NMR602.10 SAT Plan & Procedure

PROJECT: HARADH GOSP2 WIPS FACILITIES ESD EXPANSION
Project No: Doc. No. 8SA-8-PJ-030 8SA-8-PJ-030-SAT
An Invensys Company
Revision No. Date B 8th Aug 2007
SITE ACCEPTANCE TEST PLAN
INVENSYS MIDDLE EAST (TRICONEX DIV.)
PROJECT:
HARADH GOSP2 WIPS FACILITIES ESD EXPANSION SITE ACCEPTANCE TEST PLAN NMR 602.10
Invensys Middle East Triconex Division P.O.Box. 31684 Al Khobar 31952 KSA Tel: +966-3-8010000 Fax: +966-3-8010199
Client: Contractor: Owner:
Yokogawa Middle East B.S.C (c) Invensys Middle East - Triconex Div. Saudi Arabian Oil Company (S. Aramco)
Client P.O. No. Owner P.O. No. Sheet
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Table of Contents.
1. 2. REVISION RECORD SHEET ................................................................................................................................... 3 DOCUMENT APPROVAL ......................................................................................................................................... 5 2.1. 2.2. 3. 3.1. 3.2. 3.3. 4. 4.1. 4.2. 4.3. 4.4. 5. 5.1. 5.2. 5.3. 5.4. 6. 6.1. 6.2. 6.3. 6.4. 6.5. 6.6. 6.7. 6.8. 6.9. 6.10. 7. YME / SAUDI ARAMCO ........................................................................................................................................... 5 APPROVAL NOTES AND EXCEPTIONS ...................................................................................................................... 5 SCOPE ...................................................................................................................................................................... 6 APPLICABLE DOCUMENTS ....................................................................................................................................... 6 TERMS AND ABBREVIATIONS .................................................................................................................................. 6 MASTER DOCUMENTATION ..................................................................................................................................... 8 PROCESSES COMPLETED ......................................................................................................................................... 9 TEST EQUIPMENT .................................................................................................................................................... 9 PERSONNEL REQUIREMENT ................................................................................................................................... 10 TEST PLAN............................................................................................................................................................. 11 TEST RESULT RECORDING & DISCREPANCY RESOLUTION................................................................. 11 TEST SCHEDULE .................................................................................................................................................... 13 UNSTRUCTURED TESTING ..................................................................................................................................... 13 SYSTEM CONFIGURATION CHECKS WRT NEW HARDWARE SUPPLIED ................................................................... 14 VISUAL INSPECTION CHECKS ................................................................................................................................ 15 ELECTRICAL CHECKS ............................................................................................................................................ 16 POWER CONNECTION CHECKS .............................................................................................................................. 17 WIRING CHECKS.................................................................................................................................................... 18 TRICON START-UP CHECKS WRT NEW HARDWARE SUPPLIED ............................................................................... 19 SOE RETRIEVAL UTILITY CHECKS ....................................................................................................................... 20 TRICON CONFIGURATION & SPARES CHECKS WRT NEW HARDWARE SUPPLIED ................................................... 21 FAILURE MODE & DIAGNOSTICS CHECKS ............................................................................................................ 22 SYSTEM PERFORMANCE CHECKS ...................................................................................................................... 23
INTRODUCTION ........................................................................................................................................................ 6
PREREQUISITE CHECK LIST................................................................................................................................ 8
TEST PROCEDURE.................................................................................................................................................. 11
TEST PROCEDURE.................................................................................................................................................. 14
DETAILED TEST DESCRIPTION AND RESULTS ........................................................................................... 24 7.1. SYSTEM CONFIGURATION CHECKS WRT NEWLY SUPPLIED HARDWARE ...................................... 24 7.1.1. Tricon Inspection..................................................................................................................................... 24 7.1.2. Third Party Equipment Log .................................................................................................................. 24 7.2. VISUAL INSPECTION CHECKS ...................................................................................................................... 25 7.3. ELECTRICAL CHECKS..................................................................................................................................... 26 7.4. POWER CONNECTION CHECKS .................................................................................................................... 27 7.4.1. System Power (110V A.C. UPS) UP.................................................................................................... 27 7.4.2. Field Output Power (24V D.C. KEPCO) UP....................................................................................... 27 7.4.3. Distribution Check .................................................................................................................................. 27 7.4.4. System healthiness ................................................................................................................................ 27 7.4.5. Power Consumption............................................................................................................................... 28 7.5. SIGNAL WIRING CHECKS............................................................................................................................... 29 7.6. TRICON START-UP CHECKS WRT NEWLY SUPPLIED HARDWARE..................................................... 30
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7.6.1. Modifying Application ............................................................................................................................ 30 7.6.2. Tricon Hardware Check ......................................................................................................................... 30 7.7. TRICON SOE RETRIEVAL UTILITY CHECKS.............................................................................................. 31 7.7.1. Running SOE ............................................................................................................................................ 31 7.8. ESD CONFIGURATION AND SPARES CHECKS WRT NEWLY SUPPLIED HARDWARE ..................... 32 7.9. FAILURE MODE AND DIAGNOSTIC CHECKS ............................................................................................ 33 7.9.1. Tricon Power Supply Failure................................................................................................................ 33 7.9.2. Input Feed Failure ................................................................................................................................... 33 7.9.3. Complete Power Failure & Battery Backup Checks...................................................................... 33 7.10. PERFORMANCE CHECKS............................................................................................................................ 34 7.10.1. Hardware................................................................................................................................................ 34 7.10.2. Application Program: ......................................................................................................................... 34 7.10.3. Scan Time Verification....................................................................................................................... 34 7.10.4. Tricon IO & Memory Point Allocation Verification .................................................................... 34 8. COMPLETION OF SAT CERTIFICATE.............................................................................................................. 35 APPENDIX B IO LOOP CHECKSHEETS .................................................................................................................. 36 APPENDIX C PUNCH LIST ........................................................................................................................................ 37 APPENDIX D CHANGE CONTROL FORM .............................................................................................................. 38 APPENDIX E POST SAT CHECK SHEET ....................................................................................................................... 43
1. REVISION RECORD SHEET

Rev. No. B
Revision Description ISSUED FOR CDR

Revised Pages
Date 8-AUG-2007
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Received By
Date:
Return this sheet signed to Project Manager Fax +966 3 8010199 (Discard Previous revision, if any)
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2. DOCUMENT APPROVAL 2.1. YME / Saudi Aramco

Submitted for Approval by: Submittal Date: Requested Approval Date: Submitted for Approval to: Invensys Middle East (Triconex Div.) Engineering Department, Al Khobar Office 08 August 2007 15 August 2007 Project Manager HARADH GOSP2 WIPS FACILITIES ESD EXPANSION PROJECT Date: 07-AUGUST-2007 Date: 08-AUGUST-2007 Date:
Written By
Rajesh Meghani, Lead Project Engineer
Approved By Ahmed Mazrouie, Project Manager Approved By YME / Saudi Aramco
2.2. Approval Notes and Exceptions
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3.
INTRODUCTION The following sections describe the procedures for conducting Site Acceptance Test for
HARADH GOSP2 WIPS FACILITIES ESD EXPANSION PROJECT.
3.1.
Scope
The SAT document is intended to test and document that the ESD System of HARADH GOSP2 WIPS FACILITIES ESD EXPANSION PROJECT performs as it is intended to. The basic stage covered by the Test Document are:SAT test witnessed by the purchaser Test certificates as in Section 5 & 6.
Note that the SAT is outside Invensys current scope of supply. 3.2. Applicable Documents 8SA-8-PJ-030-BOM H14-J-BA-651140 H14-P-BA-651141 H14-J-BA-651142 8SA-8-PJ-030-SCS 8SA-8-PJ-030-SWD H14-J-BA-651143
1. Bill of Materials (NMR 602.4) 2. Detailed Layout Drawing (NMR 602.6) 3. Electrical Power Distribution & Grounding Drawing (NMR 602.7) 4. System Architecture Drawing (NMR 602.16) 5. System Cable Schedule (NMR 602.17) 6. Signal Wiring Database (NMR 602.19) 7. Panel Signal Wiring & Termination Drawing (NMR 602.20)
3.3.
Terms and Abbreviations 2oo3 AC AI ANSI ASTM AWG CCR CD-ROM CDR C&I Two out of Three voting Alternating current Analogue Input American National Standards Institute American Society for Testing and Materials American Wire Gauge Central Control Room Compact Disc Read only memory Critical Design Documents for Review Control & Instrumentation
Client: Contractor: Owner: Yokogawa Middle East B.S.C (c) Invensys Middle East - Triconex Div. Saudi Arabian Oil Company (S. Aramco) Client P.O. No. Owner P.O. No. Sheet XKSS6J0004-01 QDCI-H14-34-C001-NA
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CPU CSA DC DCS ESD ETA FLD GFD GND HPTB IEC I/O I/P ITP IME KOM MCB MCC NEMA NMR O/P OVD PC PCS PLC P&ID PSU QA QC QCP QM RAM SA SAMSS SAT SBL SER SOE TCP/IP TMR Tribus TRICON TUV UPS WBS YME YGW DCS
Invensys Middle East Triconex Division P.O.Box. 31684 Al Khobar 31952 KSA Tel: +966-3-8010000 Fax: +966-3-8010199 Client: Contractor: Owner:
Central Processing Unit Canadian Standards Association Direct Current Distributed Control System Emergency Shutdown System External Termination Assembly Functional Logic Diagrams Ground Fault Detection Ground HART Protocol Termination Board International Electro technical Commission Input/Output Input Inspection and Test Plan Invensys Middle East FZE (Triconex Division) Kick-off Meeting Mini Circuit Breaker Motor Control Center National Electrical Manufacturers Association Non Material Requirement Output Output Voter Diagnostics Personal Computer Process Control System Programmable Logic Controller Piping and Instrumentation Diagram Power Supply Unit Quality Assurance Quality Control Quality Control Plan Quality Manual Random Access Memory Saudi Aramco Saudi Aramco Material System Specification Site Acceptance Test Solid Brass Link Sequence of Events Recorder Sequence of Events Transmission Control Protocol/Internet Protocol Triple Modular Redundancy Triplicated I/O bus Triconex Programmable Safety System TUV Rheinland Institut fur Software, Elektronik, Bahntechnik Uninterrupted Power Supply Work Breakdown Structure Yokogawa Middle East B.S.C (c) Yokogawa DCS
Yokogawa Middle East B.S.C (c) Invensys Middle East - Triconex Div. Saudi Arabian Oil Company (S. Aramco) Client P.O. No. Owner P.O. No. Sheet XKSS6J0004-01 QDCI-H14-34-C001-NA
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4.
PREREQUISITE CHECK LIST
The following items shall be ready/completed prior to commencing of the SAT. 4.1. Master Documentation
There will be 1 set of SAT reference drawing / document for ESD system marked as MASTER during SAT. Document Bill of Materials Detailed Layout Drawing Electrical Power Distribution and Grounding Drawing System Architecture Drawing System Cable Schedule Power Requirements Signal Wiring Database Functional Block Diagram Printouts Panel Signal Wiring / Termination Drawing Tricon System Logbook Vendor Catalogues P&IDs Logic Diagrams Cause & Effect Diagrams, if any Approved Document / Drawing No. 8SA-8-PJ-030-BOM H14-J-BA-651140 H14-P-BA-651141 H14-J-BA-651142 8SA-8-PJ-030-SCS 8SA-8-PJ-030-PWR 8SA-8-PJ-030-SWD 8SA-8-PJ-030-FBD H14-J-BA-651143 To be provided by IME IME IME IME IME IME IME IME IME IME IME YME YME YME
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4.2.
Processes Completed
The following processes shall be ready/completed prior to start of the SAT. 1. 2.

4.3.
Issued For Construction IME Documents (SAT Procedure) Approved Site Acceptance Test Plan Document Test Equipment
The following test equipment shall be ready prior to start of the SAT. 1. 2. 3. 4. 5. Power Sources 110 V AC ESD-Tristation / SOE PC with TS1131 programming software 4-20mA Current source Multimeter Fluke 77 or equivalent Fuse Removal tool
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4.4.
Personnel Requirement
The following Personnel to be available for the Acceptance Test as described below. Invensys Project Engineer YME 1 Project Engineer SA 1 person each from Maintenance, Operation and Engineering discipline
Other people like Administrative personnel may also be present for specific tasks, if required.
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5. 5.1.
TEST PROCEDURE Test Plan
The Site Acceptance Test (SAT) comprises of the following test elements each with a test certificate and one consolidated punch list report. The test elements for the SAT are as follows: System configuration Check wrt new hardware supplied Visual Inspection Check Electrical Checks Power Connection Check Wiring Check Tricon Start-up Check wrt new hardware supplied SOE Retrieval Configuration & Spares Check wrt new hardware supplied Failure Mode & Diagnostics Check Performance Records Check Completion Once the system has been tested based on the above criteria, the test records will be completed and supplied to YME/SA. The test results for the SAT will be recorded in sections 7, Appendix-B &E. Appendix E contains a post-SAT check sheet covering final inspection prior to actual start up of plant. 5.2. TEST RESULT RECORDING & DISCREPANCY RESOLUTION
The control of the IME SAT is outlined below: The test record sheets supplied in the Section-7 to this document will be annotated according to the results obtained. A test record may be repeated to test a corrected punch listed point (or points). Where the test record refers to master documents the appropriate section of the master document can either be highlighted in green or pages stamped as Verified and signed off. The highlighted / stamped / marked up documents then form part of the test records. Issues / Discrepancies / Clarifications will be recorded on a Punch list sheet as the tests proceed. On completion of the SAT a consolidated Punch List will be point-by-point agreed, confirmed and written by Invensys. Punch List Form is as attached in Appendix C.
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Documentation errors shall be red lined on the original master document and punch listed. The punch-listed point shall be verified as complete when the master document is re-issued and the old red lined document stamped superseded. Logic errors shall be red lined on the Triconex logic print outs and punch listed. If the error is a minor programming error the punch-listed point may be corrected during the SAT test, in which case the red lined modification can be highlighted in green and the punch list point marked as verified. Once resolved the consolidated Punch List points will be verified as implemented / completed by all parties. The Punch List verification will be done at an agreed time. All modifications will be recorded on the Punch List, if the modification is a correction to the program / hardware due to error or misinterpretation by Invensys, this recording shall be sufficient instruction to Invensys to complete the correction. Master copies of the documentation, if affected will be updated. If the modification is a change of design, this will be recorded on a Hardware or Software Change Request, to be authorised by appropriate technical parties and a Project Impact Report completed to review commercial aspects of change. The Change Control Forms are as attached in Appendix D. In clearing the Punch List, Hardware and Software Change Requests will be generated (in effect requested by the punch list) and logged in the appropriate registers. This mechanism will then track the fixes and their test status. Tricon faults observed once the SAT has started will be logged on a Hardware Change Request form reserved for Tricon faults. Note that the action may simple, say, to reset the fault using the TS1131 software as some field wiring faults can occur during the course of the SAT in case of ESD system. In addition YME/SA may wish to run a Test Log - a free form logbook detailing order of events, observations, comments, or appropriate narratives of the SAT. If utilised, the test log will be closed on completion of the SAT. Once the SAT is initiated the software comes under formal design change control and the Tricon software version number shall be tracked with every Download All / Download Change.
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5.3.
Test Schedule
SAT will be scheduled to commence from _________ upto _________ (both days are included). Following tasks will be carried out during this period for each of the ESD system. Each day of testing will be carried out minimum in line with the following schedule. However, daily site activities will be decided by SA. Day # Day____ 1. 2. 3. 1. 2. 3. 4. 5. 1. 2. 3. 4. 5. Activities SAT Ref. Section # 4.1 4.2 4.3 4.4 4.5 4.6 4.7
System Overview System configuration Checks wrt new hardware supplied Visual Inspection Checks Electrical Checks Power Connection Checks Wiring Checks Tricon Start-up Checks wrt new hardware supplied SOE Retrieval Utility Checks
Day____
Day ____
Tricon Configuration & Spare Checks wrt new hardware supplied 4.8 Failure Mode & Diagnostics Checks 4.9 Performance Record Checks 4.10 Wrap-up SAT completion and Signoff
5.4.
Unstructured Testing
At the last day, YME/SA can take for non-destructive unstructured testing.
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6.
TEST PROCEDURE
The following sections cover in general about the intent, cross-referenced sections in this document and criteria for each kind of test to be carried out during SAT. 6.1. System Configuration Checks wrt new hardware supplied
OUTLINE: All hardware manufactured for this project is subject to client's visual inspection to confirm that all system components and accessories are in accordance with the specifications. OBJECTIVE: The purpose of this test is to verify that the following are in accordance with the reference drawings / documents. 1. Model No. of each component. 2. Quantity of each component. 3. Location of each component. REFERENCE DOCUMENT/DRAWING: 1. Bill of Materials 2. Detailed Layout Drawing 3. Tricon System Logbook TEST DETAILS: 1. Visually inspect each component based on the above objectives & verify that it is in order. Refer to Section 7.1. CRITERIA: Each component shall confirm to the reference documents.
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6.2.
Visual Inspection Checks
OUTLINE: All components and accessories supplied by Invensys or Third party are certified free from scratches and any deformities that might impair the product quality and appearance. In addition to this all components are to be labelled correctly. OBJECTIVE: The purpose of this test is to ensure that all components and accessories are free from scratches, deformities and is properly labelled for identification. REFERENCE DOCUMENT/DRAWING: 1. Detailed Layout Drawing 2. System Cable Schedule TEST DETAILS: 1. Visually inspect each component based on the above objectives & verify that it is in order. Refer to Section 7.2. CRITERIA: There should not be any external defects such as deformities / scratches that might impair the product quality or appearance and all components must be labelled properly for easy identification.
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6.3.
Electrical Checks
OUTLINE: All electrical components and wiring for this project is subject to client's inspection to confirm that all electrical wire type, size and colour are in accordance with the specifications. OBJECTIVE: The purpose of this test is to ensure that all electrical wires are of proper type, size and colour. REFERENCE DOCUMENT/DRAWING: 1. System Design Document 2. Electrical Power Distribution and Grounding Drawing
TEST DETAILS: Refer to Section 7.3.
CRITERIA: All electrical wires should be of proper type, size and colour as per specification.
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6.4.
Power Connection Checks
OUTLINE: All power and earth connections are in accordance with the approved drawings and documents. OBJECTIVE: The purpose of this test is to ensure proper power and earth connection as well as system voltage level prior to power on. REFERENCE DOCUMENT/DRAWING: 1. Electrical Power Distribution and Grounding Drawing
TEST DETAILS: Refer to Section 7.4. CRITERIA: The power connection should be proper prior to power on the cabinets.
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6.5.
Wiring Checks
OUTLINE: All signal wiring connections are in accordance with the approved drawings and documents. OBJECTIVE: The purpose of this test is to ensure proper signal wiring connection prior to Loop checks and Tricon Application Program Check. REFERENCE DOCUMENT/DRAWING: 1. Wiring Diagram
TEST DETAILS: Refer to Section 7.5. CRITERIA: All signal wiring terminal numbers and wire markers are as per referenced drawings.
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6.6.
Tricon Start-up Checks wrt new hardware supplied
OUTLINE: Successfully start up of the Tricon ESD expansion chassis # 10. OBJECTIVE: The purpose of this test is to ensure the successful start up of the Tricon expansion chassis # 10. REFERENCE DOCUMENT/DRAWING: 1. System Architecture Drawing
TEST DETAILS: Refer to Section 7.6. CRITERIA: Tricon expansion chassis # 10 should have a successful start-up and all tricon modules should have Active and Pass LED ON.
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6.7.
SOE Retrieval Utility Checks
OUTLINE: The SOE functionality wrt newly added points to be checked. OBJECTIVE: The purpose of this test is to check SOE functionality wrt newly added points. REFERENCE DOCUMENT/DRAWING: 1. System Architecture Drawing
TEST DETAILS: Refer to Section 7.7. CRITERIA: Tricon SOE Retrieval is ready to start collecting the new events.
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6.8.
Tricon Configuration & Spares Checks wrt new hardware supplied
OUTLINE: All IO points as per I/O Database need to be configured in the Tricon ESD System. OBJECTIVE: This checks the basic configuration of the TRICON project file against the quantities in the I/O database. REFERENCE DOCUMENT/DRAWING: 1. 2. Wiring Database Wiring Diagram
TEST DETAILS: Refer to Section 7.8.
CRITERIA: All IO points should be configured in Tricon Application Program.
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6.9.
Failure Mode & Diagnostics Checks
OUTLINE: The diagnostics of the Tricon in the presence of different type of failure modes such as single leg failure, I/O PLC failure, Dual leg failure, power supply failure and complete failure. OBJECTIVE: The purpose of these tests is to ensure the operation of the Tricon in the presence of a module failure. Please note that random modules may be chosen to carry out this test. REFERENCE DOCUMENT/DRAWING: 1. System Design Document
TEST DETAILS: Refer to Section 7.9. CRITERIA: Successful Failure modes operation of Tricon ESD system.
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6.10.
System Performance Checks
OUTLINE: The performance of the Tricon System to be verified. OBJECTIVE: The purpose of this test is to record the performance of the Tricon System.
TEST DETAILS: Refer to Section 7.10. CRITERIA: Tricon System performance is within limit.
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7.
DETAILED TEST DESCRIPTION AND RESULTS
The following test procedures cover the test tasks and results for each kind of test to be carried out during SAT. 7.1. SYSTEM CONFIGURATION HARDWARE CHECKS WRT NEWLY SUPPLIED
System Name: 7.1.1. Tricon Inspection Check model numbers, revisions, quantity of the Tricon modules Check Bill of materials for Tricon ESD System 7.1.2. Third Party Equipment Log Check and record all serial numbers when available for third party major equipment Record all third party equipment purchase locations when possible
Overall System Configuration Checks Test Complete
YME/SA
Date
IME
Date
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7.2.
VISUAL INSPECTION CHECKS
The following visual checks shall be carried out: Paintwork free from scratches, blemishes, deformities All mechanical connections are secure and fit properly Nuts / bolts / screws / fasteners are tight All ETA labels are fitted All Device labels are fitted All terminal block labels are fitted All system (pre-fab) cables are labelled All chassis interconnect IO Bus cables are labelled A, B, or C Randomly check crimped ends and screw connections All Tricon modules are in correct chassis / slot Verify that all system cables from chassis to ETA at Marshalling cabinet are connected correctly
Visual Inspection Checks Test Complete
YME/SA
Date
IME
Date
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7.3.
ELECTRICAL CHECKS
Wire Type / Colour Application 2.5/4/6mm2 multistranded copper conductor, 600V, 105C, PVC AC Live Insulation Black 2.5/4/6mm2 multistranded copper conductor, 600V, 105C, PVC AC Neutral Insulation White 2.5/4/6mm2 multistranded copper conductor, 600V, 105C, PVC AC Safety & Shield Insulation Green ground 2.5/4/10mm2 multistranded copper conductor, 600V, 105C, DC supply positive PVC Insulation Red 2.5/4/10mm2 multistranded copper conductor, 600V, 105C, DC supply negative PVC Insulation Black 2.5/6mm2 multistranded copper conductor, 600V, 105C, PVC DC Reference ground Insulation Green with Yellow Trace 1.5mm2 multistranded copper conductor, 600V, 105C, PVC Signal positive Insulation Black 1.5mm2 multistranded copper conductor, 600V, 105C, PVC Signal negative Insulation White All cabinet wiring shall be inspected prior to power-up. ESD System and Marshalling Cabinets: Random Cabinet power wiring visual or continuity checked against drawing Random Ferrule tagging visual check, should be clear and readable Random Point to point (resistance test) Random Point to ground (resistance test) Note: Earth bonding test shall not exceed 0.5 ohms between bonded item and appropriate earth bus bar
Electrical Checks Test Complete
YME/SA
Date
IME
Date
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7.4.
POWER CONNECTION CHECKS
The following test is to ensure proper power feed is connected to the expansion chassis # 10 prior to power on. Check expansion chassis # 10 are connected to a suitable earthing point in the cabinet Check expansion chassis # 10 is powered through MCBs 11 and 12 in the system cabinet ESD-SYS-04. Check all MCBs for the correct rating protection (refer to Electrical Power Distribution & Grounding Drg.) 7.4.1. System Power (110V A.C. UPS) UP Switch ON individual MCBs and check voltage on its output terminals, ensure the respective output devices are ON such as Tricon expansion chassis. Ensure all Tricon modules are in PASS and ACTIVE. 7.4.2. Field Output Power (24V D.C. KEPCO) UP Check voltage on the input side of the power distribution terminals (keeping the fused terminals OPEN). 7.4.3. Distribution Check On the primary power distribution terminals, CLOSE the fused terminals (+ve) one by one and check voltage at the primary power input terminals of respective ETA. On the secondary power distribution terminals, CLOSE the fused terminals (+ve) one by one and check voltage at the secondary power input terminals of respective ETA. 7.4.4. System healthiness Ensure the system healthiness as below: Ensure the expansion chassis power supply does not show any alarm Ensure no Load Fuse alarm on the Tricon DO modules after power up of the 24v DC field power supply (KEPCO).
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7.4.5. Power Consumption For each type of power feeds, measure voltage and total system current with system in noload condition and record the results: Voltage 110V AC Primary Feed 110V AC Secondary Feed 24V DC Kepco Primary power supply 24V DC Kepco Secondary power supply ------------------------------------------------Current -------------------------------------------------
Power Connection Checks Test Complete
YME/SA
Date
IME
Date
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7.5.
SIGNAL WIRING CHECKS
Randomly thel signal wiring shall be inspected prior to Loop checks and Application Program (Logic Simulation) checking. ESD System and Marshalling Cabinets: Cabinet wiring visual or continuity checked against drawing Ferrule tagging visual check, should be clear and readable Point to point (resistance test) Point to ground (resistance test) Note: Earth bonding test shall not exceed 0.5 ohms between bonded item and appropriate earth bus bar
Wiring Checks Test Complete
YME/SA
Date
IME
Date
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7.6.
TRICON START-UP CHECKS WRT NEWLY SUPPLIED HARDWARE Existing Tristation / SOE PC with the software installed will be used for the expansion Project.
7.6.1. Modifying Application Take a backup of the existing latest PT2 file on a removable medis. Run TriStation 1131 application program file copied above. Logon screen will appear and login using, name MANAGER and Password PASSWORD. Connect the TRICON, using Control Panel menu. Ensure the Tristation network node is 192.168.1.1. Modify the application software (latest PT2 file) as required to implement the changes wrt new project. Switch TRICON to Program mode. Download the program using Download all. Switch TRICON to run mode. Note the project file version is _______________ (after downloading)
(The number before the decimal point represents the number of Download Alls, the number following the decimal point is the number of Download Changes since the last Download All command.) 7.6.2. Tricon Hardware Check All Tricon modules to display ACTIVE and PASS LED ON. Check TRICON configuration against ESD System Architecture Drawing.
Tricon Start-up Checks Test Complete
YME/SA
Date
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7.7.
TRICON SOE RETRIEVAL UTILITY CHECKS Existing Tristation / SOE PC with the software installed will be used for the expansion Project.
7.7.1. Running SOE Copy the latest SOE configuration file from Engineering Station C:\Programfiles\Triconex\ TriStation1131ver4.1\Programs\XXX.SOE to SOE Station C:\Programfiles\Triconex\tr1soe\. Open new dummy file using SOE Retrieval Utility. Trinode address will be indicated as 192.168.1.1, if the SOE and TRICON communication is OK. Run the SOE retrieval to begin collecting the event.
Tricon SOE Retieval Startup Checks Test Complete
YME/SA
Date
IME
Date
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7.8.
ESD CONFIGURATION AND SPARES CHECKS WRT NEWLY SUPPLIED HARDWARE
The following section details the functional check required for TRICON system configuration. Verify existence of control program. Check the module configuration as per Rack Assignment & IO Details in DLD. Check the TRIOCN I/O addressing for the hardware points randomly. Check the TRICON I/O addressing for the software points randomly. Check the SOE block configuration. Following table details the table for IO quantity to identify the spare coverage.
Module Used Analog Inputs, TMR Digital Inputs, 24VDCTMR Digital Outputs 24VDC, TMR Analog Outputs, TMR Overall 3700A 3503E 3604E 3805E 9 10 10 0 29 Pts / Qty of Installed Installed Installed module Modules Points spares spares % 32 32 16 8 1 2 2 1 6 32 64 32 8 136 23 54 22 8 107 71.88% 84.38% 68.75% 100.00% 78.68%
Configuration and Spares Checks Test Complete
YME/SA
Date
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Date
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7.9.
FAILURE MODE AND DIAGNOSTIC CHECKS
7.9.1. Tricon Power Supply Failure Remove chassis#10 upper power supply A Check TS1131 diagnostic display shows Chassis power supply A is faulted. Ensure proper operation of the system, by actuating any one digital input. Re-insert chassis#10 upper power supply A Ensure diagnostic displays return to normal status Repeat this procedure with chassis#10 lower power supply B 7.9.2. Input Feed Failure 110VAC UPS Switch OFF 110VAC Primary Input Power Supply-1 (MCB 11). Check chassis # 10 primary power supplyis OFF. Check Main chassis shows alarm. Ensure proper operation of the system, by actuating any one digital input. Switch ON 110VAC Primary Input Power Supply-1 (MCB 11). Check chassis # 10 primary power supply is ON. Check Main chassis shows Normal. Ensure proper operation of the system, by actuating any one digital input. Repeat this procedure for Secondary Input Power Supply-2 (MCB 12). 7.9.3. Complete Power Failure & Battery Backup Checks Switch OFF complete power to the ESD Tricon modules with all modules inserted in place. Switch ON and check program running from battery backup.
Failure Mode Tests Test Complete
YME/SA
Date
IME
Date
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7.10.
PERFORMANCE CHECKS
7.10.1. Hardware
Check that the LED on all the TRICON chassis, power supplies and the IO Modules are showing normal.
7.10.2. Application Program:
The version and the dates on the application program shall be recorded. Sl.No 1 2 Application TS1131 Project File SOE Configuration file File Name Version Date
Note: Version Number of TS1131 project file indicates as - The number before the decimal point represents the number of Download Alls, & the number following the decimal point is the number of Download Changes since the last Download All command. 7.10.3. Scan Time Verification Using the Tricon Diagnostics Panel, note down the scan time for the Application Program, Scan Time set _____________mS Excess Scan time ____________mS
Note: Acceptance Criteria for the Scan Time is lower than 100ms. 7.10.4. Tricon IO & Memory Point Allocation Verification Print the Project Memory Allocation Listing Report using the TS1131 Print Report function. Check the % spare memory allocated for each variable type. Acceptance Criteria: 20% Spare memory allocated for each variable type. Performance Tests Test Complete
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Date
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Date
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8.
COMPLETION OF SAT CERTIFICATE
System Name: SAT Details SAT Location: SAT Start Date Upon completion of SAT. Ensure all punch list items are either closed or transferred to the exception list Ensure YME/SA have signed off on punch list and SAT Test Certificates Ensure all master IME drawings / documents are marked up and are ready for redrafting by others SAT Completion Date:
Completion of SAT Certificate
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Date
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APPENDIX B IO LOOP CHECKSHEETS Please refer to NMR 602.19 IO database as reference.
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APPENDIX C PUNCH LIST Find attached sample SAT Punch List Form.
SYSTEM NAME: Project Name: HARADH GOSP2 WIPS FACILITIES ESD EXP. Punch List No. Originator: Completed Verified Punch List No. Originator: Completed Verified Punch List No. Originator: Completed Verified Punch List No. Originator: Completed Verified Punch List No. Originator: Completed Verified Note: 1. Solution Problem Problem Sheet Date: Category (A / B)
Solution Problem -
Solution Problem -
Solution Problem -
Solution -
Category A: Critical to be completed and documented before SAT completion Category B: To be discussed with YME/SA.
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APPENDIX D CHANGE CONTROL FORM Change Control Forms

The following Change Control forms are the mechanism by which design changes are made, authorised, carried out and tested during Site Acceptance Test. As a summary the forms are: Hardware Change Register (HCR) Hardware Change Form (HCF) Software Change Register (SCR) Software Change Form (SCF)
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Project Number: 8SA-8-PJ030 Project: HARADH GOSP2 WIPS

FACILITIES ESD EXP.
HCF Raised By Number (Initials/date) Implemented By (Initials/date)
Hardware Change Register HCR

Summary of Change Details
Page
of
Tested By (Initials/date)
Software version on completion
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HCF Number HCF Project Number: 8SA-8-PJ-030 CHANGE Details: -
HARDWARE CHANGE FORM

HARADH GOSP2 WIPS FACILITIES ESD EXP.
State here the nature of the problem, the detail of the problem, and the proposed solution. Continue on a separate sheet and attach if necessary.
Effected Doc / Drawing Number
Title
By (Initials)
Requested By (Name & Sign): Position: Tested By (Name & Sign): Position:
Date
Date
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Project Number: 030
8SA-8-PJ-

SCF Raised By Number (Initials/date) Implemented By (Initials/date)
Software Change Register SCR

Summary of Change Details
Page
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Software version on completion
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SCF Number
SCF -
SOFTWARE CHANGE FORM

Project Number: 8SA-8-PJ-030 CHANGE Details: -
State here the nature of the problem, the detail of the problem, and the proposed solution. Continue on a separate sheet and attach if necessary.
Backup Taken By Logic Diagram Updated By
Initials
Date Date
Initials
I/O List Updated By Initials Date
Requested By (Name & Sign): Position: Tested By (Name & Sign): Position:
Date
Date
Tricon Software Version at Start:

Software Version at Finish:
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APPENDIX E Post SAT Check Sheet System Name: The following check list covers items to prepare or correct prior to actual start-up of plant. Remove any other links / shorts added for testing purposes Clean cabinets Check cabinet labels, trunk covers, cable clamps etc. are all in place Check all TRICON modules are secured with both locking screws on each module Close and lock all cabinet doors, remove keys and place in Triconex Accessories Box Archive Project File to zip disk. One copy to be handed over to SA (Maintenance) and one copy to be brought back to Invensys.
Post SAT Check Test Complete
YME/SA
Date
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Date
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NMR602.10 SAT Plan &amp; Procedure

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NMR602.10 SAT Plan &amp; Procedure

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PROJECT: HARADH GOSP2 WIPS FACILITIES ESD EXPANSION

Project No: Doc. No. 8SA-8-PJ-030 8SA-8-PJ-030-SAT

SITE ACCEPTANCE TEST PLAN

INVENSYS MIDDLE EAST (TRICONEX DIV.)

Client: Contractor: Owner:

Client P.O. No. Owner P.O. No. Sheet

NMR 602.10 Rev. B

PROJECT: HARADH GOSP2 WIPS FACILITIES ESD EXPANSION

SITE ACCEPTANCE TEST PLAN

PREREQUISITE CHECK LIST................................................................................................................................ 8

Client: Contractor: Owner:

Client P.O. No. Owner P.O. No. Sheet

NMR 602.10 Rev. B

PROJECT: HARADH GOSP2 WIPS FACILITIES ESD EXPANSION

SITE ACCEPTANCE TEST PLAN

1. REVISION RECORD SHEET

Revision Description ISSUED FOR CDR

Client P.O. No. Owner P.O. No. Sheet

NMR 602.10 Rev. B

PROJECT: HARADH GOSP2 WIPS FACILITIES ESD EXPANSION

SITE ACCEPTANCE TEST PLAN

Client: Contractor: Owner:

Client P.O. No. Owner P.O. No. Sheet

NMR 602.10 Rev. B

PROJECT: HARADH GOSP2 WIPS FACILITIES ESD EXPANSION

SITE ACCEPTANCE TEST PLAN

2. DOCUMENT APPROVAL 2.1. YME / Saudi Aramco

Rajesh Meghani, Lead Project Engineer

Approved By Ahmed Mazrouie, Project Manager Approved By YME / Saudi Aramco

2.2. Approval Notes and Exceptions

Client: Contractor: Owner:

Client P.O. No. Owner P.O. No. Sheet

NMR 602.10 Rev. B

PROJECT: HARADH GOSP2 WIPS FACILITIES ESD EXPANSION

SITE ACCEPTANCE TEST PLAN

NMR 602.10 Rev. B

PROJECT: HARADH GOSP2 WIPS FACILITIES ESD EXPANSION

SITE ACCEPTANCE TEST PLAN

NMR 602.10 Rev. B

PROJECT: HARADH GOSP2 WIPS FACILITIES ESD EXPANSION

SITE ACCEPTANCE TEST PLAN

PREREQUISITE CHECK LIST

Client: Contractor: Owner:

Client P.O. No. Owner P.O. No. Sheet

NMR 602.10 Rev. B

PROJECT: HARADH GOSP2 WIPS FACILITIES ESD EXPANSION

SITE ACCEPTANCE TEST PLAN

The following processes shall be ready/completed prior to start of the SAT. 1. 2.

Client: Contractor: Owner:

Client P.O. No. Owner P.O. No. Sheet

NMR 602.10 Rev. B

PROJECT: HARADH GOSP2 WIPS FACILITIES ESD EXPANSION

SITE ACCEPTANCE TEST PLAN

Client: Contractor: Owner:

Client P.O. No. Owner P.O. No. Sheet

NMR 602.10 Rev. B

PROJECT: HARADH GOSP2 WIPS FACILITIES ESD EXPANSION

SITE ACCEPTANCE TEST PLAN

TEST PROCEDURE Test Plan

Client: Contractor: Owner:

Client P.O. No. Owner P.O. No. Sheet

NMR 602.10 Rev. B

PROJECT: HARADH GOSP2 WIPS FACILITIES ESD EXPANSION

NMR602.10 SAT Plan & Procedure

NMR602.10 SAT Plan & Procedure