6303A HP Flare Drain Drum

1
TUNU FIELD
DEVELOPMENT PROJECT
PHASE 8
HP FLARE DRAIN DRUM & PUMPS

OPERATIONAL TEST PROCEDURE 6303A
SUB-SYSTEM 6303
00 16/10/02 D.PLATTS For comment
REV DATE ORIGINATOR DESCRIPTION APPROVED

CHECKED BY CSL
. BY START-UP
TOTAL OR PARTIAL REPRODUCTION AND/OR UTILISATION OF THIS DOCUMENT ARE

FORBIDDEN WITHOUT PRIOR WRITTEN AUTHORIZATION OF THE COMPANY
TOTALFINAELF E&P INDONESIE
COMMISSIONING
DOCUMENT NUMBER REVISION
NCP
COM OTP 6303 ? 00 PAGE : 1 OF 16
offsites
/conversion/tmp/activity_task_scratch/637390707.doc
TOTALFINAELF OPERATIONAL TEST PROCEDURE TUNU 8
DESCR: HP FLARE DRAIN
SUB-SYS: 6303 LOCATION : OFFSITES PAGE :2 OF 16
DRUM
DATE NAME AND
STEP TASK DESCRIPTION COMPLETED SIGNATURE
SUMMARY
The HP FLARE DRAIN Drum and Pumps are designed to collect
any liquid hydrocarbons that are entrained with the vented gases to the
HP Flare Network.
Any entrained liquids in this stream will drop out into the HP Flare
Drain Drum 2-V-2680
The liquids collected in the drum are pumped out using the Pumps 5-
P-4980 A & B to the NCP closed drain network or to NCP LP HC
Break Drum and from there are re-injected back into the process
stream.
Each pump has a working discharge pressure of 1.8 Barg and a flow
rate of 5 M3/H
LT 2608 and Pumps are configured as

700mm LAH starts stand-by pump
650mm starts duty pump
300mm stops duty pump
250mm stops stand-by pump pump
ON LL Level LT-2610 gives LALL-2610 and stops both pumps
RO-4980 is designed so as to achieve a minimum continuous flow of

1.9 M3/h
See attached P & ID: NCP-12-2-008-C Rev L

NCP-12-3-013
Note: as the pumps are tested with water at 1.0 density, the amps
reading might be higher.
DRUM
DATE NAME AND
1 TEST SUMMARY
1.1 AIMS OF OPERATIONAL TEST
Prove the performance of the Drain Drum 2-V-2680 & Pumps 5-P-4980A / B.
Demonstration of start / stop logic and Controls.
1.2 TEST DESCRIPTION
To check the equipment has been correctly installed and prepared for
commissioning in accordance with the vendors’ instruction.
Prepare the test for checking function of the pumps and level switches
1.3 TEMPORARY INSTALLATIONS
Potable water supply and fittings
1.4 SPECIAL PRECAUTIONS
Refer to Safe Operating Procedures.

Check that the Permit for the work is in force.
Check that all warning / precaution signs are in place.
Check that all non-essential personnel have been cleared from the area.
Ask the Control Room for a PA announcement to be made.
DRUM
DATE NAME AND
2 PLANNING AND MANPOWER
2.1 PLANNING TASKS
Complete the OTP test in one (1) day
2.2 MANPOWER ESTIMATE
Mechanical 1
Electrical 1
Instruments 1
Start-up 1
2.3 TEST DURATION ESTIMATE
1 day
2.4 POSITION IN COMMISSIONNIG SEQUENCE
After RFC is signed
2.5 VENDOR ASSISTANCE
None
DRUM
DATE NAME AND
3 TEST REQUIREMENTS
3.1 PRECOMMISSIONING ACHIEVEMENTS
Verify that the Pre-Commissioning Dossier is completed.

RFC is signed.
No Level A Punch list items are pending.
Preliminary check by disciplines to verify the package for completeness in
accordance with the latest drawings and revisions. This includes relevant
specifications and P&ID’s.
Produce a punch list as applicable
E&I function tests are complete.
Hydro-test is completed and that all spades are removed
3.2 COMMISSIONING ACHIEVEMENTS
Verify that the Commissioning Dossier is completed.

RFC is signed.
No Level A Punch list items are pending.
OTP agreed upon and signed
3.3 STATUS OF OTHER SUBSYSTEMS
7403 Process Control System

7401 Emergency Shutdown System
7305 Normal Power Distribution for 440V System
3.4 SPECIAL TOOL AND TEST EQUIPMENT
None
3.5 CONSUMABLES
Potable water
3.6 SPARES
As per commissioning spares list
DRUM
DATE NAME AND
3.7 SAFETY
Refer to Safe Operating Procedures.

Check that the Permit for the work is in force.
Check that all warning / precaution signs are in place.
Check that all non-essential personnel have been cleared from the area.
3.8 UTILITIES
Potable water
DRUM
DATE NAME AND
4 TEST PREPARATION
4.1 BLIND LIST
None
4.2 JUMPERS LIST
None
4.3 MECHANICAL PREPARATION TASKS
To ensure pumps are ready for the OTP and to provide assistance with
the test
DRUM
DATE NAME AND
5 START-UP, TUNING
5.1 START-UP STEP-BY-STEP PROCEDURE
1. Obtain Permit-to-Work.
2. Check that thedrain Drum Pump Motors 5-PM-4980 A & B are isolated at
the MCC. If not get the electrical engineer to isolate them both.
3. Inspect both pumps, and pipe-work for damaged items that will prevent
the Operational Test.
4. Check that all blind / spades have been removed or turned to be in the
correct operating position. This includes the pump suction and discharge
lines and all branches (after the hydro test).
5. Check that the both pumps outlet NRV are installed the correct way round.
6. Open up both pumps inlet strainer and check it is not blocked. Re-install
the strainer into the filter body and close the flange.
7. Open the following instrumentation isolating valves

 LT-2680
 LG-2609
 LT-2610
 PG-2680
 PG-4980A/B
 PT-4130
 Ensure HS-235 is set to position 2
 Open XV-4980 A & B
 Ensure PV-4130 set point is at 1.5 Barg
 Ensure 3” B/V to NCP closed drain network is closed
 Ensure 3 “ B/V to LP HC break Drum 2-V-3130 is clo
8. Open the inlet valve on each
9. Fill the Drum until water is seen in the local Gauge Glass (LG2609) and
LAL alarm is clear.
10. Open Pumps suction valves and let the water flow into both pump casings.
11. Vent the air from both Pumps,
DRUM
DATE NAME AND
12. Ensure there is no air left in the pump casings by opening the N2
connection valves (3 / 4 “)
13. Open the 2 X 2” minimum flow ball valves, ensur RO-4980 is installed
DRUM
DATE NAME AND
Level Transmitters function checks – Pumps not running:

1. Inform control room of intention to check the Drain Drum level transmitter and run
the Pumps on recycle back to the drum.
2. Push in both LOCAL Stop Buttons – PB –
3. De-isolate the Drain Drum Pump Motors A & B at the MCC. electrical engineer to
do this.
4. Check that the Pump Fault alarms are seen in the

PCS.
5. Select both Pumps to LOCAL control via HS – and HS

Check that PCS indication is LOCAL for XL- and XL-
6. The Drum should presently have a water level in the sight glass. If not, slowly start
filling Drum with water via the temporary water supply hose until water is seen in
the local gauge glass LG2609 and the LAL alarm is clear. Stop filling water and
measure (with tape measure) the level on the local gauge glass. Reading should be
250 mm. Actual reading: ________ MM.
Record discrepancy in the levels set point
7. Continue to fill the Drain Drum until the Leve LAH has been activated. Stop
filling and measure (with tape measure) the level on the local gauge glass. Reading
should be 700 mm. Actual reading: ________ MM.
8. Continue to fill the Drain Drum until the Leve LAHH has been activated. Stop
filling and measure (with tape measure) the level on the local gauge glass. Reading
should be 800 mm. Actual reading: ________ MM.
9.
10. When filling Drum with water via the temporary water supply hose and check the
function of the level indication on the PCS during filling.
When Local reading is at 25% PCS Reading =_____________ %

When Local reading is at 100% PCS Reading =_____
11. Continue to drain the water from the Drum via the 2” drain until the Low Low
Level alarm of LT-2610 activates ESD 3.53 Close the drain valves and measure
(with tape measure) the level on the local gauge glass. Reading should be 150 mm.
Actual reading ____MM
DRUM
DATE NAME AND
Pump A – Manual Control
14. Refill the drum until LAL is clear +150mm increase level to (400 mm)
15. Check both LOCAL Stop Buttons for pumps are still pushed in.
16. Select Pump A to LOCAL control via HS- and select Pump B to
REMOTE control HS at the pumps. Check that PCS indication is
correct
17. On PCS select Pump B to Duty (HS- Stop button still pushed i
18. Check that Pump A cannot be started from the PCS in LOCAL or
REMOTE modes using PB- on the PCS and locally by START
button PB-
19. Reset the Local Stop button PB Check that the Common Fault XA
is cleared on the PCS.
20. With Pump A control set to LOCAL on the PCS start the pump from the
local PB- Check that pump starts OK.
21. Check that RUN indication XL- is shown on the PCS.
22. Check the Pump A condition for a few minutes. Ensure the water is now
pumping in closed loop back to the drum.
23. Stop Pump A using the local Stop Push Button PB- . When Pump
has stopped reset the STOP push button. Check that PCS indication is
STOP for XL-
24. Select REMOTE mode for the pump A via HS Check that PCS
indication is REMOTE for XL
25. Restart the Pump A from the PCS START PB- Check that the Pump
starts.
26. Stop Pump A from the PCS STOP PB- . Check that the Pump stops.
DRUM
DATE NAME AND
Pump A - Auto Control (Duty Mode)
27. Select Pump A to Duty HS and Auto HS on PCS.
28. Select Pump A to REMOTE control via HS-

Note: The Pump A should now be running in Remote Automatic Mode.
29. Continue to run Pump A,simulate Low Level Alarm LT4615 and confirm
that the pump has stopped. (300mm)
Pump A - Auto Control (Standby Mode)
30. Select Pump A to STANDBY HS- on PCS.
31. Simulate ON at 650mm and observe pump starts
32. Check when Pump A starts 650 mm The gauge glass level actual reading:
______ MM
33. Check when the Pump A. stops 300 mm The gauge glass level actual
reading: ______ MM
34. Stop Pump A from PCS.
DRUM
DATE NAME AND
Pump A – Flow test To BE COMPLETED IF POSSIBLE
35. Electrically Isolate Pump A.
36. Install a temporary 3” fitting with hose to the Pump A discharge from the
pump. The discharge hose should discharge into the river. Tie down hose to
prevent moving.
37. De-isolate the Pump A.
38. Set the control to LOCAL in field and on the PCS.
39. Restart the Pump A
As the Pump is set on LOCAL operation make sure the pump is not allowed
to run dry. The system may have to be topped up with water again if the test
is not completed on the first run.
NB: To calculate the pump flow rate the flow of water must be directed
from the Drum, via the Pump A, directly into the river. Record the time it
takes for the pump to reduce the water level in the Drum from 50 % to Low
Level Alarm.
Design = 5.5 M3/hr . Working Flow Rate = 5 M3/Hr.
This volume is calculated at ****** M3.
Calculation of Flow rate = 83 Lt/Min
Actual Time Taken: __________Minutes.
Actual Flow rate = ________ M3 / Hr
40. Remove the temporary 3” fitting with hose from Pump A discharge line and
reconnect the valve and flanges.
DRUM
DATE NAME AND
Pump B – Manual Control
41. Refill the drum until LAL is clear +250mm
42. Check both LOCAL Stop Button for pumps are still pushed in.
43. Select Pump B to LOCAL control via HS- and select Pump A to
REMOTE control HS- at the pumps. Check that PCS indication is
correct
44. On PCS select Pump A to Duty (HS- . Stop button still pushed in
45. Check that Pump B cannot be started from the PCS in LOCAL or
REMOTE modes using PB- on the PCS and locally by START
button PB-
46. Reset the Local Stop button PB- Check that the Common Fault XA-
is cleared on the PCS.
47. With Pump B control set to LOCAL on the PCS start the pump from the
local PB- . Check that pump starts OK.
48. Check that RUN indication XL- is shown on the PCS.
49. Check the Pump B condition for a few minutes. Ensure the water is now
pumping in closed loop back to the drum.
50. Stop Pump B using the local Stop Push Button PB- When Pump has
stopped reset the STOP push button. Check that PCS indication is STOP
for XL-
51. Select REMOTE mode for the pump B via HS- Check that PCS
indication is REMOTE for XL-
52. Restart the Pump B from the PCS START PB- Check that the
Pump starts.
53. Stop Pump B from the PCS STOP PB- Check that the Pump stops.
Pump A - Auto Control (Duty Mode)
54. Select Pump B to Duty HS- and Auto HS- on PCS.
55. Select Pump B to REMOTE control via HS-

Note: The Pump B should now be running in Remote Automatic Mode.
56. Continue to run Pump B,simulate Low Level Alarm LT2608 and confirm
that the pump has stopped. 300mm
DRUM
DATE NAME AND
Pump B - Auto Control (Standby Mode)
57. Select Pump B to STANDBY HS- on PCS.
58. Simulate LAH 700mm and observe pump starts
59. Check when Pump B starts 700mm mm The gauge glass level actual
reading: ______ MM
60. Check when the Pump B. stops LAL 250mm The gauge glass level
actual reading: ______ MM
61. Stop Pump B from PCS
62. Pump B – Flow test
63. Electrically Isolate Pump B.
64. Install a temporary 3” fitting with hose to the Pump B discharge from the
pump. The discharge hose should discharge into the river. Tie down hose to
prevent moving.
65. De-isolate the Pump B
66. Set the control to LOCAL in field and on the PCS.
67. Restart the Pump B
As the Pump is set on LOCAL operation make sure the pump is not allowed
to run dry. The system may have to be topped up with water again if the test
is not completed on the first run.
NB: To calculate the pump flow rate the flow of water must be directed
from the Drum, via the Pump B, directly into the river. Record the time it
takes for the pump to reduce the water level in the Drum from 50 % to Low
Level Alarm.
Design = 5.5 M3/hr . Working Flow Rate = 5 M3/Hr.
This volume is calculated at ****** M3.
Calculation of Flow rate = 83 Lt/Min
Actual Time Taken: __________Minutes.
Actual Flow rate = ________ M3 / Hr
68. Remove the temporary 3” fitting with hose from Pump B discharge line and
reconnect the valve and flanges.
DRUM
DATE NAME AND
Pump A & B – Electrical Fault test
69. Check that LOCAL STOP buttons are reset. PB-
70. Select Pump A to DUTY HS on PCS.
71. Select Pump A & B to REMOTE control via HS-
Note: The Pump A should now be running in Remote Automatic Mode with
Pump B stopped.
72. Simulate an Electrical Fault (over current) on Pump A. The STANDBY

Pump B will start when Pump A stops. Confirm that this happens.
73. Check that the Common Fault XA- alarm activates on the PCS.
74. Check that Pump A cannot be restarted from PCS or Locally.
75. Remove simulated Electrical Fault from Pump A.
76. Select Pump B to DUTY HS on PCS.
77. Check Pump A & B are in REMOTE control
Note: The Pump B should now be running in Remote Automatic Mode with
Pump A stopped.
78. Simulate an Electrical Fault (over current) on Pump B. The STANDBY

Pump A will start when Pump B stops. Confirm that this happens.
79. Check that the Common Fault XA- alarm activates on the PCS and
that Available tag XL- is seen as not available on the PCS.
80. Check that Pump B cannot be restarted from PCS or Locally.
81. Remove simulated Electrical Fault from Pump B.
Electrical Fault Test is now completed.

82. Once satisfied with the test results return the system to Normal Operation
with both pumps stopped in REMOTE and all valves in the correct operating
position as per the P&ID.
83. Tidy the site.
84. Cancel the Permit-to-Work.
THIS OTP FOR PUMPs 5-P 4980A & B IS NOW COMPLETE

6303A HP Flare Drain Drum

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1

HP FLARE DRAIN DRUM & PUMPS

00 16/10/02 D.PLATTS For comment

REV DATE ORIGINATOR DESCRIPTION APPROVED

TOTAL OR PARTIAL REPRODUCTION AND/OR UTILISATION OF THIS DOCUMENT ARE

TOTALFINAELF E&P INDONESIE

LT 2608 and Pumps are configured as

ON LL Level LT-2610 gives LALL-2610 and stops both pumps

RO-4980 is designed so as to achieve a minimum continuous flow of

See attached P & ID: NCP-12-2-008-C Rev L

1.1 AIMS OF OPERATIONAL TEST

1.2 TEST DESCRIPTION

1.3 TEMPORARY INSTALLATIONS

Potable water supply and fittings

1.4 SPECIAL PRECAUTIONS

Refer to Safe Operating Procedures.

2 PLANNING AND MANPOWER

2.1 PLANNING TASKS

Complete the OTP test in one (1) day

2.2 MANPOWER ESTIMATE

2.3 TEST DURATION ESTIMATE

2.4 POSITION IN COMMISSIONNIG SEQUENCE

After RFC is signed

2.5 VENDOR ASSISTANCE

3.1 PRECOMMISSIONING ACHIEVEMENTS

Verify that the Pre-Commissioning Dossier is completed.

3.2 COMMISSIONING ACHIEVEMENTS

Verify that the Commissioning Dossier is completed.

3.3 STATUS OF OTHER SUBSYSTEMS

7403 Process Control System

3.4 SPECIAL TOOL AND TEST EQUIPMENT

As per commissioning spares list

Refer to Safe Operating Procedures.

4.1 BLIND LIST

4.2 JUMPERS LIST

4.3 MECHANICAL PREPARATION TASKS

5.1 START-UP STEP-BY-STEP PROCEDURE

7. Open the following instrumentation isolating valves

 Ensure HS-235 is set to position 2

 Open XV-4980 A & B

 Ensure PV-4130 set point is at 1.5 Barg

 Ensure 3” B/V to NCP closed drain network is closed

 Ensure 3 “ B/V to LP HC break Drum 2-V-3130 is clo

8. Open the inlet valve on each

11. Vent the air from both Pumps,

Level Transmitters function checks – Pumps not running:

2. Push in both LOCAL Stop Buttons – PB –

4. Check that the Pump Fault alarms are seen in the

5. Select both Pumps to LOCAL control via HS – and HS

When Local reading is at 25% PCS Reading =_____________ %

Pump A – Manual Control

21. Check that RUN indication XL- is shown on the PCS.

27. Select Pump A to Duty HS and Auto HS on PCS.

28. Select Pump A to REMOTE control via HS-

Pump A - Auto Control (Standby Mode)

30. Select Pump A to STANDBY HS- on PCS.

31. Simulate ON at 650mm and observe pump starts

34. Stop Pump A from PCS.

Pump A – Flow test To BE COMPLETED IF POSSIBLE

35. Electrically Isolate Pump A.

37. De-isolate the Pump A.

38. Set the control to LOCAL in field and on the PCS.

39. Restart the Pump A