Control System Specification Energy Equity Keera

ENERGY EQUITY EPIC
(SENGKANG) PTY., LTD.
PROJECT:
EPCI FOR KEERA METERING

STATION
CONTRACT NO.:
KONSORSIUM
PT FORMA OCEAN INDONESIA
CON/EEES/16/009
PT VALARBI
DOC. NO.
DOC. TITLE:
WSB-KMS-IN-SPC-002
CONTROL SYSTEM SPECIFICATION
REV: 0
PAGE 1 OF 41
APPROVED FOR
CONSTRUCTION
HSN
ISSUED FOR REVIEW
HSN
HSN
VLO
DESCRIPTION
PREPD
CHKD
24 JUNE 2016
29 APRIL 2016
24 MAY 2016
ISSUED FOR APPROVAL
REV
DATE
VLO
KZ
VLO
KZ
KZ
APPD
By
Date
CLIENT
EPCI FOR KEERA METERING STATION

Contract No.: FAC. 015/FAC/059
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WSB-KMS-IN-SPC-002
INSTRUMENTATION & CONTROL
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REVISION LOG
Document Number
Document Title
Revision
Page
Date
: WSB-KMS-IN-SPC-002
: Control System Specification.
:0
Filename: wsb-kms-in-spc-002 control system specification
Revise
Reviewer

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Revision Number Tabulation
REVISION NUMBER TABULATION
Rev.
Sheet
Rev.
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TABLE OF CONTENTS
REVISION LOG ................................................................................................... 2

TABLE OF CONTENTS .......................................................................................... 4
1
INTRODUCTION ........................................................................................... 6
1.1
General ................................................................................................... 6
1.3
Definitions and Abbreviations ..................................................................... 6
1.2
1.4
Scope ...................................................................................................... 6
References ............................................................................................... 7
1.4.1
1.4.2
2
3
4
1.5
Codes and Standards .......................................................................... 7
Order of Precedence .................................................................................. 8
AREA CLASSIFICATION ................................................................................ 9
UTILITIES .................................................................................................... 9
TECHNICAL REQUIREMENTS......................................................................... 9
4.1
4.2
General ................................................................................................... 9
System Description ................................................................................. 10
HUMAN MACHINE INTERFACE (HMI) .......................................................... 11
5.1
Graphical Display Requirement ................................................................. 14
5.3
System Configuration and Database .......................................................... 18
5.2
5.4
5.5
6
Project Specification and Other Documents ............................................ 7
5.6
Alarm Management and Display ................................................................ 17

Logging and Reporting ............................................................................. 19
Historical Data ........................................................................................ 20
Engineering Workstation .......................................................................... 20
PROCESS CONTROL AND SAFETY SHUTDOWN SYSTEM (PCS/SSS/FGS) ..... 21
6.1
Main Processor Module ............................................................................ 24
6.3
System Diagnostic and Sequence of Event ................................................. 26
6.2
6.4
6.5
6.6
6.7
6.8
6.9
Input / Output Hardware ......................................................................... 24

Controller Modules .................................................................................. 27
Communication....................................................................................... 28
Maintenance and Start up By-pass Switches ............................................... 28
Communication Interface ......................................................................... 29
Software / Firmware ................................................................................ 29
PCS/SSS/FGS Communications ................................................................. 30
6.9.1
Data Communication Network Interfaces ............................................. 30

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6.9.2
6.10
6.10.1
6.10.2
6.10.3
6.10.4
6.10.5
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Data Communication Network Interfaces ............................................. 30
Hardware Construction Requirement ...................................................... 31

System Cabinet ................................................................................ 31
Cabling and Wiring ............................................................................ 32
Earthing System ............................................................................... 33

Nameplates ...................................................................................... 33
Power Supply ................................................................................... 33
SYSTEM DOCUMENTATION ......................................................................... 34
SYSTEM SUPPORT ...................................................................................... 35
8.1
System Maintenance ............................................................................... 35
8.3
System Operator Training ........................................................................ 35
8.2
9
WSB-KMS-IN-SPC-002
10
11
12
System Maintenance Engineer / Technician Training .................................... 35
VENDOR SCOPE OF SUPPLY ........................................................................ 35

INSPECTION AND TESTING ..................................................................... 36
PREPARATION FOR SHIPMENT ................................................................ 39

QUALITY ASSURANCE SYSTEM ................................................................ 40
12.1
General .............................................................................................. 40
12.3
Non-Conformity and Corrective Action .................................................... 41
12.2
13
Quality Audits ...................................................................................... 41
WARRANTY / GUARANTEE ...................................................................... 41

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INTRODUCTION
General
Energy Equity Epic (Sengkang) is planning to develop Walanga, Sampi Sampi and
Bonge Gas Fields at South Sulawesi that expected produce 40 - 80 MMscfd of gas
from four (4) wells. From wells, associated Gas and hydrocarbon liquid will be
delivered to Keera Metering Station.
The
The
and
and
1.2
WSB-KMS-IN-SPC-002
Keera Metering Station will be designed for capacity 80 MMscfd and 600 BLPD.
Keera Metering Station will be operated in the first two (2) years for 40 MMscfd
5 BLPD. Then after two (2) years the capacity will be increased to 68 MMScfd
500 BLPD.
The main mechanical equipment of Keera Metering Station consists of Two-Phase

Inlet Separator, Coalescing Filter, Custody Meter, Three-Phase Separator (Flash
drum), Low Pressure K.O Pot, High Pressure KO Drum, HP & LP Flare Stack,
Condensate Tank, Condensate Pump, Produced Water Tank, Produced Water Pump,
Disposal Water Pond, Disposal Water Pump, Waste Water Treatment Facility and
other supporting facilities. The delivery point for sales gas is at Keera Custody
Meter. The sales gas will be further processed at LNG Plant (Buyer Facilities).
Scope
This specification covers the minimum requirements for the design, supply,
manufacture, assembly, configuration, inspection, and testing of the microprocessor
based Programmable Logic Controller (PLC) for Process Control System / Safety
Shutdown System / Fire and Gas System (PCS/SSS/FGS) and interfacing with other
systems, to be installed on Keera Metering Station.
VENDOR shall furnish a complete and operational system that functions and
complies with the requirements set forth in this specification including interfaces
with Packaged Equipment Systems. This shall include hardware, software and
services necessary to implement the functions and requirements intended, even if
not specifically mentioned in this specification. No deviations from the specification
shall be permitted without a written request and subsequent written approval from
PURCHASER/COMPANY.
1.3
Definitions and Abbreviations
The following words shall have the meaning indicated when used herein:
COMPANY
CONTRACTOR
Energy Equity Epic Sengkang Pty. Ltd, as the ultimate user

and owner.
Successful bidder to perform the detail design, procurement

and construction on behalf of COMPANY.

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INSPECTOR
VENDOR
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COMPANY and/or CONTRACTOR Representative and/or

INSPECTOR appointed by COMPANY or CONTRACTOR to
witness tests and to inspect the quality of Custody Gas
Metering Package.
Programmable Logic Controller Vendor, System Integrator,
fabricator and/or manufacturer.
PCS
Process Control System
SSS
Safety Shutdown System
PLC
Programmable Logic Controller
HART
Highway Addressable Remote Transducer
FGS
Fire and Gas System
ESD
Emergency Shutdown System
HMI
Human Interface Machine
SCADA
Supervisory Control and Data Acquisition
LAN
1.4
WSB-KMS-IN-SPC-002
Local Area Network
References
1.4.1
Project Specification and Other Documents
WSB-KMS-IN-SPC-001
Instrument General Specification
PID
All Piping and Instrumentation Diagram of Keera

Metering Station.
WSB-KMS-IN-DWG-001
1.4.2
Codes and Standards
Control System and Architecture Diagram
Unless otherwise specified the latest edition of the following standards &
codes are to be followed:
IEC 61508
IEC 61511
IEC 801
IEEE C37.90.1
ISA S51.1
Functional
Safety
of
Electrical
/
Electronic
Programmable Electronic Safety Related Systems
Programmable Electronic System (PES) for use in Safety

Applications
Electromagnetic Compatibility for Industrial
Measurement and Control Equipment.
Process
Surge Withstand Capability (SWC) Tests

Process Instrument Terminology
ANSI/ISA S84.01 Application of Safety Instrumented Systems for the

Process Industries
ISA RP
All ISA Recommended Practices

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ISO 9000
NEMA ICS-3
NEMA ICS-6
NFPA 70
SAMA PMC-33.1
UL-44 VW-1
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Quality Management and Quality Assurance Standards ISO9001 through ISO9004

Industrial Systems
Enclosures for Industrial Control and Systems

National Electrical Codes
Electromagnetic
Instrumentation
Susceptibility
of
Process
Control
Flame Test Standard for Rubber Insulated Wires and

Cables
UL-83
Thermoplastic Insulated Wires
UL-1059
Electrical Terminal Blocks
UL-472
1.5
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Surge Withstand Capability Test
Order of Precedence
Conflicts between this Specification and its associated specifications and the above
codes and standards shall be brought to the Contractor and/or Companys attention
for resolution and approval in writing. In all cases, the most stringent requirements
apply.
Should any conflict occur as a result of applying specifications, the order of
precedence shall be as follows:
a) Data sheets
b) This Specification
c) Local Regulation
d) Codes and standards referred to herein
e) Manufacturers codes and working standards
All deviations from the requirements of this Specification, its attachments and the
referenced codes and standards shall be stated in the Tender. In the absence of
such a statement, full compliance will be assumed.
Compliance by the Manufacturer with the provision of this Specification does not
relieve him of his responsibility to make the metering package complete, safe and
ready for trouble free operation and meet the specified service conditions and/or
local codes governing health and safety.

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WSB-KMS-IN-SPC-002
AREA CLASSIFICATION
UTILITIES
Date: 28 June 2016
Single phase, 240 VAC/50 Hz UPS power shall be provided to the PCS, SSS, FGS,
and various equipment packages. Conversion to other voltage levels as deemed
necessary shall be carried out in the Power Distribution cabinet and supplied to
other cabinets. Field instrument power supplies shall generally be 24V DC, derived
from the supply within the marshalling cabinets. The following systems require
power at all times:
Telecommunication Systems.
Custody Metering System.
4.1
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All system and marshalling cabinets shall be located in indoor location, safe area
(Instrument Room and Control Room) and shall be certified IP 52 as minimum.
Rev: 0
PLC System (PCS/SSS/FGS)

Workstation and Server
TECHNICAL REQUIREMENTS
General
The Keera Metering Station site will be controlled by its own dedicated control
system. All Process Control, Emergency Shutdown and Fire and Gas System
designed by same PLC complete with redundant power supply and controllers. The
station shall have a minimum of one (1) HMI units for video display of the graphics,
etc. It is intended that all operator reporting and control to be via the control
system with minimum use of local field control.
Design consideration is based on I/O count by considering ability of PCS, SSS and
FGS reliability. This integrated system shall cover the ability that suitable for the
monitoring of safety critical process variables; provide all functions necessary to
safeguard the plant operations and the initiation of safety critical / emergency
shutdowns.
Potential impact reducing of any hardware failures on production minimized by

using separate module, and selection of PCS/SSS/FGS system (Logic Solver central
parts, I/O cards and communication cards) shall be based on fault
tolerant/redundant programmable logic controller technology and shall have
hardware architecture that is certified and complies with the requirements of
company Spec. The proposed system shall use supplier standard field proven
product lines.

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System Description
The Control System (PLC) will be installed in a climate controlled room. The control
room wherein the PCS/SSS/FGS equipment will be installed is considered as a nonhazardous area.
The PCS/SSS/FGS shall be supplied with provisions for protection
errors and hardware damage resulting from electrical transients on
wiring. These transients include those generated by switching large
by power line faults, lightning strikes / lightning-included surges on
cables and RFI (radio frequency interference).
against system
power or signal
electrical loads,
power or signal
The PCS shall consist of the following subsystems:
A microprocessor-based system (PLC-Hybrid) with a high integrity process

and safety PLC system with redundant processor, redundant local control
network. A redundant power supply shall be provided from Uninterruptable
Power Supply.
The Data Highway (Ethernet TCP/IP) shall be redundant.
HMI (Human-Machine-Interface): PC-based workstations with the latest

revision of Microsoft Windows operating system software and suppliers
recommended software.
The PCS/SSS/FGS cabinets (system and marshalling) except the workstations will
be floor mounted.
The System Vendor shall provide required processors and the associated I/O for
input and output (I/O) of process data input signals, control output signals, and
other field device connections and handling. Minimum of 20% spare installed I/O
shall be provided.
As a general rule, all transmitters and positioners shall have HART protocol for
diagnostic and maintenance purpose. Calibration and maintenance shall be possible
without disconnecting loop. The engineering/HMI workstation shall be loaded with
HART protocol diagnostic software for preventive maintenance of transmitters and
positioners.
Marshalling cabinets or racks to interface the field instrumentation loop wiring with
the PCS/SSS/FGS are required. Signal wiring shall not be mixed between
marshalling cabinets. The Marshalling cabinets shall have internal light. Each I/O
point shall be protected by surge protector devices.
The system cabinets shall be IP-52, swing-rack configuration, with overall
dimensions as per data sheet (Vendor proposed). Wiring access will be by bottom
entry only. The cabinets shall have internal light and two (2) 220 VAC power
receptacles in each cabinet. Color of all cabinets shall be RAL 7032 (Light grey).

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Fan shall be provided to maintain internal panel temperature and humidity. Fault
status alarm of the fan and panel temperature high alarm shall be provided.
All system Central Processing Unit (CPU) and communication (external and
internal) performance and memory capacity shall be adequate to allow for an
image of 100% (for future expansion) in the size of the configured data base
without requiring addition, modification or upgrade and degradation of system
performance.
Vendor system integrator shall provide sufficient quantities overlays and graphic
displays requirement and shall be furnished in the Engineering Notes attached to
the PCS/SSS/FGS Datasheet.
The system shall supported by historian database or Process Historical Data with
minimum historical storage capacity of 1 year with 60 secs sampling snapshots.
The HMI workstations shall be powered by UPS 220/240 VAC 50 Hz 1-phase.
The I/O estimate is provided within I/O List. The system shall be designed to
accommodate final I/O points as per approved I/O List document. A minimum of
20% spare I/O must be installed for. This reflects also for marshalling cabinet and
system cabinet shall have spare space capacity of 30%. These requirements
applicable for I/O slot, terminal block, and field terminal assembly.
Vendor shall submit the following (as a minimum) typical logic diagrams for
PURCHASER/COMPANY review and approval:
Digital input with start-up bypass and maintenance bypass
ESD manual reset from HMI keyboard
Analogue input with start-up bypass and maintenance bypass

SDV with local manual solenoid reset
Motor control
Electrical power isolation

Fire detector
Gas detector
Voting 1 out of N inputs

ESD activation
HUMAN MACHINE INTERFACE (HMI)
The Human Machine Interface (HMI) System shall incorporate Asset Managers, File
servers, Process Historical data, Application servers, and shall consist of the
following, as a minimum:

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One (1) PC-based Operator Interface Stations, One (1) units is utilized for
PCS/SSS/FGS.
Intel Xeon E5 with 10MB L3 cache and Turbo Boost up to 3.9GHz4GB 1066
MHz DDR3 SDRAM
12GB (three 4GB) of 1866MHz DDR3 ECC memory
Dual AMD FirePro D300 graphics processors with 2GB of GDDR5 VRAM1TB
7200RPM SATA3 Hard Drive
1TB 7200RPM SATA3 Hard Drive
24X SATA DVD+/-RW Dual Layer Drive
Two (2) 42 plasma / LED screen display c/w ceiling support
Two (2) 27 16:9 aspect ratio and an astonishing 2560-by-1440 resolution
NIC Ethernet Card, 2-port UTP 10/100/1000Mbps Auto-sensing with single

shielded RJ-45 connector, 32-bit PCI-bus (Bus Master) Operation PnP,
Full/half duplex support, Easy-to-view diagnostic LEDs, VLAN
5.1 Channel, Dolby Digital support, Internal PCI Sound Card.
One (1) HP LaserJet color printer, including a one (1) year supply of ink
cartridges and paper for graphics and reports.
One (1) Dot Matrix printer for SOE, alarm/Event and data logging.
Each station supplied with software for system application, graphic

configuration, historical trending, free format report generator and multitask operation.
Hardware and software for data communication network interface.
Supplier recommended runtime software with required licenses, one (1)

copy of common data base development software.
The latest revision of Windows operating system software (latest update

level).
Latest anti-virus (corporate type) for Windows.
Oracle or MS SQL Database software.
Desktop furniture for PC, workstations, and printers shall be industrial

hardened type with fully adjustable features. Vendor to include in proposal.
ESD & PSD Wall Mounted Hand Switch.
The PCS/SSS/FGS systems programs and database shall be of Key and/or Password
(from HMI workstation) protected to prevent accidental or unauthorized program or
data changes. The access rights shall be in the following three (3) levels with sublevels:

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1) Operator
2) Supervisor
3) Engineer
The printers shall be able to be plugged in and unplugged without requiring shutting
down of the HMI workstation assigned.
The printers shall be networked on the PCS/SSS/FGS Ethernet highway to provide

redundancy, total system accessible and isolation without interface or interruption of
HMIs function.
Human Machine Interface (HMI) workstations will be powered by UPS 220/240 VAC,
1 phase, 50 Hz from a reliable Uninterruptable Power Supply (UPS). Each
workstation will be on a dedicated distribution breaker. The UPS will be supplied by
the CONTRACTOR.
HMI Workstation screen displays provide to the process operator, information on

main gas processing facility status, efficiency, alarm conditions and PCS/SSS/FGS
system health. This information allows the operator to control the main gas
processing facility effectively and with a high degree of safety. Vendor shall provide
sufficient generated screen display and operator functions.
The following screens shall be included, as a minimum:
Alarm summary
ESD system flow diagrams (Dynamic)
Symbols and color codes
Network and server status
Operator assistance for graphic selections
Operator assistance for analogue loop controls
Operator assistance for report generate and print
Operator assistance for re-assign HMI, clients and printers

Operator assistance for discrete bypasses
Operator assistance for discrete output forcing (specifying authorization)

Operator assistance for discrete controls
Operator assistance for USD, PSD, ESD / BD
Operator assistance for restart from USD, PSD, ESD / BD

Operator assistance for combustible gas
Acknowledge and reset
Start inhibit switch Status

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Maintenance Inhibit switch status
Cause and Effect Diagram
5.1
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System status
Plot plan showing major equipment locations and positions of optical fire,
gas detector, heat and smoke detectors, manual pull stations, and firewater
distribution.
Report generation of alarms and events
Sales gas delivery report
Vendor shall provide unlimited tag and screen license.
Graphical Display Requirement
The following displays shall be provided as a minimum:
Overview display
Point display
Group display
Graphic display
Trend display
Alarm display
Overview Display
The overview display shall enable operator to have an overall view of the
process
The overview display shall consist of a single page of display which will be
divided into a number of groups. Each group shall consist of a number of
instrument tags
Information related to analogue inputs shall be represented by deviation
bars with alarm limits.
Information related to discrete inputs shall be shown with tag numbers.
Any tag number on the overview display which is in alarm shall be identified
by flashing
The operator shall be capable of directly calling up the group display,
corresponding to a tag number which is in alarm, from the overview display.
Group Display
Group display shall show a limited number of points, i.e. analogue or digital
input or outputs.

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The groups shall be the same as displayed in the overview display.
Instrument tag number, description, alarm status, controller mode,

engineering, units and digital values of process variable and set points in
engineering units shall be displayed.
Each point in the group shall be displayed as an instrument face plate with
bar graph display. The number of bar graphs per point shall be based on the
function of the point i.e. control or data acquisition.
The operator shall be able to select any point in the group and make change
in controller mode, set point, output, etc.
The control valve failure position shall be incorporated in the bar graph
display. The bar graph display of output signal shall always move upwards
when the valve opens.
The discrete input / output shall be represented by on / off software lamps
and alpha-numeric description of status.
The operator shall be able to on / off switch, start / stop motors / pumps,
etc., from this display.
It shall be possible to assign a particular point to more than one group with
control being possible from only one group.
Point Display
The point display shall provide a separate detailed display for each of the
points in the system.
The display shall include the face plate and all other information displayed
for that point in the group display. Additionally, the following shall also be
included In the point display:
Tuning constants of controller
The engineer actions shall be under a key lock to prevent unauthorized

changes to these vital parameters.
All configuration parameter of the point, e.g. process variable zero and
span values, alarm limits, set point limits, controller action,
computational constants.
The point display should also include a high resolution (1 second) trend
display with a time base of 60 seconds which will be used for tuning of
control loop
Graphic Display
The graphic display shall be multi-page display with each page providing a
flow diagram of a certain section of the plant in a dynamic fashion.

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The graphic display shall show the tag numbers of important analogue /
digital variables at their respective locations on the process and shall display
their dynamic behaviour through instantaneous values, alarm status, control
modes, etc. Valve position and pump running status shall also be shown.
Operator shall be able to control the process from graphics display in a
similar fashion as the group or point displays.
The graphic display shall have a minimum of seven foreground and seven
background colours.
The following colour codes can be used for various valve positions:
Control valve open
Manual or Valve travelling
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The graphic building software shall be user friendly and interactive
Rev: 0
The graphic displays shall be capable of being configured from engineering

workstation by using standard graphic symbols of process equipment and
valves to be available in graphic symbol library, which will be part of graphic
builder software. It shall also be possible to develop user defined symbols in
the graphics.
WSB-KMS-IN-SPC-002
Control valve closed

Valve position fault
Green
Red
Flashing Magenta
Control / Valve Block in manual :
Flashing Yellow
Tag Number in White
Trend Display
The trend display shall present the data in the format of a strip chat on the
screen.
The trend display shall consist of two types:
Real time trend
Historical trend
The real time trend package shall be capable of storing and displaying real
time data with a time base of 30 minutes and sampling rates 1 of 2/10
seconds.
It shall be possible to assign any tag number including third party

equipment tag numbers to real time trend.
The historical trend package shall be capable of collecting 200 to 10,000

trend points at selectable sample rates of 2, 5, 10, 20, 30 seconds, 1, 2, 5
and 10 minutes. Minimum 1000 variables shall be trended.

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It shall be possible to assign any variable like process variable set point,
output, etc., to real time or historical trending. It shall be possible to trend
either instantaneous or average data for a particular variable. It shall be
possible to historize all analog parameters including those received from
third party equipment.
All trend data shall be stored on non-volatile memory (hard disk) of the
system so that the trend data can be archived and subsequently recalled.
The selection of trend tag number and time base shall be possible from the
operator's keyboard.
The detail trend display shall contain the information on tag number,
engineering, unit, span, present value of the point being trended, alarm
status, etc.
Alarm Management and Display
The following types of alarms shall be provided in the system for both control and
data acquisition points:
Absolute (high, high-high, low, low-low) and deviation from set point
Rate of change alarm (high and low)
System diagnostic alarms
Transducer limit alarm (bad PV)
Thermocouple open circuit
System utility alarms
Communication failure alarm with other packaged panels
All alarm generated shall be displayed in HMI by a flashing color change and audio
signal. The audible alarm signal shall have six different to distinguish between
alarms of different priorities.
The colour scheme of the alarms shall be as follows:
Trip alarm
Override indication
: Red
: Yellow (against each trip alarm)
Colour schemes for other types of alarm e.g. transducer fault, loss of
communication, etc., shall be proposed by VENDOR and approved by COMPANY.
All alarms shall latch until acknowledged individually by the operator, after which
they will change to "steady" mode until the alarm condition no longer exists.
The system must alert the operator to each alarm regardless of the currant display
on the screen. Operator shall be able to call up the relevant display with maximum
two key strokes.

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It shall be possible to assign different priorities e.g. emergency, high, low, etc to
individual alarm points.
The system shall provide a current alarm summery and historical alarm summary,
which may be displayed and printed by the operator.
The current alarm summary shall contain a minimum of 500 most recent alarms in
order of appearance. The alarm summary shall include the following information for
each alarm point:
Timestamp
Tag number
Point description
Priority of alarm
The resolution of alarm shall be at least 1 second.
The historical alarm summary shall contain minimum 1000 alarms. This summary
able to be printed and updated every 8 hourly shift. The degree of information for
each alarm point shall be similar to the current alarm summary but with additional
details like time of acknowledge and time of return to normal.
The system shall also provide detailed alarm displays resulting from self diagnostics
of the PCS/SSS/FGS system
The system diagnostic alarms shall be displayed to the operator irrespective of the
display on the screen and will help pinpoint fault in any sub-system to the I/O
Level.
The system utility alarms shall consist of cabinet power supply failure alarm,
cabinet ventilation fan failure alarm and cabinet high temperature alarm. These
alarms shall be derived from volt-free contacts inside the cabinet, which will be
monitored by the digital input cards.
It shall be possible to suppress alarms on a group basis or on an individual basis.

The system shall allow alarm to be suppressed and unsuppressed automatically by
applying specific rules.
5.3
System Configuration and Database
The system configuration and data base generations are the responsibility of
VENDOR
The following are envisaged to be provided by CONTRACTOR towards the

PCS/SSS/FGS configuration:
Selection of control strategies;
Providing custom graphic sketches and colour scheme;
Selection of control algorithms;

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Instrument data including tag numbers, range, engineering units, and service
description;
Requirements of logs and reports;
Grouping of points in various displays like group, trend, overview, etc.
VENDOR shall clearly indicate at what time which data are required and confirm the
data provided by CONTRACTOR.
VENDOR shall also request CONTRACTOR for the data required from package
equipment suppliers for configuring the serial interface to PLC.
5.4
Logging and Reporting
A report generator shall be supplied to build and change report. Reporting function
shall be initiated by a control program, by operator demand or on schedule.
All points in the system shall be capable of being logged.
The reports shall comprise VENDOR'S standard logs and reports formatted by the
engineer.
The standard logs shall mainly consist of alarm summary and event summary
report to be printed out at the end of each shift.
The event summary report shall consist of the operator actions like auto / manual
change over, manual overrides, resets, etc.
Apart from the reports and logs mentioned above approximately, five free
additional formatted reports are envisaged to be configured in the system.
The free formatted report software shall allow the engineer to decide the layout
and content of the report, which may involve mathematical calculations like
summing, efficiency calculations, etc.
Alarm and return to normal shall be printed as they occur. Alarm messages shall
contain time, tag number, service description, process data and the type of alarm.
Operator action i.e. set point change, auto manual changeover etc., shall be logged
as they occur.
Alarms associated with PCS/SSS/FGS equipment shall be logged as they occur.
All alarms and operator action printed in the log report shall have date and time
printed alongside the action

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Historical Data
The PCS/SSS/FGS shall have a historical data base which can be accessed for
trending, report generation, alarm history retrieval and event history retrieval to
both printer and operator consoles. All alarm and events shall be historized.
It shall be possible to configure the data base through the engineering workstation.
The historical data base shall also store hourly, daily, weekly and monthly averages
for logging purposes.
Each historical data base shall contain time and date of occurrence, tag ID, Tag
description and value/state and type of event. These following events shall be
stored and automatically in history files for reporting and analysis as a minimum:
Process events
Engineer events
5.6
Operator events
System events
Engineering Workstation
A portable workstation shall be provided for program development, programming

storage, fault diagnostics, system monitoring, application documentation,
configuration, tuning, trouble shooting and other maintenance functions. This shall
interface with the plant data communications network for on-line programming,
calibration, trouble shooting, etc.
The workstation shall have interface capabilities to a printer via an RS 232C or
parallel port. The workstation shall have the capability for documenting software
programs, configuration, data bases, etc.
The workstation shall be of a notebook with the following minimum hardware and
software requirements:
2.5GHz quad-core Intel Core i7 processor (Turbo Boost up to 3.7GHz) 8GB

(4GBx2) 1333MHz DDR3 SDRAM with 6MB shared L3 cache
512GB Solid State Drive
RAM 16GB of 1600MHz DDR3L
Slot-Load Dual Layer DVD Burner (DVD-RW, CD-RW)
NVIDIA GeForce GT 750M with 2GB of GDDR5 memory and automatic graphics
switching9-cell Primary Battery
Internal High-Definition 5.1 Surround Sound Audio
Primary Battery 9-cell, up to 10 hours wireless web
15.4-inch (diagonal) LED-backlit display with IPS technology; 2880-by-1800
resolution Data link protocol Gigabit Ethernet, Ethernet, Fast Ethernet
Desktop furniture shall be industrial hardened type with fully adjustable
features. Vendor to provide detail in the proposal.

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An easy-to-use cursor device like mouse or trackball

Windows operating system (latest version)
Latest anti-virus for Windows operating system
Included with all associated software required for system programming,
diagnostic, calibration and maintenance. Complete with the licenses.
The station shall be capable of supporting both on-line and off-line programming.
The station software shall enable the user to perform, as a minimum, the following
tasks:
View real time data on logic diagrams for maintenance and trouble shooting
Print I/O configuration maps identifying each module type, location and tag
name
Print the system database, including tag names, descriptions, ranges and set
point values
Print the annotated application program and cross reference
Print history log report
Print alarms (system and plant safety) with tag and date-time of occurrence
Inhibit/force the I/O points
Develop / modify logics online and offline
Upload / download application software
Run diagnostics
Advanced control development
The station shall be equipped with security access feature (key lock or password) to
access the different level of operation (i.e.; programming, monitoring, and
loading). And access to this unit should be restricted by key lock for use by
authorized personnel only.
PROCESS CONTROL AND SAFETY SHUTDOWN SYSTEM

(PCS/SSS/FGS)
PCS/SSS/FGS shall be provided in the Main Control Room with all monitoring and
control requirements for the plant and the operator interface via monitors, operator
keyboards and printers. From a PCS/SSS/FGS workstation, an operator shall be able
to control and monitor process parameters / variables as indicated on the P&IDs or
applicable drawings.
The PCS/SSS/FGS system shall be configured with redundant, parallel processors.

Design of system must be such to maximize reliability of PCS/SSS/FGS. Failure of one
processor shall result in take-over of the control by the other processor without
process upset or loss of control / data archiving functions.
The PCS/SSS/FGS system shall be designed to require minimum maintenance and

minimum routine calibration. System shall have comprehensive self-checking,

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calibration and self-diagnostic fault capabilities including self-test failure alarms.

Comprehensive system status information shall be available for display on HMIs.
The Shutdown System should be designed to provide the necessary logic, interlocks,
bypass systems, shutdown signals and alarms so that abnormal conditions detected
by field process sensors will perform the expected alarm and shutdown function.
The system should be designed for fail safe operation. In the event of fire detection,
or loss of instrument air, or loss of electrical power, or low 24 VDC, the shutdown
system will operate and shutdown the process. For all other hazards, Operator
intervention is required to affect manual shutdown. In the normal condition the
system shall be energized and de-energized when the system in the abnormal
condition.
The shutdown system shall be engineered and proposed per the requirement of
applicable cause and effect diagrams.
Output modules for shutdown will be relay type and rated at minimum 2 Amps 24
VDC, but shall be matched with the output requirement.
The system will include a sequence of event monitoring systems which will log and
time stamp changes of event in shutdown system to be displayed on the
Operator/HMI Work Station and printers, in chronological order.
When the ESD has tripped, resumption of operation shall be possible only if the
cause of ESD is eliminated and the system is manually reset.
Communications to process Input / Output (I/O) modules, and other equipment

controllers, shall be through use of redundant networks. Each PCS/SSS/FGS
microprocessor shall connect to a main (dual) data communications network with
both legs through separate links. Thus, redundant communication data links shall be
provided between all devices on the highway. Data links shall be continuously
monitored and failures alarmed as a system alarm. Fail over from one data link to
the other shall be automatic and shall not interrupt operation.
Time shall be automatically synchronized throughout the overall control system
including SSS and other sub-system PLCs. Vendor shall give detail description in his
proposal of his standard facilities to meet this requirement.
The system shall fail to a default safe state in total power failure. Recovery of the
system after power failure shall be automatic, with control loops and sequence
control placed in a restart mode of operation, which can be pre-selected in
configuration.
The start-up & maintenance bypass switches shall be provided for all process
abnormal alarms, which cause the system shutdown as defined in the cause & effect
diagrams. The switch shall be configured by software and the bypass command shall
be carried out manually from the HMI Workstations (software hand-switch) and/or

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automatically by the SSS PLC system logic. Activation from HMI shall be password
protected. Switch activation shall be annunciated and recorded.
The PCS/SSS/FGS minimum performance shall be the following:
Control loop execution speed = 0.5 sec. Maximum standard except for critical
loops which may require faster speed.
Analogue signal scan rate = 0.3 sec. Maximum standard except for critical
loops which may require faster speed.
Digital scan rate = 0.3 sec. Maximum standard except for critical loops which
may require faster speed.
Time for alarm / event switching to HMI = 0.3 sec. max.
A graphic marked as an emergency graphic shall be able to be called up within
0.3 sec max.
The indication of any variable on all displays including alarm displays shall be
updated within 1 second of its value or status change (allowing for the scan
rate).
Response time of trigger from workstation to PCS/SSS/FGS output module =
0.3 sec max.
Screen locking time to make a video copy = 1 sec max.
Screen locking time to print and display on printers = 4 sec max.
Screen display show up time = 1 sec max.
Communication speed of serial port = 57.6 K baud min.
Screen refresh time for data = 0.5 sec max.
Data communications scan rate (for read and write) = 0.5 sec max.
Data communications scan rate with other PLC (for read and write) = 0.5 sec
max.
The time to respond to foreign devices shall not exceed 1 second. Response
time will not include the time required by the foreign device to respond to the
PCS/SSS/FGS, only the actual bi-directional communication time shall be
considered
Ethernet communication baud rate = 100/1000 Mbps.
Internal communication network data rate = 10 Mb Min.
System components shall be rack-mounted, modular design, plug-in type. Modules

shall be replaceable without the need for special tools.
System components shall be removable and insertable (plugged in) under Hot
Operation. Power supply shall not be required to be shut down in order to change
out system components.
Vendor shall provide the necessary equipment to generate the different power
supplies needed by the system operation and fixed loop circuits. The power supply
shall be two (2) @ 100% redundant with over voltage protective diode isolator and
facing, to ensure that the failure of any module will not interrupt the supply of the

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system. An output strand (dry contact) shall be provided to initiate the common
system fault alarm when any supply fails.
Main Processor Module
The redundant main processor shall operate in parallel and as one integrated unit,
with each of the processors controlling one leg of the I/O bus.
The identical operating software and application programs, including fault history,
residing in each processor memory shall be executed independently.
The processor shall be provided with individual back-up to retain its memory for six
(6) months in case of a power loss. Battery degradation shall be included as part of
the diagnostic alarm.
Two (2) types of basic control shall be supported by the main processor: logic and
sequential. This domain of control shall coexist within the processor. As a
minimum, the processor shall contain the following configurable functions stored in
non-volatile memory:
Selection: High, Low, Average

Math Computation: Add / Subtract, Multiply / Divide, Square Root
I/O: Analogue Input / Output, Contact Input / Output, Linearization, Square
Root, Threshold
Boolean: AND, OR, NOT, NAND, NOR, XOR, NXOR
Miscellaneous: Timer, Delay Counter, Sequencer, Flip-flop Memory
Ladder Symbols: NO Contact, NC Contact, Energized / De-energized Output,
Latch / Unlatch On / Off Delay Timer, Counter, etc.
The list of available standard functions or algorithms shall be stated by Vendor.
It must be possible to reprogram the system using simple language, such as ladder
logic or function block.
The system must be protected from unauthorized or accidental modification of the
programs (password and/or key lock).
All facilities necessary for making modification to the logic system should be
provided as part of the portable configuration station.
6.2
Internal buses between modules (CPU, communication and I/O bus) shall each be a
redundant type. The running of sequence in parallel is required.
Input / Output Hardware
Each I/O module must connect to the backplane via a high integrity two-part
connector. No address links or switches shall be mounted on the I/O modules. The
module type identifier shall be hard-coded on the I/O module and automatically
recognized by the PLCs operating system.
Insertion of the wrong I/O card into an I/O slot shall be prevented by physical
coding devices.

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Power distribution for all field signals shall be supplied by the system vendor.
Each critical digital input shall be isolated by separate opto isolators and each
isolator shall be regularly de-energized and energized for stuck-on fault.
Status and other non-critical digital inputs may be isolated by one opto-isolator.
All analogue inputs must be taken into separate independent analogue to digital
converter circuits, the results of which shall be automatically mid-value selected.
The processors and the associated I/O shall provide for input and output (I/O) of
process data input signals, control output signals, and other field device
connections and handling. All I/O shall have surge protection in accordance with
IEEE C37.90.1.SWC, as applicable to the form of I/O. Field-installed I/O shall be
available for communication with processors via redundant networks.
The analog circuits will be HART signal on 4-20 mA DC at 24VDC. The system shall
use HART analog inputs / outputs for the PCS/SSS/FGS. The I/O system shall be
designed to detect and alarm an abnormal condition of input which will provide
transmitter / positioner diagnostics and re-ranging capabilities from the
engineering/AMS work station.
The following types of input / output modules shall be available:
HART Analog Input, AI/1: Smart input with selectable loop powered /
unpowered and analog 0-20 mA, 4-20 mA Gas and Fire detectors, 0-5 VDC, or
0-10 VDC signals from 2 or 3 wire transmitters. Analog signals from Fire and
Gas detectors shall be provided with on-line monitoring facility to check the
circuit healthiness.
Analogue I/O shall have 12 bit minimum analogue-to-digital or digital to

analogue conversion. Accuracy shall be at least +0.25% of full scale over the
entire operating temperature range. Analogue and pulse input signals shall have
a minimum of 150 VDC input over-range protection.
Each digital input shall be individually fused with blown fuse indication.
Pulse Input, A1/2: Input signal, dry contact 24 VDC or current sink / source,
with input frequency maximum 5 kHz.
HART Analog Output, AO/1: 4-20 mA DC, capable of driving up to 300 ohms
total loop resistance, with 12 bit, plus sign resolution.
Digital Input, DI/1: 24VDC as input 1 and open circuit (infinite resistance) as
input 0. Negative terminal to be at the clean instrument ground level. Field
switches volt-free contact and solid state devices
Digital Input, DI/2: High speed plus input and accumulator for flow meter input.
Digital Output, DO/1: Dry contacts rated at: 2 amperes, 24VDC; 0.5 amperes,
125VDC; and 0.2 amperes, 120VAC in the form of electro-mechanical relays

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Digital Output, DO/3: Discrete output modules shall also be available for use
with fire suppression equipment. Outputs shall be able to be configured
individually to hold last state, or fail to power up default state on loss of
communications to PLC.
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Digital Output, DO/2: Solid state output drivers shall be available, either as a
DC sink or as a DC source devices, rated for 19-31VDC, 0.5 to 2 amperes.
Rev: 0
shall be available. These shall be selectable as normally open or normally

closed.
WSB-KMS-IN-SPC-002
Digital Output shall have output modules capable of driving output signals for all
of the following categories:
Solenoid valves, motors for pumps and compressors
Clean contact fault tolerant relay outputs
PCS Interface I/O
Output modules shall fail to the open state upon the failure of all redundant
processors. Digital outputs shall be current rated for an inductive load with a
maximum of 2.0 Amp per point at 100F.
Output termination cards shall provide fusing and passive protection only.
Where PLC electromechanical relays are used on output modules, individual
output points shall be automatically tested for proper operation at least every 2
hours. Where clean contact outputs are required, a full PLC tested relay output
must be provided.
All critical digital outputs shall be capable of detecting and alarming open or
shorted circuits. If any energize-to-executive action signals are specified, line
monitoring (supervised) shall be provided. Each digital output shall be
individually fused with blown fuse indication.
The I/O modules shall be provided with diagnostic (line monitoring) facilities.
Such as open circuit, short circuit, and under-range / over-range for analog
input signal.
System Diagnostic and Sequence of Event
The system shall have self-diagnostic programs (integrated into the main
processors) that run independent of the application programs on a continuous basis
with fault detection capability down to the I/O module individual channel level. All
modules shall be replaceable on-line without causing further system degradation or
requiring shutoff of supply power. Re-initialization of replacement module shall be
automatic.
Diagnostics shall be capable of identifying, locating and reporting the following
faults, as a minimum:

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Processor failure
Processor faults; i.e. memory faults, real time clock faults etc.
Communication faults
I/O module fault
Power or fuse faults
Identification and location of faults and status shall be automatic, by means of

indicators (LED) located on each module with common fault alarm and status on
PCS/SSS/FGS.
The system shall be self-checking. The main processor modules shall run
diagnostics in between the execution of the application program in such a manner
as not to interfere with the basic cycle time operation of any program. As a
minimum, on-line diagnostics shall perform the following:
Check fault detection circuitry

Verify all RAM and ROM controls
Verify all inputs and outputs
Check the operation of the operating and application programs
Make fault information available for the user-defined annunciation
Reveal all hidden faults or the potential of a fault occurrence and provide
sufficient warning for plant maintenance to correct the situation before a
system failure occurs
The system shall have a sequence of event (SOE) post-trip and event log for all trip
variables. The system shall have the capability of archiving and generating a
sequence of events report for printout. The event report shall include but not be
limited to the following:
6.4
Change of state of discrete inputs and outputs

Alarm/trip points tag and description
Time of alarm/trip in hours/minutes/seconds/unit and date
Controller Modules
Each processor module shall have microprocessor based components capable of

performing data acquisition, regulatory controls, and sequential controls in the
Control Room. Minimum hardware, peripheral and functional requirements and
capabilities shall be as described below.
The process module shall utilize a standardized modular rack construction in

which various electronic cards (modules) are inserted into the rack card file.
Module addresses shall be switch or software selectable; i.e., any card in any
slot. No external back plane methods may be used.
All processor modules shall be designed and supplied as redundant. Processor
fail-over shall be without loss of data or control function.

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Each module shall have an onboard diagnostics, with onboard LED indicators,
defining status.
Each processor module shall have flash memory for memory retention feature
to keep configuration for minimum of 365 days with no power supplied.
The control module processor shall have the capability of being configured and
tuned from either fixed or transportable console.
Communication
6.6
WSB-KMS-IN-SPC-002
Any high integrity safety PLC (PCS/SSS/FGS) back-up communication device

(cable, interfaces) must be automatically and permanently tested to ensure
that it is not out of service. An alarm shall be generated in case of failure.
All communication error shall be alarmed, logged on a printer, and stored in a

historical file.
Transfer to a back-up communication channel shall be automatic without

disrupting the system operation, but alarmed to the operator and kept in
system historical file. A manual switch-over of the communication channel
must be possible.
Vendor will state the expected communication load, the procedure of

evaluation and the procedure for checking this load. It is expected that the
load should not exceed 50%.
Each device shall be electrically or optically isolated from the communication
data highway. Optical isolation is preferred.
Vendor shall provide complete electrical and mechanical specifications, plus

manufacturer and model number for cable and fittings of the communication
data highway. The communication cable shall be flexible for ease of
installation and termination within equipment cabinets. Cable and fittings shall
be of top quality and shall be field proven. The system shall be designed for
quick and easy connection and disconnection of devices.
All internal communication shall be redundant type. Internal communication
includes CPU to CPU communication, CPU to I/O module communication, and
CPU to external port communications.
Maintenance and Start up By-pass Switches
Maintenance bypass software switches shall be provided in order to override each

input initiating safety trip for maintenance purposes.
Start-up bypass switches shall be provided for selected inputs, which may be in an
abnormal state prior to process or equipment start-up to overcome short process or
race problems.

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Activation of a start-up bypass switch shall be carried out manually from the HMI
Workstations (software hand-switch) and/or automatically by the PCS/SSS/FSS
logic. Activation from HMI shall be password protected. Switch activation shall be
annunciated and recorded.
The start-up bypass switch shall be self-cancelling either by the initiating device
transferring to the normal or healthy state, or after a predetermined time delay.
The timer period will be adjustable. Each timer is reset separately and each startup facility is removed by its own timer.
Activation of an input bypass shall only defeat the shutdown action by ESD. The trip
function input status indication shall remain operable.
Graphic displays shall be configured by Vendor to clearly show status of each
maintenance bypass and shall include individual graphic overlays to show
remaining, activation, continuation and can be renewed.
VENDOR shall include all necessary devices (delay module, etc.) to perform bypass
functionality.
6.7
Communication Interface
Communications interface modules shall be capable of communicating with

ControlNet, Ethernet, RS-232-C, RS-485, RS-422 redundant interfaces. The
PCS/SSS/FGS shall be capable of driving the interface link with modules that are
built into the processor or that plug directly into the processor module card files.
Serial interfaces shall have a redundant hardware configuration. The PLC shall be
capable of interfacing with the following:
6.8
Other safety systems, such as high integrity safety PLC (SSS) - Ethernet
PC-based operator interface - Ethernet
PC-based program / monitoring terminals Ethernet
Software / Firmware
Standard operating system software, with full documentation, shall be provided by

VENDOR.
VENDOR
shall
provide
configuration
software
to
meet
PURCHASER/COMPANYs specific requirements. The following control and
calculation algorithms shall be provided, as a minimum:
Ladder Logic
Counter Functions
Timer Functions
Arithmetic Functions
Logic Instructions

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Computing Instructions
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PID Instructions/Control Modes

Functional Block
Block Transfer Instructions

Sequencer Instructions
Diagnostic Instructions
File Management
File Arithmetic and Logic
Advanced Control Development
PCS/SSS/FGS Communications
6.9.1
Data Communication Network Interfaces
Data communications network interface devices shall be available with the

capability of interfacing various devices with the Data Communications
Networks. Process related and control functions shall utilize ControlNet
network communications or equal. HMI operator workstations shall utilize
Ethernet. Examples of such interfaces are:
6.9.2
I/O module via redundant ControlNet

Communication with other PLCs via redundant Ethernet
Data communications via redundant Ethernet network to HMI operator
workstations
Engineering workstation computer for programming or maintenance on
Ethernet network interfaces
Ethernet extended to communications network
Data Communication Network Interfaces
The ControlNet and Ethernet data communications networks shall be dual

redundant capable of data transmission over a distance of a minimum of
500 metres. The redundant highway shall be continually checked for
availability and any fault shall be alarmed. The system shall switch to the
redundant highway on failure, without interruption of service or loss of
signals.
The system redundancy shall extend to the processor module bus interface
level. The following features shall be provided, as a minimum:

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Two (2) data communications networks shall both be active at all times
but can be operated as a single highway for an indefinite period with
no system degradation.
Communications diagnostics are to be continuous such that a failure is
alarmed in the minimum amount of time.
Each network shall accommodate up to a minimum of 32 active
devices (addressed nodes).
Each node shall have message checking capability. Detection and
alarm of node failure shall be in a minimum amount of time.
There shall be no single point of failure.
Data communications network shall be redundant with automatic node

(drop) bypass.
Any measured or calculated variable in one part of the system shall be

available to any other node in the system without hardware.
All Communication error shall be alarmed, logged on a printer and

stored in a history file.
The data protocol used shall safeguard against false data transfers. Under
operational conditions, any single event occurring at the processor module
level shall be displayed at an attached operator console with 1 second after
occurrence. Similarly, any command given at any HMI keyboard shall
complete its action within 1 second. Vendor shall demonstrate this capability
during FAT test. The same test shall be performed by the PCS/SSS/FGS,
Vendor to demonstrate that this feature has not been degraded.
Data transfers shall be made by either change in status or by exception;

i.e., contact change or analogue value change, etc., and by operator console
request.
6.10
Hardware Construction Requirement
6.10.1 System Cabinet
PCS/SSS/FGS cabinets shall be free standing type with cable entries from
the bottom. Lifting lugs shall be provided at the top of the cabinets.
Color of system and marshalling cabinets shall be RAL 7032 (Light Grey).
All free standing cabinets shall have access with double leaf hinged lift off
doors.
The cabinet layout shall be such as to provide clear access to the internals
for maintenance.

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Ventilation fans and louvers backed by dust filters shall be provided in each
cabinet.
Fan shall be provided to maintain internal panel temperature and humidity.

Fault status alarm of the fan and panel temperature high alarm shall be
provided.
Each cabinet shall be provided with internal illumination activated by door
switch.
All unused card locations shall be fitted with cover plates.
20% spare space shall be provided in all PCS/SSS/FGS cabinets.
Cable entering PCS/SSS/FGS cabinets, auxiliary consoles shall be properly

clamped with amour grounding.
The PCS/SSS/FGS cabinet shall have its own independent protection against
Radio Frequency Interference (RFI) with door open in accordance with IEC
61000-4.
All terminals carrying more than 24 VDC shall be protected against
accidental contact by means of removable cover and shall be labelled
accordingly. Signals of different voltage levels shall be run in separate
trunking and shall be segregated on the terminal boards.
The indoor cabinets shall have an ingress protection of IP 52 as minimum.
6.10.2 Cabling and Wiring

The internal wiring of the PCS/SSS/FGS will be as per VENDORs standard.
Cables shall be flame retardant with an adequate conductors cross section

not less than 1.0 mm2.
Wiring of IS and non-IS signals shall be segregated, separated junction box.

Spare cores of field cables shall be terminated in the marshalling cabinet.
Wire ends shall be provided with un-insulated bootlace ferrules and

markers.
The color coding of the signal wiring and the power supply wiring shall meet
the project specification.
System cabling between PCS/SSS/FGS cabinets and operating console, shall

be according to VENDORs standard.
All cable entries to the PCS/SSS/FGS cabinet shall be from the bottom.
Channel mounted terminal blocks with pressure type terminals make

Klippon SAK 2.5 or equal shall be used for termination of signal cables in the

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system cabinets. Larger size terminals shall be provided, if necessary for

power cables.
System cables to connect I/O modules in system cabinets with field terminal
assembly/surge protection device backplanes in the Marshalling cabinets
shall be pre-fabricated type. Tested and connected after cabinet installation
using plug and socket connections. The system cables shall be segregated
from both the power cables in controller cabinets and fields multicore cables
in the Marshalling cabinets. The system cables shall be adequately protected
and installed on cable tray. All installed I/O points shall be connected up to
field terminal block.
6.10.3 Earthing System
The PCS/SSS/FGS cabinet and console shall be provided with safety earth
and signal earth. The signal earth shall be insulated from the cabinet
structure.
6.10.4 Nameplates
All cabinets, consoles, hardwire switches, push buttons and lamps shall be
provided with laminated plastic white / black / white nameplates.
Nameplates shall be fixed to the cabinets / consoles with stainless steel
screws.
Nameplates engraving details shall be prepared by VENDOR and shall be
approved by PURCHASER/COMPANY.
In addition all equipments shall be identified with the manufacturer type and
serial number to facilitate future references.
6.10.5 Power Supply
The PCS/SSS/FGS shall utilize 230 VAC 10%, 50 Hz 5% Hz single phase

from an Uninterrupted Power Supply (UPS), for field instrument power
supply use 24 VDC supplied from main battery.
VENDOR shall provide all filters, transformers, rectifiers, etc. to convert the
above power supply to the level acceptable to the various PCS/SSS/FGS
equipment.
The maximum static transfer time of UPS which the PCS/SSS/FGS should
tolerate is 100 milli seconds.
All power supply modules provided in system equipment shall be fully

redundant.
Power supply shall be sized to accommodate 30% of I/O card and loop
consumption spares. Vendor shall submit power supply sizing calculation.

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SYSTEM DOCUMENTATION
Vendor shall be responsible to prepare System Documentation in the stages of

design progress which shall systematically describe the development of the
PCS/SSS/FGS.
The preliminary system documentation shall include all hardware aspects as a
minimum.
The document shall clearly specify the limitation of the system design, not only at
the overall system level, but also at the level of hardware and software modules, so
that the system constraint are clearly identified. In particular, the design of
communication interfaces shall be clearly specified.
The structure of the document shall reflect the mixture of standard and special
project hardware and software required modules.
As minimum, following documents shall be included:
General Arrangement Drawing (System/Power Supply/Network/Marshalling

Cabinet, Operator Consoles)
Bill of Material
I/O allocation detail for each module and rack

Power Distribution Diagram
Overall Block Diagram
Detail Wiring Diagram
Typical Earthing Drawing
System Cable Termination Schedule

Communication Diagram
Power Consumption
Operator station HMI graphic display

Inspection and Test Plan
Factory Acceptance Test Procedure and Reports

Site Acceptance Test Procedure
Start Up and Commissioning spare part list

Two-years operation spare part list
PCS/SSS/FGS program Configuration
PCS/SSS/FGS Functional Logic Diagram

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Networking System Design and Specification

Alarm Management System Design and Specification
Database Configuration Design and Specification
Vendor
shall
submit
PURCHASER/COMPANY.
complete
draft
for
review
and
agreement
by
The design specification shall be approved by PURCHASER/COMPANY prior to

commencement of equipment procurement and software works.
8.1
8.2
8.3
SYSTEM SUPPORT
System Maintenance
Vendor shall identify within his bid documentation package proposals for supporting
the system installed from the hardware maintenance aspects, software
reconfiguration aspects and the system spares aspects.
System Maintenance Engineer / Technician Training
Vendor shall identify within his bid documentation package proposals for providing
PCS/SSS/FGS maintenance engineer / technician training course for both hardware
maintenance and system reconfiguration.
System Operator Training
Vendor shall identify within his bid documentation package proposals for providing
systems operators familiarity and operational instruction courses
VENDOR SCOPE OF SUPPLY
The following is to describe the minimum scope of supply to be furnish by Vendor for
control room and equipment room. A complete and operational system that
functions and complies with requirements in this specification. The minimum Vendor
scope of supply includes but not limited to:
One (1) PCS/SSS/FGS System cabinet c/w Controller & I/O modules rack and
marshaling rack
One (1) PCS/SSS/FGS Operator/HMI workstation
Two (2) Process Asset Management Server and HMI Server c/w KVM
One (1) Graphic/Screen/Hardcopy Printer

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One (1) Desktop furniture for operator/HMI workstation.
One (1) Server Cabinet for Historian and HMI Server.
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Two (2) Plasma Monitor / OLED screen Monitor c/w Wall Mounting Support.
One (1) Desktop furniture for Metering Workstation
One (3) Desktop furniture for printers
Four (4) Chair
10 INSPECTION AND TESTING
PURCHASER/COMPANY, at its option and with prior notification, shall be permitted

free access to Vendors facilities during all phases of the work for performing visual
inspections and for routine monitoring and checking of documentation and work
progress.
Vendor shall notify PURCHASER/COMPANY at least 10 working days in advance of
starting any shop tests.
Equipment tests, including heat soak test, shall be carried out as specified on the
Inspection and Testing Requirement Sheets, which will be attached to the
PCS/SSS/FGS requisition, and in accordance with the applicable sections of the
referenced specification and standards. Criteria for acceptance of tests shall be as
established in the attached or referenced specifications and standards.
Following the System Readiness Review, the system shall be prepared for the heat
soak test, and the Factory Acceptance Test (FAT) at the Vendors (System
Integrator) staging facility.
The Vendor shall perform a heat soak test for the PCS/SSS/FGS. The Vendor shall
raise the temperature surrounding each system to 120 degrees F (105 degrees F for
work station) at 80% humidity and maintain the temperature for 72 hours.
The ambient temperature surrounding the equipment and
temperatures within the equipment shall be continuously recorded
soak by the Vendor. All interconnecting cables shall be connected
fully powered (including consoles, work station system cabinets
circuit cards).
the maximum
during the heat
and the system
with all printer
During the heat soak, the Vendor shall utilize the keyboard to call up displays,
status tables, summary tables, etc., on a regular basis. Selected input/outputs shall
be simulated and recorded by the Vendor.
A proposed test procedure shall be submitted by Vendor for approval one (1) month
prior to the Factory Acceptance Test (FAT). Vendor shall prepare a detailed Factory
Acceptance Test procedure for approval by PURCHASER/COMPANY. This document
shall include Vendors and sub-system vendors key personnel to be involved in the
Factory Acceptance Test and the testing responsibilities assigned to each party.

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Upon approval by PURCHASER/COMPANY or an authorized representative, this

document shall establish the basis for conducting the Factory Acceptance Test and
shall include, but not be limited to, the tests described in this section. The FAT
procedure list shall have one column for Vendors pre FAT responsible staffs
signature.
The
pre-FAT
must
be
completed
before
notification
to
PURCHASER/COMPANY for FAT witness.
The purpose of this testing shall be to witness Vendor performance of FAT and verify
the operation of hardware, the validity of programs, operator interface, guaranteed
accuracy and the proper functioning of components as a System, in accordance with
this specification prior to system shipment. PURCHASER/COMPANY or its authorized
representative will take an active role in the Factory Acceptance Test. "Hands On"
(with Vendors observation and advice) shall be permitted in the Factory Acceptance
Test by PURCHASER/COMPANY or its authorized representatives. Sufficient time
shall be allocated to complete the Factory Acceptance Test; correct the errors
detected, and retest the system without jeopardizing the scheduled shipment dates.
As a minimum, the following tests shall be included in the FAT:
All system functions including service functions demonstrating:
All supplied diagnostic equipment
Power failures and restarts
Complete system reloads

Overload test
Electrical insulation tests
Failure diagnostic, automatic back-up and recovery for all redundant devices
Accuracy and operation of all I/O cards
Input and output from terminals to the different displays by simulating an

input or an output (100%)
All typical type of loops tested 100%
All complex loops (two or more variables linked together), tested 100%
All display pages available on the HMI work stations, tested 100%
Printer functions, tested 100%
Application software, tested 100%
For standard software packages, 100% functional check

Real time reports generation, tested 100%
Test of PCS/SSS/FGS external communications (100%) with equipment

supplied by Vendor
Test of communication with other system package PLC. Vendor shall put
forward for providing a simulator (similar equipment to those provided) of all

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equipment which cannot be assembled at the PCS/SSS/FGS suppliers

workshop. Complete system test shall be carried out.
Radiation Immunity (RFI/EMI) Test
Functional Logic Test
Operator Interface (HMI) operation Test
Process Historical Data system functional Test
Vendor shall provide two (2) sets of latest approved document to be used during
test. Vendor shall maintain master copy for all marked-up/changes during FAT.
Factory floor space, telephone, fax machine, test equipment, 100% simulation
panel (with lights and switches), man-hours, and any support required for
successful completion of the factory acceptance tests shall be provided by Vendor
as part of the Purchase Order price. The test equipment shall include a purpose
builts simulation test panel, one switch per discrete input, one potential meter per
analogue input, one LED per discrete output, and one milli-ammeter output wired
to the marshalling panel and terminal panels for use during the pre-FAT and FAT
test.
A pre-FAT test must be conducted by Vendors test crew. The pre-FAT shall be
properly signed, item-by-item, in one column of the FAT procedure list.
Vendor shall keep accurate records of the hardware and software deficiencies,
errors, and action items encountered during each test, which shall be provided to
PURCHASER/COMPANY or its authorized representatives. These deficiencies / errors
/ action items shall be reviewed with PURCHASER/COMPANY or its authorized
representatives at the end of each day to discuss the proposed procedures and
schedule for correcting these items. PURCHASER/COMPANY or authorized
representative may require the suspension of the FAT until any such discrepancy
has been corrected. After the discrepancy has been corrected, Vendor shall repeat
the procedure or perform any other testing required to verify correct operation of
the system and that the discrepancy has been corrected. As a general, the
following guidelines shall be followed:
Errors detected during tests in the system programming and configuration shall
be listed on a punch list and corrected before the end of the factory acceptance
tests.
Errors found in drawings and documentation concerned shall be corrected by
the Vendor and issued within one month after acceptance test.
All materials rejected by the PURCHASER/COMPANYs inspector shall be

replaced by the Vendor without extra charge.
Any faults discovered during inspection and test shall be rectified before
proceeding further and all previously tested circuits affected by the work
carried out to correct the fault shall be re-tested.

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The cost of rectification and repair of defects discovered during inspection or

test shall be at the Vendors expense.
Vendor shall elaborate HSE procedures followed during FAT at the manufacturing
site.
Vendor shall carry out the Site Acceptance Test (SAT) on installation of the systems
at site. The selected checking of software and hardware to ensure the system is
complete in all respects. Vendor shall provide SAT procedure for
PURCHASER/COMPANY approval.
11 PREPARATION FOR SHIPMENT
The PCS/SSS/FGS shall be cleaned and inspected prior to packing for shipment in
order to remove accumulated water, dust and manufacturing debris. The system
shall be packed in moisture proof containers and shall be able to withstand storage
conditions of a temperature range of 0 to 140F and a relative humidity of 5 to 95%
non-condensing for up to 5 (five) years.
PCS/SSS/FGS shall not be released for shipment until all test data is approved by
PURCHASER/COMPANY.
The PCS/SSS/FGS equipment shall be packed in accordance with the best industrial
practice for electronic equipment to avoid damage due to rough handling. The
following are the basic requirements, but are not limited to:
VENDOR shall identify desiccants and inhibitors used and the required
replacement frequency.
Items not immediately packaged after manufacture shall be protected from
contamination.
Keys, disks, cartridges, special tools shall be individually packaged and

clearly identified on the outside of the package.
Equipment shall be properly protected against shock, vibration and

environmental conditions. Items subject to corrosion shall be suitably
protected.
Lifting points shall be clearly marked. Where special blocking, anchoring, or
cushioning is necessary, the essential details shall be submitted to
PURCHASER/COMPANY or an authorized representative for review.
The outermost covering shall be clearly marked with the complete VENDOR
identification and shall include the weight. PURCHASER/COMPANYs or an
authorized representative's equipment numbers shall also be marked.

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Written instructions covering the location and stacking limits of the crates or
boxes on the transport vehicle shall be specified. These shall be marked on
the container.
Cabinet shall be self-supporting. The centre of gravity and lifting points for
large and heavy equipment shall also be identified.
PURCHASER/COMPANY or an authorized representative reserves the right to

inspect the equipment prior to shipment. Vendor shall notify
PURCHASER/COMPANY or an authorized representative of each shipment no
less than 14 days prior to the date of shipment to allow
PURCHASER/COMPANY to review and inspect.
A packing list shall be placed both on the inside and outside of each individual
package or container. Packing lists itemizing contents of each box crate shall be
placed inside each shipping unit. A second copy, together with any special
instructions, must be sealed in a waterproof envelope and securely fastened to the
outside of each shipping unit. Packing lists shall state purchase order number, item
number and full description of contents.
Openings or other components subject to mechanical damage or corrosion shall be
protected. Protection shall consist of plastic or wood covers, sealing with waterproof
tape, or enclosing in temporary housing. The shipped loose items shall be created in
waterproof boxes.
Vendor shall be responsible for load out, tie down and securing for shipment of the
completed assemblies on Vendor-furnished transport. Vendor shall be responsible
for supplying any required equipment or frames and required rigging for the load
out at VENDORs facility.
VENDOR shall be responsible for transport to PURCHASER/COMPANYs designated
receiving location. Removal from transport upon arrival at designated receiving
location shall be by PURCHASER/COMPANY or designated agent.
12 QUALITY ASSURANCE SYSTEM

12.1
General
VENDOR shall submit project Quality Plans to the PURCHASER/COMPANY after award
of purchase order. This Quality Plan shall incorporate specific quality requirements of
the PURCHASER/COMPANY. Along with this document, Vendor shall also submit an
established and documented Quality System in accordance with ISO 9001/9002 or
PURCHASER/COMPANY approved equivalent.
Vendor shall maintain his QA system throughout the Purchase Order period.
The full extent of these requirements shall be applied to the sub-Vendors who get
subcontracts for whole or main parts of the work or materials. Surveillance/ audit of

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sub-Vendors shall be performed by the Vendor as necessary.

Control of sub-Vendors shall encompass measures to verify that progress and
quality of works meet all the requirements.
12.2
Quality Audits
PURCHASER/COMPANY may conduct quality audits, technical reviews, test witnesses

and inspections at source in order to verify compliance with the Purchase Order
requirements.
VENDOR shall provide free access to the PURCHASER/COMPANY or its delegated
Inspector and co-operate with the PURCHASER/COMPANY or its delegated Inspector
in the performance of all testing, witnessing and audits.
The PURCHASER/COMPANY reserves the right to audit at source at any time during
the duration of the Purchase Order and will give two weeks notice. Vendor shall
undertake to close out any findings raised as part of such an audit.
VENDOR shall co-operate in the provision of information and the supply of all
necessary Vendor / sub-Vendors personnel to allow the PURCHASER/COMPANY or
delegated Inspector to perform a meaning audit/review.
The results of any internal audits/reviews conducted by Vendor and sub-Vendors
shall be documented and made available to the PURCHASER/COMPANY within two
weeks after completion of Vendor/sub-Vendors audit/review
12.3
Non-Conformity and Corrective Action
The VENDORs shall immediately bring to PURCHASER/COMPANYs attention any

finding of non-conforming product/work, which requires repair, rework, replacement
or a concession. The PURCHASER/COMPANY will review the non-conformance and
either agrees with Vendors proposed repair procedure or agree with a concession or
reject the product/work.
VENDOR shall submit for PURCHASER/COMPANYs appraisal/approval a proper and
systematic document of non-conformities and proposed corrective actions.
13 WARRANTY / GUARANTEE
The VENDOR shall design the equipment for 25 years design life cycle and warrant
the availability of spares and service for all parts for a minimum of 5 years.

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Material and equipment shall be warranted / guaranteed by Vendor / Manufacturer

to perform in accordance with specification requirements and to be free of defects
and poor workmanship.
VENDOR shall repair or replace all defective items during the guarantee period at no
cost to PURCHASER/COMPANY.

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EPCI FOR KEERA METERING

CONTROL SYSTEM SPECIFICATION

ISSUED FOR REVIEW

ISSUED FOR APPROVAL

EPCI FOR KEERA METERING STATION

CONTROL SYSTEM SPECIFICATION

INSTRUMENTATION & CONTROL

Date: 28 June 2016

: Control System Specification.

Filename: wsb-kms-in-spc-002 control system specification

EPCI FOR KEERA METERING STATION

CONTROL SYSTEM SPECIFICATION

INSTRUMENTATION & CONTROL

Date: 28 June 2016

Revision Number Tabulation

REVISION NUMBER TABULATION

Filename: wsb-kms-in-spc-002 control system specification

EPCI FOR KEERA METERING STATION

CONTROL SYSTEM SPECIFICATION

INSTRUMENTATION & CONTROL

Date: 28 June 2016

REVISION LOG ................................................................................................... 2

Definitions and Abbreviations ..................................................................... 6

Codes and Standards .......................................................................... 7

Order of Precedence .................................................................................. 8

AREA CLASSIFICATION ................................................................................ 9

System Description ................................................................................. 10

HUMAN MACHINE INTERFACE (HMI) .......................................................... 11

Graphical Display Requirement ................................................................. 14

System Configuration and Database .......................................................... 18

Project Specification and Other Documents ............................................ 7

Alarm Management and Display ................................................................ 17

Engineering Workstation .......................................................................... 20

PROCESS CONTROL AND SAFETY SHUTDOWN SYSTEM (PCS/SSS/FGS) ..... 21

Main Processor Module ............................................................................ 24

System Diagnostic and Sequence of Event ................................................. 26

Input / Output Hardware ......................................................................... 24

Software / Firmware ................................................................................ 29

PCS/SSS/FGS Communications ................................................................. 30

Data Communication Network Interfaces ............................................. 30

Filename: wsb-kms-in-spc-002 control system specification

EPCI FOR KEERA METERING STATION

CONTROL SYSTEM SPECIFICATION

INSTRUMENTATION & CONTROL

Date: 28 June 2016

Data Communication Network Interfaces ............................................. 30

Hardware Construction Requirement ...................................................... 31

Earthing System ............................................................................... 33

Power Supply ................................................................................... 33

SYSTEM DOCUMENTATION ......................................................................... 34

SYSTEM SUPPORT ...................................................................................... 35

System Maintenance ............................................................................... 35

System Operator Training ........................................................................ 35

System Maintenance Engineer / Technician Training .................................... 35

VENDOR SCOPE OF SUPPLY ........................................................................ 35

PREPARATION FOR SHIPMENT ................................................................ 39

Non-Conformity and Corrective Action .................................................... 41

Quality Audits ...................................................................................... 41

WARRANTY / GUARANTEE ...................................................................... 41

Filename: wsb-kms-in-spc-002 control system specification

EPCI FOR KEERA METERING STATION