2.0 Performance Testing - Sue06052010 - PT

EPC-1 PRODUCTION PROCESSING FACILITIES OF BANYU URIP
PROJECT
ONSHORE PRE-COMMISSIONING & COMMISSIONING SCOPE
Tender No.:B-3207067 PERFORMANCE TESTING Revision :0 Page : 1 of 15

Description: Issue for proposal PROCEDURES Rev. Date :06-May-2010
CLIENT NAME : MOBIL CEPU LIMITED
PROJECT TITLE : BANYU URIP PROJECT
PROJECT NO : B-3207067
REV DATE REASON FOR ISSUE PREPARED DISCIPLINE TECHNICAL PROJECT CLIENT
# BY CHECK INTEGRITY APPROVAL APPROVAL
DOCUMENT TITLE : PERFORMANCE TESTING PROCEDURES
DOCUMENT NO : CONFIDENTIALITY RATING:
CLIENT REF:
THIS DOCUMENT INCLUDING DRAWINGS, PROCEDURES, SPECIFICATIONS, AND ITS CONTENTS IS THE EXCLUSIVE
PROPERITY OF EJ JOINT VENTURE INTERNATIONAL LIMITED AND IS FURNISHED ON A CONFIDENTIAL BASIS, AND
WITH THE EXPRESS AGREEMENT THAT IT WILL NEITHER BE USED, SOLD, TRANSFERRED, COPIED, TRACED,
PHOTOGRAPHED, NOR REPRODUCED IN ANY MANNER WHATSOEVER IN WHOLE OR IN PART, NOR ANY ITEM HEREIN
BE SOLD, MANUFACTURED OR ASSEMBLED WITHOUT THE WRITTEN AGREEMENT OF EJ JOINT VENTURE
INTERNATIONAL LIMITED THE RECIPIENT OF THIS DOCUMENT AGREES NOT TO DISCLOSE TO ANY OTHER PARTY
INFORMATION CONTAINED HEREIN, OR NOT TO USE SUCH INFORMATION, EXCEPT FOR THE SPECIFIC PURPOSE
INTENDED AT THE TIME OF RELEASE OF THIS DOCUMENT.
PROJECT

PERFORMANCE TESTING PROCEDURES
PERFORMANCE Testing – The process of testing each system to ensure that it meets
the design criteria established in the design specification and shown on the P&Ids.
PERFORMANCE TESTS means the operating tests of the functional systems of the PLANT in
the conditions specified, with the objective of demonstrating that the PLANT can satisfactorily be
operated in accordance with the design parameters and achieve the performance warranties
required under the CONTRACT.
1. PERFORMANCE TESTS
1.1 GENERAL
The purpose of the PERFORMANCE TESTS is to demonstrate that the commissioned

facilities comply with the design performance requirements. In the event that the
facilities fail to meet the design performance requirements, a Performance Defects list
shall be prepared and actions shall be assigned to CONTRACTOR, COMPANY and
Others.
1.2 BASIS OF TESTS
Performance test runs on the systems shall be carried out under conditions as given on
the latest revision of the relevant flow diagrams/schematics and shall have a continuous
duration as specified in
(i) this manual to determine various operating characteristics of the WORK and
(ii) to demonstrate the PERFORMANCE TESTS for the WORK. Specific

Performance requirements are listed for each system in the Attachment of
this Manual. EJ Joint Venture Pty. Ltd (EJJV) shall write the procedures for
all Onshore Performance Tests and the Offshore Performance Tests. EJJV
shall prepare procedures that will integrate the test runs to obtain the
maximum data with the minimum number of individual test runs.
EJJV’s personnel shall continue to perform the services specified under until such time
as all performance test runs have been successfully completed.
1.3 REPORTING
PROJECT

Within four (4) DAYs after the completion of each Performance Test, preliminary test
results shall be provided to COMPANY. Within seven (7) DAYs after receipt of test
results, COMPANY is to give notice to the CONSORTIUM either advising of the
successful Performance Test results or specifying areas of concern which require
CONSORTIUM action to correct. CONSORTIUM shall acknowledge receipt of such
notification and include plans to remedy the deficient areas.
Within seven (7) DAYs after the completion of each Performance Test, COMPANY will
notify CONSORTIUM of the Performance Test results and specify all areas of concern
which require CONSORTIUM action to correct. CONSORTIUM shall acknowledge
receipt of such notification and include plans to remedy the deficient areas.
1.4 CORRECTION OF DEFICIENCY
CONSORTIUM shall correct all deficiencies due to failure to meet design performance
as defined in PFD’s, P&ID’s and Equipment Data Sheets and for construction errors.
PROJECT

Attachment 1
TYPICAL EXAMPLE OF PERFORMANCE TESTS
1. CONSORTIUM PERFORMED PERFORMANCE TESTS (ONSHORE)
CONSORTIUM shall perform the following Performance Tests after Commissioning and
prior to load out. Each Performance Test shall be separately conducted and
documented.
1.1 VOICE AND DATA COMMUNICATIONS PERFORMANCE TEST
The voice and data communications provides radio and data highway communications
The platform Local Area Network for business data will be connected to the system to
provide the Wide Area Network link.
A simulated test will be performed prior to load out. The Performance Test shall be
conducted for a continuous period of twenty four (24) hours. The Performance Test
shall be performed in accordance with the SUPPLIERs’ test procedures and shall
measure the complete end-to-end bit error rate for each communication circuit (to both
destinations and repeated for stand-by equipment). The system shall be normally
loaded with voice and data communications.
All operating data shall be recorded at 15 minute intervals during the test.
Test Performance Point

End-to-end bit error rate <10-6 (HOLD)
1.2 DIESEL FUEL STORAGE TANK AND TRANSFER SKID
The diesel transfer skid shall be tested by pumping diesel back to its storage tank. The
test will be performed for each pump on the skid. A temporary meter will need to be
installed in the return line 1”-DF-805-BA.
The following tests shall be measured:

PBE-9860A Discharge Pressure, measured at 40 PSIG
PI-9860E
PBE-9860A flow rate, measured by level 25 USGPM
increase in MAD-9870 (remove elements for test)
PBE-9860B Discharge Pressure, measured at 40 PSIG
PI-9861E
PBE-9860B flow rate, measured by level 25 USGPM
increase in MAD-9870 (remove elements for test)
PROJECT

1.3 MAIN POWER GENERATION PERFORMANCE TEST
The dual fuel turbine driven generator, LAN-9530A, shall be tested at full load while
operating on diesel fuel. All other generators, permanent and temporary, shall be out of
service for the test and LAN-9530A shall supply the entire load. The load shall be
adjusted by operating both duty and stand-by electrical equipment which does not
require production of hydrocarbons on the platform. Where necessary, equipment may
be set to manual mode to maintain a constant system load.
The Performance Test shall be conducted for a continuous period of six (6) hours.

Electrical Power Load (measured at the LAN- minimum of 1040 kVA at PF of 0.8
9530A UCP) average of 1100 kVA at PF of 0.8
3 Phase voltage (measured at LAN-9530A 415 V ± 5 V
UCP)
Frequency (measured at LAN-9530A UCP) 50 Hz ± 1 Hz
All results shall be logged and trended on the platform DCS. Maximum and minimum
deviations on all measured parameters shall be reported in the test results.
1.4 STANDBY DIESEL GENERATOR PERFORMANCE TEST
The diesel engine driven standby diesel generator, LAN-9540, shall be tested at full
load. All other generators, permanent and temporary, shall be out of service for the test
and LAN-9540 shall supply the entire load. The load shall be adjusted by operating both
duty and stand-by electrical equipment which does not require production of
hydrocarbons on the platform. Where necessary, equipment may be set to manual
mode to maintain a constant system load.

Electrical Power Load (measured at the LAN- minimum of 225 kVA at PF of 0.8
9540 UCP) average of 250 kVA at PF of 0.8
3 Phase voltage (measured at LAN-9540 415 V ± 5 V
UCP)
Frequency (measured at LAN-9540 UCP) 50 Hz ± 1 Hz
All results shall be logged and trended on the platform PCDAS. Maximum and minimum
deviations on all measured parameters shall be reported in the test results.
PROJECT

1.5 PEDESTAL CRANE
The platform pedestal crane shall be installed and tested in the fabrication yard. The
Pedestal Crane Performance Test shall be performed offshore.

Main Hook Load Test at minimum working In accordance with manufacturer’s
radius, maximum working radius and at 20 ft instructions and load tables.
intervals between the minimum and
maximum
Auxiliary Hook Load Test at minimum In accordance with manufacturer’s
working radius, maximum working radius and instructions and load tables.
at 20 ft intervals between the minimum and
maximum
Secondary Hook Load Test In accordance with manufacturer’s
instructions and load tables.
Engine Maintenance Jib Load Test In accordance with manufacturer’s
Hoist Removal Jib Load Test In accordance with manufacturer’s
Main Hook Hoist Rate 80 ft per minute
Auxiliary Hook Hoist Rate 160 ft per minute
Swing Speed minimum 0.1 revolutions per minute
maximum 1.5 revolutions per minute
Load tests shall be performed in accordance with API 2C and with the ABS inspector
present.
1.6 BRIDGE CRANES (2)
The platform Bridge cranes shall be installed and tested in the fabrication yard. The
Platform Bridge Crane Performance Test shall be performed offshore.

Load Test (125% of rated capacity) In accordance with manufacturer’s
Bridge travel Speed 10 meters /min
Bridge creep Speed 3.3 meters / min
Trolley travel Speed 5 meters/min
Trolley creep Speed 1.7 meters/min
Hoist Speed Main 3.2 meters/min
Hoist Speed Creep 1 meters/min
PROJECT

Load tests shall be performed in accordance with API 2C and with the ABS inspector
present.
PROJECT

1.7 POTABLE WATER PERFORMANCE TEST
The potable water system needs to be operational to make the washroom habitable.
The potable water system includes the potable water storage tanks, potable water
pumps and potable water day storage tank.

Potable Water Microbiological Content as to World Health Organization standard
measured by sampling at the furthest user.
COMPANY will provide the laboratory
analysis service.
Potable Water Pumps flow rate (measured 45 USGPM
by change in level in the storage tank)
Potable Water Pumps discharge pressure 15 PSIG and evidence of air being
evacuated from the potable water day
tank
1.9 INSTRUMENT AIR SKID PERFORMANCE TEST
The instrument air skid shall be tested with no utility air usage and with all loads on the
instrument air system. The test shall be repeated for each air compressor and each air
dryer.
Instrument Air flow rate, measured at 75 SCFM
the outlet of the skid
Instrument Air pressure, measured at at least 165 PSIG
the instrument air receiver
Instrument Air Dew point 40°F at an instrument air flow rate of 75 SCFM
2.0 CONSORTIUM PEFORMED PERFORMANCE TESTS (FLOATING TRIAL)
CONSORTIUM shall perform the following Performance Tests after Commissioning and
after load out. Each Performance Test shall be separately conducted and documented.
2.1 FIRE WATER PUMPS

PROJECT

Each fire water pump shall be tested separately.


Water flow rate, measured through the test 2600 US gallons per minute
line and test meter (FT-9600T/FT-9601T)
Water pressure, measure at the discharge 150 PSIG
flange (PI-9600N/PI-9601N)
2.2 UTILITY SEA WATER PUMPS
Each utility sea water pump shall be tested separately. The fire water test line and test
meter shall be used by isolating the fire water pumps and replacing the check valves
with temporary spool pieces.

Water flow rate, measured through the fire 80 US gallons per minute
water test line and test meter (FT-9600T)
Water pressure, measure at the PI-9624B 150 PSIG
2.3 FLOATING TRIAL BALLAST AND INCLINE TEST
The hull shall be tested to confirm performance under Ballasting, De-Ballasting and
Incline situations. The Fire Water pumps are used for the Ballasting and De-ballasting
operation and are to be commissioned and tested prior to performance of the
Ballasting/De-Ballasting and incline tests.
The floating trial tests are:

Installed draft 31.29 m with all #5 tanks full and WPC and
EPC empty
Ballast System Function Test Confirm all valves operate during Installed Draft
test
De-ballast System Function test Eductor flow 1500 USGPM gross (500 USGPM
net)
Incline test 1.28 Degrees on any side.
3.0 COMPANY PEFORMED PERFORMANCE TESTS (OFFSHORE)
COMPANY will perform the following Performance Tests after the TLPB is installed at
site and has been received Mechanical Acceptance. Each Performance Test will be
separately conducted and documented. COMPANY will endeavor to perform
PROJECT

COMPANY’s Performance Tests within three (3) months after MECHANICAL

ACCEPTANCE. However, CONTRACTOR recognizes that events beyond COMPANY’s
control may affect the timing of the tests.
3.1 PRODUCTION PERFORMANCE TEST
The purpose of the Production Performance Test is to demonstrate the overall

hydrocarbon process facility meets its design intent. The Production Performance Test
will confirm that the facility can operate while meeting key performance conditions.
The performance test will be performed within the first months of operations, and thus
will be at a reduced flowrate from maximum design conditions. The reduced feed
conditions to the platform shall be set by COMPANY’s operators and shall be fully at the
discretion of COMPANY. The Production Performance Test shall be conducted over a
continuous twenty four (24) hour period and will confirm operations with stable levels
and pressures throughout the system. Additionally, proper operation all equipment will
be confirmed. Actual performance will be compared with required design performance
as defined on the PFD’s, P&ID’s and data sheets and a judgment will made by
COMPANY as to the whether the system can be reasonably be expected to meet
design performance .
3.2 METHANOL STORAGE TANK AND INJECTION SKIDS
The Methanol Injection Skids (ZZZ-9850A/B) shall be tested by transferring methanol

from one storage tank to the other using the 2” return line to the storage tanks. The test
will be performed for each pump on the skid. A temporary line will need to be installed at
RO – 9830F to test pumps PBA9830A/B and at RO—9832F to test pumps PBA-
9830C/D
The following tests shall be measured.

PBA-9830A Discharge Pressure measured at 60 PSIG
PI-9830C
PBA-9830A flow rate, measured by level 30 USGPM
change in the storage tanks (remove RO
9830F)
PBA-9830B Discharge Pressure measured at 60 PSIG
PI-9831C
PBA-9830B flow rate, measured by level 30 USGPM
9830F)
PBE-9845A Discharge pressure measured at 6700 PSIG
PI-9845C
PBE-9845A flow rate measured at FI-9845J 13.5 USGPM
PROJECT

PBE-9845B Discharge pressure measured at 6700 PSIG

PI-9846C
PBE-9845B flow rate measured at FI-9845J 13.5 USGPM
PBA-9840A Discharge pressure measured at 500 PSIG
PI-9840C
PBA-9840A flow rate measured at FI-9840G 1.0 USGPM
PBA-9840B Discharge pressure measured at 500 PSIG
PI-9841C
PBA-9840B flow rate measured at FT-9840G 1.0 USGPM
PBA-9830C Discharge Pressure measured 60 PSIG
at PI-9832C
PBA-9830C flow rate, measured by level 30 USGPM
9832F)
PBA-9830D Discharge Pressure measured 60 PSIG
at PI-9833C
PBA-9830D flow rate, measured by level 30 USGPM
9832F)
PBE-9845C Discharge pressure measured at 6700 PSIG
PI-9845C
PBE-9845C flow rate measured at FI-9848J 13.5 USGPM
PBE-9845C Discharge pressure measured at 6700 PSIG
PI-9847C
3.2 CHEMICAL STORAGE AND INJECTION SKIDS
The Chemical injection skidS shall be tested by pumping Chemical back to its storage
tank. The test will be performed for each pump on the skid. A temporary line will need to
be installed from the pump discharge to the storage tank fill connection.
The following tests shall be measured:

PBE-9700A Discharge pressure, measured 500 PSIG
at PI-9700E
PBE-9700A flow rate, measured by 2.3 USGPH
Calibration Chamber LG-9700F
PBE-9700B Discharge pressure, measured 500 PSIG
at PI-9701E
PBE-9700B flow rate, measured by 2.3 USGPH
Calibration Chamber LG-9700F

PROJECT

at PI-9700E
Calibration Chamber LG-9710D
at PI-9711E

at PI-9720E
at PI-9721E

at PI-9730E
at PI-9731E

at PI-9740E
at PI-9741E

at PI-9690E
at PI-9691E

PROJECT

at PI-9750E

at PI-9751E

at PI-9760E

at PI-9761E

at PI-9770E

at PI-9771E
PBE-9770C Discharge pressure, measured 7500 PSIG

at PI-9772E
PBE-9770C flow rate, measured by 0.51 USGPH
PBE-9770D Discharge pressure, measured 7500 PSIG

at PI-9773E
PBE-9770D flow rate, measured by 0.51 USGPH
PBE-9770E Discharge pressure, measured 7500 PSIG

at PI-9774E
PBE-9770E flow rate, measured by 0.51 USGPH
PBE-9770F Discharge pressure, measured 7500 PSIG

PROJECT

at PI-9775E
PBE-9770F flow rate, measured by 0.51 USGPH
PBE-9770G Discharge pressure, measured 7500 PSIG

at PI-9776E
PBE-9770G flow rate, measured by 0.51 USGPH

at PI-9780E

at PI-9781E
PBE-9780C Discharge pressure, measured 7500 PSIG

at PI-9782E
PBE-9780C flow rate, measured by 0.51 USGPH
PBE-9780D Discharge pressure, measured 7500 PSIG

at PI-9783E
PBE-9780D flow rate, measured by 0.51 USGPH
PBE-9780E Discharge pressure, measured 7500 PSIG

at PI-9784E
PBE-9780E flow rate, measured by 0.51 USGPH
PBE-9780F Discharge pressure, measured 7500 PSIG

at PI-9785E
PBE-9780F flow rate, measured by 0.51 USGPH

at PI-9790E

PROJECT

at PI-9791E
3.3 HEAT MEDIA HEATER AND CIRCULATION SYSTEM
The performance test on this system will consist of circulation of fluid (at the high
temperature of 300 F) through the loop. This will confirm the integrity and correct
hookup of the system, additionally the adequacy of the pumps to flow the fluid
through the exchanger, fired heater coil, piping, and expansion tank.

Differential Pressure 50 PSIG
Flow rate, 500 USGPM
3.4 WATER TREATING SKID
The performance test on this system will consist of circulation of fluid through the
system. This will confirm the integrity and correct hookup of the system, the
adequacy of the inlet pressure to flow through the hydrocyclones, flotation cell, and
to the overboard discharge line. In addition, the hydrocarbon concentration of the
inlet stream and the outlet stream will be measured to confirm proper operation of
the IGF.
3.5 HP/LP FLARE TIP
The HP/LP Flare Tip shall be tested to confirm that the variable slot flare tips are
adequately designed in order to produce sonic flow at the minimum flare flow rate of
10 MMSCFD.
3.6 PRODUCTION PUMPS
The Production Pumps shall be tested to confirm that the performance is within the
design tolerance of the API Pump Curves.
3.7 SHELL AND TUBE HEAT EXCHANGERS
The performance test on this system will consist of circulation of fluid through the
exchangers with available process fluids in order to verify:
• system integrity
• operation within the design criteria at a reduced flow rate.

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EPC-1 PRODUCTION PROCESSING FACILITIES OF BANYU URIP

Tender No.:B-3207067 PERFORMANCE TESTING Revision :0 Page : 1 of 15

CLIENT NAME : MOBIL CEPU LIMITED

PROJECT TITLE : BANYU URIP PROJECT

DOCUMENT TITLE : PERFORMANCE TESTING PROCEDURES

DOCUMENT NO : CONFIDENTIALITY RATING:

Tender No.:B-3207067 PERFORMANCE TESTING Revision :0 Page : 2 of 15

PERFORMANCE TESTING PROCEDURES

The purpose of the PERFORMANCE TESTS is to demonstrate that the commissioned

1.2 BASIS OF TESTS

(ii) to demonstrate the PERFORMANCE TESTS for the WORK. Specific

Tender No.:B-3207067 PERFORMANCE TESTING Revision :0 Page : 3 of 15

1.4 CORRECTION OF DEFICIENCY

Tender No.:B-3207067 PERFORMANCE TESTING Revision :0 Page : 4 of 15

1. CONSORTIUM PERFORMED PERFORMANCE TESTS (ONSHORE)

1.1 VOICE AND DATA COMMUNICATIONS PERFORMANCE TEST

Test Performance Point

1.2 DIESEL FUEL STORAGE TANK AND TRANSFER SKID

The following tests shall be measured:

Test Performance Point

Tender No.:B-3207067 PERFORMANCE TESTING Revision :0 Page : 5 of 15

1.3 MAIN POWER GENERATION PERFORMANCE TEST

Test Performance Point

1.4 STANDBY DIESEL GENERATOR PERFORMANCE TEST

Test Performance Point

Tender No.:B-3207067 PERFORMANCE TESTING Revision :0 Page : 6 of 15

1.5 PEDESTAL CRANE

Test Performance Point

1.6 BRIDGE CRANES (2)

Test Performance Point

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Tender No.:B-3207067 PERFORMANCE TESTING Revision :0 Page : 8 of 15

1.7 POTABLE WATER PERFORMANCE TEST

Test Performance Point

1.9 INSTRUMENT AIR SKID PERFORMANCE TEST

2.0 CONSORTIUM PEFORMED PERFORMANCE TESTS (FLOATING TRIAL)

2.1 FIRE WATER PUMPS

Tender No.:B-3207067 PERFORMANCE TESTING Revision :0 Page : 9 of 15

Each fire water pump shall be tested separately.

Test Performance Point

2.2 UTILITY SEA WATER PUMPS

Test Performance Point

2.3 FLOATING TRIAL BALLAST AND INCLINE TEST

Test Performance Point

3.0 COMPANY PEFORMED PERFORMANCE TESTS (OFFSHORE)

Tender No.:B-3207067 PERFORMANCE TESTING Revision :0 Page : 10 of 15

COMPANY’s Performance Tests within three (3) months after MECHANICAL

3.1 PRODUCTION PERFORMANCE TEST

The purpose of the Production Performance Test is to demonstrate the overall

3.2 METHANOL STORAGE TANK AND INJECTION SKIDS

The Methanol Injection Skids (ZZZ-9850A/B) shall be tested by transferring methanol

The following tests shall be measured.

Test Performance Point

Tender No.:B-3207067 PERFORMANCE TESTING Revision :0 Page : 11 of 15

PBE-9845B Discharge pressure measured at 6700 PSIG

3.2 CHEMICAL STORAGE AND INJECTION SKIDS

The following tests shall be measured:

Test Performance Point

PBE-9710A Discharge pressure, measured 500 PSIG

Tender No.:B-3207067 PERFORMANCE TESTING Revision :0 Page : 12 of 15

PBE-9720A Discharge pressure, measured 500 PSIG

PBE-9730A Discharge pressure, measured 500 PSIG