Mozambique

Mozambique Program

Coral South Development Project

EPCIC phase

FLNG LOOP CHECK

I.
Bu Cho Kostianovsk
EX-DE 00 30/07/18 Issue for Comment D.Seguy N.A.
M.Iacob y
YG Kang
Validity Rev.
Status number Prepared Checked Approved Company Company
Date Description
by by by Approved Endorsed
Revision Index
Company logo and business name Project name Company Document ID
4404GGCWPT00023
Coral South Development Job N.

Contractor logo and business name Contractor Document ID

71259C-0100-PP-0941

Contract n. 5000010298

Vendor logo and business name Vendor Document ID

N/A N/A

Order n. N/A
Facility / Sub Facility Name Location Scale Sheet of Sheets
Coral FLNG South – GENERAL N/A 1 of 40
Offshore
Document Title Supersedes N.

Commissioning Procedure – PP – FLNG LOOP CHECK Superseded by N.

Plant Area Plant Unit
N/A

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Project / Initiative name Coral South Development

Document Title Commissioning Procedure – CP – Flng Loop Check

This procedure defines the scope and methods used to carry out the commissioning activities of the
ABSTRACT

instrumentation loop tests

Document Verification

Prepared by Unit Signature Date

D.Seguy

Main contributions Unit Signature Date

Contractor
Prepared

Checked by Unit Signature

M.Iacob Date
Bu Cho

Approved by Unit Signature

I. Kostianovsky Date
YG Kang

Verified by Unit Signature Date

Inter-Discipline
Company

Review

Verified by Unit Signature Date

Verified by Unit Signature Date

Checked by Unit Signature Date

Company Checked

Checked by Unit Signature Date

Checked by Unit Signature Date

Approved by Unit Signature Date

Approved
Company

G. Napolitano

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It shall neither be shown to Third Parties nor used for purposes other than those for which it has been sent.
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Endorsed by Unit Signature Date

Endorsed
Company

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It shall neither be shown to Third Parties nor used for purposes other than those for which it has been sent.
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REVISION LIST
EX-DE_00 Issue for Comment

HOLD RECORD
The following beginning and end table titles are here also for Information Management purpose.
The layout should remain as is: please do not modify column headers and do not add columns to the table.
However, you can add as many rows to the table as needed.
BEGINNING OF HOLDS LIST (DO NOT MODIFY OR REMOVE THIS LINE)

1 HOLD for Vendor and engineering information to be confirmed

2 HOLD for appendix 2 B-ITR-I06 to be finalized

END OF HOLDS LIST (DO NOT MODIFY OR REMOVE THIS LINE)

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Contents

1. INTRODUCTION ...................................................................................................................... 7
1.1 BACKGROUND .............................................................................................................. 7
1.2 PROJECT LOCATION .................................................................................................... 7
1.3 COMPANY JOINT VENTURE INFORMATION ............................................................... 7
1.4 PROJECT OBJECTIVE .................................................................................................. 8
1.5 SCOPE OF THE DOCUMENT ........................................................................................ 8
1.6 ACRONYMS AND ABBREVIATIONS ............................................................................. 8
1.7 ReFERENCES .............................................................................................................. 10
1.8 Others documentation ................................................................................................ 10
1.9 SHI AND JV TJS CSU Instrument Superintendent responsibilitIES ......................... 11
1.10 Company responsibilitIES .......................................................................................... 12
1.11 Loop Test COMPLETION STRATEGIES ..................................................................... 13
1.12 Loop Testing Prerequisites......................................................................................... 13
1.12.1 loop construction/pre-commissioning completion check ........................................... 13
1.12.2 Loop Folder Dossier ................................................................................................ 13
1.12.3 Additional Documentation ........................................................................................ 14
1.12.4 Other requirements .................................................................................................. 14
1.13 Loop Test Team ........................................................................................................... 15
1.13.1 Required Tools for Loop checks .............................................................................. 15
1.14 Pre-Loop test prOCEDURE ......................................................................................... 16
1.15 Loop Test for Pressure and DP Transmitters ............................................................ 17
1.16 Loop Test for Valves ................................................................................................... 20
1.16.1 Control Valves ......................................................................................................... 20
1.16.2 Hydraulic Control Valves .......................................................................................... 20
1.16.3 ON-OFF Valves ....................................................................................................... 21
1.16.4 Emergency Shutdown Valves ESDV Spring Return ................................................. 21
1.16.5 Blow Down Valves BDV double effect...................................................................... 22
1.16.6 Blow Down Valves BDV spring return ...................................................................... 22
1.16.7 Blow Down Valves BDV hydraulic actuated spring return ........................................ 23
1.16.8 Motor Operated Valves ............................................................................................ 24
1.17 Motor LV/HV and Heater control loop test ................................................................. 25
1.18 Motor VSDS with HARWIRED control loop test......................................................... 25
1.19 OTHERS Loop Test for NON HART ANALOG OUPUT............................................... 26
1.20 Discrete Input Signal LOOP TEST .............................................................................. 27
1.21 Discrete Output Signals .............................................................................................. 28
1.22 Fire and Gas Equipment ............................................................................................. 29
1.22.1 Gas Detector ........................................................................................................... 29
1.22.2 Gas detector Loop test:............................................................................................ 29
1.22.3 Non – addressable FGS detectors ........................................................................... 33
1.22.4 Other fire and GAS items ......................................................................................... 34
1.22.5 Gas tight and Fire Damper ....................................................................................... 35
1.22.6 Manual Call Point (MCP) ......................................................................................... 36
1.22.7 Deluge Valve ........................................................................................................... 36
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1.23 Loop test ending.......................................................................................................... 37

1.24 APPENDICES ............................................................................................................... 38

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1. INTRODUCTION

1.1 BACKGROUND
The Area 4 Offshore Rovuma Basin block, with an initial area of 17,646 km2, was awarded to the Area 4
Joint Venture, for which Eni East Africa S.p.A. (EEA) was appointed as the Operator on December 2006
(with effective date February 2007).
It is located in the deep waters of the Rovuma Basin (1500 to 2300 WD) and straddles the Mozambique’s
Northern border with Tanzania, adjacent to the Area 1 block. The Rovuma Basin is part of the Tanzania-
Mozambique Coastal Basin, which has a total extension of some 80,000 km2 and a maximum thickness of
about 10 km.

Figure 1: Initial Area 4 Block Location

1.2 PROJECT LOCATION
Area 4 is situated approximately 250 km North East of Pemba and 50 km from the coastline, measured from
the western limit of the concession; the Block is about 70 km wide by 200 km long. Currently Area 4 covers a
surface of 10207 sqkm.

1.3 COMPANY JOINT VENTURE INFORMATION

EEA is the Operator of the Area 4 Block (with a 70% participation interest), with the other participants being
ENH (10% carried throughout the exploration phase), Galp Energia (10%) and Kogas (10%). CNPC holds a
28.57% participation in EEA (equal to an indirect participation of 20% in the Block).

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1.4 PROJECT OBJECTIVE

Coral South Development Project has the objective to exploit the southern portion of Coral non-straddling
reservoir through one Floating LNG (FLNG) Unit, and relevant subsea development.

1.5 SCOPE OF THE DOCUMENT

The purpose of this procedure is to describe the methods of executing the commissioning scope of work
related to the instrument loop checks of all relevant control equipment.
I/O communication functionality and diagnostic between the ICSS and field instruments shall be verified.
Note: the attachments of this Commissioning Procedure (CP) will be revised accordingly with the latest
revision prior to PP execution and not revised any time a project document is revised.

1.6 ACRONYMS AND ABBREVIATIONS

AMS Asset Management System

BDV Blow Down Valve
B-ITR-B Inspection and Test Report B
BPO By Pass Override
COMPANY (CPY) CORAL FLNG SA
CONTRACTOR (CTR) Consortium among JV IN, JV OUT, SHI IN, SHI OUT, TP IN and TP OUT
CSU Commissioning and Start-Up
DCS Distributed Control System
D&ID Duct and Instrumentation diagram
DP Differential Pressure
DPI Differential Pressure Indicator
EP Easy Plant
EPCIC Engineering Procurement Construction Integration and Commissioning
ESD Emergency Shut Down
ESDV Emergency Shut Down Valve
FC Fail Closed
FLNG Floating LNG
FO Fail Open
FGS Fire and Gas System
HART HART (Highway Addressable Remote transducer)
HV High Voltage
ICSS Instrumented Control & Safety System (DCS/ SIS/ FGS)
I/O Input/ Output Signal
ITR Instrumentation Technical Room
JB Junction Box
LR Lloyd Register
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LV Low Voltage
MAV Main Automation Vendor
MOS Maintenance Override Switch
MOV Motor Operated Valve
OWS Operator Work Station
P&ID Piping and Instrumentation Diagram
PP Project Procedure
PST Partial Stroke Test
SAT Site Acceptance Test
SDV Shut Down Valve
SLD Single Line Diagram
SIMOPS Simultaneous Operations
SIS Safety Instrumented System
SPCS SHI CMS System
TJS Technip JGC Samsung
UCP Unit Control panel

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1.7 REFERENCES

REF Designation Document Number

[P1] MAV Scope of Supply For ICSS 4404GGBIES0048T
[P2] Instrumentation and Control 4404GGBISG0043T
Philosophy
[P3] DCS Software Typicals 4404GGDISH02102
[P4] SIS Software Typicals 4404GGDISH02004
[P5] FGS Software Typicals 4404GGDISH02003
[P6] SPI Typical Loops 4404GGDIFL09008
[P7] HMI Specification 4404GGDISH02100
[P8] Supply Specification for Asset 4404GGBISF0050T
Management System
[P9] Instrumentation / Electrical 4404GGBISB9580T
Interface Philosophy
[P10] Instrument Numbering 4404GGBISG0002T
Specification
[P11] Instrument bypass & override 4404GGDWPT00049
procedure
[P12] Permit to work procedure 4404GGDFPG00549
[P13] Commissioning Witnessing and 4404GGDWPT00030
Notification Procedure
[P14] Emerson ICSS DCS SAT 4404GGGDIP107AG
procedure
[P15] Emerson ICSS DCS SAT 4404GGGDIP107AG
procedure
[P16] Emerson ICSS SIS SAT procedure 4404GGGDIP207AG
[P17] Emerson ICSS FGS SAT 4404GGGDIP307AG
procedure
[P18] Deluge valve Skid 4404GGDBPT001CH

1.8 OTHERS DOCUMENTATION

The latest revision of following documents shall be the reference

1) P&ID
2) Control Narrative
3) Cause & Effect Diagram for Safety Systems (SIS)
4) Single Line Diagram and Safety Bar
5) Cause & Effect Diagram for Fire & Gas System (FGS)
6) Alarms narrative
7) Alarm List by unit

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1.9 SHI AND JV TJS CSU INSTRUMENT SUPERINTENDENT RESPONSIBILITIES

- Supervise the completion of all loop checks during precommissioning / commissioning stage for
all the areas of FLNG project.
Note: As per Project Completion Philosophy - 4404GGBWPT0010T and Handover
Procedure - 4404GGDGPP00983, it has been agreed between JV/SHI and CPY that Loop
test would be executed as much as possible prior MC of relevant associated Subsystem
following an internal release mechanism between SHI Construction teams and SHI/JV CSU
instrumentation teams.
It is a low voltage activity that doesn’t introduce any safety risks or particular Safety SIMOPS
constraints.
Clear communication channel and notification will be of paramount important between the
SHI and JV teams to allow successful implementation of this opportunity
- Be responsible for the safety aspect, planning, the execution and coordination of the activities,
including equipment supplier representative interfaces.
- Ensure that the Instrument Rooms (ITR) are controlled as restricted areas by using appropriate
and valid work permit.
- Ensure a tool box talk to the team involved in the activity each day and at any time during the day
if the work site conditions or scope changes. (Refer to Permit to Work procedure [P12]).
- Ensure all modifications, non-conformities and minor discrepancies between design and as-built
encountered while carrying out loop testing activities are recorded by punch list in SPCS / EP
- Ensure that instrument tools and test devices are calibrated and certified before starting loop test
activities.
- Verify if radio communication tools (hand held radios) with dedicated channels are available.
- Ensure that sufficient numbers of workstations are available for loop testing.
- Provide signage, labels to their teams to indicate which equipment are under pre-commissioning
- Prepare the two weeks and daily look ahead plan to give a general overview about the next
activities to be accomplished in the next few days.
- Ensure (for loop check belonging to packageP3) vendor is attending for validation
- If By pass/Override during the commissioning phase is required, BPO form shall be filled and sign
off prior starting the activity. (refer to the Instrument Bypass/ Override procedure [P11])
- Ensure all the Bypass/Override have been removed after the loop check completion and properly
recorded in the dedicated data base. (refer to the Instrument Bypass/ Override procedure
[P11])
- Ensure SHI Construction / QM team has given the go ahead (after confirmation in SPCS / EP of
the successful completion/signature of Pre-requisite A ITRs as detailed under 1.12.1 and
confirmation that no outstanding Punch lists preventing loop test activity remain) to JV / SHI
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CSU Instrumentation teams to perform the associated instrumentation loop tests and ensure
necessary notification has been sent by JV/SHI CSU teams to SHI construction teams to
inform about loop test start/completion schedule.

1.10 COMPANY RESPONSIBILITIES

- Witness and Supervision of loop checks completion.
Note: The Classification society (LR) may witness the loop check activity but the approval and
signature of the check sheet confirming completion of the work will be by Company.
Refer to Commissioning Witnessing and Notification Procedure [P13]

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1.11 LOOP TEST COMPLETION STRATEGIES

In case of the junction box is not fully terminated/wired by the construction, i.e some secondaries
cables are not connected to the instruments, EP / SPCS should allow to perform loop checks
partially with the instruments already connected to JB.

1.12 LOOP TESTING PREREQUISITES

1.12.1 loop construction/pre-commissioning completion check
Ensure all “A” check sheets related to the loop construction/pre-commissioning are completed and
available in SPCS / EP.
- Cable continuity test sheet.
- Air/hydraulic tubing pressure test sheet.
- JB inspected and multi pair cable wiring completed.
- Cold and Hot SAT Emerson cabinet completed
- Ensure that any impacting construction punch item is clear before beginning loop
check activities.

(SHI to complete) to add here a section if they need for particular Construction / precom
interfaces with JV / SHI CSU Teams for internal release mechanism and performance of
loop testing activities prior MC

1.12.2 Loop Folder Dossier

The documents included in the loop folder shall be the latest available revision (possibly as-built).
The use of unofficial revisions with Red Line Mark-Ups is allowed only when these have been
validated by Field Engineering department and/or Instrument Superintendent.

The loop folder shall contain all documents described below:

- B-ITR-I06 Check Sheet
- Instrument Datasheet
- Related Loop P&ID/D&ID
- Instrument layout showing the position (optional, to be agreed)
- Loop Drawing
- Valid Calibration certificate when it is required
- Level studies when it is required
- Extract of the Alarms Threshold values

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1.12.3 Additional Documentation

In addition, the following documents / drawings shall be available in each Technical Room before
Loop Test started for the reference.

- Wiring Connection List

- Instrument Equipment Plot Plan
- Package Vendor Documents
- MAV Vendor Documents
- Loop check Drawings
- Alarm List by unit
- Hookup Drawings
- Instruments data sheets
- SPI Typical Loops

1.12.4 Other requirements

- Ensure availability of definitive (or temporary if needed) workstation for loop checking in the
specific ITR.
- All special equipment required for loop test shall be confirmed in advance and prepared before
starting loop test.

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1.13 LOOP TEST TEAM

JV CSU Instrumentation loop test team:

- 2 technicians in the field for generating signal and checking valve position
- 1 console operator (calling face plate, checking graphics displays, ect…).
- 1 loop check supervisor for several loop check team

SHI CSU Instrumentation loop test team:

- To be filled by SHI

COMPANY: Company representative to witness the loop test

VENDOR: Package Vendor supervisor if required (under TJS responsibility)

MAV: System engineers (DCS, SIS, FGS, AMS) located in ITR for loop checking support (Under TJV/SHI
supervision, shared between top side and sub-structure)

Note: loop check team composition will be adjusted after JV CSU Onshore manning CPY approval and
updated in the next revision of this document

1.13.1 Required Tools for Loop checks

Following tools shall be available as minimum

- Pressure calibration device and hand pumps

- multi meters, 4-20 mA generator, HART communicator
- Precision electronic thermometer, electronic thermo element calibrator
- Fire & gas testers: among others smoke generators, heat generators, IR and UV lamps, LEL
bottles, etc
- Refer to appendix 1 for additional details and complete list of models

Remarks:
- All test equipment used must carry valid certification.

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1.14 PRE-LOOP TEST PROCEDURE

At field:

1. Perform Visual inspection of the instrument installation and instrument hook up in the field prior
to energize in order to identify physical damage and verify proper installation , tubing and
termination.
2. Check if the Transmitter tag number is marked on the name plate as per loop folder
documentation

In ITR:

1. Energize the instrument (by plugging charm device) and check the led on the front. Led color
shall be green solid confirming CHARM is healthy.

CHARM LED indicators

Green Solid CHARM is functioning normally.
Downloaded and field device connected
Green Flashing (2 Hz) CHARM is healthy but configuration
is incomplete. Check configuration.
Red Solid CHARM communication fault,
may require replacement.
Red Flashing (2 Hz) Signal wiring fault, but CHARM passes all
self-tests Possibly open circuit or short
circuit on field wiring.
Red Flashing (5 Hz) CHARM failed to get Address assignment.
Check cables, Address Plug, reset
CHARM, replace CHARM.
Green/Red Alternating (5 Hz) Non-fatal fault detected. Verify
diagnostics to identify source.
Process data is still available.

2. Launch DeltaV explorer by using an engineering work station and perform a CHARM “auto
sense device”
3. Confirm the correct device has been connected to the correct channel/CHARM.
4. No discrepancy between data base and instrument device shall be found
5. Download the CHARM to the CIOC to enable the hardware
6. Open the DeltaV Diagnostics and confirm the device model, manufacturer, and revision.
7. At this point, Emerson specialist shall validate the “Charm commissioning configuration” on the
dedicated part of the B-ITR. This action will release the main loop check procedure

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1.15 LOOP TEST FOR PRESSURE AND DP TRANSMITTERS

1. Ensure loop testing prerequisites have been successfully done (refer to section 1.12)

2. Ensure pre-loop test procedure has been fully completed and validated (refer to section 1.14)

3. Ensure transmitter is isolated from the process and purged.

Note: Special attention shall be taken for DP cell levels transmitters. Depending on the hook-up
configuration, LP and HP chambers may be full of liquid anytime .In this case, no purge is allowed

4. Open the face plate and confirm the configuration:

 Tag
 Range
 Engineering unit
 Service Description (shall be clear and respecting the HMI convention)
 Alarm set point, priority
 Primary display link

5. Check hysteresis default value on the faceplate details:

Each Alarm has a default hysteresis value: to be confirmed by engineering

 Flow: 5 % of span
 Level: 5% of span
 Pressure for liquid: 5% of span
 Pressure for Gas: 2% of span
 Temperature: 1% of span

6. Confirm on the graphic display the position and the correct animation of the instrument according
to the HMI specifications [06]

7. Check the minimum process value on the face plate according to the range

8. If the minimum process value is good, connect a hand pump or a Druck to inject air pressure
according to the range. HART Communicator device can be used as well

9. Perform 0%, 25%, 50%, 75%, 100% and back to 75%, 50%, 25%, 0%

10. Transmitter output signal shall be checked on the faceplate

11. Check transmitter local indicator display on the transmitter itself

12. Alarm & trigger set points (Low, Low-Low, High and High-High) as well verified.

13. Alarm annunciator with direct access to process displays shall be checked

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14. Events and values recorded on SOE to be checked

15. Out of range to be checked. If the signal value is between 3,8mA and 20mA, no alarm shall be
displayed

16. bad PV alarm to be checked by disconnecting one wire on the instrument itself. (to be confirmed
feasibility with CHARM technologies)

Table 1: Invalid causes overview

17. Finally, B-ITR-I06 shall be filled and sign off by Mav representative, TJS responsible and CPY.

The table below is summarizing the majorities of the AI types encountered in the project and
defining which method and tools must be used.

Table 2: Analog Input types

Type of Signal Field Device Signal simulation Remarks
4-20 mA HART DP Cell /Pressure Inject Pressure by hand HART device can be
transmitter pump or pressure used
calibrator
4-20 mA HART Mass flowmeter, Vortex, Signal generation by HART device can be
Coriolis, Electromagnetic simulation used, Field Indication
flowmeter, Radar, (NB: For radar level to confirm, if
transmitter/converter transmitters, tank/capacity applicable.
shall be empty)
4-20 mA HART Capillary diaphragm Signal generation by HART device can be
sensor transmitters simulation used

4-20 mA HART Valve position feedback By performing full stroke Done during the valve
loop check
Non HART Temperature RTD RTD, Thermocouple Ambient temperature
Thermocouple Simulator to be used. shall be confirmed.
4-20 mA Non Motor (Power, Current, Generate Signal from
HART Voltage, Speed, etc) substation
MMS vibration sensors By using specific vibration
simulator device
Analyzer Using actual calibration Signal will be checked
tools such as calibration during calibration
gas.
Gas Detector Signal generation by See FGS loop check
simulation chapter

Vibration Instrument Disconnect & Reconnect

the wiring at field and
check fault alarm
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Frequency/Pulse Frequency generator shall

be used

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1.16 LOOP TEST FOR VALVES

1.16.1 Control Valves

- Ensure loop testing prerequisites have been successfully done (refer to section 1.12)

- Ensure pre-loop test procedure has been fully completed and validated (refer to section 1.14)

- Open instrument air isolation valve

- Adjust the air pressure controller as per the value indicated on the instrument plate

- Send signal to the control valve from the face plate. Stroke test (Up/Down) shall be done for 0%,
25%, 50%, 75% and 100% then 100%,75%,50%,25%,0%

- Valve position feedback to be checked at the same time with the stroke and compared with the
actual position at field

- Failure control valve position (no air, no power) shall be confirmed. (FC, FO)

- Positioner failure, mismatch alarms to be checked. This can be tested by closing the air
instrument isolation valve and purging.

1.16.2 Hydraulic Control Valves

Loop check method to be detailed by SHI

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1.16.3 ON-OFF Valves

1.16.4 Emergency Shutdown Valves ESDV Spring Return

- Ensure loop testing prerequisites have been successfully done (refer to section 1.12)

- Ensure pre-loop test procedure has been fully completed and validated (refer to section 1.14)

At field:

1. Open instrument air isolation valve

2. Adjust the air pressure controller as per the value indicated on the instrument plate

3. If external air cylinder accumulator is connected, check for sufficient air pressure available in the
air cylinder.

In ITR:

1. Put dedicated bypass override in the system to allow the open/close command

2. Solenoid valve shall be energized from SIS by forcing the DO

3. Perform full stroke test from faceplate, 0% to 100% and 100% to 0%

4. Positioner failure, discrepancy alarms to be checked. This can be tested by closing the air
instrument isolation valve and purging.

5. Check the MOS interaction on the valve (refer to [10])

6. Check on/off valve animation/dynamo on the graphic display.

7. Valve Opening and closing time shall be recorded and cross checked with the data sheet.

Note: In case of valves with more than one solenoid, the test shall be repeated for each

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At field:

1. Reset the local push button at the field if required

2. Check the input and output pressure gauge indication

3. Verify the movement of the valve. No vibration and sticky points shall be noticed

Particular testing:

- Perform partial stroke test from AMS station if applicable and record the valve signature

- Pulse test will be performed during valve loop check if applicable.

Valve with accumulator:

4. Close the main air supply valve and check if the air pressure in the accumulator is still correct.

5. Purge the accumulator and check the safe position of the valve (mainly FC for ESDV valves)

6. At the end of the test open the main instrument air supply valve

7. When the loop check is completed, check sheet shall be signed off by the team

1.16.5 Blow Down Valves BDV double effect

Mostly same method as per ESDV valves except PST is not applicable for this valve and
safe position shall be most of the time mainly FO.
Also, 2 solenoids valves are operating the valve
Refer to [P4]

1.16.6 Blow Down Valves BDV spring return

Same method as per ESDV valves except safe position shall be most of the time FO
Refer to [P4]

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1.16.7 Blow Down Valves BDV hydraulic actuated spring return

Mostly same method as per ESDV valves except PST is not applicable for this valve and
safe position shall be most of the time FO.
Also, 2 solenoids valves are operating the valve
Refer to [P4]

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1.16.8 Motor Operated Valves

- Ensure loop testing prerequisites have been successfully done (refer to section 1.12)

- Ensure pre-loop test procedure has been fully completed and validated (refer to section
1.14)

At field

1. If possible, move manually the valve approximately to the middle position

2. Ensure that the MOV is powered up from Electrical substation.

3. Put dedicated bypass in the system to allow the open/close command

4. Local Operation: set the field control unit selector in “LOCAL” mode

5. Graphic display indication shall be “LOCAL”

6. In local send a pulse open command and check if the valve is opening

7. In local send a pulse close command and check if the valve is closing

8. Then put back the field control unit selector in “Remote mode”

In ITR

1. Check on the face plate the remote status

2. Send an open command and check the position of the valve on the graphic. Valve opening
movement shall stop when the limit switch open is reached or 100% open position.

3. Send a close command and check the position of the valve on the graphic. Valve closing
movement shall stop when the limit switch close is reached or 0% close position.

4. During the valve stroke, send a Stop command from the face plate. Valve shall stop .

5. Check at the field the valve local indications if they are consistent with the graphic display.

6. Positioner failure, mismatch alarms to be checked. This can be tested by forcing the limit switch
open when the valve is not fully open. Shall be the same test for limit switch close.

7. Finally, adjust the travel timer in the faceplate details according to the time stroke value

8. When the loop check is completed, check sheet shall be signed off by the team

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1.17 MOTOR LV/HV AND HEATER CONTROL LOOP TEST

Motor LV/HV and Heater control interface are mainly software datas exchange through a redundant
serial link ( Modbus TCP/IP).

DCS/ ECS Modbus serial link shall be tested individually prior to start the functional test. Dedicated B-
ITR will be used to validate this test

Only Trip signals coming from SIS/FGS to IRP are hardwired. Signal coming from SIS/FGS through
IRP panel shall be tested by forcing the SIS DO and verifying inside the electrical cubicle if the contact
is closed with no trip. Refer to [P9]

1.18 MOTOR VSDS WITH HARWIRED CONTROL LOOP TEST

For this type of control motors, several hardwired signals (refer to [P9]) shall be loop tested:

- Running Status (DI): To be checked by jumping the contact inside the electrical cubicle and
verify the signal on the face plate

- Available (DI): To be checked by jumping the contact inside the electrical cubicle and verify the
signal on the face plate

- Electrical protection trip (DI): To be checked by jumping the contact inside the electrical cubicle
and verify the correct signal on the face plate

- Speed indication (AI): To be checked by connecting a 4-20mA inside the electrical cubicle and
verify the signal on the face plate. (several points to be simulate)

- Current value (DI): To be checked by jumping the contact inside the electrical cubicle and verify
the correct signal on the face plate

- Start command (DO): Force a “Start command” from SIS, check if the dedicated relay is
activated inside IRP and if the dry contact inside the electrical cubicle is switching

- Stop command (DO): Force a “Stop command” from SIS, check if the dedicated relay is
activated inside IRP and if the dry contact inside the electrical cubicle is switching

- Speed control set point (AO): Open the motor face plate and simulate a speed control set point
value ( 0%, 50%, 100% of range) and verified inside the VSDS control cabinet the correct value

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1.19 OTHERS LOOP TEST FOR NON HART ANALOG OUPUT

- Ensure loop testing prerequisites have been successfully done (refer to section 1.12)

- Ensure pre-loop test procedure has been fully completed and validated (refer to section 1.14)

Local panel indicator:

1. Open the face plate

2. Perform 0%, 25%, 50%, 75%, 100% and back to 75%, 50%, 25%, 0%

3. Check on the indicator at field the correct value

Remote control set point:

1. Open the face plate

2. Perform 0%, 25%, 50%, 75%, 100% and back to 75%, 50%, 25%, 0%

3. Check on UCP control panel the correct value

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1.20 DISCRETE INPUT SIGNAL LOOP TEST

There are several types of discrete input signals.

Loop test method is summarized in the table below.

Table 3: Discrete Input Signals

Group Device Loop Test Method Remarks
Field Instrument 1) Pressure Switch 1) Jumper at Field
2) Level Switch Instrument Terminals.
5) Temperature Switch 2) For Flame Detector, a
/ Thermostat UV/IR lamp shall be used
6) Speed Switch
7) Flame Detector
8) Vibration Tx /
Switch

Accessories Limit Switch (on Valve, Limit Switch Signal shall be

Damper, Guide Valve) checked during dumper/valve
stroke Test.
Manual Switch 1) Hand switch Press actual manual switch.
2) Push Button

Signal from other 1) Status Input Simulate from other system or

System 2) Alarm Input jumper at other system
Fire & Gas 1) Manual Call Point Activate MCP.
NAMUR Devices 2) Smoke Detector Activate smoke/fire detector with
3) Fire Detector appropriate tool

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1.21 DISCRETE OUTPUT SIGNALS

There are several types of discrete output signals.

Loop test method is summarized in the table below.

Table 4: Discrete Output Signals

Group Device Loop Test Method Remarks
Digital Output 1) Solenoid Simulate by forcing signal from
2) Dry contact the system
3) Bulb light

Loop check for Solenoid:

Ensure loop testing prerequisites have been successfully done (refer to section 1.12)

Ensure pre-loop test procedure has been fully completed and validated (refer to section 1.14)

1. Open the face plate and force the DO signal in order to energize the solenoid
2. Check and measure at the field the voltage. The value shall be not less than 21V. ( to be
confirmed)
3. Remove the forcing on the DO faceplate
Loop check for Dry contact:
1. Open the face plate and force the DO signal in order to close the dry contact.
2. Check and measure at the field/UCP the voltage. The value shall be 0 volt.
3. Remove the forcing on the DO faceplate and check the voltage. The value shall be 24V
approx.

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1.22 FIRE AND GAS EQUIPMENT

General remarks for Gas/Fire Detection

a) For Fire/ Gas detectors, each loop needs to be checked and tested at site individually by
using the dedicated vendor procedure. (Refer to vendor calibration procedure [X])
b) Each device need to be simulated from field and alarm needs to be confirmed at FGS
operator station.
c) Only one type of test bottle will be used for each type of test gas detector (Methane,
Hydrogen, Oxygen)
d) If NAMUR devices have to be tested, check if the fault detection is enabled

1.22.1 Gas Detector

- IR Open path gas detector

- IR Point Flammable Gas detector

- H2 Catalytic point gas detector

- Electrochemical low O2 detector

1.22.2 Gas detector Loop test:

• IR Open path gas detector

Pre loop check:

- Vendor will perform initial setup under supervision of TJS organization.

- Make sure Transmitter and Receiver units are aligned accurately with a clear line of sight
between them.

- The alignment and initial setup of the detector should only be performed by personnel trained by
vendor.

- Refer to vendor calibration procedure [X]

1. Check physical location & device tag number according to layout drawing.

2. Check status, location & tag number on FGS layout graphic & faceplate

3. Open the loop, check bad PV alarm

4. Calibration check shall be done using test filter + beam block + dirty lens filter and SHC1
handheld interrogator. (to be confirmed by vendor)

5. Check alarm (tag and description) and animation on FGS graphic display.
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• IR Point Gas Detectors

1. After powered on, give at least 30 minutes to the gas detector to stabilize with site conditions
prior to perform any calibration.

2. Check physical location & tag number according to layout drawing.

3. Check state, location & tag number on FGS layout graphic & faceplate.

4. Check zero calibration on display with ambient air.

5. to be confirmed Inject test gas (50% LEL Methane in Air) with calibration cup, and check set
point of alarms at 10% LEL and 40%LEL.

6. Span calibration shall be verified at 50% LEL, acceptance criteria should be within 45% to 55%
and includes the response time T50% of <4.5 sec., T90% of < 6.5 sec.

7. Open the loop, check bad PV alarm

8. Check alarm (tag and description) and animation on FGS graphic display.

• Catalytic Point Gas Detector (Hydrogen)

1. Check physical location & tag number according to layout drawing.

2. Check state, location & tag number on FGS layout graphic & faceplate on FGS operation station.

3. After power on, give at least 30 minutes to the gas detector to stabilize with site conditions prior
to perform any calibration.

4. Check zero calibration on display with ambient air.

5. to be confirmed Inject test gas (50% LEL Hydrogen in Air) with calibration cup, and check alarms
set point (15% LEL and 25% LEL).

6. to be confirmed Span calibration shall be verified at 50% LEL, acceptance criteria should be
within 45% to 55% and also includes the response time T90% of <30 sec.

7. Open the loop, check bad PV alarm

8. Check alarm (tag and description) and animation on FGS graphic display.

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• Low Oxygen Detector

1. Check physical location & tag number according to layout drawing.

2. Check state, location & tag number on FGS layout graphic & faceplate on FGS operation station

3. After power on, give at least 30 minutes to the gas detector to stabilize with site conditions to
perform any calibration.

4. Perform span calibration with ambient air.(20.9% Oxygen)

5. Inject test gas (99.9% N2) with calibration cup, and check low alarm set point at 19.5% of
Oxygen.

6. Open the loop, check bad PV alarm

7. Check alarm (tag and description) and animation on FGS graphic display.

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• Addressable Smoke Detector

Pre loop check :

After power ON, vendor will perform initial setup & configuration for the Addressable Fire detection
system under supervision of TJS organization. Once initial setup & configuration by vendor is
complete, TJS will perform loop check.

Simulate fault and fire condition on each F&G device in an addressable loop from field and make
sure alarm is displayed at FGS Operator. Loop fault (IN/OUT) and device fault will be check as well
for each loop.

Loop check :

1. Check physical detector location & tag number according to layout drawing.

2. Check alarm (tag and description) and animation on FGS graphic display.

3. Apply testing smoke material to each smoke detector at site.

4. MOS for Inhibit and Disable to be check on each addressable detector.

5. Check LED status on detector change to alarm.

6. Check audio visual alarm at addressable fire panel.

• Addressable Heat Detector

1. Check physical detector location & tag number according to layout drawing.

2. Apply heat to each detector at site using approved heat source for the project.

3. Check alarm (tag and description) and animation on FGS graphic display.

4. Check LED status on detector change to alarm.

5. Check audio visual alarm at addressable fire panel.

• Manual Call Point (MCP)

1. Check physical location & tag number according to layout drawing.

2. Check state, location & tag number on FGS layout graphic & faceplate on FGS operation station.

3. Use test key and activate the MCP.

4. Check LED status on detector change to alarm.

5. Check alarm (tag number and description) and dynamic graphic on FGS layout graphic.

6. Check audio visual alarm at addressable fire panel.

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1.22.3 Non – addressable FGS detectors

• IR Flame Detector

1. Ensure that the detector is kept in clean condition without any dirt blocking the light path.

2. Check physical location & tag number according to layout drawing.

3. Check alarm (tag and description) and animation on FGS graphic display.

4. Flame detectors will be tested for optical integrity (oi) external test magnet / manual oi switch or
using IR test lamp.

• Optical Smoke Detector

1. After power ON, give 4 minutes for the start-up of detector.

2. Check physical location & tag number according to layout drawing.

3. Check state, location & tag number on FGS layout graphic & faceplate on FGS OWS

4. Apply smoke to the detector and check alarm is getting activated.

5. Check alarm (tag and description) and animation on FGS graphic display.

• Heat Detector

1. Check physical detector location & tag number according to layout drawing.

2. Check state, location & tag number on FGS layout graphic & faceplate on FGS OWS

3. Apply heat to each detector at site using approved heat source for the project.

4. Check alarm (tag and description) and animation on FGS graphic display.

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1.22.4 Other fire and GAS items

• Cryogenic Spill/leak Detector

Cold spill/leak detectors are used to detect the leaks and accumulation of cryogenic marerials.

Low temperature detectors technology is a RTD resistance temperature.

Each cold spill/leak detector is providing “low temperature” alarm with a threshold set a -29DegC

(Refer to FGS Software typicals documentation [P5])

1. Check physical detector location & tag number according to layout drawing.

2. Check state, location & tag number on FGS layout graphic & faceplate on FGS OWS

3. Simulate low temperature to each detector at site by using approved decade box

4. Check alarm (tag and description) and animation on FGS graphic display.

5. Check audio visual alarm at addressable fire panel.

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1.22.5 Gas tight and Fire Damper

1. Prior to testing the damper, FGS signal shall be sent to HVAC UCP to inform we are going to
start a damper test.

2. Disconnect air tubing from header and perform blowing, then reconnect

3. Check state, location & tag number on FGS layout graphic & faceplate on FGS OWS

4. Send an open command from FGS and check if the damper valve is opened, local open
indicator shall indicate the correct position and graphic display updated accordingly

5. Send a close command from FGS and check the damper closed position, local close indicator
shall indicate the correct position and graphic display updated accordingly

6. Check the damper in failure position and DI signals going to HMI or/and HVAC

7. Finally adjust the discrepancy timer between the operating command and the limit switches feed
back

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1.22.6 Manual Call Point (MCP)

1. Check physical location & tag number according to layout drawing.

2. Check state, location & tag number on FGS layout graphic & faceplate on FGS OWS

3. Use test key and activate the MCP.

4. Check LED status on detector change to alarm.

5. Check alarm (tag and description) and animation on FGS graphic display.

1.22.7 Deluge Valve

This test to be developed as per deluge valve skid functionality according to the vendor procedure
reference [18]

1. Check Fire Water and Foam Inlet valves are closed

2. Disconnect air tubing from header and perform blowing, then reconnect

3. Check state, location & tag number on FGS layout graphic & faceplate on FGS OWS

4. Check hand valves in correct position

5. Adjust PCV settings with pressure gauges

6. Check Outlet valves is closed

7. Check position of the valves.

8. Check animation on FGS graphic display

9. Perform Test Activation Command from FGS OWS

10. Close Foam Valve from FGS OWS

11. Perform Reset Released command, activate field reset of water drain valve, and finally check
the valve position.

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1.23 LOOP TEST ENDING

• Keep the live condition at field as a loop test completion and label to indicate the
loop completion
• Confirmed anomalies or deviations to be noted on Punch List.
• Discrepancies between device, software and document not solved during loop
testing to be noted in Punch list with actions to be carried out.
• All Punch list cleared or created must be handover to the Handover department
for EP updated
• The relevant master PID must be updated (red line) by Instrument and PAS
superintendent.
• (To be confirmed) After completed loop test, CHARM device shall be color
marked "white" using white vinyl adhesive tape and be kept plugged.
• (To be confirmed) Stickers on each instrument and junction box shall indicate that
component has been fully loop tested
• (To be confirmed) After completion of loop checks, simulation mode must be
“enable” for all instruments, moreover after functional test all instrumentation
must be set in simulation mode “disable”.
• After completion of the loop check, SHI Construction department shall be
informed of Loop completion and closure of associated CSU PTW is effective
• The relevant “B” check sheet B-ITR-06 shall be sign off by Emerson, TJS CSU
lead engineer and company responsible (optional).

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1.24 APPENDICES

Appendix-1 Instrument Tools for Loop Checks

Item Description (Instrumentation)
Multimeters: Fluke 175
Process calibrator Fluke 725
Loop calibrator : GE Sensing , UPS - II (4-20mA generator)
Loop calibrator : GE Sensing, TRS - II (Multi-fonction generator/measurement)
Radios
Current simulator
Bending tubings tools
Hand Tools (screw drivers)
Tool boxes
Calibrator Beamax
Vibration simulator : Bently Nevada, TK-3
Decade box
Movable ladder for instrument accessibility
Pressure generator : GE Sensing, DPI 610C (range: -850mbar to 20 bar)
Pressure generator : GE Sensing, DPI 610HC (range: 0 to 400 bar)
Cable Stripping Tool
Crimping Tool for cable AWG 12-20
Cage spring type terminals
Commissioning barrier tape
Item Description (F&G)
Hidrogen Gas bottles (LEL)
Methane Gas bottles (LEL)
Telescopy to test the gas detectors in high position
NFD UV/IR Test lamp (TL103-UVIR)
NTDHR Heat tester
NFD Charger for TL104 (940-021)
GDIR Gas flow chamber for IR2100 (TGK_IR2100)
GDIR&GDC Regulator for gas cylinder (DET715)
NSD Smoke tester (STA)
NFDV Torch test kit for CCTV (IR-FSTT)
NSD Probe for smoke tester (P_STA)

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Appendix-2 ITR-B-I06 check sheet

(under construction/finalization) HOLD

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