icss loop test presentation updated
TRANSCRIPT
-
8/18/2019 ICSS Loop Test Presentation Updated
1/31
ICSS Loop Test PresentationBy
Eng. Ahmed Adel A. Megeid
1
-
8/18/2019 ICSS Loop Test Presentation Updated
2/31
ICSS Loop Test Presentation
• The purpose of loop test: The purpose of loop test as a part of pre!ommissioninga!ti"ities to !on#rm that the !omponents of the loop are$ired !orre!tly as per design prior to !ommissioning andstartup.
• %o!uments re&uired for loop test:1' %etail Loop %iagram
(' Inter!onne!tion $iring diagram)' P*I%+s
,' Instrument %ata sheet
-' Loop * fun!tion test !he! Lists
(
-
8/18/2019 ICSS Loop Test Presentation Updated
3/31
ICSS Loop Test Presentation
A//re"iation:
• %CS %istri/uted Control System• IPS Instrument Prote!ti"e System
• ICSS Integrated Control * Safeguarding System
• E0S Engineering 0or Station
• A2 ield Au3iliary 2oom• oundation ield/us
• 4S ire * 4as System
• 5B 5un!tion /o3
•
5B oundation ield/us 5un!tion /o3• 6MI 6uman Ma!hine Interfa!e
• 278 2emote 7perated 8al"e
)
-
8/18/2019 ICSS Loop Test Presentation Updated
4/31
ICSS Loop Test Presentation
•
MCC Motor Control Center• BMSBurner Management System
• MMS Ma!hine Monitor System
• 70S 7perating 0or Station
• S7E Se&uen!e 7f E"ents
• I2P Interposing 2elay Panel
,
-
8/18/2019 ICSS Loop Test Presentation Updated
5/31
ICSS Loop test Presentation
Introduction:
Instrument Loop %iagramLoop diagram represents detailed dra$ing sho$ing a!onne!tion from one point to !ontrol system. It !ould /e!onne!tion /et$een:
• ield instrument to !ontrol system 9or "i!e "ersa'• Signal from Lo!al Control Panel to !ontrol system 9or "i!e
"ersa'
• Signal from MCC to !ontrol system 9or "i!e "ersa'
•Signal from one !ontrol system to another !ontrol system
-
-
8/18/2019 ICSS Loop Test Presentation Updated
6/31
ICSS Loop test Presentation
Type of Loops:
1' 7pen or single Loop 9Indi!ation'
DCS
DCS
JB
JB
Transmitter
Transmitter
OWS
OWS 7pen Loop
-
8/18/2019 ICSS Loop Test Presentation Updated
7/31
ICSS Loop test Presentation
(' Closed Loop :
DCSDCS
;
JBJB
OWSOWS
Transmitter Transmitter Control ValveControl Valve
Closed Loop
-
8/18/2019 ICSS Loop Test Presentation Updated
8/31
ICSS Loop test Presentation
• Type of systems:
1' Pro!ess Control System 9%CS< PLC'
(' Safety System 9IPS< 4S< BMS< MMS<6IPPS'
=
-
8/18/2019 ICSS Loop Test Presentation Updated
9/31
ICSS Loop test Presentation• Loop Test Procedure:-
Tools 2e&uired>
• 1' 6and held Communi!ators
• (' 6P 6and Pump $ith digital 4auge * %ru!
•
)' Current sour!e 9,(? mA'<• ,' Multimeter measurement 9A87' lue<
• -' 0ater Pump for le"el transmitters loop test.
• ' T2 or %PI(? de"i!e for temperature
transmitters loop test.• ;' 2adio 90aitali' for !ommuni!ation from !ontrol
/uilding and #eld
• =' Instrument Air net$or to ready 72 using Air!ompressor $ith air dryer.
-
8/18/2019 ICSS Loop Test Presentation Updated
10/31
ICSS Loop test PresentationProcedure; (Refer to Loop Test CheckList);DCS/IPS Loop test:
A' Analog Input 9AI'test pro!edure>
6art Analog input signals shall /e tested as per Loop test!he! List re&uirements as follo$s:
1' Analog input signals shall /e tested at #"e "alues asfollo$s:
, ma at ?
= maat (-
1( ma at -?1 ma at ;-
(? ma at 1??
1?
oop Test Che!List
-
8/18/2019 ICSS Loop Test Presentation Updated
11/31
ICSS Loop test Presentation
)' Che! the "alue in the !orrespondent %CS graphi!s display,' Che! analog alarm setpoints are !orre!t
-' Che! the !orre!t units in %CS 6MI
' Che! the Alarms are re!orded in the 6istorian and S7E 9ifany' is !orre!t.
;' Che! transmitter failure alarm.=' Che! the Tag des!ription for ea!h test
11
-
8/18/2019 ICSS Loop Test Presentation Updated
12/31
ICSS Loop test Presentation• Type of 6art Transmitters used as 9AI':
1' Pressure * %iD. Pressure Transmitter:1' Pressure pump shall /e used for pressure * diDerential
pressure transmitter 96A2T *' loop test at "alues?< (-< -?< ;-< 1?? of !ali/ration range 9rising* falling'
(' ollo$ Analog Input test pro!edure as per AI testpro!edure
)' 2e!ord the result in Loop test !he! ListDCS/IPSDCS/IPS
JBJB
6Phose
OWSOWS
PTPT
HP PUMPHP PUMP
1(
-
8/18/2019 ICSS Loop Test Presentation Updated
13/31
ICSS Loop test Presentation(' Temperature Transmitter:
1'%ru! T2 temp. !ali/rator shall /e used for temp.transmitter 96A2T or ' to perform loop test at"alues ?< (-< -?< ;-< 1?? of !ali/rationrange 9rising * falling'
('ollo$ Analog Input test pro!edure as per AI testpro!edure .
)'2e!ord the result in Loop test !he! ListDCS/IPSDCS/IPS
JBJBOWSOWS
TTTT
Druck TR!eviceDruck TR!evice
T2 !a/le!onne!tion
1)
-
8/18/2019 ICSS Loop Test Presentation Updated
14/31
ICSS Loop test Presentation)A'Le"el transmitter 402 9side to side mounted':
1' 0ater pump shall /e used for 402 LT+s 96A2T or '
to perform loop test at "alues ?< (-< -?< ;-
-
8/18/2019 ICSS Loop Test Presentation Updated
15/31
ICSS Loop test Presentation
DCS/IPSDCS/IPS
JBJBOWSOWS
"T"T
Han! $el!
communicator
Han! $el!
communicator
%e"i!e !a/le
)B' Le"el transmitter 402< Top mounted:1' 6and 6eld !ommuni!ator ,;- shall /e used for 402
LT+s 96A2T or ' to simulate loop test at "alues ?<
(-< -?< ;-< 1?? of !ali/ration range 9rising *falling'.
(' ollo$ Analog Input test pro!edure as per item AI testpro!edure .)' 2e!ord the result in Loop test !he! List.
1-
-
8/18/2019 ICSS Loop Test Presentation Updated
16/31
ICSS Loop test Presentation,'lo$ transmitter Coriolis * ltraSoni!:
1' 6and held !ommuni!ator ,;- shall /e used for T+s98Cone * ltra Soni!' to simulate loop test at "alues ?<(-< -?< ;-< 1?? of !ali/ration range 9rising *falling'
(' ollo$ Analog Input test pro!edure as per AI test
pro!edure .)' 2e!ord the result in Loop test !he! List.
DCS/IPSDCS/IPS
JBJBOWSOWS
%T%T
1
Han! $el!
communicator
Han! $el!
communicator
%e"i!e !a/le
-
8/18/2019 ICSS Loop Test Presentation Updated
17/31
ICSS Loop test PresentationB) An!o" #utputs (A#) Test Procedure ( Referto Loop test check !ist):
Analog 7utput shall /e tested as per Loop test !he! Listre&uirements as follo$s:
1' All Analog 7utput signals shall /e !he! $ith - "alues:
- , mA F ?
- = mA F (-
- 1( mA F -?
- 1 mA F ;-
- (? mA F 1??
(' Che! "al"e tra"elling at #eld and measure the !urrentat IGP Positioner /y using multimeter.
)' Che! the Tag G Loop des!ription for ea!h Tag
,' 2e!ord the results in loop test !he! list
1;
oop Test Che!List
-
8/18/2019 ICSS Loop Test Presentation Updated
18/31
IGP
Positioner
T$pe of de%ices used s &ART-A#:-
1' Control 8al"e : 9Test Pro!edures':
1' or!e signal from 70S to IGP positioner of !ontrol "al"e tosimulate loop test at "alues ?< (-< -?< ;-< 1?? of air!ooler lou"er opening 9rising * falling'
(' Che! !ontrol "al"e tra"elling /y using multimeter to measuremA !urrent for!ed .
)' Che! the remaining analog output test pro!edure as per A7test pro!edure.
,' 2e!ord !ontrol "al"e mo"ing in Loop test !he! List
ICSS Loop test Presentation
DCSDCS
JBJBOWSOWS
Multimeter
1=
CVCV
-
8/18/2019 ICSS Loop Test Presentation Updated
19/31
ICSS Loop test Presentation
C) Di"it! Input (DI)test procedure:-
Type of de"i!es used as 9%I':1' 278 97pen GClose Limit s$it!h':
These signals shall /e tested $ith solenoid "al"e of 278during "al"e opening * !losing. 92efer to %7 test
pro!edure $ith 278 Solenoid "al"e' and re!ord theresults in !he! list
(' I2P 9Pump 2un * Hot A"aila/le Signals':
These signals shall /e tested during pump start Gstopsimulation test $ith MCC 92efer to %7 test pro!edure$ith I2PPump StartGStop' and re!ord the results in !he!list
1
-
8/18/2019 ICSS Loop Test Presentation Updated
20/31
ICSS Loop test Presentation
)' Push /utton and 6and s$it!hes 9M7S< 2eset<S% PB':
These signals shall /e tested /y a!ti"ate PB+s or6S+s and re!ord the results in !he! list
,' Pa!ages * diDerent !ontrol system repeatingsignals 9C< C4
-
8/18/2019 ICSS Loop Test Presentation Updated
21/31
ICSS Loop test PresentationDi"it! Inputs Test Procedures:
%igital input signals shall /e tested as per Loop test !he!list re&uirements as follo$s:
1' A!ti"ate ea!h of the digital inputs as follo$s:
7penGClose 278+s to !he! "al"e limit s$it!hes- EnergieGfor!e I2P relays for !he!ing of run and a"aila/leGun
a"aila/le signals
- or!e Pg LCP signals at LCP to !he! the response in %CS
- or!e ES%GPS% Push /uttons at ES% Console to !he! the
response in ES% and %CS(' Che! the "alue in the !orre!t %CS graphi!s display
)' Che! the Alarms are generated in the Current Alarm %isplay
,' Che! the Alarms are re!orded in the 6istorian and S7E 9ifany' is !orre!t.
(1
oop Test Che!List
-
8/18/2019 ICSS Loop Test Presentation Updated
22/31
ICSS Loop test Presentation
D) Di"it! #utputs
• %igital 7utput signals shall /e tested as per Looptest !he! list re&uirements as follo$s:
• A!ti"ate ea!h of the digital output signals /ytoggling the !orre!t system /lo!.
• Con#rm that (,8%C has /een transferred to the!orresponding #eld de"i!e /y using multimeter
• Con#rm that free !onta!t is !losed at
!orresponding #eld de"i!e /y using multimeter
((
oop Test Che!List
-
8/18/2019 ICSS Loop Test Presentation Updated
23/31
ICSS Loop test PresentationT$pe of de%ices used s (DI ' D#):-
A' 278:
The follo$ing signals shall /e tested $ith 278:1' Solenoid "al"es 928' 9%7'
(' 4JSC 9Close Limit S$it!h 9%I''
)' 4JS7 97pen Limit S$it!h 9%I''
DCSDCS
JBJB
IPS &WSIPS &WS
ROVROV
DCS OWSDCS OWS
IPSIPS
28
2JCG7
()
278 Loop
-
8/18/2019 ICSS Loop Test Presentation Updated
24/31
ICSS Loop test PresentationR# Loop Test Procedure:-
) Shutdo*n !%e:
1A' 278 tra"elling from Closing to 7pening:
1' Before starting test< Shutdo$n "al"e 9278' shall /e in!lose position. A!!ordingly !he! 4JSC in 70S andensure that it+s re!ei"ed !orre!tly 9i.e< 278 !olor is red'
(' Che! instrument air to 278 is !orre!tly adKusted tore&uired pressure.
)' rom IPSE0S> Apply (, 8%C to solenoid "al"e 928'.Che! 278 tra"elling in 70S 9i.e< 278 !olor is ello$'
,' 0hen 278 is fully open< !he! 4JS7 in 70S andensure that it+s re!ei"ed !orre!tly 9i.e< 278 !olor is4reen'
-' Ensure that "oltage applied on solenoid "al"e 928'$ithin a!!epted "alue. 9i.e< ()(, 8%C'
(,
oop Test Che!List
-
8/18/2019 ICSS Loop Test Presentation Updated
25/31
ICSS Loop test Presentation
1B' 278 tra"elling from 7pening to Closing:
1' rom IPSE0S< or!e ? 8%C to solenoid "al"e928'. Che! 278 tra"elling in 70S 9i.e< 278 !oloris ello$'
(' 0hen 278 is fully !lose< !he! 4JSC in 70S and
ensure that it+s re!ei"ed !orre!tly 9i.e< 278 !olor is2ed'
)' Ensure that the "oltage applied on the solenoid928' is ? 8%C
,' 2eopen 278< and !he! 278 fail a!tion in !ase ofsignal failure and Instrument Air ailure
-' 2e!ord all a/o"e results 928< 4JSC< 4JS7' in
Loop test !he! list
(-
-
8/18/2019 ICSS Loop Test Presentation Updated
26/31
ICSS Loop test Presentation+- B!o* do*n !%es
(A' 278 tra"elling from 7pening to Closing:
1' Before starting test< Blo$ do$n "al"e 9278' shall /e inopen position. A!!ordingly !he! 4JS7 in 70S andensure that it+s re!ei"ed !orre!tly 9i.e< 278 !olor isgreen'
('Che! instrument air to 278 is !orre!tly adKusted tore&uired pressure.
)' Che! 2S2 9reset P.B' and ensure that 2S2 signals isre!ei"ed at E0S.
,' rom IPSE0S> or!e (, 8%C to solenoid "al"e 928' and
(? mA to IGP Positioner. Che! 278 tra"elling in 70S 9i.e<278 !olor is ello$'
-' 0hen 278 is fully !lose< !he! 4JSC in 70S and ensurethat it+s re!ei"ed !orre!tly 9i.e< 278 !olor is 2ed'
' Che! the "oltage applied on solenoid "al"e 928' $ithin
a!!epted "alue. 9i.e< ()(, 8%C' (
oop Test Che!List
-
8/18/2019 ICSS Loop Test Presentation Updated
27/31
ICSS Loop test Presentation(B' 278 tra"elling from Closing to 7pening:
1' rom IPSE0S> or!e ? 8%C to solenoid "al"e928'. Che! 278 tra"elling in 70S 9i.e< 278!olor is ello$'
(' 0hen 278 is fully open< !he! 4JS7 in 70S
and ensure that it+s re!ei"ed !orre!tly 9i.e<278 !olor is green'
)' Che! the "oltage applied on the solenoid928' "oltage is ?
,' 2e!ord all signals results 928< 4JSC< 4JS7<
2S2' in relati"e Loop test !he! list
(;
-
8/18/2019 ICSS Loop Test Presentation Updated
28/31
ICSS Loop test Presentation
B) Pu,p Si"n!s Test Procedures: The follo$ing Pump signals shall /e test as %7:
1'2emote Start 9%CS%7'
('2emote Stop 9%CS%7'
)'ES% Trip 9IPS%7'
The follo$ing Pump signals shall /e test as %I :
1' Pump 2un Status 9%CS%I'
('Pump Hot A"aila/le 9%CS%I'
)' 2emoteGLo!al 9%CS%I'
(=
i
-
8/18/2019 ICSS Loop Test Presentation Updated
29/31
ICSS Loop test Presentation
• Pump Interfa!e Signals
(
DCSDCS
IPSIPS
MCCMCC
2emoteStart2emote
Stop
Lo!alG2emote
2un Status
Hot A"aila/le Status
ES% Trip
-
8/18/2019 ICSS Loop Test Presentation Updated
30/31
ICSS Loop test Presentation
• Pu,p di"it! si"n!s Test Procedure
1' MCC %ra$er shall /e s$it!hed to test Mode 9ifenergied'
(' Ensure that ES% trip signals 9JT' is Hormal andStop signals not a!ti"ated 9%7 Conta!t is !losed' /y
using multimeter)'Sele!t Pump at manual mode and apply 2emoteStart signals 96SA' from 70S and ensure that startsignals is re!ei"ed at MCC dra$er
,' Che! 2un status signal 9B' in %CS70S isre!ei"ed 9i.e< PumpGAir !ooler !olor is green'
-'Apply 2emote Stop signals 96SB' from 70S andensure that start signals is re!ei"ed at MCC dra$er
)?
-
8/18/2019 ICSS Loop Test Presentation Updated
31/31
ICSS Loop test Presentation
' Che! 2un status signal 9B' in %CS70S andensure that PumpGAir !ooler is stopped 9i.e< PumpGAir!ooler !olor is 2ed'
;' 2epeat Step )< , a/o"e< and apply ES% trip signalfrom IPSE0S
=' Che! 2un status signal 9B' in %CS70S andensure that PumpGAir !ooler is stopped 9i.e< PumpGAir!ooler !olor is 2ed'
' Apply Lo!alG2emote signals 9SL2' from #eld and
ensure that su!h signals 9SL2' is re!ei"ed at%CS70S.
1?' 2e!ord all a/o"e tests results in loop test !he!list.
)1