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ABU DHABI GAS INDUSTRIES LTD. (GASCO)


INTEGRATED PROTECTION AND CONTROL SYSTEM (IPCS)

DESIGN GENERAL SPECIFICATION

INTEGRATED PROTECTION AND CONTROL SYSTEM (IPCS)

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27/05/01

S. AZIZA

R. SUNDAR

ABDUL AZIZ AL AMERI

ISSUED FOR IMPLEMENTATION

10/11/99

A. ABDEL RAHMAN

R. SUNDAR

MOHAMMED A. SAHOO

Issued for comments

Rev

Date
DD/MM/YY

WRITTEN BY

CHECKED BY

APPROVED BY

STATUS

DOCUMENT REVISIONS
Sections changed in last revision are identified by a vertical line in the left margin

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CONTENTS

1. GENERAL ................................................................................................................................................................ 4
1.1 INTRODUCTION ...................................................................................................................................................... 4
1.2 PURPOSE .............................................................................................................................................................. 4
1.3 DEFINITIONS .......................................................................................................................................................... 4
1.4 TERMINOLOGY ....................................................................................................................................................... 4
1.5 ABBREVIATIONS ..................................................................................................................................................... 5
1.6 SCOPE OF SUPPLY ................................................................................................................................................. 5
2. CODES AND STANDARDS .................................................................................................................................... 6
3. REFERENCE DOCUMENTS ................................................................................................................................... 6
4. DOCUMENT PRECEDENCE................................................................................................................................... 6
5. SPECIFICATION DEVIATION/CONCESSION CONTROL..................................................................................... 7
6. QUALITY ASSURANCE/QUALITY CONTROL ...................................................................................................... 7
7. DOCUMENTATION.................................................................................................................................................. 8
8. SUBCONTRACTORS/SUBVENDORS ................................................................................................................... 8
9. HANDLING............................................................................................................................................................... 8
9.1 PACKAGING AND SHIPPING ..................................................................................................................................... 8
9.2 PRESERVATION AND STORAGE ...............................................................................................................................9
10. BASIC REQUIREMENTS ...................................................................................................................................... 9
10.1 BASIS OF DESIGN ................................................................................................................................................. 9
10.2 SERVICE CONDITIONS .......................................................................................................................................... 9
10.3 MAIN POWER SUPPLY ........................................................................................................................................... 9
10.4 INFORMATION TO BE SUBMITTED WITH THE TENDER................................................................................................ 9
11. FUNCTIONAL REQUIREMENTS ........................................................................................................................ 10
11.1 GENERAL .......................................................................................................................................................... 10
11.2 MOTOR PROTECTION ......................................................................................................................................... 10
11.3 MOTOR CONTROL .............................................................................................................................................. 10
11.4 AUTOMATIC MOTOR RESTART ............................................................................................................................. 11
11.5 INDICATION AND ALARM ...................................................................................................................................... 12
11.6 MEASUREMENTS AND RECORDINGS .................................................................................................................... 12
11.7 SWITCHGEAR MONITORING AND CONTROL (DELETED) ..............................................................................................
11.8 EMERGENCY SHUTDOWN (SAFETY SYSTEM) INTERFACE ....................................................................................... 12
11.9 CONFIGURING AND COMMUNICATION ................................................................................................................... 12
11.10 TEST FACILITIES .............................................................................................................................................. 14

12. PERFORMANCE REQUIREMENTS ................................................................................................................... 14

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12.1 RESPONSE TIME ................................................................................................................................................ 14


12.2 ELECTRICAL ENVIRONMENT IMMUNITY ................................................................................................................. 14
12.3 DISTURBANCE IMMUNITY .................................................................................................................................... 14
12.4 ENVIRONMENTAL WITHSTAND ............................................................................................................................. 15
12.5 COMMUNICATION INTEGRITY ...............................................................................................................................15
13. CONSTRUCTIONAL REQUIREMENTS.............................................................................................................. 15
13.1 UNIT ENCLOSURE .............................................................................................................................................. 15
13.2 SYSTEM COMPONENTS....................................................................................................................................... 15
13.3 WITHDRAWABLE TYPE MOTOR STARTERS ............................................................................................................ 15
13.4 RUNNING AND STANDBY DRIVES.......................................................................................................................... 16
13.5 POWER SUPPLY ................................................................................................................................................. 16
13.6 CURRENT AND VOLTAGE TRANSFORMERS ........................................................................................................... 16
13.7 WIRING AND TERMINATIONS ...............................................................................................................................16
13.8 MARKING .......................................................................................................................................................... 17
13.9 EARTHING ARRANGEMENT .................................................................................................................................. 17
13.10 ENGINEERING PC STATIONS .............................................................................................................................. 17
13.11 CAPACITY CENTRAL UNIT.................................................................................................................................. 17
13.12 NAMEPLATE .................................................................................................................................................... 17
14. INSPECTION AND TESTS .................................................................................................................................. 17
14.1 GENERAL .......................................................................................................................................................... 17
14.2 PERFORMANCE TESTS ....................................................................................................................................... 18
APPENDIX 1 - SIMPLIFIED BLOCK DIAGRAM INTEGRATED PROTECTION & CONTROL SYSTEM ........................................... 19
APPENDIX 2 - TYPICAL IPCS SCHEDULE ...............................................................................................................20,21

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1.

GENERAL

1.1

Introduction
This specification covers the minimum technical requirements for a micro-processor based
Integrated Protection and Control System (IPCS) incorporated into a LV and HV switchgear for
protection, control and monitoring of motors.
A simplified block diagrams of IPCS is given in Appendix 1.

1.2

Purpose
The basic purpose of the IPCS is the integration of Motor Controlgear Assemblies with Process
Control Systems utilizing micro processor based protection and control devices installed in
electrical equipment, connected to the DCS or SCADA system, via an Interface Control Unit
utilizing serial communications.
Specific requirements will be given in the schedule for IPCSs as part of the switchgear requisition.
This schedule should be used in conjunction with the requisition data sheets for LV and HV
controlgear.

1.3

Definitions
For the purposes of this specification, the following definitions shall hold:
COMPANY - ABU DHABI GAS INDUSTRIES LTD. (GASCO).
CONCESSION REQUEST - A deviation requested by the SUBCONTRACTOR or VENDOR,
usually after receiving the contract package or purchase order. Often, it refers to an authorization
to use, repair, recondition, reclaim, or release materials, components or equipment already in
progress or completely manufactured but which does not meet or comply with COMPANY
requirements. A CONCESSION REQUEST is subject to COMPANY approval.
CONTRACTOR - The party which carries out all or part of the design engineering, procurement,
construction and commissioning or management of the project.
MANUFACTURER/VENDOR - The party which manufactures and/or supplies equipment, technical
documents/drawings and services to perform the duties specified by COMPANY/CONTRACTOR.
PROJECT - (To be defined)
SHALL - Indicates a mandatory requirement.
SUBCONTRACTOR/SUBVENDOR - The party(s) which carry(s) out all or part of the design,
procurement, installation and testing of the System(s) as specified by the
CONTRACTOR/VENDOR.

1.4

Terminology
The following terms and interpretations shall apply for the purpose of this specification:
Control Module - CM
Control Module is a microprocessor based device with integrated control, monitoring and
protection functions and communication facility serving a motor starter.
Interface Control Unit - ICU
An ICU is a microprocessor based interface device used to monitor and control a number of
Control Modules via a serial bus and enabling communication with a higher level of control.
Integrated Protection Control System - IPCS

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A system comprising Control Modules, Interface Control Units, a serial bus connecting the
Control Modules to the Central Unit and a serial communication facility enabling connection of
Central Unit to a Distributed Control System (DCS).
Expected Lifetime
The expected lifetime of a Motor Control System is the time during which it remains suitable for
the application for which it was made, provided it is used and maintained in accordance with the
MANUFACTURERS instructions.
Operating Time
Total time elapsed after initial commissioning and start-up of the IPCS at site but excluding the
first three months of initial operation.
Certificate of Conformity
A certificate stating that the electrical apparatus complies with the relevant standards for
apparatus for potentially explosive atmosphere.
Mean Time Between Failure - MTBF
MTBF represents the expected value of the duration at trouble-free operation (only applicable
for repairable components) and is calculated as follows:
Operating time
(hours)
Number of faults resulting in outage
1.5

Abbreviations
CCR
CRT
DCS
ICU
IPCS
PC
MCS
RCU
RTU
SGS
IES
EWS

1.6

Central Control Room


Cathode Ray Tube
Distributed Control System
Interface Control Unit
Integrated Protection and Control System
Personal Computer
Motor Control Station
Remote Control Unit
Remote Terminal Unit (Transmission mode)
Safe Guarding System
Instrument Equipment Shelter
Engineering Work Station

Scope of supply
The scope of supply of an IPCS shall include all design activities, supply of materials, factory
acceptance tests and provision of documentations and instructions as stated in this specification.
The scope of material supply includes all IPCS components shown in Appendix 1 up to and
including the Interface Control Unit. The interconnecting cables with DCS do not form part of the
scope of supply.
Micro-processor based motor protection relays will be provided and installed within switchgear and
MCCs by others.
The scope of supply also includes start-up assistance and, if specified, site installation. The
MANUFACTURER shall indicate in his tender his capabilities for carrying out site installation work.
Equipment manufacturing record books, equipment record (data) books and operating and
maintenance manuals are required. Immediately prior to contract award the MANUFACTURER
shall give a technical presentation to COMPANY personnel

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1.6.1

Responsibility
The Purchase Order for the IPCS shall be placed direct with a control system MANUFACTURER.
The MANUFACTURER of the IPCS shall be responsible for its performance as described in this
specification and shall liaise with the switchgear/MCC and DCS MANUFACTURERs for
procedures, execution of interface and testing. Equipment MANUFACTURERS must be approved
by the COMPANY.

2.

CODES AND STANDARDS


The following codes and standards, to the extent specified herein, form a part of this specification.
When an edition date is not indicated for a code or standard, the latest edition in force at the time
of MANUFACTURERS proposal submittal shall apply:
International Electrotechnical Commission (IEC):
IEC 60060
High voltage test techniques
IEC 60068
Environmental Testing
IEC 60146
Semiconductor Convertors
IEC 60158
Low Voltage Controlgear
IEC 60255
Electrical Relays
IEC 60391
Marking of insulated conductors
IEC 60445
Identification of equipment terminals
IEC 60446
Identification of conductors by colors or numbers
IEC 60529
Degrees of protection provided by enclosures (IP code)
IEC 60801
Electromagnetic compatibility for industrial process measurement and
control equipment
IEC 60947
Low Voltage Switchgear and Controlgear
EN 50019
European Standard for Increased Safety (EN)

3.

REFERENCE DOCUMENTS
The following reference documents, to the extent specified herein, form a part of this specification.
When an edition date is not indicated for a document, the latest edition in force at the time of
MANUFACTURERS proposal submittal shall apply:

4.

DGS 1630 022

High Voltage Switchgear and Control Gear

DGS 1630 023

Low Voltage Switchgear and Control Gear

DGS 0000 004

Criticality Rating System

DOCUMENT PRECEDENCE
It shall be the MANUFACTURERS responsibility to be, or to become, knowledgeable of the
requirements of the referenced Codes and Standards.
The MANUFACTURER shall notify the CONTRACTOR of any apparent conflict between this
specification, the related data sheets, the Codes and Standards and any other specifications noted
herein. Resolution and/or interpretation precedence shall be obtained from the CONTRACTOR in
writing before proceeding with the design/manufacture.

In case of conflict, the order of precedence shall be:

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System block diagrams


Equipment Data Sheet(s)
This Specification
Design General Specifications and Standards
Industry Codes and Standards
5.

SPECIFICATION DEVIATION/CONCESSION CONTROL


Deviations from this specification are only acceptable where the MANUFACTURER has listed in
his quotation the requirements he cannot, or does not wish to comply with, and the
COMPANY/CONTRACTOR has accepted in writing the deviations before the order is placed.
In the absence of a list of deviations, it will be assumed that the MANUFACTURER complies fully
with this specification.
Any technical deviations to the Purchase Order and its attachments including, but not limited to, the
Data Sheets and Narrative Specifications shall be sought by the MANUFACTURER only through
CONCESSION REQUEST format. CONCESSION REQUESTS require CONTRACTOR'S and
COMPANY'S review/ approval, prior to the proposed technical changes being implemented.
Technical changes implemented prior to COMPANY approval are subject to rejection.

6.

QUALITY ASSURANCE/QUALITY CONTROL


The MANUFACTURER shall have in effect at all times, a QA/QC program which clearly
establishes the authority and responsibility of those responsible for the quality system. Persons
performing quality functions shall have sufficient and well defined authority to enforce quality
requirements, initiate, identify, recommend and provide solutions to quality problems and verify the
effectiveness of the corrective action.
A copy of the MANUFACTURERS QA/QC program shall be submitted to the CONTRACTOR with
its quotation for CONTRACTOR'S review and concurrence prior to award. If MANUFACTURERS
QA/QC program and facility, where the work is to be performed, is ISO 9000 certified, then only a
copy of the MANUFACTURERS ISO 9000 certificate is required. In addition, if
MANUFACTURERS facility is ISO certified, CONTRACTOR'S QA audit requirements will be
waived in favor of ISO 9000 registrar audits, unless the CONTRACTOR'S trend analysis program
indicates areas of concern.
The MANUFACTURER shall identify in purchase documents to its SUBVENDORS all applicable
QA/QC requirements imposed by the CONTRACTOR, and shall ensure compliance thereto. On
request, MANUFACTURER shall provide objective evidence of its QA/QC surveillance of its
SUBVENDORS activities.
The MANUFACTURER shall submit certified reports of production tests as soon as the tests are
completed satisfactorily.
The COMPANY/CONTRACTOR reserves the right to inspect materials and workmanship at all
stages of manufacture and to witness any or all tests. The MANUFACTURER, 30 days after award
but prior to the pre-inspection meeting, shall provide the CONTRACTOR with a copy of its
Manufacturing and Inspection Plan for review and inclusion of any mandatory
COMPANY/CONTRACTOR witness points.
The Criticality Rating (CR) System outlined in Design General Specification DGS 0000 004 shall be
used to develop the design checking levels and minimum requirements for shop inspection, testing
and materials certification.

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7.

DOCUMENTATION
The MANUFACTURER shall provide, in accordance with the purchase order requirements, the
minimum following documents:

8.

General arrangement drawings

Schematic diagrams

Programming (logic) diagrams

Equipment lists

Recommended spare parts lists

Test reports

Operating manuals incorporating installation, commissioning, operating and maintenance


instructions, and fault finding procedures.

Self-documenting facilities of the IPCS shall be demonstrated by the MANUFACTURER.

System software package.

SUBCONTRACTORS/SUBVENDORS
The MANUFACTURER shall assume unit responsibility and overall guarantee for the equipment
package and associated equipment.
The MANUFACTURER shall transmit all relevant purchase order documents including
specifications to his SUBVENDORS and SUBCONTRACTORS.
It is the MANUFACTURER'S responsibility to enforce all Purchase Order and Specification
requirements on his SUBVENDORS and SUBCONTRACTORS.
The MANUFACTURER shall submit all relevant SUBVENDOR and SUBCONTRACTOR drawings
and engineering data to the CONTRACTOR.
The MANUFACTURER shall obtain and transmit all SUBVENDOR and SUBCONTRACTOR'S
warranties to the CONTRACTOR/COMPANY, in addition to the system warranty.

9.

HANDLING

9.1

Packaging and shipping


Preparation for shipment shall be in accordance with the MANUFACTURER'S standards and as
noted herein. MANUFACTURER shall be solely responsible for the adequacy of the preparation for
shipment provisions with respect to materials and application, and to provide equipment at the
destination in ex-works condition when handled by commercial carriers.
Adequate protection shall be provided to prevent mechanical damage and atmospheric corrosion
in transit and at the job site.
Preparation for shipment and packing will be subject to inspection and rejection by
COMPANY'S/CONTRACTOR'S inspectors. All costs occasioned by such rejection shall be to the
account of the Vendor.
Separate, loose, and spare parts shall be completely boxed. Pieces of equipment and spare parts
shall be identified by item number and service and marked with CONTRACTORS order number,
tag number, and weight, both inside and outside of each individual package or container. A bill of
material shall be enclosed in each package or container of parts.

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One complete set of the installation, operation, and maintenance instructions shall be packed in
the boxes or crates with equipment. This is in addition to the number called for in the Purchase
Order.
9.2

Preservation and storage


Equipment and materials shall be protected to withstand ocean transit and extended period of
storage at the jobsite for a minimum period of 18 months. Equipment shall be protected to
safeguard against all adverse environments, such as: humidity, moisture, rain, dust, dirt, sand,
mud, salt air, salt spray, and sea water.

10.

BASIC REQUIREMENTS

10.1

Basis of design
The design of the IPCS shall be such as to minimize the risk of short circuits and shall ensure
personnel and operational safety at all times.
The design and selection of equipment and components shall be based on achieving a minimum
expected lifetime of 30 years. The IPCS including all individual components forming part of the
system shall have a MTBF of not less than 60,000 hours - based on the conditions stated in (10.2)
and (10.3).
All components shall be of a quality and reliability commensurate with the requirement to perform
protection, control, monitoring and safeguarding functions on motor starters in continuously
operating petrochemical process units, production facilities and utility installations.
The MANUFACTURER shall guarantee that the spare parts for the original equipment will remain
available for the duration of the equipment expected lifetime.

10.2

Service conditions
Unless otherwise specified, the IPCS shall be installed in controlgear assemblies, located in a
substation in which the following conditions apply:

10.3

Maximum ambient air temperature:

Relative humidity not exceeding: 60%

Altitude not exceeding:

40C

1000 m

Main power supply


For main power supplies and their variations during normal and transient conditions refer to
respective switchgear specifications.

10.4

Information to be submitted with the tender


The MANUFACTURER shall submit a technical specification of the IPCS which shall include a
description of the design, operation, construction, performance and maintenance aspects of the
equipment.
The MANUFACTURER shall verify in the tender that the equipment fully complies with this
specification. Any deviations from this specification shall be highlighted and the technical
consequences shall be noted.
The MANUFACTURER shall state in the tender the country of origin of the main components of the
system. For maintenance and trouble shooting at site, the MANUFACTURER shall indicate the
nearest service organization recommended for the location where the equipment will be installed.

10.5

Time Synchronization

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CONTRACTOR shall design/engineer and supply a Global Positional System (GPS) at different
Sub-stations to suit Project requirements. The IPCS shall be provided with a means of accepting
external time synchronization input. The IPCS vendor shall design his system(s) to accommodate
this arrangement.
10.6

The IPCS System shall be seamlessly integrated with the existing system in order to form one
overall IPCS System.

11.

FUNCTIONAL REQUIREMENTS

11.1

General
The primary purpose of the IPCS is to provide, by means of microprocessor based technology
monitoring, control and protection functions for the Circuit breaker and Contactor controlled motor
starters These functions shall provide data communication facilities with the DCS. An EWS shall
be provided in the office of Electrical Section Head with data communication link to the IPCS.
The required I/Os will be listed on data sheets attached to the material requisitions.
The IPCS shall communicate with microprocessor based motor, protection relays to permit status
to be monitored remotely.

11.2

Motor protection
Motor protection shall be provided by each individual motor starter Control Module. Its operation
shall be completely independent of other Control Modules and/or ICU.
The protection functions as described in DGS 1630 022 and DGS 1630 023 for thermal overload,
phase current unbalance, and earth fault protection shall be provided. The motor protection relay
for LV motors shall be Motor Manager III (latest version) . Refer to section 11.5 for visual
verification of alarm status and protection functions. .
The motor thermal overload protection shall simulate the motor cold and hot thermal capacity, the
heating and cooling thermal time constants, and shall provide protection against overload,
repeated starts and stalling.
This shall be achieved by creating a thermal replica of the motor requiring the input of data to
represent the thermal characteristics of the specific motor. The protection shall incorporate a
memory to take into account the thermal history of the motor before the overload occurs.
The thermal capacity utilized in accelerating the motor from standstill to rated speed shall be
memorized. After an overload trip, the restart of the motor shall be inhibited during a cool down
period which shall be only as long as required to recover sufficient thermal capacity as to ensure
one successful start of the motor without tripping of the overload protection. Indication of the
remaining time duration before a start becoming possible shall be indicated, i.e. "Restart Inhibit
Time" message.
An adjustable overload pre-alarm shall be provided. This should be accompanied by an indication
of the remaining duration before a trip will occur.

11.3

Motor control
Control Functions are required at the following locations:
Local
Local control is meant to be from a position close to the motor. This is done via at least one Motor
Control Station (MCS) by means of which the motors shall be able to be started and stopped

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manually. The MCS may have hand/auto or local/remote position in which remote automatic
control is allowed.
For contactor controlled motor starters the "off" position of the MCS can be padlocked and should
be regarded as a safety switch. In this position the MCS should be hardwired switched into the
motor starter contactor circuit.
Switching the motor "on" by means of the MCS shall be inhibited by the remote "off" controls.

Remote

Remote control is meant to be automatic process control from the process DCS, ESD or
other Control System. This type of control, if required for plant operation, shall be applied in
addition to the local control described above. Automatic process control may consist of:

a)

ON and OFF controls for non-critical applications which shall be serially wired into
the IPCS.

b)

Safeguarding, sequence and interlock control signals which shall be hardwired into the
motor starter circuit, overriding any other command issued from the CM or from the
MCS.

Any other status input from IPCS for sequence, interlock, safeguarding shall be hardwired to
DCS, ESD or other Control System through Remote I/O cabinet (RIC).

NOTE: No ON or OFF control shall be possible from the motor starter CM (s) nor from the ICU,
during normal plant operating conditions.
11.4

Automatic motor restart


An automatic restart facility shall be provided to automatically restart the motor after voltage dips of
limited durations. The restart facilities shall be provided on the individual motor starter Control
Module.
The automatic restart facility shall be initiated under the following conditions:

Voltage dip detection level 65% Un; voltage restoration detection level 90% Un; memory
4.5 s

Immediate restart after voltage dips < 0.2 s

Delayed restart after voltage dips of > 0.2 to < 4.5 s

Running of the delayed restart timer only if voltage >90% Un.

Delayed restart range 0.1 300 sec (typical)

Where process auto-restart is specified, the following functions shall be provided instead of the
above:

Voltage dip detection level 65% Un; voltage restoration detection level 90% Un

Immediate restart after voltage dips < 0.2 s

Delayed restart for voltage dips > 0.2 s, provide process on command available

Running of the delayed restart timer only if voltage > 90% Un.

Delayed restart range 0.1 300 sec (typical0

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11.5

Indication and alarm


Motor and breaker as shown on the single line diagram status indication and protection alarms
shall be provided in accordance with the IPCS schedule. Those functions should be made
available both at the motor starter and remotely i.e. to the process DCS system via the ICU.
The status of the alarm and protection functions shall be visually verifiable, at the individual Control
Modules and/or ICU, by appropriate indicators with first failure feature. Alarms associated with trip
functions shall be hand-reset, except for the thermal overload trip which shall have an automatic
reset function.
A watchdog alarm, as result of a component defect in a Control Module or in the ICU, or a
communication failure alarm shall not, on their own, result in the trip of any motor starter.

11.6

Measurements and recordings


A number of motor circuit and operational data shall be monitored and indicated in accordance with
the IPCS schedule.
The Control Module shall have either a 4-20 mA output to connect the RCU ammeter or a
dedicated 1A secondary current transformer. Additionally, this data shall be transmitted to the ICU
where the DCS can access the data for display.
Recording of events and trending of current shall be provided on a number of selected motors as
per IPCS schedule. Current trending shall be triggered (adjustable) by an overload condition and
comprise of pre- and post-event trending. Recording facilities shall be provided at the ICU.
The following trend facilities shall be provided:

11.7

A trend for motor current with a span period of no less than 30 minutes, and sampling
frequency of at least once per second with a minimum of 10 minutes pre-event trending;

Provisions to configure other trends, e.g. busbar voltage for electrical system dynamic
assessments.

Switchgear Monitoring and Control


A number of power circuit operational data shall be monitored and indicated in accordance with
IPCS schedule. In general, system data such as Voltage (V), Current (A) and Power Factor (PF)
shall be communicated to DCS and Engineering Work Station (EWS)-PC. Status of switchgear
breakers and UPS units also will be accessible to DCS and EWS.
IPCS shall also provide CRT monitoring of HV and LV distribution accessible from EWS and DCS.
The control circuits shall be capable of being configured to accept the modes of control detailed in
the requisition. Unless specified otherwise it shall not be possible to close or trip any incoming bus
section or feeder breaker from DCS or EWS. However, the above control and monitoring function
is not required if the same is achieved by another system such as Load Management System
(LMS).

11.8

Emergency shutdown (safety system) interface


Each CM shall include an inherent Emergency Shutdown (ESD) relay with a changeover contact
connected in series with the CM output relay to provide interface facilities to the ESD system.

11.9

Configuring and communication

11.9.1

Configuring
The configuration of the IPCS and its interface with the DCS shall be made in accordance with the
requirements stated on the IPCS schedules.

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One ICU shall be provided in each substation unless otherwise specified in the requisition. The
ICU shall be fully redundant including power supplies, processors, communication modules to the
DCS.
The IPCS shall be configured via a system with access restrictions of keylock and password
protection.
Configuring of the Control Module shall be possible from the Control Module or from the ICU. The
configuration of the ICU and its facilities to enable communication with the DCS shall be possible
from the ICU or via an engineering work station PC. The method shall be user friendly e.g. menu
driven.
In case of replacement of a defective motor starter Control Module the spare Control Module shall
be down loaded from the ICU with the relevant configuration after a simple initiation instruction. It
shall be possible to replace faulty CM's without disrupting communication/control with other CM's
connected to the ICU.
In the view mode, it shall be possible to monitor running data from the Control Module or ICU in the
substation.
In the engineering mode (protected by keylock or password), it shall be possible to adjust
configurations, control and protection system parameters, states and settings (in engineering
units).
11.9.2

Communication Facilities
The following levels of communication are identified in the application of the IPCS (Appendix 1):
LEVEL 1, Motor starter Level
This comprises of the Control Module mounted on the motor starter.
At level 1 the collection of data from the motor circuit takes place as well as the protection and
control of the motor. This level shall continue to operate during short voltage interruptions caused
by transients during system faults as described in (10.3). Current detection systems should be
able to cope with the thermal effects of short circuit current. Failure of a Control Module should
initiate the internal watchdog alarm transmitted via the ICU to the CCR.
All level 1 data and messages shall be communicated to the ICU, by means of a redundant serial
communication bus.
LEVEL 2, Substation Level
This comprises of an ICU which shall be redundant and its communication link to the protective
devices as well as its serial communication facilities to a DCS, as shown in Appendix I.
The ICU shall be provided with a facility to connect a PC. This PC shall be used as an EWS-PC to
allow the engineer access to all available information from individual Control Modules, both on
and off line. In addition a facility for connection of a printer shall be provided to print hard copy
event logs and/or trends.
The communication between the motor starter Control Modules and the ICU may utilize
MANUFACTURERS standard serial links and protocol, however it shall at least be provided with a
high level of security check (simple parity check is not acceptable).
In case of a communication failure between level 1 and 2, the motor starter Control Module shall
continue operation as a stand-alone unit and not result in the trip of the motor starter.
Failure of the ICU or of the serial link to the motor starter Control Modules shall initiate operator
alarms transmitted to the CCR via the DCS.
LEVEL 3, IES/CCR Level

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The data and type of messages which shall be communicated to DCS are shown in the IPCS
schedule attached to Requisition.
This comprises the communication interface between the ICU and the DCS.
The ICU shall be able to interface with the DCS via a fully redundant communication module. The
preferred interface is direct node coupling of the ICU to the DCS data highway by means of
chassis mounted communication modules capable of supporting ICU protocols and DCS highway
protocol.
Each substation ICU shall be configured such that only signals for START, STOP and motor status
are read by the DCS
11.10

Test facilities
Facilities to allow function testing of the IPCS Control Modules, without having to run motors shall
be provided.
This facility shall include provisions to test the motor starter Control Modules from the MCS and
also to be able to test the automatic restart function.
Where a higher level of control (DCS) is installed, the complete loop test from the DCS to the motor
starter Control Module should also be possible.

12.

PERFORMANCE REQUIREMENTS

12.1

Response time
The response time for a control action to be executed in the motor starters from receipt of
command from the DCS by the ICU should not exceed 0.5 second.
NOTE:

12.2

Neither the motor automatic restart nor motor protection classify under this definition as
the time response for these are governed by other, normally faster, criteria.

Electrical environment immunity


The IPCS shall be immune to voltage and frequency fluctuations within the limits given (10.3).
The IPCS shall be able to withstand the following tests in accordance with IEC 60255-5:
High voltage test
Impulse voltage withstand test
Insulation resistance
Temporary loss of control power supply shall not result in the loss of application software data nor
loss of dynamic data relevant to the operation of protection systems, e.g. available thermal
capacity of motors (up to 30 seconds), and the operation of automatic motor restart. On restoration
of power supply the system should be able to automatically resume normal operation. Battery
back-up of individual Control Modules is not allowed.

12.3

Disturbance immunity
The IPCS shall be able to withstand the following electromagnetic compatibility test requirements:

General performance requirements: In accordance with IEC 60255-6, Class 3.

Surge withstand capability test: In accordance with IEC 60255-4

Burst disturbance test: In accordance with IEC 60255-22-1

Electrostatic discharge test: In accordance with IEC 60255-22-2

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12.4

Radiated electromagnetic field disturbance test: In accordance with IEC 60255-22-3

Dielectric impulse test: In accordance with IEC 60060

Immunity to external interference: In accordance with IEC 60801 Parts 1, 2, 3, 4, 5.

Environmental withstand
The IPCS shall be able to withstand:
The temperature ranges in service, during transport, and storage: in accordance with IEC 60068-21/2.
The damp heat cyclic test: in accordance with IEC 60068-2-30
Mechanical vibration stress test: in accordance with IEC 60255-21-1/2.

12.5

Communication integrity
The communication interface bus between ICU and Control Modules shall be able to withstand the
fast transient disturbance test in accordance with IEC 60801-4 Class 3. It shall also be short circuit
protected.
Reliability of the communication bus shall be monitored in terms of overruns, quality (i.e. framing,
parity, and checksum errors), and response time-outs.
Failure of communication bus shall alarm to the CCR via the ICU but shall maintain the current
state of devices.

13.

CONSTRUCTIONAL REQUIREMENTS

13.1

Unit enclosure
The Control Module enclosure shall provide a degree of protection of not less than IP 41 in
accordance with IEC 60529.
If the ICU enclosure is mounted on the switchgear / controlgear enclosure, or Motor starter, then
IP 41 enclosure protection shall be applicable. The floor shall not be considered as forming part of
the enclosure. If the ICU is mounted separately then IP 31 enclosure protection shall be
applicable.

13.2

System components
Operating, status and diagnostic indications by means of Light Emitting Diodes (LEDs) or Liquid
Crystal Displays (LCDs) shall be used.
Programming by permanently installed key pads, a portable programmer or engineering PC
station is allowed.
Where required Printed Circuit Boards (PCBs) shall be installed in standardized electronic
equipment frames and be fitted with handgrips for easy removal. PCBs shall include visual LED
status indications and test connections on the front to facilitate fault diagnosis.

13.3

Withdrawable type motor starters


The serial bus in the motor starters between the starter Control Modules and the ICU shall be
arranged such that it is possible to withdraw the motor starters with their Control Module without
consequences for the remaining Control Modules connected to the serial bus.

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13.4

Running and standby drives


To improve the availability of running and standby drives it is strongly preferred that these drives
are connected to different serial links in the motor starters. These are normally distributed on the
switchboard sections as indicated on the requisition. The aim being that failure of one link shall
have no consequence for the availability of the standby drive.

13.5

Power supply

13.5.1

Control Modules
The power supply to the individual Control Modules shall be derived as follows :
HV and LV Switchgears and HV Motors

: 110 Vdc (Switchgear Control Supply)

LV Motors

: 240 Vac (Starter Control Supply)

The MANUFACTURER shall take into account that the supply to the Control Module will therefore
be lost when the motor starter is isolated. A centralized power supply system with a distribution
system for all Control Modules is not acceptable.
13.5.2

Interface Control Units


A power supply unit shall be provided for the ICU. The power supply shall comprise dual
redundant power supply units with automatic change over facilities and remote alarm in case of
failure of one. Power supply for the ICU shall be obtained from safe AC supplies or from
substation 110 V DC from the DC UPS, as required.

13.6

Current and voltage transformers


Current and voltage transformers required for the functioning of the IPCS shall comply with the
requirements of DGS 1630 022 and DGS 1630 023.

13.7

Wiring and terminations

13.7.1

Hardwiring and Terminals


Internal wiring, where applicable, shall be PVC or XLPE-insulated and have stranded copper
conductors. The size and type of the wires to be selected shall be based on mechanical strength,
voltage levels and, especially for current circuits, on the prospective current levels.
The minimum allowable cross-sectional area of the wires shall be 1.5 mm. Current transformer
secondary circuits shall be 2.5 mm minimum. Motor manager III protective relay secondary
circuits shall be 1.0 mm2 minimum.
Color coding of secondary wiring shall be in accordance with IEC 60446. Earth wires shall be
green/yellow striped. Wiring between two terminals shall be continuous and without joints.
Wiring ends of stranded conductors which have to be connected into bus-type contacts of
terminals, shall be provided with compression-type pre-insulated wire pins with insulation support.
In general, when lugs, wire pins, etc., are used, they shall be of the compression type.

13.7.2

Serial Wiring
Digital signals can be carried by screened twisted pair cables, coaxial cables or fibre optic cables.
The choice is usually dictated by bandwidth and lay-out requirements.
Terminating resistors, if required to prevent voltage signal reflections, shall be installed at each
end. The method of linking the Control Modules with the ICU should be such as to avoid a
common mode of failure.

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13.8

Marking
All wires shall be identified at both ends by means of ferrules of insulating material, or by plastic
code markers.
Marking shall be in accordance with the related MANUFACTURERS drawings. For marking of
conductors, reference is made to IEC 60391.
All external operating, measuring and indicating components shall be clearly identified with
permanent descriptive labels that facilitate easy recognition by the operator. All components shall
be identifiable by labels inscribed in accordance with the system of identification used on the
MANUFACTURERS drawings.
Rail mounted terminals shall be identifiable by numerical or alphabetical markings in accordance
with the MANUFACTURERS drawing and IEC 60445.

13.9

Earthing arrangement
The IPCS shall be connected to the plant earthing systems.

13.10

Engineering PC stations
The software required for the engineering PC station shall run on a stand-alone IBM compatible
PC using latest version of WINDOWS.

13.11

Capacity of central unit


In addition to the number of Control Modules specified in the requisition, spare capacity shall be
provided in the ICU to cater for additional Control Modules. The spare capacity in the ICU shall
comply with the spare requirements as laid down for motor starters/feeders in
DGS 1630 022 and DGS 1630 023.

13.12

Nameplate
The nameplate shall be made of corrosion resistant metal and be fixed to a non-removable part of
the ICU by means of durable self-threading screws or pop rivets. It shall be provided with indelible
inscriptions in the language as specified on the requisition. The following information shall be
given on the nameplate:

MANUFACTURERS name or trademark

Type designation

Purchase order number

Year of manufacture

Rated voltage of aux. Circuit (if applicable)


Degree of protection

14.

INSPECTION AND TESTS

14.1

General
Prior to dispatch, the MANUFACTURER shall verify by tests that the operation of the equipment
complies with the requirements specified on the requisition, and shall submit to the CONTRACTOR
a report incorporating the results of all tests performed.

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If specified on the requisition, a representative of the COMPANY shall witness the functional
factory acceptance tests (14.2) and shall carry out an inspection of the assembled equipment and
related documents to verify compliance with the requirements of the purchase order.
14.2

Performance tests

14.2.1

Type Tests
The MANUFACTURER shall submit to the COMPANY for review and approval, the type test result
of the electrical, disturbance and environmental immunity test requirements as per (12).

14.2.2

Functional Tests
The IPCS shall undergo a functional test to prove its compliance with the requirements of this
specification (11.0).
Testing of the IPCS shall be performed integrally with testing of the switchgear/MCC. The CM's
shall all be installed in their respective starters units and connected to the ICU. Using PC, or other
devices to emulate the DCS, host commands shall be initiated and connection ascertained at each
CM's associated cubicle. Status feedbacks from the CM's shall be read by the simulated host.
System response time will be checked. Additionally, full verification of the DCS data table interface
of the ICU shall be performed.
The MANUFACTURER shall provide the COMPANY, for his approval, a test procedure on how to
carry out those verification tests.

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LEGEND
ER
RIC
DCS
IES
CCR
IRP
EWS
CM
PC
ICU

NOTES
Engineering Room
Remote I/O Cabinet
Distributed Control System
Instrument Equipment Shelter
Central Control Room
Interposing Relay Panel
Engineering Work Station
Control Module
Personal Computer
Interface Control Unit
Serial Communication
Hard Wired

2.

3.
4.
5.
6.

Both Interface Control Units (ICU) & Serial


Communications Links Between ICU & Control
Modules shall be redundant.
Control through substation interposing relay panel is
only for critical motors (e.g. E.S.D or process
sequence control)
Communication with DCS System shall utilize
redundant link.
For remote control functions (serial versus
narawirea) refer to section 11.3 of this specification
EWS-PC (at level 2) shall be suitable for connection
with ICU No.1 or ICU No.2
For motor control station:
- Emergency stop pushbutton shall be hardwired
into contactor circuit.
- Start pushbutton shall be hardwired into the CM
-

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