ID-TUN-NG-SME-010302 Rev C - FINAL - Approved PJT

Document Number
COMMISSIONING – OPERATIONAL TEST PROCEDURE

ID-TUN-NG-SME-010302
NCP2 TECHNICAL BUILDING
INERGEN SYSTEM Revision : C Doc. Class :
Status : AFC Date : 14 Mar 2009
Document type: PRC System/Subsystem : 20202 Discipline : HSE Page 2 of 13
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This document is the property of COMPANY. It must not be stored, reproduced or disclosed to others without authorization from the COMPANY.
Document number
COMMISSIONING – OPERATIONAL TEST PROCEDURE ID-TUN-NG-SME-010302
Revision : C Doc. Class :
INERGEN SYSTEM
Document type: PRC System/Subsystem : 20202 Discipline: HSE Page 3 of 13
TABLE OF CONTENTS
page
1 TEST SUMMARY 4
1.1 Subsystem Description 4
1.2 Aims of Operational Test 4
1.3 Test Description 4
2 PLANNING AND MAN POWER 5

2.1 Test Duration/Planning 5
2.2 Manpower Estimation 5
2.3 Vendor Assistance 5
3 TEST REQUIREMENT 5
3.1 Pre Commissioning Status 5
3.2 Commissioning Status 5
3.3 Status of Other Subsystems 5
3.4 Special Tools and Test Equipment 6
3.5 Consumables 6
3.6 Commissioning Spare parts 6
3.7 Safety 6
4 TEST PREPARATION 7
4.1 General 7
4.2 ESD 7
4.3 Instruments 7
4.4 HVAC 7
4.5 Reference Documents 7
5 OPERATIONAL TEST PROCEDURE 8

5.1 Step by Step Preparation Procedure 8
5.2 Step by Step Test Procedure 9
5.2.1 Logic tests 9
5.2.2 Blank discharges 12
6 POST TEST CONDITION 13

6.1 Reinstatement 13
6.2 OTP Sign-OFF and Acceptance 13
6.3 Comments and Remarks 13
7 APPENDIX 13
7.1. Appendix 1 – Inhibit list
7.2. Appendix 2 – Process line-up drawing
This document is the property

3 of COMPANY.
It must not be stored, reproduced or disclosed to others without written authorization from COMPANY.
Document number
INERGEN SYSTEM
1. TEST SUMMARY
1.1. Sub-system Description
The system consist of 200 barg Inergen cylinders, 80 liters capacity, 24 numbers
each in Main & Reserve banks. Releasing facilities (Solenoids to allow remote
actuation and mechanical manual releasing knobs). Piping & Nozzles. Five
control & status panels (one located outside the main entrance and emergency
exit(s) of each floor).
1.2. Aims of Operational Test
This Discharge Test Procedure covers the following main activities:

Operation of all mechanical, pneumatic and electrical devices
This procedure do not cover ESD or F&G systems (which have been
demonstrated before)
1.3 Test Description
Test will be conducted in two parts:

• Logic tests without discharge, to confirm control panels operation, sounder alarms and
annunciation timer and SOV operation
• Two blank discharges (one for each floor) using only one bottle instead of the complete
Inergen bank to confirm pilots and valves are operating properly, nozzles are not
plugged, HVAC shutdown and dampers operation.

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INERGEN SYSTEM
2. PLANNING AND MANPOWER
2.1. Test Duration/Planning
Preparation and test : 2 day
2.2. Manpower Estimation
• Instrument : 1 spdt + 1 tech
• System : 1spdt
• Fireman/Safety : 3 (people comfortable with Breathing Apparatus and O2 analysers)
• Helper : 2 (to install/remove bottle)
2.3. Vendor Assistance
Not required
3. TEST REQUIREMENTS
3.1. Pre-commissioning Status
• Verify that the Pre-Commissioning dossier is completed.

• RFC or partial RFC is signed.
• No Level A Punch list items are pending.
3.2. Commissioning Status
• Verify that the Commissioning Dossier is completed (except section related with OTP).
• OTP is approved by Commissioning Team and Field Operation.
3.3. Status of Other SubSystem
• 26102 Normal power distribution

• 20502 Emergency power distribution
• 20401 Process Control System (PCS)
• 20301 ESD and F&G
• 20901 HVAC
• 28301 Technical Building

5 of COMPANY.
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INERGEN SYSTEM
3.4. Special Tools and Test Equipment
• Hand tool set / toolbox

• Communication means, hand held radio
• Vacuum sucker to remove floor ceiling
• Special vendor tools (if any)
3.5. Consumables
• Two N2 cartridge pilot gas LT30

• Tape, Tie wrap or elastic bands, paper or plastic bags to cover each nozzle
• Two additional 200 barg INERGEN cylinders (may be taken from reserve bank)
• Paper mask (dust protection)
3.6. Commissioning Spare Parts
• None
3.7. Safety
• Ensure that work permit have been signed

• Ensure there is no work interferences with other job/system
• Ensure that all person involved in the test are familiar with equipment
• Conduct the tool box meeting before performing the OTP
• Ensure that safety barrier are installed and warning sign posted
• Ensure that all people wear adequate PPE
• Ensure the communication means are operational
• Ensure persons who are not involved in the test are cleared from test area
• Ensure the technical building is evacuated and all entries are controlled
4. TEST PREPARATION
4.1. General
• Permit to Work form and associated documents to be submitted before performing

OTP.
• Ensure the air tightness of technical building is satisfactory (all MCT installed, door
adjusted), all cubicles are closed and false floors ceiling is complete
• As OTP will initiate audible and visual alarms, make sure a PA announcement is done
to inform personnel to disregard alarms activated during the test
4.2. ESD
• As the release will activate, at least, ESD1.1.1 &1.2, ensure all unexpected actions
have been inhibited and all inhibits are recorded.

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INERGEN SYSTEM
4.3. Instruments
• Ensure all instruments are in line

• Ensure N2 pilot is at the right pressure
4.4. HVAC
• Ensure HVAC in normal operation and all dampers operable
4.5. Reference Documents (in latest revision)
• ID-TUN-NC-SME-997013 Piping and Instruments diagram
• ID-TUN-NC-SME-997016 System operation philosophy
• ID-TUN-NC-SME-997019 System control and schematic
• ID-TUN-NC-SME-997021 Causes & Effects chart
• Vendor operating & maintenance manual

7 of COMPANY.
Document number
INERGEN SYSTEM
5. OPERATIONAL TEST PROCEDURE
DATE NAME AND

STEP TASK DESCRIPTION COMPLETED SIGNATURE
5.1 Step by Step Preparation
General
Permit to Work form and associated documents to be

submitted before performing OTP.
Make sure during tool box meeting everyone is well

aware of his role in the operations
INERGEN system
1. Ensure MAIN and RESERVE cylinders are isolated.
2. Ensure “Master” cylinders for blank test are installed in

MAIN and RESERVE banks
3. Isolate the N2 pilot gas to the MAIN and RESERVE

Inergen racks by closing the manual isolation valves.
4. Cover each nozzle with the paper or plastic bag.
ESD / F&G systems
5. Ensure any consequences/actions to others systems

related to ESD1.1.1 and ESD1.2 are inhibited and
inhibits are recorded
6. Install inhibits to prevent HVAC shutdown and dampers

closing (HVAC will be kept running until the blank
discharge test) and record in inhibit list
7. Ensure any I/O from/to Local control panels (12-2-LCP-

01 & 02), Local status panel (12-2-LSP-01, 02 &03),
Pre-discharge sounders & beacon lights (12-XA-222161
A to F, 12-XA-222261A/B & E/F) and from/to Inergen
system (12-SOV-222060A & B, 12-SOV-222161 &
222261, 12-ZSC-222161 & 222261 and 12-PIT-222161
& 222261) are available (knifes closed and no jumpers
nor inhibits installed)

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Document number
INERGEN SYSTEM
5.2 Step by step test procedure
During this test, all manual release, auto/inhibit

commands, pre-discharge alarm and discharge SOV will
be checked.
5.2.1 LOGIC TESTS
12-2-LCP-01 (1st floor, Main entrance LCP), 12-2-LSP-

01 & 02 (1st floor emergency exits)
1. Check all lamps are working using 12-HS-222162 lamp

test push button at LCP and 12-HS-222163 & 64 at LSP
2. Confirm “AUTO” (Amber) is displayed at LCP01, LSP-

01 & 02 and “ACTIVE” on the F&G Matrix Panel in NCR.
3. Confirm 12-HS-222162B, 12-HS-222163B and 12-HS-

222164B manual release push buttons at LCP & LSP do
not operate
4. Switch 12-HS-222162A to “Inhibit mode” and confirm

“INHIBIT” (Green) is displayed at LCP01, LSP01 & 02
and F&G Matrix in NCR.
5. Activate the manual release 12-HS-222162B push

button from LCP-01 and confirm:
Visible and audible 30 seconds pre discharge alarm is

initiated:
-1 beacon light and 1 sounder inside battery room and
inside ETR
-1 beacon light and 1 sounder outside main ETR access
After 30 sec. time delay elapsed:

-“MAIN BANK TO 1st FLOOR” 12-SOV-222161A is
energized. (make sure other SOV are not activated)
-“ACTIVATED” (Red) lamps are blinking at LCP and
LSP
- “RELEASED” (Red) lamps lit after SOV being
activated (to get the release confirmed, system may
require 12-PIT-222161 high pressure simulation)
- Selector valve to ETR, 12-SV-222161 is open
After 60 sec:
-“ACTIVED” (Red) lamps steady at LCP and LSP
6. Reset and repeat activation from LSP-01 (12-HS-

222163B)

9 of COMPANY.
Document number
INERGEN SYSTEM

222164B)
8. Reset, Switch 12-HS-222060 To “RESERVE”, activate

a manual release from either LCS or LCP and confirm
“RESERVE BANK TO 1st FLOOR” 12-SOV-222161B is
activated instead of “MAIN” SOV
9. Reset, Switch ETR system to “AUTO mode” at LCS-01,

initiate ETR discharge from ESD system (manual
remote) and confirm “RESERVE BANK TO 1st FLOOR”
SOV is activated.
12-2-LCP-02 (2nd floor, Main entrance LCP), 12-2-

LSP-03 (2nd floor emergency exit)
10. Check all lamps are working using 12-HS-222262 lamp

test push button at LCP and 12-HS-222263 at LSP
11. Confirm “AUTO” (Amber) is displayed at LCP-02, LSP-

03 and “ACTIVE” on the F&G Matrix Panel in NCR.
12. Confirm 12-HS-222262B, 12-HS-222263B manual

release push buttons at LCP & LSP do not operate
13. Switch 12-HS-222262A to “Inhibit mode” and confirm

“INHIBIT” (Green) is displayed at LCP-02, LSP-03 and
F&G Matrix in NCR.
14. Confirm manual release 12-HS-222262B push button

operate from LCP-02:
Visible and audible 30 seconds pre discharge alarm is

initiated:
-1 beacon light and 1 sounder inside ITTR
-1 beacon light and 1 sounder outside each ITTR
access
After 30 sec. time delay elapsed:

-“RESERVE BANK TO 2nd FLOOR” 12-SOV-222261B is
energized. (make sure other SOV are not activated).
-“ACTIVATED” (Red) lamps are blinking at LCP and
LSP
-“RELEASED” (Red) lamps lit after SOV being activated
(to get the release confirmed, system may require 12-
PIT-222261 pressure simulation)
- Selector valve to ITR, 12-SV-222261 is open
After 60 sec. :
-“ACTIVED” (Red) lamps are steady at LCP and LSP
This document is the10property of COMPANY.

Document number
INERGEN SYSTEM

222263B)
16. Reset, Switch 12-HS-222060 To “MAIN”, activate a

manual release from either LCS or LCP and confirm
“MAIN BANK TO 2nd FLOOR” 12-SOV-222261A is
activated
17. Reset, switch ITTR system to “AUTO mode” at LCS-03,

initiate ITTR discharge from ESD system (manual
remote) and confirm “MAIN BANK TO 2nd FLOOR” SOV
is activated
Activation from F&G Matrix Panel (NCR)
18. From the F&G Matrix in NCR, switch HS-222160 to the

ALARM position and confirm proper visual and audible
alarm in the ETR.

RELEASE position and confirm:
-“MAIN BANK TO 1st FLOOR” 12-SOV-222161A is

- Selector valve to ETR, 12-SV-222161 is open
After 60 sec. :
-“ACTIVED” (Red) lamps are steady on the F&G Matrix
in NCR
20. From the F&G Matrix in NCR, switch HS-222260C to

the Alarm position and confirm proper visual and audible
alarm in the ITTR.

RELEASE position and confirm:
-“MAIN BANK TO 2nd FLOOR” 12-SOV-222261A is

- Selector valve to ITTR, 12-SV-222261 is open
After 60 sec. :
-“ACTIVED” (Red) lamps are steady on the F&G Matrix
in NCR

Document number
INERGEN SYSTEM
5.2.2 BLANK DISCHARGE TESTS
Before starting blank discharge tests, make sure all inhibits

related to HVAC, as per inhibit list, have been removed and
technical building is cleared from non-involved people.
22. De-isolate the N2 pilot gas to the MAIN and RESERVE

Inergen racks by opening the manual isolation valves.
23. Make sure test cylinders, one on each bank are in place
and ready for activation and ensure that the remaining
cylinders are disconnected.
24. Ensure 12-HS-222060 is selected to “MAIN” bank.
25. Initiate a remote ETR discharge from ESD system and

confirm pre-alarms operate, “ACTIVATED” lamps are
blinking at LCP-01, LSP-02 & 03, HVAC is shutting
down and fire & isolation damper close. Discharge
occurs 30 seconds after being initiated. “RELEASED”
lamps lit steady after the release at LCP & LSP.
Pressure operated siren sounds (observer(s) left in ETR
to ware ear protection plugs as well as goggle and
paper mask as dust may be released during the
discharge). Confirm no release occurred in ITTR
26. After discharge completed, visually inspect each nozzle

and confirm protective bags have been blown
27. Reset, Normalize (restart HVAC) and switch 12-HS-

222060 to “RESERVE” bank
28. Initiate an ITTR discharge from ESD or locally from

LCP-02 or LSP-03 (in this case switch to “INHIBIT
mode” first) and confirm pre-alarms operates, ,
“ACTIVATED” lamps are blinking at LCP-02, LSP-03,
HVAC is shutting down and fire & isolation damper
close. Discharge occurs 30 seconds after being
initiated. “RELEASED” lamps lit steady after the release
at LCP & LSP. Pressure operated siren sounds
(observer(s) left in ITTR to ware ear protection plugs as
well as goggle and paper mask as dust may be released
during the discharge). Confirm no release occurred in
ETR
29. Reset, Normalize and switch 12-HS-222060 To “MAIN”

bank
30. remove the remains of paper bags around the nozzles

Document number
INERGEN SYSTEM
6. POST TEST CONDITIONS
6.1 Reinstatement
1. Remove all jumpers or inhibitions used for the test
2. Set the INERGEN system into operation as required by

FO.
3. Dismantle empty bottles and send them to refill
4. Replace or refill N2 pilot gas bottles
5. Tidy the site
6.2 OTP Sign-Off and Acceptance
6.3 Remarks and Comments
7. APPENDIX
7.1 Appendix 1 – Inhibit list

7.2 Appendix 2 – Process line-up diagram (ID-TUN-NC-SME-
997013)


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Document Number

COMMISSIONING – OPERATIONAL TEST PROCEDURE

Status : AFC Date : 14 Mar 2009

Document type: PRC System/Subsystem : 20202 Discipline : HSE Page 2 of 13

TABULATION OF REVISED PAGES

Document type: PRC System/Subsystem : 20202 Discipline: HSE Page 3 of 13

2 PLANNING AND MAN POWER 5

5 OPERATIONAL TEST PROCEDURE 8

6 POST TEST CONDITION 13

This document is the property

Document type: PRC System/Subsystem : 20202 Discipline: HSE Page 4 of 13

1.1. Sub-system Description

1.2. Aims of Operational Test

This Discharge Test Procedure covers the following main activities:

1.3 Test Description

Test will be conducted in two parts:

This document is the property

Document type: PRC System/Subsystem : 20202 Discipline: HSE Page 5 of 13

2. PLANNING AND MANPOWER

2.1. Test Duration/Planning

Preparation and test : 2 day

2.2. Manpower Estimation

• Instrument : 1 spdt + 1 tech

• Fireman/Safety : 3 (people comfortable with Breathing Apparatus and O2 analysers)

• Helper : 2 (to install/remove bottle)

2.3. Vendor Assistance

3.1. Pre-commissioning Status

• Verify that the Pre-Commissioning dossier is completed.

3.2. Commissioning Status

3.3. Status of Other SubSystem

• 26102 Normal power distribution

This document is the property

Document type: PRC System/Subsystem : 20202 Discipline: HSE Page 6 of 13

3.4. Special Tools and Test Equipment

• Hand tool set / toolbox

• Two N2 cartridge pilot gas LT30

3.6. Commissioning Spare Parts

• Ensure that work permit have been signed

• Permit to Work form and associated documents to be submitted before performing

This document is the property

Document type: PRC System/Subsystem : 20202 Discipline: HSE Page 7 of 13

• Ensure all instruments are in line

• Ensure HVAC in normal operation and all dampers operable

4.5. Reference Documents (in latest revision)

• ID-TUN-NC-SME-997013 Piping and Instruments diagram

• ID-TUN-NC-SME-997016 System operation philosophy

• ID-TUN-NC-SME-997019 System control and schematic

• ID-TUN-NC-SME-997021 Causes & Effects chart

• Vendor operating & maintenance manual

This document is the property

Document type: PRC System/Subsystem : 20202 Discipline: HSE Page 8 of 13

5. OPERATIONAL TEST PROCEDURE

DATE NAME AND

5.1 Step by Step Preparation

Permit to Work form and associated documents to be

Make sure during tool box meeting everyone is well

1. Ensure MAIN and RESERVE cylinders are isolated.

2. Ensure “Master” cylinders for blank test are installed in

3. Isolate the N2 pilot gas to the MAIN and RESERVE

4. Cover each nozzle with the paper or plastic bag.

ESD / F&G systems

5. Ensure any consequences/actions to others systems

6. Install inhibits to prevent HVAC shutdown and dampers