Response to FAT Procedures Rev A Comments (17-May-10)

N
o.
1

Ref Page
No.
Pg 5/ 20

Comments

Pg 5/ 20

Firing need to be carried out during FAT.

Please describe clearly on this procedures. How it is
going to be done?

Pg 5/ 20

Pg 5/ 20

Functional of pump after being installed and

integrated in the system.
Pump test is necessary to ensure the pumps are
performing duty as required by the actual system
(please describe)
Check cabling works with Megger and Continuity
Test should be done when drum cable arrived, not
AFTER lay out and terminated

Pg 5/ 20

Pg 5/ 20

Pg 5/ 20

Pg 5/ 20

Functional testing for burner including its BMS panel

shall be carried out after installation & integration in
the system.

To include perform Firing of burner and test burner

eye
To include pumps running tests. Record the
parameters.
Gross air leak testing > Please explain this.
Please include Burner test check sheet and pump
check sheet.
Refer to CSPT 20 for pump check sheet; general skid

Response
Noted. However, please note that we have the BMS panel is
a local control panel with ON/ OFF push buttons and Pilot
Lights only. We have done the FAT on the panel.
We can ONLY check its integrity with the whole once it has
been connected to Topaz PMCS and SIS. To be done during
pre-commissioning at site.
Noted. However, please note that we will only LIGHT up the
burner to confirm it is functional for 5 minutes. We do not
have glycol in the heater and continuous firing without a
medium will damage the firetube.
We will describe on the procedures in Rev B (Boss, please
help)
Kindly note that pump performance test have been carried
out in factory with BV as witness (See attached BV report).
We will NOT be carrying out another set of pump functional
testing during FAT as we DO NOT have the test medium.
(Boss, please help)
Please be advised that we have DONE the test when drum
cable arrived. However, as a standard procedure, we will
perform another set of testing after lay out and termination
for final confirmation.
Noted. To be incorporated in Rev B. Please see item 2
response.
Please refer to item 3 response.
We will NOT carry out pump running tests.
(Boss, please help)
(Boss, please help)

check sheet, pipe work check sheet, PSV, motor etc

9

Pg 5/ 20

PSV > Pop test?

(Boss, please help)

10

Pg 7/ 20

Burner and Pump Tests (please describe)

We need these 2 to be run tested upon
installation in the system
Temperature measurement

11

Pg 8/ 20

12

Pg 8/ 20

13

Pg 8/ 20

Power Cable Trays -> why it needed to be tested?

Tray?
Structural & Supports -> Is it needed for electrical?
For LV motors, in case any of it failed during re-test,
changes to a new one is to be made, repair is not
allowed
LE refers to Local Emergency Stop Station will not be
tested -> Why?

Please see item 2 and 3 responses.

We will use industrial grade LPG to light up the burner to
test for its functional. There will be no temperature
measurement for this as we do not have any temperature
gauge within the fire tube. We will only light up the burner
for not more than 5 minutes to avoid damaging the fire
tubes (not fluid surrounding it).
No test will be carried out for the pump performance. We
will test the LV motors for the pumps and its blowers.
(Boss, please help)
(Boss, please help)

14

Pg 9/ 20

PSV -> Need to be checked

Noted.

15

Pg 9/ 20

For temperature gauge -> is there calibration sheet?

(Boss/ Veera, please help)

16

Pg 9/ 20

(Boss/ Veera, please help)

17

Pg 9/ 20

For temperature element -> only equivalent

resistance of RTD or mV generated for thermocouple
will be confirmed
This is testifying the transmitter, not sensor,
use temperature bath
Level gauge -> use correct medium for functional
test.

Noted. (Boss, please help)

LES refers to Local Emergency Stop Station. It cannot be
tested during FAT because our system is directly linked or
controlled by platform PMCS and SIS. This is to be tested at
site by PCVL.

Please note that we do not have glycol available at

fabrication yard.

(Boss/ Veera, please help)

18

Pg 9/ 20

19

Pg 10/ 20

20

Pg 10/ 20

21

Pg 10/ 20

22

Pg 11/ 20

23

Pg 11/ 20

24

Pg 11/ 20

25

Pg 12/ 20

26

Pg 13/ 20

27

Pg 13/ 20

28

Pg 13/ 20

Control valve test at factory witnessed by CLIENT.

Please clarify who is the client (TOS or PCVL?)
Seat leakage test for control valve will not be done at
site
Need to provide test report and certs
Stroke check on valve need to do up and down
(between 0% to 100%) and get average

(Boss/ Ashraf, please help)

Item k. Apply a tested ok label to instrument and

include other info like test date and tester details.
Why Limit switches installed on actuated valves shall
be adjusted as per manufacturers
recommendations??
Item g -> Chocking?

Noted

Shut (S) mark or Closed (C) mark on travel indicating

scale?
Why there are 2 tables for limit switch contact change
over?

To be confirmed

Pressure Transmitter Testing

e. connect a mA meter to test the jacks. (What is
jacks?)
Pressure Transmitter Testing
g. connect pressure source to transmitter (what
source? DW??)
Pressure Transmitter Testing
j. Apply a lower scale value according to data sheets
and check whether the output is correct. If not,
correct it using the HART communicator.
> Correct using HART? If not correct, the transmitter
fail calibration and need to send back to
manufacturer.

Noted
(Boss please help and advice)

(Boss/ Veera, please help)

Typo. Should be choking

Please note that one table is for valve position changes

from closed to open and another is from open to closed. To
confirm change over status.
(Boss/ Veera, please help)
Fuel gas.
(Boss/ Veera, please help)
Please note that we are using HART communicator to test
the functional output, i.e to test if lower scale is
corresponds to 4mA and higher scale corresponds to 20 mA
or not. If not, we can use HART communicator to reset the
output.
Please note that we are not altering the calibrated range.
The transmitters are all being pre-calibrated at factory. We
are adjusting its output ONLY.

(Boss/ Veera, please top up)

29

Pg 13/ 20

Test and record linearity values - need to do up and

down (between 0% to 100%) and get average

(Boss/ Veera, please help)

30

Pg 14/ 20

(Boss/ Veera, please help) Can we comply to this?

31

Pg 15/ 20

32

Pg 16/ 20

Connect temp source to transmitter (Wheatstone

bridge for RTD and mV source for thermocouple)
Use temperature bath for sensor
Level Transmitter Testing
Please confirm if you want to test on a bench or
installed at site?
DP Transmitter Testing
Please confirm if you want to test on a bench or
installed at site?

33

Pg 16/ 20

(Boss/ Veera, please help)

34

Pg 17/ 20

35

Pg 17/ 20

36

Pg 18/ 20

37

Pg 19/ 20

38

Pg 19/ 20

DP Transmitter Testing
j. Why do we need to remove the pressure source and
reinstall the transmitter?
Instrument Tubing/ Pneumatic Tubing Leak Test
j. Release the applied pressure to where? Atm?
Instrument Tubing/ Pneumatic Tubing Leak Test
k. Blow the impulse line with what?
Instrument Cable Test
Test cable before installation. Provide check
sheet, no need witness during FAT.
Partial Loop Check Procedures
j. Connect a source to instrument
> Use real source or just 4-20 mA simulator? How
bout digital signal?
How to observe the reading at JB termination?

39

Pg 20/ 20

Provide a Table of content for Check Sheets

Noted.

40

RCU
Check

Local ammeter tested scale shall be given

Noted.

Installed at site since our level transmitter is a one part

direct mounted type.
(Boss/ Veera, please help)
(Boss/ Veera, please help)

(Boss/ Veera, please help)

(Boss/ Veera, please help)
Please note that we have already tested the cable before
installation. However, we will retest them again after
installation to confirm its continuity.
(Boss/ Veera, please help)

(Boss/ Veera, please help)

Sheet
41
42
43
44
45
46
47
48
49
50

Actuator
Check
Sheet
Earthing
Check
Sheet
Pipe Work
After Test

Why flush instrument pipework with dry air? After leak

test? Hydrotest?

(Boss/ Veera, please help)

Must do earthing resistance test to measure reading.

(Boss/ Veera, please help)

What about reinstatement leak test of the joints after

re-instation / installation??

(Boss please help)