INSTRUMENTATION FOR EQUIPMENT PACKAGESThe test program shall be designed to prove that the following aspects of the instrument and electrical equipment/system are satisfactory: Installation. Integrity. Calibration. Operation.

The following equipment shall be tested: Electrical equipment. Instruments. Panels. Cable. Impulse line tests.

The CONTRACTOR's Inspector shall perform the following inspection checks, as required:

Verify against approved documents that all items have been supplied and installed correctly. Check tagging and location of equipment for accessibility for operation and maintenance. Check appearance, paintwork, dimensions and fixing points against final agreed drawings. Check routing and segregation of all cabling. Verify that all wiring, cables and cores are correctly terminated and that cable / terminal markersand nameplates correspond to the documentation. Verify that calibration certificates, material certificates and hazardous area certification for allapplicable instrumentation equipment are available in accordance with project specifications andrequirements. Verify that welding and NDT has been performed using CONTRACTOR approved procedures andNDT reports properly reviewed and endorsed by qualified NDT Interpretation personnel. Verify that hydrostatic pressure test certificates / certification for all applicable instrumentationequipment, including impulse lines, are available in accordance with project specifications andrequirements.The following list applies to the testing: Wiring shall be tested for continuity and insulation. The test voltage shall be compatible with thewiring being tested. Instrument air systems shall be checked for leaks using dry air at a pressure 110% of maximumworking pressure. Impulse lines shall be disconnected from both the process line and the instrument, andhydraulically tested to 1.5 times process line design pressure. Instrument equipment and pipingshall be thoroughly flushed and dried on completion of test. After installation, instruments shall be calibrated and demonstrated to be within VENDORspecification. If necessary, VENDOR shall arrange for the instrument manufacturer representatives to performthe calibration and test. Certificates of test for electrical components, instruments, and associated equipment shall beavailable. Test certificates shall state values for test results unless cross-referred to test procedures givingtest criteria.The following activities shall be carried out as part of the FAT only where the tests have not alreadypreviously been completed: Verification of physical interconnections between systems, Communication checks between systems, Verification of data transfer between applications, Redundancy checks (If appropriate), Functional checks of data interfaces between package and ICSS, Failure mode performance tests. System backup and restore, including disaster recovery.

19.9.1. Hardware Inspection and TestingAll package equipment shall be inspected and tested with respect to the following: Hardware verification against approved drawings and schedules. Visual inspections and safety checks Earthing checks Power system checks Power supply redundancy tests EMI / RFI tests I/O point-to-point tests Hardwired I/O function tests FF I/O function tests. As a minimum each segment (port), including spares, shall be operationallytested by live connection of at least one Fieldbus device. The Fieldbus device shall be connected tothe terminal block designated for the field wiring or system cable. HART I/O function tests Cabinet Alarms function tests Failure and recovery of redundant modules except where redundancy is a built in feature of thesystem and does not rely on software configuration. Battery Backup tests Black start recovery tests Online replacement tests ATEX requirements5 ELECTRICAL EQUIPMENT SELECTION AND INSTALLATION5.1 LAYOUTElectrical apparatus shall be located in such a manner as to enable ease of maintenance whenin service.Location of electrical equipment within the package unit shall ensure adequate access forcabling and routing and shall be detailed on VENDORs drawings.VENDORs shall provide space on cable tray or racking for cables within package unitboundaries.Items requiring external cable connections shall be located on perimeter of packaged skid(unless a direct connection to equipment within the package is more convenient for installationand for maintenance).Installation shall also satisfy all relevant statutory and regulatory requirements applicable at theinstallation site.Adequate space shall be left between gland plates and terminal strips to ensure termination ofeach cable is practicable once all other cables have been terminated.Protection shall be provided for cables, electrical equipment, devices, and conduits wheninstalled in areas subject to physical damage or vibration. Protection shall also be provided toprotect cables, electrical equipment and conduit from damage during fabrication.Electrical equipment shall be installed in a neat manner. Trays, channels and cables shall berouted horizontally and vertically, parallel to one another or at right angles to equipment line.Working space around equipment shall as a minimum, be in accordance with manufacturersrecommendations. Sufficient aisle space shall be provided to allow for the removal ofequipment.Control panels or local controls shall be constructed and sited to prevent physical damage orinadvertent operation.Details of possible future extensions shall be provided. The VENDOR shall make allowance forthese extensions when planning the layout.Motors or generators shall not be mounted in a position where airflow is obstructed or where thehot air discharge of one machine is directed at the air intake of another.Conduits shall be arranged to allow for low point drains.5.2.1 Certified Equipment RegisterThe VENDOR shall provide copies of Hazardous Area Certificates of Compliance for all equipmentsupplied for installation in hazardous areas. A Schedule of Electrical Equipment in Hazardous Areas,showing the full details of the equipment and statutory approvals shall be provided. At a minimum,the schedule shall include the following information:Item/Tag No.Service DescriptionManufacturerModel No.Ex MarkingCertifying AuthorityCertificate NumberExpiry DateArea ClassificationIP RatingTests shall include:a) Test cables (IR and continuity) after cables have been glanded to equipment with coresisolated.b) Megger motor windings and transformer windings.c) If evidence of moisture accumulation is found, equipment must be dried out and re testedbefore operation.d) Check circuit breakers, motor starters, switches, relays and other equipment for looseconnections (both mechanical and electrical) to see that contacts and working parts arecorrectly aligned and free from dust and foreign matter.e) Check motors for proper rotation, lubrication and proper alignment.f) Perform operational tests on motor control circuits.g) Perform operational tests on control switches, alarm and shutdown devices, indicatinglights and meters for proper operation.h) On circuit breakers with adjustable trips, check both thermal and magnetic settings forproper protection.i) Check protection relay settings and perform injection tests.j) Earthing/grounding tests (both continuity and impedance) shall be carried out and resultsrecorded.Certificates of Test shall be provided for each item of electrical apparatus to prove it has beensatisfactorily tested to meet requirements of its appropriate manufacturing standards, whether ornot witnessed.If appropriate, test certificates shall state values for test results.Test certificates for tests witnessed by contractor shall be available for signature on day of test.Test instruments shall be an approved type and calibrated against certified standards orstandard instruments at regular and proper intervals, and their accuracy must be fullysubstantiated at time of tests.All electrical equipment and installations specified to operate in a hazardous area shall complywith requirements of IEV 60079-14 and IEC 60079-17. Suppliers of such equipment /installations shall provide the following documentation as a minimum to verify the integrity of theinstallation and compliance with ATEX directive and IEC 60079 requirements:a) Product Type certification issued by an Ex notified body.b) EC declarations of conformity by i) the manufacturers of individual items andii) the package Supplier responsible for the installation / assembly.c) Hazardous Area Schedule. A list of all items installed that includes required details inproject format.d) Hazardous Area Equipment - Installation Report documenting the initial inspection,required by IEC 60079-17 performed by the Supplier.

SUPPLIER shall provide a copy of the Pre-FAT test logs.SUPPLIER shall be responsible for recording all FAT results. This includes a punch list of items tobe completed before the package is accepted and shipped. SUPPLIER shall certify in writing thatthe factory test is satisfactorily completed with all errors corrected and all documents updated.The following activities shall be included in the FAT:Visual check of hardware inventory, cabinet and panel layouts and wiring vs. approveddesign drawings.For instruments not connected to a Supplier PLC, those instruments shall be checked forcontinuity back to junction boxes.For instruments not connected to a Supplier PLC, calibration reports shall be providedshowing SUPPLIER has checked for proper calibration and operation.If possible, for instruments connected to a Supplier PLC, the instruments shall be poweredand process shall be simulated to show proper calibration of instrument and properconfiguration in the control system (this includes stroking valves from the control system).For Supplier PLCs, whether PLC or other, the following activities shall be included:Check system response timesCheck system configuration loadingCheck application program loadingCheck proper takeover modes of redundant componentsCheck system diagnostic featuresDemonstrate proper system operation at power up/power down/momentary power failureand power switchover set point and functionCheck system alarmsPerform 100% check of all I/O, control configuration, and responses of outputs tosimulated inputsDemonstrate correct function of all peripherals including any fiber optic componentsDemonstrate proper data highway configuration. Test plan to be submitted forSUPPLIERs approval.Mark all corrections or changes to SUPPLIER documentation to reflect as-shipped status.Verified Cause & Effects diagrams functionality5.14 FAT ConclusionSUPPLIER shall submit to OWNER/PURCHASER, test reports to document the results of the FAT.This FAT is a major contract hold point. The equipment cannot be shipped to the field untilOWNER/PURCHASER approves the results of the test.Once OWNER/PURCHASER has approved the results of the FAT, the SUPPLIER shall scheduleall hardware to ship unless otherwise agreed to in writing.SUPPLIER shall draft and issue all changes to documentation as a result of the FAT.5.15 SATThe SAT shall consist of the following activities (as a minimum) to be performed by the SUPPLIER(SUPPLIER may recommend additional activities based on experience, and some activities maybe omitted where Supplier PLCs are not provided):Verify supplier provided instruments and panels are installed properlyVerify field terminated signal, power and ground cables are terminated properly to supplierequipmentPerform general inspection of all supplier instruments and systemsPower the system and perform diagnosticsVerify operator interfaces and other peripherals operate properlyAssist with the verification of communication highways to third party devicesVerify inputs and outputs are being properly manipulated in the systemOption: Assist with loop check of inputs and outputsOption: Assist with check of shutdown logic functions to verify outputs react properly to inputconditionsSUPPLIER shall submit a project specific SAT procedure for approval six weeks prior to packageshipment.SUPPLIER shall provide with quotation a schedule of field service rates for the two options listedabove, when SUPPLIER provides a control system.SUPPLIER shall be responsible for recording all SAT procedures and results, as well as punch listitems.9.2 Factory Acceptance Test All testing shall be identified within an Inspection & Test Plan. A schedule of tests to demonstrate compliance with this Specification and the main package specification shall be provided. It shall include as a minimum the following tests:a) A visual inspection shall be made to ensure that good workmanship and practices have been maintained throughout fabrication and assembly b) A quantitative check shall be made to ensure that all items, in specified quantities are present according to the purchase order and packing list. c) Insulation / Megger Test of all wiring d) All fuses and circuit breakers shall be checked for correct voltage and current rating.e) The electrical system shall be given a functional test to ensure total system operation. It is the intent of this test to prove the proper interaction of all control and safety devices. f) All interlockable safety devices and fail safe functions shall be tested. g) Whenever the unit is shipped in more than one piece, it shall be fully assembled and the Vendor shall ensure testing with all components assembled.5.17 DocumentationALL FINAL INSTRUMENT/CONTROL DOCUMENTATION ON CD.Prepare and submit documents in electronic media such as AutoCAD or MS Excel or other spreadsheet program as needed to mount, connect and troubleshoot the instrumentation includinginstrument locations, vessel trim details, control room equipment layout and details, control panellayouts, installation details, logic diagrams, schematics, loop diagrams, and junction box drawings.Provide instrument drawings required to provide field power, locate the field signals and junctionboxes, run conduit or tray and connect wiring or tubing.Identify power requirements including loads, breaker settings and type of power (UPSrequirements, etc.) via a table for all instruments requiring power.Include documents for inline, custom and unusual instruments to OWNER/PURCHASER forapproval and as final certified drawings.The drawings shall identify conformance with the requirements, dimensions for connections,instrument type and manufacturer, proper application, location of equipment including instrumentsand junction boxes, and interconnection diagrams with terminal numbers assigned. Emphasizesafety considerations such as protection of personnel, capital equipment and the environment.Provide control narratives for regulatory controls, sequence controls, alarm and trip lists, andlogic/shutdown controls, whether or not these controls are implemented in the Seller orOWNER/PURCHASERs control system. Provide Cause and Effect diagrams for shutdown logic.Provide complete tag listing with Seller control system register location of all data that is to be readby the PCS or written to the Seller control system by the PCS.Provide all software loaded into PLCs, PCs, and any other electronic media. This includes, but isnot limited to, operating systems, graphic programs, logic programs, printer drivers, etc. Providecopy of application programs created for control of the equipment.Provide a copy of all software licenses.Provide maintenance manuals for all instruments. Documents shall include the following:Include all the "packaged" equipment dimensional informationDepict piping, valves and instruments for the operation of the package unitInclude item numbers assigned by OWNER/PURCHASER for equipment and instruments Identify size, type and description of each item and process and utility connection toOWNER/PURCHASER pipingLocate instruments, junction and terminal boxes, panels and connections to piping, vessels andmachines on general arrangement drawings in plan and elevation viewsShow instrument air tubing and piping and valvesProvide an instrument list complete with type, manufacturer, model number and description foreach instrument and instrument valve to be supplied by the SellerInclude copies of control valve, safety relief valve, thermowell vibration and flow elementcalculationsInclude completed ISA S20 format data sheets for each instrument provided.Include parts lists and list of recommended spares for instruments as defined in the PurchaseDocuments.Include instrumentation utility requirement schedule for power, cooling water, instrument air,nitrogen, etc.Document instrument removal and reinstallation procedure where required for shippingInclude copy of all configured applications (i.e. ladder logic, function block logic, graphics, etc.)Include copy of certified test results for instruments, identified by instrument tag number (i.e. PSVset pressure tests, valve seat leakage tests, transmitter calibration test, etc.)

5.0 PACKAGE COMPLETION AND TESTING 5.1 General Prior to despatch all equipment shall be tested in accordance with the main equipment specification and specified design codes. The packaging completion and testing requirements are covered below. 5.2 Pressure Testing 5.2.1 All fabricated piping spools shall be individually pressure tested in accordance with the appropriate system design pressure and design code requirements. The assembled systems shall be leak tested. Vulnerable equipment and instrumentation may be isolated or removed for this activity. Test pressures shall be maintained for a sufficient period (not less than 30 minutes) to permit complete inspection unless otherwise directed by design code or specification.5.2.2 All equipment and assembled systems shall be fully drained and dried to remove all traces of the test medium. Water used for hydrostatic testing of stainless steel components shall have a chloride content of less than 30 ppm and suitably inhibited. 5.3 System Cleaning 5.3.1 All equipment components and piping spools shall be cleaned by appropriate means prior to package assembly. Stainless steel pipe spools shall be pickled and passivated. Carbon steel lines in gas or clean services shall be de-scaled by pickling. 5.3.2 Following package assembly, all piping systems shall be flushed to meet a cleanliness criterion specified by the supplier. Equipment and instrumentation may be isolated or removed for this activity. Typically, equipment bearings will be by-passed. After flushing, the system shall be drained and completely dried ready for putting into service or testing. The system cleaning and drying shall be repeated after testing. Preservation for transportation and storage shall be applied to the clean and dry system. Vulnerable instrumentation and equipment may be removed from the skid and packed separately for transportation. Open ends and connections must be sealed and protected against ingress of moisture and debris. 5.4 Instrument Calibration and Setting 5.4.1 All package instrumentation shall be check-calibrated and correctly set in accordance with the Suppliers instrument schedule during the package assembly. The Suppliers instrument check-calibration and settings records shall be retained by the supplier with copies included within the package certification dossier along with the instrument Suppliers original calibration certification. 5.4.2 Instrument systems shall be connected as far as possible to simulate field operation. Field inputs shall be simulated by appropriate switches, variable voltage or current generators. Serial interfaces shall be tested using PCs utilising link specific software. Field outputs shall be simulated by utilising pilot lights, milliammeters, solenoids, etc. All simulators shall be fully wired up before testing commences. The tests shall demonstrate that the equipment functions as intended.Lifting Equipment Test All lifting equipment supplied shall be subject to proof load/functional testing and be certified by a recognised independent competent authority acceptable to the Purchaser. The devices shall be uniquely identified with serial numbers and the Safe Working Load (SWL) for traceability back to the certification. Functional testing of the fully assembled lifting system shall include but not limited to lifting, lowering and traversing the rated load over its required length of travel in accordance with approved procedures. 5.6 Electrical Testing Electrical wiring and equipment shall be tested in accordance with the applicable NEMA & IEEE Standard. Tests shall include wiring continuity; function tests to prove proper operation of controls, alarms and protective devices; insulation and earth continuity tests. 6.0 MECHANICAL HANDLING 6.1 General 6.1.1 For routine maintenance and breakdown, the supplier shall provide a mechanical handling plan for the package. This may be part of the general arrangement drawing. Mechanical handling shall besingle man, or 110 lb. (50 kg), if access is provided for two men. In addition, mechanical handling shall be provided if the lift is complicated or complex. The plan shall show runway beams, pad-eyes etc, and include the rating of runway beams, pad-eyes, hoists and minimum hook heights and withdrawal space requirements. 6.1.2 For equipment items not accessible by an external mechanical handling system, such as equipment within the skid limits, the supplier shall supply a system. The system shall be designed to transport the equipment to a laydown area. This may be outside the package skid limits. 6.1.3 Special lifting frames, spreader beams and other attachments that are required for maintenance removal of some items of major equipment, e.g., rotors, pump cartridges, etc, shall be supplied by the equipment supplier. Any special tools required for maintenance shall also be supplied by the equipment supplier.