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IRANIAN CENTRAL CHAGALESH

OIL FIELDS COMPANY CONSULTING


(ICOFC) ENGINEERS

Project Title : Basic Engineering Of PROGRAM NO.: 1720 1 OF 38


Farashband Gas Refinery PROJECT NO.: 17202 Rev. 3
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

Final Issue
Contractor Client
Date: 90/04/12 Date:
Sign: Sign:

Specification For Control System (DCS)

CHAGALESH
THE ORIGINAL AND ALL COPIES OF THIS DOCUMENT TOGETHER CONSULTING
WITH THE COPYRIGHT THEREIN ARE THE SOLE PROPERTY OF ENGINEERS
IRANIAN CENTRAL OIL FIELDS COMPANY. CHCE Document Number:
CH-207-IN-SP-002
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

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Farashband Gas Refinery PROJECT NO.: 17202 Rev. 3
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

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3 FI S.Rasouli S.Aghajani N.Movahedi 90.04.12


2 FI S.Rasouli S.Aghajani N.Movahedi 90.01.31
1 FI S.Rasouli L.Shahkaman N.Movahedi 89.01.25
0 IFR S.Rasouli L.Shahkaman N.Movahedi 88.12.26
Prepared Checked Approved Date Checked Approved Date
Status
REV.

Contractor Client

Document Revisions
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

Project Title : Basic Engineering Of PROGRAM NO.: 1720 3 OF 38


Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

1.0 GENERAL 6
2.0 SCOPE 6
3.0 USE OF LANGUAGE AND ABBREVIATIONS 6
4.0 CODES AND STANDARDS 7
5.0 CONFLICTING REQUIREMENTS 7
6.0 GENERAL 8
6.1 VENDOR RESPONSIBILITY 8
6.2 DEVIATIONS 9
6.3 APPROVALS 9
6.4 GUARANTEES 9
6.5 SPARES 10
6.6 TRAINING 10
7.0 ENVIRONMENTAL AND UTILITY DESIGN CRITERIA 10
7.1 ENVIRONMENTAL CONDITIONS 10
7.2 ELECTRICAL SUPPLIES 11
7.3 ELECTRICAL POWER DISTRIBUTION 12
8.0 DESIGN AND CONSTRUCTION 12
8.1 GENERAL 12
8.2 SYSTEMS AVAILABILITY AND REDUNDANCY 13
8.3 MECHANICAL AND RFI PROTECTION 13
8.4 HARDWARE REQUIREMENTS 14
8.4.1 CENTRAL PROCESSING UNIT (CPU) 14
8.4.2 OPERATOR INTERFACE SUB-SYSTEM 15
8.4.3 VIDEO DISPLAY UNIT (VDU) 16
8.4.4 COMPUTER ELECTRONICS 16
8.4.5 PRINTERS 16
8.4.6 KEYBOARD & POINTING DEVICE 17
8.5 I/O MODULES 17
8.5.1 ANALOG INPUT 17
8.5.2 ANALOG OUTPUT 18
8.5.3 DIGITAL INPUT 18
8.5.4 DIGITAL OUTPUT 18
8.6 SPARE CAPACITY/EXPANDABILITY 19
8.7 SOFTWARE REQUIREMENTS 19
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

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Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

8.7.1 GRAPHIC DISPLAY 19


8.7.2 GROUP DISPLAY 20
8.7.3 ALARM AND EVENT DISPLAY 20
8.7.4 TREND DISPLAY 21
8.7.5 REAL TIME TREND 21
8.7.6 HISTORICAL TREND 22
8.7.7 SELF-DIAGNOSTIC DISPLAY 22
8.7.8 REPORTS 22
8.7.9 CONFIGURATION TOOLS 23
8.7.10 SYSTEM SECURITY 23
8.8 COMMUNICATIONS 24
8.8.1 COMMUNICATION WITH EXTERNAL SYSTEMS 24
8.9 CABINETS AND RACKS 25
8.9.1 GENERAL 25
8.9.2 SYSTEM CABINETS 26
8.9.3 MARSHALLING CABINETS 26
8.9.4 SYSTEM WIRING REQUIREMENTS 27
8.9.5 GROUNDING 27
9.0 INSPECTION AND TESTING 28
9.1 GENERAL 28
9.2 INSPECTION 29
9.3 TESTING 30
10.0 PREPARATION FOR SHIPMENT 32
11.0 VENDOR DOCUMENTATION 32
12.0 QUALITY ASSURANCE 33
13.0 ADDITIONAL PROTECTIONS 34
13.1 SHIELDING 34
13.2 GROUNDING AND BONDING PRINCIPLES 35
13.2.1 STRUCTURES 35
13.2.2 NON-ELECTRICAL UTILITIES 35
13.2.3 HEATING, VENTILATION, AND AIR-CONDITIONING 35
13.2.4 COMPUTERS AND DATA PROCESSING 35
13.2.5 CONTROLS 36
13.3 LINE FILTERS 36
13.3.1 SIGNAL LINES. (DATA, CONTROL ETC…) 36
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

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Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

13.3.2 CONNECTIVITY 36
13.4 MISCELLANEOUS 37
13.5 INSPECTIONS AND TESTING 37
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

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Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

1.0 GENERAL

Title of Project: Basic Engineering of Farashband Gas Refinery Development


Client: Iranian Central Oil Fields Company (ICOFC)
Location: Farashband Production Unit which is located 170 Km, East of Shiraz.

2.0 SCOPE

This specification applies to cover the minimum requirements for design, manufacturing,
inspection and testing of Control System for Farashband Gas Refinery Development for
Iranian Central Oil Fields Company (ICOFC).
The Control system shall interface with other systems such as ESD and F&G systems to
ensure a safe and operable plant.

3.0 USE OF LANGUAGE AND ABBREVIATIONS

Throughout this specification, the words "will", "may", "should", "shall" when used have
meaning as follows:
• "will" is used normally in conjunction with an action by ICOFC,
• "may" is used where alternatives are equally acceptable,
• "Shall" is used where a provision is mandatory.
• "should" is used where a solution is preferred,
The following is a listing of abbreviation used within this document:

Abbreviation Description
DCS Distributed Control System
EMC Electromagnetic Compatibility
ESD Emergency Shut-down System
F&G Fire and Gas System
HMI Human-Machine Interface
I/O Input / Output
IE Instrument Earth
IP Ingress Protection
IPCS Integrated Process Control System
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

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Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

I.S. Intrinsically Safe / Intrinsic Safety


ISE Intrinsically Safe Earth
ITR Instrument Technical Room
LCD Liquid Crystal Display
N.I.S Non-Intrinsically Safe
P&ID Piping & Instrumentation Diagrams
PE Plant Earth
PLC Programmable Logic Controller
RTD Resistive Temperature Detector
UPS Un-interruptible Power Supply

4.0 CODES AND STANDARDS

The latest edition of standards that shall be used as the basis for this specification is listed
below:

STANDARD TITLE
IPS-E-IN-190(1) Engineering Standard for transmission Systems
IPS-C-IN-190 Installation and Construction Standard for transmission Systems
IPS-M-IN-190(1) Material and Equipment Standard for transmission Systems
IPS-G-IN-220 Engineering and Installation Standard for Control Centers
IPS-M-IN-220 Material Standard for Control Panels and System Cabinets
API RP 552 Transmission Systems
IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere
IEC 60092 General Instrumentation, Control and Communication Cables
IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)
IEC 61000 Electromagnetic Compatibility (EMC)
IEC 61131 Programmable Controllers
ISA RP 60.8 Electrical guide for control centres

5.0 CONFLICTING REQUIREMENTS

In case of any conflict, the priority shall be as following:


• Data Sheet / Requisition Sheet
• Drawings
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

Project Title : Basic Engineering Of PROGRAM NO.: 1720 8 OF 38


Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

• This Engineering Specification


• Control and Instrument Design Criteria
• IPS Standard
• International Codes & Standards
• The Most Stringent Codes or Standards
The "ICOFC" shall be consulted in writing in every case of conflict. The latest edition of
standards and codes shall be applied at the commencement of the bidding period. Any
deviation from the above mentioned standards and this specification shall be clearly
mentioned in the Vendor's proposal.

6.0 GENERAL

The plant is controlled from an Integrated Process Control System (IPCS) that consist of
the following major sub-systems:
• Distributed Control System (DCS)
• Emergency Control System (ESD)
• Fire and Gas System (FGS)

6.1 VENDOR RESPONSIBILITY

Whilst the “Purchaser” defines the minimum requirements, the Vendor shall be totally
responsible for the design of the system including all materials used in its manufacture,
performance, construction, inspection and testing, all of which shall fully comply with the
performance and other requirements as detailed in this specification and associated
documentation.
In addition, the Vendor shall ensure that the system design and all components comply
with all relevant codes, standards and regulations whether specifically referred to or not.
The Vendor shall submit a timetable for periodic maintenance, calibration and Cleaning of
the system and its components.
The Supplier shall provide the following services:
• Project Management/Planning/Reporting
• Supply of system hardware/software including auxiliary equipment
• Supply of system & interconnection cables
• Test and Certification
• Packing and Shipment
• Spare Part (Commissioning/Start-up and two years operation) and Consumables
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

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Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

• Training (Including fundamental, operation, engineering and configuration,


programming, Hardware/software maintenance, HART devices software
configuration, maintenance and external systems interface)
• Onsite services (System SAT, Installation, Commissioning and Start-up assistance)
• Special Equipment or tools for installation , commissioning, testing, calibration and
maintenance)
• System configuration/programming
• Software updating
• Site acceptance test
• Documentation as per section 11
• Guarantee as per section 6.4
• Quality management requirements
All required software and source codes shall be provided to Client after system start-up. It
shall be no need to Vendor attendance in case of requirement for re-installation of system
software and application programs on the new stations.

6.2 DEVIATIONS

All deviations from the requirements of any of the Data sheets, Specifications, Codes,
Standards, Regulations, Guidance Notes, etc, shall be agreed with Purchaser before
proceeding.
In the absence of such a statement, it shall be understood that all listed requirements are
accepted. Any costs associated with re-engineering and/or provision of additional materials
subsequently identified as being required together with re-inspection and re-testing shall be
done by the Vendor and the changes incorporated with slippage to neither schedule nor
delay in commissioning.

6.3 APPROVALS

The system shall have approval from international recognized agencies such as UL, FM,
BASEEFA, PTB, etc.

6.4 GUARANTEES

Supplier shall guarantee to support and supply spare parts for the supplied hardware,
software and accessories for at least 10 years from the date of shipment.
The Vendor shall also guarantee that the equipment supplied is free from fault in design,
workmanship and material, and is of adequate design and proper material to fulfill
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

Project Title : Basic Engineering Of PROGRAM NO.: 1720 10 OF 38


Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

satisfactorily the specified operating conditions. If any failure or defect in design, material,
workmanship or operating characteristics develop under the start-up and commissioning
periods or during the first 24 months of shipment or 18 months of operation (whichever is
closer), the supplier shall make all required repairs, alterations or replacements of the
defective equipment, free of charge, and shall pay transportation fees involved to and from
Client’s site

6.5 SPARES

The Vendor shall supply spare parts for Pre-commissioning, commissioning, and two years
of operation. Moreover the Vendor shall guarantee that he will supply spare parts for his
system or instruments whenever required by the Purchaser, up to 10 years.

6.6 TRAINING

Control system supplier shall provide details of training program, including course outline,
training location, personnel number, duration of training and other relevant items at the bid
stage.

7.0 ENVIRONMENTAL AND UTILITY DESIGN CRITERIA

7.1 ENVIRONMENTAL CONDITIONS

Instruments shall be designed for use under the following design conditions, unless
otherwise specified:

Description Unit Farashband site


Maximum Absolute Ambient Temperature °C 43
Minimum Absolute Ambient Temperature °C -6.5
Average Maximum Absolute Ambient
°C 41.1
Temperature
Average Minimum Absolute Ambient
°C -3.6
Temperature
Average Maximum Mean Ambient
°C 27.1
Temperature
Average Minimum Mean Ambient
°C 9.8
Temperature
Black Body Sun Temperature °C 88
Minimum Of Soil Temperature °C 15
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

Project Title : Basic Engineering Of PROGRAM NO.: 1720 11 OF 38


Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

Maximum Of Soil Temperature °C 30


Maximum Average Humidity % 65
Minimum Average Humidity % 29.5
Maximum Rainfall During in Year mm 390.5
Maximum Rainfall During One Day mm 73
Maximum Wind Velocity km/hr 75
Wind Velocity For Process Calculation km/hr 16
Max. Wind Velocity at Ground Level Km/hr 125
Wind Direction - North West-South East
Design snow load kg/m2 150
Sea Level m 880
Seismic Zone 4

For the above conditions special care will be paid to:


- Enclosures of equipment for outdoor installation
- Painting and coating of metal parts to resist the severe environmental conditions
- Any environmental derating factors shall be considered by Vendor before design.
The control room and ITR are provided normally with an air conditioned environment
controlled at 22ºC±2°C and is classified as a safe area. Despite that, it is essential that
Vendor supplied equipment can function normally without degradation or without
affecting the overall system availability.

7.2 ELECTRICAL SUPPLIES

All DCS equipment shall be powered from external UPS power source, in 110 VAC 50
Hz, single phase (By others).
The 110 VAC power source shall be used as the main secured power source of the DCS
equipment. Two (2) feeders shall be available (hot/stand-by).
Equipment such as printers, stations, etc. shall be powered by a single UPS feeder.
24 VDC power supply shall be generated internally to system cabinets.
The Supplier shall define and supply the power distribution networks to the different parts
of the cabinet.
-Power supplies shall be supplied in redundant configuration and shall be sized 30 % in
3
excess of the estimated maximum demand.
-Where a VENDOR requires a different supply, then the VENDOR shall provide all
necessary equipment, power supplies, AC/DC distribution and protection, fuses, circuit-
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
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Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

breakers, earth leakage detection and terminals to interface his equipment with the project
3
electrical distribution equipment.
-All power supplies over 50 volts shall be shrouded and labelled
-Galvanic isolation shall be provided as required.
Analogue input/output terminal assemblies shall accept 24 V DC sources allowing for 4-
20 mA isolated signals.
The failure of the power supply will lead to dedicated power failure alarms.

7.3 ELECTRICAL POWER DISTRIBUTION

Electrical power distribution for the system cabinets and other system hardware shall form
3 part of the Vendor’s scope of supply. Redundant Power supply feeders as specified above
will be made available by the CONTRACTOR & COMPANY for the system. The
minimum requirement for the power distribution shall be as below:
Redundant power distribution boards with incoming fused isolators and miniature circuit
breakers for distribution.
Redundant feeders to all redundant consuming devices.
Redundant feeders with selector switches for non-redundant consuming devices.
Power isolation means at both ends of the power cables

8.0 DESIGN AND CONSTRUCTION

8.1 GENERAL

Field instruments connected directly to the DCS system shall be SMART field devices
with HART protocol.
Unit operation and supervision shall be carried out from PC-based operator stations.
The instruments and control systems shall be so designed to have the highest possible
reliability and minimize the system failure in order to achieve safe and satisfactory start
up, continuous, accurate, Efficient and satisfactory operation with minimum maintenance.
Highly descriptive troubleshooting instruction covered in supplier standard maintenance
manuals shall include sufficient information and required data to help with easy fault
location and isolation.
DCS and related equipments shall be shop fabricated and wired up to the terminals, tested
and ready for installation and interconnection at site.
The DCS shall, to all possible extent, be assembled using standard software and hardware
building blocks. Process operational logic shall be carried out within the DCS itself.
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

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Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

Industry standard for hardware and software shall be used to achieve multi-Vendor
interoperability.
It shall be possible to add I/O and controllers to the existing equipment or replacing
existing equipment, on-line and under full power without disrupting the current system
operation. The system shall also provide the capability to add consoles, interfaces, host
computer controllers, etc. to the existing data highway without affecting the current
highway communications. These new devices shall then be capable of being configured
and calibrated on-line without affecting the current system operation from the engineering
workstations.
The control system shall be capable of being extended by simply extending the data
highway cables for a plant-wide integrated system.
DCS shall be the latest proven type and version.

8.2 SYSTEMS AVAILABILITY AND REDUNDANCY

The systems shall be designed to achieve an availability of 99.99% with an assumed Mean
3 Time to Repair (MTTR) of four hours.
In order to meet the required system availability, redundant and/or fault tolerant
technology shall be incorporated.
However, the following equipment shall be redundant unless otherwise stated in the
system specification:
Control system communication network including cabling, modems, fibre optic cabling
and other related hardware
Control processors
Mass data storage devices
Power supplies
The redundant systems shall be designed so that, on failure, automatic changeover to the
other unit shall take place. It shall be possible to replace and test the failed unit without
disrupting control of the process.
In order to meet the required safety plant, discrete I/O cards should be “fail safe”.

8.3 MECHANICAL AND RFI PROTECTION

The minimum mechanical protection for indoor cabinets and marshalling racks shall be
IP42. Supplier’s equipment shall be immune to spurious outputs, spurious process
3
indications, or damage due to RFI, EMI, or induced switching surge in accordance with
IEC-61000-4 parts 1 thru 6 inclusive.
The system shall be constructed so that:
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OIL FIELDS COMPANY CONSULTING
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Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

• The electromagnetic disturbances generated are limited to the levels indicated in the
codes.
• The system has an appropriate level of intrinsic immunity against electromagnetic
disturbances allowing its correct operation according to its purpose.
The Supplier shall provide erection instructions so that, once installed, the EMC
requirements are maintained.

8.4 HARDWARE REQUIREMENTS

8.4.1 CENTRAL PROCESSING UNIT (CPU)

CPU shall utilize proven generation microprocessor, open standard connectivity and will
be capable to receive and transmit different signals and perform regulatory control and/or
logic sequence control.
Control functions will be physically distributed among different devices exchanging
information in a peer-to-peer mode. Microprocessors shall have non-volatile memory or
battery back-up with alarming of the battery failure in the system and shall perform their
control functions without access to operator stations or communication buses. Loss of
communication to operator workstation and bus shall not stop communication between
process and CPU or stop working.
Control devices shall be designed to minimize the consequence of a card failure. Self-
diagnostic shall be an integral design feature to enable a device performance to gracefully
degrade through multiple well-defined performance levels.
CPU’s shall be fully redundant in double modular redundant arrangement fed from
different power sources to ensure control strategy integrity for all control loops and to
ensure continued automatic control in the event of hardware failure (single failure in the
controller or in the control I/O subsystem).
Repair/Exchange of defective module shall be possible without affecting plant operation.
Failure of any controller shall cause an alarm to be generated on the operator workstations
and shall be logged. Loss of both CPUs shall cause system outputs to drive to predefined
fail-safe condition. Operating system software and user-written configuration shall be
resident on a non-volatile memory.
Resetting the controller shall reload the configuration without the necessity of a new
download from a central data base; during this process the outputs shall maintain the last
values. The instrument or internal tags within a system shall be organized as a real time
data base. Point will be identified by their tags (or equivalent) not by their physical
address, and shall be accessible by other devices.
It shall be possible to determine the sequence of the execution of tags (or blocks).
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Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

Self-diagnosis for the CPU’s shall be provided. The system memory and user RAM shall
be checked at frequent intervals. Errors shall be immediately alarmed, but shall not
shutdown or de-activate the DCS unit itself. The system shall be able to report
communication or CPU error.
No operator action shall be required for restart of the system following a complete power
failure. Recovery of the process control units after power failure shall be automatic with
control loops and sequence control placed in specific predefined modes of operation.
The controllers need to be supplied with a maximum set of functionality to allow easy
configuration of the system and comfortable operation of the plant.
To minimize configuration effort, the process control unit shall have pre-configured data-
acquisition and control algorithms. It shall be possible to add user-defined functions
written with a programming language. The algorithm shall be adjustable from any operator
workstation provided that the access control allows it.
Each input could be conditioned according to the requirements with filtering,
compensation, sampling/holding and bad measure detection.
During operation, switching from auto to manual output mode or set-point switching from
local to remote shall be bump-less without manual adjustment of balancing.
The controller must handle a large number of binary inputs and outputs and support logic
functions such as AND, OR, XOR, NOT as well as timers, delays, counters.
Controller shall be capable of registering and stamping events in the exact sequence of
arrival.

8.4.2 OPERATOR INTERFACE SUB-SYSTEM

All operator and engineering stations shall support MS-Windows latest edition
environment as well as OPC connectivity for communications, via appropriate server and
routers, to external locations.
Each workstation shall be an industry standard PC. Technical specifications of supplied
workstations shall be based on the latest technology.
An Ethernet interface with TCP/IP protocol shall be provided if required.
Each workstation shall be provided with its own dedicated electronics. It shall be identical
in hardware and software, presentation, operation, performance and capabilities.
Each operator workstation shall be capable of accessing plant-wide process data.
It shall be possible to operate the whole of the plant through each operator workstation.
The failure of one operator workstation shall only cause the loss of the associated operator
workstation and all others shall continue to function.
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

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Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

Access codes may be used to separate the operation of different units. However, each
operator workstation shall be potentially capable of operation and monitoring of the total
plant.
In the case of one operator workstation failure, it shall be possible to replace the defected
station with any of other operator workstations.
It is required that all engineering functions and detailed diagnostics be performed via an
engineering workstation. The levels of security access shall be provided for use of the
operator, supervisor or engineer as appropriate.

8.4.3 VIDEO DISPLAY UNIT (VDU)

VDU’s shall be suitable for mounting in the operating and engineering workstations and
shall support following features:
• 21” LCD (dual head for operating workstations)
• High resolution (min 1600 x 1200 Pixel)
• Low radiation according to TCO’99 & ISO 9241
• meet the requirement of ISO 9241
Loudspeakers are preferably to be integrated in the VDU’s. Additional Loudspeakers may
be required if integration is not supported.

8.4.4 COMPUTER ELECTRONICS

The computer electronics used for operator workstation, engineering station and other
workstations shall consist of a microprocessor based system that supports the keyboard(s),
VDU(s), drives(s) and printer(s) to transmit and receive data from devices via the data
communication system.
All electronics shall be classified for industrial use. They shall be of latest proven
technology and generation at time of procurement.

8.4.5 PRINTERS

All printers shall be “addressable” from each operator workstations via network to enable
print out from any connected workstation to allow for the following functionality:
• Print out all alarms and events as well as alarm acknowledgement in a chronological
order as stamped in process control unit
• Print out all operator actions (change of control modes, limits, start/stop, shutdown
procedure and other specific status changes) as soon as they occur
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Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

• Print out lists, reports and text-based information provided by the system or generated
in an integrated computing modules and/or external process control.
• Print out color screenshot from the actual graphic from any operator station When a
printer is out of order (paper out or other fault conditions), alarms or events shall be
stored into operator stations and printed when printer returns to normal operations.

8.4.6 KEYBOARD & POINTING DEVICE

PC Keyboard (preferably membrane type) and mouse or track-ball for each operator
station shall be provided for full interface capability to process, loop configuration and
system check. The keyboard shall enable the user to perform operating, trend grouping and
configured function with dedicated and/or variable keys.
Pointing device shall allow performing certain actions by pointing and clicking. It shall not
be capable to initiate a control function directly by pointing to a target; confirmation must
be made such as by pressing additionally the “enter” key or a standard “mouse click”.

8.5 I/O MODULES

I/O modules shall be capable of supporting various types of signal from all kind of
continuous and discrete sensors/devices.
The modules shall be self contained and independent modules, capable of being removed
from and inserted into a fully powered and operational rack without risk of damage.
Failure and subsequent replacement of an I/O module shall not affect other modules.
An LED indication of power, error condition, and status shall be provided on each module.
All loops, i.e. all I/O channels, have to be electrically isolated from each other. The
connection between remote I/O stations and the system bus in the main control room shall
be redundant.
For analog and digital signals, intrinsically safe galvanic isolators shall be provided
mounted in marshalling cabinets, supplier to provide with bid full details of the IS
characteristics of galvanic isolators.

8.5.1 ANALOG INPUT

The input modules have to be able to communicate with field devices via HART protocol.
Supplier shall state the maximum resistance and maximum loop length allowed for 4-20
mA analogue inputs.
4-20mA analogue input modules shall power majority of field transmitters. Signal filtering
and short circuit protection by current limiting or fuses shall be provided for each channel.
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Accidental application of main supply voltage or test voltages shall not damage the
modules. Supplier shall state limits that his standard equipment can withstand.
Supplier shall provide details in his proposal of all available analogue input types and
ranges that can be accommodated with his standard DCS.
The equipment shall accept SMART/HART transmitters operating in 4-20mA analogue
mode for process control with digital device information superimposed on it.
Remote SMART transmitter calibration and maintenance shall be provided directly
through DCS or through a dedicated PC based system.

8.5.2 ANALOG OUTPUT

Analogue output modules shall be powered by DCS using 24V DC supply. Analog outputs
shall be fully redundant. Supplier shall state the maximum resistance and maximum loop
length allowed for 4-20mA analogue output. The output interfaces should be able to
operate at least from 5% below to 5% above the standard 0-100% signal range.

8.5.3 DIGITAL INPUT

Digital inputs will be signals from volt free contacts or proximity switches powered by
DCS using 24V DC. Supplier’s system shall accommodate both normally open and
normally close contacts.
Supplier's interface shall include circuitry to insure that any "chatter" or "bounce"
encountered during contact closure does not initiate an erroneous alarm.
I/O isolation shall be provided where required, for signal from devices externally powered
or which may be subject to high voltages (e.g. AC power).

8.5.4 DIGITAL OUTPUT

Digital outputs shall be relay type, isolated, free of voltage.


The contact outputs shall allow for:
• maintained or latched contact
• Normally open/normally closed outputs. Fail-safe position for each channel is required.
• Powering the contact(s) of output relays for field devices. Supplier to advise proposed
scheme with bid.
Output relays shall be capable of handling a 2A inductive load at 24V DC.
Relays shall be plug-in type with socket, hermetically sealed with gold plate contact and
provided with LED indication. Mercury switches are not acceptable.
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8.6 SPARE CAPACITY/EXPANDABILITY

A minimum of 20% installed spare capacity for all types of input/output signals shall be
allowed to provide sufficient increase during the detail design phase, and 20% spare space
capacity should be allowed for future expansion. This is to include for later addition of
new I/O chassis, terminals, etc. as required.
The system shall also be designed such that after commissioning, no more than 70% of the
system software (capacity/memory) is utilized.
The system communication networks shall allow an increase of 70% in terms of number of
nodes with no noticeable degradation of system performance and access time.
All system internal communication networks shall be adequate to allow for an increase of
30% in the size of the configured database with no noticeable degradation of system
performance and access time.
The supplied controllers and associated I/O sub-system shall be sized and supplied with
stated spare capacity. All spare capacity of I/O cards for each type of I/O signal shall be
installed and wired prior to FAT.

8.7 SOFTWARE REQUIREMENTS

8.7.1 GRAPHIC DISPLAY

Graphic pages shall be the primary tool for the operator to monitor and control the plant.
These pages shall graphically show process lines, equipment and associated
instrumentation.
From these graphics the operator shall be able to view plant status, operate loops, start/stop
sequences, start/stop motors, and etc.
All graphic pages shall be subjected to Client’s approval.
The following information shall be made available, as a minimum, from the graphic pages:
• Measured value for each AI
• Measured value and output for each controller
• Status of DIs and DOs via change of state and color of the device e.g. valve.
• Alarms, if any, for both AIs and DIs
• Input inhibit/override status of instruments or equipment
Page links from one graphic to another shall be provided. Buttons allow the operator to
navigate to the previous and the next page as well as to pages that are related to the actual
page due to the process.
Additional graphics shall be provided as overview graphics; overview of the plant, and
unit overview. The unit overview shall be a simplified representation of one unit. It shall
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contain page links, i.e. buttons with which the operator can navigate to each individual
graphic of the respective unit.
The plant overview shall be the same for the complete process plant with all its process
units. Their page links shall call up the respective unit overview.
Access to group displays directly from the overview graphics shall be possible.

8.7.2 GROUP DISPLAY

The group display shall indicate the status of control loops and process variables, which
are pre-assigned in a group. The group display will contain 8 loops or tagged points that
correspond to the grouping in the overview display.
Group display shall associate with graphical interface to present process input and output,
set points, mode of control loop, alarm status, etc.
For analogue points, information such as process variables, set-points and outputs shall be
shown as bar graphs as well as numeric values. For digital points the relevant status shall
be displayed. Numeric values of set-points, process variables and output of controllers
shall be displayed in engineering units.
Each point shall be identified by tag name and service description.
From this display it shall be possible to view real-time and historical trends relevant to the
loop. From these displays the following operations shall be possible:
• Change set-points and control mode (auto/manual)
• start/stop motors
• Manipulation of controller output
• Single loop selection to access the loop detail display. Loops or variables controlled by
external systems interfaced to the DCS will be presented in similar way.
There should be no limitation to assign a tag in several pages of the group displays.

8.7.3 ALARM AND EVENT DISPLAY

The DCS shall be able to manage process, safety and system alarms from any operator
station and ensure the following:
• Manage alarms into system status, process and safety alarms. Process alarms are
generated by deviations from normal operating conditions and safety alarms are
generated by the safety systems ESD or the FGS system.
• Different levels of alarm priorities shall be distinguished by audible and visual means.
• Alarm function shall be automatically printed and historized. In addition, an indication
of the alarm status shall appear on the current display on each operator workstation and
provide a cross-reference to the alarmed variable page.
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• It shall be possible to chronologically and systematically display a summary of all


alarms on standard alarm displays. The alarm display shall list the tag number and
description, process unit, type of alarm and acknowledge status, time and date for each
alarm as a minimum. Process and system alarms shall have segregated summary
display.
• Display and print with time stamp of all events and operator actions (e.g. set-point
changes, selection, stop/start drives, etc), including; as a minimum; time and date of
occurrence and event description.
• The possibility to inhibit alarms on each operator station shall be protected by access
control.
• The system shall be provided with the capability of grouping alarms on the basis of
process units, alarm priority, etc, so that unnecessary alarms can be filtered.
• Alarm acknowledgement function shall acknowledge an alarm on all operator stations.
• All alarms and events shall be captured and recorded.
• The alarms will be stored in a FIFO (first in- first out) memory containing 10000
alarms considering nevertheless that system and process alarms shall not be lost in the
event that alarm summary buffer overflows and new alarms occur.

8.7.4 TREND DISPLAY

The system shall be capable of displaying both real time and historical trends in graphical
form for one or more analogue or digital variables. The following information related to
trends shall be displayed on screen:
• pre-set values, set-points, outputs and calculated values for analogue variables
• status of digital variables
• engineering units
Real time and historical trends will be displayed in groups of up to 8 parameters
simultaneously on one trend display. Each variable shall be represented by a different
color and shall be dynamically addressable by each pen. Standard features such as zoom,
scaling of time axis, etc. make it easier to analyze the trend characteristics.
Trend time resolution will be configurable from 1 second up to 60 minutes
The physical scale shall be automatically adjusted to the minimum and maximum of the
physical value displayed. A manual adjustment of the scale shall be possible.
The operator shall be able to configure online new trend groups as required.

8.7.5 REAL TIME TREND


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All analogue variables shall be provided with real time trending capability. These include
analogue values received via serial links.
The DCS shall be capable of producing real time trends with a Vendor-defined sampling
time. The System shall be capable of real time trending of digital input.
The DCS shall provide loop tuning displays with trend display of process variable, set-
point and output signal with Vendor-defined sampling time.
The smallest duration that the DCS can produce real time trends and possible sampling
times shall be provided by Vendor at control system bid stage.

8.7.6 HISTORICAL TREND

All analogue variables shall be historically trended and archived.


The DCS shall be able to store analogue process points or calculated variables for Vendor-
defined duration with a Vendor-defined scan time. It shall be possible to store groups of
variables with different scan time.
Maximum possible storage duration shall be provided by Vendor at control system bid
stage.

8.7.7 SELF-DIAGNOSTIC DISPLAY

Dedicated graphic displays shall be made available to show the status of each device
equipped with diagnostic functions. The system shall indicate the faulty component when
failure has been detected.
The system shall allow the operators or the maintenance personnel to interrogate the field
device to determine the nature of failure. The system shall also allow the field device to be
configured.

8.7.8 REPORTS

It shall be possible to print reports of all measured and calculated parameters, operator
actions, alarms etc. from operator workstations.
Standard and custom report configuration facilities shall be provided. Reports may be
printed by scheduled printing at end of shift, daily, and weekly and monthly basis or by a
user-defined function key at any time.
The report format shall be as per Vendor’s standard, however Vendor shall not only
consider and implement Client demands but also indicate the capabilities and feature of the
report provided with the system.
The report may be generated by scheduled printing or by a user-defined function key at
any time.
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8.7.9 CONFIGURATION TOOLS

Changes in the user-written configuration shall be downloaded to the CPU’s on line from
engineering workstation without bumps on the outputs and without affecting the normal
operation of the part of configuration which has not been modified.
The Engineering Workstation shall be complete with configuration tools for all DCS
nodes, including the facility to build custom graphics, report generation and Field devices
configuration as well as interrogation.
Tools for easy configuration control strategies shall be available. These tools shall be user-
friendly, modular, object oriented and self-documenting. No low-level programming shall
be used to implement the standard functions. The necessary standard system software
package such as compiler, linker, cross assembler, debugger, system diagnostic, picture
generation, text and database editors shall be available.
Configuration and tuning facilities shall be accessible only through software or hardware
keys or password access.
All system configuration and programming tools shall be according to IEC 61131
standard. The following tools shall be supplied as a minimum:
• At least one high level programming language
• Ladder logic programming language;
• Functional block programming language;

8.7.10 SYSTEM SECURITY

The system shall support at least three different levels of access control either via the use
3 of a removable key and/or by entering a pre-configured password. It shall also be possible
to configure user-specified functions to each level.

View only this level shall facilitate 'View only' functions and will not require a key or
password.

Operator Level this level shall include typical operator functions and will require a key or
password.

Supervisor Level this level shall include all the operator functions as well as the pre-
configured supervisory functions and will require a key or password.

Engineering Level this level shall include all functions and will require a key or password.
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Different type of keys shall be used for the operator, supervisory and engineering levels.
Once removed, access shall revert to the 'View only' level.

8.8 COMMUNICATIONS

All communication networks of the DCS shall be based on a digital communication bus
providing a high speed and reliable data transfer between all systems modules (operator
interfaces, I/O cards, controllers etc.).
The digital communication link shall be capable of utilizing fiber optic or coaxial cable
(depending on the manufacturer’s standard and distance of the system components to be
connected) that provides a high-speed communication path between all control devices,
interface modules and multiple operator interfaces.
Any DCS back-up communication device (cables, 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.
Communication system shall have diagnostic capabilities and the failure of an active
communication link as well as switching over to reserve link shall be transparent to all
components on the communication link.
Transfer to a back-up communication channel shall be automatic and without disrupting
the system operation, but alarmed at the operator station and logged to the system
historical file. A manual switchover of the communication channel must be possible.
It shall be possible to connect or disconnect any devices to/from the communication
subsystem without disrupting normal operation. A failure of any connected module shall
not affect the communication between the other modules, subsystems and nodes.
Each device shall be electrically or optically isolated from the data communication system.
Optical isolation is preferred.

8.8.1 COMMUNICATION WITH EXTERNAL SYSTEMS

Point to point serial links and interconnecting cables shall be provided by Supplier to
connect the DCS and the relevant external system such as Emergency Shutdown System
(ESD), Fire & Gas System (FGS) and etc.
Serial communications shall be redundant if performing control functions and non-
redundant if for alarm/indication only.
Serial interfaces to other control devices will generally be RS-485 with MODBUS RTU
protocol. Redundant ports on a single module shall not be used for redundant
communication, due to loss of communication in case of replacing module.
DCS Supplier shall provide the following:
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• Hardware interface equipment, including cables, communication modules, line drivers,


Fittings and all other necessary items
• Software driver(s) to enable the communication functions
Each point shall have the possibility to be alarmed individually. These alarms shall be
processed by the DCS in the same manner as other process alarms detailed above.
Supplier shall describe, in detail, all interfaces, links, and software tools supplied. Supplier
shall provide the entire interface configuration specifications and information that allow
external systems Suppliers configure their communication ports.
The DCS Supplier shall demonstrate the functionality of data exchange between DCS and
other systems during FATs at the third party supplier’s works and at DCS supplier’s
works.

8.9 CABINETS AND RACKS

8.9.1 GENERAL

The supplier’s standard system cabinets shall be used. The cabinet design shall allow full
and easy access to all components, connections, terminations and assemblies. Supplier
shall adhere to following minimum requirements:
• Cabinets shall be free-standing and constructed taking into account delivery and
installation requirements.
• Overall cabinet dimensions to be approximately 2100mm high x 800mm wide and
800mm deep with front and rear removable and lockable hinged doors.
• Protection class for indoor cabinets shall be IP 42 minimum.
• Cabinets’ finish to be smooth. They shall be painted according to IPS standard. Any
other painting shall be subject to Client’s approval.
• Separate earthing bus-bars shall be provided for Plant Earth (PE), Instrument Earth
(IE) and Intrinsically Safe Earth (ISE).
• Provisions for termination screens on an individual basis shall be provided.
• The cabinet layouts shall allow full and easy access for installation and maintenance
requirements.
• Cable access shall be bottom entry via suitable cable clamping mechanisms.
• The panels and cabinets shall be totally enclosed by cold rolled steel; thickness shall be
as per IPS standard.
• Care shall be taken to have the faces of panels flat and smooth
• Panels and cabinets shall be fixed to the frame using anti – vibration mountings
• All cabinets shall be equipped with removable lifting eyes.
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• Control panel front door shall be provided with a glass window to facilitate viewing
modules condition, LEDs, and etc.
The following devices shall be installed in each control panel/cabinet:
• Internal lighting (at the top of the panel/cabinet) controlled by a door switch
• A fan (if required) with fuses and switch
• Ventilation louvers and filtering units to ensure adequate heat dissipation and dust
protection
• Panel/cabinet bottom plate for cable access
• Door key locking device
• Drawings pocket
All cabinets shall be fully equipped, wired, tested and ready to be installed on site. The
Supplier shall also implement the required spare capacity and expandability (20% installed
3
spares with an additional 20% spare space for future expansion.)

8.9.2 SYSTEM CABINETS

System cabinets shall include all equipment required by an “operating system” such as
CPU (Central Processor Unit), power supply distribution, controller units, I/O modules,
HART/Smart modules including interface with communication cards and power supplies.

8.9.3 MARSHALLING CABINETS

These racks shall perform the marshalling function between:


• Incoming multi-pair cables from the field or control room to be wired on field
terminals with disconnect and test facility.
• System cables provided by Supplier to be connected to plug in type connectors within
the system cabinets and marshalling racks.
I/O signals shall be grouped based on IS and NIS and the following signal types:
• 4-20mA Analogues
• mV/RTD Signals
• Discrete (Digital) Signals
Digital inputs and outputs shall be fuse protected if not protected by the system I/O card.
Field terminations shall be rail mounted type.
Sufficient terminals to accommodate all the cores and screens of incoming and outgoing
cables using knife-edge terminals complete with markers shall be provided. All terminals
shall be complete with test facility.
IS terminals shall be colored light blue.
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Partitions shall be included between terminals for different voltages and when required by
the regulations. AC terminals shall be shrouded and flashed accordingly.
Separation between signal and power wiring shall be maintained.
All IS/NIS field cables shall be terminated at terminals. Spare cores shall be terminated at
spare terminals (one per core). Galvanic isolators for all spare I/O shall be provided.

8.9.4 SYSTEM WIRING REQUIREMENTS

Supplier is responsible for the provision of all interconnection cabling and flexible leads to
peripherals etc., including cores between marshalling cabinets and system cabinets.
All wiring inside cabinets shall run in dedicated plastic ducts or wire ways, and neatly
loomed and secured with tie – wraps and anchors.
All discrete wiring shall be multi stranded with sufficient current carrying capacity. A
3
minimum cross sectional area of 1.5 mm2 shall be used unless otherwise stated.
Wire ways/ ducting shall be to provide sufficient segregation between AC and DC wiring
and will be able to accommodate 30% more wiring.
System card bins shall be interconnected with plug and socket type system cables or
ribbon type cables and edge connectors. The sockets and both ends of the cables shall be
labeled with the “Origin” and “Destination” tags.

8.9.5 GROUNDING

The cabinets and panels shall be provided with the following earth bars:
• Safety earth bar (For electrical supplies, bond to metallic frames of cabinets and
panels)
• Instrument earth bar (for earthing field cable screens in accordance with NIS device
requirements)
• Intrinsic safety earth bar (for earthing IS cable screens and barriers)
A tinned copper safety earth bus bar shall be mounted inside the cabinet or panel and
connected to the frames. Separate tinned copper ground bus bars shall be provided with
clear demarcation in each cabinet or panel for instrument earth and IS earth. Instrument
earth bus bar and IS earth bus bar shall be isolated from each other and from the safety
earth.
All metal parts of the equipment not associated with the circuits shall be bonded to the
main chassis. Serrated washers shall be used to ensure electrical contact between metal
parts.
Doors and other removable parts shall be bonded using flexible braided earth straps,
suitably sleeved for protection.
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The earthing system shall be organized into separate circuits, as required for protection and
for reference. The circuits shall be completely independent. Supplier shall detail the
requirements of the earthing system (power, signals, shields, etc.).

9.0 INSPECTION AND TESTING

9.1 GENERAL

In addition to the quality assurance requirements referred to in this specification, the


following shall also be complied with:
• All instrumentation and controls shall be inspected and tested by the Vendor in
accordance with relevant standards/ specifications as a minimum.
• All tests and corrective work shall be recorded to the Purchaser’s approval.
• The panel Vendor shall ensure that all inspection and tests are completed and
satisfactory.
• The Purchaser reserves the right to any additional inspection work if Vendor’s
preparations are found to be unsatisfactory.
This specification is concerned with final inspection and testing of equipment prior to
dispatch. Preliminary inspection e.g. to examine cabinets or consoles during or on
completion of fabrication will be performed as necessary and recorded separately.
Vendor shall not offer the equipment for testing until he has carried out his own shop tests
to the latest approved drawings and documents and has ensured that the equipment is
functioning satisfactorily and is complete in all aspects. Certificates and completed test
dossiers shall be available as evidence of this work.
Following the Vendor’s Internal Factory Acceptance Tests (IFAT), the Vendor shall
demonstrate that the equipment fully meets all requisition requirements in accordance with
the requirements of this specification, related and referenced documents. Purchaser’s
inspector(s) will be present throughout the demonstration, and deviations from this
specification may occur only with the Purchaser’s agreement. Such deviations shall be
recorded.
For the demonstration, Vendor shall provide:
• Two complete sets of the latest reviewed drawings, specifications and data sheets for
the system(s), and operation/maintenance procedures
• All necessary personnel with relevant equipment to perform the tests
• A test plan, procedure and test record dossier for all tests to be carried out
Faults discovered during inspection and testing shall be rectified as work proceeds and all
previously tested circuits affected by the repair work shall be retested. Vendor shall mark
up and retain one set of drawings and data sheet for the subsequent production of ‘as built’
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information. The equipment shall be tested as a fully assembled package complete with all
cabinets, electronic modules, operator stations, etc, and complete with all cord sets and
interconnections. Where an assembly or circuit is incomplete for any reason or where
temporary wiring is installed, then the inspector’s agreement must be obtained, and details
shall be recorded.
A report and completed test dossier shall be produced by the inspector on completion of all
inspection and testing, or at intervals as testing proceeds. A release certificate will be
issued by the inspector when all testing has been completed to his satisfaction, and
equipment may then be dispatched to site.
Purchaser’s Factory Acceptance Test (PFAT) shall include but not be limited to:
• Visual inspection
• Elevated temperature tests
• Hardware testing
• Functional testing
Vendor shall formally submit a test procedure for the PFAT to Purchaser for review at last
eight weeks prior to presenting the system for test. The content of this procedure shall be
discussed in detail with Purchaser prior to formal submission.

9.2 INSPECTION

All individual items of equipment and the completed system shall be subject to shop
inspection by the Purchaser.
The offered system shall be visually inspected to ensure that it has been constructed to the
specifications, data sheets and to the approved drawings. This shall include but not be
restricted to the following:
• Use of instruments and components previously approved by the Purchaser.
• Standard of components and assemblies finishing.
• Overall dimensions, fixing points, and lifting points to approved drawings.
• Frameworks sufficiently rigid to support equipment without distortion.
• Individual instruments accessible for adjustment and / or maintenance without removal
of wiring, supports and other instruments.
• Heat generation equipment suitably located with provision for cooling, if necessary.
• Tags, nameplates and warning labels provided as per specifications.
• Terminals and wiring segregated and protected and secured to meet hazardous area and
electrical safety requirements.
• Wiring and trunking to be sized colored and identified in accordance with codes and
specification.
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• Adequate space allocated for future additions and changes, as specified in the technical
documentation.
• Earthing, both for instrument and electrical purposes according to Vendor’s agreed
standard, if any, and with Purchaser’s specification requirements.
• Identification of fuse holder with the fuse rating and service, and examination of fuses
and isolating to ensure that they are connected to the correct circuits.
• Checking of circuits for the correct polarity.

9.3 TESTING

These test procedures shall satisfy the requirements of relevant standards for instruments
panels as a minimum and shall include but not be limited to the following items:
• All panel wiring including system interconnection wiring shall be tested for insulation
and the test voltage shall be compatible with the wiring being tested (equipment likely
to be damaged shall be disconnected for these tests).
• All panel wiring shall be tested for continuity against Purchaser approved wiring
diagrams.
• All equipment shall be tested for electromagnetic interference according to BS 6667
part 3 to show immunity or degradation of normal operation from EMI.
• Wiring identification for all panels.
• Full simulated function tests of the complete unit with all equipment in position and
connected to suitable temporary supplies. These tests must be performed at the
maximum operating voltage limits and at the limits of ambient temperature. The
Vendor shall provide the test simulator consisting of dedicated devices for every input
and dedicate dummy loads with indication of the status of every output. The test
simulator shall only be connected to the field connection terminals or systems cable
terminations and the input – output interface shall be individually labeled to facilitate
testing. The Vendor shall obtain Purchaser’s approval of supply unit characteristics and
simulated input – output interface.
If a component failure occurs, all tests shall be repeated so that all components have
undergone the minimum testing specified.
During the functional tests, all equipment shall be powered up and shall remain powered
throughout the test period. Test equipment shall be connected at field terminals only and
not at any intermediate point, with the objective of testing the complete system, or system
loops, as it will be installed. If termination and marshalling racks have been shipped in
advance, testing shall be from the test panel.
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

Project Title : Basic Engineering Of PROGRAM NO.: 1720 31 OF 38


Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

For circuits with milliamp input or output circuits, resistors shall be introduced at the field
terminals to simulate field devices, and the resistance varied up to the maximum permitted
by the manufacturer’s specification.
Alarm circuits shall be checked by open circuiting inputs at the field termination rack or
test panel.
Alarms shall be tested to verify that:
• The correct alarm display operates on all appropriate pages.
• There is no interaction with any other non associated circuit.
• The alarm sequence is correct.
• The alarm suppression facilities are correctly implemented.
• Logging facilities at display and printer are in the correct format and resolution.
Where alarms are derived from an analogue signal within the DCS, the alarm operation
shall be verified by varying the signal input.
Alarms and displays shall be fully checked. All equipment failure modes e.g. failure
safety, power supply disconnection, etc. shall be checked.
The completed system shall be tested at three stages:
• Board and assembly level checks in accordance with the Vendor’s QA/QC plans and
procedures.
• Vendor’s internal factory acceptance tests (IFAT) on the completed system.
• Purchaser’s factory acceptance tests (PFAT) of the completed system. Provision shall
be made for the Client’s attendance in FAT.
Communication link between Process Control System and F&G system shall be tested
during PFAT at Process Control System Vendor factory with F&G simulator system.
Necessary coordination and providing the simulator at Process Control System Vendor
factory shall be considered by supplier.
This specification relates only to PFAT (3rd stage), but test procedures and certificates of
conformity for 1st and 2nd stage tests shall be submitted to Purchaser’s inspectors to verify
that Vendor’s own QA plans and procedures have been implemented at all phases of
system assembly. Such procedures and certificates shall be available to Purchaser’s
representatives at the time of commencement of PFAT.
Final acceptance testing shall however take place when installed and connected to ensure
compliance with, but not restricted to, the scope and requirements of relevant
standards/specifications.
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

Project Title : Basic Engineering Of PROGRAM NO.: 1720 32 OF 38


Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

10.0 PREPARATION FOR SHIPMENT

The Vendor and any sub – Vendor shall comply with the preservation and packing
specification and the marking. Documentation and dispatch instructions shall be provided
after satisfactory completion of all tests and inspections.
The Vendor shall take all precautions deemed necessary for protection during shipment
and additionally during storage in a marine environment including the following:
• A desiccant shall be provided inside all enclosures to prevent damage by high
humidity.
• The Vendor shall supply a recommended procedure for long term storage (up to 12
months) with the quotation.
• Equipment shall be suitably packed including any dismantling, transit fastening and
bracing necessary to prevent distortion or damage during shipment.
• Each individual carton or box shall be marked with the instrument tag number on the
top and side of the carton.
Supplier shall submit the packing specification and the Purchaser’s prior approval.
No items of equipment shall be shipped without the Purchaser’s prior approval.

11.0 VENDOR DOCUMENTATION

Supplier shall prepare and supply the following technical documentation:


• Bill of materials including quantity and manufacturer
• System Architecture schematic with all subsystems and peripherals (including room
and building locations).
• Functional Design Specification. FDS sections and layout shall be agreed with
Purchaser.
• Block diagram of the system with all cabinets and peripherals showing the
interconnecting cables and room/building locations.
• Overall dimensional drawing of each equipment, indicating cabinets, VDU, printer,
etc.
• Equipment fixing details showing weights, shock loading, minimum clearance to other
items of equipment and wall.
• System cable list/ schedule (including gland size)
• Drawings for relevant cable interconnections between suppliers’ equipment (and if
necessary other equipment) showing all necessary terminal/pin and wire identification
references for onsite connection.
• I/O schedule in a format to be decided during detail design. Cross Wiring Schedule
from field terminals to I/O cards
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

Project Title : Basic Engineering Of PROGRAM NO.: 1720 33 OF 38


Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

• System power consumption


• Power distribution diagrams
• Documentation required from authorities to obtain export licenses to destination
country
• Reference manuals of all software packages and hardware modules
• User and maintenance manuals of configuration tools
• System programming details
• System configuration (including redundancy of components and interfaces to other
equipment and systems)
• Performance calculations
• Availability/reliability analysis
• Instrumentation loop diagram for all equipment in Supplier’s scope
• Color hard copy for all the custom graphic displays
• DCS address table of serial data exchanged with external systems
• Installation recommendation – documents to take into consideration local conditions
• Operating and maintenance system manuals
• Susceptibility of RFI and EMI
• Acceptance test procedures (FAT, SAT)
• Spare Parts list (including parts for Commissioning/Start-up and two years operation
and Consumables)
• All relevant and necessary certification i.e. hazardous area/IS certificates
• Application software details
• As-built drawings after commissioning

12.0 QUALITY ASSURANCE

The Vendor shall preferably operate a quality system to the appropriate part of ISO 9000:
2000 or an equally recognized national QA standard, commensurate with the type of goods
and scope of services provided.
The Vendor shall provide a copy of his QA manual which shall describe the Vendor’s
quality system.
The documentation of the quality system shall include quality management objectives,
policies and organization to demonstrate compliance with the QA standard stated in the
contract.
Purchaser, or appointed representative, reserves the right to carry out quality audits at the
Vendor’s/sub – Vendor’s office and works, to verify that the quality system is being met.
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

Project Title : Basic Engineering Of PROGRAM NO.: 1720 34 OF 38


Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

The Vendor quality plan shall be provided showing the planned activities, resources and
events serving to implement and record the implementation of the Vendor quality system
relevant to the goods.
The quality plan shall list documentation/design reviews and for each item of equipment,
major assembly or sub – supplier item, the principal manufacturing steps, type of
inspection/test, the controlling procedure, and the acceptance standard. The quality plan
shall include space for Purchaser to advice whether the inspection will be by Purchaser,
third party, or Client. Vendor shall indicate on the quality plan all surveillance that Vendor
will carry out of sub – Vendor’s goods.
Vendor may use his standard format of quality plan.
The quality plan will be discussed with the Vendor during any pre – production meeting at
the Vendor’s works. The agreed quality plan will be held by the Vendor. Supplier’s
inspector, Purchaser’s inspector, and any other authorized inspectors will demonstrate
successful conformity of each inspection activity with the agreed quality plan.
The Vendor shall give his sub – contractors or Suppliers assistance in attaining the
required standard if necessary. This shall not relieve the Vendor of his responsibility for
the quality of the completed work.
Vendor shall organize prefabrication/inspection meetings with the Purchaser and the
nominated inspection agency.

13.0 ADDITIONAL PROTECTIONS

These requirements shall be provided for the protection of personnel, equipments,


buildings and structures against the hazards posed by electromagnetic pulse for the
reduction of noise and electromagnetic interference.
The electromagnetic pulse protection shall be achieved by means of:
- Shielding
- Bonding & Grounding
- Line Filters

13.1 SHIELDING

a. The shielding shall provide at least 80 dB attenuation to electric and magnetic fields and
plane waves in frequency range from 150 kHz to 10 GHz when the building or shelter is
tested in accordance with MIL STD 285.
b. The attenuation requirements apply at all locations within the control & ITR building.
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

Project Title : Basic Engineering Of PROGRAM NO.: 1720 35 OF 38


Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

c. All doors, apertures (e.g. inlet/outlets) entry panel, and any penetration through the shield
must be treated in such a way that the shield attenuation is not degraded below the figure
quoted in a. above.
Prevention of degradation of electrical continuity and therefore the attenuation capability
of doors and panels is a serious maintenance concern. The design of doors, panels and
apertures must consider the long term effects of ageing, corrosion and mechanical stress on
all mating surfaces from the shield to the door, panel or apertures.

13.2 GROUNDING AND BONDING PRINCIPLES

13.2.1 STRUCTURES

1- All structural joints should be electrically well bonded.


2- No untreated grounding conductors may penetrate or cross the structural boundary.
External grounding conductors must be bonded to the outside of the structure. Internal
grounding conductors must be bonded to the interior surface of the structure or enclosure.

13.2.2 NON-ELECTRICAL UTILITIES

1- Utility pipes must be bonded to the structure at the point of penetration. If possible,
peripheral bonding to a penetration panel or through a shielded entrance vault is preferred.
2- All utility pipes should be bonded to the earth electrode subsystem at the point of crossing
the subsystem. Utility pipes should have an insulating section inserted immediately outside
the earth electrode subsystem.
3- All utility pipes outside the zone oil boundary should be below grade.\

13.2.3 HEATING, VENTILATION, AND AIR-CONDITIONING

Filters and TPDs installed for noise suppression and transient protection must be grounded
to their mounting enclosures (which presumably are mounted directly on the housing of
the HVAC equipment) with direct Connections or with minimum length conductors.

13.2.4 COMPUTERS AND DATA PROCESSING

1- A signal reference subsystem must be established. This ground reference subsystem will
consist of multiple interconnections between equipment cabinets, frames, and racks;
between conduit, raceway, and wire way; between these communication subsystem
members and structure; and shall incorporate raised floors into the reference subsystem.
2- Where space and accessibility exist, a wire mesh grid may be installed at floor level or
overhead to supplement the above cabling network. Equipment enclosures and racks
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

Project Title : Basic Engineering Of PROGRAM NO.: 1720 36 OF 38


Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

should be bonded to this wire mesh. The mesh should be bonded to structure at each point
where structural members are accessible.
3- Both ends of shielded cable shall be terminated to case or enclosure. Continuous peripheral
bonding of the shield is best.
4- Filters and TPDs installed for noise suppression and transient protection must be directly
grounded to the enclosures of the protected equipment. TPDs installed in distribution
frames and junction boxes must be terminated directly to the ground bus or to the
mounting enclosure. The ground bus and the mounting enclosure must be bonded to the
fault protection subsystem with minimum length conductors.

13.2.5 CONTROLS

1- Both ends of shielded cable shall be terminated to case or enclosure. Continuous peripheral
bonding of the shield is best.
2- Filters and TPDs installed for noise suppression and transient protection must be directly
grounded to the enclosures of the protected equipment. TPDs installed in distribution
frames and junction boxes must be terminated directly to the ground bus or to the
mounting enclosure. The ground bus and the mounting enclosure must be bonded to the
fault protection subsystem with minimum length conductors.

13.3 LINE FILTERS

All lines (power, telephone, data, control etc.,) entering the shelters shall be protected by
an adequate filter.

13.3.1 SIGNAL LINES. (DATA, CONTROL ETC…)

a. Impedance and band pass: to be specified according to particular requirements.


b. Attenuation: 100dB outside the band pass, within a range from 100 kHz to 10 GHz.

13.3.2 CONNECTIVITY

The advantages of the use of fiber optics to connect data related systems should be
considered. These advantages are that when penetrating the shield no filters are required,
thus reducing the cost of filters and associated work services, a reduction in heat generated
and in space required.
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

Project Title : Basic Engineering Of PROGRAM NO.: 1720 37 OF 38


Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

13.4 MISCELLANEOUS

a. Normally cables shall be routed near the floor or ceiling. If circumstances dictate routing
cables on both floor and ceiling, care must be taken to ensure that loops are not formed.
b. Fire resistant cables shall be use for Control system, Fire fighting systems and B-25-1
building accordance with BS 6387, IEC 60331.
c. Cable outer shields shall be grounded insures that the shields are continuous, and closed
throughout their lengths.
d. Power and signal cables in ferrous conduit shall be buried as deeply as is economically
feasible (greater than 0.9 meter (3 feet)) to reduce current surges and to slope wave fronts
induced on the cables.
e. Known sensitive equipments shall not be located in corners.

13.5 INSPECTIONS AND TESTING

Thorough inspection and testing programs are imperative to assess the effectiveness of the
EMP protection measures utilized.
a. Inspections. Inspect the facility for the following:
1- Verify that the EMP survey at the facility has been properly performed and documented.
2- Verify that shielding provided is sufficient to meet system needs (both known and
predicted).
3- Verify that doors and ventilation ports are shielded along with the walls.
4- Verify that all power lines supplying the shielded areas are protected with power line
filters.
5- Verify that all electrical conduits are steel inside the shielded areas.
6- Verify that any wiring ducts are totally enclosed.
7- Verify that all metal shields are grounded.
8- Verify that all seams and joints are well bonded by welding, solder, or knitted wire
gaskets.
9- Verify that all metallic utility lines are bonded to the shield at the point of entrance.
10- Verify that all openings required for visual access is covered with wire screen or
conductive glass and that the screen or glass is carefully bonded to the enclosure around
the perimeter of the opening.
11- Verify that all doors are metal with solid, uniform contact around the edges.
12- Verify that all bonds are of the type that will provide the least resistance possible for the
application, preferably direct bonding with no intervening conductor.
13- Verify that the bonding surfaces are cleaned of all such solid materials and moisture.
IRANIAN CENTRAL CHAGALESH
OIL FIELDS COMPANY CONSULTING
(ICOFC) ENGINEERS

Project Title : Basic Engineering Of PROGRAM NO.: 1720 38 OF 38


Farashband Gas Refinery PROJECT NO.: 17202 Rev. 2
Development
Document Number: 17202B-6000-IN-SPC-1002
Document Title: Specification For Control System (DCS)

14- After bonding, verify that the completed bond is sealed against the entrance of moisture
into the mating region.
15- Verify that all metallic penetrations and shielded cables through the facility shield are
bonded to the entry plate.
16- Verify that filters specified in the design are installed as shown on the engineering
drawings.
17- Verify that all power line filter cases are directly bonded to the equipment case or
enclosure.
18- Verify that filters are bonded to any subassembly enclosure used to maintain shield
effectiveness.
19- Verify that filters on control and signal lines are installed in a manner that maintains the
integrity of the shield.
b. Testing. Measure the bonding resistance of each bond. One milliohm or less should be the
acceptable value of the resistance measured.
c. Inspection and test records. Inspection and test records shall be maintained for the facility
with the periodic maintenance records and shall be used as the baseline for determining any
corrective actions that are necessary as a result of unacceptable conditions found during
normal routine maintenance activities.
The requirements and effects of the clause 17 shall be considered by detail designer.