r-as0010-qa-proc-7036 cfu factory acceptance test procedurer_1

8/13/2019 R-As0010-Qa-proc-7036 Cfu Factory Acceptance Test Procedurer_1

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CLIENT : BLACK GOLD OIL & GAS (BGOG)

PROJECT : SAMARANG REDEVELOPMENT PHASE-2

PRODUCED WATER TREATMENT PACKAGE

DOCUMENT TITLE : CFU FACTORY ACCEPTANCE TEST PROCEDURE

CAMERON DOCUMENT NO : R-AS0010-QA-PROC-7036

CLIENT DOCUMENT NO : SMP-C-QA-CAM-0010

TAG NO. : A - 400

1 Issued for Review 16-May-2013 JH THK CS

Rev Description Date By Checked Approved

Process SystemsCameron (Singapore) Pte Ltd

No. 2 Gul Circle, Jurong Industrial EstateSingapore 629560, Tel: +65 6861 3355

PROJECT NO. R-AS0010

PO NO. BGO&G.PO/139/12

SHEET 1 OF 19



CFU FACTORY ACCEPTACE TEST PROCEDURE

Document No.: SMP-C-CAM-0010Rev.: 1

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Cameron (Singapore) Plt LtdA Subsidary of Cameron International Corporation2 Gul Circle, Jurong Industrial EstateSingapore 629560

CONTENTS

1.0 INTRODUCTION ...................................................................................... 3 2.0

INTENT ..................................................................................................... 4

3.0 PROBLEM REPORT/PUNCH LIST .......................................................... 4

3.1 RECORDING PROBLEM OBSERVATION .............................................................. 4 3.2 REPORT TYPES ..................................................................................................... 4 3.3 ACTION CATEGORIES ........................................................................................... 4 3.4 SCREENING BODY ................................................................................................ 4 3.5 COMPLETION OF THE PUNCH LIST ..................................................................... 5

4.0 FAT LOCATION ....................................................................................... 5 5.0 PREPARATION ........................................................................................ 6 6.0 TEST PROCEDURE ................................................................................. 6 PART I - MECHANICAL COMPLETION ........................................................... 7

6.1 CFU VESSELS ........................................................................................................ 8 6.2 STRUCTURE ........................................................................................................... 9 6.3 PIPING ................................................................................................................... 10 6.4 TUBING ................................................................................................................. 10

PART II - E&I COMPLETION AND TESTING ................................................. 12 6.5 INSTRUMENT INSTALLATION & TESTING ......................................................... 13

6.5.1 Instrument Air Distribution System ............................................................................... 13 6.5.2 Automated Shutdown Valve ......................................................................................... 14 6.5.3 Pressure Control Valve ................................................................................................ 15 6.5.4 Pressure Transmitter .................................................................................................... 16 6.5.5 Flow Indicator ............................................................................................................... 16 6.5.6 Pressure Indicator ........................................................................................................ 17 6.5.7 Level Gauge & Level Switch ......................................................................................... 17

7.0 ATTACHMENT ....................................................................................... 19





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1.0 INTRODUCTION

This document describes the testing procedures for the final inspection and function testing of

the CFU skid at the fabricator’s premise (PVDT) prior to delivery. The objective is to verify

equipment conformance to the approved Technical Drawings, Technical Datasheet and

Specifications contained in the project.

Inspections will be carried out in line with the Project Inspection and Test plans and referenceto those will be made during the final inspection.

Functional testing of instruments will be carried out in line with contract requirements but,

unless agreed otherwise, this will not be regarded as a full pre commissioning operation.

Certain instruments and valving that form part of the unit will be function and calibration tested

by the manufacturers prior to goods dispatch. Therefore documentation from these tests (if

applicable) together with the Manufacturer Data Record shall be made available during the

FAT. It’s up to the inspector’s discretion to conduct random check if required.

A full detailed P & ID check shall precede the functional testing.

During the course of Inspection and testing, issues requiring correction or attention will berecorded on a Punch list for later agreement and closing out

On completion of the Inspection and testing this Document will be signed by all parties.Signing off of the document will either give unconditional or conditional acceptance asreferenced in the final section. Conditional acceptance may be given whilst referring todocumentation or punch list items needing to be addressed and closed out.

It is the responsibility of the Cameron Representative to carry out the inspections prior to theClient unless otherwise agreed.

Irrespective of Client internal procedures, Cameron will always maintain its own punch list andwill add to that any Client or Third Party issues which have been agreed.

Where there is a dispute as to the validity of any punch list item, this will be recorded but notedthat it has to be confirmed and agreed. These items will be referred back to the ProjectManager for resolution with Client.

The final punch list accompanying the package to site will reference its latest revision status

and only those items still outstanding will be recorded. All previously closed out items will bedeleted.

Reference Documents:

Purchase Order from Black Gold: BGO&G.PO/139/12

Vendor Documentation Master List: R-AS0010-PM-LIST-1001

Piping & Instrumentation Diagram: R-AS0010-PR-PIDR-1101

Compact Flotation Skid General Piping & Equipment Arrangement Plan, Section &

Isometric View: R-AS0010-ME-GADR-2000

Isometric Shop Drawings: R-AS0010-PI-ISDR-6004

Instrument Hook-Up Drawing: R-AS0010-IN-ECDR-3004





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2.0 INTENT

This procedure describes in detail the requirements for checking mechanical completion of

components and instrument functionality against the project specifications before delivery.

3.0 PROBLEM REPORT/PUNCH LIST

3.1 RECORDING PROBLEM OBSERVATION

Any hardware problem or deviations observed during testing shall be recorded in a Problem

Report or Punch List throughout the FAT (Refer Form F-12 attached).

The Punch List will be screened for action approval as stated below.

3.2 REPORT TYPES

Before hardware is modified there must be an agreement as to whether the modification is a

result of a fault or represents a change in specification. Problem Report / Punch List will

therefore fall into one of three types.

Comments

Minor problem due to technical fault

Faults

Hardware fault not meeting the project specification.

Engineering Change Request

Change from the project specification as accepted by the Client.

3.3 ACTION CATEGORIES

Each item on the Punch List will be assigned one of the three action categories.

Category

1: Action to be taken.

2: Requires design review before implementation.

3: No immediate action to be taken, action or remark during installation.

3.4 SCREENING BODY





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A screening body consists of representative from Client and Contractor as minimum to screen

the punch list.

The screening body will carry out the following functions:

1. Decide the type of the problem punch list, e.g. comments, fault or engineering change

request.

2. Assign an action category to a punch list.

- For items classified as category 2, the Screening Body will delegate any required

investigations to the representatives with an agreed date for completion.

- Technical queries under category 2 raised by the Contractor representative will be

considered by the Screening Body and if the item is to be implemented it will be givena category 1 status (the change in status of a Problem Report can only be altered by

the Screening Body). During FAT, problems identified will be dealt with on a daily

basis, when possible.

3. To append approval signature to a Punch List for action complete.

4. To issue an action punch list.

NOTE 1: Only category 1 status Punch List will be implemented.

NOTE 2: No changes should be made until agreement is reached on the responsibility

for commercial impact of the punch list if applicable.

3.5 COMPLETION OF THE PUNCH LIST

When a problem/deviation is corrected to clear a Problem Punch List, a note must be made on

the Problem Report / Punch List to state which items have been modified.

As stated above, Punch List with a fault type and action category 1 must be fixed during the

FAT. The engineering team at Cameron/PVD Tech will be on standby for this purpose.

When the Problem Report is of a more severe nature, the screening body and therepresentatives of the client must agree on a date before which the problem is to be fixed.

Both the client and the project manager must approve for verification of the correctness of

functioning of the system, in relation to the Problem Report. This would be before shipment, or

at an agreed alternative date.

4.0 FAT LOCATION

The FAT for Compact Flotation Unit – A-400 packages will be performed at PVD Tech’ Work

Shop.





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PVD Trading and Technical Services J.S.CFabrication Yard Address:

Dong Xuyen Industrial Zone, Vung Tau City, Vietnam

5.0 PREPARATION

An in house FAT shall be conducted and completed by Cameron/PVD Tech before the actual

FAT with client witness. This is to ensure everything that is needed during the FAT is available

and allows a pre-screening of punch list.

The following documents are to be considered during the preparation stage:

The MDR, individual FAT Report of all component parts (Free Issue Items by Cameron)

shall be available.

ITP, drawings and procedures have the relevant approvals.

The MDR, Test Report under PVD Tech’s scope of work such as CFU Vessel, Piping,

Structure.

Inspection Check List Record, Punch List Form (F01-F10);

Tools and Measure Device;

Other

6.0 TEST PROCEDURE

In general, all equipment, instrument, piping, structure which are shown on P&ID and Package

General Arrangement shall be checked for correctness in terms of function and installation as

well as completion during the FAT.

The FAT will divide to two main parts include:

PART 1: MECHNICAL COMPLETION

PART 2: E&I COMPLETION

NOTE: In case of items which need to be extra checked or missed in this document. We will use the

backup Inspection Checklist Record as per Form-12 to manual fill and signed off during handle FAT.





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PART I - MECHANICAL COMPLETION





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6.1 CFU VESSELS

The Mechanical Completion Inspection of the Compact Flotation Vessels is performed using

the P&ID, General Arrangement Drawing, and Details Fabrication Drawings. The following

check points for Vessels will be taken in account during conduct of FAT. Details from the

check points will be compiled with relevant information and signed off by parties at the end.

Refer to Form F-01 be attached at the end of this document

No. Check Point Action

1 Documentation

Check Manufacturing Data Record which fabrication at the PVD Tech

including:

- Check Material Certificates Record

- Welding Inspection Record

- NDT Record including PMI Testing Record

- Pickling & Passivation Record

- Painting Record

- Hydro Test Record

- Final Dimension Record

- Lifting Device Certificates

- U-stamp Certificate

- Third Party Certificate

- As Built DWG

2 Check Components

Check exterior components have been properly fabricated &

completed.

- Conform to CFU Vessel V-400A GA DWG: SMP-C-ME-0002;- Conform to CFU Vessel V-400B GA DWG: SMP-C-ME-0008;

- Conform to Details DWG for Vessel V-400 A: SMP-C-ME-

0003;

- Conform to Details DWG for Vessel V-400 A: SMP-C-ME-

0009;

3 Alignment Check Check equipment has been installed and aligned properly.

3Verify Interface

Connections

Check interface connection include interface connection nozzles,

Dimension interface for mounting of vessel.

4Visual Inspection for

PaintingCheck application of paint without damage.

5 Name Plate Check properly information on name plate. Conform to DWG: Nameplate Drawing: SMP-C-ME-0003 /SMP-C-ME-0009;

6 Earthing Lugs Check Earthing lugs have properly installed.

7 Lifting SetCheck lifting device including Sling, Shackle and corresponding

Testing Certificates.

Following Basic Drawings to be used during inspection of CFU Vessels:

- P&ID: SMP-C-PR-0001

- Datasheet: SMP-C-ME-007

- Vessels GA Drawings: SMP-C-ME-0002/ SMP-C-ME-0008;

- Vessel Details Drawings: SMP-C-ME-0003/ SMP-C-ME-0009;





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Note that all internal parts shall be excluded from this FAT procedure, Cameron bear full

responsibility for these items due to confidentiality and performance warranty agreements.

6.2 STRUCTURE

The structure for Compact Flotation Unit skid includes:

- Base Frame- Access Platform, Handrail & Ladder- Drip Pan- Piping Support- Equipment Support- Instrument Support

The following major checking points will be taken to account during conduct FAT. For more

details refer to Form F-02 attached at the end of this document

No. Check Point Action

1

Check Components,

General Dimension &

Installation Location

Check components have completed fabrication and installation.

Correct dimension and location

- Base Frame conform to General Arrangement DWG – Structure

Frame: SMP-C-ST-0031;

- Platform conform to General Arrangement DWG – Platform:

SMP-C-ST-0032;

- Handrail conform to General Arrangement DWG – Handrail:

SMP-C-ST-0033;

- Grating conform to General Arrangement DWG – Grating: SMP-

C-ST-0034;

- Drip Pan conform to Detail Structure DWG for Drip Pan: SMP-C-

ST-0042;

- Equipment Support conform to CFU Equipment support details:

SMP-C-ST-0041;

- Lifting Device conform to CFU Lifting Arrangement DWG: SMP-

C-ST-0040;

- Pipe Support conform to Pipe Support Location & Detail DWG:

SMP-C-P-0530;

2

Visual Inspection for

Painting &

Galvanization

Check painting & galvanization according to spec requirements

3 Earthing Check required earthing has properly installed.

Following Basic Drawings to be used during inspection of Structure:

- General Arrangement DWG – Structure Frame: SMP-C-ST-0031;

- General Arrangement DWG – Platform: SMP-C-ST-0032;

- General Arrangement DWG – Handrail: SMP-C-ST-0033;

- General Arrangement DWG – Grating: SMP-C-ST-0034;

- Detail Structure DWG for Drip Pan: SMP-C-ST-0042;





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- CFU Equipment support details: SMP-C-ST-0041;

- CFU Lifting Arrangement DWG: SMP-C-ST-0040;

- Pipe Support Location & Detail DWG: SMP-C-P-0530;

6.3 PIPING

In general, the following major check points will be taken in account during conduct FAT for

these connections. For more details refer to Form F-03 attached at the end of this document

No. Test Action

1 Documentation

Check Manufacturing Data Record (Welding Map, Material InspectionReport, Welding Report, NDE Report, Dimensions Check Record,Hydrostatic Test Report, Flushing, Cleaning & Drying Report, SandBlasting & Painting Report, Leak Test Report, Flange management,Certificate for Valves & Accessories)

2 Check Components

Inspection product to ensure that fabrication & Installation completedC/W DWGs and specification approved.

- Part List Check- Vent- Drain- Support Location- Manual valves installed correctly, tagged and can be

operated freely.

- Tag. Name- Flow Code- Blind Ends- Bolt Tightening- Cleaning & Drying- Painting- End closed (if applicable)

3Installation Location,

Sequence & Alignment

Verify general dimensions, Installation Location, Sequence of

Installation and Alignment including

- Check interface for connection of instrument and Tie-in point.

- Check pipe support installed.

Following Basic Drawings to be used during inspection of Piping

- Piping & Instrumentation Diagram (PID): SPM-C-PR-0001

- Package GA Drawing: SPM-C-ME-001

- Pipe Support Location & Detail DWG: SMP-C-P-0530;

- Piping Isometric DWG: SMP-C-P-0502;

6.4 TUBING

The tubing work includes:

- Sample system;





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- Supply instrument air to instruments;

- Close Drain for Level Gauges;

The following major check points will be taken in account during FAT. For more details refer to

Form F-04 attached at the end of this document

No. Test Action

1 Documentation Check Certificates for Tube, Fittings and connectors

2Installation Location,

Sequence & Alignment

Verify general dimensions, Installation Location, Sequence of

Installation and Alignment including

- Check component and connection to instrument

- Check pipe supports are installed

Following Basic Drawings to be used during inspection of Tubing


- Package GA Drawing: SPM-C-ME-001





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PART II - E&I COMPLETION AND TESTING





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6.5 INSTRUMENT INSTALLATION & TESTING

Confirm the instrument installation, hook up is properly completed and function tested in

accordance with latest project approved documents and that all closed out items of punch

listing have been reviewed and passed as satisfactory. In general all instruments shall be

checked and verified during FAT, refer to instrument list “SPM-C-I-9501” to be taken to

account.

6.5.1 Instrument Air Distribution System

Before instruments are function tested, the instrument air distribution system on the skid shall

be commissioned to make sure the air supply is clean without dust and debris. After that the

air supply output can be adjusted by the regulator to suit the instrument requirements.

The following steps to clean the instrument air distribution system shall be completed:

Connect a 7 barg (100 psig) clean dry instrument air supply to the skid edge termination

flange at TP-0029.

Disconnect the instruments from airline and blow the main instrument air header and

tubing supply lines to instruments for cleaning of dust and debris.

Open up supplies to individual instruments and set air pressure

Check all air supply piping for leaks.

Note that mechanical completion check will be a part of piping and tubing check.

The following main check points will be taken into account during the FAT. For more details

refer to Form F-05 attached at the end of this document

No.Test Action

1Clean Instrument Air

Header

Properly clean instrument air header to make sure no dust, debris is

present

2Instrument air supply &

Leak check for tubing

Setting pressure of instrument air supply for individual instrument

Confirm to:

1. PIC - 415 set @ 4.0 barg2. PCV - 415 set @ 4.0 barg

3. ABV - 400 set @ 4.0 barg

4. LAL - 405A set @ 4.0 barg

5. LAL - 405B set @ 4.0 barg

6. PIT- 415 set @ 4.0 barg

Confirm air supply line to instrument without leak

Following Basic Drawings to be used during inspection of Instrument Air Distribution


- Hook Up DWG: SPM-C-I-0002





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- Instrument Datasheets

6.5.2 Automated Shutdown Valve

(ABV-400 and Shutdown Panel)

The following main check points will be taken into account during the FAT for the automatedshut down valve (ABV-400) and shutdown panel. For more details refer to Form F-05 attachedat the end of this document.

No.Test Action

1 Documentation

Check conformance certificates of ABV valve and shutdown panel

Individual Instrument FAT Report at Manufacturer shall be available

during FAT for review

2Visual Check &

Installation

Check ABV-400 and shutdown panel have properly installed without

any damage.

- Visual Check for signs of damage

- Verify valid calibration certificate is available

- Check Properly Tag. Name of Valves

- Confirm valve, shutdown panel have properly installed as per

Instrument Hook up DWG.

- Confirm tubing work (process & instrument air) is adequately

supported and the installation is done correctly.

- Confirm valve, shutdown panel have properly bonded

earthing

3 Function Test- Individual function check and confirm Range/Setting

Valve Open/Close Function Test

- Supply Instrument Air to Valve and Stroke

- Check status of valve with Instrument Air Input Fail

- Check status of valve with Signal Input Fail

Open SR-400 Close SR-400

Input Reading 1 barg 0 barg

Output

Instrument Air Input Fail Close Open

Signal Input Fail

Following Basic Drawings to be used during inspection of ABV-400 & Shutdown Panel







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- Instrument Datasheet – Automated Ball Valve: SPM-C-I-2311

6.5.3 Pressure Control Valve

(PCV-400, PCV-415, PIC-415)

The following main check points will be taken into account during the FAT for the PressureControl Valve (PCV-400, PCV-415) and pressure indicator & controller (PIC-415). For moredetails refer to Form F-06 attached at the end of this document.

No.Test Action

1 DocumentationCheck properly certificates of PCV valve and PICIndividual Instrument FAT Report at Manufacturer shall be available


2Visual Check &

Installation

Check PCV and PIC have properly installed without any damage.



- Check Properly Tag. Name

- Confirm PCV, PIC have properly installed as per Instrument

Hook up DWG.



- Confirm PCV, PIC have properly bonded earthing


Function Test – Valve Open Inspection

- Supply Instrument Air to Valve and check % travel

- Check status of valve with Instrument Air Input Fail

- Check status of valve with Signal Input Fail

Band% 0 25 50 75 100 100 75 50 25 0

Input (barg) 0.2 0.45 0.7 0.95 1.2 1.2 0.95 0.7 0.45 0.2

Output Reading

Travel%

Instrument Air Fail Close Open

Signal Fail Close Open

Following Basic Drawings to be used during inspection of Control Valve



- Instrument Datasheet – Pressure Control Valve: SPM-C-I-2301





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6.5.4 Pressure Transmitter

(PT- 401, PT- 415)

The following check points will be taken into account during the FAT for the PressureTransmitter (PT- 401, PT- 415). For more details refer to Form F-07 attached at the end of thisdocument.

No.Test Action

1 Documentation

Check properly certificates of Pressure Transmitters



2Visual Check &

Installation

Check Pressure Transmitters have properly installed without any

damage.

- Visual Check for signs of damage- Verify valid calibration certificate is available


- Confirm Pressure Transmitters have properly installed as per




- Confirm Pressure Transmitters have properly bonded

earthing

Following Basic Drawings to be used during inspection of Pressure Transmitters

- Piping & Instrumentation Diagram (PID): SPM-C-PR-0001- Hook Up DWG: SPM-C-I-0002

- Instrument Datasheet – Pressure Transmitters: SPM-C-I-2303

6.5.5 Flow Indicator

(FI- 401A/B, FI- 402A/B, FI- 403A/B, FI- 404A/B, FI-413)

The following check points will be taken into account during the FAT for Flow Indicators. For

more details refer to Form F-08 attached at the end of this document.

No.Test Action

1 Documentation

Check properly certificates of Flow Indicators



2Visual Check &

Installation

Check Flow Indicators have properly installed without any damage.



- Verify measurement range






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- Confirm Flow Indicator have properly installed as per


Following Basic Drawings to be used during inspection of Flow Indicator


- Hook Up DWG: SPM-C-I-0002- Instrument Datasheet – Flow Gauge Rotameter: SPM-C-I-2306

- Instrument Datasheet – Orifice dP Type Flow Gauge: SPM-C-I-2313

6.5.6 Pressure Indicator

(PI- 406A/B, PI- 407A/B, PI- 408A/B, PI- 409A/B, PI- 411A/B, PI- 412A/B, PI- 413A/B, PI-414A/B, PI- 406A/B, PI- 416)

The following check points will be taken into account during the FAT for Pressure Indicators.For more details refer to Form F-09 attached at the end of this document.

No.Test Action

1 Documentation

Check properly certificates of Pressure Indicators

Individual Calibration Certificates shall be available during FAT for

review

2Visual Check &

Installation

Check Pressure Indicators have properly installed without any

damage.


- Verify valid calibration certificate is available- Verify measurement range


- Confirm Pressure Indicator have properly installed as per


- Confirm tubing work is adequately supported and the

installation is done correctly.

Following Basic Drawings to be used during inspection of Flow Indicator


- Hook Up DWG: SPM-C-I-0002- Instrument Datasheet – Pressure Indicator: SPM-C-I-2304

6.5.7 Level Gauge & Level Switch

(LG-405A/B, LS-405A/B)

The following check points will be taken into account during the FAT for the Level Gauge (LG-405A/B) and Level Switch (LS-405A/B). For more details refer to Form F-10 attached at the

end of this document.





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No.Test Action

1 Documentation

Check properly certificates of LG & LS



2Visual Check &

Installation

Check LG and LS have properly installed without any damage.



- Confirm LG/LS have properly installed as per Instrument

Hook up DWG.

- Confirm tubing work is adequately supported and the

installation is done correctly.


Following Basic Drawings to be used during inspection of LG/LS



- Instrument Datasheet – Level Gauge & Switch: SPM-C-I-2302





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Cameron (Singapore) Plt Ltd

7.0 ATTACHMENT

NOTE: Attachments to be submitted in the next revision.

MECHNICAL

1. INSPECTION CHECKLIST RECORD FORM – F01 (PRESSURE VESSEL – 0 PAGES)

2. INSPECTION CHECKLIST RECORD FORM – F02 (STRUCTURE - 0 PAGES)

3. INSPECTION CHECKLIST RECORD FORM –- F03 (PIPING - 0 PAGES)

4. INSPECTION CHECKLIST RECORD FORM –- F04 (TUBING - 0 PAGES)

E&I

5. INSPECTION CHECKLIST RECORD FORM – F05 (SHUTDOWN VALVE - 0 PAGES)

6. INSPECTION CHECKLIST RECORD FORM – F06 (CONTROL VALVE - 0 PAGES)

7. INSPECTION CHECKLIST RECORD FORM – F07 (PRESSURE TRANSMITTER - 0 PAGES)

8. INSPECTION CHECKLIST RECORD FORM – F08 (FLOW INDICATOR - 0 PAGES)

9. INSPECTION CHECKLIST RECORD FORM – F09 (PRESSURE INDICATOR - 0 PAGES)

10. INSPECTION CHECKLIST RECORD FORM – F10 (LG/LS - 0 PAGES)

OTHER

11. PUNCH LIST FORM – F11 (01 PAGE)

12. INSPECTION CHECKLIST RECORD FORM – F12 (02 PAGES) – BACK UP