Functional Acceptance
Test Procedure
Equipment : Client :
Consortium PT. Istana Karang
Laut & Energypack Power
NITROGEN GENERATOR PACKAGE Generation Ltd.
Project :
3000 BBL / DAY CAPACITY SEMI REGENERATIVE PO No. : 070-227-2018
CATALYTIC REFORMING UNIT & ASSOCIATED
FACILITIES AT RASHIDPUR, BAHUBOL, HABIGANJ,
BANGLADESH
Factory Inspection:
Name Sign Date
Checked by
Checked by
Checked by
Witnessed by
Witnessed by
Witnessed by
Page 1 of 10
Functional Acceptance
Test Procedure
I. Physical Check
Indicator
Description Manufacturer Model S.N Checked
Range
A. Instrumentation
- Pressure Indicator
400-PG-1104
400-PG-1103
- Pressure Transmitter
400-PT-1105
- Pressure Safety Valve
400-PSV-1402
- Air Filter
PK-411-PF01 A & B
PK-411-AF01 A & B
PK-411-PF02 A & B
PK-411-AF02 A & B
PK-411-PF03 A & B
PK-411-AF03 A & B
B. Control System
- Enclosure for Lead-Lag
Control Panel
- HMI, 7” Touch Screen
- ON / OFF Selector Switch
- Reset Push Button
- ESD Push Button
- PLC Unit
Processor
Analog I/O Module
- 24VDC Power Supply
- MCB
- Relay
- Terminal Block
Page 2 of 10
Functional Acceptance
Test Procedure
C. Compressor Unit PK-411-K-
01
- Local Control System
(DELCOS XL)
Pressure Sensor
Oil Temperature
sensor
- Oil Separator
- Screw Compressor with
Electric Motor Driven.
- Cooler Fan and Motor.
- Starter Motor.
D. Compressor Unit PK-411-K-
02
- Local Control System
(DELCOS XL)
Pressure Sensor
Oil Temperature
sensor
- Oil Separator
- Screw Compressor with
Electric Motor Driven.
- Cooler Fan and Motor.
- Starter Motor.
E. Refrigerant Dryer PK-411-
RD-01
- Local Starter System Air
Dryer
- Air Dryer Sytem Package
F. Catalytic Converter PK-411-
CC-01
- Converter Vessel
- Control Catalytic
Converter
- Pre Filter
Page 3 of 10
Functional Acceptance
Test Procedure
- After Filter
- Minimum Pressure Closing
Valve
G. N2 Generator PSA PK-411-
NG-01
- Absorber Column
- Control Panel N2
Generator
- Cycle Pressure Gauge
- Valve for Equalization of
Pressure
- Valve for Cycle Operation
- Valve for Delivery
Nitrogen to Product
- Safety Relief Valve
- Exhoust Pipe ( Silencer )
H. Wire Tagging
I. Name Plate
Page 4 of 10
Functional Acceptance
Test Procedure
II. Functional Test Manual Operation
Indicating
Description Checked Remark
Device
Before the Compressor is operated, make sure all
valves open positions. Refer to P&ID
A. Compressor-1 Operation from Local
Control Panel.
- Turn on Breaker for the Local Control Delcos XL
Panel of Compressor-1 Comp-1 is on
- Set Unload Pressure at 10 BARG Delcos XL
- Set Load Pressure at 8.0 BARG Delcos XL
- Make sure the CTC Converter before to Running Lamp
“START” the compressor. On
Compressor
- Push the “START” button
Comp-1
running
Direction of
- Make sure the Compressor-1 is motor rotation
functioning properly. and no alarm
message in
Delcos XL
- Check the Oil Level level Gauge
- Check the Oil Temperature Delcos XL
Delcos XL &
- Check the LOAD & UNLOAD operation
Compressor
- Check the electric motor current when: -
Unload Status:
Load Status
Ampere Meter
Notice: the motor was tested at a voltage of
400 V and a frequency of 50 Hz
- If the compressor unload for .......minutes -
Compressor-1
then the compressor will stop
stand by
automatically.
Page 5 of 10
Functional Acceptance
Test Procedure
Indicating
Description Checked Remark
Device
- ESD (Emergency Shutdown) Comp-1 Local Control
test Panel Comp-1
- After Individual Test set the Compressor Local Control
to Remote Operation Panel Comp-1
B. Compressor-2 Operation from Local
Control Panel.
- Turn on Breaker for the Local Control Delcos XL
Panel of Compressor-2 Comp-2 on
- Set Unload Pressure at 10 BARG Delcos XL
- Set Load Pressure at 8.0 BARG Delcos XL
- Make sure the CTC Converter before to Running Lamp
“START” the compressor. On
- Push the “START” button Compressor-2
running
Direction of
- Make sure the Compressor-2 is motor rotation
functioning properly. and no alarm
message in
Delcos XL
- Check the Oil Level Level Gauge
- Check the Oil Temperature Delcos XL
Delcos XL &
- Check the LOAD & UNLOAD operation
Compressor
- Check the electric motor current when:
Unload Status:
Load Status Ampere Meter
Notice: the motor was tested at a voltage of
400 V and a frequency of 50 Hz
- If the compressor unload for .......minutes
Compressor-2
then the compressor will stop
stand by
automatically.
- ESD (Emergency Shutdown) Comp-2 Local Control
testing Panel Comp-2
Page 6 of 10
Functional Acceptance
Test Procedure
Indicating
Description Checked Remark
Device
- After Individual test set the Compressor Local Control
to Remote Operation Panel Comp-1
C. CTC Converter Operation from Local
Control Panel.
- Turn on Breaker for CTC Converter
- Located switch on Local “Position”.
- Start the CTC Coverter by switched On Yellow
the Handle. Indicator on
- When the Green Indicator on, CTC Green
Converter already in running position. Indicator on
Temperature
- Make sure the CTC Converter working
Indicator on
properly.
and No Alarm.
- After Individual test set the CTC to
Remote Operation
D. Air dryer Operation from Local Control
Panel.
- Turn on Breaker for Air Dryer
- Start the Air Dryer by switched On the Display
Handle postion local. “dry”on Panel
- Set the dryer to Operation Mode Timed
(tim).
- Make sure the Air Dryer working No Alarm
properly. Indicator ON.
- After Individual test set the Air Dryers to
Remote Operation
E. PSA N2 Generator Operation from Local
Control Panel.
- Turn on Breaker for Air Dryer
- Push “START” button. HMI PSA N2
- Make sure the Air Dryer working No Alarm
properly. Indicator ON.
Page 7 of 10
Functional Acceptance
Test Procedure
III. Functional Test LEAD-LAG PANEL
Indicating
Description Checked Remark
Device
A. MANUAL Operation from LEAD-LAG
Control Panel.
- Push the MENU button and select
HMI
MANUAL OPERATION.
- Set the Pressure Set Point for Comp-1 &
Comp-2
LOAD Pressure at 8.0 BARG
UNLOAD Pressure at 10 BARG
ALARM Pressure:
- Low Pressure at 6 BARG
- High Pressure at 10.3 BARG
ALARM Shutdown:
- Low Low Pressure at 5 BARG
- High High Pressure at 10.5 BARG
CTC
- Push the START button of CTC
Converter is
Converter
running
- Make sure CTC Converter in operation Green Light
condition On
Air Dryer is
- Push the START button of Air Dryer
running
PSA N2
- Push the START button of PSA N2
Generator is
Generator
running
Compressor-1
- Push the START button of Comp-1
is running
- Make sure the Compressor Comp-1 is
Compressor-1
functioning properly
- Check the LOAD & UNLOAD HMI &
Operation for Compressor-1 Compressor-1
- If the compressor-1 unload for .......
minutes then the compressor will stop HMI &
automatically. Compressor-1
Stop to Load : ………second
Compressor-1
- Push the STOP button Comp-1
stop.
Compressor-2
- Push the START button of Comp-2
is running
Page 8 of 10
Functional Acceptance
Test Procedure
- Make sure the Compressor-2 is
Compressor-2
functioning properly
- Check the LOAD & UNLOAD HMI &
Operation for Compressor-2 Compressor-2
- If the compressor-2 unload for .......
minutes then the compressor will stop HMI &
automatically. Compressor-2
Stop to Load : ………second
Compressor-2
- Push the STOP button Comp-2
stop.
B. MANUAL Operation from LEAD-LAG
Control Panel.
- Push the MENU button and select
HMI
AUTO OPERATION.
- Enter value for Parameter Setting as
followings :
Comp. Lead (Comp-1 or Comp-2).
Duration Unit (Minute, Hour or
Day).
Duration Lead ( minimal: 1 )
Unload Press. at 10 BARG
Lead Press. at 8.5 BARG
Lag Press. at 7.5 BARG
PAH (Pressure Alarm High) at 10.3
BARG.
PSHH (Pressure Shutdown High
High at 10.5 BARG.
PAL (Pressure Alarm Low) at 6
BARG.
PSLL (pressure Shutdown Low
Low) at 5 BARG.
- Select the OPERATING MODE to
HMI
AUTO.
CTC
Converter,
- Push the START button. Comp-1 & 2,
Air Dryer,
PSA N2
running,
- Make sure the Compressor CTC HMI &
Page 9 of 10
Functional Acceptance
Test Procedure
Converter, Comp-1 & 2, Air Dryer, PSA Compressor,
N2 are functioning properly. etc
- Check the LEAD, LAG and UNLOAD HMI &
operation. Compressor
- Check the Duration Lead operation. HMI
Lead-Lag
- ESD (Emergency Shutdown) Testing.
Control Panel
HMI &
- Test open channel pressure transmitter
Compressor
Page 10 of 10
