Commissioning Procedure For Instrument and Electrical
Commissioning Procedure For Instrument and Electrical
Commissioning Procedure For Instrument and Electrical
Instrument
Project/PO No.
Author’s Org.
Next Revision Date
NA
Company Approval
Description of Change
ENGINEERING
NO DESCRIPTION/REF. CLIENT COMMENTS BY BY
RESPONSE
Page 2 of 18
Commissioning Procedure for Instrument and Electrical
Table of Contents
1. INTRODUCTION ......................................................................................................... 4
2. OBJECTIVE ................................................................................................................. 5
3. SCOPE......................................................................................................................... 5
4. DEFINITION ................................................................................................................. 5
5. ABBREVIATION .......................................................................................................... 6
6. REFERENCE ............................................................................................................... 6
7. SITE INSPECTION, TESTING AND COMMISSIONING PROCESSES .................... 6
8. PLANNING, SYSTEM / SUB-SYSTEM AND COMPLETION MANAGEMENT
SYSTEM & CERTIFICATION ...................................................................................... 9
9. COMMISSIONING PROCEDURE ............................................................................. 10
10. APPENDICES ............................................................................................................ 18
Page 3 of 18
Commissioning Procedure for Instrument and Electrical
1. INTRODUCTION
BP Berau is operating two LNG trains in the south shore of Bintuni Bay, West Papua. The
Tangguh LNG plant capacity is 7.6 mtpa and has been in operation since 2009. Gas for two
trains is fed from two offshore platforms of Vorwata gas field through two pipelines of
approximately 19 km VRA to ORF and 18 km VRB to ORF. Figure 1 shows aerial view of
Tangguh LNG plant.
The Vorwata gas field is to date the only producing field in the Tangguh complex. One of the
primary Vorwata subsurface-related risks is that a combination of subsurface, well, pipeline,
and/or plant operational risks will lead to insufficient field deliverability to meet the LNG plant
requirement. To meet the Gas Sale Agreement (GSA), drilling of VRB infill wells is required
to increase Vorwata Offtake as part of Vorwata Field Development Plan.
VRB-10 and VRB-11 will be two candidates of VRB infill wells, drilled back-to-back, with the
aim to provide additional Offtake from the VRB platform development area to mitigate the
risk of insufficient field deliverability to meet the LNG plant requirement.
Page 4 of 18
Commissioning Procedure for Instrument and Electrical
2. OBJECTIVE
The purpose of this document is to provide Commissioning Procedure for Instrument and
Electrical guideline for Tangguh Infill Well Tie-in.
3. SCOPE
The purpose of this document is to provide Commissioning Procedure for Instrument and
Electrical guideline for Tangguh Infill Well Tie-in including:
a. Inspection, Calibration and Testing of Commissioning procedure for :
- Instrument & Electrical Cable Installation.
- Shut-in Tubing High Pressure (SITHP).
- Pressure Down Hole Gauge (PDHG).
- Choke Valve.
- On Off Valve Annulus Bleed Off.
- Sand Monitoring.
- Wet Gas Flow Meter.
- Well Head Control Panel (WHCP).
- Motor Control Center (MCC)
b. Technical preparation of all required documents for execution of Commissioning by
considering the aspect of Safety, Health and Environment.
c. Execution of Commissioning.
4. DEFINITION
Page 5 of 18
Commissioning Procedure for Instrument and Electrical
5. ABBREVIATION
6. REFERENCE
a. Site inspection, testing, and commissioning tasks for Instrument and Electrical shall be
performed in accordance with project control of work process and site specific safety
management system requirements.
- Instrument and Electrical isolation.
- High Pressure testing (gas/water).
- Working with ionising radiation, including potential effects on nucleonic
instrumentation.
Page 6 of 18
Commissioning Procedure for Instrument and Electrical
Material Receipt
a. As soon as possible following receipt of an item (other than bulk materials) at site,
contractor shall check for transit damage, shortage, anomaly, documentation, and
certification. Thoroughness of check shall be determined by complexity, criticality, and
fragility of item.
b. Contractor shall advise inspector of any damage found and proposed corrective action.
Alternatively, inspector may choose to witness contractor check or conduct his own.
c. Item received at site without required certification shall be quarantined under instruction
of QA manager.
a. After inspection, equipment and materials shall be stored and preserved in accordance
with Vendor recommended procedures and with due regard to equipment criticality.
b. Preservation management system shall be implemented. Upon system handover to
operating authority, preservation records shall be formally passed over.
c. Projects shall consider using same team to perform preservation activities for duration of
the project. Otherwise, handover from construction to commissioning shall be formally
Page 7 of 18
Commissioning Procedure for Instrument and Electrical
a. Specify and ensure purchase of commissioning spares and specialist tools required for
equipment.
b. Take into account Vendor recommendations, as well as location of facilities and ease of
access to spares.
a. Test equipment control and calibration system shall be established to ensure that
equipment for inspection, testing, measuring, and commissioning is properly controlled
and calibrated.
b. Test and inspection equipment shall be suitable for intended purpose. Regularly
maintained and serviced.
c. Test equipment control and calibration systems shall include calibration procedures for
each type of instrument with a frequency and accuracy of calibration.
a. Commissioning authority shall Identify FAT and SAT of critical equipment, FAT done by
QC third party which will not be involved on Commisioning while SAT done by
commissioning personnel.
b. FAT and SAT procedure document shall be written to define the purpose and scope of
FAT and SAT, required test equipment, roles (vendor, inspector, etc.), and expected test
results.
Page 8 of 18
Commissioning Procedure for Instrument and Electrical
c. BP representatives attending FAT and SAT shall perform punchlisting of equipment with
Vendor representatives.
d. BP representatives shall witness key performance testing and inform Vendor of any
unsatisfactory performance.
e. Personnel attending FAT and SAT shall compile a report to record events.
8.1. Planning
CONTRACTOR shall submit Commissioning Plan based on the information from this
document early during detail engineering.
CONTRACTOR shall submit the overall integrated schedule. CONTRACTOR shall submit
Commissioning schedule for activities, sequence and duration.
CONTRACTOR shall also submit the manpower loading plan against the schedule of the
activities.
CONTRACTOR shall get COMPANY’s approval for those documents. Commissioning
authority shall ensure that:
a. Commissioning duration is based upon properly resourced and scheduled sequence of
system and subsystem handovers.
b. Construction and commissioning schedules are integrated.
To maintain the consistency with overall Tangguh Project commissioning strategy. GPF
systems have been devided into units, systems (primary system) and sub-system
(secondary systems).
The unit, system, and sub-system definition shall follow Commissioning System Numbering.
CONTRACTOR shall develop the System and Sub-system definitions by developing Limit of
System Handover (LOSH) drawing. The LOSH shall utilize P&ID, Electrical Single Line
Diagram, WHCP Diagram, BPCS, SIS, FGS and ICCS network diagram, and Platform/Civil
detail drawing.
Page 9 of 18
Commissioning Procedure for Instrument and Electrical
Contractor shall provide and use software dedicated for completion management system
which complies with BP Certification process.
The software supports project completions from construction up to hand over, including
preservation.
The software is used for developing list of items to be tested and its associated check
sheets and test sheets (known as Inspection Test Record -ITR), systems/sub system
definitions, completion certificates, progress reporting, punch list recording and reporting, for
both Pre-commissioning and Commissioning.
The software shall be able to provide preservation check sheets as required from material
arrival at fabrication yard up to pre-start up.
Inspection and Test Record (ITR) are test sheets used to record test performed for
installation conformity (“A” check sheets) and test performed for commissioning preparation
conformity (“B” check sheets”). A specialist will be required to administer the database.
It is important that the system shall be the sustainable completion systems from construction
phase up to handover to operation.
CONTRACTOR shall provide training for COMPANY, this include the foundation and
database management. The trainer shall be from supplier.
9. COMMISSIONING PROCEDURE
Commissioning procedures will be developed by EPC & EPCI Contractors with approval by
BP Commissioning Manager for all necessary activities required to put the equipment and
facilities into service.
At the suppliers’ facilities, this will include Factory Acceptance Testing and/or System
Integration Testing. At the fabrication sites and at the final location, this will include dynamic
verification, energized function testing, operational testing, running-in, on-line testing, start-
up of utility systems, and all pre-start-up activities of the process plant.
Commissioning activities will be executed in accordance with the agreed procedures, by
system and/or subsystem, and will culminate in formal acceptance by BP Commissioning
Team.
Page 10 of 18
Commissioning Procedure for Instrument and Electrical
Acceptance will require demonstration that the proposed system or subsystem is complete,
operates as intended and that verifiable evidence in the form of Inspection and Test
Records and the commissioning procedure, has been completed and accepted.
Instrument & Electrical cable installation, Instrument & Electrical System Cabling Continuity
test and checks, Instrument and Electrical cable connection to Field device / Junction box /
panel cabling are installed in accordance with relevant installation wiring diagram document
should have been carried out after installation complete. This may be verified from the
installation Handover document.
b. Instrument pressure transmitter connected to control system, loop test shall include
system measurement, processing, control action and display.
Page 11 of 18
Commissioning Procedure for Instrument and Electrical
a. Instrument & Electrical Hook-up installation, Mechanical Installation, Power test and
communication test should have been carried out during installation on the sand
monitoring system. This may be verified from the installation Handover document.
b. Power-up check
- A non-intrusive solid detector/Sensor with high alarm indication and Transmitters
- Impedance Field Electronics
Page 12 of 18
Commissioning Procedure for Instrument and Electrical
- System Test, check all the reading from Sand Monitoring device to ICSS system are
correct and that they are updated.
d. Operations
- Check during first flow.
- Well testing.
- Integrated to the existing ICSS, for control and monitoring in the existing BPCS, for
interlocking shutdown system in the existing SIS.
a. Instrument & Electrical Hook-up installation, Mechanical Installation, Power test and
communication test should have been carried out during installation on the Wet Gas
Flow meter. This may be verified from the installation Handover document.
b. System Configuration Checks.
- Master Empty Pipe Refference
- Water and Gas Reference Points
- System Test, check all the reading from WetGas Flowmeter device to Supervisory
system are correct and that they are updated.
c. Pressure Test
- Connect high pressure pump unit to WetGas Flowmeter device installation piping.
- Rig up chart recorder appropriate for the required test pressure
- Ensuring that the system to be tested is open to atmosphere at the highest available
point, flush through with test liquid until the air is expelled.
- Close the bleed point and slowly increase the pressure to 35 bar. Allow the pressure
to stabilise and hold for 5 minutes with no drop on the chart recorder.
- Once the pressure is brought up to test pressure, it should be allowed to stabilise
and pressure increased again to test pressure.
d. Set-up the data value:
- Gas and Liquid PVT Parameters
- Gas and Liquid computed mass attenuation
- Gas and Liquid Acquired reference points (if applicable)
e. The Wet Gas Flowmeter shall have uncertainty of less than (+/- 5%) of reading of the
mass flow of the gas phase, over the full designated operating range.
f. The Wet Gas Flowmeter shall have uncertainty of less than (+/- 10%) of reading of the
mass flow of the liquid phase, over the full designated operating range.
Page 13 of 18
Commissioning Procedure for Instrument and Electrical
g. Data validation / First Flow, it is recomended that a through quality check of the first
flowing data through the WetGas Flowmeter devices is undertaken to ensure
consistency of result.
h. Integrated to the existing ICSS (BPCS&SIS), for control and monitoring in the existing
BPCS, for interlocking shutdown system in the existing SIS.
a. Ensure all required works, inspection, and cleaning have been completed, Ensure the
Wellhead Control Panel shall be cleaned and flushed prior to Commissioning. Wellhead
Control Panel will be flushed by nitrogen or clean dry air, followed by Castrol TransAqua
HT hydraulic oil and proved to NAS 6 cleanliness.
b. Ensure the test location is well suitable for the test with considering to all other
surrounding plants, buildings, public areas and other equipment and structures in the
vicinity
c. Ensure the hydraulic oil used for the testing is clean Castrol TransAqua HT Hydraulic
Oil. 200 Litres of the hydraulic oil will be prepared and made available for the test.
d. The utilities and equipment available and required are:
- Power supply 415 VAC, 3 phase, 50 Hz
- Multimeter
- Turn the switch inside the panel to turn on the panel illumination lamp.
- All the Hart transmitters shall be powered from ICSS.
Page 14 of 18
Commissioning Procedure for Instrument and Electrical
f. Functional Test
- To ensure all the functions as required in the specification are provided and work
according to requirements.
- First Test to Confirm the components and the hydraulic loops are functioning.
- Second Test to check the primary function
- At every stage of pressurization, please check for visible sign of leaks and make
sure that the pressure holds.
- Test Hydraulic Pump and Filters, Test Hand Pump and Filters
- Charge the Accumulator, SCSSSV/SMV/SWV hydraulic supply line using regulator.
- Open SCSSSV / SMV / SWV, Close SCSSSV / SMV / SWV and re-open SCSSSV /
SMV / SWV.
- Charge Control Loop hydraulic supply line by using regulator, charge the
accumulator.
- Open SCSSSV / SMV / SWV, Close SCSSSV / SMV / SWV and re-open SCSSSV /
SMV / SWV.
g. Adequacy check of existing HPU and WHCP after additional new VRB infill wells (VRB-
10 & VRB11) needs to be done as part of this VRB Infill Wells Tie-in project scope.
Control System configuration and installation, cable connection to Field device / Junction
box / panel cabling are installed in accordance with relevant installation wiring diagram
document should have been carried out after installation complete. This may be verified
from the installation Handover document.
Control System instrument test that are including but not limited to:
- Individual loop test for every Sub-systems.
- Control function in Manual/Automatic/Cascade Mode with correct alarm setting and
control action (Direct or Reverse) for every sub system.
- Communication with subsystem Pressure Down Hole Gauge (PDHG).
- Communication with subsystem On-Off Valve Annulus Bleed Off.
- Communication with subsystem Sand Monitoring.
- Communication with subsystem Wet Gas Flow Meter.
- Communication with subsystem Well-Head Control Panel (WHCP).
- Interlock Logic on SIS, refer to Cause & Effect for every Sub-system.
Page 15 of 18
Commissioning Procedure for Instrument and Electrical
Electrical MCC installation, cable connection to Field device / Junction box / panel cabling
are installed in accordance with relevant installation wiring diagram document should have
been carried out after installation complete. This may be verified from the installation
Handover document.
MCC Test shall be performed to confirm:
- Tightness of bus bar split joint
- Bus bar insulation resistance
- Earth (ground) continuity
- Assembly leveling.
- Alignment of each plugging unit.
Static and general commissioning procedures for Instrument and Electrical are used for
tasks which are carried out frequently and generally completed by one discipline in a single
work location on an individual item of equipment.
They are short in duration and simple in content and are low risk in the event of an error.
These procedures are deemed required to facilitate the use of the B check sheet.
The CONTRACTOR Commissioning Manager should issue static and general
commissioning procedures specific to their project to support the completion of B check
sheets, and subject to be approved by COMPANY Commissioning.
Commissioning procedures for Instrument and Electrical to support B check sheets should
include but not be limited to:
a. Safety instrument system - validation and function testing procedure
g. Choke Valve
i. Sand Monitoring
Page 16 of 18
Commissioning Procedure for Instrument and Electrical
Final preparations shall consist of preparing all instrumentation for plant startup. As a
minimum, instrument commissioning shall consist of the following tasks:
a. Confirm that all checkout and calibration tasks have been completed.
b. Bypass process control valves and other final elements, or place in out-of-service
status as dictated by startup requirements.
c. Ensure the process signal lines free / secure and blow down (Medium cleanliness
using air blow and decompression blow) process signal lines.
e. Check all seal legs. Fill the legs with specified seal fluids as required.
f. Place all ICSS (BPCS & SIS) and WHCP controllers in manual mode or in any mode
that dictated by Start-up Procedure.
g. Hydraulic supply and signal lines, and check them for leaks.
h. Make electrical power supplies and/or hydraulic pressure sources ready for service.
i. Confirm that all electrical and hydraulic power systems are operating properly.
j. Confirm that all fuses (especially ones that were replaced) are of the designed rating.
l. Make preliminary adjustments of control modes by setting the proportional band at 100
percent and by setting the rate and reset at minimum.
n. Each instrument and loop shall remain powered or pressurized with switches and
valves set for startup requirements.
Any instrument that has been removed/disconnected during line flushing and hydrostatic
testing shall be rechecked for operation.
Page 17 of 18
Commissioning Procedure for Instrument and Electrical
A functional check is required to check the configuration of the ICSS (BPCS & SIS).
Shutdown and interlock responses shall be checked against the shutdown/interlock logic
diagram and cause/effect drawings.
The complete interlock system shall then be checked for correct sequence of operation.
Each interlock input and output shall be tested for functionality.
In most cases this may be a duplication of loop testing, unless loop testing is done
simultaneously. On alarm or shutdown loops, field switches must make/break contact as
prescribed on data sheets.
Once individual loops have been tested, the functionality of the logic of the ICSS shall be
tested.
Due to the difficulty of monitoring all ICSS outputs during field testing, CONTRACTOR’s
field testing of ICSS logic shall not take the place of full-function Factory
Acceptance Testing with all inputs simulated and all outputs wired to test light panels.
10. APPENDICES
Page 18 of 18
Appendix – 1. Wellhead Control Panel Drawings.
Appendix – 2 Wiring Diagram Drawing List