ICSS Loop Test Presentation Updated

8/18/2019 ICSS Loop Test Presentation Updated

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ICSS Loop Test PresentationBy

Eng. Ahmed Adel A. Megeid

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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

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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

)


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•

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

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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

-


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Type of Loops:

1' 7pen or single Loop 9Indi!ation'

DCS

DCS

JB

JB

Transmitter

Transmitter

OWS

OWS 7pen Loop


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(' Closed Loop :

DCSDCS

;

JBJB

OWSOWS

Transmitter Transmitter Control ValveControl Valve

Closed Loop


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• Type of systems:

1' Pro!ess Control System 9%CS< PLC'

(' Safety System 9IPS< 4S< BMS< MMS<6IPPS'

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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.


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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??

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oop Test Che!List


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)' 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

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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(


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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)


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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 ?< (-< -?< ;-


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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-


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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


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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


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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


DCSDCS

JBJBOWSOWS

Multimeter

1=

CVCV


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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

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)' 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


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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.

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oop Test Che!List


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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


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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


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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


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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

(-


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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


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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

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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'

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• Pump Interfa!e Signals

(

DCSDCS

IPSIPS

MCCMCC

2emoteStart2emote

Stop

Lo!alG2emote

2un Status

Hot A"aila/le Status

ES% Trip


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• 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

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' 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.

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ICSS Loop Test Presentation Updated

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