Pre Commissioning Manual

SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REV–CPF EPC Document Number

I

Document Title Pre-commissioning Manual

INTRODUCTION

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A

OBJECTIVE

4 4

B

DEFINITIONS

7

C

DATA AND INFORMATION

8

D

TOOLS AND EQUIPMENT

8

E

SAFETY

9

II

OVER VIEW OF THE PLANT

10

III

SYSTEMS DESCRIPTION

10

A . SYSTEM DEFINITION

10

B . SYSTEM APPROACH

11

C . SYSTEM APPROACH

12

D . PRE-COMMISSIONING SYSTEM LIST

12

IV

PROJECT COMPLETION SYSTEM: WinPCS

14

V

PRE-COMMISSIONING GUIDELINES

16

VI

PRE-COMMISSIONING PROCEDURES

17

A . GENERAL

17

B . INSPECTION AND TESTING

17

B.1.1 CHECKING AGAINST P&IDs

18

B.1.2 VESSELS AND TANKS

19

B.1.3 ROTATING EQUIPMENT

19

B.1.4 VENDOR PACKAGE ITEMS

21

B.1.5 PROCESS PIPING

21

B.1.6 HYDROTESTING AND CLEANLINESS OF LINES

23

B.1.7 LEAK TESTING & INERTING

26

B.1.8 BUILDINGS

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C

ELECTRICAL

27

D

INSTRUMENTATION

36

E

MISCELLANEOUS MECHANICAL EQUIPMENT

43

F

PRE-COMMISSIONING FORMS

43

G

PUNCH LIST CATEGORIZATION TABLE

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I. INTRODUCTION A. OBJECTIVE The objective of this "Pre-commissioning Manual" is to provide a detailed, uniform system for verification, inspection, testing, documentation and preparing for operation of the SIBA GAS development Project. When the procedures outlined in this manual are completed it marks the respective item or system is pre-commissioned, and is ready for commissioning. This manual will be used by the Pre-commissioning Team to verify and document that all equipment and systems have been checked out and are ready for commissioning. The pre-commissioning team shall ensure that all procedures described in this manual are followed and documented with appropriate forms at every stage of pre-commissioning. The completion activities are separated in two phases, called Pre-commissioning and Commissioning, this split generally corresponds to static and dynamic testing phases respectively. Commissioning is considered complete, after completion of Performance Test Run. PRE-COMMISSIONING The pre-commissioning phase includes three main types of field activities: a) Systematic conformity checks, carried out on each item of equipment or component, such as pressure gauges, level gauges, motors, cables, etc., to verify their visual condition, the quality of the installation, the compliance with project drawings and specifications, manufacturer’s instructions, safety rules, codes, standards and good engineering practice. Conformity check will be carried on constructed facility against the design and P&ID. These visual checks will be carried out to find the gaps / deviations in the constructed facility with respect to the approved drawings issued for construction. The facility will be checked for provision of all the instruments/equipments, their operability / maintainability issues, correct installation etc. All the gaps thus found out will be listed on the punch lists. b) Equipment static/de-energized tests, to ensure critical components quality and condition. This “cold” testing covers all discipline activities, e.g., calibration of instruments, machinery alignments, setting of safety valves, pressure testing of piping (hydro/pneumatic), cable continuity, etc. c) Checking installation, cleaning, flushing and drying of the pipe lines and the vessels shall be carried out as part of pre-commissioning of the facility.



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The completion of Pre-commissioning activities marks the end of the “Mechanical Completion”. The Plant status thus reached at the end of Pre-commissioning phase is called “Ready For Commissioning (RFC)”. The implementation of each pre-commissioning procedure will be immediately followed by completing the applicable pre-commissioning check lists / forms for the respective equipment / pipelines. If any item is not in line with drawings and or specification, it will be noted on the punch list form of the system / sub-system. The Punch list items shall be categorized / marked “A” “B” and “C” as defined below 

“A” - Items are those activities that must be completed prior to Mechanical Completion.



“B” - Items are those activities that must be completed prior to Hydrocarbon Introduction.



“C” - Items are those activities that must be completed prior to issuance of Performance Acceptance Certificate

When all ‘A’ punch list items from the “Pre-commissioning Punch list” are attended and cleared then the system is considered as “Ready for Commissioning (RFC)”.

COMMISSIONING The commissioning phase essentially includes the four categories of tasks as follows: a)

Dynamic verifications of each elementary electrical and instrument function that the plant equipment is designed to achieve, performs properly. Typical examples of such tests are electrical motors uncoupled runs, instrument loop tests, electrical breakers operation. The energization of the electrical distribution network is part of this activity.

b) The mechanical runs, the actual running and on-line tests for a significant period of the plant utilities, and wherever applicable, of the main process equipment in closed loop c) A number of activities related to preparation of the plant for feed Hydrocarbon introduction, such as loading of various chemicals, catalysts, molecular sieves, activated carbon, etc., d) Hydrocarbon Introduction and Performance Test.



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Once commissioning activities are complete, the plant reaches the “Initial Operation or Reliability Test Run”.

Following summarizes the activities and milestones of the pre-commissioning, commissioning phases.

SUMMARY OF COMPLETION ACTIVITIES PHASE

ACTIVITIES

MILESTONE

CONFORMITY CHECKS PRE-COMMISSIONING

STATIC TESTS FLUSHING & CLEANING

MECHANICAL COMPLETION (or Ready for Commissioning RFC)

ENERGIZATION DYNAMIC TESTS EQUIPMENT RUNNING-IN COMMISSIONING PRE-START UP ACTIVITIES HYDROCARBON INTRODUCTION AND PERFORMANCE TEST RUN

START OF INITIAL OPERATION (RELIABILITY RUN)



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B. DEFINITIONS  

 

         



BASIC FUNCTION: group of items of equipment that performs an elementary function of the plant / process. PRE-COMMISSIONING: corresponds to non-operating adjustments and cold checks performed at the end of the construction phase to verify that the installation conforms to plan, specifications, drawings, instructions and applicable codes and rules. This phase leads to ready for commissioning (RFC) stage, also called mechanical completion (MC). PRECOMMISSIONING CHECK LIST: definition of the scope of work conformity checks to be performed on elementary items of equipment. COMMISSIONING: corresponds to dynamic test and pre-start up activities associated with the operation of items of equipment or facilities for Hydrocarbon Introduction followed by Performance Test. The utility system is operational during commissioning phase and utility streams are available at the required specifications [for example, Instrument Air (IA) with required dew point]. COMPLETION ACTIVITIES: pre-commissioning and commissioning operations HAND OVER DOSSIER: compilation of the construction, pre-commissioning, commissioning and performance test support documents of a subsystem / system. MECHANICAL COMPLETION: status of the plant when all subsystems are made ready for commissioning. PRELIMINARY CHECKS: verifications of a subsystem to become ready for commissioning stage. PRE-START UP ACTIVITIES: process operations of preparing the system / sub system ready for oil or gas-in.(Hydrocarbon Introduction to the processing units) PUNCH LIST: is a detailed list of items requiring completion or correction before the acceptance of the works at different stages such as mechanical completion or hand over. READY FOR COMMISSIONING: status of a subsystem when all pre-commissioning operations on that subsystem are complete. READY FOR START-UP: status of the plant when all systems of the plant are commissioned and are ready to receive the Hydrocarbon Introduction for operation start up. STATUS INDEX: list of equipments subjected to pre-commissioning operations and summary of the pre-commissioning scope of work. SYSTEM: major subdivision of an installation, being either process or utility, including the various equipments required for that system to operate as stand-alone. Examples: 1. Gas Turbines System 2. Cooling water System 3. Compressed Air System SUBSYSTEM: subdivision of a system that performs a given operational function. Each system may be divided if necessary into functional sub-systems corresponding to independent pre-commissioning and commissioning activities based on its location in the process or the pre-commissioning and commissioning stages.

SIBA FIELD DEVELOPMENT PROJECT KEIL/SIBA/2015/C-051-REV–CPF EPC Document Title Pre-commissioning Manual

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TECHNICAL DATA BASE: list of basic functions constituting a subsystem, i.e. physical description of that subsystem. WinPCS: WinPCS is a windows Project Completion, certificate tracking System employed for this project.

C. DATA AND INFORMATION The Pre-commissioning Team shall need a complete set of drawings and data listed below: 1. Design drawings of the complete facilities, stamped "AS BUILD/ISSUED FOR CONSTRUCTION (IFC)" where applicable. 2. Vendor-supplied equipment design specifications, installation drawings, and operation and maintenance manuals.

D. TOOLS AND EQUIPMENT Pre-commissioning work described in the manual will require all necessary tools, test instruments, water & air supply and electric power shall be available for the Pre-commissioning operations. Each craftsman such as mechanical technician, instrument technician, or electrician, who is assisting the Pre-commissioning Team, shall have his normal tool kit available. In addition a list of equipments / tools required for instrumentation and electrical checkout is given in the respective Pre-commissioning Procedures. Temporary electric power supply will be available for pre-commissioning. All necessary tags, warning tapes, barricade tapes and safety gears supply shall be available at the site. The following signs in Arabic and English shall be posted at strategic locations before proceeding with the appropriate Pre-commissioning activities: Tags:

-

No smoking Danger, high voltage Do not enter beyond this point

E. SAFETY The following safety gears (PPE) supply shall be available to all personnel involved in the pre commissioning: -

Ear Protection Safety Glasses


-


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Hard Hats First Aid Kit Face Shield Chemical Gloves Safety Goggles Safety Boots Boiler suits/overalls Safety belts / harness to work at height Self Contained Breathing Apparatus-SCBA (if required during Nitrogen handling)

Permit to Work (PTW) will be controlled by PETROJET till mechanical completion (MC) stage or energization of substation, whichever is early. Thereafter permit to work (PTW) will be controlled by Company (KEIL) following their existing system and procedures.


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II. Over View of the Plant: The Siba field will be developed in two phases – Phase 1 and Phase 2. Phase 1 development will include, but not be limited to, the infield gathering system consisting of two wellheads, Christmas tree at the wellheads, chemical injection skids in the individual wellheads, flow lines from the two wells, a gathering hub, a trunk line from the gathering hub to CPF, the CPF consisting of Train # 1 of the Gas Processing Plant and all other units, an export system for the products (dry export gas, LPG and condensate) consisting of export pipelines and custody metering stations, infrastructure and utilities and all other ancillary units in the facility. Phase 2 development will include, but not be limited to, installation and tie-in of the Train # 2 of the Gas Processing Plant and ancillary units. COMPANY has specified that the whole system from wellhead to export pipeline shall be capable of a peak production rate of 110 mmscfd (by the completion of Phase 2). The target availability for the whole system is currently assumed to be 96%.

III. SYSTEM DESCRIPTION A.

System Definition System: A system is a major subdivision of an installation or facility, either process or utility, that performs a major operational function of the plant. The system includes all components/equipments that allow it to operate. Typical example of a system is: •

Compressed Air System

Sub-System: A sub-system is a further division of a system that performs a given operational function with no or little interference from the other sub-systems. Typical example of a subsystem is : •

Instrument Air

At the pre-commissioning stage same system, sub-systems format will be used to check the completeness of the construction phase (Mechanical Completion).



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WinPCS will be used to collect and store the data from Pre-commissioning and Commissioning stages of the project. B.

System Approach The pre-commissioning activities will be carried out system wise. All the data will be assimilated system wise and stored in WinPCS. The general approach during pre-commissioning is described below: 

When the system is ready for Pre-commissioning, Company shall be informed in writing, the intent to start the installation checks / pre-commissioning activities. Company will be requested to witness the activities.



All the Pre-commissioning documents (viz., Pre-commissioning / installation checklists, Punch lists etc) shall be maintained for each system. On completion of these documents, these will be stored system wise / sub-system wise in WinPCS.



Each item on the installation / pre-commissioning check lists shall be completed or checked, signed and dated by the pre-commissioning representative from PETROJET.



The P&ID (Piping and Instrumentation Diagram) of each system / sub-system shall be colormarked when each item in the list is checked against the ‘Issued for Construction’ P&ID of the system / sub-system subjected to punching.



Should an item in the check list is not completed or not meeting the design drawings and specifications, the Pre-commissioning / Commissioning Coordinator shall compile a punch list of all such items. The coordinator will categorize the punch list based on the punch list Categorization Table (Defined in this document). The categorized punch list shall be transmitted to Company for review and approval.



Pre-commissioning shall be considered as complete only after all systems are checked and any required follow-up corrective action on punch list items which are to be addressed for start of commissioning (Category ‘A’) are completed. The Company approval shall be obtained for completion of pre-commissioning.


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C. STAGES OF SYSTEM COMPLETION Following is the sequence of Pre-Commissioning of each of the system 

Mechanical Completion checks



Installation checks per P&ID



Pre-commissioning check lists of all equipments for Mechanical, Electrical and Instrumentation.



Flushing (or air blowing), cleaning, drying and inerting of the piping and equipment



Leak tests (For lines, vendor packages etc)



Purging for commissioning (If applicable)

D. PRE-COMMISSIONING SYSTEM LIST

SIBA FIELD DEVELOPMENT PROJECT System and Sub-System Lists System

Area code

Subarea code

Subsystem

System Number

System Defination

Process 020

000X

XX

01

SYS-020-01

DIESEL STORAGE AND SUPPLY SYSTEM

020

000X

XX

02

SYS-020-02

AIR COMPRESSOR AND DRYER; AIR AND NITROGEN

020

000X

XX

03

SYS-020-03

RAW WATER SYSTEM

020

000X

XX

04

SYS-020-04

POTABLE WATER SYSTEM

020 020 020 020 020 020 020 020 020 020

000X 000X 000X 000X 000X 000X 000X 000X 000X 000X

XX XX XX XX XX XX XX XX XX XX

05 06 07 08 09 10 11 12 13 14

SYS-020-05 SYS-020-06 SYS-020-07 SYS-020-08 SYS-020-09 SYS-020-10 SYS-020-11 SYS-020-12 SYS-020-13 SYS-020-14

FIRE WATER SYSTEM GAS TURBINES DEMIN WATER SYSTEM OILY WATER SYSTEM COOLING WATER SYSTEM CLOSED DRAIN SYSTEM HP/LP FLARE SYSTEM AMINE STORAGE FUEL GAS SYSTEM GAS INTAKE SYSTEM


Document Number

020 020 020

000X 000X 000X

XX XX XX

020

000X

070

Rev. Date

SYS-020-15 SYS-020-16 SYS-020-17

GAS TREATMENT PLANT

XX 18 ELECTRICAL

SYS-020-18

DRY GAS EXPORT

000X

XX

01

SYS-070-01

11KV GENERATORS

070

000X

XX

02

SYS-070-02

070 070 070 070 070 070 070 070 070 070 070 070

000X 000X 000X 000X 000X 000X 000X 000X 000X 000X 000X 000X

XX XX XX XX XX XX XX XX XX XX XX XX

03 04 05 06 07 08 09 10 11 12 13 14

SYS-070-03 SYS-070-04 SYS-070-05 SYS-070-06 SYS-070-07 SYS-070-08 SYS-070-09 SYS-070-10 SYS-070-11 SYS-070-12 SYS-070-13 SYS-070-14

070 070

000X 000X

071 071 072

15 16 17

Page

XX 15 SYS-070-15 XX 16 SYS-070-16 CATHODIC PROTECTION 000X XX 01 SYS-071-01 000X XX 02 SYS-071-02 ELECTRICAL HEAT TRACING SYSTEM 000X XX 01 SYS-072-01 INSTRUMENTS

080

000X

XX

01

SYS-080-01

080

000X

XX

02

SYS-080-02

080 080 080 080 080

000X 000X 000X 000X 000X

XX XX XX XX XX

081 081

000X 000X

043

000X

000 000

000X 000X

03 04 05 06 07 TELECOM XX 01 XX 02 HVAC XX LIFE SAFETY XX 01 XX 02

SYS-080-03 SYS-080-04 SYS-080-05 SYS-080-06 SYS-080-07

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LPG STORAGE AND EXPORT CONDENSATE STORAGE AND EXPORT

11 KV SWITCHGEAR / OUTDOOR ISOLATORS TRANSFORMERS 3.3 KV SWITCHGEAR 400V SWITCHBOARD DC UPS POWER MANAGEMENT SYSTEM (PMS) EMERGENCY DG SET AC UPS CONTINUOUS RATED DG SET SOLAR POWER SYSTEM EXTERNAL CABLE (11KV) 400V DISTRIBUTION BOARDS POWER AND CONTROL CABLES EARTHING AND LIGHTNING PROTECTION LIGHTING AND SMALL POWER CATHODIC PROTECTION - DRAIN LINES CATHODIC PROTECTION - MOUNDED BULLET EHT system INTEGRATED CONTROL AND SAFETY SYSTEM (ICSS) ICSS AT METERING STATIONS - SAFETY MANAGE (SM) HIGH INTEGRITY PRESSURE PROTECTION SYSTEM (HIPPS) WELL HEAD CONTROL SYSTEM (WHCS) HUB CONTROL SYSTEM (HCS) MULTI-PHASE FLOW METER (MPFM) FLOW METERING SYSTEMS

SYS-081-01 SYS-081-02

TELECOM SYSTEM

SYS-043-1

HVAC system

SYS-000-01 SYS-000-02

DELUGE SPRAY SYSTEM DELUGE FOAM SYSTEM

FIBER OPTIC CABLING SYSTEM


Document Number

000 000 000

000X 000X 000X

XX XX XX

03 04 05

SYS-000-03 SYS-000-04 SYS-000-05

000

000X

XX

06

SYS-000-06

000 000

000X 000X

XX XX

07 08

SYS-000-07 SYS-000-08

000

000X

XX

09

SYS-000-09

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SPRINKLER SYSTEM FIRE HYDRANT / MONITOR SYSTEM FIRE PUMP HOUSE NOVEC GAS BASED CLEAN AGENT SYSTEM CF3I GAS BASED RIM SEAL FIRE PROTECTION SYSTEM WATER FOAM TENDER VEHICLE FIRE FIGHTING AND SAFETY EQUIPMENTS

PROJECT COMPLETION SYSTEM – WinPCS

The project will employ the WinPCS database. This enables the project to greatly control and simplify the collection of data and includes scanning software that can sign off, organize and store all procedures and documents produced by WinPCS when completed in the field by various discipline authorities. WinPCS is a powerful tool for data collection helping the project to organize their engineering, and test & inspection data. WinPCS allows all documentations related to equipments and systems to be stored in WinPCS and thereby makes information easily retrievable and valuable to the operation of the project. This will help and simplify the handling and status review of all documents. At the same time the project will achieve a full set of records related to installation, calibration, functional tests and certificates, in the form of electronic copy. 

WinPCS administrator / Turnover Coordinator ensures the integrity of the system, sub-system limitation, the engineering data, project document data and vendor data; provides the inputs for the development of the reports, monitor the inputs and create the daily and weekly status reports, as required.



System and Sub-system boundaries shall be prepared utilizing design data in the form of marked-up:  P & IDs  Electrical Single Line Diagrams (SLD)  Fire & Gas Drawings  Telecom Drawings  Instrument Block Diagram  HVAC Flow Diagrams  Plot Plans (for Civil)



WinPCS administrator will maintain pre-commissioning completion status including other supporting information such as punch list etc.



Generate the necessary forms and records for recording completion activities and acceptance and verification.



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

Report completion status throughout all project completion stages.



Provide overall completion status of all facilities, systems, sub-systems and other plant areas.



Provide standardized documentation and indices for all certification completion aspects of the project.



WinPCS Administrator / Turnover Coordinator will ensure that Quality control Records(QCRs), System Acceptance forms, Mechanical Completion (MC) Certificate, Ready For Start up (RFSU) Certificate, Plant Performance Test Records, Initial Acceptance (IA) Certificate, Final Handover Certificates and other documentation for specific systems, buildings and areas are prepared and collated for Turnover to Company in accordance with project requirements.



Prepare the WinPCS standard reports and other agreed status reports on daily basis and forward to construction and pre-commissioning authorities for their feedback during the Progress Review Meeting.

The check sheets those will be used during Pre-commissioning and Commissioning for gathering the data of the checks of these stages will be shared separately. These check sheets will be stored in the WinPCS and used during the Pre-commissioning and Commissioning activities.


V.


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PRE-COMMISSIONING GUIDELINES

The following guidelines summarize all activities required to be completed during the precommissioning phase of the project. Detailed procedures for these activities are provided in the next section of the manual. The pre-commissioning check of each piece of equipment is to be as complete and comprehensive as possible to ensure that the equipment is installed as specified and will operate as designed. Proper pre-commissioning will ensure that the facilities can be made operable with the least number of problems. a) b) c) d)

The Pre-commissioning Team shall become familiar with all data and information. The Pre-commissioning Team shall start the pre-commissioning checks as early as possible. Witness or conduct and record all ground/earthing tests for all wiring. Witness or calibrate and test all instruments in accordance with the Pre-commissioning Procedures, and record all the calibration & test data on the checklists provided for each instrument and instrument loop. e) Verify that all materials used for the construction of the facilities are new and damage-free. f) Verify that lubricants, oils, coolants, etc., required for all equipments are available on the job site and in good condition (i.e. not contaminated). g) Check the following safety systems: 1. 2. 3. 4. 5. 6. 7.

Ensure that portable fire extinguishers are in place. Check all electrical closures. Ensure that all escape routes are clear of obstacles. Ensure that all PSV outlet block valves are locked open (LO). Wear appropriate personal protective equipments (PPEs) Clear the movement of unauthorized personnel in the work area. Ensure wind socks are mounted in designated locations to create awareness of wind direction 8. Be aware of designated emergency assembly location (Safe Assembly Point or Muster Point). j) Ensure that the following safety equipments are available in the field at designated places,     

First aid kit Self Contained Breathing Apparatus (SCBA) LEL meter / Oxygen meter Spark Arrestors for vehicles Oxygen measuring kit



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VI. PRE-COMMISSIONING PROCEDURES A. GENERAL The Pre-commissioning of the facility will be carried out system wise. All Pre-commissioning documents (Viz. Pre-commissioning / installation check lists, punch lists, mechanical completion certificate) shall be maintained system wise in WinPCS. For each system, a set of installation / Pre-commissioning check list banks shall be compiled covering all the items in the system. When a system is ready for Pre-commissioning, Company shall be informed in writing of the intent to carry out Pre-commissioning activities. Specific pre-commissioning procedures and instructions for inspections, tests, and/or calibration of each item and system are provided in Section B through E. These procedures and instructions shall be followed throughout pre-commissioning activities and completing the checklists. Ensure that the debris is removed and the work place is clean. While the pre-commissioning checks and tests are being performed, all discrepancies, damaged or missing equipment and/or parts there of, malfunctions, missing documents, discrepancies arising out of safe operating, maintenance and accessibility of equipment/machinery pipe fittings (valves etc.) and instrumentation (viz. pressure transmitter, control valves etc.) shall be identified and recorded in the pre-commissioning punch lists. These punch list items should be attended to and rectified. B. INSPECTION AND TESTING Pre-commissioning shall be conducted as follows: 1. The pre-commissioning of the facility shall be carried out system wise. All pre-commissioning documents (viz. Pre-commissioning / installation check lists, punch lists, etc) shall be maintained for each system separately. 2. For each system, a set of installation/pre-commissioning check list blanks shall be compiled covering all the items in the system. When a system is ready for pre-commissioning, Company shall be informed in writing of the intent to start the installation/pre-commissioning activity / checks. 3. Each item on the installation/pre-commissioning checklists shall be checked for construction, installation completion and related approval. 4. Each item on the installation/pre-commissioning checklists shall be completed or checked, signed and dated by the Pre-commissioning Representative from PETROJET



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a. Separate field work punch lists shall be used by the field staff conducting the precommissioning work and the information shall be transcribed on to a master set for signatures and date. These will be stored in WinPCS. b. The master set of punch lists shall remain intact as a back up. c. As each punch list is compiled in the master set, it is suggested to highlight the item(s) be by color in the master set of Process and Instrument Diagrams (P&IDs). 5. Should an item is incomplete or not meeting the design drawings and specifications, the Precommissioning Representative shall compile a punch list of all such items. This punch list (after categorization) and pre-commissioning checklists shall be transmitted to Company for review and approval. 6. Pre-commissioning shall be considered complete only after all equipments and systems are checked, and any required follow-up corrective action on the categorized punch-list is completed. The approval of Company shall be obtained for the clearance of all punch list items. B.1.1 CHECKING AGAINST P&IDs The pre-commissioning team shall divide the plant area into systems and subsystems and shall check the system/subsystem against the relevant P&IDs approved for construction. The important checks are listed as follows: FIELD CHECKS: 

 

      

Check that control valves, flow orifices and check valves are installed in the right direction. Ensure that proper isolation valves (gate, globe, ball, plug or butterfly valves) are installed in right direction as per P&IDs. Check the correct relief valves are installed in equipment/piping as per the P&IDs (check tag plate details). Check that the locking arrangement for “locked open” and “locked closed” valves are installed on specific valves. The spectacle blinds are inserted in ‘open’ or ‘closed’ positions as shown in P&IDs. Check that all drains from the equipments / vessels etc. are connected to the closed / open drain header. Check that all vents from the equipments / vessels etc. are connected to flare system or routed to safe location as per P&ID. Check all piping/fittings meet the specification as per P&ID. Check that correct type of insulation (hot/cold/personnel protection) and tracing are installed on hot systems or cold systems as per P&ID. Check that adequate tie-out valves as per P&ID are installed in proper locations of the system. Check all piping specification breaks are as shown in P&ID. Ensure that proper slope is provided as shown in P&ID in flare, drain and gravity flow liquid lines / headers.


 

B.1.2


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Check specific distance / clearance is provided as mentioned in P&ID for pipeline and instruments. Check the compliance for the notes given in the P&IDs.

VESSELS AND TANKS Review all vessels and tanks for compliance with specifications as follows: 1. Verify that nameplate data is in accordance with specifications, drawings and vendor data. 2. Verify that mist extractors, weirs, baffles, sand jets, anodes, ladders, float guides, floats, Vortex breakers and all internals have been installed as per approved drawings for construction. 3. Verify that all nozzles are connected to appropriate piping, instruments or anodes, or are blinded in accordance with the IFC drawings. 4. If applicable, verify that tank gauging equipment is properly installed and operates freely. 5. Check for any external damage to the vessel, or tank shell, heads nozzles and supports. 6. Verify that all spectacle blinds are installed in the proper position in accordance with the issued P&IDs for construction (IFC). 7. Verify that the vessel or tank has been successfully hydro tested. 8. Verify that the external paint and coatings are in accordance with the specifications as to surface preparation, application, type, color, and thickness, and that any damaged coating has been repaired. 9. Verify that vessels, tanks or drums are grounded to the ground loop. 10. Verify that all safety relief valves and pressure / vacuum relief valves, flame arrestors, emergency hatches are installed as per issued P&ID for construction (IFC). 11. Check that the right types of internals for the equipments (e.g. demisters, inlet devices, filter element, bed support, etc.) are correctly installed and verify for any damage to internals.

B.1.3

ROTATING EQUIPMENT The Pre-commissioning Team shall use the specific vendor data books as reference for each piece of rotating equipment when conducting pre-commissioning work. Vendor procedures shall take precedence if different from the procedure listed below. 1.

All rotating equipments a) Verify that the name plate data is in accordance with specifications, drawings and vendor data. b) Verify that equipment is firmly anchored and dowels are in place.


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c) Verify that driver, coupling and driven equipment is properly aligned. Alignment shall be checked in cold and hot condition, in accordance with procedures in the vendor manual. It is recommended to use the Rota-align (Laser Alignment Device) for the alignment of all critical rotating equipment. d) Check that all guards are firmly secured to protect personnel from rotating shafts, couplings, and belts. Check that proper clearances are maintained between rotating parts and guards. e) Verify that the external paint and coatings are in accordance with the specifications as to application, type, color, and thickness, and that any damaged coating has been repaired. f) Verify that recommended quantities of spare parts, materials and lubricants are on hand. Refer to vendor data books. 2.

Electrical motor drivers In addition to the procedure in this manual, specific electrical procedures shall be used as detailed in the specific vendor data books.

3. Pumps   



Verify that temporary suction strainers are installed on all pumps. Verify that discharge check valves are installed in the proper flow direction on all pumps. Verify that vent and drain valves are installed on all pumps and they are free to operate. Verify that specified instrumentation is installed, checked and calibrated in accordance with description given below in this manual. Centrifugal or rotary gear pump shaft seals shall be checked with the following procedures:

Stuffing Boxes (1) Verify that the stuffing box packing is of the correct type and material for the pump shaft and the process fluid. Check that the stuffing box gland is tightened evenly so as to prevent excessive leakage but not so tight as to overheat the packing during initial startup. (2)

If the stuffing box is equipped with external lubrication, verify that the lubricator or oiler is filled with the proper lubricant.

Mechanical Seals (1) Verify that seal flush lines and strainers are clean and will allow free flow of process fluid.



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2) Check seal oil reservoirs, gauge glasses, tubing connections, and level switch installation, etc. to verify that the system is undamaged and that reservoir is filled to the correct operating level with proper oil as specified in the vendor data book. B.1.4 VENDOR PACKAGE ITEMS The vendor package items which essentially fall under the category of package should be precommissioned as per the procedure given in the respective vendor manuals. Vendor representatives shall be involved in the pre-commissioning of the package. Record all the data as per the procedure and store it in WinPCS. B.1.5 PROCESS PIPING 1. Process piping After construction is completed, the piping and pipelines must be cleaned of all construction debris, hydrostatically pressure tested, dried and inerted, if required. Vessels and tanks are to be cleaned internally before man ways are closed and bolted. The process lines to and from the vessels, however, must be cleaned by water flushing or air blowing. The hydrostatic test water can be used to flush the lines connected to vessel bottom. Note: The flushing and blowing of process lines can be done before or after hydrostatic testing. It is suggested that it be done before hydro testing. Then all flanges broken to clean the lines will have new gaskets and will be included in the test. All orifice plates can then be installed and joints tested.

Experience has shown that the time and effort put into flushing and blowing systems and pipelines prior to start up results in less trouble encountered during and immediately following start up. Special attention shall be given to the lines upstream of control valves and upstream of pumps. Before draining water from vessels, make sure that a high point vent on the vessel is opened to prevent pulling vacuum on the vessel. The Pre-commissioning Team shall use the specifications, plans and detailed drawings for reference in checking all piping systems to determine that they have been properly fabricated, installed and tested. a. Verify that all piping tie-in points match with the drawings. b. Verify that all temporary blinds have been removed and that all spectacle blinds are in the correct position for operation, as shown in the P&IDs. c. Verify that the material and ANSI pressure rating of all piping, flanges, valves, and equipment are in accordance with the drawings by checking the records.



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d. Verify that welding procedures and weld examinations are in accordance with the specifications, by checking construction records. e. Verify that hydro testing (or pneumatic testing) has been successfully completed at the required pressure, either by witnessing the work or checking construction records. Also check the following: 



   

Verify that the correct Testing Medium has been used for hydro testing e.g. hydro test water for stainless steel pipes shall not contain chlorides above 100 ppm or it should be inhibited water. Potable water is the recommended for hydrotesting purpose. Verify that hydro test fluids were drained from all systems after the completion of tests, and disposed of away from the site as directed. Open hydrotest vents to ensure complete draining. Verify that process and utility systems have been flushed properly by water. Pre-identified line will be chemically cleaned, viz. the inlet lines of the compressors. Verify that all blinds, temporary spools, valves and fittings used for hydro testing have been removed. Verify that all process piping systems are essentially free of water after testing, if required air drying can be done. Make up required water level in the Utility Water System as soon as it is pre-commissioned.

f. Check that all piping has no arc burns, and has not been damaged during shipment and construction. g. Verify that insulation and heat tracing is installed in accordance with the specifications, plans, and drawings. h. Verify that all flange gaskets are installed and that bolts after fixing, shall protrude equal lengths either side of the flanged joint. i. Verify that insulating flange kits are installed as shown on the drawings. j. Verify that valves are installed in right position properly as per P&ID: 1) Nameplate data, including valve type, pressure/temperature rating, and materials are as specified and shown on the drawings. 2) Check valves, globe valves, and choke valves are installed in the correct flow direction. 3) Block valves, where applicable, are installed in the correct flow direction. 4) Valve handles are properly located for clearance and ease of operation. 5) All valves operate freely and all valve stems should be greased.



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B.1.6 HYDRO TESTING & CLEANLINESS OF LINES 1.

Hydrostatic Testing 

This test is carried out by filling water in the pipe to be tested and increasing the pressure to the specified pressure. Normally, a portable positive displacement pump will be used to raise the pressure. This test should not be confused with other less severe tests generally carried out before a start-up to check tightness of connections.



The hydrostatic testing is done by construction personnel. Pipe work to be tested is generally divided into groups (hydrotest packs) of similar test pressures and isolated from other sections by installing suitable blinds or disconnection. A low pressure air test can be performed on the sections of the unit prior to a hydrostatic test so that any open lines or flanges may be discovered and taken care of before water is admitted. However, a hydrostatic test is necessary for final testing. A low pressure air test may be used in place of hydrostatic test for low design pressure, flare lines. It should be remembered that in pressure testing of vessels and towers that the test gauge should be placed at the bottom of the vessel so that the liquid head will be taken into account. Site hydrotest is not required for shop fabricated vessels. Before introducing water into a tower or vessel, vents should be opened. Same vents should also be opened before draining the test water. After the test, reduce the pressure developed during the hydrostatic test very slowly and gradually. All water testing and cleaning (hydrotesting and other) shall be done with water that has low chloride content (preferably potable water). Since it will not be practical to pressure test all equipment in the plant simultaneously, the plant should be divided into sections (namely Test packs) as governed by the test pressure for each section. Blinds must be made and installed in the system to isolate sections. Blind all safety valves and disconnect all instruments. Some further suggestions which should be followed prior to and during the hydrostatic test period are as follows:



    



1. Relief valves must be removed or blinded. 2. All items under test must be liquid filled and all air vented. 3. Internals such as level ball floats, which are not designed for the test pressure, must be removed before the testing. 4. All the instruments and control valves must be isolated and removed. 5. Orifice plates shall not be installed. 6. Items, such as connecting piping to a vessel under test, which are capable of withstanding the test pressure, may be subjected to the test. 7. Items, such as vessels connected to piping under test, which are not capable of withstanding the test pressure, must be isolated by blinding. 8. A water filled system must be vented while draining to avoid collapsing of the equipment, which is not designed for vacuum. 9. All relief valves (PSV’s) must be bench tested and set before final installation.



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Prior to filling and pressurizing, it shall be ensured that:         



Hydrotest clearance certificate is endorsed by the QA/QC section. Warning signs are displayed to restrict the entry of unauthorized personnel into the testing area. All pressure gauges have valid calibration and calibration status for each gauge is available on it. The filling hose from the pressure generator is connected to the lower most drain point of the system to be tested. The pressure generator and the high and low sections of the pipe loop to be tested are provided with separate pressure gauges. The hydrostatic test pressure shall not be less than 1.5 times the design pressure or as per contractual requirement. The test gauge used for hydrotesting shall be calibrated prior to hydrotest and gauge identification shall be indicated on the pressure test report. The piping subjected to hydrotest shall be brought up to the pressure and shall be held under pressure for a period of approximately 1 hour for above ground (AG) pipes and 24 hours for underground (UG) pipes before a detailed inspection is started. Leaks and defects, if any, shall be rectified after the pressure is brought down and media is drained. The system / line shall be pressurized to the test pressure and maintained for sufficient time duration to enable Company inspection, if required. On completion of holding time, the line shall be de-pressurized using the high level vent points. The contractor shall prepare a hydrotest report with supporting documentation.

2. Flushing   

   

Flushing shall be carried out prior to pressure testing (Leak test / Tightness Test) of the line. Flushing of the system shall not include pumps. The flow through the screen shall preferably be horizontal. Precautions shall be taken to place screens in a location where the dirt particles will not drop into an inaccessible place in the line during flushing. If this happens, it would not be possible to remove the dirt after removal of the screen. Flushing shall be carried out by introducing a calculated quantity of water through the system at a sufficient velocity. Flushing shall be continued for a minimum time till flushing media becomes clear at the exit point. All temporary strainers shall be periodically checked during flushing and if contaminated with sediment, shall be cleaned. On completion of flushing, any blinds installed for the purpose of flushing shall be removed unless otherwise required. Dismantled joints shall be provided with new gaskets. Remove the instruments which are susceptible for damage, like flow meter, during flushing.



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3. Draining a. The hold up duration between filling and commencing draining of a system under test shall be no longer than 24 hours. b. Upon completion of draining, the system shall be dried and it will be ensured that no residual water pockets remains. c. Open high level vents to ensure complete draining of the pipelines/systems. 4. Air Blowing / drying The pipe lines are dried by air blowing. This operation helps to clean the pipe lines of dirt, debris, scales etc. and guarantees the cleanliness of lines for smooth start-up.   

The cleanliness of the lines must be witnessed by all the concerned parties and relevant quality documents will be maintained. A dedicated mobile compressor may be used for this air blowing / drying operation. As a standard practice for air blowing, care must be taken, not to blow into a vessel or equipment.

The preparation for air blowing shall include following:   

Preparation of detailed procedure outlining the proposed methods and loop covered, supported by marked up P&IDs. This will generally be a combination of hydrotest packs, as far as possible. Temporary blow spools will be fabricated and installed taking into account the line pressure and air velocities. These spools will have identification marks. The inline instruments, susceptible to damage by air blowing, shall be removed or isolated from the air blowing operation.

5. Piping Hand Cleaning Hand cleaning may be required in situations where air blowing is not practical or is time consuming. The items / areas or parts of equipment that may require hand cleaning are as follows: a. Control Valves /PSV cleaning prior to reinstatement: The control valves /PSVs will be brushed out with soft brush and then air blown with hand held air hose or blower. b. Equipment Nozzles: The equipment nozzles will be cleaned by brushing. Special care must be taken in case of rotating equipment so that dirt does not enter the machine.



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c. Small Spools: usually pump suction/discharge spools are removed for flushing, some drain lines and sample connections on vessels are not flushed. These require blowing out using a hand held air hose/blower. d. Large Spools: These are usually long lengths of line which do not require cleaning or lines which are inspected and certified as clean prior to erection. These can be cleaned by sending a man down the line with a brush to sweep the sand / debris out. (Note: In this case utmost care should be taken and this activity should be reviewed with site HSE personnel to decide whether this is a confined space entry) 6. Chemical Cleaning: The inlet process pipe lines associated with compressor package will be subjected to chemical cleaning. The detailed cleaning procedure will be worked out with the specialist contractor who will carry out this operation. 7. Reinstatement of the System The system shall be reinstated, as per construction drawings, after the testing. Blanks and spool pieces provided for test purposes shall be removed and permanent service gaskets shall be provided where test gaskets were used during the test. Thorough inspection of the incoming lines of the rotating equipment will be carried out before reinstatement of these lines. The intention is to ensure that the pipeline are clean up to the equipment throat. Special care must be taken in case of rotating equipment inlet lines, for the portion after the temporary strainers till the throat of the equipment.

B.1.7 Leak Test and Inerting Leak tests are carried out on all systems after flushing and cleaning operations to prove the integrity of the following  

Gaskets and other flange joints Miscellaneous connections like vents, drains, safety valves and instruments.



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After leak test, inerting of the system will be carried out. All the pipelines which will handle hydrocarbons will be inerted with nitrogen and a positive pressure will be maintained in the lines.

B.1.8 BUILDINGS 1.

Verify that all buildings have been constructed in accordance with the applicable drawings, specifications, and standards

C.

ELECTRICAL

1.

General PETROJET shall inspect and test each item on the pre-commissioning check list in accordance with the procedures outlined in the following sections. Each item of equipment shall be inspected upon arrival at site. Should any piece of equipment show signs of damage, the carrier shall be notified immediately. Testing of each item listed in the enclosed “Electrical Equipment Schedule” shall be performed as much as practicable after installation.

2.

Test Equipment a) The following is a list of recommended test equipments as a minimum, required to perform the pre-commissioning test on the electrical equipment as per the “Equipment Schedule”.

(1) Multimeter (2) Clamp on – Ammeter (3) Ductor tester (4) 500 - 5000 V megger (5) Phase rotation indicator (6) Primary injection test set (7) Secondary injection test set (8) Grounding resistance test set (9) Any special test device required to perform any recommended test by the equipment vendor. b) All test instrument sets shall be calibrated prior to use for testing. If any instrument is subjected to physical or electrical damage, that instrument must be calibrated before it goes to subsequent usage for testing. 3.

Pre-commissioning Procedure All electrical equipments shall be inspected for physical damage before



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installation. A pre-commissioning representative shall inspect the inside and outside of the equipment enclosures. Internally the equipment shall be inspected for missing, loose and out of place components. 3.1

Insulation Testing Insulation tests shall be carried out at the pre-commissioning stage and prior to energizing the equipment and cables. The following two methods shall be used: a) Insulation Resistance (IR) testing for motors, transformers, LV switchgear and all equipment other than those items susceptible to damage by over voltage (example electronic components). b)

High voltage AC or DC testing for HV switchgear and HV cables.

3.1.1 Insulation Resistance (IR) Test IR testing shall be carried out using a DC voltage megger. 3.1.2 High voltage test     

Before executing high voltage test, insulation resistance test shall be done. High voltage testing shall be done either by applying AC (power frequency) or DC voltage at a level above the normal operating voltage. DC high voltage test equipment shall be used for HV cables. AC high voltage test equipment shall be used for HV switchgear and generators. Current Leakage versus time shall be recorded during HV testing of cables.

3.1.3 Polarization Index (PI) PI is the ratio between the insulation resistance measured after 1 minute and after 10 minutes of continuous testing at the appropriate voltage (PI = R 10 min / R1 min).

3.1.4 Interpretation of Results  

Should the reading obtained for IR or PI fall below the recommended minimum values as per IEC, then the equipment shall not be energized or subjected to high voltage testing. Appropriate action shall be taken e.g. drying to normalize the figures.







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Should “flash over” occur during high voltage testing then the test shall be deemed to have “failed”. Appropriate method / measures shall be taken (e.g. cleaning, drying, repair) to eliminate the cause. After elimination of the cause retesting shall be performed.

3.2 Conductivity and Earth Resistance Tests 3.2.1 Conductivity Test   

Conductivity tests shall be done on switchgear bus bar connections and switchgear earth system joints to establish their tightness and condition. Conductivity testing shall be done using a low resistance test set “ductor test” with a 10 A (DC) output. For identical connections the measured value shall not differ by more than 20%.

3.2.2 Earth Resistance Test 3.2.2.1 Earth Electrodes 

All earth electrodes shall be tested by the measurement of electrode resistance against the mass of earth using an earth resistance megger. For resistance values for respective systems refer Electrical Design Basis and approved Earthing Calculations.

3.3 Wiring and Terminal Checks

3.4

 Electrical wiring shall be checked against the schematic diagram.  The tightness of all terminals shall be verified. Functional Test Functional testing shall be done to prove the correct operation of the complete system.

4.0

Testing and Pre-commissioning Procedures

4.1

Hazardous Area Equipment

4.1.1

Installation 

All items of electrical equipment including bulk ordered material installed in a hazardous area shall be inspected strictly in accordance with Area Classification requirements.


 


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Special care shall be taken to ensure that cable glanding has been carried out correctly. Certificates shall be examined to ensure that the installation is in compliance with the certification requirements.

4.2 HV Switchgear Testing 4.2.1 The type, model and rating of the switchgear shall be identified. 4.2.2 The equipment shall be inspected to ensure that it is free from mechanical damage. 4.2.3

Initial Checks

4.2.3.1 Initial checks on the installed switchgear shall be done as per the HV switchgear installation check sheet and the vendor manuals. 4.2.3.2 The alignment of the circuit breaker truck in the panel for free movement, and engagement of mating contacts shall be checked for all panels. In case of any discrepancy, these shall be rectified. 4.2.4

Ductor Test This test shall be carried out to ascertain the contact resistance of the circuit breaker and bus bar joints.

4.2.5

Circuit Breaker Test

4.2.5.1

Individual CBs, shall be checked / tested as detailed in the form for “HV Circuit Breaker and Cubicle Test Sheet” and the results recorded.

4.2.5.2 Breakers shall be tested “MANUALLY” and “ELECTRICALLY”, both in “TEST” and “SERVICE” positions. 4.2.5.3 “Trips” for the breakers shall be simulated from the protective relays and “process interlocks”. “Caution” shall be exercised that no power is fed to the end equipment while performing the tests. 4.2.6

Earthing  

Earth continuity bar in the switchgear shall be tested for continuity and contact resistance. Earth bar connection to the earth grid shall be tested for tightness and continuity.


4.2.7


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Testing of “Protection Relays”

4.2.7.1 Testing General 

Relays shall be tested and commissioned in accordance with the manufacturer’s instructions. Use shall be made of the standard test forms.



C.T. ratio shall be verified by primary current injection. Caution shall be exercised that while energizing the primary of the C.T., secondary of the C.T is not accidentally opened.



All protection relays shall be first tested at the normal setting (wherever possible) to verify their operating parameters by primary injection.



Wherever it is not possible to use a primary injection test set because of extreme current requirements, the relays shall be tested by secondary injections.



Relay testing shall include verification of operation of the switching devices tripping mechanism, all alarms and inter trip and lockouts.

4.2.7.2 Testing of IDMT O/C Relay The following parameters of the adopted setting of the relay shall be checked and recorded.

    

Current sensitivity. Curve Timer multiplier data Instantaneous element The above parameters shall be recorded for all the 3 phases viz R, Y, B & earth fault.  After recording the above adopted settings, secondary injection tests shall be done.  Test shall start with verification C.T shorting switches by withdrawing the relay elements.  D.C. supply voltage shall then be checked and a trip test shall be carried out.  After carrying out the above test ‘The current level to trip I inst” the current level not to trip I inst. and current sensitivity for all the three phases & earth fault shall be done at the adopted setting.  After the above test & setting, current injection 2 times the set current and then current injection 5 times the set current shall be done.  All test data of the above shall be recorded in the format for inverse time over current relay test sheet.



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4.2.7.3 Testing of Under Voltage Relays  

The relays shall be tested for “PICK UP” & “DROP OFF” voltage levels for various relay settings by adopting different percentages of set voltages. All the test values and other relay data shall be recorded in the format for / under voltage relay test sheet.

4.2.7.4 Testing of Differential Relay o o

o o

o o o

Interposing C.T. ratio and connections shall be first verified before commencing the test on the relay. “PICK UP” test shall be carried out by keeping the pick up current tap setting at various set points and injection of current shall be done on all three phases and pick up values shall be recorded. The operating time of the relay shall be tested by setting taps at various values. Current shall be injected on all the three phases and the operating time shall be recorded. Percentage bias current test shall be carried out. The relay shall be set at various bias taps and current injected through the bias and operating coil of the relay. The through current and the operating current shall be recorded and the percentage bias arrived at shall be calculated (according to the manufacturer’s manual) and the data recorded. The bias test shall be conducted on all the three phases. The test data and the other relay shall be recorded in the format for “Differential Relay Test Sheet”. The recorded data shall be verified against the manufacturer’s data / specifications. The final setting of the relay shall be checked and the data shall be recorded.

4.2.7.5 Testing of Motor Protection Relay o

o

o

As per the recommended procedure of the relay manufacturer, this relay shall first be tested for the current settings. The pick up values for “negative phase sequence unit, O/C unit and instantaneous O/C unit and earth fault unit shall be measured and recorded for all the three phases. After completing the above tests, the relay shall be tested to check the accuracy of the timer settings. The current shall be injected at different phases and the “pick up current” and “the pick up time: at 150 % of the set current shall be measured and recorded. The above data shall be recorded in the format for “Motor Protection Relay Test Sheet”.



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4.3 Power Management System Panel Testing 4.3.1 Visual inspection to ensure that all components/equipments are intact & free from damage. 4.3.2 Isolation Test  Ensure all main switches, circuit breakers, PLC power supplies, Interface cards, cables from direct connected devices are disconnected  Check impedance between all power distribution circuits and ensure it approaches infinity 4.3.3 Check the continuity of all the earthing systems. 4.3.4 Power up the PMS panel by switching on first the UPS supply & then the non-ups supply and check the distribution of supply. 4.3.5 Control logics Hardware check.  Before engaging the interface card, ensure that the power supply is turned off.  Ensure all jumpers, interface card switches, adaptors are set correctly. 4.3.6 System I/O interface test.  All the field inputs & outputs including both serial & hardwired cables shall be hooked up to the system.  Check the functioning of input/output signals from serial link with DCS,ESD,MV/LV Switch gears, Vests Controller, GTG control panel, AC/DC UPS system etc.  Check the functioning of input/output signals from hardwired link with Thyristor control panel, HVAC panel, EDG control panel, Battery room exhaust fan etc. 4.3.7 Software test.  The programming display will be checked to verify the functionality of all controls, inputs/outputs, status, alarm, measurement, etc.  Check the printout of the software output data. 4.4

Testing of Power Transformers        

Initial tests as per the Transformer Installation Check Sheet shall be done and recorded. Ratio test shall be done by applying low voltage on high tension side and measuring on low tension side of the transformer. Vector group test, shall be done to verify the vector group for the transformer. DGPT2 relay shall be tested for proper functioning of the alarm & trip contacts. Oil temperature indicators shall be calibrated with a standard thermometer. Neutral CTs mounted in the transformer shall be tested. Earth resistance of body to earth and neutral to earth shall be measured and recorded. The “Stability Test” for the differential protection of the transformer shall be done.


4.5


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LV Switchgear Testing

4.5.1

Initial Checks  

The checks shall be carried out and recorded as per the “L.V. Switchgear Installation Check Sheet” “Ductor Test” shall be carried out on all bus bar joints, circuit breaker bus bar plug in contact and isolator contacts.

4.5.2 Test for Circuit Breaker & Starter / Switch Fuse Units     

4.6 4.6.1

Test on circuit breakers shall be carried out as detailed in “LV Circuit Breaker Test Sheet”. Starters & switch fuse units shall be checked & tested as per the “LV Starter / Switch Fuse Unit Test Sheet” and the results shall be recorded. Male / female contacts mating for both power & control circuitry shall be checked for proper operation. The protection relays, CTs & PTs shall be tested as described under the LV Switchgear Testing. Remote “Switching” & Tripping” of the starters shall be checked.

Testing for Lighting & Other Distribution Boards & Sockets etc. Initial Check

 Check for proper wiring and termination of the circuits and earthing.  Check for proper installation of the boards as per vendor recommendations. 4.6.2 Pre-commissioning Tests 4.6.2.1 Tests for Lighting DBs and small power 

  

After checking and ensuring that all wiring is correct and of good IR value, the fittings shall be energized and functioning of the fitting and the on-off operation of all switches shall be tested. During this test, the isolator shall be in “manual” position. Photo electric cells shall be tested and the functioning of the fittings shall be tested with the selector switch in “auto” position. Welding sockets shall be energized and phasing, earthing and output voltage shall be checked. The check sheet for “Lighting and Small Power Fittings” shall be completed.


4.7


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Testing of Motors

4.7.1 Initial Check The details of the motor shall be recorded in the check sheet for Electrical Motor            4.7.2

Pre-commissioning Test    

  4.8

Polarization Index (PI) for stator windings shall be measured. If required the motor stator windings shall be warmed up, to improve the polarization index. Insulation resistance of the motor space heaters, if provided, shall be measured. The winding temperature detector shall be checked for compliance to the specification. The insulation resistance of the temperature detector to earth shall be measured. The motor shall be uncoupled from the driven equipment and the shaft shall be observed for free rotation. The starter shall now be closed and the motor bumped to check the direction of rotation.

Emergency DG Set 

4.9

Name of the manufacturer. Type. Rating. Serial number. Tag number. Rated voltage, current and frequency. Rated speed and winding type. Hazardous Area Classification. Class of insulation. Bearing details at DE & NDE. Space heater rating, voltage and resistance.

Testing and Pre-commissioning activities shall be carried out as per vendor’s recommendation and under their supervision.

Uninterrupted Power Supply System (UPS) 



4.10


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Electrical Heat Tracing 


D. INSTRUMENTATION 1. General These instrumentation procedures are intended to provide a comprehensive and coordinated means to ensure that all instrumentation items have been installed and calibrated according to the specifications & drawings and to serve as a procedure for pre-commissioning the systems. a. The calibration and checkout procedure necessary to complete the form shall be in accordance with this specification. This checkout generally consists of an installation check and measurement of output, with input provided via test equipment, to ensure that the instrumentation is performing correctly in accordance with the specifications and that no damage was caused during installation. The technician shall also complete the equipment documentation section of the form (i.e., manufacturer, model, serial number, etc.), if not previously included. The wiring shall be checked point to point for continuity, ground faults, and termination correctness. Tubing shall be checked point to point for leaks and termination correctness. Should a problem exist, it shall be noted on the checklist. Specify the exact problem and corrective action taken, if any, to correct it. b. Instruments shall meet the manufacturer's specifications. Instruments which do not satisfy the manufacturer's specification shall be repaired or a replacement is sought.


Document Number

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c. The manufacturer's recommended calibration procedure shall be used for all instrument calibrations. The following sections are, in some cases, additional requirements for specified instruments. d. All instruments shall comply with the specification sheet for:         

Instrument Tag Number Model Number Size and Connection Material of Construction Instrument Range of Calibration Valve Action Control Modes on Controller/DCS Thermowell Length Ball, Globe and any other type valve where specified

e. Instrument Commissioning which consist of,    

Functional Testing and operation of control loops Process Control System Shutdown System Fire and Gas (F&G) detection system

is part of the commissioning activities of the plant, which are likely to be taken up parallel with pre-commissioning activities. 2. Test Equipment The minimum test equipment, with accuracies shown, shall as a minimum consist of: Accuracy Instrumentation       

Inclined water manometer Pneumatic calibrator Dead weight tester Precision pressure gauge Digital voltmeter Current and/or voltage generator Precision potentiometer

(% Full Scale) 0.1 0.15 0.1 0.25 0.1 0.25 0.1


Document Number

Page

Rev. Date

 

Precision temperature potentiometer Precision wire wound resistor decade box

+1 deg. C 0.25

 

Milli-Ammeter Temperature bath with precision thermometer

0.1 0.25

 

Stop watch Misc. Manufacturer's signal

0.1 second 0.25

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Generators required for testing  3.

Test Air compressor

-

General instrument checkout        

All instruments and accessories shall be visually inspected for damage after installation. If damage is observed, corrective action shall be initiated. A checklist shall be completed for each instrument that was inspected. All instruments shall be left free of shipping restraints and stops. Glass shall be left clean. Temporary protective devices shall be removed prior to placing instruments in service. Verify that all instruments and tubing are correctly tagged, labeled, and installed at the correct location. All primary elements shall be checked for proper installation with respect to direction of flow, elevation, orientation, insertion depth, and any other applicable considerations. Verify instrument piping and / or tubing shown on the P&IDs and the Instrumentation Schematic Drawings for fitting type, materials, connection sizes, and rating. Verify that adequate brackets and supports have been used to maintain a continuity of rigid construction. On installations which involve instrument seal pots or reference legs, the system shall be filled with the recommended fluid. Verify that the air supply for each instrument is correctly provided. Do not install primary elements until the process line has been flushed clean. All transmitters shall be disconnected from the process lines and vented to atmosphere for overpressure protection during hydrotesting.

Prior to beginning the instrument operational check and calibration, the following leak tests shall be performed: 



Pressurize the instrument air headers with clean filtered instrument air, and spray all screwed and flanged connections with a soapy solution (leak-test). Repair all leaks. Each header branch, lateral, and instrument air take-off shall be blown through to remove all foreign material. Open valves or remove flange or pipe caps at each header extremity to obtain maximum air velocity in the piping. Process tubing that has not received a hydrostatic test shall be pressurized to the maximum working pressure of the connected instrument with water or, in exceptional cases, nitrogen gas. If


  


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nitrogen is used, spray all fittings with a soapy solution. If liquid is used, hold test for five (5) minutes without loss of pressure. Pneumatic transmission lines are to be disconnected from all receiving instruments (I/Ps, switches etc.) and blown through to remove deposits. The lines are then to be reconnected to all of the receiving instruments and tested for leaks. Pneumatic output control lines are to be disconnected and blown through to remove deposits. All solenoid valves should be bypassed during this cleaning blow down. The lines are then to be reconnected to the device and leak tested. All Pneumatic Control tubing is to be leak tested with a bubbler apparatus. Allowable tolerance is four or less bubbles per minutes. All connections used for the leak testing are soap leak tested after the bubble test. The same is true for fittings disconnected for calibration and action of instrument.

4.

Process Transmitters (Electronic) calibration-General       

Disconnect field wiring from transmitter and connect a receiver test instrument which will provide the required power to the transmitter. Accurately read the transmitter output as specified on the instrument checklist. Vary the process input signal to the transmitter, as required by the checklist, and check output for proper zero and span. Transmitters are to be rechecked at 0%, 25%, 50%, 75% and 100% of span. If zero and span are not correct, adjust until instrument meets specifications and repeat the above step until correct. Remove test connections, and reconnect field wiring and process inputs. Ensure that all covers and protective devices are replaced and secure. Transmitters with indicators shall have the indicators calibrated with the transmitters For displacer level transmitters use water as the process fluid and ensure that associated vessel block valves are closed during the test.

5. Pressure / Temperature Indicator (Direct reading) a) b) c) d) e) 6.

Verify that the installation is in accordance with the installation drawings. Check the tag number and range. Check for visible damage. Ensure that the face is clean and facing in a direction easily visible to the operator. Check for liquid in gauge (for liquid filled gauge) and that the gauge is zeroed properly. Flow Element (Orifice)

a) Check the meter run with the mechanical flow diagram to ensure proper installation in relation to the direction of flow.



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b) Check the upstream and downstream pipe lengths to verify that they are according to specifications. c) Check the pressure taps to ensure that the high and low pressure sides of the orifice are connected to the corresponding sides of the field instrument. d) Remove orifice plate carrier, wherever installed, out of the assembly as per manufacturers recommended practice. e) Check the orifice size against the Instrument Specification Sheet and verify that the orifice plate is installed with the square edge upstream. f) Replace orifice plate as per manufacturers recommended practice. 7.

Level Transmitters (displacer type) a) Check for the Transmitter and accessories free of damage. b) Check for correct Tagging and the label is visible. c) Check and ensure the level transmitter is installed at correct elevation and the instrument connections are properly bolted. d) Check for free access for operation and maintenance. e) Check the isolation and vent / drain provision matches to the AFC drawing. f) Disconnect field wiring from transmitter and connect a receiver test instrument and check for zero error & span and get it corrected. g) Remove test connections, and reconnect field wiring and process inputs. h) Ensure that all covers and protective devices are replaced and secure. i) Where possible all float or displacer elements shall be checked for pin hole leaks i.e. immerse element in bath of clear hot water and inspect for Air Bubble Streams. j) For displacer type level transmitters use water as the process fluid and ensure that associated vessel block valves are closed during the test.

8.

Control valve calibration (General)

(a)

Control Valves shall be inspected rigidly and ascertained to conform to both the specification sheet and the valve nameplate. The following points shall be verified:

(b)

(1)

Valve connection size and type.

(2)

Valve Action.

(3)

Travel direction indicator installation.

(4)

Any special features.

(5)

Actuator type, size and bench set.

The valve shall be stroked the entire length and the actuator spring compression shall be adjusted if necessary. The valve shall be checked to ensure that it seats properly when the appropriate signal (bench set) is applied to the actuator.


(c) 9.


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Verify that the valve position matches for "fail open" or "fail close" operation. Control Valve (With Positioner) a) Turn on the air supply to the positioner, and set the regulator at the proper air pressure. b) Slowly increase the input using the test device while observing the positioner output pressure and valve position. c) Note the positioner output pressure and the input whenever the valve begins to move. d) Stroke the valve for 0%, 25%, 50% and 100% open and close and check the hysterisis. e) Note the positioner output pressure and the input. f) If the input operating range of the control valve is not the same as that shown on the checkout form, recalibrate the valve positioner assembly as per the manufacturer's recommendations. g) Vary the input signal as required by the checklist and note the required data. h) Disconnect the test equipment.

10.

Shutdown valve a) Verify that the valve, actuator and control box are in accordance with the specifications and are installed in accordance with the drawings. b) Connect 24 V DC supply to solenoid valve and keep it energized. c) Connect a 5.5 bar(g) air supply to the shutdown valve actuator supply. Use the permanent air supply, if operational; otherwise, connect a temporary supply to the branch from the air supply header. (Note : Check minimum air pressure available is 4.5 barg) d) Check the operation of the limit switches for open / close position and adjust as necessary. e) Check the open / closing time of the valve as per specification. Stroke the valve for repeatability and check the satisfactory operation of the limit switches. f) Reduce the air supply pressure to a minimum specified and re-check satisfactory operation of the valve. g) Check the Fail-Safe operation against specification. h) Check the partial stroke test as per the manufacturer’s instruction and specification. i) Where air reservoir or other peripheral device is concerned, check the piping in accordance with the appropriate pneumatic hook up. j) After the shutdown valve test is complete, disconnect temporary air supply, test equipment, and reconnect the valve to the field connections.

11.

Wiring checks Wiring/Loop and Continuity Checks: A point to point wiring and loop check shall be performed to verify correct connection of all wiring and response of instruments interconnection schedule loop schematics and wiring



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diagrams shall be utilized by the technician as required to ensure a complete and correct functioning of system.    12.

Any discrepancy observed shall be brought to the attention of the Pre-commissioning Representative before wiring hookup changes are made. The wiring check shall be made utilizing a Volt/ohm meter with the resistance scale set at 10 ohms. Loop schematics shall be used to carry out the checking. Loop Test Procedures

a) Visually inspect all items of the loop and set air/electrical supplies where appropriate. In particular check the air supply pressures for control valves and in accordance with their specification. b) For electric loops, check all signal polarities and adjust any loop impedances if applicable. c) Manually, or with applied input signal, transmitter output signals of 0%, 50% and 100% shall be generated to check the response of all other instruments and control valves in the loop. d) Instrument zero settings and calibration adjustments shall be made as necessary, unless the instrument is of the ‘SMART’ type. In the case of ‘SMART’ based instruments the instrument settings should be checked using a hand held communicator of the correct type against manufacturer’s data and instrument data check sheet. e) Switch controller to ‘Manual’ operation and check the valve stroke correctly. Valve positioner gauges should also be checked during this stage. f) With set-point, measured variable and control output all at 50% check for bumpless auto/manual change over where applicable and adjust if necessary according to manufacturer’s instructions. g) Check all associated alarm or trip functions by varying the transmitter signal and adjust switch level accordingly. h) Trips and alarms not covered by the above tests i.e. direct process operated switches such as float switches, etc should be separately tested for correct operation. i) All systems shall be checked for correct ‘fail-safe’ operation including ‘burn-out’ features of thermocouple systems. j) Thermocouples and resistance bulbs shall be removed from their wells and inspected for damage. Resistance bulb resistances shall be measured and recorded together with the ambient temperature. k) After the above check, all elements will be replaced in their protective wells ensuring that the element length matches the associated well length. l) On re-connection a detailed inspection should be made of all connections to ensure TC polarities and 3-wire resistance bulb connections are correct. m) Analyzers and other special systems should be fully checked and calibrated to manufacturer’s instructions with consent of the Supervising Engineer. It shall be agreed where supplier’s engineers are required to give assistance and when necessary the contractor shall give the supervising engineer adequate notice so that arrangements may be made.



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13. DCS / ESD System a) b) c) d) e) f) 14.

Wiring Checks UPS power up and commissioning. Power on new DCS & new shutdown system and allow warm up time. Loop check by simulation of signals from marshalling cabinets all DCS I/Os. Loop check from field instruments and other instrument loops. Loop check from the field the fire detection and protection system. Serial Interface

a) Check the physical connection of serial link cable at the DCS and at the non DCS end. b) Set the communication parameters (Baud rate, parity, address etc.) at DCS. c) Simulate and check that the communication and individual I/O mapping is satisfactory.

15.

Fire & Gas detection system a) Carry out wiring checks b) Simulate from field and check for the alarm / shutdown function as per C & E matrix. c) Check the alarm on the DCS over serial link.

E.

MISCELLANEOUS MECHANICAL EQUIPMENT Verify that all Miscellaneous Mechanical Equipments have been installed according to specification and applicable drawings.

F.

PRE-COMMISSIONING FORMS

Attached


Document Number

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G . PUNCH LIST CATEGORIZATION TABLE “A” punch item

“B” punch item

(From)

(Fit & Function)

“C” Punch item (Not Required for Safe Operation)

Piping

Static equipment Reactors Rotating Equipment

Piping,Fitting&Supports Valves,Gaskets,Bolting

Paint & Non essential

Erected according to

Final,Reinstatement,QA/QC

Insulation

Design

Documentation.

Setting,Supports

Internals,Gaskets.Bolting


Final Closure.

Insulation

Internals,Catalyst,Gaskets,


Bolting Final Closure.

Insulation

Machine&piping

There shoud no “C”

Aligment,Trip,

items allowed for

Control,Lube System

Rotating Equipment

Setting,Supports Setting,Supports

Motor Control

Installation and

Control and Logic Fully


centers

resistance testing

Functional

items allowed for switch,Gear and Transformers

Electrical Equiment

Setting,Supports

(motors)

Machine&piping Aligment,


Control,Trip, Fully

items allowed for

Functional

Electric motors

Electrical Equiment

Installation and



(Transformers/light

resistance testing

Functional

items allowed for

ing)

switch,Gear and Transformers

DCS Including

Installation and



Remote I/O

Continuity Checks

Functional

items allowed for control systems

Instrument Sensing

Installation and

&Control Loops

Continuity Checks

Control and Logic Fully Functional

There shoud no “C” items allowed for control systems


Document Number

PLC

Page

Rev. Date

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Installation and



Continuity Checks

Functional

items allowed for control systems

Solenoids and Trip

Installation and

Circuits

Continuity Checks

Fully Functional

There shoud no “C” items allowed for control systems

Buildings

Structural Components

Building Utilities including Fire and Gas

Minor Repairs and paint

Pre Commissioning Manual

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