Professional Documents
Culture Documents
20298-01-EJ12-002
Project Title
1.1 General
PCPL intends to develop the Mehar Field by installing a Gathering System, Gas
Processing Facility (GPF) and Product Storage & Loading Facilities. The field facilities
will be developed in two phases, Phase-I and Phase-2. Phase-1 development will cater
to 55 MMSCFD of gas productions and Phase-2 will cater to 80 MMSCFD of gas
productions. The expected condensate production rate is 6600 BPD for Phase-I and
7000 BPD for Phase-2. From GPF, treated sales gas will be exported through a new
pipeline to existing SSGCL/SNGPL gas pipeline. Stabilized condensate and produced
LPG will be exported by road tankers.
Mehar Block is located in the Kirthar Fold belt area, in the Middle Indus Basin. Mehar
field is located about 190 km west of Sukkur and 400 km north of Karachi in Sindh
province. The environment is arid and the terrain is mountainous. Mazarani gas field,
operated by PPL is situated about 25 km to the north, while Zamzama gas field
operated by BHP is situated about 70 km to the north of Mehar Field.
Mehar field consists of Pab and Ranikot formations. The wells will be connected to the
new GPF through a Gathering System. There will be a total of 8 wells (4 in Pab & 4 in
Ranikot) in Phase-1 and 3 additional wells (2 in Pab & 1 in Ranikot), totaling 11, in
Phase-2 of the Mehar field development.
1.2 Scope
This Specification, together with all reference documentation, defines the minimum
technical requirements for the design, fabrication, configuration, testing, documentation
and preparation for shipment of a microprocessor based Safety Instrumented System
(SIS) for Mehar Gas Development Project.
The SIS shall be a single integrated hardware platform used for Emergency Shut Down
functions for all plant facilities.
Normal plant monitoring, regulation and data acquisition will be by means of the
PMCS.
The VENDOR shall supply a standard field-proven fully integrated SIS system that
exceed the requested functions or performance are acceptable provided the system is
made up of field-proven hardware and software modules. The VENDOR shall clearly
identify any design which is nonstandard or does not have a history of at least six field-
installed systems which have been in similar service for two years or longer.
SIS, FGS and PMCS can be manufactured and supplied by same vendor and shall be
interfacing on same network. Physically the systems shall be separate from each other.
VECO Doc. No. 20298-01-EJ12-002
Project Title
1.4 Abbreviations
DC Direct Current
SSV Safety Surface Valve
SCSSV Surface Controlled Subsurface Safety Valve
TMR Triple Modular Redundant
SIL Safety Integrated Level
DI Digital Input
DO Digital Output
AO Analog Output
AI Analog Input
CCR Central Control Room
VECO Doc. No. 20298-01-EJ12-002
Project Title
Wellhead facilities, Gathering stations and GPF area has been tentatively selected at a
location about 190 km west of Sukkur and 300 km north of Karachi in Sindh Province.
The environment is arid the terrain is mountain.
Elevation above mean sea level (GPF) : 54m (Site-IV) / 56m (Site-l)
All instruments shall be certified as EEx’i’ IIA/IIB per ATEX Directive. Suitable isolators
shall be provided in control room. EEx’d’ protection shall be used for solenoid valves &
where not available.
Detector & device enclosures, in field, shall be dust proof, weather proof to IP 65, as a
minimum. All external surfaces shall be suitably painted for corrosion protection.
Codes, specifications and standards referred to within this specification, form a part of
the requirements of this specification in a manner and to the extent specified within
those codes and standards.
Unless otherwise specified, the latest edition or revision to these codes specifications,
and standards in force at the time of Request for Quotation (RFQ) and/or Purchase
Order (PO) shall apply.
No deviations from the Codes and Standards listed in this document will be allowed
unless such deviations are clearly identified in the bids, with the reasoning. In addition,
they must be approved in writing by COMPANY.
The VENDOR shall have responsibility for complete engineering approach to the SIS
design, fabrication, engineering, staging, testing, documentation, shipment and
commissioning this shall include but not be limited to the integration between Well
Head facilities, Gathering Stations and Gas Processing Facilities.
SIS programming shall be conducted as a joint exercise between the VENDOR and the
EPCC CONTRACTOR. The EPCC CONTRACTOR should inform the COMPANY in
writing well in advance before the exercise begins; the COMPANY shall advise the
EPCC CONTRACTOR if it desires to be a part of the exercise. The VENDOR shall
supply engineering documentation, which shall include appropriate SIS input to the
COMPANY'S CAD generated instrument loop diagrams.
The COMPANY’S approval of the manufacture and model number of equipment and
approval of the VENDOR'S drawings/documents does not in any way affect the
VENDOR'S full responsibility to supply strictly in accordance with project specifications,
codes and standards.
VECO Doc. No. 20298-01-EJ12-002
Project Title
The Vendor shall supply, but is not limited to, the following:
• Open book pricing valid for 12 months for additions or deletions of hardware;
• Plant SIS LAN connectors, splitters, taps, etc. as required by the system and
the application, including the SIS LAN cable;
• All operating and application software with licenses as called for by this
Specification and the Purchase Order. This shall be the latest revision of all
proprietary software and all software revisions and manual upgrades, which
may be released during the first year after Purchase Order award;
• All necessary interfaces required to run the operating, Windows GUI and the
SIS PLC application software;
• All SIS testing services including the pre-FAT, FAT and IFAT (with PMCS,
TALS, FGS & RTUs.) test. All tests shall be conducted in the VENDOR'S
premises using the VENDOR’S utilities and test equipment;
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Every deviation from design documentation must be brought to the attention of the
COMPANY, whose written approval must be obtained before any work can commence.
If no exceptions are stated, or the COMPANY'S approval of a deviation is not given,
then full compliance will be assumed and required.
VECO Doc. No. 20298-01-EJ12-002
Project Title
• Gathering stations.
Following are the key functional requirements for the Gas Processing Facility SIS.
Gathering Station manifold are un-manned and will be monitored and controlled by an
RTU. The RTU will be the integrated control system of the Gathering Station manifold
and is not included in this specification.
Wellhead Surface Facilities are un-manned and will be monitored and controlled by an
RTU. The RTU will be the integrated control system of the wellhead facilities and is not
included in this specification.
5.1 General
The overall availability of the SIS (Logic Solver central parts, I/O cards and
communication cards) shall be based on TUV SIL 3 certified Redundant
programmable logic controller technology and shall have hardware architecture such
that it is capable of being certified to DIN V 19250(TUV) class 6 (or higher) and comply
with the requirements of IEC 61508. The overall availability of the SIS shall be >
99.999%. The proposed system shall use VENDOR standard field proven product
lines. No product development shall be undertaken during the length of the contract.
The projected life of the installation is 25(twenty-five) years. The SIS must be capable
of sustaining an equivalent operational life and be guaranteed by the VENDOR to be
capable of being supported for at least this period of time. This may be achieved by
the VENDOR guaranteeing product development and supply for five years followed by
upgradeable development and support for a further twenty years.
VECO Doc. No. 20298-01-EJ12-002
Project Title
Only new equipment shall be supplied. No second hand or obsolete equipment shall
be supplied. All hardware items shall be standard modules from existing product
ranges. No prototype equipment shall be utilized.
The SIS shall incorporate precious metal plating of component lead wiring, connectors,
etc. Construction shall not use techniques which are prone to damage by corrosive
atmospheric pollutants or vibration (e.g. wire wrapping).
The SIS shall be provided with integrated sequence of event recorder capability for
system maintenance and shutdown. System shall have capability to retrieve, display
and print information about events from dedicated SIS work station and any of the
network printers. After any trip, the user can review event data in Event log displays on
the HMI screen.
Sequence of event recorder stores data in a History file for 60 days minimum before
and after a trip of the controlled process. The user can create displays and printout to
help evaluate system behavior before during and after the trip in order to determine the
cause of the problem.
Sequence of event recorder display formats include Bar, Chart, Trend line, Tabular,
Static position and profile.
The automatic backup and restart features shall be provided which enables Sequence
of event recorder to automatically save the trip database. After auto backup takes
place, Sequence of event recorder is ready to restart collection of historical data
without human intervention.
5.2.1 Hardware
The SIS shall incorporate a TUV SIL 3 certified Redundant rack mounted
construction in which various electronic cards are inserted into a card chassis. The
various chassis’s are to be located within the SIS cabinets. Card addresses shall be
software selectable (i.e. any card in any slot). No external backplane or piggy-back
methods shall be used.
A figure of less than 100 milliseconds between an input state change and a
corresponding output state change shall be achievable by the offered system.
Controllers shall be sized to meet the project requirements in the form of available slots
or algorithms, points and address plus 10 percent to allow for the project growth. In
addition there shall be 30 percent capacity for future growth. Scan time shall not be
more than 300 msec.
VECO Doc. No. 20298-01-EJ12-002
Project Title
The SIS shall, as a minimum, perform the logic as shown on the C&E diagrams.
All logic programs shall reside in password protected battery backed memory
(VENDOR to use latest devices) in order to maintain logic security. Interrogation from
the engineering HMI shall be available, but shall have 4 levels of passwords plus key
switch security.
The SIS shall be simple and flexible with regards to programming of logic connections.
The SIS shall only be able to be programmed off-line from a Pentium PC and Microsoft
Windows GUI. The SIS programming software package shall conform to IEC 61131: 1-
3 and shall also provide the facility for automatically documenting and annotating logic
program. The logic program shall be liberally commented throughout, to assist with
fault-finding and maintenance. The software-programming package shall produce logic
diagrams in function block format. TUV certification shall be provided for the logic
generated in the system.
As a minimum but not limited to, the following logic operators and algorithms shall be
available in the SIS:
• Equal to;
• Greater than;
• Less than;
• AND operation;
• OR operation;
• NAND operation;
• NOR operation;
• XOR operation;
• Logical negation;
• Latch toggle;
• Sequencers.
Facilities shall be provided for majority voting techniques to be applied to multiple input,
logic or output paths, with discrepancy and trip actuation indication alarms as
appropriate.
This shall include standard system modules, an extensive library of standard proven
function blocks and application specific function blocks.
A change control procedure that leaves an audit trail of approved logic programming
modifications shall be implemented. This shall include paper records and identification
of version within application code.
5.3.1 General
The I/O cards shall utilize modular mount construction. All I/O’s shall be point isolated,
failure of single point shall not fail whole card.
All digital I/O cards shall provide LED indication of the status of each I/O point,
independent of any bypass, override or latch function. All I/O cards shall provide LED
identification of card status (faulty, healthy, etc).
All I/O circuits shall include a current limiting transformer to prevent damage upon
short-circuiting of I/O field circuit conductors. All I/O circuits shall provide transient
suppression in accordance with IEEE 472 and undergo surge withstand capability
testing. Lightning suppression devices are required. As a standard, all I/O circuits shall
be individually isolated, utilizing integral solid-state optical or transformer isolators. In
addition, all 240V AC I/O circuits shall incorporate external interposing relays. Each
I/O circuit shall be individually fused with automatic blown fuse monitoring. This shall
be in the form of resetable electronic fuses.
For all I/O circuits, the negative terminal at the I/O card in the system cabinet shall be
at the clean instrument earth level. All other points in the circuits shall be isolated from
earth.
All I/O shall be time stamped by the controllers and have a resolution of at least 100
milliseconds.
All inputs shall be self resetting, however, alarms will latch. This alarm latching will be
performed by the PMCS. The SIS shall use / implement a pulse extension to ensure
VECO Doc. No. 20298-01-EJ12-002
Project Title
• A clock synchronization signal from the PMCS to the SIS. This shall be powered
and fused at 24 VDC, 1A by the PMCS.
The field devices shall be coupled to the signal conditioning circuits of the logic system.
Signal conditioning shall include galvanic isolation, non-integrating input filters and time
delays to isolate field equipment from system logic and to prevent operation of the
system by any mechanical vibration.
All DI points shall be latched in their latest driven state until scanned or read into the
SIS.
A start-up bypass function shall be provided for selected DI points, which may be in an
abnormal state prior to process start-up (eg. pressure low-low). These points are
shown on the SIS I/O schedule. The start-up bypasses shall be manually activated.
VECO Doc. No. 20298-01-EJ12-002
Project Title
Any flow trips should be initiated via a delay-off timer (adjustable 0 to 10 seconds) to
remove the problem of nuisance trips caused by transient dips in the flow rate.
“Smart” transmitters using the HART protocol shall be used to sense abnormal process
conditions use of switches is not permitted.
The SIS shall provide communication interfaces to HART field devices (transmitters,
transducers and actuators). These interfaces shall give the host processors access to
the digital information encoded with the 4 to 20mA analogue process variable signal.
The digital information shall be passed to and from the host processor using a remote
I/O.
The SIS software shall enable transfer of HART field devices status information to the
PMCS, thus enabling remote transmitter programming and remote diagnostic from the
PMCS.
• Dry contacts rated at 4A for 24V DC or at 2A (hold-in)/8A (in-rush) for 240V AC.
These shall be selectable as normally-open or normally-closed, momentary or
maintained. The voltage will be supplied externally from the SIS (including
individual fuse protection where required) by the COMPANY'S panel. These will
VECO Doc. No. 20298-01-EJ12-002
Project Title
Each DO circuit shall incorporate an output driver to activate the field device and a
logic protection device to guard against field generated interference.
Output defeats shall not be incorporated into the SIS. The design of multiple path logic
systems shall allow testing of the SIS electronics without the use of output defeats.
AI points shall be 4 to 20mA DC with a maximum input resistance of 250 ohms. The
following is the type of AI point:
• The 24V DC loop power shall be supplied by the SIS and the current shall be
sourced by the SIS. These will generally be used where a single field transmitter
will be signal conditioned within the SIS to generate both high-high and low-low
trip points;
All events where AI points move through an alarm point shall be latched until scanned
or read into the SIS.
All AI points shall be automatically monitored for short-circuit (above a threshold over
20mA) and open-circuit (below a threshold under 4mA) faults. The thresholds shall be
fully programmable.
All AI points shall be individually isolated and individually fused on the high (supply)
side. The fuse rating shall be 250mA. All AI points shall have an individual power
regulator to provide field transmitter power.
Maintenance override and start-up bypass functions shall be provided for selected AI
points. These points are shown on the SIS I/O schedule. Maintenance override and
start-up bypass functions shall be implemented after signal conditioning and alarm
generation has occurred.
All AO points shall be individually isolated and individually fused on the high (supply)
side. The fuse rating shall be 250mA. All AO points shall have an individual power
regulator to provide field transmitter power.
Output defeats shall not be incorporated in the SIS. The design of multiple path logic
systems shall allow testing of the SIS electronics without the use of output defeats.
The preferred mode for data exchange with the PMCS and their related amount is that
the SIS is interfaced to the PMCS bus as a “system node”, thus also allowing a
common time basis between PMCS and SIS. This way of interfacing is required to be
“a catalogue product” and not a “project application”, allowing the best performance
both for data transfer to operator interface. If not otherwise possible a standard serial
interface will be provided.
The SIS operator interface shall be available from the PMCS operator HMI by way of
interactive graphics (by others). A peer to peer Ethernet link shall be established
between the SIS and the PMCS in the Auxiliary Room in order to provide this operator
interface.
• Status of all SIS I/O, including, as applicable, field status, maintenance override
status, start-up bypass status, latch status, logic status, etc.;
• ESD faults and status, including discrepancy alarms on multiple path logic
systems, power supply faults, etc.;
• PSD/ESD operator interface panel integral to the PMCS operator HMI on which a
number of manually operated devices shall be installed. These are the covered
SIS zone pushbuttons, covered Blowdown pushbuttons, SIS indication lights and
SIS Output Zone Reset pushbuttons.
The PMCS will co-ordinate alarm handling of process pre-alarms and process
shutdown alarms transferred from the SIS. These will be interleaved on common alarm
lists in the PMCS. In order to synchronize alarm time stamping, the PMCS shall
periodically reset the SIS clock via a hardwired digital output from the PMCS to the SIS
(eg. at 1 am every morning, as determined by the PMCS master clock). Note: this may
be achieved by use of network time protocols NTP or equivalent. Alarm points shall be
VECO Doc. No. 20298-01-EJ12-002
Project Title
The operator interface shall be designed so that faults on any part of the operator
interface or failure of the communication link between the SIS and the PMCS shall not
degrade the stand-alone functionality or the reliability of the shutdown actions of the
ESD.
The operator interface shall be designed so that “no information” is synonymous with a
healthy system. That is, with the process conditions normal, no bypass(s) or
override(s) operated, all outputs in the healthy, reset position and no faults on the
system, and then all associated alarms will be off.
A system integration specification for the interface between the SIS and the PMCS /
Transmission interface equipment (for RTUs) shall be produced by the SIS VENDOR
for implementation at the PMCS/Telecommunication end of the interface by the
VENDORS and at the SIS end of the interface by the SIS VENDOR.
The SIS shall also be capable to communicate with Ethernet/IP (Ethernet Industrial
Protocol) capable of handling large amounts of data at speeds of 100 Mbps or better.
At GPF it shall be connected directly to ICSS data highway.
Peer to Peer communication shall be provided between PMCS, FGS and SIS. The
communication between these systems shall be provided on the common PMCS data
highway.
SIS system shall provide voltage free relay contact for a hardwired connection to TLAS
for safety requirements.
The VENDOR shall be responsible for the programming, testing and performance of
the interfaces. The COMPANY will provide technical assistance and input where
applicable.
Common EWS for PMCS, SIS and FGS shall be provided. For details of engineering
HMI refer Doc 12-MEGP-I-1021 sec 10.
For manual CCR shutdown purposes, and to provide back-up indication of SIS status,
a hardwired ESD emergency panel will be provided with the SIS for installation within
VECO Doc. No. 20298-01-EJ12-002
Project Title
The Critical Controls Panel shall include as a minimum the following SIS functions:
The panel shall have 20% space for additional electrical devices to be installed by
others where rewired. In addition, 20% spare wiring terminals shall also provided for
future wiring in the control panel.
The design emphasis shall be to provide a simple facility, easily operated under
emergency conditions.
The PMCS VENDOR has the responsibility for the construction of the operator
console. The SIS VENDOR has the responsibility of the critical controls panel and shall
coordinate all integration and design issues with the PMCS VENDOR to ensure the
critical controls panel is integrated within the operator console design. However, it is
the intention of this PROJECT that the SIS and the PMCS will be supplied by a single
vendor.
5.8 Expandability
The capacity of the SIS is defined by the SIS I/O list. In order to allow for expansion, a
minimum of 20% installed backplane spare capacity shall be provided, in addition to
20% installed I/O capacity. The 20% spare shall be abover the overall capacity of the
SIS for both Train 1 & 2, Phase 1 & 2.
The SIS shall be designed such that input/output and logic module expansion by
modular addition is possible without impacting the current system operation.
Expansion shall be able to be implemented with the SIS fully powered and operational.
Expansion shall be achieved by straight addition, not modification, of hardware and
with a minimum of software and programming changes.
VECO Doc. No. 20298-01-EJ12-002
Project Title
The SIS shall tolerate a power interruption time of 1 second without disrupting its
operation.
Loss of power to the SIS, (beyond the power ride-out period) shall, upon subsequent
restoration of power, result in automatic reboot of the system to full operation within
five minutes. However, the system logic shall revert to its fail safe state after automatic
reboot.
The VENDOR shall state the availability of the proposed SIS as a whole. This should
exceed 99.999% based upon a modular change-out maintenance philosophy utilizing
held spares. It is critical that single point component failure shall not result in the loss of
availability of the entire ESD.
MTTR = Mean Time to Repair (assume one hour based on time to diagnose the fault
and make an on-line card replacement)
MTBF and MTTR data shall be based upon field installed equipment data and not
theoretical data.
Comprehensive SIS status information and control of the diagnostic routines shall be
available at the SIS engineering HMI which shall include, as a minimum, the following
functions:
• Fault and status indication, including discrepancy alarms on multiple path logic
systems;
In case of a hardware fault occurring, the diagnostic software shall display on the
PMCS / SIS engineering HMI and PMCS operator HMI time stamped address location
information and provide a graphical presentation of the faulty card location together
with descriptive fault repair instructions.
All SIS shutdown paths shall be tested from input to output automatically with a new
test being initiated at least every thirty minutes. The diagnostic routines shall involve
the generation and monitoring of test pulses which are fast enough to not affect
electro-mechanical output devices. If a test shows that the expected change at the
output is not in accordance with the known C&E relationship (held in a diagnostic map)
then an alarm shall be generated. This testing shall be overridden by an input
changing into the shutdown state. The automatic test system shall have a watch-dog
to monitor its own operation. If this fails, an alarm shall be generated. Tests shall be
able to be manually initiated at any time.
The design of the SIS shall be on a modular basis to simplify fault finding, with
maintenance being by replacement of complete cards so as to minimize down-time.
All controller, communication, non-volatile memory, and I/O circuit cards shall have
multiple red and green LED indicators to facilitate the identification and repair of failed
cards.
The SIS shall provide the capability to replace a failed part with a spare, on-line and
under power without affecting the existing SIS operation.
The SIS shall be designed to provide maximum ease of equipment servicing. All
necessary hardware, software, drawings and test equipment required to execute fault
identification shall be provided by the VENDOR.
The initiating field input devices for the PSD & ESD functions shall be unique to each
function.
Output devices for the actuation of isolation / battery limit valves or electrical drive
control circuits are the same for both the PSD and ESD functions (if required by both).
Segregation of these two functions is only at the logic level, i.e. outputs; marshalling,
field cables, field termination panels and end element field devices are common.
The initiating field input devices for the PSD and ESD functions shall be coupled to the
SIS I/O signal conditioning circuits.
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This facility shall be provided on a per instrument basis, for selected inputs which may
be in an abnormal state prior to process start-up (e.g. pressure low-low) as specified
on the relevant PSD input/output list or C&E’s.
Activation of a start-up bypass shall be a protected manual operation carried out on the
operators console and only defeat the PSD function.
The operator shall, at any time, be able to cancel a start-up bypass. This shall, unless
the normal or healthy state has been reached, cause a trip to occur.
The bypass shall be self-cancelling either by the initiating device transferring to the
normal or healthy state, or after a pre-determined time delay. If cancelled automatically
by the initiating device the input circuitry shall prevent nuisance trips being caused by
oscillation of the input around the reset value.
Attempted operation of the bypass with the process in the normal or healthy state shall
have no effect.
Indication of the status of the bypass shall be provided on the operator’s console.
Output defeats shall not be incorporated into the SIS function. The design of multiple
path logic shall allow testing of the SIS function hardware.
In order to minimize the level of operating personnel required to run the plant facilities,
the following SIS reset philosophy shall be adopted.
Once a PSD has been initiated, manual intervention shall be required to reset the
shutdown function. This will involve a common reset of the PSD function from the
control room operator console, which shall remotely reset the emergency shutdown
valves, shutdown valves and blowdown valves and restart motors. This shall either be
on a one-by-one reset basis or on a process group reset basis. The reset facilities on
the control room operator console for the PSD function shall be for the whole function.
Once an SIS has been initiated, manual intervention shall be required to reset the
shutdown function. This will involve a reset of the SIS zone from the control room SIS
operator interface panel, forming part of the PMCS operator console furniture, as well
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Where sequential operation is required for safe shutdown or blowdown, the interlocking
shall be performed within the ESD.
• If blowdown valves are not confirmed closed then an alarm shall be generated.
However, there shall be no automatic emergency shutdown initiated by this
condition;
The electrical portion of the ESD, including all wiring, shall be in accordance British
Standard Wiring Rules. The VENDOR shall bring to the attention of the COMPANY all
deviations from this standard for clarification and final ruling.
Exposure of personnel to voltages greater than 24V (AC or DC) shall be prevented.
This shall be accomplished by complying with the requirements of BS 7671, in
particular, by ensuring adequate safety earthing, by segregation of different voltage
levels and by covering and labeling of equipment at voltages greater than 24V DC.
The ESD, as offered, shall be supplied with provisions for protecting against system
errors and hardware damage resulting from electrical transients on power or signal
wiring. These transients include those generated by switching large electrical loads, by
power line faults and due to lightning strikes which induce surges on power or signal
cables. The IEEE Standard 472 shall apply to all SIS power inputs and signal inputs
from field devices.
The most common sources of electromagnetic radiation are portable VHF hand-held
radio transceivers with 5 watts of power and portable UHF hand-held radio transceivers
with 4 watts of power. Other sources are fixed radio stations, vehicle radio
transmitters, commutator type electrical devices and spurious sources such as from
welders and contactors. The SIS shall be immune from these EMI/RFI interferences in
accordance with SAMA PMC 33.1. Particular attention shall be given to the immunity
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Errors caused by RFI shall not exceed 0.1% of span for exposure to field strength of 10
volts/meter over the frequency range of 10 to l000MHz. A certified test report shall be
required in the proposal to verify this performance. The VENDOR'S equipment shall
meet all applicable RFI emissions standards. The VENDOR’S equipment shall not
cause RFI interference to the COMPANY'S hand held radios. The VENDOR shall
provide a hand held radio (preferably Motorola Saber I Handie Talkie or equivalent of
5W RF output and VHF 450 - 520 MHz frequency band) to be used for the factory
acceptance test (FAT) of RFI susceptibility.
The SIS equipment shall be designed to operate on a 240V AC 50Hz power. SIS
equipment shall be powered from two separate UPS feeders from different distribution
boards. UPS shall be supplied by others in accordance with the power requirements as
determined by the SIS VENDOR and the COMPANY. The vendor shall design and
install power buses in such a manner as to accept individual UPS feeders and
distribute individual branch feeder to SIS chassis and redundant field I/O power supply
loads. Voltage will be ±2% with a maximum transient voltage depression of 20% and
frequency regulation will be ±1%. This is the only power that will be provided to the
SIS equipment.
The VENDOR shall provide power supply systems for the SIS equipment mounted in
the system cabinets and all field devices associated with the ESD. At least 30% spare
capacity shall be provided.
Power supply sizing should assume the following power loading for field devices;
The power loading for all other field devices (i.e. system powered DI and AI) shall be
based upon the SIS VENDOR’S standard power loading figures.
Parallel redundant power supplies with automatic change-over to protect against power
supply failure shall be provided for SIS equipment mounted in the system cabinets.
Each power supply shall be capable of supplying power to the entire ESD. Both power
supplies must be on line at all times, each supplying power to the load. Failed power
supplies shall be removable without disconnecting power from any part of the SIS or
affecting operation.
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Each power supply shall be provided with a pilot light and with a fault detector. Failure
of any power supply, including incoming power feeders, fuses and circuit breakers,
shall be alarmed by the SIS through the use of a common SIS unit alarm digital input.
Output current on power supplies shall be locally indicated in order to confirm that
supply capacity exceeds current usage.
24VDC power required for internal SIS components and to power field instruments
including relays shall be from the SIS cabinet supplied by VENDOR.
All metal enclosures supplied shall have a minimum of one 6mm x 20mm copper safety
earth bus bar across the full width of the panel. All metal racks, internal panels and
fabrications, cable tray, doors and detachable panels shall be earth bonded together to
this safety earth with a flexible copper braid strap of at least 2.5mm2 to ensure
effective earthing. The safety earth will also be used to connect the earth core from the
multi-core plus earth field control cables being used for solenoid valves.
Each system cabinet and marshalling cabinet shall be provided with one 6mm x 20mm
copper galvanically isolated instrument earth bus bar across the full width of, and
insulated from the panel. The instrument earth shall be used for earthing system
electronics, the negative terminals of DC power supplies and field circuits, and the
electrostatic screens from multi-pair field instrument cables.
All system and marshalling cabinet earth bars shall be clearly labeled.
All wiring shall comply with the requirements of BS7671 Electrical Installations and
shall be carried out using not less than 1mm² flexible stranded, annealed copper
conductors and PVC insulation. Insulation resistance shall be 500 Volts.
The VENDOR shall connect to one side only of the incoming and outgoing terminal
blocks. A terminal shall be allowed for each incoming and outgoing wire. No more
than one wire is to be connected to each side of any one terminal. Where more than
one wire is to be connected on one side for looping purposes, a preformed link or comb
between adjacent terminals shall be provided.
All wiring shall be fitted with PVC insulated crimp pins or lugs. These shall be wire pins
for 1mm2 conductors and lugs for 24V DC power distribution conductors. Separate
pins or lugs, as applicable, shall be used for each conductor. The size of pin or lug
shall be suited to the size of conductor to be terminated and crimped with the pin or lug
manufacturer's approved crimp tool. A method of stripping insulation which does not
damage the wire shall be employed.
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An allowance shall be made on the length of wire at each terminal to permit cutting and
remaking of the wire termination at least once without interference with the main run of
the wire and loom.
Terminal blocks shall be Klippon type SAKR polyamide type test/disconnect knife
terminals (or COMPANY approved equivalent) of a size suitable for the particular size
wiring being used. Terminal mounting shall be Klippon terminal rail type TS32 (or
COMPANY approved equivalent). Each terminal shall be clearly tagged with terminal
number. Terminals shall be arranged in groups as per their service. All spare cable
cores shall be terminated into terminal blocks and connected to the instrument earth.
Terminal strips shall be designed so each incoming and outgoing cable can be
terminated such that all cores of the cable fan out in a logical sequence onto a single
uninterrupted section of the terminal strip. The terminal strips shall be fixed such that
terminal screw slots are accessible from outside the compartment to facilitate ease of
wire termination.
All terminated wiring shall have individual alpha-numerical identification in the form of
Grafoplast (or COMPANY approved equivalent) push-on sleeves.
No equipment or terminal block/rail in the system cabinets shall be mounted less than
400mm above the floor. No equipment or terminal block/rail in the marshalling
cabinets shall be mounted less than 200mm above the floor.
A minimum of 50mm shall be allowed between each terminal row and any plastic
slotted trunking to permit sufficient clearance to facilitate fanning of conductors whilst
providing easy access for terminations and identification markers. Terminals shall be
mounted on rails that are attached to a back pan/support and not directly to the surface
of the enclosure.
Wiring of voltages greater than 24V (AC or DC) shall be separated from instrument
signal wiring.
All wiring shall run such that it is accessible, neat and tidy. All wiring shall be run in
trunking and loomed with cable ties. Trunking shall be installed in accordance with the
approved layout drawings and shall allow for 30% spare capacity.
The SIS power supply shall have conditioning/filtering and voltage regulation for
immunity against switching surges, as required.
Each field circuit shall be individually fused and a SIS alarm shall be generated in the
case of fuse failure. These shall be in the form of reset table electronic fuses or
indicating cartridge style.
All items shall be selected, sized, constructed and specified with a power rating of
sufficient magnitude to withstand short circuit conditions associated with the
application.
5.17.1 General
The VENDOR shall supply SIS system cabinets and marshalling cabinets.
Cabinets shall be the VENDOR’S or third party standard modular construction. Choice
of cabinet type (if there is more than one VENDOR standard) shall be such as to limit
weight and dimensional size consistent with good operational and maintenance
practices. An overall maximum height limit of 2200mm (including the plinth) applies.
All cabinets shall be sized to allow for the installation of all equipment as identified in
the Purchase Order, plus 20% spare. In particular the SIS system cabinets in the
auxiliary room shall have reserve space for at least two additional I/O racks.
Cabinets shall be identical to what the PMCS, FGS are providing for uniformity.
Any deviations from these requirements shall be brought to the COMPANY'S attention
for approval.
5.17.2 Structural
The SIS system and marshalling cabinets will be located in a non-hazardous area and
shall be ingress protected to IP54 as defined in IEC 60529.
The SIS system and marshalling cabinets shall have sufficient structural members and
panels shall be stiffened as necessary to prevent deformation/distortion due to
equipment weight and/or from dynamic loads experienced during transportation.
(Shipping dynamic loads/vibration defined as 0.5g vertical, 0.5g longitudinal, 0.25g
lateral).
All SIS cabinets shall be designed to provide adequate heat dissipation. Where forced
ventilation is required, fans and air filters that are easily accessible for maintenance
shall be provided by the VENDOR. Where forced ventilation is required, the VENDOR
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Access to the SIS system and marshalling cabinets shall be from front and back
vertically hinged doors. Hinged doors shall be mounted on lift-off type hinges and shall
be capable of being swung through an angle of not less than 100o from the closed
position. The lift-off hinges shall have unequal length pins to enable the door to be
refitted with ease.
Doors shall be secured in position by a lockable three point locking mechanism and
locks shall have identical keys.
Drawing holders (A3 size) with paper access slots shall be provided on the inside of all
doors.
Suitable removable lifting lugs (pad eyes, complete with bolt hole plug) shall be
provided at the top of all SIS system and marshalling cabinets to enable them to be
lifted as complete sub units. It is the VENDOR’S responsibility to ensure that the panel
construction takes account of the loads and stresses imposed by such lifts.
The threads of all nuts, bolts, screws and studs of 5mm diameter and above on
cabinets supplied in accordance with this Specification shall comply with British
Standards. Where possible, all nuts shall be of the captive type in order to prevent loss
upon dismantling and to aid reassembly.
The VENDOR’S standard shop paint finish for equipment will be acceptable if good
industry practices are followed in surface preparation and cleaning. COMPANY shall
be consulted for the final color.
The VENDOR shall supply one liter of each paint type used in surface preparation and
painting for use by the COMPANY for site touch-up work.
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The VENDOR shall include the provision of programming services. The programming
activity shall be executed in the VENDOR’S premises using the VENDOR’S
programming tools and assisted as necessary by the COMPANY.
At the completion of the staging test, the VENDOR shall update the final approved SIS
program. This program shall be generated from the operating software and shall be
free from software patches. The final approved program shall be delivered on a fully
tested and verified system program tape or disk. These shall be supplied complete in a
compartmented storage case with suitable labeling. The VENDOR shall also retain a
copy of this program revision.
The VENDOR shall include the provision of the services of a qualified field service
representative to assist with the installation of circuit cards, peripheral devices and
software in addition to the initialization of SIS power. This service shall also include a
functional test and verification of the SIS power distribution and earthing.
The Vendor shall supply spare parts for start up and commissioning. These will be
required in order to avoid using any of the operational spare parts. The Vendor must
take into consideration the remoteness of Site when deciding which spares and what
quantities are offered.
Spare parts will generally be held by the COMPANY on the shelf at the Mehar Gas
Development Facilities, not as hot running spares. All spare parts shall be clearly
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The Vendor shall submit a spare parts quotation for two years’ continuous operation.
The Vendor must take into consideration the remoteness of Site when deciding which
spares and what quantities are offered.
8.1 General
The SIS shall be subject to rigorous QA and testing programs at all stages of
manufacture. Quality assurance and testing shall be designed to simulate as closely
as possible local conditions. The testing programs shall be based on ISA RP55.1 and
outline methods, procedures and simulation facilities proposed.
The VENDOR shall ensure that adequate notice (a minimum of fifteen working days, in
writing) is given to the COMPANY and the Inspector to enable them to arrange their
visits to suit the manufacturing program in accordance with the conditions of the
requisition documents.
The acceptance of the work by the Inspector and/or his release of the equipment for
shipment shall in no way release or relieve the VENDOR from any responsibility for
carrying out all of the provisions of this Specification and/or relevant documentation,
nor does the COMPANY by such approval and/or release, assume any responsibility
whatever for such provisions.
All test and inspection data shall be legible including the name and signature of the
VENDOR and, where applicable, the Inspector.
If any part of the equipment is damaged after tests have been completed, retesting of
the affected parts is mandatory. The method of repair shall be in accordance with the
VENDOR’S standard procedures.
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The VENDOR shall supply supervision, specialist personnel and all necessary
materials to support the inspection and testing. This shall include all the equipment
and signal generation gear adequate to simulate all inputs simultaneously on a loop
containing multiple inputs.
Testing shall be carried out by the VENDOR and may or may not be witnessed by the
COMPANY or the COMPANY'S representative (the Inspector) at various stages as the
SIS equipment is manufactured and assembled. Locations are detailed below:
All power supplies shall be checked for correct voltage and frequency and all cables
shall be checked for insulation resistance (Megger checked at 500V AC) before any
testing is initiated. Test equipment shall be connected to field connection terminals
only.
The QA and testing program for printed circuit boards (PCBs) and electronic
components should include as a minimum:
These tests need not be witnessed by the Inspector, but certification along with a
detailed report on the tests shall be provided. On completion of testing the serial
numbers of all equipment shall be recorded for checking on arrival at Site. The results
of the pre-FAT shall form part of the Manufacturers Data Report.
The VENDOR shall be responsible for generating the FAT procedures. The pass/fail
criteria shall be 100% correct performance otherwise the faulty item shall be rectified or
replaced at the VENDOR'S cost.
The FAT shall include the testing and acceptance of both hardware and proprietary
system software. All proprietary system software shall be complete and resident in the
SIS prior to the start of FAT. All documentation and listings must be free of markups.
All hardware diagnostic programs shall be run at the start of FAT. These shall be the
diagnostic programs which have been used for processing the system in the
VENDOR’S factory.
During the FAT, the SIS shall be made available to the Inspector for sufficient periods
to verify satisfactory performance. The Inspector will reserve the right to witness the
entire FAT as a nonparticipating observer. The FAT procedure will be signed off by the
VENDOR and the Inspector and a copy of the signed off FAT procedures and related
printouts shall be furnished to the Inspector at the successful conclusion of the FAT.
However, the FAT is not an inspection and test hold point.
The IFAT test will be carried out after the entire SIS equipment has been shipped to
the nominated staging test site. The staging test of the SIS will be conducted in
conjunction with the staging tests of other equipment with which it must interface in
order to verify the correct operation of all interfaces.
The VENDOR shall be responsible for generating the staging test procedures that shall
include pass/fail criteria.
All system HMIs shall be hooked up to the data highway and the whole of the final
configuration data base shall be loaded, tested and signed off by the Inspector.
System diagnostics shall be exercised, and failure modes shall be demonstrated.
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All loops in the system shall be tested by applying a simulated signal (or signals in the
case of complex loops) at the terminal strip in the marshalling cabinet and observing
the effect on the screen, including alarms. Alarms shall not be simply tested by
adjusting the alarm setting. Outputs should also be manipulated and the result
measured again from the marshalling cabinet. All equipment associated with a loop
shall be tested as a system. Circuits shall generally be tested one at a time. However,
where cascade or similar controls are involved, these shall be tested as one complete
system. These tests are not required for calibration purposes.
Prior to the commencement of the SAT, the following activities will have been
performed by the COMPANY with optional technical assistance provided by the
VENDOR:
• A deficiency report written and appropriate action taken to rectify any problems;
• The SIS powered up and functionally tested with the appropriate test equipment.
The process controllers, operator HMIs and peripherals powered up and tested with
diagnostic routines.
Communications established among all components of the system and tested using
the appropriate test equipment.
• All alarm status, analog and pulse inputs, control outputs of each processor
module checked with simulated input and output loads;
• Each analog device calibrated, the system function verified, followed by the
interrogation of each analog point and the operation of each final control
element.
The SAT procedure will be derived from the FAT and the staging test. The FAT
procedure shall be modified to take account of the field environment.
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After the completion of the SAT, each system will be subject to an availability test for a
continuous sixty day period. The availability test will be conducted by the COMPANY
and will consist of monitoring the system availability during the sixty-day period.
The SIS provided by the VENDOR shall have an overall availability of 99.999%.
If the system does not meet the 99.999% availability requirement during the availability
test conducted by the COMPANY, the VENDOR shall be responsible for repairing or
upgrading the SIS (at the VENDOR’S expense) in order to meet the requirement. The
COMPANY will then repeat the availability test and the sixty-day period will begin again
following the repairs and upgrades.
The availability test will be conducted concurrently with normal plant operations.
The Inspector will periodically visit the VENDOR shop facilities and inspect system
progress from a hardware and software perspective in accordance with Inspection and
Test Plan.
At the satisfactory conclusion of the FAT the staging test and the SAT, an appropriate
certificate of acceptance shall be provided by the VENDOR.
Attached to these certificates shall be all test records and other pertinent
documentation. These shall form part of the Manufacturer's Data Report (MDR).
Final acceptance of the SIS shall be on satisfactory completion of the warranty period.
9.0 DOCUMENTATION
9.1 General
The VENDOR shall provide hard copies of drawings and other appropriate documents
developed on his system, with the data stored on either floppy disks or tapes, in a
format compatible with AutoCAD, for future use and modification by the COMPANY as
required.
All documents shall be in the English language, with the data stored on CDs, in format
compatible with Microsoft Word.
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The VENDOR shall produce a Functional Specification for approval by the COMPANY.
This Functional Specification shall detail all hardware and miscellaneous materials to
be supplied against the specification, full details of the exact functionality, performance
and self-checking which will be available from the SIS and full definition of the interface
to all peripheral equipment. The emphasis of the functional specification shall be on
the functionality of the ESD.
9.3 Drawings
All SIS drawings shall be prepared and submitted in accordance with recognized
standards. Wherever practicable, every effort shall be made to minimize the total
number of drawings prepared by use of common drawings wherever practicable
without loss of clarity.
Prior to start of manufacture, the VENDOR shall submit all drawings for the
COMPANY’S approval.
‘As-built’ revisions shall be prepared and final issue. Any information or data revised
during staging tests or SAT shall be provided before the commencement of the
availability test. Each drawing shall be clearly marked ‘As-built’ and dated.
VENDOR and EPCC CONTRACTOR shall also comply with the requirements of
documentation specified in PCPL procedure CSP-03.
The COMPANY will provide the VENDOR with the following information:
• ESD I/O schedule including, but not limited to, the following information for each
loop:
- Tag number;
- Service description;
- I/O type;
- I/O range;
- I/O units;
• The COMPANY'S requirements for graphic displays, report format details, tabular
displays, etc.;
The VENDOR shall supply complete SIS data for inclusion in the COMPANY's
instrument loop diagrams. This data shall include, but not be limited to, the following:
• Hardware addresses including cabinet, rack, card slot and point in the
VENDOR’S standard notation;
Operations and maintenance manuals shall be provided and shall include, but not be
limited to, the following documents:
• A complete set of the VENDOR’S standard manuals for site preparation and
installation, operation, configuration, maintenance and troubleshooting as
applicable to the SIS hardware and software supplied;
The VENDOR shall follow its standard practice provided this meets the intent of the
above requirements.
A system log shall be maintained by the COMPANY and the VENDOR from the time
the staging tests start, through the SAT and on through the warranty period.
The system log shall note all software, hardware and configuration changes and log
the following:
• Summary of a problem;