SAUDI ARAMCO BI-21-00036
ACOUSTIC LEAK DETECTION SYSTEM
FAT Rev. A
(Factory Acceptance Test Procedure)
Date Released: May 2010
Prepared By:
ACOUSTIC SYSTEMS INCORPORATED
9803 Whithorn Drive Houston, Texas 77095
Telephone 281-345-9995 FAX 281-345-9998
TABLE OF CONTENTS
1. INTRODUCTION ................................................................................................................................................. 2
1.1 SCOPE ............................................................................................................................................................. 2 1.2 LIST OF TERMS AND ABBREVIATIONS ............................................................................................................. 2 1.3 SYSTEM DOCUMENTATION ............................................................................................................................ 3 1.4 SYSTEM DESCRIPTION .................................................................................................................................. 3
2. PREREQUISITES ............................................................................................................................................... 7
2.1 EQUIPMENT CHECK LIST COMPARED WITH PURCHASE ORDER ................................................................... 7 2.2 SYSTEM DOCUMENTATION AVAILABLE: ........................................................................................................ 7 2.3 INSPECTIONS AND PRE-TESTING .................................................................................................................. 7 2.4 TEST EQUIPMENT .......................................................................................................................................... 8 2.5 MULTI-METER CALIBRATION CERTIFICATE DATA .......................................................................................... 8
3. TEST CONFIGURATION .................................................................................................................................. 8
4. RE-TEST PROCEDURE .................................................................................................................................... 8
5. TEST DOCUMENTATION ................................................................................................................................ 8
6. TEST LOG ........................................................................................................................................................... 8
7. TEST DISCREPANCIES / CORRECTIONS .................................................................................................. 9
8. SYSTEM DESCRIPTION AND PRELIMINARY OBSERVATIONS ......................................................... 10
8.1 SYSTEM STARTUP ....................................................................................................................................... 10 8.2 POWER CONSUMPTION ............................................................................................................................... 10 8.3 CPU OPERATION......................................................................................................................................... 12 8.4 POLL RECOGNITION ..................................................................................................................................... 12 8.5 REMAINING LEDS ........................................................................................................................................ 12 8.6 VERIFY CORRECT READING OF WAVEALERT SENSOR INPUTS ................................................................. 13 8.7 RECORD CPU USAGE ................................................................................................................................. 13
9. SYSTEM SETTINGS ........................................................................................................................................ 14
10. FALSE ALARM SIMULATION ................................................................................................................... 15
11. SIMULATED FAULT TESTS ...................................................................................................................... 15
11.1 INTERRUPTION OF COMMUNICATIONS ..................................................................................................... 15 11.2 WAVEALERT RESTART FLAG .................................................................................................................. 16 11.3 MASTERCOMM RESTART FLAG ............................................................................................................... 16 11.4 ACOUSTIC SENSOR STATUS INDICATIONS .............................................................................................. 17
11.4.1 Acoustic Sensor Fault Flags Set and Reset (OFF) ...................................................................... 17 11.4.2 Acoustic Sensor Fault Flags Set and Reset (Out of Range--Low) ............................................ 18 11.4.3 Acoustic Sensor Fault Flags Set and Reset (Out of Range--High) ........................................... 19 11.4.4 Acoustic Sensor Fault Flags Set and Reset (FAULT) on HMI ................................................... 20
11.5 WAVEALERT FAULT FLAGS SET AND RESET .......................................................................................... 21 11.6 SYNCHRONIZATION FAULT FLAG TESTS ................................................................................................. 21 11.7 SECOND SYNCHRONIZATION FAULT FLAG TEST .................................................................................... 22
12. LEAK ALARM, DISPLAY AND BUFFER TESTS ................................................................................... 22
12.1 EVENT MESSAGE DEVELOPMENT ........................................................................................................... 22 12.2 LEAK ALARM DEVELOPMENT ................................................................................................................... 22
13. SIMULATED ACOUSTIC LEAK TESTS BY PNEUMATIC LEAKS .................................................... 23
13.1 PRELIMINARY ........................................................................................................................................... 23 13.2 SIMULATED LEAK ALARMS ...................................................................................................................... 24 13.3 LEAK LOCATION ALGORITHM ................................................................................................................... 24
14. ANALOG DOWNLOAD TESTS ................................................................................................................. 25
15. ASI SCADA / HMI INSTALLATION AND BACKUP ............................................................................... 25
16. RECORD ASI HMI / SCADA DISPLAYS ................................................................................................. 25
17. SECURITY PASSWORDS .......................................................................................................................... 26
18. DETAILED HARDWARE AND COMPONENT LIST .............................................................................. 27
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ACOUSTIC LEAK DETECTION SYSTEM FACTORY ACCEPTANCE TEST
ACOUSTIC SYSTEMS INCORPORATED QUALITY ASSURANCE
TEST RECORD DATE: _________________
TESTED BY: ACOUSTIC SYSTEMS INC.______________WITNESSED BY:_____________ MasterComm VIII ADDRESS NUMBER AND SERIAL NUMBER: ________ Ok___ by_____ WaveAlert VIII ADDRESS NUMBERS AND SERIAL NUMBERS: ________ Ok___ by_____ ________ Ok___ by_____ Sensor SERIAL NUMBERS: ___________Ok _ by___ ___________Ok _ by___ ___________Ok _ by___ ___________Ok _ by___ GPS Antenna SERIAL NUMBERS: ___________Ok _ by___ ___________Ok _ by___ ___________Ok _ by___ ASI Leak Computer ___________Ok___ by____
Please note, all parameter values entered in the system during the FAT are for test purpose only, the actual values will be determined during SAT.
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1. Introduction
1.1 Scope
This document describes the conditions, requirements, plans, procedures, success criteria and responsibilities for performance for the FAT. The FAT will demonstrate (all that is possible within the ASI Factory environment) the ALDS (Acoustic Leak Detection System) will satisfy all requirements of the Project Specification.
1.2 List of Terms and Abbreviations
The following are descriptions of the WaveAlert parameters that are adjustable from the MasterComm.
Minimum Threshold --Least value of the dynamic threshold for which an acoustic event will be declared by a WaveAlert VIII Site Processor. Lower settings will increase sensitivity to leaks but increase the chances for a false alarm.
Dynamic Threshold Control— Determines how sensitive the dynamic threshold will be to background pipeline noise. Lower settings will increase sensitivity to leaks but increase the chances for a false alarm.
A to B Delay--Equal to the acoustic travel time between elements in the dual sensor array in units of 10 msec.
Site Location--Kilometer or mile post of WaveAlert sensor site location.
Muting Zone --Acoustic event signals located within this distance of a WaveAlert sensor will not be used for a leak declaration employing data from that Site Processor only. The pipeline is not protected within a zone extending inward from the Site Processors at either end of the pipeline (units of meters).
Acoustic Velocity— The Sound Velocity within the pipeline segment, in units of meters/second. This value is primarily used to determine the location of the leak. The actual sound velocity will be determined during SAT.
Dynamic Detection Index – This is the peak value of the real-time acoustic analysis. Among other criteria this value must exceed the Dynamic Threshold before a potential leak event is declared.
Dynamic Threshold – This value is determined primarily by the Minimum Threshold setting, the Dynamic Threshold Control and prevalent acoustic noise in the pipeline and therefore will vary with the acoustic noise in the pipeline. The Dynamic Detection Index must exceed this value before a potential leak event is declared.
Sensor X Pressure (psig) – This value is the current static pressure measured by the acoustic sensor. This value is not used for acoustic leak detection but rather provides information on the status of the sensor (i.e. if is functioning and in contact with the pipeline fluid). Typical unit are psig (pounds per square inch gauge pressure).
Sensor X Signal Type – This value provides a reading of the current acoustic analysis for this particular sensor. This value is used in the determination of the Dynamic Detection Index.
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1.3 System Documentation
Wiring Diagrams Electrical Power Distribution Drawings Interconnection Drawings Communications Description Manual Operator’s Manual Hardware/Maintenance Manual ASI SCADA Installation and Backup Manual
1.4 System Description
The WaveAlert ALDS under test was designed for installation on the Aramco Riyadh Power Plant PP-10 Pipeline (see Figure 1). The system consists of two WaveAlerts D2 Site Processors, one MasterComm Node Processor and the ASI Leak Computer. The WaveAlert Site Processors apply several layers of filters to reject potential false alarms and record the occurrence of potential leak events. These records contain data such as signal amplitude, time, current filter parameters, etc. The MasterComm applies additional filters and locates leaks from event records from two or more WaveAlerts. All data for leaks, events and system settings are displayed on the ASI Leak Computer. When the circuit numbers are available they will be added to the Operator’s Display on the ASI Leak Computer. Sensor A and B signals, dynamic pressure signals shall have engineering units on configuration and engineering screens. The system will include historical trends for pressure signals and will be configurable. The LSB and MSB accumulators shall be combined in one value in order to have a single GMT time. The system will identify when two consecutive sensors have been disconnected. This verification avoids false alarms caused by field power outages that may affect two sites served by the same power system. The kilometer markers as shown on the operators display shall have the same values as markers on the engineering drawings. Shrinkable labels will be provided on all sensor cables inside sensor enclosures and cabinets. Labels will be provided for all terminal blocks. Four values of sensor status will be provided: (1) NORMAL (sensor operating and in normal range), (2) OFF (sensor disconnected), (3) OUT OF RANGE (sensor output is out of normal range) and (4) FAULT (sensor not operating as expected). All LDS software shall be Microsoft Windows compatible.
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Figure 1
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Overview This FAT will demonstrate and test all operating parts of the WaveAlert ALDS. Each WaveAlert Site Processor will be communicating with the MasterComm through Ethernet. Except for two sensors each sensor input will be simulated by a resistor network. Two sensors will be connected to a short pipe under pressure to simulate a pipeline. The MasterComm Node Processor will be connected to the ASI Leak Computer and to a PC which will simulate the OSPAS system. Simulated leak tests, simulated fault conditions and communications tests will comprise the bulk of the test procedure.
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2. Prerequisites
2.1 Equipment Check List compared with Purchase Order
Ok___ by_____
2.2 System Documentation Available: Wiring Drawings, provides details of wiring between all components of the WaveAlert ALDS Ok___ by_____ Electrical Power Distribution Drawings, provides details of power requirements for each component of the WaveAlert ALDS Ok___ by_____ Interconnection Drawings, provides details of the interconnections of the WaveAlert ALDS and ASI PC and OSPAS Ok___ by_____ Communications Description Manual, provides details for the Modbus Communications Protocol used by the WaveAlert ALDS and includes a list of data mapping addresses for OSPAS SCADA interface will be provided with the variable type and description. MODBUS addresses shall be defined during SAT. Ok___ by_____ Operator’s Manual, provides instructions using the ASI Leak Computer and software Ok___ by_____ Hardware/Maintenance Manual, provides details on the WaveAlert Site Processor and MasterComm Node Processor including maintenance and repair Ok___ by_____ HMI / SCADA Installation and System Backup Manual, provides instructions for the LDS HMI / SCADA installation and backup of all HMI / SCADA software. Ok___ by_____
2.3 Inspections and Pre-Testing
All WaveAlert and MasterComm Processors were inspected using the WaveAlert MasterComm Inspection Form. All Sensor assemblies were inspected and tested using the Sensor Assembly Inspection Form. All GPS receivers and antennas were inspected using the GPS Receiver-Antenna Inspection form. All WaveAlert and MasterComm Processors were tested using the WaveAlert Device Test Procedure. Inspect all wiring, wiring termination, power supply, sensor wiring, sensor enclosure, sensor pressure connection, communication equipment and workstation. This FAT test will also be preformed prior to the official test preformed in the presence of the customer.
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2.4 Test Equipment
Test equipment (equipment used to test the system, not part of the purchase order equipment) will include: A. Laptop Computer to simulate OSPAS SCADA B. Resistor Test Array Test to simulate sensor inputs. The resistor arrays
can be switched from normal current levels to under current and over current levels to simulate sensor faults.
C. Pipe loop to simulate pipeline under pressure. Pipe loop description: Test Pipe length: 215 meters (sensors located at each end) Test Pipe diameter: 1 inch Nominal pressure: 80 - 120 psi Nominal temperature: 30 C Pressurized fluid: clean dry air
D. Multi-meter to measure currents
2.5 Multi-meter Calibration Certificate Data
Instrument: ________________________________________ Serial Number: ___________________ Calibration Date: __________________
3. Test Configuration
A. All WaveAlerts Site Processors are connected to the MasterComm Comm
Port 1 through a Ethernet switch and Modems (if required). B. The ASI Leak Computer is connected to the MasterComm Comm Port 2
(polling the MasterComm using the Modbus RTU protocol). C. A laptop computer simulating OSPAS is connected to the MasterComm
Comm Port 3 (polling the MasterComm using the Modbus RTU protocol). D. Resistor arrays are connected to the sensor inputs in order to simulate
sensor faults. E. Two sensors are connected to the pipe test loop and pneumatic tests are
performed by connecting the sensors to the input terminals of two WaveAlerts.
4. Re-Test Procedure
If any re-test are required due to problems or failed tests, the problem will be correct and re-test will be performed as soon as possible.
5. Test Documentation
During leak tests, leak reports will be automatically printed. These reports will be added to the FAT Test Documentation.
6. Test Log
At the completion of each test a witness will check and initial that the test is completed successfully.
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7. Test Discrepancies / Corrections
If a test fails or needs correction, the failure or correction will be listed below: Test Number:__________ Description of Failure or Correction: ________________________________________________________________________________________________________________________________________________________________________ Test Number:__________ Description of Failure or Correction: ________________________________________________________________________________________________________________________________________________________________________ Test Number:__________ Description of Failure or Correction: ________________________________________________________________________________________________________________________________________________________________________ Test Number:__________ Description of Failure or Correction: ________________________________________________________________________________________________________________________________________________________________________ Test Number:__________ Description of Failure or Correction: ________________________________________________________________________________________________________________________________________________________________________ Test Number:__________ Description of Failure or Correction: ________________________________________________________________________________________________________________________________________________________________________ Test Number:__________ Description of Failure or Correction: ________________________________________________________________________________________________________________________________________________________________________
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8. System Description and Preliminary Observations
The WaveAlert ALDS contains the following components: A. MasterComm VIII Node Processor: Poll the WaveAlert Site
Processors for leak data and makes the final leak determination including leak location.
B. WaveAlert VIII Site Processor: Monitors the pipeline for acoustic leak events applying a series of filters to reject false alarms.
C. Acoustic Sensor: WaveAlert sensor used to listen for acoustic leak events on the pipeline.
D. ASI Leak Computer: Displays leak data and provides a way to adjust system parameters.
E. Laptop Computer connected to the MasterComm serial port COM 3 to simulate the link with OSPAS SCADA. The laptop must run MODBUS protocol and it must be configured as master.
Refer to Figure 2 for diagram of WaveAlert FAT system.
8.1 System Startup
The ALDS is designed to start automatically upon application of power. This includes computers (Windows XP log-in is required after startup and depending on security settings HMI / SCADA will also require log-in) as well as the MasterComm and WaveAlerts. Remove power momentarily and reapply. Verify that the subsystem starts automatically.
Shut Down and Restart
Leak Computer Ok _____
MasterComm Ok _____
WaveAlert 1, Site 1 Ok _____
WaveAlert 2, Site 2 Ok _____
Ok___ by_____
8.2 Power Consumption
Select one of the WaveAlerts and measure current consumption using a digital multi-meter. Current should measure between 0.2 and 0.4 amps.
Current Measured______________ Ok___ by_____
Measure the current consumption of the MasterComm using a digital multi-meter. Current should measure between 0.2 and 0.4 amps.
Current Measured______________ Ok___ by_____
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8.3 CPU Operation
All green CPU LEDs on MasterComms and WaveAlerts flash regularly with period of 0.4 +/- 0.1 seconds. All green Power LED’s on MasterComm and WaveAlerts are steady on.
Ok___ by_____
8.4 Poll Recognition
When the MasterComm polls the WaveAlert using Modbus protocol, the WaveAlert will only respond if the poll is configured properly. Please refer to the Communication Description Manual for details. For most WaveAlerts, communication code is set up to relay any poll detected on COMM PORT 1 to COMM PORT 2 and 3. This function is NOT being used in the Aramco ALDS; it is only mentioned because the COMM PORT 2 and 3 LED’s will flash upon receipt of a poll from the MasterComm. All TX / RX green LED’s flash signifying poll and reply on MasterComm and WaveAlerts Comm1.
Ok___ by_____ On the MasterComm the TX / RX green LED’s flash signifying poll and reply on Comm Port 2 when polled by the ASI Leak Computer.
Ok___ by_____ On the MasterComm the TX / RX green LED’s flash signifying poll and reply on Comm 3 when polled by the OSPAS simulator.
Ok___ by_____
8.5 Remaining LEDs
All other LED's on the WaveAlerts and MasterComm should be off.
Ok___ by_____
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8.6 Verify Correct Reading of WaveAlert Sensor Inputs
Attach a 700 ohm resistor to all sensor inputs and record all sensor pressure readings on the HMI / SCADA engineer display. Sensor pressure readings should be close to full scale. For WaveAlert Sites with Sensor A only, enter N/A for Sensor B.
SITE 1 Sensor A
SITE 1 Sensor B
SITE 2 Sensor A
SITE 2 Sensor B
Sensor Pressure Readings
_______
_______
_______
_______
Ok___ by_____
8.7 Record CPU Usage
CPU Usage during non-leak conditions: ________________ Memory Usage during non-leak conditions: ________________ CPU Usage during leak simulation conditions: ________________ Memory Usage during leak simulation conditions: ________________ Ok___ by_____
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9. SYSTEM SETTINGS
For each one of the following items, verify the system response. Using the ASI Leak Computer and OSPAS simulator verify the following values (change values if necessary):
GPS Time Zone +3
Current Date MC date should match computer date
Acoustic Velocity for Each Pipeline 316
Ok___ by_____
On the Change Analog Values Screen, enter the following values for each location:
Dynamic Threshold Control 40
Minimum Threshold 200
Sensor A Delay (10 msec increments) 5
Site Location (As determined from System Drawings or default values)
SITE 01: 0 KM SITE 02: 30 KM
Muting Zone Length 10
Sensor Tolerance 100
Ok___ by_____ The MasterComm will connect to OSPAS using the serial port COM 3. COM 3 settings are 1200 baud, 8 bit, no parity, 1 stop bit. The communication protocol is MODBUS and the LDS shall provide the following signals:
1.- Leak Alarm
2.- Leak Location
3 – Active Flag (Only included in system with backup MasterComm)
4.- LDS Fault Status
Ok___ by_____
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10. FALSE ALARM SIMULATION
Select two adjacent WaveAlerts and disconnect the sensors at about the same time. This should NOT generate a false leak alarm.
Ok___ by_____
11. SIMULATED FAULT TESTS
11.1 Interruption of Communications
1. Communication Line Dip. Brief communication outage for 1 second between HMI PC and COM 2 in MasterComm. Verify the status of the LDS MasterComm LED's panel and HMI PC display.
Ok___ by_____
2. Disconnect the cable from MasterComm serial port COM 2, after a brief period an alarm is generated in ASI leak computer showing communication failure with all site processors from MasterComm side.
Ok___ by_____
3. MasterComm serial port COM 1 disconnected. Verify the status of the Master Com LED's panel after disconnecting the serial port com 1 connected to the switch.
Ok___ by_____
4. Disconnect the cable from MasterComm serial port COM 1, after a brief period an alarm is generated in ASI leak computer and OSPAS simulator showing communication failure with all site processors from MasterComm side.
Ok___ by_____
5. MasterComm serial port COM 2 disconnected. Verify the status of the Master Comm LED's panel after disconnecting the serial port.
Ok___ by_____
6. MasterComm serial port COM3 disconnected. Verify the status of the Master Comm LED's panel after disconnecting the serial port.
Ok___ by_____
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7. Using two analog modems configured in the 4 wire full duplex mode, disconnect the phone line connection at one modem for one second. Verify system response. Location of Communication Test: Site #________
Ok___ by_____
8. Using two analog modems configured in the 4 wire full duplex mode, disconnect the phone line connection at one modem for 60 seconds. Verify system response. Location of Communication Test: Site #________
Ok___ by_____
9. Break Communications between MasterComm and all WaveAlerts. Do a leak test and after 5 minutes reconnect Communications. The leak alarm should be displayed in the Computer.
Ok___ by_____
11.2 WaveAlert Restart Flag
Press the reset switch on each WaveAlert one at a time and observe that the “WaveAlert Restart Flag” is set and is visible in ASI leak computer.
SITE 1 SITE 2
Indicator on icon while WaveAlert Restarts
Ok _____ Ok _____
Ok___ by_____
11.3 MasterComm Restart Flag
Press the reset switch on the MasterComm and observe that the “MasterComm Restart Flag” is set and is visible in ASI leak computer. Ok___ by_____ Clear the “MasterComm Restart Flag” with the “Clear Reset Button and observe that the “MasterComm Restart Flag” is reset and is not visible in ASI leak computer. Ok___ by_____
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11.4 Acoustic Sensor Status Indications
Refer to the following table for the different Sensor Status Indications as shown in the following tests:
Sensor Current
Acoustic Sensor indicates OFF
Less than 1.0 mA
OUT OF RANGE (low current)
1.0 mA to 3.0 mA
OUT OF RANGE (high current)
Greater than 22 mA
FAULT
Sensor current is not within the “Sensor Error Constant” as compared sensors at
adjacent sites
11.4.1 Acoustic Sensor Fault Flags Set and Reset (OFF)
When the sensor input current drops below 1 mA, the sensor indicator will read “OFF”. Disconnect each sensor (Ignore acoustic alarms or events generated.) Sensor readings at SCADA should read OFF. For WaveAlert Sites with Sensor A only, enter N/A for Sensor B.
SITE 1 Sensor A
SITE 1 Sensor B
SITE 2 Sensor A
SITE 2 Sensor B
Acoustic Sensor indicates OFF
Ok _____
Ok _____
Ok _____
Ok _____
The WaveAlert on the Mimic changes color to red
Ok _____
Ok _____
Ok _____
Ok _____
The Sensor Fault LED is ON
Ok _____
Ok _____
Ok _____
Ok _____
Ok___ by_____
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11.4.2 Acoustic Sensor Fault Flags Set and Reset (Out of Range--Low)
Adjust the resistor array to reduce the current to about 2.0 mA. (Ignore acoustic alarms or events generated.) Fault alarms are created when the current is less than about 3.0 mA. For WaveAlert Sites with Sensor A only, enter N/A for Sensor B.
SITE 1 Sensor A
SITE 1 Sensor B
SITE 2 Sensor A
SITE 2 Sensor B
Acoustic Sensor Fault Flag set at Leak Computer and OSPAS simulator
Ok _____
Ok _____
Ok _____
Ok _____
The WaveAlert on the Mimic changes color to red
Ok _____
Ok _____
Ok _____
Ok _____
The Sensor Fault LED is ON
Ok _____
Ok _____
Ok _____
Ok _____
Ok___ by_____
Increase the input current to 20 mA.
SITE 1 Sensor A
SITE 1 Sensor B
SITE 2 Sensor A
SITE 2 Sensor B
Acoustic Sensor Fault Flag reset at Leak Computer and OSPAS simulator
Ok _____
Ok _____
Ok _____
Ok _____
The WaveAlert on the Mimic changes color to normal
Ok _____
Ok _____
Ok _____
Ok _____
The Sensor Fault LED is OFF
Ok _____
Ok _____
Ok _____
Ok _____
SITE 3 Sensor A
SITE 3 Sensor B
SITE 4 Sensor A
SITE 4 Sensor B
Acoustic Sensor Fault Flag reset at Leak Computer and OSPAS simulator
Ok _____
Ok _____
Ok _____
Ok _____
The WaveAlert on the Mimic changes color to normal
Ok _____
Ok _____
Ok _____
Ok _____
The Sensor Fault LED is OFF
Ok _____
Ok _____
Ok _____
Ok _____
Ok___ by_____
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11.4.3 Acoustic Sensor Fault Flags Set and Reset (Out of Range--High)
Adjust the resistor array to increase the current to about 27 mA at each input. Fault alarms are created when the current is above about 22.0 mA.
SITE 1 Sensor A
SITE 1 Sensor B
SITE 2 Sensor A
SITE 2 Sensor B
Acoustic Sensor Fault Flag set at Leak Computer and OSPAS simulator
Ok _____
Ok _____
Ok _____
Ok _____
The WaveAlert on the Mimic changes color to red
Ok _____
Ok _____
Ok _____
Ok _____
The Sensor Fault LED is ON
Ok _____
Ok _____
Ok _____
Ok _____
Ok___ by_____
Decrease the input current to about 20 mA.
SITE 1 Sensor A
SITE 1 Sensor B
SITE 2 Sensor A
SITE 2 Sensor B
Acoustic Sensor Fault Flag reset at Leak Computer and OSPAS simulator
Ok _____
Ok _____
Ok _____
Ok _____
The WaveAlert on the Mimic changes color to normal
Ok _____
Ok _____
Ok _____
Ok _____
The Sensor Fault LED is OFF
Ok _____
Ok _____
Ok _____
Ok _____
SITE 3 Sensor A
SITE 3 Sensor B
SITE 4 Sensor A
SITE 4 Sensor B
Acoustic Sensor Fault Flag reset at Leak Computer and OSPAS simulator
Ok _____
Ok _____
Ok _____
Ok _____
The WaveAlert on the Mimic changes color to normal
Ok _____
Ok _____
Ok _____
Ok _____
The Sensor Fault LED is OFF
Ok _____
Ok _____
Ok _____
Ok _____
Ok___ by_____
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11.4.4 Acoustic Sensor Fault Flags Set and Reset (FAULT) on HMI
Add fault resistor one at a time to each sensor input (Ignore acoustic alarms or events generated.) Sensor readings at SCADA should read FAULT. For WaveAlert Sites with Sensor A only, enter N/A for Sensor B.
SITE 1 Sensor A
SITE 1 Sensor B
SITE 2 Sensor A
SITE 2 Sensor B
Acoustic Sensor indicates FAULT
Ok _____
Ok _____
Ok _____
Ok _____
The WaveAlert on the Mimic changes color to red
Ok _____
Ok _____
Ok _____
Ok _____
Ok___ by_____
Remove the fault resistors.
SITE 1 Sensor A
SITE 1 Sensor B
SITE 2 Sensor A
SITE 2 Sensor B
Acoustic Sensor indicates NORMAL
Ok _____
Ok _____
Ok _____
Ok _____
The WaveAlert on the Mimic changes color to normal
Ok _____
Ok _____
Ok _____
Ok _____
Ok___ by_____
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11.5 WaveAlert Fault Flags Set and Reset
With power applied, disconnect the communication cable from the WaveAlert. When the WaveAlert fails to communicate with the MasterComm, the WaveAlert Fault Flag is set in the MasterComm and displayed at the ASI Leak Computer and OSPAS simulator. (Ignore other fault flags for the WaveAlert under test.) Replace the communication cable after each individual test.
SITE 1 SITE 2
WaveAlert Fault Flag set and cleared
Ok _____ Ok _____
Ok___ by_____
11.6 Synchronization Fault Flag Tests
GPS (Global Positioning System) is used to time synchronize all WaveAlert and MasterComm. This provides the ability to accurately time stamp an event at two or more WaveAlerts and to then locate a leak between the WaveAlerts. Although loss of the GPS signal will generate an Sync Fault, the WaveAlert ALDS will maintain synchronization for several hours without the GPS signal. Disconnect the GPS antenna from each unit with a GPS antenna to simulate a sync fault.
WVLT 1 WVLT 2
The Sync Fault is on.
Ok _____
Ok _____
Ok___ by_____
Reconnect the GPS antenna, sync fault clears.
WVLT 1 WVLT 2
The Sync Fault is off.
Ok _____
Ok _____
Ok___ by_____
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11.7 Second Synchronization Fault Flag Test
Disconnect the GPS antenna from one WaveAlert and turn power off and on at the WaveAlert observe that the WaveAlert is out of sync with all other WaveAlerts and that the Sync Fault Flag is set. Reconnect the GPS antenna after a few minutes the WaveAlert will again be in sync and the fault flag will be cleared.
Ok___ by_____
12. LEAK ALARM, DISPLAY AND BUFFER TESTS
Purpose: To assure that Acoustic Alarms are developed properly.
12.1 Event Message Development
Initiate a Single Event Test on each WaveAlert, using the Mouse at the ASI Computer. An acoustic event is produced.
SITE 1 SITE 2
Event LED flashes on briefly.
Ok _____
Ok _____
Ok___ by_____
12.2 Leak Alarm Development
Enable leak report printer. In sequence, perform two successive simulated leak tests using the Mouse at the ASI Computer. Do not clear the first leak, the second test leak alarm appears after the first is cleared.
SITES _ and _
A Leak Alarm is displayed with the correct Location
Ok _____
Location
__________
An Alarm Message is printed with the correct Location
Ok _____
The alarm file is created in D:\M1_FILES\Test_Files.
Ok _____
Ok___ by_____
Record the Leak Time displayed on the Leak Alarm Message
Time ______ Clear the first leak message
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SITES _ and _
A Leak Alarm is displayed with the correct Location
Ok _____
Location
__________
An Alarm Message is printed with the correct Location
Ok _____
The alarm file is created in D:\M1_FILES\Test_Files.
Ok _____
Ok___ by_____
Record the leak time displayed on the Leak Alarm Message
Time ______ Clear the last leak alarm:
SITES _ and _ SITES _ and _
The Leak Alarm is cleared
Ok _____
Ok _____
The Leak Alarm LED extinguishes
Ok _____ Ok _____
Ok___ by_____
13. SIMULATED ACOUSTIC LEAK TESTS BY PNEUMATIC LEAKS
13.1 Preliminary
Connect the Acoustic Sensors to the field terminals on SITES 1 and 2.
The test requires that signals be received at two Acoustic Sensors to declare that a leak has occurred. Individual signals, however, are reported as acoustic events. In sequence, close valve to one of the Acoustic Sensors (valve 1 or 3) with the other valve open (valve 1 or 3). Initiate a simulated event on the open valve sensor by opening the line valve (valve 2 or 4).
SITE ___ SITE ___
Event LED flashes on briefly.
Ok _____
Ok _____
Ok___ by_____
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13.2 Simulated Leak Alarms
Open valves on sensors (valves 1 and 3). Repressurize the line. Initiate a simulated leak event by opening the line valve (valve 5). The resulting leak should be located at about the midpoint of the pipeline segment since the time of arrival at the two transducers is almost the same.
Ok___ by_____
Record the following information:
t1
t2
Dynam Press 1
Dynam Press 2
Time Difference
Location Displayed
Note: Location is calculated from:
X = [ S1 + S2 + v t ] / 2 where S1 and S2 are the respective site locations, v is the acoustic
velocity and t = (t1 – t2). (Enter the time value from the lower site number as the t1 value in this equation, higher site number time is t2). Acknowledge the leak alarm. All alarms return to normal.
Ok___ by_____
13.3 Leak Location Algorithm
To simulate an off-center leak, pressurize the line and close all valves. Open the valve on SITE 1 sensor only (valve 1 or 3). Open the leak test valve (valve 2 or 4). Close the valve on SITE 1 sensor. Approximately 3 seconds later, open the leak test valve (valve 2 or 4) first and then quickly open the valve on SITE 2 sensor (valve 1 or 3). The resulting leak should be located nearer SITE 1.
Ok___ by_____ Record the following information: Acknowledge the leak alarm. All alarms return to normal.
t1
t2
Dynam Press 1
Dynam Press 2
Time Difference
Location Displayed
Ok___ by_____
ASI FAT Page 25
14. ANALOG DOWNLOAD TESTS
Verify modifying of system parameters. On the Engineering Display of each computer system (alternate entering values between ASI Leak Computer and OSPAS simulator) entering the following for each site:
Analog Description SITE 1 SITE 2
Dynamic Threshold Control 61 62
Minimum Threshold 101 102
A to B Delay 21 22
Site Location (km) 30 40
Muting Zone Length 50 60
Verify that the values appear on the Engineering Screen. Also verify the Minimum Threshold setting by observing the threshold setting in the diagnostic port on each WaveAlert.
Ok___ by_____
15. ASI SCADA / HMI Installation and Backup
Demonstration of SCADA / HMI Installation and backup.
16. Record ASI HMI / SCADA Displays
Perform a screen capture of each HMI / SCADA display and attach printouts of each display to the FAT document.
ASI FAT Page 26
17. SECURITY PASSWORDS
Security passwords will be enabled for engineering, operator and administrator level.
NAME LOGIN NAME PASSWORD
Administrator ADMIN admin
Engineer ENG1 eng1
Operator OP1 op1
Witnessed by (Saudi Aramco personnel): ____________________________
ASI FAT Page 27
18. Detailed Hardware and Component List
ITEM
NUMBER ITEM DESCRIPTION TAG NUMBER SERIAL NUMBER QUANTITY
1 MasterComm VIII Node
Processor With 19 Inch Rack Mount Panel
----------- 1
2 DELL PC Workstation with 19
Inch Monitor ----------- 1
3 HP LaserJet Printer ----------- 1
4 GE Fanuc Proficy HMI / SCADA ----------- 1
5 WaveAlert VIII D2 Site Processor 1
6 WaveAlert VIII D2 Site Processor 1
9 WaveAlert Acoustic Sensor with
Explosion Proof Enclosure 1
10 WaveAlert Acoustic Sensor with
Explosion Proof Enclosure 1
11 WaveAlert Acoustic Sensor with
Explosion Proof Enclosure 1
12 WaveAlert Acoustic Sensor with
Explosion Proof Enclosure 1
15 Waterproof GPS Antenna -----------
3
16 GPS Antenna Cable ----------- ----------- 3
17 ALDS Communication Specification Manual
----------- ----------- 1
18 ALDS Operators Manual ----------- ----------- 1
19 WaveAlert / MasterComm
Hardware Manual ----------- ----------- 1
20 ASI SCADA Installation and
Backup Manual ----------- ----------- 1
ASI FAT Page 28
Certificate of Completion
Acoustic Leak Detection System for
___________ This is to Certify that the Factory Acceptance Tests have been successfully completed on this date, _______________________. Testing performed by: ____________________________ Name: Title: Witnessed by: ____________________________
