Procedimientos Tecnicos

No. 530-U07-00336 REV.
0
STANDARD TEST AND COMMISSIONING PAGE 1 OF 10
CLASS: TECHNICAL
PROCEDURE
EFFECTIVE:28 MAY 2014
INTERLOCKS TESTING
Prepared by Reviewing Manager Manager, ES&H Compliance Manager, Startup & Operating
Assurance Services
G. Collazos D.R. Young J.W. Vincoli J.M. Diaz
1.0 PURPOSE
This procedure provides a standardized approach for the testing, verification and documentation of safety
instrumented functions, hereinafter Interlocks, in the period from commissioning until turnover to the
customer.
2.0 SCOPE
2.1 Applicability
a. This procedure covers documentation of Interlock validation for projects that issue Cause & Effect
(C&E) Diagrams for which a Bechtel entity or subcontractor has startup/commissioning responsibility.
b. This procedure is to be implemented after loop checks associated with the interlocks are completed.
These checks are to be performed by simulating process conditions.
c. The intent of this procedure is to verify that the as-installed control and / or safety system elements
meet safety Interlock design requirements per approved project drawings (Piping & Instrumentation
Diagrams [P&IDs] and C&E diagrams).
Alarm Summary Narratives may or may not be provided by Engineering; but, if provided,
are to be considered supplemental to P&IDs and C&Es.
d. This procedure is not applicable to the following:

 Instrument calibrations
 Loop checks
 Periodic Safety Integrity Level (SIL)-required Interlock checks (maintenance function)
 Periodic partial / full stroke valve tests
 Periodic stroking of valves & testing electrical equipment starts/stops (maintenance function)
 Testing stroke times of valves
 Testing volume tank capacities and/or failure actions of control valves equipped with or without
volume tanks and/or trip switches
2.2 Deviations
Deviation from this procedure shall be documented by the Project Startup Manager (PSUM), and
approved by the Global Business Unit (GBU) Manager of Startup (MOS) and the Corporate Manager of
Startup.
3.0 DEFINITIONS
3.1 Cause & Effect (C&E) Diagram
Helps identify, sort, and display possible causes of a specific problem or quality characteristic.
Graphically illustrates the relationship between a given outcome and all the factors that influence the
outcome.
Bechtel Confidential
©Bechtel Corporation 2014. Contains information that is confidential and proprietary to Bechtel or its affiliates, clients or suppliers, and may
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No. 530-U07-00336 REV. 0
INTERLOCKS TESTING PAGE 2 OF 10
3.2 Commissioning
Activities required to verify that functionality of permanently installed components at a system level is in
accordance with the design intent; includes energized and dynamic testing.
3.3 Critical Process System
A system which, once running and an operational problem occurs, may need to be put into a "Safe State"
to avoid adverse Environmental, Safety, and Health (ES&H) consequences.
3.4 Distributed Control System (DCS)
A digital processor-based control system in which the controller elements are not located centrally, but
are distributed throughout the system with each component subsystem controlled by one or more
controllers and interconnected by a communications network for monitoring and integrated control.
3.5 Interlock
Consists of an engineered set of hardware and software controls that, together, provide a level of
protection to: 1) prevent an adverse configuration from being created, or 2) initiate a corrective action to
mitigate an undesired configuration.
3.6 Safety Instrumented System (SIS)
An engineered set of hardware and software controls which are especially used on Critical Process
Systems. The SIS is designed to reduce the likelihood or the severity of the impact of an identified event,
thus helping to protect personnel, equipment and the environment.
3.7 Simulation of Process Conditions
A technique where process conditions (pressure, temperature, etc.) are simulated through use of a pump
or heat source, etc., on a sensor. Where not practicable, the simulation can be through use of a signal
generator applied to the associated transmitter.
3.8 Startup
Post-commissioning activities required to bring the facility to full design operation. It may include first
introduction of feedstocks for production or first export of power.
3.9 Test Record (TR)
Provides evidence of the performance of the independent inspection, performance, verification or test of
an item, product, or activity and to acknowledge the acceptance and compliance to specified criteria.
4.0 REFERENCES
Interfacing references are referred to directly in this Instruction. Supporting references are not referred to
directly, but provide supporting or related information to this procedure’s subject matter including
elements such as training, guidance, and other information relevant to the successful execution of this
process.
STCPs and associated Commentary, Administrative Instructions, and Manuals are
located on BecWeb, go to the main BecWeb page, select “Functions and Services”, and
select “Startup & Operating Services”.
4.1 Interfacing References
4.1.1 Standard Test & Commissioning Procedure, 520-U07-00226, Control of Temporary Modifications
4.1.2 Standard Work Process Procedure 4MP-T81-01307, System and Equipment Safety Lockout/Tagout
4.1.3 Standard Work Process Procedure 4MP-T81-01601, Systems Completion and Turnover
4.1.4 Standard Work Process Procedure 4MP-T81-03314, Working on or Near Energized Circuits
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4.1.5 Bechtel Environmental Safety & Health (BESH) Core Process CP-105, Safety Task Analysis & Risk
Reduction Talk/Job Hazard Analysis
4.2 Supporting References
4.2.1 Bechtel Environmental Safety & Health (BESH) Core Process CP-205, Personal Protective
Equipment
4.2.2 Electrical Schematic Diagrams
4.2.3 Piping and Instrument Diagrams (P&IDs)
4.2.4 Interlock Narratives
4.2.5 Vendor’s Instruction Manual and Drawings
4.2.6 Cause and Effect Diagrams
5.0 RESPONSIBILITIES
5.1 Project Startup Manager (PSUM)
The PSUM is responsible for the overall execution of the Startup/Commissioning Program and ensures
Startup activities are performed in compliance with department and project procedures.
5.2 System Startup Specialist
The System Startup Specialist is responsible for coordinating all Interlock testing related activities for
his/her assigned systems.
5.3 Startup Specialist
The Startup Specialist is responsible for detailed checkout and testing in accordance with this procedure;
coordinating with discipline engineers, operations, and test performers to accomplish testing and
completion of procedure test records; and performing all evolutions of this procedure.
5.4 Operations Supervisor (OS)
The OS is responsible for day-to-day operation of the facility (Startup Shift Supervisor, Startup Operations
Supervisor, Control Room Operations Supervisor, etc.).
5.5 DCS Startup Supervisor (DCSSS)
The DCSSS has the primary responsibility for testing activities associated with the DCS, and verifying
logic has been implemented in accordance with the contract, applicable design documents, codes,
specifications, and standards.
5.6 Environmental Safety and Health (ES&H) Representative
The ES&H Representative participates in and provides input to Safety Task Analysis Risk Reduction Talk
(STARRT)/Job Hazard Analysis (JHA), and provides ES&H coverage for test activities and walkdowns.
6.0 REQUIREMENTS
6.1 General
 Attachment A-1 and Attachment A-2 show the work process for interlocks testing.
 The PSUM shall ensure the applicable test attributes are listed on the TR.
The forms located in the Attachment section of this procedure may be modified at the
discretion of the PSUM.
 Interlock-related rotating field equipment (pumps, motors, fans, compressors, turbines, etc.) should
not be operated during the course of Interlock verifications, when practicable.
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 The System Startup Specialist shall ensure temporary alterations installed during testing are
documented on Attachment B (Interlock Test Record). Temporary alterations that are to remain
following completion of testing shall be logged according to the requirements of Standard Test &
Commissioning Procedure 520-U07-00226, Control of Temporary Modifications.
 The System Startup Specialist shall document any anomalies, partial test completion, or other
information pertinent to the test in the comments section of Attachment B (Interlock Test Record).
 The Startup Specialist ensures a Temporary Modification Form is completed when safety-critical
elements must be bypassed to perform testing of an interlock.
The systems associated with the interlock pose the potential of an incident due to the
contents within the affected system. The Temporary Modification Form shall be
completed in accordance with Standard Test & Commissioning Procedure 520-U07-
00226, Control of Temporary Modifications. Bypasses for Safety-Critical elements
associated with systems that do not yet pose the potential of an incident due to the
contents within the affected system (those not yet loaded with process materials) do not
require the Temporary Modification form and may be documented on Attachment B
(Interlock Test Record).
 Operation of equipment is to be performed according to established operating procedures and

applicable vendor operating and maintenance instructions.
6.2 Prerequisites and Safety Precautions
The Startup Specialist, with assistance from the Startup System Specialist, ensures the following
prerequisites and safety precautions are verified only after all components within the Interlock scope have
been successfully calibrated and loop-checked.
6.2.1 Prerequisites
a. Equipment to be tested is under jurisdictional control of the Bechtel organization responsible for
performing the testing. For example if that organization is Commissioning / Startup, the
equipment must be turned over in accordance with Standard Work Process Procedure 4MP-T81-
01601, Systems Completion and Turnover.
b. Verify test equipment is calibrated within its normal calibration interval and documented on
Attachment B (Interlock Test Record).
1. The preferred method of interlock and protection verification is to simulate the actual process
condition (e.g., with hand pump, dry block calibrator, etc.). This ensures the sense (+/-) is
verified through all logic. HART communicators and mV signal generators may be used but
are not as preferable as process simulation.
2. If actual process conditioning has been verified during the loop-check, then communicator
simulation may be considered adequate.
c. Vendor’s instruction manual(s) should be reviewed for special precautions or limitations specific
to system components.
6.2.2 Safety Precautions
a. Areas under test must be clean and free of loose debris and only authorized personnel are
permitted in test areas.
b. Equipment Lockout/Tagout (LOTO) requirements in support of this activity must be implemented
in accordance with Standard Work Process Procedure 4MP-T81-01307, System and Equipment
Safety Lockout/Tagout.
c. Conduct a pre-test briefing incorporating STARRT/JHA, with assistance from the ES&H
Representative, in accordance with Bechtel Environmental Safety & Health (BESH) Core Process
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CP-105, Safety Task Analysis & Risk Reduction Talk/Job Hazard Analysis. Discuss test
performance and expected results with involved personnel.
d. Ensure adequate access is provided to all required areas during the test. Where permanent
access is not provided, scaffolding or a manlift must be provided in accordance with project
procedures.
e. Ensure clear communications are established between field test personnel and DCS/SIS
personnel. Also ensure the control room operations team is kept up-to-date regarding testing
activities.
f. Ensure the requirements of Standard Work Process Procedure 4MP-T81-03314, Working on or
Near Energized Circuits are implemented as appropriate.
6.3 Work Process
The System Startup Specialist, working with the Startup Specialist, ensures that all prerequisites are met,
and properly set up.
Immediately terminate testing if any anomalies occur (e.g., unusual noises, smoke, etc.)
or if design limits that may compromise the safety of personnel or equipment are
exceeded. Immediately notify the PSUM and the project ES&H Representative (if
applicable) of such occurrences.
6.3.1 Setup/Checkout
a. The System Startup Specialist ensures interlocks are pre-checked.
b. The Startup Specialist works with Engineering to resolve documentation errors (if any) prior to
formal notification (if required) of interlock test and / or demonstration for witnessed verification.
c. The Startup Specialist ensures that all interlock-associated valves and / or drives (starters only as
rotating equipment is not intended to be operated) are functionally verified from every hand switch
(HS) device whether it is:
 hard-wired in the field
 hard-wired on the operations console
 a soft switch within the DCS
 all of the above
d. The Startup Specialist and DCSSS ensure the following are performed for each initiator equipped
with a DCS Maintenance Bypass:
Activate and de-activate the DCS Maintenance Bypass and ensure both states ring in to
the DCS Alarm Summary.
1. With the DCS Maintenance Bypass ON, activate the initiator and ensure the interlock does
not activate.
2. With the initiator still activated, remove the DCS Maintenance Bypass and ensure the
Interlock activates as designed.
3. Clear the initiator then re-activate to ensure the Interlock functions as designed and that
related DCS Alarm Summary alarms indicate as required.
e. The Startup Specialist ensures the following is performed for each initiator not equipped with a
DCS Maintenance Bypass:
 Activate each initiator in turn, and verify that all actions designed to take place upon interlock
activation actually take place including DCS Alarm Summary activation.
1. For each initiator, loss of power initiates the interlock.
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2. Generate the trip signal using the proper test equipment (e.g., hand pump, signal generator,
etc.).
f. The Startup Specialist ensures that interlock checks successfully performed are highlighted in
yellow on their respective C&E diagrams.
1. All exceptions noted during the course of testing are to be resolved and then clearly noted
“resolved” on Attachment B (Interlock Test Record).
2. Exceptions found (if any) are to be identified, documented on Attachment B, and resolved.
Once resolved, the Interlock is to be completely re-demonstrated as determined by the
testing engineer(s).
3. The Interlocks Test Record shall not be signed off as completed if there are any unresolved
exceptions.
g. The System Startup Specialist shall ensure the Interlock Test Record is signed (printed name,
and signature and date) by the testing and witnessing parties clearly noting the company they
represent.
h. Witness signature will be “as required”, and will be determined by the requirements of each
specific contract.
i. The System Startup Specialist shall ensure any Temporary Modification is restored and closed.
6.3.2 Restoration
a. The Startup Specialist verifies temporary alterations made during the performance of this test
have been restored or controlled according to Standard Test & Commissioning Procedure 520-
U07-00226, Control of Temporary Modifications.
b. The Startup Specialist verifies temporary test equipment has been removed, and all permanent
system connections and equipment have been restored.
c. The Startup Specialist verifies equipment and system(s) affected by this procedure are restored
to conditions as specified by the person responsible for the system(s).
d. The Startup Specialist notifies the OS that testing is complete.
6.3.3 Acceptance Criteria
The interlock shall function per design documents.
6.4 Records
The Startup Specialist shall ensure the following records are entered into the Electronic Document
Management System (EDMS), e.g., InfoWorks® in accordance with applicable project procedures.
 Attachment B – Interlock Test Record
 P&ID(s), as appropriate
 Highlighted C&E Drawing
 C&E Narratives (as appropriate)
 Logic Diagrams (as appropriate)
7.0 ATTACHMENTS
Attachment A-1 – Work Process for Interlock Testing (Prerequisites and Safety Precautions)
Attachment A-2 – Work Process for Interlock Testing
Attachment B – Interlock Test Record
No. 530-U07-00336 REV. 0
Attachment A-1 – Work Process for Interlocks Testing (Prerequisites and Safety Precautions)
Project Startup Manager DCS Startup Supervisor Operations Supervisor Environmental, Safety & Health
System Startup Specialist Startup Specialist
(PSUM) (DCSSS) (OS) Representative
Start
Ensure applicable test Ensure temporary

attributes are listed on alterations installed during
the TR testing are documented
Complete Temporary Modification Form for safety-critical

elements that are bypassed
Ensure equipment to be tested is under jurisdiction of the

Bechtel organization responsible for testing
Verify test equipment is calibrated
Review vendor instruction manual(s) for special precautions or

limitations
Ensure test areas are clean
Ensure equipment LOTO requirements are implemented

(as necessary)
Conduct pre-test briefing (incorporating STARRT/JHA) Assist
Ensure adequate access is provided to all required areas

during testing
Ensure clear communications are established between field

test personnel and DCS/SIS personnel.
Ensure requirements of SWPP-3314 are implemented as

appropriate
A-2
No. 530-U07-00336 REV. 0
Attachment A-2 – Work Process for Interlocks Testing

Immediately terminate testing if any anomalies occur (e.g., unusual noises, smoke, etc.)
or if design limits that may compromise the safety of personnel or equipment are
exceeded. Immediately notify the PSUM and the project ES&H Representative (if
applicable) of such occurrences
Project Startup Manager DCS Startup Supervisor Operations Supervisor Environmental, Safety & Health
System Startup Specialist Startup Specialist
(PSUM) (DCSSS) (OS) Representative
A-1
Ensure interlocks are pre- Documentation No

checked errors?
Yes
Work with Engineering to

resolve errors
Ensure all interlock-associated

valves and/or drives are
functionally verified from HS
devices
Ensure interlock checks are performed for each initiator equipped

with a DCS maintenance bypass
Ensure interlock checks are performed for each initiator NOT

equipped with a DCS maintenance bypass
Ensure the Interlock Test Ensure successful interlock

Record is completed and checks are highlighted ion the
signed/dated respective C&E diagram
Ensure C&E diagrams are

entered into the EDMS
Ensure the Temporary

Modification Form is completed
and closed
Verify temporary test equipment

is removed and system
connections to permanent
equipment replaced and secure
Verify equipment/systems
affected by the procedure are
restored
Notify the OS when testing is Ensure interlock functions

complete per design documents
Ensure records are complete
and included in the interlock
testing folder or acceptance
package
End
No. 530-U07-00336 REV. 0
Attachment B – Interlock Test Record

Link to native file: Form 531-U07-00336-B
SDN No.: Sheet 1 of ___
INTERLOCK TEST RECORD

Facility/Project: Unit No. Project No.
ry
System Name/No.: Interlock No./Name:
ra
Prerequisites complete and safety precautions read and complied with?
lib
System Startup Specialist (Print Name):
KM
System Startup Specialist (Signature): Date:
Temporary Modification Required? Yes No
O
EQUIPMENT NAMEPLATE DATA
SU
Initiator 1: Bypass Final Control Element 1:
C
e
th
TEST DATA
in
Final Control Element position Open Closed Last N/A:

S
Final Control Element position Open Closed Last N/A:

M
INTERLOCK DETAILS
R
Input Desired Condition Actual Condition

FO
Input 1
Input 2
e
se
Input 3
Input 4
—
Final control elem1

E
Final control elem2

PL
Final control elem3

M
Final control elem4

SA
Temporary Modification Resolved? Yes
System Startup Specialist (Print Name):
System Startup Specialist (Signature): Date:
No. 530-U07-00336 REV. 0
Attachment B – Interlock Test Record (continued)
SDN No.: Sheet ___ of ___

MEASURING AND TEST EQUIPMENT
TEST INSTRUMENT MANUF./MODEL M&TE/TAG NUMBER CAL. DUE DATE
ry
ra
lib
TEST MODIFICATIONS
INSTALLED RESTORED
KM
MODIFICATION SYSTEM STARTUP SYSTEM STARTUP SPECIALIST /
SPECIALIST / DATE DATE
O
SU
C
Comments:
e
th
in
S
M
R
FO
e
Approvals
se
Performed by:
—
Print Name Signature Date

E
System Startup
PL
Specialist:
Same as Performed by
M
SA
Reviewed by:
Other (if applicable):
Entity Print Name Signature Date
Form 531-U07-00336-B, Interlocks Testing – Rev. 0

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No. 530-U07-00336 REV.

G. Collazos D.R. Young J.W. Vincoli J.M. Diaz

d. This procedure is not applicable to the following:

 Operation of equipment is to be performed according to established operating procedures and

1. For each initiator, loss of power initiates the interlock.

Ensure applicable test Ensure temporary

Complete Temporary Modification Form for safety-critical

Ensure equipment to be tested is under jurisdiction of the

Verify test equipment is calibrated

Review vendor instruction manual(s) for special precautions or

Ensure test areas are clean

Ensure equipment LOTO requirements are implemented

Conduct pre-test briefing (incorporating STARRT/JHA) Assist

Ensure adequate access is provided to all required areas

Ensure clear communications are established between field

Ensure requirements of SWPP-3314 are implemented as

Attachment A-2 – Work Process for Interlocks Testing

Ensure interlocks are pre- Documentation No

Work with Engineering to

Ensure all interlock-associated

Ensure interlock checks are performed for each initiator equipped

Ensure interlock checks are performed for each initiator NOT

Ensure the Interlock Test Ensure successful interlock

Ensure C&E diagrams are

Ensure the Temporary

Verify temporary test equipment

Notify the OS when testing is Ensure interlock functions

Attachment B – Interlock Test Record

SDN No.: Sheet 1 of ___

INTERLOCK TEST RECORD

Temporary Modification Required? Yes No

Initiator 2: Bypass Final Control Element 2:

Final Control Element position Open Closed Last N/A:

Final Control Element position Open Closed Last N/A:

Input Desired Condition Actual Condition

Final control elem1

Final control elem2

Final control elem3

Final control elem4

Temporary Modification Resolved? Yes

System Startup Specialist (Print Name):

System Startup Specialist (Signature): Date:

Attachment B – Interlock Test Record (continued)

SDN No.: Sheet ___ of ___

Print Name Signature Date

Other (if applicable):

Entity Print Name Signature Date

Form 531-U07-00336-B, Interlocks Testing – Rev. 0

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