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PERTAMINA EP
MATINDOK GAS DEVELOPMENT PROJECT (MGDP)
PA / PO NUMBER : TP.01.01/KONS.MTD.7518/0070/XII/2014
TOTAL OR PARTIAL REPRODUCTION AND/OR UTILIZATION OF THIS DOCUMENT ARE FORBIDDEN WITHOUT PRIOR WRITTEN
AUTHORIZATION OF PT. PERTAMINA EP
TABLE OF CONTENTS
PAGE
1 GENERAL 1
2 SCOPE 1
3 INSTRUMENT PACKAGE EQUIPMENTS 2
4 POWER REQUIREMENT 2
5 WIRING REFFERENCE, DRAWING AND DOCUMENTS 3
6 PACKAGE EQUIPMENTS 4
6.1 HARDWARE ALARM INDICATION LAMPS 4
6.2 HMI SIMATIC TP1200 4
TOUCH SCREEN MENU BUTTONS 4
6.3 HMI TP1200 SCREEN DISPLAY 6
7 REDUNDANT PLC - MAIN COMPONENTS 9
8 PARAMETER SETTING POINT 10
8,1 PRESSURE TRANSMITTER 10
8.1.1 LEAD SETTING PRESSURE 10
8.1.2 LAG SETTING PRESSURE 10
8.1.3 TIMER SETTING 10
8.1.3 OVER PRESSURE 10
8.1.4 SHUTDOWN PRESSURE 10
8.1.5 DISCHARGE PRESSURE OF UNIT COMPRESSOR-A 10
8.1.6 DISCHARGE PRESSURE OF UNIT COMPRESSOR-B 10
8.1.7 DIFFERENTIAL PRESSURE OIL SEPARATOR-A 10
8.1.8 DIFFERENTIAL PRESSURE OIL SEPARATOR-B 10
8.1.9 DIFFERENTIAL PRESSURE OIL FILTER-A 10
8.1.10 DIFFERENTIAL PRESSURE OIL FILTER-B 10
9 CONTROL PHILOSHOPY 11
9,1 Touch MANUAL - AUTO Mode 11
9,2 Touch LEAD-LAG Mode 11
9,3 HMI Screen Display Parameters 11
10 INTERFACE 12
11 DRYER RUNNING 12
12 REMOTE ESD 12
13 RESET 12
14 STEP OF TEST 13
14,1 Checking All Power Cable Connection And Voltages 13
14,2 Setting Parameter on PLC / HMI 13
14,3 Control Simulation Test 13
14,4 Motor Rotation Check 14
14,5 Single Compressor Running 14
14,6 Two Compressor Running in Sequence 14
14,7 Touch UNLOAD key button for both Compressors 15
14,8 Touch LOAD key button Compressor-A 15
14,9 Touch LOAD key button Compressor-B 15
14,10 Select Compressor-B as Lead position 15
15 Dryer Running 15
16 Running Dewpoint Analyzer 16
17 PLC Alarm 16
1 GENERAL
Two units Screw Air Compressor 373-C-1001A and 373-C-1001B which each compressor has capacity 1397 Nm3/Hr,
Max. Press.147 psig, 250 kW, 3Ph/6600VAC/50Hz, are mounted on Compressor skid, and two unit Air Dryer
373-D-1003A/B and 373-D-1003C/D which each unit dryer has capacity 1406 Nm3/Hr, Design Press. 180 psig which
are mounted on Dryer Skid 373-V-1002A/B.
The package has been equiped with Pre-Filter 373-Y-10014A/B and After Flter 373-Y-10015A/B.
The both compressors and dryers are modified as per requirement, from standard local micro processor base to PLC base
Siemens Simatic FS-400H SIL-3 Redundant Simatic STEP 7 Prof. 2010 SR4/V13 Combo PLC Programming software
software which is assemblied in Local Control Panel 373-LCP-V1001/2
And all transducers sensor standard are modified to transmitters, and standard local starter of main motor and fan motor
will be from customer MCC starter.
The Local Control Panel 373-LCP-V1001/2 will control both compressors and both air dryer in according to local and remote,
individual and lead-lag or sequence operartion, and the 373-LCP-V1001/2 has been equiped with HMI TP1200 Comfort
operator 12" touch screen display with redundant CPU, redundant power supply and redundant communication to
Customer PCS.
The compressors and dryers may operate individual running with its auto re-start position and dual running as lead-lag
operation and base on load-unload setting requirement.
All parameters, status, run hours and Alarms of compressor and dryers are may displayed in Panel View.
The dryer was equiped with dew point analyzer to monitor the air drying quality.
The both compressor and dryer are may monitored from Control Room via Ethernet TCP/IP Communication Cable from
Local Control Panel 373-LCP-V1001/2 to Customer PCS Communication Port.
The Pressure transmitter 373-PIT-1006 as lead-lag pressure transmitter will be provided for sensing both compressor
and dryer running in lead lag operation and in load-unload auto re-start, this PIT-1006 will be mounted at Dry Receiver.
During local individual running in load-unload pressure, the sensing pressure will use with its discharge Pressure
transmitter 4APT-A/B.
2 SCOPE
This procedure covers the testing work of two units Compressors and two unit dryers and with other equipment dew point
Analyzer and lead-lag pressure transmitter are will be controlled thrue PLC Local Control Panel 373-LCP-V1001/2 at decided
vendor rental workshop who has the available facilities.
During the SAT the Starter of Main motor Compressor and Fan motor cooler will use original starter from MCC by Customer.
During the test will be concerned to main package performance including their alarms and safety devices with real and
simulation testing as per availabilities.
SITE ACCEPTANCE TEST Doc. No.: MTDF-FRM-IN-1030-3222-B1105-1001
PROCEDURE
FOR
Rev. No.: 3
AIR COMPRESSOR AND AIR DRYER PACKAGE
1 Unit Local Control Panel PLC base with Siemens Simatic S7-400FH Redundant SIL-3 373-LCP-V1001/2 373-V-1002A/B
with HMI TP1200 Comfort Operator 12" touch. Redundant CPU, Redundant Power Mounted at Dryer Skid
Suply and Redund. Comm. in Ethernet TCP/IP with FO Cable interface to PCS as Inlet Dryer
The panel is free standing type, Bartec Manifacturer, Type/Size A7-3136-800/1800/600,
Material SS316L, 3.5 mm Thick., NEMA-4X, Certification ATEX, II 3(2)G Ex nA nC de
[op is Gb] II C T3 Gc, IP-66 , Front & Rear Door, bottom cable entries and completed
with Lifting Hager.
4 POWER REQUIREMENT
The power requirement for the Instrument Air Package as follow :
Customer Source
Equipment Power Voltage Electrical Equipment Room
1 Main Motor Compressor-A (373-V-1001A) 250 kW is driven via MCC-A with DOL Starter 3 Ph, 6600 VAC, 50Hz MCC Room
2 Main Motor Compressor-B (373-V-1001B) 250 kW is driven via MCC-A with DOL Starter 3 Ph, 6600 VAC, 50Hz MCC Room
3 Fan Motor Cooler-A , 18.5 kW is driven via MCC-A with DOL Starter 3 Ph, 400 VAC, 50Hz MCC Room
4 Fan Motor Cooler-B , 18.5 kW is driven via MCC-B with DOL Starter 3 Ph, 400 VAC, 50Hz MCC Room
5 Main Motor Compressor-A Space Heater 120 Watt 1 Ph, 230 VAC, 50Hz MCC Room
6 Main Motor Compressor-B Space Heater 120 Watt 1 Ph, 230 VAC, 50Hz MCC Room
7 Control Power for PLC Local Control Panel 1 Ph, 230 VAC, 50Hz Electrical Equipment Room
373-LCP-V1001/2 UPS Distribution Panel
SITE ACCEPTANCE TEST Doc. No. : MTDF-FRM-IN-1030-3222-B1105-1001
PROCEDURE
FOR
Rev. No. : 3
AIR COMPRESSOR AND AIR DRYER PACKAGE
6 PACKAGE EQUIPMENTS
ESD
ESD
Push Button
The PLC Control Panel 373-LCP-V1001/2 was equiped with Human Machine Interface as HMI TP1200 Screen 12" in Color and
touch screen type, with some parameters, status indication and instruction as follows :
Lead Pressure
Unload Pressure Value - psig
Load Pressure Value - psig
Lag Pressure
Unload Pressure Value - psig
Load Pressure Value - psig
Return :
Go to Setpoint Page
Go to Main
SITE ACCEPTANCE TEST Doc. No. : MTDF-FRM-IN-1030-3222-B1105-1001
PROCEDURE
FOR
Rev. No. : 3
AIR COMPRESSOR AND AIR DRYER PACKAGE
A ENCLOSURE
1 ENCLOSURE SIZE 800(W)x1800(H)x600(D), THICK.3MM BARTEC A7-56D1-800/1800/600-31 1 EA
MATERIAL STAINLESS STEEL 316L, FREE STANDING,
CLASS 1 DIV. 2, NEMA-4X , IP-66, BOTTOM ENTRY,
2 VORTEC COOLER AF4640SS, IP66, 820W, Q=930NL/MIN. BARTEC AF4640SS 1 EA
AUSLASS OUTLET FOR VORTEX PROTECTION ENCLOSURE SIZE 200(W)x300(H)x200(D) BARTEC 1 EA
B PLC MODULES
2 SIMATIC F7-400FH SAFETY CONTROLLER SIL-3 (BUNDLE) SIEMENS 6ES7656-8CF33-1EFO 2 EA
3 PROCESSOR CPU 414H SIEMENS 6ES7414-5HM06-0AB0 2 EA
4 RAM MEMORY CARD 4MB SIEMENS 6ES7952-1AM00-0AA0 2 EA
5 SINCRONOUS MODULE, C/W FO CABLE 1M SIEMENS 6ES7960-1AA06-0XA0 + 4 EA
6ES7960-1AA04-5AA0
6 ETHERNET COMMUNICATION MODULE CP-443-1 SIEMENS 6GK7443-1EX30-0EX0 2 EA
7 POWER SUPPLY PS407 120/230VAC 10A SIEMENS 6ES7407-0KR02-0AA0 4 EA
8 BACK UP BATTERY SIEMENS 6ES7971-0BA00 8 EA
9 RACK UP 2-H ( 2x9 SLOTS) SIEMENS 6ES7400-27A10-0AA0 1 EA
11 VORTEC COOLER EA
C SOFTWARE
1 SIMATIC WINCC COMFORT V13 ENGINEERING SOFTWARE SIEMENS 6AV2101-0AA03-0AA5 1 EA
2 SIMATIC STEP 7 PROF. 2010 SR4/V13 COMBO PLC PROGRAMMING SOFTWARE SIEMENS 6ES7810-5CC11-0YA5 1 EA
3 SIMATIC FAILSAFE LIBRARY PROGRAMMING SOFTWARE SIEMENS 6ES7833-1CC02-0YA5 1 EA
4 SIMATIC CONTROL FUNCTION CHART (CFC) SOFTWARE SIEMENS 6ES7658-1EX08-0YA5 1 EA
SITE ACCEPTANCE TEST Doc. No. : MTDF-FRM-IN-1030-3222-B1105-1001
PROCEDURE
FOR
Rev. No. : 3
AIR COMPRESSOR AND AIR DRYER PACKAGE
SETTING
8.1.1 LEAD SETTING PRESSURE PRESSURE RANGE 0 - 147 psig PIT-1006
LOAD 105 psig
UNLOAD 135 psig
9 CONTROL PHILOSHOPY
Two units compressor 373-C-1001A and 373-C-1001B are powered by Customer MCC with 3Ph/6600VAC/50Hz for
main motor Compressors and 3Ph/400VAC/50Hz for Fan motor cooler, including their space heater power 1Ph/230VAC/
50Hz.
The both Compressor will operate individually or sequencing/Lead-Lag operation in auto running together with two units
Air Dryer 373-D-1003A/B and 373-D-1003C/D will follow with compressor running in accordance with lead - lag unit operation.
Both Air Compressors and Air Dryers are controlled by one Local Control Panel 373-LCP-V1001/2 which it is built in PLC
base with Simatic 7F-400FH Safety Controller Redundant SIL-3 assembly with Siemens component and in Simatic Step 7
Profesional 2010 SR4/V13 Combo PLC Programming Software.
The Local Cntrol Panel has been equiped with HMI TP1200 Comfort Operator touch screen color.
The both compressors, dryers and Local Control Panel are mounted at hazardouse field area Zone 2.
The both compressor may operate individually or sequently, by Select Local Manual it means the compressor will
operate manually on its Load-unload setting and as auto run and individually.
By Select in Auto, it means the compressor will operate in sequent or lead-lag operation base on their load unload
setting.
In case of Unit 373-C-1001A select in Lead, automatically the unit 373-C-1001B will be as Lag operate and both
Compressors will be running in auto re-start and auto lead - lag on their load unload pressure setting requirement.
Change select to Lead unit 373-C-1001B automatically the unit 373-C-1001A will be running and operate on Lag
setting pressure.
During Local or Individual operation the sensing pressure of both unit compressors by own each unit discharge
transmitter 4APT- A/B. and in case of sequent operation the pressure setting will use the down stream transmitter
PIT-1006 at Receiver.
The setting between 4APT-A/B shall be litle bit higher 3 psig higher than PIT-1006 due to pressure drop estimation
between up stream to down stream pressure distribution.
Running in AUTO, all parameters setting and pressure may indicate and monitored by Local Control Panel
373-LCP-V1001/2 all parameters are may displayed on HMI TP1200 as digitally, and could be monitored by PCS at
Control Room, and by Push the ESD Button both Compressors will Stop Running as Emergency Stop, and the
historical alarms display will indicate on HMI Screen.
To re-start Compressor, all alarms caused shall be released at first and then Ready to Start will indicate to re-start
compressor.
10 INTERFACE
The interface of all parameters, status and command of both Compressor and Dryer are via Ethernet TCP/IP data communication
cable except the the remote ESD for Shutdown system will be in normally close dry contact signal.
11 DRYER RUNNING
Running dryer is manually ON / OFF Selector via Unit Control Panel 373-LCP-V1001/2, By Select ON it means the dryer will
running on auto regenerating and purging sequently between Vessel A to B for 373-D-1003A/B and between vessel C to D for
373-D-1003C/D base on timer setting ( 5 minutes for regenerating period and 10 seconds for vessel purge period and the
setting will indicated as digitally on Panel View display.
The dryer parameters which are displyed on HMI TP1200 as follow :
Dewpoint parameter AI-1001 with its alarm setting, The ON / OFF status of dryer, failure alarm of dryer and runhours of dryers.
12 REMOTE ESD
The shutdown of both compressor come from PCS thrue dry contact signal, which its command come from PCS ESD
sytem, which the hardware connection in Normally Close. During Push the button to shutdown, the both compressor will
stop running with shutdown condition.
During push the button to shutdown from customer PSD, the both compressor will stop running with shutdown condition,
and the dryers will stop running too in accodance with lead-lag operation is in associattion with dryer operation.
13 RESET
The RESET will be in Touch button on panel view In case of alarms and or shutdown to be released and back to normal
condition, by touch the RESET button all condition will be normally and returned to Ready to Start, except if the cause
of alarm not yet correctified the control will be in still alarm.
Correctify the alarm caustion at first and then touch the RESET button , the controll will be normally Ready to Start.
SITE ACCEPTANCE TEST Doc. No.: MTDF-FRM-IN-1030-3222-B1105-1001
PROCEDURE
FOR
Rev. No.: 3
AIR COMPRESSOR AND AIR DRYER PACKAGE
14 STEP OF TEST
14,1 Checking All Power Cable Connection And Voltages Actual Check
- From Starter to Main Motor Phase to Phase 6600 VAC VAC
- From Starter to Fan Motor Phase to Phase 400 VAC VAC
- Control Cable for PLC Panel Phase to Neutral 230 VAC VAC
1st FAN Motor rotation Touch START button for few second (3 - 5 sec.) and then touch STOP
button the main motor are still not running due to the stop less
than delay running setting.
2nd MAIN Motor rotation Touch START button for few second (8 - 10 sec.) and then touch
STOP button
Running by Local
For Compressor-A
Select By Local Mode for local running
Touch Start Button - The compressor will running in Unload Condition for few second and then Load automatically
and Touch Stop button - for Stop running Compressor.
Check the parameter and indication properly and make record
In case to unload running while in local operation, the Unload touch button on HMI TP1200 may could be touched.
For long operation the local operation is not recomended.
For Compressor-B
Do the same above intruction for Compressor-B
Check the parameter and indication properly and make record
Dryer Running
The dryer running shall be thrue Local Control Panel 373-LCP-V1001/2 by Select the Dryer ON/OFF Selector switch.
- Motor Voltage ( Test Record, See Test Form Attachment Page 17-18 )
- Starting Current (Fan and main Motor)
- Load-Unload Current (Ampere)
- Main Motor Bearing Vibration
- Sound Level
14,8 Touch LOAD key button Compressor-A ( Test Record, See Test Form Attachment Page 17-18 )
Check all parameter and indication properly and make record as folow
- LOAD Current (Ampere)
- FULL LOAD Current (Ampere)
- Pressure (psig)
- Temperature (Deg. F)
14,9 Touch LOAD key button Compressor-B ( Test Record, See Test Form Attachment Page 17-18 )
Check all parameter and indication properly and make record as folow
- LOAD Current (Ampere)
- FULL LOAD Current (Ampere)
- Pressure (psig)
- Temperature (Deg. F)
14,10 Select Compressor-B as Lead position ( Test Record, See Test Form Attachment Page 17-18 )
In case of select Lead-B position while both Compressors are in running, the selection from Lead-A
to Lead-B is not influence the running on their load-unload pressure setting.
is not influence the running and its load-unload pressure setting of both compressors except the duty
from Compressor-A as duty (Lead) Comressor-B as Stanby (Lag), change to Compressor-B as duty (Lead)
Compressor-A as standby (Lag).
( Test Record, See Test Form Attachment Page 17-18 )
15 Dryer Running
Switch ON Dryer ON/OFF Selector by Selector or by Touch Dryer ON on HMI TP1200 for 373-D-1003A/B,
and 373-D-1003C/D
Chech the dryer parameters and status indications properly on HMI TP1200 screen view and Recorded
- Regenerating Timer of Vessel-A & B
- Regenerating Timer of Vessel-C & D
17 PLC Alarm ( Test Record, See Test Form Attachment Page 17-18 )
a. Disconnecting Power Supply Primary by Simulation
b. Disconnecting Power Supply Secondary by Simulation
c. Disconnecting Power Supply Primary Processor by Simulation
d. Disconnecting Power Supply Secondary Processor by Simulation
SITE ACCEPTANCE TEST Doc. No. : MTDF-FRM-IN-1030-3222-B1105-1001
PROCEDURE
FOR
Rev. No. : 3
AIR COMPRESSOR AND AIR DRYER PACKAGE
18 TEST RECORDS
Compressor-A Compressor-B
Full Load Current Full Load Current
(Amp.) (Amp.)
(Amp.) (Amp.)
(Amp.) (Amp.)
Load
Main Mtr-A Main Mtr-B Good : 4.5 mm/s
DE Bearing NDE Bearing DE Bearing NDE Bearing Warning : > 4.5 mm/s
(mm/s) (mm/s) (mm/s) (mm/s)
(mm/s) (mm/s) (mm/s) (mm/s)
(mm/s) (mm/s) (mm/s) (mm/s)
Unload
Main Mtr-A Main Mtr-B
DE Bearing NDE Bearing DE Bearing NDE Bearing
(mm/s) (mm/s) (mm/s) (mm/s)
(mm/s) (mm/s) (mm/s) (mm/s)
(mm/s) (mm/s) (mm/s) (mm/s)
TEST RECORDS
5. Sound Level
85 dB
Compressor-A Compressor-B
1 m distance 5 m distance 1 m distance 5 m distance
(dB) (dB) (dB) (dB)
7. Dew Point
At Running Time After 30 min After 1 Hour After 1.5 Hours After 2 Hours -40 deg. F
Dewpoint Value (oF) (oF) (oF) (oF)
8. Running Hours
Comp A Start Finish 2 hours
Comp B Start Finish 2 hours
Note :