NIOEC SPECIFICATION
FOR
SECOND EDITION
APRIL , 2007
THIS STANDARD IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL
RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY,
REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN
CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY
APRIL, 2007 NIOEC-SP-70-08 (2)
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REVISION INDEX
1 26 51 76
2 27 52 77
3 28 53 78
4 29 54 79
5 30 55 80
6 31 56 81
7 32 57 82
8 33 58 83
9 34 59 84
10 35 60 85
11 36 61 86
12 37 62 87
13 38 63 88
14 39 64 89
15 40 65 90
16 41 66 91
17 42 67 92
18 43 68 93
19 44 69 94
20 45 70 95
21 46 71 96
22 47 72 97
23 48 73 98
24 49 74 99
25 50 75 100
NOTES:
1) THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION.
2) REMARKS RELATED TO EACH REVISION SHOW A BRIEF DESCRIPTION. THESE REMARKS SHALL BE
INTERPRETED IN CONJUNCTION WITH THE REVISED TEXT MARKED BY REVISION NUMBERS.
3) WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL
DOCUMENT.
4) NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET.
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4
3
2
1
0 APRIL, 2007 ASHRAFNIA ORDOOBADI FARZAM SAJEDI
REV. DATE PREPARED CHECKED APPROVED AUTHORIZED
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APRIL, 2007 NIOEC-SP-70-08 (2)
9.7.3 Algorithms................................................................................................................................23
9.7.4 Input Scanning.........................................................................................................................23
9.7.5 Control Loop Execution Frequency ......................................................................................23
9.7.6 Output Functions.....................................................................................................................23
9.7.7 Setpoint Clamps.......................................................................................................................23
9.7.8 Windup protection .................................................................................................................23
9.7.9 Sequential Control...................................................................................................................24
9.7.10 Sequence Language ...............................................................................................................24
9.7.11 Auto-tuning ............................................................................................................................24
9.7.12 Fuzzy Logic Control & Algorithms .....................................................................................24
9.7.13 Control Execution Monitoring............................................................................................24
9.7.14 Predictive Maintenance Diagnostics....................................................................................24
9.7.15 Loop Performance Monitoring ............................................................................................25
9.7.16 Process Simulation ................................................................................................................25
9.8 Configuration and Database .....................................................................................................25
9.8.1 Configuration...........................................................................................................................25
9.8.2 Configuration Tool..................................................................................................................25
9.8.3 Tag Parameters .......................................................................................................................26
9.8.4 Engineering Units....................................................................................................................26
9.8.5 Data Base, Reporting and Modification Utilities..................................................................26
9.8.6 System Access ..........................................................................................................................27
9.9 Operator and Engineering Stations..........................................................................................27
9.9.1 General .....................................................................................................................................27
9.9.2 Operator Stations ....................................................................................................................27
9.9.3 Engineering Stations ...............................................................................................................27
9.9.4 Monitors ...................................................................................................................................28
9.9.5 Display Hardcopy....................................................................................................................28
9.9.6 Printers.....................................................................................................................................28
9.10 Displays and Graphics .............................................................................................................28
9.10.1 Updating Capability..............................................................................................................28
9.10.2 Displays and Graphics Access..............................................................................................28
9.10.3 Hierarchical Displays............................................................................................................28
9.10.4 Paging .....................................................................................................................................28
9.10.5 Invalid Values ........................................................................................................................28
9.10.6 Faceplates...............................................................................................................................29
9.10.7 System and Diagnostic Displays...........................................................................................29
9.10.8 Graphics .................................................................................................................................30
9.11 Alarm and Message Handling.................................................................................................31
9.11.1 Categorizing Messages..........................................................................................................31
9.11.2 Operator Actions ...................................................................................................................32
9.11.3 Engineer Actions ...................................................................................................................32
9.11.4 Process Alarm Initiation.......................................................................................................32
9.11.5 System Alarm Initiation........................................................................................................33
9.11.6 Process and System Alarms History Retention ..................................................................33
9.11.7 Process and System Alarms Audible Annunciation...........................................................33
9.11.8 Process and System Alarms Visible Annunciation.............................................................33
9.12 Diagnostics ................................................................................................................................33
9.13 Data Historization ....................................................................................................................34
9.14 Trend Displays..........................................................................................................................35
9.15 Reports ......................................................................................................................................36
9.16 Availability................................................................................................................................36
9.17 External Interface ....................................................................................................................37
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9.17.1 Serial Interface - Subsystems ...............................................................................................37
9.17.2 OPC Interface........................................................................................................................37
9.18 Engineering Tools.....................................................................................................................37
9.19 Embedded Advanced Control Tools.......................................................................................37
9.20 Management Information System ..........................................................................................38
9.21 Maintenance Planning and Scheduling System.....................................................................38
9.22 Plant Start Up and Shutdown Monitoring System ...............................................................38
9.23 Automatic Start-up Sequence System ....................................................................................38
9.24 Auto Tuner................................................................................................................................39
9.25 Special Requirements............................................................................................................39
9.25.1 Multi-variable Constrained Model Predictive Control (MPC).........................................39
9.25.2 Virtual Sensors and Quality Estimation .............................................................................40
9.25.3 Control Simulation................................................................................................................40
10. NAMEPLATES ..........................................................................................................................40
11. PAINTING AND RUST PREVENTION.................................................................................41
11.1 Paint Specification....................................................................................................................41
11.2 Paint Colour..............................................................................................................................41
11.3 Special Requirements...............................................................................................................41
11.4 Surface Treatment....................................................................................................................41
12. DOCUMENTATION .................................................................................................................41
12.1 General ......................................................................................................................................41
12.2 Design Documents ....................................................................................................................41
12.3 On line Documentation ............................................................................................................41
13. INSPECTIONS AND TESTING ..............................................................................................41
13.1 General ......................................................................................................................................41
13.2 Factory Acceptance Test (FAT) ..............................................................................................42
13.3 Test Completion........................................................................................................................42
14. INSTALLATION, START UP AND COMMISSIONING ....................................................43
14.1 Installation ................................................................................................................................43
14.2 Checks .......................................................................................................................................43
14.3 Power up....................................................................................................................................43
14.4 SAT ............................................................................................................................................43
14.5 Commissioning .........................................................................................................................43
14.6 Test Equipment ........................................................................................................................43
14.7 Documents.................................................................................................................................43
15. SPARES PARTS SUPPLY........................................................................................................44
15.1 Construction, Pre-commissioning and Commissioning Spare Parts...................................44
15.2 Spare Parts for Two Years of Operation ...............................................................................44
15.3 Maintenance Tools ...................................................................................................................44
16. TRAINING .................................................................................................................................44
17. GUARANTEES ..........................................................................................................................44
APPENDIX I.....................................................................................................................................46
MAINTENANCE PLANNING AND SCHEDULING SYSTEM................................................46
APPENDIX II ...................................................................................................................................55
PLANT START UP AND SHUTDOWN MONITORING SYSTEM .........................................55
APPENDIX III..................................................................................................................................57
VENDOR’S DOCUMENT SUPPLY (VDC) .................................................................................57
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1. SCOPE
This specification defines NIOEC’s minimum requirements for the design, manufacture, test and
inspection of Process Control System (PCS).
Deviations from this specification will only be permitted on obtaining written approval from
NIOEC.
2. REFERENCES
Throughout this specification the following dated and undated standards and codes are referred to.
These referenced documents shall, to the extent specified herein, form a part of this specification.
For undated references, the latest edition of the referenced document (including any supplements
and amendments) applies. For dated references, the edition cited applies.
The applicability of changes in the dated references that occur after the cited date shall be mutually
agreed upon by NIOEC and the vendor /contractor.
EN (EUROPEAN STANDARDS)
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IEC 61158-2 "Foundation Fieldbus Standard
For Use In Industrial Control
Systems - Physical Layer
Specification And Service
Definition”
IEC 61131-3 “Sequential Function Charts”
IEC 60332 “Test On Electric Cables Under
Fire Conditions”
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NIOEC SP (NIOEC SPECIFICATIONS)
NIOEC -SP-70-01 “Specification For
Instrumentation”
3. UNITS
International System of Units (SI) shall be used in accordance with NIOEC-SP-00-10, unless
otherwise specified.
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Cycle: The scanning of inputs, execution of algorithms and transmission of output values to
devices.
Dead band: The range through which an input signal may be varied without initiating an action or
observable change in output signal.
Discrete Control: Control where inputs, algorithms, and, outputs are based on logical (yes or no)
values.
Equipment or System: Process Control System (hardware/software)
Faceplate: A graphic element that mimics the front panel of an analogue controller instrument,
hardwired push-button or switch. The same is true for the graphical representation on the Operator
Interface
Factory Acceptance Test (FAT): The final test at the vendor's facility of the integrated system
being purchased.
Fieldbus Foundation: An independent, non-profit organization established to support
standardization of the ISA/IEC Foundation Fieldbus standard.
Foundation Fieldbus: A Fieldbus that conforms to all Fieldbus Foundation specifications.
Foundation Fieldbus Segment: Grouping of Foundation Fieldbus devices connected to the
automation system through an H1 interface module.
Foundation Fieldbus Trunk: Main path of a Foundation Fieldbus. The trunk line connects the
system H1 module to power supply / power conditioning assembly.
Foundation Fieldbus Spur: A spur branches off the Foundation Fieldbus trunk.
Function Block Application Process: Fieldbus Foundation specification defining the plant or
factory applications that perform one or more automatic monitoring and control functions.
H1: Wiring which connects Foundation Fieldbus devices used for control applications such as
temperature, level, and flow control. Devices can be powered directly from the Foundation Fieldbus
and will operate on existing wiring that was previously used for 4-20 mA devices.
Invalid Value: The state of a tag value which indicates that the quantity being measured or
calculated is out-of-range, not measurable or calculable.
Logs: Files or printouts of information in chronological order.
Mode: Control block operational condition, such as manual, automatic, or cascade.
Module: An assembly of interconnected components that constitute an identifiable device,
instrument, or piece of equipment. A module can be disconnected, removed as a unit, and replaced
with a spare. It has definable performance characteristics that permit it to be tested as a unit.
OPC (Object Linking and Embedding for Process Control): Software application which allows
bi-directional real time data flow between two separate applications. These applications may be
running on the same or on separate servers.
Operational Data: The statistical data such as alarm limits, tuning parameters, and clamping
values, as opposed to process data such as input values, output values and setpoints.
Operator Station: A station used by an operator to perform the functions required to monitor and
control his assigned units.
Plant Area: The designated points (inputs, outputs, and calculated values) that belong to a
geographic or functional section of a plant.
Plug and Play: The ability of hardware equipment to automatically identify itself to the system.
When the equipment is powered up it is automatically assigned a unique identity without the need
to set any dip switches.
Point: A process variable derived from an input signal or calculated in a process calculation.
Profibus: Open bus system, standardized in the German DIN 19 245.
Purchaser: In cases where this specification is part of a direct order, Purchaser shall mean the National
Iranian Oil Engineering and Construction Company. Where this specification forms part of contract
documents, Purchaser shall mean the Contractor. In references to inspection by Purchaser, when this
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APRIL, 2007 NIOEC-SP-70-08 (2)
specification forms part of contract documents, this shall be construed to mean that NIOEC shall also have
the right of inspection.
Redundant Configuration: A system/subsystem configuration that provides automatic switchover,
in the event of a failure, without loss of a system function.
Regulatory Control: The functions of process measurement, control algorithm execution, and final
control device manipulation that provide closed loop control of a plant process.
Reliability: The probability that the system or component will perform its intended function for a
specified period of time.
Self-Diagnostic: The capability of an electronic device to monitor its own status and indicate faults
that occur within the device.
Supervisory Control: Higher level control functions that interface with regulatory controllers and
other automation system equipment to provide for integrated control.
System Access Restriction: Access control by key lock, password or other equivalent method.
System Alarm: Alarm that occurs as a result of an automation system hardware or software fault.
System Operating Software: The vendor's standard software that performs the basic functions of
the system.
Tag: A collection of attributes that specify either a control loop or a process variable, or a
measured input, or a calculated value, or some combination of these, and all associated control and
output algorithms. Each tag is unique.
Tag ID: The unique alphanumeric code assigned to inputs, outputs, equipment items, and control
blocks. The tag ID might include the plant area identifier.
Station: A set of electronic equipment including, at a minimum, one PC, one monitor and one
keyboard.
5. ABBREVIATIONS
EMI: Electromagnetic Interference
ESD: Emergency Shut Down
FAT: Factory Acceptance Test
FSD: Functional Specification Document
ILD: Instrument Loop Diagram
MOV: Motor Operated Valve
MTBF: Mean Time Between Failures
PC: Personal Computer
PCS: Process Control System
RFI: Radio Frequency Interference
SAT: Site Acceptance Test
SOE: Sequence of Events
UPS: Un-interruptible Power Supply
6. PRODUCT HISTORY
Equipment shall be of the same model and design as used in similar plants and operating/ambient
conditions with at least three (3) years of satisfactory operational history.
7. CERTIFICATION AND APPROVALS
The equipment shall bear CE marking in accordance with EMC- Directive 89/336/EEC, and the
conformity certificates shall be provided.
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The VENDOR shall also submit certificates/records of type test approval of the system, based on
recognised national or international standards, which for CENLEC regulations shall be LCIE, TUV,
PTB, BASEEFA and for NEC regulations shall be FM or UL.
9. SYSTEM DESCRIPTION
9.1 Configuration
Configuration of the system and the specifics quantities of hardware will be specified in the specific
project documents.
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9.2 PCS Architecture
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APRIL, 2007 NIOEC-SP-70-08 (2)
Software design shall be such that future revisions or updates of the system operating software will
not affect the successful operation of the system.
The system shall allow for upgrading of system operating software on all redundant modules of the
system without the necessity of shutting down the process, without losing the operator interface,
and without the loss of access to any control function.
Application software shall not require modifications in order to be able to run under new releases of
the system operating software. Any new release of system software shall be backward compatible
with files created using the previous software releases.
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Any module with an MTBF of less than 10,000.0 hours shall be clearly identified by the VENDOR.
b) On-line Diagnostics
The system must include comprehensive on-line diagnostics with the following minimum features:
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APRIL, 2007 NIOEC-SP-70-08 (2)
Redundant Control Module processors shall perform calculations in parallel and synchronised
manner, so that switching from main processor to backup cause no interruption to analogue or
digital output signal and without any data loss.
The built-in diagnostics shall include a mechanism to validate the calculation results of redundant
processors before sending the calculation results to field devices. Validation shall incorporate a
function to check for any difference in the calculation results of the redundant processors. If such
error occurs, the built-in diagnostic function shall determine which calculation was invalid and
select the processor output with the correct calculation. Vendor shall clearly describe how his
system architecture supports this requirement.
Control Module processors shall utilize Error Correction Code (ECC) on the main memory to
reduce errors that may be caused by main memory (RAM).
Real-time network shall utilize CRC and frame length check as minimum precaution for securing
real-time data transfer.
System alarms initiated by the self-diagnostics functions must alert the operator at the Operator
Station within 3 seconds. System alarms and diagnostic displays must be available for all operator
stations.
The on-line diagnostic program shall consist of a malfunctions check program that will alert the
operator upon the detection of a fault. This shall be a unique and separate system from plant alarms.
The self-diagnostics shall, as a minimum, detect a fault or malfunction in the following:
• Real-time network diagnostics which shall include, as minimum, errors due to wrong address,
wrong frame length, and response wait time-over, other side busy, and receive data check sum
error, network configuration error, and communication timer error. Real-time LAN shall include
error counters;
• Power supplies and fans;
• All PCS cards (controllers. Processors, hardwired analogue and digital I/Os, etc.);
• Printers;
• Control Module CPU ROM Sum Check Error;
• Control Module algorithm execution error;
• Calculation function execution error;
• On-line/offline downloads error;
• Recovery Message;
• Third party system communication error, and link failure;
• Redundant Control Module database difference among processors;
• Instantaneous AC power supply failure/recovery to the Control Module;
• Diagnostics shall cover hardware, software and firmware of the PCS.
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9.2.11 PCS Battery back-up
All volatile memory devices within the system shall be provided with memory power supply battery
back- up. The battery back up shall have a minimum capacity of 72 hours and shall be independent
of the PCS UPS system at the UPS downtime. The PCS shall monitor the status of the its dc power
distribution system in order to alert the operator of the malfunctions.
Power failure to a control module for less than 72 hours shall not require the down load of the
control module.
Each Operator stations shall be loaded from its own bulk memory automatically when power is
recovered.
a) General
The control response period shall be used as the measure of PCS performance. The control system
can perform proportional, integral, derivative (PID) control using any combination of hardware and
software. Functions (e.g. signal selectors, summers, calculation blocks, etc.) associated with
controllers shall not increase the control response period.
In case of licensed process units, the maximum allowable control response period shall basically
follow the process licensors operational requirements. However following figures are the minimum
requirements if no special requirements are specified by the licensors.
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Temperature 1000
Level 1000
* Shorter control response periods may be required for certain control services (e.g.
compressor anti-surge, reactor temperature, etc.). Multi-variable advanced process
control may be implemented with longer control response periods.
In general, the shorter the control response period, the better the control performance. Control
response periods longer than those listed above may degrade performance and affect unit
operability.
NOTES: 1- The criteria shown in the above table are typical requirements if there are no
requirements on such special requirement where applicable. The maximum allowable control
response period shall basically follow to the process licensors operational requirements.
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APRIL, 2007 NIOEC-SP-70-08 (2)
e) Indicator performance
Indicator data acquisition rate shall be used as a measure of performance. Indicator data acquisition
rate is defined as the total time the control system takes to read the process data from the input
processor and conditions it for visual display.
For initial system sizing and configuration, an acquisition rate of 2 seconds shall be used. Where
indicated data is used in control scheme, the acquisition rate shall follow the controller execution
rate listed elsewhere in this Specification.
f) Scanning
The PCS shall scan all data-points at least once every second. All calculated points associated with
a scanned data-point shall be computed at that data-points scan rate. No pulses shall be lost to
totalisers between scans.
g) Alarm/Event Handling
All alarms and events shall be guaranteed to be displayed and printed at the relevant control room
within 2 seconds of occurring at the field equipment. Alarm/event acceptance shall be complete
within 1 second of acceptance action by the operator.
The PCS shall be capable of handling up to 100 alarm and events per second without affecting
alarm event or display handling.
Each PCS cabinet equipment shall be capable of buffering one event per data-point up to a
maximum of 100 per equipment when all changes cannot be transmitted completely or a
communications failure occurs to the control room operator stations.
h) Displays
Call up time to bring full display with all information of a standard operation display shall be within
two seconds. All dynamic data including historical trends embedded in graphic displays shall be
presented on the monitor within the call up time.
All operational displays and customised graphics shall have a data refresh rate of 1 second and all
other facilities shall have an initiation response time within 2 seconds of the request being made i.e.
reports and logs.
j) PCS Loading
The equipment shall be designed so that under full load conditions, the loading of Processing shall
be less than 80%, and that of the Memory shall fall below 70%.
Network load in normal operating condition shall not exceed 50%. This load shall be calculated
based on the conditions of "No alarm status" and "All operator displays are continuously updated
at one-second cycle with 50 dynamic data per display" occurring simultaneously.
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APRIL, 2007 NIOEC-SP-70-08 (2)
The performance figures shall be maintained by the PCS at all times independent of system loading.
The VENDOR shall provide typical and guaranteed figures for the system offered and the
equipment shall be guaranteed for satisfactory performance at all operating conditions specified by
the PURCHASER.
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APRIL, 2007 NIOEC-SP-70-08 (2)
All incoming and outgoing field cables shall terminate on the terminals of I.S. Isolators in the cabinet.
Cable shields shall be grounded at the cabinet via exclusive terminals. The vendor shall also provide
I.S. Isolators.
c) Non Intrinsically Safe signals
All incoming and outgoing field cables shall terminate on feed through type fused terminals
Multi-core cables shall be used to interconnect the cabinet to PCS cabinets.
d) All field cables shall be multi cores individually or overall screened twisted pairs, armoured and
overall sheath type. Cable screens shall be terminated in the Marshalling Cabinets. All cables shall
be identified and suitably tagged with polarity indication.
• Categories
PCS Marshalling Cabinets shall be sub-divided and segregated into the following categories and
types:
a) Analogue circuits by process unit and IS/non-IS type signals.
b) Digital circuits by process unit and IS/non-IS type signals.
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APRIL, 2007 NIOEC-SP-70-08 (2)
• Wiring of different signal levels shall be adequately segregated in accordance with the
appropriate standards and codes. Field termination side of terminal banks shall be reserved for
field cabling only Field cabling shall occupy dedicated cable trays and wire-ways.
• Power cables shall be separated at least 300 mm from all signal cables. Vendor shall take care to
avoid electrical interfaces.
• Plugs and sockets shall have nameplates on the mounting plate identifying their number.
e) Power Distribution
• Power distribution shall be divided into individually protected branch circuits
• Branch circuit protection device shall be a circuit breaker. Time-current characteristic shall be
such that the upstream protection device shall not operate for a fault in the branch circuit.
• Each module/component in cabinets requiring AC power shall have its own circuit breaker
within the cabinet.
• Each DC power supply unit, within the cabinets, stations etc., shall have its own AC and DC
circuit breakers.
• For further distribution of cabinet DC power supply to electronic cards/modules, such as
controllers, with built in fuse protection, isolating switches shall be provided.
• Branch circuit disconnect switch is required for branch circuits protected by fuses. Switch shall
be connected ahead of the fuse.
• Each console, printer, annunciator shall have dedicated circuit breaker.
• Analogue inputs and outputs shall be fused at the marshalling cabinet terminals when the 24
VDC loop power is not supplied through the I/O card.
• All field I/O’s in a non I.S. installation shall have the ability to disconnect power to each field
instrument individually at the marshalling panel by means of a fused terminal or a disconnect
terminal. This is to enable the removal of an individual instrument for maintenance.
• All digital outputs shall be fused at the marshalling panel terminals.
f) Terminals
• Terminals shall be selected according to field and panel conductor size and rating. Terminals
shall be Screw type, Klippon or equivalent. Wire ends shall have crimp-on vinyl self insulating,
locking type lugs.
• Medium duty, 300-600 Volts rating barrier type, non-hygroscopic material type terminal blocks
shall be provided.
• Terminals shall be either tinned or silver plated and terminal numbers shall be clearly identified.
• Terminals shall be so located that they are easily accessible.
• Adequate space and/or barriers shall be provided to facilitate easy maintenance work.
• Terminal blocks shall be mounted on channels with a minimum of 25-mm spacers between
cannel and mounting surface.
• Separation between the terminal rows shall be 200-mm minimum.
• Terminal blocks shall be mounted vertically.
• Different signal levels shall run on different terminal rows and shall be physically segregated by
space or barriers.
• The relevant signal level on any terminal row shall be clearly marked on the terminals.
• Terminals shall be individually identified alpha-numerically. Banks of terminals shall be
labelled as to service. Field cabling shall govern terminal grouping i.e., terminals shall be
arranged to accommodate the field cables in sequential rows.
• Spare terminal rail space shall be provided such that the prepared and equipped spare capacity
within the corresponding cabinet/bay can be fully utilised. As a minimum, 20% spare space
shall be provided on each rail for future field cable terminals. All field cable cores and screens
shall be terminated on terminals.
• Only one conductor shall be terminated in each side of a terminal. All Looping shall be by
means of jumper bars.
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• Protective covers shall be provided over all power distribution terminals to reduce the
likelihood of accidental short-circuits and contact by maintenance personnel. Appropriate and
clear identification and warning labels shall be provided.
• Terminals shall be so arranged that all incoming and outgoing cables have a minimum straight
length of 150 mm from the point of entry.
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• To simplify installation and maintenance, the modules shall be designed for front access only,
with all user functions, diagnostics and cabling available from the module fronts.
• The racks shall be mounted in industrial type cabinets.
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9.5 Inputs and Outputs
9.7.1 Calculations
Algorithm calculations shall be performed in floating point engineering units or other such
equivalent methods that do not require scaling.
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9.7.3 Algorithms
Standard Foundation Fieldbus software algorithms shall be available to perform regulatory control
functions. These process control functions shall be performed by predefined algorithms with
configurable parameters.
Standard Foundation Fieldbus control algorithms shall be identical regardless of whether they reside
in system controllers or the H1 field devices.
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9.7.9 Sequential Control
The system shall be capable of performing the following sequential control without any
modifications to the standard configuration software.
9.7.11 Auto-tuning
An auto-tuning facility shall be available in the automation system. It shall be:
This auto-tuning facility shall allow tuning of PID and fuzzy logic control blocks whether they
reside in the controller or the Fieldbus device. An easy-to-use graphical interface shall be provided
for auto-tuning.
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9.7.15 Loop Performance Monitoring
The automation system shall monitor all active control loops and set a flag upon detecting
degradation in any loop performance or upon detecting an abnormal condition in a measurement,
actuator, or control block.
The following conditions shall be flagged:
A variability index shall be calculated for each loop. This index shall be used to quantify the
following and present the results graphically: loop utilization; bad, uncertain and limited
measurement status; control action limitation; and process variability. Excessive variability shall be
automatically flagged.
This capability shall be a standard feature of the system. No additional configuration shall be
required to add it. The system shall automatically detect when new control modules are added or
deleted in the configuration and activate loop performance monitoring.
This facility shall run on a stand alone PC and shall emulate the controller I/O and process. It shall
be able to simulate up to 8 controllers at the same time.
During training activities, a training tool shall be available to capture and record all trainee actions
in a session report. The report shall contain information such as the scenario name used,
malfunction name(s) used, and event log messages. It shall become part of the documentation for
the employee’s performance during the training.
9.8.1 Configuration
a) Engineering Station
It shall be possible to install more than one engineering station in a system.
Only one engineering station shall be necessary to perform all traditional and Foundation Fieldbus
configuration, database generation, and editing. However, it shall also be possible to use multiple
engineering stations simultaneously for configuration, database generation and editing.
The automation system shall use a single, global configuration database to be shared by all
components of the system. User shall not be required to enter the same data or configuration more
than once.
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The system shall have the capability of collecting and monitoring revision information for any item
in the configuration database.
The system shall document who made the change and when the change was made.
Differences between two versions of the configuration shall be viewed in either text or graphical
formats.
The system shall provide the ability to roll back a single item or the entire database to a previous
revision.
The functionality of version control shall not require any configuration.
It shall be possible to print configuration change histories for any item in the configuration database
b) Configuration Displays
Configuration displays shall be provided to aid in system configuration. All displays and tags will
reside in one global database shared by the entire system. No data mapping between systems shall
be allowed.
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If a failure is detected in any backup equipment, the operator shall be notified and the failure shall
be logged.
9.9.1 General
Failure of any component shall not cause the failure of more than one station.
Each operator and engineering station shall have access to, either directly or through a network, an
electronic log, as well as optional printer for logging alarms, system events and other information.
• Each station shall have access to a minimum of two printers, of which at least one should be a
colour printer.
• The operator interface software shall be capable of acting as a Dynamic Data Exchange (D-
DE) or OLE (Object Linking and Embedding) for Process Control (OPC) client or server to
share real-time data with DDE or OPC compliant applications.
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• Each engineering station shall be capable of being operated in a standalone mode with access
to all graphic displays and their functions.
• A QWERTY keyboard shall be provided with each engineering station.
• Removable storage media shall be provided at each engineering station.
• Configuration and on-line operation should be password-protected with at least three levels
of security (Engineering/configuration, supervisor, and operator) to avoid inadvertent
changes.
9.9.4 Monitors
Monitors for operator stations shall be LCD type with 21 inches nominal in diagonal measurement,
with 1024 x 768 resolutions.
9.9.6 Printers
Laser printers shall be supplied and supported.
9.10.4 Paging
It shall be possible to cycle through a predefined series of displays with a maximum of one operator
action.
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9.10.6 Faceplates
Faceplates shall show dynamic process and status information about a single control loop and shall
permit an operator to change control parameter values or mode for the loop.
The system shall automatically provide default faceplates for each tag. User shall not be required to
configure a faceplate detail display for each tag or control module.
Faceplates shall be defined to pop-up when the appropriate location on a process graphic is selected
with the mouse.
Faceplates shall display the following information as applicable:
• Tag ID.
• Tag descriptor.
• Process input, setpoint, and output values displayed numerically with engineering units.
• Process input, setpoint, and output in bar graph representation.
• Auto/manual mode and remote/local setpoint status.
• Visual indication for alarm status.
• Symbolic and alphanumeric indication of discrete states both for two state devices and multi-
state devices.
It shall be possible to perform the following control actions from a faceplate:
• Change control block mode.
• Change setpoint and other operator settable parameters.
• Issue commands to multi-state devices
• Adjust outputs in manual mode
Single faceplates shall be provided for control and indication of multi-state devices. For example, a
motor operated valve shall indicate open, closed, intermediate position, and fault.
First out trap in a series of interlocks/permissive for discrete control devices shall be displayed by
description on the operator interface.
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9.10.8 Graphics
a) General
A standard utility shall be provided to generate and modify user-defined colour dynamic graphics.
The utility shall have the capability to make a copy of an existing graphic in order to build a new
graphic that is similar. It shall use the same tag IDs that are used in the process database to access
real-time variables from any database. No intermediate index numbers or addressing shall be
required. It shall be subject to system access protection.
The system shall provide the facility to place a new graphic in service without interrupting an
operator's ability to control the plant.
The system shall make it possible to scan images and use them in a graphic display to help an
operator easily identify the process parameters being operated. Dynamic information shall easily be
added to the images.
All control, monitoring, and status attributes of any tag shall be displayable on graphics. For
analogue points this requirement includes measurement, setpoint, alarm limits, and output. For
digital points this requirement includes input and output status. Status information includes: alarm
status, control mode, and control status.
Numeric data shall be configurable on an individual basis. If the decimal point is not used, it shall
be suppressed.
Each state of a multi-state device shall be indicated by a unique foreground/background colour
combination.
It shall be possible for inactive alarm or status messages to be invisible to the operator.
Symbolic representation of data on the graphics shall be performed by colour changes (foreground
and background independently), and flashing in any combination.
Users shall be able to create symbols and store them in a permanent library. The graphic builder
utility shall have facilities to maintain this library with version control.
A screen target that calls up other displays shall be configurable.
There should not be a limitation of the number of graphic display pages that can be configured on a
single operating station
All control parameters shall be accessible through the graphic display. Navigation through the
displays should be easy and intuitive. One overview graphic display per process unit shall be
provided in order to quickly access the detailed graphics- Viewing of information in real-time shall
include all remote setpoint; whether calculated or not.
All loop controllers shall have faceplates. These faceplates shall allow easy access to tuning
variables, trending, setpoint values (both local and remote), alarm settings, auto/manual,
remote/local, and percent output-
Pop-up functions (faceplates, trends, reports etc.) should allow large amounts of detailed
information to be quickly accessed without extensive clutter on a process graphic.
The PCS output display for all control valves shall be configured such that it is readily apparent to
the operator how the output must be changed to manually open or close the valve. Configuration
such that an indication of 0% output is dosed and 100% is open regardless of valve failure action, or
other labelling methods, may be used.
Each Graphic display shall include not more than 50 live data for ease of operator interaction.
Each display shall have its own number and descriptive title clearly displayed in the display. For an
easy and fast call up of a graphic display, each graphic display of the unit shall be represented by an
assigned function key on the operator keyboard. Each station shall be able to support at least 100
graphic displays.
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b) Call up of Graphic displays
Operator shall be able to call Graphic displays using any one of the following procedures:
• Entering the unique Graphic display number.
• Referring to an index display and selecting by cursor.
• Selecting the particular assigned function key on the keyboard.
c) Operation of Graphic displays
Each symbol representing an instrument shall be a touch/cursor target on the graphic
display, i.e. by selecting or touching the target, the operator shall be able to:
• Call the target Point /Loop relevant Group, Detail or Trend display.
• Perform Loop manipulation, via a dedicated purpose designed part of the
screen, such as loop parameter change, Auto/Manual change, interaction with
the final control element etc.
Process lines shall enter the display on the left and leave the display on the right.
Service and source/destination address shall be clearly shown for each line.
It shall be possible, by selecting the source or destination addresses to move to the
relevant preceding or following graphic displays.
d) Presentation of live data
Each display shall include live data such as process variables, set points, control outputs, on/off status
of rotating equipment, open /close status of valves, alarms.
Live data shall be refreshed in less than 1 second.
Indication of measurements and set points shall be in numerical format in relevant units.
Status signals shall be shown by descriptive format such as ON, OFF, OPEN, CLOSE and/or by colour
change.
Alarms and invalid values shall be clearly indicated and prompted to alert the operator.
Date and time shall be indicated in every screen continuously.
Alarm functions shall be implemented using the data acquisition and shared processing equipment
of the control system. All alarms shall be visually and audibly indicated and shall be connected to
event logging facilities.
b) Critical Alarms
These alarms are considered to be of high importance and are associated with a process condition or
a special circumstance that requires immediate operator action. Examples are shutdown pre -alarms,
shutdown alarms, and critical equipment alarms.
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Alarms in this category require a unique display and audible tone to clearly distinguish them from
non critical alarms. Critical alarms shall be distinguished from other alarms by a unique colour,
grouping, or graphical display on the PCS and/or displayed on a separate, "back lighted-nameplate"
annunciator panel located above or adjacent to the operator station.
c) Non-Critical Alarms
This category alarm is generally for services not associated with a shutdown function or critical
equipment protection.
Process and designated system alarms shall be annunciated, displayed and stored in electronic
history files. Normal plant operator actions, events and normal system actions and events shall not
be alarmed; however, they shall be stored in history files if designated.
Alarms shall have the capability of being configured at the unit or control point level.
Alarms and messages shall be grouped to allow the user to readily identify and respond to alarms
and conditions (e.g., in priority sequence) in his area of responsibility.
For any process alarm, it shall be possible, by no more than one operator action, for an operator to
access a display from which he may take corrective action.
The five highest priority alarms shall be displayed in descending order of priority.
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• Process variable rate-of-change high
• Process variable deviation from set point
• Process variable invalid value
For digital tags, the configurable triggers for process alarms shall change of state
Twelve alarm priorities level should be made available. Each priority should be user configurable
for a unique priority name, horn sound, and colour annunciation on graphic displays.
A list of inhibited alarms shall be available to be displayed and printed.
9.12 Diagnostics
On-line and off-line diagnostics shall be provided to assist in system maintenance and
troubleshooting. Diagnostics shall be provided for every major system component and peripheral.
This shall include segment as well as device diagnostics and firmware diagnostics in the devices. If
diagnostics do not exist for particular peripheral devices (for example printers and terminals,) the
system must detect and provide an error indication for the failure of these devices.
It shall be possible to configure, monitor, and troubleshoot Foundation Fieldbus devices and HART
devices from the control room. The automation system shall be capable of storing calibration
information and device status history for each field device. It shall also be possible for the
automation system to upload field device configuration changes implemented in the field. Once the
configuration information is stored in the automation system, it shall be possible to download it to
any other similar device, whether a new or replacement device.
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Existing signal wiring shall be used to pass field device data to the diagnostic utility. This shall not
degrade the operation of the system in any way.
It shall be possible to remotely access the system by modem for troubleshooting purposes. User
shall have the capability to disable this feature without disconnecting the modem.
The system shall be supplied with a complete asset management system including:
• Dynamic Error Band – An overall valve/actuator/instrument response to input signal changes.
• Drive Signal – A plot of input versus the drive signal
• Output Signal – A plot of the travel versus the drive signal of a digital valve controller and the
output pressure signal versus the drive signal of the digital transducer
• Step Response – A tool to review response to input signal changes. Dead time, stroking time,
overshoot, and response time can all be determined from this curve.
• Valve Signature – A plot of actuator travel versus actuator pressure. It is used for operational
analysis of the valve and actuator operation, independent of the instrument. Comparison of this
curve to the original factory curve can uncover deterioration in performance.
The system shall provide an audit trail and automatically generate a historical record. Events
recorded in the audit trail shall include device configuration records, as found/as left tests and
diagnostic information. Records shall be tied to plant location and to a specific device. It shall be
possible to view records for an entire plant or for a single device.
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e) Storage capacity that is capable of retaining daily averages and weekly averages of the process
variable values for a period of one year shall also be provided. The control system equipment shall
be able to access and display the stored data at (lie operator station console and/or other console on
demand at any time.
f) Data stored for historical review shall be accessible in grouped trend display format. The
grouping of the process variables shall be logical with respect to the process. Configuration of trend
displays shall have the capability for operators to set up additional trend displays of selected
variables for specific troubleshooting activities. Different colours shall be used for each variable
trended. Additional trend display capacity shall be available for at least 10 percent of the historical
trend display groups.
g) The control system must be capable of archiving historical data onto removable media.
A configurable, real time and historical data collection package shall be available to support
trending, logging, and reporting. The automation system shall be able to support multiple historian
packages. It shall be possible to collect historical parameters on multiple stations providing
historical backup capability. It shall be possible to supply redundant on-line storage media.
On-line process point collection and storage shall not require any additional configuration other that
the normal module configuration. It shall be possible to enable data historization for each module
within its standard configuration.
The historian shall be capable of collecting continuous history for up to 20,000 parameters.
Historical data must be available to remote desktop PC’s, using standard, off-the-shelf viewing and
analysis software, including Microsoft Excel and Access
The historian shall be integrated into control strategy configuration, such that a separate historian
configuration database does not need to be maintained. Each control strategy would maintain its
own historical configuration information. When a new control strategy is created and downloaded,
it shall include the history definition and the history definition is downloaded to the historian.
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being trended, all events about the loop shall also be displayed. This shall include any of the events
listed in Diagnostics, Alarm and Events such as operator changes to loop SP or tuning changes to
gain or loop alarms.
Each loop controller shall have a trending display for tuning. This tuning display shall show the
loop controller tuning values and include the capability to change the loop controller tuning values
while trending. Different colours shall be used for each parameter trended. The minimum controller
parameters trended shall be:
• Setpoint
• Process variable
• Controller output signal
Trending intervals shall be user selectable between 0.25 seconds to 5 seconds. The overall trend
display must show as a minimum between 1 minute and 20 minutes of trending per following table:
9.15 Reports
A reporting utility shall be provided. It shall be possible to use any variable in the system or the
history files in a report. It shall be possible for all reports to be displayed on a station screen as well
as printed on a report printer. Hourly, daily, monthly, end-of-month, quarterly and yearly reports
shall be supported. Reports shall be printed and/or saved to disk when a process event occurs. It
shall be possible to activate a report in the following manner:
• Upon demand (operator request)
• Scheduled (shift, daily and monthly)
• Upon event occurrence
It shall be possible to transfer data via standard off-the-shelf software tools to generic report writers.
9.16 Availability
A single failure anywhere in the segment shall not result in the loss of regulatory control to more
control loops than those associated with a single process input/output/H1 card. Failure of any single
device shall not affect the ability of the system to communicate with other devices in the system.
Switchover shall not disrupt any system functions.
Redundant equipment and software shall be continuously monitored for errors. All modules shall be
diagnosed on-line. Errors shall be alarmed with an error message identifying the failed module.
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• The tools shall enable the automation system to perform the following:
• Optimize control and steady state objectives by continuously calculating the best move
sequence for each manipulated variable and on-line process performance monitoring of
continuous, batch, and semi-batch processes,
• Identifying under-performing loops and abnormal operating conditions with completely
automated process-monitoring software,
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• Tuning PID and Fuzzy logic control blocks, as well as simulating process response to
recommended tuning parameters,
• Include Fuzzy logic control in the same engineering environment as the automation system’s
PID-based control,
• Solving small but difficult multivariable control problems, which have been handled with
complex PID-based control, with a model predictive control block,
• Simulating a controller in a single PC for control strategy development and testing.
The software shall provide the operators with accurate information about the process and
equipment's current performance as well as validated information relating to performance
economics such as cost of poor performance and inefficiency.
The software shall be able to provide model based, performance monitoring and optimization
designed to achieve optimal plant performance by continuously adjusting operating conditions in
reaction to changing process conditions.
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1) Easy-to-understand sequence programs could be created.
The sequence programs must be written in user friendly flow chart format. For easy visual
confirmation of the progress through each sequence, icons in the chart shall change color as specific
steps in the sequence are completed.
2) Operators could build an entire programming system by themselves.
No special skills shall be required to build a sequence program system. Operators should be able to
easily incorporate their operation know-how in the system. Operation know-how can be
standardized and shared among the operators.
3) The know-how of expert operator's could be handed on to less experienced operators.
4) Operator workloads shall be reduced.
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The MPC algorithm shall be executed in smaller applications (4 manipulated variables or less) as
fast as once per second. The MPC algorithm shall execute in an optionally redundant control system
processor as opposed to a station for purposes of availability.
The MPC algorithm shall be capable of maximizing or minimizing a selected process input until
one manipulated variable approaches its limit.
It shall be possible to construct the process model without the requirement to interface to an
external process historian.
10. NAMEPLATES
Each cabinet, module, station, peripheral included in Vendor’s scope of supply shall have
its individual nameplate as follows:
• Nameplates shall be plastic type with a glossy black laminated surface and opaque white base
• Nameplates for outdoor equipment shall be stainless steel
• Nameplates shall be securely fixed at both ends with stainless steel screws
• Nameplate size, characters and character format shall be submitted for Purchaser’s review and
approval
• English lettering shall be used
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Vendor’s mark and nameplate shall also be required for each station, cabinet and rack containing
manufacturer’s name, manufacturing date and production number. Material and format shall be the
same as other nameplates discussed above.
Each station and cabinet shall have both front and rear side nameplates.
12. DOCUMENTATION
12.1 General
The documentation to be supplied with the equipment shall be sufficient to operate, maintain, repair
and re configure the hardware and software throughout the operational lifetime of the system.
Document types are specified in Appendix III; Vendor Documents Schedule (VDS).
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13.2 Factory Acceptance Test (FAT)
a) General
The VENDOR shall submit test procedures for Purchaser’s approval prior to the FAT.
The VENDOR shall satisfactorily test the Equipment prior to the Factory Acceptance Tests, and
submit test procedures to Purchaser prior to the FAT.
The VENDOR shall notify the PURCHASER a minimum of 30 days in advance of his intention to
carry out tests so that arrangements can be made to witness the event.
For FAT, the VENDOR shall make available time, space and assistance to ensure the
PURCHASER is given all possible assistance.
VENDOR shall provide all goods, materials and services for all the tests and shall provide all test
equipment required to test out the equipment and to simulate all field inputs, outputs and serial links
and monitor all output operations.
FAT shall be as complete as practicable with all interfacing equipment available from other
systems, and shall be a detailed function test covering all stages of the equipment's operation.
b) Unit Tests
All controls shall be checked during the test for correct operations and a full functional test shall be
carried out to confirm compliance with the specification.
All faults discovered shall be rectified at the Vendor’s cost and the affected system offered for re-
test.
The tests shall comprise the following tests as a minimum:
• Visual, mechanical and electrical inspection of all equipment for conformance to drawing and
specification.
• Hardware testing e.g. ADC calibration, switching, and automatic redundancy checks etc.
• Power supply testing for load and switching.
• RFI and EMI tests.
• Database checking.
• Functional loop checks for 100% of the controllers, I/O modules and field termination
assemblies. The system final database shall be used for these tests.
• CPU and memory maximum loading capacity checks.
• Factory as-built documentation shall also be checked.
c) System Software Tests
The PCS software tests shall comprise the following tests as a minimum:
• Functional tests of the operating system, i.e. setpoint, control changes.
• Configuration tests of the standard system i.e. alarm limit changes etc.
• Functional tests of all utility programs.
• Functional tests of all VENDORS supplied application software.
• Functional tests of communication with all third party equipment.
d) Performance Tests
The performance tests shall comprise the following tests as a minimum.
System response tests to confirm that the performance requirements of specification are met, i.e.,
display call up times, scanning times, alarm handling and process load.
System integration tests to confirm all functions are operational and dependency between functions
is present.
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14.2 Checks
VENDOR specialists shall be responsible to check that the following minimum requirements have
been fulfilled:
• Correct installation of cabinets and stations.
• Replacement of equipment in cabinets and station removed for transportation.
• Connection and installation of all system cables and internal cable connections.
• Connection of all power and earthing cables and resistance checks.
14.3 Power up
Vendor specialists shall power up the system and check that following requirements have been
completed:
All Vendors standard hardware, software and diagnostics checks have been completed, including all
processor failure mode, redundancy, security access and restart procedures.
Communication checks have run with data transmission corruption being acceptable within the
Vendor’s published specification.
14.4 SAT
The VENDOR shall submit SAT Test Procedures for Purchaser’s approval prior to the Test. Vendor
specialists shall then perform Site Acceptance Test (SAT) for Purchaser’s approval. Full functional
test shall be carried out at this stage.
The VENDOR shall specify the need for any special test equipment and site support
required for installation and commissioning.
14.5 Commissioning
Vendor may be required to provide a site-based specialist to assist the Purchaser with the following
activities during commissioning:
• Operator guidance.
• Loop tuning.
• Control loop configuration amendments.
• Resolve system faults.
• Vendor shall confirm in his quotation, his commitments to render the above-mentioned.
14.7 Documents
The VENDOR shall provide agreed as-built documents and drawings following site
commissioning.
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15. SPARES PARTS SUPPLY
15.1 Construction, Pre-commissioning and Commissioning Spare Parts
VENDOR shall recommend the spares for construction, pre-commissioning,
commissioning and construction allowance, which will be purchased together with the
equipment, and include the cost of spares in the quotation.
16. TRAINING
VENDORS shall be required to provide training as follows:
• Training of Operators to overtake System operation
• Training of Technicians to perform System maintenance work
• Training of Engineers to be in charge of System configuration (hardware and
software) and advanced system maintenance work
Operators will normally be trained at site while the Technicians and Engineers are to be
dispatched to Vendor’s works to receive their respective training.
17. GUARANTEES
Vendors shall guarantee that he is able to support and supply spare parts for the supplied
hardware, software and firmware for at least 10 years from the date of shipment.
Completion of commissioning does not end Vendor's involvement: Vendor shall be able to provide
support either by telephone or site attendance, and where appropriate, modems shall be provided,
with client authorization, to permit remote connection to the equipment or the operator interface to
diagnose problems and make adjustments.
Vendor shall be in a position to offer system maintenance contract services to:
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If the VENDOR believes that parts of the system will be withdrawn from sale after 10
years, he shall provide a statement detailing the equipment to be withdrawn, the timing
and how updated parts can replace the withdrawn parts.
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 fulfil
satisfactorily the specified operating conditions.
Should any failure or defect in design, material, workmanship or operating
characteristics develop under the start-up and commissioning periods or during the first
12 months of operation, but not later than 24 months from the date of shipment, the
Vendor shall make all required repairs, alterations or replacements of the defective
equipment, free of charge, and shall pay transportation fees involved to and from
NIOEC’s site.
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APPENDIX I
MAINTENANCE PLANNING AND SCHEDULING SYSTEM
1. GENERAL
This specification defines the minimum functional requirements for the Maintenance Planning and
Scheduling System, which shall, according to the requirements of the project specifications and the
size of the PCS and the maintenance data, be carried out within the PCS or shall be carried out
within a third party package, acquiring its data from the PCS database.
2. BASIC FUNCTIONS
The Maintenance Planning and Scheduling System shall provide the means to manage maintenance
history and maintenance schedule of the main rotary machinery.
The system shall use a database of the items of the rotary machinery to store the related
maintenance data including run/stop status, which will be input from the PCS and maintenance date,
past maintenance reports/notes and that shall be entered by the maintenance personnel in every
maintenance cycle.
Upon request of the maintenance personnel, the system shall display and report maintenance history
of the required items or forecast their next maintenance dates based on the said data base. However
when the system detects any equipment whose maintenance date has expired, the system shall
automatically send a message to the plant operator of the relevant unit via PCS console to notify
him of maintenance requirement of the equipment.
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3. DATA STRUCTURE
3.1 Data Type
Following data shall be held in the system:
• Equipment Identification Data
• Maintenance Scheduling and Forecasting Data
• Maintenance Records
The system shall store, update and delete these date in accordance with the requirements of the
maintenance personnel
3.1.1 Equipment Identification data
This data shall consist of a unique Item number for each equipment and the following subsidiary
data:
• Unit Name
• Item Number
• Service
• Equipment Type
• Equipment Driver
• Rated Power
• Installation Date
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3.1.2 Maintenance Scheduling and Forecasting Data
This data shall be provided as follows:
• Maintenance Cycle.
• Last Maintenance Date.
• Expected Maintenance Date based on Maintenance Cycle.
• Scheduled Maintenance Date specified by maintenance personnel.
• Running Time calculated by the system.
• Number of Days until the Next Maintenance Date from the Current date.
3.1.3 Maintenance Records (Last 30 Records)
The last 30 records of maintenance shall constitute the maintenance records and include the
following:
• Maintenance Date
• Maintenance Type
• Comments for each maintenance work
3.2 Configuration of Data word
The following data word configuration shall be foreseen:
3.2.1 Equipment Identification Data
Data Number of Characters
UNIT NAME 4
ITEM NUMBER 8
SERVICE 20
EQUIPMENT TYPE 5
EQUIPMENT DRIVER 8
RATED POWER FLOATING
INSTALLATION DATE DATE
ON LINE SUGNAL TAG NAME 8
RUN STOP STATUS 4
ON LINE SIGNAL AVAILABILITY 4
RUN/STOP STATUS AUTO UPDATE 4
Maintenance Cycle(Day) 4
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Last Maintenance Date Date
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• Equipment Driver
• Rated Power
• Installation Date
• Last Maintenance Date
• Running Time
• Maintenance Date
• Comments for each maintenance work
c) New Maintenance date earlier than or Equal to Current date But Later than Last Maintenance
date.
Consequences:
• Last Maintenance date—> New Maintenance date
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• Running time—> Initialized
• Personnel can enter the new Comments
(Current Date+ Maintenance Cycle)- (Running Time from Last Maintenance Date)
Running Time shall be calculated once per hour for all the items according to the Run/Stop Status.
For items with dedicated on line On/Off signals, it shall be possible to specify whether Run/Stop
Status shall be automatically updated in accordance with the on-line On/Off signal, by setting
Run/Stop Status auto update flag to Yes or No.
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4.2.4 Functional Requirements
The display shall provide the facility to retrieve maintenance forecasting information and/or
Scheduled Maintenance date.
4.2.4.1 Items subject to Maintenance within specified period:
When this mode is selected, the system shall display the items to undergo maintenance within the
period specified by the personnel on the screen. Items with expired Maintenance date shall also be
displayed.
4.2.4.2 Items with expired Maintenance date:
When this mode is selected, the system shall display the list of the items with expired Maintenance
date.
4.2.4.3 All items of the selected unit
Upon selection of this mode, the system shall ask for Unit name. Then the system shall display the
Maintenance forecasting item list for all items in the specified unit.
4.2.4.4 Scheduled maintenance date input and update the system shall, upon selection of this mode,
ask the personnel to input Unit name. Then the system shall display the list of all the items of the
specified unit and allow the personnel to specify the Scheduled maintenance date. The Scheduled
maintenance date specified in this display shall be used as the Next maintenance date instead of
Expected maintenance date.
After selecting the End key the system shall require confirmation of the personnel whether to store
the specified Scheduled maintenance date.
4.2.4.5 Run/Stop status input the system shall, upon selection of this mode, prompt the personnel to
input the Unit name.
The system shall then display the list of the all items in the unit and allow the personnel to specify
the Run/Stop status and Run/Stop status auto update.
If Run/Stop status auto update is set to "Yes" for any equipment whose on-line signal availability is
"Yes", then the Run/Stop status shall be determined by on-line On/Off signal and the manual input
of the status shall be ignored. After selecting the End key the system shall require confirmation of
the personnel whether to store the specified maintenance date.
4.2.4.6 Print out
Through the display, the personnel shall be able to request the system to print more detailed
information on printers.
All the information and data in the system shall be printable through individual/group listing.
4.3 Maintenance History Display Function
4.3.1 Data Displayed
The following data shall be displayed for this function:
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• Unit Name
• Item Number
• Service
• Equipment Type
• Equipment Driver
• Rated Power
• Installation Date
• Maintenance Date
• Comments for each maintenance work
4.3.2 Functional Requirements
Through a dedicated display, maintenance personnel shall be able to inspect the previous
maintenance records.
After the personnel selects, on the display, how many of the latest records are to be displayed and
enters the Item number at the prompt, all the pertaining data as listed in paragraph 4.3.1 shall be
displayed.
4.4 Equipment Identification Data Update function
4.4.1 Data Displayed
The following data shall be displayed for this function:
• Unit Name
• Item Number
• Service
• Equipment Type
• Equipment Driver
• Rated Power
• Installation Date
• Maintenance Cycle
• Run/Stop Status
• Maintenance Date
• On-line Signal Availability
• On-line Signal Tag Name
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4.4.3 Functional Requirements
4.4.3.1 Edit Mode
Upon entering Item number for any equipment, the system shall display all related information. The
displayed data, except for Item number, can then be modified by the personnel on the screen.
After selecting the End key the system shall require confirmation of the personnel whether to store
the specified date. If confirmed, the system shall overwrite the data, otherwise the system shall
return to the Menu.
4.4.3.2 Append Mode
In this mode a display shall be used so that the personnel can add a new equipment identification
data.
After selecting the End key the system shall require confirmation of the personnel whether to store
the specified date. If confirmed, the system shall store the data. Otherwise the system shall return to
the Menu.
A warning message shall be initiated if the specified Item number already exists in the stored data
and shall not store the specified data.
Adequate data file spare capacity shall be foreseen for the Append function.
4.4.3.3 Delete Mode
When the Item number is entered at the prompt, the system shall fill in the rest of the data.. Then
the system shall prompt the personnel to decide whether the system should delete the specified data.
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APPENDIX II
PLANT START UP AND SHUTDOWN MONITORING SYSTEM
1. GENERAL
This specification defines the minimum functional requirements for the Plant Start Up and Shut Down
Monitoring System.
2. BASIC FUNCTION
The Plant Start Up and Shut Down Monitoring System provides the means to overview the plant
operational status through graphic displays showing simplified process flow diagrams and indicating
Run/Stop or On/Off status of main equipment. The displays shall be available in PCS consoles of
each control room for the relevant process units. These displays can, if so requested, be available as
a whole in the centralized console(s) located in the Management Information centre.
3. MONITORING DISPLAYS
Operational status of the equipment shall be indicated by colour coding the equipment symbols on
the graphic displays. The system is intended to monitor the status of the main process pumps, main
compressors and fired heaters. Each equipment service shall be provided with Run/Stop indication
and Auto/Manual mode selection. When on Auto mode, the system shall use on line signals to
indicate Run/Stop status. When on Manual mode the status shall be indicated in accordance with the
Run/Stop status entered by Operators.
Equipment with no on-line signals to PCS shall only use the Manual mode.
4. Colour Coding
The proposed colour coding for the displays shall be as follows:
• Equipment symbols
Run or On: Blue
Stop or Off: Red
• Equipment item number
Red : Manual mode
Blue : Auto mode
• Towers or Vessels
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APRIL, 2007 NIOEC-SP-70-08 (2)
Green with yellow outline
• Process lines
Green
• Others
White
5. CRITERIA FOR STATUS INDICATION
The following criteria shall govern the indication of Run/Stop status.
5.1 Run/Stop status shall be indicated in accordance with online On/Off signal or on-line process
signal or manual input. The extent of the application of the status monitoring system and the actual
signal to be used will be defined in the project specifications.
5.2 Upon selection of Auto mode for the equipment services with on-line signals, the following rules
shall be applied for determination of Run/Stop status:
a) For the equipment services with on-line process signal, Run status shall be indicated when the
signal value is above the Start Limit. This limit shall be changeable for each signal. However, as a
default this limit shall be 5% of the instrument range of on-line process signal. In case multiple on-line
process signals are used for a equipment service, Run status shall be indicated when one of the process
signals exceeds the Start Limit. Stop status shall be indicated when all the signals fall below their
respective limit values.
In case of Bad process signals, i.e. "BAD PV", the system shall display an appropriate error message
on CRT and re-set to the Manual mode.
a) For the equipment services with on-line On/Off signals and multiple equipment items. Run
status shall be indicated when one or more of the on-line On/Off signals become "On".
b) For the equipment services with Manual mode input only, the system shall not permit to change
the mode to "Auto".
c) Manual entry of the operational status shall be carried out through PCS consoles.
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APPENDIX III
VENDOR’S DOCUMENT SUPPLY (VDC)
DOCUMEN
DOCUMENTS
DOCUMENTS AFTER TS AFTER
DESCRIPTION WITH
PURCHASE ORDER FINALISAT
QUOTATION
ION
QUANT
ITY
QUANTITY ISSUE AND QUANTITY
TYPE PURPOSE TYPE AND TYPE
1. GENERAL
1.3 CATALOGUES 4C
2. SHIPPING INFORMATION 4C FI 2C 2C+1R
2.1 NET & GROSS WEIGHTS 4C FI 2C 2C+1R
2.2 MEASUREMENTS 4C FI 2C 2C+1R
2.3 PACKING, KNOCKDOWN AND FI 2C 2C+1R
TRANSPORTATION PROCEDURES
3. SCHEDULES
3.1 DESIGN WORK SCHEDULE 4C FI 2C 2C+1R
3.2. MANUFACTURING SCHEDULE 4C FI 2C 2C+1R
3.3 DOCUMENT SUBMISSION SCHEDULE FI 2C 2C+1R
3.4 TEST AND INSPECTION SCHEDULE FI 2C 2C+1R
3.5 SHIPPING SCHEDULE FI 2C 2C+1R
4. REPORTING
4.1 STATUS REPORTS FI
4.2 TEST AND INSPECTION REPORTS FA 2C 2C+1R
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APRIL, 2007 NIOEC-SP-70-08 (2)
7.1 DRAWING & DOCUMENT LIST FA 2C 2C+1R
7.2 POWER CONSUMPTION LIST AND 4C FI 2C 2C+1R
HEAT DISSIPATION
7.3 POWER SUPPLY & DISTRIBUTION FA 2C 2C+1R
DRAWINGS
7.4 DIMENSIONAL DRAWINGS 4C FI 2C 2C+1R
7.5 SYSTEM CONFIGURATION 4C FA 2C 2C+1R
7.6 FOUNDATION DESIGN BASE AND 4C FA 2C 2C+1R
ANCHORING DETAILS
7.7 GROUNDING SYSTEM FA 2C 2C+1R
7.8 NAMEPLATE LIST FA 2C 2C+1R
7.9 PRELIMINARY SYSTEM PLOT 4C FA 2C 2C+1R
PLAN IN CONTROL ROOM &
EQUIPMENT ROOM
7.10 MTBF FIGURES 4C FA 2C 2C+1R
7.11 HARDWARE SPECIFICATION 4C FA 2C 2C+1R
7.12 INTERNAL & EXTERNAL LAYOUT 4C FA 2C 2C+1R
DRAWINGS
7.13 INTER WIRING DRAWINGS 4C FA 2C 2C+1R
7.14 TERMINAL ARRANGEMENT 4C FA 2C 2C+1R
DRAWINGS
7.15 WIRING CONNECTION LIST 4C FI 2C 2C+1R
7.16 INTERCONNECTION DRAWINGS 4C FI 2C 2C+1R
BETWEEN EQUIPMENT IN CONTROL
ROOM AND EQUIPMENT ROOM
7.17 I/O ASSIGNMENT LIST 4C FA 2C 2C+1R
7.18 DETAILED LOOP DRAWINGS 4C FA 2C 2C+1R
INCLUDING FIELD INSTRUMENTS
(TRANSMITTERS, CONTROL VALVES, ETC.)
7.19 GRAPHIC DISPLAYS DIAGRAMS 4C FA 2C 2C+1R
7.20 INTERLOCK DIAGRAMS 4C FA 2C 2C+1R
7.21 SOFTWARE SPECIFICATION 4C FA 2C 2C+1R
INCLUDING APPLICATION SOFTWARE
ABBREVIATIONS:
C: COPIES
R: REPRODUCIBLE
FI: FOR PURCHASER’S INFORMATION
FA: FOR PURCHASER’S APPROVAL
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