PROCEDURE NO: PROJECT SPECIFIC PROCEDURE PSP-RESAK HTI-24 HUC REVISION NO. 0 PRE-COMMISSIONING AND COMMISSIONING PROCEDURE FOR PETRONAS CARIGALI SDN BHD KUALA LUMPUR DAYANG ENTERPRISE SDN BHD PCSB PREPARED BY WeviEWED BY [APPROVED BY nevieweppy | arPRoven py ney. | pare Taam [OS | on [Defoe [mw [Oe STOC| ese Im | CHPRE-COMMISSIONING AND COMMISSIONING PROCEDURE PROCEDURE NO. PSP-RESAK HTI-24 REVISION NO. 0 fee PAGE 1 OF 43 DESCRIPTION PAGE 10 PURPOSE 3 20 scoPE, 3 30 REFERENCES 3 4.0 DEFINITIONS 3 5.0 PROCEDURE 3 5.1 Testing and Commissioning 4 5.2. System Defintion 4 5.3 Common Scope of Work 5-36 60 SPECIAL REQUIREMENTS 36 7.0 RECORDS 36 8.0 DRAWINGS 36 9.0 ACCEPTANCE CRITERIA 36-38 10.0 COMMISSIONING GUIDELINES 39-42 ATTACHMENT Figure | ‘System Definition for Resak HTI HUC Work.PRE-COMMISSIONING AND COMMISSIONING PROCEDURE HUC PROCEDURE NO. PSP-RESAK HT! REVISION NO. 0 PAGE 2 OF 43 4 1.0 2.0 3.0 PURPOSE ‘The purpose of testing and commissioning is to ensure that all facilities and equipment which are categorised into a specific system are fully tested and commissioned in the platform, in which all system are fully operable in accordance to CARIGALI requirement. SCOPE OF WORK ‘The testing and commissioning scope of work covers all ofishore hook-up, operational performance testing and static system, which were accepted during yard commissioning hand-over and get ready for operational acceptance by CARIGALL. REFERENCES Contract Document - CH2/C3/2006/DFHD/354 CSP-120 Rev. 1 - Testing and Pre-Commissioning Guideline QA-WI-007 Rev.3 - Inspection, Measuring & Test Equipment FSP-DESB-T24 - Hydrotesting Procedure CSP-04 = Project Procedure GuidelinesPRE-COMMISSIONING AND COMMISSIONING PROCEDURE PROCEDURE NO. PSP-RESAK HTI-24 REVISION NO. 0 HUC PAGE 3 OF 43 4.0 DEFINITIONS 41 42 43 Inspection Series of observation on any installation of the equipment package to ensure compliance to the approved drawings, specification and contract contents. ‘The inspection shall be conducted by DESB QA/QC Inspector to verify completeness of fabrication work prior to acceptance by Testing and Commissioning team. Checklists shall be documented throughout the inspections period. ‘The CARIGALI Construction Check Sheet shall be completed during this session ‘Testing and Pre-Commissioning Includes static test, functional test, loop test, reinstatement test and other form of testing to verify integrity of system components associated to the packages. DESB shall issue advice (verbal or written) to CARIGALI at least one (1) day in advance before conducting pre-commissioning. Calibration and functional test checksheets shall be part of pre~ commissioning documents. Commissioning ‘Commissioning shall be carried out after the system are made functional and operational as per design intent and specifications in accordance with the contract Commissioning includes equipment test run, panel energization and integrity test of newly installed equipment.PRE-COMMISSIONING AND COMMISSIONING PROCEDURE HUC PROCEDURE NO. PSP-RESAK HTI-24 REVISION NO. 0 PAGE 4 OF 43 44 45 * Commissioning Checksheets shall be established to form part of “Final Documentation” and shall be compiled on system by system basis to be handed over to HUC Team for further action during HUC offshore activities. Preservation * Upon completion all the above Inspection, Testing & Commissioning, all the equipment, control panel shall be preserved in accordance with manufacturer and CARIGALI standard procedure and specification. Abbreviations Qavac = Quality Assurance/Quality Control NCR = Non-Conformance Report DESB = Dayang Enterprise Sdn Bhd PCSB = Petronas Carigali Sin Bhd Des. = Distributed Control System ps = Shutdown System FNG = Fire & Gas System MCC = Motor Control Centre IMCS = Integrated Motor Control System v0, = Input/Output SPIR = Spare Parts List And Interchangeability Record MCB = Main Circuit Breaker TCB = Thermal Circuit Breaker LIC - Level Indicator Controller Lev = Level Control ValvePROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK HTL-24 COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 5 OF 43 5.0 PROCEDURE 5.1 Testing and commissioning Prior to perform testing and commissioning acti ties, the method and sequence shall be established as follows:~ 5.1.1 Work Scope Demarcation 5.1.1.1 In-House Test DESB may proceed to conduct with the house commissioning prior to conduct and witness officially by CARIGALL A notice (verbal or written) to CARIGALI shall be submitted one day before the testing to be carried out. 5.1.1.2 DESB Work scope ‘The following testing and commissioning activities will be carried out by DESB team but not be limited to:~ a) b) 2 4) 9) D 8) Reinstatement Test Nitrogen Purging Chemical Cleaning Loop check for all instrument up to DCS & SDS system Instrument Calibration Testing and commissioning of equipment, package and System by System Hydrotest 5.1.1.3 3" Party/Vendor Workscope Vendor shall be involved in the testing and commissioning of the following systems: a » °) d DCS system SDS system FnG System MCC/IMCS SystemPROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK HTE-24 COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 6 OF 43 52 5.1.2 Commissioning Preparation a) » °) 4d Ensure and compile all the QC Release Note, Sign-Off Installation Checksheets, NCR, Punchlists and Work Permit (If any). Ensure the availability of specification, procedure, vendor data, relevant extract contract documents and vendor representative at site, Check and ensure the availability of tools, testing equipment, special tools and dummy items. Check and ensure the availability of consumables such as Lube Oil, Lubrication, Silica Gel, and Chemical ete. Ensure that the gauges, chart recorders are calibrated with valid certificates. Adherence to Safety Precautions. System Definition Al faci -s and equipment are categorised into specific system where in a system is defined as a configuration of pipeworks or equipment that fall within the same process medium, Systems are further categorized into sub-system and sub-sub system. Each subsequent category identifies the relevant system in more details, Systems applicable for the Resak HT project at the different levels are shown as per Figure |PROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK HTI-24 COMMISSIONING PROCEDURE HUC REVISION NO. 0 PAGE 7 OF 43 $3 Common Scope of Work ‘The standard and common scope of works for similar equipment such as pumps, cables, piping etc. under the different system and sub-system is readily identifiable as depicted in the following sub-sections. 5.3.1 General 53.11 53.1.2 53.13 53.14 53.15 5.3.2 Piping 5.3.21 Verify equipment manuals, reference drawings, factory calibration certificates, test reports and test certificates are available. Verity equipment skid structure and on-skid items are damage free, Verify name plate data for all items are as per datasheet and specification and P&ID's. Verify tagging and numbering for all items are correct. Verify equipment temporary shipping braces, stopper and other protective structures are removed, Verify flushing has been completed which shall include the following activities:- i) Pipe work is flushed clean using a volume flow and a minimum velocity of three (3) meters per second. ii) All valves including actuated valves included in flushing are in open positions. iii) When vessels are included in flushing, ensure that the vessels are opened and checked internally.PRE-COMMISSIONING AND FeeuEShiearrad COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 8 OF 43 iv) Pipin terior is verified to be clean after flushing. ¥) Strainers are re-instated to normal positions after flushing. 5.3.2.2 Verify hiydrotesting has been completed which shall include the following activities:- “Note: Prior to hydrotesting all the related completed record for piping such as RT, NDT has been compiled as per hydrotesting test packages and limit. i. Pipe work flanges and branches are adequately bolted and tightened. ii, Leak test of valves has been done based on acceptance criteria on API 6D and BS 5351 Codes and Standards. iii, Non-return valves and swing check valves are returned to normal positions after completion of hydrotesting. iv, Temporary spade and blinds are removed after hydrotesting. v. Pipe works are drained and purged with dry clean air. vi, All instruments and relief valves, removals shall be reinstated to original locations. 5.3.2.3 Verify pipe work is internally cleaned and preservation applied after pickling or acid cleaning . 5.3.2.4 Perform reinstatement test which shall include the following activities i. Perform internal inspection and verify cleaning of vessels is completed and Final Closure Certificates have been issued, ii, Perform the line checking against Piping and Instrumentation Diagram (P&ID) drawings as follows:-PROCEDURE NO. PRE-COMMISSIONING AND PERERA? COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 9 OF 43 a) Verify valves, flanges and piping items are properly installed and tightened. b) Verify gaskets installed are of the right specificat ©) Verify pipeworks are adequately supported. 4) Verify check valves are installed in the right direction, ©) Verify line instrument and isolation valves have been leak tested. The respective set value for the instrument shall also be configured with P&ID. 1) Verify colour-coding, line numbering and directional arrow are provided correctly. 2) Perform functional test on all manually operated, isolation and block valves. 5.3.3. Mechanical 5.33.1 Verify hold down bolts and vibration dampeners have been adequately installed and tightened. 5.33.2. Verify skid and equipment levelness as recommended by Vendor. If grouting is applied, Vendor Representative concurrence may be required during inspections. 5.3.3.3 Secure and preserve equipment after commissioning works, 5.3.4 Electrical 5.3.4.1 Verify nameplate data, tagging and numbering of cables, relays and devices,PROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK HTI-24 COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 10 OF 43, 5.3.4.2 53.4.3 53.44 53.45 Verify electrical cables are installed correctly, continuity checked and insulation tested. Verify electrical junction box installations and power cable terminations are completed as per specifications, Verify all earthing connections are terminated and tested. Power supply should remain in “ON” position after completion of commissioning activities. 5.3.5. Instrumentation 53.5.1 53.5.2 53.5.3 53.5.4 53.5.5 Verify all individual instruments comply with CARIGALI specifications prior to calibration by comparing instrument name tags and datasheets to the specifications. Verify instruments installation, testing and calibration are completed and recorded on standard forms and checksheets. Verity calibration and pop test certificates of all relief valves. Verify that all tubing’s for primary process, secondary signal, instrument air supply, sample lines and hydraulic lines are leak tested to the specification requirements as per CSP. Verify that all instrument junction box installations and cable termination are correctly installed. Verify completion of instrument and control cable insulation resistance checks and continuity checks. All thermocouples, electrical and instrument wiring shall be checked for polarity and continuity.PRE-COMMISSIONING AND COMMISSIONING PROCEDURE PROCEDURE NO, PSP-RESAK HTI-24 HUC REVISION NO. 0 PAGE 11 OF 43 5.3.5.6 5.3.5.7 5.3.5.8 Verify instrument isolation valves could be opened and closed easily and sight glasses are not obstrueted with paint, etc Perform loop checking off all indication control, alarm and shutdown feature from field instruments to control panel, eg. DCS & SDS with other local panels. This includes stroking of valves i.e. shutdown valves, control valves, etc. and function testing of local control panel. Perform matrix test by executing alarm and shutdown test of system by simulating a fault condition at the primary element. It shall be ensure that the correct operational sequence and action of all components are as per specifications,PROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK HTL24 COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 12 OF 43 5.3.6 Scope of Work (System) ‘The detailed scope of work for the predetermined systems shall include other relevant details from vendors manual and drawings. All these details are essential for acquiring accurate and complete scope of works for the specific system/sub-system, The subsequent pages depict the detailed scope of work for the predetermined systems. (To include overall system limit/demonstration) 1 System 100- Process ‘Sub-System 120 - Process Gas Sub-Sub-System 121 - Gas Collection & Recei 5.3.6.1.1 System Description The sub-sub system is generally associated with its boundaries define from the gas/condensate receiver to the slug catcher. Process gas is received from TBDR-A via 24” subsea pipeline at RDP-A by newly installed Gas/Condensate Receiver facilities at RDP-A, The process gas will be routed to Slug Cather for further process. This Sub-sub system includes Gas/Condensate Receiver (R-2950), Riser Valves, Motorised Valves, associated piping and instrumentation, Refer to P&ID: RDP-A-B-10209 rev.PROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK HTL-24 COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 13 OF 43 5.36.1.2. Commissioning scope of work i iii) Piping Refer to Section 5,3.2~ Common Piping scope of work. Mechanical a) Refer to Section 5.3.3. — Common Mechanical scope of work. b) Verify quick opening closure as per specification and manufacturer standard. ©) Perform internal inspection of the receiver and issue final closure certificate. Electrical a) None Instrumentation 8) Refer to Section 5.3.5 ~ Common Instrumentation scope of work. b) Verify stroke test for shutdown valve have been completed ©) Verify all pressure transmitters have been calibrated and certificated. All set values are accordance with approved P&ID. a) Verify all pressure gauges have been calibrated and certificated. ©) Verify all tubing have been leak tested. £) Perform control signal loop check from/to DCS & SDS system,PROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK HTI-24 COMMISSIONING PROCEDURE HUC REVISION NO. 0 PAGE 14 OF 43 5.3.6.2 System 100 - Process ‘Sub-System 120 - Process Gas ‘Sub-Sub-System 122 - Slug Catcher 5.3.6.2.1 5.3.6.2.2 System Description ‘The gas/condensate from receiver are routed to a 1 x 100% Slug Catcher where the gas/condensate will be separated. ‘The liquid level in the Slug Catcher is monitored and controlled by level instruments (LIC) which will modulate the opening of level control valves (LCV). The outlets of the Slug Catcher are routed to the suction scrubber (gas) and newly installed TCB condensate pump (liquid) respectively. This Sub-sub system consists of Slug Catcher (V-2010), Analyzer (QUA-2010), associated piping and instrument. Refer to P&ID: RDP-A-B-10210 rev.1 Commissioning scope of work Piping a) Refer to Section 5.3.2 - Common Piping scope of work, ‘Mechanical a) Refer to Section 5.3,3 - Common Mechanical Scope of work. b) Perform inspection of slug catcher for cleanliness and issue final closure certificate.PRE-COMMISSIONING AND COMMISSIONING PROCEDURE PROCEDURE NO. PSP-RESAK HTI-24 HUC REVISION NO. 0 PAGE 15 OF 43 iii, Electrical a) Refer to Section 5.3.4 - Common Electrical scope of work. Instrumentation a) Refer to Section 5.3.5 — Common Instrumentation scope of work. b) Perform modulating/loop checking for Level Control Valve and Level Transmitter. ©) Verify stroke test for shutdown valve have been completed. @ Verify all pressure transmitters have been calibrated and certificated. All set values are accordance with approved P&ID. ©) Verify all pressure gauges have been calibrated and certificated. f) Verify all tubing have been leak tested, 8) Perform control signal loop check from to DCS & SDS system.PROCEDURE NO. PRE-COMMISSIONING AND. PSP-RESAK HTI-24 COMMISSIONING PROCEDURE HUC REVISION NO. 0 PAGE 16 OF 43 5.3.6.3 System 200 - Process Utilities ‘Sub-System 220 — Condensate ‘Sub-Sub-System 221 — Condensate Collection 5.3.6.3.1 53.6.3.2 System Description The condensate from the Slug Catcher will be transferred to TBC Condensate Pumps at RCPP via RDP-A/RCPP-A bridge. The newly installed | x 100% TBC condensate pump (P-3000) will be operated constantly where the existing pump (P-3055) will be used as standby. The condensate from the new TBC Pump will comingle with condensate fiom other pumps and will be transferred to the respective gas/condensate trains. This Sub-sub system consists of TBC Condensate Pump (P-3000), Condensate Pump (P-3055), associated piping and instruments. Refer to P&ID: RCPP-A-B-0063 rev.1 Commissioning scope of work i) Piping a) Refer to Section 5.3.2 - Common Piping scope of work. ii) Mechanical a) Refer to Section 5.3.3 — Common Mechanical Scope of work. b) Perform functional test for TBC Condensate Pump iii) Electrical a) Refer to Section 5.3.4 ~ Common Electrical scope of work.PROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK HTI-24 COMMISSIONING PROCEDURE HUC REVISION NO. 0 PAGE 17 OF 43 iv) Instrumentation Refer to Section 5.3.5 — Common Instrumentation scope of work. 5.3.64 System 400 - Safety and Firefighting Sub-System 410 ~ Firefighting Sub-Sub System 411 - Firewater 5.3.6.4.1 5.3.6.4.2 System Description Firewater shall be drawn from RCPP-A to RDP-A for firefighting purposes. A firewater ring main covering the entire platform shall be provided. Hose connections, accessible throughout the platform shall be provided on the ring main, A newly installed firewater station to cover new gas/condensate receiver. The existing firewater monitor (ZMW-5302) is relocated to cover the new installation of RDP-A Slug Catcher. This sub-sub system consists of firewater ring main, firewater monitors, deluge valve, hose connections, associated piping and instrumentation. Refer to P&ID; RDP-A-B-10027 rev.1 Commissioning scope of work i) Piping a) Refer to Section 5.3.2 ~ Common Piping scope of work. ii) Mechanical a) Perform Light Water Station test. b) Perform Fire monitor functional test.PROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK HTT-24 COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 18 OF 43 53.6.5 iii) Electrical a) None iv) Instrumentation a) Refer to Section 5.3.5 - Instrumentation scope of work. System 500 - Power ‘Sub-System 520 - Main Power Distribution Common Sub-Sub-System 522 - Low Voltage Motor Control Centre & Switchgear 5.3.6.5. System Description This Sub-sub system consists of new 415 VAC LV Motor Control Centre (MCC-7719). ‘The new 415 VAC LV Motor Control Centre provides low voltage 3 phase power for the newly installed TBC Condensate Pump. The new MCC also provides LV 3 phase power to the new Lube Oil Pump & SB Pump. Refer to SLD: RCPP-E-0129 rev.1 5.3.6.5.2 Commissioning scope of work i) Piping a) None ii) Mechanical a) None Lube OilPROCEDURE Ne PRE-COMMISSIONING AND PSP-RESAK TTA COMMISSIONING PROCEDURE HUC REVISION NO. 0 PAGE 19 OF 43, iii) Electrical a b) i) dD LS) I) Refer to Section 5.3.4 - Common Electrical scope of work. Check the area classification of the location of distribution board installed. Ensure that all. parts of the system meet the classification requirements and the environmental conditions. Test the operation of circuit ACB/MCCB and verify that itis in good condition, Check all components including the ammeter accordance with approved drawings. Check quantity of circuit accordance with approved drawings. Check the mechanical part of the MCC and verify it is in condition, Inspect tightness of all busbar bolted connections. Perform Insulation test for switchboard anti- condensation heater. Perform resistance test of busbar bolted connection (Ducter). Perform Insulation test of switchboard busbars (line-to-line, line-to-ground). Check switchboard earthing bar and earthing connection. Energize the MCC by competent chargeman,PRE-COMMISSIONING AND PSP-RESAK BT COMMISSIONING PROCEDURE PROCEDURE NO. 4 HUC REVISION NO. 0 PAGE 20 OF 43 53.6.6 m) Check incoming power supply and outgoing power supply using calibrated JBE/SIRIM approved test equipment. iv) Instrumentation a) Verify “TRIP* command from SDS system. b) Verify ‘START-STOP-RUN’ indication fronvto DCS system. ‘System 500 - Power ‘Sub-System $40 - Minor Power Distribution Sub-Sub-System 541 - Small Power and Lighting 5.3.6.6.1 5.3.6.6.2 System Deseription All lights provided for Slug Catcher area are suitable for Zone 2 EEx ed II T3 A/B 1P66 min. All junction boxes provided on this system are suitable for Zone 2 EEx ed II A/B T3 IP66 min. The cable entry to junction shall be provided at both sides. All newly installed and relocated lighting fixtures shall be tested according to CSP. ‘Commissioning scope of work i) Piping a) None ii) Mechanical a) NonePROCEDURE NO. PRE-COMMISSIONING AND ESPRESAK HTT 4 COMMISSIONING PROCEDURE HUC REVISION NO. 0 PAGE 21 OF 43 iii) Electrical a) b) d) 8) 4) Refer to Section 5.3.4 - Common Electrical scope of work. Inspect and check complete installation of lighting fixtures, power supply cables, cable glands and spare cable entry plugs are correctly provided accordance with the approved drawing. Check the area classification of the location where the lighting, junction and end devices are installed. Ensure that all parts of the system meet the classification requirements and the environmental conditions. Check quantity of lighting fittings in a circuit accordance with approved drawings. Check the lighting cireuit numbering and loadings against circuit fuses size and main MCB rating, Inspect lighting distribution board bus bar connections, Retighten of bolts if required. Energize and verify the lightings operations in each circuit for 24 hours. Test the operation of circuit MCB and verify that it controls the correct lighting circuit, Measure the incoming and branch cireuit voltage at the lighting distribution board with all the cireuit on, iv) Instrumentation a) NonePRE-COMMISSIONING AND PSP-RESAK HT! COMMISSIONING PROCEDURE PROCEDURE NO. 4 REVISION NO. 0 HUC PAGE 22 OF 43 5.3.6.7 System 500 - Power Sub- System 540 - Minor Power Sub-Sub-System 543 - _Earthing and Lightning Protection 5.3.6.7.1 System Description Sub-sub system 543 consists of earthing ring and branch conductors, earthing bar, earthing resistors, earthing boss, cable wire armour bonding and junetion boxes. 5.3.6.7.2. Commissioning scope of work i) Piping a) None Mechanical a) None iii) Electrical a) Refer to Section 5.3.4 — Common Electrical scope of work. b) Inspect and check earth cable lugs, earth boss stud diameter and welding, and earth resistor connections.Ensure that earthing layout and connections conform to the design. ©) 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 plate or kick pipes.PRE-COMMISSIONING AND COMMISSIONING PROCEDURE HUC PROCEDURE NO. PSP-RESAK HTI-24 REVISION NO. 0 PAGE 23 OF 43 f) Check that earth cable sizes are correct. 2) Con ity and resistance checks on bonding of cable wire armour/braid, brass cable glands and equipment frame to earth, main earth resistance and earth loop resistance. h) Check, inspect and test Neutral Earthing Resistor such as measuring ohmic value, insulation resistance test and di-electtic test. iv) Instrumentation a) NonePROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK HTI-24 COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 24 OF 43 53.6.8 System 600 - Controls Sub-System 610 - Process Control Sub-Sub-System 611 - Distributed Control System (DCS) 53.6. 1 System Description Sub-sub system 611 consists of a microprocessor-based Distributed Control System (DCS) which utilizes buted processors with conventional hardwired signal as to perform loop and sequence controls, interfacing to input and output (I/O) points from field devices on local, remote platforms, interface with emergency shutdown di system and operator interface function, 5.3.6.8.2 Commissioning scope of work i) Piping a) None ii) Mechanical a) None iii) Electrical a) Refer to Section 5.3.4 - Common Electrical scope of work. iv) Instrumentation a) Refer to Section 5.3.5 - Common Instrumentation scope of work. b) Check wire terminals for solid and clean connections. ) Check for manual operations of switches and pushbuttons.PRE-COMMISSIONING AND COMMISSIONING PROCEDURE PROCEDURE NO. PSP-RESAK HTI-24 HUC REVISION NO. 0 PAGE 25 OF 43 d) Check if control switches, push buttons and main circuit breaker function correctly. ©) Check for internals fault and proper operation of the system under the supervision of vendor's representative. Verify interface loops of the system to other systems through the use of either simulated or actual inputs. 1.With multimeter, check the following resistance levels. + signal to - signal 50 K ohms + signal to shield >20 M ohms ~ signal to shield >20 M ohms + signal to instrument ground >20 M ohms - signal to instrument ground >20 M ohms Shield to instrument ground >20 M ohms. 2.Check capacitance values should be; + signal to - signal 1 micro farad. + signal to shield <300 nF. - signal to shield <300 nF. + signal to instrument ground <300 nF. - signal to instrument ground <300 nF. Shield to instrument ground <300 nF.PRE-COMMISSIONING AND COMMISSIONING PROCEDURE PROCEDURE NO. PSP-RESAK HTI-24 HUC REVISION NO. 0 PAGE 26 OF 43 5.3.6.9 System 600 - Control Sub-System 610 - Process Monitoring and Control System ‘Sub-Sub-System 613 — Instrument Controls 53.6.9.1 5.3.6.9.2 System Description The Integrated Motor Control System provides the emergency shutdown function for the new TBC Condensate Pump Motor via newly installed — MCC-719. DCS system continuously monitors the process variables and SDS system automatically initiates shutdown to Motor via IMCS central interface unit if any of the variables is outside the predetermined safe limit. However, it is not intended for process control purposes. ‘These sub-sub-system components include the programmable logic controller based IMCS panel, MCC-7719, associated cabling and junction boxes. Commissioning scope of work ) Piping a) None ii) Mechanical a) None iii) Electrical a) Refer to Section 5.3.4 ~ Common Electrical scope of work.PRE-COMMISSIONING AND COMMISSIONING PROCEDURE PROCEDURE NO. PSP-RESAK HTI-24 HUC REVISION NO. 0 PAGE 27 OF 43 Instrumentation ” b) Refer to Section 5.3.5 ~ Common Instrumentation scope of work. Very input and output (1/0) cards, processor and power supply cards are functioning properly. Verify the latest revision of shutdown logic software is downloaded. Perform system interface check with field devices. Verify start-up bypass, maintenance override, alarm and shutdown acknowledge and reset features are functioning correctly. Perform complete shutdown logic test as per cause and effect matrix test eg. fault tolerance and redundancy, power failure, fault diagnostic alarm and shutdown logs, etc. Note: Vendor representative assistance may be required,PRE-COMMISSIONING AND Pease COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 28 OF 43 5.3.6.10 System 600 — Controls Sub-System 620 - Alarm and Shutdown ‘Sub-Sub-System 621- Alarm and Shutdown Panel 53.6.10.1 System Description ‘The Shutdown System (SDS) panel provides the emergency shutdown function for the entire facility. It continuously monitors the process variables and automatically initiates shutdown and blowdown if any of the variables is outside the predetermined safe limit. However, it is not intended for process control purposes. These sub-sub-system components include the programmable logic controller based shutdown panel, field devices such as transmitters (SDS), shutdown valves, etc., associated cabling and junction boxes. 5.3.6.10.2. Commissioning scope of work i) Piping a) None ii) Mechanical a) None Electrical a) Refer to Section 5.3.4 — Common Electrical scope of work.PRE-COMMISSIONING AND PROCEDURE NO. PSP-RESAK HTI-24 COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 29 OF 43 iy) Instrumentation a) Refer to Section 5.3.5 - Common Instrumentation scope of work. b) Very input and output (1/0) cards, processor and power supply cards are functioning properly. ©) Verify the latest revision of shutdown logic software is downloaded. d) Perform system interface check with field devices, ©) Verify start-up bypass, maintenance override, alarm and shutdown acknowledge and reset features are functioning correctly. £) Perform complete shutdown logic test as per cause and effect matrix drawing. 2) Perform complete —_ system integrity test e.g. fault tolerance and redundancy, power failure, fault diagnostic alarm and shutdown logs, ete, Note: Vendor representative assistance may be required.PRE-COMMISSIONING AND COMMISSIONING PROCEDURE HUC PROCEDURE NO. PSP-RESAK HT! 4 REVISION NO. 0 PAGE 30 OF 43 5.3.6.1 System 600 - Controls ‘Sub-System 630 — Fire and Gas ‘Sub-Sub-System 631- Fire and Gas Panel 5.3.6.11.1 System Description Sub-sub system 631 consists of fire and gas panel for monitoring all fire detection devices. The devices control the automatic release of fixed fire extinguishing items on the platform and interface, with other sub system for shutdown and alarms. This includes thermal, flame, smoke and gas detector, pressure switches, break glass stations, manual stations, solenoid valves, fire dampers, cables and junction box. This sub system is also interfaced fo platform alarm and shutdown and process control system, The new fire & gas detectors for RDP-A Receiver & Slug Catcher and RCPP-A TBC Condensate Pump shall be tested according to the cause & effect matrix. 5.3.6.11.2Commissioning scope of work i) Piping a) None ii) Mechanical a) None iii) Electrical a) Refer to Section 5.34 — Common Electrical scope of work.PROCEDURE N¢ PRE-COMMISSIONING AND PSP-RESAK HTL-24 COMMISSIONING PROCEDURE REVISION NO. 0 PAGE 31 OF 43 iv) Instrumentation a) Refer to Section 5.3.5 — Common Instrumentation scope of work. b) Verify nameplate and equipment data conform to specification, ©) Verify wire terminals for solid and clean connections. d) Check all lugs and connectors for correct tagging and numbering. ©) Verify control switches, pushbuttons functions correctly. £) Perform fire and gas detection device loop check. g) Perform simulation of all system inputs. h) Verify the corresponding outputs are in accordance with fire and gas cause and effect matrix. Note: Fire and gas panel vendor representative assistance may be required.PROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK HTI-24 COMMISSIONING PROCEDURE HUC REVISION NO. 0 PAGE 32 OF 43 5.3.6.12 System 600 - Controls Sub-System 630 — Fire and Gas Detection Sub-Sub-System 632 - Pneumatic Fire and Gas Detection 5.3.6.12.1 5.3.6.12.2 System Description Sub-sub system 632 includes all the fusible plug oops and other pneumatic sensors used. for monitoring fire in strategic locations throughout the platform, Fusible plug loops are normally hook-up to the deluge valve panel which serve as an input for fire detection, Deluge valve panel senses the release of fusible plug loop pressure by means of charge pressure switch low and send it as an input signal to Fire and Gas panel which senses output to de- energize deluge valve solenoid to open deluge valve and discharge water to the sprinkler system. Deluge valve panel in tum will send feedback signal when fire and gas panel when deluge is activated, The new fusible plug loops only cater the new Condensate Pump at RCPP-A since there is no fusible plug loop system at RDP-A platform. ‘The testing for the new loops shall be carried out during shutdown after’ the tie-in works completed, ‘Commissioning scope of work i) Piping a) None ii) Mechanical a) NonePROCEDURE NO. PRE-COMMISSIONING AND Ber aes tye COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 33 OF 43 iii) Electrical a) Refer to Section 5.34 — Common Electtical scope of work. iv) Instrumentation a) Refer to Section 5.3.5 — Common Instrumentation scope of work. b) Verify quantity and temperature rating of fusible plug on each loop. ©) Charging the system from deluge panel and/ monitor the charge pressure indication, 4) Simulate all system inputs such as release of each fusible plug loop and verify that the corresponding output is in accordance with fire and gas cause and effect matrix, Note: Vendor representative assistance may be required.PROC! IRE NO. PRE-COMMISSIONING AND fer eae COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 34 OF3 43 5.3.6.13. System 700 - Telecommunications Sub-System 710 ~ Communications Equipment Sub-Sub-System 711 — HF/VHF/UHF Radio 5.3.6.13.1 System Description The radio system provides the means of communication between the RCPP-A platform and TBCP-A platform. The system components include the Microwave Radio Equipment cabinet (UWE-9290), antennas (ANT-9280C & ANT- 9281B), associated cabling and junction boxes. Refer to Block Diagram: RCPP-T-9010 rev.0 5.3.6.13.2 Commissioning scope of work i) Piping a) None ii) Mechanical a) None iii) Electrical a) None iv) _ Instrumentation a) Verify cable insulation resistance and continuity test. b) Verify completeness of power distribution system for the radio equipment.PRE-COMMISSIONING AND FSP RESAKHT EA COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 35 OF 43 ©) Verify & establish communication between RCPP-A platform and TBCP- Aplatform Note: Telecommunication vendor representative assistance may be required. 5.3.6.14 System 800 - Miscellaneous Facilities Sub-System 810 — Lifting Equipment ‘Sub-Sub-System 813 - Monorail and Trolley Hoist 5.3.6.14.1 System Description Monorail Manual Trolley Hoist, tagged: B-7416 (5 MT) is installed on RCPP- A platform. It’s located under Mezzanine Deck to cater the installation & maintenance works for new TBC Condensate Pump. 5.3.6.14.2 Commissioning scope of work i) Piping a) None ii) Mechanical a) Refer to Section 5.33 - Common Mechanical scope of work. ») fy no physical damage to the ig chain.PROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK HTI-24 COMMISSIONING PROCEDURE REVISION NO. 0 ne PAGE 36 OF 43 iii) Electrical a) None iv) Instrumentation b) None 6.0 SPECIAL REQUIREMENTS None 7.0 RECORDS None 8.0 DRAWINGS 8.1 List Of Approved For Construction (AFC) Drawings 8.1.1 DESB shall ensure that drawings of the latest revision to be used for testing and commissioning activities. 8.1.2 The list of AFC drawings are provided in the workpack. 8.2 Vendor Data 8.2.1 DESB shall ensure that all relevant vendor data ie. drawing, manual and ifications are available upon testing and Commissioning activities.PROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK HTI-24 COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 37 OF 43 9.0 | ACCEPTANCE CRITERIA OL Mechanical a) b) °) Static Equipment include Slug Catcher Vessel & Gas/Condensate Receiver - _Allrelevant equipment installation checks completed, - Internal visual inspection. = Vessel internal cleanliness = Verify Quick Closure Door installation for Launcher and Receiver = Issue Final Closure Certificate Pumps - Allrelevant equipment installation checks completed. - Final alignment check after piping connected to suction and discharge line. - Final inspection for ai/gas supply, drain and vent lines - Motor Couple Run (Electrical) Monorail Hoist = All relevant equipment installation check completed. ~ Function and operational test of equipmentPROCEDURE NO. PRE-COMMISSIONING AND PEP RESAK Tinio4 COMMISSIONING PROCEDURE REVISION NO. 0 92 93 HUC PAGE 38 OF 43 Piping 2) Verify flushing had been completed b) Verify hydro testing has been completed ©) Pipe work is intemally cleaned and preserved 4) Perform reinstatement test had been completed follow system reinstatement test procedure ) Verify insulation and cladding conforms to specification and drawings (if any). Electrical a) The LV cable insulation resistance test to the ground shall be not less than 20 mega ohms using 500 VDC. b) The LV Motor insulation resistance test of winding to the ground shall be not less than 10 mega ohms using 500 VDC megger. ©) The duration of Low Voltage Motor running test shall be not less than 30 minutes, d) — The earthing resistance values shall not exceed 1 ohm for single cables earthed at one point. ©) The duration of lighting system energization shall be 24 hours light on. 1) The discharge light on of emergeney lighting shall be not less than 1 hour. 2) The performance duration test of battery and battery charger after discharge test should be 24 hours or as per factory recommendations.PROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK ETE COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 39 OF 43 94 Instrument a) The instrument cable insulation resistance to the ground shall be not less than 20 mega ohms by using 500 VDC megger. b) The bubble rate after pressurizing or tubing leak test shall be less than 6 bubbles per minutes. ©) The acceptance of pressure reading on a a gauge or manometer shall not fall at a rate exceeding 68.9 millibar or one (1) psi per hour. 4) Instrument air supply line shall be pressurized to 1.1 times of the working pressure and shall not fall at a rate exceeding 68.9 milibar or one (1) psi per hour. ©) Process Impulse Line shall be pressurized to 1.5 times of the working pressure and shall not fall at a rate exceeding 68.9 millibar or one (1) psi per hour: 1) The sample line shall be pressure test at a minimum 1.5 times of the design process piping pressure and pressure reading shall not fall at a rate exceeding 68.9 millibar or one (1) psi per hour. 2) All instruments shall be individually calibrated using a 3 point check at 0%, 50% and 100% rising and falling at set range. h) All instrument calibration maximum error such as Transmitters, Recorders, Indicators, Controllers and Transducers shall not exceed + 0.5% of span. {) All testing and calibration equipment used shall be certified by third party.PROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK BTI-24 COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 40 OF 43 10.0 COMMISSIONING GUIDELINES 10.1 10.2 General a) After the equipments have been installed they shall be inspected and tested for correct operation as part of the system. This procedure covers the complete inspection and testing of all equipment and instrument system installed on site up to and including commissioning. b) The inspection, testing and commissioning works shall be carried out in accordance with the requirement of PTS 62.10.08.11-Gen. ‘Field inspection and testing of instruments and instrument system’ and CSP Testing & Pre- Commissioning. Note: The progress of inspection and testing shall be indicated on a bar chart. The bar chart shall be up dated at least weekly to indicate the state of readiness and remaining workload. ©) Special attention shall be laid to that test which can only be done after plant/platform flushing. 4) An early stage of the installation the contractor shall inform the responsible discipline engineer when the testing of the equipment will start to enable the principal’s personnel to attend the tests. Faults found in the contactor’s work shall be arrested by the contractor at his own expense, ©) The results of inspection and testing shall be recorded by the contractor and made available to the construction team discipline engineers. Inspection 10.2.1 Field visual inspection shall ensure that each equipment: a) Has the correct tag number, range and ete. b) sin the proper place. ©) _Iscorrectly and rigidly installed d) Is properly earthed where necessary. ©) Is suitable protected against adverse environment conditions. 10.2.2 Attention shall also be paid to the final accessibility of the instrument and the free necessary for removal or partial disassembly.COMMISSIONING PROCEDURE PI E NO. PRE-COMMISSIONING AND AP RESe rea REVISION NO. 0 HUC PAGE 41 OF 43 10.3 10.4 10.5 10.6 Impulse Line a) With the process isolating valve closed, all instruments and impulse line shall be pressure tested to a pressure of 1.5 times the intended operating pressure or to the ‘maximum allowable working pressure of the instrument whichever is the lower. b) Pressure testing shall be done with Nitrogen. After pressure testing, the impulse lines shall be disconnected from the process connections, after which the instrument and the impulse lines shall be carefully drained and blown out. For safety reasons stainless steel tubes shall be used for testing purposes and not copper. Gas cylinders may be used for high pressure testing. Pneumatic Tubing 8) Leak testing of pneumatic tubes shall be carried out using the bubbler method and afier the test the pneumatic signal, loops shall be subjected to a full operation test. Special attention shall be paid to the connection line-up between 3-way or 4-way solenoid valves and relevant final control element. Field Instrument a) All individual instruments will have been tested and calibrated (to be done at onshore yard upon delivery) and re-calibrate before installation if found any unusual condition or defected and a detailed testing of the instrument should therefore not be necessary at this stage unless the function testing, reveals an abnormal behavior. b) Control valves and shut-off valves equipped with actuators (complete with associated tubing, solenoid valves, quick exhausts, boosters and positioners) shall be tested for full-stroke time. Loop Cheeking a) All instrument loops shall be fully tested for correct functioning where necessary by simulating the signals. b) All controllers shall have their setting for proportional, integral and derivative actions adjusted to a calculated value “Loop Check’ forms, of a format to be agreed with the principle, shall be applied for recording the results.PROCEDURE NO. PRE-COMMISSIONING AND PSP-RESAK BTI-24 COMMISSIONING PROCEDURE REVISION NO. 0 HUC PAGE 42 OF 43 10.7 Note: The following equipment shall also receive attention at this stage: ©) special high-signal or low-signal selectors and calculating relays, ete shall be adjusted d) the mechanical min/max stop all control valve shall also adjusted Electric/Electronic System a) All electric/electronic equipment systems and cables shall be subject to earth-fault tests, continuity tests and full operational test, if necessary by simulating process condition. Special attention is required to ensure the correct voltage of the electricity supply. b) Thermocouples and their cabling shall be checked for correct connection with regard to polarity. c) All the connections for cable screening shall be carefully checked, especially with regard to earthing at one point only. 4) High voltage insulation testing shall not damage the instrumentations ©) Programmable logic control (PLC) equipment shall be tested in accordance with the manufacturer recommendations. #) System for binary logic functions, such as those for alarm annuneiation, safeguarding and/or sequential control, shall be fully tested for correct operation by simulating process conditions at the transmitter. 2) Connection from (single-pole) double-throw initialing switches shall be carefully checked for correct action. All settings for initiators, time delay ete shall be adjusted at this stage h) For programmable logic control system (PLC's) especially, it is advisable that plant operators make dry runs with the plant and related systems in order to familiarize themselves with these, and to debug the programmed. i) _ ICS systems shall be tested in accordance with manufacturer’s recommendations Note: The method of testing and the recording of the results shail be agreed with the principal.PROCEDURE NO. PRE-COMMISSIONING AND pee ae eae COMMISSIONING PROCEDURE - REVISION NO. 0 HUC PAGE 43 OF 43 10.8 Utility Supplies a) The instrument electricity supply shall be fully tested including automatic —switch- over actions. The batteries shall be subjected to a discharge capacity test under full load conditions. b) The instrument air supply station shall be fully tested, including automatic starting of due standby compressor(s). Note: Under no circumstances shall alr from other sources be used for the instrumentation. ©) All air supply shall be blow out and leak-tested with air or nitrogen at a pressure at 10 bar (with valves to individual consumers closed). Note:Leak testing of joints shall be done with a suitable leak detector. 4) Pressure testing of these pipes with water or other liquids is not allowed. €) In view of personnel safety, testing shall be done outside normal working hours. All personnel engaged in the testing procedure shall wear face masks. f) To avoid unauthorized shut-off of the instrument air, it is advisable to look all (main) valves in open positions or to remove the hand wheel.