Site Acceptance Test Procedure Last Rev1

Document Title:

Site Acceptance Procedure

COPI Doc No.:

D-84531-DY-MM1-PRO-ST-01-0002

Originator: COPI Group Owner: Area: Location: System: Document Type: Discipline / Subdiscipline: Old COPI Document No.:

PT SAAG Utama Project Dayung Dayung Station Temporary Systems Procedure/Work Instruction/Job Note Mechanical / Mechanical -

01

IFU

7 Aug 11

Issued for Use

0B

IFA

6 Aug 11

Issued for Approval

0A

IFC

3 Aug 11

Issued for Comment

Rev

Status

Issue Date

Putra Kurnia

Ronald G Moore

Adi Prihanto

Wayan Mega Budiartha

Wes Richins

Putra Kurnia

Ronald G Moore

Adi Prihanto

Wayan Mega Budiartha

Wes Richins

Putra Kurnia

Ronald G Moore

Adi Prihanto

Wayan Mega Budiartha

Wes Richins

Prepared

Checked

Approved

Project Engineer

Project Manager

Reason for Issue Contractor Approvals

COPI Approvals

Printed initials in the approval boxes confirm that the document has been signed. The originals are held within Document Management.

Procedure/Work Instruction/Job Note Site Acceptance Test Procedure

D-84531-DY-MM1-PRO-ST-01-0002 - Rev. 01

ConocoPhillips (Grissik) Ltd.

Page 2 of 11

Revision Sheet ConocoPhillips (Grissik) Ltd.

REVISION

DATE

DESCRIPTION OF CHANGE

0A

3 Aug 2011

Issued for Comment

0B

6 Aug 2011

Issued for Approval

01

7 Aug 2011

Issued for Use

Additional Approvers (If Applicable) Name

Designation

Signature

Date

Procedure/Work Instruction/Job Note Site Acceptance Test Procedure

D-84531-DY-MM1-PRO-ST-01-0002 - Rev. 01

ConocoPhillips (Grissik) Ltd.

Page 3 of 11

Contents Contents ……………………………………………………………………………………………….................. 3 1. Purpose ………………………………………………………………………………………………………... 4 2. Scope …………………………………………………………………………………………………………... 4 3. Responsibilities ……………………………………………………………………………………………… 4 4. Sequence …………………….……………………………………………………………………………….. 4 5. Alarm and Trip Set-Points ………………………………………………………………………………….. 5 6. Procedure ……………………………………………………………………………………………………... 5 7. Readiness for Operation Certificate ……………………………………………………………………. 11

Appendix Appendix A – P&ID Gas Compressor Package Appendix B – P&ID Fuel Gas Conditioning Package Appendix C – PFD Dayung Station-Field Facilities Gas Compression Unit Appendix D – Compressor Cause and Effect Shutdown Matrix Appendix E – Compressor and Engine Pre-Start Check List Appendix F – Compressor Unloaded Run Test Check List Appendix G – Compressor Loaded Run Test Check List Appendix H – Site Acceptance Test Checklist

Procedure/Work Instruction/Job Note Site Acceptance Test Procedure

D-84531-DY-MM1-PRO-ST-01-0002 - Rev. 01

ConocoPhillips (Grissik) Ltd.

Page 4 of 11

1. Purpose This document describes the guidance procedure for Site Acceptance Test (SAT) of gas compressor package units and all associated piping and instrumentation which will be involved during SAT.

2. Scope The scope of this procedure covers all aspects for SAT of the gas compressor package unit including all parameters that shall need to be checked, witnessed, and signed off by all concerned parties.

3. Responsibilities The responsibilities for the Site Acceptance Test of gas compressor package reside with a number of different parties. The following table defines the activities and party responsible. Description of Item

Responsible

Support

Open starting gas and fuel gas discharge valve

SAAG

Project, Operations, GSI

Manual Purge of gas compressor package

SAAG

Project, Operations, GSI

Perform unloaded run of gas compressor package

SAAG

Project, Operations, GSI

Perform loaded run of gas compressor package

SAAG

Project, Operations, GSI

Perform SAT of gas compressor package

SAAG

Project, Operations, GSI

4. Sequence The following step generally describes the sequence of works for Site Acceptance Test (SAT) of compressors unit: 1. Open the starting gas discharge valve and fuel gas discharge valve at the upstream of fuel gas treatment skid piping. 2. If required, depressurized gas compressor package piping by start-up by pass valve and blow down valve until the pressure reach 150 psi 3. Perform unloaded run test for all 4 (four) compressor units for about 30 minutes using compressor start-up by pass until the engine speed reach 1100 rpm. Monitor and log the compressor parameter as specified in Appendix F from the idle speed 700 rpm to 1100 rpm at 100 rpm interval to ensure they remain within parameters as specified by compressors manufacturer. 4. On satisfactory of unloaded run test, reduce engine speed to 900 rpm and perform loaded run test for all 4 (four) compressor units for about 4 (four) hours using station recycle valve by slowly open ball valve suction line to compressors unit. Keep open all ball valves suction line until compressor suction pressure reach 950 psi. Once completed gradually increase the engine speed until the engine speed reach 1150 rpm.

Procedure/Work Instruction/Job Note Site Acceptance Test Procedure

D-84531-DY-MM1-PRO-ST-01-0002 - Rev. 01

ConocoPhillips (Grissik) Ltd.

Page 5 of 11

Monitor and log the compressors parameter as specified in Appendix G and ensure that there are no indication alarms at compressor control panel. (During initial loaded run test, compressor suction pressure shall be continuously monitored at each compressor local control panel until compressor suction pressure reach 950 psi and compressor start-up by pass valve in close position) 5. Perform Site Acceptance Test (SAT) of all 4 (four) compressor units by slowly open 16” station suction valves. Prior to SAT please ensure that 12” station discharge valve should be NORMALLY OPEN (see Appendix C) After all 4 (four) compressors has been successfully tested (no alarms indication in compressor local control panel / Dayung control room and no one compressor shutdown due to fail function of compressors unit) for 72 (seventy two) hours, the compressors now will ready for placed in service (PIS) at inside area of Dayung Gas Gathering Station.

5. Alarm and Trip Set-points The compressor unit has been completed with some alarm indications, which can be monitored at local control panel and some of them (common alarms) can be monitored at Dayung control room, and trip set points to protect the equipment from damage. Please refer to document “P&ID gas compressor package” in the Appendix A and “Compressor Cause and Effect Shutdown Matrix”, in the Appendix D for compressor alarm set-points and shutdown settings.

6. Procedure This procedure describes the step by step detail for conducting Site Acceptance Test (SAT) for compressors unit that will be placed in Dayung Gas Gathering Station. This site procedure has only valid for the following Gas Compressor sets: 1. Tag No.

: 01-SAE-402 (L-071)

Manufacturer

: Waukesha / Ariel (USA)

Type

: Reciprocating

Model

: Waukesha L7042GSI ESM/Ariel JGK2

Serial No.

: C-16008/1 & F-31910

Normal Capacity

: 67 MMSCFD

Normal Suction Pressure

: 950 Psig

Max Discharge Pressure

: 1300 Psig

Max Continuous Speed

: 1200 rpm

2. Tag No.

: 01-SAE-302 (L-072)

Manufacturer

: Waukesha / Ariel (USA)

Type

: Reciprocating

Procedure/Work Instruction/Job Note Site Acceptance Test Procedure

D-84531-DY-MM1-PRO-ST-01-0002 - Rev. 01

ConocoPhillips (Grissik) Ltd.

Page 6 of 11

Model

: Waukesha L5794GSI ESM/Ariel JGK2

Serial No.

: C-621257 & F-35014

Normal Capacity

: 67 MMSCFD

Normal Suction Pressure

: 950 Psig

Max Discharge Pressure

: 1300 Psig

Max Continuous Speed

: 1200 rpm

3. Tag No.

: 01-SAE-202 (L-073)

Manufacturer

: Waukesha / Ariel (USA)

Type

: Reciprocating

Model

: Waukesha L5794GSI ESM/Ariel JGK2

Serial No.

: 5283701106 & F-27596

Normal Capacity

: 67 MMSCFD

Normal Suction Pressure

: 950 Psig

Max Discharge Pressure

: 1300 Psig

Max Continuous Speed

: 1200 rpm

4. Tag No.

: 01-SAE-102 (L-074)

Manufacturer

: Waukesha / Ariel (USA)

Type

: Reciprocating

Model

: Waukesha L5794GSI ESM/Ariel JGK2

Serial No.

: 5283701089 & F-35017

Normal Capacity

: 67 MMSCFD

Normal Suction Pressure

: 950 Psig

Max Discharge Pressure

: 1300 Psig

Max Continuous Speed

: 1200 rpm

6.1. Preparation STEP

RESPONSIBILITY

ACTION Ensure

1

COPI Project

that

Pre-commissioning

/commissioning activity is complete and all punch lists have been closed Prepare all necessary tools, including

2

SAAG

measurement tools, and ensure that the measurement tools have been certified by an authorized legal body

3

COPI Project, COPI Operation and SAAG

Conduct PJSM before jobs begin

Procedure/Work Instruction/Job Note Site Acceptance Test Procedure

D-84531-DY-MM1-PRO-ST-01-0002 - Rev. 01

ConocoPhillips (Grissik) Ltd.

Page 7 of 11

6.2. Individual Compressor Unloaded Run Test STEP

RESPONSIBILITY

ACTION Ensure that 16” station suction valve and 10” ball valve suction line to compressor

1

COPI Project and SAAG

unit in close position. Meanwhile 12” discharge header, 10” gate valve suction line and 2 x 3” gate valve discharge line are in open position Carry

2

SAAG

out

all

requirements

of

the

Compressor and Engine Pre-start Check Lists prior to as specified in Appendix E Ensure that inlet PCV (XV-101) and

3

SAAG

permeate PCV (PV-307) has been set-up for

normal

operating

parameter

as

indicated in P&ID (See Appendix B) 4

SAAG

5

SAAG

6

SAAG

Ensure that ball valve V-204 and ball valve V-311 are open Open slowly ball valve V-700 at the suction line of fuel gas treatment skid Open the gate valve at the upstream of fuel gas line Flaring fuel gas to ensure no condensate

7

SAAG

gas trapped in the fuel gas line to compressor for about 10 - 15 minutes If required, depressurized gas inside the compressor until the suction pressure

8

SAAG

reach 150 psi by opening start-up by pass valve and blow down valve. Before that please ensure that these valves are close Push the reset (HS-7401) PB at UCP. Once reset is successful and all the Class A alarms are healthy, ESD healthy output

9

SAAG

signal from Murphy controller to ESM ( XS-512A) will be energized with 24VDC signal. A time delay will be initiated after which the shutdown signal from ESM (XS-

Procedure/Work Instruction/Job Note Site Acceptance Test Procedure

D-84531-DY-MM1-PRO-ST-01-0002 - Rev. 01

ConocoPhillips (Grissik) Ltd.

Page 8 of 11

514A) shall be ensured to be healthy else the unit will not start 

Push Start Push Button on the UCP then UCP shall send “Start” signal to ESM (XS-511A) and also will energize stop command (XS-510) to ESM to be healthy.



The ESM will now take over to start the engine and compressor pre-lube pump through the same solenoid valve XY-704A.



ESM will start the pre-lube pump timer (set

for

300

seconds).

The

compressor oil pressure must reach its start permissive (14 psig) within timer. If not the start signal from ESM 10

signal is de-energized and the engine

SAAG

essentially goes into a stop sequence 

Once the start permissive is obtained from the lube oil pressure of engine and compressor, gas motor starter will crank

the

engine

to

start

the

compressor unit 

As soon as the unit started, normally the engine speed will raise-up to 600 rpm and will reach the idle speed at 700 rpm. Let the engine to run at the idle speed for about 10 – 15 minutes and

monitor

all

compressor

parameters at UCP to ensure that there are no alarms and no abnormal parameter reading in compressor unit Gradually increase the engine speed until 11

SAAG

1100 rpm at 100 rpm interval to see if any alarms, abnormal parameter reading and abnormal sound from compressor unit

Procedure/Work Instruction/Job Note Site Acceptance Test Procedure

D-84531-DY-MM1-PRO-ST-01-0002 - Rev. 01

ConocoPhillips (Grissik) Ltd.

Page 9 of 11

Gradually decrease the engine speed 12

SAAG

back to 900 rpm

6.3. Individual Compressor Loaded Run Test STEP

RESPONSIBILITY

ACTION 

Slowly open the ball valve suction line in to compressor unit to let the process

gas

flow

through

compressors unit. 

Keep maintain the suction pressure at 950 psi by regulating valve opening of ball valve suction line and valve closing of start-up by pass valve.

 1

SAAG

Once the pressure has reached, the compressor start-up by pass valve shall completely closed and ball valve suction line shall be in open position

During this time, one OPERATOR shall stand-by

near

compressor

UCP

suction

to

monitor

pressure

and

another one OPERATOR shall standby at the ball valve suction line to keep maintain compressor suction pressure 

Increase the engine speed until 1150 rpm and keep maintain at this speed for 4 (four) hours.

2

SAAG



Monitor and log the compressors parameter at 1 (one) hour interval and ensure that there are no indication alarms at compressor control panel.



Gradually decrease the engine speed until 800 rpm and run at this speed for

3

SAAG

3 (three) minutes (Cool Down Time 

Stop the compressor using the normal mode by pushing the Stop Pushbutton at the UCP

Procedure/Work Instruction/Job Note Site Acceptance Test Procedure

D-84531-DY-MM1-PRO-ST-01-0002 - Rev. 01

ConocoPhillips (Grissik) Ltd.

Page 10 of 11



The UCP will send a stop command to ESM (XS-510A) to de-energized to close signal to fuel gas valve (XY601A) and the ESM will close the fuel valve (XY-605A) and the engine will shutdown.



The ESM will start the engine and compressor pre-lube pumps and will run the post lube for 3 (three) minutes

6.4. Compressor Site Acceptance Test (SAT) Compressors Site Acceptance Test (SAT) shall be done after successfully individual compressor loaded run test. This is the most critical activity to figure out performance reliability of the compressors unit before they are ready to operation. The compressors unit are said to be ACCEPTABLE FOR USE if the following criteria has been fulfilled. 

The compressor unit has been tested online in life plant for 3 x 24 hour without any re-setting in the compressors unit.



No Class A Alarm indicated in the compressor UCP during SAT



No one of the compressor trip due to shutdown signal from compressor unit. In case compressor shutdown due to failure from plant, the total time duration will be counted based on the last total time duration for the trip unit.



The compressors can deliver 195 MMCFD, which is recorded at COPI gas metering system, of gas at 1350 psig in the compressor discharge line.



The emission gas from compressor unit shall be below the limit of emission gas standard as stated by Indonesian government regulation STEP

RESPONSIBILITY

1

COPI Project and SAAG

ACTION Ensure that 16” station suction valve and 12” station discharge are in open position Together perform unloaded run test for all

2

SAAG

compressors for about 30 minutes. Follow the steps as specified in the chapter 6.2 

3

Perform loaded run test for compressor unit L-071. Follow the

COPI Operation and

steps 1 and 2 as specified in the

SAAG

chapter 6.3 

Perform loaded run test for

Procedure/Work Instruction/Job Note Site Acceptance Test Procedure

D-84531-DY-MM1-PRO-ST-01-0002 - Rev. 01

ConocoPhillips (Grissik) Ltd.

Page 11 of 11

compressor unit L-072. Meanwhile COPI OPERATOR shall be slowly close station by pass valve until 50 (fifty) percent opening 

Perform loaded run test for compressor unit L-073. Meanwhile COPI operator shall be slowly close station by pass valve until the valve completely close



Setting the engine speed and compressor pocket clearance in order

4

SAAG and GSI

to achieve compressor capacity 195 MMSCFD at compressor discharge pressure 1300 psig 

Monitor and log all compressor parameters every 1 (one) hour including engine speed, vibration level, noise level, resistance

5

SAAG

grounding and emission level to figure out if the compressor has been designed according with engineering specification as agreed by COPI and SAAG. 

After 18 hours running, one of the running units, L-071, shall be shutdown and alter with the stand-by unit, L-074. This shall be continuously

6

done, every 18 hours, to all

SAAG

compressor units respectively 

2nd 18 hours: L-072; L-073; L-074



3rd 18 hours: L-071; L-073; L-074



4th 18 hours: L-071; L-072; L-074

7. Readiness for Operation Certificate On the successful or agreed conclusion of the Site Acceptance Test (SAT), a readiness for operation certificate shall be signed by the all the witnessing parties.