Project No.

2205
100 GPM Amine Sweetening Unit Plant

Site Acceptance Test (SAT)

Protocol
Revision: A
May, 2012

A 02/27/2012 Original V. Blanco S. Kennedy

REV. DATE ISSUE PREPARED BY REVISED BY APPROVED BY
 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

TABLE OF CONTENTS

SECTION PAGE
1. INTRODUCTION 3
2. REQUIRED FIELD CONDITIONS 3
3. METHODOLOGY OF EXECUTION 3
4. REQUIRED DOCUMENTS 4
4.1. REFERENCES DOCUMENTS 4
4.2. ANNEXES TO THIS DOCUMENT 4
4.3. MANUFACTURERS’ TECHNICAL DOCUMENTS 4
5. REQUIRED TOOLS AND ACCESSORIES 7
6. PROCESS EQUIPMENT AND HARDWARE VERIFICATION 8
6.1. PROCESS MAIN COMPONENTS 8
6.2. POWER SYSTEM COMPONENTS 8
6.3. CONTROL SYSTEM COMPONENTS 8
7. ELECTRICAL CONNECTIONS VERIFICATION 10
7.1. ELECTRICAL POWER CONNECTIONS 10
7.2. ELECTRICAL DISTRIBUTION EQUIPMENT POWER-UP 10
7.3. CONTROL SYSTEM POWER-UP 11
8. I/O SIGNALS VERIFICATION 12
8.1. ANALOG INPUTS 12
8.2. ANALOG OUTPUTS 13
8.3. DIGITAL INPUTS 14
8.4. DIGITAL OUTPUTS 15
8.5. ANALOG INPUTS FROM MCC VIA MODBUS 16
9. PID CONTROL LOOPS 17
9.1. PID LOOPS IN AUTO MODE 17
9.2. PID LOOPS IN MANUAL MODE 18
10. PUMPS/MOTORS 19
10.1. “FUERA DE SERVICIO” STATUS 19
10.2. OPERATION IN MANUAL MODE 19
10.3. OPERATION IN AUTO MODE 20
10.4. “FAILED TO START/STOP” STATUS 20
11. OTHERS EQUIPMENT 22
11.1. ON-LINE H2S ANALYZER AT-101 22
11.2. RB-212 CONTROL PANEL 23
12. INTERLOCKS 25
13. SHUTDOWN PROCEDURE 26
14. ANNEXS 27

SAT-P No. SP-12-PPE-2205 Page 2 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

1. INTRODUCTION
This document contains the procedure for implementing the project SAT “Control System for 100 GPM
Amine Sweetening Unit Plant, inside JOULE’s battery limits, as a guidance for complete tasks of
verification, testing and adjustments on-site necessary for a good start-up of system. This test should be
integrated and coordinated by all disciplines involved.

2. REQUIRED FIELD CONDITIONS

Before beginning this procedure, a proper setup is mandatory to the success of the test. Verify the
following field conditions:

• Tested assembly, installation tie-ins of all process components according to process design
• Tested physical signals connection between field instruments and PLC I/O Modules (through JBs)
• Tested physical power feed connection on all field instrument that requires power from MCC building
• Tested physical power feed connection on all field motor/pumps from MCC
• Tested physical control connection on all field motor/pumps from MCC
• Installed communication links between all components of Control System
• Tested electrical services for all system components and services at the required VAC levels
• Proper functioning of all related services (electricity, light, A/C, fuel gas, instrument air, etc.)
• Tested and confirmed the direction of rotation for all motors
• Unless otherwise stated and agreed, all motors must be mechanically decoupled from the pumps
• Unless otherwise stated and agreed, all fuel gas lines must be closed
• Unless otherwise stated and agreed, all electrical ON/OFF breakers/switches must be in OFF
• Should be provided all security, hygiene and environment norms at the work place
• All related works, including installation, calibration, testing and adjustment, previous or during the
test, shall be done by qualified and experienced personnel

3. METHODOLOGY OF EXECUTION
In the following sections, each step must be executed as indicated. Test execution requests, differently
than indicated, should be analyzed and approved by ALL parties involved. Upon completion of each step,
indicate pass or fail in appropriate column. If all items listed under the Pass / Fail column are Pass, record
a trial result of ‘Pass’ next to “Test Pass or Fail”. If any result is Fail, then enter ‘Fail’ under the trial result.
Note the discrepancy in the discrepancy table (Annex J) and take appropriate action to remedy the
problem. The witness(es) designed should sign and date at the end of the test on the line provided.

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

SAT-P No. SP-12-PPE-2205 Page 3 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

4. REQUIRED DOCUMENTS
For to the satisfactory execution of this SAT should be provided, at least, all documentation related to
project that reflect as-built conditions and fully describe the methods of installation, operation and
maintenance of the system or any of its individual components.

4.1. REFERENCES DOCUMENTS

Should be used as reference in all sections the latest as built revision of the following documents
generated by JOULE and approved by MPG in the design and fabrication phases:

No. DRAWING AND DOCUMENTS Document No.

1. 2205 - Plot Plan of Cable Tray with Piping Details 11-2205-CCM503-Rev0
2. 2205 - 100 GPM Amine Sweetening Unit – Process Flow Diagram 11-2205-100-Rev1b
3. 2205 - P&ID 100 GPM Amine Sweetening Unit Plant Inlet & Outlet 11-2205-119-RevF
4. 2205 - P&ID 100 GPM Amine Sweetening Unit Contacting Section 11-2205-120-RevF
5. 2205 - P&ID 100 GPM Amine Sweetening Unit Regeneration Section 11-2205-121-RevF
6. 2205 - Process Information For Analog Signal Rev 1
7. 2205 - I/O Signals Schedule 11-2205-002-Rev6
8. 2205 - MCC101 Motors Signals Wiring Rev 1
9. 2205 - DCS Signals Point to Point Wiring Rev 6
10. 2205 - 100 GPM Amine Plant-MCC-101 - Electrical Loads Schedule Rev 6
11. 2205 - 100 GPM Amine Plant-MCC-101 - Cable Schedule Rev 6
12. 2205 - 100 GPM Amine Plant-MCC-101 480V Sch. Rev 4
13. 2205 - Site Acceptance Test Protocol PLC/HMI Rev 1

4.2. ANNEXES TO THIS DOCUMENT

Should be used when required in this document the latest as built revision of the following
documents generated by JOULE and approved by MPG in factory testing phase:

No. DRAWING AND DOCUMENTS Document No.

A 2205 - Control System Inventory Rev 1
B 2205 - PLC & HMI Control System Architecture Rev 2
C 2205 - PLC Control Panel Detail for Construction Rev 2
D 2205 - PLC Control Panel Power Wiring Diagram Rev 2
E 2205 - Computers Panel Detail for Construction Rev 2
F 2205 - Computers Panel Power Wiring Diagram Rev 2
G 2205 - Cross Reference Wiring I/O Signals Rev 2
H 2205 - RB212-CP-WD-002, 002A, 002B Rev 5
I 2205 - Cause & Effect Diagram Rev 2
J 2205 - Discrepancy Log

4.3. MANUFACTURERS’ TECHNICAL DOCUMENTS

The manufacturers' technical documents must include procedures for installation, assembly,
operation, preventive maintenance and/or troubleshooting of each individual component. These

SAT-P No. SP-12-PPE-2205 Page 4 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

documents, that are part of supply to MPG, can be delivered in hardcopy format or in electronic
format (CDs).

Hardcopies

No. DOCUMENTS, DRAWINGS and LICENSES QTY

1. TRACHTE. Joule Processing, LLC. Northern Mexico MCC Building 12’-0”x32’-0”x11’-8” 1
2. EATON CUTTLER-HAMMER. Motor Control Center F2100, Renewal Parts 1
3. EATON CUTTLER-HAMMER. Instruction For Installation IQ-DP-4000 1
4. EATON CUTTLER-HAMMER. Instruction For RS-485 PONY 1
5. EATON CUTTLER-HAMMER. Instruction For DIGITRIP RMS 310 1
6. EATON CUTTLER-HAMMER. Set of 7 electrical drawings 1
7. EATON CUTTLER-HAMMER. Set of 4 electrical drawings 1
8. EATON CUTTLER-HAMMER. MSDS ANGI 61 Dark Gray Paint 1
9. SQUARE D. Energy Efficient Transformers, Low Voltage General Purpose Dry Type 1
10. TRIPP LITE. UPS Owner’s Manual 1
11. TRIPP LITE. External Battery Pack Owner’s Manual 1
12. DELL. Warranty and Support Information 4
13. DELL. Safety, Environmental and Regulatory Information 4
14. DELL. 512e Hard Drive, Important Information 3
15. D-LINK. Getting Started Guide for D-LINK Web Smart Switch 1
16. EPSON FX-890/FX-2190 User’s Guide 1
17. GENERAL MONITORS. Models FL3100/FL3101 UV/IR and UV only Flame Detectors1 1
18. ESP SAFETY INC. SSS-903 Toxic Gas Detector, Instruction Guide 1
19. ESP SAFETY INC. SGOES Infrared Hydrocarbon Gas Detector, Operation Manual 1
20. EVENT ENGINEERING. Model 330&331 Hydrogen Sulfide Analyzers Operator’s Manual 1
21. BEBCO EPS. Model 1002 Type Y or Z. Installation and Operation Manual 1
22. MICROSOFT. Microsoft Office Home and Business 2010 License 3

Electronics Copies (CDs and Memory Sticks)

No. DOCUMENTS, DRAWINGS and LICENSES QTY

1. DELL. Windows 7 Operating System, Reinstallation DVD 3
2. DELL. Windows Server Operating System 1
3. DELL. Drivers and Documentation 6
4. DELL. Drivers and Documentation E170S/190S Flat Panel Monitor 1
5. DELL. Application 3
6. ROXIO. Creator Starter 3
7. EPSON. FX-2190/FX-890 Printer Software 1
8. EPSON. 10/100 Base TX Int. Print Server 1
9. ROCKWELL AUTOMATION. FactoryTalk View Site Edition 3
10. ROCKWELL AUTOMATION / SPECTER. WIN-911, Alarm Notification Software 3
11. ROCKWELL AUTOMATION. Historian Site Edition 1
12. ALLAN BRADLEY. CONTROLOGIX Hardware System 1
13. INVENSYS-FOXBORO. FoxDoc Documentation, e.IB Electronic Instruction Book 1
14. EVENT ENGINEERING. Event H2S Software, Software Manual and H2S Manual 1

SAT-P No. SP-12-PPE-2205 Page 5 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

SAT-P No. SP-12-PPE-2205 Page 6 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

5. REQUIRED TOOLS AND ACCESORIES

During the SAT, JOULE shall furnish all tools and test equipment required for configuration and testing
the Control System components. JOULE shall send to MPG a list with these accessories before entrance
to the plant for approval. After approval, the JOULE will proceed to locate its labeled accessories in a
suitable and safe place. This list will be used as a check to remove the accessories from plant after SAT. If
necessary, this list will be submitted to the security department from plan for registration. For to the
satisfactory execution of SAT should be provided, at least, the following tools and accessories:

No. TOOL DESCRIPTION QUANTITY

1. Software RS-LOGIX 5000 installed in a Laptop 1
2. HART Simulator 1
3. MODBUS Simulator 1
4. 4 to 20mA Generator 1
5. Multimeter 1
6. Communication Radios 2
7. H2S and CO2 Portable Detector 1
8. Several hand tools

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

SAT-P No. SP-12-PPE-2205 Page 7 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

6. PROCESS EQUIPMENT AND HARDWARE VERIFICATION

All system components supplied by JOULE should be visually inventoried in order to verify its availability
as part of the complete system. Additionally, must be verified its proper location, installation and
process/electrical/communication connections in the compliance with international and local standards.

6.1. PROCESS MAIN COMPONENTS

All process main components should be inventoried and verified their correct locations based on the
latest and approved as built design. Additionally should be visually verified all internal process
connections and process tie-ins at battery limits.

Test Description P(pass)/F(fail)

• Verify location, proper installation and process connections of SKID A1
• Verify location, proper installation and process connections of SKID A2
• Verify location, proper installation and process connections of SKID B
• Verify location, proper installation and process connections of AREA C
• Verify location, proper installation and process connections of SKID D
• Verify location, proper installation and process connections of SKID E
• Verify location, proper installation and process connections of SKID F
• Verify location, proper installation and process connections of AREA G
• Verify location, proper installation and process connections of AREA H
• Verify location, proper installation and process connections of SKID I
• Verify location, proper installation and process connections of SKID J
• Verify location, proper installation and process connections of SKID K
• Verify location, proper installation and electrical connection of Control Building

6.2. POWER SYSTEM COMPONENTS

All power system components should be inventoried and verified their correct locations based on the
latest and approved as built design.

Test Description P(pass)/F(fail)

• Verify proper location, installation and serial numbers of MCC Breaker Panel
• Verify proper location, installation and serial numbers of TRANSFORMER
• Verify proper location, installation and serial numbers of UPS/BATTERY
• Verify proper location, installation of MCC Building Main Breaker Panel

6.3. CONTROL SYSTEM COMPONENTS

CONTROL SYSTEM COMPONENTS

All control system components should be inventoried and verified their correct locations based on
the latest and approved as built design. For Control System components inventory verification refers
to Annex A

SAT-P No. SP-12-PPE-2205 Page 8 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

Test Description P(pass)/F(fail)

• Verify proper location and serial numbers of PLC modules/accessories
• Verify proper location and serial number of computer SERVERFAT/accessories
• Verify proper location and serial number of computer EST_INGEN/accessories
• Verify proper location and serial number of computer CLIENTE_1_PC/accessories
• Verify proper location and serial number of computer CLIENTE_2_PC/accessories
• Verify proper location and serial number of ETHERNET SWITCH
• Verify proper location and serial number of PRINTER
• Verify proper location and installation of Junction Box JB-A1
• Verify proper location and installation of Junction Box JB-A2
• Verify proper location and installation of Junction Box JB-B
• Verify proper location and installation of Junction Box JB-B
• Verify proper location and installation of Junction Box JB-D
• Verify proper location and installation of Junction Box JB-E
• Verify proper location and installation of Junction Box JB-F
• Verify proper location and installation of Junction Box JB-H
• Verify proper location and installation of Junction Box JB-I
• Verify proper location and installation of Junction Box JB-J
• Verify proper location and installation of Junction Box JB-K
• Verify proper location and installation of Re-boiler Control Panel
• Verify proper location and installation of H2S Analyzer AT-101
• Verify proper location and installation of enclosures/panels in control room
• Verify ergonomics factors (locations, distances, chairs, lighting, services, etc.)

CONTROL SYSTEM ARCHITECTURE

For all control system components should be visually verified the correct network connection based
on the latest and approved as built design. For PLC System Architecture refers to Annexes B, C and E.

Test Description P(pass)/F(fail)

• Verify proper routing and distribution of network cables
• Verify proper network connection of Ethernet devices to ETHERNET SWITCH
• Verify proper routing signals connections from Junction Boxes to PLC
• Verify proper routing signals connections from MCC to PLC
• Verify MCC Serial MODBUS connection from MCC to PLC

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

SAT-P No. SP-12-PPE-2205 Page 9 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

7. ELECTRICAL CONNECTIONS VERIFICATION

The electrical connection verification will be done in three (3) stages:
1. Visual verification of electrical connection of distribution components and control system
components, in order to confirm no bad or no missing connections.
2. Application electrical power in distribution components and services (MCC, Transformer, Main
Breaker Panel and UPS)
3. Application electrical power in control system components (PLC and HMI’s components)

Should be done the correct electrical power-up connections based on latest approved design “as built”. If
required, for components power-up procedures, refers to manufacturers' technical documents.

7.1. ELECTRICAL POWER CONNECTIONS

For all control system components should be visually verified the correct electrical power connection
based on the latest and approved as built design. If required, for components installation procedures,
refers to manufacturers' technical documents.

Test Description P(pass)/F(fail)

• Verify main breaker installation in MPG substation (should be OFF at this stage)
• Verify main power lines installation from MPG substation to JOULE MCC Panel
• Verify main power lines connection in MCC Panel (should be OFF at this stage)
• Verify Pump/motors connections (control and power) to MCC
• Verify 480/208/120 Transformer connection to MCC
• Verify Main Breaker Panel connection to 480/208/120 Transformer
• Verify UPS connection to MCC Building Main Breaker Panel
• Verify PLC Panel and Computers Panel connection to UPS
• Verify internal services of building connections to Main Breaker Panel
• Verify Re-boiler Control Panel and H2S Analyzer connections to UPS

7.2. ELECTRICAL DISTRIBUTION EQUIPMENT POWER-UP

Electrical power should be applied to each single electrical distribution components and verify the
power-up with proper tools or, if apply, monitoring self diagnostic routines; always under safety
procedures. It should be confirmed the electrical integrity and operation of the individual
components. Any modules failing the tests will be repaired or replaced.

Test Description P(pass)/F(fail)

• Energize Main breaker cell for JOULE Amine Plant in MPG substation
• Verify right voltage levels in MCC breaker cell in MPG substation
• Energize MCC Panel for JOULE Amine Plant in MCC Control Building
• Verify right voltage levels in each MCC cells in MCC Control Building
• Verify right voltage level in 480/208/120 Transformer output
• Verify right voltage levels in each circuit in MCC Building Main Breaker Panel
• Energize and verify internal and external lighting in MCC Control Building
• Energize and verify air conditioning in MCC Control Building

SAT-P No. SP-12-PPE-2205 Page 10 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

• Energize UPS and verify operation in frontal status indicators

7.3. CONTROL SYSTEM POWER-UP

Electrical power should be applied to each single electrical distribution components and verify the
power-up with proper tools or, if apply, monitoring self diagnostic routines; always under safety
procedures. It should be confirmed the electrical integrity and operation of the individual
components. Any modules failing the tests will be repaired or replaced. For PLC and HMI systems
refers to Annex D and F

Test Description P(pass)/F(fail)

• Set the OPERATION MODE switch of PLC to PROGRAM mode
• Energize the PLC Control Panel and Computers Panel
• Verify right voltage levels in PLC Control Panel and Computers Panel
• Verify frontal status indicators on PLC system
• Connect computer and open the RSLogix application
• Verify that JOULE Amine Plant application is opened on the RSLogix
• Verify that PLC is on PROGRAM mode
• Energize the HMI System: ETHERNET Switch, Server, Stations and printer
• Open the Factory Talk Application
• Verify that JOULE Amine Plant application is opened on the FT View
• Verify that all computer show the display related to 100 GPM Amine Plant
• After verification of safe conditions in field turn the PLC to RUN mode

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

SAT-P No. SP-12-PPE-2205 Page 11 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

8. I/O SIGNALS VERIFICATION

This section verifies the electrical continuity and correspondence of each I/O point from the instrument
in field until screens in HMI. This procedure verifies, at the same time, the integrity of the physical and
logical connection of each signal. If is required, it can be done a previous point-to-point verification from
Junction Boxes until Interface Modules in PLC Panel. Use the document in Annex X for follow-up.
8.1. ANALOG INPUTS
For AI signal follow-up and verification refers to Annex G
1. For each signal, using HART or 4-20mA SIMULATOR connected in field instrument, simulate 4, 12
and 20mA and verify corresponding 0%, 50% and 100% of the process range in HMI screen.
2. For each signal simulate the alarm value associated with the signal do the following:
a. Simulate the signal to a non alarm value
b. Generate the corresponding value to simulate the High, High-High, Low and Low-Low alarms,
if apply, and then verify the designed process value.
c. Check that all signal alarms are reset/acknowledge.
Tag No. Min Range Max Range Units Operat. at H Alarm H-H Alarm Low Alarm L-L Alarm P(pass)/F(fail)
AT-101 0 100 Ppm <3 4 5
AT-102 0 100 Ppm 15 25
AT-103 0 100 ppm 15 25
AT-104 0 100.0 %lel 40 60
AT-105 0 100 ppm 15 25
FT-101 0 160 gpm 110.0 136 27
FT-102 0 8000 scfh 5500.0 7200 1440
FT-103 0 8000 scfh 5500.0 7680 1200
FT-105 0 4MM scfh 2.917MM 3.4 2.0
FT-106 0 2M gpm 1.458M 1.7 1.2
LT-101 0 100 % 50 80 20
LT-102 0 100 % 50 80 20
LT-103 0 100 % 50 80 20
LT-104 0 100 % 50 80 20 10
LT-105 0 100 % 50 80 20 10
LT-110 0 100 % 50 80 90 20
LT-111 0 100 % 50 80 20
PT-101 0 100 psig 40 80 20
PT-105 0 100 psig 12 15 5
TT-105 0 200 ºF 80 85 40
TT-106 0 300 ºF 130 150 60
TT-107 0 300 ºF 130 150 60
TT-108 0 400 ºF 238 300 80
TT-111 0 800 ºF 600 640 160
PT-109 0 450 psig 350 360 90
PT-110 0 450 psig 350 360 90
TT-109 0 160 ºF 77 128 32
TT-110 0 160 ºF 77 128 32

WITNESS (ES):
JOULE Name/Signature: Date:

MPG Name/Signature: Date:

SAT-P No. SP-12-PPE-2205 Page 12 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

8.2. ANALOG OUTPUTS

For AO signal follow-up and verification refers to Annex G

1. For each signal, place the PID in MANUAL mode
2. For each signal, from the HMI screen set 0%, 50% and 100% and verifies the corresponding 4, 12
and 20mA with MULTIMETER in field instrument and verify the corresponding open percentage
on the actuator.

Tag No. Minimum Range Medium Range Maximum Range P(pass)/F(fail)

FY-101 0% 50% 100%
FY-102 0% 50% 100%
FY-103 0% 50% 100%
FY-106 0% 50% 100%
LY-101 0% 50% 100%
LY-102 0% 50% 100%
LY-103 0% 50% 100%
LY-104 0% 50% 100%
LY-105 0% 50% 100%
LY-110 0% 50% 100%
LY-111 0% 50% 100%
PY-101 0% 50% 100%
PY-105 0% 50% 100%
TY-105 0% 50% 100%
TY-106 0% 50% 100%
TY-107 0% 50% 100%

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

SAT-P No. SP-12-PPE-2205 Page 13 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

8.3. DIGITAL INPUTS

For DI signal follow-up and verification refers to Annex G
1. For each signal, connect a jumper in field instrument, simulating a CLOSE CONTACT and verify
corresponding status change in HMI screen
2. Verify that the designed alarm appear on the HMI screen

Tag No. Normal State Alarm State P(pass)/F(fail)

ASH-101/A
ASHH-101/B
ASH-102/A
ASHH-102/B
ASH-102/C
ASH-103/A
ASHH-103/B
ASH-103/C
ASH-104/A
ASHH-104/B
ASH-105/C
ASH-105/A
ASHH-105/B
ASH-105/C
XS-101/A
XS-101/AA
XS-101/B
XS-101/BB
XS-102/A
XS-102/AA
XS-102/B
XS-102/BB
XS-103/A
XS-103/AA
XS-103/B
XS-103/BB
XS-104
XS-104/A
XS-105
XS-106
XSHH-109
XSH-109
XSHH-110
XSH-110/A
XSHH-111
PSL-111/A
PSL-111/B
PSH-112/A
PSH-112/B
XSH-111/A
ZSC-107
ZSO-107
ZSC-108
ZSO-108
VSHH-101/A
VSHH-101/B
VSHH-102/A

SAT-P No. SP-12-PPE-2205 Page 14 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

Tag No. Normal State Alarm State P(pass)/F(fail)

VSHH-102/B
PSL-113

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

8.4. DIGITAL OUTPUTS

For DO signal follow-up and verification refers to Annex G

1. For each signal, from the HMI screen or forcing in PLC, send an OPEN/CLOSE command and
verifies the corresponding 24VDC value with MULTIMETER in field instrument and verifies the
corresponding change in local status of actuator, pump/motor or signaling.

Tag No. Normal State Alarm State P(pass)/F(fail)

HY-101/A
HY-101/B
HY-102/A
HY-102/B
HY-103/A
HY-103/B
XYV-107
XYV-108
XY-101/AB
XY-112
XY-113/A
XY-113/B

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

SAT-P No. SP-12-PPE-2205 Page 15 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

8.5. ANALOG INPUTS FROM MCC VIA MODBUS

1. From the MODBUS Signals, Check the value on HMI screen

Tag No. Min Range Max Range Units Operat. at H Alarm H-H Alarm Low Alarm L-L Alarm P(pass)/F(fail)
Ia 0 600 amp 250 4 5
Ib 0 600 amp 250 15 25
Ic 0 600 amp 250 15 25
Vab 0 600 volts 480 40 60
Vbc 0 600 volts 480 15 25
Vca 0 600 volts 480 136 27
W kW 7200 1440
VAR kVAR 7680 1200
VA kVA 3.4 2.0
pf 0 100 % 85 1.7 1.2
freq Hz 60 80 20
W kW

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

SAT-P No. SP-12-PPE-2205 Page 16 of 28

 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

9. PID CONTROL LOOPS

The control loops perform the automatic regulatory control of the process. In this section is verified its
performance as was designed in functional description phase by MPG and JOULE.

9.1. PID LOOPS IN AUTO MODE

For AI signal verification refers to document 2205 - Process Information for Analog Signal. Use the
following table for record of results.
1. For each control loop, open the schematic (faceplate) associated with PID control loop clicking on
the image:
2.

3. Verify that the PID is in AUTO mode.

4. For each loop, using HART SIMULATOR or 4-20mA SIMULATOR connected in field instrument,
simulate the PROCESS VARIABLE signal value with 4, 8, 12, 16 and 20mA (corresponding to 0%,
25%, 50%, 75%, 100%). For each simulated value check in the RSLogix and in the HMI screen on
the PID operation faceplate, that the value corresponds to the specified range.
5. For each loop, from the HMI screen set 0%, 25%, 50%, 75% and 100% of the SETPOINT value and
verify that the value is setup on the RSLogix and corresponds to the specified range. Verify in
field the corresponding open percentage on the actuator in field.
6. For each loop, try overriding a value in the OUTPUT from the operation faceplate in the HMI and
verify that it is not possible.
7. For each loop, in faceplate configure the constants KP, KI and KD based on typical values for type
of PROCESS VARIABLE.

PID in AUTO Mode table

PROCESS VARIABLE SET POINT / OUTPUT

LOOP
0% 25% 50% 75% 100% 0% OUT 25% OUT 50% OUT 75% OUT 100% OUT
FC-101
LC-103
PC-101
TC-105
LC-104
LC-106
PC-105
TC-106
TC-107
FC-102
FC-103
FC-106

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100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

LC-101
LC-102
LC-110
LC-111

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

9.2. PID LOOPS IN MANUAL MODE

1. Place the PID in MANUAL mode and verify that the tag associated with the mode of operation
(_MO) on the corresponding PID is set to “1” in the RSLogix and the faceplate is placed in
MANUAL mode on HMI screen.
2. For each loop, from the HMI screen set 0%, 25%, 50%, 75% and 100% of the OUTPUT value and
verify that the value is setup on the RSLogix and corresponds to the specified range. Compare
this value with the open percentage on the actuator in field. Record results in the following table
3. Try overriding a value in the SETPOINT from the operation faceplate in the HMI and verify that it
is not possible.
4. Place the automatic mode PID

PID in MANUAL Mode Table

OUTPUT
LOOP
0% 25% 50% 75% 100%
FC-101
LC-103
PC-101
TC-105
LC-104
LC-106
PC-105
TC-106
TC-107
FC-102
FC-103
FC-106
LC-101

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 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

LC-102
LC-110
LC-111

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

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 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

10.PUMPS/MOTORS
For start this test, it must be reviewed and confirmed the direction of rotation of all motors and. Unless
otherwise stated and agreed, all motors must be mechanically decoupled from the pumps. All HOA
switches in field and breaker levers in MCC should be in OFF position. The indicated procedure should be
done for each pump/motor

10.1. “FUERA DE SERVICIO” STATUS

1. On field, verify HOA (HAND-OFF-AUTO) switch in OFF position

2. On HMI screen, verify “FUERA DE SERVICIO” status and pump blinking in YELLOW color
3. On HMI screen, verify the motor shows HAND status

Tag No. HOA in OFF “FUERA DE SERVICIO” status P(pass)/F(fail)

AX-216A
AX-216B
P-213A
P-213B
P-211A
P-211B

10.2. OPERATION IN MANUAL MODE

1. On HMI screen, verify “FUERA DE SERVICIO” status and pump blinking in YELLOW color
2. On field, verify motor decoupled (if apply) and set the HOA switch to HAND position
3. On HMI screen, verify the motor shows HAND status
4. On HMI screen, verify OPERANDO condition and status ON (green color) and no alarms
5. On MCC Panel verify status ON
6. On field, verify motor running
7. On field, simulate the motor vibration switch to the alarm state
8. On HMI screen, verify vibration alarm and BOMBA PARADA occurs
9. On field, verify the motor stops
10. On field, set the HOA switch to OFF position

HOA in “BOMBA OPERANDO” Motor running HOA in “BOMBA PARADA” VSHH

Tag No. P(pass)/F(fail)
HAND status in HMI screen in field OFF status in HMI screen simulation
AX-216A
AX-216B
P-213A
P-213B
P-211A
P-211B

10.3. OPERATION IN AUTO MODE

1. On field, verify motor decoupled (if apply) and set the HOA switch to AUTO position
2. On HMI screen, verify the motor shows AUTO status
3. On HMI screen, verify on-service status and verify status OFF (red color)
4. If the motor has a Vibration Switch ensure it is set to the non alarm state
5. On HMI screen, click on selected pump symbol, it will appear the corresponding windows button

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100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

6. On HMI screen, verify all permissive are met and no interlocks activated
7. On HMI screen, start the motor pushing in ARRANQUE button
8. On HMI screen, verify OPERANDO condition and status ON (green color) and no alarms
9. On field, verify motor running
10. On HMI screen, stop the pump/motor pushing in PARADA button
11. On HMI screen, verify PARADA condition and status OFF (red color) and no alarms
12. On field, verify the motor stops
13. On HMI screen, start the motor pushing in ARRANQUE button
14. On HMI screen, verify BOMBA/MOTOR OPERANDO status and no alarms
11. On field, simulate the motor vibration switch to the alarm state
12. On HMI screen, verify vibration alarm and BOMBA PARADA occurs
13. On field, verify the motor stops

HOA in “BOMBA OPERANDO” Motor running “BOMBA PARADA” Motor stop VSHH
Tag No. P(pass)/F(fail)
AUTO status in HMI screen in field status in HMI screen in field simulation
AX-216A
AX-216B
P-213A
P-213B
P-211A
P-211B

10.4. “FAILED TO START/STOP” STATUS

1. On HMI screen, verify on-service status and verify status OFF (red color)
2. On HMI screen, verify the motor shows AUTO status
3. On PLC, force the bit of BOMBA/MOTOR OPERANDO status to “0” (OFF, Apagada)
4. On HMI screen, start the motor pushing in ARRANQUE button
5. On field, verify motor running
6. On HMI screen, verify that the FALLA AL ARRANCAR alarm occurs after 10secs with a green
blinking indication
7. On HMI screen, push RESET button and verify motor status in initial condition (OFF)
8. On field, verify the motor stops
9. On HMI screen or PLC, unforced the bit of BOMBA/MOTOR OPERANDO status
10. On HMI screen, start the motor pushing in ARRANQUE button
11. On field, verify motor running
12. On PLC, force the bit of BOMBA/MOTOR PARADA status to “1” (ON, Encendida)
13. On HMI screen, stop the pump/motor pushing in PARADA button
14. On HMI screen, verify that the FALLA AL PARAR alarm occurs after 10secs with a red blinking
indication
15. On HMI screen or PLC, unforce the bit of BOMBA/MOTOR PARADA status
16. On HMI screen, push RESET button and verify motor status in initial condition (OFF)

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 Project No. 2205
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100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

17. On HMI screen, stop the pump/motor pushing in PARADA button

18. On HMI screen, verify BOMBA/MOTOR PARADA status and no alarms
19. On field, verify the motor stops

HOA in “BOMBA OPERANDO” Failed to start “BOMBA PARADA” Failed to stop

Tag No. P(pass)/F(fail)
AUTO bit forced to “0” (OFF) alarm bit forced to “1” (ON) alarm
AX-216A
AX-216B
P-213A
P-213B
P-211A
P-211B

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

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 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

11.OTHERS EQUIPMENT
This section covers the test procedures in the equipment or subsystem that are integrated to the main
control system but have its own control system sequencing and/or Human Machine Interface (HMI).
They are the ON-LINE H2S ANALYZER AT-101 and the RB-212 CONTROL PANEL.

11.1. ON-LINE H2S ANALYZER AT-101

This section contains the procedure for testing the right power up of ON-LINE H2S ANALYZER AT-
101. It is supposed that the signals were checked in Section 8, I/O SIGNALS VERIFICATION. This
analyzer was configured, functionally tested and calibrated at the factory. All test and calibration
data is documented in the factory calibration report. (See at the end of manufacturer’s manual).
New procedures for calibration, maintenance and troubleshooting are not part of this test and, if
required, they should be done by the user follow the manufacturer’s manual.

Testing Procedure
1. Verify location, proper installation and process connections
2. Verify internal design: sampler intake, sampler conditioning,
3. Verify internal power and signals wiring
4. Set power ON and verify power-up on Operator Interface
5. On Operator Interface, push BYPASS button and verify inhibition of all analyzer alarms to a non-
alarm state, and sets the analog 4-20mA output to 2mA. The Bypass LED illuminates when
Bypass mode is enabled.
6. On Operator Interface, push SCROLL RIGHT [→] button and verify movement of cursor to the
right. Also verify SAVE configuration adjustments.
7. On Operator Interface, push SCROLL LEFT [←] button and verify movement of e cursor to the
left. Also verify CANCEL configuration adjustments.
8. On Operator Interface, push MENU/SET Button and verify cycling through the menu options.
Also verify increasing of numerical values when making configuration adjustments
9. Verify communication of EnventH2S software (loaded in portable computer) with a 331
analyzer, plugging between them the supplied RS-232 cable and following the steps for on-line
requesting information from the analyzer

Power and SCROLL SCROLL

Process Internal BYPASS MENU/SET Software
Tag No. signals RIGHT [→] LEFT [←] P(pass)/F(fail)
Location design button button comm.
wiring button button
AT-101

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

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 Project No. 2205
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100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

11.1. RB-212 CONTROL PANEL

This section contains the procedure for testing the right power-up a local operation of RB-212
CONTROL PANEL. It is supposed that this test will be done WITHOUT FUEL GAS in the line and only
will be tester the Operator Interface and solenoids valve action. For RB-212 CONTROL PANEL
verification refers to Annex H.

GNERAL

1. Verify location, proper installation and process connections

2. Verify internal arrangement: flame controllers and sensors, igniter, purge system
3. Verify internal power and signals connections

BURNER A

1. On Operator Interface, set power ON verify SYSTEM ON status

2. Push START button, verify PILOT VALVE, INGTION status and igniter/solenoid action
3. Push STOP button before 10sec, verify system stop and solenoid close
4. Push START button, verify PILOT VALVE, INGTION status and igniter/solenoid action
5. Verify ALARM FAILURE status after 10sec (no pilot flame detected)
6. Push RESET button, verify system stop and alarm are clean
7. Push START button, verify PILOT VALVE, INGTION status and igniter/solenoid action
8. Open door before 10sec, verify PANEL LO PRESS status and system stop
9. Push RESET button, verify system stop and alarm are clean
10. Push START button, verify PILOT VALVE, INGTION status and igniter/solenoid action
11. Simulate failure in PSL-102, verify MAIN IN LO PRESS status and system stop
12. Push RESET button, verify system stop and alarm are clean
13. Push START button, verify PILOT VALVE, INGTION status and igniter/solenoid action
14. Simulate failure in PSH-107, verify BURNER IN HI PRESS status and system stop
15. Push RESET button, verify system stop and alarm are clean
16. Push START button, verify PILOT VALVE, INGTION status and igniter/solenoid action
17. From the HMI screen send a EMERGENCY SHUTDOWN command
18. On Operator Interface, verify MAIN ESD C/ROOM status and system stop
19. Push RESET button, verify system stop and alarm are clean

BURNER B

1. On Operator Interface, set power ON verify SYSTEM ON status

2. Push START button, verify PILOT VALVE, INGTION status and igniter/solenoid action
3. Push STOP button before 10sec, verify system stop and solenoid close
4. Push START button, verify PILOT VALVE, INGTION status and igniter/solenoid action
5. Verify ALARM FAILURE status after 10sec (no pilot flame detected)
6. Push RESET button, verify system stop and alarm are clean
7. Push START button, verify PILOT VALVE, INGTION status and igniter/solenoid action
8. Open door before 10sec, verify PANEL LO PRESS status and system stop
9. Push RESET button, verify system stop and alarm are clean
10. Push START button, verify PILOT VALVE, INGTION status and igniter/solenoid action
11. Simulate failure in PSL-102, verify MAIN IN LO PRESS status and system stop

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 Project No. 2205
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100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

12. Push RESET button, verify system stop and alarm are clean
13. Push START button, verify PILOT VALVE, INGTION status and igniter/solenoid action
14. Simulate failure in PSH-107, verify BURNER IN HI PRESS status and system stop
15. Push RESET button, verify system stop and alarm are clean
16. Push START button, verify PILOT VALVE, INGTION status and igniter/solenoid action
17. From the HMI screen send a EMERGENCY SHUTDOWN command
18. On Operator Interface, verify MAIN ESD C/ROOM status and system stop
19. Push RESET button, verify system stop and alarm are clean

Power PANEL MAIN BURNER

MAIN
Process Internal and Power START STOP ALARM RESET LO LO IN HI
Tag No. ESD P(pass)/F(fail)
Locat. design signals ON button button Failure button PRESS PRESS PRESS
C/R
wiring Alarm Alarm Alarm
BURNER
A
BURNER
B

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

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 Project No. 2205
Revision A
100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

12.INTERLOCKS
In this section are verified all designed applications (strategies and interlocks) executed by the control
system in automatic operation in order to keep the system in safety process condition during the normal
operation. For this test, it should be provided all required hardware and/or software (simulators or
forcing in control sequence) in order to have available the required process conditions. All conditions for
each unit process to be tested must be previously agreed between PPE and SUPPLIER

12.1. Testing Procedure

Refer to Cause & Effect Diagram, Annex I and PIDs

1. From the RS Logix force the normal operation conditions
2. Force one trip condition at a time
3. Check the correspondent result according to the P&IDs and Cause and Effect Diagram

Interlock Description P(pass)/F(fail)

1 LAHH-110 closes valves SDV-107, SDV-108 and SDV-1000
AAHH-102, AAHH-102B, AAHH-103, AAHH-103B, AAHH-104, AAHH-104B, AAHH-105, AAHH-
2 105B, XAHH-109, XAHH-110 or XAHH-111 closes valves SDV-107 and SDV-108 and stop the
pumps P-213A, P-213B, P-211A and P-211B and coolers AX-216A and AX-216B
3 LAHH-104 stop pumps P-213A and P-213B
4 LAHH-105 stop pumps P-211A and P-211B
5 VAHH-102A stop pump 213A
6 VAHH-102B stop pump 213B
7 VAHH-101A stop the motor AXM-216A
8 VAHH-101B stop the motor AXM-216B
9 AAHH-101, AAHH-101B closes valves SDV-107, SDV-108

WITNESS (ES):

JOULE Name/Signature: Date:

MPG Name/Signature: Date:

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 Project No. 2205
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100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

13.SHUTDOWN
In this section are verified all designed applications for normal and abnormal shutdown procedures

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 Project No. 2205
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100 GPM Amine Sweetening Unit Plant
Site Acceptance Test (SAT) Protocol May, 2012

ATTACHMENT

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