TUNU FIELD

DEVELOPMENT PROJECT
PHASE 8

OPERATIONAL TEST PROCEDURE

Open Drain Drum & Pump – FKP
SUB-SYSTEM 6502

00 30/05/02 ALIMUNDIN- For Comments

PLATTS
REV DATE ORIGINATOR DESCRIPTION APPROVED
CHECKED BY CSL
. BY START-UP

TOTAL OR PARTIAL REPRODUCTION AND/OR UTILISATION OF THIS DOCUMENT ARE

FORBIDDEN WITHOUT PRIOR WRITTEN AUTHORIZATION OF THE COMPANY

TOTALFINAELF E&P INDONESIE

COMMISSIONING
DOCUMENT NUMBER REVISION

COM OTP NCP 6502 16 B 00 PAGE : 1 OF 11

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SUMMARY

The open drain system is designed to gather accidentally spilled

hydrocarbon liquids and water from around the Flare Knock Out
Platform and NMP-2 facilities and collect it safely in the Open
Drains Drum 5–V 4960
The design of the system is to pump all collected fluids to the NCP
Open Drain Network, where it will be separated and either sent to
the hydrocarbon system or to the Disposal tube.
The pump 5-P-4990 is a centrifugal type pump driven by electric
motor, giving a discharge pressure of 1.6 Barg and 10 M3/h flow.
The pump discharge header is fitted with a restriction orifice plate,
ensuring a continuous minimum flow protection for the pump. The
orifice is sized to ensure a minimum flow of 4M3/h. Also on the
discharge header but located Offsite is a 1mtr liquid seal pocket
Normal pump operation is to start at 750mm vessel level and to
stop at 600mm level, these signals are from LIT-4961.
A high level signal, set at 800mm and a low level signal, set at
550mm are also sent from LIT-4961.
LIT-4960 set at 450mm activates LALL-4960, which in turn trips
the pump motor on ESD-3.24B.
Should the pump not be available for any reason, the vessel is
fitted with an internal overflow pipe, this pipe extends into the
bottom vessel and will overflow to the river when the level reaches
900mm of the vessel.
Another feature of the vessel is the drain to the Platform edge,
should it be required to completely drain the vessel for match or
any other reason, it is possible to drain liquids straight into a
suitable drain barge.

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1 TEST SUMMARY

1.1 AIMS OF OPERATIONAL TEST

Prove the performance of the Open Drain Pump 5 -P 4990

Prove the start / stop logic of the Open Drain Pump 5 -P 4990 to the PCS and
Electrical MCC.

1.2 TEST DESCRIPTION

To check the equipment has been correctly installed and prepared for
commissioning in accordance with the vendors’ instruction.

1.3 TEMPORARY INSTALLATIONS

Potable water connection to the vessel 2” UC

1.4 SPECIAL PRECAUTIONS

Refer to Safe Operating Procedures.

Check that the Permit for the work is in force.
Check that all warning / precaution signs are in place.
Check that all non-essential personnel have been cleared from the area.
Ask the Control Room for a PA announcement to be made.

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2 PLANNING AND MANPOWER

2.1 PLANNING TASKS

Complete the OTP test in one (1) day

2.2 MANPOWER ESTIMATE

Mechanical 1
Electrical 1
Process 1
Start-up 1
Panel operator 1

2.3 TEST DURATION ESTIMATE

1 day

2.4 POSITION IN COMMISSIONNIG SEQUENCE

After RFC is signed

2.5 VENDOR ASSISTANCE

None

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3 TEST REQUIREMENTS

3.1 PRECOMMISSIONING ACHIEVEMENTS

Verify that the Pre-Commissioning are completed.

RFC is signed.
No Level A Punch list items are pending.
Preliminary check by disciplines to verify the system for completeness in
accordance with the latest drawings and revisions. This includes relevant
specifications and P&ID’s.
Produce a punch list as applicable
E&I function tests are complete.
Hydro-test is completed and that all spades are removed

3.2 COMMISSIONING ACHIEVEMENTS

Verify that the Pre-Commissioning AND Commissioning Dossiers are

completed.
RFC is signed.
No Level A Punch list items are pending .PL agreed upon by CSR & CSL
OTP agreed upon and signed

3.3 STATUS OF OTHER SUBSYSTEMS

7403 PCS ready

7401 ESD ready
7305/6 Normal power distribution 400V ready
6502 FKP Open drain

3.4 SPECIAL TOOL AND TEST EQUIPMENT

None

3.5 CONSUMABLES
Fresh water

3.6 SPARES

As per commissioning spares list

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3.7 SAFETY

Refer to Safe Operating Procedures.

Check that the Permit for the work is in force.
Check that all warning / precaution signs are in place.
Check that all non-essential personnel have been cleared from the area.
Ask the Control Room for a PA announcement to be made.

3.8 UTILITIES

None

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4 TEST PREPARATION

4.1 BLIND LIST

None

4.2 JUMPERS LIST

None

4.3 MECHANICAL PREPARATION TASKS

To provide assistance with the test

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5 START-UP, TUNING

5.1 START-UP STEP-BY-STEP PROCEDURE

This section covers the scope of work required to prepare equipment items,
system and sub-system for the operating tests.

1. Obtain Permit-to-Work.

2. Ensure MCC breaker is isolated for motor on pump 5-P-4990

3. Inspect the pump (5-P 4990) and pipe-work for damaged items that
will prevent the Operational Test.

4. Check that all blinds have been removed from the pump suction and
discharge lines and all branches from the Open Drain Drum after the
hydro test.

5. Check that the Open Drain pump outlet Non Return valve is installed
the correct way round.

6. Ensure the discharge orifice is installed RO-4960

7. Ensure the 3” Spark arrestor and the 2” anti-syphon s are installed

8. Open the following valves on the Open Drain Drum 5-V 4960

 All Instrument Level valves – LIT4960, LIT4961, PG4991,

PG4992, & LI4962

9. Close the following valves on the Open Drain Drum 5-V 4910:

 1 X 2” ball valve on pump discharge header

 2 X 2” future inst connections
 1 X 2” UC
 2 X 2” drain valves to platform edge
 1 X 3” ball valve and 1 X 3” globe valves on drain to platform edge

Connect a temporary water hose to the highest point DRIP PAN and fill
the Open Drain Drum until water is seen flowing from the upper future
inst connection 2” valve, close valve and continue filling until LAH-4961
is activated

The Pump is now ready for the Operational Test.

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DEMONSTRATION OF OPEN DRAIN PUMP 5-P 4990 and CONTROLS

1. Inform control room of intention to check the level transmitters of the

Open Drain Drum and run the Open Drain Pump in recycle mode, e.g.: no
flow of fluid to NCP open drain network

2. Ensure the pump motor is electrically isolated and cannot be started from
the MCC or the Control Room

3. Check that the pump cannot be started locally in either the LOCAL or
REMOTE modes (HS-4990-1).

4. Connect the temporary water hose to supply from the highest point of drip
pans and fill the open drain until 5LAH-4961 is active.

5. Check the 5LALL-4960 at PCS is clear.

6. Ensure pump suction and discharge valves are lined up.

7. Set the control to LOCAL on the MCC. (HS-4990-2).

8. Ensure the indication is LOCAL in PCS. ( XL-4990-1).

9. Request electrical to energize breaker for 5MP-4990

10.Start the Open Drain Pump locally using PB-4990-1 and check that pump
starts OK. Check the pump condition for a few minutes. Check that PCS
indication is RUN for XL-4990-2.

11.Stop the pump by push and lock emergency stop push botton on local.
PB-4990-2.

12.Checked the pump fault alarm XA-4990 display on PCS.

13.Check the pump 2P-4990 cannot be started from local PB-4990-1.

14.Checked the pump cannot be started from the CR using PB-4990-4.

15.Reset the local Emergency Stop button PB-4990-2. Check that the
Common Fault alarm XA-4990-1 is cleared on the PCS.

16.Set the control to REMOTE on the MCC. (HS-4990-2). Ensure the

display on PCS XL-4990-1 is in REMOTE. Set the pump start in manual
HS-4990-2

17.Start the Open Drain Pump REMOTE using PB-4990-4 and check that
pump starts OK. Check that PCS indication is RUN for XL-4990-2.

18.Check that the pump stops using the Remote Push Button PB-4990-3.
Check that PCS indication is STOP for XL-4990-3.

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19.Set the control on the PCS from REMOTE MANUAL to REMOTE

AUTO using HS-4990-2.

20.The Open Drain Pump will start automatically when the level in the
Drum is above the 750 mm level . Check that the pump starts OK. Check
the pump condition for a few minutes.

21.The water should now be re-circulating in a closed loop.

22.Slowly open the 3” drain valve at D2 - 3”-SW-B05-4957. This will allow

the level of the tank to fall under your control.

23.Check when the Pump cuts out. The level should be about 600 mm.

24.Close the 3” drain valve at D2 - 3”-SW-B05-4957.

25.Start filling the Drum with water again via the temporary water supply
hose and check when the Pump starts. Stop filling the Drum with water.

26.Set the control to LOCAL on the MCC. (HS 4990-1)

27.Restart the pump and once the flow is stable fill out the OPERATIONAL
TEST RECORD SHEET for CENTRIFUGAL PUMP – FORM 5221.

As the Pump is set on LOCAL operation make sure the pump is not allowed
to run dry. The system may have to be topped up with water again if the
test is not completed on the first run.

During the Pump test monitor the Drum Pressure Gauge PG 4992. This
should read 0 Barg.

To calculate the pump flow rates the flow of water from the Open Drain
Drum. Record the time it takes for the pump to reduce the water level in
the Drum from 750 mm to 600mm. Design Flow Rate = 10 M3/Hr
This volume is calculated at ……. M3.

ACTUAL TIME TAKEN: __________ Seconds.

Actual Flow rate = ________ M3 / Hr

28.Once satisfied with the test results return the system to Normal Operation
with the pump stopped in REMOTE and all valves in the correct operating
position.

DEMONSTRATION OF FKP OPEN DRAIN PUMP 5-P 4990

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Electrical Fault test

29. Fill Drum with water until over flow to river.

30. Check that LOCAL STOP button is reset. PB4990-2.

31. Select FKP Open Drain Pump to REMOTE control via HS4990-1.
Note: The Pump should now be running in Remote Automatic Mode.

32. Simulate an Electrical Fault (over current) on the Open Drain Pump.
The Pump should stop. Confirm that this happens.

33. Check that the Common Fault XA4990-1 alarm activates on the PCS
and that Available tag XL4990-2 is seen as not available on the PCS.

34. Check that Open Drain Pump cannot be restarted from PCS or Locally.

35. Remove simulated Electrical Fault from Open Drain Pump.

LALL trip in

36. Select REMOTE mode for Open Drain pump to LOCAL HS 4990-1.

37. Put the pump in test mode ( MCC)

38. Empty the Drum with via the 3” valve to the disposal tube, until the
LALL4960 (200mm) activates

39. The pump should trip ( SD3.24B)

40. Check if it’s the case for the breakers.

41. Reset the SD level 3.24B.and de-isolated the pump.

42. Select LOCAL mode for open drain pump to REMOTE HS 4990-1.

43. Tidy the site.

44. Cancel the Permit-to-Work.

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