ICAPS SOFTWARE

ENGINEERING MANUAL

Integrated
Commissioning
And
Progress
System

ICAPS

ENGINEERING MANUAL
Index Description Date Issued by
1 ICAPS R3 10/2005 Capgemini
2 ICAPS R3.10.02 11/2007 Capgemini

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 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

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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.

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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.

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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.

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 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.

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 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.

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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.

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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 Yes Any existing SYS Number from Dictionary Character 30
Number
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

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 (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

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3. ENGINEERING IMPORT FORMAT EXAMPLES
Table 2 Example of ITEM Import File
Revision Revision Item Number Item Name Item Associated Associated Manufacturer Manufacturer Manufacturer PO Serial Comments Data1 … Data15
Number Type Type SubSystem Module Model Name Type Number Number
Code Number Code
1c 01-30-CJF-04-2S Comm. Cable From ICAB 9677 TBD C-Z-09-1 C-Z-09-1
CCR to PLC I/O
Cabinet (FW)
1c 01-30-HSL-254A CRUSHER EMERG. INST 9615 FW
STOP
1c 01-30-HSL-254B CRUSHER EMERG. INST 9615 FW
STOP
1c 01-30-JBF-04 Junction Box ZCLA 9615 TBD Foster F.W. CR-
Wheleer 102
1c 01-30-WY-01F Control Cable CABL 9615 TBD Foster
Wheleer
1c 01-30-WY-03F Control Cable CABL 9615 TBD Foster
Wheleer
1c 01-30-WY-06F Control Cable CABL 9615 TBD Foster
Wheleer
1c 01-30-WY-07E Control Cable CABL 9615 TBD Foster
Wheleer
1c 01-30-ZSH- INST 9615 FW
250A/B
1c 01-30HS-241A CR-101 - Pull Cord INST 9615 FW
Switch

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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.

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5. GLOSSARY
It is the group of STATIC and DE-
ENERGIZED verifications to be carried out in
PRECOMMISSIONING
order to ensure that the installation adheres to
the Project Engineering Documents.
It is the group of DYNAMIC and ENERGIZED
COMMISSIONING tests to be carried out in order to ensure that the
installation is ready for start-up.

It is a subdivision of an installation that

SYSTEM
performs a proper operational function.
It is the minimum portion of the Plant required
for Commissioning purpose, and at the same
SUBSYSTEM
time, will be the handover package to
Operations.
It is the smallest group of items for a single
BASIC FUNCTION
Commissioning task.

It is the smallest portion of an installation for a

ITEM
Precommissioning Task.

It is any of the Pre Commissioning or

TASK ACTIVITY
Commissioning execution type of work,

It is each individual precommissioning or

TASK commissioning job applies on an item, , a test
pack, a Basic Function or a subsystem.
Table 8 OPERCOM Glossary

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6. APPENDIX

6.1. Appendix 1: The Typical Phases of a Project

6.2. Appendix 2: OPERCOM Methodology

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TOTAL ICAPS Engineering Manual Page 15 / 19
 APPENDIX 2 – OPERCOM METHODOLOGY
THE COMPLETION ACTIVITIES

COMPLETION ACTIVITY COMPLETION ACTIVITY

PREPARATION EXECUTION
(GSEXP-103) (GSEXP-105 & GSEXP-107)

I GENERAL OPERCOM PREPARATION IV – PRECOMMISSIONING EXECUTION

(GSEXP-105)
1) Subsystem Preparation
2) Start-Up Sequence Preparation 1) Conformity Checks
3) Coloured Marked-Up Drawing Preparation 2) Static Tests
4) Subsystem Engineering List Preparation 3) Piping Tests

II – PRECOMMISSIONING PREPARATION IV – COMMISSIONING EXECUTION

(GSEXP-107)
1) Status Index Preparation
2) Precomm. Dossier Preparation 1) Preliminary Checks
3) Precomm. Manpower Estimate Preparation 2) Functionnal Tests
4) Long Precomm. Task Preparation 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

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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.

Equipment Progress
Branch Branch
Project Project Seq

Subproject Subproject Seq

System Stage

Subsystem
Tasks
Tasks Substage
Tasks

Item

Users Group
Punch
Lists

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.)

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 Piping &
- Vessels Preparation

Commissioning
(PVP)
Operational Tests

Tasks
(OTS)
Functional Tests
(FTS)
Preliminary Checks
(PRC)

PreCommissioning
Static Tests
(STS)

Tasks
Piping Tests
(PIP)
Conformity Checks
(CCK)

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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.

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