Logic Check Function Check Procedure
Logic Check Function Check Procedure
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Qatar Petroleum
Petrofac ~
TITLE:
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Approved for
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Issued for
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DESCRIPTION
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10/05/11
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11/10/11(,
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Pagel of 15
Rev.
DOCUMENT NO.
2971-0-05-0071
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Date: 11/10/11
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~ RevisionD~scription
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CONTENTS
1.0
PURPOSE. ......................................................................................................... 4
2.0
SCOPE ............................................................................................................. 4
3.0
REFERENCES ..................................................................................................... 4
4.0
DEFINITIONS ..................................................................................................... 5
5.0
ABBREVIATIONS ................................................................................................. 5
6.0
6.1
6.2
7.0
8.0
PRE-REQUiSiTES ................................................................................................. 7
9.0
PROCEDURE ...................................................................................................... 7
9.1
9.2
9.2.1
9.2.2
9.2.3
9.2.4
9.2.5
Phase 1 - Testing
Phase 2 - Testing
Phase 3 - Testing
Phase 4 - Testing
Phase 5 - Testing
.. ........................... 7
9.3
10.0
11.0
ATTACHMENTS ................................................................................................ 13
11.1
ATTACHMENT 1 - FUNCTION CONTROL LOOP NARRATIVES & LOGIC SEQUENCE TEST ......................... 14
11.2
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1.0
PURPOSE
The purpose of this procedure is to describe the minimum applicable requirements and
acceptance criteria for the logic / function testing activities on the Gas Sweetening Facilities
Project (GSF) at Mesaieed & Dukhan. It describes the method for performing the tests that will
demonstrate that the Cause and Effects - F&G, Cause and Effects - ESD and function control
narratives meet the design intent and the project specifications.
2.0
SCOPE
This procedure applies to the plant process and safeguarding, F&G detection equipment and
plant process equipments including all vendor supplied packages at the Acid Gas Removal Plant
Part-2 (AGRP).
3.0
REFERENCES
Scope of Work
Control Narrative
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4_0
DEFINITIONS
Commissioning
CONTRACTOR
5.0
Commissioning comprises those activities undertaken after PreCommissioning to verify that the dynamic functioning of
systems and subsystems is in accordance with specified
requirements, and to verify as accurately as possible that the
system is "Ready for Start-Up"_
Equipment
PetroPCS
Pre-Commissioning
QP
Qatar Petroleum
Vendor
ABBREVIATIONS
AGRP
BGU
CaE
ESD
Emergency Shutdown
faG
FAT
FCN
FGS
H2 S
HMI
IPS
LEL
JHA
MCC
MOS
paiD
PB
Push Button
PPM
PTW
Permit to Work
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6.0
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6.1
QP Commissioning Team
6.2
Overall control of CONTRACTOR Commissioning team during the execution of the logic /
functional checking activities.
Commissioning Engineer
Responsible for the safety of all personnel assigned to him, ensuring that the JHA,
applicable permits and control measures are in place prior to applying the procedure.
Responsible for supporting the testing team and for setting all applicable test
requirements and conditions.
Responsible for coordinatingCthe works with other parties that may be required and parties
affected by executing the procedure.
Responsible for ensuring QP representative (s) is notified and is at the test site as
required.
Responsible for applying all necessary forces and overrides to reset all executive actions to
a healthy condition and keeping the required records.
Responsible for initiating the change request form in case of any required software
modification such as alarms / trips set points.
7.0
Responsible for ensuring that the work as outlined in this procedure is performed safely
and all safeguards and controls are complied with.
Responsible for preparing the equipment or system for the activities outlined in this
procedure.
All works executed under this procedure shall be performed in accordance with the project's
HSSE Plan.
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A Risk Assessment is to be carried out for the all the activities involved with Logic checking
a Functional Checking of the plant.
The Risk Assessment should identify the hazards, persons involved, the risk associated with
the specific activities and the mitigating measures required to reduce the risk and
hazards.
Conduct a 'tool box talk' prior to start of logic checking / functional checking activity to
review Risk Assessment, safety considerations, potential hazards and mitigating measures
for conducting the activity.
8.0
PRE-REQUISITES
Verify the completion of the duly signed PetroPCS 'A' check sheets as per the system list.
Verify the completion of the duly signed PetroPCS 'B' check sheets as per the system list.
This corresponds to 5-point Instrument Loop check (include FCS alarms and IPS trip set
points) completion ('B' check sheets) duly witnessed and signed off by QP.
Identify the various vendor engineers' involvement during the execution of the work.
Hold a tool box talk involving all concerned parties / members about the testing and test
activities.
Plan the interface with the Vendor, Process, Mechanical and Commissioning teams and QP.
9.0
9.1
PROCEDURE
Ensure all safeguards and controls / isolations / de-isolations are in place before
proceeding with the instructions in the procedure.
Establish the required communication among the relevant teams / crew members.
Complete the Fire a Gas Cause a Effect checks for the specified process area as per
section 9.1.
Complete the ESD Cause a Effect checks for the specified process area as per section 9.2.
Complete the function control narratives checks for the specified process area as per
section 9.3.
Prior to starting the FaG caE checks (while testing individual detectors), Orange ESD
(Level 1) of the respective process area shall be in the 'Off state' (inhibited from
Software).
The Software inhibits on the Orange ESD shall be removed prior to the testing of the voting
logic (Confirmed gas and confirmed fire). At the same time, the effects of the respective
process equipments, blowdown and shutdown valves trip / open / close commands must
be inhibited.
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All applicable test equipments / test gases, recommended by the vendor (s), must be
made available.
Prior to starting the FaG caE tests, all detectors and associated alarms / indications on
the remote FCS HMI Mimic panel must have been tested as part of the instruments loop
checks (Effects)_
Test Sequence
The testing is in 2 steps.
Testing of individual detectors against low level and high level alarms and their respective
effects.
Testing of the voting logic (2 out of the total number of detectors in a zone / process
area) and verifying the effects_
10% LEL of methane in air for HVAC air intakes at battery rooms, LER and substation
15% LEL for ventilation and combustion air intakes at EDG and Hot Oil Heater
20% LEL of methane in air for HVAC air intakes at battery rooms, LER and substation
25% LEL for ventilation and combustion air intakes at EDG and Hot Oil Heater
Finally, the voting logic will be tested by applying test gas (60% LEL) to any 2 out of the total
numbers of flammable gas detectors (zone wise) to generate a confirmed gas detection and
the effects will be checked as per the CaE charts.
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Two more '2 00 N' combinations shall be tested to give more assurance. This will not include
the two detectors tested earlier. (One test carried out with sample gas and the other test by
simulation from the marshalling cabinets.)
Confirmed Toxic Gas Detection
Individual HzS detectors in all zones will be tested by applying test gas to generate 10 ppm
indications and the respective high toxic gas alarm effects will be checked as per the CaE
charts.
Finally, the voting logic will be tested by applying test gas to any 2 out of total numbers of HzS
detectors (Process area wise for all zones) to generate confirmed toxic gas detection and the
effects will be checked as per the CaE charts.
Two more '2 00 N' combinations shall be tested to give more assurance. This will not include
the two detectors tested earlier. (One test carried out with sample gas and the other test by
simulation from the marshalling cabinets.)
Confirmed Fire Detection
Individual flame and smoke detectors in all zones will be tested with the use of test
equipments to generate a fire detection (Fire alarm) indication and the respective effects will
be checked as per the CaE charts.
.'
After verification of all the flame and smoke detectors, the voting logic will be testing by
activating '2 00 N' detectors in each Fire Zone to generate a confirmed fire detection alarm and
the effects will be checked as per the CaE charts.
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Two more '2 00 N' combinations shall be tested to give more assurance. This will not include
the two detectors tested earlier. (One test carried out with test equipment and the other test
by simulation from the marshalling cabinets.)
9.2
Pre-requisites
Verification of all documentation such as, 'B' checks sheets for instrument loop checks of
shutdown valves, blowdown valves, buttons, ESD reset PB, remote ESD PB, all MOS enable
key switches and MOS lamps on the ESD Matrix Panel, all MCC interface signals to FCS/IPS,
in all SUb-systems in a priority turnover system.
All applicable test equipments (for simulation of trip alarms) recommended by the vendor
must be made available.
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Execution
All ESDCaE will be completed in 5 phases in a sequential manner. Against a specific Cause, all
associated Effects ('X' marks) mentioned on the Cause a Effects chart will be verified.
ESD Cause a Effects test will be carried out plant area wise based on the priorities sequence
determined by the project schedule.
This will facilitate turning over the priority process systems for Nitrogen leak test and
subsequent Commissioning activities.
All motors (uncoupled) will be kept in 'test mode' (on the MCC feeder) to ensure no physical
run of the motors. All motors' remote run command I feedback should have been already
tested as part of loop testing.
Except the Effects which are to be tested on the priority Cause a Effects testing system,
remaining all Effects will be inhibited and recorded as per section 10.0 of this document.
9.2.1
Simulate Plant StartUp on the HMI graphics sheets and confirm that all parameters are
healthy. The technical write of the Start Up sequence, tested as part of the software FAT,
shall be made available during the testing operation.
Individual process IPS trip alarms and machine health monitoring protection trip alarms
will be initiated and the effects will be checked as per the CaE charts (process
equipments trip and shutdown)
9.2.2
Simulate Plant StartUp on the HMI graphics sheets and confirm that all parameters are
healthy. The technical write of the StartUp sequence, tested as part of the software FAT,
shall be made available during the testing operation.
Initiate a process Level 3 ESD as a Cause and verify all associated Effects as per the CaE
charts.
Initiate a Level 3 ESD field PB as a Cause and verify all associated Effects as per the caE
charts.
9.2.3
Simulate Plant StartUp on the HMI graphics sheets and confirm that all parameters are
healthy. The technical write of the StartUp sequence, tested as part of the software FAT,
shall be made available during the testing operation.
Initiate a process Yellow ESD as a Cause and verify all associated Effects as per the caE
charts.
Initiate Yellow ESD control room PB (Yellow) as a Cause and verify all associated Effects as
per the CaE charts.
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Initiate Yellow ESD field PB as a Cause and verify all associated Effects as per the CaE
charts_
Initiate confirmed fire and flammable gas signals from the respective fire zone (which
covers the respective process equipment area) and verify that a Yellow ESD is enabled as
Effect.
9.2.4
Simulate Plant Start-Up on the HMI graphics sheets and confirm that all parameters are
healthy. The technical write of the Start-Up sequence, tested as part of the software FAT,
shall be made available during the testing operation.
Initiate Orange ESD control room PB (Orange) as a Cause and verify all associated Effects
as per the CaE charts.
Initiate confirmed fire and flammable gas signals from the respective fire zone (which
covers the respective process equipment area) and verify that an Orange ESD is enabled as
Effect.
Initiate toxic gas from the respective fire zone (which covers the respective process
equipment area) and verify that an Orange ESD is enabled as Effect.
9.2.5
Simulate Plant Start-Up on the HMI graphics sheets and confirm that all parameters are
healthy. The technical write of the Start-Up sequence, tested as part of the software FAT,
shall be made available during the testing operation.
Initiate Red ESD control room PB (Red) as a Cause and verify all associated Effects as per
the CaE charts.
Initiate Red ESD main gate PB as a Cause and verify all associated Effects as per the CaE
charts.
Notes:
Effects against a cause which was earlier an Effect itself will not be repeated_
In a process system where multiple sets of equipments are present, ESD caE checks will be
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completed by grouping the equipments_ None associated equipments / valves (not part
of the test) shutdowns will be inhibited in the software and recorded as per section 10_0_
These will be removed at the end of the test_
All Cause 8: Effects checks will be tested by keeping the MCC feeders in 'test mode' to
avoid the unnecessary actual runs_ Equipments will be simulated as in normal running
condition (Ex: motor available status healthy condition)_ During the C8:E checks, it shall be
verified that the activation of a respective Cause will result in the motor's available status
turning into trip status without having to physically trip the motor.
A complete EsD C8:E test post Start Up will also be carried out allowing for all cause 8:
effect to take effect_
9_3
Identification of the priority turnover system/sub-systems since FCN checks will be carried
out on a system/sub-system level or on a group of systems/sub-systems together_
Completion of all field instrument loop checks of shutdown valves, blowdown valves,
control valves, vendor packages instruments, FCs and IPS transmitters, EsD push buttons,
EsD reset push buttons, remote EsD PB, all MOs enable key switches on the hard wired
console, MOs lamps on the local panels, all MCC interface signals to FCs/ IPS and
verification of the check sheets have been completed and loaded into PetroPCs_
All applicable test equipments (for simulation of trip alarms) recommended by the vendors
must be made available_
Prior to FCN, all the controllers will be confirmed in Manual mode and all the valves will
be opened manually from respective controller.
Execution
The control narrative shall be verified, line by line to ensure that the correct
implementation of the program_
Air fails action to be verified in the field as per the control narrative document.
For controllers working in Manual, Auto or Cascade, the applicable mode will be checked_
Controllers action in Auto mode, Cascade mode, Ratio mode as applicable are tested on
the FCs HMI by varying (rising / decreasing) the process value the software simulation
blocks_
Direct / reverse action will also be confirmed in the manner described above_
Split range control action will also be confirmed in the manner described above_
All these are confirmed during the software FAT and will be tested again during SIT and
subsequently signed off by QP_
Notes:
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Simulation of the process alarms mentioned in the control narrative will be with test
equipments from the marshalling cabinets, wherever possible.
Possible simulation of process input values will be completed from the software by
changing the values (rising / decreasing) to avoid the use of 2 or more communicators.
All the process input signals from the field instrument are already tested as part of the
instrument loop checks.
Any deviations from the control narrative shall be recorded on the punch list and
corrected at a later stage under the control of a software change request.
10.0
11.0
A 'overrides, inhibits and forced signals' log book shall be maintained inline with the
requirements of the procedure for control of overrides, inhibits and forced signals (Doc.
No. 2971-4-05-0005) to record/track the various bypasses installation/removal.
A Master copy of the caE-ESD, CaE-FaG, Function control narratives will be made
available in Control room HMPS and all tests will be recorded on it. These copies will be
later signed off by CONTRACTOR and QP for record keeping.
A detailed log book (Engineering deviations) will be maintained inline with the software
change control procedure (Doc. No. 2971-4-05-0002) to record the deviations of configured
alarms and trip set points on the graphics and on the project's 'Alarm, Trip a Set-point
schedule' .
"The PetroPCS check sheets attached in section 11.0 of this document are applicable for
this procedure
ATTACHMENTS
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TAG
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Record Ho~
SUS-SYSTEM Ho.
No.
DRAWING
Cu\'A "un
I-0105C
Rev. : 1
No.
~~::g~.NO:
I AREA
LooP
Sht. N6.
, ~'Q""' No.
SHT. NO.
Rev. No.
..
,-
I OF TEST
TEST RESULTS
COMPLETED BY
Signature
Name
Date
APPROVED BY
ACCEPTED BY
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11.2
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Record No:
m
TAG No.
SUB-SYSTEM No.
DRAWING No.
Control I Safeguarding System Site Acceptance Shall be in accordance with the manufacturers
recommendations and with the factory acceptance test Procedures and results
Item
1.
2.
3.
Description of check
Result
All items shown on Cause a Effect Drawings shaU be proven during precommissioning
Causes andJ,ffect aGtions checked and confirmed as per the Cause a Effect
Drawinll Data
Attach As built CaE Drawinll sil/ned by company as witnessed for full or part CaE
test from field input to field output
REMARKS/OBSERVATIONS:
COMPLETED BY
Signature
Name
Date
APPROVED BY
ACCEPTED BY