Professional Documents
Culture Documents
SPECIFICATION FOR
11,14,15,21,23,24,28,31,41,42,45,46
10-Jul-2014 H.GH
03 2013.09.25 Issued for Approval Tang Jiandong Bao Yu Cao Ying RAJ
02 2013.06.10 Issued for Approval Tang Jiandong Bao Yu Cao Ying RAJ
01 2012.12.30 Issued for Comments Tang Jiandong Bao Yu Cao Ying RAJ
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FEEDSERVICEFORSURFACEFACILITIES
DEVELOPMENTOFSOUTHAZADEGANPROJECT
Contents
Contents ..................................................................................................................3
1.0 GENERAL.............................................................................................................................6
1.1 Introduction........................................................................................................................6
1.2 Definitions..........................................................................................................................6
1.3 Abbreviations....................................................................................................................6
2.0 CODESANDSTANDARDS..................................................................................................10
2.3 Specification....................................................................................................................11
3.0 VENDORSQUALIFICATION&RESPONSIBILITY...............................................................12
3.6 Planning...........................................................................................................................14
4.0 SYSTEMREQUIREMENTS..................................................................................................14
4.4 Workstations....................................................................................................................17
5.0 COMMUNICATION............................................................................................................26
6.0 POWERANDGROUNDINGREQUIREMENTS....................................................................28
6.4 Grounding........................................................................................................................29
7.0 CABINETSANDCONSOLES................................................................................................29
7.1 Cabinets...........................................................................................................................29
7.2 Consoles..........................................................................................................................32
8.0 SYSTEMSOFTWARE..........................................................................................................33
8.5 Reports.............................................................................................................................37
9.0 SPARE&EXPANSIONCAPABILITY.....................................................................................41
10.0 TESTANDINSPECTIONS....................................................................................................43
11.0 ONSITEASSISTANCE.........................................................................................................46
11.2 Training............................................................................................................................46
12.0 DOCUMENTATION.............................................................................................................46
13.0 SHIPPING,PACKINGANDMARKING................................................................................50
FEEDSERVICEFORSURFACEFACILITIES
DEVELOPMENTOFSOUTHAZADEGANPROJECT
1.1 Introduction
CNPCI is responsible for development operations of the South Azadegan oil field located in
the southwest of the Islamic Republic of Iran, close to the border of Iran and Iraq and 80km
west of Ahwaz city in Khuzestan province.
This specification defines the minimum requirements of the surface facilities development
of the South Azadegan Oilfield for the design, fabrication, testing, and inspection of
Distributed Control System.
1.2 Definitions
1.3 Abbreviations
AC Alternating Current
DC Direct Current
I/O Inputs/Outputs
Azadegan field facilities shall be designed, constructed and operated in accordance with
the IPS (Iranian Petroleum Standards, 5th edition in 2010) supplemented, where necessary,
by internationally recognized standards.
1 Material requisition;
2 Datasheets, drawings, and specifications;
3 IPS;
4 International Standards.
VENDOR shall have at least 5 years experience of similar engineering applications where
the system has been in use.
VENDOR shall provide user list included user name, site location, running time, and brief
project summary in the bid.
VENDOR shall provide the licence and certification to prove that the application of the
provided equipment shall be appropriate and legal for the project.
All hardware and software to be provided shall have been installed for at least 5 similar
applications, within the last 5 years with a proven history of operation and reliability.
Previous examples of where the hardware, firmware and software being offered in the
proposal have been installed and are in current operation should be cased referenced.
A satisfactory functional integration between SCADA, DCS and SSS (ESD+F&G) systems
shall be provided.
The following characteristics shall be provided:
The DCS & SSS diagnostic messages shall be automatically detected and displayed at
the DCS Operators Interface in the same format and with same modalities.
Alarms generated from the SSS will also be sent to DCS. Operators can acknowledge
and clear alarms at the DCS. However, the same alarm shown on SSS can not be
cleared from DCS and has to be acknowledged and cleared at SSS.
The clock of DCS and SSS Systems is synchronized with the same source from the
SCADA system.
Each Automation System (including SSS, CTMS, CCS and LCP of package equipment)
shall be linked with the DCS system bus via a physical redundant serial interface with
Below text shall be added:
Control systems redundant fiber optic network will be supplied to handle transmission of
control Systems data. This will include the DCS highway, the TUV approved safety
highway and the FEEDSERVICEFORSURFACEFACILITIES
IPCS information network.Different control systems shall utilize
DEVELOPMENTOFSOUTHAZADEGANPROJECT
different cores.
As the IPCS vendor will be the main user of the network, he will undertake the design
responsibility
DocumentNo. for it, to ensure that it can be fullyDiscipline
SA01GENXXXSDINSPDS0003B03 optimized, and to ensure thatIN the
Rev. structure is configured03 correctly for his networks. The DCS vendor shall be responsible
System GEN
Stage for the management ofBnetwork and Provision of fiber Page optic patch panels,14/50
patch cords,
Ethernet switches, media converters,
DocumentTitle hubs, Distributed
Specificationfor Routers, repeaters etc.
Control System
The
hot fiber optic
back-up cables shall
configuration. beserial
This supplied and installed
interface shall beby others. DCS node.
a dedicated
DCS vendor is required to supply optical fiber patch panels for interlinking the various
3.6 Planning
components in his scope of supply.
The DCS vendor shall provide optical transmission method and to provide his optical link
A milestone schedule shall be set-up by VENDOR and approved by COMPANY before
systembudget. Vendor
execution. Thisshall also advise
schedule of theallprotocol
shall show he will
target dates foruse,
DCS and their proposed
system speed of
implementation.
operationto
Any deviation andthe
bandwidth.
established schedule must have the COMPANYs approval. The
VENDOR shall report job progress in writing on a monthly basis.
4.0 SYSTEM REQUIREMENTS
The DCS scope shall include provision of all system cabinets, marshalling cabinet system
cables, workstation and consoles, plus generation of the system database, controls and
displays. The DCS systems should be a comprehensive, integrative, flexible configuration
and standardization process control system, and should adopt the late developed and
improved new technique; new equipment and below text shall
new system but be added:
they must be the practicable
and mature system in the world. ",Power Distribution Panels (PDP) for AC
power supplies distribution to all system
The selected DCS shall be of state-of-the-artpanels proven, OCDs
design, having
, other a history of reliable
peripheral
operation in oil field central process facility typeequipment
applications of similar
of the IPCS,"architecture, size and
complexity. All requirements of the project shall be met by software packages and by
hardware in service at the time of DCS SUPPLIERs bid.
Thetext
Below DCS shall
shall bebe employed for process monitoring and for regulatory and sequential control.
added:
TheItDCS
shallsystems
comprise engineer
shall interface,
be supplied operator interface,
in accordance with modules for data acquisition and
processing including computer based modules,
the Functional Design Specification (FDS), which shall be plus dual redundant data highways for high
speed digital communication.
developed by the vendor after award of Purchase Order.
TheField
Functional Design
inputs and Specification
outputs (I/O) shallshall be based to
be hardwired onthe DCS via marshalling cabinet, thence
thistospecification,
the DCS I/O and approved
modules by client. systems cables with plug and socket connectors. I/O
via pre-formed
from/to other systems may be hardwired, or may be via serial link, dependent on the system
and/or constraints of integrity/economy. Regulatory and sequential controls may be located
in the DCS controllers, or in function-specific dedicated DCS modules, dependent on
function and control complexity. As a general principle simple regulatory control and
sequences will be located in the DCS controllers.
Control buildings shall include the central control room (CCR) and local equipment rooms
(LER). All control buildings shall be compliant with IPS-G-IN-220.
Control and equipment rooms, will be air-conditioned dust proof. However, the plants are
required to continue to operate without failure, without error and without incurring long or
short-term damage to the equipment when the HVAC is out of commission at the conditions
indicated hereinafter.
All electric/electronic equipment within the buildings must operate satisfactorily in an
FEEDSERVICEFORSURFACEFACILITIES
DEVELOPMENTOFSOUTHAZADEGANPROJECT
The system shall continue to operate in HVAC upset conditions for at least 1 hour. In
order to minimize maintenance and the requirement for spares, the equipment shall
be designed to operate in the worst ambient conditions to which it will be exposed.
The installed DCS shall guarantee an EMC for an electromagnetic environment of level 2 as
per the IEC 61000 4-3 and IEC 61000 4-4.
It shall be possible to store the equipment packed in wooden cases for up to 6 months,
within the environmental conditions specified in the COMPANY specifications.
Instrument systems shall be suitable for continuous operation in according with those
service conditions stated in section 3.1 of this specification, which will be available for
environmental requirement at each plant.
In the event of plant failure, the equipment should also be suitable for short term continuous
operation where dusty and dry atmosphere exist with temperature in excess of 52.
In order to minimize maintenance and the requirement for spares, the equipment shall be
designed to operate in the worst ambient conditions to which it will be exposed. (Eg
temperature fluctuations: -4.4-52, humidity levels 25.9%-76.4% , severe dust).
The locations of plant hazard groupings are shown on the Project Drawing entitled "
Hazadards Area Classification .
All materials and Installation methods shall as a minimum satisfy the requirements for the
FEEDSERVICEFORSURFACEFACILITIES
DEVELOPMENTOFSOUTHAZADEGANPROJECT
4.3.1 Key
If hardware Keys are used for access, they shall be of such a type that removal of the key
FEEDSERVICEFORSURFACEFACILITIES
DEVELOPMENTOFSOUTHAZADEGANPROJECT
4.3.2 Passwords
If passwords are used for access, it shall be possible for the user to configure different
passwords for levels 1, 2 and 3. The password shall have a maximum of any 12
alphanumeric characters, and shall not be echoed back to the screen as it is typed.
Interruptions due to loss of power to the system beyond the period protected by battery
back-up and subsequent restoration of power shall result in automatic rebooting of the
system. The designs, which require manual reloading of configurations prior to resuming
operations, are not acceptable. All control unit configurations shall reside in non-volatile
memory so that no re-configuration shall be required in case of power failure and
restoration.
The restoration of power shall result in automatic reboot and all control loops and sequence
control shall be placed in a user specifiable mode of operation.
VENDOR shall specify in the bid the degraded mode operation of the proposed system,
when failure occurs. The system shall be designed for maximum reliability, safety and
integrity while maintaining an availability which shall be 99.9%, where availability is defined
as:
MeanTimeToFailure( MTTF ) (100)
Availability %
MTTF MeanTimeTo Re pair ( MTTR )
VENDOR shall provide in its proposal the Mean Time to Failures (MTTF) and the availability
figures, with method of calculation and all assumption clearly stated, based on the proposed
redundancy and in accordance with the requirements stated in this specification.
For calculation purpose the VENDOR shall assume that the recommended spares and
suitably trained personnel are available and the Mean Time to Repair (MTTR) is four (4)
hours.
4.4 Workstations
Operator workstations shall be served as dedicated operator workstations and data servers,
and be of redundant application. In case of any one failure, the other shall replace it to
realize full function. Any DCS Operator Console shall be used for configuration
purpose in case of Engineer workstation failure, and the access to the configuration
activities shall be protected by means of hardware and software keys.
Engineer workstation shall be served as both engineer and operator workstation, and the
FEEDSERVICEFORSURFACEFACILITIES
DEVELOPMENTOFSOUTHAZADEGANPROJECT
CTEP 2 5
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Each GOSP 1 2
I/O cards should complete the input and output of the process data.
The style of I/O cards should include the following kinds:
Analog Input: 4~20mADC two-wire system (where transmitter needs to be powered
from separate 24VDC supply or where power is derived from the I/O module);
Analog Input: 1~5VDC,0~10mADC
Analog Output: 4~20mADC,1~5VDC
Pulse Input: 0~6000Hz, amplitude<24V 2 Ampere at 24V DC.
Digital Input: NO/NC passive contactor
Digital Output: NO/NC passive contactor (contact capacity is 230VAC 5A), equipped
with intermediate relays
Digital Output: 24 VDC for SOVs and relays powered directly by DCS system.
Temperature signal input card with linear treating capacityinput signal shall be: IEC
standard Pt100 platinum resistance temperature detector.
The overall accuracy of I/O system shall be 0.2% F.S. minimally subject to the following
conditions:
- The output signal reconstructed from the digitally stored data.
- The stated accuracy shall apply individually to each input/output pair with the system
operating at a data rate up to the maximum rate for all I/O channels.
Isolate type I/O card shall be used for the isolating between input, output, power and
channel.
I/O card should have the function of identifying site connection turnoff or short and alarm.
Analog Input and analog output cards for process control shall be redundant.
The digital input and digital output signals from or to the electrical equipments powered by
230V or above such as pumps, compressors and burners status or trip/stop commands,
shall be equipped with relays for isolation.
The I/O cards shall be capable of being removed and inserted into the I/O rack under power,
without affecting any other I/O cards in the rack.
Analogue output cards shall have an individual D/A converter for each analogue output. The
scan rate (output update) for analogue outputs, which are part of control loops, shall not be
more than 0.25 seconds. All analogue output cards shall have an individual power regulator
to provide isolated power for loop outputs. As a standard, all analogue output points shall be
individually either optically or galvanic isolated.
Analogue to digital conversion shall be as minimum of 16 bits. Each analogue input card can
not have more than 16 inputs.
The control system shall perform an integrity check on the entire output loop. The system
shall provide out-of-calibrated-range alarms for all outputs. All calibration constants of the
output cards shall be handled using software without the need for any potentiometers on the
output cards. The maximum resistance and the maximum loop length for the analogue
outputs shall be clearly stated. Failure on output cards shall be indicated with an error status
on each card and an additional error indication on a system status display on Control Room.
Each analogue output card can not have more than 16 outputs.
The system shall accommodate both normally open and normally close contacts. The digital
input modules shall include circuitry to ensure that any chatter or bounce encountered
during contact closure does not initiate an erroneous alarm. The input contacts, generally,
will be free of voltage and ungrounded; it shall be powered by the digital input modules using
24 V DC.
The scan rate for digital inputs, which are part of sequential control loops, shall not be more
than 0.25 seconds. The scan rate for digital inputs not involved in sequential control loops
shall not be more than 0.5 seconds. As standard, all digital input points shall be individually
either optically or galvanic isolated.
Each digital input card shall be individually fused and equipped with blown fuse LED
indication. Each input point shall be individually protected against over-current. Digital input
card circuits shall be isolated channel-to-channel and channel-to-ground. Each digital input
card can not have more than 32 inputs.
FEEDSERVICEFORSURFACEFACILITIES
DEVELOPMENTOFSOUTHAZADEGANPROJECT
Solid state of digital outputs shall be 24 VDC and be capable providing at least 300 mA to
the external coil.
The scan rate (output update) for digital outputs, which are part of sequential control loops,
shall not be more than 0.25 seconds. The scan rate (output update) for digital outputs not
involved in sequential control loops, shall not be more than 0.5 seconds. Each digital output
card shall be individually fused and equipped with blown fuse LED indication. Each output
shall be individually protected against over-current. Digital output circuits shall be provided
with protection for the switching of inductive loads. Each digital output card can not have
more than 32 outputs.
Relay contacts shall be
Each channel of digital outputs cards shall be equipped with interposing relay. Relays shall
SPDT available free of
be complied with the following requirements (as minimum):
voltage, 2 Ampere at
Maintained latching contact 24V DC.
Normally open/normally closed outputs selectable fail-safe position for each channel
shall required.
Relays shall be suitable for inductive field devices with 24 VDC coil, like solenoid
valves.
Relay contacts shall be SPDT available free of voltage, and each contact set shall be
totally independent of any other contact set. Relay contact rating shall be 230V AC 5A.
Relays shall be plug-in type with socket, hermetically sealed with heavy silver contact.
Mercury switches are not acceptable.
When the SSS system (either the ESD system or the Fire & Gas system) identifies an
Emergency condition, it will operate one or more outputs in accordance to the approved
Interlocks and sequences. If the initiating Emergency condition then becomes healthy again,
a reset will be required prior to the outputs being energized.
The reset shall be generated from the DCS operator workstation in the control room and the
relevant command transferred to the SSS (ESD or F&G) systems via the communication
system.
All channels for external connection of I/O modules, telecom modules and power modules
shall be equipped with Surge Protective Devices.
Surge Protection Devices shall be supplied by famous and experienced VENDOR.
The minimum technical requirements shall be as follows but not limited to:
For 24VDC, AI, AO, DI, DO signal loop protection, the maximum surge capacity should be
no less than 20KA/line,(8/20s) Leakage current: 1A
For 24V Analogue loop protection, the limiting voltage of surge protector should be no more
than 40V under the testing waveform of IEEE C62.41 recommendation (Testing waveform:
6KV/3KA)
For RTD loop protection, the Accuracy degradation should be less than 0.1%RTD 100
The leakage current should be no more than 0.3A.
The DCS vendor shall provide GPS receivers for the systems. Time
For 3-wire loop protection,
synchronization fullbe
shall line-line
performed protection shall betime
at a specific required.
every
Surge protector should be mounted on 35mm DIN rail, grounding via
24 hours. The DCS shall set the time in the sub-systems data links
achieved to own metal
by its
each system. The time synchronization facility
clamp on DIN rail, external grounding wiring is not accepted. shall enable all sub-systems
to display identical times to assist in plant upset investigations.
4.10 The
Timetime synchronization facility shall adjust the sub-system times to match
Synchronization
the local daylight savings time changes in the spring and autumn. The
The timesystem shall have this
synchronization among function to set Automation Systems, e.g. DCS, SSS (ESD,
the various
the new
F&G), PLC, daylight
CTMS, savings
should time to by
be achieved be means
manually enabled.
of GPS The provided
receiver system will beSCADA.
with
shipped with this function disabled.
In case The
of GPS receiverisfault,
SUPPLIER requiredall time synchronizations
to liaise shall be suppliers/
with the sub-systems from the internal clock of
manufacturers to determine how the time synchronization is to be carried
out to better than one second.
FEEDSERVICEFORSURFACEFACILITIES
DEVELOPMENTOFSOUTHAZADEGANPROJECT
Each equipment module shall be clearly marked with its identity number, serial number and
firmware/software revision index.
The tag numbering convention for those instruments belonging to the DCS will follow the
coding shown in the P&ID. Software programming for the DCSs can use tags based on
standard alphanumerical characters. Tag number service descriptive text can use standard
alphanumerical characters and need not follow any specific coding system.
The structure of the system and relevant marshalling cabinets shall be designed on the
basis of the above and the following main requirements.
Several remote I/O stations could be considered for long distance process monitoring and
control as requirement.
Remote I/O stations shall consist of cabinets, power units, communication units, required
input and/or output modules, surge protective devices, relays, wiring terminals and all
accessories etc.
Power supply modules and I/O modules for process control function shall be of duplicate
redundancy, and their specification shall be compliant with the above technical requirements.
Dual redundancy will not be considered for modules used for monitor and display purpose
only.
Data transmission bus between each remote I/O station and central DCS system shall be
via the fibre optical cables and interfaces, and the fibre optical cables and interface modules
shall be duplicate redundant and separated physically. The fibre optical cables,
optical/electrical devices, optical terminal boxes and ODF, and all required accessories shall
also be in the DCS VENDORs scope.
The VENDOR shall specify with the bid the maximum length between the communication
network and the remote I/O units.
Several instrument/electrical interface cabinets with required interposing relays and signal
isolators located in the place shall be considered for motors and/or starters of remote control
and monitoring.
The cables between the marshalling cabinets and the I/E interface cabinets shall be
provided by the system VENDOR.
FEEDSERVICEFORSURFACEFACILITIES
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The communication system for data communication between operator stations, process
Control Units, Data Acquisition Units, etc. shall be carried out with redundant cables and
redundant communication module. The automatic changes over between the
communication system and the relevant back-up system shall be displayed.
It shall be possible to disconnect or connect whatever unit of the system without interfering
with any other unit connected with the bus. Transmission speed shall guarantee the
up-dating of the operator station database every one second.
Interaction signals, cascade loops, sequences must be configured in the same process
station as far as possible. However the system shall allow communication among process
stations with a transmission speed of about 50 variables per second.
Redundant Ethernet supporting TCP/IP with redundant network switches shall be
considered among controllers, workstations, and others. VENDOR shall supply Ethernet
TCP/IP cables and connection hardware to link all operating stations, engineer workstation
and associated printers. Hardware for future connection by COMPANY shall be provided.
The DCS system communication network shall be at least 10M/100M base-T and be in a
redundant configuration with automatic switchover. DCS communication subsystems shall
be designed for loading not more than 60 percent of the engineered system under worst
case conditions.
The communication subsystem protocol shall include codes such as CRC (Cyclic
Redundancy Check), parity error, overrun error, etc., in order to detect errors and take
protective action to assure a high degree of transmission reliability. Diagnostics shall be
continuous and failure alarms shall take priority.
No single node point failure shall disable the communication network. Extensive error
checking shall be provided to ensure that accepted messages contain the same information
that was sent, and that neither noise nor hardwares failure has caused erroneous data to be
incorporated in the message received. Self-diagnostic shall provide system status to the
Operator and alarm any fault and take appropriate protective action.
Cables for internal communication shall be in the scope of DCS.
Redundant 2-wire RS485 interfaces shall be provided for communication with Safety and
Shutdown System. MODBUS RTU protocol shall be supported.
DCS communication modules/controllers for SSS shall be dedicated and separated from
those for other third-part self-governed equipments to ensure adequate reliability and
transmission speed. Any method of connecting SSS communication with others in series for
sharing one communication modules/controllers shall not be accepted.
FEEDSERVICEFORSURFACEFACILITIES
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DCS shall provide adequate and physically separated 2-wire RS485 communication
modules and support MODBUS RTU protocol, to communicate with a lot of sub-control
systems of the self-governed package or equipments. Each communication interface shall
be of duplicate redundancy. Communication gateways or wiring connectors, and surge
protective devices shall be in the scope of DCS VENDORs supply.
When communication fault in the self-governed equipments is detected, a communication
alarm shall be generated to inform the Operator.
The communication will be restored as soon as the self-governed returns to its normal status.
The sub-control system shall send to DCS all the necessary signals coming from the field
plus other miscellaneous information. DCS shall be have the ability to accept, store and
process all data from the self-governed packages especially for the huge packages such as
compressors, export pumps which have a large quantity of data.
VENDOR shall list the programmable controllers that can communicate with the system,
specifying references, the communication protocol, type of connection and third party
communication module requirements.
The DCS Vendor shall have the responsibility of approving provided protocols, interfaces,
and all other required parameters from the control systems of the packaged equipments.
The DCS VENDOR shall provide DC Power for CPU, I/O cards, subsystems, field
instruments, field Solenoid Valves, etc. The power supply shall be fed from the AC electrical
power of DCS. Power supply output voltage shall be 24 VDC nominal. Each power supply
shall be sized so that it will carry no more than 75 percent of capacity under maximum loads.
The internal structure of the power supply distribution system related to the internal
equipment shall guarantee:
Internal power supply distribution organized in subsystems fed from separate circuits;
Power supply for each system operating in such a way that DCS does not degrade or
influence the operability of the equipment fed by a failed circuit feeders;
FEEDSERVICEFORSURFACEFACILITIES
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The DCS shall be capable of monitoring and reporting the status of AC and DC power
supplies to the operator. The VENDOR shall add these signals to the system inputs. Failure
of any power supply shall cause a system alarm.
On the front panel of AC power cabinet, Ammeter and Voltmeter shall be provided and
installed for local indication.
6.4 Grounding
VENDOR will be responsible for ensuring (DCS) connection to the provided earthing
system.
For grounding details please refer the document
SA01-GENXXX-SDIN-SPDS-0010Specification for Cabinet for panel grounding and the
document SA01-GENXXX-SDIN-SPDS-0016 Specification for C&I Earthing- for other
details.
AC power for lighting fixtures and maintenance sockets shall be provided from non-UPS
sources.
7.1 Cabinets
The bid shall contain the option relevant to Maintenance Data system termination units
installed inside the marshalling cabinets with adequate wiring. The option shall include the
cables, with connectors at both ends, between marshalling cabinets and Maintenance Data
system PC based station. Details of the proposed connections shall be provided with offer.
7.1.2 Nameplates
All cabinets, consoles, etc., front and rear, shall be fitted with nameplates, giving designation
and type in sufficient detail for positive identification of the item, located above each door or
bay. The equipment numbering format shall be submitted to the COMPANY for approval.
Each device and component inside the cabinets shall be identified with engraved
nameplates installed with stainless steel screws.
The cabinets shall be provided with a redundant extraction fan system, in order to dissipate
heat produced by electronic circuits during operation. A temperature-detecting system shall
also be fitted to activate a high-temperature alarm in the system. The fans shall be suitable
for continuous operation, mounted on self-lubricated bearings. The filters for the extraction
system shall be of easy replaceable type. Single fan failure shall be alarmed and transmitted
to the system.
The cables shall be with low emission of smokes, toxic and corrosive gases. Connector
cable entrances shall be from bottom, adequate supports shall be provided for cable
hooking.
Wiring inside cabinets shall be run in dedicated PVC wiring ducts with covering lids. Fill shall
not exceed 60% capacity. VENDOR-installed cables shall be supported and provided with a
strain relief mechanism for cable connectors. Cable support and strain relief mechanism
shall be supplied for other cables entering cabinets. Cable entry to cabinets and consoles
shall be from the bottom. All opening remaining after entry of cables shall be sealed against
the ingress of dust. The dust seals shall be easily removable to enable entry of future cables.
VENDOR-installed cables shall be designed and installed in such a way as to allow cable
disconnection in order to maintain the equipment easily. Cables shall not interfere with
removal of boards.
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.
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.
FEEDSERVICEFORSURFACEFACILITIES
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The VENDOR shall provide all required software suitable to monitor and control the facilities
at the maximum extent possible of efficiency and safety. The software principles,
methodology and relevant parameters shall be approved by COMPANY prior to the
commencement of its development and implementation. Special care shall be taken about
the presentation of those Key parameters which are of essential use to plant operators such
as Engineering Units, services description, graphics, etc. Any reworks due to unsatisfactory
configuration implemented without COMPANY approval will be at VENDOR care and cost.
The provided minimum software shall include but not be limited as following:
System software;
Tools and driver software;
Anti-virus software;
Data base software;
Configuration software;
Picture editting and compiling software;
Communication software, including required server and client function;
Maintains software;
Diagnostic software, including on-line and off-line diagnostic;
Control and computation software.
The DCS shall have a Common Relational Data Base structure. This software structure
together with the communication software provides the means of sharing the functional and
processing intelligence resident in each element of the system with the ability to exchange
information from any point in the system, according to a suitable access hierarchy.
Suitable system maintenance software shall be provided within the DCS in order to monitor
DCS equipment including all input and output card status jointly with relevant field
instruments status and the reason for failure. Historisation and reports of past failures shall
be available.
Moreover the maintenance software shall organize and archive the I/O cards and relevant
field transmitters characteristic for easy retrieval on demand.
The basic software of the operating system shall be oriented toward real time applications
for the process control and supervision, support multitasking and multiprocessor functions,
manage the communication network through interface task and guarantee the support for
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Comprehensive system diagnostics shall be provided to detect problems, and to let the
operator know where the problem is located. The diagnostic features of the system shall
provide for timely, reliable detection and notification of both software and hardware errors.
Diagnostics design shall ensure minimal loss of critical operating time while repairs take
place. A diagnostic message shall be shown to the operator in case of system malfunction.
The diagnostic software shall verify the operation status of equipment and software of the
DCS. As minimum requirements, the diagnostic software shall: verify dynamically the points
configured in the database; verify the status of the electronics at card level; monitor and
verify the measurement acquisition channels; address fault and malfunctioning messages
for a clear and unambiguous identification of the interested element and control the status of
all the DCS power supply. Two different diagnostic software packages shall be provided
including, but not being limited to, the requirements indicated hereinafter.
This software shall operate on all of the parts in-line of the system. It shall have, as primary
objective, the detection of operation anomalies, the evaluation of their gravity, the
transmission of alarm messages to the operator, and the implementation of suitable actions
such as exclusion of the fault equipment, switching to the back-up equipment (if any),
re-addressing of the inputs on other peripheral units, etc. They shall also configure
messages relevant to anomalies, malfunctioning and faults in the monitored equipment (i.e.
fault signals from power VENDORs, cards, etc).
This software is applied off-line to the system. Its scope is to detect the reasons of the failure
or the defect in the DCS equipment. A system of diagnostic programs, which will allow
testing of the components of the system, they shall be resident in the DCS system ready to
be activated on request.
This section defines the function blocks and process controllers requirements.
Control blocks shall be able to perform automatic mode switching based on external or
internal inputs. Mode switching shall include:
Auto/manual switching
Local/remote setpoint switching (open/close cascade)
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Operating station should possess of perfect alarm function, evidence difference should be
existed between alarm for process variable and alarm for system failure, it should arbitrary
classify, partition, group the alarm for process variable, automation record and print alarm
information, distinguish the first grade accident to alarm, record alarm sequence with the
time accuracy of second.
Alarm for process variable should include the following kinds at least:
alarm of absolute value and deviation;
alarm of setting point over limits;
switching capacity alarm;
alarm for running out of 4~20mA for transmitters by identification;
alarm for output exceeding limits;
alarm for change rate exceeding limits;
The alarm value for process variable shall be set by operating staff or project technical staff
at the time of programming. Before the alarm being acknowledged, the process variable
alarm will display with twinkling mode, with a different colour and voice (difference in volume
and frequency) for distinguishing the status of alarm point.
The results of diagnosing for system and self-diagnosed by system internal shall display on
the system-diagnosing graphic, if it is diagnosed as failure, acousto-optic alarm form shall
be used to notice the relative person.
The realization of control function is to combine the needed control functional modules as
per the requirements; the common control functional modules should include the following
kinds at least:
PIDP=0~2000%I=0~400 miniatureD=0~800;
Cascade control, deviation control, dead-zone control,
PID parameter self-adjusting function;
the calculations of extracting a root, plus/reduce, multiply/divide, function generator;
lead/lagging, time-delay, damping;
high, low, high-high, low-low and deviation overflow alarm;
sampling control;
figure filter, switch control;
manual operating output;
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8.5 Reports
The system shall include facilities for both fixed and custom formatted reports. Report
printout shall be automatic, at pre-set time intervals, or via keyboard request.
Pre-formatted reports shall use VENDORs standard facilities for presentation of:-
(1) Instantaneous and cumulative values
(2) Hourly averages
(3) Shift (12 hours) averages
(4) Daily averages
It shall be possible that each of the above be allocated as sections of a total report.
History Services shall provide historical process information recording and playback facilities
on the DCS. The software shall be able to sample data from any variable on any node in the
system. History Service recordings shall be archived for at least 24 hours as permanent
records of process variables and/or records of alarm and event messages along with the
operator responses. Playback of data points can be compared with current trends.
Recorded variables can be included in reports and also transferred to other software
applications.
A data compression algorithm shall be provided in order to reduce the amount of disk space
required.
It shall be possible to transfer historical data either to removable media or to Maintenance
and Reporting console for long-term historical data storage. It shall be possible to recall any
display and historical data that has been stored on removable media from any console.
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This section addresses the capabilities required for system software configuration. The
program shall provide the data base structures to be used to implement the required control
and data acquisition functions. The main functions required through the program will be:
Implementing a database
Modifying the database
Updating the database
Generating reports about a database
An editor shall be provided to generate or modify data base and configuration data.
Configuration displays shall be provided to aid in system configuration. A "template" facility
shall be provided to facilitate the creation of multiple points with common parameters except
for minor changes, such as Tag ID and I/O address. This template can be defined once and
then used as the basis for each point. On-line configuration changes shall automatically
update all modules and Tags affected by the change. On-line configuration changes shall
follow a validation sequence requiring a final acknowledgement step before the change is
transmitted.
The control system shall be capable either partial or full downloads. Full downloads will be
utilized upon initial configuration and partial downloads will be made as the control unit is
modified. The control system shall be capable of partial on-line downloads. During partial
downloads, control unit outputs shall freeze in their last state until the download is complete
and the new loop configuration takes control.
LCD, keyboard of operator, keyboard of engineer, mouse or cabinet ball of operating station
shall provide the "man-machine" interface of inspection, control process, maintenance
equipment for operators.
The following colour graphics shall be seen at operating station by process operators for the
process of operation and inspection:
menu graphic: list out a catalog for the whole graphics displayed, the needed graphic
can be called from this graphic directly;
Team graphic: Each graphic will display a team, each team has 8 loops.
The setting value, measuring value, deflecting value, high and low limit value, output value,
manual/automation station, alarm of each loop shall be displayed under the same mode as
the common instrument. It can enter single point display graphic thereout.
Single point graphic: Each graphic display one loop of the team graphic. This loop can be
called from team graphic; also can be called by instrument bit. The whole information of this
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The project technical staff could carry on the system program generation, user flow diagram
and various drawing generation on this graphic convenience, and use currency high-level
language or special high-level language to generation various records, report forms. Project
technical staff graphic should include the following:
System programming graphic: project technical staff can carry on the system configuration
generation, network generation and various displays drawing generation sequence control
and logic control generation on the graphic.
User drawing generation graphic: use CAD method to generate the user flow diagram and
other needed drawing by user, this require the necessary symbol library.
High-level programming graphic: project technical staff should be able to use the high-level
language supplied by DCS VENDOR to workout various report form documents and partly
optimize softwarethe high-level language used by process control should be possess of
real-time propertyDCS VENDOR should show the offered high-level language kind, the
usable memory capacity for the user, the limit condition for real-time control, and so on.
Online recording and report forms generating graphic: the following online records should be
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The DCS alarm display will also be used for emergency alarms relevant to interlock
implemented in the SSS system. Process alarms shall be managed by the DCS and
grouped based on user selectable priority levels. The first priority shall be assigned to the
emergency alarms coming from SSS system. Pre-programmed routines in accordance to
the ISA S-18.1 standard shall be available in the standard library of the DCS.
Process alarms shall be audibly identified and presented to the operator regardless of the
display on the VDU. At least two distinct audible signal alarms shall be available. A distinct
audible signal alarms relevant to each alarm level, shall be evaluated. The system shall
have the capability and shall be configured in order to suppress nuisance alarms created by:
Start-up or shutdown conditions scheduled for a process unit or single equipment or
machine
Equipment not in service or not running and ready for back up
Initialization of algorithm
Sensors under maintenance
A report of suppressed alarms shall be available for display and printing.
The audible signals shall sound each time that alarm occur and shall continue to sound until
acknowledged by an operator. The visual signal shall indicate the plant area in which the
alarm has occurred. Input alarms shall carry a user-selectable priority level. For each
process alarm configured for printing, the alarm shall be logged on the alarm printer at the
time the alarm occurs. The following information shall be printed for each alarm:
Alarm tag ID
Alarm description
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All system devices connected to the communication network shall be monitored for failures.
An alarm shall be generated for each failure detected. It shall be possible for system alarms
to be logged on a printer separate from the process alarm printer.
Alarms shall be displayed on the appropriate alarm display according to the plant area
points assignment. Multi-page displays may be used for alarm summaries. The alarm
summary display shall list alarms in tabular format in order of occurrence with the most
recent alarm at the top. The alarm message shall contain the following information:
Alarm tag ID
Alarm description
Type of alarm
Priority level
Date and Time of alarm and return to normal in hours: minutes: seconds in a 24 hour format.
9.0 SPARE & EXPANSION CAPABILITY
The percentages stated in the following table are related to the base system. The base
system is defined as the quantity of hardware and software sufficient to safety monitor and
control the Plants in accordance to the Detail Design developed by VENDOR and approved
by COMPANY and needed to meet the requirements of this specification, at commissioning
phase.
The control processors for each relevant Control Unit shall not be loaded more than 70 % of
their processing capacity.
The system shall be delivered with a 30% of equipped spares for each typology of variables
distributed throughout the DCS. The I/Os relevant to the redundant signals can not be
mixed up with I/Os relevant to the no-redundant signals in order to average the required
spares.
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A 30% of the analogue inputs shall be reserved for critical loops. Based on process analysis
implemented during detail design by VENDOR, a list of critical loops and relevant criteria
shall be submitted to the COMPANY for approval.
30% minimum of data resident in the DCS database relevant to any input variables and/or
calculated values and/or manually implemented values shall be stored up to 6 months
minimum. Those data will be identified and specified during detail design by VENDOR and
approved by COMPANY.
Required spare parts for commission and 2-year operation shall be provided by VENDOR
together with the system.
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This paragraph indicates the minimum tests to be applied to the DCS and Automation
sub-system (integrated test). The purpose of this paragraph is to supply the guidelines for
tests, in order to ensure that the DCS meets all functional requirements.
The tests will be developed in different phases based on the procedures submitted by the
VENDOR and approved by the COMPANY. These phases are defined hereinafter.
A system register shall be prepared at the beginning of the test period, to be used for
annotating the successful completion of each test and any corrective action requested.
All components (including printed circuits, subassemblies and modules) shall be factory
tested and documented in accordance with national or international standards. The
component test shall comprise inspection as per VENDORs quality control procedure.
The test is performed and documented by the VENDOR. The COMPANY reserves the right
to make inspections to ensure the application of the procedures listed below. This test shall
be certified by exhaustive documentation, supplied by VENDOR, which, if approved, shall
constitute the PRE-TESTING CERTIFICATE.
The test listed below shall be considered an integral part of the pre-testing in factory:
Environmental test
Combined system test
Tests required at FAT
The intent of this test is to confirm that the system meets all user requirements. This test will
take place, prior to delivery, at the VENDORs factory. The FAT shall be done with the DCS
completely assembled, including the operator consoles, engineering workstation, printers,
communication links, etc. It will include the Maintenance Data System, if the relevant option
will be requested by COMPANY. The test is performed by the VENDOR, and witnessed by
the COMPANY. Accommodation and transport costs for COMPANYs attendance at the
FAT will be covered by VENDOR.
The DCS may comprise some products not furnished by the DCS VENDOR. The products
specified for integration shall not jeopardise the user requirements and shall be installed,
wired and tested together with the DCS.
The FAT activities will be carried out based on the procedure submitted by the VENDOR
and approved by the COMPANY. The VENDOR shall supply to the COMPANY the FAT
procedure and relevant planning at least 3 months before the starting date of the FAT in
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This paragraph defines the minimum tests to be carried out to test the DCS and subsystems
as whole.
Visual inspection
Cabinetry inspection
AC and DC circuit test
Diagnostics (operational)
Servers and workstations test (operational)
Communication links test
Functional test
Module replacement test
Power supply failure and reset
Redundancy test
Application SW test with 100% I/Os simulated.
Communication test with integrated Automation Systems
Communication test with Systems PLC based
10.3.2 Faults
On testing any component of the system found defective due to hardware shall be replaced
and retested. If the defective component can be repaired, it shall be demonstrated
subsequently during the FAT. Any operational defect due to the software configuration shall
be corrected as soon as possible within the FAT period and the validity of the correction
demonstrated subsequently during the FAT. A fault found during the operational test will not
hold up the testing. However, any fault or lack of design shall be solved before FAT
completion. Any impact to the planning of the FAT due to any deviation from COMPANY
requirements will be at VENDORs care and cost. The FAT approval by COMPANY will be a
pre-condition dispatch the system to site.
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On reaching the site, and after the system installation, the DCS shall be subjected to the
SAT. The objective of the SAT is to demonstrate the correctness of installation and that the
system maintains all the requirements of the technical specifications after being installed in
field and with system elements/cables connected within the DCS. The SAT shall basically
be the repetition of FAT procedures without field instruments check.
The VENDOR and their personnel employed for the test shall be appointed prior to the
commencement of the same. VENDOR shall be responsible for carrying out the test and
solving any problems that may arise during the SAT, under the supervision of COMPANY
appointees. Before starting the SAT, VENDOR shall have identified and transported to site
all the equipment and associated documentation. All spare parts deemed necessary for test
performance shall be made available at site. No modification shall be made to system
hardware and/or software without the prior agreement with the COMPANY.
The SAT activities will be carried out based on the procedure submitted by the VENDOR
and approved by the COMPANY. The VENDOR shall supply to the COMPANY the
procedure at least 2 months before the starting date of the SAT in order to receive the
approval.
Below text shall be replaced:
10.5The Operational
objective of the SAT is toTest
Availability demonstrate
(System the correctness of installation and that
Commissioning)
the system maintains all the requirements of the technical specifications after being
The operational availability test (OAT) shall be conducted after the SAT and upon
installed in field and with system elements/cables connected within the DCS
completion of the Plant loop check. The OAT shall be performed to demonstrate the
system.of the system to carry out the functions required in this specification, once it is in
availability
The SAT
operation shall
with thebeplant
basically the repetition
running. of FAT
The duration of procedures withbe
the OAT will field I/Osame
the check.of Plant
Vendor shallitindicate
commissioning; in his
means that thebid proposal
system support basehas
commissioning andto facilities for systems
be considered as integral
partduring
of theSAT and ongoing support during plant commissioning.
commissioning relevant to the whole plant. The system availability shall be
calculated considering the following definitions.
Vendor shall be responsible for carrying out the test and solving any problem that
may arise during
Operating SAT, under
Time (OT): the supervision
the period of client
of time during whichappointees.
all the functions are operable or
Before starting the SAT, vendor shall have identified
may be operated within the required response times. Operating and transported to site
time can be all the
calculated
equipment
starting fromandthe
associated documentation.
overall test period and subtracting the inactive periods requested by
All spare parts deemed necessaryCOMPANY,
the VENDOR and granted by utilised forshall
for test performance making any modifications
be made available at to
methodologies
site. and test equipment found necessary only during the performance of the
test itself.
No modification shall be made to system hardware and/or software without the
prior agreement time
Out-of-service with the client.
(OST): theThe SATofactivities
period will be
time during carried
which at out based
least one on the is
function
procedure
inoperablesubmitted
or cannotby
bethe VENDOR
operated andthe
within approved
requiredbyresponse
client. times.
TheNo modification
formula shall
utilised for be made to
calculating thesystem
availability is as follows:
hardware and/or software without the prior agreement with the client.
The VENDOR
Availabili ty shall supply to the client the procedure at least 2 months before the
OT
of
starting dateOT the SAT in order to receive the approval.
OST
The VENDOR shall demonstrate the following availability values for the system:
99.95 % for the real time functions
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In order to provide rapid response for services or part replacement, the VENDOR shall
maintain regional field service centres for the plant location. The location of these centres
shall be indicated in the VENDOR's proposal.
VENDOR shall guarantee support for all system hardware and firmware with spare parts
and service for ten (10) years from the placement of order.
11.2 Training
All drawings and specifications shall be supplied with both paper printout and electronic files.
Source files shall be implemented by means of AUTOCAD 2000 or later version and
Microsoft Office suite. Where standard drawings and documentation, which cannot be
produced with AUTOCAD, the source files provided to the COMPANY shall be Acrobat.
The form, the contents and relevant details and extent of description/representation of each
document shall be subject to specific COMPANY approval.
The VENDOR shall be responsible for supplying documentation revisions or changes due to
inaccuracies, installation requirements, omissions determined by usage, and design or
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System Manual 6
Software Manual 6
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Hardware Manual 6
Maintenance Manual 6
Operation Manual 10
The VENDOR shall determine if any manuals other than those listed are required and, in
consultation with the COMPANY, shall determine the contents of all manuals. For the
manuals listed above, the following descriptions shall be used as guides:
System Manual: This manual shall include a description of the operation of the system as a
whole and of its interrelated units. The functional description shall include the intended use,
capabilities, and limitations of the system. The system manual shall contain a functional
description of the software, with simplified logic diagrams.
Software Manual: This manual shall contain detailed information on all VENDOR-furnished
software.
Computer Operators Manual: This manual shall contain in brief form, information and
procedures relating to the operation of the computer. VENDOR-furnished compiling,
assembling and de-bugging software shall be described with step-by-step operations and
procedure.
Hardware Manual: This manual shall contain physical descriptions of hardware.
Descriptions shall be brief. Special attention shall be given to avoiding the inclusion of
repetitious details that are easily illustrated or tabulated. The quick-reference hardware data
contained in this manual consists of pertinent technical information, such as nameplate data,
functional characteristics, capabilities, special characteristics and related information.
Maintenance Manual: This manual shall include applicable data on the electronic and
mechanical hardware which must be maintained. Maintenance manuals shall include factory
settings and test results of all field adjusted hardware parameters, such as timing tests of
peripherals, etc. Detailed requirements for this manual shall include the following:
Preventive Maintenance: Instructions shall be included for maintenance procedures,
examinations, tests, and adjustments which should be performed periodically under
operating conditions for the purpose of preventing failure or impairment of the system.
Trouble-shooting: This manual shall provide the maintenance technician with adequate
details for quickly locating the cause of a hardware malfunction. The discussions shall
contain concise information on how the hardware operates, guides for localizing faults to the
printed circuit card level, listings of possible sources of trouble, symptoms, probable causes,
use of test equipment and instructions for remedying faults.
Repair: Instructions shall be provided for the removal, repair, adjustment, and replacement
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After satisfactory completion of Factory Acceptance Test, VENDOR shall disconnect all
equipment and prepare the systems for shipment. All interconnecting cables shall be clearly
labelled. Cabinets shall be shipped intact and packed using COMPANYs packing and
shipping procedures.
All equipments and materials described in this specification shall be prepared and crated for
shipment in such a manner as to protect them from damage in transit. The VENDOR shall
be responsible for and make good at his own expense any and all damage due to improper
crating, preparation, and shipment. The VENDOR shall ship equipment assembled and
completely wired whenever possible.
1. Boxes and Crates
All boxes and crates shall be of good, strong material, substantially constructed, completely
weatherproof and suitable for international air freight. Each box or crate shall be marked with
the COMPANYs order number and item number. Sensitive equipment shall be crated with
enclosed impact recording and tip-an-tell indicating devices. Electronic cards and equipment
shall be enclosed in anti-static packaging.
2. Packing Lists
Packing lists shall be securely attached to the outside of each crate. In addition a Pro
Forma Invoice may be required at the Customs Office at the Port of Entry.