ICAPS SOFTWAREENGINEERING MANUAL Index Description Date Issued by 1 ICAPS R3 10/2005 Capgemini 2 ICAPS R3.10.02 11/2007 Capgemini TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 1 / 19 Commissioning Commissioning And And Progress Progress System System Integrated Integrated ICAPS ENGINEERING MANUAL TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 2 / 19 TABLE OF CONTENTS 1. Introduction________________________________________________________3 1.1. Aims of the Engineering Manual _________________________________3 1.2. OPERCOM Methodology ______________________________________3 1.3. ICAPS______________________________________________________4 2. Engineering Import-Export Module _____________________________________5 2.1. Main Principles of the Module___________________________________5 2.1.1 Introduction____________________________________________5 2.1.2 Data format ____________________________________________5 2.1.3 Database code __________________________________________5 2.1.4 Automatic numbering ____________________________________5 2.1.5 Revision Types _________________________________________6 2.1.6 Log report _____________________________________________6 2.1.7 Users groups ___________________________________________6 2.1.8 Import / Export SYSTAL _________________________________7 2.1.9 Punch List Import _______________________________________7 2.2. Man Machine Interface (MMI) __________________________________8 2.3. Importing Engineering Data_____________________________________9 2.3.1 Introduction____________________________________________9 2.3.2 Import of Items _________________________________________9 3. Engineering Import Format Examples __________________________________11 4. Revision Types ____________________________________________________12 5. Glossary _________________________________________________________13 6. Appendix_________________________________________________________14 6.1. Appendix 1: The Typical Phases of a Project ______________________14 6.2. Appendix 2: OPERCOM Methodology ___________________________14 6.3. Appendix 3 – Project breakdown ________________________________17 6.4. Appendix 5 - Import Log Report ________________________________19 6.5. Functional Specifications of Import / Export Module ________________19 TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 3 / 19 1. INTRODUCTION 1.1. Aims of the Engineering Manual ICAPS is the Integrated Commissioning And Progress System application to be used with the TOTAL’s OPERCOM methodology. This ENGINEERING MANUAL intends to explain the importing rules of Engineering data in the ICAPS software. - Definition of the main principles of the IMPORT / EXPORT module. - Definition of the engineering data file format and mandatory data. This manual is only an introduction of the mechanism of Import into ICAPS. For a complete description of the Import/Export rules associated with each type of import, please refer to the “Engineering Manual – Annexe1” Manual. 1.2. OPERCOM Methodology The typical phases of a Project are shown in APPENDIX 1 with the main completion activities highlighted. The five major precommissioning and commissioning activities detailed in APPENDIX 2 are: - General OPERCOM preparation, - Precommissioning preparation, - Commissioning preparation, - Precommissioning execution, - Commissioning execution. The OPERCOM methodology has been developed to handle the preparation and the execution works of both the precommissioning and the commissioning. Its main objective is to allow a smooth transfer of the installation from the Construction to the Operator, as quickly as possible, in full confidence, and with all the required safety. The OPERCOM methodology consists of the following documents : - GSEXP-101 : Precommissioning and commissioning guidelines. - GSEXP-103 : Precommissioning and commissioning preparation. - GSEXP-105 : Precommissioning execution. - GSEXP-107 : Commissioning execution. OPERCOM methodology is used with the commissioning software ICAPS. The main goal of this Manual is to help the contractor to perform the completion work preparation, which must be started early in the Project, during the engineering phase. The major preparation work concerns the engineering equipment lists which should be provided using the OPERCOM system approach presented in MD- COM01 and SP-COM512. In addition to that, those lists must be built in order to suit the formats required by ICAPS. TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 4 / 19 1.3. ICAPS ICAPS provides to the precommissioning and commissioning teams the means to : - Import the engineering equipment lists into the OPERCOM database, - Prepare the precommissioning and commissioning databases, - Prepare the precommissioning and commissioning dossiers, including all the OPERCOM datasheets, - Define the precommissioning and commissioning execution staff requirement, - Follow-up the precommissioning and commissioning execution, - Report progress and status. The APPENDIX 3 gives the architecture of the software. It shows the main hierarchies and links involved in the model, which are: - The physical hierarchy for the equipment breakdown, - The task hierarchy for the associated completion tasks. The transfer of engineering data is done using the IMPORT / EXPORT module. TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 5 / 19 2. ENGINEERING IMPORT-EXPORT MODULE 2.1. Main Principles of the Module 2.1.1 Introduction The IMPORT / EXPORT module is an easy tool to allow to : - Import all the engineering data required by ICAPS to create the OPERCOM database. - Import / export parts or complete OPERCOM database (Status Index, Technical DataBase,…) during the completion activities (revised lists,…). In order to allow import, it is necessary to fix the engineering list formats, which is the main target of this document. 2.1.2 Data format - The typical type of import / export files is Microsoft Excel (.xls). - The date format is local date (see regional parameters). - The number format is standard. - No difference is done with small and capital letters. Codes and Tag numbers are all stored in capital letters. - Field name lengths are defined in this document. When imported names are longer, they are truncated. - ICAPS element Types are mandatory. “N/A” should be used when Types are not available. - Tag number must be unique for the whole project. (see in the following chapter) - ICAPS considers equipment elements as objects (Items, BF’s,…) ; some of these objects have detailed data tables. When importing those detailed data, the data tables should be presented in a specific order with column names identified as Data1, Data2,…. The meaning of the column identifiers is not shown in the import file and the user should refer to Type definition for it. The content of the detailed data field is limited to 50 characters. - Each object can be identified by the following identifiers : - Code (Any alpha-numerical value, i.e. A for priority, abbreviation,…), - Number (Any alpha-numerical value, i.e. B2350, 2150, …), - Name (Pressure Gauge,…), - Description (Air Inlet Pressure Gauge,…). 2.1.3 Database code Each database of the project is identified by a letter. This letter is used for merged database. 2.1.4 Automatic numbering The database letter is used in the automatic creation of the task number, OT/PVP number and punch list number. TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 6 / 19 Object number format: Object Format Task <B>1xxxxxxx OT/PVP <B>2xxxxxxx Punch list <B>3xxxxxxx <B> is the database letter. xxxxxxx are a single number. 2.1.5 Revision Types The engineering lists are generally revised several times during the Project. In order to update the OPERCOM database when a new revision is issued, all the imported engineering data should be provided with a Revision Number and a Revision Type. The Revision Number is the last one for the current data. The Revision Type is a Capital letter to characterise the import Action (See Table 6) Note : The ICAPS User can specify an engineering revision range to limit the import to that selection of data. 2.1.6 Log report Following engineering data file import, a log file is created which provides a registered history of the errors during import (…\importXXX_Date_Time.xls XXX = IT, BF …). An example of the ICAPS Import Log Report is shown in APPENDIX 5. This file provides the following information: - An Item Import Global Status Report; "General" Sheet with: - Date and time at the end of import, - Number of records (excluded after rev no comparison, excluded after error, deleted, created, modified, updated, excluded due to unknown action…..) - Excluded due to unknown action. - List of rejected sheets. - A Successful Imported item list; "Item Good" Sheet with inserted records into ICAPS, - A List of errors (data not following ICAPS import rules). Errors are presented in 2 sheets. The imported data concerned by the error is stored in the first sheet; "Item Bad" Sheet, the error code is stored in the second sheet; "Item Errors" Sheet. This is to allow later import of the data after correction, 2.1.7 Users groups ICAPS R2 includes a new concept: users groups. A users groups allows to split tasks in a project depending on who is responsible for the task realization. Every ICAPS user belongs to one and only one users groups. TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 7 / 19 When a task is created from the MMI or from Initialization, it is automatically allocated to the users groups of the connected user. A users groups is characterised by a code and a name. From import: When tasks are created in the local database, the users groups must be empty. The task number is automaticaly created and the user group is the users group of the connected user. When tasks are created in a remote database and then imported in the local database, the users groups must be given in the import files. There is no export/import facilities for the users groups. However, during a task import in order to merge two database, if the users group of a task does not exist while it is in the import file, it is automatically created by the system before the task creation. Security: A user can create/modify/delete tasks and associated punch lists of his group. A user can modify/delete tasks and associated punch lists of another group only if his access level is 4. A user with a level 4 access can create tasks of another group if he imports tasks from another database. 2.1.8 Import / Export SYSTAL ICAPS R3.10 includes a new concept : import and export SYSTAL. A user with a level 4 access can import SYSTAL only for a modification revision code. No Creation and Deletion allowed for SYSTAL. 2.1.9 Punch List Import ICAPS R3.10 includes a new concept : management Punch List Actors with ICAPS login. A user who is not a ‘Punch List User’ can’t import PunchLists even if user with level 4. TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 8 / 19 2.2. Man Machine Interface (MMI) The import user interface is shown on the following screen view (FIGURE 1) : Figure 1- Import MMI Among the several possible importing facilities, this document presents only the import of Items which concern the Engineering preparation. They are required to build the OPERCOM database (Main Equipment, Instruments, Cables, piping, ...). - The Item Number list contain data for all the other equipment. TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 9 / 19 2.3. Importing Engineering Data 2.3.1 Introduction The two engineering data importing formats are presented in the following paragraphs. It is strongly recommended to comply with those 2 formats from the beginning of the engineering data list preparation in order to avoid a later conversion to the data formats required by ICAPS. In any case, the Engineering team is in charge of the data file conversion to the ICAPS file formats. Some of the imported data are mandatory in the engineering equipment lists as they are necessary to use ICAPS. All the other data are optional, however, it is recommended to supply them as they are used during the execution and it is appropriate to gather them at this time, when they are available. 2.3.2 Import of Items All the engineering equipment elements are imported into ICAPS using the format shown in the Table1. This EXCEL file "items.xls" must contain only one worksheet named: Item. The mandatory data in this Item import file are as follows : - Revision Number, - Revision Type, - Item Number (and Old Item Number when modified), - Item Type Code, Table 1 ICAPS Import File Format for Items Field Name Mandatory Valid entries Data Type Length Revision Number Yes Any value Standard 3 Revision Type Yes See § 4.2 - Table 6 (C,D,M) Character 1 Item Number Yes Any value Character 30 Old Item Number Yes (A) Any existing ITEM Number from Dictionary Character 30 Item Name No Any value Character 50 Item Type Code Yes See § 4.3 - Table 7 Character 10 Associated SubSystem Number Yes Any existing SYS Number from Dictionary Character 30 Associated Module Code no Any existing MODULE code from Dictionary Character 30 Manufacturer Model No Any value Character 30 Manufacturer Name No Any value Character 30 Manufacturer Type No Any value Character 30 PO Number No Any value Character 30 Item Serial Number No Any value Character 30 Comments NO Any value Character 50 Data1 No (B) Detail DATA(1) Content - any value = Control Type if Instrument items Character 50 Data2 No Detail DATA(2) Content - any value Character 50 . . . Data15 No Detail. DATA(15) Content - any value Character 50 TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 10 / 19 (A) Only when Item Number has been modified (Revision Type = M) (B) In the case of instrument items, the Control_Type should be entered in Data1. (Refer to § 4.1-Table 5 for the list of Control_Types). An example of engineering data import file is provided in § 3 -Table 3 TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 11 / 19 3. ENGINEERING IMPORT FORMAT EXAMPLES Table 2 Example of ITEM Import File Revision Number Revision Type Item Number Item Name Item Type Code Associated SubSystem Number Associated Module Code Manufacturer Model Manufacturer Name Manufacturer Type PO Number Serial Number Comments Data1 … Data15 1 c 01-30-CJF-04-2S Comm. Cable From CCR to PLC I/O Cabinet (FW) ICAB 9677 TBD C-Z-09-1 C-Z-09-1 1 c 01-30-HSL-254A CRUSHER EMERG. STOP INST 9615 FW 1 c 01-30-HSL-254B CRUSHER EMERG. STOP INST 9615 FW 1 c 01-30-JBF-04 Junction Box ZCLA 9615 TBD Foster Wheleer F.W. CR- 102 1 c 01-30-WY-01F Control Cable CABL 9615 TBD Foster Wheleer 1 c 01-30-WY-03F Control Cable CABL 9615 TBD Foster Wheleer 1 c 01-30-WY-06F Control Cable CABL 9615 TBD Foster Wheleer 1 c 01-30-WY-07E Control Cable CABL 9615 TBD Foster Wheleer 1 c 01-30-ZSH- 250A/B INST 9615 FW 1 c 01-30HS-241A CR-101 - Pull Cord Switch INST 9615 FW TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 12 / 19 4. REVISION TYPES C CREATION OF A NEW ELEMENT D DELETION OF AN EXISTING ELEMENT M MODIFICATION OF AN EXISTING ELEMENT U UPDATE OF AN EXISTING ELEMENT Table 6 Revision Types Which difference between Modification and Update? You have to choice the ‘M’ code if you want to change the name of an element or the links between it and its fathers (for example, change an item from Basic Function). You only have to use the ‘U’ code if you plan to modify data information about the element, not data structure. TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 13 / 19 5. GLOSSARY PRECOMMISSIONING It is the group of STATIC and DE- ENERGIZED verifications to be carried out in order to ensure that the installation adheres to the Project Engineering Documents. COMMISSIONING It is the group of DYNAMIC and ENERGIZED tests to be carried out in order to ensure that the installation is ready for start-up. SYSTEM It is a subdivision of an installation that performs a proper operational function. SUBSYSTEM It is the minimum portion of the Plant required for Commissioning purpose, and at the same time, will be the handover package to Operations. BASIC FUNCTION It is the smallest group of items for a single Commissioning task. ITEM It is the smallest portion of an installation for a Precommissioning Task. TASK ACTIVITY It is any of the Pre Commissioning or Commissioning execution type of work, TASK It is each individual precommissioning or commissioning job applies on an item, , a test pack, a Basic Function or a subsystem. Table 8 OPERCOM Glossary TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 14 / 19 6. APPENDIX 6.1. Appendix 1: The Typical Phases of a Project 6.2. Appendix 2: OPERCOM Methodology TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 15 / 19 TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 16 / 19 COMPLETION ACTIVITY PREPARATION (GSEXP-103) COMPLETION ACTIVITY EXECUTION (GSEXP-105 & GSEXP-107) I GENERAL OPERCOM PREPARATION 1) Subsystem Preparation 2) Start-Up Sequence Preparation 3) Coloured Marked-Up Drawing Preparation 4) Subsystem Engineering List Preparation IV – PRECOMMISSIONING EXECUTION (GSEXP-105) 1) Conformity Checks 2) Static Tests 3) Piping Tests II – PRECOMMISSIONING PREPARATION 1) Status Index Preparation 2) Precomm. Dossier Preparation 3) Precomm. Manpower Estimate Preparation 4) Long Precomm. Task Preparation IV – COMMISSIONING EXECUTION (GSEXP-107) 1) Preliminary Checks 2) Functionnal Tests 3) Operating tests 4) Pipinp & Vessels Preparation III COMMISSIONING PREPARATION 1) Technical Database Preparation 2) Comm. Dossier Preparation 3) Comm. Manpower Estimate Preparation 4) Long Comm. Task Preparation APPENDIX 2 – OPERCOM METHODOLOGY THE COMPLETION ACTIVITIES TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 17 / 19 6.3. Appendix 3 – Project breakdown ICAPS database includes all technical and organizational data for P/Com and Com activity preparation and follow-up during execution. All data inside one ICAPS database must be related to a unique project. ICAPS database is organized in 4 main branches as follow: – Equipment Branch : Defines all project equipment using a hierarchical arrangement – Task Branch: Defines all P/C and Comm. Tasks within the project. Each task is associated to equipment and to a progress substage. Each task is part of a task activity and is linked to one or several disciplines. – Progress Branch : Defines project sequence using a four levels hierarchy – Punch list Branch: Defines all Punch List items during the overall project. Users Group Tasks Punch Lists Progress Branch Equipment Branch Project Subproject System Project Seq Subproject Seq Stage Substage Tasks Tasks Item Subsystem Data written in italic are optionnal. General order of execution for different Task Activities is defined below (bottom corresponds to first tasks and upper part is for latest tasks.) TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 18 / 19 C o m m i s s i o n i n g T a s k s P r e C o m m i s s i o n i n g T a s k s Operational Tests (OTS) - Piping & Vessels Preparation (PVP) Functional Tests (FTS) Conformity Checks (CCK) Piping Tests (PIP) Static Tests (STS) Preliminary Checks (PRC) TOTAL TOTAL TOTAL TOTAL ICAPS Engineering Manual Page 19 / 19 6.4. Appendix 5 - Import Log Report 6.5. Functional Specifications of Import / Export Module This technical document lists type by type the rules applied for import in and export from ICAPS database. Please refer to the following document: “ICAPS Engineering Manual – Annexe 1.doc” for more details about Import and Export rules.