Engineering Handbook for Projects Automation

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Engineering Handbook for Projects Automation

Table of Contents:
1 2 3 4 PURPOSE AND SCOPE ........................................................................................... 2 STAGE 4 OVERVIEW FLOWCHART........................................................................ 2 PROJECT ORGANISATION AND RESPONSIBILITIES ........................................... 4 STAGE 4 STEPS....................................................................................................... 5 4.1 DESIGN BASIS............................................................................................ 5 4.1.1 Establish Design Basis ................................................................... 5 4.1.2 Engineering Strategy ...................................................................... 8 4.2 BASIC ENGINEERING AND REVIEW ....................................................... 10 4.2.1 Update Functional Design Specification........................................ 10 4.2.2 Basic Engineering, Hardware and Software.................................. 12 4.2.3 Exchange Data ............................................................................. 14 4.2.4 Basic Engineering Design Review ................................................ 16 4.2.5 FSA .............................................................................................. 17 4.3 PURCHASE REQUISITION ....................................................................... 19 4.3.1 Produce Purchase Requisition to Supply Management ................ 19 4.3.2 Technical requirements for Packing shipping Storage and Preservation ................................................................................. 21 4.4 CHANGE MANAGEMENT ......................................................................... 22 4.5 DETAIL ENGINEERING............................................................................. 25 4.5.1 Technical Kick-off Meeting............................................................ 26 4.5.2 System Setup ............................................................................... 28 4.5.3 Establish SW & HW Typicals ........................................................ 33 4.5.4 HW Design ................................................................................... 36 4.5.5 Application Programming.............................................................. 42 4.5.6 System Details.............................................................................. 45 4.5.7 Documentation ............................................................................. 48 4.5.8 Design Review / System Verification ............................................ 50 4.6 TEST AND VERIFICATION........................................................................ 51 4.6.1 Test Planning................................................................................ 51 4.6.2 Prepare Test Procedure and Protocol........................................... 53 4.6.3 Internal Acceptance Test .............................................................. 55 4.6.4 Factory Acceptance Test .............................................................. 57 Appendix: Words and Abridgements ................................................................... 59 Revisions................................................................................................................ 61
5 6
SKELETON: 3AJD000045-001, REV. C NOINA/DTQ; TTT VERSION: 01.02.DTI01
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PURPOSE AND SCOPE
The purpose of this engineering handbook is to describe and provide a guideline for the work process needed to perform engineering, production, test and verification activities and delivery of automation products and services. This handbook describes the main principles for automation system engineering, with references to relevant review activities. Detailed, product related work process descriptions, will supplement the descriptions in this document. The Engineering Work Process Manual includes Roles & responsibilities matrix in general and pr detailed stage. In general terms roles are described out of a typical project organisation chart.
STAGE 4 OVERVIEW FLOWCHART
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Explanation of the flow diagrams Colours Forms : predefined process (reference to another process) : internal storage : document Blue box: For both Safety and normal process projects Green box: For safety projects Yellow box: input from customer(s) / Sales (specified) Orange box: data from another Stage (not stage 4) Red border: does not have the document Yellow border:
: database : process : decision : data : card : stored data
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PROJECT ORGANISATION AND RESPONSIBILITIES
The Project organisation presented below is a generic illustration. The principals in chain of command and roles are applicable in the projects executed by NOINA OGP.
Roles & Responsibilities is described in the Project roles & responsibility document, 3AJG000407-120 document.
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4 4.1
STAGE 4 STEPS DESIGN BASIS
Design Basis includes the following main processes:

Establish Design Basis Engineering Strategy
4.1.1
Establish Design Basis
The purpose of this activity is to establish the design basis for the system engineering activities. Design basis means all documentation and information relevant for performance of the project engineering activities.
CONTROL INPUT Scope of Supply FDS & Bill of Material QA Plan Stage 3 OUTPUT
Contract specifications Classification society requirements Rules and regulations Standards
Safety Plan Stage 3
4.1.1 Establish Design Basis
Review Use Checklist 4-1-1 Establish Design Basis. Technical doc. filed according to project requirements EDMS Bid documents
Evaluate completeness and consistency of Tech. Input doc.
Evaluate Bids Engineering strategy Project Exection Document from Sales
Updated SDL
QA Plan Stage 3 Detailed design documentation * Vital Interface documentation
Complience List Vital interface scope and schedule Review QA/Safety Plan from Stage 3
Safety Plan Stage 3
Bid correspondence (for supplementary information)
Documentation from similar projects
Input to Risk Evaluation Ref Stage 3
Quotations from sub - suppliers
ABB project libraries and typicals
Update Project Delivery Plan
SRS
SAR from Sales
Alarm specification
Alarm Philosophy
4.1.1.1 Responsibility The System responsible person (lead engineer) is responsible for this activity.
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The input documents to this activity will normally be the following:

a. b. c. d. e. f. g. h. i. j. k. l. m. n.
Scope of supply (Cabinet tags, equipment, Systems) Scope of Work (Services, work processes, activities, ABBs roles) Technical Specification (Customer technical Requirements) Contract specifications Classification society requirements Rules and regulations Standards Detailed design documentation (C&E, SCD, I/O List, HSI, Alarm philosophy) Bid docs including technically related documents Bid correspondence (for supplementary information, Bid clarification moms, deviations) Quotations from sub - suppliers ABB project libraries and typical Documentation from similar projects Vital interface documentation (
IEC 61511 Required input a. Safety Requirement Specification (SRS) b. Safety Plan c. Safety Analysis Report (SAR) Other Mandatory input documents: a. Compliance list b. QA plan 4.1.1.3 Activity description During this activity, all information relevant for project system and detail engineering will be collected, according to the above list. Project technical personnel will familiarize themselves with the material, and check for completeness and consistency. All documents will be registered and filed, according to project requirements. Design documents will be made available to project team members. Evaluate the Project Execution Strategy to get the premises made by Sales and Management and Customer. Identify Risk and Opportunities. Update the QA and Safety Plan 4.1.1.4 Quality control activities The Check list for review of design basis shell be filled out. Activities will be recorded in a MOM. Compliance list from bid phase will be updated, possible deviations highlighted. 4.1.1.5 Activity output The output from this activity will be:
a.
Design basis documents registered, evaluated, filed and made available for project use.
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Possible deviations and non compliances highlighted to customer. Updated SDL Update Risk list Update QA plan Updated Safety Plan
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Engineering Strategy
The purpose of this activity is to establish critical functions for the project Execution. These activities are critical to get established immediately. The Data exchange format should have been established in the Sales process, but this is the time to verify the correct data exchange format to be used. The Data exchange format is dependent on the SW library to be used in the project.
4.1.2.1 Responsibility The System responsible person (lead engineer) is responsible for this activity. 4.1.2.2 Activity input The input documents to this activity will normally be the following:
a. b. c. d. e. f. g. h.
Scope of supply Contract specifications Classification society requirements Rules and regulations Standards Detailed design documentation Bid, including technically related documents Bid correspondence (for supplementary information)
VOR Database
Query Database
EDMS
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Quotations from sub - suppliers ABB project libraries and typical Documentation from similar projects
4.1.2.3 Activity description These activities is critical to get implemented at the start-up of the project The use of Engineering Tools. Folder structures in EDMS and the rules how to use EDMS. How to handle Configuration Management regarding establish of Baseline, delivery and documenting a SIL loop change and other requirements to version handling of SW and HW. Change Management rules and Tool use to be established. Data exchange format: The purpose of this activity is to define and document the data exchange format based on hardware and software solutions to be utilized in the project. The process differs between the Technical exchange of I/O information and other requirements for documentation formats. 4.1.2.4 Quality control activities 4.1.2.5 Activity output The output from this activity will be:
a. b. c. d. e.
Established Engineering Tool Established Query / Change Management System Established how to handle Configuration Version control Established Document structure Folder structure etc. Established Data exchange format with customer and I/O list resp. contractor.
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BASIC ENGINEERING AND REVIEW Update FDS Basic Engineering HW & SW Exchange Data Review Basic Design & FSA Update Functional Design Specification
Basic Engineering includes the following main processes:

4.2.1
The purpose of this activity is to update the Functional Design Specification (FDS) from bid phase. New information or change in functionality during the sales process is documented in other types of documents. All functions must be documented in one document, the FDS. The FDS forms the foundation and the constitutional document of basic and detailed design. The FDS shall not contain detailed information, which will cause the FDS to be updated due to other changes than functional changes.
4.2.1.1 Responsibility The systems responsible engineer (lead engineer) will be responsible for this activity. If IEC61511 is required, the Safety Manager is responsible for the SAR to be completed. 4.2.1.2 Activity input The inputs for this activity will be
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Design basis FDS from Sales Possible changes from bid to contract SAR SRS Non Compliance list
4.2.1.3 Activity description The FDS from bid phase will often focus on product and sales related information. In the project phase, more process related information should be included in the FDS and references to typical solutions and work methods should be given. Changes in the scope of supply, that can have influence on the content of the FDS may also have occurred. If IEC61511 or SIL loops are required in this project the Safety Analysis Report should be reviewed. If no SAR is available the SAR must be made based on the SRS from Customer or Engineering Company. 4.2.1.4 Quality control activities The FDS will go through an internal review before being issued to the customer. The need for project external review should be evaluated, depending on project technical complexity. If IEC61511 is required, use SAR checklist. 4.2.1.5 Control documents None. 4.2.1.6 Activity output
a. b. c.
FDS updated, and issued to customer for review. SAR updated. NON Compliance list updated.
4.2.1.7 Material
MS Word
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Basic Engineering, Hardware and Software
The purpose of this activity is to define and document all hardware and software solutions to be utilized in the project. The need for project specific solutions must be identified.
CONTROL SAR INPUT Programming Guideline NON SIL Modules Programming Guideline Safety Modules Customer requirements OUTPUT
4.2.2 Basic Engineering HW & SW

Evaluate Project Technical Requirments Evaluate SW solutions
Cabinet Footprint
Check point before proceding
Power consumption and heat dissipation
ABB Oli & Gas Std Library
Evaluate HW solutions FDS Evaluate Display Elements and presentation Spesification & Configuration from 800xA Sales Wizard
HW Design Guideline
Update Test & Inspection Plan (QA/Safety Plan)
List and description of external communication links
Application SW Safety Requirement Specification
Evaluate Network Configuration
List of solutions and typicals for graphic displays
Create Test Procedures
Evaluate 3' party interface & Communication protocols
Link in EDMS- List of HW /SW solutions & typicals
MOM - List of Std and Non Std solutions
Evaluate SAR and produce Application SW Safety Requirement Spec Review
Data to PIMS (Managment Systems) System Topology Checklist
4.2.2.1 Activity input The inputs to this activity will be design basis, and updated FDS.
a. b. c.
ABB Oil & Gas Library documents FDS Specification & Configuration from 800xA Sales Wizard
4.2.2.2 Activity description The following activities will normally be performed in this stage:
a.
Identify, list and if necessary describe hardware and software solutions and typical to be used in the project, including project specific solutions. Identify, list and if necessary describe solutions and typical for graphic displays to be used in the project, including possible project specific solutions. Evaluate the Network configuration. Identify and if necessary describe possible data transfer to IMS. Identify and if necessary describe possible external communication links. Copy the HW/SW solutions from ABB Oil & Gas Std Library into EDMS project folder structure.
b.
c. d. e. f.
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4.2.2.3 Control documents SAR Customer requirements
4.2.2.4 Activity output Output documents, such as Guidelines are documents that will be used as they are. These documents may be modified depending on customer requirements. Guidelines are found in ABB Oil & Gas Std Library.
a. b. c.
Programming Guideline for NON SIL Modules Programming Guideline SIL Modules HW Design Guideline
Other documents to be produced:

a. b. c. d. e. f. g. h. i. j. k.
List and description of external communication links List of solutions and typicals for graphic display Link in EDMS- List of HW /SW solutions & typicals System Topology Cabinet Footprint Power Consumption and heat dissipation Test & Inspection plan to be updated Application SW requirement Specification ? Create Test Procedures Data to PIMS (Management Systems) Control Typical for Electro Control (PMS, ECS)
MOM/Checklists to be used and signed:

a. b.
MOM - List of Std and non-std solutions Checklist for Application SW requirement Specification ?
4.2.2.5 Material
a. b.
MS Word Adobe (.pdf)
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Produce Detailed Design documents and SAR
Based on the FDS and evaluated solutions Detailed design documents and SAR shall be produced. DFDS are typical detailed descriptions of a design of the system to be delivered DFDS for F&G Asset system
SAR og nr vi trenger en SAR. 4.2.4 Exchange Data
The purpose of this activity is to define and document the data exchange format based on hardware and software solutions to be utilized in the project. The process differs between the Technical exchange of I/O information and other requirements for documentation formats.
CONTROL INPUT OUTPUT
Other Technical input data: C&E, Detector layout, Sequence diagrams, etc
4.2.3 Exchange Data

Check input for consistency 4.4 Query management
SignalList from Customer or EPC
ABB Import signallist new Version & Verify Content SPI
Report Signal List abrivations
VOR
NO
Signal List or data Compleet
NO
Report Deviations to EPC
3.3.2 Change Mangement
YES
YES Make I/O Allocation pr Application/Node? SPI Report List of HW modules
Save version
SPI Check point before proceding
Tools & Methods SPI FD BDM Autocad Excel
SPI
Change Management System
4.3 Purchase Requsition
4.2.4.1 Activity input The inputs to this activity will be I/O list from or other input data from EPC. Typical documents:
a. b. c.
I/O signal list (Excel or SPI file) C&E Detector Layout
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4.2.4.2 Activity description The following activities will normally be performed in this stage:
a. b.
All input to be stored in EDMS The I/O list must be evaluated for changes and consistency. The I/O list shall be imported as a new version into a tool (SPI) and a Validation report to be produced, containing changes and errors of any kind. C&E, Layouts, sequence diagrams to be evaluated
c.
4.2.4.3 Quality control activities The project shall identify any deviations or changes in the signal list from EPC or Customer. The Evaluation is based on the Change report in SPI. 4.2.4.4 Activity output
a.
Deviation report - The deviation report must be handled by the Change Management process (4.4) in case the deviation is of VOR or other issue. HW design and procurement may be affected and must be updated. This activity shall also be accepted by the Change Management process in order to proceed.
b.
4.2.4.5 Material
a. b.
SPI Smart Plant Instrumentation Change Management System
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Basic Engineering Design Review
The basic engineering activities will be followed by a design review. The need for project external review should be evaluated, depending on project technical complexity. The purpose of this activity is to stop and review the baseline that has been established by the project before continuing with Detained design. The purpose is to avoid any design mistakes and verify the robustness of the design. A functional Safety Assessment must be performed before continuing with Safety related activities in Detailed Design.
CONTROL
BASELINE Design Baseline
INPUT
FDS
SAR
IEC61511 requirements
Standards
OUTPUT
4.2.4 Review Basic Design & FSA
MOM/ Beasic Design Review Meeting - List of deviations and uncertancy
Produced documents from Stage 4.1 /4.2
Is the design according to Requirements and Scope of supply? Final Evaluation before Detaied Engineering can start
MOM/Checklist FSA
Perform FSA
MOM FSA
Acceptance to proceed GO
Ready to Purchase Update Project Plan
Safety Verification and Validation Team (FSA) 4.2.2 Basic Engineering HW and SW
NO GO
GO
Process Feedback to Line organisation
Process defined in ABB Quality system
MS Word
.pdf
4.2.5.1 Activity input The inputs to this activity will be documents produced earlier in stage 4.1 (Design Basis) and 4.2 (Basic Engineering and Review). 4.2.5.2 Activity description The following activities will normally be performed in this stage:
a.
Evaluation of the complete design. Use the prepared MOM Basic Design Review Meeting. Update the Project Plan regarding, Detailed design, Test & inspection The independent Safety Verification and Validation Team shall perform a FSA in order to evaluate the design against Requirements in IEC61511.
b. c.
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4.2.5.3 Quality control activities FDS to be used as the control document. SAR IEC61511 Guidelines Other Standards referred to in Customer Requirement Specification.
4.2.5.4 Activity output The output from this activity will typically be:
a. b. c. d. e.
List of deviations and risks Updated project Plan MOM from FSA MOM - Process evaluation and improvements to Line Management Redo design cause of Major findings.
Dependent for the nature of the findings in this activity the document Functional Description may be needed to be update. 4.2.5.5 Material
a. b.
MS Word .PDF
4.2.6
FSA
The purpose of this activity is to perform a Functional Safety Assessment on all issues related to IEC61511 requirements. The FSA is mandatory in respect to IEC61511. 4.2.6.1 Activity input The inputs to this activity will be design basis, and updated FDS. 4.2.6.2 Activity description

The project shall request the Safety Verification and Validation team to perform a FSA. The FSA shall contain traces of :
a. b. c. d. e. f. g.
Solution Baseline Configuration Management Documentation and Change Management (Traceability) Test & Verification Competence of the engineers in the Basic Engineering Stage. Knowledge of IEC 61511. Design Documents SAR - present Safety Guidelines - present
4.2.6.3 Control documents

a.
IEC 61511
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4.2.6.4 Activity output

a. b. c.
MOM from FSA. MOM non Safety requirements Go or no-go on design
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PURCHASE REQUISITION Produce Purchase Requisition to Supply Management
The purpose of this activity is to validate and prepare Purchase requisition, Packing and shipment .
CONTROL
INPUT
OUTPUT
4.3 Purshase Requsition

Documents from 4.1 Design Basis 4.3.1. Produce Engineering Inout to Supply Management Checklist for purchase Order Request Ref Stage 6.2.2
Inout Package to SM including:
Documents from 4.2 Basic Engineering and Review
Bill of Material Technical Specifications Project Specisifations
Scope of Work
Laws, rules & regulations
SDRL Stage 6 Test & Verification Requirements
Contractual requirements
Bill of material, Wizard from Sales
Manual Purchase requsition Ref Stage 6.2.2 Or Generated from SAP
ABB Standard Procedure
4.3.2 Technical Requirements for Packing, Shipping, Storage and Preservation
Work Instriction for Packing, shipping, storage and Storage Ref Stage 6.2.4
Packing list Ref Stage 6.2.4
Suppliers Procedure
800xA Wizard
MS Word
.pdf
4.3.1.1 Responsibility The system responsible engineer (lead engineer) will be responsible for this activity. 4.3.1.2 Activity input The inputs for this activity will be
a. b. c.
Design basis FDS from bid phase Possible changes from bid to contract
4.3.1.3 Activity description The FDS from bid phase will often focus on product and sales related information. In the project phase, more process related information should be included in the FDS, and references to typical solutions and work methods should be given. Changes in the scope of supply, which can have influence on the content of the FDS, may also have occurred. 4.3.1.4 Quality control activities Supply Management shall .
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FDS updated, and issued to customer for review. 4.3.1.6 Material

a. b. c.
800xA Wizard MS Word .PDF
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Technical requirements for Packing shipping Storage and Preservation
The purpose of this activity is to update the Functional Design Specification (FDS) from bid phase. 4.3.2.1 Responsibility The system responsible engineer (lead engineer) will be responsible for this activity. 4.3.2.2 Activity input The inputs for this activity will be
a. b. c.
Design basis FDS from bid phase Possible changes from bid to contract
4.3.2.3 Activity description The FDS from bid phase will often focus on product and sales related information. In the project phase, more process related information should be included in the FDS, and references to typical solutions and work methods should be given. Changes in the scope of supply, that can have influence on the content of the FDS, may also have occurred. 4.3.2.4 Quality control activities The FDS will go through an internal review before being issued to the customer. The need for project external review should be evaluated, depending on project technical complexity. 4.3.2.5 Activity output FDS updated, and issued to customer for review.
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CHANGE MANAGEMENT
The purpose of Change management is to have a systematic way of handle any issues that can be questioned during the project life cycle. Change management helps the project keep track of any change and the administration of each issue. The Change Management Process is a generic process used in all Stages and steps of Project Execution.
Change Management includes management of: a. Errors b.Changes (Modifications) c.Omissions A VOR,NCR and/or Query might be the part of the cause or the solution of a Change.
= SIS specific documents = ABB internal and delivery docs. may include SIS activities = Customer documents Project Management Stage 3 INPUT Functional Safety Management Manual Engineering Handbook Stage 4 OUTPUT Establish A Change database Evaluate - Review Change Functional Safety Change Impact Assessment CONTROL
Mail / Correspondance
4.4 Change Management
Updated FEMs
Testing
Register Error or Change or Omission
Plan -Time -Cost -Resource YES
Approve
Implement
Close - Update Status
Attatchment to Query or FEM: Change Impact Assessment Form
Corrective Action NB! A change is related to the following activites and time spent: Review-Plan-Approve-Implement-Close - Update Design Documents - Update User Manuals - Update Test documents - Update HW drawings - Review documents - Programming -Testing according to Requirements - Update EDMS, SPI, CMDB etc Updated Design Documents
4.1 Design Basis 4.2 Basic Engineering
YES Reject YES Clarify with EPC or Customer
Who has athority to issue change requests? See Communication Plan Stage 3
Send VOR request Stage 3.2.6 Product Error NCR
Updated Test Documents
Query to Customer
Generate Internal Reply
VOR request
Register Query
Categorise Query (Internal/External)
Approve External for sending
Evaluate Reply
Close - Update Status
Non Conformacy Report (NCR)
Reject Remedy - Configuration Management - Change Management
The closure of a Query might result in the creation of a change
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The Project Manger is responsible for the following activities:

a. b.
Establish Change Management System Handling of commercial issues connected to changes
The system responsible engineer (lead engineer) will be responsible for this activity.
c. d. e. f. g.
Weekly follow up Evaluate Plan Assigning personnel to execute Close activity Register fault Opportunities Register customer requirements, change issues etc.
All project members engineer (lead engineer) will be responsible for.

a. b. c.
4.4.1.2 Activity input The inputs for this activity will be

a. b. c. d.
Correspondence Findings Corrective actions Registration of errors or malfunctions
4.4.1.3 Activity description The change process is generic and shall be used in every step/stage during Project Execution. The Change Management Process Tool shall be established as a mandatory action in the start of the project. 4.4.1.4 Quality control activities Embedded in process tool and follow up. 4.4.1.5 Activity output The output of the process is to maintain the Change registry
Follow-up report
a. b. c. d.
VOR request Updated documentation, design & test. NCR Store Functional Safety Impact Change Assessment Report in EDMS.
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The Tools to use is the Remedy database, and the Change Management option. Users must be defined. The following Quality and follow up functionality is embedded in the tool:
a. b. c.
Correspondence follows the case Assignments and priorities Task and case tracking (Mandatory for IEC61508/61511 issues)
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DETAIL ENGINEERING
After completion of Basic Engineering and the design the go ahead is to start production. Concurrent engineering shall be a goal to achieve. Parallel activities and coordination are crucial factors for success. The following Main activities are included in detailed engineering.

Technical Kick-off Meeting System Set-up Establish SW & HW Typical HW Design Application Programming System Detail
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Technical Kick-off Meeting
The Purpose of the Technical Kick off is to prepare the team for the coming stages. This applies to Project Plans, Project Rules & Guidelines, Use of Tools, VOR and Query handling, Maintaining Documentation etc NOTE! This technical meeting is in addition to stage 3.1.1.4 Expand Project Team
4.5.1.1 Responsibility System responsible is responsible for holding the Technical Kick-off, and project engineer will normally be responsibility for this activity. Definition of project specific responsibility is to be defined in the document Project Description. Project Manager is responsible for stage 3.1.1.4 Expand Project Team. 4.5.1.2 Activity input

Template for 4-1-5 MOM technical Kick-off Meeting Vital interface information, meaning any information that is relevant to the production of HW, SW, Plans and documentation
4.5.1.3 Activity description The Technical Kick-off meeting is an internal project meeting where technical scope and Design is presented to each member of the production team and lead personnel. Stage 3.1.1.4 Expand project Team includes project plans, milestones, project description and other commercial and administrative topics.
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4.5.1.4 Quality control activities In conjunction with stage 3.1.1.4 Expand Project Team a Technical Kick off meeting must be held for all members of the production team and lead personnel. For each new member, a minimum technical kick off is required, to ensure that task and projects rules are followed and understood. 4.5.1.5 Activity output
Record of 4-5-1 MOM Technical Kick-off meeting.
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The purpose with this process is to set-up the 800xA system in the correct order and to verify the completeness and performance of the system before any other application is included. This process makes sure that the project is able to maintain and store vital information. This information is to be delivered and used in later Processes/Stages.
4.5.2.1 Responsibility IT Lead is responsible for this activity. IT Lead reports to System Responsible before startup and after completion. 4.5.2.2 Activity input Input information is crucial for System Set-up. Performing System set-up without this information has no purpose and will cause hazels later on in the project. The System set-uper shall use the 800xA installation manual to look-up information in each step described in short word below. The following input documents/information must be obtained:
System Topology o o System connections and network IP addresses & Tagnames (provided by customer) See release notes in ABB documents and files from Solution bank. MS security updates found in ABB Oil & Gas Library bank or in MS update.
Service Packs & hot fixes o o
User information; password & access rights (provided by customer)
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System extensions & roll-ups Licenses: o o o o o Licenses for MS OS OEM (Bundle) licenses Licenses for MS Office OEM (Bundle) licenses Oracle licenses System recovery/ backup license (Ghost, Backup exec) 800xA
4.5.2.3 Activity description Initial setup: Mainly to configure the Domain Controller and prepare other servers and clients

Disk partition on servers and clients Main partition large enough for 800xA SW, recommended 40GByte Verify and install Microsoft OS service packs and hot fixes on all machines. (See ABB doc) IP Addresses and Machine naming, gateways, net masking, domain name or workgroup name Define users, password and rights on domain controller o Use standard 800xA users Rights for each user Rules of username syntax Rules for password syntax Etc ( See 800xA Manuals ) Time Zone Key board language Location (Site location) Time & Date syntax Input Language (Note! Must be US-English) Define policy - Domain o o o o
NOTE! Do not change domain name and server ip- addresses
Regional options o o o o o
Network:

Set-up the network according to System Topology drawing. Switches Configuration of Switches if necessary (if Fiber rings)
Hookup: Connect servers and join the domain

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Set up of each network port according to 800xA installation manual. Typicaly: o o
Create image (Backup) recommended DVD media.
800xA pre- installation:

VB on Engineering Stations and Aspect servers to deployment MS office, professional, on all machines. Licenses for 800xA and other MS products see input License.
800xA installation:
Start installation of 800xA and follow the Wizard. Note ! When asked for User type in <Domain name>\<User name> Complete 800xA installation.
Post 800xA installation checks:

Verify ip-addresses on all network ports Verify Name and domain membership Verify 800xA system o See Service structure System status viewer, in plant explorer Aspect system up and running
Installation of additional system files:
Note! Stop necessary processes prior to installation of additional service packs etc.- see release notes Install and include service packs, follow procedure in release note. Install and include roll-ups, follow procedure in release notes for roll-up. Install and include own System extensions Import Software Typical library (ABB Oil & Gas Library) o Install primitives on all clients and servers.
Backup & Cloning: This is the time to backup the system System Backup (Maintenance structure in plant explorer) You have now possibility to clone the completed servers except the domain. Cloning:

Create image. Restore image on target.
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Change SID and rename computer name and ip- address on target
Post installation Configuration (see manual):

Control network Connectivity and OPC server setups Affinity configuration Event collector Asset Optimizer ( to be explored) HART control network Time Synchronization (domain & controllers) Firmware upgrade of controllers. RNRP IP forwarding, redundancy (See System topology) Cyclic System Back-up
Virus protection: Virus protection program can harm the system. It is important to set-up the Virus program with minimum of functionality, but enough to protect your system. It is recommended to include the following typical functionality. See the Virus protection manual by ABB.
Scanning of added storage media diskettes, flash memory sticks
Validation & Verification: This activity is to make sure the system is healty and system is ready for receiving libraries, application and graphics etc.
Verify 800xA system o o See Service structure System status viewer, in plant explorer If fault indications, investigate and fix. On OPC server panel verify DA and AE connections o If fault indications, investigate and fix. Path to a config file is correct. Verify content of config file is correct. Verify Auto load settings
OPC servers o
System Back-up
Afterwards:
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In projects with several 800xA systems e.g Engineering System + Development System + Training Simulator + Testing System it is important that all systems are consistent in configuration. Common configuration, included in each system:

Same System extensions Same SW revisions (MS, Rollups etc)
Adding a New Client & Server:
See Cloning.
4.5.2.4 Quality control activities Checklists:
Checklist for System Set-up to be used and signed.
Test procedures: Small systems (>= 10 servers)
Minimum Test procedure System Test & Verification to be used and signed (2 day testing) Medium Test procedure System Test & Verification to be used and signed (5 day testing) Full Test procedure System Test & Verification to be used and signed (15 day testing)
Medium systems (< 10 < = 20 servers)
Large systems (< 20 servers)
4.5.2.5 Activity output Testing: Network file over according to RNRP Backup recovery of clients & Servers (8 hours test) Fail over test of redundancy Verify affinity settings Switch test

set-up after blackout broken ring
Configuration Management: Normal procedure in all projects is to document the System configuration. The following documents and information shall be produced. The project must pay special attention to IEC 61511 requirements regarding traceability on safety equipment, firmware and application.

Software revisions document (Information collection tool) License document User, password, addresses, HW id and tag name document
The files and information must be stored in EDMS or project disk or CRDB.
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Establish SW & HW Typicals
The purpose with these activities is to establish the SW solutions and HW solutions to be used in the project. From earlier process in Basic design, new or modified solutions are detected. These solutions must be produced and tested before included in the project library. Special attention to SIL required solutions is needed. It is recommended to include personnel with knowledge of ABB oil & gas Std library.
4.5.3.1 Responsibility Recourses & Skills:
SW solutions o know-how of how to produce SW solutions in 800xA, meaning programming & documenting design, requirements and test. Guidelines for SW development to be followed. Engineer with experience of how to define a new typical, document and test the solution. Guidelines for HW solutions to be followed.
HW solutions o
System responsible for Library solutions is responsible for QA assurance. FB/HIS responsible to approve all records. Safety Manager or Safety responsible in the Project. Authority?
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FDS From Basic Design SAR From Sales Alarm Philosophy from EPC or Customer. Documents from 4.2.2 Basic Engineering HW & SW Vital Interface documentation (Communication Protocols) HW definition files:
Generic SW description to establish communication between 800xA and 3rd party. o o .gsd files is delivered by HW component supplier, The .gsd file is converted to a HW definition file and imported to 800xA Control IT.
Examples of HW components: Profibus against ABB VSD drives. Alarm Development Procedure: Contains Conversion rules from logical priorities (EPC) to ABB technical priority numbers. Contain Justification of each alarm presented in the system (for Info & test). 4.5.3.3 Activity description This activity is meant for those who are going to produce a new Control Module, Function Block or HW typical. It is mandatory to follow the V-model in all its steps. Requirements from different input or control documents must be traceable in the Detailed Design documents and test documents. 4.5.3.4 Quality control activities When a new Control Module is made, these Guidelines can be used:

Programming Guideline Safety Modules IEC61511 Programming Guideline NON SIL Modules HW Design Guideline o A project Specific Guideline of how to produce, usage of components, cabinet requirements, location of components, Wires and Cables to be used.
ISO 90003 Software engineering. Guide to the application of ISO 9001 Computer SW
Instruction Line Organisation Alarm philosophy Alarm Development Procedure 4.5.3.5 Activity output If there is need to modify or create new Control Modules/Function Block or HW Typical the project must produce the following documents. Otherwise proceed to next stage. Design Document FB/CM/HIS Test Spec/Record FB/CM/HIS Design Document HW Typical Test Spec/Record HW Typical Checklist Code Review
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Update the ABB Oil & Gas Lib.
4.5.3.6 Material Tools and Methods which can be used are: a. SPI b. FD c. BDM d. Autocad e. Excel
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4.5.4.1 Responsibility HW Lead is responsible for this activity. 4.5.4.2 Activity input There are 3 types of Input information: 1. Component data 2. Tag/Signal data 3. Documents form Sales Component data: The purpose with component data is to update the Engineering Tool with all its components. The components data will be used in reports and construction data later in the HW design process. Tag Signal Data: The Tag /Signal data is information provided by the EPC. The Data Exchange format was defined with the EPC in the Sales process or in the beginning of the Engineering Process. The Tag signal data in an early stage can be limited, but must include all parameters specified in the Data Exchange format before SW production can be started.
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It is important to transfer all relevant Tag/Signal data for both SW and HW design. For HW design less data is required. See data exchange format. When defining the data exchange format with EPC the full range of data shall be agreed upon. Normally HW information is established earlier than SW information by the EPC. Meaning typically alarm limits, units, gain, HIS display no is not present at this stage. Tag/Signal data must be evaluated for faults & Changes before use. Documents from Sales: From the Sales Process a 800xA Wizard File is handed over to the Project. The Wizard files include: a. Topology drawing b. Controller & I/O Cards specification and location c. I/O count d. Power & Heat dissipation calculations e. Evaluation of the configuration 4.5.4.3 Control Documents The Guideline for Tools and Methods is
An ABB Line Management instruction of what tools and methods to use. This Guideline shall be followed.
The HW Design Guideline is
A project Specific Guideline of how to produce, usage of components, cabinet requirements, location of components, Wires and Cables to be used.
4.5.4.4 Activity description The Guideline for Tools and Methods describes what tools to use to construct or produce the required reports, information and documentation. The Activity is divided in to 2 parts. Part 1 is for component construction and update. Without all relevant components included in the tool HW construction will not be able to generate the desired output. Part 2 is the HW construction part where the engineer constructs the System cabinets & RIO cabinets with Controller, I/O cards, Relays, Barriers, Fuses, Cables, Power and communication and Allocates Signals. Part 1: General information: All components to be defined in the tool must include all its used connections.
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Such as, I/O wiring termination socket identification, Power connections identification and Communication socket information. For the Electrician to understand how to and where to connect the wire or cable, the definition of a connection is the real labeling in the component it selves. Define/Construct HW Typicals in a Tool: The HW typical is defined by engineers with instruments and electrical skills. HW typical consists of an I/O card, a Termination socket, Termination information (number of signal wires) and additional equipments . Each HW typical has a reference name. Defining the HW Typical in the Tool enables the user to allocate a field signal to a matching HW typical during I/O allocation. For Spare part lists and Cabinet lists reports can be made for counting components. Define/Construct ABB components in a Tool All ABB components used in the project must be defined in the tool. The following information must be included: Name, Article number and data, Description, Technical specifications (such as: weight, metrics, power connections, signal connections and communication connections) Information to be used to produce desired output:

I/O cards Power
Define/Construct 3party components in a Tool All 3rd party components used in the project must be defined in the tool. The following information must be included: Name, Article number and data, Description, Technical specifications (such as: weight, metrics, power connections, signal connections and communication connections) Information to be used to produce desired output:

Modems Barriers Relays Switches Cables & Wires Etc.
Loading SPI with Tag data. - Get change report if an existing database is already available
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I/O allocation is to assign a signal to a Channel on an I/O card. Though I/O allocation can be done efficient; the engineer shall consider each signal requirements before allocation to a HW typical and channel. The I/O allocation can start up as a CET activity, as early as possible. This will increase the quality of the design and preventing re-design cause of wrong channel or HW typical assignment. The process of assigning a signal to a cabinet/node, HW-Typical and channel shall be performed as a corporation between the EPC instrument responsible, ABB HW engineer and SW Node responsible. Before Channel assignment the signal must be assigned to a Node/Cabinet and associated with a HW-Typical. I/O allocation must be performed before x-wiring can be done.
NB! Do not mix different voltage levels.

Typically is the voltage level or current level different for an F&G system. (0-20mA) Parallel equipment, A & B side
X-wiring: After I/O allocation, X-wiring activity can start. Automatic X-wiring functions shall be used whenever present in tool. For any automatic function that can be used, both ends must have the same reference, TAGNAME. Barriers and relays are component placed in between the channel and the Termination unit. The user needs to connect one side of the barrier to the I/O channel, to establish a reference for the automatic Xwiring function to work properly. X-wiring reports and cable labels may now be produced. Moving signals from one node/cabinet to another is done in the tool, by disconnecting the wires to the channel and reallocated the signal to another node/cabinet and assigning it to the new channel. Power Connections: All I/O cards and termination units of a HW typical shall be defined with Power connections. The power connections shall be labeled as they are described on the component it selves. Connect power wires between the modules. Cable lists and labels may now be produced Communication Connections:
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All Communication connections to a component shall be defined in the tool. Detained information of the type of communication media, socket etc shall be defined. The communication connections shall be labeled as they are described on the component it selves. Connect communication cables between the modules. Cable lists and labels may now be produced Update CMDB: After and during construction the project configuration representing types, articles, versions etc must be maintained. Information shall be stored in a Configuration Management Database Final activity of HW design is the HW assembly. This activity is done by an electrical/mechanical assembly shop. The assembly company needs to have the necessary certificates to issue CE-compliance. .. To start-up the assembly activity following must be prepared and available:

Approved Hardware Documentation Completed received equipment. PO / agreement with the workshop. The assembly company needs to have the necessary certificates to issue CE-compliance. ..
The work starts by hand over the above items and perform a short presentation of the scope of the work together with the workman that shall do the job. The responsible engineer must be available for clarifications and follow-up. After receiving the Assembled HW, inspection & test on the equipment is performed. Use the General Checklist for HW inspection. The test is performed as part of the Integration Test.
4.5.4.5 Quality control activities Evaluating Input: For each revision of the EPC input an evaluation or change report must be made. Evaluation of the input data is essential to detect faults, errors or diversions. Module test: The module test means a test limited to a piece of equipment or function, which may be practical to be tested separately according to dedicated test procedure. Such modules test can be:

Typical Communication to RIO, Profibus Typical Instrument loop including Modem, relays and barriers
The need for such module tests shall clearly be identified and defined in the Quality Control Plan, and be recorded. Cabinet test: General HW test after assembly has been made is part of the Integration test.
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HW Visual inspection test To be recorded.
Loop testing: Is performed preferably as an own activity either between IAT and FAT, or after FAT. Loop testing is anyhow performed in the Installation & Commissioning phase of the project. 4.5.4.6 Activity output The following output is produced. 1. Circuit diagrams a. System supervision b. Communication c. Power 2. Cable lists 3. Cable & Wiring labels 4. X-wiring lists 5. Fuse lists 6. Spare Part list
4.5.4.7 Materials

SPI Smart Plant Instrumentation 800xA Sales Wizard AutoCad Remedy CMBD module
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Application Programming
This activity is only applicable when program languages and skills deviates form controller requirements. The purpose is to produce program code according to specification made in the basic engineering phase.
4.5.5.1 Responsibility

System Responsible authorizes start of this step. SW Lead is responsible for this step SW Lead is responsible for Checked by signature in all documents for this stage. IT Lead is responsible for loading SW libraries and other firmware software. HW Lead is responsible for I/O allocation SW Application Engineer is responsible for production and testing. Competent engineer is required for SIL applications, if not supervised by a competent body in IEC61511.
Signal data in Engineering Tool
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The Stage 4.2.3 (Data exchange) must have been performed in advance of this activity. SCD - System Control Diagram If applicable for the application engineer to program the application, (from EPC) Sequence Documentation, (from EPC) Sequence flowchart, (from EPC) PSD/ESD Hiearki, (from EPC) Alarm Development Procedure, (from EPC or ABB) Safety Area Chart, (from EPC)
Pre requisites:
Data populated and prepared in Engineering Tool (SPI) o HW Lead and SW Application Engineer verify content of tag information. HW Definition Files included in Application Programming Tool All SW libraries loaded into target system. Description of the actual logic P&IDs, Design Documents (SCD), C&E etc are available. o Design Input documents must be stored in Document DB. All test documents has been produced.
4.5.5.3 Activity description Note: Database signal list should be received from customer on electronic format, from where it can be transferred into the target system without needing to type everything manually. The preferred format for control logic is System Control Diagram (SCD) if possible. Detail regarding implementation is dependent of the actual used technology, which may be ADVANT, AC800 or CMC70 etc. A general reference is therefore made to the system manuals for the actual equipment. Implementation of standard protocols like MODBUS or PROFIBUS is performed according to general system guidelines for such work in addition to actual agreed signal specification. Alarm Development Procedure: Contains Conversion rules from logical priorities (EPC) to ABB technical priority numbers. Contain Justification of each alarm presented in the system (for Info & test). The Tools & Methods that can be used are:

SPI Smart Plant Instrumentation FD BDM AutoCad Excel
4.5.5.4 Quality control activities Module Test

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The module test means a test limited to a piece of equipment or function, which may be practical to test separately according to dedicated test procedure. Such module test can be: 1. Basic HW module test 2. Module test software typical 3. Module test communication Protocol 4. Module test special calculation algorithm. The need for such module tests shall clearly be identified and defined in the Quality Control Plan. Guidelines that can be useful are:

Application Programming Guideline Application Programming Guideline, Safety Applications
Other documents:

Alarm specification FDS Functional Design Specification SAR SW SRS Safety Requirement Specification o Application SW SRS
4.5.5.5 Activity output The application must be implemented and tested, according to quality procedures and requirements.
Signed Application Test records
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The purpose of this activity is to add details and complete the operator graphics according to the specification made in the basic engineering phase. This process is closely related to the Application Programming process. Activities in this process must be prepared in advance of the application programming process, even though this is a concurrent process to the Application Programming process.
4.5.6.1 Responsibility Depending on the work and responsibility matrix in the project this process is a concurrent Engineering process with the Application Programming and HW Design process. Overall responsible for this process to be executed is the Projects System responsible. Node or Sub System responsible is responsible to organizing input, activities and checking the output of part of this process. 4.5.6.2 Activity input Inputs are sorted into the detailed activities described for this process: Definitions: General Definition ?? Hardware Definition 1. HW definition files for components used in the project. Typically Communication and I/O Cards files, Profibus files, Foundation Fieldbus instrument and component files. Alarm Definition
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2. Alarm specification Information Manager Definition 3. Log group & Log files HMI Design (Operator Environment Definition) 4. PSD/ESD Hiearki Safety displays 5. F&G detector Layout - F&G room/area displays 6. Plant area chart F&G overview displays 7. Safety Area Charts C&E displays 8. P&ID Process displays Work Place definition 9. A File : Default Workplace definition from ABB O&G library
4.5.6.3 Activity description After the Initial Set-up, validation and test of the system, System Details shall be added
Application Programming
System Detail
Initial System
The Process can be divided in to 2 main topics.

1. 2.
Including definition files Operator Graphics
Load of HW definition files:

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Generic sw description to establish communication between 800xA and 3 party. .gsd files is delivered by HW component supplier, The .gsd file is converted to a HW definition file and imported to 800xA Control IT. Examples of HW components: Profibus against ABB VSD drives. Work place definition:

Alarm definition: (standard ABB O&G Work Place), Implementation of Alarm Philosophy. Workplace file
Building Operator Graphics according to Project HMI Guidelines. 4.5.6.4 Quality control activities Operator Graphics shall be verified according to Project 4.5.6.5 Activity output Checklist 800xA Wizard
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4.5.7
Documentation
The purpose of this activity is to be a remainder that changes made in the detail-engineering phase may have impact on existing documentation and that these documents must be updated.
4.5.7.1 Responsibility 4.5.7.2 Activity input a) SMDL b) Internal Documents c) Design input 4.5.7.3 Activity description Internal Procedures for Document Control
Take each Document and run it through the Document Checklist, and then store the Documents in a Document Tool Review the documents Issue according to SMDL in a submital form Send
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Update the Manufacturing Record Book Update Project Documentation Final Issue
4.5.7.4 Quality control activities Contract requirements for Document Control Document Checklist (Guide) 4.5.7.5 Activity output The output from this activity is typically:

Hardware documentation Complete Hardware Program code / logic for controllers Operator graphical display Updated project documentation
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Design Review / System Verification
The purpose of this activity is to be a remainder that changes made in the detail-engineering phase may have impact on existing documentation and that these documents must be updated.
4.5.8.1 Responsibility System responsible is responsible for this activity. 4.5.8.2 Activity input 4.5.8.3 Activity description 4.5.8.4 Quality control activities FSA 4.5.8.5 Activity output
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TEST AND VERIFICATION
The purpose with this activity is to verify and document that the produced product is complying with specifications and requirements according to predefined tested defined in the Quality & Safety Control Plan.

Module Test (if necessary), already part in stage 4.5. Internal Acceptance Test (IAT) Factory Acceptance Test (FAT)
The FAT test will be identical to the IAT with the exception that the customer will participate and witness the FAT test. The FAT document must be approved by the customer before FAT can start. Revisions on the design input must be included in FAT document and approved by the customer. The need for such module tests shall clearly be identified and defined in the Quality Control Plan.
4.6.1
Test Planning
The purpose of this activity is to make a plan of the basics for the IAT and FAT tests.
4.6.1.1 Responsibility 4.6.1.2 Activity input

FDS SAR Documents from 4.1 (Design Basis) / 4.2 (Basic Engineering and Review) IAT/FAT Procedure from stage 4.5 (Detail Engineering)
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Project Plan Stage 3 4-6-1 MOM - Test Planning Queries / FEMs
4.6.1.3 Activity description There are three fields that might be wise to go through in the MOM to make an optimal Test Plan and to establish Log books:
Information check o o o o o o o Make sure that the FAT procedure is approved and issued Verify completeness of Project Documentation Reuse of previous Test Records from other projects Check for queries to be solved before IAT/FAT Verify the completeness of HW Cabinets, wiring and documentation Verify the completeness of delivery system (Network) Verify the completeness of the applications
Tools o o Verify the Tools/Instruments that are necessary for the IAT/FAT Check that the Test Area is in good order, and that the equipment are in place
Accomplishment o o Identify the Resource to participate in IAT/FAT Parallel Testing / several test teams ?
4.6.1.4 4.6.1.5 Quality control activities

Test and Inspection plan HES o All HES activities shall be planned with involved personnel

4-6-1 MOM Test Planning Test Plan for IAT and FAT; time, area, equipment, personnel
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Prepare Test Procedure and Protocol
The purpose with this step is to write down Test Procedures and Protocols for IAT and FAT, in such a way that the tests can be accomplished in the next steps.
4.6.2.1 Responsibility SW Lead is responsible for these activities. 4.6.2.2 Activity input

FDS SAR Documents from 4.1 (Design Basis) / 4.2 (Basic Engineering and Review) FAT test procedure Project Plan Stage 3 4-6-1 MOM Test Planning
4.6.2.3 Activity description Use the outcome from the 4-6-1 MOM and previous Test Procedures and Protocols from other projects. Update the IAT/FAT Procedures and Protocols to fit this project,
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4.6.2.4 Quality control activities Test and Inspection plan HES
4.6.2.5 Activity output Test Procedure and Protocol for IAT and FAT
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Internal Acceptance Test
The purpose of the IAT is to verify that all aspects regarding the produced product is complying with the requirements, and will normally cover following types of verification:
Visual Inspection shall verify that all equipment is in accordance with the arrangement drawings, which components are in proper conditions and are installed in accordance with good fabrication practice. I/O Test shall be carried out to verify that all I/O input channels are functioning according to specifications. Application Test shall verify that the system is configured with specified number of signals and variables, and that the correct calculation formula is applied. System Test shall verify that overall system specification is meeting the contractual requirements.
CONTROL
FDS
SAR
INPUT
OUTPUT
4.6.3 Internal Acceptance Test

Test & Inspection plan HW Test Visula Inspection Load Application & Verify System Status Checklists HW inspetion 4.6.2 IAT Procedure Concurrent Engineering Test each module/ application If applicable I/O test
(Try not at this stage)
Power up systems
Verify System Idle
Signed IAT Test Protocol Start 3'party systems Load 3'party application / Communication & Verify System Test each 3'rd party module/ application
No
Run System Test Update Test and Inspection Plan Updated Test & Inspection Plan
4.4 Use Query Management to log deviations
4.6.3.1 Responsibility 4.6.3.2 Activity input

IAT Procedure from 4.6.2 Test and Inspection plan
4.6.3.3 Activity description Begin with a HW Test Inspection Power up the systems Verify the System idle Load Application and Verify the System Status
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Each module/application shall be tested with I/O-test: If it is applicable: a. Start the 3rd party systems b. Load 3rd party application, communication and verify systems c. Test each 3rd party module/application d. Run the System Test
Else: Run the System Test
If the test shows deviations, it shall be Logged according to 4.4 Query Management. Update the Test and Inspection Plan 4.6.3.4 Quality control activities

FDS SAR Test and Inspection Plan

Checklist HW inspection Signed IAT Test Record Updated Test & Inspection Plan
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4.6.4
Factory Acceptance Test
4.6.4.1 Responsibility System responsible is responsibility for this activity. Definition of project specific responsibility is to be defined in the document Project Description. 4.6.4.2 Activity input

Checklist HW inspection FAT Procedures from 4.6.2 Signed Records from IAT Design Basis Functional Description Complete Project Documentation Complete Hardware Complete Software functions
4.6.4.3 Activity description The FAT test will be the identical with the IAT with the exception that the customer will participate and witness this test.
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4.6.4.4 Quality control activities

FDS SAR Test & Inspection plan
4.6.4.5 Activity output The output from this activity will be:

Approved hardware Approved software functions
When the NCR are closed the system delivery is ready for delivery to customer.
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Appendix: Words and Abridgements Description Basic Design Management Cause and Effect Control Management? Configuration Management Database Electronic Database Management Systems Engineering Process .? Excel? Factory Acceptance Test Function Block Function Designer Functional Design Specification Foundation Fieldbus Functional Safety Assessment Health Environment Security Human System Interface Hardware Input/Output Internal Acceptance Test Keyboard Muse and Screen solution Minutes of Meetings Non Conformacy Report OLE for Process Control Process & Instrument Data Interface between Smart Plant Instrumentation and 800xA Project Manager Purchase order Quality Assurance Remote Input Output
Word BDM C&E CAEX CM CMDB CRDB EDMS EPC Excell F&G system FAT FB FD FDS FF FSA HES HSI/HMI HW I/O IAT KVM MOM NCR OPC P&ID PETI PM PO QA RIO RNRP
Instruction
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Safety Analysis Report System Control Diagram Suppliers Data List (Safety systems) Safety Moduls ? Smart Plant Instrumentation Safety Requirement Specification? Software Size of deviations??? 4.2.3.4 Variable Speed Drive
Instruction
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Revisions Page (P) Description Chapt. (C) Whole doc. Issued for implementation Whole doc Issued for review Whole doc Date Dept./Init. 10.09.03/HEPE 30.05.07/STTR 07.06.06/JEER
Rev. B C

Engineering Handbook for Projects Automation

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Engineering Handbook for Projects Automation

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Instruction

Issued by department Date Lang.

NOPID/ATPA/ 08.06.2007 Oil & Gas Engineering

Engineering Handbook for Projects Automation

SKELETON: 3AJD000045-001, REV. C NOINA/DTQ; TTT VERSION: 01.02.DTI01

PURPOSE AND SCOPE

STAGE 4 OVERVIEW FLOWCHART

SKELETON: 3AJD000045-001, REV. C NOINA/DTQ; TTT VERSION: 01.02.DTI01

: database : process : decision : data : card : stored data

SKELETON: 3AJD000045-001, REV. C NOINA/DTQ; TTT VERSION: 01.02.DTI01

PROJECT ORGANISATION AND RESPONSIBILITIES

SKELETON: 3AJD000045-001, REV. C NOINA/DTQ; TTT VERSION: 01.02.DTI01

STAGE 4 STEPS DESIGN BASIS

Design Basis includes the following main processes:

Establish Design Basis Engineering Strategy

Establish Design Basis

Contract specifications Classification society requirements Rules and regulations Standards

Safety Plan Stage 3

4.1.1 Establish Design Basis

Evaluate completeness and consistency of Tech. Input doc.

Evaluate Bids Engineering strategy Project Exection Document from Sales

QA Plan Stage 3 Detailed design documentation * Vital Interface documentation

Safety Plan Stage 3

Bid correspondence (for supplementary information)

Documentation from similar projects

Input to Risk Evaluation Ref Stage 3

Quotations from sub - suppliers

ABB project libraries and typicals

Update Project Delivery Plan

SAR from Sales

SKELETON: 3AJD000045-001, REV. C NOINA/DTQ; TTT VERSION: 01.02.DTI01

NOPID/ATPA 4.1.1.2 Activity input

The input documents to this activity will normally be the following:

SKELETON: 3AJD000045-001, REV. C NOINA/DTQ; TTT VERSION: 01.02.DTI01

SKELETON: 3AJD000045-001, REV. C NOINA/DTQ; TTT VERSION: 01.02.DTI01

SKELETON: 3AJD000045-001, REV. C NOINA/DTQ; TTT VERSION: 01.02.DTI01

SKELETON: 3AJD000045-001, REV. C NOINA/DTQ; TTT VERSION: 01.02.DTI01

Basic Engineering includes the following main processes:

SKELETON: 3AJD000045-001, REV. C NOINA/DTQ; TTT VERSION: 01.02.DTI01

Basic Engineering, Hardware and Software

4.2.2 Basic Engineering HW & SW

Check point before proceding

Power consumption and heat dissipation

ABB Oli & Gas Std Library

Update Test & Inspection Plan (QA/Safety Plan)

List and description of external communication links

Application SW Safety Requirement Specification

Evaluate Network Configuration

List of solutions and typicals for graphic displays

Create Test Procedures

Evaluate 3' party interface & Communication protocols

Link in EDMS- List of HW /SW solutions & typicals

MOM - List of Std and Non Std solutions

Evaluate SAR and produce Application SW Safety Requirement Spec Review

Data to PIMS (Managment Systems) System Topology Checklist

SKELETON: 3AJD000045-001, REV. C NOINA/DTQ; TTT VERSION: 01.02.DTI01

4.2.2.3 Control documents SAR Customer requirements

Other documents to be produced:

MOM/Checklists to be used and signed:

MS Word Adobe (.pdf)

SKELETON: 3AJD000045-001, REV. C NOINA/DTQ; TTT VERSION: 01.02.DTI01

Produce Detailed Design documents and SAR