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AL BARAKA CO

LPG UNIT INSTALLATION EQUIPMENT TESTING


PRE-COMMISSIONING & COMMISSIONING

INSTRUMENTATION & AUTOMATION


ENGINEERING REVIEWING REPORT

Prepared By. YAMEN ABUATWERAT

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Project name
LPG UNIT INSTALLATION TESTING PRE-COMMISSIONING & COMMISSIONING

Company
ALBARAK BRICKS MANUFACTURING COMPANY

Document Title
PROCESS REVIEWING REPORT
Company Document Number

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ALBARAK BRICKS MANUFACTURING COMPANY

Document Title
INSTRUMETATION & AUTOMATION ENGINEERING REVIEWING REPORT
Company Document Number

9. INSTRUMENTATION REVIEWING & VERIFICATION


Instrumentation and automation reviewing and verification activities have been carried out
either at site or at office according to the followings:

Vendor/Supplier design documentation in term of quantity, installation, and


connection.

LPG unit situation (as built unit) verification for location, quantities, installation and
connection.

Comparison with international standard and NOC National Oil Specifications


requirements.

Complying with requirements of operate ability, accessibility, maintainability and


safety insurance.

The instrumentation part of this report including the following main items:
9.1

EXISTING DOCUMENTS

9.2

WAREHOUSE

9.3

LPG TANKS

9.4

VAPORIZER & REDUCTION UNIT

9.5

BOILERS UNIT

9.6

RECOMMENDATION

9.7

NEXT STAGE DELIVERABLES

9.8

NEXT STAGE ACTIVITIES

9.9

PRELIMINARY ELECTRICAL NEXT STAGE DELIVERALES

9.10 PRELIMINARY ELECTRICAL NEXT STAGE DELIVERALES


9.11 CONCLUTION

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INSTRUMETATION & AUTOMATION ENGINEERING REVIEWING REPORT
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9.1 EXISTING DOCUMENTS


The existing documentation are not enough and not completed too in terms of technical
information required, for this reason there are some reference catalogues or specifications
collected by contacting with same vendors or supplier in order to cover all required
information and complete understanding.

9.2 WAREHOUSE
The Warehouse is not organized well and no existing instruments spare parts;
Instruments spare parts are very important during the operating in order to reduce the down
time of the LPG unit.
Instruments spare part to be listed on engineering stage.

9.3 LPG TANKS


All instruments related to LPG tanks have been deeply verified according to vendor
documentation in terms of type, installation, connection, material and quantities as
summarized below.

9.3.1

Level Switches
-

Vendor/Supplier : VALCO

Type : Multipoint / Floating / Quantity : 2

Comment: Level switch cables to be removed and rewired, cable type not accepted
as well as the cable length, which is depending on the new location of the control
panel.

9.3.2

Level Indicators
-

Vendor/Supplier : COPRIM

Type : Magnetic Transmission / Quantity : 2

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9.3.3

Pressure Indicators
-

Vendor/Supplier : OMET

Type : BOURDON Tube / Quantity : 2

Comment: Isolating valves are missing

9.3.4

9.3.5

9.3.6

9.3.7

9.3.8

Temperature Indicators
-

Vendor/Supplier : OMET

Type : Bimetal / Quantity : 2

Pressure Relief Valves


-

Vendor/Supplier : COPRIM

Type : Pressure relief valve/ Quantity : 2

Pneumatic Actuators
-

Vendor/Supplier : GT ATTUATORI

Type : Single acting spring return/ Quantity : 8

Flow Indicator
-

Vendor/Supplier : NUOVA migas

Type : Flow indicator/ Quantity : 1

Air System (Air Compressor)


-

Vendor/Supplier : COPRIM

Type : Motor monophase 220 Vac / Quantity : 1

Comment: Plastic Tubing to be confirmed during next stage.


If the Owner will not provide the plastic tubing specification we cannot accept the
existing one.

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Approximately all instruments are complying with vendor documentation.


LPG Tanks Instrumentation details specification will be prepared during next stage.

9.3.9

LPG Tanks Control Panel


-

Vendor/Supplier: COPRIM / QUADRO

No existing wiring diagram for this panel

Wiring diagram was sketchy drawn (by hand), then to be redrawing by CAD
during the engineering stage.

It seems that there are some mistakes and failures during this test

Operating switches for LPG tank 2 has failure on its contacts

Relay responsible for pneumatic pressure system has failure in one of its
contacts

There is a short circuit between R1 and T1, means there is a failure equipment to
be replacement.

Three phase motors has wrong tag names

More and more of effort as well as investigation will be done latter on during the
Test stage according to the our engineering design)

Standard diagram will be prepared

Field instruments wiring outside the panel to be replaced and rewired

Comments
-

LPG tanks control panel to be relocated according to safety and hazardous area
classification report.

It has been concluded that some modification will be done on this panel

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ALBARAK BRICKS MANUFACTURING COMPANY

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INSTRUMETATION & AUTOMATION ENGINEERING REVIEWING REPORT
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9.4 VAPORIZER & REDUCTION UNIT


- Since Vaporizer and reduction unit supplied by SAMTECH gas systems as one Package,
so all instrumentation verification executed based on supplier documentation.
- Vaporizer instruments installation and connection verified without comments
- More investigation about reduction unit is needed during engineering and test stages for
installation, connection, process data and operating, no reference documents available yet.

Vaporizer and reduction unit instruments list including the main required information will be
prepared during next engineering stage.

9.5 BOILERS UNIT


- Boilers unit supplied by FERROLI, no reference documents available
- More investigation about Boilers unit and associated instruments is needed during
engineering and test stages for installation, connection, process data and operating, no
reference documents available yet.

- Boilers unit control panel wiring and operating will be approved during the test stage.
- Since the Boilers and relevant panel are supplied as one package, consequence no problem
assumed from them.

Boilers unit instruments list including the main required information will be prepared during
next engineering stage.

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COMMISSIONING

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Company
ALBARAK BRICKS MANUFACTURING COMPANY

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INSTRUMETATION & AUTOMATION ENGINEERING REVIEWING REPORT
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9.6 RECOMMENDATIONS
Its highlighted that the below recommendation shall be considered to meet the operating
conditions:

1.

All instruments shall be numbered (Tagged)

2.

LPG tanks control panel shall be relocated, assumed location near by Boilers room

3.

More investigation and some modification for LPG tanks panel is required

4.

Instruments spar parts shall be supplied

5.

Level switch extracting bar is missing, its very important during the maintenance

6.

Field instrumentation and electrical cables shall be removed

7.

New instrumentation and electrical cables shall be purchased

8.

Instrumentation and electrical cables routing shall be redesigned

9.

Instruments Air system Tubing shall be removed and replaced by new one

10. All instruments shall be calibrated during the test stage


11. All existing and new documentation shall be archived
12. Warehouse shall be organized by proper way and procedure
13. New control room location and design shall be shared and approved by instrumentation
and electrical engineers

ADDITIONAL RECOMMENDATION

14. Water sprinkling system to be considered as per safety requirement


15. Fire fighting system shall be considered as per safety requirement
16. An electrical engineer to be considered for next stage to cover the electrical engineering
scope of work

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INSTRUMETATION & AUTOMATION ENGINEERING REVIEWING REPORT
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9.7 NEXT STAGE DELIVERALES


The following instrumentation and automation deliverables list shall be prepared during the
engineering stage and to be used as a reference documents with conjunction to vendor or
supplier documentation for all project stages commissioning, test, operating and
maintenance:

1.

LPG tanks instruments list

2.

LPG tank instruments data sheet

3.

Vaporizer and reduction unit instruments list

4.

Boilers unit instruments list

5.

Instrumentation cables data sheet

6.

Instrumentation cable list

7.

Instrumentation cables connection and installation accessorise list

8.

Main cable routing layout

9.

LPG tanks control panel wiring diagram

10. Water sprinkling control system wiring diagram


11. Instrumentation Air system network layout
12. Instrumentation Air system tubing specification

Required team to prepare the above deliverables

Instrumentation Engineer

Automation Engineer

CAD Designer

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LPG UNIT INSTALLATION TESTING PRE-COMMISSIONING &
COMMISSIONING

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ALBARAK BRICKS MANUFACTURING COMPANY

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INSTRUMETATION & AUTOMATION ENGINEERING REVIEWING REPORT
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9.8 NEXT STAGE ACTIVITIES


The below instrumentation and automation activities shall be carried out in order to cover
commissioning, test and start-up stages:

1.

Instruments tag numbers

2.

Instruments commissioning

3.

Field instruments wiring

4.

Participate in LPG control panel location and installation

5.

LPG tanks control panel wiring

6.

Instrumentation cables routing

7.

Instrumentation Air system connection

8.

Instruments calibration and test

9.

Start-Up Participation

10. Participate in operating philosophy and operating training


11. Firefighting system design support and assistance
12. Participate in Firefighting system installation and connection

Required team to cover the above activities:

Instrumentation supervisor

Automation supervisor

Instrumentation technician

Automation technician

Project Name
LPG UNIT INSTALLATION TESTING PRE-COMMISSIONING &
COMMISSIONING

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ALBARAK BRICKS MANUFACTURING COMPANY

Document Title
INSTRUMETATION & AUTOMATION ENGINEERING REVIEWING REPORT
Company Document Number

9.9 PRELIMINARY ELECTRICAL NEXT STAGE DELIVERALES


1.

Electrical cable list

2.

Electrical cables connection and installation accessorise list

3.

Main cable routing layout

4.

Lighting system design

5.

Lighting system equipments list

6.

Water spraying system design

9.10 PRELIMINARY ELECTRICAL NEXT STAGE ACTIVITIES


1.

All electrical panels power supply wiring

2.

Main cable routing layout

3.

Lighting system installation and wiring

4.

Water spraying pumps installation and wiring

The final electrical deliverables and activities lists will be provided by an electrical engineer

9.11 CONCLUTION
Main highlighted conclusion points from this report are:
-

LPG unit can be modified and operated from instrumentation and automation point of
view with respect to all recommendations, safety, and fire fighting conditions.

LPG tanks control panel shall be relocated

Some modifications for LPG control panel are required

LPG tanks instruments are accepted

Vaporizer instruments are accepted

More investigation for Vaporizer reduction unit is needed

More investigation for Boilers unit is needed

Instrumentation cables to be replaced

Air tubing type to be approved