAK TEST REPORT

43.

BLIND STATUS REPORT

44.

PUNCH LIST ENTRY FORM

APPENDIX 4. OPERATIONAL TEST SHEET 45.

GENERAL PURPOSE

46.

CENTRIFUGAL PUMP

47.

RECIPROCATING PUMP

48.

AXIAL PUMP

49.

AIR COMPRESSOR – Sheet 1

50.

AIR COMPRESSOR – Sheet 2

51.

CENTRIFUGAL COMPRESSOR – Sheet 1

52.

CENTRIFUGAL COMPRESSOR – Sheet 2

53.

RECIPROCATING COMPRESSOR – Sheet 1

54.

RECIPROCATING COMPRESSOR – Sheet 2

55.

SCREW COMPRESSOR – Sheet 1

56.

SCREW COMPRESSOR – Sheet 2

57.

DIESEL ENGINE – Sheet 1

58.

DIESEL ENGINE – Sheet 2

APPENDIX 5. PRELIMINARY CHECK LISTS 59.

PIPING

60.

ELECTRICAL

61.

INSTRUMENTATION

62.

MECHANICAL

63.

TELECOMMUNICATION

APPENDIX 6. PIPING / MECHANICAL TEST FORMS 64.

LEAK TEST

65.

VESSEL FINAL INSPECTION AND CLOSEOUT

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1. General 1.1 Purpose The purpose of this procedure is to provide a detailed procedure for testing, documenting and preparing for Commissioning and start up. It is intended that this procedure will be used by the Commissioning team to verify and document that all equipment and systems have been checked out and are ready for start up. This presents the procedures to be followed for Commissioning the various systems for preparing the plant initial start up and operation.

1.2 Scope This procedure defines the responsibilities associated with the execution of the Commissioning activities and provides a detailed procedure for Commissioning and initial start up.

2. Commissioning Organization 2.1 Commissioning Team CONTRACTOR will provide a fully qualified and experienced Commissioning Team for the direction, supervision and control of Commissioning, and execute start-up and performance test works. They will maintain care, custody and control of the plant until the successful hand over of the plant facilities. The Commissioning Team will be settled at Site when construction about 70 % is completed and will be located under CONTRACTOR Site Manager and his major roles are ; •

For the soft-landing, Commissioning team will participate the Precommissioning phase doing support the construction execution team for technical supervision and planning during the interface between construction and Commissioning phase.

•

All of Commissioning Activities, achieving the Ready for Start-up Certificates.

•

Executing start-up and performance test activities.

The team will comprise CONTRACTOR’s Commissioning managers, engineers, supervisors, operators and maintenance staff. Specialists from the various vendors and technology providers (Licensor) will also be represented on the team. The source of key persons will be from CONTRACTOR’s own and some supervisors will be from direct hired Korean and other country’s people depending on the Project. CONTRACTOR will nominate a Commissioning Manager covering the operation of the whole plant, who will perform all activities from the Precommissioning phase to performance test in collaboration with OWNER and the Licensors.

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2.2 Organization Chart Organization Charts for the Commissioning and start-up phases are shown as following.

0

[Organization Chart]

Commissioning & Start up Organization Owner

Contractor Commissioning Manager

Commissioning & Operation Team Vendor Supervisors Licensor Supervisors

Maintenance Team

Shift Work - C&I - Electric - Rotating - Piping

Day Work

Operation Manager

Operation Team

Shift Foreman Board Operator Field Operators

Shift Work -Board Supervisor -Field Supervisor

Comm' Engineer & Staffs

Maintenance Team

Engineering Team

- Piping - C&I - Electrical

- Process - Piping - C&I - Electrical - Rotating - Stationary

‐ Rotating - Others

Shift Foreman Board Operator Field Operators

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3. Commissioning execution activities 3.1 Preamble This procedure provides the information, procedures, and support documents required to carryout on-site Commissioning activities in a planned, safe and efficient manner. This procedure will be read in conjunction with the relevant document as below; •

Overall Pre-commissioning, Commissioning and Start up Execution Plan HD-2208-00-PP-45-00-0901

•

“Precommissioning Procedure” HD-2208-00-PP-45-00-0905

•

“Performance Test Procedure” HD-2208-00-PP-45-00-0907

3.2 General requirements 3.2.1 Definitions For a better and easy reference the following definitions have been used in the present document: •

Basic Function: Group of items of equipment that performs an elementary function of the facilities.

•

Commissioning: Includes all activities required to make the facilities ready for Start-Up. Means all work, activities and tests from issuance of the Mechanical Completion Certificate of a Portion or the whole of the Facilities and shall be considered completed when satisfactory and stable operation is achieved as determined by the Contract. Stable and satisfactory operation will be demonstrated over a 24 hours period. Operating data will be collected during this period and submitted.

•

Completion Activities: Different milestones such as Ready for Commissioning (RFC), Ready for Start-up (RFSU) and Provisional Acceptance Certificate (PAC), if required

•

Conformity Checks: Checks done to ensure that all items/equipments comply with Project Specifications and have been correctly installed.

•

Functional Test: Online test of an instrumental, electrical or telecommunication Basic Function.

•

Functional Test Sheet: Supporting document to record the results of a Functional Test.

•

Handover: means handing over the Plant to OWNER after performance tested and accepted by OWNER.

•

Handover Certificate: means the certificate issued by OWNER to CONTRACTOR stating that the PLANT is performance tested and brought into operational condition and handed over to OWNER.

•

Mechanical Completion: PLANT has been installed in accordance with specifications, design drawings, and other CONTRACT requirements.

0

0

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•

Operational Test: Online test of a System or Sub-system in conditions as close as possible to the normal operating conditions.

•

Party/Parties: means in the singular either OWNER or CONTRACTOR, as appropriate, and in the plural both OWNER and CONTRACTOR.

•

Performance Tests: Performance test of the system will comply with System performance tests. The Facilities shall be subject to Performance Acceptance Test, which shall be carried out by the CONTRACTOR in accordance with the Performance Test Procedure.

•

Pre-Commissioning: Includes all activities required to make the facilities ready for Commissioning. The inspections, tests and safety audits carried out to ensure the readiness of the facility for Commissioning. The Pre-Commissioning activities will commence as soon as construction progress allows and these activities will run in parallel, where this is possible safety and without risk of invalidating any preCommissioning achieved. The phase includes, for example, flushing, final vessel boxing up, initial excitation of electrical and instrument control systems, electrical motor no load runs, instrument loop checks & Functional Test and Mechanical Running Test.

•

Ready for Commissioning: Status of a System or Sub-system when all PreCommissioning operations on that Sub-system or System are complete.

•

Ready for Commissioning (RFC) Certificate : Certificate issued by CONTRACTOR and APPROVED by OWNER for each functional System of the PLANTS stating that it is mechanically complete and it has been tested and Pre-Commissioned in accordance with the requirement of CONTRACT.

•

Ready for Start-Up: Status of the PLANT when all System or Sub-systems required for feed-in have been satisfactorily commissioned and the same have been duly certified by OWNER.

•

Ready for Start-Up (RFSU) Certificate : Certificate issued by CONTRACTOR and APPROVED by OWNER for each functional sub-system of the PLANT stating that the Commissioning activities have been performed in accordance with requirements of the CONTRACT.

0

• Start-Up: Includes all activities required for introduction of feedstock in the PLANT with the assistance of OWNER to bring the PLANT to a steady state enabling production of products to specifications. • Static / De-energized Tests: Tests required ensuring the integrity of the item / equipment. • Sub-System: Subdivision of a System • System: Major subdivision of the plant, being either process or utility, including all the equipment required for that System to operate. • Technical Data Base: List of Basic Functions constituting a Sub-system.

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3.2.2 Standards and codes Commissioning will comply with Commissioning Procedure and Standards and Codes referenced in the contractual documentation. Any waiver from this present Commissioning Procedure on the technical contents of Commissioning activities will be sought through the approval from OWNER. 3.2.3 Safety Commissioning activities will be carried out only by competent and experienced personnel. Commissioning will be responsible for the safety procedures and Permit to Work applied on the equipment and areas under their responsibility. Commissioning will comply with the OWNER’s safety rules and with the country’s safety regulations. Commissioning will be responsible for its internal safety organisation and control. 3.2.4 RFC and RFSU The Commissioning activities will be carried out by subsystem. The subsystems will have been defined during the preparation phase and it will approved by OWNER, as well as the sequence of subsystems Commissioning, established so that it meets the start-up priorities. The transfers of responsibility from the Precommissioning to the Commissioning will take place on a subsystem basis. The transfer for a given subsystem will take place when it has reached the “Ready for Commissioning” status, i.e. when all Precommissioning operations on that subsystem are complete. It will be formalised by the signature by both parties and the OWNER of the “Ready for Commissioning Certificate”, and of the mutually agreed “Ready for Commissioning Punch list”. Once the Commissioning activities of a subsystem is complete, it will be formalised by the signature by both CONTRACTOR and OWNER of the “Ready for Start Up Certificate” and of the mutually agreed “Ready for Start-up Punch list”. Utility Start up and Operation are part of Plant Commissioning activities. Then Plant is started up and put in operation with the assistance of the OWNER. This will be formalised by the signature by both CONTRACTOR and OWNER of the “Provisional Acceptance Certificate” on Plant basis.

3.3 Scope of Work 3.3.1 Introduction The scope of work of the Commissioning execution activities will include the following:

0

•

Precommissioning witnessing

•

Preliminary checks

•

Functional tests witnessing

•

Pre-start-up activities

•

Operational tests

•

Support activities

•

Documentation tasks.

These activities are defined hereafter. 5/56



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3.3.2 Precommissioning Witnessing The Commissioning will can perform witnessing of critical Precommissioning activities, listed hereafter:

0

•

Setting of PSV’s

•

Piping flushing, cleaning and drying

•

Machinery cold alignments

•

Electrical functional test and energizing

•

20 % of Instrument calibrations at random

•

Functional tests of control and instrument

There is no specific witnessing procedure: the above tests will could be attended by a suitably qualified Commissioning Engineer, and the relevant Precommissioning test sheets countersigned, on the successful completion of the tests. 3.3.3 Preliminary Checks The Commissioning will perform Preliminary Checks, as defined in chapter 4. 0

3.3.4 Functional Tests Witnessing The Commissioning will perform Functional Tests Witnessing as defined in chapter 5. 3.3.5 Pre-start-up Activities The Commissioning will perform Pre-start up activities, as defined in chapter 6. 3.3.6 Operational Tests The Commissioning will perform Operational Tests, as defined in chapter 7. 3.3.7 Support Activities Commissioning will perform, organise and follow-up all the following support required carry-out the Commissioning activities:

0

•

Logistics: housing, catering, offices, transportation means

•

Material: spares, consumables, test equipment, temporary equipment, documentation

•

Execution personnel: mobilisation, administration, organisation

•

Vendors: mobilisation, assistance

•

Planning: forecast, program, histograms, man-hours

•

Punch lists: follow-up, clearance.

3.3.8 Documentation Tasks 3.3.8.1 Test Sheets and Reports The Commissioning will follow the present procedure and will adapt or amend all test sheets and report forms as required, and develop new test sheets, report forms, and procedures whenever relevant documents are not available in the procedure.

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3.3.8.2 Drawings up-dating Commissioning will up-date the following documents transmitted at the ready for Commissioning stage by the Pre-commissioning CONTRACTOR: •

PID’s

•

Single line diagrams

•

Interconnecting diagrams

•

Interlock logic diagrams

• •

ESD / F&G matrixes

•

Blind List Status

The up-dating will include all modifications carried-out on site during the Commissioning execution phase, start up and operation phase so that a set of “As-built” drawings is available at the time of the Handover of Plant to the OWNER. 3.3.8.3 Punch List The subsystems punch lists once mutually agreed at the Ready for Commissioning stage between the CONTRACTOR and the OWNER will be continually updated during the Commissioning operations by the Commissioning Personnel and the OWNER by adding all newly discovered items and deleting cleared ones. During the Commissioning of the plant, these new items discovered by the CONTRACTOR/OWNER during their cross inspection of the plant will be included by the Commissioning in the punch list, which then becomes the combined “Ready for Start up” punch list which would be continually cleared before Start–up and before issue of Provisional Acceptance Certificate by the CONTRACTOR. 3.3.8.4 Commissioning Report Forms The Commissioning will fill-up, sign, and obtain signatures of other parties whenever required, on all Commissioning report forms, functional test sheets, operational test procedures, and any other activity support form. e The various Master Forms of Commissioning support documents available in the present specification are attached in Appendixes as below: Description 0

0

Appendix

Sample of Electrical Functional Test Sheet

Appendix 1

Sample of Instrument Functional Test Sheet

Appendix 2

Pre-Start up Activities

Appendix 3

Operational Test Sheet

Appendix 4

Preliminary Check Lists

Appendix 5

Piping/Mechanical Test Forms

Appendix 6

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3.3.8.5 RFSU Dossier The Commissioning will compile all documentation pertaining to the Commissioning operations in a specific RFSU Dossier, arranged by subsystem, which will contain all the information required to demonstrate to the OWNER that the subsystem has reached the “Ready for Startup” status. This dossier will include the following: 1. RFSU Certificate 2. Commissioning Reports

0

0

•

Preliminary Checks Reports

•

Functional Test Sheets

•

Pre-Start-up Activities Reports

•

Operational Test Procedure

•

Mechanical Reports if required

•

Vendors Reports

3. RFSU Punch List 4. As-built Drawings

3.4 Responsibilities 3.4.1 General An integrated task force will carry out Commissioning of the facilities, which will include the following personnel: •

OWNER

•

CONTRACTOR

•

Vendor’s specialists for major equipment and control systems

The task force, hereafter called the Commissioning team will work in close co-ordination with OWNER operation representatives.

3.4.2 OWNER Personnel for Commissioning Activities The OWNER will support the CONTRACTOR Commissioning team with operating and maintenance personnel. The exact composition will be jointly discussed between CONTRACTOR and OWNER on site from an Integrated Commissioning team. During the Commissioning phase, OWNER personnel will be fully integrated into the Commissioning team. This integrated team approach will aid the smooth hand over of the section or unit after the completion of the Commissioning activities. The transfer of responsibility from CONTRACTOR to OWNER is signified by the issuance of the Turnover Certificate.

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3.4.3 CONTRACTOR Personnel CONTRACTOR will carry out the Commissioning activities. This will include the preparation of the relevant plans and schedules, preparation of the Commissioning documentation, performance of the necessary inspection and test activities. CONTRACTOR is responsible for the safety and quality of the Commissioning work to be carried out. The CONTRACTOR’s Commissioning Manager will direct all Commissioning and support activities, until OWNER has issued the Turnover Certificate. A close liaison between CONTRACTOR and OWNER operations will be required to coordinate the Commissioning activities. CONTRACTOR will coordinate the Commissioning activities with OWNER personnel prior to the commencement Commissioning activities. At this time there will be an integrated Commissioning team of CONTRACTOR and OWNER personnel.

3.4.4 Vendors Specialists When Vendor Specialists are mobilized by the Commissioning Manager as per the vendor call out schedule, the Vendor Specialists will assist the Commissioning team as required. These vendor specialists will work together with the Discipline Engineers, operation supervisor, and maintenance supervisor. 3.4.5 Communication & Reporting •

Weekly Programme : The Commissioning activities will be fully integrated by CONTRACTOR into the overall Project plans and schedules. The Commissioning Manager will issue a weekly status/progress report comparing the weekly targets. Weekly reports for each unit will be issued regularly on site to follow the progress of the activities. During critical periods additional reporting may be required. A “Two Weeks Look Ahead Schedule” will also be issued showing the main Commissioning activities schedule for the next two weeks.

•

Co-ordination Meetings : Routine co-ordination meetings will be held between CONTRACTOR Commissioning Manager and OWNER Commissioning Coordinators. A weekly management meeting will be held to analyze the general progress, the main areas of concern and define the coming week’s program. During the pre-Commissioning and Commissioning phase one weekly meeting between the CONTRACTOR Commissioning Manager and OWNER Commissioning Coordinator will take place to co-ordinate the forthcoming inspections and testing. During the Commissioning phase a OWNER / CONTRACTOR daily briefing meeting of short duration summarizing the previous 24 hours activities and define the next 24 hours program. This will enable close co-ordination and co-operation between the two parties.

•

Instruction and Reporting : The following documents will be used for instructions and reporting: 9 PC&C work instructions issued by the Commissioning Manager. 9 Daily operating instruction book. 9/56



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9 Weekly reports. 9 Monthly reports. It may be necessary to have instructions book and reporting book per section/unit. This will be discussed between OWNER Operating Team and CONTRACTOR Commissioning Team during field execution period.

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4. Preliminary Checks 4.1 Introduction 4.1.1 Purpose The Preliminary Checks, first task of site Commissioning activities, are the cross-verification by the Commissioning that the Construction has achieved its full Precommissioning scope of work. These checks are carried-out on a subsystem basis. 4.1.2 Principles When the Precommissioning scope of work is complete on a given subsystem, the Commissioning Superintendent will receive the formal notification that this subsystem is “Ready For Commissioning” (RFC) together with the RFC Dossier of the subsystem. Before signature of the RFC certificate, which formalises the transfer of responsibility for the operation and maintenance of that subsystem from the Construction to the Commissioning, the OWNER will initiate the Preliminary Checks, consisting in: •

The assessment that all Precommissioning tasks have been performed. This will be achieved by a thorough review of the Precommissioning Status Indexes, Check Lists and Test Sheets included in the RFC Dossier. This work will be done under the responsibility of each discipline leader.

• •

The review of the “As-built” drawings, which will be carried-out at the same time. The verification on site that the subsystem equipment conforms to all project documents. This will be achieved by a thorough visual inspection of the subsystem facilities, by representatives of each discipline of the Commissioning team: -

Piping

-

Mechanical

-

Electrical

-

Instruments

Since the inspection is visual, no dismantling will usually be required. However, in some cases, e.g. the verification of the quality of a gasket, some elementary dismantling may be required. Upon completion of their inspections, each discipline specialist will: -

Complete the relevant report forms

-

Compile their punch list items in the ready for Commissioning punch list.

Once the OWNER is satisfied that the subsystem has reached the ready for Commissioning status, its acceptance will be formalised by the signature of the subsystem RFC certificate and its attached RFC punch list, which has been discussed and agreed upon with the CONTRACTOR.

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4.2 Operators Preliminary Checks 4.2.1 Piping 4.2.1.1 Review of Documentation The Commissioning operators will review the piping Precommissioning operations reported in the Precommissioning dossier and make sure that: 0

•

All pipework has been properly flushed, dried and pressure tested, and that all related test sheets are filled-in and signed

•

All relevant piping check lists have been filled-in and signed

•

All as-built drawings are available.

4.2.1.2 Review of Facilities The Commissioning operation supervisor will work-out all lines and verify the operability and the conformity of the pipework with project specifications and drawings, the key document being the as-built PID’s. The following is a list of points that will be systematically addressed during this site survey: 4.2.1.2.1 Non-return Valves, Control Valves, certain Globe Valves Ensure these are installed with the flow direction arrow (stamped or tagged on the valve body) in the correct direction. 4.2.1.2.2 All Valves Check that packing followers are correctly tightened and that the valves open and close smoothly. Check for LO/LC & Lockout Status. Check for interferences with surrounding equipment. Check for easy operability. 4.2.1.2.3 Sample Connections Are these correctly placed, i.e., not in a dead-end? Are they of the type indicated on the P&ID, i.e., double valve, block and needle, etc.? Is there room enough to insert the sample bottle? 4.2.1.2.4 Pump Suction Strainers Can the strainer body be de-pressured and drained? Can a drain hose be coupled to the drain connection without problem? Can the strainer be pulled without problem? 4.2.1.2.5 Spectacle Blinds Can they be swung easily? Are they installed in such a way that they can be swung without problems? 4.2.1.2.6 Piping Low Points, High Points and Slopes Check these are in accordance with the P&ID, that drains/vents are installed /equipped with plugs and slops are correct. 12/56



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Check that Drains/Vents used for hydraulic tests are seal-weld. 4.2.1.2.7 Pipe Supports Check spring hanger transit pins have been removed. Check slipper pads are situated correctly in their guides and not tack-weld. Check pipe clamps are tight. 4.2.1.2.8 Steam Traps Ensure these are correctly installed and that they blow to a safe location. Check integrity of isolation and bypass valves. Check for expansion room after warm-up. 4.2.1.2.9 Safety Valves If these vent to atmosphere, check that the exhaust line is adequately supported and drainable if there is low point. If paired safety valves with a key lock system are installed, check the lock system is in good order and that the keys are available and labelled. Check block valve against LO/LC Status. 4.2.1.2.10 Insulation Check that piping insulation on hot, cold and personnel protection service lines is in good condition and has been completed; in some cases insulation may not be completed until just prior to start-up. Check that the insulation cannot become saturated with water during flushing operations or inclement weather. Check that insulation does not interfere with equipment operability/accessibility. 4.2.1.2.11 Earthing In some piping applications flanges are coupled by an earthing strap, check integrity of strap and connections. 4.2.1.2.12 Gaskets and Joints If soft metal ring joint flanges are installed, ensure that a check has been carried out, during Precommissioning, of flange face integrity. This type of flange/joint is often used in hot, high temperature services. Where spiral wound gaskets are employed, it is important to check that the correct rating has been employed. Spiral wound gaskets should never be used for dismantling. If pipework is to be dismantled for flushing, this type of gasket is frequently replaced, temporarily, by an asbestos compound gasket. The correct gasket must be installed prior to handing over the system for start-up. 4.2.1.2.13 Blinds 0

At the ready for Commissioning stage a blind status report must have been prepared and issued by the Precommissioning team. Blind status report is managed / updated during Commissioning by Commissioning Team. Copy will be in RFSU dossier. The principal reasons for a blind status report are as follows: •

To record where the blinds are situated and why and

•

To ensure that the blinds are removed prior to start-up. 13/56



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0

In the case of spectacle blinds and certain other blinds, it may be necessary that these remain in position at the time of start-up; however, a battery limits blind status report will be issued prior to start-up in order that blind status may be readily checked.

0

The blind status report (see Form No. 4662 of Appendix 3) will contain the following information: - Line number (ex.: P&ID), size and service - P&ID No. -

Blind number

-

Blind size and rating, i.e., 150, 300, etc.

-

Date installed plus signature

-

Date removed plus signature.

- Why this blind inserted.

0

It is often the case that blinds are installed, during Construction and Pre-Commissioning, for hydrostatic tests, flushing, etc., and these are frequently forgotten if not correctly listed. It also happens that blinds without tags (handles) are installed, in this case it is extremely difficult to tell the difference between a blind and the edge of spiral wound metal gasket. Therefore, blinds will always have a stamp on the handle clearly readable for easy identification. 4.2.1.2.14 Accessibility Check accessibility of valves and other equipment. Not accessible valves located in piperacks, will be equipped with chainwheels and chains, or extended spindles. Check for escaping ways availability. 4.2.1.2.15 Safety Check all safety aspects related to piping, i.e. protruding valves spindles. 4.2.1.2.16 Operability Check operability aspects, such as the location of pressure gauges installed at pumps discharge that must be readable while manoeuvring the discharge valves, the level gauges of capacities to be visible from the drain valves locations, etc.

4.2.2 Vessels 4.2.2.1 Classification For the purpose of Commissioning, the following items of equipment are considered as vessels: • •

Tray columns, scrubbers, etc. Drums: overhead receivers, HP and LP separators, oil/gas separators, knock-out drums, surge drums, flash drums etc

•

Sphere storage tanks

•

Storage silos and blending silo

•

Oily water separators

•

Shell and tube heat exchangers, plate type exchangers, vaporisers, fin tube exchanger 14/56

COMMISSIONING PROCEDURE •

Steamer and dryer

•

Hoppers


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4.2.2.2 Review of Documentation The Commissioning operators will review the vessels Precommissioning operations reported in the Precommissioning dossier and make sure that: •

All vessels fabricated on site, or not tested at the MANUFACTURER’s, have been pressure tested and that all related test sheets are filled-in and signed

•

All vessels have been properly flushed, cleaned, and dried-out if applicable

•

All internals have been correctly installed and checked off

•

All relevant vessels check lists have been filled-in and signed

•


4.2.2.3 Review of Facilities 4.2.2.3.1 Organization As a general rule the vessels will be opened for inspection at the RFC stage, and closed (by the construction team) immediately after the completion of the preliminary checks (if they are satisfactory). However, in some cases, it may be necessary for construction purpose to close the vessels prior to RFC. In this case, the preliminary checks relating to the internal inspection of the concerned vessels will be carried-out before closure even if the entire sub-system is not yet formally ready for Commissioning. 0

The inspection people who will charge of internals inspection will be choose commonly with qualified person among operation people of company Before entering any vessel, the person responsible will obtain a vessel entry permit which will include an atmospheric analysis and the verification that suitable means of entry and exit are provided If the vessel is in any way physically connected to a “live” system, it must be suitably blinded and a blind list provided. Persons entering a vessel for inspection or rectification work may require the following items: •

Measuring tape

•

Spirit level to check tray levels, etc.

•

Intrinsically-safe low voltage lighting or flashlight

•

Tools

•

Notebook, pen, paintpen or chalk to tag defects.

Once the physical checks have been successfully performed, the vessels closure (manholes, access doors) will be carried-out by the Construction.

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For the Commissioning, the Superintendent in charge of vessels preliminary checks will be entitled to sign it after completion of the checks and clearance of the punch list items. It is therefore recommended to carry-out the vessels preliminary checks as close as possible to the closure operation. In any case, the final approval for vessels closure will be given by the OWNER. 4.2.2.3.2 External Checks The following checks will be carried-out by the Commissioning operators on site on all vessels: •

Check maker’s nameplate details are correct

•

Check access ladders and platforms are correctly installed and in good order

• Check nozzles and manways are as shown on updated P&ID and engineering drawings •

Check integrity of insulation

•

Ensure fire detectors, sprinklers, deluge systems, foam heads are correctly installed

•

Carefully inspect the outer skin of pressure vessels to ensure that at no time has unauthorised welding taken place; sometimes scaffolding is temporarily tack welded in place by mistake. Most pressure vessels are marked “no welding” to avoid such mishaps but nevertheless one can never discount human error. If such a case is discovered, the vessel in question should be handled back to the construction team for rectification, i.e., stress-relieving, non-destructive testing, etc.

4.2.2.3.3 Internal Checks The following checks will be carried-out on site, based on equipment design drawings: •

All vessels Verify the maker’s nameplate details are correct and verify all nozzles are correctly sized and orientated. In situations where manways are specified in baffles in particular vessels, a check will be made to ensure that these manways are actually installed with appropriate bolting and gaskets, as specified on the drawings. Ensure all foreign bodies have been removed from the vessels and vessels skirts. This includes scaffolding, ladders, tools, etc. It is not anticipated that any change will be required on any of the towers or vessels, nor to the drawings. However, absolutely no changes are to be made or approved in the field. Any changes to the design drawings or to the equipment must have prior approval by the OWNER.

•

Towers, Columns Verify all towers and vessels are clean and free of any debris, excess rust, etc. (for the most part this requires hand cleaning). Check that manway gaskets are of proper size and materials, and that manway studs/bolts are properly tightened. Verify types of trays and types of valves in tray decks. Check tray support rings for welding and dimensions. Make sure that tray valves are not corroded or stuck.

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Check downcomers for proper vertical alignment and clearance between bottom of downcomers and deckplate. Check tray overflow weirs for proper dimensions and welding/bolting. Check bolting of tray segments to support rings – these must be tight, and in some cases, the underside nuts require tack welding. Verify this against the drawings. Check tray decks, tray valves, and all internal bolting for proper materials of construction. Bolting must also be checked for proper size and installation of washers. Verify tower/vessel materials of construction. Check each tray deck for horizontal deflection. Decks should be flat within a tolerance of plus or minus 0.5 %, measured at four equidistant points with a spirit level. Check that splash weirs are installed, and that they are properly secured by bolting or welding, per the drawings. Verify that required tray gaskets are properly installed, and that they are of the proper materials. Verify that all nozzles are open from the inside of the tower and that they are neither plugged nor restricted with foreign articles, dirt, etc. •

Drums Check especially that wire mesh pads, vortex breakers, weirs, baffles and any other internals are in place and that they are securely attached and of the correct dimensions.

•

Shell and Tube Exchangers Exchangers delivered by sea may have had their tubes filled with grease or other preservatives, be certain this has been removed prior to the Ready for Commissioning Signatures.

•

Kettle-type Exchangers/Vaporizers Many of these exchangers have internal baffles or weirs; check that these are correctly installed.

4.2.2.3.4 Safety Equipment Most safety equipment checks will be performed, as for the other subsystems, by the various discipline specialists, following the type of safety equipment (F&G detection, CO2 release system, deluges network, etc.), and in accordance with the procedures, specific to each discipline, developed in the present chapter. However Life Saving and Fire-fighting equipment does not belong to any of the usual discipline. Therefore, unless the Commissioning Team includes a safety specialist, the following preliminary checks will be performed by the Commissioning operators: •

Verify accessibility to all safety equipment, particularly to all fire-fighting equipment (extinguishers, monitors, hydrants, deluge valves)

•

Check escape ways are free from obstacles, clearly marked by escape signs, adequately illuminated, and that they allow escaping from any location

•

Verify that all equipment check lists are filled-in and signed.

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4.3 Mechanical Preliminary Checks These checks will be carried-out essentially on rotating/reciprocating equipment: pumps, compressors, diesel engines, and on miscellaneous mechanical equipment: cranes, hoists, HVAC units, etc. They will be performed by suitably qualified rotating/reciprocating equipment specialists and mechanical Commissioning supervisors. 4.3.1 Review of Documentation The Commissioning mechanical specialists will review the mechanical Precommissioning operations reported in the Precommissioning Dossier and make sure that: •

All rotating equipment has been cold aligned and that alignment records are available

•

Couplings have been installed

• • •

Suction and discharge piping have been correctly installed and freed of stresses according to vendor’s requirements or recommendations Suction strainers have been installed if required Fans and drivers have been correctly aligned and that fans pitch and clearance have been set

•

All relevant check lists have been filled-in and signed

•

All as-built installation drawings are available.

4.3.2 Review of Facilities The Commissioning mechanical engineers in charge of the Preliminary Checks will thoroughly inspect visually all mechanical equipment. This inspection will be based on the following reference documents: •

Installation drawings

•

PID’s

•

Vendor’s drawings and manuals

•

Data sheets.

The following is a list of points that will be systematically addressed during the site survey: •

Name plates

•

External damage – painting – insulation

•

Conformity to project standards and codes, Vendor drawings, Vendor recommendations, safety rules and good practice

•

Ancillary equipment: condition, quality of installation

•

Availability of lubricating and seal oil fluids in quantity and quality

•

Free rotation of rotating equipment

•

Connection of suction/discharge piping

•

Piping supports in the vicinity of the equipment

•

Safety protections installation and setting

•

Coolant installation and condition 18/56



•

Seals, packing installation

•

Removal of transport/shipping supports, bracings, and stops

•

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Removal of all rust preventives, oil, grease, etc., used to preserve the equipment during the construction phase.

The above is given as a guide line and is to be completed and adapted to each type of equipment by the specialist responsible for the preliminary checks.

4.4 Electrical Preliminary Checks 4.4.1 Review of documentation The Commissioning electrical engineers and supervisors will review the electrical Precommissioning operations reported in the Precommissioning dossier and make sure that: •

•

The following de-energised tests have been carried-out, and that tests results were properly filled-in and signed: -

Insulation resistance measurements

-

Di-electric strength tests

-

Cables continuity tests

-

Earthing resistance measurements

The transformers have been filled-in with oil, oil samples tested, with positive test results available.

•

Batteries have been filled-in with electrolyte.

•

All relevant check lists have been filled-in and signed.

•


4.4.2 Review of Facilities The Commissioning electrical engineers and supervisors will carry-out a thorough visual inspection of the electrical equipment, the following points being systematically addressed during the site survey: 4.4.2.1 Motors Check for mechanical damage. Check nameplate: verify that the motor has all characteristics as defined in the data sheet; especially that it is suitable for the hazardous area classification. Check start/stop pushbuttons for installation, tagging, accessibility, and, where applicable that amps indicator is properly marked for overload. Verify oil levels, grease, and packings. Verify installation of pressurisation system where applicable. Check visually the earth connections and the cable junction boxes. 4.4.2.2 Transformers Inspect for mechanical damage. 19/56



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Check earthing is in accordance with project specifications. Check fluid levels and verify that there is no leak. Where applicable, check tap-changer operation position and locking. Verify if desiccant is installed and in good condition. Check nameplate and correspondence of the characteristics to the project specification (data sheet). Check cables connections and tagging. 4.4.2.3 Switchboards Inspect for mechanical damage (external and within the cubicles). Open and close each cubicle of the concerned system or subsystem. They must operate freely. Verify earthing conforms to project specification. Verify by spot check (which requires removing some cover plates) the proper fixation of cables on bus bars. In case of any defect the check must become systematic. 0

Check tagging and state of Lock out / Tag out on the all of MCC panel. 4.4.2.4 Generators Inspect for mechanical damage. Verify nameplates, and check characteristics conform to the project data sheets. Record HV cables numbers. Check heaters installation, check cooling system for damage. Check earthing conforms to project specification. 4.4.2.5 Lighting Check that lighting fittings positions and number conform to project drawings (normal and emergency). Check orientation of lighting fittings. Check installation of lighting of level gauge glasses. Visually check earthing. 4.4.2.6 Other Equipment Check for mechanical damage. Verify that characteristics match project data sheets. Check earthing conforms to project specifications. Verify quality of installation. Inspect cables segregation in cables racks and cables packing at junction boxes.

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4.5 Instrument Preliminary Checks 4.5.1 Review of Documentation The Commissioning instrument engineers and supervisors will review the instrument Precommissioning operations reported in the Precommissioning Dossier and make sure that: •

0

Instrument cables have been tested for continuity and insulation and that test results are available

•

Instruments have been calibrated and that calibration test sheets are available

•

All relevant check lists have been filled-in and signed

•


• Interlock Logic bypass status. 4.5.2 Review of Facilities The Commissioning instrument engineers will carry-out a thorough visual inspection of the instrument equipment, the following points being systematically addressed during the site survey. 4.5.2.1 ESD Valves Control Panel Check condition, installation, accessibility, conformity to project drawings and specifications. Check manually the operation of the “manual reset” solenoid valves. 4.5.2.2 Automatic Valves Check installation; verify that all connections are completed and satisfactory, that the valve is installed according to flow direction. Verify that the stem packing is properly tightened. Check the condition of the valve and of its associated equipment. 4.5.2.3 Flow Measurement Devices Verify installation conforms to project specification. Check that they are properly sized and installed according to flow direction. Verify impulse tubing. Check traces heating and insulation where applicable. Check drainage facilities. 4.5.2.4 Locally Mounted Instrument (Pressure Gauges, Temperature Indicators, Gauge Glasses etc.) Verify condition, installation, range, visibility, accessibility, rating, trace heating and insulation where applicable. Check drainage facilities. 4.5.2.5 Other Equipment (Pressure Transmitter etc.) Check condition, installation, accessibility, conformity. When applicable, check valves, connections, isolation, drainage, insulation and trace heating, cable trays segregation.

4.6 Reports 4.6.1 Punch Lists Every Commissioning discipline specialist carrying-out Preliminary Checks will record all anomalies discovered, but also suggestions, proposed modifications, and in general any type of comments in a Punch List Entry Form. 21/56



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Once the preliminary checks of one subsystem are completed, the system leader will review the preliminary punch list thus compiled, and the system leader will decide which items of the punch list will be retained for incorporation in the ready for Commissioning punch list, in accordance with the Punch List Management Procedure. The system leader will also initiate actions for those items that are not purely related to conformity of construction: requests of modification, specific studies, etc. Follow-up inspections will later be required to ensure all deficiencies have been corrected. A typical punch list entry form is as following. 4.6.2 Task Reports Preliminary Checks Task Report Form will be filled-in by each discipline and by sub-system upon completion of the tasks, and filed in the Commissioning dossier. See Appendix 5. The same form will be used for progress calculations.

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5. Functional Tests 5.1 Introduction 5.1.1 Purpose of Functional Tests The functional tests are the dynamic checking that each elementary electrical, instrument, and telecommunication function included in the plant design performs properly. The purpose of this Commissioning specification is to provide Commissioning personnel team with all the information required to conduct the functional testing activities in a planned, safe, and logical manner. 5.1.2 Scope of Functional Test The Electrical Functional Testing including Energizing of electrical system on the Article 5. 1 of the “Precommissioning Procedure” will be performed and completed during precommissioning stage. The instrument functional tests including logic tests will be performed and completed during Precommissioning stage as described on the Article 5.2 of the “Precommissioning Procedure”.

5.1.3 Principles 5.1.3.1 Basic Functions For commodity, an item or group of items of equipment that performs an elementary function of the plant is named a “Basic Function”. A Basic Function is therefore the smallest equipment, on part of equipment, which may be considered independent from the following two points of view:

0

•

Running in normal operation

•

Energisation.

All possible types of Basic Functions are listed and defined in the present specification, by relevant discipline, i.e. electrical and instruments. 5.1.3.2 Functional Testing A “Functional Test” is the live test applied to a given basic function; hence it is a single-discipline activity. The present specification defines for each type of Basic Function, the scope of work of the functional test that will be applied to this Basic Function. Every basic function of the plant, in the three above disciplines, will be subject to a functional test, be it part of field or package equipment. Should a functional test fail, the failed item Commissioning will repeat the test, after the fault has been fixed by the CONTRACTOR until the test requirements are fully satisfied. 5.1.3.3 Tests Reporting Functional tests results will be reported on “Functional Test Sheets”, which are available in this specification for every type of basic function (Appendix 1.2.). There will be one functional test sheet by test, i.e. by Basic Function. The One copy of functional test sheets will be grouped by discipline and subsystems in the Commissioning Dossiers. 23/56



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5.1.3.4 Technical Data All basic functions, grouped by subsystem, discipline and type of basic function, are listed in the Technical Data. The Data indicates, for each basic function, the type of Commissioning operation required, by reference to the task report form of this operation, and it also gives other relevant information (set points, drawings No., etc.). The completion date of each activity is also recorded, so that it is a working document used to follow up the Commissioning progress. 5.1.4 Reference Documents For each subsystem the following documents, transmitted from Precommissioning, will be needed to allow functional testing to take place:

0

•

Data Sheets

•

Precommissioning Punch Lists

•

Precommissioning Check Lists

•

Precommissioning test sheets

•

As-built drawings (marked up)

•

As-built electrical cable schedule

•

Marked-up SLD’s

•

Instrument calibration sheets

•

Test certificates for: -

•

Air piping Air tubing Hydraulic tubing Vendor documentation.

5.1.5 Test Equipment Functional tests require specific test equipment, which will have been defined during the precommissioning preparation viz. Commissioning Tools and Equipment List. 5.1.6 Arrangement of the Functional Test Specification The present specification is split by discipline as follows: •

Subchapter 5.2: Electrical functional testing

•

Subchapter 5.3: Instruments functional testing

Each subchapter contains: •

The applicable methodology

•

The list and coding of basic functions and the scope of testing

•

The support test sheets.

Are also included miscellaneous information depending on each discipline.

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5.2 Electrical Functional Testing 5.2.1 Introduction The purpose of the electrical functional testing is either to energise electrical equipment in order to check their proper operation, most of the time off-load, before multidiscipline on-load operational tests, or to verify the ability of the equipment to be energized safely during the operational tests. The functional testing comprises mainly the tests of the electrical protections and interlocks/interfaces with other equipment with or without energization. The insulation of the equipment as well as their proper connection have been tested during Precommissioning and corresponding check lists and test sheets have been produced to prove it. The fact remains that, some time could have elapsed before the Commissioning is started and that insulation has deteriorated. Ultimately the person who energises equipment is responsible for it and has to ascertain that it can be done safely. This is why the functional tests include simplified measurement of the insulation resistance which can be done in the feeding switchboard and do not require any disconnection of cable. In the unlikely event that insulation to earth is found not acceptable, the procedure of Precommissioning test shall be applied to the faulty equipment. The HV tests could be detrimental to the life expectancy of equipment and shall not be repeated unduly. In all cases the continuity of the circuits shall be visually checked as well as proper connection to earth before energisation. These above electrical functional tests, power receiving and energizing will be performed and completed during Precommissioning stage, and the required maintenance works will be performed until the handover relevant electrical systems to Company. 5.2.2 5.2.3 Methodology For the purpose of functional testing, the electrical installation has been divided into 11 different equipment categories titled Basic Function Types and numbered P1 to P11. Certain Basic Function Types have been further sub-divided using codes indicated by letters. This codification has been necessary due to various classifications within a Basic Function Type e.g. Basic Function Type P6 (electric motor) has been further divided into P6 A and B. 0

A specific Commissioning functional test sheet has been designed for each appropriate equipment type as described by a Basic Function Type/Code e.g. FP6 A is the Commissioning functional test sheet for HV electric motors. For each basic function installed, a functional test sheet will be completed by the electrical Precommissioning Team and reviewed during Commissioning stage. Further Commissioning functional test sheets, not dedicated to a basic function type, have been designed for: •

Protection relays associated with HV equipment

•

Protection relays associated with LV equipment

•

ESD inputs to MCC cubicles, intertrip signals between HV and LV circuit breakers, etc. 25/56



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These test sheets will be used completed by the electrical Precommissioning Team and used during the preparation of the Commissioning and depending on the type of equipment, attached to the related functional test sheets. A full list and master forms of all Commissioning test sheets are available in paragraph 5.2.7. The completion of the test sheets requires equipment tests, checks, calibrations, etc., after which the equipment is ready either for operational testing or putting into service, whichever is applicable. 5.2.4 List and coding of Electrical Basic Functions •

P1 – Emergency Generator

•

P2 – UPS System

•

P3 – DC System

•

P4 – Switchboards -

0

A - HV Switchgear C – LV Switchgear K – Emergency Load Center

•

P5 – Transformers

•

P7 – Motor -

• •

A – HV motor C – LV motor P10 – Heaters Directly fed from MCC or distribution board Controlled via step controller or Thyristor controlled P11 - Misc. User

-

Hoists Crane P12 – Lighting Small Power and Trace Heating

•

A – Lighting and small power (by distribution board) P15 - Earthing Loop (Power only)

•

P16 - ECS (Display Logic)

•

5.2.5 Description and Test of Basic Functions 5.2.5.1 Function P1, Emergency Generator 5.2.5.1.1 Description of Function Alternator, Control panel, AVR and all associated power and control cabling Alternator CB and all associated electrical protection.

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5.2.5.1.2 Functional Testing For functional testing purpose, functional test sheets have been designed and are included in 5.2.7: 5.2.5.2 Function P2, UPS system 5.2.5.2.1 Description of Function Batteries, battery chargers, inverters, by-pass transformer, static switch and by-pass isolator. Feeder CB’s and associated cabling from LV switchboard/MCC and associated protection. 5.2.5.2.2 Functional Testing For functional testing purpose, test sheet P2 “UPS System” is to be used. It is included in 5.2.7. 5.2.5.3 Function P3, DC system 5.2.5.3.1 Description of Function Batteries, battery charger, DC distribution board and associated protection Feeder CB’s and associated cabling from LV switchboard/MCC. 5.2.5.3.2 Functional Testing For functional testing purpose, functional test sheet P3 “DC System” is to be used. It is included in 5.2.6. 0

5.2.5.4 Function P4, Switchboard/MCC 5.2.5.4.1 Description of Function Incoming CB’s bus-bars, bus-section, all protection, auxiliary supplies and associated cabling. Cable supplied switchboard/MCC to include feeder CB’s and associated cabling. 5.2.5.4.2 Functional Testing For functional testing purpose, three different functional test sheets have been designed. They are included in 5.2.7. In addition to the scope of work on the function test sheet it is also required to produce marked up drawings to indicate parameters of functions testing. Prior to energisation of the switchboard, a switching procedure is to be produced by the senior authorised or authorised person detailing the sequence of switching and events. This is to be in the form of a signed document, the original retained by the Senior authorised or authorised person and a copy attached to the function test sheet. Functional test sheets are: •

P4A: HV Switchboard

•

P4C: LV Switchboard

•

P4K: Emergency Load Center

For the testing of electrical protections on LV and HV switchboards the following will apply: •

Primary current injection tests will be performed in the Vendor’s premises according to a specific requirement in the purchase order. These tests will be supported by documents and witnessed by a OWNER representative. 27/56



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•

Commissioning will only carry out secondary current injection tests. They will also check that the equipment conforms to the data sheet, especially characteristics of CT’s.

•

If for any reason the factory tests have not been performed or are not properly documented Commissioning will verify the conformity of CTs cabling and current ratios by primary current injection tests and the relays by secondary current injection tests.

5.2.5.5 Function P5, Transformers 5.2.5.5.1 Description of Function Transformer with its associated power and control cables. Feeder CB’s, protection, neutral earthing resistor and bus-duct where applicable. 5.2.5.5.2 Functional Testing For functional testing purpose, functional test sheets have been designed. They are included in 5.2.7. 5.2.5.6 Function P7, Electric Motors 5.2.5.6.1 Description of Function Motor with its power and control cabling including motor heater. CONTRACTOR panel or CB, all associated protection and field devices. 0

5.2.5.6.2 Functional Testing For functional testing purpose, three different functional test sheets have been designed. They are included in 5.2.7. They are: •

P7A: HV Motor

•

P7C: LV Motor

5.2.5.7 Function P10, Heaters 5.2.5.7.1 Description of Function Heater associated JB’s, field control device, feeder CB, protection and associated power and control cabling. 5.2.5.7.2 Functional Testing For functional testing purpose, functional test sheet “P10: Heaters” is to be used. It is included in 5.2.7. 5.2.5.8 Function P11, Miscellaneous User 5.2.5.8.1 Description of Function Feeder CB protection and associated cabling. Control panel, motors with local protection, cabling and all associated electrical equipment. 5.2.5.8.2 Functional Testing For functional testing purpose, functional test sheet “P11: Miscellaneous User” is to be used. It is included in 5.2.7. 28/56



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5.2.5.9 Function P12, Lighting, Small power 5.2.5.9.1 Description of Function Cabling, Luminaries, sockets, JBs and heating tapes. 5.2.5.9.2 Functional Testing For functional testing purposes, two different functional test sheets have been designed. They are included in 5.2.7. They are: •

P12A : Lighting and Small Power (completed by circuit)

5.2.5.10 Function P15, Power Earthing Loop 5.2.5.10.1 Description of Function • • 0

Module earth bars and earthing ring within module (this is a pre-Commissioning task). Total earth ring including all cabling between modules and to main earth (this is a function testing task).

5.2.5.10.2 Functional Testing For functional testing purpose, functional test sheet “P15: Earthing Loop” is to be used. It is included in 5.2.7. 5.2.5.11 Function P16, ECS Display Logic 5.2.5.11.1 Description of Function Feeder CB’s, associated cabling, VDU’s and keyboard’s. Note: Ref. Serial links in ECS System. These are to be function tested using a J3 functional test sheet which appears in the Instrumentation Section of this specification. 5.2.5.11.2 Functional Testing For functional testing purposes, functional test sheet “P16: ECS Display Logic” is to be used. It is included in 5.2.7. 5.2.5.12 Test Values to be used during Functional Testing These values (Megger voltage, HV pressure test voltage, etc.) are to be defined for each project depending on the type of equipment used. These parameters shall be taken from the relevant IEC, CENELEC or National Standard and in all cases shall not exceed the Vendor recommendation.

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5.2.6 Basic Functions: Electrical basic functions are listed here below : Basic function type

Title

P1

Emergency generator

P2

UPS System

P3

DC Systems

P4

Switchboard Load Center

P5

Power transformer

P7

Electrical motor HV and LV

P10

Heater

P11

Miscellaneous user

P12A

Lighting and small power

P15

Power earthing loop

P16

ECS display

5.2.7 Electrical Functional Test Sheets 0

Appendix 1 gives the master forms of the electrical function test sheets listed here below : 5.2.7.1 Functional Test Sheets related to a Basic Function Form No.

Basic function type

Equipment description

FP1B

P1

Emergency generator

FP2

P2

UPS System

FP3

P3

DC System

FP4A

P4A

HV Switchboard

FP4C

P4C

LV Switchboard

FP4K

P4K

Emergency Load Center

FP5

P5A and C

HV Transformer

FP7A

P7A

HV Motor

FP7C

P7C

LV Motor

FP10

P10

Electrical Heaters

FP11

P11

Miscellaneous User

FP12A

P12A

Lighting and small power

FP15

P15

Earthing Loop

FP16

P16

ECS Display Logic

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5.3 Instrument Functional Testing 5.3.1 Introduction 0

The purpose of this specification is to provide the Instrument Commissioning personnel with the information and support documents required to conduct the instrument functional testing with a procedure standard for all projects. The purpose of the instrument functional testing is the dynamic verification that each individual instrument (other than local indicators) performs properly. It is therefore mainly the loop testing, functional testing and logics testing.

0

These instrument loop testing, basic functional tests and logic tests will be performed and completed during Precommissioning phase as described on the Article 5.2 of the “Precommissioning Procedure”. 5.3.2 Methodology For the purpose of functional testing, the instruments have been divided into 11 different equipment categories titled Basic Function Types and numbered J01, J03 to J07 and J10 to J13 and J15. The J01 Basic Function (Instrument loop) has been further sub-divided using codes indicated by letters. This codification has been necessary due to various classifications within this Basic Function. J01 is therefore sub-divided in J01 A to J01 F. A specific Commissioning functional test sheet has been designed for each appropriate equipment type as described by a Basic Function Type/Code e.g. FJ01 E is the Commissioning functional test sheet for gas detectors. For each basic function of the plant, a functional test sheet will be completed by the Instrument Precommissioning personnel.

0

Paragraph 5.3.4 describes the functional test to be carried out on each type of basic function. A full list and master forms of all Instrument Functional Test Sheets are available in paragraph 5.3.5. 5.3.2.1 Case of Software Modifications With respect to process control and safety systems, the functional testing will often imply softwares modifications (program, logics, configuration, displays) which will not appear directly on the Functional test sheets. Therefore a detailed software rectification procedure will be applied to ensure no software rectification is carried out without adequate authorisation and back-up documentation updated accordingly. This procedure will be written by the Precommissioning Instrument Engineer for each specific project, as it depends on the type of process and safety systems selected for that project. 5.3.2.2 Case of DCS and PLC Hardware The Commissioning of this equipment is not covered by standard forms, as it is specific to the equipment selected for the Project. The MANUFACTURER’s procedure will therefore be followed.

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5.3.3 List and Coding of Instrument Basic Functions •

J01 – Instrument Loop

•

A – Process control loop B – Process open or closed loop C – ESD/F&G digital loop D – ESD analog loop E – Gas detection F - XV, HV and MOV J03 – Data communication link

•

J04 – Single machine control logic

•

J05 – Selective operation control logic

•

J06 – F&G logic

•

J07 – F&G display

•

J10 – ESD logic

•

J11 – ESD display

•

J12 – Process display

•

J13 – Relief valve

•

J15 – Earthing segregation

-

0

5.3.4 Tests of Basic Functions 5.3.4.1 Function J1, Instrument Loop 5.3.4.1.1 Loop Components Calibration Procedure •

P or DP transmitter force balance type Test equipment to perform calibration will be checked prior to testing and accuracy will be reviewed against vendor specification. A pneumatic calibrator or deadweight balance should be used where applicable. Simulate three points 0 %, 50 %, 100 %. Slowly decrease input signal and check output falling. Adjust zero/span as necessary.

•

DP used for level measurement As before except that the zero elevation or suppression will be set after calibration.

•

Transmitter – Level displacer type For transmitter designed for use on services other than water at ambient temperature it is preferred that the liquid in the tank to be used where possible. If this is not practicable, water shall be used and adjustment shall be made for SG at operation conditions. Interface level shall be calculated accordingly. Connect water supply to float chamber.

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Connect output as follows: -

Electronic – to suitable test meter

-

Pneumatic – via a capacity chamber to a test gauge.

Check 0 %, 50 %, 100 % by raising water level in chamber and note the relevant output. Check hysteresis. Adjust zero/span as necessary. •

Temperature transmitter : resistance thermometer type Connect a suitable resistance box to the input terminals. Using the temperature/resistance chart apply the correct value of resistance for the measuring thermometer. Simulate 0 %, 50 %, 100 % of the instrument range. Adjust zero/span as necessary.

•

Alarm and trip setting Simulate an input signal corresponding to the setting.

•

I/P converter Check correct air supply pressure.

0

Simulate 4/20 mA input signal by current generator. Check output pressure at test gauge for 0 %, 50 %, 100 % input signal. Adjust zero/span as necessary. •

Positioner and control valve Check correct air supply pressure. Simulate input signal by pneumatic calibrator. Check output gauge. Check the stroke 0 %, 50 %, 100 %. Check correct action of the valve in accordance with data sheet. Adjust zero/span as necessary.

•

Gas detector Depending on type of detector used: -

Use reference gas samples to activate 20 % and 50 % LEL

-

Check deviation on monitor and correct adjustment if necessary.

-

Align detector and reflective element to achieve maximum response. Test alarm using alarm filter.

•

Analyser Check correct sampling hook-up. Verify that installation conforms to Vendors recommendations and that signal and earthing details are correct.

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Check calibration with sample at 0 %, 50 %, 100 % when applicable of scale and check response times. Adjust zero and span as necessary. •

HV / XV and MOV Check air supply pressure. Simulate action with air signal. Check correct action of the valve. Check manual action. Check status indication.

5.3.4.1.2 Functional Test Procedures J1A – Process control loop •

0

Preliminary -

Preparation of functional test sheet.

-

Check documentation is valid and up to date.

-

Record addresses and loop type.

-

Connect loop to terminals.

-

Check earth isolation of the loop.

•

Transmitter -

Controller in manual mode.

-

Apply an appropriate source to the transmitter.

-

Check zero.

-

Check 0 %, 50 %, 100 %, and record all console readings.

-

Check and record setting of alarms.

-

Accept and reset value of each alarm.

•

Valve -

In manual mode, stroke the valve from console.

-

Check limit switches when applicable.

-

Check failsafe position.

-

In auto mode, check controller action.

-

Check alignment when applicable.

-

Open or close the valve by fast action on console and record valve travel time.

•

Display -

Check and record correct inputs on display (mimic, group alarm table, alarm priority and printer). Associated tags: Check and record all tags associated to the Basic Function. Record Basic Functions associated to the loop (SDV’s, other split range valve if any). 34/56



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J1B – Process open/closed loop •

Preliminary -


-


-

Record addresses and loop type.

-


-


•

Analog input -


-

Check 0 %, 50 %, 100 %, 50 %, 0 % and record all console readings.

-

Check setting of alarms and trips.

•

Digital input -

Check normal status.

-

Change status.

•

0

Output -

Record types of status and output.

-

Check normal status.

-

Check failsafe status.

•

Display -

Check correct inputs on display (mimic, group alarm table, alarm priority and printer).

-

Associated tags: Check and record all associated tags or basic function.

.

J1C – ESD and F&G digital loop •

Preliminary -


-


-

Record addresses and check fault monitoring.

-


-


•

Input -

Check Normal status.

-

Change status.

-

Accept and Reset the alarm when applicable.

-

Check Inhibit function.

•

Output -

Check Power up and normal status. 35/56

COMMISSIONING PROCEDURE -

Check Failsafe status.

-

Check Override function.

-

Check change status.

•


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Display -

Check the operator interface for all change of status (BHL, printer, mimic, status table) or console and on local display where applicable. Associated tags: Check and record all associated tags or basic function.

J1D – ESD analog loop •

Preliminary -


-


-

Record addresses and check fault monitoring.

-


-


•

0

Transmitter -


-

Check 0 %, 50 %, 100 % and record all console/meter readings.

-

Check setting of trips.

-

Accept and record reset value of each trip.

-


-

Check fault monitoring on card and console.

•

Display -

Check the operator interface for all change of status (BHL, printer, mimic, status table, analog histogram).

J1E – Gas detector •

Preliminary -


-


-


-


•

Detector -

Apply a 20 % LEL sample on the head of detector and record the value on card and on console. Adjust if necessary.

-

Same as above with a 50 % LEL sample.

-

Accept and record reset value of each alarm on card and on console.

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COMMISSIONING PROCEDURE -


-

Check response time.

•


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Display -

Check the operator interface for all change of status (BHL, printer, mimic, status table, gas histogram) on console and on local display. Check fault monitoring on card and console.

J1F – XV / HV and MOV •

Preliminary -


-


-

Record addresses.

-


-


•

0

Valve -

Check normal position.

-

Remote operation of the valve and record travel time.

-

Check failsafe position.

-

Check that the limit switches are energized.

-

Check field reset.

-

Check Override operation.

-

Check operation with accumulator (ensure minimum number of operations achieved).

-

Check limit stops where applicable.

-

Check conformity between local/remote position indicators and actual position of the valve.

-

Check valve local position indicators.

-

Check fault monitoring on card and console.

-

Check discrepancy alarm.

•

Display -

Check correct inputs on display (Printer, mimic, status table).

5.3.4.2 Function J3, data communication link 5.3.4.2.1 Principle The functional tests corresponding to these functions will be done in conjunction with Vendor representatives as a part of the power-up of each link and a dedicated test sheet will be completed. In addition to the connection of the communication link, some fault conditions will be simulated to ensure that the system reports the fault and operates the change over when applicable.

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5.3.4.2.2 Test procedures •


•


•

Record type of link and protocol used (RS232, MODBUS, Ethernet, etc.).

•

Check continuity insulation and connection of the communication cable.

•

Establish communication link.

•

Check integrity of communication of primary and secondary link.

•

Ensure no communication fault is reported.

•

Simulate communication fault (cable and comms. Cards) and ensure that the correct message is displayed and change over operates.

5.3.4.3 Function J4/J5, single machine control logic/Selective control logic 5.3.4.3.1 Principle The logic function carried out by conventional relays or software configuration (PCS or programmable logic controller) is assumed not alterable. For each J04 and J05 a specific test procedure will detail the different checks to be performed in order to verify that the logic is operating as specified. It will consist of a simulation of all possible combinations of inputs and outputs for the logic including black start and normal start sequence as well as alarm functions, trip conditions and various modes of operation (auto, manual). 0

Selective control logic change over will be checked to verify stop/start conditions where there is change over or stand-by requirements, and various modes of operation (manual, auto, duty, stand-by). 5.3.4.3.2 Test procedure •


•


•

Check that associated J01 and J04 functional tests have been performed.

•

Follow specific test procedure.

5.3.4.4 Function J6, F&G logic 5.3.4.4.1 Principle The Fire and Gas logic will be tested on a basis of a Fire Zone. All type of inputs will be activated and the corresponding effects will be checked against cause and effect diagrams. 5.3.4.4.2 Test procedure •


•


• •

Simulate each type of input and check the corresponding effects against the cause and effect diagram. Check inhibit function. 38/56



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5.3.4.5 Function J7, F&G display 5.3.4.5.1 Principle These tests will be done on a basis of a Fire Zone. For each Fire Area all the displays of the hierarchy will be checked including local VDU displays as well as corresponding special functions displays. Alarm and Detail mimics will be checked against Plot Plan, or Fire and Gas layout drawings. 5.3.4.5.2 Test procedure •


•


•

Record display type.

•

Check fixed and active parts of the display against configuration drawings or F&G layout.

•

Check corresponding special functions displays.

5.3.4.6 Function J10, ESD logic 5.3.4.6.1 Principle One functional test of ESD logic will be done for each input or group of inputs generating a shutdown (classified by level, zone, etc. according to the Project). The input will be activated and the corresponding effects will be checked against cause and effect diagrams. 0

5.3.4.6.2 Test procedure •


•


•

Record and check all tags and associated basic functions concerned with the logic test.

•

Simulate each type of input generating a shutdown and check the corresponding effects against the cause and effect diagram.

5.3.4.7 Function J11, ESD display 5.3.4.7.1 Principle These tests will be done on a basis of one test sheet per Zone display. For each Zone all the displays of the hierarchy will be checked as well as the corresponding special functions displays. 5.3.4.7.2 Test procedure •


•


•

Record display type.

•

Check fixed and active parts of the display hierarchy.

•

Check corresponding special functions displays.

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5.3.4.8 Function J12, process display 5.3.4.8.1 Principle These tests will be done on the basis of one functional test sheet per DCS Display. 5.3.4.8.2 Test procedure •


•


•

Check fixed background frame and active elements (tag No. and position) against “as built” configuration documents.

5.3.4.9 Function J13, relief valve 5.3.4.9.1 Principle Although there is not real functional test for relief valves, a test sheet will be completed to record the data of installation after calibration. 5.3.4.9.2 Test procedure

0

•


•


•

Check date of installation after calibration.

•

Indicate locking device status.

•

Record setting and test certificate date

5.3.4.10 Function J15, earthing segregation 5.3.4.10.1 Principle For these functional tests the method will differ depending on whether the equipment is powered or not. The segregation of the IS earth, clean earth and computer earth to each other and individually to mechanical earth has to be established. These tests will be carried out by cabinet/panel individually or in sets depending on the earth bar arrangements. It is assumed for these tests that cabinets/panels will be powered. Any tests carried out will therefore be voltage and not continuity. For each test the cables from the individual cabinet/panel dedicated earth bars to the main earth bars will be disconnected at the cabinet/panel. The mechanical/chassis earth shall remain connected. In the powered up state the voltage to which the IS/clean earth/computer earth bars elevate to after disconnection of the links to the module earths are removed, will give an indication of connections between any of the systems. Under normal conditions the IS earth bar and the OV rails are tied, whereas the clean earth and computer earth are “stand alone”. In the ESD cabinets there is not an IS rail and the OV rail and clean earth are tied.

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5.3.4.10.2 Observations If after disconnection to the module earth links, the IS and clean rails elevate the same voltage, there is a fault between the two, as only one of them should be connected to the OV. Earthing either of the rails will verify this if both return to OV. If after disconnection to the module earth, the IS/OV rail remains at OV a fault is likely down the mechanical/chassis earth. A power pack should be used to elevate the rail to + 5 VDC (approximately). If this cannot be achieved, the current output of the power pack should be monitored for a possible earth loop between the OV and mechanical earth. Equipment isolated The above procedure is alternative to isolating cabinet/power supplies. Whenever possible, supplies should be isolated and standard resistance checks carried out with a multimeter (NOT a megger). 5.3.4.10.3 Test procedure

0

•


•


•

Disconnect clean and IS earth connections to platform earth.

•

Disconnect computer earth cable connections if any.

•

Follow specific test procedure.

5.3.5 Instrument functional test sheets Appendix 2 gives the master forms of the instrument functional test sheets listed here below: Form No.

Basic Function Type

Equipment Description

FJ01 A1

J1A

Process Control loop DCS

FJ01 A2

J1A

Process Control loop Local

FJ01 A3

J1A

Process Control loop PCS

FJ01 B

J1B

Process open/closed loop DCS

FJ01 C1

J1C

F&G digital loop

FJ01 C2

J1C

ESD digital loop

FJ01 D

J1D

ESD analog loop

FJ01 E

J1E

Gas detector

FJ01 F

J1F

XV/HV

FJ01H

J1F

MOV

FJ03

J3

Data communication link

FJ04

J4

Single Machine control logic

FJ05

J5

Selective operation control logic

FJ06

J6

F&G Logic

FJ07

J7

F&G Display

FJ10

J10

ESD Logic 41/56


COMMISSIONING PROCEDURE Form No.

0

Basic Function Type

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Equipment Description

FJ11

J11

ESD Display

FJ12

J12

Process Display

FJ13

J13

Relief valve

FJ15

J15

Earthing segregation

5.4 LOGIC TEST PROCEDURE When all loop tests and basic functional test have been individually completed during precommissioning, Interlock systems shall be tested in order to confirm that the instrument composed system satisfy the required action on the Cause & Effect Diagram and Logic Diagram as process interlock. The interlock system test will be carried out during Precommissioning as a part of functional test, Vendor supervisors and Company will assign to witness and confirm the actions. 0

5.4.1.1

As individual loops consisting of inputs and/or outputs, the test procedure for these shall follow the same general procedure described for loops above.

5.4.1.2

As a complete system follows the below additions:

y A custom test procedure shall be written by CONTRACTOR and agreed upon by OWNER for each system. y Each system shall be powered up and a normal healthy condition simulated through simulating the appropriate state at all field sensors. y Each field sensor shall then be exercised and the system observed to perform in accordance with the design, logic diagrams or any other approved project documentation describing the performance of the system. y For sequencing systems, the system sequence shall first have the initial conditions set up and then be run and all events observed as happening in accordance with the project documentation describing the performance of the system. 5.4.1.3

For both types of systems, all ancillary functions (e.g. resets indications, maintenance over-rides, start-up bypasses, etc.) shall be tested.

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6. Pre-start up activities 6.1 Introduction Before undertaking the Commissioning operational tests (refer to chapter 5) and/or introducing the feed into the plant, a number of specific process operations must be carried out on the pipework and vessels, which are grouped under the generic terminology of "Pre start-up activities". These operations, the preparation and execution of which are an integral part of the Commissioning activities, are the following: 6.1.1 Leak tests 0

The Commissioning supervisors will review the system leak test report in the Precommissioning Dossier. General subsystems or circuits pressure tests carried out at the pipe work maximum operating pressure, just before feedstock in. Leak tests are systematically performed on any subsystem including pipework. 6.1.2 Dry-out Removal of liquid water and moisture from facilities and achievement of a given water dew-point require to satisfy process requirement.

0

Drying-out is performed on all equipment for plant sections designed to run at low temperatures, to avoid hydrates formation during the start-up phase. The Refractory drying out of fired heater will be carried out on the vendor’s supervision when required utilities are available. 6.1.3 Chemical / Catalyst Loading Filling-up of certain types of vessels with their Packings, Chemicals and Catalysts is a part of Precommissioning work, that will be carried out during Precommissioning stage. The loading of I-82 (PENEX Reactor Catalyst) will be carried out during Commissioning phase. The Commissioning supervisors will review the chemical and catalyst loading report in the Precommissioning Dossier. Whenever such type of material must be loaded on site, a loading procedure will be required from the patented SUPPLIER, and for some products one of his representatives will attend the loading operation.

0

As part of the Precommissioning activities, the preparation and supervision of these operations will be carried out by the Precommissioning personnel. However, in case the representative of the Vendor is not available on site, the Commissioning personnel will issue his own detailed procedures and to carry out the operation by precommissioning personnel. 6.1.4 Inertness

0

In case of reaction loops, removal of oxygen from pipework and vessels by nitrogen in order to prevent explosion of hydrocarbons are required. And if there are no reaction loops, removal of oxygen from pipework and vessels by steam or nitrogen.

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Should any of the above activities be unsuccessful, it will be repeated by the CONTRACTOR, until the process specification requirements are fully satisfied. The present specification is divided into four (4) subchapters, each dealing with one of the above operations. It contains detailed procedures that will allow the Commissioning personnel to perform them properly as well as the requirements for support documentation.

6.2 Catalyst loading of vessels 6.2.1 Preamble This specification addresses the loading of process vessels with Catalysts, molecular sieves and desiccants. Whenever such type of material must be loaded on site, a loading procedure will be required from the patented SUPPLIER, and for some products one of his representatives will attend the loading operation. As part of the Precommissioning activities, the preparation and supervision of these operations will be carried out by the Precommissioning personnel. However, in case the representative of the Vendor is not available on site, the Commissioning personnel will issue his own detailed procedures and to carry out the operation by precommissioning personnel. , in line with the guidelines given hereafter. 6.2.2 Preliminary inspection It is of primary importance to inspect the vessel before loading. The inspection will concentrate on the following points: •

Conformity of the vessel to the project drawings and specifications, but also to the patented SUPPLIER drawings and specifications.

•

Quality of the internals: if some internals are installed during or after the loading operation on they will be inspected at their storage location. The inspection of the internals will consist in verifying that:

0

-

The material conforms to specification (mesh, trays, distributors, joints, baskets, etc.).

-

They are in conformity with the drawings (shape, size, holes, etc.).

-

They are installed in accordance with the drawings. Special attention will be paid to the internals arrangement (distribution pipes for instance), the horizontality of trays, the position of the joints, the tightening of bolts and nuts.

•

Cleanliness. The equipment must be perfectly clean and rust free. This is also applicable to the vessel itself.

•

In the same way the product to be loaded will be inspected to assess its condition, storage conditions and conformity.

6.2.3 Loading preparation The loading preparation includes: • •

The organization of transportation and lifting of the material to be loaded The preparation and installation of the equipment necessary to perform the operation: platforms, funnels, hoppers, loading socks, ladders, lighting, ventilation means, safety protective equipment, e.g. breathing protections, rain protections if necessary, rope, buckets, etc. 44/56



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One person will be nominated Loading Leader and will be responsible for the loading preparation and operation. 6.2.4 Loading operation 6.2.4.1 Methods There are several ways of loading, the three most common ways of loading are the following: •

Hand loading

•

Sock loading or dense loading using equipment

As a general rule, free fall in the vessel of the material to be loaded is forbidden. It will be accepted only if requested by the MANUFACTURER's representative or if clearly specified in the MANUFACTURER's procedures. 6.2.4.2 Hand loading The material will be lowered inside the vessel either by hand (buckets) or by a crane (hopper with a manual sliding valve at the bottom) and spread by hand by the personnel inside the vessel. This way of loading can be used on any type of product, but the process is rather slow and therefore it is applicable only when small quantities are concerned. 6.2.4.3 Sock loading or dense loading using equipment A funnel will be installed at the top opening of the reactor. It is recommended to equip this funnel with a slide valve. A canvas tube is clamped on the funnel outlet and inserted in the reactor. This tube is known as "sock". To overcome the problem of sock plugging large diameter socks (10 cm and above) will be used. Fire-fighting hoses are perfectly suitable. 0

Two hoppers will be used to carry the material to be loaded from the ground level to the vessel top (one hopper is filled up on the ground while the other one is used to transfer the material). Their content will be dropped into the funnel. The personnel inside the vessel will hand control the flow of the product (on the sock) to avoid free fall and spray it by moving the sock around. The sock will be shortened regularly according to the level increase, but always with no excessive drop of the material. This is an effective method for loading as Experience shows that several tons or m3 can be loaded per hour. The dense loading using specified equipment will follows the recommendations of Catalyst vendors or Licensors. 6.2.4.4 Special precautions during loading Some fragile material may not withstand direct stepping. In this case people inside the vessels will stand on boards or plates that will be rearranged as often as necessary to match the level increase. It is of upmost importance not to forget anything inside the vessel (helmets, boards, rags, tools, etc.). It is therefore necessary that a strict control be made at the vessel entry to ensure that all that was introduced in the vessel will be recovered at the end of the operation. Several methods can be used: numbering, marking, listing, etc.

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Safety precautions have to be defined and strictly applied. They will differ following the type of product and vessel. The safety precaution will be listed at the preparation stage and all necessary material supplied accordingly. If the material is to be loaded to a given height in the vessel, or if there is an interface level between two different products, the level on the vessel walls will be chalk marked early enough to avoid trespassing it. 6.2.5 Completion works When the loading operation is completed all vessel top internals will be installed (tray, distributors, etc.) and where satisfactory the vessel will be closed using new gaskets/joints. 0

A loading sketch will be issued. This loading sketch will indicate the actual levels of the material(s) and the quantities loaded (weight and/or volume). To establish the loading sketch, an engineering drawing of the vessel will be used. 6.2.6 Reports The loading procedures, with support drawings and sketches, all reports and results will be filed in the corresponding subsystem Precommissioning Dossier. The Commissioning supervisors will review the chemical and catalyst loading report. Each loading operation will also be supported by a specific Commissioning loading report form (see Form No.4561 of Appendix 3).

6.3 Inertness Procedure Inert gas purging is most frequently required to remove air from petroleum processing equipment in order to avoid the risk of forming an explosive mixture of oxygen and gas. In some cases inert gas purging is employed to avoid the ingress of air into equipment containing sensitive catalysts, or wet air into equipment which must be kept as dry as possible, such as refrigeration units. Air contains 21 % oxygen (O2) and therefore when mixed with a petroleum gas all the essential ingredients of an explosive mixture are provided. The preparation and execution of the inertness of all oil and gas process equipment prior to oil or gas-in is a Commissioning responsibility. Equipment inertness shall be performed by the method of pressurisation followed by rapid atmospheric depressurization through the largest vents. The main objective of inertness is to achieve an Oxygen content of less than 2% for all oil/gas production installation and less than 0.2% for catalyst service. Equipment under non-hydrocarbon services shall not be inerted unless otherwise in specific cases as per vendor recommendations. Two main approaches to equipment inertness shall be used. Other than these two types mentioned below, steaming out the system could be considered for inertness in some cases. 6.3.1 Equipment With Less Than 7 Kg/cm2g Operating Pressure This approach involves pressurising the system with Nitrogen to 2 Kg/cm2g and depressurize it to 0.2 Kg/cm2g through vents and drains at the end of headers. This pressurisation/ depressurization is repeated the second time and the Oxygen content of less than 2.0% will be achieved.

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This inertness approach shall be used on all air leak test packs except Instrument Air/ Process Air/Utility Air lines. Note that it may be possible to combine a number of leak test packs for a single inertness operation. It is essential that each pressurisation to 2 Kg/cm2g is done so that pressurisation of Nitrogen is made at one extremity and depressurization is done at the other end to ensure maximum air is expelled. Note that positive pressure must be maintained at the end of depressurization.N2 pressure of 0.1 to 0.2 Kg/cm2g is maintained in the System. Pressure is checked by using ‘U’ tube. 6.3.2 Equipment With Over 7 Kg/cm2g Operating Pressure; This approach will be by single depressurization (to atmosphere or to other equipment) immediately after the successful completion of Nitrogen leak test. After the single depressurization, the Oxygen content will be less than 2%. Note that positive pressure must be maintained at the end of depressurization.N2 pressure of 0.1 to 0.2 Kg/cm2g is maintained in the system. Note that in both approaches, a portable oxygen analyser is used to determine the final Oxygen content. 6.3.3 Inertness criterion The content to be achieved depends upon the type of installation. It will therefore be determined on a case by case basis. For traditional oil and gas processing plants, the maximum acceptable O2 content shall be no more than 2 %. 6.3.4 Steaming and Fuel Gas Floating 0

For the Crude unit, the steaming to remove the O2 in the system and the fuel gas floating to filling fuel gas in the system will be carried out just before initial Feed cut-in, the procedure will be based on the process operating manual. 6.3.5 Reports The inert gas purging procedures, with support drawings and sketches, all reports and results will be filed in the corresponding subsystem Commissioning Dossier. Each purging operation will also be supported by a specific Commissioning Inertness report form (see Form No.4661 of Appendix 3).

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7. Operational tests 7.1 Introduction 7.1.1 Definition and purpose of operational tests Once all basic functions of a subsystem have been functionally tested (refer to chapter 3) and that all other relevant pre-start-up activities for that subsystem are complete (refer to chapter 6), the subsystem equipment will be subject, wherever applicable, to an operational test. This operational test consists of bringing the subsystem equipment into operation under conditions as close as possible to normal, during a significant period, not only to live test the automated devices, controls, normal and shutdown sequences, but also to reveal possible mechanical or electrical faults (water, tightness, vibrations, overheating, overloading, etc.) which may occur during prolonged normal use. The purpose of the operational tests is therefore to prove that the main equipment is mechanically sound, and that each subsystem equipment, as a whole, is ready for normal operation. The operational tests are the key Commissioning activity: the establishment of relevant procedures, the tests preparation and their execution, the engineering of temporary facilities wherever required to allow operational testing, the organisation and the supply of all required means, are part of the Commissioning scope of work. Should a step of an operational test be unsuccessful, the Commissioning will repeat the Operational test, until the parties involved are fully satisfied. 7.1.2 Principles 7.1.2.1 Equipment subject to operational tests As a general rule, will be subject to an operational test: •

All Major subsystem equipments Typical examples: -

•

Air and process compressors

A number of subsystems which, although they do not include major rotating equipment, perform a vital function of the plant, and minor/general rotating equipment. Typical examples: -

ESD/F&G

-

Hydraulics

-

Deluges.

7.1.2.2 Contents of the operational tests A typical operational test will comprise the three following steps: • • •

The mechanical preparation of the equipment, and the overall preparation of the subsystem to the test The first start-up, then the tuning or de-bugging, if required, of the subsystem. The demonstration to OWNER of the proper functioning of the main equipment and of the whole subsystem. 48/56

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7.1.2.3 Procedures The above scope of work will be carried-out in accordance with operational test procedures (OTP's), issued during the Commissioning preparation phase as per a standard format. All OTP's will be approved by the OWNER. 7.1.2.4 Test fluids The operational tests, as a general rule, take place before oil and gas-in, hence: • • •

0

The process equipment will be tested in recycle, usually with water or oil for pumps, air for compressors and blowers. Test fluid should be considered based on system fluid. Reasonable temporary recycle facilities, if required, will be engineered and built to allow operational testing.

When running the equipment with a substitute fluid is impossible, the operational test can take place with the normal process fluid, oil or gas during initial operation. In this case, the equipment will therefore be brought under gas or oil by the OWNER, then operationally tested in recycle by the Commissioning. 7.1.3 Scope of the specification The exact content of each operational test depends on the type and brand of equipment, process, control system, etc., of the plant. It cannot then be specified. The Commissioning Team will therefore have to work-out a procedure specific to each subsystem equipment to be tested. The scope of the present specification, as a consequence, will be limited to providing: •

A list of the equipment/subsystems to be tested operationally

•

Guidelines on the extent of testing

•

A procedure format.

7.2 Scope of test 0

7.2.1 List and Time of operational tests During the Commissioning preparation plan, the exact list of operational tests will be established by the CONTRACTOR and approved by the OWNER.

0

The operational test of rotating equipment will be carried out during initial start up stage with process fluids as close as design condition, but the items which are requested by Company can carry out during possible time of Pecommissioning stage or Commissioning stage. 7.2.2 Operational tests of process and utilities The three phases of the operational test, namely: •

The test preparation

•

The start-up and tuning

•

The demonstration

are detailed herebelow, for these systems including process and/or rotating equipment. 49/56



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7.2.2.1 Test preparation 7.2.2.1.1 Mechanical preparation Since the equipment of the subsystem will have already been made ready for start-up from the instrument, electrical, and telecommunication points of view during the functional testing phase of the Commissioning, the mechanical preparation of the rotating equipment of the system will be the first task of the operational test. Detailed procedures and support forms will be established to cover this phase, which will address all points listed here below, whenever relevant to the concerned equipment: •

Visual inspection

•

Cleanliness

•

Removal of preservation

•

Freedom of rotation

•

Final alignment checks

•

Lubrication

•

Lube, seal, and hydraulic oils filling

•

Lube, seal and hydraulic oils flushing

•

Oils quality analysis

•

Couplings of driver and driven unit

•

Filling of consumables

•

Filters and oil cartridges inspection

•

Connection of temporary facilities

•

Running and verification of all auxiliaries

•

Cranking tests.

A number of typical mechanical preparation check lists are available in paragraph 7.4. They will be completed or amended to match the particularities of the equipment to be prepared, and specific forms will be issued, on the basis of the Vendor's documentation, for those not available here. 7.2.2.1.2 Subsystem preparation In parallel with the main equipment mechanical preparation, the subsystem itself will be made ready for testing, including: •

The leak test of temporary facilities that may have been erected to allow test of the equipment in recycle

•

The loop filling-up with the test fluid

•

The lining-up of all circuits and instrumentation

•

The running and supply of all utilities

•

The preparation of safety equipment

•

The pressurisation of the system

•

The preparation of test equipment, spares and special tools 50/56


The installation, if required, of blinds and jumpers.

•

Obtain PTW etc


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This phase, specific to the subsystem to be tested, will be covered by a detailed procedure. 7.2.2.2 Start up and tuning Once the subsystem is ready for its first start-up, it will be started-up following a detailed step by step procedure, most generally available for the major rotating equipment from the MANUFACTURER. This second phase of the operational test is essentially devised for planning and resources purposes, as the major equipment is seldom 100 % ready for demonstration to the OWNER right from the first try. Some allowance must therefore be considered to troubleshoot and debug the equipment. Therefore, the equipment will be started a first time and run during a significant period to discover any mechanical defect and fix all discovered problems such as oil leaks or main sequences faults. 7.2.2.3 Demonstration Core of the operational test, and always witnessed by OWNER’s representative, the demonstration phase will be aimed at proving that the main equipment is mechanically sound and the subsystem ready for normal operation. This demonstration will be performed in accordance with a step by step procedure, that will include the following verifications, wherever relevant for the concerned equipment. •

•

Actual dynamic verifications that all sequences and interlocks of the main equipment, of its auxiliaries, and of the whole subsystem (or subsystems, if they are interlocked), perform properly: -

Start/stop normal sequences

-

Hot/cold start

-

Emergency shutdown

-

Depressurization

-

Air/motor/battery/hydraulic starts

-

Automatic/manual modes

-

Remote/local modes

-

Duty/stand-by modes

-

Auxiliaries changeover

Actual dynamic verifications that the control system of the main equipment and the whole subsystem performs properly: -

Pressure/speed/level/flow/temperature controls

-

Data gathering

-

Remote/local controls.

For compressors: -

Anti-surge. 51/56



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Actual verifications that the main equipment is mechanically sound, by taking all required readings during several hours after stabilisation, of: -

Noise

-

Equipment, bearings, gearbox vibrations

-

Lube oil/coolant flows, temperatures, pressures

-

Bearings, combustion chambers, exhaust temperatures

and by carrying out a thorough survey of: -

Seals integrity

-

Fuel and oil leaks

-

Piping vibrations

-

Strainers and filters ΔP's

-

Oil consumption

-

Signs of mechanical wear

-

(After test) hot alignment and final inspection.

•

Actual verification of the equipment performance: -

By taking process or electrical readings during several hours after stabilisation, at various loads By plotting of actual performance against theoretical characteristics.

A number of typical mechanical/process readings record forms are given in paragraph 6. They will be completed or amended to match the particularities of the equipment to be test run, and specific forms will be issued, for those not available here. •

Actual dynamic verifications that the key process and equipment alarms and trips function properly: -

ESD pushbuttons

-

F&G detection

-

High/low levels

-

High/low pressures

-

High/low temperatures

-

Overspeeds.

However, it is not recommended for major items of equipment, e.g. turbo-compressors, to initiate numerous shutdowns and restarts, as it affects the lifetime of the equipment. Hence only all critical protections will be tested with actual equipment shutdown. The other protections will be tested with the trip action by-passed. 7.2.3 Operational tests of ESD/F&G systems In several countries, official regulations enforce the ESD/F&G systems tests, which are usually attended by the relevant authorities. In this case, the test procedures will be devised to comply with the local regulations. Where no specific regulation exists, the following will apply.

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7.2.3.1 Systems architecture ESD/F&G systems can be technically divided into: •

Input loops

•

Logic unit (PLC or relays)

•

Output loops.

The configuration of the system, the logic part of it essentially, is specific to the installation. The main configuration cases are: •

Master/slave

•

Coincidence

•

Two out of three voting system.

ESD systems are designed so that they include a hierarchy of effects. Assuming the highest ESD level (total plant shutdown and depressurization) is named level 1, each of levels 2, 3, and 4 will affect less equipment that the respective higher levels. These systems most often apply a cascade principle, where each level will activate lower levels in addition to its specific outputs. 7.2.3.2 System Logic test 0

Each input and output loop, and the system logic will have been tested during the functional test phase of the Precommissioning. The ESD and F&G operational tests will consist in testing the whole system, from the input elements (transmitter, detector, pushbutton, etc.) until the activated equipment (ESD valve, blowdown valve motor trip, etc.). Considering the system architecture, these operational tests will be organised as follows: 7.2.3.2.1 ESD systems The shutdown levels will be tested, starting by the lowest level, to end by the highest one. For each category of inputs that give identical effects, one input will be selected at random, and the shutdown will be initiated. It will then be verified that all expected outputs of this shutdown level thus triggered have been activated and that the connected equipment has performed as expected. The other inputs of this category will also be tested systematically but without resetting all equipment that was operated by the previous test. It will only be made sure that at least one output from each lower shutdown activated by the tested shutdown level has actually been activated. As the ESD tests will be performed before the plant start-up it will be impossible to check the action on non-running equipment e.g. electrical motors. In this case one will make sure that the trip element of the equipment concerned is activated e.g.: trip relay for electrical motors. Some ESD tests will be done with the plant in operation. All categories of inputs will be tested in the same way, thus ensuring the proper functioning of all inputs and outputs, and of the shutdown logic in all its possible configurations. The reference document will be the ESD matrix Logic Diagram.

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7.2.3.2.2 F&G systems The procedure applied to test operationally the F&G systems will be exactly that used for ESD, but for the following points: •

Detectors being grouped by loops, only one detector by loop will be selected at random to initiate a given range of actions (then, for each category of loops giving the same effects, one will be tested in real, the other simulated, as for ESD).

•

CO2 or will not be actually released, the test consisting only in activating the last solenoid valve, disconnected from the CO2 bottle.

•

The deluge valves will be activated, the fire pumps started up and the deluges actually released, but the two latter effects only once per area. The platform or facilities will therefore be systematically deluged once, the continuing tests also activating the deluge valves, but with their block valves closed.

•

The reference document will be the F&G matrix Logic Diagram.

7.2.4 Operational tests of lifting equipment The load testing of lifting equipment is assimilated to an operational test, consequently it will follow the requirements of the present specification. In particular, an operational test procedure will be issued by the Commissioning during the preparation phase, which will cover the following aspects: •

Preparation tasks in accordance with pre-test check lists, a number of which are available in chapter 6. They will be completed or amended to match to specificity of the equipment to be prepared.

•

No-load test, so as to verify the equipment operates satisfactorily and to adjust all safety protections.

•

Load test, that will take place with attendance, as required, of local authorities, certifying authorities, and OWNER. The load test report will be completed and signed by all relevant parties.

7.3 Procedures format During the preparation phase of the Commissioning activities, the operational test procedures (OTP's) will be established by the Commissioning personnel. These procedures will be issued to OWNER for their comments and approval. The following format will be followed: 0

•

Test summary, including: -

Aim of the operational test

-

Test description

-

Temporary installations

-

Special precautions.

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Planning and manpower, including: -

Planning tasks

-

Manpower estimate

-

Test duration estimate

-

Position in Commissioning sequence

-

Vendor assistance.

•

0

Test requirements, including: -

Precommissioning achievements

-

Commissioning achievements

-

Status of other subsystems

-

Special tool and test equipment

-

Consumables

-

Spares

-

Safety

-

Utilities.

•

Test preparation, including: -

Blind list

-

Jumpers list

-

Mechanical preparation tasks.

•

Start-up and tuning, including: -

•

Start-up step by step procedure. Test procedure, including:

-

Operational test report form

-

Step by step demonstration tests

-

Process data recording

-

Equipment data recording.

•

Post-test conditions, including: -

Reinstatement tasks

-

Preservation

-

Subsystem status.

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7.4 Typical report forms 0

Appendix 4 Operational Test Sheets gives the Master Forms of the support documents listed here below: Title

Form No.

Operational Test Report – General Purpose

5200

Centrifugal Pumps Pre-test Check list and Record sheet

5220

Reciprocating Pumps Pre-test Check list and Record Sheet

5222

Metering Pump Pre/Test Check List and Record Sheet

5256

Air Compressor Pre-test Check list and Record Sheet

5286

Centrifugal Compressor Pre-test Check list and Record Sheet

5224

Reciprocating Compressor Pre-test Check list and Record Sheet

5226

Screw Compressor Pre/Test Check List and Record Sheet

5249

Diesel Engines Pre-test Check list and Record Sheet

5228

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Contractor Commissioning Procedure

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