OWNER REFERENCE

Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 1 / 22

Project Specification – Procedure for Loop Testing

PROJECT SPECIFICATION

PROCEDURE FOR LOOP TESTING

OWNER Approval: PETRONAS

Name:
Date (DD-MMM-YY):

Signature:

Document Class: X

Pages modified under this revision:

Patrice Merlet
60987R-0001-FOR-0003_E

2013.04.05
Bernard Caussanel Jean-Marc Maurice
2013.04.03 10:56:28
2013.04.05
17:47:05 +02'00' +08'00' 08:55:36 +02'00'

0 03-Apr-13 IFD – Issued Approved For Design B.CAUSSANEL P.MERLET JM. MAURICE
A 18-Feb-13 IFR – Issued For Review B.CAUSSANEL P.MERLET JM. MAURICE
DATE WRITTEN BY CHECKED BY APPROVED BY
REV. STATUS – REVISION MEMO
DD-MMM-YY (name & visa) (name & visa) (name & visa)

Sections changed in last revision are identified by a vertical line in the margin.

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
Electronic Filename: RAPID-FE1-TPX-CMM-SPN-0001-0928_0.docx
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 2 / 22

Project Specification – Procedure for Loop Testing

CONTENTS

1. PURPOSE ............................................................................................................................................................................ 3
2. REFERENCE DOCUMENTS ........................................................................................................................................... 3
3. ACRONYMS AND DEFINITIONS .................................................................................................................................. 3
4. CODES AND STANDARDS .............................................................................................................................................. 6
4.1 APPLICABLE CODES & STANDARDS .............................................................................................................................. 6
4.2 ORDER OF PRECEDENCE ................................................................................................................................................ 6
5. SCOPE OF WORK FOR INSTRUMENT LOOP TEST ................................................................................................ 6
5.1 PURPOSE OF INSTRUMENT LOOP TEST .......................................................................................................................... 6
5.2 INSTRUMENT SIGNALS FOR LOOP TEST ......................................................................................................................... 7
5.3 ANALOG INPUT (AI) SIGNAL (CONVENTIONAL SIGNAL) ............................................................................................... 7
5.4 ANALOG OUTPUT (AO) SIGNAL (CONVENTIONAL SIGNAL) .......................................................................................... 9
5.5 DIGITAL INPUT SIGNAL ................................................................................................................................................. 9
5.6 DIGITAL OUTPUT SIGNAL ........................................................................................................................................... 10
5.7 SERIAL COMMUNICATION SIGNAL (MODBUS, PROFIBUS, ETC...) ................................................................................ 11
6. LOOP TEST EXECUTION ............................................................................................................................................. 12
6.1 GENERAL PREPARATION PRIOR TO LOOP TEST ........................................................................................................... 12
6.2 LOOP TEST TEAM COMPOSITION ................................................................................................................................. 13
6.3 GENERAL NOTES FOR LOOP TEST ............................................................................................................................... 13
6.4 DCS SIGNAL LOOP TESTING ........................................................................................................................................ 14
6.5 ESD SIGNALS LOOP TESTING ..................................................................................................................................... 15
6.6 PACKAGE SIGNALS LOOP TESTING .............................................................................................................................. 16
6.7 FIRE & GAS SYSTEM SIGNALS LOOP TESTING ............................................................................................................. 17
6.8 ELECTRICAL SIGNALS LOOP TESTING ......................................................................................................................... 18
6.9 ANALYSER SIGNALS LOOP TESTING ............................................................................................................................ 19
6.10 LOOP TEST FOR MOV ................................................................................................................................................. 20
7. POST WORK .................................................................................................................................................................... 20
7.1 COMPLETION ON CABINETS INSIDE CONTROL ROOM .................................................................................................. 20
7.2 COMPLETION ON FIELD DEVICES ................................................................................................................................ 20
7.3 COMPLETION ON DOCUMENTATION ............................................................................................................................ 21

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 3 / 22

Project Specification – Procedure for Loop Testing

1. PURPOSE
PETRONAS intends to build a grassroots Refinery and a Petrochemical Complex by developing
the project RAPID (Refinery and Petrochemical Integrated Development) to meet both domestic
and regional demands. The refinery shall process 300,000 BPSD of Basrah light crude.
The present Project Specification covers the requirements for best practices when conducting
instrument loop test as a part of pre-commissioning stage at site.
These requirements shall be used as a base statement for Loop Testing activities which will be
performed during Pre-commissioning phase and shall be followed and adopted by all concerned
parties (EPCC CONTRACTORS and OWNER) during engineering phase (preparation works) and
during the execution phase.

2. REFERENCE DOCUMENTS
RAPID-FE1-TPX-INC-DES-0001-0002 (60987R-0001-JSD-1510-0001), Project Specification –
Instrument and Control Design Basis
RAPID-FE1-TPX-INC-DES-0001-9002 (60987R-0001-JSD-1500-9003), “Inspection & Functional
Testing of Instruments” Supplement to PETRONAS Technical Standards (PTS 62.10.08.11 dated
Nov 2009)
RAPID-FE1-TPX-CMM-SPN-0001-0927 (60987R-0001-JSS-9000-0927), Project Specification –
Procedure for Instrument Systems SAT
RAPID-FE1-TPX-CMM-PRC-0001-0901 (60987R-0001-PP-0901), Pre-commissioning &
Commissioning Execution Plan
RAPID-FE1-TPX-CMM-PRC-0001-0902 (60987R-0001-PP-0902), Commissioning & and Start-
Up Roles and Responsibilities Matrix

3. ACRONYMS AND DEFINITIONS

The following terms used in this document have the meaning defined below:
CONTRACT The Form Of Agreement together with the documents in order of
priority, including the exhibits, drawings, specifications and
documents referred to and in the order of precedence listed in the
Form of Agreement.
CONTRACTOR The person or persons, company, join venture or consortium whose
proposal has been accepted by OWNER for Engineering,
Procurement, Construction and Commissioning Contract for the
PROJECT including its personnel, representatives, successors and
permitted assignee.
OWNER Petroliam Nasional Berhad (PETRONAS) which includes its
representative, successors, nominees and permitted assigns and shall
where the context so admits and requires, also include its employees,
agents and designated representative.
PROJECT Refinery And Petrochemicals Integrated Development (RAPID)
Project in the State of Johor, Malaysia.
SCOPE OF WORK The scope of work to be performed and services to be rendered by
CONTRACTOR under the CONTRACT in relation to the realization
of the PROJECT.

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 4 / 22

Project Specification – Procedure for Loop Testing

SUBCONTRACTOR Any third party Subcontractor engaged by CONTRACTOR in

connection with the WORK.

WORK Works, tasks and WORK to be performed by CONTRACTOR as

specified in or to be inferred from the CONTRACT, more specially
set out in the SCOPE OF WORK which may be modified by
CHANGE ORDER.

The acronyms used in this document have the meaning defined below:
- ACMS Automated Corrosion Monitoring System
- AMADAS Analyser Management And Data Acquisition System
- APC Advanced Process Control
- ASC Anti Surge Control
- BCS Blending Control System
- CCR Central Control Room
- CEMS Continuous Emission Monitoring System
- CMMS Computerized Maintenance Management System
- CPMS Controller Performance Monitoring System
- CV Control Valve
- CSN Control System Network
- CTR Central Technical Room
- DCS Distributed Control System
- ENMCS Electrical Network Monitoring & Control System
- EDV Emergency Depressurization Valve
- EIV Emergency Isolation Valves
- ESD Emergency Shut Down System
- EWS Engineering Workstation
- FAR Field Auxiliary Room
- FAT Factory Acceptance Test
- FAP Fire Alarm Panel
- FEED Front-End Engineering Design
- FGS Fire & Gas System
- GCS GPS (Global Positioning System) Clock System
- HART Highway Addressable Remote Transducer
- HIPPS High Integrity Pressure Protection System
- HMI Human Machine Interface
- HVAC Heating, Ventilation and Air Conditioning
- IAMS Instrument Asset Management System
- IER Instrument Engineering Room
- IMCS Integrated Motor Control System
- IPF Instrumented Protective Functions
- IS Intrinsically Safe
- JB Junction Bow
Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 5 / 22

Project Specification – Procedure for Loop Testing

- LBAS LPG Bottle Plant Automation System

- LBB Laboratory Building
- LCD Liquid Crystal Display
- LCS Local Control Station
- LIMS Laboratory Information Management System
- LP Local Panel
- MAC Main Automation Contractor
- MCB Main Control Building
- MCC Motor Control Centre
- MCS Metering Control System
- MMS Machine Monitoring System
- MOV Motor Operated Valve
- OLE Object Linking and Embedding
- OMS Oil Movement System
- OPC OLE for Process Control
- OSB Operational Shelter Building
- OTS Operator Training Simulator
- OWS Operator Workstation
- P&ID Piping and Instrumentation Diagram
- PIMS Plant Information Management System
- PAGA Public Address General Alarm
- PCN Process Control Network
- PCP Pengerang Cogeneration Plant
- PDWT Pengerang Deep Water Terminal
- PIN Plant Information Network
- PLC Programmable Logic Controller
- PP Poly-Propylene
- PTS PETRONAS Technical Standard
- QMI Quality Measurement Instrumentation
- RAPID Refinery And Petrochemicals Integrated Development
- RIO Remote Input / Output
- SOE Sequence of Events
- SOV Solenoid Operating Valve
- SIL Safety Integrity Level
- SPWMS Solid Product Warehouse Management System
- TGS Tank Gauging System
- TSO Tight Shut-Off
- TTLR Tanker Truck Loading Rack System
- TÜV Technischer Überwachungsverein
(German: Technical Monitoring Association)
- UPS Uninterruptible Power Supply

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 6 / 22

Project Specification – Procedure for Loop Testing

4. CODES AND STANDARDS

4.1 Applicable Codes & Standards

Refer to RAPID-FE1-TPX-INC-DES-0001-9002 (60987R-0001-JSD-1500-9003), “Inspection &
Functional Testing of Instruments” Supplement to PETRONAS Technical Standards (PTS
62.10.08.11 dated Nov 2009)
Unless otherwise specified, the latest applicable revision of codes and standards shall be
considered.

4.2 Order of precedence

In case of conflict between Laws, Project Specifications and Codes & Standards, the following
order of precedence shall be considered:
- 1. Malaysian Laws and applicable regulatory requirements,
- 2. Project Specifications and supplemented PTS,
- 3. Applicable Malaysian Codes and Standards,
- 4. Applicable International Codes and Standards.
If a Lower Level requirement is more stringent than an upper one in the above documents, a
request shall be raised to OWNER for written decision before proceeding with the Design,
Manufacture or Construction.

5. SCOPE OF WORK FOR INSTRUMENT LOOP TEST

5.1 Purpose of Instrument Loop Test

The purpose of the instrument loop test is to confirm I/O communication functionality and
diagnostic between the Instrument Control System and field instruments.
I/O communication between two systems cabinet shall also be verified as part of instrument loop
test.
Instrument loop test is the final chance to check for instrument installation and wiring construction
completion as a complete signal loop. It is also the most important activity before sequence/logic
function test and system handover.
Instrument Loop test shall be carried out as a joint activity with EPCC CONTRACTOR, MAC,
VENDORS and OWNER. All I/O‟s shall be checked on System HMI (such as DCS Console) or
HMI on Cabinet.
Major Instrument Control Systems on RAPID are listed as follows:
(1) DCS
(2) ESD
(3) FGS
(4) ASC (Compressor control system)
(5) BMS
(6) BCS
(7) PLC

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 7 / 22

Project Specification – Procedure for Loop Testing

(8) MMS
(9) AMADAS
(10) TGS
(11) MCS
(12) OMS
(13) IAMS
(14) ACMS
(15) CEMS

5.2 Instrument Signals for Loop Test

Instrument Control System has the following signal types for its I/O communication.

a. AI/AO (4-20mA HART)

b. DI/DO (Digital Input/Output Signals with 24VDC)

c. Wireless Signal

d. Serial Communication (Profibus or Modbus Signals with other Systems)

e. OPC Communication (OPC Signals with other Systems)

All the above signals will be checked during loop test. During loop test, field instrument devices
will be energized from technical room and they will be the live equipment. Therefore there are
several steps to carry out the loop test. Major steps of loop test are as follows:
 Step 1: Confirm the completion of construction system wise.
 Step 2: Energize the field devices from control room (close the knife edge terminal or fuse)
 Step 3: Signal test to verify its functionality
 Step 4: Confirm the configuration in the system (Tag, Range, Description, etc.)
 Step 5: Keep the live condition at field as a loop test completion
Step 1, Step 2, Step 4 and Step 5 are the same for all signal types. However, Step 3, which is the
signal test, is considered several different methods according to the signal type. The method of
signal test for each signal type is described hereafter.

5.3 Analog Input (AI) Signal

The Analog input signal for instrument system used in the project is 4-20 mA HART.
Signal injection test (Up/Down) shall be done for 0%, 50% and 100% of full range of DCS (and
other systems, where applicable). Indication and local indication on Transmitter will be confirmed.
In general, signal will be injected according to the below table:

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 8 / 22

Project Specification – Procedure for Loop Testing

Signal Field Device Signal Injection Remarks

Protocol
HART Pressure/DP Transmitter pressure transmitter: Simulate by
(1) CPMS from
Simulate by Handheld
Control Room is
Communicator from field
the alternative if
Or portable pressure it is practical
generator from field (1)
Temperature:
Temperature Transmitter
(3) Using Decade Box from
field
Displacer (2)
Mass Flow Meter, etc
Non Motor (Power, Current, Inject by Signal Generator
HART Voltage, Speed, etc) (Case by Case) from Field if
the simulation is not
HVAC Temp, etc
practical
MMS Devices
Analyzer Using actual calibration Signal will be
tools such as calibration gas. checked during
Gas Detector
calibration
RTD, Thermocouple Temperature Signal
Generator shall be used.
Burn-out by disconnecting
the wire and ambient
temperature shall be
confirmed.
Notes:
(1) For DP and pressure transmitters used for indication and control, a hand-held instrument
communicator can be used to simulate the output signal. For emergency shutdown transmitters
and critical control loops, a hand held pressure calibrator shall be used to apply pressure to the
instrument in case of loop test.
(2) Level transmitters and controllers are tested by filling the displacer cages with water in case of
loop test.
(3) For temperature transmitter, burn-out check by disconnecting the wire between temperature
element and transmitter and ambient temperature check shall be included as part of loop test.
If field instrument needs to be calibrated at site, loop test will be carried out at the same time field
instrument is being calibrated. For example, analyzer, gas detector, special flow meter such as
ultrasonic type, etc.
If alarm set is specified for the analog indication, alarm indication shall be checked as follows:
 Open alarm summary on DCS and/or Vendor PLC, if available, and check alarm indication
according to the alarm setting.
 Open Sequence of events and Check SOE record (if applicable for safety system)

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 9 / 22

Project Specification – Procedure for Loop Testing

5.4 Analog Output (AO) Signal (Conventional Signal)

The Analog Output signal for instrument system used in RAPID project is conventional signal
(4-20 mA)
Stroke test (Up/Down) for Control Valve shall be done for 0%, 25%, 50%, 75% and 100%.
If the device is not valve, Output signal shall be checked at 0%, 50% and 100%.

Signal Protocol Field Device Signal Output Remarks

HART Shut Down Valve Simulate from
Control Room to
I/P Converter
manipulate valve or
Local Indicator transfer the value.
Non HART Other PLC, Local Simulate from
Panel Control Room or
Local Panel to
manipulate valve or
transfer the value.

When Field device is Control Valve, its failure action and controller action will be confirmed
during loop test.
When Field device is Remote Indicator, output shall be given from Control Room to field and field
indication will be confirmed to match with the Control Room. Field Transmitter and Remote
Indicator may be tested together if they are in the same loop.
For hardware interface signal between two different systems, current and voltage signals shall be
checked using a multi-meter at tie-in point.

5.5 Digital Input Signal

There are several discrete input signals (contact signal) to the instrument system. Loop test method
for them is summarized in the below table.
For the pressure switch, actual pressure test is not considered in general. If pressure switch is used
for the safety function, Fire and Gas system or critical control loop, the same rule for analog input
signal loop test shall be applied. Refer to section 5.3.
If the discrete signal generates the alarm or it is the alarm signal, alarm indication on DCS alarm
summary and its record in historian or SOE shall be confirmed.

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 10 / 22

Project Specification – Procedure for Loop Testing

Group Device Loop Test Method Remarks

Field 1) Pressure Switch Jumper at Field Instrument
Instrument Terminals.
2) Float Level Switch
3) Capacitance Level
Switch
4) Tuning Fork Level
Switch
5) Temperature Switch
/ Thermostat
6) Speed Switch

Accessories 1) Valve Limit Switch Actual Limit Switch Signal

shall be checked during valve
stroke Test.

Manual Switch 1) Hand switch Press actual manual switch.

2) Push Button

Signal from 1) Status Input Simulate from other system.

other System
2) Alarm Input

MCC 1) Running Feedback Simulate from MCC. Test shall be

carried out with
Electrical
Group.
MCC shall be
in Test position.
Fire & Gas 1) Manual Call Point Refer to Section 6.7
Devices
2) Smoke Detector

5.6 Digital Output Signal

There are several digital output signals (contact signal) from the instrument system. Loop test
method for them is summarized in the below table:

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 11 / 22

Project Specification – Procedure for Loop Testing

Group Device Loop Test Method Remarks

Valve Stroke 1) On-Off Valve Open/Close valves and confirm
its operation at field.
2) Trip Valve (SOV)
Signal Output 1) Status Output Simulate from the system
to System
2) Alarm Output

MCC 1) Remote Start/Stop Simulate from the system Test shall be

carried out with
2) Trip Signal
Electrical Gr.
3) Start Interlock
MCC shall be in
Condition
Test position.

5.7 Wireless Signal

Wireless Infrastructure are provided for implementation of process Wireless field Instrumentation
and for safety purpose i.e. safety mustering. Wireless field instrumentation is applied to monitoring
loop only.
The wireless Analog input signal for instrument system used in the project is based on Wireless
HART technology.
Signal injection test (Up/Down) shall be done for 0%, 50% and 100% of full range of DCS (and
other systems, where applicable). Indication and local indication on Transmitter will be confirmed.
For DP and pressure transmitters used for indication, a hand-held instrument communicator will be
used to simulate the output signal.
For temperature transmitter, a decade box will be used.
If field instrument needs to be calibrated at site, loop test will be carried out at the same time field
instrument is being calibrated.

5.8 Serial Communication Signal (Modbus, Profibus, etc...)

Serial Communication Signals between two different systems shall be tested according to the
Communication Address List provided by Vendor. 100% of the address check shall be done.
Communication signals would be checked up to DCS graphics and/or Alarm summary page.
These communications tests are usually performed during SAT (Site acceptance test) and
reconfirmed during loop test.

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 12 / 22

Project Specification – Procedure for Loop Testing

6. LOOP TEST EXECUTION

6.1 General Preparation prior to Loop Test

6.1.1 Field Construction

Prior to start Instrument Loop Test, it is necessary to confirm, upon the instrument to be tested,
that related field construction activities have been completed and system has been handed over to
commissioning. Following construction test status shall be available in the Completion Database:
 Field Instrument installation report
 Instrument calibration report
 Air supply/ signal leak test
 Field mounted junction Box or Local panel installation report
 Cable insulation & continuity check report
 Equipment panel inspection in Control Room
All the above construction test reports shall be logged and stored in the Completion Database of
the PROJECT. Construction completion status, which is mandatory for loop test, will be checked
in the Completion Database prior starting the loop testing.
A Loop release form shall be issued for each instrument to confirm readiness of the Loop.

Notes:
- Instrument impulse tubing leak test completion is not mandatory condition for the loop test
readiness.
- If for any reason, the wiring has to be disconnected, for construction punch clearance, the
Instrument loop test will not be started if ready or will be re-tested if it has been already
performed.

6.1.2 Reference documents for Loop Test (Loop Folder)

The Loop Folders shall be prepared in advance by CONTRACTOR before Loop Test can be
started. The content includes
 Loop release form (refer to 6.1.1)
 Loop Test check sheet (refer to 6.1.5)
 P&ID
 Wiring Connection drawings
 Alarm Set Point List
 Loop Drawing
 Package Vendor Documents (If applicable)

6.1.3 Required Tools for Loop Test

Following tools shall be available as minimum:

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 13 / 22

Project Specification – Procedure for Loop Testing

 Handheld Communicator with calibration certificate

 4-20mA generator for non-HART Type Transmitters with calibration certificate
 Digital Calibrator, Fluke 702 or equivalent with calibration certificate
 Portable Pressure generator with calibration certificate
 Multi-meter, Buzzer, Standard Tools with calibration certificate
 Radio

6.1.4 Loop Test check sheet

Loop Test check sheet shall be prepared by CONTRACTOR during Engineering phase as part of
COMMISSIONING preparation WORKS (refer to RAPID-FE1-TPX-CMM-PRC-0001-0901,
(60987R-0001-PP-0901), Pre-commissioning Execution Plan).
Loop Test Check Sheet shows all the necessary data such as Tag Number, Loop Number,
MAP/System Number, P&ID Number, System Name, Signal Type, Range, Set Point, etc.
Loop test data, result and comments shall be recorded in this sheet uploaded in the Completion
Database after successful test of the loop.

6.2 Loop Test Team composition

Following work team shall be arranged as a minimum by CONTRACTOR
Team A: Field Team
Team B: Control Room Team (located in FAR or MCB)
Team C: VENDOR or Specialised Team
OWNER: OWNER representative to witness the test
Team B will be located in the FAR as a first choice since all the related equipment such as
System Cabinet, Marshaling Cabinet and Operator Consoles are located in the FAR. It allows also
starting Loop check without having all communication completed between FAR and Main
Control Building .
Team communication shall be done using hand portable radios.

6.3 General Notes for Loop Test

6.3.1 DCS or other systems Configuration Check

Configuration shall be checked during Loop Test on DCS and/or other systems Graphics and
Face Plates:
 Service Description
 Indication Range
 Alarm& Trip Setting, Alarm Priority
 Graphic Indication

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 14 / 22

Project Specification – Procedure for Loop Testing

6.3.2 Sub-system Serial Communication Check

Subsystem communicates with DCS shall be checked. Signal should be checked on DCS
Graphics and Face Plate. Verification by DCS reading:
 ESD
 FGS
 RIO
 MMS
 ASC
 PLC
 AMADAS
 ENMCS and IMCS
 BMS
 BCS
 ASC
 MCS
 Etc..

6.3.3 Field Installation Check

Following points shall be checked visually before Loop Test:
 Field cable Earthling Check
 Differential Pressure Transmitter High/Low pressure Side
 CV Flow Direction

6.3.4 Valve Operation at Field

When operate the valves (CV, UZV, KSV, MOV, etc), Loop Test Crew shall confirm the process
condition and safety at field prior to loop test.
If Loop Test Crew find some abnormal condition or unsafe conditions, it is necessary to report to
control room prior to operate the valve.

6.4 DCS signal loop Testing

DCS has the following type of signals:
 AI/AO (Conventional Analogue Input/Output Signals with 4-20mA)
 DI/DO (Discrete Input/Output Signals with 24VDC)
 Modbus Serial (Modbus Serial Communication Signals with other Systems)
 OPC Signals (OPC Communication Signals with other Systems)

Simplified schematic for DCS signals are provided as following figure:

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 15 / 22

Project Specification – Procedure for Loop Testing

Field FAR CCR

room
Team A Team B Team B (*)
DCS OS DCS OS

DCS DCS DCS System

Marshalling System Cabinet
JB
Cabinet Cabinet

DCS Network

6.5 ESD Signals Loop Testing

For shut down valve, i.e. UZV, KSV and Control Valve with Solenoid, valve operation
functionality shall be checked to verify solenoid is working fine by full opening and closing.
Stroke Function shall be tested and its stroke time shall be measured and recorded. Some valve
accessories such as Limit Switch, Solenoid Valve, pressure switch, will be tested at the same time
to complete one valve completely.
Test item for Shut down Valve are summarized as follows:
 Stroke Test
 Limit Switch Test
 Trip Test (Stroking Time)
Simplified schematic for IPS/HIPPS signals are provided as following figure

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 16 / 22

Project Specification – Procedure for Loop Testing

Field FAR CCR

Team A Team B Team B (*)

ESD DCS DCS ESD

OS

ESD ESD DCS DCS ESD

Marshal System System System System
JB
ling Cabinet Cabinet Cabinet Cabinet
Cabinet

DCS
Network
ESD Network

6.6 Package Signals Loop testing

Communication checks between systems shall be confirmed by MAC and Package Vendor
together during the SAT activities (refer to RAPID-FE1-TPX-CMM-SPN-0001-0927, (60987R-
0001-JSS-9000-0927)).
Simplified schematic for Package PLC signals are provided as following figure:

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 17 / 22

Project Specification – Procedure for Loop Testing

Field FAR MCB

Team A Team C Team B Team B (*)

MMI (if any)

DCS OS DCS OS

Marshalling System DCS System DCS System

JB Cabinet Cabinet Cabinet Cabinet

DCS Network

6.7 Fire & Gas System Signals Loop testing

Followings are the specific items for Fire & Gas devices;
 Flame Detector (UV/IR)
4-20mA non-HART Signal is used. Loop Test will be done by simulating the condition with
UV/IR Test Lamp.
 Combustible Gas Detector
4-20mA non-HART Signal is used. Loop Test will be done together with the Detector Calibration
by using sample gas cylinder.
 Toxic (H2S) Gas Detector
4-20mA non-HART Signal is used. Loop Test will be done together with the Detector Calibration
by using sample gas cylinder.
 Photo Optical Smoke Detector
Contact Signal is used for smoke detector alarm. This signal will be simulated by smoke gas
detector test tool provided by VENDOR.
 Manual Call Point
Contact Signal is used for manual call point alarm. Manual Call Point will be activated for
generating actual alarm signal from field.

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 18 / 22

Project Specification – Procedure for Loop Testing

Other F&G devices such as pressure transmitter, valve, temperature/pressure switch, etc will be
tested as same as other systems.

Field FAR MCB

Team A Team B Team B (*)

FGS DCS OS DCS OS FGS OS

FGS FGS DCS System DCS FGS

Marshalling System Cabinet System System
JB
Cabinet Cabinet Cabinet Cabinet

DCS Network

FGS Network

6.8 Electrical Signals Loop testing

When signal related to MCC is tested, following shall be coordinated with Electrical Group.
 MCC in Test Position
 LCS (Local Control Station) position.
Loop Test for signals (local start/stop, DCS start/stop, running status, electrical fault) between
MCC and DCS shall be done together with CONTRACTOR Electrical Group. Before Loop Test
starts, MCC shall be switched to „TEST‟ position.

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 19 / 22

Project Specification – Procedure for Loop Testing

Field SUB FAR MCB

Team A Team A Team B Team B (*)
Team C
IMCS DCS OS DCS OS
SYSTEM

MCC IRP DCS DCS System DCS System

Cabinet DCS Network Cabinet
LCS Marshalling

ESD/FGS

ESD ESD
Marshalling System
Cabinet

6.9 Analyser Signals Loop testing

Analyser signals shall be tested during Analyzer calibration using calibration cylinders (zero
span, gas mixture etc….). Analyser shall be subject to a detailed Site acceptance procedure
including all calibration requirements.
Simplified schematic for Analyzer signals are provided as following figures:

Field FAR MCB

Team A Team B Team B (*)
Team C AMADAS
DCS OS DCS OS SERVER

Marshalling DCS DCS System

Analyzer System Cabinet
House/ Shelter Cabinet
JB

DCS Network
AMADAS Network

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 20 / 22

Project Specification – Procedure for Loop Testing

6.10 Loop Test for MOV

Before Loop Test starts, following activities shall be done as for the preparation work:
 Manual Operation by hand wheel shall be done and Valve shall be opened at middle position
manually.
 Energize MOV Actuator from MCC (MOV Actuator shall be in Local Position.) with
Electrical Group.
Once MOV Actuator is energized, followings have to be done as for Loop Test.
 Download the MOV configuration from DCS if applicable.
 Local Operation Test (MOV Actuator shall be operated in Local Position). Full stroke
operation shall be checked. And its operation shall be monitored at DCS in Control Room.
 Change to Remote Position and operate from Control Room remotely as a loop test.
 Status Indications on DCS shall be checked.

6.11 Loop Test Split between different CONTRACTORS

In some of the Sub-stations, Remote Input/Output are installed and connected to the respective
systems in relevant FAR. In some cases, the Remote I/O cabinet and the System cabinet are under
the responsibility of different CONTRACTORs.
The split of loop test shall be carried out by the different CONTRACTOR accordingly
The loop test shall be performed in 2 steps:
Step1: By CONTRACTOR “A”: validation from the Field Instrument to the Remote I/O cabinet.
Step 2: By CONTRACTOR “B”: validation from the Remote I/O cabinet to the Workstation in
FAR.

7. POST WORK
When loop test is completed successfully, signal will be live as a permanent condition. If some
comments are raised during loop test, comments shall be capture as punch item.

7.1 Completion on Cabinets inside Control Room

After completion of Loop Test, condition of each signal inside cabinet shall be as follows;
 Keep knife-edge terminal close
 Keep fuse on
 Keep power on
 Sticker (with Loop test date) to be put on terminals inside cabinet for notification

7.2 Completion on Field Devices

After completion of Loop Test, condition of each device at field shall be as follows;
 For Valves:
1) Keep air supply valve open

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 21 / 22

Project Specification – Procedure for Loop Testing

2) All cover to be boxed-up

3) Sticker (with Loop test date)to be put on the actuator for notification
 For Field Transmitters:
1) Keep equalizing valve open
2) Keep isolation valve close
3) Keep drain/vent close
4) All cover to be boxed-up
5) Sticker (with Loop test date)to be put on the actuator for notification
 For JB
1) All cover to be boxed-up
2) Sticker to be put on terminals inside JB for notification

7.3 Completion on Documentation

After completion of Loop Test, following documentation is required:
1) As-built Mark-up (Red line with Sign) if any
2) Loop Test Report shall be signed off as a test record
3) Loop Test Check sheet shall be recorded in completion Database.

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization
 OWNER REFERENCE
Project Package Originator Discipline Doc. Type Unit n° Serial n°

RAPID FE1 TPX CMM SPN 0001 0928

CONTRACTOR REFERENCE Rev. Page
PETRONAS RAPID PROJECT Project Unit n° Doc. Type Doc. Code Sequent. n°
FEED PHASE 60987R 0001 JSS 9000 0928 0 22 / 22

Project Specification – Procedure for Loop Testing

System VENDOR CONTRACTOR OWNER

Hand over data base

Loop Test
Attachment Check Sheet

Construction
Reports

Attachment Loop Drawing

Loop release Loop Test

Application Request for Loop
(I/O wise) Test

Vendor S/V Contractor rep.

(System) rep.representative
Representative Owner Representative

Vendor S/V Loop Test

(Package)

Original Copy
For Record
Record
Hand over data base
View
File Loop Test
Certificate
Loop Test
Check Sheet

Loop Drawing

All parties shall confirm and sign off

Subject to the provision of Article 13 of the CONTRACT, TECHNIP hereby grant PETRONAS the copyright of this
document. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
CONFIDENTIAL – Not to disclose without authorization