Integrated Control and Safety System (ICSS) Site Acceptance Test Procedure

IRAN OFFSHORE OIL COMPANY
BAHREGAN CRUDE OIL STORAGE TANKS DEVELOPMENT

(PIPING, MANIFOLD, CONTROL SYSTEM & FIRE FIGHTING)
Document Title Document Number

COMPANY CONTRACTOR PROJECT DIS DOC SEQ REV Page 1 of 42
ICSS SAT PROCEDURE
IOOC IDHC BPD INS PRO 009 R2
Integrated Control and Safety System

(ICSS)
SITE ACCEPTANCE TEST PROCEDURE
02 04/05/2020 Issued For Approved T.S. M.B. M.B.

01 03/02/2020 Issued For Approved T.S. M.B. M.B.
00 17-10-2016 Issued For Approved A.B R.A R.A
Prepared Checked Approved Reviewed Approved
Rev. Date Description
Vendor’s/ Supplier’s Name EPCI EPCI


ICSS SAT PROCEDURE
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ICSS SAT PROCEDURE
1. Table of Content
Contents
1. Table of Content ........................................................................................................................................................ 3
2. Introduction ................................................................................................................................................................ 5
2.1. Project Description ........................................................................................................................................... 5
2.2. Definition .......................................................................................................................................................... 5
2.3. Abbreviations ................................................................................................................................................... 5
2.4. References....................................................................................................................................................... 6
3. Scope of SAT ............................................................................................................................................................ 8
3.1. Purpose of SAT................................................................................................................................................ 8
3.2. Scope ............................................................................................................................................................... 8
4. Integrated Control & Safety System .......................................................................................................................... 9
4.1. SAT Schedule & Key Milestones ..................................................................................................................... 9
4.1.1. SAT Schedule ................................................................................................................................................. 9
4.1.2. Structured Testing .......................................................................................................................................... 9
4.1.3. SAT Organization.......................................................................................................................................... 10
4.1.4. Pre-requisite of SAT...................................................................................................................................... 11
4.1.5. Engineering Drawings and Document ............................................................................................................ 11
4.1.6. Correction Procedure for Discrepancies ......................................................................................................... 11
4.2. Attachment-1 (SAT Procedure & Report Forms) ........................................................................................... 13
4.2.1. Introduction ................................................................................................................................................ 13
4.2.2. GENERAL ..................................................................................................................................................... 13
4.2.3. SAT Schedule ............................................................................................................................................... 14
4.2.4. Hardware Inspection .................................................................................................................................... 15
4.2.5. Standard System Function Test ..................................................................................................................... 17



ICSS SAT PROCEDURE
4.2.6. ICSS System Performance ............................................................................................................................. 24
4.2.7. Printer Functional check ............................................................................................................................... 25
4.2.8. Operator Station Application Check. .............................................................................................................. 26
4.2.9. ICSS System marshalling cabinets .................................................................................................................. 31
4.2.10. Auxiliary Console Inspection: .................................................................................................................... 35
5. Signal and Logic Testing ......................................................................................................................................... 38
6. Fire and Gas System .............................................................................................................................................. 39
7. TGS Testing ............................................................................................................................................................ 40
8. Tank Gauging System ............................................................................................................................................. 41
9. Communication Testing .......................................................................................................................................... 42



ICSS SAT PROCEDURE
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:
 Integrated Control & Safety System

 F&G Devices and related accessories
 Tank Gauging System
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:
 "Company" mean Iranian Offshore Oil Company (IOOC).
 "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
LPG: Loleh Pey Gostar Co.
IDEH: Iras Design Engineering & Human resources
F&G: Fire Alarm & Gas Monitoring
DCS: Distributed Control System



ICSS SAT PROCEDURE
ESD: Emergency Shutdown
AI: Analog Input
AO: Analog Output
CPU: Central Processing Unit
DI: Digital Input DO: Digital Output
EWS: Engineering Work Station
FCS: Field Control Station
FCU: Field Control Unit
FDS: Functional Design Specification
HIS: Human Interface Station
I/O: Input / Output
IOM: Input / Output Module
P&ID: Piping and Instrument Diagram
SAT: Site Acceptance Test
UPS: Uninterrupted Power Supply
2.4. References
Following documents are use as based on the requirements of and submitted
Table 2.4. 1 – Reference List
Item Document Title



ICSS SAT PROCEDURE
1 Functional Design Specification

2 Bill of Materials
3 Detailed layout Drawings
4 Site Acceptance Test Plan
5 System Architecture Drawing
6 Internal Circuit Diagram
7 System Cable Schedule
8 Internal Wiring Drawing
9 ICSS SYSTEM Graphics


ICSS SAT PROCEDURE
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
 ICSS SYSTEM Operator Stations (HMI).
 Printers.
 System Cabinets.
 Marshalling Cabinets.
 System Prefabricated Cables.
 Installation of VNET bus (ICSS SYSTEM's real time redundant and maintenance bus) as per design.
6. These documents will be provide in SAT time:
SAT Procedure & Report, I/O SAT, Power Distribution Checks List, MTO Check List, Layout Drawing of Cabinet


ICSS SAT PROCEDURE
4. Integrated Control & Safety System

4.1. SAT Schedule & Key Milestones
4.1.1. SAT Schedule

Internal Testing (Pre-SAT):
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.
The SAT consists of the following:
 Structured Testing
 Unstructured Testing
4.1.2. Structured Testing

The Structured Test consists of 100 % hardwired I/O Testing by applying & measuring signals at
the ICSS SYSTEM cabinets. It also consists of the ICSS SYSTEM Functional Test (without applying
external signals to I/O modules but by using the Test Function). The Test Function de-couples
only the I/O related processing in the ICSS SYSTEM while rest of the ICSS SYSTEM Configuration
remains unchanged and provides a kind of loop back type of I/O data within ICSS SYSTEM for
testing the configuration.
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,
 Graphics and Standard displays.

 Simple loops and Complex loops.


ICSS SAT PROCEDURE
 Sequence logics and Interlock logics, if applicable.

 Log Reports
4.1.3. SAT Organization

The SAT organization consists of personnel from IDEH, Assignments of each member of SAT
organization and a brief description of their role is described below.
Table 4.1.4. 2 IDEH Personnel for SAT
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.
IDEH Technician One technician to support throughout SAT.
Note: IDEH will be assign number of SAT personnel according to SAT timing schedule.
Table 4.1.4. 3 Tools & Test equipment for SAT
Tools / Materials Description QTY SPARE

Calibrator with 4-20 mA 4-20 mA source and Resistance source, to feed & check
1 nos. 1 nos.
source analog and RTD inputs.
and Resistance source To check 4-20 mA analog outputs & Continuity / Voltage
Digital Multimeter 1 nos. 1 nos.
checking for Digital I/0s.
Tool Kit 1 sets 1 sets


ICSS SAT PROCEDURE
4.1.4. Pre-requisite of SAT

The system readiness for the SAT is verified by engineering drawings / documents prepared
by IDEH, which are approved results of IDEH internal tests (Pre-SAT).
4.1.5. Engineering Drawings and Document

The following documents reviewed and approved by IOOC shall be used for reference:
 Functional Design Specification.
 Bill of Materials.
 Detailed layout Drawings.
 Site Acceptance Test Plan.
 System Architecture Drawing.
 Internal Circuit Diagram.
 System Cable Schedule.
 Internal Wiring Drawing.
 ICSS SYSTEM Graphics
4.1.6. Correction Procedure for Discrepancies

Discrepancies encountered during the SAT are logged individually as 'Punch List' items. Each
log shall contain a description of problem, discrepancy type, a proposed solution, an estimated
time of resolving the problem, completion verified by and remarks.
If a discrepancy is found to be a warranty item, it needs to be immediately resolved to minimize

a schedule impact after reporting to.
If a discrepancy is determined as a change of scope, a cost and schedule shall be

discussed with 1. No work will be done on the discrepancy for scope change until it is
approved and authorized for implementation.
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


ICSS SAT PROCEDURE
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.


ICSS SAT PROCEDURE
4.2. Attachment-1 (SAT Procedure & Report Forms)
4.2.1. Introduction
The ICSS SYSTEM Site Acceptance Test (SAT) is carried out in accordance with HMI procedure.
4.2.2. GENERAL
1. The SAT consists of three main parts as listed below:

 Inspection & testing of ICSS SYSTEM Hardware
 ICSS SYSTEM Application software test
 Inspection & testing of ICSS SYSTEM Interface Cabinets.
 The system shall be energized before start of SAT.
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.


ICSS SAT PROCEDURE
4.2.3. SAT Schedule

IDEH Project Manager is responsible for the overall execution of the SAT and will be the prime
interface between the Client inspectors and IDEH engineers, through the SAT period.
Duration of SAT: 20 DAYS (Extendable)
Place: Site.
Witnessed by: LPG and IOOC
Test Conductor: Shall be informed later.
Work Duration: From 7 AM to 6 PM
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.


ICSS SAT PROCEDURE
4.2.4. Hardware Inspection
4.2.4.1 Overall System Configuration OUTLINE:
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:
Following approved drawings / documents.

1. Bill of Materials
2. System Architecture
PROCEDURE:
1. Visually inspect each component based on the above objectives & verify that it is in order.
CRITERIA:
Each component shall confirm to the reference documents.

COMMENTS:
Test Result PASS / FAIL
Date


ICSS SAT PROCEDURE
4.2.4.2 Node Labeling & I/O Assignment
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:

1. Bill of Materials
2. I/0 Configuration Report
PROCEDURE:
1. Visually check that the I/O modules are installed in the correct position & correct in quantity
2. Visually check that all the labeling is in order.
CRITERIA:
The quantity and location of the NU & I/O modules are in accordance with the above reference.
COMMENTS:
Date


ICSS SAT PROCEDURE
4.2.5. Standard System Function Test
4.2.5.1 System Startup
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


ICSS SAT PROCEDURE
4.2.5.2 ICSS System CPU Redundancy
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


ICSS SAT PROCEDURE
4.2.5.3 ICSS System Bus Redundancy
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.
Note: PB bus is connected between CPU and IM.
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
SYSTEM Control/Communication functions should not be affected.
Appropriate system diagnostics are reported in the system alarm display.
COMMENTS:
Date


ICSS SAT PROCEDURE
4.2.5.4 System Hardware OUTLINE:
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
PROCEDURE: (Full check any of the following)

1. Call the system status display screen in any HMI & observe that all the system hardware are in
normal/healthy condition.
2. Stop one of the CPU in any of the station by activating stop button in the CPU & observe for CPU
failure alarm in HMI.
3. Remove any I/O Module from the Node unit and observe the status display.
4. Switch OFF Power supplies in any of the station & observe for power supply failure alarm in HMI &
switch ON to check normal status.
5. Remove one of the connectors of the communication modules and observe for the
communication link failure.
CRITERIA:
To ensure the system hardware are healthy & hardware failure alarms are generated when specific
hardware failures are simulated.
COMMENTS:
Date


ICSS SAT PROCEDURE
4.2.5.5 VNET Bus Redundancy OUTLINE:
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


ICSS SAT PROCEDURE
4.2.5.6 Effect of Failure of HMI
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


ICSS SAT PROCEDURE
4.2.5.7 Redundancy of I/O Modules OUTLINE:
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"
3. Ready lamp on the redundant I/O module shall be still "ON".
COMMENTS:
Date


ICSS SAT PROCEDURE
4.2.6. ICSS System Performance

4.2.6.1. System Loading & Resource Check
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:
The purpose of test is to verify the loading of CPU
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:
1. To ensure that the CPU loading is within acceptable limit.

2. To ensure that the usage of Function Blocks / ICSS SYSTEM resources are not extended to
maximum limit & to verify the availability of spare function blocks. (Refer to Appendix-1, Page-4)
COMMENTS:
Date


ICSS SAT PROCEDURE
4.2.7. Printer Functional check

OUTLINE:
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


ICSS SAT PROCEDURE
4.2.8. Operator Station Application Check.

4.2.8.1. Graphic Window Check
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:
Following approved drawings / documents. Graphics Display Sketches provided by
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.


ICSS SAT PROCEDURE
COMMENTS
Date


ICSS SAT PROCEDURE
4.2.8.2. Faceplate Window Check OUTLINE:
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


ICSS SAT PROCEDURE
4.2.8.3. Tuning Window Check.
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


ICSS SAT PROCEDURE
4.2.8.4. HMI Messages Report
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


ICSS SAT PROCEDURE
4.2.9. ICSS System marshalling cabinets

4.2.9.1. Appearance & Construction
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:

1. IA & GA Drawings of cabinets
PROCEDURE:
1. Visually check that all components are free from scratches and any kind of deformation.
2. Visually check that all the components are mounted as indicated in the reference drawings.
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


ICSS SAT PROCEDURE
4.2.9.2. Wiring Check
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:

1. IA & GA Drawings of cabinets
2. Wiring Diagrams
PROCEDURE:
1. Visually check that all the terminal numbering & wire markers are as per the reference drawings.
2. Full check wiring continuity for correctness.
3. Check wire markers for correctness.
4. Check the functionality of all fans in ICSS SYSTEM Field Interfacing Cabinets to verify proper
ventilation.
CRITERIA:
All the signal & power wiring terminal numbers & wire markers are as per reference drawings.
COMMENTS:
Date


ICSS SAT PROCEDURE
4.2.9.3. Loop Checking
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:

1. Panel circuit diagram
2. Panel Internal Layout
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.


ICSS SAT PROCEDURE
CRITERIA:
1. All the signals, both analog and digital are correctly displayed in the system as per reference
documents.
2. ICSS SYSTEM tag allocation is as per the I/O assignment.
3. Functionality of the Hardware I/O Module

4. Functionality of the Thermocouple/RTD transmitters
5. Wiring in the Field Interface cabinet loops are configured & function correctly.
COMMENTS:
Date


ICSS SAT PROCEDURE
4.2.10. Auxiliary Console Inspection:

OUTLINE:
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:
Following approved drawings / documents: 1. IA & GA Drawings for Consoles

PROCEDURE:
1. Visually check that Auxiliary console is free from scratches and any kind of deformation.
2. Visually check that layout / service description of Pull/Pushbuttons, Indicating Lamp and
Selector- switches are as indicated in the reference drawings.
3. Activate each PB / SS and verify the required operation at the terminal blocks.
4. Apply respective voltage to Indicating lamps to check the functionality.
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

ICSS SAT PROCEDURE
OWS/EWS Component Check List
Station No. Name Specification Result Remarks
01.01 ICSS SYSTEM  Pass  Fail
02.01 IPC  Pass  Fail
02.02 Monitor  Pass  Fail
02.03 Printer  Pass  Fail
02.04 Speaker  Pass  Fail
02.05 Keyboard  Pass  Fail
02.06 Mouse  Pass  Fail


ICSS SAT PROCEDURE
SAT Completion Certification
CERTIFICATE OF ICSS SYSTEM SITE ACCEPTANCE TEST (ICSS SYSTEM SAT)
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]
1. Refer to "SAT PROCEDURE & REPORT" record and its appendices.

2. Refer to attached "ICSS SYSTEM SAT Punch List Summary".
RESULT PASS / FAIL
SIGNED BY:

ICSS SAT PROCEDURE
5. Signal and Logic Testing
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.
2. Keep one operation person in field while logic checking.
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.
7. For pumps-check trip alarm in faceplate and alarm window.
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

ICSS SAT PROCEDURE
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.
16. Finally mark-up in master copy Cause & Effect.
6. Fire and Gas System

The SAT activities of Fire & Gas System shall be carried out in our workshop and include the witnessed following
tests:
a) Mechanical check 100%
b) Panel electrical check 100%
c) Power consumption of the panel 100%
d) Check of the software panel 100%
e) Check of the system diagnostics 100%
f) Detectors functional test 100%
g) Functional test of the manual call points, sirens and lamps 70%
h) Packing check 100%


ICSS SAT PROCEDURE
7. TGS Testing
In this part, tank gauging system has been checked.
OBJECTIVE:
The purpose of this test is to ensure that signal and device of Tank Gauging System.
REFERENCE: None
PROCEDURE:
1. Location of the radar Tag no. to be checked for each tank.
2. Location of the J.B. Tag no. to be checked for each tank.
3. Tag number & Description of the Tag to be checked.
4. Based on type of radar connection like multi-drop (daisy chain), etc. to be checked for each
one.
5. Monitor of CIU888 to be checked.
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.
8. Make online connection to the Engauge software for each radar.
9. There are lots of parameter shows in online connection and make notes for each calibrated
parameters of tank.
10. Definition parameters of Entis-Pro software and online connection by Engauge

software to be checked and make note for each one.

ICSS SAT PROCEDURE
8. Tank Gauging System

The SAT activities of Tank Gauging System shall be carried out in our workshop and include the witnessed following
tests and documents and test report same as ICSS SAT Procedure:
a) Mechanical check 100%
b) Panel electrical check 100%
c) Power consumption of the panel 100%
d) Check of the software panel 100%
e) Check of the system diagnostics 100%
f) Functional test of the CIU 100%
g) Functional test of the Radar 100%
h) Packing check 100%


ICSS SAT PROCEDURE
9. Communication Testing
In this part, DCS, ESD and TGS have been checked.
OBJECTIVE:
The purpose of this test is to ensure that health communication of DCS, ESD and TGS.
REFERENCE: None
PROCEDURE:
1. Switches power to be checked.
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.
5. Tag number of each Ethernet cable from switch to IPCs 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.

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