TUNU FIELD

DEVELOPMENT PROJECT
PHASE 8

TURBOCOMPRESSOR TRAIN A
PRE-COOLERS
OPERATIONAL TEST PROCEDURE

SUB-SYSTEM 6004

00 18/02/02 D.P / C.H For Comment

REV DATE ORIGINATOR DESCRIPTION APPROVED

CHECKED BY CSL
. BY START-UP

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

FORBIDDEN WITHOUT PRIOR WRITTEN AUTHORIZATION OF THE COMPANY

TOTALFINAELF E&P INDONESIE

COMMISSIONING
DOCUMENT NUMBER REVISION

COM OTP NCP 6004 01 00 PAGE : 1 OF 11

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SUMMARY
There are 4 Gas Compressor Pre-Coolers per train tagged 5-A 0160
A/B/C/D (Train A) and 5-A 0170 A/B/C/D (Train B).
They are of the air-cooled forced draft design.
Each cooler can be stopped or started independently of each other, either
by local or remote signals, and all are equipped with independent
vibration switches

P&ID Reference : NCP-12-1-013-C Rev D

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1 TEST SUMMARY
1.1 AIMS OF OPERATIONAL TEST

The object of this OTP is to prove the start / stop logic of the
Compressor Pre-Cooler Train A, No 5-A 0160 to the PCS and
Electrical MCC’s.
To ensure fans stop when the vibration protection switches are activated

1.2 TEST DESCRIPTION

To check that the equipment has been correctly installed and

prepared for commissioning in accordance with the vendors’
instruction.
Prepare the test for checking function of the Fans.

1.3 TEMPORARY INSTALLATIONS

None

1.4 SPECIAL PRECAUTIONS

Refer to Safe Operating Procedures.

Check that the Permit for the work is in force.
Check that all warning / precaution signs are in place.
Check that all non-essential personnel have been cleared from the
area.
Ask the Control Room for a PA announcement to be made.

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2 PLANNING AND MANPOWER

2.1 PLANNING TASKS

Complete the OTP test in one (1) day

2.2 MANPOWER ESTIMATE

Mechanical 1
Electrical 1
Start-up 1

2.3 TEST DURATION ESTIMATE

1 day

2.4 POSITION IN COMMISSIONNIG SEQUENCE

After RFC is signed

2.5 VENDOR ASSISTANCE

None

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3 TEST REQUIREMENTS
3.1 PRECOMMISSIONING ACHIEVEMENTS

 Verify that the Pre-Commissioning is completed.

 RFC is signed.
 No Level A punch list items are pending.
 Preliminary check by disciplines to verify the Gas Pre-Cooler package for
completeness in accordance with the latest drawings and revisions.
This includes relevant specifications and P&ID’s.
 Produce a punch list as applicable
 E&I function tests are complete.
 Hydro-test is completed and that all spades are removed
 Check that shipping lugs and locks have been removed from bundles ends
3.2 COMMISSIONING ACHIEVEMENTS

 Verify that the Commissioning Dossiers is completed.

 RFC is signed.
 OTP agreed upon and signed
3.3 STATUS OF OTHER SUBSYSTEMS
7403 PCS ready
7401 ESD ready
7305/6 Normal power distribution 400V ready
3.4 SPECIAL TOOL AND TEST EQUIPMENT
None
3.5 CONSUMABLES
None
3.6 SPARES
As per commissioning spares list
3.7 SAFETY

 Refer to Safe Operating Procedures.

 Check that the Permit for the work is in force.
 Check that all warning / precaution signs are in place.
 Check that all non-essential personnel have been cleared from the area.
 Ask the Control Room for a PA announcement to be made.
3.8 UTILITIES
None

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4 TEST PREPARATION

4.1 BLIND LIST

None

4.2 JUMPERS LIST

None

4.3 MECHANICAL PREPARATION TASKS

To provide assistance with the test

To ensure all grease connections are available and grease lines are full
To control that the shipping lugs and locks have been removed
To check belt, pulleys, guards installation

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5 START-UP, TUNING & PROCEDURE

5.1 START-UP STEP-BY-STEP PROCEDURE

DEMONSTRATION OF GAS COMPRESSOR PRE-COOLER TRAIN A,

Tags 5-A- 0160A/B/C/D

Fan Control for 5 - A 0160 A

1 Inform control room of intention to run Pre-Cooler 5-A 0160 A

2 Push in STOP Button PB 0160 A2

3 Check that the Pre-Cooler Fan 5-A 0160 A cannot be started from
the local START button PB 0160 A1

4 Check that the FAULT alarm XA 0160 A1 is seen on PCS

5 Reset the local STOP button PB0160 A2 Check that the FAULT
alarm XA 0160 A1 is cleared

6 Check that STOP indication XL 0160 A2 is shown on the PCS.

7 Start the Pre-Cooler Fan 5-A 0160 A from the local START
PB 0160 A1 Check that the Pre-Cooler Fan starts OK.

8 Check that RUN indication XL 0160 A2 is shown on the PCS.

9 Check the Fan is rotating in the correct direction. Check the Fan
condition for a few minutes, while checking the fan blades tip
clearance with housing.

10 Simulate an Electrical Fault (over current) on the Pre-Cooler Fan

5-A 0160 A Motor. Check that the Fan stops.

11 Check that the FAULT alarm XA0160 A1 is on PCS

12 Reset the motor trip and restart the Fan.

13 Stop Cooling Fan using the local STOP Push Button PB0160 A2.
When Cooling Fan has stopped reset the STOP push button.

14 Start the pre-cooler Fan 5-A 0160 A using the local Push Button
PB0160 A1. Simulate a vibration by hammering the structure
supporting the cooler until the VSHH 0161 A trips

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15 The motor should be stopped.

Check that the VSHH 0161 A alarm is seen on
Check locally that the motor is stopped. Reset the motor trip.

16 Select REMOTE mode on local switch HS-0160 A1

17 Verify that XL-0160 A1 shows Remote position

18 Start Fan from PCS PB-0160 A3

19 Ensure RUNNING indication is on XL-0160 A2

20 Stop fan from PCS PB-0160 A4

Demonstration of Fan Control for 5 - A 0160 A is now complete

Fan Control for 5 - A 0160 B

1 Inform control room of intention to run Pre-Cooler 5-A 0160 B

2 Push in STOP Button PB 0160 B2

3 Check that the Pre-Cooler Fan 5-A 0160 B cannot be started from
the local START button PB 0160 B1

4 Check that the FAULT alarm XA 0160 B1 is seen on PCS

5 Reset the local STOP button PB0160 B2 Check that the FAULT
alarm XA 0160 B1 is cleared

6 Check that STOP indication XL 0160 B2 is shown on the PCS.

7 Start the Pre-Cooler Fan 5-A 0160 B from the local START
PB 0160 B1 Check that the Pre-Cooler Fan starts OK.

8 Check that RUN indication XL 0160 B2 is shown on the PCS.

9 Check the Fan is rotating in the correct direction. Check the Fan
condition for a few minutes, while checking the fan blades tip
clearance with housing.

10 Simulate an Electrical Fault (over current) on the Pre-Cooler Fan

5-A 0160 B Motor. Check that the Fan stops.

11 Check that the FAULT alarm XA0160 B1 is on PCS

12 Reset the motor trip and restart the Fan.

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13 Stop Cooling Fan using the local STOP Push Button PB0160 B2.
When Cooling Fan has stopped reset the STOP push button.

14 Start the pre-cooler Fan 5-A 0160 B using the local Push Button
PB0160 B1. Simulate a vibration by hammering the structure
supporting the cooler until the VSHH 0161 B trips

15 The motor should be stopped.

Check that the VSHH 0161 B alarm is seen on
Check locally that the motor is stopped. Reset the motor trip.

16 Select REMOTE mode on local switch HS-0160 B1

17 Verify that XL-0160 B1 shows Remote position

18 Start Fan from PCS PB-0160 B3

19 Ensure RUNNING indication is on XL-0160 B2

20 Stop fan from PCS PB-0160 B4

Demonstration of Fan Control for 5 - A 0160 B is now complete

Fan Control for 4 - A 0160 C

1 Inform control room of intention to run Pre-Cooler 5-A 0160 C

2 Push in STOP Button PB 0160 C2

3 Check that the Pre-Cooler Fan 5-A 0160 C cannot be started from
the local START button PB 0160 C1

4 Check that the FAULT alarm XA 0160 C1 is seen on PCS

5 Reset the local STOP button PB0160 C2 Check that the FAULT
alarm XA 0160 C1 is cleared

6 Check that STOP indication XL 0160 C2 is shown on the PCS.

7 Start the Pre-Cooler Fan 5-A 0160 C from the local START
PB 0160 C1 Check that the Pre-Cooler Fan starts OK.

8 Check that RUN indication XL 0160 C2 is shown on the PCS.

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9 Check the Fan is rotating in the correct direction. Check the Fan
condition for a few minutes, while checking the fan blades tip
clearance with housing.

10 Simulate an Electrical Fault (over current) on the Pre-Cooler Fan

5-A 0160 C Motor. Check that the Fan stops.

11 Check that the FAULT alarm XA0160 C1 is on PCS

12 Reset the motor trip and restart the Fan.

13 Stop Cooling Fan using the local STOP Push Button PB0160 C2.
When Cooling Fan has stopped reset the STOP push button.

14 Start the pre-cooler Fan 5-A 0160 C using the local Push Button
PB0160 C1. Simulate a vibration by hammering the structure
supporting the cooler until the VSHH 0161 C trips

15 The motor should be stopped.

Check that the VSHH 0161 C alarm is seen on
Check locally that the motor is stopped. Reset the motor trip.

16 Select REMOTE mode on local switch HS-0160 C1

17 Verify that XL-0160 C1 shows Remote position

18 Start Fan from PCS PB-0160 C3

19 Ensure RUNNING indication is on XL-0160 C2

20 Stop fan from PCS PB-0160 C4

Demonstration of Fan Control for 5 - A 0160 C is now complete

Fan Control for 4 - A 0160 D

1 Inform control room of intention to run Pre-Cooler 5-A 0160 D

2 Push in STOP Button PB 0160 D2

3 Check that the Pre-Cooler Fan 5-A 0160 D cannot be started from
the local START button PB 0160 D1

4 Check that the FAULT alarm XA 0160 D1 is seen on PCS

5 Reset the local STOP button PB0160 D2 Check that the FAULT
alarm XA 0160 D1 is cleared

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6 Check that STOP indication XL 0160 D2 is shown on the PCS.

7 Start the Pre-Cooler Fan 5-A 0160 D from the local START
PB 0160 D1 Check that the Pre-Cooler Fan starts OK.

8 Check that RUN indication XL 0160 D2 is shown on the PCS.

9 Check the Fan is rotating in the correct direction. Check the Fan
condition for a few minutes, while checking the fan blades tip
clearance with housing.

10 Simulate an Electrical Fault (over current) on the Pre-Cooler Fan

5-A 0160 D Motor. Check that the Fan stops.

11 Check that the FAULT alarm XA0160 D1 is on PCS

12 Reset the motor trip and restart the Fan.

13 Stop Cooling Fan using the local STOP Push Button PB0160 D2.
When Cooling Fan has stopped reset the STOP push button.

14 Start the pre-cooler Fan 5-A 0160 D using the local Push Button
PB0160 D1. Simulate a vibration by hammering the structure
supporting the cooler until the VSHH 0161 D trips

15 The motor should be stopped.

Check that the VSHH 0161 D alarm is seen on
Check locally that the motor is stopped. Reset the motor trip.

16 Select REMOTE mode on local switch HS-0160 D1

17 Verify that XL-0160 D1 shows Remote position

18 Start Fan from PCS PB-0160 D3

19 Ensure RUNNING indication is on XL-0160 D2

20 Stop fan from PCS PB-0160 D4

Demonstration of Fan Control for 5 - A 0160 D is no w complete

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