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PETROTEL - LUKOIL
ANNUAL TEST PROCEDURE

Tag : 75-k-1 RECYCLE GAS COMPRESSOR


Emetteur : Document N° : A2C788231 Page
DR- 2/14
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1. GENERALITIES

The SIL2 agreement forces the maintenance operator to check annually the good functioning of the SIL2
items.

In order to realise this tests, one “Annual test push button” is placed inside the control panel.

Moreover, the maintenance operator will need a computer with the programming software
RSLOGIX5000 revision 10.0 (ROCKWELL).

During this test, the following points are checked :

- Trip signals : All trip & stop signals shall be activated in order to verify that process
parameters are monitored properly and that the system reacts properly when a
fault condition arises.

- Proof test for inputs : This test must be performed to make sure that no inputs are stuck in
ON or OFF position.

- Proof test for outputs : This test must be performed to make sure that no outputs are stuck in
ON or OFF position.

- Pulse test for outputs : This test must be performed to make sure that all outputs are capable
of changing state

- Proof test for analog inputs : This test must be performed to make sure that all inputs are
operational and can vary data values.

- Calibrate analog inputs : Each analog inputs shall be calibrated to make sure the accuracy of
the signal.
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2. TRIP SIGNALS TESTING

The maintenance operator have to actuate the following signals and verify that process parameters are
monitored properly and that the system reacts properly when a fault condition arises:

Check that the correct trip appears on the Panel View and on the DCS.
Check that the compressor stops.

The results of the test shall be noted on the corresponding sheet (see appendix 1).

3. PROOF TEST FOR INPUTS

The maintenance operator have to push the “Annual test push button” and verify that no input alarms
appears.

Check that no alarm appears on the Panel View or on the DCS.

The results of the test shall be noted on the corresponding sheet (see appendix 2).

4. PROOF TEST FOR OUTPUTS

The maintenance operator have to push the “Annual test push button” and verify that no output alarms
appears.

Check that no alarm appears on the Panel View or on the DCS.

The results of the test shall be noted on the corresponding sheet (see appendix 3).
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5. PULSE TEST FOR OUTPUTS

The maintenance operator use the RSLOGIX5000 revision 10.0 to perform this test.

Select the I/O configuration menu, then select the outpouts cards (1756-OB16D), the following screen
appears.
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For each output select the “Test” button.

Check that no alarm appears on result column.

The results of the test shall be noted on the corresponding sheet (see appendix 4).

6. PROOF TEST FOR ANALOG IN PUTS

The maintenance operator have to push the “Annual test push button” and verify that no input alarms
appears.

Check that no alarm appears on the Panel View or on the DCS.

The results of the test shall be noted on the corresponding sheet (see appendix 5).
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7. ANALOG INPUTS CALIBRATING

The maintenance operator have to calibrate each SIL2 transmitters.

When all transmitters are calibrated, the operator have to calibrate the analog inputs in the PLC with the
RSLOGIX5000 revision 10.0 software.

Select the I/O configuration menu, then select the analog inputs cards (1756-IF8), the following screen
appears.
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Remove the terminal block from the analog input card and replace it with a spare terminal block.

Wire a 0 / +10 V generator on the followings terminals :


- Terminal 2 (+) & 9 (-) for channel 0
- Terminal 4 (+) & 9 (-) for channel 1
- Terminal 6 (+) & 9 (-) for channel 2
- Terminal 8 (+) & 9 (-) for channel 3
- Terminal 12 (+) & 9 (-) for channel 4
- Terminal 14 (+) & 9 (-) for channel 5
- Terminal 16 (+) & 9 (-) for channel 6
- Terminal 18 (+) & 9 (-) for channel 7

Refers to the ROCKWELL documentation “1756-6.5.9 CONTROLLOGIX Analog I/O modules user
manual” (chapter 11) to operate the calibration (see appendix 7).

The results of the test shall be noted on the corresponding sheet (see appendix 6).
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Name :
Visa :
APPENDIX 1
TRIP SIGNALS TESTING
Date :

DIGITAL INPUTS

Tag Description Results (OK / NOK)


HS258 STOP COMPRESSOR (from LP)
HS261 EMERGENCY SHUTDOWN (FROM LP)
XA252 OIL PUMP FAULT 102 (from MCC)
XA254 OIL PUMP FAULT 103 (from MCC)
XA256 COMPRESSOR FAULT (from MCC)
SPARE
XS-204 TRIP COMPRESSOR (from ESD)
XA257 MONITORING FAILURE (from BENTLY NEVADA)
XA201A COMMON TRIP WITH DEPRESSURISATION (from BENTLY NEVADA)
XA201B COMMON TRIP WITHOUT DEPRESSURISATION (from BENTLY NEVADA)

HS258 STOP COMPRESSOR (from LP)

ANALOG INPUTS

Tag Description Results (OK / NOK)


TT0127 LUBE OIL RESERVOIR TEMPERA TURE

PT0113A LUBE OIL SUPPLY HEADER PRESSURE

PDT0216A SEPARATION GAS PRESSURE

PT0222A SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT (SUCTION SIDE)


SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT (DISCHARGE
PT0223A SIDE)
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Name :
Visa :
APPENDIX 2
PROOF TEST FOR INPUTS
Date :

DIGITAL INPUTS CARD 1

INPUT Tag Description Results (OK / NOK)


INPUT 1 HS258 STOP COMPRESSOR (from LP) (input 1)
INPUT 2 HS261 EMERGENCY SHUTDOWN (FROM LP) (input 1)
INPUT 3 XA252 OIL PUMP FAULT 102 (from MCC) (input 1)
INPUT 4 XA254 OIL PUMP FAULT 103 (from MCC) (input 1)
INPUT 5 XA256 COMPRESSOR FAULT (from MCC) (input 1)
INPUT 6 SPARE (input 1)
INPUT 7 XS-204 TRIP COMPRESSOR (from ESD) (input 1)
INPUT 8 XA257 MONITORING FAILURE (from BENTLY NEVADA) (input 1)
INPUT 9 COMMON TRIP WITH DEPRESSURISATION (from BENTLY
XA201A
NEVADA) (input 1)
INPUT 10 COMMON TRIP WITHOUT DEPRESSURISATION (from BENTLY
XA201B
NEVADA) (input 1)
INPUT 11 SPARE (input 1)
INPUT 12 SPARE (input 1)
INPUT 13 SPARE (input 1)
INPUT 14 SPARE (input 1)
INPUT 15 SPARE (input 1)
INPUT 16 SPARE (input 1)

DIGITAL INPUTS CARD 2

INPUT Tag Description Results (OK / NOK)


INPUT 1 HS258 STOP COMPRESSOR (from LP) (input 2)
INPUT 2 HS261 EMERGENCY SHUTDOWN (FROM LP) (input 2)
INPUT 3 XA252 OIL PUMP FAULT 102 (from MCC) (input 2)
INPUT 4 XA254 OIL PUMP FAULT 103 (from MCC) (input 2)
INPUT 5 XA256 COMPRESSOR FAULT (from MCC) (input 2)
INPUT 6 SPARE (input 2)
INPUT 7 XS-204 TRIP COMPRESSOR (from ESD) (input 2)
INPUT 8 XA257 MONITORING FAILURE (from BENTLY NEVADA) (input 2)
INPUT 9 COMMON TRIP WITH DEPRESSURISATION (from BENTLY
XA201A
NEVADA) (input 2)
INPUT 10 COMMON TRIP WITHOUT DEPRESSURISATION (from BENTLY
XA201B
NEVADA) (input 2)
INPUT 11 SPARE (input 2)
INPUT 12 SPARE (input 2)
INPUT 13 SPARE (input 2)
INPUT 14 SPARE (input 2)
INPUT 15 SPARE (input 2)
INPUT 16 SPARE (input 2)
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Name :
Visa :
APPENDIX 3
PROOF TEST FOR OUTPUTS
Date :

DIGITAL OUTPUT CARD 1

INPUT Tag Description Results (OK / NOK)


OUTPUT 1 HS265 STOP OIL PUMP 102 (to MCC)
OUTPUT 2 HS267 STOP OIL PUMP 103 (to MCC)
OUTPUT 3 HS269 STOP COMPRESSOR (to MCC)
OUTPUT 4 FY203 QUICK OPEN ANTI-SURGE VALVE
OUTPUT 5 XA270 CUT OUT POWER SUPPLY OUTPUT CARD 2
OUTPUT 6 SPARE
OUTPUT 7 SPARE
OUTPUT 8 SPARE
OUTPUT 9 SPARE
OUTPUT 10 SPARE
OUTPUT 11 SPARE
OUTPUT 12 SPARE
OUTPUT 13 SPARE
OUTPUT 14 SPARE
OUTPUT 15 SPARE
OUTPUT 16 SPARE

DIGITAL OUTPUTS CARD 2

INPUT Tag Description Results (OK / NOK)


OUTPUT 1 XA271 CUT OUT POWER SUPPLY OUTPUT CARD 1
OUTPUT 2 XA272 CUT OUT POWER SUPPLY INPUT CARD 1
OUTPUT 3 XA273 CUT OUT POWER SUPPLY INPUT CARD 2
OUTPUT 4 SPARE
OUTPUT 5 SPARE
OUTPUT 6 SPARE
OUTPUT 7 SPARE
OUTPUT 8 SPARE
OUTPUT 9 SPARE
OUTPUT 10 SPARE
OUTPUT 11 SPARE
OUTPUT 12 SPARE
OUTPUT 13 SPARE
OUTPUT 14 SPARE
OUTPUT 15 SPARE
OUTPUT 16 SPARE
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Name :
Visa :
APPENDIX 4
PULSE TEST FOR OUTPUTS
Date :

DIGITAL OUTPUT CARD 1

OUTPUT Tag Description Results (OK / NOK)


OUTPUT 1 HS265 STOP OIL PUMP 102 (to MCC)
OUTPUT 2 HS267 STOP OIL PUMP 103 (to MCC)
OUTPUT 3 HS269 STOP COMPRESSOR (to MCC)
OUTPUT 4 FY203 QUICK OPEN ANTI-SURGE VALVE
OUTPUT 5 XA270 CUT OUT POWER SUPPLY OUTPUT CARD 2
OUTPUT 6 SPARE
OUTPUT 7 SPARE
OUTPUT 8 SPARE
OUTPUT 9 SPARE
OUTPUT 10 SPARE
OUTPUT 11 SPARE
OUTPUT 12 SPARE
OUTPUT 13 SPARE
OUTPUT 14 SPARE
OUTPUT 15 SPARE
OUTPUT 16 SPARE

DIGITAL OUTPUTS CARD 2

OUTPUT Tag Description Results (OK / NOK)


OUTPUT 1 XA271 CUT OUT POWER SUPPLY OUTPUT CARD 1
OUTPUT 2 XA272 CUT OUT POWER SUPPLY INPUT CARD 1
OUTPUT 3 XA273 CUT OUT POWER SUPPLY INPUT CARD 2
OUTPUT 4 SPARE
OUTPUT 5 SPARE
OUTPUT 6 SPARE
OUTPUT 7 SPARE
OUTPUT 8 SPARE
OUTPUT 9 SPARE
OUTPUT 10 SPARE
OUTPUT 11 SPARE
OUTPUT 12 SPARE
OUTPUT 13 SPARE
OUTPUT 14 SPARE
OUTPUT 15 SPARE
OUTPUT 16 SPARE
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Name :
Visa :
APPENDIX 5
PROOF TEST FOR
Date :
ANALOG INPUTS

ANALOG INPUTS CARD 1

INPUT Tag Description Results (OK / NOK)


INPUT 1 TT0127 LUBE OIL RESERVOIR TEMPERATURE (input 1)
INPUT 2 PT0113A LUBE OIL SUPPLY HEADER PRESSURE (input 1)
INPUT 3 PDT0216A SEPARATION GAS PRESSURE (input 1)
INPUT 4 SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT
PT0222A (SUCTION SIDE) (input 1)
INPUT 5 SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT
PT0223A (DISCHARGE SIDE) (input 1)
INPUT 6 SPARE
INPUT 7 SPARE
INPUT 8 SPARE

ANALOG INPUTS CARD 2

INPUT Tag Description Results (OK / NOK)


INPUT 1 TT0127 LUBE OIL RESERVOIR TEMPERATURE (input 2)
INPUT 2 PT0113B LUBE OIL SUPPLY HEADER PRESSURE (input 2)
INPUT 3 PDT0216B SEPARATION GAS PRESSURE (input 2)
INPUT 4 SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT
PT0222B (SUCTION SIDE) (input 2)
INPUT 5 SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT
PT0223B (DISCHARGE SIDE) (input 2)
INPUT 6 SPARE
INPUT 7 SPARE
INPUT 8 SPARE
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Name :
Visa :
APPENDIX 6
CALIBRATING FOR
Date :
ANALOG INPUTS

ANALOG INPUTS CARD 1

Transmitters Software
INPUT Tag Description calibration calibration
(OK / NOK) (OK / NOK)
INPUT 1 TT0127 LUBE OIL RESERVOIR TEMPERATURE (input 1)
INPUT 2 PT0113A LUBE OIL SUPPLY HEADER PRESSURE (input 1)
INPUT 3 PDT0216A SEPARATION GAS PRESSURE (input 1)
INPUT 4 SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT
PT0222A (SUCTION SIDE) (input 1)
INPUT 5 SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT
PT0223A (DISCHARGE SIDE) (input 1)
INPUT 6 SPARE
INPUT 7 SPARE
INPUT 8 SPARE

ANALOG INPUTS CARD 2

Transmitters Software
INPUT Tag Description calibration calibration
(OK / NOK) (OK / NOK)
INPUT 1 TT0127 LUBE OIL RESERVOIR TEMPERATURE (input 2)
INPUT 2 PT0113B LUBE OIL SUPPLY HEADER PRESSURE (input 2)
INPUT 3 PDT0216B SEPARA TION GAS PRESSURE (input 2)
INPUT 4 SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT
PT0222B (SUCTION SIDE) (input 2)
INPUT 5 SEAL GAS PANEL PRESSURE DEPRESSURIZATION UNIT
PT0223B (DISCHARGE SIDE) (input 2)
INPUT 6 SPARE
INPUT 7 SPARE
INPUT 8 SPARE
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APPENDIX 7

CALIBRATION FOR ANALOG INPUT CARD


DOCUMENTATION
Chapter 11

Calibrating the ControlLogix Analog


I/O Modules

What This Chapter Contains This chapter describes how to calibrate ControlLogix analog
modules. The following table describes what this chapter contains
and its location.
For information about: See page:
Difference Between Calibrating An Input 11-2
Module and Calibrating An Output Module
Calibrating Input Modules 11-3
Calibrating the 1756-IF16 11-3
or 1756-IF8 Modules
Calibrating the 1756-IF6I Module 11-7
Calibrating the 1756-IR6I Module 11-12
Calibrating the 1756-IT6I Module 11-15
Calibrating Output Modules 11-18
Calibrating the 1756-OF6CI Module 11-18
Calibrating the 1756-OF6VI Module 11-22
Calibrating the 1756-OF4 11-26
or 1756-OF8 Modules
Chapter Summary and What’s Next 11-30
Your ControlLogix analog I/O module comes from the factory with a
default calibration. You may choose to recalibrate your module to
increase its accuracy for your specific application.
This chapter is broken into two sections, calibrating input modules
and calibrating output modules.
You do not have to configure a module before you calibrate it. If you
decide to calibrate your analog I/O modules first, you must add them
to your program. To see how to add a new module to your program,
see page 10-4.
Important: Analog I/O modules can be calibrated on a channel by
channel basis or with the channels grouped together.
Regardless of which option you choose, we recommend
you calibrate all channels on your module each time you
calibrate. This will help you maintain consistent
calibration readings and improve module accuracy.

Calibration is meant to correct any hardware inaccuracies


that may be present on a particular channel. The
calibration procedure compares a known standard, either
input signal or recorded output, with the channel’s
performance and then calculating a linear correction
factor between the measured and the ideal.

The linear calibration correction factor is applied on


every input or output same to obtain maximum accuracy.

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11-2 Calibrating the ControlLogix Analog I/O Modules

Difference Between Calibrating Although the purpose of calibrating analog modules is the same for input
An Input Module and and output modules, to improve the module’s accuracy and repeatability, the
Calibrating An Output Module procedures involved differs for each.
When you calibrate input modules, you use current, voltage or ohms
calibrators to send a signal to the module to calibrate it.

When you calibrate output modules, you use a digital multimeter (DMM) to
measure the signal the module is sending out.

To maintain your module’s accuracy specifications, we recommend you use


calibration instruments with specific ranges. The following table lists the
recommended instruments for each module.

Table 11.A
Recommended Calibration Instruments for ControlLogix Analog Modules
Modules: Recommended instrument ranges:
1756-IF16 & 1756-IF8 0 to 10.25V source +/-150µV Voltage
1756-IF6I 0 to 10.00V source +/-150µV Voltage
1.00 to 20.00mA source +/-0.15µA Current
1756-IR6I 1.0 and 487.0Ω resistors1 +/-0.01%
1756-IT6I -12mV to 78mV source +/-0.3µV
1756-OF4 & 1756-OF8 DMM better than 0.3mV or 0.6µA
1756-OF6VI DMM with resolution better than 0.5mV
1756-OF6CI DMM with resolution better than 1.0µA
1
We suggest you use the following precision resistors:
KRL Electronics
534A1-1R0T 1.0 Ohm 0.01% / 534A1-487R0T 487 Ohm 0.01%
A precision decade resistor box can also be used that meets or exceeds the required
accuracy specifications. The user is responsible for assuring that the decade box
maintains accuracy by periodic calibration as specified by the following vendors:
Electro Scientific Industries IET Labs Julie Research Labs
Portland, OR Westbury, NY New York, NY
Series DB 42 HARS-X Series DR100 Series

Calibrate in Either Program or Run Mode


You must be online to calibrate your analog I/O modules. When you are
online, you can choose either Program or Run Mode as the state of your
program during calibration. We recommend the module not be actively
controlling a process when you calibrate it.
Important: The module will freeze the state of each channel and will not
update the controller with new data until after calibration ends.
This could be hazardous if active control were attempted during
calibration.
We recommend that you change your controller to Program Mode before
beginning calibration.

Use this pull-down menu to


change to Run or Program Mode.

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Calibrating the ControlLogix Analog I/O Modules 11-3

Calibrating Input Modules Input calibration is a multi-step process that involves multiple services
being sent to the module. This section has three parts. Each input module
requires attention be paid to specific calibration ranges.

Calibrating the 1756-IF16 or 1756-IF8 Modules

This module can be used for applications requiring voltage or current. You
can only calibrate the module using a voltage signal.

The 1756-IF16 and 1756-IF8 offer 4 input ranges:

• -10 to 10V
• 0 to 5V
• 0 to 10V
• 0 to 20mA

Important: Regardless of what application range is selected prior to


calibration, all calibration uses a +/-10V range.

While you are online, you must access the modules’ properties page. To see
how to reach this page, see page 10-19.

Follow these steps:

1. Connect your voltage calibrator to the module.

2. Go to the Calibration page. (Click on the tab for this page.)

Click here to
start calibration

You see this warning.

Click here to continue calibration with the Click here to change to Program Mode be-
channels frozen at their current values fore continuing with calibration

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11-4 Calibrating the ControlLogix Analog I/O Modules

3. Set the channels to be calibrated.

1. Choose the channels you


want to calibrate here

2. Choose whether you want


to calibrate channels in
groups or one at a time here

3. Click here to continue

The low reference screen appears first.

This screen shows which


channels will be calibrated
for a low reference and the
range of that calibration.

It also shows what refer-


ence signal is expected on
the input.

Click here to return to the last screen Click here to calibrate


and make any necessary changes the low reference

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Calibrating the ControlLogix Analog I/O Modules 11-5

4. Set the calibrator for the low reference and apply it to the module.

This screen displays the status of each channel after calibrating for a low
reference. If all channels are OK, continue, as shown below. If any
channels report an Error, retry Step 5 until the status is OK.

Click here to continue

5. Set the calibrator for the high reference and apply it to the module.

This screen shows which


channels will be calibrated
for a high reference and the
range of that calibration.

It also shows what refer-


ence signal is expected at
the input.

Click here to calibrate


the high reference

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11-6 Calibrating the ControlLogix Analog I/O Modules

This screen displays the status of each channel after calibrating for a high
reference. If all channels are OK, continue, as shown below. If any
channels report an Error, retry Step 6 until the status is OK.

Click here to continue

After you have completed both low and high reference calibration, this
screen shows the status of both.

Click here to finish calibration and re-


turn the module to normal operation

Publication 1756-6.5.9 - November 1998