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26071-100-530-GST-00013 Method Statement For Instrument Logic Function Test - 00A
26071-100-530-GST-00013 Method Statement For Instrument Logic Function Test - 00A
: 26071-100-530-GST-00013
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REVISION LOG
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TABLE OF CONTENTS
1 PURPOSE ............................................................................................................................... 4
2 SCOPE OF WORK................................................................................................................. 4
3 DEFINITION .......................................................................................................................... 4
4 REFERENCE ........................................................................................................................... 5
9 HAZARDS ............................................................................................................................15
11 ATTACHMENTS ..............................................................................................................17
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1 PURPOSE
The purpose of this Method Statement is to describe and establish HSE and
Commissioning requirements for Logic & Function Test works to be executed by Contractor
for Commissioning Inside Battery Limits (ISBL) and Outside Battery Limit (OSBL) for The
Refinery Development Master Plan (RDMP) Project RU V Balikpapan (hereinafter referred
to as PROJECT).
2 SCOPE OF WORK
This Method Statement covers for all the activities related to Instrument
Logic & Function Test works and provides problem statement or description of work.
3 DEFINITION
Terms Definition
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4 REFERENCE
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5 WORK PREPARATION
Before commencement of work, below Logic & Function Test preparation & safety
requirements shall be done by authorized person on site.
All the personnel working in the field will be given relevant safety orientation training
and formal site induction. All the personnel will be made aware of safety procedures
and requirements to be ensured on the entire task to be executed on site. Daily toolbox
tasks will be held at the site prior to commence of work activities. All the personnel
working in the site shall wear the appropriate PPE.
Check and confirm all equipment and tools be used at site, having valid and approved
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The Permit Holder shall hold PTW while working is ongoing and fully supervise all
activities from safety point of view. Welfare facilities shall be prepared by the
Subcontractor in terms of site requirements.
Isolate the excavated area with warning tape and warning signs in order to control
access to the work area by unauthorized workers.
Before work starts, ensure that all work permits have been obtained from Company
and other authorities, as required for site conditions.
Gas monitoring shall be conducted by Authorized Gas Tester who trained & Certified
Company approved 3rd party agency (if required).
All types of gas detector shall have valid calibration certificate and periodically
calibrated.
All workers who involved in confined space work shall be conducted medical fitness
exam and special training prior to start work inside confined space.
Confined space rescue items shall be prepared and entry attendant shall monitor all
confined space works.
Qualified first aider & trained rescuer shall be standby in case of emergency situations.
Ensure that all equipment such as winch machine, megger and crane shall have valid
3rd party inspection certificate which issued by the Company approved 3rd party
Agency.
Heat stress prevention means such as shelter, drinking water, and work regimen shall
be implemented while working hours.
Inspection of all electrical tools shall be carried out by the Contractor’s inspector prior
to start activities for color coding purpose and operator and / or construction supervisor
shall conduct daily inspection for all electrical tools to ensure good conditions.
Working inside operation area Supervisor shall follow the Company safety work
practices while working inside operation area.
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Prepare/use the appropriate fire extinguisher / fire blanket and easily accessible /
visible.
Make sure the power supply properly turns off or isolated before.
Safety Shoes
Hand Gloves
Safety glasses
Safety Coverall
Safety Helmet
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Hearing Protection
a) Loop Test shall be completed before Logic and Function Test. In case all of the
associated Loop Test cannot be completed before the Logic Test, those loops shall be
listed as punch in the test report with clear reason. In case of loop not impact on logic
& function test, test shall be carried out with consent from company.
b) FAT and SAT Test result shall be reviewed and shall ensure that comments
have been reflected.
c) The document mentioned in this document shall be prepared for the Logic
Test.
i. During the functional test there is a possibility that some of the process/utility
systems and equipment may have already been commissioned and
simultaneously operated. Hence it needs to be ensured that the
respective Effects are properly isolated so that there is no initiation any
trip/stop/close/open functions of the physical devices. For this reason,
instrument functional testing group to ensure continuous coordination
with the relevant process/ utilities commissioning engineer. (SIMOPS)
ii. Instrument engineer checks that all forcing (override, bypass) required
for the test are implemented in the configuration. These shall be properly
done and recorded. Bypass override should stay active less than a day.
Long term bypass shall be approved before application, recorded and
reported to iPMT.
iii. Electrical engineer checks MCC status (availability, fault status) to be
sure the equipment has been put in test mode. (if relevant) For electrical
motors, Cubicles shall be in “TEST” mode and electrical engineer
confirms that no motors will start on field.
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e) Simulate input condition step by step and check and verify that output changes
are in accordance with the approved Logic Diagram and Cause & Effect.
f) Alarm and trip conditions shall also be simulated to verify that output is
activated according to Logic Diagram and Cause & Effect.
iii. Correspondence of warning and emergency alarm set point values in BPCS,
SIS and FGS to the values approved in Logic Diagram and Cause & Effect.
g) Prompt interlocking algorithm for all input signals, being used in the interlock
algorithm of the process facility shall be tested.
iii. Correspondence of interlock set point values in SIS, FGS to the values
in the approved logic diagram and cause and effect
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iv. Correct display of input signal value and presence of changes in the
dynamic shape status on the mnemonic diagram, appearance of
records in the event log, registration of interlock trigger on the
mnemonic diagrams with cause and effect table
h) Parameters such as Range, Engineering Unit, PID Setting, Fail Position and etc.
shall be checked and verified.
iv. Correct displaying of input signal value and presence of changes in the
dynamic shape status.
v. Change in the output analog signal level pursuant to the values set by
the control principle
i) Set value in BPCS, SIS, FGS and Package PLC shall be checked with the set
value in the approved Logic diagram and Cause & Effect.
Construction Manager
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Subcontractor
Instrument Foreman
a) Responsible for the proper execution of all related works as per this method
statement
Instrument Manager
a) Shall ensure and control the overall Logic & Function test activates.
b) Shall be responsible for compliance with procedure and provides all resources
necessary to effectively implement throughout the Logic & Function Test period.
c) Shall ensure that all personnel involved in the job are fully aware of all quality
control requirements.
d) Shall monitor the quality and progress of the work and ensure project schedule
archives.
Instrument Engineer
a) Shall identify any problem, which may affect the completion or progress of the job
and propose the remedial action to instrument manager for resolving the problem.
b) Shall be responsible for Logic & Function test and ensures that work is completed
on the schedule and in conformity with control narrative, cause & effect, instrument
data sheets, loop diagram, and related document & drawing.
c) Shall be responsible for all the coordination work with other departments which
related to the Logic & Function Test
d) Shall be responsible for mobilization of the vendor supervisor, if required.
e) Shall review the appropriate drawings and data sheets and then check safety
condition at the test area according to daily test schedule.
Instrument Supervisor
a) Shall be responsible for all test equipment has its own certification or is to be
certified and calibrated by recognizing institute.
b) Shall be responsible for the arrangement of all resources required for executing the
planned work.
c) Shall be responsible for the coordination with instrument engineer regarding the
schedule and if any major comment received from the Company inspectors during
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Document Controller
a) Shall be responsible for maintaining the entire instrument database (such as all
necessary documents including control narrative, cause & effect and loop diagram.).
b) Shall coordinate with instrument engineer and supervisor to check the readiness of
the control narrative, Cause & effect and update the Logic & Function test record.
QA/QC Manager
a) QA/QC Manager has the overall responsibility for all QA/QC activities of the project.
He shall be interacting with Instrument Manager related to all QA/QC activities. He
shall be responsible for Nonconformance Management and Quality Audit.
QA/QC Engineer
a) QA/QC Engineer shall be responsible for the QA/QC activities, document control
and traceability, non-conformance management and compilation of instrument work
in Logic & Function test documents.
QA/QC Inspectors
a) QA/QC Inspectors shall be responsible for Site QA/QC activities, coordination with
HSSE authorities for instrument work in Logic & Function test activities at the site.
HSSE Officer
a) HSSE Officer shall monitor all the works that they are carried out and advice
supervisors for corrective measures, if required. He shall ensure holding of pre-task
HSSE meeting / daily toolbox talks covering details of specific tasks and specific job
risks involved in the workforce. He shall also ensure the appropriate mode
communication in case emergency.
8 TOOL&EQUIPMENT
HART Communicator (according to IEC 61158 CP 9/1 HART Version 7)
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9 HAZARDS
9.1.1 Delay for Permit issue : Prompt and accurate PTW process should be addressed
early in the morning with Company's cooperation.
9.1.2 Unnecessary preparation and argument : All work's information should be discussed
with RDMP JO prior to processing the PTW to avoid unnecessary preparation and
argument.
9.1.3 Stop of Permit(work) : Working area should be prepared for required job and cleaned
to avoid the stop of PTW(work).
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9.2.1 Worker is exposed to the electric shock from the high-voltage equipment and
instruments.
9.2.2 Injury accident due to improper handling of tools / equipment
9.2.3 Use the correct insulated tools during Logic & Function Test
9.2.4 Supervisor shall ensure workers are trained and competent to handle tools and
equipment
9.2.5 Supervisor shall ensure PTW is in place and all workers have signed the JSA prior to
work start
9.2.6 Supervisor shall inform all workers of PTW condition before work starts.
9.2.7 Use approved ladders, scaffolding and safety harness.
9.2.8 Use approved panel wiring system and insure there are lugs on all wires after label
has been placed
9.2.9 Mark terminals before working on wires. Mark unmarked wires.
Provide common safety equipment such as Fire Extinguishers, Fire Blanket, PPE etc.
at site in accordance with HSE Regulations.
Develop safety awareness for project team and erection team in any work condition.
Prior to start of work to ensure that all relevant work permits have been obtained from
RDMP JO, as per requirements.
Prior to start work, all pieces of construction equipment are to be inspected by the
Subcontractor’s safety department to ensure that all the certificates are valid and are in
accordance with RDMP JO HSE Regulations.
All certificates and permits relevant to the particular job shall be kept at site for
verification.
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11 ATTACHMENTS
ATTACHMENT #1. Index for Control Narrative Diagram, Cause & Effect,
Instrument Index, Loop diagram and Wiring diagram
ATTACHMENT #2. ITR (Inspection Test Report) for Instrument Logic function test
ATTACHMENT #3. JSA
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Attachment#1
Index for Control Narrative Diagram, Cause &
Effect, Instrument Index, Loop diagram and
Wiring diagram
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1. Control Narrative
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Attachment#2
ITR for Logic & Function Test
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Project Engineering, Procurement and Construction (EPC) Inside Battery Limits (ISBL) and Outside Battery Limit
(OSBL) for The Refinery Development Master Plan (RDMP) Project RU V Balikpapan
1 Relevant individual loops of ICSS & UCP/LCP have been checked and test sheet is
completed.
2 Check that the latest revision of relevant documents is used as a reference during the test.
3 Pre-defined parameter (timers, default values, etc.) for complex loop verified and checked as
per control narrative into the configuration
4 Overall Function working properly (Basic PID / Cascade / Split Range / Ramp Down /
Sequence logic / Any other control function in documents )
5 Cripple mode tested ( Bad PV input -> Last good value hold output)
9 Control Narrative / Interlock Narrative / Logic Diagram is marked up showing extents of test
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Name
Signature
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Project Engineering, Procurement and Construction (EPC) Inside Battery Limits (ISBL) and Outside Battery Limit
(OSBL) for The Refinery Development Master Plan (RDMP) Project RU V Balikpapan
1 Relevant individual loops of ICSS & UCP/LCP have been checked and test sheet is
completed.
2 Check that the latest revision of relevant documents is used as a reference during the test.
7 Master C&E / Interlock Narrative / Logic Diagram is marked up showing extents of test
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Name
Signature
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Attachment#3
JSA
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