Petrofac

Total Facilities Solutions

DCS,ESD & F&G SYSTEMS

BY: SHAIK FIRDOSI

September 2005
Petrofac
Total Facilities Solutions CONTROL SYSTEMS
PLANT CONTROL SYSTEMS :
(PROCESS AUTOMATION SYSTEM: PAS)

• DCS :DISTRIBUTED CONTROL SYSTEM.

(FCS: FOUNDATION FIELDBUS CONTROL SYSTEM)

SAFEGUARDING SYSTEM:
• EMERGENCY SHUTDOWN SYSTEM (PLC BASED).
(IPS: INSTRUMENT PROTECTIVE SYSTEM)

• FIRE & GAS DETECTION SYSTEM (PLC BASED).

(FGS: FIRE & GAS SYSTEM)

September 2005
Petrofac
DCS :DISTRIBUTED
Total Facilities Solutions CONTROL SYSTEM.

• DCS Control System is used for controlling the

process plant, by maintaining the process variables
within the allowable operating range.

• DCS is the first control action to keep the plant

running safely and in optimization state.

September 2005
 Petrofac Typical configuration diagram of DCS
Total Facilities Solutions

Operator Operator Engineering

Console Console Console Printer

Data link (Communication

Network)
Control Gateway
Room Power Supply Module,
Supervisory Communication
Module, Controller
Computer Cards etc.

Field or
Control Marshalling
Room Cabinets

JB
JB

Field
September 2005
Petrofac CONTROL SYSTEM
Total Facilities Solutions ARCHITECTURE

September 2005
Petrofac
Total Facilities Solutions

September 2005
Petrofac
Total Facilities Solutions DCS COMPONENTS
• SYSTEM MARSHALLING CABINET.
• SYSTEM CABINET.
• ENGINEERING STATION.
• OPERATING STATION.
• COMMUNICATION LINK HARDWARE.
• LOCAL AREA NETWORK
• SOFTWARE PACKAGES.
• GPS CLOCK.
• PRINTERS, PLASMAS, CONTROL DESKS (CONSOLES).
• MISC. FURNITURE (Eg. CHAIRS, FILING CABINETS, WHITE
BOARDS)

September 2005
Petrofac
SYSTEM MARSHALLING CABINET
Total Facilities Solutions

• FIELD CABLE TERMINALS: All FIELD CABLES

WHICH ARE COMING FROM JUNCTION BOXES
OR FROM FIELD DEVICES ARE CONNECTED TO
CONTROL SYSTEM THROUGH TERMINALS IN
MARSHALLING CABINET.

• FIELD TERMINATION ASSEMBLY (FTA): TO

ASSEMBLE THE FIELD SIGNALS FROM FILED
CABLE TERMINALS AND CONNECTED TO I/O
CARDS THROUGH SYSTEM CABLES ( MULTI
CORE CABLE).

September 2005
Petrofac
SYSTEM MARSHALLING CABINET
Total Facilities Solutions

• POWER SUPPLY:
• 230 VAC: TO PROVIDE POWER TO INTERNAL
CABINET UTILITIES (LIGHT, FUN, FLOW SWITCH)
AND TO 230VAC/24VDC POWER CONVERTER.

• 24VDC POWER CONVERTER: TO PROVIDE

POWER TO FTA BOARDS, FIELDBUS POWER
SEGMENT AND TO FIELD DEVICES IF IT IS
REQUIRED TWO SEPARATE WIRES FOR POWER.

September 2005
Petrofac
Total Facilities Solutions SYSTEM CABINET
• POWER DISTRIBUTION BOARDS: TO PROVIDE
POWER TO ALL RACKS.

• RACK: DIVIDED TO CPU RACK, I/O RACK,

COMMUNICATION RACK.

• RACK CONSISTS OF SLOTS (TYPICAL 10 SLOTS):

• FIRST TWO SLOTS: REDUNDANT POWER
DISTRIBUTION CARDS WHICH PROVIDE POWER
TO THE CARDS WITHIN THE SAME RACK.

September 2005
Petrofac
Total Facilities Solutions SYSTEM CABINET
• OTHER SLOTS: CAN BE EITHER:
• REDUNDANT I/O CARDS: AI, AO, DO, DI AND FF
CARDS WHICH ARE CONNECTED TO FTA (FIELD
TERMINAL ASSEMBLY) THROUGH SYSTEM
CABLE.
• COMMUNICATION CARDS: TO COMMUNICATE
DCS SYSTEM WITH OTHER SUB-SYSTEMS.
• REDUNDANT INTERNAL COMMUNICATION
CABLES TO CONNECT BETWEEN DIFFERENT
RACK.
• REDUNDANT NETWORK CABLE TO CONNECT
BETWEEN DIFFERENT CONTROLLERS.

September 2005
Petrofac
Total Facilities Solutions
ENGINEERING STATION

• THE ENGINEERING STATION IS DESIGNED TO

DO ALL ENGINEERING WORK SUCH AS:
• CHANGING IN THE LOGIC.
• CHANGING IN GRAPHIC BUILDER.
• CHANGING ALARM, TRIP SET POINT.
• IT HAS PROTECTED ENGINEERING USER NAME
AND PASSWORD.

September 2005
Petrofac
Total Facilities Solutions OPERATING STATION
• OPERATING STATION HAS DIFFERENT LEVEL OF
USER NAME AND PASSWORD, AND IT IS
DESIGNED TO PROVIDE SOME FACILITIES TO
OPERATOR:
• MONITORING THE PLANT.
• CONTROLLING THE PLANT BY CHANGING THE
SET POINT OF SOME CONTROLLERS.
• OPERATING AND MAINTAINING THE PLANT BY
ACTIVATING SOME BUTTONS SUCH AS: MOS,
START & STOP, AND RESET BUTTONS.

September 2005
Petrofac
COMMUNICATION
Total Facilities Solutions LINK HARDWARE

• IN RACK SLOTS THERE ARE SOME

COMMUNICATION CARDS WHICH
COMMUNICATE WITH OTHER SYSTEM
PACKAGES THROUGH SERIAL LINK (RS 232, RS
485) FOR SHORT LENGTH, AND FIBER OPTIC
FOR LONG LENGTH.

September 2005
Petrofac
Total Facilities Solutions LOCAL AREA NETWORK
• IT IS REDUNDANT COMMUNICATION LINK
BETWEEN ALL PARTS OF DCS, IT RECENTLY
DEPENDS ON ETHERNET PROTOCOL FOR MOST
VENDORS.
• IT CONNECTS BETWEEN:
• DCS CONTROLLERS.
• OPERATOR AND ENGINEERING STATIONS.
• OTHER SOFTWARE STATION SUCH AS: AMS
(ASSET MANAGEMENT SYSTEM), CCTV AND
OPC.

September 2005
Petrofac
Total Facilities Solutions DCS SOFTWARE'S
• STANDARD OPERATING & MONITORING
FUNCTION
• LONG TERM DATA ARCHIVE, REPORT PACKAGE
• GRAPHIC BUILDER PACKAGE
• FOUNDATION FIELDBUS COMMUNICATION
PACKAGE
• SERVER FOR REMOTE OPERATION &
MONITORING FUNC.
• ELECTRONIC INSTRUCTION MANUAL.
• ADVANCE ALARM MANAGEMENT PACKAGE.
• AMS (ASSET MANAGEMENT SYSTEM).

September 2005
Petrofac
Total Facilities Solutions GPS CLOCK
• THE FUNCTION OF GPS CLOCK MODULE IS TO
MAINTAIN THE SAME TIME IN ALL DCS
CONTROLLERS AND PC’s ACCORDING TO
LOCAL TIME.
• IT CONSISTS OF:
• GPS ANTENNA WHICH RECEIVES TIME FORM
THE SATELLITE AND TRANSMITS IT TO GPS
MODULE.
• GPS MODULE IS CONNECTED TO NETWORK
THROUGH SWITCHES OR GATEWAY.

September 2005
Petrofac FEATURES AND CAPABILITIES OF DISTRIBUTED CONTROL
Total Facilities Solutions SYSTEM

• MODULAR SYSTEM
• EXPANDING CAPABILITY

• COLOR CRT BASED, PRE-PROGRAMMED, OPERATOR INTERFACE

• CONFIGURABLE CONTROLLERS
• WIDE SELECTION OF CONTROLLER ALGORITHMS
• DATA HIGHWAYS
• COMMUNICATION CAPABILITY BETWEEN DIFFERENT UNITS
• EXTENSIVE DIAGNOSTICS
• REDUNDANCY

September 2005
Petrofac
Total Facilities Solutions TYPICAL LOOP FF AI/AO

September 2005
Petrofac
Total Facilities Solutions TYPICAL LOOP FOR FF AI

September 2005
Petrofac
Total Facilities Solutions TYPICAL LOOP AI

September 2005
Petrofac
Total Facilities Solutions TYPICAL LOOP DI/DO

September 2005
Petrofac
Total Facilities Solutions SYSTEM ENGG. ACTIVITIES

• INQUIRY SPECIFICATION
• OFFER EVALUATIONS WITH TECHNICAL QUERIES
• TECHNICAL BID EVALUATION
• PURCHASE ORDER
• KICK OF MEETING
• DRAWING CHECKING
• PRE-FAT & FAT INSPECTIONS
• SIT :SYSTEM INTEGRATION TESTS
• DISPATCH
• SAT
• COMMISSIONING

September 2005
Petrofac
Total Facilities Solutions DOCUMENTATION

INPUT DOCUMENTS TO THE VENDOR :

• P&ID’S (INCLUDING PACKAGE VENDOR P&ID’S)

• DCS DATABASE (INCLUDING SERIAL LINK DATABASE)
• CABLE SCHEDULE & TERMINATION DETAILS
• ALARM & TRIP SCHEDULE
• TREND GROUPS, ALARM GROUPING & MANAGEMENT
• CAUSE & EFFECT ,CONTROL PHILOSOPHY ,IPF
NARRATIVE.

September 2005
Petrofac
Total Facilities Solutions DOCUMENT. (CONTD)

INPUT DOCUMENTS TO THE VENDOR :

• GRAPHIC IMPLEMENTATION PHILOSOPHY (IF ANY)

• INST LOCATION LAYOUT, CABLE LENGTHS.
• CONTROL ROOM LAYOUT.
• MISCELLANEOUS DETAILS LIKE TELECOM EQUIPMENT
DETAILS LIKE CCTV,INTERCOM ETC.

September 2005
Petrofac
Total Facilities Solutions DOCUMENT. (CONTD)

DOCUMENTS FROM THE VENDOR :

• DOCUMENT SCHEDULE
• MONTHLY/WEEKLY PROGRESS REPORTS
• PROJECT QUALITY PLAN & INSPECTION TEST PLANS
• FDS:FUNCTIONAL DESIGN SPECIFICATION
• SYSTEM ARCHITECTURE
• BILL OF MATERIAL
• CONTROL ROOM LAYOUT
• I/O NEST LOADING

September 2005
Petrofac
Total Facilities Solutions DOCUMENT. (CONTD)

DOCUMENTS FROM THE VENDOR :

• POWER CONSUMPTION & HEAT DISSIPATION DETAILS.

• CABINET GA AND DIMENSIONAL DRAWINGS, INTERNAL
WIRING AND LAYOUT DRAWINGS (MARSHALING CABINET,
POWER DISTRIBUTION CABINET, SYSTEM CABINET)
• CONSOLE LAYOUTS & WIRING
• GRAPHICS
• SYSTEM CABLE SCHEDULES

September 2005
Petrofac
Total Facilities Solutions DOCUMENT. (CONTD)

DOCUMENTS FROM THE VENDOR :

• POWER DISTRIBUTION PLAN

• GROUNDING SCHEMES
• LOOP TYPICAL
• FUNCTIONAL LOGIC DIAGRAMS
• FAT/SAT AND SIT PROCEDURES
• FIELDBUS SEGMENT DESIGN REVIEW
• FIELDBUS SEGMENT NETWORK DRAWINGS

September 2005
Petrofac
SAFEGUARDING
Total Facilities Solutions SYSTEMS ESD (IPS)

ESD SYSTEM IS THE PROTECTIVE SYSTEM FOR

THE PLANT WHEN THE PROCESS VARIABLE IS
ACCEDING THE ALLOWABLE OPERATING RANG.

FEATURES
• TUV –GERMANY : CERTIFIED
• FUNCTIONAL SAFETY CLASSIFICATION AS PER
IEC-61508
• SYSTEM CYCLE TIME : TYPICAL 300ms FOR ESD.

September 2005
Petrofac
SAFEGUARDING SYSTEMS
Total Facilities Solutions

AVAILABILITY OF THE SYSTEM (99.999%):

• Pfd(av): PROBABILITY OF FAILURE ON DEMAND.
• MTBF: MEAN TIME BETWEEN FAILURES.
• MTTR:MEAN TIME TO REPAIR.

DUAL REDUNDANT CONFIGURATION SYSTEM

• 1oo2D : 1 OUT OF 2 WITH DIAGNOSTICS.
REDUNDANT I/O , REDUNDANT PROCESSOR,
REDUNDANT POWER SUPPLY, REDUNDANT
COMM BUS.

September 2005
Petrofac
SAFEGUARDING SYSTEMS
Total Facilities Solutions

HARDWARE
• SAME DCS HARDWARE, AND SOME
ADDITIONAL HARDWARE ARE ALSO REQUIRED:

• SEQUENCE OF EVENTS PC,

• ESD CONSOLE.

• ESD ENGINEERING STATION.

September 2005
Petrofac
Total Facilities SolutionsFIRE & GAS SYSTEMS FGS

• FGS SYSTEM IS ALSO SAFEGUARDING SYSTEM WHICH

PROVIDES EARLY DETECTION OF FIRE AND GAS
LEAKAGE AND TAKES THE PROTECTIVE ACTIONS SUCH
AS:
• START FIRE PUMP WATER.
• TRIP THE PLANT BY HARDWARE CONNECTION BETWEEN
ESD AND FGS.
FEATURES:
• TUV –GERMANY : CERTIFIED
• FUNCTIONAL SAFETY CLASSIFICATION AS PER IEC-61508
• SYSTEM CYCLE TIME : 500 ms FOR FGS.

September 2005
Petrofac
FUNCTIONAL REQUIREMENTS OF FGS
Total Facilities Solutions

• CONTINUOUS AND AUTOMATIC MONITORING

FOR FIRE, GAS OR SMOKE.
• ALERT OPERATOR TO THE PRESENCE AND
LOCATION OF FIRE, GAS OR SMOKE.
• INITIATE ACTIVE FIRE PROTECTION SYSTEM.
• VOTING LOGIC:
• 1OON: USE TO INITIATE AN ALARM AND MAY
ACTIVATE THE BEACONS AND SOUNDERS.
• 2OON: USE TO INITIATE AN ALARM, ACTIVATE
THE BEACONS AND SOUNDERS AND TRIP THE
PLANT.

September 2005
Petrofac
DESIGN CONSIDERATIONS DETECTOR SYSTEM
Total Facilities Solutions

• ALL AREA SHOULD BE INDIVIDUALLY ASSESSED

FOR HAZARDS THAT COULD RESULT IN FIRE
AND GAS RELEASE.
• PLANT TO BE SEGREGATED INTO ZONES.
• ALL FGS DETECTORS SHOULD BE INTEGRATED
IN AN OVERALL SAFETY SHUTDOWN
SYSTEM(IPS) THROUGH HARDWIRE LINK.
• ALARM ANNUNCIATION AND LOGGING ON MAIN
FGS PANEL.
• IDENTIFICATION TYPES OF ALARMS (FIRE,
FLAMMABLE GAS, TOXIC GAS, SMOKE).

September 2005
Petrofac
Total Facilities Solutions
FGS SYSTEM

September 2005
Petrofac
Total Facilities Solutions FGS HARDWARE
HARDWARE
• SAME DCS HARDWARE, AND SOME
ADDITIONAL HARDWARE ARE ALSO REQUIRED:

• SEQUENCE OF EVENTS PC,

• FGS CONSOLE.

• FGS ENGINEERING STATION.

September 2005
Petrofac
Total Facilities Solutions THANK YOU

YOKOGAWA DCS FAT

AT JEBEL-ALI

September 2005