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The test program shall be designed to prove that the following aspects of the instrument and electrical
equipment/system are satisfactory:
Installation.
Integrity.
Calibration.
Operation.
The following equipment shall be tested:
Electrical equipment.
Instruments.
Panels.
Cable.
Impulse line tests.
The CONTRACTOR's Inspector shall perform the following inspection checks, as required:
Verify against approved documents that all items have been supplied and installed correctly.
Check tagging and location of equipment for accessibility for operation and maintenance.
Check appearance, paintwork, dimensions and fixing points against final agreed drawings.
Check routing and segregation of all cabling.
Verify that all wiring, cables and cores are correctly terminated and that cable / terminal markers
and nameplates correspond to the documentation.
Verify that calibration certificates, material certificates and hazardous area certification for all
applicable instrumentation equipment are available in accordance with project specifications and
requirements.
Verify that welding and NDT has been performed using CONTRACTOR approved procedures and
NDT reports properly reviewed and endorsed by qualified NDT Interpretation personnel.
Verify that hydrostatic pressure test certificates / certification for all applicable instrumentation
equipment, including impulse lines, are available in accordance with project specifications and
requirements.
The following list applies to the testing:
Wiring shall be tested for continuity and insulation. The test voltage shall be compatible with the
wiring being tested.
Instrument air systems shall be checked for leaks using dry air at a pressure 110% of maximum
working pressure.
Impulse lines shall be disconnected from both the process line and the instrument, and
hydraulically tested to 1.5 times process line design pressure. Instrument equipment and piping
shall be thoroughly flushed and dried on completion of test.
After installation, instruments shall be calibrated and demonstrated to be within VENDOR
specification.
If necessary, VENDOR shall arrange for the instrument manufacturer representatives to perform
the calibration and test.
Certificates of test for electrical components, instruments, and associated equipment shall be
available.
Test certificates shall state values for test results unless cross-referred to test procedures giving
test criteria.
The following activities shall be carried out as part of the FAT only where the tests have not already
previously been completed:
Verification of physical interconnections between systems,
Communication checks between systems,
Verification of data transfer between applications,
Redundancy checks (If appropriate),
Functional checks of data interfaces between package and ICSS,
Failure mode performance tests.
System backup and restore, including disaster recovery.
connections (both mechanical and electrical) to see that contacts and working parts are
correctly aligned and free from dust and foreign matter.
e) Check motors for proper rotation, lubrication and proper alignment.
f) Perform operational tests on motor control circuits.
g) Perform operational tests on control switches, alarm and shutdown devices, indicating
lights and meters for proper operation.
h) On circuit breakers with adjustable trips, check both thermal and magnetic settings for
proper protection.
i) Check protection relay settings and perform injection tests.
j) Earthing/grounding tests (both continuity and impedance) shall be carried out and results
recorded.
Certificates of Test shall be provided for each item of electrical apparatus to prove it has been
satisfactorily tested to meet requirements of its appropriate manufacturing standards, whether or
not witnessed.
If appropriate, test certificates shall state values for test results.
Test certificates for tests witnessed by contractor shall be available for signature on day of test.
Test instruments shall be an approved type and calibrated against certified standards or
standard instruments at regular and proper intervals, and their accuracy must be fully
substantiated at time of tests.
All electrical equipment and installations specified to operate in a hazardous area shall comply
with requirements of IEV 60079-14 and IEC 60079-17. Suppliers of such equipment /
installations shall provide the following documentation as a minimum to verify the integrity of the
installation and compliance with ATEX directive and IEC 60079 requirements:
a) Product Type certification issued by an Ex notified body.
b) EC declarations of conformity by
i) the manufacturers of individual items and
ii) the package Supplier responsible for the installation / assembly.
c) Hazardous Area Schedule. A list of all items installed that includes required details in
project format.
d) Hazardous Area Equipment - Installation Report documenting the initial inspection,
required by IEC 60079-17 performed by the Supplier.
Locate instruments, junction and terminal boxes, panels and connections to piping, vessels and
machines on general arrangement drawings in plan and elevation views
Show instrument air tubing and piping and valves
Provide an instrument list complete with type, manufacturer, model number and description for
each instrument and instrument valve to be supplied by the Seller
Include copies of control valve, safety relief valve, thermowell vibration and flow element
calculations
Include completed ISA S20 format data sheets for each instrument provided.
Include parts lists and list of recommended spares for instruments as defined in the Purchase
Documents.
Include instrumentation utility requirement schedule for power, cooling water, instrument air,
nitrogen, etc.
Document instrument removal and reinstallation procedure where required for shipping
Include copy of all configured applications (i.e. ladder logic, function block logic, graphics, etc.)
Include copy of certified test results for instruments, identified by instrument tag number (i.e. PSV
set pressure tests, valve seat leakage tests, transmitter calibration test, etc.)
calibration and settings records shall be retained by the supplier with copies included within the
package certification dossier along with the instrument Suppliers original calibration certification.
5.4.2 Instrument systems shall be connected as far as possible to simulate field
operation. Field inputs shall be simulated by appropriate switches, variable voltage or
current generators. Serial interfaces shall be tested using PCs utilising link specific
software. Field outputs shall be simulated by utilising pilot lights, milliammeters,
solenoids, etc. All simulators shall be fully wired up before testing commences. The tests
shall demonstrate that the equipment functions as intended.
Lifting Equipment Test
All lifting equipment supplied shall be subject to proof load/functional testing and be certified by a
recognised independent competent authority acceptable to the Purchaser. The devices shall be
uniquely identified with serial numbers and the Safe Working Load (SWL) for traceability back to the
certification. Functional testing of the fully assembled lifting system shall include but not limited to
lifting, lowering and traversing the rated load over its required length of travel in accordance with
approved procedures.
5.6 Electrical Testing
Electrical wiring and equipment shall be tested in accordance with the applicable NEMA & IEEE
Standard. Tests shall include wiring continuity; function tests to prove proper operation of controls,
alarms and protective devices; insulation and earth continuity tests.
6.0 MECHANICAL HANDLING
6.1 General
6.1.1 For routine maintenance and breakdown, the supplier shall provide a mechanical handling plan
for the package. This may be part of the general arrangement drawing. Mechanical handling shall
besingle man, or 110 lb. (50 kg), if access is provided for two men. In addition, mechanical handling
shall be provided if the lift is complicated or complex. The plan shall show runway beams, pad-eyes
etc, and include the rating of runway beams, pad-eyes, hoists and minimum hook heights and
withdrawal space requirements.
6.1.2 For equipment items not accessible by an external mechanical handling system, such as
equipment within the skid limits, the supplier shall supply a system. The system shall be designed to
transport the equipment to a laydown area. This may be outside the package skid limits.
6.1.3 Special lifting frames, spreader beams and other attachments that are required for
maintenance removal of some items of major equipment, e.g., rotors, pump cartridges,
etc, shall be supplied by the equipment supplier. Any special tools required for
maintenance shall also be supplied by the equipment supplier.