C-54 NOC

NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES C.54

COMMISSIONING OF MICROPROCESSOR BASED INSTRUMENT SYSTEMS

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

GENERAL ENGINEERING SPECIFICATION COMMISSIONING OF MICROPROCESSOR BASED

GES C.54 Page 2 of 18

INSTRUMENT SYSTEMS Rev 0 1999 INDEX SEC TITLE PAGE 1.0 SCOPE OF SPECIFICATION 3 1.1 Introduction 3 1.2 Other NOC Specifications 3 1.3 Functional Test Sheets 4 2.0 DEFINITIONS 4 2.1 Technical 4 2.2 Contractual 5 3.0 DESIGN 6 3.1 Codes and Standards 6 3.2 Factory Acceptance Tests (FAT) and Checks 7 3.3 Factory System Integration Tests (SIT) and Checks 8 3.4 Installation and Site Testing 8 3.5 Instrument System Handover to Operations 14 4.0 QA/QC 14 5.0 SOFTWARE QUALITY CONTROL 15 6.0 DOCUMENTATION 16 6.1 Drawings and Documentation 16 6.2 Test Discrepancy Report and Co-Ordination 16 7.0 SUB INDEX OF FUNCTIONAL TEST SHEETS 17 DATA SHEETS (22 Forms, comprising 23 sheets)



INSTRUMENT SYSTEMS Rev 0 1999 1.0 SCOPE OF SPECIFICATION 1.1 Introduction 1.1.1 This specification covers the minimum requirements for the factory testing checks, operability testing and

site testing of microprocessor based instrument systems, leading to their field commissioning. 1.1.2 This General Specification together with the Scope of Work defined for the project, will form part of the

Purchase Order/Contract and applies to microprocessor based instrument systems for refineries, onshore oil and gas installations and processing facilities including items purchased either directly or part of a package. Depending on the project scope for some packages the testing and commissioning of these instrument system may be in the package Vendor/Contractor's scope of work.

1.1.3 In the event of any conflict between this specification, the Purchase Order/Contract and any other

applicable Codes and Standards, the Vendor/Contractor shall inform the Owner. Written clarification on how to proceed shall be obtained from the Owner before proceeding with the affected portion of the works as failure to do so shall indicate full compliance; any remedial work then necessary shall be at the Vendor/Contractor's expense.

1.1.4 The Vendor/Contractor and/or the Vendor/Contractor's Commissioning team shall comply fully with the

provisions laid down in this specification. Any exception must be authorised in writing by the Owner. It is the Vendor/Contractor's responsibility to ensure that the complete system is inspected and tested

throughout all stages to ensure a smooth, damage and trouble free start of the plant and without any danger to the operations personnel.

1.1.5 This is a General Specification and as such it must be tailored to the project specific or system specific

requirements. 1.1.6 This specification does not include the field commissioning of Management Information Systems which is

covered by GES J.25. Also, this specification does not cover the training of various personnel on microprocessor based instrument systems.

1.2 Other NOC Specifications The following NOC General Engineering specifications are an integral part of this specification and any

exceptions shall be approved in advance by the Owner: GES A.06 Site Data GES B.01 Central Control Buildings GES C.55 Field Installation, Calibration and Testing of Instruments GES J.12 Indoor Control Panels and Cabinets GES J.16 Instrument Cable and Cabling GES J.17 Earthing of Instrument Systems GES J.20 Distributed Control Systems (DCS) GES J.22 Field Automation (SCADA) Systems GES J.23 Emergency Shutdown Systems GES J.24 Fire and Gas Instrumentation



INSTRUMENT SYSTEMS Rev 0 1999 GES J.25 Management Information Systems GES J.29 Centralised Tank Farm Monitoring Systems GES L.07 A.C. Uninterupptible Power Supplies (UPS) GES L.27 Electrical Requirements for Control Rooms including Wiring 1.3 Functional Test Sheets Functional Test Sheets are included in Section 7.0 of this specification and shall be completed by the

Vendor/Contractor during commissioning. 2.0 DEFINITIONS 2.1 Technical The technical terms used in this specification are defined as follows: DCS Distributed Control System or an acronym often used to describe a generic, microprocessor based,

regulatory control system. ESD An abbreviation for Emergency Shutdown Systems. Factory Acceptance Test (FAT) A formal factory tests designed to demonstrate that the system fulfils the requirements of the Design

Specification. The FAT is developed jointly between the Vendor/Contractor and the Owner. Fault Tolerance A system which includes hardware or software fault detection features and redundant hardware, which

allows the system to continue performing its specified function after faults have been detected. HAZOP Acronym for Hazards and Operability study which is a systematic, detailed, hazards analysis technique

applied to processes to identify and qualify deviations from the intended design or normal operation which have the potential to place the plant or personnel at risk.

I/O (Input/Outputs) The discrete inputs or outputs connected to the field elements. Operability Test (OT) Operability Test is designed to verify the integrity of the system after it has been delivered and installed at

site. The OT is developed by the Owner and/or the Vendor/Contractor. If a Vendor/Contractor is involved then the OT shall be the responsibility of the Vendor/Contractor.



INSTRUMENT SYSTEMS Rev 0 1999 Process Control System A generic term which includes all systems which are used to control the process e.g. DCS, PLC, dedicated

single purpose controllers but excludes ESD and F&G related systems. Protocol A set of rules governing information in a communication system. Protocol is sometimes also referred to as

"data link control". Ready for Handover Certificate An official agreement between the Vendor/Contractor and the Owner that the commissioning of a system

or a sub-system is complete. The certificate is signed once the system handover is completed. Redundant System Systems with duplicated or triplicated hardware or duplicated Power Supply Units to provide uninterrupted

operation in the event of the failure of a single channel/module. (see also Fault Tolerance) SCADA Supervisory Control and Data Aquisition. Site Acceptance Test (SAT) SAT is designed to verify the satisfactory performance of the system as defined in the job specification and

that all system interfaces are tested. SAT is developed by the Owner and/or the Vendor/Contractor. If the Vendor/Contractor is involved then the SAT is the responsibility of the Vendor/Contractor.

System Integration Testing (SIT) Testing of system sizing and data communication links between different systems eg between SCADA and

DCS to verify that the systems can function together as a complete overall system as designed. 2.2 Contractual The commercial terms used in this specification are defined as follows: Owner The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities. Vendor The company supplying the equipment and material. Contractor The main contractor for a defined piece of work Sub-Contractor A company awarded a contract by a Contractor to do part of the work awarded to the Contractor. Inspection Authority The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and



INSTRUMENT SYSTEMS Rev 0 1999 facilities have been designed, constructed, inspected and tested in accordance with the requirements of this specification and the Purchase Order/Contract.

Inspector A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,

who verifies that the equipment and facilities have been designed, constructed, inspected and tested in accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN 3.1 Codes and Standards The checks and tests carried out to this specification shall conform to the current edition of the following

Codes and Standards: American Petroleum Institute (API) API RP 552 Transmission Systems API RP 554 Process Instrumentation and Control British Standards Institution (BSI) BS(EN 60546) Controllers with Analogue Signals for use in Industrial Process Control Part 1 - Methods for Evaluating Performance Part 2 - Guide to Inspection and Routine Testing BS 5515 Code of Practice for Documentation of Computer Based Systems BS 5760 Guide to Reliability Testing of Systems, Equipment and Components BS 6238 Code of Practice for Performance Monitoring of Computer-based Systems BS 6488 Code of Practice for Configuration Management of Computer-based Systems BS 6667 Electromagnetic Compatibility for Industrial Process Measurement and Control Instrument Society of America (ISA) S 51.1 Process Instrumentation Terminology (ANSI) International Standards Organisation (ISO) ISO 9001/3 Quality Systems (Equivalent to BS 5750) 3.2 Factory Acceptance Tests (FAT) and Checks 3.2.1 General The following notes apply to all microprocessor based instrument control systems. Field commissioning of

the instrument systems will not be initiated unless it has been verified that all the following tests have been completed during the FAT stage. Any incomplete tests or checks shall be completed at site and



INSTRUMENT SYSTEMS Rev 0 1999 shortcomings rectified before proceeding with the commissioning activities.

3.2.2 FAT Tests and Checks (a) An inventory check to verify the existence of all parts, modules, cables, interface equipment and

other associated equipment. (b) Database checks to verify the Vendor/Contractor's system design capabilities. It should be possible

to build, load and modify a system or sub-system database. (c) Simulation and testing of system monitoring and security features. Tests shall include component

failures, cable breaks and power failures. (d) Demonstration to check the capabilities of all operator interfaces. System architecture including

external serial interfaces and devices shall be verified in accordance with the job specification. (e) All database configuration and displays and features shall be tested for operation in accordance

with their job specification. (f) Testing (and installation - if applicable) of spare parts. (g) Testing of all hardware and software custom options considered as part of Vendor/Contractor's

Purchase Order/Contract. (h) A power supply test to verify the ability of the system to compensate for input power variations.

System performance should not be affected or impaired by such variations. Maximum/minimum input voltage and (if possible) frequency levels shall be simulated and system satisfactory performance verified. Satisfactory performance is relevant to the ability of the system to function normally during the specified and agreed supply input variations.

(i) An error free, Owner specified (48 minimum to 100 hour maximum) heat soak test to identify the

failures, if any. (j) Fault tolerant tests to verify the operation of redundant processors, PSU's, I/O's, cables,

communication links, bridges/routers, storage devices and operator interfaces such as VDU, printer etc.

(k) A check to verify that the system start up can be implemented using the Vendor/Contractor's start

up procedure. (l) A check to verify that the trouble shooting can be carried out by using the Vendor/Contractor's

supplied trouble shooting manual. (m) A check to verify that, if relevant, the equipment meets the requirements of the associated

hazardous area classification. 3.3 Factory System Integration Tests (SIT) and Checks 3.3.1 These tests and checks may be conducted either at Vendor/Contractor's works or at another location agreed

between the Vendor/Contractor and the Owner. Tests shall include tests of all data links and transfer of all data sets between different systems. Proper functioning of all communication links and information transfer between various databases shall be verified by using either actual equipment (preferred) or Vendor/Contractor supplied simulators. The test procedure for this shall be approved by the Owner.

3.3.2 As a minimum the following characteristics shall be checked for the communication of data sets and



INSTRUMENT SYSTEMS Rev 0 1999 communication links:

Compatibility/conformity; Correctness of the information being transmitted; Completeness; Testability; Standardisation; Sufficiency of the information being transmitted; Efficiency; Speed/Loading; Resilience; Exception responses; Action on responses; Conversation structure; Data structure; Data status structure; Communication errors operator interface i.e. fault reporting; Fault tracing methodology; Transmission distance capability. 3.4 Installation and Site Testing 3.4.1 Installation Site Survey (a) If the project schedule requires an early shipment of the system, then arrangements shall be made

to provide air conditioned storage facilities for the system. (b) Prior to the start of system installation, a check shall be made by the Vendor/Contractor that: - Control room or other appropriate flooring has been checked for adherence to specific

coating, weight load, channelling and similar requirements. - Cable routing and wireways have been checked for proper placement. - Air conditioning system and the fire detection and fire protection system is operating. - The environmental conditions in equipment and in the control room and equipment room

are within the constraints specified by the Vendor/Contractor - All building work is complete and that the environment is dust free. (c) All lighting and power facilities need to be commissioned at this stage. (d) Control building Fire and Gas detection systems must be functional before the testing and

commissioning of any other systems is undertaken. 3.4.2 System Installation (a) Installation shall be co-ordinated by the Owner for the Vendor/Contractor responsible for the

installation. (b) If the control room has computer room type modular raised floor, field wiring, power cables,

grounding conductors, wiring harness sets, etc., should be placed in position before installing the floor tiles.

(c) The Vendor/Contractor may be required to conduct a pre-installation inspection of the site to

ensure all necessary preparations have been made.



INSTRUMENT SYSTEMS Rev 0 1999 (d) The Vendor/Contractor shall be responsible for making field wiring, power and ground

connections. (e) The termination cabinets shall normally be installed before the installation of any system, so that

field cables can be pulled and terminated. (f) The system interconnection cables and connection cables to other devices, e.g., annunciators,

DCS/SCADA systems, shall then be connected. All I/O "knife" switches within the termination cabinets shall have been set to the open position before connecting the termination cabinets to the system.

(g) Each step in the installation shall be checked and a final inspection made to ensure that all

connections have been made properly. (h) The system can then be handed over to the Owner's team for operability tests and loop checking

on a point basis. (i) Unless otherwise previously agreed, no radio transmitter or walkie talkies are allowed in the

vicinity of the system panel. 3.4.3 Operability Tests (a) These tests shall be witnessed by the Owner but carried out by the Vendor/Contractor. (b) The Vendor/Contractor shall be responsible for supplying all estimated necessary spare parts and

all the test equipment including input signal generators, output signal, indicator calibration equipment and any other specialised test equipment.

(c) If specified by the project documentation, it shall be the Vendor/Contractor's responsibility to

provide site inspection and installation supervision. The Vendor/Contractor's requirements for all power and system grounds shall be verified prior to start-up of the system.

(d) All electrical equipment such as UPS and isolation transformers shall be tested and completely

operational prior to the start of the Operability Testing. Proper power distribution shall be verified and proper allocation and usage of breakers and fuses shall be checked before powering up any component. Checks shall be carried out to make sure that:

- Not too many users have been placed on a single breaker or a fuse. - Loss of single breaker or a fuse will not jeopardise the facility. The same check shall be

carried out for terminal strip and I/O cards etc. (e) Before connecting the power supplies, the correct and stable operation of the UPS system, the

integrity of all earthing systems and the allocation and rating of protection fuses and relays shall have been checked.

(f) Depending on the system and subject to decision by the Owner some or all of the following

Operability Tests/Checks shall be carried out by the Vendor/Contractor and witnessed by the Commissioning team:

- Inventory checks and hardware examination to ensure that all modules are in

their correct location and are firmly fixed and secure. - The database can then be loaded into the system, if required.



INSTRUMENT SYSTEMS Rev 0 1999 - Each component shall then be powered up and test routines performed to

determine that it is functioning properly. Such checks may include lights on system modules, alarms on the operator interface, temperature inputs for the ambient readings, pressure and flow for minimum readings, system communications, and loop voltages.

- The system architecture and hardware functionality checks shall be carried out

by exercising the capabilities of all system components. - System security tests shall be repeated to verify operations in the field. - Error free Owner agreed (48 to 100 hours) heat soak test procedure originally

carried out at the FAT stage shall be repeated, to demonstrate that the system is fully functional.

(g) Proper operation of any UPS type of supply shall be verified by simulating failure scenarios and

monitoring the response of the system. 3.4.4 Site Tests - General (a) Site Acceptance Tests will consist of two parts; stand alone Operability Tests (Section 3.4.3) and

actual Acceptance Tests. After this the system can be handed over to Operations. (b) Site acceptance tests shall be witnessed by the Owner but conducted by the Vendor/Contractor. (c) Prior to the final Site Acceptance Tests the system under test shall be fully integrated with the field

sensors, output devices and all direct and communication links. However, at the stage of loop testing without power these shall be disconnected using knife edge or other approved isolators.

(d) All field devices shall be installed, cabled and calibrated prior to the start of SAT. (e) Any hardware and software revisions must, if at all possible, be implemented prior to FAT. These

revisions shall include all high priorities discrepancies identified during the previous FAT and Operability Testing.

(f) Database to be used shall be the controlled and final operating database. (g) The SAT procedure shall consist of an error free test with all interfaces operational. The system

shall be exercised as if it is operating in the normal plant environment but without process fluid taking into account due differences when using alternative fluids. The duration of the test shall be as specified in project specification.

(h) Any change made to any version of the software or hardware from the previous testing shall

require retesting of the appropriate procedure as defined in Section 5.0 of this specification. (i) Full records shall be kept of any proposed modifications, punch lists and similar documentation. 3.4.5 Loop Checks - Unpowered (a) It is assumed that power is available and it is isolated at the withdrawable fuses or miniature

circuit breakers etc. The loops themselves are not powered but this can be implemented by lifting loop fuses, unplugging remote terminal panel cables or similar disconnection actions.

(b) High voltage circuit testing methods shall not be used for testing circuits involving connected

components. If high voltage test methods are proposed, all instruments are to be removed or electrically isolated.



INSTRUMENT SYSTEMS Rev 0 1999 (c) The checklist is to include: - Confirm hazardous area classification matches or exceeds the actual area

classification; - Checks of hazardous area certification against labelling and for special

provisions, e.g. type of gland, temperature limits, intrinsically safe barriers etc; - Check glands and terminations are properly made off, sealed, labelled and

numbered; - Check voltage and polarity of the supply to each loop, the supply is not to be

connected to the loop; - With the microprocessor system isolated, the loop test shall be conducted from

the computer input/output (I/O) back to the instrument terminations; - Check resistance of system grounding to plant earth; - Check continuity of screen to clean earth; - Check freedom of loop and screen cabling from earth faults, stray voltages etc; - Check correct fitting of any applicable end of line provisions such as resistors,

diodes etc. and that no unrecorded modifications have been made to instruments or junction boxes;

- Check wire and device tagging; - Check communications to the SMART transmitters. 3.4.6 Loop Checks Under Power (a) The serial link from I/O to the system processor typically to the controller on the Distributed

Control System (DCS) shall not be connected. At this stage the field measurement will not be displayed, and the outputs to the field shall be injected at the disconnected DCS I/O. The purpose is to prove the operation of the field devices and any installed barrier systems through to the I/O, under power.

(b) The system shall then be powered one loop at a time and the functions of each loop input/output

checked. Field signal simulation shall always approximate to actual conditions whenever possible i.e. For a pressure instrument, pressure shall be applied at the instrument, an injected 4-20 mA signal shall not be used for simulation. Thermocouple and Resistance Temperature Device (RTD) simulation shall be by millivolt generator and decade resistance box respectively. Outputs shall be directed to the actual field valve or other device to prove the correct operation.

3.4.7 System Communications and Power Tests (Typically for DCS/SCADA) (a) This is a confirmation of the Factory Acceptance Test under loop powered conditions. Reference

shall be made to the Functional Test Sheets attached to this specification. (b) When all I/O interfaces have been proved, the system shall be powered down and the I/Os

connected to the DCS input cards. Vendor/Contractor shall prove by simulation (from the instrument in the field wherever possible) the operation of the control loops, alarm functions, line break and signal viability functions, recording and printer functions, failure modes, trending, paging up and down and updating, soft and hardware redundancy and all other features of the system and graphics configuration.



INSTRUMENT SYSTEMS Rev 0 1999 (c) Since the functioning of the I/Os has been proved, reversion to signal and output simulation at the

I/O interface is permissible to aid fault finding of the computer faceplate and graphics functions. Where convenient, valve outputs can be fed back as measured variable inputs through a software delay. However, after all fault finding, the complete system shall be powered up and the full system check undertaken with signals on all I/Os in a simulated plant running mode. The actions of the system under field signal/output conditions must then be reconfirmed.

The functions of each loop, pages of alarms, printer operation, trend storage etc. shall be listed on

individual check-lists and a positive checking procedure adopted. General statements are not acceptable.

3.4.8 Externally Interfaced Equipment The functions of external devices such as ESD, F&G, package control panels and analysers shall be

checked in the same fashion and the control and data interfaces with the computer confirmed and recorded on a check-list.

3.4.9 Signals from non-Instrument Systems Where complete checking of the system requires operation or simulation of parts of the plant which are

outside the Instrument scope e.g. starting of Heating, Ventilation and Air Conditioning (HVAC) and motors, operation of Motor Operated Valve (MOV) etc., the Vendor/Contractor shall organise joint testing procedures with the other disciplines, to enable comprehensive system testing to be performed and recorded on the check-lists.

3.4.10 Commissioning of Flow Computers (a) A check for the commissioning/start-up spare parts shall be carried out to make sure that these are

all present before any checks are carried out. (b) The flow computers shall be powered for a minimum of one week before any field tests and

checks are carried out. (c) All features of the flow computer shall be checked. These shall include such as system behaviour

following power failure, system diagnostics, programming features. (d) All inputs to the flow computer shall be actuated at the source and the results shall be checked at

the system display at the computer as well at the operator workstation/terminal. (e) The computer shall be run to check specific calculations at random. 3.4.11 Radio Frequency Interference Test The system shall be checked for immunity to radio frequency interference. Such tests shall be conducted

using a portable 5 Watt radio transmitter. With all cabinet doors closed, equipment shall be unaffected when the transmitter is keyed at a proximity of not closer than 3 ft (1m). The frequency of these tests shall be agreed with the Owner. Trip amplifiers and alarm inputs are to be powered and their inputs set close to their alarm setting. Computer inputs are to be set close to their alarm points.

Since the tests are by their nature non-specific, various simulated plant operations shall be conducted, page

changes etc. Observations shall be made in the plant and in the control room and any unexpected results shall be analysed to determine if radio interference is the cause. Vendor/Contractor shall eliminate any faults and retest to the Owner's satisfaction.

Besides these tests, checks shall be made with the radio transmitter out in the field adjacent to field input

devices/transmitters to ensure that there is no effect on the system. 3.4.12 Power Rating and Distribution



INSTRUMENT SYSTEMS Rev 0 1999 (a) The total electrical load and power factor shall be measured for the complete system and the

various isolated sub-systems. All values shall be recorded and checked against the relevant fuse/MCB. The fuses shall be checked that they are of the correct rating for the service, it shall be confirmed that only the correct sections of the plant are isolated when the fuse/MCB is withdrawn, and that fuse/MCB failure on redundant items does not cause loss of plant operations.

(b) Tests shall be made to confirm that sections of the plant can be brought 'on' and 'off load' without

causing voltage changes in the system to a level that affects the normal operation. 3.4.13 Site Acceptance System Integration Testing (a) These tests will be conducted upon completion of the installation by the Vendor/Contractor and

satisfactory site tests of the individual systems. (b) These tests will include verification of correct system operation under varying communication

conditions for both the normal and standby links. (c) Proper operation of all application oriented functions will be verified in the real environment,

including system response times and system loading performance. (d) The test report shall carry the following minimum information: Test number and title; Test objective; Test procedure; Check list; Comments; Fault report; Reservations/further action; Time and date; Space for various witnesses signature.



INSTRUMENT SYSTEMS Rev 0 1999 3.5 Instrument System Handover to Operations 3.5.1 Handover Philosophy A handover procedure for handing over instrument systems from Commissioning to the Owner shall be

developed as a project specific basis. The procedure shall try to optimise the aims listed below: - To ensure that commissioning activities are only done once; - To ensure that systems are handed over at the most convenient time; - To ensure that the systems are ready to run on-line; - To ensure maximum co-operation and interface between the Commissioning team and the Owner

so as to minimise the use of site personnel and to minimise disruptions to start up schedule; - To minimise man-hours and paperwork. 3.5.2 Handover Procedure - General (a) Complete instrument systems may be handed over, or these may be split along the process system

lines in which case the handover may be on sub-system basis. (b) A full agreed procedure, tailored to the specific events shall be used. (c) A certificate of fitness shall be issued in respect of each system or a sub-system as appropriate. 3.5.3 Ready for Handover Checklist a) Functional tests are completed. b) Commissioning checks are completed. c) Operational tests are completed. d) Handover dossier is finalised. e) All punch list items are cleared or responsibility for outstanding punch list items is agreed and

included in the exceptions list. f) Handover signatures can then be obtained from the relevant parties concerned. g) Until the system responsibility is transferred the system remains the responsibility of the

commissioning team. h) All relevant Work Permits have been obtained, especially in the case of partial handover. 3.5.4 Handover to Operations After the completion of signatures the system will come under the care and custody of the Owner. 4.0 QA/QC 4.1 The QA/QC requirements listed in the appropriate system specification also apply to the commissioning of

instrument systems. 4.2 The Vendor/Contractor shall comply with the requirements of the relevant British Standards outlined in

Section 3.1 of this specification. The Vendor/Contractor shall also be required to comply with his own in-house procedure for software development and documentation.

4.3 The Vendor/Contractor shall have ISO 9000 registration and comply with ISO 9001/3. 4.4 The number of audits/monitoring periods is not fixed, therefore the Vendor/Contractor shall agree with the

Owner the frequency of these tasks following placements of order.



INSTRUMENT SYSTEMS Rev 0 1999 5.0 SOFTWARE QUALITY CONTROL 5.1 A formal procedure shall be developed on a project basis for controlling the access to, modification of,

issuing of and implementation of the software associated with various instrument systems. 5.2 Access to all software shall be limited to qualified, competent and authorised personnel. 5.3 Levels of authorisation shall be developed. Embedded software and software related to safety critical

system shall required the highest level of authorisation. Changes such as a control set point change or other minor changes may be at the lowest level.

5.4 The procedure shall specify and name the people who will be responsible for checking and authorising

changes at various levels. 5.5 A record shall be maintained of the degree of assessment of the proposed changes to ensure that the

original level of safety and integrity level is maintained. 5.6 The procedure shall also specify the required documents that need to be produced to record all aspects of

the change. 5.7 The control of software version in use and the update of it shall be strictly controlled. 5.8 If there are any spare parts which contain software in permanent memory (firmware) the procedure shall

incorporate steps to make sure that only the original software version is used. Alternatively the version used shall be totally compatible with the original software (i.e. upwardly compatible) and with other hardware and software.

5.9 The procedure shall detail the method of checking the version number of the software. 5.10 All consequences of incorporating new, enhanced version of the embedded software shall be fully

considered before use. 5.11 `Buddy' checking shall be prohibited when carrying out any safety related software modification. Only a

qualified, experienced and nominated person may carry out the checking function. All safety related software modifications shall be subjected to a HAZOP review before the modification is actually carried out.

5.12 If errors are found in the embedded software, these shall be reported to the Vendor/Contractor or the

manufacturer. The corrections shall be incorporated into the system only after checking and testing of the corrected code.

5.13 All Vendor/Contractor and Sub-Vendor/Sub-Contractor software packages shall be identified by revision

and date. All software loadings and changes from the commencement of the project shall only be from such identified software and all activities shall be entered in a Project Log Book and signed and dated.

5.14 Security copies of the software shall be held on a `grandfather', `father' and `son' basis. Two copies of each

version shall be generated. These will be stored in different locations in a fire safe environment. 5.15 Unless otherwise stated, Vendor/Contractor shall place two identical copies of the commissioned master of

his software in an escrow, the details of which shall be agreed with the Owner. 6.0 DOCUMENTATION 6.1 Drawings and Documentation



INSTRUMENT SYSTEMS Rev 0 1999 The Vendor/Contractor shall make available for use during the test, two complete copies of all relevant

drawings and documents. It is preferred that one copy is in roll-file format for ease of access. As a minimum, these shall include:

Instrument Schedule/List: Instrument data sheets. Cable Schedule. Cause and Effect Charts. Loop diagram. Loop schedules. Control circuit diagrams. Single Line Diagrams. Screen Hierarchy. Junction box termination schedules. Functional configuration block diagrams. Parameter listings e.g. DCS configuration Data Sheets, set point schedules etc. Process Description (DCS). Ladder logic diagrams for the Programmable Logic Controller (PLC) for ESD, Process Logic,

F&G. Instrument layout drawings P&IDs Operating Manuals 6.2 Test Discrepancy Report and Co-Ordination 6.2.1 All problems related to the systems encountered during testing will be documented on a Test Discrepancy

Report Form (see Section 7.0 for sample).



INSTRUMENT SYSTEMS Rev 0 1999 All problems shall be prioritised as follows:

Description Priority

System Down, Total Failure Severe Degradation, Major Function Lost Some Degradation, Minor Function Lost Functional Discrepancy/Documentation Discrepancy Minor Problem Enhancement, Request for a Change Beyond Original Design

1 2 3 4 5 6

6.2.2 Authorised signatures by the Vendor/Contractor and Owner are required when the above report is filled and

again when it is signed off. 6.2.3 It shall be the Vendor/Contractor's responsibility to resolve outstanding system problems as documented on

the above report 6.2.4 All final documentation provided by the Vendor/Contractor shall accurately reflect the system as operated.

The documentation must include revisions resulting from Acceptance and Operability Testing. If there are any contradictions between documentation and the system as tested, these will be reported as a discrepancy on the report.

6.2.5 Each category of system testing; (FAT, SIT, OT and SAT) will only be considered successful when all test

procedures have been implemented and all the following conditions have been met. a) The system has been tested continuously for at least 100 hours with no failures which result in the

loss of total system functions. b) No Priority 1, 2 or 3 Discrepancy Reports are outstanding. c) No more than 10 Priority 4 or 5 Discrepancy Reports are outstanding. d) Performance of all hardware and software has been satisfactory as defined in the job specification. 6.2.6 Previous acceptance or approval of equipment by the Owner shall in no case be constructed as a guarantee

of the acceptance of the system. 6.2.7 Generally failure of the system shall constitute grounds for a test restart. The Owner shall decide which

component failure constitutes grounds for test restart. 7.0 SUB INDEX OF FUNCTIONAL TESTS SHEETS (Including Discrepancy Report) Attached to this specification are various test sheets, which may be used as appropriate, during

commissioning activities. The test sheets are listed below (1 sheet unless otherwise stated): Wellhead loop Wellhead valves Process Control Loop - PCS (2 sheets) Process Control Loop - DCS Process Open/Closed Loop



INSTRUMENT SYSTEMS Rev 0 1999 Process Display Gas Detector Fire & Gas Digital Loop Fire & Gas Logic Fire & Gas Display ESD Digital Loop ESD Analogue Loop ESD Logic ESD Display Single Machine Control Logic Selective Operation Control Logic Valves (ESDV/BDV/XV) Supervisory Computer Database Data Communication Link Earthing Segregation Functional Test Discrepancy Report Functional Test Observations Continuation Sheet S:\NOC9077\ADMIN\SPECIFICATIONS\C-SERIES\C-54\GESC54RF

DATA SHEET No.

P.O. / CONTRACT No.

CLIENT

PLANT LOCATION SHEET of

SERVICE VENDOR / CONTRACTOR ITEM No.BASIC FUNCTION No. SUBSYSTEMDESCRIPTION LOCATIONSERVICE TASK No.DRAWING No. REVISIONCABINET PID No. CAL

ASSOCIATED TAGS UNIT

LOOP TYPE OPEN CLOSED

CONTROL UNIT ADDRESSES:TAG/ASS. TAGS ADDRESS * CHANNEL * SIGNAL TYPE * SETTING

INPUT: ANALOG DIGITAL

0% 50% 100% SETTINGCONSOLEALARM SETTING HIGH/HIGH HIGHALARM RESETALARM SETTING LOW/LOW LOWALARM RESET

CONDITIONS: NORMAL: OPEN: CLOSED: TRIP/ALARM: OPEN: CLOSED:

OUTPUT: CONTROL/TRIP ALARM

FAILSAFE POSITION: OPEN: CLOSED:


DISPLAY:MIMIC * GROUP * ALM TABLE * ALM RESN * PRINTER *

CONTROL UNIT *DCS *

OBSERVATIONS: (USE CONTINUATION SHEET IF REQUIRED)

SIMULATOR USED:

NOTE: * TO BE AMENDED TO CORRESPOND TO SPECIFIC PROJECT SYSTEM

PRINT NAME SIGNATURE DATE

TESTED BY

ACCEPTED BY VENDOR / CONTRACTOR

OWNER

COMMISSIONING TEAM

CERTIFYING AUTHORITY

(C) 1999 NATIONAL OIL CORPORATION. The information on this sheet may be used only for the purpose for which it is supplied by NOC.

INSTRUMENT COMMISSIONING FUNCTIONAL TEST SHEET

WELLHEAD LOOP

S:\c-series\c-54\DC5401r0.xls

DATA SHEET No.

P.O. / CONTRACT No.

CLIENT


SERVICE VENDOR / CONTRACTOR ITEM No.

PROJECT : SYSTEM : PRIORITY : DISCREPANCY NUMBER :

1 2 3 4 5 6 (SEE NOTES)

ABSTRACT OF PROBLEM :

MATERIAL SUBMITTED WITH REPORT : SUBMISSION DATE : VENDOR / CONTRACTOR :

COMMISSIONING :

OWNER :

DESCRIPTION OF PROBLEM (BY OWNER) : SIGN OFF DATE : VENDOR / CONTRACTOR :

COMMISSIONING :

OWNER :

DESCRIPTION OF RESOLUTION (BY VENDOR / DISCREPANCY REPORT :

CONTRACTOR) :

COMMISSIONING RESPONSE :

OWNER RESPONSE :

NOTES :1. PRIORITY CATEGORIES :

DESCRIPTION PRIORITY

SYSTEM DOWN, TOTAL FAILURE 1

SEVERE DEGRADATION, MAJOR FUNCTION LOST 2

SOME DEGRADATION, MINOR FUNCTION LOST 3

FUNCTIONAL DISCREPANCY/DOCUMENTATION DISCREPANCY 4

MINOR PROBLEM 5

ENHANCEMENT, REQUEST FOR A CHANGE BEYOND ORIGINAL DESIGN 6


INSTRUMENT COMMISSIONING FUNCTIONAL TEST DISCREPANCY REPORT


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT


SERVICE VENDOR / CONTRACTOR ITEM No.BASIC FUNCTION No. SUBSYSTEMDESCRIPTION LOCATIONSERVICE TASK No.DRAWING No. REVISION

ASSOCIATED PANELS / CABINETS / CONSOLES

EQUIPMENT No. :EQUIPMENT No. :EQUIPMENT No. :

DISCONNECTIONS CARRIED OUT :

CLEAN EARTH I.S. EARTH COMPUTER EARTH

TEST RESULTS:

TO MECHANICAL CLEAN I.S.FROM EARTH EARTH EARTH

CLEANI.S.

COMPUTER



TESTED BY


OWNER

COMMISSIONING TEAM




EARTHING SEGREGATION


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT



FROM : LOCATION : TO : LOCATION :

SYSTEM: SYSTEM:CABINET: CABINET:CONSOLE: CONSOLE:MODULE: MODULE:

SPECIFY LINK TYPE :

TEST RESULT:ORIGIN DESTINATION

TEST ALARM DISPLAY PR. OUT ALARM DISPLAY PR. OUTLINK FAILURECARD FAILUREPROCESSOR FAILURECHANGE OVER



TESTED BY


OWNER

COMMISSIONING TEAM




DATA COMMUNICATION LINK


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT



TEST PROCEDURE REFERENCE

GROUP OF TAGS

REFERENCE

TEST RESULTS

TAG DESCRIPTION SOURCE UNITS RANGE DCS COMPUTER COMMENTSVERIFICATION ADDRESS ADDRESS



TESTED BY


OWNER

COMMISSIONING TEAM




SUPERVISORY COMPUTER DATABASE


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT


SERVICE VENDOR / CONTRACTOR ITEM No.BASIC FUNCTION No. SUBSYSTEMDESCRIPTION LOCATIONSERVICE TASK No.DRAWING No. REVISIONCABINET PID No.

ASSOCIATED TAGS

TESTING CHANNEL: A B C

TRAY: SLOT: CHANNEL:

FAULT MONITORING: CARD OR INTERFACE CARD CONSOLE DIAGNOSTIC

ASSOCIATED TAGS

TAGS TEST RESULTS FAULT MONITORING

VALVE: XV ESDV BDV ACCUMULATOR OPERATION

TRAVEL TIME FAILSAFE POSITION: OPEN CLOSED

LIMIT STOP (BDV) OVERRIDE OP. NORMAL POSITION: OPEN CLOSED

FIELD RESET: STAT.DISCREP. REMOTE POSITION: OPEN CLOSED

DISPLAY TYPE: ALARMPRINTER

CONFORMITY BETWEEN INDICATORS AND ACTUAL POSITION

ESDV = EMERGENCY SHUTDOWN VALVE ; BDV = BLOW DOWN VALVE ; XV = MISCELLANEOUS VALVEOBSERVATIONS: (USE CONTINUATION SHEET IF REQUIRED)


TESTED BY


OWNER

COMMISSIONING TEAM




VALVES (ESDV / BDV / XV)


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT



TEST PROCEDURE No. REV

ASSOCIATED BASIC FUNCTIONS:

BASIC FUNCTION TYPE CHECKED BASIC FUNCTION TYPE CHECKED



TESTED BY


OWNER

COMMISSIONING TEAM




SELECTIVE OPERATION CONTROL LOGIC


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT



TEST PROCEDURE No. REV

ASSOCIATED BASIC FUNCTIONS:

BASIC FUNCTION TYPE CHECKED BASIC FUNCTION TYPE CHECKED



TESTED BY


OWNER

COMMISSIONING TEAM




SINGLE MACHINE CONTROL LOGIC


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT



DISPLAY No.

CONFIGURATION DRG No. REV

DISPLAY TYPE:

OVERVIEW : MIMIC : TABLE :

ALARM : DETAIL : STATUS :

GAS HISTOGRAM :

TEST RESULT:

BACKGROUND CHECK :

ACTIVE ELEMENTS CHECK : TARGETS CHECK

ASSOCIATED DISPLAY LINKS CHECK :

SPECIAL FUNCTIONS: RESET :

DISCREPANCIES :

OVERRIDE :



TESTED BY


OWNER

COMMISSIONING TEAM



INSTRUMENT COMMISSIONING FUNCTIONAL TEST SHEET ESD DISPLAY


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT



CAUSE AND EFFECT DRG No. REV

ESD MATRIX LOGIC DIAGRAM No. REV

ESD LEVEL OR ZONE

INPUT TAGS BF CHECKED OUTPUT TAGS BF CHECKED



TESTED BY


OWNER

COMMISSIONING TEAM



INSTRUMENT COMMISSIONING FUNCTIONAL TEST SHEET ESD LOGIC


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT



ASSOCIATED TAGS




SYSTEM ADDRESSES:ADDRESS

TAGS PLC DCS TEST RESULT FAULT MONITORING

TRANSMITTER0% 50% 100% 100% 50% 0%

METER / CONSOLEREADING

TRIP ALARM/SETTING ANALOG.HISTO. ACCEPT RESETHIGHLOW

INHIBIT

DISPLAY TYPE: ALARM PRINTER YES NOLOCAL CHECKEDCONSOLE



TESTED BY


OWNER

COMMISSIONING TEAM




ESD ANALOGUE LOOP


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT



ASSOCIATED TAGS




SYSTEM ADDRESSES :ADDRESS

TAGS CARD DCS FAULT MONITORING TEST RESULT

TEST RESULTS:

INPUT: NORMAL CONDITIONS OPEN CLOSED

TRIP/FAULT CONDITIONS OPEN CLOSED INHIBIT

OUTPUT:

NORMAL STATUS: NC NO OVERRIDE

POWER STATUS: ON OFF OPEN CLOSED

FAILSAFE POSITION: ON OFF OPEN CLOSED

CHANGE STATUS ON INPUT CHANGE:

DISPLAY TYPE: ALARMPRINTER



TESTED BY


OWNER

COMMISSIONING TEAM




ESD DIGITAL LOOP


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT



DISPLAY No.

CONFIGURATION DRG No. REV

DISPLAY TYPE:

OVERVIEW : MIMIC : TABLE :

ALARM : DETAIL : STATUS :

GAS HISTOGRAM :

TEST RESULT:

BACKGROUND CHECK :



SPECIAL FUNCTIONS: DELUGE :

FANS / DAMPERS :

HALON SUBSTITUTE / CO2 / CA :

FIREWATER PUMPS :



TESTED BY


OWNER

COMMISSIONING TEAM




FIRE & GAS DISPLAY


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT



CAUSE AND EFFECT DRG No. REV

LOGIC DIAGRAM No. REV

FIRE AREA

DETECTION : INPUT TYPE

ALARM TRIP VOTING

PROTECTION: DELUGESPRINKLERHALON SUBSTITUTE / CO2 / CASHUTDOWNBLOWDOWNHVAC**

* SPECIFY

SPECIAL FUNCTIONS: INHIBIT*

* SPECIFY



TESTED BY


OWNER

COMMISSIONING TEAM




FIRE & GAS LOGIC


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT



ASSOCIATED TAGS




ADDRESS FAULT TESTTAGS CARD PLC DCS MONITORING RESULT

TEST RESULTS:

INPUT: NORMAL CONDITIONS OPEN CLOSED

TRIP/FAULT CONDITIONS OPEN CLOSED INHIBIT

OUTPUT:

NORMAL STATUS: NC NO OVERRIDE

POWER STATUS: ON OFF OPEN CLOSED

FAILSAFE POSITION: ON OFF OPEN CLOSED

CHANGE STATUS ON INPUT CHANGE:

DISPLAY TYPE: ALARMLOCAL (F & G) PRINTERCONSOLE



TESTED BY


OWNER

COMMISSIONING TEAM




FIRE & GAS DIGITAL LOOP


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT


SERVICE VENDOR / CONTRACTOR ITEM No.BASIC FUNCTION No. SUBSYSTEMDESCRIPTION LOCATIONSERVICE TASK No.DRAWING No. REVISIONCABINET FIRE AREA

ASSOCIATED TAGS DATA SHEET



FAULT MONITORING: CARD (100% LEVEL) CONSOLE DIAGNOSTIC

DETECTOR: 1st FLOOR 2nd FLOOR FAULTCARD METERALARM CARDALARM CONSOLEGAS HISTOGRAM

1st LEVEL ACCEPT CONSOLE: RESET CARD: RESET CONSOLE:

2nd LEVEL ACCEPT CONSOLE: RESET CARD: RESET CONSOLE:

INHIBIT : GAS HEAD SERIAL No.

GAS SAMPLE: 1st LEVEL =TYPE 2nd LEVEL =* SPECIFY * LEVEL =

DISPLAY TYPE: ALARM HISTOGRAMPRINTER

LOCAL CONSOLE



TESTED BY


OWNER

COMMISSIONING TEAM




GAS DETECTOR


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT



DISPLAY No. :

CONFIGURATION DRG No. : REV :

TEST RESULTS:

BACKGROUND CHECK :





TESTED BY


OWNER

COMMISSIONING TEAM




PROCESS DISPLAY


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT





SYSTEM ADDRESSES:TAGS ADDRESS TEST RESULTS

TRANSMITTER

INPUT: ANALOG DIGITAL

TRANSMITTER:0% 50% 100% 50% 0%

METER / CONSOLEALARM SETTING LOW / HIGH /ALARM READING METER / CONSOLE /


OUTPUT: CONTROL/TRIP: ALARM: VALVE TYPE:

FAILSAFE POSITION: OPEN: CLOSED:


DISPLAY: MIMIC * GROUP * STATUS *




TESTED BY


OWNER

COMMISSIONING TEAM




PROCESS OPEN / CLOSED LOOP


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT




LOOP TYPE DIRECT REVERSE CASCADE SPLIT RANGE

SYSTEM ADDRESSES:TAGS ADDRESS TEST RESULTS

TRANSMITTERVALVE 1VALVE 2

TRANSMITTER:

0% 50% 100%METER / CONSOLEALARM SETTING LOW / HIGH /ALARM READING METER / CONSOLE /

CONTROL VALVE:FAILSAFE POSITION LIMIT SWITCHES

0% 50% 100% OPEN CLOSED LOCKED OPEN CLOSEDVALVE 1.VALVE 2.

DISPLAY: MIMIC GROUP STATUS



TESTED BY


OWNER

COMMISSIONING TEAM




PROCESS CONTROL LOOP - DCS


DATA SHEET No.

P.O. / CONTRACT No.

CLIENT

PLANT LOCATION SHEET 2 of 2




TAGS No.TAG NUMBERS DESCRIPTION RANGE / SETTING UNITS

RISING FALLING0% 50% 100% 50% 0%

CONSOLEALARM SETTING LOW / HIGH /ALARM READING CONSOLE /

CONTROLLERALIGNMENT CHECK:

FAILSAFE POSITION LIMIT SWITCHESTAG No. 0% 50% 100% 50% 0% OPEN CLOSED LOCKED OPEN CLOSED



TESTED BY


OWNER

COMMISSIONING TEAM




PROCESS CONTROL LOOP - PCS

S:\c-series\c-54\DC5403Br0.xls

DATA SHEET No.

P.O. / CONTRACT No.

CLIENT

PLANT LOCATION SHEET 1 of 2




ASSOCIATED TAGSTAG/ASS. TAGS SYSTEM ADDRESS PLC * 1/2 RACK * POSN * CHANNEL * RESULTS *

TRANSMITTER:RISING FALLING

50% 100% 50%CONSOLEALARM SETTING LOW / HIGH /ALARM READING CONSOLE /

CONTROL VALVE: FAILSAFE POSITION LIMIT SWITCHESVALVE TAG 0% 50% 100% 50% 0% OPEN CLOSED LOCKED OPEN CLOSED

DISPLAY: MIMIC * GROUP * STATUS *PCS:OTHER:

OBSERVATIONS: (USE CONTINUATION SHEET IF REQUIRED)PRINTERCHECKED

YES NO



TESTED BY


OWNER

COMMISSIONING TEAM




PROCESS CONTROL LOOP - PCS

S:\c-series\c-54\DC5403Ar0.xls

DATA SHEET No.

P.O. / CONTRACT No.

CLIENT





CONTROL UNIT ADDRESSES:TAG/ASS. TAGS ADDRESS * CHANNEL * SIGNAL TYPE * TEST RESULTS *

HS *ZSC *ZSO *XL *PT *PT *

VALVE TAG: ESDV

FAILSAFE POSITION

INFERRED VALVE POSITION:TAG: PT OPEN CLOSEDINDICATION SETPOINTINDICATION READING

CHOKE VALVE: HVTAG 0% 50% 100% ALARM SETTING ALARM READING

HS *PT *PT *ZI *

DISPLAY:MIMIC * GROUP * ALM TABLE * ALM RESN * PRINTER *

CONTROL UNIT *DCS *


SIMULATOR USED:



TESTED BY


OWNER

COMMISSIONING TEAM




WELLHEAD VALVES


DATA SHEET No.

INTRUMENT / LOOP P.O. / CONTRACT No.

CLIENT




TESTED BY


OWNER

COMMISSIONING TEAM



INSTRUMENT COMMISSIONING FUNCTIONAL TEST OBSERVATIONS CONTINUATION SHEET


Documents

C-54 NOC