Integrated Control and Safety System (ICSS) Site Acceptance Test Procedure
Integrated Control and Safety System (ICSS) Site Acceptance Test Procedure
Integrated Control and Safety System (ICSS) Site Acceptance Test Procedure
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IRAN OFFSHORE OIL COMPANY
1. Table of Content
Contents
1. Table of Content ........................................................................................................................................................ 3
2. Introduction ................................................................................................................................................................ 5
2.4. References....................................................................................................................................................... 6
2. Introduction
2.1. Project Description
THE BAHREGAN CRUDE OIL STORAGE TANKS is located at Longitude between 50° 16' to 28' and Latitude
between 29° 40' to 50'. The location of this project is besides the existing plant facilities along the north coast of
Persian Gulf. Iranian Offshore Oil Company (IOOC) has awarded BAHREGAN Crude Oil Storage Tanks
Development EPC Project to LOLEH PEY GOSTAR CO. IDEH Company to perform Basic & Detailed Engineering, as
well as procurement, fabrication, installation, pre-commissioning & commissioning for:
2.2. Definition
The following words and expressions shall have the meanings hereby assigned to them except where the context of this
document otherwise requires:
"EPC Contractor / Purchaser "means Company mentioned in the Contract as part of the "other part" and includes its
successors and permitted assignees. (LPG)
"IDEH” means IRAS DESIGN ENGINEERING & HUMAN RESOURCES who provides goods or services to a company.
Whenever terms appear in this document as capitalized terms, they shall have the meaning ascribed to them here above.
2.3. Abbreviations
IOOC: Iranian Offshore Oil Company
2.4. References
Following documents are use as based on the requirements of and submitted
3. Scope of SAT
3.1. Purpose of SAT
SAT is to demonstrate that the hardware and software functionality of the ICSS SYSTEM satisfy requirements defined in the
specification documents.
In this project specifically, the test period for ICSS SYSTEM SAT is referred to as the "SAT" which will be conducted in IDEH.
This document mainly details the SAT activities.
3.2. Scope
IDEH's scope of work for SAT is as follows:
1. IDEH has prepared the SAT PROCEDURE for ICSS SYSTEM, based on the requirements of and submitted for review and
approval of Client.
2. IDEH is to assign a dedicated test conductor to ensure smooth execution and successful completion of SAT within the
schedule. Also supply necessary manpower, tools and materials to carry out the SAT.
3. As for the unstructured test, which is described later in HMI document, it is prepared and conducted by –IDEH personnel
and IDEH is to assist in its smooth execution.
4. Necessary components required for ICSS SYSTEM SAT will be staged in IDEH workshop.
5. The following ICSS SYSTEM hardware will be staged in IDEH workshop for SAT
Printers.
System Cabinets.
Marshalling Cabinets.
Installation of VNET bus (ICSS SYSTEM's real time redundant and maintenance bus) as per design.
SAT Procedure & Report, I/O SAT, Power Distribution Checks List, MTO Check List, Layout Drawing of Cabinet
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This phase is to verify proper functioning of the ICSS SYSTEM in IDEH before the SAT. HMI
includes the ICSS SYSTEM architecture and network. All components are connected and
tested to see the proper functioning of ICSS SYSTEM. Purpose of Pre-SAT is to ensure proper
functioning of the ICSS SYSTEM and to identify and correct any non-conformance to the
project requirements prior to SAT.
Structured Testing
Unstructured Testing
I/O Test part of Structured Test starts with the system diagnostic testing of ICSS SYSTEM to see
proper functioning of ICSS SYSTEM hardware including the visual inspection. Listed below are
all the tests involved:
All ICSS SYSTEM hardware I/O related configurations are tested on a loop basis by applying
signals from the ICSS SYSTEM Field Interface panels and verified through custom graphics
and standard ICSS SYSTEM displays such as a tuning display on a tag basis, control groups.
Functional Test part of the Structured Test includes all control application tests. Tests shall be
carried to check the correctness of various attributes pertaining to the following,
Assignment Description
Responsible for coordination of SAT between IDEH and LPG and
IDEH Project Manager IOOC control of punch-list.
IDEH Lead Project Engineer Responsible for Execution of SAT.
Note: IDEH will be assign number of SAT personnel according to SAT timing schedule.
After implementing the solution for a problem, it is demonstrated, witnessed and signed-off. If a
problem cannot be resolved within a given time, further action will be discussed and one of the
following actions is taken depending on the nature and impact of the problem.
1. Test Suspension: It is judged that a further test cannot be done until a problem is resolved
so that the test is suspended.
2. Test Resumption: An impact of problem is limited only to it or is less so that the test can
be resumed from where it was suspended. Development of solution to the problem is
continued in parallel to the test and demonstrated when it is ready.
3. Test Restart: It is found after development of a solution to a problem, that because of
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nature or impact of the problem or solution or due to other related problems, a test shall be
restarted not from where it was suspended but restarting of other related test items, which
have been completed in progress.
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4.2.1. Introduction
The ICSS SYSTEM Site Acceptance Test (SAT) is carried out in accordance with HMI procedure.
4.2.2. GENERAL
2. Attached Component Check-sheets shall be used during SAT in order to keep record of all items,
which are tested with their results (Appendix-1).
3. Any non-conforming item discovered during the SAT will be recorded in the 'Punch List' form
(Appendix-2).
4. Towards the end of each day, a daily progress meeting will be held to discuss the progress
achieved and problems observed if any.
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Place: Site.
Lunch: 12PM to 2 PM
Teams There will be two teams formed for the SAT testing. One shall be testing the Hardware I/O
Loop checking and the other the software consisting of the Graphics, alarms etc. Also refer attached
SAT schedule for more details.
Schedule of SAT: Shall be informed later.
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All hardware manufactured for HMI project is subject to client visual inspection to confirm that all
components and accessories are in accordance with 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. Station No. of each component.
3. Quantity of each component.
REFERENCE:
CRITERIA:
Date
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OUTLINE:
All Node Units (NU) & I/O module positions are defined during the engineering phase of the project.
OBJECTIVE:
The purpose of this test is to verify that all NU & I/O modules are correct in quantity and that each item is
installed in the right position.
REFERENCE:
PROCEDURE:
1. Visually check that the I/O modules are installed in the correct position & correct in quantity
CRITERIA:
The quantity and location of the NU & I/O modules are in accordance with the above reference.
COMMENTS:
Date
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OUTLINE:
Each component of the system normally goes to its operating environment automatically on
power up, provided that all operation / application software are stored in their respective media.
OBJECTIVE:
The purpose of this test is to ensure that all components automatically boot up when going from
'Of environment to 'Operating' environment.
REFERENCE: None
PROCEDURE:
1. Power off components individually or the system as a whole.
2. Power on each component individually.
CRITERIA:
Each component boots up automatically to its operating environment.
COMMENTS:
Date
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OUTLINE:
The dual CPUs back up each other. During operation, one of them will be active while the ot her
will remain as standby. The standby CPU is constantly updated with every memory writes cycle.
OBJECTIVE:
The purpose of this test is to verify that the standby CPU becomes 'active' when the active CPU
fails, and that all loop data remains the same after switchover.
REFERENCE: None
1. Select a loop & monitor it on HMI.
2. Stop the active CPU by activating the STOP.
3. Check the system alarm messages displays on HMI.
CRITERIA:
The control shall be transferred promptly and correctly to the standby CPU as observed
through the "Control Station Status window" displayed on the HMI, without affecting the value
being monitored.
COMMENTS:
Date
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OUTLINE:
The dual redundant PB bus allows the I/O data to be communicated from/to the node unit (NU) to / from
the FCU unit.
OBJECTIVE:
To verify that the PB bus communication is not affected, in case of failure of one PB bus.
REFERENCE: None
PROCEDURE:
1. Wire up one control loop, output to input, to make a closed loop. (If required)
2. Display the tuning panel for HMI tag to observe the control action.
3. Disable one of the PB bus.
4. Check for the corresponding system alarm messages on the HMI.
5. Check the controller on the HMI, to confirm ICSS SYSTEM control functions are normal.
6. Repeat the test for the other buses.
CRITERIA:
On failure of one of the bus, the other bus should continue to function normally. The ICSS
COMMENTS:
Date
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The system hardware healthiness is displayed in the 'System status display window' screen on HMI (which
includes CPU, Power supply, Node unit, I/O Modules, Communication modules etc.)
OBJECTIVE:
1. The purpose of this test is to verify that all System Hardware are in healthy condition.
2. To ensure that the system hardware displayed in system status display generates the respective
alarm in case of specific hardware failure.
REFERENCE: None
To ensure the system hardware are healthy & hardware failure alarms are generated when specific
hardware failures are simulated.
COMMENTS:
Date
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The inter-station communication bus provides communication between the human Machine
Interface (HMI), operator stations (OS) and the Programmable Logic controller (ICSS SYSTEM). It is
therefore crucial that failure of one bus does not affect any other part of the system.
OBJECTIVE:
The purpose of this test is to ensure that failure of one of the inter-station communication buses
(VNET) has no effect on the normal data highway communications.
REFERENCE: None
PROCEDURE:
1. Disconnect one inter-station communication bus; observe the system alarms in HMI.
2. Connect the failed BUS; wait till it recovers. Perform Step-1 again with the second bus &
observe the system alarm in HMI.
3. Connect the failed BUS & wait till it recovers; observe the system alarms in HMI.
CRITERIA:
The human Machine interface station (HMI) can still change and monitor data in the ICSS
SYSTEM without any disturbance, when one communication bus has failed.
COMMENTS:
Date
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OUTLINE:
With multiple HMI in the configuration, failure of one HMI will not affect the Plant Operation.
OBJECTIVE:
The purpose of this test is to confirm that there is no effect on the monitored Tag due to failure of an HMI.
REFERENCE: None
PROCEDURE:
1. Display the same Operation Window for a particular Tag on two of the H IS's.
2. Also display the Trend of that Tag on another HMI.
3. Perform Operation through one of the HMI.
4. Shutdown the HMI under operation to simulate the Failure.
5. Observe the Operation Window on the second HMI.
CRITERIA:
The trend data display is normal. Operation can still be continued through the Window on another
HMI. (Refer to Appendix-1, Page-7)
COMMENTS:
Date
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The Redundant I/O Modules in the Field Control Station back up each other. During operation, one of
them will be active while the other will remain as a standby. The standby I/O Module is constantly
updated.
OBJECTIVE:
The purpose of this test is to verify that the redundant standby I/O Module becomes 'active' when the
primary I/O Module fails, and that all loop data remains the same after switchover to the redundant
backup I/O Module.
REFERENCE: None.
PROCEDURE:
1. Select a loop & monitor it on HMI.
2. Remove Primary I/O Module from the Node unit.
3. Check the system alarm messages displays on HMI.
4. Observe the value of the monitored loop
5. Check for the system alarm messages display on the HMI.
CRITERIA:
1. The control shall be transferred promptly and correctly to the redundant I/O Module as observed
through the "Control Station Status window" displayed on the HMI, without affecting the value being
monitored.
2. The other redundant I/O module will still be functioning normally as observed on the "Control
Station status display panel"
COMMENTS:
Date
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OUTLINE:
1. The System Loading Status Display shows the total load of the CPU in ICSS system.
2. The custom developed software for HMI Project is loaded to the respective ICSS.
3. Using Resource Information Tool to check the usage of Function blocks in ICSS SYSTEM.
OBJECTIVE:
REFERENCE: None.
PROCEDURE:
A. SYSTEM LOADING:
1. Call the System Status Display window.
2. Select ICSS SYSTEM to monitor the idle time.
B. RESOURCES INFORMATION CHECKS.
1. Open the System View in an Operation Station.
2. Select ICSS SYSTEM Tab & Select "Cycle Time" to check the custom software loaded in an each
ICSS SYSTEM with respect to the project.
CRITERIA:
COMMENTS:
Date
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The process alarms, system alarms, screen-print and log reports are printed in the printer assigned for
HMI purpose.
OBJECTIVE:
To ensure that the alarm messages and log reports are printed as required.
REFERENCE: None.
PROCEDURE:
1. Ensure that the printer is 'On-line'.
2. Simulate some system alarms or process alarms and check if they are being printed page-wise.
3. Change 'Scheduled time' for a log report to initialize printing and check if report is being printed.
4. Screen-print from any of the HMI.
CRITERIA:
1. System / Process alarms shall be printed on the printer.
2. Log reports shall be printed as per definition.
3. Color Printer should print screen prints from the HMI / ENG on demand.
COMMENTS:
Date
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OUTLINE:
The graphics are used for operation of the plant by monitoring & controlling various instruments.
OBJECTIVE:
The purpose of this check is to confirm that the graphic windows are generated and are functioning
according to the specifications.
REFERENCE:
PROCEDURE:
1. Call up the Graphic Window.
2. Compare the display with the sketch / specification.
3. Check the colors of various lines / equipment.
4. Check the dynamic data by changing the process value.
5. Check the graphic modifiers by simulating conditions as applicable.
6. Repeat the above for all graphic Windows.
CRITERIA:
1. Graphic symbols and process lines are correctly displayed as per specifications.
2. Colors are displayed as per reference documents.
3. Dynamic data are displayed correctly.
4. Graphic Modifiers are functioning correctly.
5. Cursor targets call the correct window and/or faceplate.
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COMMENTS
Date
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Faceplates can be displayed on a window. Process variable, Set point, Output, Loop status and Alarm
status are shown on each faceplate.
OBJECTIVE:
The purpose of this test is to verify the proper format of display and functioning of the Control Group
windows.
REFERENCE:
1. None
PROCEDURE:
1. Call up the Faceplate window.
2. Data modification by increment/decrement keys.
3. Direct entry of data and loop status using direct data input keys.
4. Display of corresponding tuning window by clicking on the individual tags
CRITERIA:
The faceplate window is displayed correctly.
COMMENTS:
Date
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OUTLINE:
Tuning Window is used to adjust the control parameters of feedback and sequence control instruments.
OBJECTIVE:
The purpose of this test is to verify the proper display format and functioning of the Tuning window.
REFERENCE: None
PROCEDURE:
1. Perform data changes.
2. Manipulate the tuning trend.
CRITERIA:
The Tuning window is displayed correctly & operations can be done as applicable.
COMMENTS:
Date
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OUTLINE:
The HMI historical Messages function records all alarms, operator entries (logs), process parameter
changes, etc. as they occur during the course of the operation.
OBJECTIVE:
The purpose of this test is to verify the correct operation of the HMI historical Messaging function.
REFERENCE: None
PROCEDURE:
1. Call up the HMI historical Message Window.
2. Change Instrument mode and data entry or simulate some alarms
3. Call up the appropriate HMI historical Message display or select "ALL".
CRITERIA:
HMI historical Message should recall events or operator changes process parameters data, events with
date and time in its order.
COMMENTS:
Date
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OUTLINE:
All components and accessories supplied by IDEH has part of ICSS SYSTEM are certified free from
scratches and any deformities, which might impair the product quality and appearance.
OBJECTIVE:
The purpose of this test is to ensure that ICSS SYSTEM Marshalling cabinets / Network cabinet /
Auxiliary cabinet are free from scratches and deformities.
REFERENCE:
CRITERIA:
1. There should not be any external defects such as deformities, scratches that might impair the
product quality or appearance.
2. Mounting of components is as per reference drawings.
COMMENTS:
Date
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OUTLINE:
The signal wiring and power wiring of ICSS SYSTEM Field Interfacing Cabinets are done as per the
specifications and as per the wiring diagrams.
OBJECTIVE:
The purpose of this test is to ensure that all internal wiring for signals, internal power distribution and
terminal assignments are done as per requirement.
REFERENCE:
COMMENTS:
Date
IRAN OFFSHORE OIL COMPANY
OUTLINE:
System Cables from the existing marshalling cabinets (at site) are connected to the duplicating terminal
boards of the Field Interfacing Cabinets. Some of the Thermocouple signals from the existing marshalling
cabinets (at site) are directly connected to the terminal boards and signal converters. System cables for
the digital signals from the existing marshalling cabinets are connected to the I/O modules.
OBJECTIVE:
The purpose of this test is to ensure that the cabinet wiring matches with the I/O assignment in the
ICSS System and all the loop connections are correctly configured in the system. And the wiring in the
marshalling cabinets / auxiliary cabinet is as per the wiring data base and the wiring diagrams.
REFERENCE:
PROCEDURE:
1. For analog input signal inject 4-20 mA signal at the corresponding Simulation terminal board
terminals to simulate the field input signal. Call the corresponding Tag number faceplate on the
Operator console and check for display of correct value. The signal shall be fed corresponding to
0%, 50%, and 100%. Also check the open circuit condition (10P).
2. For analog output, call the relevant closed loop tag number one by one, put in MAN mode and
change the output from the Operator console. Check the output at the corresponding Simulation
terminal board terminals using a multimeter. Simulation shall be for 0%, 50% and 100%.
3. For digital inputs, short the corresponding Simulation terminal board input terminals. Call up the
corresponding Tag Faceplate on the Operator console and check for change of state in the tag
faceplate in the HMI.
4. For digital outputs force the output from the Operator console check the status of contacts at the
corresponding Simulation terminal board output terminals.
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CRITERIA:
1. All the signals, both analog and digital are correctly displayed in the system as per reference
documents.
5. Wiring in the Field Interface cabinet loops are configured & function correctly.
COMMENTS:
Date
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All accessories supplied by IDEH as part of ICSS system are certified free from scratches and any
deformities, which might impair the product quality and appearance.
OBJECTIVE:
1. The purpose of this test is to ensure that Auxiliary Console is free from scratches, deformities
& also to ensure that internal wiring / terminal assignments are done as per requirement.
2. To check the functionality of all Pull/Push buttons, Indicating lamp & Selector switches are
as per the specification.
REFERENCE:
CRITERIA:
1. There should not be any external defects, deformities or scratches that might impair the
product quality or appearance.
2. Mounting / Internal wiring of Pull/Pushbuttons, Indicating lamps & Selector-switches in
Auxiliary console are as per reference drawings. (Refer to Appendix-1, Page-12)
COMMENTS:
Date
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BAHREGAN CRUDE OIL STORAGE TANKS DEVELOPMENT
(PIPING, MANIFOLD, CONTROL SYSTEM & FIRE FIGHTING)
This is to certify that the ICSS System (as per the scope of Customer P.O. No. ---------- Dated -----
------) has been tested during the Site Acceptance Test [ICSS SYSTEM SAT] at IDEH (IRAS
TARH) Shop, Tehran. It is found to function as per the project specifications and requirements
and is accepted as a deliverable material requirement.
PROJECT
P.O. No.
CUSTOMER: END –
USER:
[COMMENTS]
SIGNED BY:
IRAN OFFSHORE OIL COMPANY
BAHREGAN CRUDE OIL STORAGE TANKS DEVELOPMENT
(PIPING, MANIFOLD, CONTROL SYSTEM & FIRE FIGHTING)
In this part, logic test and transfer scenario have been checked.
OBJECTIVE:
The purpose of this test is to ensure that signal and logic of DCS, ESD and F&G program are
compatible with Cause & Effect.
REFERENCE: None
PROCEDURE:
1. Compare the cause & effect matrix with logic, graphic pages and note for changes to be
done like resets, tag no., effect, etc.
3. If MOV or control valve has close while creating a cause, keep them open before creating
case. When MOVs or control valves goes to close condition during logic checking, check
whether it is opening or note. It should not operate till case exits.
4. The valves for the causes to be simulated- refer latest Alarm and Trip schedule.
5. Check for causes & effects alarms in Alarm window and changes in DCS & ESD graphics.
6. Check for effects actually in field only and confirm with the logic.
8. Keep one copy of Cause & Effect Matrix and highlight what are really actuated in field. If
only trip alarm or ESD signal check, don’t highlight it, write punch point.
9. If there are no clearance for MOVs and pumps, check for DCS and ESD signal & alarms in
faceplate & alarm window.
10. Once cause & Effect is activated, while normalizing carefully check for hysteresis & resets
which are mentioned in Casus & Effect.
11. Whatever Effects not checked, clearly mention in Cause & Effect sign -off page that is has to
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BAHREGAN CRUDE OIL STORAGE TANKS DEVELOPMENT
(PIPING, MANIFOLD, CONTROL SYSTEM & FIRE FIGHTING)
be checked again.
12. While checking control narrative, refer update document. Check for actual action as per our
process condition.
13. For Fire & Gas logic checks, the simulation to be done from field & effects to be check in
field.
14. Check for Cause & Effects alarm in Alarm window and check for changes in IRIDE graphics
and F&G Cause & Effect Matrix.
15. Highlight in Cause & Effect page, which are actually happened in field only. If only signal
checked don’t highlight, write punch point.
g) Functional test of the manual call points, sirens and lamps 70%
7. TGS Testing
OBJECTIVE:
The purpose of this test is to ensure that signal and device of Tank Gauging System.
REFERENCE: None
PROCEDURE:
4. Based on type of radar connection like multi-drop (daisy chain), etc. to be checked for each
one.
6. Engineering and operatory station checks have connection to the Entis-Pro monitoring
software.
7. Open Engauge software and plug in Ethernet cable to CIU888 and Engineering Station.
9. There are lots of parameter shows in online connection and make notes for each calibrated
parameters of tank.
9. Communication Testing
OBJECTIVE:
The purpose of this test is to ensure that health communication of DCS, ESD and TGS.
REFERENCE: None
PROCEDURE:
2. Tag number of each Ethernet cable from DCS and ESD CPU to switch to be checked.
3. Tag number of each Modbus-TCP cable from DCS and RTU to switch to be checked.
4. Tag number of each Modbus-RTU cable port from DCS to TGS to be checked.
6. Send and receive data of CPU to be visual checked by person in DCS and ESD cabinet.
7. Send and receive data of Modbus-TCP card to be visual checked by person in DCS and RTU
cabinet.
8. Send and receive data of Modbus-RTU to be visual checked by person in DCS and TGS
cabinet.
9. Based on redundant system of DCS, ESD and TGS, in order to check each communicate
system, plug out each cable of DCS, ESD and TGS and then to be checked one by one.