ID-TUN-NG-SME-011282 Rev B - FINAL - Approved PJT

Document number
ID-TUN-NG-SME-011282
COMMISSIONING & OPERATIONAL TEST PROCEDURE –
NCP ICSS MODIFICATION Revision : B Doc. Class : 1
Status : AFC Rev. Date : 06/09/2008
Document type: PRC System/Subsystem : 40303 Discipline : INS Page 2 of 22
TABULATION OF REVISED PAGES

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This document is the property of COMPANY. It must not be stored, reproduced or disclosed to others without authorization from the COMPANY.
Document number
Status : AFC Rev. Date 06/09/2008
TABLE OF CONTENTS
1. TEST SUMMARY 4
1.1 AIMS OF THE DOCUMENT 4
1.2 TEST PROCEDURE 4
2. PLANNING & MAN POWER 5
2.1 DETAIL MODIFICATION 5
2.2 PLANNING / SEQUENCE 5
2.3 MAN-POWER ESTIMATION. 6
2.4 TEST DURATION ESTIMATION. 6
2.5 VENDOR ASSISTANCE. 6
3. TEST REQUIREMENTS 6
3.1 PRECOMMISSIONING ACHIEVEMENTS 6
3.2 COMMISSIONING ACHIEVEMENTS 6
3.3 STATUS OF OTHER SUBSYSTEMS 6
3.4 SPECIAL TOOL AND TEST EQUIPMENT 6
3.5 CONSUMABLES 7
3.6 SPARES 7
3.7 SAFETY 7
3.8 UTILITIES 7
3.9 REFERENCE DOCUMENTS 7
4. TEST PREPARATIONS 7
4.1 JUMPER LIST 7
5. STEP BY STEP TEST PROCEDURE 8
5.1 VERIFICATION OF TASK #1, #5, #15, #16, #17, #18 & #19 8
5.2 VERIFICATION OF TASK #8 9
5.3 VERIFICATION OF TASK #9 & #10 11
5.11 VERIFICATION OF TASK #2, #20 & #22 19
6. POST TEST CONDITION 22
6.1 REMOVAL INHIBITS & JUMPERS 22
This document is the property of COMPANY.

It must not be stored, reproduced or disclosed to others without written authorization from COMPANY.
Document number
SUMMARY
Existing NCP ICSS (PCS display & SSS) are modified to accommodate new NCP-2
(LP platform). Also new shutdown philosophies are implemented as well such as
removal of common ESD-0 and become individual ESD 1.0 and interlock for
simultaneous blow down.
1. TEST SUMMARY
1.1 AIMS OF THE DOCUMENT

To demonstrate that the NCP ICSS operates in accordance with the ESD and F&G
Logic diagram, and engineering document.
1.2 TEST PROCEDURE

Commissioning & operational test will be performed at the same time and limited to
the modified parts.
Test result will be checked on NCP SSS Maintenance Console, NCP ITR Yokogawa
console or NCR Yokogawa console (if available during the test), and new ESD Matrix
panel.
Commissioning FTS (Functional Test Sheet) will be used to record the result of both
commissioning & operational test. These FTS have been prepared in accordance with
the ESD and F&G Logic diagram, and engineering document.

Document number
2. PLANNING & MAN POWER
2.1 DETAIL MODIFICATION
Task
Description
No
1 Deletion of ESD 0 bar & PB-0001 (ESD 0-NCR).
2 Renaming of ESD 1.0B from ESD 0.1B with same action as ESD 0.1 and new PB-0001 (ESD 1.0B - NCR).
Modification of Simultaneous Depressurization ( PB0001 - ESD1.0.B, PB0002, PB0003, PB0004, PB0005,
3 PB0006 - ESD 1.B).
4 P2P signal to NCP2 - US 03201 from NCP ESD 1.B
5 Removal of GTS's automatic shutdown from NCP ESD1.2 B ESD (US0146 & US0134), ESD 3.1.1B
(US0138), ESD 3.2.1B (US0142 - US0147), ESD 3.3.1.B (US0139), ESD 3.4.1.B (US0140), ESD 3.5.1B
B (US0148 - US0143), ESD 3.6.1.B (US0141), ESD 3.11.1B (US0144), ESD 3.7.4B (US0149 - US0131).
6 P2P signal to NCP2 - US 03216 from NCP - ESD 1.2B
7 P2P signal to NCP2 - US 03111 from NCP - ESD 1.3B
FCW Case 6 from NCP ESD 3.1.1.B, ESD 3.2.1.B, ESD 3.3.1.B, ESD 3.4.1.B, ESD 3.5.1B, ESD 3.6.1B,
8 ESD 3.11.1.B
9 P2P signal to NMP3 - US03122 from NCP - ESD 3.7.2.B
10 New PSDV113100 connected to existing NCP - ESD 3.7.2.B.
11 P2P signal to NMP3 - US03123 from NCP - ESD 3.8.2.B
12 New PSDV113101 connected to existing NCP - ESD 3.8.2.B.
13 FCW Case 7 from NCP - ESD 3.7.4.B
14 FCW Case 4 from existing US0235 or US0335. FCW Case 5 from existing US0235 and US0335.
15 Deletion of ESD 0 Back-up signal (USS).
16 Renaming of existing ESD bar 0.2.B to ESD 1.0.2.B
B 17 Renaming description 8US9710 to Electrical Isolation HV/Control Supply OWT ESD 1.X.C
18 Renaming Description of US0115 from ESD 0.1.C OWTP to ESD 1.0.C OWTP
19 Renaming of existing ESD bar 0.3.B to ESD 1.0.3.B
20 Additional adjustable time delay on SSS outputs for 230 VAC UPS Electrical isolation. Set at 3 minutes.
21 P2P to NCP2, US03227 from NCP ESD 2.B
22 P2P to NCP2, US03206 from NCP ESD 1.0.B
23 Additional Loss of P2P on ESD 2 bar input.
24 Peer to peer points commissioning from NPU - NCP - OWT to validate Star networks.
2.2 PLANNING / SEQUENCE

- Verification of Task #1, #5, #15, #16, #17, #18 & #19
- Verification of Task #8
- Verification of Task #9 & #10
- Verification of Task #11& #12
- Verification of Task #21 & #23
- Verification of Task #2, #20 & #22
- Verification of Task #24 (together with NCP & OWT)
- Verification of Task #3 (together with NCP & OWT)

Document number
2.3 MAN-POWER ESTIMATION.
PERSONNEL MANHOURS
PJC/CMS Instrument SPV 6 days 60 h
2 PJC/CMS Instrument Technicians 6 days 120 h
One Production Operator at NCR or NPU
ITR 6 days 60 h
One NPU CS Technician 6 days 60 h
B
One Triconex Vendor 6 days 60 h
One Yokogawa Vendor 6 days 60 h
TOTAL MANHOUR 420 h
2.4 TEST DURATION ESTIMATION.

6 days
2.5 VENDOR ASSISTANCE.

One Triconex (SSS) Vendor & one Yokogawa (PCS) vendor
3. TEST REQUIREMENTS
3.1 PRECOMMISSIONING ACHIEVEMENTS
• Verify that the Pre-Commissioning is completed.
• No Level A Punch list items are pending.
• NCP SSS modification is completed & downloaded
• NCP PCS modification is completed & downloaded
• Produce punch list as applicable
• Commissioning & Operational Test Procedure – NCP ICSS modification agreed
upon and signed
3.2 COMMISSIONING ACHIEVEMENTS

N/A
3.3 STATUS OF OTHER SUBSYSTEMS

N/A
3.4 SPECIAL TOOL AND TEST EQUIPMENT

- Standard Instrument hand tools & wire jumper
- AVO Multimeter.
- 4-20mA generator (to simulate sensors)
- communication means, hand held radio

Document number
3.5 CONSUMABLES
N/A
3.6 SPARES
N/A
3.7 SAFETY
• Work permit shall be raised and issued prior to commencement of the test.
• Pre-job safety tool box meeting shall be conducted with all persons who involve in the
test.
• Site personnel shall maintain communication with control room by means of hand
held radio.
3.8 UTILITIES
N/A
3.9 REFERENCE DOCUMENTS

• Marked-up as per FAT, NCP/NMP2/NPU/OWT ESD logic diagram, doc no: ID-
TUN-NO-SOME-159501 rev C.
• NCP/NMP2 and OWT ESD I/O Assignment, doc no: ID-TUN-NS-PTI-709025 rev
0C.
• ESD Graphic Displays (Mark-up), doc no: ID-TUN-NS-PTI-709004 rev 0B.
• PCS Graphic Displays (Mark-up), doc no: ID-TUN-NS-PTI-709002 rev 0B.
• SSS Safety Network Upgrade Procedure, doc no: ID-TUN-NS-PTI-990209 rev 0A.
• PID, doc no: ID-TUN-NO-MEI-129509 rev 0G.
• PID, doc no: ID-TUN-NO-MEI-129510 rev 0G.
4. TEST PREPARATIONS
4.1 JUMPER LIST
As per operations requirement (under NPU/MNT control & action).

Document number
5. STEP BY STEP TEST PROCEDURE

5.1 VERIFICATION OF TASK #1, #5, #15, #16, #17, #18 & #19
#1 Deletion of ESD 0 bar & PB-0001 (ESD 0-NCR).
#5 Removal of GTS's automatic shutdown from NCP ESD1.2 B ESD (US0134 &
US0146), ESD 3.1.1B (US0138), ESD 3.2.1B (US0142 - US0147), ESD 3.3.1.B
(US0139), ESD 3.4.1.B (US0140), ESD 3.5.1B (US0148 - US0143), ESD 3.6.1.B
(US0141), ESD 3.11.1B (US0144), ESD 3.7.4B (US0149 - US0131).
#15 Deletion of ESD 0 Back-up signal (USS).
B
#16 Renaming of existing ESD bar 0.2.B to ESD 1.0.2.B
#17 Renaming description 8US9710 to Electrical Isolation HV/Control Supply
OWT ESD 1.X.C
#18 Renaming Description of US0115 from ESD 0.1.C OWTP to ESD 1.0.C
OWTP
#19 Renaming of existing ESD bar 0.3.B to ESD 1.0.3.B
- No commissioning activity, only verification & confirmation on PCS display of the
task #1, #5, #16, #17, #18 & #19.
- Filled & signed the FTS.
Performed by Witnessed by
Name
Department
Signature
Date

Document number
5.2 VERIFICATION OF TASK #8

#8 FCW Case 6 from NCP ESD 3.1.1.B, ESD 3.2.1.B, ESD 3.3.1.B, ESD 3.4.1.B,
ESD 3.5.1B, ESD 3.6.1B, ESD 3.11.1.B
- Normalize ESD 3.1.B, ESD 3.2.B, ESD 3.3.B, ESD 3.4.B, ESD 3.5.B, ESD 3.6.B,
ESD 3.11.B bar.
- Normalize ESD 3.1.1.B, ESD 3.2.1.B, ESD 3.3.1.B, ESD 3.4.1.B, ESD 3.5.1B, ESD
3.6.1B, ESD 3.11.1.B bar.
- Verify FCW case 6 is normal at NCR C200.
- Simulate/force PAHH1056 or PALL1051 from SSS laptop to trip.

- Verify that ESD 3.1.B bar & ESD 3.1.1B bar are trip.
- Verify FCW case 6 is trip at NCR C200.
- Simulate/force PAHH1056 or PALL1051 from SSS laptop to normal.
- ESD 3.1.B & ESD 3.1.1B can be resetted.






Document number

- Remove all the forcing.
Note:
- Full function of FCW will be commissioned separately during GTS transfer.
Name
Department
Signature
Date

Document number
5.3 VERIFICATION OF TASK #9 & #10

#9 P2P signal to NMP3 - US03122 from NCP - ESD 3.7.2.B.
#10 New PSDV113100 connected to existing NCP - ESD 3.7.2.B.
- Normalize ESD 3.7.2.B bar.
- Verify US03122 is normal from PCS display / SSS laptop.
- Put jumper to simulate PSL PSDV 113100 in MC.
- Simulate ZT of PSDV 113100 to close position with mA generator from MC and
verify the PCS display.
- Simulate local reset PSDV 113100 with jumper in MC
- Open PSDV 113100 from PCS
- Check in MC, output for PSDV 113100 is ON and PCS display.
- Wait until discrepancy in PCS Display.
- Simulate ZT of PSDV 113100 to Open position with mA generator from MC and
- Remove jumper for PSL PSDV 113100 in MC and verify PCS display.
- Open PSDV 113100 from PCS and put back jumper for PSL PSDV 113100.
- Simulate/forcing LAHH0141 from SSS laptop to trip.
- Verify that ESD 3.7.2.B bar is trip
- Verify PSDV 113100 close from PCS display
- Verify US03122 is trip from PCS display / SSS laptop.
verify the PCS display
- Remove the forcing
Name
Department
Signature
Date

Document number

#11 P2P signal to NMP3 - US03123 from NCP - ESD 3.8.2.B
#12 New PSDV113101 connected to existing NCP - ESD 3.8.2.B.
- Normalize ESD 3.8.2.B bar.
- Verify US03123 is normal from PCS display / SSS laptop.
- Put jumper to simulate PSL PSDV 113101 in MC.
- Open PSDV 113101 from PCS
- Check in MC, output for PSDV 113101 is ON and PCS display.
- Wait until discrepancy in PCS Display.
- Simulate ZT of PSDV 113101 to Open position with mA generator from MC and
- Remove jumper for PSL PSDV 113101 in MC and verify PCS display.
- Open PSDV 113101 from PCS and put back jumper for PSL PSDV 113101.
- Simulate/forcing LAHH0151 from SSS laptop to trip.
- Verify that ESD 3.8.2.B bar is trip
- Verify PSDV 113101 close from PCS display
- Verify US03123 is trip from PCS display / SSS laptop.
verify the PCS display
- Remove the forcing
Name
Department
Signature
Date

Document number

#13 FCW Case 7 from NCP - ESD 3.7.4.B
- Normalize ESD 3.7.4.B, ESD 3.7.2.B & ESD 3.8.2.B bar
- Simulate / force LAHH0141 from SSS laptop to trip.
- Verify that ESD 3.7.2.B trip, ESD 3.8.2.B & ESD 3.7.4.B are still normal
- Verify FCW case 7 still normal at NCR C200.
- Simulate / force LAHH0151 from SSS laptop to trip.
- Verify that ESD 3.8.2.B & ESD 3.7.4.B are trip
- Verify FCW case 7 trip at NCR C200.
- Simulate / force LAHH0141 from SSS laptop to normal.
- ESD 3.7.2.B can be reset, after ESD 3.7.4 B can be reset.
- Remove the forcing.
Note:
Name
Department
Signature
Date

Document number

#14 FCW Case 4 from existing US0235 or US0335. FCW Case 5 from existing
US0235 and US0335.
- Normalize US0235 & US0335 by put inhibits or simulate / force from SSS laptop.
- Verify FCW case 5 is normal at SSS laptop.
- Simulate / force US0235 to trip from SSS laptop or MIC (remove inhibit).
- Normalize US0235 by put inhibits or simulate / force from SSS laptop.
- Verify FCW case 4 still trip at NCR C200.
- Verify FCW case 5 is trip at SSS laptop.
Note:
Name
Department
Signature
Date

Document number

#21 P2P to NCP2, US03227 from NCP ESD 2.B.
#23 Additional Loss of P2P on ESD 2 bar input.
- Put inhibit Loss of P2P NPU, OWT & NCP2 and verify on MIC & PCS.
- Normalize ESD 2 bar and verify US03227 on PCS display & SSS laptop.
- Remove inhibit Loss of P2P NPU and verify on MIC & PCS.
- Verify that ESD 2 bar trip and US03227 trip on PCS display and SSS laptop.
- Put inhibit Loss of P2P NPU and verify on MIC & PCS.
- Remove inhibit Loss of P2P OWT and verify on MIC & PCS.
- Put inhibit Loss of P2P OWT and verify on MIC & PCS.
- Remove inhibit Loss of P2P NCP2 and verify on MIC & PCS.
- Put inhibit Loss of P2P NCP2 and verify on MIC & PCS.
Notes:
- Peer to peer network may not ready. This verification to check if lost P2P with OWT,
NPU or NCP2, ESD 2 bar will trip.
- Peer to peer network status will be verified during verification of task #24. (§5.12)
- After verification of task #24 (§5.12), only Loss of P2P NCP2 will be inhibited until
NCP2 ready. Loss of P2P NPU & OWT can be removed.
Name
Department
Signature
Date

Document number

#7 P2P signal to NCP2 - US 03111 from NCP - ESD 1.3B.
- Normalize ESD 1.3.B bar
- Verify US 03111 is normal from SSS laptop
- Simulate / force from SSS laptop PB0007 to trip
- Verify that ESD 1.3.B trip, US 03111 is trip from SSS laptop
- Simulate / force from SSS laptop PB0007 to normal
- Verify that ESD 1.3.B can be resetted.
- Verify US03111 is normal from SSS laptop
Name
Department
Signature
Date

Document number

#6 P2P signal to NCP2 - US 03216 from NCP - ESD 1.2B
- Normalize ESD 1.2.B bar
- Simulate / force from SSS laptop 5US0136 or 5US0135 to trip
- Verify that ESD 1.2.B trip, US 03216 is trip from SSS laptop
- Simulate / force from SSS laptop 5US0136 or 5US0135 to normal
- Verify that ESD 1.2.B can be resetted.
Name
Department
Signature
Date

Document number

#4 P2P signal to NCP2 - US 03201 from NCP ESD 1.B
- Normalize ESD 1.B bar
- Simulate / force from SSS laptop PB0002 or PB0003 or PB0004 or PB0005 or
PB0006 to trip
- Verify that ESD 1.B trip, US 03201 is trip from SSS laptop
- Simulate / force from SSS laptop PB0002 or PB0003 or PB0004 or PB0005 or
PB0006 to normal
- Verify that ESD 1.B can be resetted.
Name
Department
Signature
Date

Document number
5.11 VERIFICATION OF TASK #2, #20 & #22

#2 Renaming of ESD 1.0B from ESD 0.1B with same action as ESD 0.1 and new
PB-0001 (ESD 1.0B - NCR).
#20 Additional adjustable time delay on SSS outputs for 230 VAC UPS
Electrical isolation. Set at 3 minutes.
#22 P2P to NCP2, US03206 from NCP ESD 1.0.B
- Normalize ESD 1.0.B and ESD 1.0.2.B bar
- Verify that US 03206 is normal from SSS laptop.
- Activate PB-0001 from NCR and start the stopwatch
- Verify ESD 1.0B trip and ESD 1.0.2.B trip.
- Verify that US 03206 is trip from SSS laptop.
- Verify that 230 VAC UPS trip (SSS DO) after 3 minutes.
- Put inhibit PB-0001 and verify in MIC & PCS displays
- ESD 1.0.B can be resetted.
- Verify that US 03206 is normal from SSS laptop.
- After ESD 1.0.2.B can be resetted, 230 VAC UPS normal (SSS DO).
- Normalize PB-0004 from NCR and remove inhibit PB-0004.
Note:
- To avoid actual UPS trip, NPU/MNT shall isolate the UPS accordingly
Name
Department
Signature
Date

Document number

#24 Peer to peer points commissioning from NPU - NCP - OWT to validate Star
networks.
- Refer to Commissioning & Operational Test Procedure NPU ICSS Modification §5.8,
Verification of Task #17.
Name
Department
Signature
Date

Document number

#3 Modification of Simultaneous Depressurization (PB0001 - ESD1.0.B,
PB0002, PB0003, PB0004, PB0005, PB0006 - ESD 1.B).
- Refer to Commissioning & Operational Test Procedure NPU ICSS Modification §5.9,
Verification of Task #3.
Name
Department
Signature
Date

Document number
6. POST TEST CONDITION

Put the NCP system back to normal operation after commissioning & operational test
completion.
6.1 REMOVAL INHIBITS & JUMPERS

Remove all temporary inhibits / jumpers / force points which were previously installed
by NPU/MNT. The remaining inhibits lists will be kept until NCP2 platform ready:
1. Loss P2P NCP2


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Status : AFC Rev. Date : 06/09/2008

Document type: PRC System/Subsystem : 40303 Discipline : INS Page 2 of 22

TABULATION OF REVISED PAGES

Status : AFC Rev. Date 06/09/2008

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1.1 AIMS OF THE DOCUMENT

1.2 TEST PROCEDURE

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2. PLANNING & MAN POWER

2.1 DETAIL MODIFICATION

2.2 PLANNING / SEQUENCE

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2.3 MAN-POWER ESTIMATION.

2.4 TEST DURATION ESTIMATION.

2.5 VENDOR ASSISTANCE.

3.2 COMMISSIONING ACHIEVEMENTS

3.3 STATUS OF OTHER SUBSYSTEMS

3.4 SPECIAL TOOL AND TEST EQUIPMENT

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3.9 REFERENCE DOCUMENTS

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5. STEP BY STEP TEST PROCEDURE

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5.2 VERIFICATION OF TASK #8

- Simulate/force PAHH1056 or PALL1051 from SSS laptop to trip.

- Simulate/force PAHH0132 or PALL0130 from SSS laptop to trip.

- Simulate/force PAHH1066 or PALL1061 from SSS laptop to trip.

- Simulate/force PAHH0112 or PALL0110 from SSS laptop to trip.

- Simulate/force PAHH1076 or PALL1071 from SSS laptop to trip.

- Verify FCW case 6 is normal at NCR C200.

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- Simulate/force PAHH0162 or PALL0160 from SSS laptop to trip.

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5.3 VERIFICATION OF TASK #9 & #10

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5.4 VERIFICATION OF TASK #11 & #12

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5.5 VERIFICATION OF TASK #13

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