AD090213-QMS-2013 REV.

FLOW TEST PROCEDURE (CONDENSATE)

TABLE OF CONTENT

1.0

INTRODUCTION

2.0

SCOPE

3.0

RELATED DOCUMENTS

4.0

PRE-REQUISITE REQUIREMENT

5.0

TEST SETUP

6.0

PREPARATION

7.0

PROCEDURE

8.0

ATTACHMENT

Transwater API Sdn. Bhd. Confidential & Proprietary

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FLOW TEST PROCEDURE (CONDENSATE)

1.0

INTRODUCTION

Integrated testing of the metering control panel consisting of flow computers, PLC system etc with the skid mounted instruments shall be carried out once the testing of individual instruments are completed. Water shall be circulated through the metering and proving skid and functionality of the entire metering system shall be tested.

The purpose of this test to ensure the functionality of the metering and proving system as a whole as well as to demonstrate the repeatability and linearity of the metering system by proving method.

2.0

SCOPE

This procedure applies to the manner by which flow test is conducted for Condensate Metering Skid for Kinabalu NAG Development Project.

Items listed below are not governed under the scope of this procedure as they have a separate procedure to determine their functionality: Pressure Transmitter Temperature Transmitter Density meter Auto-sampling

Refer to Section 6.7 (Test Result) for detail.

3.0

RELATED DOCUMENTS

AD090213-PIP-2001 AD090213-SYS-0001 AD090213-SYS-0007 AD090213-INS-2001 AD090213-MEC-2002 AD090213-MEC-2003 AD090213-INS-2002

Piping and Instrumentation Diagram (Condensate) System Block Diagram/ Architecture Detailed Functional Design Specification Cable Schedule (Condensate) General Arrangements Drawings (Condensate) Equipment Layout (Condensate) Electrical/ Instrumentation Wiring Drawings (Condensate)

AD090213-INS-2003 AD090213-INS-2018 AD090213-INS-2019

Transwater API Sdn. Bhd. Confidential & Proprietary

Junction Box Termination Drawings (Condensate) Instrument Hook-Up (Condensate) Instrument Loop Drawings (Condensate)
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FLOW TEST PROCEDURE (CONDENSATE)

AD090213-SYS-0002 AD090213-SYS-0003 AD090213-CMM-0003

Functional Block Diagram MMI Graphics User Operating Manual System Package

4.0

PRE REQUISITE REQUIREMENTS

Prior to start of Flow test, all the criteria below shall have to be met: a) Flow test procedure must have been approved by PCSB b) Functional test shall be conducted on all individual skid equipment inclusive of mechanical, instrument and computing system. c) Full integration of all equipments in the field with the supervisory control panel must have been completed. d) Visual inspection shall be performed on the completed skid prior to flow introduction. All visible problems shall be fixed before starting the flow test.

5.0

TEST SETUP

The flow set up at the flow rig located at Tepat Teknik Sdn. Bhd. yard, fabricator for Transwater API, has a pump pumping water from a tank. The water is flown through the skid and back to the tank to create a close loop. The test is performed to ensure the functionality of the metering system along with the prover skid. A simple schematic for the flow set up is shown below in Figure 1.

Water will be fed from the open top water tank to the test line by means of a water pump as

presented in schematic diagram below.

Open Tank

Metering Stream under test with prover

Pump

Figure 1
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6.0

PREPARATION

The flow test requires the following preparatory work before the test can be performed.

1. Locate the required stream on metering skid, and the respective Flow Computer at Metering Cabinet which is inside an air conditioned cabin. 2. Set up the metering and prover skid (Connect tank outlet to pump inlet, pump discharge to skid inlet and outlet of skid to the tank inlet) as shown in Figure 1. 3. Wire up the instruments on the skids to the Metering Cabinet by temporarily interconnecting cables between the skid junction boxes and Metering Cabinet. 4. The metering skid is purged by dry N2 gas at 50 psi prior to the in-house flow test. 5. Water used for testing shall be treated water to minimize corrosion effect. Chlorine content should be below 50 ppm. 6. Ensure appropriate electrical connections are made and isolation provided for pump, prover hydraulic motor and motor operated valves. 7. Instrument air is available and pneumatic connections are made available for Flow Control Valve minimum pressure of 4.2 barg is available during test.

7.0

PROCEDURE

7.1

Test medium

Water is to be used as the test medium for the flow test.

7.2

Testing Envelope

Flow tests will be conducted as per design data below: Fluid flow rate : 10 to 183.93 m3/ hour

The test shall be carried out within below flow envelope or any where near the value specified below: No. 1 2 3 4 5 Flow Setting (%) 20 40 60 80 100 Estimated Liquid Flowrate (m3/hour) 37 74 111 147 184

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7.3

Flow Test

Once the preparation is done and proper connections are ensured, the stream is filled up with holding volume of water by separate water hose.

The power to the Metering Cabinet is switched on and the signals from the instruments are made sure are received at the Metering Cabinet by the flow computer.

Power to the motor operated valves is switched on and MOV are functioning from PLC. Instrument air is available for Flow Control Valve. Crack open the Control valve from the flow computer. The inlet and outlet motor operated valves (MOV) on the respective streams are opened for stream -1 and closed for stream-2. When needed, the prover take off and prover return valves shall be operated from PLC.

Ensure alignment of valves is as per desired and correct positions. The supply to the pump is switched on. The pump starts flow the water through the skid and prover. Vent out any air in the metering and prover skids through the vent connections provided. The water is also made to flow through the prover by opening the bypass valve. The flow rate of water can be monitored from the metering cabinet through the turbine meter attached to stream 1 or 2, where applicable.

Once the water starts flowing continuously and the actual flow can be varied by adjusting the current supplied to the pump at 20%, 40%, 60%, 80% and 100% of stream normal flow rate. For this purpose, a frequency inverter shall be installed together with the pump.

Check instrument reading on local display of instrument and at respective flow computer and back up computer.

Individual instrument reading are checked at the local display on the instrument with the values at the respective flow computers.

Functionality check for MOV shall be done manually (by hand), remotely (from MMI) and locally. MOVs functional test could also be done prior to introduction of water into metering stream.

Functionality check for FCV shall be done by controlling the valve opening at 0%, 25%, 50%, 75% and 100% from MMI. Valve failure shall be simulated by isolating instrument air supply or power to the FCV. The valve should open once the air or power supply is isolated in order to pass the Fail Open requirement. FCVs functional test could also be done prior to introduction of water into metering stream.

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7.4

Batching operation

Check and ensure that all the field instruments like PT, DPT, TT, FV, MOV etc of the metering skid are integrated well with the metering panel and all field parameters are displayed correctly in the HMI.

Water shall be circulated through the metering system to establish steady flow though the system.

Perform the batching operation as described in the approved function design specification (AD090213-SYS-0007).

7.5

Proving operation

While batching operation is under progress; perform the proving operation as described in the approved functional design specification to check the functionality of the system. Proving operation shall be checked at min, normal & four equi-spaced flow points in between flow rate. Proving report generation and printing, Meter Factor down loading etc shall be checked. 7.6 Test Certificate for Integrated Functional Test

Upon completion of the integrated functional test, the result sheet shall be completed and signed by parties. Proving linearity and repeatability shall be shown in proving report generated by MMI and all related parties shall acknowledge the accepted result and sign on the report. Note: After flow test water shall be drained and the preservations shall be done to avoid corrosion to all internals. All connection and entries shall be sealed to prevent subsequent ingress of moisture and dirt.

7.7

Test Results

Instruments below will be subjected to a separate validation test which will be regarded as their functionality test. Validation test will be conducted prior to the flow test. Thus, the detail test result for these instruments will be presented in a separate report. The instruments involved are:

Pressure Transmitter Temperature Transmitter Density meter

Auto-sampling functional test will be conducted separately and the report will be done by the sampling system vendor (Exact Alliance) and will be submitted separately.
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FLOW TEST PROCEDURE (CONDENSATE)

The functionality of each item below shall be determined during proving. Should all the meter factor, linearity and repeatability of the proving result meets the criteria, all of these items shall be considered to have passed their respective functionality test. The instruments involved are:

Turbine Meter Compact Prover Flow Computer MMI Panel Power Consumption

Proving report shall be printed out using the MMI, and all required calculations shall be shown to PCSB and to be printed on a formal report. The report shall be required to show the linearity and repeatability of the system.

Functionality of items below will be recorded in test acceptance form as per Attachment 1:

Motor Operated Valve Flow Control Valve

8.0

ATTACHMENT

ATTACHMENT 1 Functional Test Result Sheet

Transwater API Sdn. Bhd. Confidential & Proprietary

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FLOW TEST PROCEDURE (CONDENSATE)

ATTACHMENT 1 Functionality Test Result Sheet

Transwater API Sdn. Bhd. Confidential & Proprietary

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FLOW TEST PROCEDURE (CONDENSATE)

Client Project

: :

Date

i) No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ii) No 1 2 3

Motor Operated Valves Details MOV 3200A MOV 3200B MOV 3201A MOV 3201B MOV 3202A MOV 3202B MOV 3210A MOV 3210B MOV 3211A MOV 3211B MOV 3212A MOV 3212B MOV 3220A MOV 3220B Flow Control Valves Details FCV 3200 FCV 3210 FCV 3220 Valve Position 100% 75% 50% 25% 0% Valve Fail Manual Stroke Open Close Local operation Open Close Remote operation Open Close

VERIFICATION CONTRACTOR (TRANSWATER API)

Representative:

CLIENT
Representative:

Name: Date:

Name: Date:

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