FAT Procedure Gresik

PT ANSI MEGA INSTRUMENINDO

Factory Acceptance Test

Procedure

System Metering Gas Orifice

Gresik Station10” ANSI 300#

Pengadaan dan Konstruksi Pembangunan Pipa Transmisi

dari Gresik - Semarang,

Pengadaan 10” & 16” Meter System

AJ

Revision

Date Description By Checked By

Approved by

1. GENERAL

FAT Procedure of 56


1.1. Scope

This document represents the Factory Acceptance Test Procedures and Test Records for the Orifice Gas

Metering and Regulation System. Its completeness is dependent upon not only the carrying out and

recording of the schedule tests and results; it is reliant on the inclusion of all required documentation such as

calibration certificates. The document is written in such a way to make it usable for testing on simulation or

live signals.

The test procedures detailed in this document are designed to provide a level of confidence in the operation

of the Orifice Gas Metering and Regulation System integrated with the control panel. The detailed purpose

of this procedure is to verify that the instruments conform to specifications, are installed correctly, function

according to design, meet manufacturer's accuracy guarantees, and obtain a permanent record of the

results.

Individual test data record sheets are generated as a single item. These test sheets are to be duplicated as

required to repeat tests to the COMPANY’s satisfaction. The relevant details for the item of equipment under

test are to be entered prior to printing out the sheets.

Individual instrument loops will be checked prior to the full system tests. Procedure and Test Record Sheets

are provided in this document. Signed instrument test sheets shall be made available for inspection during

the systems test enabling functional checks only to be made.

Where possible the calculations are carried out, the calculations used will be provided for COMPANY’s

inspection.

1.2. Definitions and Abbreviations

COMPANY PERTAMINA GAS as the ultimate end user and owner

CONTRACTOR Party selected by COMPANY to perform the survey, engineering, detailed

design, procurement, programming, installation, testing, pre-commissioning,

commissioning and trial operation of system supplied under PROJECT

VENDOR Party which supplies equipment/materials or services specified and ordered

by CONTRACTOR

MANUFACTURER Party which manufactures equipment/materials specified and ordered by

CONTRACTOR

INSTALLATION CHECKOUT The quality control functions required to ensure that instrumentation are

according to specification and installed correctly, properly calibrated,

functionally operational, and ready for COMPANY acceptance.

CALIBRATION A certain action performed on instruments and control devices requiring testing and adjustment to ensure that they are of the proper range, functioning correctly, and have certain accuracy as guaranteed by MANUFACTURER.

FUNCTIONAL LOOP CHECK The functional operation of a system to verify that each mechanical,

pneumatic, and electrical component operates according to the instrument

FAT Procedure of 56


specification, loop drawing, datasheet, wiring diagram and the P&lDs. This

is normally done by introducing a simulated process input, observing the

results at the various components, and observing the final element as

inputs are cycled through the operating conditions.

PRESSURE TESTING The quality control function required to prove the mechanical integrity of the

instrument pipe, valves, and fittings. The testing is intended to ensure that

there is no leakage occurs at mechanical junction.

PROJECT Pengadaan Pengembangan Meter Jawa Timur – KEI Gas Metering System

– Waru & Gresik Station

1.3. Codes and Standard

The publications listed below form part of this specification. Each publication shall be the latest revision and

addendum in effect on the date this Specification is issued for construction unless noted otherwise. Except

as modified by the requirements specified herein or the details of the drawings, Work included in this

Specification shall conform to the applicable provisions of these publications.

AGA 3/API 14.3 Orifice Metering of Natural Gas and Other Related Hydrocarbon Fluids

AGA Report #8 Compressibility Factors of Natural Gas and Other Related Hydrocarbon Gases

API RP 551 Process Measurement Instrumentation

API RP 554 Process Instrumentation and Control

API RP 555 Process Analyzers

GPA 2172 Calculation of Gross Heating Value, Relative Density and Compressibility Factor for

Natural Gas Mixture from Compositional Analysis

GPA 2261 Analysis for Natural Gas and Similar Gaseous Mixture by Gas Chromatography

1.4. Conflicting Requirements

In case of conflict between this Specification and its associated Specifications and the above Codes and

Standards, the Vendor shall bring the matter to the COMPANY’s attention for resolution and approval in

writing. However, the most stringent requirement shall apply.

Should any conflicts between this specification and other documents, the following order of precedence shall

govern: Scope of Work

Data Sheets.

This Specification

Other COMPANY Specifications

Other Referenced Publications

Approved for Construction Drawings

Vendor’s Code

FAT Procedure of 56


2. COMMON PROCEDURE

1. Each transmitter should be calibrated prior to the loop test, since all transmitters are installed after

workshop calibration conducted. FAT cannot be commenced before workshop calibration

conducted.

The final loop test shall be performed to ensure that the installed instrumentations are functionally

correct.

2. FAT shall be witnessed and approved by all related parties as mentioned in approved ITP.

3. Adequate skilled manpower and technically/organizationally skilled supervision is required to provide

proper test and meet the time schedule of the job. In most instances COMPANY and/or

CONTRACTOR representative will witness the entire test and countersign the test report.

4. Where interlock inputs have already been proven during loop tests, these inputs may be by pass.

Input is given to prove interlock function. All other inputs shall be proven at the sequence test.

5. Where interlock inputs and/or outputs are associated with electrical equipment such as valves, the

sequence test shall be carried out in conjunction with the mechanical and electrical discipline to

insure protection to equipment.

6. Tests are essentially functional and if an inoperative or badly calibrated or otherwise unsatisfactory

test result is encountered, all results for that loop should be considered null and void. The relevant

earlier tests shall be repeated, as necessary, after rework, replacement or repair. The test shall then

be completely repeated for that particular loop.

3. CALIBRATION

Every single instrument shall be individually calibrated and all signed calibration sheets shall be compiled and

attached to FAT dossier. These sheets will be used for acceptance as being witnessed and prerequisite prior to

FAT activities. CONTRACTOR shall use calibration method according to oil and gas industry standard practice.

The following instruments must be put in highly attention e.g.:

1. Moisture Analyzer

2. Gas Chromatograph

3. Control Valve

4. Shutdown Valve

5. Pressure Safety Valve – 3rd party company appointed by MIGAS to witness the test

6. Transmitters

FAT Procedure of 56


4. INSTALLATION CHECKOUT

4.1 General

Installation checkout shall consist of a thorough inspection of components to ensure that they are according

to specification, installed correctly, calibrated, and functional. To ensure this status is achieved, the following

shall be performed:

1. Calibration: This should have been completed before start of final checkout. Records should be

available to verify that calibration is satisfactory.

2. Pressure Testing: This should have been completed before start of final checkout. Records should

be available to verify this function.

3. Continuity Testing, Resistance Testing, and Meggering: These should have been completed before

checkout. Records should be available to verify these functions

4. Piping Leakage Testing : This should have been completed before start of final checkout. Records

should be available to verify this function.

4.2 Scope of Activities

1. A check, using the P&lDs and the instrument data sheets, shall be made after installation to make sure

instruments are in place and according to specification.

2. Each instrument installation shall be checked against the instrument installation detail drawing for

correct and complete installation. Direction of flow through control valves, proper hook-up of flow

meters, and tubing of instruments should be checked.

3. Thermocouples shall be checked during loop check for type, length, polarity, shielding, and proper

identification. Each thermocouple shall be checked for continuity and grounds. Loop check will be

accomplished by applying a millivolt signal to the extension wires and observing the output on the

final elements. No calibration is required.

4. Orifice plates shall be visually checked for nameplate data and for an upstream sharp edge. Bore

should be callipered to check for compliance with specification. Orifice plate shall be checked to

ensure installation for correct orientation (upstream and downstream) with the process flow.

5. Control valve accessories such as position switches, handwheels, boosters, and relays shall be

visually checked.

6. Control valves and regulators shall be checked to ensure installation is in the correct orientation with

the process flow.

7. Top-works shall be checked for acceptable orientation. Valve stems shall be clean of objectionable

materials such as paint, concrete spatter, or protective tape. Limit and position switches and limit

stops, where required, shall have been installed and adjusted. Lubricators shall be installed where

required.

8. Relief valves shall be checked against specifications and P&ID to ensure proper valve is in place.

They shall be checked to ensure no blinds or gags have been left in place.

9. Analyzers shall be visually inspected for proper installation.

a. Check availability of standard and calibration cylinders provided by CONTRACTOR.

b. Check carrier gas cylinders and manifolds for size, proper connection, pressure, and

tagging

c. Check the analyser housing for proper area classification. If the housing is purged, check

the purging system for proper operation, alarms, and shutdown if purge pressure is lost.

d. Check availability of required utilities. Check power connections to the analyzer and AC

circuits to the distribution panel.

10. Panel instruments and panels shall be checked as follows:

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a. Nameplates, both front and rear, shall be checked for tag number, service, location, and

proper spelling.

b. Charts and scales shall be checked for range in accordance with the individual Instrument

Data sheets and shall be fitted to the respective instruments. Remove chart drive fuses to

avoid chart usage until ready to turn over to owner.

5. FUNCTIONAL LOOP CHECK

Competent personnel shall be provided to supervise a function check of instrument systems to ensure a

correct installation. This will include local control elements, inputs, outputs, and control room devices

including flow computer consoles and accessories.

1. Functional testing shall be done by simulation of process conditions at the instrument input.

2. The loop shall be functionally checked as needed to verify that every component, mechanical and

electrical, is undamaged and functional, verify loop integrity with respect to signal ranges and

directions, and direction of action of final control elements. This shall be done by simulation of

process inputs and outputs by a pressure or electronic source at 0-25-50-75-100 percent up and

down scale.

3. Deviations from the correct operation of the system, as determined by these tests, shall be

corrected.

4. Conflicting data encountered between calibration ranges of field devices and displayed or configured

ranges within the distributed control system shall be brought to the attention of COMPANY for

resolution.

5. When the instrument loop has been verified by the functional loop check, the all parties should sign

the appropriate records for loop acceptance as being witnessed.

A punch-list shall be made and formally issued listing discrepant items.

COMPANY will release acceptance of FAT, if the CONTRACTOR has completed all test proving that the

whole instruments have worked properly.

FAT Procedure of 56


LIST OF TEST AND INSPECTION

1. Inspection of Metering Skid Dimensional Detail

2. Inspection of Paint Work

3. Equipment Layout and Pipe Configuration

4. Inspection of Name Plates

5. Inspection of Junction Box, Cable and Cable Gland Installation

6. Panel Physical and Dimension Verification

7. Panel Visual Inspection

8. Panel Wiring Visual Inspection

9. List of Metering System Instrument / Equipment

10. Moisture Analyzer Test

11. Hidrocarbon Dew Point Analyzer Test

12. Simulation Test

13. Gas Chromatograph Verification

14. Interface to Gas Chromatograph Test

15. Supervisory Computer Operation Test

16. Flow Computer Test Record

FAT Procedure of 56


1.0 INSPECTION OF METERING SKID DIMENSIONAL DETAIL

The metering skid will be measured after assembly of all instruments. Dimensions shall be checked

against the approved drawings.

Actual dimensions measured shall be updated onto dimensional report and as-built drawings.

Dimensional Tolerance for inlet and outlet flanges shall be as follows:

1. Flange center height from skid base bottom : ± 6.0 mm

2. Inclination angle of inlet/outlet flange : 1/2o

Linear dimensional tolerances shall be as follows:

Dimensional Classification Up to 1000 mm Up to 2000 mm Over 2000 mm

Tolerance ± 7.0 mm ± 11.0 mm ± 20.0 mm

2.0 INSPECTION OF PAINT WORK

The final assembled skid shall be randomly checked on the paint dry film thickness (DFT) both on

the pipes and skid structures using calibrated Elcometer. Damaged area or area requiring touch-up,

shall be repaired as per painting repair procedure.

3.0 EQUIPMENT LAYOUT AND PIPE CONFIGURATION

The metering shall be checked for correct installation of the instrument against approved hook up

drawing. Scope of inspection shall include visual check on the piping, skid frame and instruments for

any physical damage, and functionality of the manual and actuated valves.

Metering skid piping work shall be checked against the approved P&ID for the correct size of piping,

fittings (reducers, blind flanges, etc.) used. Check will also ensure that proper position and

installation for all instruments against hook up drawing.

4.0 INSPECTION OF NAME PLATES

The final assembled skid shall be checked on nameplates used. Nameplates shall be represented

installed device.

5.0 INSPECTION OF JUNCTION BOX, CABLE AND CABLE GLAND INSTALLATION

This is to ensure that the metering skid is fabricated in accordance to the construction drawings and

adequate cable accessories’ installed.

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1. Junction Box : Material, nameplate, grounding, classification, certification,

adequate terminal block, wire marker, termination diagram

installation, etc.

2. Cable : cable specification, correct cable installation, cable number

installation, cable fixing installation, cable way installation, spared

cable, etc.3. Cable gland : Material, correct size, classification, cable gland shroud, compound,

etc

6.0 PANEL PHYSICAL AND DIMENSION VERIFICATION

This procedure ensures that the control panel is fabricated in accordance to the construction

drawings.

With reference to the Panel Layout and Wiring Diagram Drawing

1. Inspection Method

After an assembly of the equipment in the factory, the components as shown in the

approved drawing will be measured, with a vernier caliper, and/or a steel measuring tape.

2. Standard for Judgment

Confirm that the results are within the allowable tolerance as shown in the Dimensional

Examination Result Report.

3. Dimensional Examination Result Report

All the results are to be recorded in the Dimensional Examination Result Report

7.0 PANEL VISUAL INSPECTION

This procedure ensures that the control panels are installed in accordance to the construction

drawings.



After assembly of the equipment, the visual inspection is carried out. As for the painting,

color tone and gloss will be visually inspected and confirm a wiring condition by the

watching.


Confirm that all the shapes and construction are corresponding to the approved drawings

(external views of equipment and panels) and that they are free from any deformation,

stains and dirt which may be harmful when it is used. Confirm that the painting is uniform in

free from any drops or stains, and the wiring is complete.

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3. Visual Inspection Result Report

All the results are to be recorded in the Visual Inspection Result Report

8.0 PANEL WIRING VISUAL INSPECTION

This procedure ensures that the wiring of the control panels are installed in accordance to the

construction drawings.



The type, color, size of the cable including cable duct shall be visually checked with the

specification and approval drawing. The cable marks shall be checked visually compared

with the terminal block assignment.

The grounding of the instrument cable shall also be checked and compared with the

approved drawing.


The type, color, size of the cable and conduit shall be satisfactory to requirements of the

specification and description of the approval drawing. The cable mark and connection shall

be complied with the approval drawing.

3. Visual Inspection Result Report

All the results are to be recorded in the Wiring Test Result Report

9.0 LIST OF METERING SYSTEM INSTRUMENT / EQUIPMENT

This procedure verifies that the equipment is installed properly in the control panel in accordance to

the Panel Layout drawing.

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10.0 MOISTURE ANALYZER TEST

10.1 Operational Functional Test Moisture Analyzer

10.1.1 Scope

This document describes the procedure by which a device shall be functionally tested to

determine its acceptability. This document also provides the vehicle for specifying,

documenting, and recording the testing requirement specific to each device.

10.1.2 Procedure

An Operational Function Requirement Data Sheet shall be prepared for each device to be

tested. The device shall be operated in accordance with the functional test requirements

and with manufacturers provided specification. The completed Operational Function Data

Sheet together with the Test Results, its supporting data and documents attached shall

become the Operational Function Test Report.

10.1.3 Application

This procedure is applicable to Operational Function Test requirements typical of the

following:

1. The application of power to confirm that motors rotate, switches work, electronics

are powered, etc.

2. The operation of controls to confirm that the particular control affects the correct

function and the particular switch controls the correct device.

3. The measurement of electrical signals to confirm that instrument outputs exist in

their proper form; i.e., milliamp or millivolts, the checking of alarms, their sense and

trip confirmation.

4. In the case of Process Analyzers, it shall be checked with a suitable test sample

certified by an authorized, acceptable authority and/or laboratory. This is to verify

that Manufacturer's original calibration is still valid. Analyzers shall not be re-

calibrated unless an obvious discrepancy is found and the re-calibration completely

documented.

5. Test methods and procedure will be attached for individual component

10.2 Calibration

10.2.1 Scope

This document describes the procedure by which the calibration of a device shall be tested

to determine its acceptability. This document also provides the vehicle for specifying,

documenting and recording the testing requirements specific to each device.

10.2.2 Procedure

A Calibration Requirements Data Sheet shall be prepared for each device to be tested. The

device shall be operated in accordance with the calibration test requirements. The

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completed Calibration Requirements Data Sheet, with the results recorded, supporting data

and documents attached shall become the Calibration Test Report.

10.2.3 Application

Calibration of each analyzer shall be in accordance with each Vendor's Calibration

Procedure. The Calibration Procedure to be provided by the tester to the Client upon receipt

from the Analyzer Vendor.

The following are calibration requirement data to be listed or tested if applicable:

1. Calibration Standards

2. Accuracy Tests

3. Repeatability Tests

4. Stability Tests

Acceptance Criteria

a. Accuracy is the degree of conformity of an indicated Value to a recognized,

accepted standard. The maximum positive and negative deviation observed in

testing an analyzer under specified conditions and by a specified procedure. It shall

be expressed as a percent of span.

b. Repeatability is the ability of the analyzer to produce the same output whenever

the same sample is introduced into the analyzer. The closeness of agreement

among a number of consecutive measurements of the output for the same value of

the input. It shall be expressed as a standard deviation.

c. Stability is to operate the analyzer continuously with the same sample for as

specified period of time. The maximum variation in output

11.0 SIMULATION TEST

This test is to ensure adequacy between field measurement and computer reading based on

specified allowable error.

With reference to the Datasheet, P&ID and Cable Termination Diagram


The Simulation Test Report shall be prepared for each device to be tested.

The Equivalent signal(s) shall be “set” to the relevant input parameter of the device.

Corresponding output/ display shall be recorded and compared with calculated value.

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Error shall be less than 1%

3. Test Result Report

Results is to be recorded in the Simulation/Calibration Test Result Report

12.0 GAS CHROMATOGRAPH VERIFICATION

The Gas Chromatograph will be verified using calibration gas as sample gas. The GC shall analyze

the calibration gas as a sample stream. Analysis reports shall be obtained, and the results shall be

tabulated and compared against the calibration gas composition mentioned on the certificate

provided by gas manufacturer.

Test Procedure

1. On the GC and GC controller, force the running of calibration gas as sample stream.

2. Let the GC run for 6 consecutive analysis.

3. If the gas analysis of the calibration gas is within the tolerance, then the test is completed.

4. If the analysis is out of the tolerance, then complete the calibration sheet and investigate the

cause of the non-compliance and repeat the test.

Average, standard deviation, and repeatability of heating value shall be calculated and documented.

13.0 INTERFACE TO GAS CHROMATOGRAPH TEST

This procedure confirms the availability of the data from Gas Chromatograph to metering panel and

also verification of the metering panel to ensure that the gas chromatograph real times data is

correctly transfer to flow computer.

Test Procedure

1. After interfacing with supervisory computer HMI, the visual inspection is carried out.

2. Navigate HMI graphic to compare data in gas chromatograph.

3. Confirm that all the data are correct.

14.0 SUPERVISORY COMPUTER OPERATION TEST

This procedure confirms the availability of all data of HMI on the Supervisory Computer, and also

verification of the HMI Graphics Pages to ensure that the HMI is developed in accordance to the

related P&ID and project standard.

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Test Procedure

1. After interfacing with supervisory computer HMI, the visual inspection is carried out.

2. Navigate HMI graphic page by page for verification

3. Confirm that all the color code, symbol and graphic layout are corresponding to related

P&ID

This procedure also confirms the capability of supervisory computer is having security code system

that controls and provides a limit access of personnel to the unit in accordance with their

responsibility and level authority.

15.0 FLOW COMPUTER TEST RECORD

Verify that all reports are archived on the FC hard drive. Select and print a report from the archive

and attach the document.

Check serial Modbus communication between gas chromatograph and flow computer via verification

of addresses and serial configuration.

AGA 8 Comparison between calculation and measurement shall also be conducted to ensure

inaccuracy is not exceed from specified value

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APPENDIX

REPORT FORMS

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Project Name : Pengembangan Meter Jawa Timur, Pengadaan 8 & 3 Meter System

Client : PT. Pertamina Gas

Skid No. : MET-1004 (KEI Waru Metering Skid 8”- ANSI 600#)

DIMENSIONAL INSPECTION REPORT (ASSEMBLED)

No Location Drawing Dim

Actual Dim

Deviation Judgment Remarks

1 Skid Metering Section

Panjang 9379

Lebar 2166

Tinggi 890

2 Skid Regulating Section

Panjang 5032

Lebar 2166

Tinggi 890

3 Metering Upstream (A) 3513

4 Metering Downstream (A) 3513

5 Metering Upstream (B) 2056

6 Metering Downstream (B) 2056

7 Flange Inlet Regulator Section to Flange Outlet

5032

8 Center bypass to center PCV

1762

Performed By Performed By Witnessed ByPT. Surya Cipta Teknik PT. Handiyan Hottap Instrumen PT. Pertamina Gas

Date : Date : Date :

Witnessed By Witnessed By Witnessed ByKangean Energy Indonesia Ltd. BPMIGAS Ditjen Migas


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INSPECTION OF PAINT WORK REPORT

No Finding Description Action by

Due Date

Complete Date

Sign Remarks

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18





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INSPECTION OF EQUIPMENT LAYOUT AND PIPE CONFIGURATION REPORT


Due Date

Complete Date

Sign Remarks

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18





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INSPECTION OF NAME PLATES REPORT


Due Date

Complete Date

Sign Remarks

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18





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INSPECTION OF JUNCTION BOX AND CABLE GLAND INSTALLATION REPORT


Due Date

Complete Date

Sign Remarks

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18





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INSPECTION OF WIRE AND WIRE MARKERS INSTALLATION REPORT


Due Date

Complete Date

Sign Remarks

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18





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DIMENSIONAL EXAMINATION RESULT REPORT

Unit: in millimetres

Panel Name Drawing Size Measured Size Tolerance

FC Panel W : 800 W :

D : 800 D :

H : 2000 H :

Judgment

Unit: in mm.

Panel Body Dimension

0~1000

1000~2000

2000~3000

Allowable Tolerance

± 5.0 mm.

± 7.0 mm.

± 10.0 mm.





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PANEL VISUAL INSPECTION RESULT REPORT

Item Standard for Judgment Pass/Fail

FC Panel

1 Shapes and Construction of all components are identical with those specified in the approved drawings; thickness, color coating

2 Free from any deformation, stains or dirt, which may be harmful when they are used

3 Water Proof Protection (certification must be attached)

4 General Condition Clean & Unblemished

5 Equipment Layout and dimension

6 Captive nuts with claws inside the swing-frame

Remarks





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WIRING VISUAL INSPECTION REPORT

Item Standard for Judgment Pass/Fail

FC Panel

1 Cable type, color and size

2 Terminal & Cable marker & numbering

3 Labeling

4 Ground Cable & Ground System Connection

Remarks





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INVENTORY CHECK REPORT

1. Panel Hardware Bill of Materials

Item Model Number Description Q’ty Pass/Fail

1 Omni 6000 Flow computer 2

2. HMI Hardware & Software Bill of Materials

Item Manufacturer Description/Model Q’ty Pass/Fail

1 Dell PC Workstation 1

2 Epson Dot Matrix Printer LX-300 1

3

4

5

6





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ANALYZER PIPING AND TUBING LEAK TEST RECORD

Analyzer Tag No. : MA-1004

Ref. Drawing :

Piping Description Tester Date Test Result Action Taken Remarks

Fast Loop Sample In

Fast Loop Sample Out

Sample to Analyzer

Sample Return

Flare Vent

Atmospheric Vent

Utility (Purge N2)

Transport Line

Interconnection





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ANALYZER ELECTRICAL CONTINUITY & INSULATION TEST RECORD


Ref. Drawing :

Description Tester Date Test Result Action Taken Remarks

1. Electrical Continuity Test

Power

Ground

Signal

Alarm

2. Insulation Test (Voltage applied on Megger Meter 500 V)

Power

Ground

Alarm





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ANALYZER OPERATIONAL FUNCTION TEST RECORD


Ref. Drawing :

Description Tester Date Test Result Action Taken

Remarks

Power

Ground

Signal

Alarm

Analyzer

Regulator Valves

Shut Off Valves

Pressure Regulators

Flowmeters

Pressure Gauges

Relief Valves

Check Valves





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ANALYZER CALIBRATION RECORD


Ref. Drawing :

1. Analyzer Data

Tag No Model No

Analyzer Type Serial No

Manufacturer Range

2. Power Requirement

Supply Voltage

Supply Frequency

3. Calibration Method: Connect cylinder purified Nitrogen gas to the analyzer via the sampling conditioning system. Introduced Moisture by activating the Moisture Generator within the analyzer. Output of the analyzer is tie in to a chart recorder for 3 continuous cycle.

4. Calibration Standards

Component Name Range Measured Standard Value Phase





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5. Record of Testing

A

N

A

L

Y

Z

E

R

D

A

T

A

Tag No S

T

A

N

D

A

R

D

D

A

T

A

Cylinder No

Service Cylinder No

Type Cylinder No

Serial No

Manufacturer

Application Portable Manufacturer and Date

Online X

Interlock Specification/ Certification

* attachéd certificateAlarm Hard SP

Soft SP

Remarks:

Ambient Temperature :

Changes : +/- 1 degC

Remarks:

Accuracy: +/- of reading

Date Standard Sample

Standard Value (X)

Analyzer Reading

(Y)

% Deviation = ((X-Y)/SPAN)

x 100

Performed by

Remarks





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SIMULATION TEST RECORD

Tag No : PT-1004-1A

Engineering Unit : psig Low Scale: 0

Service : Process Line Pressure Meter #1 High Scale: 600

% I/P Current Expected FC Reading HMI Reading Error of FS Pass/Fail

(mA) (psig) (psig) (psig) (FC-Exp)/FS

0 4.000 0

25 8.000 150

50 12.000 300

75 16.000 450

100 20.000 600

75 16.000 450

50 12.000 300

25 8.000 150

0 4.000 0

Allowable tolerance





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Tag No PT-1004-1B

Engineering Unit : psig Low Scale: 0

Service : Process Line Pressure Meter #2 High Scale: 600


(mA) (psig) (psig) (psig) (FC-Exp)/FS

0 4.000 0

25 8.000 150

50 12.000 300

75 16.000 450

100 20.000 600

75 16.000 450

50 12.000 300

25 8.000 150

0 4.000 0

Allowable tolerance





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Tag No : TT-1004-1A

Engineering Unit : deg F Low Scale: 0

Service : Process Line Temperature Meter #1 High Scale: 200


(mA) (deg F) (deg F) (deg F) (FC-Exp)/FS

0 4.000 0

25 8.000 50

50 12.000 100

75 16.000 150

100 20.000 200

75 16.000 150

50 12.000 100

25 8.000 50

0 4.000 0

Allowable tolerance





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Tag No : TT-1004-1B

Engineering Unit : deg F Low Scale: 0

Service : Process Line Temperature Meter #2 High Scale: 200


(mA) (deg F) (deg F) (deg F) (FC-Exp)/FS

0 4.000 0

25 8.000 50

50 12.000 100

75 16.000 150

100 20.000 200

75 16.000 150

50 12.000 100

25 8.000 50

0 4.000 0

Allowable tolerance





FAT Procedure of 56






Tag No : DPT-1004-2A-L

Engineering Unit : in H2O Low Scale: 0

Service Differential Pressure Low Case at Meter #1 High Scale: 50


(mA) (in H2O) (in H2O) (in H2O) (FC-Exp)/FS

0 4.000 0

25 8.000 12.5

50 12.000 25

75 16.000 37.5

100 20.000 50

75 16.000 37.5

50 12.000 25

25 8.000 12.5

0 4.000 0

Allowable tolerance





FAT Procedure of 56






Tag No : DPT-1004-2B-L


Service : Differential Pressure Low Case at Meter #2 High Scale: 50



0 4.000 0

25 8.000 12.5

50 12.000 25

75 16.000 37.5

100 20.000 50

75 16.000 37.5

50 12.000 25

25 8.000 12.5

0 4.000 0

Allowable tolerance





FAT Procedure of 56






Tag No : DPT-1004-2A-H


Service Differential Pressure High Case at Meter #1 High Scale: 200



0 4.000 0

25 8.000 50

50 12.000 100

75 16.000 150

100 20.000 200

75 16.000 150

50 12.000 100

25 8.000 50

0 4.000 0

Allowable tolerance





FAT Procedure of 56






Tag No : DPT-1004-2B-H


Service Differential Pressure High Case at Meter #2 High Scale: 200



0 4.000 0

25 8.000 50

50 12.000 100

75 16.000 150

100 20.000 200

75 16.000 150

50 12.000 100

25 8.000 50

0 4.000 0

Allowable tolerance





FAT Procedure of 56





FUNCTION TEST RECORD

Tag No : FCR-1004-1A

Engineering Unit : in H2O (Diff. Pressure) Low Scale: 0 High Scale: 200

Engineering Unit : psig (Pressure) Low Scale: 0 High Scale: 750

Engineering Unit : deg F (Temperature) Low Scale: 0 High Scale: 200

Service : FCR at Meter #1

Diff Press(%) 0 25 50 75 100 75 50 25 0

Expected 0 50 100 150 200 150 100 50 0

Recorded

Pass/Fail

Static Press (%)

0 25 50 75 100 75 50 25 0

Expected 0 162,5 325 487,5 750 487,5 325 162,5 0

Recorded

Pass/Fail

Temp (%) 0 25 50 75 100 75 50 25 0

Expected 0 50 100 150 200 150 100 50 0

Recorded

Pass/Fail





FAT Procedure of 56






Tag No : FCR-1004-1B

Engineering Unit : in H2O (Diff. Pressure) Low Scale: 0 High Scale: 200

Engineering Unit : psig (Pressure) Low Scale: 0 High Scale: 750

Engineering Unit : deg F (Temperature) Low Scale: 0 High Scale: 200

Service : FCR at Meter #2

Diff Press (%) 0 25 50 75 100 75 50 25 0

Expected 0 50 100 150 200 150 100 50 0

Recorded

Pass/Fail

Static Press (%)

0 25 50 75 100 75 50 25 0

Expected 0 162,5 325 487,5 750 487,5 325 162,5 0

Recorded

Pass/Fail

Temp (%) 0 25 50 75 100 75 50 25 0

Expected 0 50 100 150 200 150 100 50 0

Recorded

Pass/Fail





FAT Procedure of 56






Tag No : DPT-1004-1A

Engineering Unit : mBar Low Scale: 0

Service : Differential Pressure at Filter Meter #1 High Scale: 1000

% I/P Current Expected HMI Reading Pass / Fail

(mA) (mBar) (mBar)

0 4.000 0

25 8.000 250

50 12.000 500

75 16.000 750

100 20.000 1000

75 16.000 750

50 12.000 500

25 8.000 250

0 4.000 0





FAT Procedure of 56






Tag No : DPT-1004-2A

Engineering Unit : mBar Low Scale: 0

Service : Differential Pressure at Filter Meter #2 High Scale: 1000

% I/P Current Expected HMI Reading Pass / Fail

(mA) (mBar) (mBar)

0 4.000 0

25 8.000 250

50 12.000 500

75 16.000 750

100 20.000 1000

75 16.000 750

50 12.000 500

25 8.000 250

0 4.000 0





FAT Procedure of 56





GAS CHROMATOGRAPH REPEATABILITY TEST

(6 TIMES CONSECUTIVE TESTS)

Analyzer Tag No. : GC-1004

Ref. Drawing :

Test No :

Calibration Gas Certified Gas Composition

Chromatograph Analysis

Test No. :

Difference ASTM D 1945 Criteria

Pass/Fail

Component Mole % Mole % Mole % Mole %

C1

C2

C3

iC4

nC4

iC5

nC5

C6

C7+

CO2

H2S

N2

Tables below provide the given repeatability tolerances based on ASTM D1945.

ComponentMole %

Repeatability%

0 to 0.1 0.01

0.1 to 1.0 0.04

1.0 to 5.0 0.07

5.0 to 10 0.08

Over 10 0. 0.10





FAT Procedure of 56





GPA 2172 HEATING VALUE CALCULATION (6 TIMES CONSECUTIVE TESTS)

Analyzer Tag No. : GC-MET-1004 Base Temperature : 60 deg F

Ref. Drawing : Base Pressure : 14.7 psia

Component GHV/fraction mole % mole GHV

C1

C2

C3

iC4

nC4

iC5

nC5

C6

C7+

CO2

H2S

N2

TOTAL

Parameters Calculation Flow Computer Error (%)

Ideal Heating Value (btu/scf)

Zbase (calculated from AGA8)

Actual Heating Value (btu/scf)

Wobbe Index





FAT Procedure of 56





REPEATABILITY RESULT

Calibration gas heating value (btu/scf) = ISO 6976 – 1995 (Kelton)

No Actual Heating Value Error (%) Pass/Fail

Expressed in %, relative to the value of the heating value : % GHv = 100 * 22 * ( GHv / avg. GHv)

Therefore,

Standard Deviation

Average

Repeatability





FAT Procedure of 56





AGA 8 CALCULATION

Analyzer Tag No. : GC-1004 Base Temperture : 60 deg FRef. Drawing : Base Pressure : 14.7 psiaLine Temperature :Line Pressure :

Component Fraction mole Component Fraction mole

C1 nC5

C2 C6

C3 C7+

iC4 CO2

nC4 H2S

iC5 N2

AGA 8 OUTPUT COMPARISON


Standard density (lb/ft3)

Flowing density (lb/ft3)

Base compressibility Factor (Zb)

Flowing compressibility Factor (Zf)

Gas Molecular Weight (Mr)

Air Molecular Weight (Mr-air)

Air base compressibility factor (Zb-air)

Specific Gravity / Relative Density





FAT Procedure of 56





GAS CHROMATOGRAPH COMMUNICATION TEST RECORD

Analyzer Tag No. : GC-1004

Ref. Drawing :

Component Gas standard (% mole)

GC local reading

(% mole)

FC Reading

(% mole)

HMI Reading

(% mole)

Error (%) Pass/Fail

C1

C2

C3

iC4

nC4

iC5

nC5

C6

C7+

CO2

H2S

N2

Tables below provide the given repeatability tolerances based on ASTM D1945.

ComponentMole %

Repeatability%

0 to 0.1 0.01

0.1 to 1.0 0.04

1.0 to 5.0 0.07

5.0 to 10 0.08

Over 10 0. 0.10





FAT Procedure of 56





SUPERVISORY COMPUTER OPERATION TEST RECORD

Description Pass/Fail Remarks

Communication supervisory computer to Ethernet switch with 10 Base T-Ethernet or Modbus TCP

Software system setup for MMI

Layout process template as per P&ID

Security access / priority level





FAT Procedure of 56





FLOW COMPUTER TEST RECORD

1. Report Generation


Layout, content, data correctness : current report

Layout, content, data correctness : daily report

Layout, content, data correctness : monthly report

2. Modbus Communication


Modbus Mapping Test





FAT Procedure of 56





FLOW CALCULATION TEST RECORD

Trial

Simulated Signal Flow Rate

Error

%RemarksDiff.

Press in H2O

Line Temp

ºF

Line Press

PSIG

Calculated

MMSCFD

Actual

MMSCFD

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

FAT Procedure of 56


25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45





FAT Procedure of 56





FLOW CALCULATION – AGA3 1992

INPUT PARAMETER

Pipe ID inch

Orifice Bore inch

Differential Pressure in H2O

Upstream Static Pressure psig

Temperature deg. F

Dynamic Viscosity cP

Specific Heat Ratio

INPUT PARAMETER FROM AGA8 CALCULATION

Base Compressibility, Zb

Flowing Compressibility, Zf

Standard Density lb/ft3

Flowing Density lb/ft3

INPUT PARAMETER FROM GPA 2172 CALCULATION

Actual Heating Value Btu/scf

AGA 3 OUTPUT COMPARISON


Mass Flowrate (M.lb/day)

Std. Volume Flowrate (MMSCFD)

Energy Rate (MMBtu/d)





FAT Procedure of 56


DRAWINGATTACHMENT

FAT Procedure of 56


LIST OF DRAWING

1. P&ID

2. General Arrangement

3. System Architechture

4. Panel Detail

5. Wiring and Power Distribution

6. Field Junction Wiring Diagram

FAT Procedure of 56


ATTACHMENT

FAT Procedure of 56


LIST OF ATTACHMENT

1. Bill Of Material

2. Cable Scedule

3. Continuity Test Instrument Cable Report

4. Insulation Test Instrument Cable Report

5. Individual Instrument Test Report

6. Instrument Data Sheet

7. Certificates

FAT Procedure of 56

FAT Procedure Gresik

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