ICSS Loop Test Presentation Updated

ICSS Loop Test Presentation
By
Eng. Ahmed Adel A. Megeid

The purpose of loop test:
The purpose of loop test as a part of pre-commissioning
activities to confirm that the components of the loop are
wired correctly as per design prior to commissioning and
start-up.
Documents required for loop test:

1)
2)
3)
4)
5)
Detail Loop Diagram

Interconnection wiring diagram
P&IDs
Instrument Data sheet
Loop & function test check Lists
2

Abbreviation:
DCS Distributed Control System
IPS Instrument Protective System
ICSS Integrated Control & Safeguarding System
EWS Engineering Work Station
FAR Field Auxiliary Room
FF Foundation Fieldbus
FGS Fire & Gas System
JB Junction box
FFJB Foundation Fieldbus Junction box
HMI Human Machine Interface
ROV Remote Operated Valve
MCC Motor Control Center

BMSBurner Management System
MMS Machine Monitor System
OWS Operating Work Station
SOE Sequence Of Events
IRP Interposing Relay Panel
ICSS Loop test Presentation

Introduction:
Instrument Loop Diagram
Loop diagram represents detailed drawing showing a
connection from one point to control system. It could be
connection between:
Field instrument to control system (or vice versa)
Signal from Local Control Panel to control system (or vice
versa)
Signal from MCC to control system (or vice versa)
Signal from one control system to another control system

Type of Loops:
1) Open or single Loop (Indication)
DCS
DCS
OWS
OWS
Open Loop
JB
JB
Transmitter
Transmitter

2) Closed Loop :
OWS
OWS
DCS
DCS
Closed Loop
JB
JB
Transmitter
Transmitter
Control
ControlValve
Valve

Type of systems:
1) Process Control System (DCS, PLC)
2) Safety System (IPS, FGS, BMS, MMS,
HIPPS)

Loop Test Procedure:-
Tools Required;
1) Hand held Communicators
2) HP Hand Pump with digital Gauge & Druck
3) Current source (4-20 mA),
4) Multi-meter measurement (AVO) Fluke,
5) Water Pump for level transmitters loop test.
6 ) TRX or DPI-620 device for temperature
transmitters loop test.
7) Radio (Waki-talki) for communication from control
building and field
8) Instrument Air network to ready OR using Air
compressor with air dryer.
9

Procedure; (Refer to Loop Test Check
List);
DCS/IPS Loop test:
A) Analog Input (AI)test procedure;
Hart Analog input signals shall be tested as per Loop test
check List requirements as follows:
1) Analog input signals shall be tested at five values as
follows:
- 4 ma
at 0%
- 8 maat 25%
- 12 ma at 50%
-16 ma at 75%
- 20 ma at 100%
Loop Test Check
List
10

3) Check the value in the correspondent DCS graphics display
4) Check analog alarm set-points are correct
5) Check the correct units in DCS HMI
6) Check the Alarms are recorded in the Historian and SOE (if
any) is correct.
7) Check transmitter failure alarm.
8) Check the Tag description for each test
11

Type of Hart Transmitters used as (AI):1) Pressure & Diff. Pressure Transmitter:
1) Pressure pump shall be used for pressure & differential
pressure transmitter (HART &FF) loop test at values
0%, 25%, 50%, 75%, 100% of calibration range (rising
& falling)
2) Follow Analog Input test procedure as per AI test
procedure
3) Record the result in Loop test check List
DCS/IPS
DCS/IPS
HP
HPPUMP
PUMP
JB
JB
OWS
OWS
PT
PT
HP
hose
12

2) Temperature Transmitter:1)Druck TRX temp. calibrator shall be used for temp.
transmitter (HART or FF) to perform loop test at
values 0%, 25%, 50%, 75%, 100% of calibration
range (rising & falling)
2)Follow Analog Input test procedure as per AI test
procedure .
DCS/IPS
3)Record the result in Loop testDCS/IPS
check List
OWS
OWS
Druck
DruckTRX
TRX
device
device
JB
JB
TT
TT
TRX cable
connectio
n
13
3A)Level transmitter GWR (side to side mounted):1) Water pump shall be used for GWR- LTs (HART or FF)
to perform loop test at values 0%, 25%, 50%, 75%,
100% of calibration range (rising & falling) by using
water.
2) Follow Analog Input test procedure as per item AI test
procedure .
DCS/IPS
DCS/IPS
3) Record the result in Loop test
check List
JB
JB
OWS
OWS
Water
WaterPump
Pump
LT
LT
Hose
14
3B) Level transmitter GWR, Top mounted:1) Hand Held communicator 475 shall be used for GWR
LTs (HART or FF) to simulate loop test at values 0%,
25%, 50%, 75%, 100% of calibration range (rising &
falling).
2) Follow Analog Input test procedure as per item AI test
procedure .
DCS/IPS
DCS/IPS
3) Record the result in Loop test check List.
JB
JB
OWS
OWS
Hand
Handheld
held
communicator
communicator
LT
LT
Device cable
15

4)Flow transmitter Coriolis & Ultra-Sonic:1) Hand held communicator 475 shall be used for FTs(VCone & Ultra Sonic) to simulate loop test at values 0%,
25%, 50%, 75%, 100% of calibration range (rising &
falling)
2) Follow Analog Input test procedure as per AI test
procedure .
3) Record the result in Loop test check List.
DCS/IPS
DCS/IPS
OWS
OWS
JB
JB
Hand
Handheld
held
communicator
communicator
Device cable
FT
FT
16

B) Analog Outputs (AO) Test Procedure ( Refer
to Loop test check list):
Analog Output shall be tested as per Loop test check List
requirements as follows:1) All Analog Output signals shall be check with 5 values:
- 4 mA 0 %
- 8 mA 25 %
Loop Test Check
List
- 12 mA 50 %
- 16 mA 75 %
- 20 mA 100 %
2) Check valve travelling at field and measure the current
at I/P Positioner by using multi-meter.
3) Check the Tag / Loop description for each Tag
4) Record the results in loop test check list
17

Type of devices used as HART-AO:1) Control Valve :- (Test Procedures):
1) Force signal from OWS to I/P positioner of control valve to
simulate loop test at values 0%, 25%, 50%, 75%, 100% of air
cooler louver opening (rising & falling)
2) Check control valve travelling by using multi-meter to measure
mA current forced .
3) Check the remaining analog output test procedure as per AO
test procedure.
4) Record control valve moving in Loop test check List
DCS
DCS
OWS
OWS
JB
JB
CV
CV
Multimeter
I/P
Positioner
18

C) Digital Input (DI)test procedure:Type of devices used as (DI):1) ROV (Open /Close Limit switch):
These signals shall be tested with solenoid valve of ROV
during valve opening & closing. (Refer to DO test
procedure with ROV Solenoid valve) and record the
results in check list
2) IRP (Pump Run & Not Available Signals):
These signals shall be tested during pump start /stop
simulation test with MCC (Refer to DO test procedure
with IRP-Pump Start/Stop) and record the results in check
list
19

3) Push button and Hand switches (MOS, Reset,
SD PB):
These signals shall be tested by activate PBs or
HSs and record the results in check list
4) Packages & different control system repeating
signals (CF, CG,CSA, CTA, Running Status,..,etc):
Such signals shall be simulated at package LCP
by using Jumpers at Terminal block, check the
status at OWS and record the results in check list
20

Digital Inputs Test Procedures:
Digital input signals shall be tested as per Loop test check
list requirements as follows:
Loop Test Check
List
1) Activate each of the digital inputs as follows:

- Open/Close ROVs to check valve limit switches
- Energize/force IRP relays for checking of run and available/unavailable signals
- Force Pkg LCP signals at LCP to check the response in DCS
- Force ESD/PSD Push buttons at ESD Console to check the
response in ESD and DCS
2) Check the value in the correct DCS graphics display
3) Check the Alarms are generated in the Current Alarm Display
4) Check the Alarms are recorded in the Historian and SOE (if
any) is correct.
21

D) Digital Outputs
Digital Output signals shall be tested as per Loop
test check list requirements as follows:
Loop Test Check
List
Activate each of the digital output signals by

toggling the correct system block.
Confirm that 24VDC has been transferred to the
corresponding field device by using multi-meter
Confirm that free contact is closed at
corresponding field device by using multi-meter
22

Type of devices used as (DI & DO):A) ROV:
The following signals shall be tested with ROV:
1) Solenoid valves (RXV) (DO)
2) GZSC (Close Limit Switch (DI))
3) GZSO (Open Limit Switch (DI))
ROV Loop
DCS
DCS
IPS
IPS
IPS
IPSEWS
EWS
DCS
DCSOWS
OWS
JB
JB
RZC/O
RXV
ROV
ROV
23

ROV Loop Test Procedure:Loop Test Check
List
1) Shutdown Valve:
1-A) ROV travelling from Closing to Opening:
1) Before starting test, Shutdown valve (ROV) shall be in
close position. Accordingly check GZSC in OWS and
ensure that its received correctly (i.e, ROV color is red)
2) Check instrument air to ROV is correctly adjusted to
required pressure.
3) From IPS-EWS; Apply 24 VDC to solenoid valve (RXV).
Check ROV travelling in OWS (i.e, ROV color is Yellow)
4) When ROV is fully open, check GZSO in OWS and
ensure that its received correctly (i.e, ROV color is
Green)
5) Ensure that voltage applied on solenoid valve (RXV)
within accepted value. (i.e, 23-24 VDC)
24

1-B) ROV travelling from Opening to Closing:
1) From IPS-EWS, Force 0 VDC to solenoid valve
(RXV). Check ROV travelling in OWS (i.e, ROV color
is Yellow)
2) When ROV is fully close, check GZSC in OWS and
Red)
3) Ensure that the voltage applied on the solenoid
(RXV) is 0 VDC
4) Re-open ROV, and check ROV fail action in case of
signal failure and Instrument Air Failure
5) Record all above results (RXV, GZSC, GZSO) in
Loop test check list

25

2- Blow down Valves
Loop Test Check
List
2-A) ROV travelling from Opening to Closing:1) Before starting test, Blow down valve (ROV) shall be in
open position. Accordingly check GZSO in OWS and
green)
2) Check instrument air to ROV is correctly adjusted to
required pressure.
3) Check RSR (reset P.B) and ensure that RSR signals is
received at EWS.
4) From IPS-EWS; Force 24 VDC to solenoid valve (RXV) and
20 mA to I/P Positioner. Check ROV travelling in OWS (i.e,
ROV color is Yellow)
5) When ROV is fully close, check GZSC in OWS and ensure
that its received correctly (i.e, ROV color is Red)
6) Check the voltage applied on solenoid valve (RXV) within
accepted value. (i.e, 23-24 VDC)
26

2-B) ROV travelling from Closing to Opening:
1) From IPS-EWS; Force 0 VDC to solenoid valve
(RXV). Check ROV travelling in OWS (i.e, ROV
color is Yellow)
2) When ROV is fully open, check GZSO in OWS
and ensure that its received correctly (i.e,
ROV color is green)
3) Check the voltage applied on the solenoid
(RXV) voltage is 0
4) Record all signals results (RXV, GZSC, GZSO,
RSR) in relative Loop test check list
27

B) Pump Signals Test Procedures:
- The following Pump signals shall be test as DO:
1)Remote Start (DCS-DO)
2)Remote Stop (DCS-DO)
3)ESD Trip (IPS-DO)
- The following Pump signals shall be test as DI :
1) Pump Run Status (DCS-DI)
2)Pump Not Available (DCS-DI)
3) Remote/Local (DCS-DI)
28

Pump Interface Signals
DCS
DCS
Remote
Start
Remote
MCC
MCC
Stop
Local/Remot
e
Run Status
Not Available Status
IPS
IPS
ESD Trip
29

Pump digital signals Test Procedure
1) MCC Drawer shall be switched to test Mode (if
energized)
2) Ensure that ESD trip signals (XZT) is Normal and
Stop signals not activated (DO Contact is closed) by
using multi-meter
3)Select Pump at manual mode and apply Remote
Start signals (HSA) from OWS and ensure that start
signals is received at MCC drawer
4) Check Run status signal (XB) in DCS-OWS is
received (i.e, Pump/Air cooler color is green)
5)Apply Remote Stop signals (HSB) from OWS and
ensure that start signals is received at MCC drawer
30

6) Check Run status signal (XB) in DCS-OWS and
ensure that Pump/Air cooler is stopped (i.e, Pump/Air
cooler color is Red)
7) Repeat Step 3, 4 above, and apply ESD trip signal
from IPS-EWS
8) Check Run status signal (XB) in DCS-OWS and
ensure that Pump/Air cooler is stopped (i.e, Pump/Air
cooler color is Red)
9) Apply Local/Remote signals (XSLR) from field and
ensure that such signals (XSLR) is received at
DCS_OWS.
10) Record all above tests results in loop test check
list.
31

ICSS Loop Test Presentation Updated

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ICSS Loop Test Presentation Updated

Uploaded by

Copyright:

Available Formats

ICSS Loop Test Presentation