TPC Proc

TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A
HOOK-UP AND
COMMISSIONING
PETRA RESOURCES SDN BHD

(172962-D)
PAGE 1 OF 72
TABLE OF CONTENTS
SECTION
DESCRIPTION
1.0
PURPOSE
2.0
SCOPE
2.1 System Definition

2.2 System Description and Scope of Works
2.3 Common Scope of Works
3
8
8
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
General
Piping
Mechanical
Electrical
Instrumentation
PAGE
8
9
13
14
14
2.4 System by System Scope of Work for TKP-A

2.5 System by System Scope of Work for TKQ-A
2.6 System by System Scope of Work for WLDP-C
17
34
35
REFERENCES
49
3.1 Codes & Standards

3.2 Construction Drawings
3.3 Petronas Technical Specification
49
49
49
4.0
DEFINITON
50
5.0
PROCEDURE
51
3.0
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
SECTION
HOOK-UP AND
COMMISSIONING
PAGE 2 OF 72
5.1 Mechanical Equipment & Piping Commissioning

Procedure
DESCRIPTION
5.1.1 System Reinstatement Procedure
5.1.2 Nitrogen Purging Procedure
5.2 Electrical Commissioning Procedures
5.2.1 Navigational Aids
5.2.2 Small Power and Lighting
5.2.3 Earthing and Lighting Procedures
5.3 Instrumentation Commissioning Procedures
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.3.8
6.0
Construction Verifications
Loop Test of Pressure Instrument
Loop Test of Temperature Instrument
Loop Test of Flow Instruments
Loop Test of Level Instruments
Loop Test of Final Control Elements
Alarm & Shutdown Panel
Pneumatic Fire & Gas Detection
CHECKSHEET LISTING
51
PAGE
51
54
55
55
56
57
58
58
60
62
63
64
67
69
71
72
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
PAGE 3 OF 72
1.0 PURPOSE
The Testing, Pre-Commissioning and Commissioning Procedure is prepared to be
used as a reference in performing the Pre-commissioning and Commissioning
activities for Topside Modification for SKO Pipeline Rejuvenation Project
PL381/210. It is PRSBs intention to ensure that all systems were fully tested and
commissioned, to the maximum extent possible and to the satisfaction of PCSB.
The objectives of testing and commissioning are to:a) To verify all equipment are installed in accordance to AFC drawings, scope of
works and manuals.
b) To proves all equipment are able to function according to its design
specification, requirements and intended purpose.
c) To compiles test data and results with all other documents into a complete
equipment final documentation.
d) Pre-determine outstanding activities (punch-list).
2.0 SCOPE
2.1 SYSTEM DEFINITION
a) Topside Modification for SKO Pipeline Rejuvenation Project PL381/210
includes pre-shutdown, shutdown and post shutdown activities. All
facilities and equipment are categorized into a specific system. A system
is defined as configuration of pipe works or equipment that falls within the
same process medium.
b) A system is easily identifiable from the Piping and Instrumentation Diagram
(P&ID) drawings.
TESTING,
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PROCEDURE NO:
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PAGE 4 OF 72
c) Systems are broken down into two more categories; sub-system and subsub-systems. Each subsequent category identifies the relevant system in
more detail.
d) PRSB shall identify and select only the relevant systems applicable to the
work scopes.
TESTING,
PRECOMMISSIONING &
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PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

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PAGE 5 OF 72
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

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PAGE 6 OF 72
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
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PAGE 7 OF 72
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
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PAGE 8 OF 72
2.2 SYSTEM DESCRIPTION AND SCOPE OF WORKS

a) System description provides, to some extent, information on the
processes, the system point of origin and ending, the equipment involved
and other pertinent facts.
b) Scope of Works for this Commissioning Procedure depicts activities
required to be performed by PRSB during Pre-commissioning and
Commissioning Stages. Activities described with words like verify, check
or ensure mean the tasks should have been completed during
Construction and only to be checked upon Pre-commissioning and
Commissioning stage using the relevant documentation. Should there is
a need to re-perform any of the completed activity on the basis of
equipment or material flaw or failure this shall be executed upon
concurrence by PCSB.
c) Activities described with the word perform mean the tasks to be executed
during Commissioning stage only. This includes assisting the vendor
representative / under supervision for power-up, start-up and as required.
d) PRSB is responsible for identifying and developing the Scope of Works
that are not depicted in this section.
2.3 COMMON SCOPE OF WORKS
2.3.1 GENERAL
a) Verify equipment manuals, reference drawings, factory calibration
certificates, test reports and test certificates are available.
b) Verify equipment skid structure and on-skid items are free of any
damage.
TESTING,
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PROCEDURE
PROCEDURE NO:
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PAGE 9 OF 72
c) Verify nameplate data for all items are as per datasheet and
specification.
d) Verify tagging and numbering for all items are correct.
e) Verify equipment temporary shipping braces, stoppers and other
protective structures are removed.
2.3.2 PIPING
a) Verify pipe internal flushing had been completed which shall include
the following activities:1.
2.
3.
4.
5.
6.
7.
8.
For piping not permitted to be flushed with water due to process

/operational reasons, air or suitable flushing medium can be
used upon PCSB approval.
Before filling water into the system, all equipment and
instrumentation such as but not limited to check valves, flow
nozzles and strainers, where debris are likely to be trapped, shall
be removed or spaded off.
All piping fabrication works like welding, inspection and NDE
shall be completed by Contractor prior to the work.
The piping system shall be checked to be able to sustain the load
during flushing and temporary support shall be added if
necessary.
Flushing water shall be free from dirt and impurities as per test
water specifications.
All ball valves shall be in the fully open position. All instrument
accessories shall be removed or blinded off.
The drain point at the lowest valve or flange connection in the
system shall be established and identified in the isometric
drawing.
The pump shall be connected to the filling point at the highest
practical location available on the system.
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
9.
10.
11.
12.
13.
14.
15.
HOOK-UP AND
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PAGE 10 OF 72
Intermediate vent and drain points shall be located and

identified in the test package and isometric drawing.
Open the lowest drain point and start the pump to flush water
from the system down to the discharge overboard.
Flush all lines with a minimum volume flow (velocity) of three (3)
meters per second from high to low suitable points to ensure
thorough flushing.
During the flushing operation, open necessary intermediate
drains to ensure cleanliness at stub points and dead pockets.
Close all intermediate vents and continue flushing operation
until the water flowing at the lowest drain point is clean. Test
samples shall be taken until the water from the test system is
free of dirt and foreign materials by using a 10m mesh filter.
When the flushing water discharge is clear and free from any
debris or foreign material to the satisfaction of PCSB
representative, stop the pump and close the valves downstream
of the pump discharge and draining points.
Disconnect the pump from the system and retain the system full
of water, ready to continue for hydrotest if the water meets the
hydrotest medium specifications. If otherwise, the water shall be
thoroughly drained and the system shall be filled up with the
hydrotest medium.
b) Verify hydro testing had been completed which shall include the
following activities:1. All instruments and relief valves that are not to be included in
the hydrotest shall be removed and their connections blinded
off.
2. All equipment and skid packages that are not to be included in
the hydrotest shall be isolated with properly designed spectacle
blinds.
3. All vent valves shall be opened and shall remain opened until
there is a steady overflow of test water at the vent valves.
4. Fill in water preferably at the lowest practical point in the
system. Filling operation pressure shall not exceed 1-2 barg.
5. The sequence of closure of vent valves shall be from the lowest
TESTING,
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PROCEDURE NO:
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REVISION NO: A

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PAGE 11 OF 72
to the highest system vent point.

6. All temporary pipes, connections and blanking devices shall be
installed to withstand the test pressure.
7. Water to be used shall be potable water.
8. All pipe supports and foundation shall be made sure to be able
to withstand the total load that will be imposed on them during
hydrotest.
9. The hydrotest pressure at any point in the metallic piping
system shall be not less than 1.5 times the flange rating (per
respective piping class at test temperature) or as specified in
the approved piping isometric drawing and test package,
whichever is higher.
10. As a guideline, the incremental pressures should not be less
than 3 barg and not to exceed 10 barg.
11. During hydrotest, ball valves shall be half open, globe and gate
valves shall be fully open and check valves shall be defeated by
reversing the valves, removing the valve plates, or replacing the
valve with a suitably designed dummy spool.
12. Once the holding time starts, PCSB representative shall sign off
the chart to mark the beginning of the pressure holding. Once
the holding time ends, PCSB representative shall sign off the
chart to mark the end of the pressure holding. The beginning
and end time of the holding time shall be checked to confirm
meeting the duration requirement.
13. On completion of inspection, the pressure shall be reduced
gradually to zero (0) gage pressure. The depressurizing rate
should follow the same rate as pressurizing. No joint
connection shall be open unless it has been checked and
verified that all pressure gauge readings show zero
pressure.
c) Verify pipework is internally cleaned and preservation applied (as
required) after hydrostatic testing is completed.
d) Perform reinstatement test which shall include the following activities
(refer to Section 5.1.2 for details):-
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

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PAGE 12 OF 72
i. Perform internal inspection and verify cleaning of vessels is

completed and "Final Closure Certificates" have been issued.
ii. Perform line checking against Process and Instrumentation
Diagram (P&ID) drawings as follows:a)
b)
c)
d)
e)
f)
g)
Verify valves, flanges and piping items were properly

installed and tightened,
Verify gaskets installed are of the right specification,
Verify pipework were adequately supported,
Verify check valves were installed in the right direction,
Verify line instrument and isolation valves has been leak
tested and tag numbering are correct as per P & ID
Verify color coding, line numbering and directional arrow
are provided correctly, and
Perform functional test of all manually-operated, isolation
and block valves.
e) Reinstatement of the system shall be performed at 1.1 x maximum

operating pressure or at pressure equal to ninety five (95) percent
of the lowest rated relief valve set point (if PSV is available) at the
line depending whichever is higher.
f) Verify test instruments used have a range of fifty (50) percent higher
than the test pressure. Test instrument validity period do not exceed
six (6) months after certification or re-calibration by third party.
g) Verify insulation and cladding confirm to specification and drawings
(as required).
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
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REVISION NO: A

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PAGE 13 OF 72
2.3.3 MECHANICAL
a) Verify equipment nameplate data and tagging is correct as per Design
and specifications.
b) Verify hold down bolts and vibration dampeners (if available) has been
adequately installed and tightened.
c) Verify skid and equipment levelness as recommended by
manufacturer or vendor.
Should grouting is applied; Vendor
Representative Concurrence may be required during inspections.
d) Verify alignment check between driver and driven equipment i.e.
engine to gearbox and/or gearbox to compressor, etc., is completed
and the values are within vendor acceptable values.
Note: Vendor Representative Assistance and concurrence may be
required.
e) Check lube oil for contamination and correct level.
necessary.
Replace if
f) Check air, fuel and lube oil filters for cleanliness and replace as
necessary.
g) Check lubrication or greasing of all external bearings.
h) Check cooling system and ensure coolant and corrosion inhibitor are
added.
i) Verify internal cleanliness of vessel / tank, internal fittings / elements
is installed prior to final closure of the vessel / tank.
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
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REVISION NO: A

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PAGE 14 OF 72
j) Check final closure of vessel / tank with proper gasket.
2.3.4 ELECTRICAL
a) Verify nameplate data, tagging and numbering of cables, relays,
devices.
b) Verify electrical cables are installed correctly, continuity checked and
insulation tested.
c) Verify electrical junction box installations and power cable terminations
are completed as per specification.
d) Verify all Earth connections are terminated.
e) Perform uncoupled run test of electric motors after motor windings and
space heaters are insulation tested and that all motors are rotating in
correct direction as per vendor datasheet.
f) Perform coupled run test of electric-motor-driven equipment.
g) De-energize subsystems after completion of commissioning activities.
2.3.5 INSTRUMENTATION
iii) Verify all individual instruments comply with CARIGALI specifications
prior to calibration by comparing instrument name tags and datasheets
to the specifications.
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
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REVISION NO: A

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PAGE 15 OF 72
iv) Verify instrument installations, testing and calibrations are completed

and recorded on standard forms and check sheets.
Note: Completion of these activities shall be clearly indicated by
attaching color-coded labels or stickers to each instrument or instrument
system.
v) Verify calibration and pop test certificates of all relief valves.
vi) Verify that all tubing for primary process, secondary signal, instrument
air supply, sample lines and hydraulic lines are leak tested to the
specification requirements (see instrumentation commissioning
procedure under Section 5.3).
vii) Verify that all instrument junction box installations and cable
terminations are correctly installed.
viii) Verify completion of instrument and control cable insulation resistance
checks and continuity checks.
All thermocouples, electric and
instrument wirings shall be checked for polarity and continuity.
ix) Verify instrumentation isolation valves could be opened and closed
easily and sight glasses are not obstructed with paint, etc.
x) Perform loop checking of all indication, control, alarm and shutdown
features from field instruments to Instrument Control Panel (ICS) or
Distributed Control System (DCS). This includes stroking of valves i.e.
shutdown valves, blow down valves, control valves, etc. and function
testing of local control panel.
xi) Perform alarm and shutdown test of system by simulating a fault
condition at the primary element. It shall be ensured that the correct
TESTING,
PRECOMMISSIONING &
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PROCEDURE NO:
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PAGE 16 OF 72
operational sequence and action of all components are as per

specifications.
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

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PAGE 17 OF 72
2.4 SYSTEM BY SYSTEM SCOPE OF WORK FOR TKP-A

SYSTEM SCOPE OF WORK
The subsequent pages depict the detailed Scope of Works for the predetermined systems. P&ID drawing numbers to depict the mentioned systems
/ sub-systems are also included reference.
System
- 100: PROCESS
Sub-System
- 120: PROCESS LIQUID
Sub-Sub-System
- 122: LIQUID COLLECTION AND RECEIVING
System Description
Separation of incoming crude is common on most facilities. Separation vessels are

equipped with internal weirs;baffle plate, etc. to segregate crude, gas and water. Gas
being the lightest would be released at the top of the vessel whereas water and crude
outlets are generally located at the bottom of the vessel.
It comprises of several pressure vessels such as a HP Separator, LP Separator, Test
Separator, Surge vessel, relief valves and special items such as interlock. It also involves
associated instrumentations such as pressure and temperature gauges, transmitters,
level indicators, flow element and etc.
The workscope involved for this system is sectional spool replacement at existing Line
200-PL-011-1101X (TP-11/12), upstream of V-300
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System
-100:
PROCESS
Sub-System
-120:
PROCESS LIQUID
Sub-Sub-System -126:
PAGE 18 OF 72
PL METERING & EXPORT/OFFLOADING
System Description
Liquid transfer and metering are an integration of several skid equipments originating from
the discharge nozzle of a separator or a surge vessel, through a pumping subsystem and
a metering subsystem before ending at the shutdown valve downstream of the scraper
launcher.
It comprises of an extensive array of pipeworks with Crude Oil Transfer Pump (COTP),
metering runs, flow element (e.g. turbine, orifice), Meter Prover (if applicable), Auto
Sampling Sampling Station (if applicable), Export Launcher, Heat Tracing / Exchanger /
Heater. All signal are hardwired to its Metering Control System consisting flow computers
and supervisory computer. It also includes a variety of instruments like shutdown valves,
control valves for various applications, transmitters and indicators. Several local control
panels for individual equipment are also involved.
The workscope include installation of :
1. Scraper Launcher, L-1350 and associated instrumentation & process liquid line.
2. 2. H2S Analyzer, XA-1350 c/w sampling points (inlet & outlet)
3. 3. Corrosion monitoring special items (SP-13501/13502/13503/13504)
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PROCEDURE NO:
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System
- 200: PROCESS UTILITIES
Sub-System
- 220: INERT GAS
Sub-Sub-System - 221:
PAGE 19 OF 72
NITROGEN
System Description
Inert gas such as nitrogen which contain low oxygen is admitted into process system to
make the atmosphere in the tanks inert so that explosive environment may not occur even
if any ignition source is generated.
The major equipment for nitrogen generation are generator, absorption vessels,
receivers, distribution header and control panels.
Nitrogen bottle is normally provided as back up for purging and blanketing where it
distributed to FG system, HP/LP flare, produce water degreaser, stripping and blanket
gas to glycol flash vessel.
The workscope involved in this system is installation of N2 Skid, A-5910 for L1350's
purging activities.
TESTING,
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PROCEDURE
PROCEDURE NO:
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System
Sub-System
- 230: VENT
PAGE 20 OF 72
ATMOSPHERIC VENT
System Description
Atmospheric vent system or low pressure vent generally implies venting of gas or
pneumatic air to atmosphere. The system starts at the discharge of a particular equipment
like a compressor or vessel such as knockout drum, scraper receiver/launcher and etc. It
comprises of pipeworks and minimal equipment like flame arrestors and rupture disks.
The workscope includes vent lines from Scraper Launcher L-1350, Chemical Injection
Skids A-6810A/B, Chemical Transfer Pumps Skid A-6811, H2S Analyzer XA-1350 and
Sump Tank Skid A-6500 to existing 50-V-002-1101.
TESTING,
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PROCEDURE NO:
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System
Sub-system
- 250: DRAIN
PAGE 21 OF 72
OPEN DRAIN (NON-HAZARDOUS)
System Description
Open drain system sometimes called ''non-hazardous drain'' involves drainage of wastes
overboard of the facility. A good example of an open drain is the downcomer line for
disposal of drilling mud. Sometimes, it is synanymous with atmospheric or nonpressurised drain lines. This sub-subsystem generally associated with pipeworks only.
The workscope includes spool replacement at existing open drain header 150-D-0051101 and drain lines of H2S Analyzer XA-1350, Scraper Launcher L-1350, Sump Pump
Skid A-6511, Sump Pump Tank Skid A-6500, Chemical Injection Skids A-6810A/B &
Chemical Injection Transfer Pumps Skid A-6811.
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
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System
Sub-system
- 250: DRAIN
PAGE 22 OF 72
CLOSED DRAIN
System Description
Closed drain sometimes called pressurised drain or hazardous drain, is meant to handle
waste media which could contaminate the environment. A distintive feature of the system
is that it involves a waste collector called ''sump caisson''. Pumping equipment called
''sump pump'' is provided to recycle hydrocarbon waste material back to into
the process system for further extraction.
Closed drain system may contain equipment such as relief valves, a pump, a prime mover
in the form of electric or pneumatic motor. It also involves associated instrumentation
including indicators and etc.
The workscope include ;
1. Sump Pump Skid, A-6511 & Sump Tank Skid, A-6500 and associated pipeworks
& instrumentation.
2. Spool replacement at existing closed drain header 150-BD-004-1101X
3. Closed drain line of Scraper Launcher, L-1350
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PROCEDURE NO:
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PAGE 23 OF 72
System
Sub-System
- 270: CHEMICAL INJECTION / TREATMENT
CORROSION INHIBITOR
System Description
Corrosion inhibitor is injected to prevent formation of corrosion-based microbiological
bacteria & lessen the corrosion inside the pipe wall. It commonly applied when carbon
steel piping is used as it tends to corrode with hydrocarbon media. Equipment comprises
of chemical storage/mixing tank, transfer pumps, injection pumps, injection DBB valves
& tubings, and associated piping, valves & instrumentations.
The major equipment are storage tank, transfer pumps, callibration gauge, injection
pumps and associated instruments.
The workscope includes installation of CI skid A-6810 & transfer pump skid A-6811
complete with associated pipeworks & instrumentation. Corrosion & Scale Inhibitor
injection will be integrated into one CI skid, A-6810A.
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
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REVISION NO: A

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PAGE 24 OF 72
System
Sub-System
SCALE IHIBITOR
System Description
Scale inhibitor is used to control or prevent scale deposition in the production conduit or
completion system. The chemicals may be continuously injected through an injection
point in the completion, or periodic squeeze treatments may be undertaken to place the
inhibitor in the reservoir matrix for subsequent commingling with produced fluids.
complete with associated pipeworks & instrumentation. Corrosion & Scale Inhibitor
injection will be integrated into one CI skid, A-6810A.
TESTING,
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PROCEDURE NO:
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REVISION NO: A

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PAGE 25 OF 72
System
Sub-System
Sub-Sub-System - 279-1: BIOCIDE

System Description
Biocide is used to control or prevent microbiologically induced corrosion (MIC) in the
pipeline and production system. The chemicals may be continuously injected through an
injection point in the piping & pipeline system. This biocide is poisonous to organism and
will inhibit their metabolism and annihilate them.
complete with associated pipeworks & instrumentation. The injection of this biocide will
be located at upstream of V-300 at TKP-A.
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

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System
- 300: GENERAL UTILITIES
Sub-System
- 320: COMPRESSED AIR
PAGE 26 OF 72
INSTRUMENT AIR
System Description
Compressed air for instrument and utility applications is provided by two rotary-type screw
compressors. The compressors are set up to operate one as a lead and the other as a
standby unit. A dedicated controller is provided at each compressor for automatic loading
and unloading. Another type of compressor is packaged integrally geared centrifugal air
compressor.
The major equipment includes air compressors and all associated drive equipment and
accessories (including all in the skid scrubbers, coolers and air intake equipment and etc)
and local control panels. Instrument air dryer and control panel, valves, moisture analyzer,
junction boxes and associated piping.
The workscope includes spool replacement at line 50-IA-1003-1808, instrument air piping
at Chemical Transfer Pumps Skid, A-6811 and instrument tubing line for H2S Analyzer,
XA-1350.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

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System
- 400: SAFETY
Sub-System
- 420: LIFESAVING EQUIPMENT
PAGE 27 OF 72
SAFETY SHOWER & EYEWASH
System Description
The workscope involved for this sub-sub system include installation of Safety Shower &
Eyewash Station and portable eyewash. These items are required to clean up operation
personnel whenever chemical/hydrocarbon splash up or spillage onto personnel
occurred.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
System
- 500: POWER
Sub-System
- 540: SMALL POWER AND LIGHTENING
PAGE 28 OF 72
NORMAL DISTRIBUTION BOARD
System Description
The normal small power and lighting distribution system consists of the normal distribution
boards for both small power and lighting, cabling from normal MCC to the normal
distribution boards and the outgoing circuits of the distribution boards.
The major component includes distribution boards and cables. The workscopes involved
is installation of Distribution Board, DB-1000 and associated power cables.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
PAGE 29 OF 72
System
-500:
POWER
Sub-System
-550:
EARTHING AND LIGHTNING PROTECTION
Sub-Sub-System -551:
EARTHING
System Description
This system covers the overall earthing of the plant/platform. However, individual
equipment earthing shall be part of the respective equipment. Only the main earth grid
and connection to the platform are considered as part of this system.
Alternating current (AC) system neutrals for power generation and distribution systems
(namely High Voltage and Low Voltage generators, transformers, reactors, switchboards,
motors and Uninteruptible Power Supply Unit) are connected to one common earth grid
up to jacket leg or as per design requirements.
Equipments are bonded to the platform structure. Screens of signal cables which are
connected to instrument earth and intrinsically safe earth maybe looped together to a
common or separate earth grid and connected to the jacket leg or as per design
requirements. Lightning conductor system complete with air termination are
interconnected together to have a separate grid extending up to the jacket leg.
This system consists of Earth electrodes, earthing ring and branch conductors, earthing
bar, earthing resistors, earthing boss, cable wire armour bonding and junction boxes.
Steelworks of the structural legs which are buried into the seabed are considered to be
the Earth Electrode for offshore platforms.
The workscope includes installation of earth boss for Scraper Launcher L-1350, Nitrogen
Bank Skid A-5910, Chemical Injection Skids A-6810A/B, Chemical Transfer Pump Skid
A-6811, H2S Analyzer XA-1350, Sump Tank Skid A-6500, Sump Pump Skid A-6511,
motorized operated valves (MOV-13504 & MOV-13505) and vertical ladder at ABV
service platform.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
System
- 500: POWER
Sub-System
- 570: CONSUMERS CONTROLLER
PAGE 30 OF 72
LIGHTENING
System Description
This system covers the lighting circuits and fixtures (normal and emergency) from cabling
of DB up to individual lighting fixtures. The major components include cabling, junction
boxes, lighting fixtures.
The workscopes includes installation of following items ; 1. 2 x 36W Normal Fluorescent Light and associated power cables - 2 nos.
2. 2 x 36W Normal Fluorescent Light with battery Pack, 3hrs back-up and associated
power cables - 3 nos.
3. 150W Floodlight and associated power cables - 2 nos.
4. JB-62A
5. JB-62B
6. EJB-63A
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
System
- 600: POWER
Sub-System
- 620: SAFEGUARDING SYSTEM
PAGE 31 OF 72
FUSIBLE PLUG LOOPS
System Description
Fusible plug loops is used for monitoring fire in strategic locations throughout the facility
by means of pressurized system in a closed loop and the fusible plug melts when the
temperature exceeds the melting point. Fusible plug loops are normally hook-up to FGS
or deluge valve panel (pneumatic system) which as an input for the detection.
Deluge valve panel senses the release of fusible plug loop pressure by means of change
pressure switch low and send it as an input signal to Fire and Gas Panel which sends
output to de-energise deluge valve solenoid to open the deluge valve and discharge water
to sprinkler system. Deluge valve panel in turn will send feedback signal to Fire and Gas
Panel when deluge is activated.
Electronic transmitter also may be provided in some installations to monitor charge
pressure and connected to FGS for operation of fire water pump and deluge system.
The major components include initiating elements (fusible plugs) and final control
elements, complete with associated cabling, tubing and junction boxes, fusible loop
charge panel, kill knobs and other pneumatic sensors, interface with the Shutdown
System / Safety Instrumented System.
The workscope includes installation of fusible plugs for all new skids (Nitrogen Bank Skid
A-5910, Chemical Injection Skids A-6810A/B, Chemical Transfer Pump Skid A-6811, H2S
Analyzer XA-1350, Sump Tank Skid A-6500 and Sump Pump Skid A-6511), Scraper
Launcher L-1350, motorised operated valves (MOV-13054/13505) and ABV-1350.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
System
- 600: CONTROL
Sub-System
- 620: SAFEGUARDING SYSTEM
PAGE 32 OF 72
INSTRUMENT CONTROL PANEL
System Description
This system provides pneumatic or electronic for control and safeguarding system to
control and protect the production facilities from process abnormalities and provide
shutdown functions and status indication, including the interface with Fire & Gas System
and Emergency Shutdown System.
The major components include pneumatic or electronic panel containing functional logics
connected to initiators and final control elements, complete with necessary
instrumentation, cable, tubing, junction boxes and etc.
The workscope includes modification at existing ICP and installation of PEH/PEL-1350
with associated signal lines.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
System
- 800: MISCELLANEOUS
Sub-System
- 850: STRUCTURAL
PAGE 33 OF 72
TOPSIDE
System Description
The topside structure is designed to sustain the weight of the dead and variable
equipment loads. Live loads, environmental loads, bridges reaction, earthquake loads
accidental loads from dropped object and future facilities. The topside consist of cellar
deck, sub cellar deck, mezzanine deck, main deck, venting/flaring boom and etc.
The workscopes are listed as follow ; 1. Deck Strengthening at Cellar & Sea Deck
2. Removal of existing beams, bracing, handrails & gratings (CD)
3. Deck Extension - Panel 4 & 5 c/w diagonal bracing, tubular supports, gratings,
and handrails
4. Sump Pump Deck Extension c/w tubular supports, gratings & handrails.
5. Deck Extension - Panel 1, 2 & 3 c/w diagonal bracing, tubular supports, loose
beams, gratings, handrails and pipe coaming
6. ABV Service Platform c/w tubular supports, ladder, gratings & handrails.
7. Drip pan (under Panel 1 & 2)
8. Removal of existing SDV Service Platform
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
PAGE 34 OF 72
2.5 SYSTEM BY SYSTEM SCOPE OF WORK FOR TKQ-A

System
- 500: POWER
Sub-System
- 520: POWER DISTRIBUTION
LOW VOLTAGE SWITCHGEAR AND MOTOR CONTROL

CENTER
System Description
This system cover the low voltage switchgear and low voltage motor control centre up to
the outgoing feeders. All incoming cables/busduct to the respective switchgear shall be
part of this system.
The major equipments includes 415 volts Switchboards / Motor control Centre which
consist of a main bus-bar systems, 415 volts utilization feeders, 415 volts motor starter
feeders, supply cables, control cables, protection relays, metering, potential and current
transformers.
The workscope involved for this system is modification at existing spare starter of LV
Switchboard (TKK-A/TKQ-A bridge) to become new feeder and L5-H, Main LV
Switchboard (TKQ-A)
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
PAGE 35 OF 72
2.6 SYSTEM BY SYSTEM SCOPE OF WORK FOR WLDP-C

System
- 100: PROCESS
Sub-System
- 120: PROCESS LIQUID
PL COLLECTION AND RECEIVING
System Description
This system generally associated with process crude with its boundaries defined from the
wellheads to the respective collection headers and/or from receiving pipeline riser to the
inlet of a separator vessel.
Equipments in this system includes production headers, receiver, allocation metering and
production manifold. It also includes associated instruments such as pressure &
temperature gauges and transmitters.
The workscope include installation of :
1. Scraper Receiver, R-1330 and associated instrumentation & process liquid line.
2. H2S Analyzer, XA-1330 c/w sampling points (inlet & outlet)
3. Corrosion monitoring special items (SP-13301/13302/13303/13304)
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
System
- 200: PROCESS
Sub-System
- 210: UTILITY GAS
PAGE 36 OF 72
INSTRUMENT GAS
System Description
The gas extracted from wellfluid for use as instrument supply medium is inherently wet
such that this has to go through a system to slightly enhance the quality of gas to be used
for instrumentation.
Major equipment involved are gas scrubbers, filters and associated level control systems,
pressure monitoring loop, control valves, all line piping, tubing, headers, valves and other
associated instrumentation.
The workscope includes instrument gas supply tubing to H2S Analyzer, XA-1330.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
System
- 200: PROCESS
Sub-System
- 220: INERT GAS
PAGE 37 OF 72
NITROGEN
System Description
Inert gas such as nitrogen which contain low oxygen is admitted into process system to
make the atmosphere in the tanks inert so that explosive environment may not occur even
if any ignition source is generated.
The major equipment for nitrogen generation are generator, absorption vessels,
receivers, distribution header and control panels.
Nitrogen bottle is normally provided as back up for purging and blanketing where it
distributed to FG system, HP/LP flare, produce water degreaser, stripping and blanket
gas to glycol flash vessel.
The workscope involved in this system is installation of N2 Skid, A-5910 for R-1330's
purging activities.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
System
- 200: PROCESS
Sub-System
- 230: VENT
HOOK-UP AND
COMMISSIONING
PAGE 38 OF 72
ATMOSPHERIC VENT
System Description
Atmospheric vent system or low pressure vent generally implies venting of gas or
pneumatic air to atmosphere. The system starts at the discharge of a particular equipment
like a compressor or vessel such as knockout drum, scraper receiver/launcher and etc. It
comprises of pipeworks and minimal equipment like flame arrestors and rupture disks.
The workscope includes vent lines from Scraper Receiver R-1330 and H2S Analyzer XA1330 existing line 50-VH-6203-11432.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
System
- 200: PROCESS
Sub-System
- 250: DRAIN
HOOK-UP AND
COMMISSIONING
PAGE 39 OF 72
OPEN DRAIN (NON-HAZARDOUS)
System Description
Open drain system sometimes called ''non-hazardous drain'' involves drainage of wastes
overboard of the facility. A good example of an open drain is the downcomer line for
disposal of drilling mud. Sometimes, it is synonymous with atmospheric or nonpressurised drain lines. This sub-subsystem generally associated with pipeworks only.
The workscope includes installation of open drain line from Scrapper Receiver R-1330
and H2S Analyzer XA-1330 to existing line 50-D-6205-11430 at TP-101.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
System
- 200: PROCESS
Sub-System
- 250: DRAIN
HOOK-UP AND
COMMISSIONING
PAGE 40 OF 72
CLOSED DRAIN
System Description
Closed drain sometimes called pressurised drain or hazardous drain, is meant to handle
waste media which could contaminate the environment. A distintive feature of the system
is that it involves a waste collector called ''sump caisson''. Pumping equipment called
''sump pump'' is provided to recycle hydrocarbon waste material back to into the process
system for further extraction.
Closed drain system may contain equipment such as relief valves, a pump, a prime mover
in the form of electric or pneumatic motor. It also involves associated instrumentation
including indicators and etc.
The workscope include installation of closed drain line from Scraper receiver R-1330 to
existing line 2''-PD-6411-11430.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
System
- 400: SAFETY
Sub-System
- 410: FIRE FIGHTING
PAGE 41 OF 72
TOTAL FLOODING FIRE SUPPRESSION AND FIRE

EXTINGUISHER
System Description
CO2 is now use in areas where fire supression using water or Halon Gas as medium is
not permissible, CO2 discharge is triggered by Fire and Gas Detection and also by
manual operation. When fire is detected in a certain area, the sensor will send signal to
the fire alarm panel which in turn would open the release valve. A timer delay is installed
to allow for personnel inside the control room to leave the premises before the CO2 is
released.
This includes firefighting in the form of CO2 and associated equipment such as gas
cylinders, storage cabinet, discharge manifold, release valve solenoid and discharge
nozzles.
The workscope includes provision of ;1. 9kg Dry Chemical Powder Portable Extinguisher c/w Safety Sign
2. 9L Foam (AFF) Portable Fire Extinguisher c/w Safety Sign
3. Fire Extinguisher Box
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
System
- 400: SAFETY
Sub-System
- 420: LIVESAVING EQUIPMENT
PAGE 42 OF 72
SAFETY SHOWER & EYEWASH
System Description
The workscope involved for this sub-sub system include installation of portable eyewash.
This item is required to clean up operation personnel whenever chemical / hydrocarbon
splash up or spillage onto personnel occurred.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
System
- 500: POWER
Sub-System
- 520: POWER DISTRIBUTION
PAGE 43 OF 72
LOW VOLTAGE SWITCHGEAR AND MOTOR CONTROL

CENTER
System Description
This system cover the low voltage switchgear and low voltage motor control centre up to
the outgoing feeders. All incoming cables/busduct to the respective switchgear shall be
part of this system.
The major equipments includes 415 volts Switchboards / Motor Control Centre which
consist of a main bus-bar systems, 415 volts utilization feeders, 415 volts motor starter
feeders, supply cables, control cables, protection relays, metering, potential and current
transformers.
The workscope involved for this system is modification at existing spare space of LV
Switchboard N0. 2 (WLP-C/WLDPC bridge) to become new feeder for MOV
13304/13305.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
PAGE 44 OF 72
System
- 500: POWER
Sub-System
- 550: EARTHING AND LIGHTNING PROTECTION
EARTHING
System Description
This system covers the overall earthing of the plant/platform. However, individual
equipment earthing shall be part of the respective equipment. Only the main earth grid
and connection to the platform are considered as part of this system.
Alternating current (AC) system neutrals for power generation and distribution systems
(namely High Voltage and Low Voltage generators, transformers, reactors, switchboards,
motors and Uninteruptible Power Supply Unit) are connected to one common earth grid
up to jacket leg or as per design requirements.
Equipments are bonded to the platform structure. Screens of signal cables which are
connected to instrument earth and intrinsically safe earth maybe looped together to a
common or separate earth grid and connected to the jacket leg or as per design
requirements. Lightning conductor system complete with air termination are
interconnected together to have a separate grid extending up to the jacket leg.
This system consists of Earth electrodes, earthing ring and branch conductors, earthing
bar, earthing resistors, earthing boss, cable wire armour bonding and junction boxes.
Steelworks of the structural legs which are buried into the seabed are considered to be
the Earth Electrode for offshore platforms.
The workscope includes installation of earth boss for Scrapper Receiver R-1330, MOV13304/13305, ABV-1330, H2S Analyzer XA-1330, N2 Skid A-5910 and vertical ladder at
ABV service platform.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
System
- 500: POWER
Sub-System
- 570: CONSUMER CONTROL
PAGE 45 OF 72
LIGHTING
System Description
This system covers the lighting circuits and fixtures (normal and emergency) from cabling
of DB up to individual lighting fixtures. The major components include cabling, junction
boxes, lighting fixtures.
The workscopes includes installation of following items ; 1. JB-01B
2. JB-02B
3. EJB-01A
4. 2 x 36W Normal Fluorescent Light with battery Pack, 3hrs back-up and
associated power cables - 2 nos.
5. 2 x 36W Normal Fluorescent Light and associated power cables - 2 nos.
6. 150W Floodlight and associated power cables - 3 nos.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
PAGE 46 OF 72
System
- 600: CONTROL AND SAFEGUARDING SYSTEM
Sub-System
- 620: SAFEGUADING SYSTEM
FUSIBLE PLUG LOOPS
System Description
Fusible plug loops is used for monitoring fire in strategic locations throughout the facility
by means of pressurized system in a closed loop and the fusible plug melts when the
temperature exceeds the melting point. Fusible plug loops are normally hook-up to FGS
or deluge valve panel (pneumatic system) which as an input for the detection.
Deluge valve panel senses the release of fusible plug loop pressure by means of change
pressure switch low and send it as an input signal to Fire and Gas Panel which sends
output to de-energise deluge valve solenoid to open the deluge valve and discharge water
to sprinkler system. Deluge valve panel in turn will send feedback signal to Fire and Gas
Panel when deluge is activated.
Electronic transmitter also may be provided in some installations to monitor charge
pressure and connected to FGS for operation of fire water pump and delyge system.
The major components include initiating elements (fusible plugs) and final control
elements, complete with associated cabling, tubing and junction boxes, fusible loop
charge panel, kill knobs and other pneumatic sensors, interface with the Shutdown
System / Safety Instrumented System.
The workscope includes installation of fusible plugs for Scraper Receiver R-1330, H2S
Analyzer XA-1330 and ABV-1330.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
PAGE 47 OF 72
System
- 600: CONTROL AND SAFEGUARDING SYSTEM
Sub-System
- 620: SAFEGUADING SYSTEM
INSTRUMENT CONTROL PANEL
System Description
This system provides pneumatic or electronic for control and safeguarding system to
control and protect the production facilities from process abnormalities and provide
shutdown functions and status indication, including the interface with Fire & Gas System
and Emergency Shutdown System.
The major components include pneumatic or electronic panel containing functional logics
connected to initiators and final control elements, complete with necessary
instrumentation, cable, tubing, junction boxes and etc.
The workscope includes installation ; 1. PEH/PEL-1330 with associated signal lines to Transit Line Control Box.
2. Gas supply line to ABV-1330
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
System
- 800: MISCELLANEOUS
Sub-System
- 850: STRUCTURAL
PAGE 48 OF 72
TOPSIDE
System Description
The topside structure is designed to sustain the weight of the dead and variable
equipment loads. Live loads, environmental loads, bridges reaction, earthquake loads
accidental loads from dropped object and future facilities.
The topside consist of cellar deck, sub cellar deck, mezzanine deck, main deck,
venting/flaring boom and etc.
The workscopes are listed as follow ; 1. Deck Strengthening at CD
2. Removal of existing beams, bracing, handrails & gratings (CD)
3. Deck Extension - Panel 1, 2 & 3 c/w diagonal bracing, tubular supports, loose
beams, gratings, handrails and pipe coaming.
4. Drip pan under Panel 2 & 3
5. ABV Service Platform at leg B3 c/w tubular supports, ladder, gratings, handrails
and other loose members.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
PAGE 49 OF 72
3.0 REFERENCES
The information in this section highlights the documents that could be made as references
while performing testing and commissioning activities.
3.1 CODES & STANDARDS

These are documents recognized worldwide based on long term experiences in the
industry for many years. Examples are Codes and Standards produced by institutions
such as the American Petroleum Institute (API), American Society of Mechanical
Engineers (ASME) and so forth. Some of the relevant Codes and Standards deemed
required for testing and commissioning activities are:ASME Section VIII
ANSI B31.3
ISO-2372-1974
ISO-2372-1974
API RP 550
Unfired Pressure Vessel,

Chemical Plant and Petroleum Refinery Piping,
Mechanical Vibration of Machines,
Mechanical Vibration of Certain Rotating Electrical Machinery,
Instrument and Controls Manual for Refinery Service
3.2 CONSTRUCTION DRAWINGS

Only construction drawings of the latest revision are used for testing and commissioning
activities. In an event a conflict arise from interpretation of the requirements in the above
documents, CARIGALI personnel shall be consulted by PRSB for clarification.
3.3 PETRONAS TECHNICAL SPECIFICATION
Below is a minimum listing of PETRONAS Technical Specifications (PTS) which contents
are considered directly relevant for testing and commissioning activities. More information
& details should be retrieved from specific equipment specs.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
20.094
20.167
50.007
50.013
32.32.10.10
32.80.10.30
61.10.08.11
62.10.08.11
63.10.08.11
70.10.70.11
70.10.80.11
70.10.90.11
70.10.90.81
HOOK-UP AND
COMMISSIONING
PAGE 50 OF 72
Accuracy Requirements for Field Measurements,

Commissioning Engineering Manual,
Inspection Manual,
Handling, Storage and Preservation of Materials and Equipment,
Flow Instruments,
PLC-based Instrumented Protective Systems,
Field Inspection Prior To Commissioning of Mechanical Equipment,
Field Inspection & Testing of Instruments and System,
Field Commissioning and Maintenance of Electrical Installation and
Equipment,
The Preservation of Old and New Equipment and Piping Standing Idle,
Cleaning of Equipment,
Spare Part for Initial and Normal Operation, and
SPIR Form.
4.0 DEFINITIONS
Testing
Commissioning
Performance Test No-Load Test
Load Test
Endurance Test
Client
Contractor
An act of examination, trial or proof.

An act of putting certain item into active service and
confirmation of meeting on design intend.
Trial or proof as to the way in which the equipment
functions according to design intend.
A trial or proof as to the way in which an individual
machinery functions.
A trial or proof as to the way in which machinery function
together up to design limit.
A trial of proof as to the ability to carry on through, usually
for a specific period of time.
PETRONAS Carigali Sdn. Bhd. (PCSB)
Petra Resources Sdn. Bhd. (PRSB)
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
PAGE 51 OF 72
5.0 PROCEDURE
This section provides a description of the procedures involving testing and commissioning
activities.
PRSB shall utilized fully vendor manuals and procedures as the vendor data tend to
provide more explicit details.
5.1 MECHANICAL EQUIPMENT AND PIPING COMMISSIONING PROCEDURES
5.1.1 SYSTEM REINSTATEMENT PROCEDURE

This general procedure serves as a guideline for the commissioning of piping system.
Reinstatement Pressure
i) The purpose of re-instatement is to confirm that all joints including isolating valves,
relief valves and block valves are leak free. Tight shut-off valves can be checked
for positive shut-off during the test.
ii) All valves and spectacle blinds shall be installed as if the systems were in
operational mode.
iii) System shall be reinstated at 95% of the set point of the lowest rated relief valve
in the system or,
iv) If no relief valves are present, system shall be re-instated at one 110% of the
maximum system operating pressure whichever is lower.
Reinstatement Test Packages
Reinstatement test packages shall be prepared by PRSB for CARIGALI approval. The
test packages shall:-
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
PAGE 52 OF 72
i) Identify the extent of the test, define the test media and quantify the amount of reinstatement media required.
ii) Define valve and spectacle blind positions during the re-instatement test as per
operational mode.
iii) Identify bleed, injection and measurement points.
iv) Identify and tag joints within the system that are not be covered in the test.
v) Any leak shall be rectified by de-pressurizing the line first. Leaking valves shall be
re-conditioned or replaced as per CARIGALI's recommendation.
Test Instruments
i) Instruments used for reinstatement leak test shall be the on-line instruments,
otherwise if not available to install a calibrated instruments witnessed by CARIGALI
representative.
ii) If applicable, calibration record shall be established and signed by the instrument
technician conducting the calibration test and CARIGALI representative witnessing
the test. The following shall be required to be installed should on-line instrument
are not available;
a) Test Gauges - range shall be 50% higher than the test pressure.
b) Minimum dial size of four (4) inches and accuracy up to one-fourth (1/4) of 1
percent of the full scale.
Test Medium
i) The test medium is determined on the system process requirement i.e. process
hydrocarbon, water, instrument air, etc.
ii) Generally, water or utility air is commonly utilized apart from Process Gas line and
Vent headers where-in Nitrogen shall be used.
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
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Test Procedure
i) Line check the system as per the respective test package which covers the
following:a) Valves and flanges were properly installed and tightened.
b) Check valves were installed on the right direction.
c) Vent and drain valve if any.
d) Line instrument and isolation valve.
e) Relief/safety valve and interlocking device.
f) Color-coded bond, line numbers and directional arrows.
ii) Hook-up the source of reinstatement media and test instruments as shown on the
test pack.
iii) Install danger tags to all line valves, bleed valves, drain and vent valves.
iv) Isolate temporarily on-line instruments from the system.
v) Where air is used as the test medium, a preliminary check of the pressure not
greater than 14 psig shall be conducted. The pressure shall then be gradually
increased in increments not greater than 10 percent of the system test pressure.
vi) When water is used as test medium, pressure shall be increased in increments
equal to 15, 25, 50, 75 and 100 percent of test pressure.
vii) Check for leaks using mixture of soap or snoop leak detector at each pressure
increment.
viii)Open on-line pressure gauges isolating valve while gradually increasing the
pressure at the system.
ix) Upon reaching the test pressure, the system shall be held for one hour.
Note: Leaks occurring during this one-hour holding period shall require the start
of a new one-hour period after the leaks have been rectified.
x) Conduct system pressurization and de-pressurization sequence as highlighted in
the test package to determine and identify any leaking valves.
xi) De-pressurize the system.
xii) Retrieve the danger tags and clean-up the area.
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
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REVISION NO: A

(172962-D)
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Test Reports
The test report package for each system shall contain:i) Discrepancies and leaking valves highlighted on the instatement test pack.
ii) Recorded pressure readings during the test signed by the commissioning engineer
and CARIGALI representative.
iii) Calibration record of the instruments (if applicable).
iv) Issue reinstatement test acceptance certificate.
5.1.2
NITROGEN PURGING PROCEDURE
Objective
The objective is to purge oxygen from the hydrocarbon systems i.e. process gas, process
liquid and fuel gas, prior to introduction of hydrocarbon. This is accomplished by
introducing nitrogen into the system to less than 4 percent oxygen.
Whenever Nitrogen was used during re-instatement leak test, the test pressure of the
Nitrogen is commonly dropped to the pressure required for purging and leaves the
medium in the system for blanketing. Should water or compressed air was used the
following procedures shall be adhered;
Preparation
i) Verify mechanical completion, commissioning and other preparatory activities have
been completed, and all relevant check sheets and certification formalities complied
correctly up this point.
Procedure
Package should include listing of nitrogen fitting points, venting points and oxygen
analysis point.
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PROCEDURE NO:
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i) Isolate the system to be purged by closing all isolation valves except nitrogen fitting
point.
ii) Fit nitrogen connection as indicated, open the block valve, adjust regulator to
required setting and commence admitting nitrogen.
iii) Allow pressures in the system to rise to around 2 bar gauge and then shut the
nitrogen supply.
iv) Hold the pressure for 30 minutes to allow dilution of oxygen.
v) After holding for 30 minutes, open up the vent valves. As pressures now fall, reopen nitrogen supply to maintain a reasonably steady flow.
vi) Continue venting for around four (4) hours, ensuring a constant flow of nitrogen
through all designated routes. Appropriate adjustment to nitrogen input and output
to maintain appropriate pressure.
vii) When four (4) hours have elapsed commence checking oxygen content for every
15 minutes on each of the listed points. Keep record of the time and test results.
viii)Upon two (2) consecutive test from all sample point show less than two (2) percent
oxygen, close all vent valves and allow pressures to reach about 5 pounds per
square inch (PSI) gauge.
ix) Shut off the nitrogen supply.
x) Maintain a positive pressure until system gas up or hydrocarbon introduction.
5.2 ELECTRICAL COMMISSIONING PROCEDURES
5.2.1 NAVIGATIONAL AIDS

a. Re-check insulation resistance of individual circuit without the lanterns being in
place
b. Energize alternating current (AC) power supply of navaid battery charger from AC
switchboard.
TESTING,
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PROCEDURE NO:
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c. Test navigational aid battery system to make sure the battery have the required
capacity from the rate of discharge to supply load. Record the discharging voltage
and current at 15 minutes interval.
d. Energise navigational aid lanterns direct current (DC) distribution board.
e. Measure incoming and branch circuit voltage at distribution board with all circuit
on. Ensure voltage value is within the allowable voltage drop.
f. Verify navigational aid lanterns operations in each circuit and measure the lantern
terminal voltage.
g. Check and functional test the lamp changer operation.
h. Check the navigational aid lanterns synchronization.
i. Test the operation of photocells (if present)
j. Perform test of Navigational Aid system for 72 hours.
5.2.2 SMALL POWER AND LIGHTINGS
a. Energize the distribution panel of the equipment rack from alternating current (AC)
switchboard or low voltage motor control center.
b. Energize individual lighting and small power circuit.
c. Measure the incoming and branch circuits voltage at the distribution panel with all
the circuits on.
d. Perform battery charge and discharge tests ( for emergency light fittings with
battery pack)
e. Perform "Able" and "Disable" control circuit test.
f. Test operation of photocell (if present)
g. Test operation of circuit wall-mounted switches and verify that it controls the correct
light fittings.
h. Measure the voltage at each point.
i. Test ground continuity of grounded pole. Trip test of receptacles due to earth fault
by earth leakage circuit breaker (ELCB) tester.
j. Perform test of small power system for seventy two (72) hours.
TESTING,
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COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
5.2.3
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EARTHING AND LIGHTNING PROTECTION
a. Inspect earth cable lugs, earth boss stud diameter and welding, and earth resistor
connections.
b. Ensure that earthing layout and connections conform to the design.
c. Inspect that all contacts are cleaned, greased and bonded with denso tape where
applicable.
d. Check tightness of all earth connection.
e. Check earth cable protection such as kick plates or kick pipes.
f. Check that earth cable sizes are correct.
g. Continuity and resistance checks shall be performed for the following:i) Bonding of cable wire armor or braid, brass cable glands and equipment
frame to earth,
ii) Main earth resistance, and
iii) Earth loop resistance.
Note: Resistance values shall not exceed one (1) ohm for signal cables earthed at
one point. The Ohmic resistance of the lightning conductor system without earth
connection should be about one-half (0.5) ohm. If it exceeds one (1) ohm, then
there shall be some faults either electrically or mechanically, which shall be
inspected and defects rectified.
b) Measure resistance ohmic value of the Neutral Earthing Resistor (NER).

c) Inspect the NER internal connections, supports and fixing details.
d) Perform insulation resistance test on the NER.
e) Document al tests and checks performed.
f) Preserve equipment if not to be used for other activities.
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
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PAGE 58 OF 72
5.3 INSTRUMENTATION COMMISSIONING PROCEDURES
5.3.1 CONSTRUCTION VERIFICATIONS

After each instrument and components of a loop have been installed and hooked-up it is
necessary to check that the work has been carried out in satisfactory manner in
accordance with the hook-up drawing.
After verifying against available documentation that installations are completed, loop test
to check that each instrument and components of the loop function correctly as per design
requirement shall be performed. Test or simulated signals may be injected into the loop
in order to verify correct responses. The installation progress and loop test status shall
be monitored as follows:Instrument Installation Progress Records
i) The completed installation is defined as when all necessary connections (tubing
and wiring) are completed for all instruments within a loop and should now be ready
for loop checking and testing.
ii) The status of installation, tubing and wiring shall be indicated by dates when these
work are completed and inspected satisfactorily.
Instrument Loop Test Status Summary
i) Loop test is completed when all the necessary tests have been conducted and the
results are satisfactory.
ii) The loop test results must be accepted by CARIGALI representative to reach this
status.
iii) The following records shall be updated regularly for work progress monitoring and
reporting.
TESTING,
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PROCEDURE
PROCEDURE NO:
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REVISION NO: A

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Commissioning Construction Checks and Tests

i) All air signal lines shall be disconnected and blown through with filtered instrument
air. The lines shall then be blanked off and pressurized for bubble test.
Note: The bubble rate after pressurizing shall be less than three (3) bubbles per
minute.
ii) Instrument air supply lines shall be isolated from the instrument and pressurized
to 1.5 times the maximum working pressure. It is later isolated from pressure
source and for acceptance, the pressure reading on a gauge or manometer shall
not fall at a rate exceeding 68.9 millibar or one (1) psi per hour.
iii) Process impulse line shall be isolated from instruments and pressurized
hydraulically to 1.5 times of the maximum working pressure, they shall then be
isolated from the pressure source and for acceptance the pressure reading on a
gauge or manometer shall not fall at a rate exceeding 68.9 millibar or one (1) psi
per hour.
iv) The sample lines shall be checked for leakage by means of a pressure test at a
minimum of 1.5 times of the design process piping pressure. It is later isolated
from pressure source and for acceptance, the pressure reading on a gauge or
manometer shall not fall at a rate exceeding 68.9 millibar or one (1) psi per hour.
v) Fluid sample lines shall be flushed with water and gas sample lines shall be flushed
with air or nitrogen.
vi) All hydraulic lines shall be flushed and pressurized hydraulically to 1.5 times of the
maximum working pressure. It shall then be isolated form the pressure source.
Note: For acceptance, the pressure reading on a gauge or manometer shall not fall
at a rate exceeding 68.9 millibar or one (1) psi per hour.
vii) During cable installation and before connection, all thermocouple, electric or
electronic instrument wiring shall be checked for polarity and continuity.
TESTING,
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PROCEDURE NO:
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viii)Shields shall be connected and grounded for the above tests. Continuity and single
point grounding of all shields shall also be verified.
ix) The calibration of all instruments within a loop shall be completed before loop
checking is carried out. The loop check shall be the basis upon which instruments
are subsequently accepted.
x) Control loops shall be checked as in above and additionally the control valve shall
be stroked using the manual station and checked in the auto position to verify
correct controller action.
xi) Alarm and shutdown system shall be tested by the PRSB as a loop by simulating
a fault condition at the primary element. It shall be ensured that the correct
operational sequence and action of all components are as per specifications.
5.3.2 LOOP TEST OF PRESSURE INSTRUMENTS

Pressure Transmitter
i) Connect the pressure gauge and hydraulic pump to the process impulse line.
ii) Apply pressure of 0, 25, 50, 75 and 100 percent of range and confirm a correct
transmitter output signal of 4 to 20 milliamperes is received at control panel.
iii) Verify correct controller action to the final control element.
iv) Verify correct Recorder and Indicator reading at control panel.
v) Ensure that all relevant alarms are functioning correctly.
vi) Commissioning checksheet to be duly filled in and witnessed by CARIGALI and
PRSB Quality Control personnel.
Pressure Switch (Electric)

i) Review calibration sheet for pressure switch and other instruments in the loop.
ii) For Pressure Switch Low (Falling Pressure)
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a. Increase applied pressure above the reset point to indicate normal condition
at control panel.
b. Decrease applied pressure to the desired set point and observe change of
status from normal to alarm condition.
c. Ensure that all relevant alarms are functioning correctly.
d. Commissioning checksheet to be duly filled in and witnessed by CARIGALI
and PRSB Quality Control personnel.
iii) For Pressure Switch High (Rising Pressure)
a. Increase applied pressure to the required set point to observe change of status
from normal to alarm condition. Contact should change from normally-close to
normally-open positions (NC to NO).
b. Ensure that all relevant alarms are functioning correctly.
c. Decrease applied pressure below the reset point and observe change of status
from alarm to normal condition. Contact should change from normally-open
position to normally-close position.
d. Commissioning checksheet to be dully filled in and witnessed by CARIGALI
Pneumatic Pressure Switch

i)
For Pressure Switch Low (Falling Pressure)

a. Increase applied pressure above the reset point to indicate normal condition
at control panel.
b. Decrease applied pressure to the desired set point and observe change of
c. Ensure that all relevant alarms are functioning correctly
d. Commissioning check sheet to be dully filled in and witnessed by CARIGALI
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
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REVISION NO: A

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ii) For Pressure Switch High (Rising Pressure)

a. Increase applied pressure to the required set point and observe change of
b. Ensure that all relevant alarms are functioning correctly.
c. Decrease applied pressure below the reset point and observe change of status
from alarm to normal condition.
d. Commissioning checksheet to be dully filled in and witnessed by CARIGALI
5.3.3
LOOP TEST OF TEMPERATURE INSTRUMENTS
Resistance-Temperature-Detector (RTD) Transmitters

i) Connect a decade resistance box to the temperature transmitter.
ii) Induce equivalent resistances at 0, 25, 50, 75 and 100 percent of the temperature
range and confirm the correct recorder or indicator reading at respective control
panel in the control room.
iii) Ensure that all relevant alarms are functioning correctly.
iv) Commissioning check sheet to be duly filled in and witnessed by CARIGALI and
PRSB Quality Control personnel.
Temperature Switches (Electric)
i) Review calibration sheet for temperature switch and other instruments in the loop.
ii) Actuate the switch by actual or simulation input.
Note: For temperature-low switch, contact should change from normally-open (NO)
position to normally-close (NC) position. For temperature-high switch, contact
should change from normally-close (NC) to normally-open (NO) position.
TESTING,
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PROCEDURE
PROCEDURE NO:
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REVISION NO: A

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iii) Observe the change from normal to alarm condition ensure that all relevant alarms
are functioning correctly.
iv) Commissioning check sheet to be dully filled in and witnessed by CARIGALI
representative and PRSB Quality Control personnel.
5.3.4 LOOP TEST OF FLOW INSTRUMENTS

Flow Transmitters - Differential Pressure Cell Type
i) Connect test equipment to flow transmitter
ii) Induce signal of 0, 25, 75 and 100 percent of the differential pressure range and
confirm correct transmitter output (e.g. linear or square root) of 4 to 20 milliamperes
is received at control panel.
iv) Apply pressure to the high side of transmitter with the low side vent to atmosphere.
v) Record test results in Instrument closed loop checksheet (ITS-1007) and shall be
witnessed by PCSB representative and PRSB Quality Control personnel.
Flow Switches
i) Connect test equipment to flow transmitter.
ii) Push the trigger assembly to the left and right, then observe the change of contact
from normally-open (NO) position to normally-close (NC) position and vice versa.
iii) Ensure all relevant alarms are functioning as per drawings.
iv) Record test results in Instrument Closed Loop checksheet (ITS-1007) and shall be
Gas Flow Totalizer
i) Verify that installation checks and inspections including calibration of instruments
had been performed based on the PCSB check sheet (ITS-1002)
TESTING,
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PROCEDURE NO:
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REVISION NO: A
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(172962-D)
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ii) Simulated process input signals to pressure, temperature, and flow transmitter
shall be applied as shown in the tabulation below.
Element
Step 1
Step 2
Step 3
Step 4
Flow
100
50
25
Pressure
25
25
50
100
Temperature
100
100
25
50
Note: Units are in percentage

iii) Manually entered orifice coefficient shall be checked.
iv) At each step individual pressure temperature and flow signals from transmitter
shall be checked against control panel indicator and Distributed Control System
(DCS) Cathode-Ray-Tube (CRT) display.
v) Manual calculation shall be performed and compared with rate indication at each
step.
vi) Hold simulated process signal values constant at each step for 5 minutes to verify
correct accumulation on counters at control panel and CRT. Result shall be
recorded in PCSB instrument closed loop check sheet (ITS-1007) for each loop.
5.3.5 LOOP TEST OF LEVEL INSTRUMENTS

Level Transmitter (Electric) - Differential Pressure Cell Type
i) Induce signal of 0, 25, 75 and 100 percent of the differential pressure range.
ii) Confirm correct transmitter output of 4 to 20 milliamperes is received at control
panel.
iv) Ensure that all relevant alarms are functioning correctly.
TESTING,
PRECOMMISSIONING &
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PROCEDURE
PROCEDURE NO:
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REVISION NO: A

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Level Transmitter (Electric) - Displacer or Float Type
i) Hook-up test equipment and instrument loop to be tested.
ii) Fill in water at 0, 25, 50, 75 and 100 percent of the range.
iii) Confirm correct transmitter output signal of 4 to 20 milliamperes is received at
control panel.
iv) Verify correct controller action to the final control element.
v) Ensure that all relevant alarms are functioning correctly.
vi) Record test results in Instrument closed loop checksheet (ITS-1007) and shall be
Level Transmitter (Pneumatic) - Displacer or Float Type
i) Hook-up test equipment and instrument loop to be tested.
ii) Fill in water at 0, 25, 50, 75 and 100 percent of the range.
iii) Confirm correct transmitter output signal of 20 to 100 kilo-pascal (kPa) is received
at Instrument Control Panel.
iv) Verify correct controller action to the final control element.
Level Switch (Electric) - Displacer or Float Type
i) Hook-up test equipment and instrument to be tested.
ii) For Level Switch Low (Falling Level)
a. Increase calibrating level above the reset point to indicate normal condition at
control panel. Contact should change from normally-open (NO) position to
normally-closed (NC) position.
TESTING,
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b. Decrease calibrating level to the required set point and observe change of status
from normal to alarm condition. Contact should change from normally-closed
(NC) position to normally-open (NO) position.
c. Ensure that all relevant alarms are functioning correctly.
d. Record test results in Instrument closed loop checksheet (ITS-1007) and shall
be witnessed by PCSB representative and PRSB Quality Control personnel.
iii) For Level Switch High (Rising Level)
a) Increase calibrating level to the required set point. Contact should change from
normally-close (NC) position to normally-open (NO) position.
b) Ensure that all relevant alarms are functioning correctly.
c) Decrease calibrating level below the reset point and observe change of status
from alarm to normal condition. Contact should change from normally-open
(NO) position to normally-close (NC) position.
d) Record test results in Instrument closed loop checksheet (ITS-1007) and shall
be witnessed by PCSB representative and PRSB Quality Control personnel.
Level Switch (Pneumatic) - Displacer or Float Type

i) Hook-up test equipment and instrument to be tested.
ii) For Level Switch Low (Falling Level)
a) Increase calibrating level above the reset point to indicate normal condition at
control panel. Confirm 200 kPa output from the switch.
b) Decrease calibrating level to the required set point and observe change of status
from normal to alarm condition. Confirm zero (0) kPa output from the switch.
c) Ensure that all relevant alarms are functioning correctly.
d) Commissioning checksheet to be dully filled in and witnessed by PCSB
iii) For Level Switch High (Rising Level)
a) Increase calibrating level to the required set point to observe change of status
from normal to alarm condition. Confirm zero (0) kPa output from the switch.
TESTING,
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REVISION NO: A

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b) Ensure that all relevant alarms are functioning correctly.

c) Decrease calibrating level below the reset point and observe change of status
from alarm to normal condition. Confirm 200 kPa output from the switch.
d) Ensure that all relevant alarms are functioning correctly.
e) Commissioning checksheet to be dully filled in and witnessed by PCSB
representative and PRSB Quality Control personnel
5.3.6
LOOP TEST OF FINAL CONTROL ELEMENTS
Control Valves
i) Prior to testing, set the proportional band for controller, set the auto/manual
selector to "Manual" and ensure control action is according to specification.
ii) Simulate controller output signals at 0, 25, 50, 75 and 100 percent to control valve
transducer and positioner. Confirm the control valve is functioning correctly.
iii) Turn Auto/Manual selector to "Auto". Confirm that the control valve and other
instrument within the loop is functioning as per design requirements and
specifications.
iv) Commissioning check sheet to be duly filled in and witnessed by PCSB
Shutdown Valve
i) Supply the specified instrument air to shutdown valve.
ii) When 24 volts of direct current output signal from Control Panel is supplied to
energize the solenoid valve, the shutdown valve should open.
iii) Confirm limit switches is functioning by observing the shutdown valve status
indication which changes from close to open (in the form of either lamp or screen
color changes from red to green).
iv) If manual reset is provided to the solenoid valve or pilot valve, manually reset the
solenoid valve or pilot valve before the shutdown valve opens.
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PROCEDURE NO:
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v) When 24 volts of direct current output signal from Control Panel is cut off to deenergize the solenoid valve the shutdown valve should close.
vi) Confirm limit switches is functioning by observing the shutdown valve status
indication which changes from open to close (either lamp or screen color changes
from green to red).
vii) In case the shutdown valve action is controlled by a pneumatic relay with air pilot
signal from Local Pneumatic Panel, confirm the shutdown valve opens when the
air pilot signal to pneumatic relay is healthy.
Note: If manual reset is provided, manually reset the pneumatic relay before the
shutdown valve opens.
viii)During shutdown condition reset handle is immediately released when air pilot
signal to pneumatic relay is unhealthy. The shutdown valve should close. If limit
switch is provided with shutdown valve confirm the status indication changes
correctly to the valve opening and closing action.
ix) Commissioning check sheet to be duly filled in and witnessed by PCSB
Blowdown Valves
i) Supply the specified instrument air to blowdown valve.
ii) When 24 volts of direct current output signal from Control Panel is supplied to
energize the solenoid valve, the blowdown valve should close.
iii) Confirm limit switches is functioning by observing the blowdown valve status
indication which changes from open to close (either lamp or screen color indication
change from red to green).
iv) When 24 volts of direct current output signal from Control Panel is cut off to deenergize the solenoid valve, the blowdown valve should close.
v) Confirm limit switches is functioning by observing the blowdown valve status
indication which changes from close to open (either lamp or screen color changes
from green to red).
TESTING,
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vi) In case the blowdown valve action is controlled by a pneumatic relay with air pilot
signal from Local Pneumatic Panel, confirm the shutdown valve closes when the
air pilot signal to pneumatic relay is healthy.
Note: During shutdown condition when air pilot signal to pneumatic relay is
unhealthy the shutdown valve should open.
vii) If limit switch is provided with the blowdown valves, confirm the status indication
changes correctly to the valve opening and closing action.
viii)Commissioning checksheet to be duly filled in and witnessed by PCSB
5.3.7 ALARM AND SHUTDOWN PANEL
System Energisation
i) Perform visual check to verify completeness of field devices such as breakglass,
switch, transmitter, cables, junction boxes, marshalling cabinet and panel installation.
ii) Verify completeness of cable insulation resistance and continuity tests.
iii) Inspect all power supply distribution wiring to ensure correct polarity and secured
connections.
iv) Connect the power supplies to the incoming terminals, close each circuit breaker and
insert associated fuse. Confirm that only correct group of terminals are energized.
v) Measure the voltage at the incoming terminals and panel/cabinet distribution. Confirm
that the voltage is not significantly different from the power supply voltage.
Loop checking
i) Upload the latest revision to the alarm and shutdown logic software.
ii) Perform loop check from input field devices e.g breakglass, switches, pushbuttons,
transmitter, etc to the panel.
TESTING,
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PROCEDURE NO:
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iii) Perform loop check from panel to output field devices i.e shutdown/blowdown valves
and motor control center (MCC)
iv) Perform system interface check with Fire and Gas Distributed Control System and
General Platform Alarm system.
Operational System Test
i) Achieve System Healthy status by setting all inputs to normal state.
ii) Change the state of one of the inputs that causes the Emergency Shutdown and
Blowdown (ESD1) to alarm/shutdown condition.
iii) Verify the input change of state is annunciated on the ASD Console, DCS and
Maintenance Computer Log.
iv) Confirm that resetting the system without changing the state of the input back to
normal will not restore System Healthy condition.
v) Normalize the input and reset the system.
vi) Repeat steps ii) to iv) for all other ESD inputs.
vii) Repeat steps ii) to iv) for all other Process Shutdown (PSD) and Unit Shutdown (USD)
viii) Activate the Start-Up Bypass of an input which has similar facility.
ix) Confirm that the system does not trip when the input changes from normal to alarm
/shutdown state. Nonetheless, the input change of state is annunciated on the ASD
Console, DCS and Maintenance Computer Log.
x) Repeat steps viii) to ix) for all inputs with Start-Up Bypass facility.
xi) Activate the Maintenance Override of an input which has such facility.
xii) Confirm that the system does not trip when the input changes from normal to alarm
/shutdown state. Nonetheless, the input change of state is annunciated on the ASD
Console, DCS and Maintenance Computer Log.
xiii) Repeat steps xi) to xii) for all inputs with Maintenance Override facility.
xiv) Test other normal operation (non-shutdown) logic and confirm correct operation of
equipment per the operational logic.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
PAGE 71 OF 72
5.3.8 PNEUMATIC FIRE & GAS DETECTION

i) Bubble leak test the fusible plug and kill knob circuit. Verify that there is no bubble.
ii) After completing the leak test and all tubing are completely hook-up, charge the fusible
plug loop and kill knob circuit from deluge panel and monitor the charge pressure.
iii) Perform instrument loop check on fusible plug loops, kill knob circuit and associated
instruments.
iv) Activate manually kill knob circuit and check its operation.
v) Simulate all system inputs such as release of fusible plug loop pressure and kill knob
activation.
vi) Verify corresponding outputs are in accordance with Fire and Gas cause and effect
matrix including checking for visual and audible alarms.
Note: Fire and Gas Panel vendor or operation assistance may be required.
iii) Documentation of all checks and tests made.
TESTING,
PRECOMMISSIONING &
COMMISSIONING
PROCEDURE
PROCEDURE NO:
PSP-CS-PL381-003
REVISION NO: A

(172962-D)
HOOK-UP AND
COMMISSIONING
PAGE 72 OF 72
6.0 CHECKSHEET LISTING

Listed below is a directory of available checksheets prepared by PCSB under CSP-20
Rev.1, testing and commissioning procedure. PRSB shall provide and review the
checksheet contents for completeness and for selecting only the relevant sheet to the
Works.
6.1 INSPECTION TEST RECORD LISTING

(Refer to Appendix)

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TESTING,

PETRA RESOURCES SDN BHD

2.1 System Definition

2.4 System by System Scope of Work for TKP-A

3.1 Codes & Standards

PETRA RESOURCES SDN BHD

5.1 Mechanical Equipment & Piping Commissioning

PETRA RESOURCES SDN BHD

PETRA RESOURCES SDN BHD

PETRA RESOURCES SDN BHD

PETRA RESOURCES SDN BHD

PETRA RESOURCES SDN BHD

PETRA RESOURCES SDN BHD

2.2 SYSTEM DESCRIPTION AND SCOPE OF WORKS

PETRA RESOURCES SDN BHD

For piping not permitted to be flushed with water due to process

PETRA RESOURCES SDN BHD

Intermediate vent and drain points shall be located and

PETRA RESOURCES SDN BHD

to the highest system vent point.

PETRA RESOURCES SDN BHD

i. Perform internal inspection and verify cleaning of vessels is

Verify valves, flanges and piping items were properly

e) Reinstatement of the system shall be performed at 1.1 x maximum

PETRA RESOURCES SDN BHD

PETRA RESOURCES SDN BHD

j) Check final closure of vessel / tank with proper gasket.

PETRA RESOURCES SDN BHD

iv) Verify instrument installations, testing and calibrations are completed

PETRA RESOURCES SDN BHD

operational sequence and action of all components are as per

PETRA RESOURCES SDN BHD

2.4 SYSTEM BY SYSTEM SCOPE OF WORK FOR TKP-A

- 120: PROCESS LIQUID

- 122: LIQUID COLLECTION AND RECEIVING

Separation of incoming crude is common on most facilities. Separation vessels are

PETRA RESOURCES SDN BHD

PL METERING & EXPORT/OFFLOADING

PETRA RESOURCES SDN BHD

- 200: PROCESS UTILITIES

- 220: INERT GAS

PETRA RESOURCES SDN BHD

- 200: PROCESS UTILITIES

PETRA RESOURCES SDN BHD

- 200: PROCESS UTILITIES

OPEN DRAIN (NON-HAZARDOUS)

PETRA RESOURCES SDN BHD

- 200: PROCESS UTILITIES

PETRA RESOURCES SDN BHD

- 200: PROCESS UTILITIES

- 270: CHEMICAL INJECTION / TREATMENT

PETRA RESOURCES SDN BHD

- 200: PROCESS UTILITIES

- 270: CHEMICAL INJECTION / TREATMENT

PETRA RESOURCES SDN BHD

- 200: PROCESS UTILITIES

- 270: CHEMICAL INJECTION / TREATMENT

Sub-Sub-System - 279-1: BIOCIDE

PETRA RESOURCES SDN BHD

- 300: GENERAL UTILITIES

- 320: COMPRESSED AIR

PETRA RESOURCES SDN BHD

- 420: LIFESAVING EQUIPMENT