MQ SP I 7010 PDF

Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification: MQ-SP-I-7010
Project Name: Date: 14 Jan 2011

Contract Number: Page: 1 of 36
Revision: 1
SPECIFICATION – SAFETY INSTRUMENTED SYSTEMS
This specification has been revised as indicated below and described in the revision record on the following
page. Please destroy all previous revisions.
Revision Date Originator's Reviewed/Checked By Pages

No. Name & Initials Name & Initials
A 8/04/2010 Cory A. Haynes Vincent E. Mezzano 38
0 11/04/2010 Cory A. Haynes Anna M. Pham 36
1 1/14/2011 Cory A. Haynes Anna M. Pham 36
APPROVALS SIGNATURES DATE
Lead Engineer Thomas B. Robinson

Project Manager: Russell Shulz
Client Approval:
ISSUED FOR : Construction X Other Approved

Revision: 1
Record of Revisions
Revision Date Description
No.
A 8/04/2010 Issued for Approval, Table of Contents Only
0 11/04/2010 Issued for Review/Approval
1 1/14/2011 Issued Approved

Revision: 1
TABLE OF CONTENTS
Section
1.0 SCOPE ............................................................................................................................................................... 5

1.1 General ................................................................................................................................................ 5
2.0 REFERENCES ................................................................................................................................................. 5
2.1 Codes and Standards ......................................................................................................................... 5
2.2 Project Specifications and Drawings ............................................................................................... 7
2.3 Conflicts .............................................................................................................................................. 7
3.0 DEFINITIONS AND ABBREVIATIONS..................................................................................................... 8
3.1 Definitions ........................................................................................................................................... 8
3.2 Abbreviations ..................................................................................................................................... 8
4.0 ENVIRONMENTAL CONDITIONS ............................................................................................................ 9
4.1 Design Temperature .......................................................................................................................... 9
4.2 Design Sound Pressure Levels (Noise)...........................................................................................10
5.0 GENERAL REQUIREMENTS ....................................................................................................................11
5.1 General requirements......................................................................................................................11
5.2 Operating Conditions ......................................................................................................................12
5.3 Safety Function Requirements .......................................................................................................12
5.4 System Redundancy.........................................................................................................................13
5.5 Automatic Testing and Diagnostics ...............................................................................................13
5.6 System response time.......................................................................................................................14
6.0 SYSTEM ARCHITECTURE........................................................................................................................15
6.1 Component Architecture.................................................................................................................15
6.2 Remote I/O’s.....................................................................................................................................15
6.3 System Hardware.............................................................................................................................15
6.4 Central Processing Unit (CPU) ......................................................................................................16
6.5 Input Bypass Switches.....................................................................................................................16
6.6 Sequence of Events Requirements .................................................................................................17
6.7 Emergency Manual Shutdown Switches .......................................................................................17
6.8 Digital Input/Output Isolation........................................................................................................18
6.9 Data Communication.......................................................................................................................18
Revision: 1
6.10 Input/Output System .......................................................................................................................19

6.11 SIS Software .....................................................................................................................................20
6.12 Program Requirements ...................................................................................................................21
6.13 Cabinets.............................................................................................................................................22
6.14 Marshalling / Termination Cabinets .............................................................................................23
6.15 Wiring and Cabling .........................................................................................................................24
7.0 ELECTRICAL REQUIREMENTS .............................................................................................................26
7.1 Area Classification...........................................................................................................................26
7.2 Transient, Static and Electromagnetic Interference (EMI) Protection.....................................26
7.3 Power.................................................................................................................................................26
7.4 Wiring and Connection ...................................................................................................................27
7.5 Heat Loading ....................................................................................................................................27
7.6 Grounding.........................................................................................................................................27
8.0 DRAWINGS, DOCUMENTATION AND DATA REQUIREMENTS ...................................................28
8.1 Design Drawings...............................................................................................................................28
8.2 Design Interface ...............................................................................................................................28
8.3 Supplier Documents.........................................................................................................................29
8.4 System Logs ......................................................................................................................................30
8.5 Requirements with Proposal...........................................................................................................30
9.0 INSPECTION AND TESTING ....................................................................................................................33
9.1 General ..............................................................................................................................................33
9.2 Factory Acceptance Test (FAT) .....................................................................................................33
9.3 Site Acceptance Test (SAT) ............................................................................................................34
10.0 COMMISSIONING AND START-UP ........................................................................................................35
10.1 General ..............................................................................................................................................35
11.0 PACKING AND SHIPPING .........................................................................................................................35
11.1 General ..............................................................................................................................................35
12.0 SPECIAL TOOLS, TESTING AND CALIBRATION..............................................................................36
12.1 General ..............................................................................................................................................36
Revision: 1
1.0 SCOPE
1.1 General
A. This specification defines the design criteria, supply, assembly, testing, and delivery
of the Safety Instrumented Systems (SIS) for Power and Water Utility Company for
Jubail and Yanbu (MARAFIQ) Projects located at the existing COMPANY
complexes at Jubail Industrial City and Yanbu Industrial City, in the Kingdom of
Saudi Arabia.
B. This SIS specification covers the functional and technical requirements for SIL 3
TUV AKA Class 6 SIS logic solver. The logic solver shall incorporate architecture,
utilizing a fault tolerant redundant controller system with single I/O.
C. This SIS specification together with the attachments and request for quotation RFQ
documents, defines the minimum technical requirements for the supply, design,
materials & fabrication, testing, and documentation.
D. SIS shall provide safeguarding and emergency shutdown functions and shall be
physically separate from other plant control systems (e.g. DCS, PLC, etc.)
E. The equipment furnished according to this specification shall conform to the

requirements contained herein, unless modified in writing by the attachments or an
addendum to these specifications.
2.0 REFERENCES
2.1 Codes and Standards
A. The selection of material and equipment, and the design, construction, maintenance,
and repair of equipment and facilities covered by this specification shall comply
with the latest edition of the references listed below, unless otherwise noted.
B. ISA – International Society of Automation
 ISA 5.1 : Instrumentation Symbols and Identification
 ISA 71.03 : Environmental Conditions for Process Measurement and Control

Systems: Mechanical Influences
 ISA 84.00.01 – Part 1 (IEC 61511-1 Mod) : Functional Safety : Safety

Instrumented Systems for the Process Industry Sector – Part 1: Framework,
Definitions, System, hardware and Software Requirements

Instrumented Systems for the Process Industry Sector – Part 2: Guidelines for the
Application of ISA 84.00.01 – Part 1 (IEC 61511-1 Mod) – Informative
Revision: 1

Instrumented Systems for the Process Industry Sector – Part 3: Guidance for the
Determination of the Required Safety Integrity Levels – Informative
 ISA 91.01 : Identification of Emergency Shutdown Systems and Controls
C. IEC-International Electrotechnical Commission
 IEC 60079 : Electrical apparatus for explosive gas atmospheres
 IEC 60409 : Guides for the Inclusion of Reliability Clauses into Specification of
Components (or Parts) for Electronic Equipment
 IEC 60529 : Degrees of Protection for Enclosures
 IEC 60801-3 : Electromagnetic Compatibility for Industrial Process Measurement

& Control Systems
 IEC 61000 : Electromagnetic compatibility (EMC)
 IEC 61000-4-2 : Electromagnetic compatibility (EMC) - Part 4-2: Testing and

measurement techniques - Electrostatic discharge immunity test
 IEC 61131-3 : Programmable Controllers - Part 3: Programming Languages
 IEC 61508-1 : Functional Safety of Electrical/Electronic/Programmable

Electronic Safety-Related Systems - Part 1: General Requirements
 IEC 61511-1 : Functional Safety - Safety Instrumented Systems for the Process
Industry Sector - Part 1: Framework, Definitions, System, Hardware and Software
Requirements
Industry Sector - Part 2: Guidelines for the Application of IEC 61511-1
Industry Sector - Part 3: Guidance for the Determination of the Required Safety
Integrity Levels
D. IEEE – Institute of Electrical and Electronics Engineers
 IEEE 1100 : Powering and Grounding Sensitive Electronic Equipment
 IEEE C37.90.1 : Standard for Surge Withstand Capability (SWC) Tests for
Relays and Relay Systems Associated with Electric Power Apparatus
Revision: 1
E. Miscellaneous
 MIL HDBK 217E : Reliability Prediction of Electronic Equipment
 NEMA : National Electrical Manufacturer’s Association
 FM : Factory Mutual Standard
 UL : Underwriters Laboratories
2.2 Project Specifications and Drawings
A. All equipment and accessories covered by this specification shall comply with all
Project Specifications and Drawings listed herein.
B. MARAFIQ Standards and Specifications
Specification No. Title

MQ-SP-I-7012-1 Process Control Systems (DCS)
MQ-SP-I-7016 Control Panels
MQ-SP-I-7017 Fire and Gas Detection Systems
MQ-SP-T-7811 Fiber Optic Cable
MQ-SP-E-6001 Electrical Design
MQ-SP-E-6009 Uninterruptible Power Supplies
MQ-SP-E-6018 Low Voltage Power and Control Cable
2.3 Conflicts
A. In the event of conflict within this specification, the SIS Supplier shall request a
written clarification. All exceptions to the specification and conflicts with the
existing system installation must be in writing, and shall reference the
section/paragraph.
Revision: 1
3.0 DEFINITIONS AND ABBREVIATIONS
3.1 Definitions
A. Terms used in this document are defined as follows:
SIS SUPPLIER Supplier of SIS equipment purchased by CONTRACTOR.

COMPANY Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) or
designated representative.
CONTRACTOR Other Engineering, Procurement and Construction contractor responsible
for one or more of the plants / facilities associated with the MARAFIQ
projects.
SYSTEM Refers to the integrated SIS as specified in this document.
3.2 Abbreviations
AIB Approved Independent Backups
CCR Central Control Room
DCS Distributed Control System
EMI Electromagnetic Interference
EWS Engineering Workstation
FAR Field Auxiliary Room
FAT Factory Acceptance Test
FMEA Failure Mode and Effect Analysis
HMI Human Machine Interface
ICS Integrated Control System is the collective name assigned to the core
control system components. This includes the following;
 Distributed Control System (DCS)
 Safety Instrumented System (SIS)
 Fire & Gas System (FGS)
LED Light Emitting Diode
LCD Liquid Crystal Display
MTTFd Mean Time to Failure to a Dangerous Mode

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PEC Programmable Electronic Controller logic solver portion of SIS
PFD Probability of Failure on Demand
PLC Programmable Logic Controller
PSU Power Supply Unit
SAT Site Acceptance Test
SER Sequence of Event Recording
SIS Safety Instrumented System
SIL Safety Integrity Level
TÜV Technischer Überwachungs-Verein
UPS Uninterruptible Power Supply
4.0 ENVIRONMENTAL CONDITIONS
4.1 Design Temperature
A. The SIS shall normally be installed and operated in an air conditioned environment
which will be maintained at the following conditions:
1. 21 ºC ± 3 ºC and 50% ± 10% Relative Humidity
B. SIS Supplier standard equipment shall be fully operational so as to perform per

specifications at any air temperature range from 5 to 40 ºC in all the Control Rooms,
Operator Shelters and Field Auxiliary Rooms, and a relative humidity range of 40 to
60 percent non-condensing. The SIS shall have no failures when operated at 50 ºC
room temperature and relative humidity of 95% for a 4 hour period (in case of air-
condition loss). SIS Supplier shall specify any environment limitations to the
Company.
C. SIS Supplier equipment installed in local control panels / field control cabins shall
meet the design temperature at the following conditions:
1. 9.0 to 50.0 ºC and 22 to 95 % Relative Humidity

Revision: 1
D. SIS Supplier shall include a “High temperature” option for equipment to meet this
requirement.
E. For components exposed to the sun the surface design temperature shall be 85 ºC.
4.2 Design Sound Pressure Levels (Noise)
A. The maximum acceptable sound pressure level for each piece of equipment installed
in the Control Rooms shall be 60 dBA measured at a distance of 1 meter lateral from
the source and 1.5 meter vertical from floor with a sound level meter using the “A-
weighted” sound level scale. Sound level measurement shall be based on tests
carried out per IEC standards.
Revision: 1
5.0 GENERAL REQUIREMENTS
5.1 General requirements

A. A separate Distributed Control System (DCS) will be installed for process control.
Any failure in the DCS should not affect the operation of the SIS. The SIS will be
interconnected to the corresponding DCS to ensure that control and emergency
shutdown (safeguarding) actions are coordinated and that the process operator can
view the status of the SIS and all SIS connected field devices on the process control
system operator console. These interconnections, however, shall be designed to
ensure that the functional independence and security of the SIS is not compromised.
B. SIS shall have networked SIS Engineering Work Stations (EWS) and a printer
supplied by the SIS Supplier for programming, setpoint changes, maintenance
information, testing etc. SIS EWS shall be located in the CCR.
C. In addition to the SIS dedicated EWS in the CCR, the SIS Supplier shall provide 3
laptop computers with the same functionality and capability of the SIS engineering
work stations.
D. All SIS equipment shall be of field proven design within an industrial process safety
environment. All hardware, firmware, and software (excluding application
software) that are supplied shall have been field proven. One adequate measure
would be 1000 unit years of operation (e.g., 1000 units operating for one year or 200
units operating for five years) without excessive problems. New Operating System
software releases (upgrades) shall be proven in service before the SIS is allowed to
be upgraded. The 1000 unit years of operation shall apply to upgrades as well as
hardware components.
E. All modules and subassemblies performing similar functions shall be

interchangeable.
F. The SIS shall execute sequential logical functions, where its high speed, high
reliability, ruggedness and cyclical operation ensure a best performance.
G. The SIS Supplier shall furnish a complete, fully assembled, operational SIS
inclusive of all hardware, software, wiring and cables, and documentation.
H. The SIS shall provide a fault tolerant execution of process safety functions. All
components of the SIS, including communication links within the system and
network communication, shall conform to fault tolerant requirements and be
certified. Communication with DCS shall be redundant, and communication with
Engineering Work Station (EWS) can be simplex.
I. The SIS shall be of a rugged construction. Manufacturers published data of high

ambient temperature for components and assemblies shall not be less than 70°C
(158°F).
Revision: 1
J. The main operator interface is at each DCS console. All SIS alarms, status and
analog values shall be displayed on graphic displays on the DCS operator stations
for SIS and safeguarding.
K. Bypass switches shall be through configured (software) bypass switches on DCS

operator station graphic displays for SIS and safeguarding. See section 6.5 for
further requirements for bypass functionality.
5.2 Operating Conditions
A. The SIS and associated hardware shall operate 24 hours a day, 365 days per year.
B. The SIS shall be installed in a controlled environment within Field Auxilary Rooms
(FARs) or the Central Control Room (CCR).
5.3 Safety Function Requirements
A. The system shall be a fault tolerant microprocessor based design, which protects the
controlled process from intermittent, transient, and permanent system faults. Any
single system fault shall not degrade system safety or functionality or impact
operation of the controlled process. The system architecture shall have full
diagnostic coverage and have a TUV AKA6 or greater test certification rating.
B. Any fault resulting in a system failure shall be such that all failure modes are fail-
safe to the OFF and Open state. This includes all module removal and cable faults.
C. The SIS system shall be designed for maximum reliability, safety and integrity while
maintaining the required PFD and safety availability, which is defined as:
1. Safety Availability = 1 – PFDavg
2. This value is dependent on the Safety Integrity Level (SIL) required as referenced
in the following table:
PROBABILITY OF FAILURE
SAFETY AVAILABILITY
SIL ON DEMAND-AVERAGE
RANGE (%)
RANGE (PFDAVG)
SIL 1 10-1 to 10-2 0.9 to 0.99
SIL 2 10-2 to 10-3 0.99 to 0.999
SIL 3 10-3 to 10-4 0.999 to 0.9999
SIL 4 10-4 to 10-5 0.9999 to 0.99999
D. Availability figure for SIS system must be provided by the Supplier as part of the
quotation, with method of calculation and all assumptions clearly stated. Data for
failure rates shall be derived from MIL HDBK 217E wherever possible.
Revision: 1
5.4 System Redundancy
A. Each system shall be configured in redundant format for safety functions down to
I/O level / PSU’s to establish signal integrity. Each of the internal signal paths shall
be completely isolated and operate completely independent of each other.
B. There shall be no single failure point that can affect more than one channel. Failure
of any single active component supplied within the system shall not cause a
shutdown action, and during such a failure, the system shall remain on - line and
shall maintain the process safety protection. Additionally, the system shall
accommodate a means for alarming the fault.
C. It shall be possible to replace and repair any faulty system module without
degrading the safety performance of the system. The transition to the healthy
module shall be bumpless (i.e. no loss of control).
D. Input and output signals shall be designed as de-energized to trip. Where inputs and
outputs for energized to trip circuits are required these shall be configured as line
monitored loops.
5.5 Automatic Testing and Diagnostics
A. The system shall incorporate comprehensive self-diagnostics such that all permanent
and transient faults are identified, alarmed and reported. Diagnostics shall be
capable of identifying, locating and reporting the following faults as a minimum:
1. CPU failure or changeover in a redundant CPU configuration
2. CPU fault, i.e. Memory faults RTC faults etc
3. Communication faults
4. Application / operating system program and hardware configuration discrepancies
5. I/O module faults
6. Signal discrepancy on input and outputs
7. Power or fuse faults
8. Over temperature conditions
B. I/O module diagnostics shall be able to detect and alarm I/O point fault of the
following types:
1. "Stuck-on" - short circuited failure of a discrete input or output

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2. "Stuck-off" - open circuit failure of a discrete output
C. All testing described shall be performed automatically on-line and without

disturbing the process or reducing the reliability of the SIS.
D. The SIS shall have the capability for automatically executing on-line testing
including the application program.
5.6 System response time

A. The time between an event at the SIS system input and the corresponding SIS
system output shall not exceed 200 milliseconds (The application execution time
including diagnostics shall not exceed 100 msec).
B. The SIS SUPPLIER shall specify in the proposal the estimated maximum response
time assuming worst-case conditions for analog signals retransmitted to the DCS.
C. The SIS SUPPLIER shall indicate the minimum response time for all quoted
systems.
D. The necessary actions shall be taken to ensure that mean time to repair figures of the
SIS does not deteriorate so as to jeopardize plant safety or plant availability. The SIS
Supplier shall provide deterioration times from SIL 3 to SIL 2 due to component
failure.
E. Any time delay due to system constraints between SIS trip initiation and DCS alarm
presentation shall be less than 3 seconds.
F. The first trip action occurring in any area (first failure) shall be detected by the SIS.
A first up flag shall be transmitted to the DCS and the DCS display shall
differentiate the first up alarms from subsequent alarms, until the first up reset is
activated and the first up flag removed by the SIS. First up reset is done using a
separate switch in the DCS or preferably when the trip function itself is reset
(avoiding the need for a separate first up reset).
Revision: 1
6.0 SYSTEM ARCHITECTURE
6.1 Component Architecture
A. The SIS system shall consist of the following components:
1. Redundant CPU to ensure fault tolerant operation.
2. Input/Output (I/O) racks with fault tolerant I/O module.
3. Fault tolerant redundant power supply units to support CPU and I/O's.
4. Communication modules for fault tolerant communication with DCS.
6.2 Remote I/O’s
A. The system shall support remote I/O’s in a fault tolerant manner. All remote I/O’s
shall employ a fiber–optic link. The system response time from input to output
through the controller CPU shall be the same as with local I/O.
6.3 System Hardware
A. I/O counts shall include 20% spares installed. Rack configuration power loading
(modules) shall not exceed Supplier-published limitation. Field power supplies shall
be 100% redundant. Load for either shall not exceed 70% of maximum field load
requirements. All loads shall be connected to more than one power supply.
B. On CPU power loss, the program shall be maintained by battery for up to six
months. Battery condition indicating lights of low battery voltage shall be provided
before battery failure. The CPU shall have on-line self diagnostic and alarm
capabilities to detect malfunctions in the system such as a memory scan timer or "
Watchdog Timer" (Supplier shall provide more information for single point failure).
The CPU shall monitor execution of the program and service all input/output data
channels and remote processors. The CPU shall perform continuous on-line with
error detection and shall alert the operator of any malfunction.
C. SIS Supplier shall provide an external hardwired “watchdog” timer to monitor the
execution of the SIS and application programs.
D. SIS Supplier shall state power supply loads for cabinets and slots. Power supplies
shall be redundant with automatic switch over on failure, and generating a failure
alarm. All SIS equipment shall be provided with dual power supplies capable of
being powered from two independent sources. Field and system power supplies
shall be separate and isolated.
E. SIS Supplier shall specify a total number of each type of device that the system will
support, including PLC interfaces, consoles, control electronics, computers, etc.
Revision: 1
F. SIS Supplier shall provide networking capabilities for each SIS. SIS network shall
be certified.
G. All SIS hardware shall be mounted in cabinets for installation in CCR or FARs. All
SIS equipment shall be laid out by the SIS Supplier and approved by Company /
Contractor.
H. Each electronic module including I/O, CPU and communication modules shall be
furnished with diagnostic indicators to indicate correct operation of that module.
6.4 Central Processing Unit (CPU)
A. The SIS shall contain redundant main Processor Modules, in parallel. Each
Processor module shall consist of adequate microprocessor error correcting Random
Access Memory (RAM).
B. SIS Supplier shall specify proposed memory requirements. Each processor shall
provide sufficient memory for the initial configuration plus 50% excess for future
expansion without degradation to system performance including scan time
requirements.
C. The processors shall continuously scan all stored logic, inputs and outputs, and
execute all outputs during the scan cycle. Each microprocessor shall be capable of
scanning and updating the I/O and executing user-defined logic at a minimum of 4
times per second. A real time clock with a 10 msec (or less) resolution shall be
available for time dependent function such as rate calculations.
D. The processors shall be capable of controlling all application safety function

operations, performing data loading functions, and communicating with various user
devices through the use of one or more internal programs consisting of ladder logic,
ASCII output, floating point math, and other required safety application function
blocks.
E. The processor shall have indicating lights (LED’s) to indicate processor malfunction
and the capability for remote indication (remote alarm).
F. The processor shall be mechanically and electrically isolated.
6.5 Input Bypass Switches
A. The SIS shall incorporate individual software input bypass switches for each field
device to permit testing and maintenance.
B. All software-input bypasses shall be operable from the DCS Operator interface
display graphics.
C. The Software bypasses shall be password protected.

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D. Input bypass switches shall not bypass nor disable outputs to annunciators, LCD
alarm displays or data loggers.
E. The operation of input bypass switches shall be alarmed and logged by the DCS and
SOE recorder.
F. An initiator input bypass shall not deactivate the alarm associated with the process
parameter alarm or indication.
G. All bypasses that are activated shall be alarmed, logged and the device(s) bypassed
shall be so indicated as bypassed on the graphic display. Bypasses shall be re-
alarmed If not de-activated after a certain period time (time to be set by the Shift
Supervisor with password protection).
6.6 Sequence of Events Requirements
A. SIS Supplier shall provide all necessary hardware and software required to
implement Sequence of Events (SOE) recording and logging for all SIS system
initiator inputs and outputs. The SOE functionality shall be implemented within a
redundant SOE Station with the capability to archive alarms events for all plants.
B. During an initiation event, the SOE recording shall collect tag readings for a pre-
configured list of tags and shall store this information in history and be available to
the operators at the DCS operator consoles. The initiation events shall be time
stamped to within 10ms resolution. The operator shall be able to demand a
hardcopy report or bring up an SOE display. The SOE events shall be stored in
history within the Redundant SOE Station with redundant storage but preferably
these events will be automatically moved into long term history to the plant data
historian.
6.7 Emergency Manual Shutdown Switches
A. Emergency manual shutdown switches shall be implemented in one of the following

ways in order of preference:
1. Hardwired directly to the shutdown device as well as input to the SIS.
2. Hardwired to the output power terminals to disconnect the output power as well
as input to the SIS.
3. Hardwired directly to the input of the SIS.

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6.8 Digital Input/Output Isolation
A. Input and output signals of different voltages/currents and IS circuits, (i.e. motor
control circuits) shall be isolated from each other and the mixing of circuit
voltages/currents which are out of phase or involve separate grounding systems shall
be prevented.
6.9 Data Communication

A. Plant operation requires a single operator window for DCS and SIS data. As such,
the SIS shall provide capability to interface with DCS for complete information
exchange, which is considered critical and hence a redundant interface shall be
provided.
B. The SIS shall have proven communication facilities with the selected Yokogawa
CENTUM VP DCS system. The SIS Supplier shall provide details of successful
interface to the DCS system. The SIS Supplier shall supply, in the proposal, a list of
services and hardware to provide a complete working SIS/DCS interface.
C. SIS shall be interfaced to the DCS through redundant data links. Any requirements
to “write” from the DCS to data points in the SIS must utilize safety certified
protocols that shall not in any way impact the safe operation of the SIS. SIS Supplier
may also quote as an option for the SIS to be integrated into Control System
architecture via direct tie to the control bus provided the following conditions are
met:
1. Operation of the SIS is completely unaffected by DCS faults or failures.
2. SIS power supply shall be completely independent from the DCS power supply.
D. Full 1:1 redundancy shall be provided for all components and systems involved in
communications between the SIS system and the DCS system.
E. The SIS shall support multiple communication ports for communications with
external devices such as program development stations, operator devices, and other
foreign devices.
F. All communication ports shall permit connection and disconnection without

interrupting system operation.
G. A communication diagnostic functionality shall be integrated in the SIS and DCS /

3rd party vendors. An Alarm shall be generated when communication failure or
malfunction between the SIS and DCS / 3rd party vendors occur.
H. The following DCS/SIS communication data shall be exchanged per the following
table:
Revision: 1
Operator Interface Communication Module
Update Time &

Information Classification mode of Request
Process Alarms Critical Immediate on occurrence

Complete I/O Mapping (Digital & Critical Regular 1Sec cycle
Analog)
Complete Software parameter Critical Regular 1Sec cycle
mapping such as Timers, Counters,
Flags, words etc.
Processor Diagnostics & I/O Rack Temporary Critical On occurrence
Diagnostics On request
Failover diagnostics Temporary Critical On occurrence
On request
Sequence of event Files Temporary Critical On occurrence
On request
Other Non Critical On request
Master Clock setting originating Critical Regular

probably from the DCS system (or
other designated external device)
I. SIS Supplier shall propose their DCS interface with the SIS, which satisfies the
above requirements. Supplier shall also propose a method of maintaining complete
SIS engineering functions. This shall be through a separate network based PC
Engineering Workstation (EWS) located in the CCR.
6.10 Input/Output System
A. Each discrete input and output shall have a status indicating light or LED for normal
state. For inputs, the light shall be on in normal state. For outputs, the light shall be
on when the output is active (field circuit energized).
B. Output for inductive loads shall be rated for 2 A continuous and 10 A surge current
at 70°C.
C. Current requirements to drive any input shall not exceed 20 mA.
D. I/O racks shall have rack fault indication and the capability for remote indication.
E. All I/O modules shall permit insertion and removal without interrupting the
operation of the system.
F. Insertion of wrong I/O card into an I/O slot shall not be possible.
Revision: 1
G. The SIS shall be capable of receiving 4-20mA signals from externally powered
devices (e.g. 4-wire device).
H. Tyoically, I/O points per channel shall be as follows:
1. Digital Inputs – 16 points
2. Digital Outputs – 16 points (isolated)
3. Analog Input – 16 points
4. Analog Output – 8 points
5. Thermocouple Input – 16 points (isolated)
I. The SIS shall have capability for supervised output modules.
J. The SIS shall meet the following I/O requirements:
1. 4-20mA, 24V DC analogue inputs powered by the system.
2. Digital inputs, 24V DC powered by the system.
3. Digital inputs, 24V DC Volt free contacts.
4. Digital outputs, 24V DC (1 amp resistive) volt free contacts
5. Digital outputs, 24V DC (l amp resistive) powered by the system.
6. Digital outputs, 220 VAC for solenoid valves powered by the system.
7. Digital outputs, 220 VAC for Motor Control Centre Interface externally powered.
8. The I/O cards shall incorporate galvanic or optical isolation.
6.11 SIS Software
A. The SIS shall comply with IEC 61131-3 software to execute logic shown in project
documents, and the following guidelines:
1. SIS logic shall not normally perform any process control function.
2. The SIS logic shall generate all digital alarms, and status-bits reflecting the
process conditions. Digital points, used in communications to DCS, or other
devices, shall be grouped in dedicated files by type of parameter, separately for
each data link with an external processor.
Revision: 1
3. Upon shutdown all outputs shall assume a fail-safe position. Upon restoration of
power all equipment shall remain in its "shutdown" condition (safe mode) until
the operator initiates the reset action.
6.12 Program Requirements
A. The SIS shall be programmed using commercially available software. Software

shall support on-line and off-line programming. One copy of the programming
software shall be furnished for each system as a deliverable to the engineering
contractor, complete with instruction manuals.
B. Programming software shall be capable of function block, ladder diagrams and

structured text with self-documentation capability. All programs shall have complete
function block containing descriptive rung comments; tags, identification of all bits
and words used, and is augmented with necessary full narrative descriptions for each
logic section.
C. The system shall provide the ability to track memory utilization, allocation and
calculate total scan time of the application program.
D. SIS I/O lists shall be provided. Complete listing of all data table files, words, and
bit assignments used throughout the programs containing the alias address, symbolic
or tag name, and cross reference within the programs shall be provided also in
exportable electronic format.
E. Dip switch, Push-wheel, and Jumper Plug listing shall be provided if applicable.
Switch setting listings for all hardware shall be provided. The listing shall be
segregated by physical enclosure or device and shall contain:
1. Equipment ID tag
2. Type of device
3. System Address (Data Highway station number, I/O rack address, or port and
device address)
4. Switch number with setting
5. Definition of switch set parameters
F. Examples of devices are logic processors, power supplies, resource managers,

chassis, analog modules, I/O Adapter modules, communication modules.
Revision: 1
6.13 Cabinets
A. The cabinets shall be rugged industrial type enclosures, which conform to the
NEMA 1 "Enclosures for Industrial Controls and Systems". Open racks are not
acceptable.
B. The cabinets shall be of the same manufacturer and model as the DCS Supplier’s
Rittal enclosures. They shall be hinged to open from the same side as the DCS
Supplier’s cabinets. Cabinet surface shall be primed and painted in accordance with
the DCS Supplier’s standard.
C. The cabinet shall be supplied to house the processor module, I/O modules,
communication modules, power supplies, and other system components, completely
wired, assembled, tested and ready for installation, with bottom entry for field
wiring.
D. Industrial Circuit Breakers with trip indication shall be supplied for each power
source.
E. All cabinets shall be equipped with a safety copper ground bus and an isolated
copper ground bus (6 mm x 25 mm x 25-mm minimum). The buses shall have
connectors to accept No. 4 AWG ground cable.
F. All cabinets and other enclosures shall be free of sharp edges and corners both
internally and externally.
G. All equipment and cabinets shall be constructed to withstand continuous vibration as

per ISA 71.03. The equipment shall not come loose or be damaged in any way due
to vibration.
H. Redundant (dual) SIS mounted cooling fans shall be provided and shall be
individually fed from SIS Supplier's installed circuit breakers with fuse, mounted in
the cabinet. Cooling fan noise level shall be no higher than 55 DBA measured at a
distance of 3 feet from source with cabinet doors closed. The redundant fans shall
be sized to maintain the temperature inside the cabinet lower than 30°C (to be tested
during FAT)
I. Filters associated with cooling mechanisms shall be readily and easily accessible
and replaceable.
J. All equipment shall be properly identified with labels and tags that conform to
project specification.
K. Legends and instruction information appearing on the surface of enclosures shall be

applied in such a manner as to be legible and permanent.
L. The exterior and interior shall have minimum of two (2) finish coats of premium
quality enamel.
Revision: 1
M. Access to cabinets shall be by dual (front and back) full length, hinged removable,
lockable doors. A common key shall be used for all locks. No equipment shall be
mounted on doors or side panels. A full coverage plexiglass window shall be
provided so that viewing of equipment and status LEDs is possible without opening
the enclosure door.
N. For each cabinet, individual hardwired alarm contacts shall be pre-wired to terminal
blocks and grouped as a common alarm for Contractor / Company use. These shall
include as a minimum; power supply failure, cabinet hi temperature (set at 40°C),
and cabinet fan failure.
O. Warning labels (in English and Arabic) shall be placed on equipment with
hazardous voltages to protect operators and service personnel. In addition, the
mechanical design of the equipment shall be such that personnel are protected from
such hazards as accidental contact with hazardous voltages, sharp edges, and hot
equipment.
6.14 Marshalling / Termination Cabinets
A. Termination cabinets shall be used to interface with all field signals.
B. Field I/O cables shall be terminated in core order onto vertically mounted knife edge
disconnect terminals. All spare cores shall be terminated along with the utilized
cores. The internal side of the terminals shall be cross wired to the system signal
conditioning cards. All crisscross wiring shall be by the SIS Supplier. Cable
identifier markers shall be mounted to the terminal rail between individual groups of
terminals. A minimum of 800 terminals shall be fitted in the termination cabinet,
(this will include for future spare terminals to allow for possible future cabling). The
detailed requirements for the size and arrangement of these cabinets shall be
developed in the SIS Functional Design Specification.
C. For IS circuits the field cables will terminate directly onto the barrier base with cross
wiring to the signal conditioning cards from the 'safe' side of the barrier base. Spare
IS wires shall be terminated onto the barrier mounting rail or into standard (non
disconnect) terminals. Isolating type (not Zener) barriers (MTL type or equal) shall
be provided. Sufficient spare space shall be provided to allow the mounting of extra
barriers should the spare cores in the cable be required.
D. Field cables and system cables shall have separate trunking. For IS circuits the
trunking and terminals shall be blue.
E. Signals of different voltage levels, different type (analog, digital, etc.) and IS
circuits shall not be mixed on the same rail.
F. Termination cabinets shall be provided with undrilled removable gland plates for all
field cable entry into the cabinets.
Revision: 1
G. All replaceable components (such as, IS barriers, relays, etc.) shall be provided with
plug-in base, so component can be removed /replaced without disconnecting wiring.
H. SIS Supplier shall include proposed termination cabinet layout in proposal.
6.15 Wiring and Cabling
A. All system cables, ribbon cables, serial interface cables, printer cables etc. shall be
within SIS Supplier's scope.
B. System cables between equipment cabinets, termination cabinets and peripherals

shall utilize plug and socket techniques to the maximum extent possible. Each cable
shall be supplied with a unique cable marker at both ends. Cable schedules/block
diagrams shall be provided to enable quick hook-up at site.
C. Crimped pins shall be used on all stranded wire termination's into Weidmueller
modular disconnect type terminals (WTR or equal). All wires shall be tagged using
slip on heat shrink type markers. Tag numbering shall be subject to approval.
D. Terminals shall be clearly identified. Group headers shall be used to identify

rows/groups of terminals.
E. Electrical wiring shall be designed per IEC, digital communication, and DC wiring
shall be segregated. Contractor will provide dual 220 V AC ± 1 %, 60 Hz ± 2%
single phase and neutral power supplies from a UPS system (UPS provided by
others). Each incoming cable shall be capable of taking the full load of the system.
The SIS Supplier shall include for the monitoring of both the UPS feeders. Incomer
fault signals shall be connected into the systems via digital inputs.
F. Terminal blocks for main power supplies, lighting, output and input signals shall be
provided with fuses and blown fuse indicators or current limiting devices where
applicable. All interconnecting wiring shall be run through wire-ways.
G. The SIS Supplier shall provide all special or custom data communication cables
(copper or fiber), including both end connections.
H. All I/O wiring shall terminate on compression type terminal strips on SIS Supplier
supplied termination panels. The SIS Supplier supplied termination panels shall be
located in a marshalling cabinet supplied by SIS Supplier. SIS Supplier shall supply
interconnecting cables between the termination panel and the I/O module.
I. All internal system and cabinet wiring shall be permanently labeled at each end with
from-to numbering system. All internal wiring shall be neatly turned, laced and
properly harnessed. All internal cable bundles shall be placed in appropriate covered
raceways and secured. Raceways shall not be more than 50% filled when shipped.
Splicing shall not be used to extend wires or cables.
Revision: 1
J. All I/O system interconnecting cables in the SIS Supplier's system shall have plugs
terminated at both ends. Plugs and receptacles shall be marked or keyed to avoid
incorrect mating. All cable plugs and receptacles shall have means to prevent
accidental disconnection. Cable clamps or molded cables, which grip the jacket,
shall be used to secure cables to connectors.
K. Field cable connection is by others to the field terminal strip in the marshalling
cabinet.
L. SIS Supplier shall provide all hardware required to complete the wiring and
connection of the SIS.
M. Terminal blocks shall be segregated as per voltage levels, Signal types, I.S. and non-
I.S. circuits to allow quick identification of wires:
1. Power distribution
2. Discrete inputs
3. Discrete outputs
4. Analogue inputs
5. Analogue outputs
N. Wherever possible, separation between power and signal wiring need to be 300mm.
Circuit supply terminal blocks shall be fused.
O. Wiring and related cable-trays shall be segregated in the same groups as for
termination.
P. Location of terminal blocks shall provide suitable separation of discrete and

analogue circuit wiring to prevent noise interference.
Q. Terminal connectors for analogue modules shall include terminals for terminating
one shielded wire per signal loop.
Revision: 1
7.0 ELECTRICAL REQUIREMENTS
7.1 Area Classification
A. The SIS system devices will be installed primarily in an unclassified "General

Purpose" area in accordance with IEC. All electronic I/O cards, processors etc., for
SIS shall be housed in the same cabinets where devices are grouped together.
7.2 Transient, Static and Electromagnetic Interference (EMI) Protection
A. All electrical equipment shall incorporate electrical transient protection on the

power input and on all interfaces to inputs and outputs. As a minimum, the system
shall meet test requirements of IEEE C37.90.1, Tests for Electrical Transient
Protection.
B. As a minimum, the system shall be able to withstand applied surges without damage
to components and without operating errors according to the requirements of IEEE
Std. C37.90.1, Surge Withstand Capability (SWC).
C. The system shall be internally protected against system errors and hardware damage
resulting from connecting and disconnecting devices or removing or inserting
printed circuit boards in the system.
D. As a minimum, the system shall be capable of withstanding electrostatic discharges

in accordance with IEC 61000-4-2, level 3 tests. This assumes the system is properly
grounded according to manufacturer’s recommended practices.
E. The SIS Supplier shall ensure the system performs as specified , without errors or
hardware damage, when exposed to broadband and narrowband radiated EMI or
RFI.
F. The SIS shall satisfactorily meet (EMI/RFI) susceptibility testing per IEC 61000
standards.
G. The equipment design shall incorporate techniques such as isolation, shielding,

grounding, gasketing, filtering, and bonding as necessary to meet this requirement.
H. Alternatively, the SIS Supplier may use other equivalent industry standards to
substantiate EMI immunity. These shall be provided with the proposal.
7.3 Power
A. The SIS Supplier shall provide with his proposal a detailed definition of power
requirements for the system. Power supply for modules and field instruments shall
be redundant and have at least 40% reserve for future expansion. The Supplier shall
include the following:
Revision: 1
1. AC voltage and frequency tolerances
2. Requirements for isolation from the AC power system if necessary.
3. Current requirements during normal operation and start-up in-rushes.
B. The SIS Supplier shall propose a complete, detailed redundant power supply system
to meet the needs of his own equipment as well as the needs of the field loads.
C. The proposed system shall be based on 220 V AC ± 1 %, 60 Hz ± 2% single phase

and neutral power supplies from separate Uninterruptible Power Supply (UPS)
feeders.
D. The SIS Supplier shall be responsible for electrical protection coordination to

preclude propagation of faults.
7.4 Wiring and Connection
A. Each cabinet or device requiring a separate AC power feed shall be provided with an
approved field wiring termination to circuit breaker, suitable for the service. The SIS
Supplier shall provide a definition of all service wiring requirements with his
quotation.
7.5 Heat Loading
A. SIS Supplier shall provide the total heat generated by the equipment being provided;
itemized by cabinet, in Btu/Hr. This will be used for verifying the size of building
air conditioning units.
7.6 Grounding
A. SIS Supplier shall provide the grounding for the system per IEEE-1100 guideline.
Each cabinet shall be supplied with an isolated ground bar and safety ground bar.
Revision: 1
8.0 DRAWINGS, DOCUMENTATION AND DATA REQUIREMENTS
Documentation of the complete system shall be provided in accordance with, but not limited to, the
general requirements in this specification and as listed in the material requisition document.
8.1 Design Drawings
A. Prior to start of hardware fitting out the SIS Supplier shall submit relevant drawings
for review and approval in accordance with the Drawing and Data Commitment
Form.
B. After completion of FAT the SIS Supplier shall issue a complete set of updated
drawings reflecting any modifications made during the FAT.
C. Final as built documents shall be submitted by SIS Supplier after incorporating field
modifications up to Contractor turnover of the SYSTEM.
8.2 Design Interface
A. The SIS Supplier shall develop / define the system configuration with input from
Contractor. Configuration definition shall be provided to Contractor / Company for
review and comment.
B. Contractor shall supply via electronic means to SIS Supplier information to

configure the I/O databases. The minimum information to be provided by
Contractor will include tag names, service descriptions, I/O type, engineering units,
scale ranges, alarm settings and trip points, IS loop and special power requirements.
As necessary the Contractor shall provide to the SIS Supplier P & IDs, cabling
interconnection drawings, logic diagrams or cause & effect charts, and control
building layouts showing equipment positions and cable routing, etc.
C. SIS Supplier / Contractor shall perform a site survey to verify and collect all
information of the existing SYSTEM to design and configure additions, upgrades or
replacement of SIS components and subsystems.
D. SIS Supplier shall supply electronic files of the configured databases for importing
by Contractor into the instrument index database.
Revision: 1
8.3 Supplier Documents
A. The SIS Supplier shall furnish all drawings, documents, data and software required
to accurately define the design of the SIS.
As a minimum the following shall be provided:
1. Supplier document index
2. Spare part requirements
3. Catalog data
4. Quality plan
5. Manufacturing plan / schedule
6. Inspection and testing plan
7. Test data / records
8. List of materials
9. Overall system block diagram
10. Interface block diagram
11. Dimensional outline drawings
12. Location / equipment layouts
13. Physical wiring diagrams
14. List of cables
15. Power and earthing distribution diagrams / schedules
16. Heat dissipation and power consumption
17. Certificates of compliance
18. Mean Time between undisclosed failure & disclosed failures data
19. Installation, operation and maintenance manuals
20. System loading calculations

Revision: 1
21. System availability calculations
22. Functional design specifications
23. Engineering manual containing all application configuration and operating data
24. FAT documentation (procedure / test records)
25. SAT documentation (procedure / test records)
26. Standard software manuals (original CD’s of system software and licenses)
27. Electronic back-up of system configuration and application programming
8.4 System Logs
A. A system log (punch list) shall be maintained once system integration starts and
through FAT. The log shall indicate all problems noted by date, type of problem and
action taken to correct the problem. The system shall not be released for shipment
prior to the clearing of all log items.
B. A system log (punch list) shall be maintained once system integration starts at site to
mechanical completion. The log shall indicate all problems noted by date, type of
problem and action taken to correct the problem. The system shall not be accepted
by Company prior to the clearing of all log items.
8.5 Requirements with Proposal
A. SIS Supplier shall include the following in his technical proposal:
1. Project execution plan for manufacturing, testing, site survey and installation (tie-in
to existing system both hardware and software):
Revision: 1
 Organization chart
 Preliminary Schedule - preliminary project schedule for the proposed system

identifying major milestones including equipment design, manufacture,
testing and delivery. The schedule should include all SIS Supplier,
Contractor and Company activities critical to the proper management of the
work. The schedule should also identify dates for information to be supplied
by Contractor
 Communications
 Location of project execution
 Reporting
2. A list of conflicts / exceptions / deviations referenced to the relevant paragraphs of

this specification and all referenced specifications, codes and standards which are
part of this specification, if applicable.
3. List of concerns and / or optional proposals.
4. Itemized list of equipment separated by unit or area.
5. Technical literature and product specifications on the equipment such as network

switches, servers, workstations, printers, logic solvers (including available standard
algorithms, libraries and templates), I/O cards, archive devices, communications
subsystem, etc. included in the proposal.
6. System block/architecture diagram including interfaces to equipment not supplied

by SIS Supplier.
7. Commitment to supply drawings and data required by Contractor, complete with

dates for submittal.
8. FDS Contents page/format.
9. Preliminary equipment layout drawings with dimensions.
10. Proposed termination cabinet design and layout.
11. General grounding and power requirements.
12. Standard software capability.
13. Details and costs of software options that may be applicable to this project.
14. Details and costs of software licensing requirements.

Revision: 1
15. List of standard pre-configured serial link software packages which are available to
interface with the DCS.
16. Price list of commissioning and start-up spares and also a spares list for two years
continuous operation.
17. Price list of consumables such as disks, printer paper and accessories, tapes, etc.
required for 12 months operation.
18. The procedure and length of time required for repair and/or replacement of parts.
19. Power requirements of all the users and also the heat dissipation of consoles and
equipment cabinets.
20. Suppliers quality control procedures for inspection and testing of all parts,
assemblies and complete system, including procedures for thermal cycling,
inspection and testing of the parts, circuit boards, assemblies of the entire system.
21. Reliability and Availability calculations. Field experience data is preferred.
22. Details of diagnostics and fault reporting including any covert faults which are not
expected to be revealed by the automatic test facility and diagnostics.
23. Details of suitable training courses, their duration's, schedule and associated costs
for the following levels of personnel: engineer; maintenance technician, operator.
Availability for On-site training and/or in the Kingdom of Saudi Arabia or Region.
Revision: 1
9.0 INSPECTION AND TESTING
9.1 General
A. Testing of components and systems shall be in accordance with the codes and
standards listed in section 2.0.
B. SIS Supplier shall provide his standard QA/QC procedure for manufacturing and
testing with the proposal. The SIS Supplier shall successfully pass a pre-award QA
audit conducted at the discretion of Contractor or Company prior to the award of the
contract.
C. All electronic modules or components utilized within the system shall be

functionally tested and burned-in by manufacturer prior to the system assembly.
(100% active continuous burn-in of a minimum of 24 hours) This shall include a
powered heat soak test.
D. The SIS Supplier shall fully test the complete system. The test shall include
complete functional testing for all I/O included in the scope of supply. Test shall
demonstrate full functionality and conformance to the requirements of the functional
specifications, logic drawings, and communication feature. The testing shall be
witnessed by Contractor / Company authorized representatives.
E. The electronic hardware shall be assembled, configured per job requirements and
given a complete functional hardware test including a 24 hour system running test.
F. The complete system (including marshalling cabinets with electronics components)

shall be subjected to heat soak without any product failure prior to FAT with system
in running State. Heat soak test shall be run at 60°C for 12 hours followed by the
temperature being lowered to the ambient temperature then raised to 60°C in 24
hours cycles until 48 hours has elapsed.
G. The SIS Supplier shall perform a complete point-to-point functional test of the entire
system prior to starting the Factory Acceptance Test (FAT).
9.2 Factory Acceptance Test (FAT)
A. The Factory Acceptance Test (FAT) procedure shall be developed by SIS Supplier
and submitted at least twelve (12) weeks prior to test for Contractor / Company’s
approval.
Revision: 1
B. The Factory Acceptance Test shall be performed by the SIS Supplier and witnessed
by Contractor / Company personnel. This test shall consist of a 100% functional test
of each input and output, review of all component, software configuration user
programs, and communication with the DCS and software checkout. All complete
safety functions shall be tested including operation and display functions. Test shall
be performed using simulated inputs and outputs. SIS Supplier shall state in his
proposal the amount of time and cost required for this function. The Contractor /
Company will assign personnel to witness these tests. These personnel will also
witness any subsequent modifications of hardware and software as a result of the
test until the test is completed to the satisfaction of the Contractor / Company.
C. During the Factory Acceptance Test at the SIS Supplier's facility, simulated I/O
supplied by the SIS Supplier for the test shall be wired to the system and labeled
with tag numbers prior to the test. SIS Supplier shall supply clerical and technical
support, including troubleshooting equipment, and working space such as desk,
telephone and fax.
D. SIS Supplier shall provide every item (including but not limited to, facilities,
personnel, technicians, materials, tools, communications, equipment and power)
required to perform and document the FAT.
E. The FAT acceptance certificate shall be signed off by SIS Supplier, Contractor /
Company personnel at the successful conclusion of testing.
F. Once the system has been accepted, the SIS Supplier shall make records of
configuration and programming data on approved storage media.
9.3 Site Acceptance Test (SAT)
A. The SAT procedure shall be derived from the FAT and shall be developed by the
SIS Supplier in consultation with Contractor / Company. The SAT will be
performed upon completion of SIS Supplier’s installation hardware checks.
B. The purpose of the SAT shall be to ensure the systems have been correctly installed
at site and are functioning as witnessed during the FAT. Secondly, the SAT shall
ensure that the systems are in a state of readiness to begin connection/re-connection
and power up of loops in preparation for functional loop checks.
C. The test shall be for 100% of the hard ware and shall prove the correct operation of
at least one point per I/O module. SAT will be witnessed and signed off by SIS
Supplier and Contractor/Company's personnel.
Revision: 1
10.0 COMMISSIONING AND START-UP
10.1 General
A. The SIS Supplier shall provide support personnel knowledgeable of system

configuration and programming to assist in functional loop checks, functional
Interlock/Logic/Sequence checks, start-up and training. Personnel assigned shall
bring their own tools, programming and test equipment. The SIS Supplier shall state
in their proposal, hourly rates and billable expenses, such as travel, accommodation,
meals, etc., for field support services.
B. The SIS Supplier shall provide a minimum of one portable (laptop computer) per
SIS system with the required software for commissioning, start-up and post start-up
maintenance function for each SIS.
11.0 PACKING AND SHIPPING
11.1 General
A. SIS Supplier shall submit packing specification for approval. The SIS Supplier shall
provide details of any special requirements that are to be considered during
transportation of the equipment.
B. The equipment shall be marked and packed to give adequate protection during
shipment in accordance with the requirements of the Purchaser's order
documentation.
C. The shipment shall include all Commissioning Spares as identified in the Purchase
Requisition documents.
D. Where cards, components, modules, instruments, and ancillary equipment has been
removed and packed separately; these items must be clearly identified as well as
being listed such on the inventory. Any shipping stops / safety clamps / filler
compounds / drying agents included shall also be clearly detailed on associated
documents.
E. All documents associated with shipping and unpacking must be affixed to the
outside of the shipment package (NOT PLACED INSIDE) and a copy issued
separately. All materials used for shipping purposes must take into account the site
storage climate in order that damage cannot occur due to possible overheating or
exposure to Sunlight, etc. Where doubt exists as to the suitability of packing
materials, then the packaging must carry warning labels, eg -- Keep out of Direct
Sunlight -- both in Arabic and English.
Revision: 1
12.0 SPECIAL TOOLS, TESTING AND CALIBRATION
12.1 General
A. The SIS Supplier shall provide all tools, test and calibration equipment necessary for
FAT.
B. The SIS Supplier shall provide a list of all special tools and test equipment
recommended for installation of all hardware supplied by the SIS Supplier and to
generally service and maintain the system equipment to its maximum reliability.
C. SIS Supplier shall identify any OEM (Original Equipment Manufacturer) equipment
for which they do not provide test equipment.
D. The SIS Supplier shall provide all special tools necessary for installation of the SIS.
E. The SIS Supplier shall provide all special test and calibration equipment necessary
for SAT and commissioning of the SIS.

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Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification: MQ-SP-I-7010

Project Name: Date: 14 Jan 2011

SPECIFICATION – SAFETY INSTRUMENTED SYSTEMS

Revision Date Originator's Reviewed/Checked By Pages

APPROVALS SIGNATURES DATE

Lead Engineer Thomas B. Robinson

ISSUED FOR : Construction X Other Approved

SPECIFICATION – SAFETY INSTRUMENTED SYSTEMS

A 8/04/2010 Issued for Approval, Table of Contents Only

0 11/04/2010 Issued for Review/Approval

1 1/14/2011 Issued Approved

SPECIFICATION – SAFETY INSTRUMENTED SYSTEMS

1.0 SCOPE ............................................................................................................................................................... 5

SPECIFICATION – SAFETY INSTRUMENTED SYSTEMS

6.10 Input/Output System .......................................................................................................................19

SPECIFICATION – SAFETY INSTRUMENTED SYSTEMS

E. The equipment furnished according to this specification shall conform to the

2.1 Codes and Standards

B. ISA – International Society of Automation

 ISA 5.1 : Instrumentation Symbols and Identification

 ISA 71.03 : Environmental Conditions for Process Measurement and Control

 ISA 84.00.01 – Part 1 (IEC 61511-1 Mod) : Functional Safety : Safety

 ISA 84.00.01 – Part 2 (IEC 61511-2 Mod) : Functional Safety : Safety

SPECIFICATION – SAFETY INSTRUMENTED SYSTEMS

 ISA 84.00.01 – Part 3 (IEC 61511-3 Mod) : Functional Safety : Safety

 ISA 91.01 : Identification of Emergency Shutdown Systems and Controls

C. IEC-International Electrotechnical Commission

 IEC 60079 : Electrical apparatus for explosive gas atmospheres

 IEC 60529 : Degrees of Protection for Enclosures

 IEC 60801-3 : Electromagnetic Compatibility for Industrial Process Measurement

 IEC 61000 : Electromagnetic compatibility (EMC)

 IEC 61000-4-2 : Electromagnetic compatibility (EMC) - Part 4-2: Testing and

 IEC 61131-3 : Programmable Controllers - Part 3: Programming Languages

 IEC 61508-1 : Functional Safety of Electrical/Electronic/Programmable

D. IEEE – Institute of Electrical and Electronics Engineers

 IEEE 1100 : Powering and Grounding Sensitive Electronic Equipment

SPECIFICATION – SAFETY INSTRUMENTED SYSTEMS

 MIL HDBK 217E : Reliability Prediction of Electronic Equipment

 NEMA : National Electrical Manufacturer’s Association

 FM : Factory Mutual Standard

2.2 Project Specifications and Drawings

B. MARAFIQ Standards and Specifications

Specification No. Title

SPECIFICATION – SAFETY INSTRUMENTED SYSTEMS

3.0 DEFINITIONS AND ABBREVIATIONS

A. Terms used in this document are defined as follows:

SIS SUPPLIER Supplier of SIS equipment purchased by CONTRACTOR.

AIB Approved Independent Backups

CCR Central Control Room

DCS Distributed Control System

EMI Electromagnetic Interference

EWS Engineering Workstation

FAR Field Auxiliary Room

FAT Factory Acceptance Test

FMEA Failure Mode and Effect Analysis

HMI Human Machine Interface

LCD Liquid Crystal Display

MTTFd Mean Time to Failure to a Dangerous Mode

SPECIFICATION – SAFETY INSTRUMENTED SYSTEMS

PEC Programmable Electronic Controller logic solver portion of SIS

PFD Probability of Failure on Demand

PLC Programmable Logic Controller

PSU Power Supply Unit