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220802DJPCME705 - Rev02 - Loop Test Procedure
220802DJPCME705 - Rev02 - Loop Test Procedure
EPCI-2
Contract N.
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JANGKRIK COMPLEX PROJECT
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EniMuara Bakau B.V. 02 EX-CO
The purpose of this document is to provide general Loop Test procedure in Jangkrik new field
development. This procedure define the requirements for preparation and execution Loop Test
activities during commissioning work of Jangkrik new field developments.
Document Verification
Signature
Prepared by Date
Arief Bashori 13-May-2020
Vendor Prepared
Signature
Checked by Date
Basir Sinaga 13-May-2020
Signature
Approval by Date
Jakarias Haloho 13-May-2020
Proj. Dev.
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REVISION LIST
RECORD OF AMENDMENT
No Section Para No Description of Changes
HOLD LIST
Section Description of Hold
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TABLE OF CONTENTS
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1.0 INTRODUCTION
1.1 Project Overview
Jangkrik field is located about 70 km from the coast, in the MuaraBakau permit area,
Makassar Strait, offshore Kalimantan, at water depth ranging from 250 to 500 m. ENI
through its Indonesian subsidiary, operates the MuaraBakau PSC.
The treated gas and condensate from FPU are exported via 24 inch treated gas export
pipeline and 4 inch condensate export pipeline to shore at Sapi landfall. An onshore
receiving facility (ORF) fiscal metering system for gas and condensate is located
approximately 4 km downstream of Sapi Landfall. Gas and condensate pipelines are the
tie-in to existing East Kalimantan pipeline network. Another tie-in at KM 21.65 is required
for the gas line to allow the full capacity of jangkrik gas. For this purpose, a 15 km of new
pipelines is to be installed parallel to existing line with TEPI’s ROW from ORF to KM 21.65,
and will be tie-in to existing 20 inch Handil-Nilam pipeline and modification to be done at
Nilam, BEM, and KM 53 inside POMA area. Final destination of Jangkrik treated gas is to
the Bontang LNG Plant and domestic Bontang market; and the final destination of Jangkrik
condensate is to Senipah Plant.
2.0 REFERENCES
The following documents are referred to in this document.
2.1 Company Reference
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[C15] Standard color for insulation for low frequency cable wires. IEC 60304
[C16] Thermocouple. IEC 60584-1/2
[C17] RTD. IEC 60751
[C18] Size, units, symbols, conversion factors and conversion tables. ISO 31
Measurement of fluid flow by means of Orifice plates, nozzles and venturi
[C19] inserted in filled piping circular profile.
ISO 5167
3.2 Abbreviation
Abbreviation Description
CPY Company (ENI Muara Bakau B.V)
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KM 53 Kilometer 53 Location
DP Distribution Panel
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E&IPrecomm and : Responsible for the operating and carry out loop testing
Comm Supervisor as per approved procedure, COMPANY specification and
HSSE requirements. He shall also responsible for
assessing to the work permit at site prior to start the loop
testing (drawing, risk assessment, etc).
E&I Technician :
Responsible for the protection, connection,
disconnection for all instrument required for testing
(Instrument Function Test)..
The minimum man power required in one small group shall be consist of but not limited to:
Qty
No Position
(Persons)
1 E&I Precomm and CommEngineer 1
2 E&I Precomm and CommSupervisor 1
3 E&I Precomm and Comm Technician 2
4 Safety Man 1
5 Medic 1
4.2. Tools
The following tools are commonly used for Electrical and Instrument Hook up:
No Tools Qty
1 Multitester 1
2 Insulation resistant tester 1
3 Hand pump 2
4 Digital test gauge 2
5 Hand Tools Kit 2 Set
6 Termination Tools 2 Set
7 Hart Comm 1
8 Current Injector 1
9 Gas Tester 1
10 RTD Loop Calibrator 1
11 Regulator for Nitrogen 1
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- Field-installed Instrument.
Inspection and test for equipment installed shall be performed in accordance with
manufacturer’s instruction.
1. Field-Installed Instrument
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2. Instrument Cable
a) Visual Inspection.
- Each instrument cable is installed so that water cannot travel along the wiring in
to the connecting instrument.
b) Continuity test.
Continuity and identification test shall be performed for each wire and its shielding
between the terminal of field instruments and the terminal marshaling cabinet,
using a telephone or a buzzer and multi meter (Ω).
Insulation resistance result shall be performed with a 100V or 500V megger, and
involve disconnecting the cable from the terminal both at the field instrument and
the marshaling cabinet or designated equipment.
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Before reconnecting the cables, residual electrical current in the cable shall be
discharge to earth. The test result shall be record.
a) Visual Inspection.
A continuity and leak test shall be performed on all air signal lines. Prior to the
test, the tubing shall be flushed with air. The tubing shall be pressurized to a
pressure of 1.0 kg/cm²G. All tubing connection shall be coated with soapy
water to detect leak. The test result shall be recorded.
Instrument hydraulic signal line shall be treated same as pneumatic signal line, but
media for leak test shall be done by water filling which injected by portable
hydraulic pump.
No soapy water is required to confirm any leakage on hydraulic tubing line, it will be
showed by drop pressure on test gauge or appear visually in each connection. The
test result shall be recorded.
a) Visual Inspection
- Each impulse line meets the requirement of the “Instrument Impulse Line”
drawing i.e. regarding material, rating, slope, etc.
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- Test Fluid
- Test pressure shall be 1.5 time the normal operating pressure or the
maximum allowable working pressure of the instrument (Whichever is
lower), with minimum test pressure of 1.0 kg/cm²G. If maximum allowable
working pressure of the instrument is lower than 1.0 kg/cm²G, instrument
shall be disconnected from the impulse line.
- Testing Procedure.
After closing the process isolation valve and the opening the equalizing
valve (If installed), test fluid shall be fed in to the impulse line from a vent
or drain plug. Use soapy water to confirm there are no leaking, and record
the test result.
- Test procedure
The system shall be blown through with air by disconnecting the pneumatic
tube at the inlet of the air regulator and opening of the shut-off valve
minimum of five time until the air system is confirmed to be cleaned.
The pneumatic tube shall be reconnected and the air supply pipe
pressurized to the test pressure. All joint and connection shall be coated
with soapy water and examined for leaks. After testing and depressurizing
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the air supply piping, instrument air shall be introduced carefully to the
system by opening the first take-off valve.
Then the shut-off valve shall be opened and testes in the same way as the
air supply piping.
Local non-interactive, e.g. PI. This category does not require function testing;
calibration and installation are covered by the Check sheet as completed by
Construction.
Local control and indication with no local/remote panel interaction, e.g FE-FIT/FQI.
This category requires loop and function testing.
Ensure devices are hooked up properly and wire connection has been installed
properly.
All individual devices shall be checked as part of the loop test. A check
calibration/performance test shall be carried out over the range of each loop
device.
Check / set any trip / alarm in the loop, simulate process signal to initiate the
switch/ controller/ detector/ control valve traveling/ other devices and check the
action, check for correct zero-span readings, including displays, alarms etc. at
ESD/DCS depend on each device signal type. All trips shall be set to the value on
the data sheet.
Raise the process input signal and record the corresponding output signal and/or
scale readings at 0-25-50-75-100% of the device range. Differential pressure
devices shall be subject to a static alignment check.
This document is property of Eni Muara Bakau B.V.
It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
220802DJPCME705 Revision Index
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Note: The readings should always be taken when the signals in the 'rising' state.
Lower the process input signal and record the corresponding output signal and/or
scale readings at 100-75-50-25-0%.
Note: The readings should always be taken when the signals in the 'falling' state.
The percentage error calculated for the above tests should not exceed the
manufacturer's stated limits for accuracy and hysteresis.
Switches
Alarm output for all switches (PSHH & PSLL) shall be tested as per approved
datasheet. This type is not require linearity test. Applied pressure source (for pressure
switch type) or water (for level switch type) to the devices and monitor switches output
at Engineering Work Station/HMI/Laptop, ensure alarm is appear at HMI.
Note the bench setting operating range of the diaphragm actuator from its data plate
or specification sheet, i.e. bench-set of actuator irrespective of positioner. Note the
operating range of the positioner input and output. Where the positioner is fitted with a
by-pass valve (omitted in split-range service) switch the valve to the signal input
connection. If a positioner by-pass is not fitted, disconnect the air connection from the
actuator case and connect the variable air supply, with test gauge, direct to the
diaphragm head.
The actuator should then be checked for travel, independent from positioner with
rising and falling signals at 0-25-50-75-100% of valve stroke.
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After checking the valve stroke without positioner, the stroke should be checked with
the positioner in service. Connect an air/gas supply to the Positioner 'supply'
connection and adjust to 0.4 bar above the maximum operating range of the
actuator. Switch the positioner by- pass valve to the ‘on’ position. If no by-pass is
fitted, re-connect the positioner output to the actuator and connect the variable
air supply to the positioner signal connection.
operation pressure (MOP). All valve accessories shall be checked for correct function,
this shall include limit switches, solenoid valves and any associated test over-ride
facilities.
Leak testing shall cover with piping leak test procedure. Valve function test shall carry
out with max
- Open manual valve and make sure pressure indicated at pressure gauge Set
on min IA pressure, refer to data sheet.
- Check valve condition and local indication (3D Beacon) at closed position
- Inject N2/Air Supply for Solenoid Valve and make sure solenoid valve move
from close to open position (Record stroke time close to open/ Time to close
and time to open shall be recorded.)
- Cut N2/Air Supply for Solenoid Valve and make sure solenoid valve move
from close to open position (Record stroke time close to open)
- Check local indication is in Open position. Limit switch (ZSC/ZSO) status shall
be checked during fully open, fully close, and travelling position.
Flow Meter
Flow meter in facility is only for flow measurement. It will be treated as common DP type
transmitter. Loop testing shall be performed as mentioned on general electronic loop test
activity.
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Energize DC volt power supply, warm up the instrument for a few minutes, make sure
that Transmitter is in operable condition. Make sure local display show pressure is in
0 psig and no flow available.
Before perform loop testing, check field device and control system are successfully
communication handshake and signal from field able to be monitored at HMI Display
or laptop.
Loop testing will be performed by simulated input value from Laptop/Pressure Source
and monitor output at local display. Value on local display shall be monitored and
informedby Radio.
Inject pressure by applied hand pump to upscale range value 0%, 25%, 50%, 75%,
100% and downscale range values 100%, 75%, 50%, 25%, 0%. Monitor pressure
value and flow calculation on local display and HMI.
For more detail testing and flow calculation data shall refer to vendor document.
7.0 ATTACHMENT
ATACHMENT A LOOP CHECK ANALOG CHECK SHEET
ATACHMENT B LOOP CHECK DIGITAL CHECK SHEET
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ATACHMENT A
LOOP CHECK ANALOG CHECK SHEET
VALVE RESPONSE
Valve Tag Failure Action Valve Function Valve Action Response Time in 'Sec' Acceptance
FC FO FL ON/OFF Modulating DIRECT RESERVE
Confirm the following details for the Test Equipment used to complete the test :
No. Test Equipment Description Model No. Serial No. Cal Cert No. Expiry Date
Remarks :
Punch List Y N
Signature
Name
Date
SHEET 1 OF 1
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ATACHMENT B
LOOP CHECK DIGITAL CHECK SHEET
Item No : Module :
Task Location : Dwg / PID :
Estimated Time (MH) : User Group :
System ID: Expended Time (MH) :
Sub-system :
Type of Signal Push Button/Hand Switch Inter Panel Signal Switching Inputs
Pressure Temperature Flow
Others (Specify)……….
Confirm the following details for the Test equipment used to complete the test :
Signature
Name
Date
SHEET 1 OF 1