ESD DRY-TEST PROCEDURE

PT PUPUK INDONESIA ENERGI

GRESIK GAS COGENERATION PLANT PROJECT

CONTRACT NO : 010/SP/DIR/XI/2015

PROJECT CODE : P-6001

JOB NO : 781502

DOC NO : GGCP-00-P0-PR-013-PP

PURPOSE :ISSUED FOR REVIEW

CONTRACTOR :

PT PP (Persero) Tbk – DIVISI EPC

REV. NO. DATE DESCRIPTION PREPARED CHECKED APPROVED

2 22/05/2017 Issued for Information AK TWB FIA FP

1 04/04/2017 Issued for Information AK WR/HH GWN/FIA FP

0 09/01/2017 Issued for Review AK WR/HH GWN/FIA FP

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PROCEDURE DATE : 22/05/2017

REV :2

REVISION CONTROL SHEET

REV. NO. DATE DESCRIPTION

0 09/01/2017 Issued for Review

1 30/03/2017 - PMC comment has been followed up

2 22/05/2017 - Adding Tag number for each equipment

- Adding procedure activation

- Revise as per PIE comment

DISTRIBUTION ORDER

EXTERNAL ISSUE PT PP (Persero) Tbk - INTERNAL ISSUE

CHIEF ADMINISTRATION
PT PUPUK INDONESIA ENERGI PROJECT MANAGER

TRACTEBEL / CONNUSA ENGINEERING MANAGER CHIEF SHE

CONSTRUCTION MANAGER

PROCUREMENT MANAGER

PROJECT CONTROL MANAGER

SHE MANAGER

QC MANAGER

CHIEF ENGINEERING

CHIEF PROJECT CONTROL

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TABLE OF CONTENT

1. INTRODUCTION

1.1 Scope ……………………………………………………………………………………………………………………4

1.2 Definition …………………………………………………………..……………………………………………………4
1.3 Project Reference Document…………………………………….…………………………………………………....4
1.4 Abbreviations…………………………………………………………………………………………………………....4
2. WORKING PROCEDURE……………………………………..…………………………….………………………….5
2.1 Work Flow……………………………….……………………..………………………………………….………….…5
2.2 Document Review……………………………………………..…………………………………………….……….…5
2.3 Application Form……………………………………………..………………………………..……………….…….…5
2.4 Equipment Review……………………………………………..………………………………...……………….……5
3. ESD DRY RUN TEST AND ACCEPTANCE CRITERIA……………………………………………………….……6
4. ACTIVATION PROCEDURE…………………………………………………………………………………….……..7
5. WITNESS………………………………………………………………………………………………………….……..7
6. RECORD AND ACCEPTANCE TEST………………………………………………………………………………..7

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1. INTRODUCTION
1.1. Scope
This procedure covers general requirements for ESD Dry Test Procedure as a part of pre-
commissioning procedure for Gresik Gas Cogeneration Plant (GGCP).This function is to makesure
the ESD system covering from the input element (push button local and remote) to the toll activation
(ESD valve, EDP valve, motor trip, equipment trip, etc.) is well functioning
1.2. Definition
The following words shall have the meaning indicated when used herein:
Owner : PT. PUPUK INDONESIA ENERGI
Consultant PMC : TRACTEBEL ENGINEERING S.A. &PT. CONNUSA ENERGINDO
Contractor : PT. PP (Persero) Tbk. – DIVISI EPC
Engineering Consultant : PT. REKAYASA ENGINEERING
Vendor/Subcontractor : The party that manufactures or supplies equipment and services to
perform the duties specified by the Owner or Contractor

1.3. Project Reference Document

Instrument IO list for BOP GGCP-00-I0-EL-002-PP rev. 3
Shutdown philosophy GGCP-00-P0-ES-009-PP rev. 3
Process Control Philosophy GGCP-00-P0-ES-004-PP rev. 1
Safety Interlock System GGCP-00-I0-DW-010-PP rev. 2
Fire Detection and Alarm cause and effect GGCP-00-I0-El-004-PP rev. 3
P & ID GGCP Project

1.4. Abbreviations
The following abbreviations are used within this document:
GGCP Gresik Gas Cogeneration Plant
EPC Engineering Procurement Construction
ESD Emergency Shutdown
XV On-off valve

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2.1 Work Flow

Finish Document and Preparing Report Witness and

Equipment Review approval

Planning for ESD Record Information

test

: By Contractor
Preparing Detail
Review
procedure : By Owner

Check of wiring Information

loop diagram

Application for
Instrument test

Execution work:
1. Preliminary check: Review document, pre
hocked Equipment
2. ESD dry-test procedure

2.2 DOCUMENT REVIEW

Before conducting ESD dry-test, commissioning engineer/supervisor review the completeness of

document such as construction and pre-commissioning reports for all instrument component and
equipment related with ESD system will be tested including ESD valve, equipment running,
communication system, etc. Documents t h a t h a v e to be checked are:
 ESD Loop Test Report.
 ESD dry-test procedure
 ESD Logic Test Report.
 ESD Panel Test Report.
 Motor Solo Run Test Report.
 Pump Running Test Report.
 Air Fan Cooler Test Report.

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2.3 APPLICATION FORM

This application shall be submitted and informed to Owner before execution work or this.
The detail of this application has been attached in Attachment 1.

2.4 EQUIPMENT REVIEW

Before conducting ESD dry run test, commissioning engineer I supervisor shall check all ESD
valve visually. Manual reset operation of solenoid valve shall be checked during equipment
review.

3. ESD DRY RUN TEST and ACCEPTANCE CRITERIA

Before conducting ESD dry run test, the running status of all mechanical motor related with ESD shall be
simulated at Operator Console PCS. For Gas Turbine Generator (GTG), close isolation valve fuel gas and
reset ESD valve from fuel gas system for GTG simulation on running status condition.
ESD dry run test shall be conducted from ESD push button at Control Room. Activation of ESD push
button from Control Room can be done by operator to activate ESD. ESD dry run test from ESD push
button at Control Room shall be conducted as following:
1. Simulate all mechanical motors (including air fin cooler motor) and turbine to running condition.
2. Reset all ESD valves from ESD panel. Ensure no alarm or warning on ESD panel at Control
Room.
3. Ensure all personnel who will do witness, near to the valve I equipment which will be witnessed.
Two or more Commissioning engineer should be standby at control room and MCC room.
4. Witnessed shall be executed total output of ESD.
5. Confirmation from all personnel at plant area about each valve position based on operating
condition and light indicator of each equipment t h a t will be witnessed on operating condition
also (simulating without operating equipment)..
6. Activate ESD by pushing ESD push button (ESD-001) at Control Room.
7. Confirm all alarms appear in ESD panel at Control Room.
8. Confirm all ESD valves (12-SDV-701) close and all equipment trip, appropriate with Safety
Interlock System.
9. Confirm Gas Turbine Generator trip. Confirm back feeding f rom Am urea II PKG or SS UBB
PKG automatically start after GTG trip. By check 20kV MV Switchgear (outgoing breaker must
stay closed).
10. Confirm Package boiler trip (03-ESD-201& 03-ESD-202).
11. Confirm HRSG trip (02-ESD-101 & 02-ESD-102)
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12. Confirm WWTP trip (06-ESD-426)

13. Confirm WTP and Demin Plant trip (05-ESD-326)
14. Confirm Compress Air (10-ESD-526A,10-ESD-526B,10-ESD-526C)& Desiccant dryer (10-ESD-
532,10-ESD-535,10-PSD-539) trip.
15. Confirm Cooling Tower Fan (04-ESD-302A & 04-ESD-302B) trip.
16. Confirm Circulating Cooling Water Pump (04-ESD-302A & 04-ESD-302B) and Make up Cooling
tower pump (04-ESD-301A & 04-ESD-301B) trip.
17. Confirm 12-SDV-701(Gas Metering Package) closed.
18. After all trip status has appeared based on Safety Interlock System, then active ESD reset
switch and re-latch all solenoid on ESD valves

4. PROCEDURE FOR ACTIVATION

The Procedure for activation is attached on attachment:
1. ESD-001 General ESD Push Button (attachment 3)
2. 01-ESD-001 GTG ESD Push Button (attachment 4)
3. 02-ESD-001 HRSG ESD Push Button (attachment 5)
4. 03-ESD-001 Boiler ESD Push Button (attachment 6)
5. FAS-001 Confirm Fire ESD (attachment 7)

5. WITNESS
Witness and approval shall be made in the presence of Owner's, PMC Consultant’s and Contractor’s
inspectors.

6. REPORT AND RECORD

The test result shall be reported by the form sheets such as Attachment 2

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Attachment – 1 “APPLICATION FOR ESD DRY RUN SYSTEM ”

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APPLICATION FOR ESD DRY RUN SYSTEM TEST

Date Issued :

From : PT. PP (Persero), tbk

To : PT. PI Energi

We would like to have your presence for ESD dry run test according to the following schedules

Date/Time :

Location :

Note :

Signature,

PT. PP (Persero), tbk

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Attachment – 2 “APPLICATION FOR ESD DRY RUNSYSTEM ”

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Area : Sub System :

Valve shall be closed :

Valve Tag Description Local activation Remote Activation

Valve shall be closed :

Valve Tag Description Local activation Remote Activation

Valve shall be closed :

Valve Tag Description Local activation Remote Activation

Valve Tag Description Local activation Remote Activation

PT. PP (Persero), tbk PT. PI Energi Tractebel Connusa

Name
Position
Signature
Date

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Attachment – 3 “PROCEDURE ACTIVATION GENERAL ESD PUSH BUTTON ”

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Attachment – 4 “PROCEDURE ACTIVATION GTG ESD PUSH BUTTON ”

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Attachment – 5 “PROCEDURE ACTIVATION HRSG ESD PUSH BUTTON ”

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Attachment – 6 “PROCEDURE ACTIVATION BOILER ESD PUSH BUTTON ”

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Attachment – 7 “FIRE ALARM (FAS-101) CONFRIM FIRE ESD SHUTDOWN”

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