Contractor Commissioning Procedure

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COMMISSIONING PROCEDURE

PROJECT

: ARZEW REFINERY REHABILITATION AND

ADAPTATION PROJECT (ARZEW)

PROJECT NO. : DEV-Z-22-08

LOCATION :

ARZEW,

ALGERIA

COMPANY :

SONATRACH

I F C

0 Nov.20.2011 Issue For Construction D. J. Lee C. S. Jeon S. J. Hur

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REVISION LOG

REV. NO. REV. DATE REVISED _PAGE REVISION DESCRIPTION

A Dec.06,2010 Issue for Approval

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7. EMERGENCY LOAD CENTER – Sheet 1 8. EMERGENCY LOAD CENTER – Sheet 2 9. HV TRANSFORMER 10. LV TRANSFORMER 11. HV MOTOR – Sheet 1 12. HV MOTOR – Sheet 1 13. LV MOTOR – Sheet 1 14. LV MOTOR – Sheet 2 15. ELECTRICAL HEATER 16. MISCELLANEOUS USER

17. LIGHTING AND SMALL POWER 18. EARTHING LOOP

19. ECS DISPLAY LOGIC

APPENDIX 2. INSTRUMENT FUNCTIONAL TEST SHEET

20. PROCESS CONTROL LOOP DCS 21. PROCESS CONTROL LOOP LOCAL 22. PROCESS CONTROL LOOP PCS 23. PROCESS OPEN / CLOSED LOOP DCS 24. F & G DIGITAL LOOP

25. ESD DIGITAL LOOP 26. ESD ANALOG LOOP 27. GAS DETECTOR 28. XV / HV

29. MOV

30. DATA COMMUNICATION LINK 31. SINGLE MACHINE CONTROL LOGIC

32. SELECTIVE OPERATION CONTROL LOGIC 33. F & G LOGIC 34. F & G DISPLAY 35. ESD LOGIC 36. ESD DISPLAY 37. PROCESS DISPLAY 38. RELIEF VALVE 39. EARTHING SEGREGATION

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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

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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.

[Organization Chart]

Owner

Contractor

Commissioning & Start up Organization

Operation Manager Commissioning Manager Comm' Engineer & Staffs Engineering Team Commissioning & Operation Team Operation Team Shift Work -Board Supervisor -Field Supervisor Shift Foreman Board Operator Field Operators Maintenance Team Day Work Shift Work - C&I - Electric - Rotating - Piping Maintenance Team - Piping - C&I - Electrical ‐ Rotating - Others - Process - Piping - C&I - Electrical - Rotating - Stationary Vendor Supervisors Licensor Supervisors Shift Foreman Board Operator Field Operators 0

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3. Commissioning execution activities

3.1 Preamble

This procedure provides the information, procedures, and support documents required to carry-out 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.

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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 pre-Commissioning 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 Pre-Commissioning 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.

• 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. 0

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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: • Precommissioning witnessing

• Preliminary checks • Functional tests witnessing

• Pre-start-up activities • Operational tests • Support activities • Documentation tasks. These activities are defined hereafter. 0

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3.3.2 Precommissioning Witnessing

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

• 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. 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:

• 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 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 Start-up” status.

This dossier will include the following: 1. RFSU Certificate

2. Commissioning Reports

• 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.

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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:

• 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.

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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

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. 0

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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.

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.

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 0

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• Steamer and dryer • Hoppers

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 • All as-built drawings are available.

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.

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

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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

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• Seals, packing installation

• Removal of transport/shipping supports, bracings, and stops

• 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. • All as-built drawings are available.

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

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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.

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. 0

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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:

• 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

• All as-built drawings are available.

• Interlock Logic bypass status.

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.

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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.

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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:

• 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.

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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:

• 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

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.

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.

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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 - 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

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.

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

Batteries, battery charger, DC distribution board and associated protection Feeder CB’s and associated cabling from LV switchboard/MCC.

For functional testing purpose, functional test sheet P3 “DC System” is to be used. It is included in 5.2.6.

5.2.5.4 Function P4, Switchboard/MCC

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.

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.

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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

Transformer with its associated power and control cables. Feeder CB’s, protection, neutral earthing resistor and bus-duct where applicable.

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

Motor with its power and control cabling including motor heater. CONTRACTOR panel or CB, all associated protection and field devices.

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.

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

Feeder CB protection and associated cabling. Control panel, motors with local protection, cabling and all associated electrical equipment.

For functional testing purpose, functional test sheet “P11: Miscellaneous User” is to be used. It is included in 5.2.7.

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5.2.5.9 Function P12, Lighting, Small power

Cabling, Luminaries, sockets, JBs and heating tapes.

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

• 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).

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

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.

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

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

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.

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.

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

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.