Pre-commissioning & Loop Checking Procedure
Pre-commissioning & Loop Checking Procedure
Pre-commissioning & Loop Checking Procedure
INSTRUMENTATION PRE-
1800-8130-G000-PR-35 COMMISSIONING & Page 1 of 13
LOOP CHECKING
INSTRUMENTATION PRE-COMMISSIONING
AND
LOOP CHECKING PROCEDURE
INSTRUMENTATION PRE-
1800-8130-G000-PR-35 COMMISSIONING & Page 2 of 13
LOOP CHECKING
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July / 07 Adopted to 1800 project Hugo F Revelo
1. PURPOSE 3
2. SCOPE 3
3. REFERENCES 3
4. RESPONSIBILITY 4
5. Pre-commissioning & Loop Checking Documentation 4
6. INSTALLATION INSPECTION 5
7. TEST EQUIPMENT AND SPECIAL TOOLS 5
8. POWER AND INSTRUMENT CABLE TESTING 6
9. POWER AND GROUNDING TEST 6
10. INSTRUMENT CALIBRATION 6
11. MARKINGS 6
12. TERMINATION INSPECTION 6
13. FUNCTIONALITY CHECKOUT 7
14. LOOP CHECKING 7
15. PRE-COMMISSIONING PROCEDURES 8
15.1 TRANSMITTER CIRCUIT TEST 8
15.2 SWITCH / PULSE CIRCUIT TEST 9
15.3 ANALYZER / TRANSDUCER CIRCUIT TEST 9
15.4 THERMOCOUPLE CIRCUIT TEST 9
15.5 RTD CIRCUIT TEST 10
15.6 MOTOR OPERATED VALVE TEST 10
15.7 PNUEMATIC CONTROL VALVE TEST 11
15.8 24VDC DISCRETE INPUTS 11
15.9 117VAC DISCRETE OUTPUTS 11
15.10 125VDC DISCRETE OUTPUTS 11
15.11 FOUNDATION FIELD BUS 12
15.11.1 FF CABLE CONTINUITY & INSULATION TEST 12
15.11.2 FF CIRCUIT TEST 12
15.12 SPECIAL EQUIPMENT ( DCS, ESD, ANALYZER SHELTER,,
VMS, CCC, FIRE ALARM & DETECTION, VESDA SYSTEM 12
16. ATTACHMENT 13
RABIGH PROJECT
ON SITE EXECUTION PROCEDURE
INSTRUMENTATION PRE-
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LOOP CHECKING
1. PURPOSE
This plan defines the minimum mandatory requirements governing the activities and test
procedure during loop checking and pre-commissioning which will be carried out by
Instrumentation Department.
2. SCOPE
This plan shall be applied for MS1 & MS2 facilities which require to be LOOP TESTED. This
procedure serves as proposal for the plan activities of loop checking & pre-com to ensure
that all works are in fully compliance with PetroRabigh Specifications and approved
drawings.
In case of conflicts between this document and other applicable Company Standards and
Test Procedures, the Company Standards and Procedures shall prevail.
3. REFERENCES
3.1 Company References
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LOOP CHECKING
4. RESPONSIBILITY
Subcontractor shall be responsible for Testing of all instrument loops including cables
testing, impulse line pressure test, control valves leak test & instruments calibration from
time of receipt at the job shop/site until acceptance of the item by TR and Petro Rabigh.
Subcontractor Superintendent, through the Field Supervisors, shall have responsibility for
the actual performance of all work directly related to the storage and handling, installation
and pre-commissioning (this shall include any such work performed for subcontractors by
other parties).
Also the Superintendent/Supervisor shall enforce housekeeping requirements in or around
the working areas.
TR personnel are responsible of the supervision of the overall work related to instruments
installation and testing.
TR / Subcontractor QC Inspector are responsible to ensure the following:
1. Conducting surveillance and Inspection duties for every activities pertaining to
instruments installation, calibrations and testing.
2. Ensuring there is efficient recording and reporting for all test results.
3. Preparation of relevant documents, test reports, related IFC drawings necessary
for the Loop Checking Folders and Pre-commissioning activities.
4. Prepare and organize PetroRabigh request for inspection as per scheduled test
and work priorities and proceed with Client Witnessing of Test or work as required.
5. Check that all tested loops shall be signed-off by Contractor and Client’s
representative as final acceptance of the loops.
Prior to pre-commissioning, the commissioning team representative shall ensure that all
construction related items have been completed, tested and signed off. Additionally, the
team representative shall familiarize himself of the tasks at hand and be fully capable of
directing the work that is to be done during the pre-commissioning phase. Once all
formalities are completed, all wiring tested for continuity, shield integrity verified and
documentation gathered, manpower identified, pre-commissioning can begin. Note that
readiness of all field loops, completion of all preliminary tests and calibration shall be
confirmed by TR and PetroRabigh representatives before pre-commissioning begins.
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LOOP CHECKING
6. INSTALLATION INSPECTION
All equipment shall be inspected on completion of field installation. All designated approval
parties must sign off the following equipment.
The following test equipment and special tools will be used for pre-commissioning activities.
RABIGH PROJECT
ON SITE EXECUTION PROCEDURE
INSTRUMENTATION PRE-
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LOOP CHECKING
All cables will be tested and loop resistance tabulated by the construction contractor prior to
field and CONTROL ROOM termination. All cables must be tested and signed off by all
designated approved parties.
Refer to Electrical SAT power and grounding test procedures. All DCS/TMR/PMR, Fire
Alarm/Fire Detection, Vesda and VMS power and grounding will be tested and approved
prior to field signal connections.
All instruments are to be calibration checked as required to the specs in data sheet by
qualified technicians using industry’s recognized methods. The certified personnel shall be
responsible for documenting individual instrument calibration and functional checks. These
records, kept by the Contractor, shall clearly show the extent of checkout and calibration,
and shall be made available to PetroRabigh inspection before installation. Transmitters and
receivers shall be calibrated independently using the manufacturer’s recommendations and
methods outlined in their respective service instruction manuals. As a minimum, Instruments
shall be calibrated both upscale and downscale at five points of the measuring range (0%,
25%, 50%, 75%, 100%) corresponding to transmitter signal outputs of mA, or digital readout.
A separate method of statement for Instrument Calibration will be submitted for more
detailed procedures. For Foundation Fieldbus (FF) Devices, it is not necessarily that the
device must be bench calibrated. Configuration check will be done during loop checking,
however, it is on Project requirements & Vendor’s recommendation if bench calibration is
needed.
11. MARKINGS
After successful completion of each calibration and testing, the instrument shall be marked
with coloured label sticker bearing the date of calibration and testing with initials of the
witnessing party. The colour code shall be as follows:
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ON SITE EXECUTION PROCEDURE
INSTRUMENTATION PRE-
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LOOP CHECKING
The DCS and other Packaged Instrument Equipments functionality testing is performed
during the factory acceptance FAT. Testing and logic must be re-tested during the Site
Acceptance Test. Documentation SAT to confirm that the above testing has been performed
and approved must be available prior to commissioning.
As per Project QCP# 1800-8830-PR-1200, Par. 9.0, Loop Checking will be done as follows:
A. The applicable checks as indicated on the Loop Test Certificate will be carried out.
This certificate (TR-Petro Rabigh Precommissioning Forms) will act as check sheet and
all items listed will be considered. Loop checking is a minimum two persons operation,
but the responsibility for the loop as a unit is with the people whom fills in and sign the
Loop Certificate Completion ( Pre-commissioning Form # 1800-8130-PF-J-014 ) after all
applicable tests.
B. Ensure that prior to loop checking, preliminary loop checks had already been
satisfactorily conducted by an organized pre-commissioning team from Subcontractor
and monitored by TRG and PetroRabigh representative/s.
C. Subcontractor shall ensure that highly capable loop checking group members are
assigned to carry out this task.
F. Ensure that all test equipments and instruments to be used in the field are with valid
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ON SITE EXECUTION PROCEDURE
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LOOP CHECKING
G. Ensure that reliable 2-way communication means is ready and available whenever a call
from the instrument end is made to the designated DCS console operator.
H. Apply power to instruments one by one. Check each instrument for overheating and
trouble after power-up. Allow at least one hour for instrument to warm-up before
beginning any test, or as per manufacturer’s recommendations.
I. Loop will be tested injecting the appropriate signal to sensor. For loops which have
components located some distance apart, at least two persons in constant
communication with each other shall be involved in the testing. One person shall be
responsible for simulation of measured variable shall at all times remains at measured
device. The other person shall inspect all other devices in the loop and confirm their
operation is correct in response to changes in the measures variable. Configuration of
the DCS will be checked during the test.
K. Loops with a controller shall be tested in two parts; measurement and output. The
measurement part shall be tested as above. The output shall be tested by the action of
one person varying the controller output over its complete range, with other person
confirming the correct operation of the regulation device by observing its response to
such actions.
L. On completion of the function checks on the loop, Loop Test Certificate ( Loop Check
Sign Off Sheet (1800-8130-PF-J-014) shall be signed by the person responsible for the
complete test.
M. Devices that passed the loop test and accepted by witnessing party shall be marked with
coloured label ( RED Sticker ) with date and witness initial, as per par. 11.
N. Loops involving MCC equipment will be tested with the Electrical Engineer in charge.
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LOOP CHECKING
E. For Non-smart transmitters case (4-20mA) source to be used for simulation purpose
instead of hand pump.
F. Alarms function (in DCS) shall be checked by simulating/Verifying the required signal.
G. Transmitter loop test should be performed after completion of the impulse line works
including pressure test.
H. Marked and signed off Pre-commissioning documents.
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LOOP CHECKING
out test. Check correctness of the direction of the flow indicator at the body of the valve
against the P&ID.
D. Check if Air supply is available in filter regulator pressure gauge and electrical supply at
Solenoid contact terminal block.
E. From the DCS, stroke the valve from 0% to 100% opening and closing. Check
action of the valve and correctness of position indicator and Limit Switches.
The time for stroking the valve upon reaching the full open/close must be noted
and recorded.
F. Fail action upon lost of air supply or power failure must be checked locally and in DCS
graphic indication as well as Limit switch indication.
G. Marked and signed off Pre-commissioning documents.
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LOOP CHECKING
A. All Fieldbus cables shall be megger tested after glanding but before terminating.
Each megger test certificate is to be recorded on the megger test certificate and
witnessed by inspection (TR – Petro Rabigh Pre-com Form 1800-8130-PF-J-015 )
B. Using the FBT-3 Fieldbus monitor, connect to the field terminals remote from the
Power conditioner (H1-PS) and measure and record voltage.
C. Push the FBT-3 mode botton once and read the Link Active Scheduler (LAS)
Function. The LAS signal should indicate “OK”
D. Push the FBT-3 mode button three times to get the noise average function. The
Reading should indicate “OK”. and show the noise level detailed below:
25mV or less - Excellent
25 - 50mV - Good
50 - 100mV - Marginal
100 or more - Poor
E. Remove the field bus segment cable ( +,-, and shield ) at terminal block connector
Terminal from the Fieldbus Power Supply (H1-PS). Remove only the connector to the
field wiring; it is not necessary to remove the connector to the H1 card (DCS).
Removing the connector to the field wiring isolates the field wiring from the H1 card and
power supply, and enables to make resistance and capacitance measurements. Make
sure that bare hands do not come in contact with meter leads or segment wiring.
F. Measure resistance on H1 segment conductors at the removed Relcom terminal block
Connector coming in from the field and record results.
15.12 SPECIAL EQUIPMENTS ( DCS, ESD, ANALYZER, VMS, CCC, FIRE ALARM
SYSTEM
FOUNDATION FIELDBUS & VESDA SYSTEM )
Pre-commissioning will be done as per Vendor’s procedures and equipment manuals
using their special tools and software under direct supervision from their representative.
Subcontractor will only give manpower assistance as deemed necessary.
RABIGH PROJECT
ON SITE EXECUTION PROCEDURE
INSTRUMENTATION PRE-
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LOOP CHECKING