CONOCOPHILLIPS INDONESIA INC. LTD.

Contract No. CS70-12398

NORTH BELUT PROJECT

WHP EPC

VENDOR DOCUMENTS
FOR
WELLHEAD CONTROL PANELS
PO No : A-84508-9787-4W-2200
TAG No : 32-QJP-001 & 32-QJP-101

PERFORMANCE TESTING AND

ACCEPTANCE TEST PROCEDURE

Document No.
ID-F-NB-P-JP-002-H05-0001
PT. NIPPON STEEL CONSTRUCTION
INDONESIA

RE VENDOR NISCONI COPI RETURN

ISSUE
V
Reviewed Approved Issue Date Reviewed Approved Issued Date STATUS DATE
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PROCEDURE

For
D MOS MAN 25-Juni-07
Comments
For 26-Dec.-
0 MOS MAN
Construction 07

REV REVISION NOTES

D Issue For Approval
0 Approved For Construction
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TABLE OF CONTENTS

1 GENERAL 4

2 VISUAL INSPECTION TEST 4

2.1 Body Inspection 4

2.2 Internal View Inspection 4

3 FUNCTIONAL TEST 5

3.1 Preparation before Test 5

3.2 WHCP Function and Leak Test 5

3.2.1 Start & Stop Motor Pump on Manual Condition (Without PLC Simulator) 5
3.2.2 Start & Stop Motor Pump on Remote Condition (With PLC Simulator) 5
- Pump 30-QJP-101-2A 6
- Pump 30-QJP-101-2B 6
- Pump 30-QJP-101-1A 6
- Pump 30-QJP-101-2B 7
- Hand Pump for Medium Pressure Supply 7
- Hand Pump for High Pressure Supply 7

4 CLEANLINESS TEST 8

5 RECORDING OF INSPECTION AND TEST DATA 8

FORM 1 - VISUAL INSPECTION 9

FORM 2 - HPU PERFORMANCE TEST 10

FORM 3 – FUNCTION TEST 11

FORM 4 – PUNCH LIST DURING FAT 34

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1 GENERAL

The purpose of this document is to define the procedure of Factory

Acceptance Test for Wellhead Control Panel and Hydraulic Power Unit

The verification and tests specified hereafter is considered being compliance

to be carried out on the unit and its equipment.

The document to be handed over shall include at least:

No Document
Documents Company Doc. Num.
. Number
General Arrangement Drawing 837005-IN-WHCP-
1 ID-F-NB-P-JP-002-B01-0001
006
Schematic Diagram 837005-IN-WHCP-
2 ID-F-NB-P-JP-002-C03-0101
009
Instrument Data Sheets 837005-IN-WHCP-
3 ID-F-NB-P-JP-002-C15-0001
010
Block Wiring Diagram 837005-IN-WHCP-
4 ID-F-NB-P-JP-002-C19-0001
011
Name Plate Format Drawings 837005-IN-WHCP-
5 ID-F-NB-P-JP-002-D01-0101
013
Detailed Fabrication Drawings 837005-IN-WHCP-
6 ID-F-NB-P-JP-002-D04-0001
014
Electrical Connection Diagram 837005-IN-WHCP-
7 ID-F-NB-P-JP-002-D06-0101
015
Instrument/Electrical Panel Detail 837005-IN-WHCP-
8 ID-F-NB-P-JP-002-E01-0101
Drawings 016
Calculation notes 837005-IN-WHCP-
9 ID-F-NB-P-JP-002-F04-0001
018
Cause and Effect Chart 837005-IN-WHCP-
10 ID-F-NB-P-JP-002-C16-0001
029

2 VISUAL INSPECTION TEST

The visual inspection test consists of (Form 1):

2.1 Body Inspection

 General aspect
 Size (Dimensional Check)
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 Labeling
 Front Side
 Left Side
 Right Side
 Rear Side

2.2 Internal View Inspection

 General Aspect
 Equipment Conformity (Data sheet and test reports)
 Equipment Location
 Tubing work
 Wiring & Termination
 Labeling
 Cleanliness
 Accessibility

3 FUNCTIONAL TEST

3.1 Preparation before Test

Pressurized the initial Pressure in Hydraulic Accumulator with Nitrogen gas (90% of
minimum operating pressure) and the results shall be recorded.

Required several preparation & check items to be done, before running the
Wellhead Control Panel as follows:
 Fill the hydraulic tank with “Tellus 32” until 75% of the full tank.
 Tighten all the tubing and pipe connection.
 Plug the output to all Wing Valve, SSV, and SCSSV bulkheads.
 Open all valve
 Close the ball valve in return line.
 Connect Pressure Transmitters to Junction Box.
 Connect SOV to Junction Box.
 Connect Push Button to Junction Box.
 Connect all Junction Box to PLC simulator.
 Install power and control cable to each motor.
 Show oil cleanliness to NAS 1638 class 6.

3.2 WHCP Function and Leak Test

The Function test will be perform for each module of well and all part of
instruments. For the leak test will be perform and record. Duration for the leak test
is 12 hours.
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3.2.1 Start & Stop Motor Pump on Manual Condition (Without PLC
Simulator)

The purposes of this test are to ensure Motor can be run by Local control station on
Wellhead Control Panel and to ensure a relief valves setting pressure are working
properly.

Without PLC simulator motor can be run until the pressure reach set point of relief
valve (3,300 psig for MP & 6,050 psig for HP), because if we used PLC simulator
motor will be stop at 3,000 psig (MP) & 5,500 psig (HP) according to set point of
start & stop for motor. The test result will be reported (Form 2 A).

3.2.2 Start & Stop Motor Pump on Remote Condition (With PLC Simulator)

The purposes of this test are to ensure the whole system will work properly after
WHCP are connected to PSD system. The PSD system represent by PLC Simulator.

For pressurize the system we sequence to start & stop the motor pump. Depend
which motor pump need to be used.

- Pump 30-QJP-001-2A

Working Step:
1. Open the line of pump 30-QJP-001-2A (AC-4, AC-5, AC-6, AC-8,CD-13)
2. Open isolation valve to accumulator CA5 & CA6, and close the return line
3. Start the motor and automatically stop when the pressure of the hydraulic
already reach 3000 Psig (Check on PI-1020A and PT-1014)
4. Check the running time duration of the motor to reach the desired
operating pressure.
5. If the pressure lines drop before 30 minutes, check the fitting and tubing
connections, which leakage may occur, repeat step 4 to 7.

- Pump 30-QJP-001-2B

Working Step:
1. Close valve AC-3
2. Open the return/bleed line of accumulator CA-5 & CA6
3. Check on PI-1020B, the pressure should back to initial pressure.
4. Close return/bleed line of accumulator CA-5 & CA-6
5. Close the line to Pump 30-QJP-001-2A (AC-4), open valve AC-3
6. Open the line of pump 30-QJP-001-2B (AC-9, AC-10, AC-11, CD-14)
7. Start the motor and automatically stop when the pressure of the hydraulic
already reaches 3000 Psig (Check on PI-1020B and PT-1014).
6. Check the running time duration of the motor to reach the desired
operating pressure.
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PROCEDURE

- Pump 30-QJP-001-1A

Working Step:
1. Valve AC-2 open position
2. Open the line of pump 30-QJP-001-1A (AC-12, AC-13, AC-14, AC-16, CD-
15)
3. Open isolation valve to accumulator CA-11 & CA-12, and close the return
line
4. Start the motor and automatically stop the motor if the pressure of the
hydraulic already reach 5500 Psig (Check on PI-1021A and PT-1015)
5. Check the running time duration of the motor to reach the desired
operating pressure.
6. While all motor in stop condition, wait for 30 minutes. If the line pressure
keeps in the working pressure, mean the Hydraulic Unit working properly.
7. If the pressure line drops before 30 minutes, check the fitting and tubing
connections, which leakage may occur, repeat step 4 to 7.

- Pump 30-QJP-001-1B

Working Step:
1. Close valve AC-2
2. Open the return/bleed line of accumulator CA-11, CA-12
3. Check on PI-1021A, the pressure should back to initial pressure.
4. Close return/bleed line of accumulator CA-11, CA-12
5. Close the line to pump 30-QJP-001-1A (AC-12)
6. Open the line of pump 30-QJP-001-1B (AC-17, AC-18, AC-19)
7. Start the motor and automatically stop the motor if the pressures of the
hydraulic already reach 5500 Psig (Check on PI-1021B and PT-1015).
8. Check the running time duration of the motor to reach the desired
operating pressure.

- Hand Pump for Medium Pressure Supply

Working Step :
1. Close valve AC-3
2. Open return line of accumulator CA-5 and CA-6
3. Check the pressure on PI-1020A and PI-1020B, the pressure should back
to initial pressure
4. Close the return line of accumulator CA-5 and CA-6.
5. Close valves AC-9, AC-8, and CD-14.
6. Open Valves AC-3, AC-4, AC-5, AC-6, AC-7, AG-1, CD-13.
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7. Open valve AB-11 and start the hand pump until the pressure on PI-1020A
reach 3300 psi

- Hand Pump for High Pressure Supply

Working Step :
1. Close valve AC-2
2. Open return line of accumulator CA-11 and CA-12
3. Check the pressure on PI-1021A and PI-1021B, the pressure should back
to initial pressure
4. Close the return line of accumulator CA-11 and CA-12.
5. Close valves AC-17, AC-16, and CD-16.
6. Open Valves AC-2, AC-12, AC-13, AC-14, AC-15, Af-1, CD-15.
7. Open valve AB-12 and start the hand pump until the pressure on PI-1021A
reach 6050 psi

For the detailed instruction WHCP Function test fill the WHCP function test Form
(Form 3)

4 CLEANLINESS TEST

Cleaning test shall be done to check particle contamination level of hydraulic oil
after circulating in the HPU unit. System Cleanliness standard will refer to NAS
1638 class 6 (AEROSPACE INDUSTRIES ASSOCIATION OF AMERICA, INC.).

5 RECORDING OF INSPECTION AND TEST DATA

The result of the checks and measurement done during Factory Acceptance Test
shall be recorded on the following test forms:

 FORM 1 – VISUAL INSPECTION

 FORM 2 – HPU PERFORMANCE TEST AND LEAK TEST
 FORM 3 – WHCP FUNCTION TEST
 FORM 4 – PUNC LIST DURING FAT
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PROCEDURE

FORM 1 - VISUAL INSPECTION

A. BODY INSPECTION

CONFORMITY
Aspect To be Checked Yes No N/A
General Aspect
Size (Dimensional Check)
Front Side
Rear Side
Right Side
Left Side

B. INTERNAL VIEW INSPECTION

CONFORMITY
Aspect To be Checked Yes No N/A
Equipment Conformity
Equipment Location
Labeling
Cleanliness
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PROCEDURE

Tubing Works
Wiring and Terminations

TEST DATE: ACCEPTED REJECTED PUNCH LIST

/ /
PT INDOKOMAS PT NISCONI INDONESIA CONOCOPHILLIPS IND INC.LTD

NAME & NAME & NAME &

SIGNATURE SIGNATURE SIGNATURE

FORM 2 - HPU PERFORMANCE TEST

A. PUMP MOTOR PERFORMANCE

Electrical Motor Power Consumption (0 – 6,050 & 3,300 PSI)

Running Stop
Tag Number Time Remarks
Ampere Voltage Ampere Voltage
30-QDE-101-1A
30-QDE-101-1B
30-QDE-101-2A
30-QDE-101-2B
Electrical Motor Power Consumption (5,300 PSI – 5,500 PSI)
Running Stop
Tag Number Time Remarks
Ampere Voltage Ampere Voltage
30-QDE-101-1A
30-QDE-101-1B
Electrical Motor Power Consumption (2,800 PSI – 3,000 PSI)
30-QDE-101-2A
30-QDE-101-2B

B. PRESSURE RELIEF VALVE FUNCTION TEST

Tag Number Set at (Psig) Result Remarks

FA1 6050
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FA2 6050
FA3 6050
FB1 3300
FB2 3300

C. LEAK TEST

Recorded

TEST DATE: ACCEPTED REJECTED PUNCH LIST

/ /
CONOCOPHILLIPS IND
PT INDOKOMAS : PT NISCONI INDONESIA
INC.LTD

NAME & NAME &

NAME &
SIGNATURE SIGNATURE
SIGNATURE
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FORM 4 – PUNCH LIST DURING FAT

ACTION CLEARANC
No. PUNCH LIST DESCRIPTION REMARKS
BY E STATUS

TEST DATE: ACCEPTED REJECTED PUNCH LIST

/ /
PT INDOKOMAS : PT NISCONI INDONESIA CONOCOPHILLIPS IND INC.LTD

NAME & NAME & NAME &

SIGNATURE SIGNATURE SIGNATURE