Sls 35 Mec PR 022 - Fat Procedure Rpa

CONTRACT NUMBER :
TP.01.03/U.DEP.IP
GENERAL
.SKG/1922/11/2014
DOCUMENT NUMBER :
16 PAGES
SLS-35-MEC-PR-022
PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN KONSTRUKSI

PEMBANGUNAN SKG RANTAU PANJANG DAN SKG PANGKALAN
BRANDAN
FAT PROCEDURE - FLARE PACKAGE
RANTAU PANJANG
21/05/14
Issued for Review
Rev.
Date
Status
MDY
MDY
HNK
Prep'd
Checked
Approved
PT KOTAMINYAK INTERNUSA
Checked
Approved
WIKA
PERTAGAS
PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN

KONSTRUKSI PEMBANGUNAN SKG RANTAU
PANJANG DAN SKG PANGKALAN BRANDAN
SLS-35-MEC-PR-022
Date :
21/05/14
FAT PROCEDURE FLARE PACKAGE

RANTAU PANJANG
Rev. A
Page 2 of 12
REVISION SHEET
REVISION
CODE
Page
A
REVISION
CODE
Page
D
REVISION
CODE
Page
D
Page
D
REVISION
CODE
A
Appe
ndix
REVISION
CODE
A

SLS-35-MEC-PR-022
Rev. A

RANTAU PANJANG
Date :
21/05/14
Page 3 of 12
REVISION SHEET
Rev.
Code
Chapter
Page
Implementation
Comment (Yes/No)
Note
Remarks

SLS-35-MEC-PR-022
Rev. A

RANTAU PANJANG
Date :
21/05/14
Page 4 of 12
Table of Content
1. General
2. References
3. Control Panel Test
3.1 Visual Inspection Test
3.2 Electrical System Power Up
3.3 PLC I/O
3.3.1. PLC Digital Input
3.3.2. PLC Digital Output
3.4 Function Test Process
3.4.1 Manual Operation
3.4.2 Auto Operation
4. Punch List
ATTACHMENT
5
5
5
5
6
6
6
8
6
6
10
11
12

SLS-35-MEC-PR-022
Rev. A

RANTAU PANJANG
Date :
21/05/14
Page 5 of 12
1.GEN ERAL
Factory Acceptance Test (FAT) is the stage to justify, show and prove that all process and activities such
as fabrication, panel assembly, programming etc are in accordance with the documents specification and meet
the user requirements.
The Purpose of this document is to define the procedure of Factory Acceptance Test of the Process
Control of Pilot Flame Flare Ignition and Shutdown System. The test will also include Visual Inspection Test,
Electrical System Power Up, PLC I/O and Cause and Effect. HP/LP Flare local control panel.
2. R EFEREN CES
1
P&ID (WIKA-RPA-FI-PID-001)
Panel Layout (WIKA-RPA-FI-EE-001)
Wiring Diagram (WIKA-RPA-FI-EE-002)
General Arrangement (SLS-30-MEC-DW-009)
3.C ONTR OL PAN EL TEST

3.1 Vi su al In sp ection Test
NO
DESCRIPTION
DIMENSIONAL CHECK
ENCLOSURE DETAILS
-Flatness and Smoothness
-Panel Arrangement
-Dimension
-Enclosure doors
*Open and shut freely
*Lock securely
*Seal
COMPONENTS
Completeness and correctness of components
(comply with equipment List)
WIRING AND TERMINATION

-Color Code and Label
-Terminal Labeled
POINT TO POINT WIRING CHECK
ACCEPTABLE SIGNATURE

SLS-35-MEC-PR-022
Rev. A

RANTAU PANJANG
Date :
21/05/14
Page 6 of 12
3.2 El ectri cal S yst em Pow er-Up

First of all, Power 220 VAC - 240 VAC is off, switch off all MCB and Fuses and switch off the toggle
switch in PLC Power Supply
Connect all equipment Input Signal
Connect all equipment Incoming Power
Connect 220 VAC - 240 VAC General Incoming Power to Main Terminal
Switch on power 220 VAC - 240 VAC and measure incoming voltage
Item to be check :
1. MCB
2. 24 VDC Power Supply
VISUAL POWER SYSTEM TEST
NO
ITEM TO BE INSPECTED
RESULT
CONFIRM
MAIN MCB 2P/ 10A

1
Main Power
Incoming terminal has 220 VAC 240VAC
DISTRIBUTION MCB
2
PLC
Power Supply Unit 24VDC
3.3 PLC I/O

Prior to performing loop verification, check the entire loop per loop diagram to ensure all wires are
connected
3.3.1. PLC Di git al Inp ut
Digital Input Loop Check by force each input and see the PLC data
TAG NAME
PLC
NO
P&ID TAG
DEFINITION
PROGRAM
ADDRESS
SYSTEM START
1
SYSTEM START
I1.0
Push Button Start
(PB-101)
SYSTEM STOP
2
SYSTEM STOP
I1.1
Push Button Stop
(PB-102)
RESET
3
RESET
I1.2
Push Button Reset
(PB-103)
LAMP TEST
4
LAMP TEST
I1.3
Push Button Lamp Test
(PB-104)
FFG MANUAL #01
Push Button FFG Manual
5
FFG MANUAL #01 I1.4
(PB-105)
#01
CONFIRM

SLS-35-MEC-PR-022
6
7
8
9
10
11
12
13
14
15
16
FFG MANUAL #01

(PB-106)
FFG MANUAL #03
(PB-107)
AUTO
(HS-101)
MANUAL
(HS-101)
EMERGENCY
SHUTDOWN
(PB-108)
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
Rev. A

RANTAU PANJANG
FFG MANUAL #02 I1.5

FFG MANUAL #03 I1.6
Date :
21/05/14
Page 7 of 12

#02
#03
AUTO
I1.7
Selector Switch AUTO
MANUAL
I1.8
Selector Switch MANUAL
ESD
I1.9
Push Button ESD
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
I1.10
I1.11
I1.12
I1.13
I1.14
I1.15
Spare
Spare
Spare
Spare
Spare
Spare
3.3.2. PLC Di git al Out put

Digital Output Loop Check by force each output and see the PLC data
Digital Output 01
NO
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P&ID TAG
Manual (UI-102)
Auto (UI-103)
Pilots On (UI-104)
Pilot #1 Off (UI-105)
SV-001 Open (UI-108)
Ignition Chamber #1
Ignition Chamber #2
Ignition Chamber #3
Alarm Horn
Lamp Test
Spare
Spare
TAG NAME
PROGRAM
Manual Indicating
Auto
Pilots On
Pilot #1 Off
Pilot #2 Off
Pilot #3 Off
SV-001
SV-002
SV-003
Ignition Transformer #1
Horn
Lamp Test
Spare
Spare
PLC
ADDRESS
O1.0
O1.1
O1.2
O1.3
O1.4
O1.5
O1.6
O1.7
O1.8
O1.9
O1.10
O1.11
O1.12
O1.13
O1.14
O1.15
DEFINITION
Manual FFG Ignition
Auto FFG Ignition
All Pilots is On
Pilot #1 is Off
Pilot #2 is Off
Pilot #3 is Off
SOV 001 OPEN
SOV 002 OPEN
SOV 003 OPEN
Ignition on Chamber #1
Alarm Horn
Lamp Test
Spare
Spare
CONFIRM

SLS-35-MEC-PR-022
Rev. A

RANTAU PANJANG
Date :
21/05/14
Page 8 of 12
Digital Output 02
NO
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P&ID TAG
Common Alarm (XA101)
Pilot Flame Failure (XA102)
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
TAG NAME
PROGRAM
PLC
ADDRESS
DEFINITION
Common Alarm
O2.0
Common Alarm
Pilot Flame Failure
O2.1
Pilot Flame Failure
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
O2.2
O2.3
O2.4
O2.5
O2.6
O2.7
O2.8
O2.9
O2.10
O2.11
O2.12
O2.13
O2.14
O2.15
All Pilots is On
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
Spare
CONFIRM

SLS-35-MEC-PR-022
Rev. A

RANTAU PANJANG
Date :
21/05/14
Page 9 of 12
3.4 FUN CT ION TEST PROCES S

The Function Test is an operational checking for overall system including loop test, real pilot flame flare
ignition test with fuel gas (LPG) is introduced into the system up to produces flame on pilot TIP.
BEFORE TURNING THE SELECTOR SWITCH POWER OFF-ON
a) Make sure incoming power with multi meter tools, power supply 220-240VAC
TURN THE SELECTOR SWITCH FROM OFF TO ON POSITION
3.4.1 Manu al Op eratio n
MANUAL
The MANUAL mode provides manual ignition of the pilot burners.
TURN THE SELECTOR SWITCH AUTO/MANUAL
a) The system can operate with manual or auto condition
TURN THE SELECTOR SWITCH AUTO/MANUAL TO MANUAL POSITION
1. MANUAL/HS-101 will be ON
2. Open manual ball valve (VB-01) before and ball valve (VB-02) after pressure regulator valve (PCV001) at instrument air line.
3. Open manual ball valve (VB-03) before and ball valve (VB-04) after pressure regulator valve (PCV002) at fuel gas line.
4. Open manual ball valve (VB-05) & ball valve (VB-06) before and ball valve (VB-07) after pressure
regulator valve (PCV-003) at fuel gas line to pilot gas.
5. See pressure indicator (PI-001) at instrument air line, approx. 1.4 barg.
6. See pressure indicator (PI-002) at fuel gas line, approx.0.4 barg.
7. See pressure indicator (PI-003) at fuel gas line, approx. 1.5 barg.
8. Ignite For FFG #1 / Pilot #1
9. Open bypass ball valve (VB-08) for pilot #1
10. Press FFG MANUAL#1 to ignite chamber #1, see sight port to show fire ball, and fire ball will send to
Pilot #1. Closed ball valve (VB-08).
Pilot #2. Closed ball valve (VB-09)
Pilot #3. Closed ball valve (VB-10)
Please push momentary only, do not hold more than 3 seconds.

SLS-35-MEC-PR-022
Rev. A

RANTAU PANJANG
Date :
21/05/14
Page 10 of 12
3.4.2 Auto Oper ation

TURN THE SELECTOR SWITCH AUTO/MANUAL HS-101 TO AUTO POSITION
1. AUTO/HS-101 will be ON
2. Open manual ball valve (VB-01) before and ball valve (VB-02) after pressure regulator valve (PCV001) at instrument air line.
3. Open manual ball valve (VB-03) before and ball valve (VB-04) after pressure regulator valve (PCV002) at fuel gas line.
4. Open manual ball valve (VB-05) & ball valve (VB-06) before and ball valve (VB-07) after pressure
regulator valve (PCV-003) at fuel gas line to pilot gas.
5. See pressure indicator (PI-001) at instrument air line, approx. 1.4 barg.
6. See pressure indicator (PI-002) at fuel gas line, approx.0.4 barg.
7. See pressure indicator (PI-003) at fuel gas line, approx. 1.5 barg.
8. Press SYSTEM START (PB-101) to produce spark plug at ignition chamber.
9. Shut off Valve for pilot #1 (SV-001), pilot #2 (SV-002), pilot #3 (SV-003) will control automatically
from PLC
10. Sequence of ignition begin. See logic diagram for detail
11. See sight port at spark plug to show fire ball (Ignition Chamber)
12. Fire ball will send to pilot and ignition successful.
13. Pilot fuel gas line will maintain fire at pilot gas line.
14. After FFG Pilot show the temperature till 300 C, all lamp pilot off is off , if each of the pilot fail to
ignite till 5 minute, the alarm will be ON (Fail Status).
Note :
1. This process depend on the pilot condition, where pilot detection temperature below 300 OC, it will work
for that line, but only one line permissive to open due to operation procedure.
2. Make sure all bypass ball valve is closed.
3. See attached flow chart and cause and effect for your reference.
TESTED BY
WITNESSED BY
WITNESSED BY
KMI
WIKA
PERTAMINA GAS
10

SLS-35-MEC-PR-022
Rev. A

RANTAU PANJANG
Date :
21/05/14
Page 11 of 12
4. PUNCH LIST
ITEM
VERIFICATION
DESCRIPTION
ACTION BY
11
RESULT
SIGN

SLS-35-MEC-PR-022
Rev. A

RANTAU PANJANG
ATTACHMENT
12
Date :
21/05/14
Page 12 of 12
LOGIC DIAGRAM
RANTAU PANJANG
KOTA MINYAK INTERNUSA

CLIENT :
PT. PERTAMINA GAS
CONTRACTOR :
PT. WIJAYA KARYA
PROJECT :
FLARE STACK PACKAGE AND FLARE IGNITION PACKAGE
PROYEK JASA PERANCANGAN, PENGADAAN DAN KONSTRUKSI
BRANDAN
DRW TITLE :
NOTES
WIKA-RPA-FI-PID-001
P&ID
8 MAY 2014
DRAWING NO.
DESCRIPTION
REV
DATE
REFERENCE DRAWING
LOGIC DIAGRAM RANTAU PANJANG
ISSUED FOR APPROVAL
RASH
MDY
HNK
WIKA
DESCRIPTION
DRW
CHK
APP
CUST
DATE
DRAWING NUMBER
SHEET
APP
8 MAY 2014
WIKA-PBR-FI-EE-003
1 FROM 4
REVISION
DESIGN OFFICE
SYMBOL
MEANING
Prosess
Decission
Controll Transfer
Terminator
On Page-reference
Y
yes
no
Pilot
not Pilot
T DN
Timer Finish Counting
Alarm On
Alarm Horn On & General Alarm On

CLIENT :
PT. PERTAMINA GAS
CONTRACTOR :
PT. WIJAYA KARYA
PROJECT :
BRANDAN
DRW TITLE :
NOTES
WIKA-RPA-FI-PID-001
P&ID
8 MAY 2014
DRAWING NO.
DESCRIPTION
REV
DATE
REFERENCE DRAWING
ISSUED FOR APPROVAL
RASH
MDY
HNK
WIKA
DESCRIPTION
DRW
CHK
APP
CUST
DATE
DRAWING NUMBER
SHEET
APP
8 MAY 2014
WIKA-PBR-FI-EE-003
2 FROM 4
REVISION
DESIGN OFFICE
POWER ON
AUTO
Y
N
System Start
Y
Y
Y
PILOT 1 OFF
Y
N
Process A
PILOT 1 OFF
System Reset
Y
Y
PILOT 2 OFF
Process B
PILOT 2 OFF
N
ALL SOV
CLOSED
(001,002,003)
ALL IGN
STOP(1,2,3)
ALARM ON
Y
PILOT 3 OFF
Process C
PILOT 3 OFF
N
N
System Stop
Y
Pilot Flame
Failure
PILOTS ON
CLIENT :
Standby Mode
PT. PERTAMINA GAS

CONTRACTOR :
PT. WIJAYA KARYA

- PILOT 1 OFF if TE-117A <= 300 OC
- PILOT 2 OFF if TE-117B <= 300 OC
- PILOT 3 OFF if TE-117C <= 300 OC
- PILOTS ON = PILOT 1 OFF & PILOT
2 OFF & PILOT 3 OFF
- PILOT FLAME FAILURE if after 5
minutes after start ALL PILOTS NOT
ON (Only for Auto Mode)
- Standby Mode = immediately reignite the pilot if one/all the pilots
turned off
NOTES
PROJECT :
BRANDAN
DRW TITLE :
WIKA-RPA-FI-PID-001
P&ID
8 MAY 2014
DRAWING NO.
DESCRIPTION
REV
DATE
REFERENCE DRAWING
ISSUED FOR APPROVAL
RASH
MDY
HNK
WIKA
DESCRIPTION
DRW
CHK
APP
CUST
DATE
DRAWING NUMBER
SHEET
APP
8 MAY 2014
WIKA-PBR-FI-EE-003
3 FROM 4
REVISION
DESIGN OFFICE
MANUAL
Ignition TRF 2
OFF
Ignition TRF 1
OFF
FFG MANUAL 1
FFG MANUAL 2
FFG MANUAL 3
Y
Ignition TRF 2 ON
Ignition TRF 1 ON
FFG MANUAL 1
Ignition TRF 3
OFF
FFG MANUAL 2
Ignition TRF 3 ON
FFG MANUAL 3

CLIENT :
PT. PERTAMINA GAS
CONTRACTOR :
PT. WIJAYA KARYA
PROJECT :
BRANDAN
- PILOT 1 OFF if TE-117A <= 300 OC

- PILOT 2 OFF if TE-117B <= 300 OC
- PILOT 3 OFF if TE-117C <= 300 OC
- PILOTS ON = PILOT 1 OFF & PILOT
2 OFF & PILOT 3 OFF
NOTES
DRW TITLE :
WIKA-RPA-FI-PID-001
P&ID
8 MAY 2014
ISSUED FOR APPROVAL
RASH
MDY
HNK
WIKA
DRAWING NO.
DESCRIPTION
REV
DATE
DESCRIPTION
DRW
CHK
APP
CUST
DATE
DRAWING NUMBER
SHEET
APP
8 MAY 2014
WIKA-PBR-FI-EE-003
4 FROM 4
REFERENCE DRAWING
REVISION
DESIGN OFFICE

Sls 35 Mec PR 022 - Fat Procedure Rpa

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CONTRACT NUMBER :

PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN KONSTRUKSI

Issued for Review

PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN

FAT PROCEDURE FLARE PACKAGE

PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN

FAT PROCEDURE FLARE PACKAGE

PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN

FAT PROCEDURE FLARE PACKAGE

PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN

FAT PROCEDURE FLARE PACKAGE

Panel Layout (WIKA-RPA-FI-EE-001)

Wiring Diagram (WIKA-RPA-FI-EE-002)

General Arrangement (SLS-30-MEC-DW-009)

3.C ONTR OL PAN EL TEST

WIRING AND TERMINATION

POINT TO POINT WIRING CHECK

PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN

FAT PROCEDURE FLARE PACKAGE

3.2 El ectri cal S yst em Pow er-Up

MAIN MCB 2P/ 10A

Incoming terminal has 220 VAC 240VAC

Power Supply Unit 24VDC

3.3 PLC I/O

PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN

FFG MANUAL #01

FAT PROCEDURE FLARE PACKAGE

FFG MANUAL #02 I1.5

Push Button FFG Manual

Selector Switch AUTO

Selector Switch MANUAL

Push Button ESD

3.3.2. PLC Di git al Out put

PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN

FAT PROCEDURE FLARE PACKAGE

Pilot Flame Failure

Pilot Flame Failure

PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN

FAT PROCEDURE FLARE PACKAGE

3.4 FUN CT ION TEST PROCES S

PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN

FAT PROCEDURE FLARE PACKAGE

3.4.2 Auto Oper ation

PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN

FAT PROCEDURE FLARE PACKAGE

PAKET 1 : JASA PERANCANGAN, PENGADAAN DAN

FAT PROCEDURE FLARE PACKAGE

KOTA MINYAK INTERNUSA

LOGIC DIAGRAM RANTAU PANJANG

ISSUED FOR APPROVAL

Timer Finish Counting

Alarm Horn On & General Alarm On

KOTA MINYAK INTERNUSA

LOGIC DIAGRAM RANTAU PANJANG

ISSUED FOR APPROVAL

KOTA MINYAK INTERNUSA

PT. PERTAMINA GAS

PT. WIJAYA KARYA

LOGIC DIAGRAM RANTAU PANJANG

ISSUED FOR APPROVAL

KOTA MINYAK INTERNUSA

- PILOT 1 OFF if TE-117A <= 300 OC