Installation Procedure
Installation Procedure
CLASS 1
STATUS CODE : A = Issued for comments – B = Issued for approval – C = Approved – D = As Built
TABLE OF CONTENTS
1. INTRODUCTION.............................................................................................................................. 5
1.1. PURPOSE .............................................................................................................................................. 5
1.2. SCOPE ................................................................................................................................................... 5
1.3. DEFINITION ......................................................................................................................................... 6
2. ABBREVIATIONS ............................................................................................................................ 6
1. INTRODUCTION
1.1. PURPOSE
The purpose of this method statement is to define a clear and safe procedure for the
installation of Sisi Nubi project Honeywell Icon consoles (ICS) and related equipments
located in TATUN Control Room in addition to the associated Server cabinet located in
Instrument Technical Room.
The procedure covers the software modifications and the hardware steps necessary to
safely install the equipments in the Tatun Control Room.
1.2. SCOPE
This Method Statement provides a safe procedure for the installation of the Sisi Nubi
project HMI consoles, alarm and screen copy printers and Server cabinet in the
Instrument Technical Room. The equipments detail is as follow:
• HMI Console SN1-OCS-01 Honeywell Icon Console.
• HMI Console SN1-OCS-02 Honeywell Icon Console.
• Alarm Printer SN1-P-2180 EPSON LQ 2180
• Screen Copy Printer SN1-P-4700 HP LaserJet 4700n
• Server Cabinet SN1-ER-6204 Dell P2850, C200, …
• EWS SN1-EWS Dell W470, Monitor 20”, kbd.
Site survey has been carried out on 1st and 2nd November 2006 in order to collect the
necessary information to write the present document.
1.3. DEFINITION
2. ABBREVIATIONS
AC : Alternative Current
AI : Analogue Input
AO : Analogue Output
EMC : Electro Magnetic Compatibility
EMI : Electro Magnetic Interference
ESD : Emergency Shutdown System
EWS : Engineering Work Station
FCW : flow Control of Wells
FAT : Factory Acceptance Test
FGS : Fire & Gas System
FTA : Field Termination Assembly
HMI : Human Machine Interface
HMI : Human/Machine Interface
MTBF : Mean Time between Failures
MTTR : Mean Time to Repair
MTU : Master Terminal Unit
OCS : Operator Control Station
PCS : Process Control System
PDMS : Process Data Management System
PLC : Programmable Logic Controller
RFI : Radio Frequency Interference
RAID : Redundant Array of Independent Disks
SIL : Safety Integrity Level
SSS : Safety Shutdown System
TCR : Tatun Control Room
TR : Technical Room
UCN : Universal Control Network
UPS : Un-interruptible Power Supply
VDU : Visual Display Unit
VFC : Volt Free Contact
3. GENERAL INFORMATION
3.2. RESPONSIBILITIES
2. TCSS shall be responsible for any damage to and/or tampering with existing facilities
and TCSS, in such instances, shall restore these back to original conditions
acceptable to COMPANY.
4. TCSS shall be responsible for enforcing safety regulation and ensuring that work is
carried out according to construction practices and COMPANY Safety Manual and
Procedure.
5. TCSS Lead Engineer is responsible for obtaining an approval from the COMPANY
before any work can be started.
7. TCSS will provide manpower such as instrument technician and / or helpers to open
the false floor, to install/decommission the cabinets/consoles and to install/remove
the cables.
8. TCSS supervisor is responsible to keep the working area clean and tidy.
Representatives:
The installation of the Sisi Nubi project system cabinets and consoles in TATUN control
room requires equipments manipulation and construction works (e.g. support chassis
installation …). These tasks shall not affect the existing running units as no installation
nor connection to existing system equipment is required. In order to minimize operator
disruption, as far as possible all construction, preparation, … work is done in COMPANY
maintenance workshop.
Barricades and warning signs will be posted in the Tatun Control Room to indicate the
false floor opened areas.
1. All personnel working within the existing plant area shall use Personal Protective
Equipment (PPE) as minimum:
a. Safety Helmet,
b. Safety Shoes,
c. Safety goggles,
d. Long sleeves,
e. Gloves.
2. Warning signs shall be provided and posted inside TATUN control room to segregate
the working areas from the other running system.
4. TCSS shall always be aware of the safety procedures adopted by the COMPANY
and in case of fire or emergency, emergency telephone numbers are always be
available with the workers involved with this work.
5. All work will be coordinated at all times with Company Plant Operators.
6. The engineers and supervisors will make sure that all the people who are working in
the control room for TCSS are always aware of the safety procedures to be followed
during any possible FIRE or GAS alarm.
7. Any hot work shall not be performed without a hot work permit signed by COMPANY
Control engineer , Operation supervisor and/or shift controller.
8. A daily permit will be obtained from the Company Plant Operators. The tag No. of the
cabinets/consoles to be manipulated shall be indicated on the work permit and a list
of the cable number shall be attached or indicated on the work permit. All the other
cabinets not associated with this activity will be locked. TCSS and subcontractor
personnel will not be allowed to open any cabinet other than what is indicated on the
work permit.
9. Barricades and warning signs will be posted in the Tatun Control Room to indicate
the false floor opened areas.
10. Separate hot work permits shall be issued for the use of a drilling machine and
caldwelding of the earth connections (if caldwelding is necessary).
11. All CTR/TCSS/Sub-Contractor staff that arrives on CPU or NPU sites shall follow Site
Safety induction by FO-Safety Officer at the first time of their arrival.
12. Daily Safety talks shall be performed by CTR/TCSS Supervisors prior performing any
job in the morning.
3.5. EQUIPMENT
Honeywell Icon HMI consoles are installed at former location of ICS consoles 69-OCS-
01, 69-OCS-02 and 68-OCS-05 as per TATUN CONTROL ROOM MODIFICATION
LAYOUT (SN1-62-070-001-C Rev. B.A).
Support chassis for SN1-OCS-02 console is placed in order to follow the 5,5 m diameter
circle arrangement (this represent the average diameter value measured during site
survey). Icon console 15° elbow frame placed between consoles induce the same
orientation.
Chassis is bolted to the ground concrete floor using Dyna Bolt hanging screws in order to
allow level adjustment as per ground/false floors possible variation. Ref. ICON
CONSOLE MOUNTING DETAILS drawing for hanging system details.
Chassis is connected to the IPE earth loop. Ref. TATUN PCS/SSS CABLE
SCHEDULE/LIST.
Support chassis for SN1-OCS-01 console is placed in order to follow the 5,5 m diameter
circle arrangement (this represent the average diameter value measured during site
survey). Icon console 15° elbow frame placed between consoles induce the same
orientation.
Chassis is bolted to the ground concrete floor using Dyna Bolt hanging screws in order to
allow level adjustment as per ground/false floors possible variation. Ref. ICON
CONSOLE MOUNTING DETAILS drawing for hanging system details.
Chassis is connected to the IPE earth loop. Ref. TATUN PCS/SSS CABLE
SCHEDULE/LIST.
Honeywell Icon HMI console SN1-OCS-02 is placed on its support chassis and fixed
using 4 adjustable hanging screws. Ref. ICON CONSOLE MOUNTING DETAILS
drawing for hanging system details.
Console SN1-OCS-02 is connected to the IPE earth loop. Ref. TATUN PCS/SSS CABLE
SCHEDULE/LIST and TATUN – ICON GENERAL ARRANGEMENT DRAWING for
connection point detail.
15° elbows (Top and Bottom) are placed on Honeywell Icon HMI console SN1-OCS-02.
Honeywell Icon HMI console SN1-OCS-01 is placed on its support chassis and fixed
using 4 adjustable hanging screws. Ref. ICON CONSOLE MOUNTING DETAILS
drawing for hanging system details.
15° elbows (Top and Bottom) are fixed on Honeywell Icon HMI console SN1-OCS-01.
Console SN1-OCS-01 is connected to the IPE earth loop. Ref. TATUN PCS/SSS CABLE
SCHEDULE/LIST and TATUN – ICON GENERAL ARRANGEMENT DRAWING for
connection point detail.
UPS-10-36 power supply cable is reused. Ref. Tatun 69-OCS-01 & 69-OCS-02
decommissioning procedure. Beforehand, COMPANY Electrical maintenance engineer
has performed continuity and megger tests.
UPS-10-36 power supply cable is wired to SN1-OCS-01 Power In terminal block. Ref.
TATUN – ICON GENERAL ARRANGEMENT DRAWING.
DB-UPS-10, MCB 36 shall remain Off until SAT procedure is performed. The SAT
procedure is covered in a separate document.
UPS-10-37 power supply cable is reused. Ref. Tatun 69-OCS-01 & 69-OCS-02
decommissioning procedure. Beforehand, COMPANY Electrical maintenance engineer
has performed continuity and megger tests.
UPS-10-37 power supply cable is wired to SN1-OCS-02 Power In terminal block. Ref.
TATUN – ICON GENERAL ARRANGEMENT DRAWING.
DB-UPS-10, MCB 37 shall remain Off until SAT procedure is performed. The SAT
procedure is covered in a separate document.
The following network cables are laid from SN1-ER-6204 Server cabinet location in
Instrument Technical Room to SN1-OCS-01 and SN1-OCS-02 consoles located in
Control Room Ref TATUN PCS/SSS CABLE SCHEDULE/LIST:
• SN1ESF1-LINKA/SN1SWA-PORT8
• SN1ESF1-LINKB/SN1SWB-PORT8
• SN1ESF2-LINKA/SN1SWA-PORT9
• SN1ESF2-LINKB/SN1SWB-PORT9
Network cables length is 25 meters. The path used for the network cables is described in
drawing # SN1-62-070-002-C.
Existing spare MCT are used. As far as existing spare MCT and network cable trays
allow redundant communication cables will be routed by 2 different ways.
Network cables shall be properly stored under the false floor at a suitable location in
order not to bother further supports installations work at SN1-ER-6204 Server cabinet
location.
FTE Network cables are properly laid and connected to their respective Ethernet ports on
OCS workstations. Ref. SN1-62-070-357-C Rev.B.B.
Honeywell Icon HMI consoles SN1-OCS-01 & SN1-OCS-02 are ready for Pre-
commissioning activities. Pre-commissioning and SAT procedures are covered in
separate documents.
Important note:
A smoke detector is placed at the location defined for the Server Cabinet SN1-ER-6204.
Therefore, this one shall be relocated to a position defined by COMPANY. Relocation
activities are under COMPANY responsibility and Scope of Work.
Support chassis for SN1-ER-6204 server cabinet is placed in order to have its front panel
lined up with the existing panel front panels. Rear side of the cabinet is not lined up with
other cabinets as server cabinet is 1000 mm width. Ref. SN1-62-070-002-C Rev. A.A.
TECHNICAL ROOM MODIFICATION LAYOUT sheet 03 drawing.
Chassis is bolted to the ground concrete floor using Dyna Bolt hanging screws in order to
allow level adjustment as per ground/false floors possible variation. Ref. SN1-62-070-
002-C Rev. A.A. EQUIPMENT SUPPORT DETAIL sheet 20 drawing for hanging system
details.
Chassis is connected to the IPE earth loop. Ref. TATUN PCS/SSS CABLE
SCHEDULE/LIST and SN1-62-070-002-C Rev. A.A. TECHNICAL ROOM EARTHING
LAYOUT MODIFICATION sheet 06.
SN1-ER-6204 server cabinet is placed on its support chassis and fixed using 4 hanging
bolts. Ref. SN1-62-070-002-C Rev. A.A. EQUIPMENT SUPPORT DETAIL sheet 20
drawing for hanging system details.
SN1-ER-6204 server cabinet is connected to the IPE earth loop. Ref. TATUN PCS/SSS
CABLE SCHEDULE/LIST and SN1-62-070-002-C Rev. A.A. TECHNICAL ROOM
EARTHING LAYOUT MODIFICATION sheet 06.
Only 6A spare feeder breakers are available in existing UPS-10-DB. Then three
temporary solutions are conceivable and considered to power supply the server cabinet
SN1-ER-6204.
1. Replace 2 x 6A spare feeders by 25 or 32A feeder breakers. This work shall be done
“On-Line” to keep the Control Room existing equipment’s up and running.
2. Use 2 (two) 6A feeders is parallel to avoid “On-Line” electrical work.
3. Use a stand-alone 5KVA UPS (e.g. office UPS), connected to emergency lighting
panel Distribution Board (LP-E-01).
For these 3 options, power cable laid by TCSS is long enough to be re-routed to the
definitive connection located in the “New” UPS DB.
Proposal No 3 is the preferred one to be implemented with regards to the safety and
because it is not as difficult as the 2 others in term of technical implementation, moreover
it does not affect the load of the existing UPS.
Consequently, the present procedure considers the power supply option #3.
Prerequisite:
2x 25A (or 32A) rated MCB and associated Distribution board (DB) shall be available
from temporary UPS.
UPS-xx-01 power supply cable is laid from DB-UPS-xx distribution board panel
(temporary) to Server Cabinet. Continuity and megger checks are performed.
UPS-xx-02 power supply cable is laid from DB-UPS-xx distribution board panel
(temporary) to Server Cabinet. Continuity and megger checks are performed.
DB-UPS-xx, MCB 01 and MCB 02 shall remain Off until SAT procedure is performed.
The SAT procedure is covered in a separate document.
The following network cables are raised from the false floor. The network cables are
properly laid inside cabinet using the dedicated cable duct:
• SN1SWA-PORT8/SN1ESF1-LINKA
• SN1SWB-PORT8/SN1ESF1-LINKB
• SN1SWA-PORT9/SN1ESF2-LINKA
• SN1SWB-PORT9/SN1ESF2-LINKB
FTE Network cables are connected to their respective Ethernet ports on FTE switch A
and B. Ref. SN1-62-070-357-C Rev.B.B.
SN1-P-2180 alarm printer is installed on double deck printer table formally used by 69-
PRT-01 and 69-PRT-02 (Yokogawa). The double deck printer table is shared with TMB2
alarm printer.
The following network cable is laid from SN1-ER-6204 Server cabinet location in
Instrument Technical Room to SN1-P-2180 printer located in Control Room Ref TATUN
PCS/SSS CABLE SCHEDULE/LIST:
• SN1P2180-COM1/SN1SWA-PORT11
Network cables length is 25 meters. The path used for the network cables is described in
drawing # SN1-62-070-002-C.
The following network cable is raised from the false floor. The network cable is properly
laid inside cabinet using the dedicated cable duct:
• SN1SWA-PORT11/SN1P2180-COM1
FTE Network cable is connected to its respective Ethernet port on FTE switch A. Ref.
SN1-62-070-357-C Rev.B.B.
69-PRT-03 and 69-PRT-04 (Yokogawa) alarm printers are shifted on double deck printer
table delivered by TMB2 project.
Sisi Nubi and TMB2 laser jet printers arte placed on the table previously used by 69-
PRT-03 and 69-PRT-04 (Yokogawa) alarm printers.
SN1-P-4700 screen copy printer power cord is plug on UPS-10-46-1 wall socket.
The following network cable is laid from SN1-ER-6204 Server cabinet location in
Instrument Technical Room to SN1-P-4700 printer located in Control Room Ref TATUN
PCS/SSS CABLE SCHEDULE/LIST:
• SN1P4700-COM1/SN1SWB-PORT11
Network cables length is 25 meters. The path used for the network cables is described in
drawing # SN1-62-070-002-C.
The following network cable is raised from the false floor. The network cable is properly
laid inside cabinet using the dedicated cable duct:
• SN1SWB-PORT11/SN1P4700-COM1
FTE Network cable is connected to its respective Ethernet port on FTE switch B. Ref.
SN1-62-070-357-C Rev.B.B.
Engineering Work Station is installed in Engineers Office. Desk is shared with Yokogawa
system EWS. Ref. SN1-62-070-002-C Rev. A.A. TECHNICAL ROOM EARTHING
LAYOUT MODIFICATION sheet 04.
SN1-EWS workstation and monitor power cords are plugged on UPS-10-xx-y wall
socket.
The following network cables are laid from SN1-ER-6204 Server cabinet location in
Instrument Technical Room to SN1-EWS workstation located in Engineers Office Ref
TATUN PCS/SSS CABLE SCHEDULE/LIST:
• SN1-EWS-LINKA/SN1SWA-PORT10
• SN1-EWS-LINKB/SN1SWB-PORT10
Network cables length is 35 meters. The path used for the network cables is described in
drawing # SN1-62-070-002-C.
Existing spare MCT are used. As far as existing spare MCT and network cable trays
allow redundant communication cables will be routed by 2 different ways.
The following network cable is raised from the false floor. The network cable is properly
laid inside cabinet using the dedicated cable duct:
• SN1SWA-PORT10/SN1-EWS-LINKA
• SN1SWB-PORT10/SN1-EWS-LINKB
FTE Network cables are connected to their respective Ethernet ports on FTE switch A
and B. Ref. SN1-62-070-357-C Rev.B.B.
9. SCHEDULE/PLANNING
Ref. Appendix D
Appendix A
CPU1/2 UPS POWER SUPPLY PANEL SCHEDULE UPS-10 / DB-UPS-10
Appendix B
TATUN CONTROL ROOM MODIFICATION LAYOUT
Appendix C
TATUN CONTROL ROOM EQUIPMENTS LAYOUT, CABLES ROUTING &
SUPPORT DETAILS
Appendix D
SCHEDULE/PLANNING
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