Control & Safety System Specification

CONTRACT NO.
:
INSTRUMENTATION &
SP3MK-005/
TELECOMMUNICATION PG3400/2022-S7
DOCUMENT NO.:
PAGE 45
SNBP-EPC-00-INS-SPC-003
JASA PERANCANGAN, PENGADAAN, DAN KONSTRUKSI PEMBANGUNAN
PIPA GAS SENIPAH – RU V BALIKPAPAN
CONTROL AND SAFETY SYSTEM SPESIFICATION
B 06/05/2022 Issued For Approved SW ASW EFC

25/04/202
A Issued For Review SW ASW EFC
2
PREP’
CHK’D APV’D CHK’D APV’D
REV. DATE DESCRIPTION D
PT PGAS SOLUTION PT PERTAMINA GAS
JASA PERANCANGAN, PENGADAAN, DAN
KONSTRUKSI PEMBANGUNAN PIPA GAS
SENIPAH – RU V BALIKPAPAN
Document No. Rev. CONTROL & SAFETY SYSTEM Date: 12/04/2022
SNBP-EPC-00-INS=SPC-001 A SPECIFICATION Page 2 of 38
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REVISION NOTES
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TABLE OF CONTENT
TABLE OF CONTENT................................................................................................................................ 3
LIST OF TABLE.......................................................................................................................................... 5
1. INTRODUCTION.................................................................................................................................. 6
1.1. Project Overview......................................................................................................................... 6
1.2. Objective..................................................................................................................................... 6
2. DEFINITION......................................................................................................................................... 7
3. ABBREVIATION................................................................................................................................... 7
4. CODES AND STANDARD................................................................................................................... 8
5. CONDITION OF SERVICE................................................................................................................. 10
5.1. Environmental Condition........................................................................................................... 10
5.2. Standard Condition................................................................................................................... 10
5.3. Electrical Power Supply........................................................................................................... 10
5.4. Hazardous Area Classification.................................................................................................. 11
5.5. Ingress Protection.................................................................................................................... 11
6. DESIGN LIFE AND RELIABILITY.................................................................................................... 11
7. CONTROL & SAFETY REQUIREMENT............................................................................................ 12
7.1. General requirement................................................................................................................. 12
7.2. Design Criteria.......................................................................................................................... 13
7.3. System Integration.................................................................................................................... 14
7.4. VENDOR Responsibility.......................................................................................................... 15
8. PCS/SIS HARDWARE AND SOFTWARE REQUIREMENTS............................................................16
8.1. PCS/SIS Hardware Design Requirements................................................................................16
8.1.1. Input / Output Module.............................................................................................. 18
8.1.2. Controller Modules.................................................................................................... 20
8.1.3. Communication Interface.......................................................................................... 20
8.2. Software Firmware.................................................................................................................... 22
9. HUMAN MACHINE INTERFACE (HMI).............................................................................................. 23
9.1. Pcs / Sis Graphic Requirement................................................................................................. 23
9.2. Alarm Management System...................................................................................................... 24
9.3. System Configuration and Database........................................................................................ 24
9.4. Logging and Reporting.............................................................................................................. 25
9.5. Engineering Work Station & Operating Work Station................................................................25
9.6. Event and Alarm Logging Printer.............................................................................................. 27
10. OTHER REQUIREMENTS................................................................................................................. 27
10.1. System and Marshalling Cabinet Requirements......................................................................27
10.2. Electrical Requirements........................................................................................................... 29

10.2.1. Power Supply........................................................................................................... 29
10.2.2. Cabling..................................................................................................................... 31
10.3. NAME PLATES......................................................................................................................... 31
11. PROJECT MANAGEMENT................................................................................................................ 31
11.1. Project Personnel..................................................................................................................... 31
11.2. Project Schedule....................................................................................................................... 32
11.3. Progress Reporting................................................................................................................... 32
11.4. Coordination Meetings.............................................................................................................. 32
11.5. System engineering.................................................................................................................. 33
11.5.1. Consultating Service................................................................................................. 33
11.5.2. Configuration Services.............................................................................................. 33
12. INSPECTION AND TESTING............................................................................................................ 33
12.1. Test Procedures....................................................................................................................... 33
12.2. Test Equipment......................................................................................................................... 34
12.3. Function Test............................................................................................................................ 34
13. QUALITY CONTROL.......................................................................................................................... 35
14. TRAINING.......................................................................................................................................... 35
14.1. System Engineer Training......................................................................................................... 36
14.2. Maintenance/Support Training.................................................................................................. 36
14.3. Operator Training...................................................................................................................... 36
15. SPARE PARTS & SPECIAL TOOLS.................................................................................................. 36
15.1. Spares...................................................................................................................................... 36
16. PREPARATION OF SHIPMENT........................................................................................................ 37
17. GUARANTEE..................................................................................................................................... 37
18. VENDOR DATA................................................................................................................................. 38
LIST OF TABLE
Tabel 2-1 List of Definitions........................................................................................................................ 7

Tabel 3-1 List of Abbreviatons.................................................................................................................... 7
Tabel 6-1 Environment condition.............................................................................................................. 10
1. INTRODUCTION
1.1. Project Overview

PT Pertamina Gas (Pertagas) plans to deliver gas from Senipah KP 7.2 (tap off from 42”
pipeline) that is operated by Pertamina Hulu Mahakan to PT Pertamina (Persero)
Refinery Unit (RU) V Balikpapan, East Kalimantan, to fulfill the gas demand at Refinery
Unit (RU) V Balikpapan as part of the RDMP program.
The Onshore Pipeline along approximately 77.5 km Senipah – RU V Balikpapan scope
will comprise of development of mini facility in Senipah and RU V Balikpapan area
consist of gas metering, pigging facilities, utilities and an onshore gas pipeline.
Figure 1-1 Pipeline Route from Senipah to Refinery Unit (RU) V Balikpapan
1.2. Objective
This document provides Control & Safety system Specification for the the design
materials, engineering, manufacture, painting, inspection and testing , complete with
internal part, spares, and VENDOR data to carry out the installation of control and
safety system for the detail engineering design Onshore Gas facility Pipeline Senipah –
RU Balikpapan
This specification and its referenced documents listed in the following section
below are to establish a minimum level of acceptable quality & not intended to be all -
inclusive. The requirements set forth do not relieve VENDOR of his responsibility to
perform all services in a safe manner, to meet applicable codes and standards, to
comply with government regulations or to supply a product capable of performing its
intended service.
This specification does not dictate detailed design of the equipment or assembly of
components. It is intended that those responsibilities be retained fully by the
VENDOR so that all equipment and process warranties remain unmitigated.
In the case of conflict between documents, VENDOR shall bring the conflicted
documents to the CONTRACTOR and/or COMPANY for resolution and approval in
writing. Should any conflict occur as a result of applying specifications VENDOR shall
follow the order of precedence stated in document “Rencana Kerja & Syarat”.
2. DEFINITION
Definitions used in this document will not violate other definitions used in other
documents which is:
Tabel 2-1 List of Definitions
Definitions Descriptions
COMPANY PT Pertamina Gas ( Pertagas ) as the owner of the Senipah –
RU V Balikpapan Onshore Pipeline Project
CONTRACTOR PT PGAS Solution, the party that carries out all or part of the
detail engineering, procurement, construction, installation and
commissioning as per contract
VENDOR The party which supply materials, equipment, technical
document/drawing, and service to perform the duties by the
CONTRACTOR.
MANUFACTURER Party which manufactures equipment/materials specified and
ordered by CONTRACTOR (or COMPANY).
DIMET Directorate of Metrology, Ministry of Trade of Indonesian
Republic
3. ABBREVIATION
Tabel 3-2 List of Abbreviatons
Abbreviations Descriptions
CPU Central Processing Unit
CRS Customer Receipt Station
ESD Emergency Shutdown System
FAT Factory Acceptance Test
F&G Fire and Gas
HMI Human Mechine Interface

HVAC Hrating Ventilating & Air Conditioning
IEC International Electronical Commission
IR Infra Red
Abbreviations Descriptions
IS Intrisically Safe
ISA International Society of Automation
ITP Inspection & Test Plan
LEL Lower Explosive Limit
LV Low Voltage
MTBF Mean Time Between Failure
MTTR Mean Time To Repair
N-IS Non – Intrinsically Safe
OWS Operating WorkStation
PCS Process Control System
PLC Programmable Logic Control
SIS Safety Instrumented System
UV Ultra Violet
4. CODES AND STANDARD

The design shall be in accordance with good engineering practices and in compliance
with the latest editions and revisions (unless noted otherwise) of the following
Company's Specifications and Regulations, Codes, Standards, as applicable:
CODE ANNOTATON
Recommended Practice for Classification of Locations for
API RP 500 Electrical Installations at Petroleum Facilities Classified as
Class I, Division I and Division 2
API RP 554 Process Control Systems
API RP 670 Machenery Protection System
IEC 60079 Explosive Atmospheres
IEC 61131 Programmable Controllers
IEC 61508 Electronic Functional Safety Package
IEC 61511 Functional Safety - Safety Instrumented Systems for the
Process Industry Sector
IEC 61000 Electromagnetic compatibility (EMC)
IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)
ISO 80000 Quantities and Units
ISO 9001 Quality Management Systems - Requirements
Quality Management Systems - Guidelines for the
ISO 9002
Application of ISO 9001
NFPA 70 National Electrical Code (NEC)
NFPA 72 National Fire Alarm and Signaling Code
NFPA 75 Standard for the Protection of Information Technology
Equipment
Indonesia Codes & Regulations

Peraturan Pemerintah Pengaturan dan Pengawasan Keselamatan Kerja di
Nomor 19 Tahun 1973 Bidang
Pertambangan
Peraturan Pemerintah Keselamatan Kerja pada Pemurnian dan Pengolahan
Nomor 11 Tahun 1979 Minyak dan Gas Bumi
KepMen Pertambang-an Penggunaan Spektrum Frekuensi Radio dan Orbit Satelit
& Energi No. 300K / 38 /
M/PE / 1997
UU. No. 22 2001 Undang – Undang Republik Indonesia tentang Minyak dan
Gas Bumi
PP. No. 35 2004 Peraturan Pemerintah Republik Indonesia tentang
Kegiatan
Usaha Hulu Minyak dan Gas Bumi
KepMen LH No.129/2003 Keputusan Menteri Negara Lingkungan Hidup tentang
Baku
Mutu Emisi Usaha dan atau Kegiatan Minyak dan Gas
Bumi
SK Dirgen. MIGAS No. Keputusan Ditjen Migas tentang Pedoman dan Tata Cara
84/K/38/DJM/1998 Pemeriksaan Keselamatan Kerja atas Instalasi, Peralatan,
dan Teknik yang Dipergunakan dalam Usaha
Pertambangan Minyak dan Gas Bumi dan Pengusahaan
Sumber Daya Panas Bumi
5. CONDITION OF SERVICE
All equipment shall be designed for installation and operation onshore and be suitable
for the climatic and site conditions described in this specification and equipment
datasheets.
The design and installation materials shall be in all respects for continuous operation in
high humidity, tropical environment
5.1. Environmental Condition

The environmental data is currently assumed and shown on the
following table. The environmental data will be updated once the data is available.
Tabel 5-3 Environment condition
Parameter Unit Data

Ambient Temperature °C 17 – 35
Wind Velocity (Normal) m/s 1.7 – 9.18
Wind Velocity (Min/Max) m/s 0 / 20
Relative Humidity (Min/Max) % 50 / 100
Ground Conductivity W/m.K 0.78 (Onshore)
5.2. Standard Condition

The Standard condition for the calculation shall be ;
Parameter Unit Data

Temperature °C 15.6
Pressure psia 14.7
5.3. Electrical Power Supply
The power for Senipah shall be supplied from PLN powergrid. The following power
supply will be delivered:
 400/230 VAC, 3-phase, 4-wire, 50 Hz for motor & LV distribution
 220 VAC, 1-phase, 2-wire, 50 Hz via UPS feeder
Meanwhile, the power for RU V Balikpapan shall be taken from RU V power

distribution. The following power supply will be delivered:
 400/230 VAC, 3-phase, 4-wire, 50 Hz for motor & LV distribution
 220 VAC, 1-phase, 2-wire, 50 Hz via UPS feeder
Conversion to other voltage levels (e.g. 24 VDC) as deemed necessary shall be

carried out by the Vendor inside the system cabinets/unit control panels. Field
instrument power supplies shall generally be 24 VDC, derived from the supply
within the system cabinet. All necessary power converters to provide other
voltage as required for the complete system operation shall be the responsibility
of the VENDOR.
Both CRS facility are also provided with Emergency Diesel Generator (EDG) for
power backup.
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6.1
5.4. Hazardous Area Classification

The hazardous area classification of the equipment shall be specified in the datasheet.
All equipments shall be suitable for installation in electrical area classification in which
they are installed. However, as a minimum rating, the electrical & instrumentation
items shall be suitable for Class 1, Div. 2, Gas Group IIA, Temperature Class T3. If the
instrument device located at Class 1, Div. 1 area due to the minimal distance
requirement, the electronic instrument device shall be follow stringent

specification/requirement.
Explosion Proof (Ex d) protection method shall be provided for instrument installation in
Class 1, Div. 2 area. Intrinsically safe (IS) protection can be considered if Ex d for
certain instruments, such as analyzer, is not available.
5.5. Ingress Protection

Instrumentation & control equipment mounted in open areas shall be protected against
ingress of solids and liquid as follows :
 For indoor area : minimum IP 42 as defined in IEC 60529

 For outdoor area : minimum IP 65 as defined in IEC 60529
Electronic components of instrumentation shall be tropicalized. Appropriate measures

shall be taken in housings and enclosures to deal with condensation arising from daily
temperature fluctuations.
6. DESIGN LIFE AND RELIABILITY

The design life of the facility and all associated equipment, components and
systems is minimum 20 years. The design life shall be achievable with minimum
onsite maintenance and a maximum availability.
All components which for practical, safety or cost-efficiency reasons are

unable to meet the required design life shall be identified as soon as possible.
Their expected service life shall be informed to CONTRACTOR and
COMPANY and provision made in the system design for maintenance to
extend component life or routine change-out.
7. CONTROL & SAFETY REQUIREMENT
7.1. General requirement

Control and safety system for Customer Receipt Station (CRS) facility at Senipah and
RU V Balikpapan shall be provided as integrated system comprises Process Control
System (PCS), Safety Instrumented System (SIS) and 3rd party control and monitoring
systems supplied by package VENDORs, i.e. Sales Gas Metering Package and
Instrument Air Compressor Package. The SIS shall be comprised of ESD and F&G
system, with function as safeguarding facility and fire & gas detection system. The SIS
shall be SIL 2 compliance for RU V Balikpapan CRS and Senipah CRS, as minimum.
The segregation between ESD and F&G system is in chasis level and I/O module. The
segregation between ESD and F&G system shall be in chassis and I/O module level.
Each system shall be designed to operate independently, however all systems in CRS
facility shall be integrated by means of control network. Communication between facility
PCS/SIS and 3rd party system shall be provided by Ethernet TCP/IP and hardwire
interconnection respectively. Other protocol shall be approved by COMPANY.
The metering data and all data status from Process Control System (PCS) and
Safety Instrumented System (SIS) at Senipah and RU-V shall be able to be monitored
from SCADA system in Pertagas Balikpapan office. Data communication from both
CRS facility shall be via communication link (VSAT, Microwave, fibre optic or GSM
provider).
CRS facility shall be designed as normally manned facility. PCS/SIS shall be provided
with 2 (two) Human Machine Interface (HMI) to be installed in Metering Operator Room
as operator interface station. Both HMI shall be configured as common operator
interface for PCS and SIS. The Metering Operator Room shall be provided both in
Senipah and RU V.
The PCS shall be engineered to perform the following functions:

 Control and monitoring of process units
 Supervision of mechanical package equipments
 Operator interfaces of Senipah & RU V facility
 Alarms processing and managing
 Events, production data dan report managing
 Production data trending
Meanwhile the SIS shall be engineered to perform the following functions:
 Safeguarding of process and utility facilities
 Fire & Gas monitoring
 Sequence of events and trip
7.2. Design Criteria

The PCS/SIS shall be provided with high degree of tolerance to malfunctions of
hardware, software and operator mistake in keying. Any fault developed shall have its
effect localized to that part of the PCS/SIS, rendering operational of the rest of the
parts with a possible reduction in level of functionality.
SIS are essential systems of the facility operability and safety, therefore these systems
shall be provided as fail safe systems with high reliability.
The PLC-based PCS/SIS shall accomodate discrete I/O and a wide range of analog
I/O from field devices located throughout the facility. The system shall be provide with
dedicated power supplies and system/marshaling cabinet.
The system shall be designed to incorporate the present requirements and the
possibility of future expansion. The PCS/SIS PLC shall be modular to enable an easily
expandable architecture and should not require a major change out or replacement of
the existing equipment for this expansion.
The system shall be capable of storing instruction to implement control functions such
as PID analog control, sequencing, timing counting, arithmetics, data manipulation and
communication to control plant equipment and process. Selected system shall be
utilize a proven technology. System security, reliability, and availability shall have been
proven in operation.
The PCS/SIS VENDOR shall provide a system that is both hardware and software
expandable and upgradeable in order to allow future connection of the process plant
I/O to the system network.
The PCS/SIS system shall provide a high degree of availability and low MTTR with
adequate diagnostic features and shall have full autonomy in control and monitoring of
the facility. PCS/SIS shall be provided as redundant system. The redundancy shall
include controller power supply modules, communication interface, and control
network.
The PCS/SIS shall be engineered to meet the Availability (A) as follows:

 PCS : 99. 5% or better
 SIS : 99.9% or better
VENDOR shall provide calculation of Availability (A) and Mean Time Between Failure
(MTBF) for each system (PCS, ESD, F&G, Servers, Work Stations and Control
Network) based on Mean Time To Repair (MTTR) of 4 (four) hours. The calculation shall
be submitted subject to COMPANY and CONTRACTOR approval.
Any system components which has MTBF of less than 10,000 hours shall be identified
by VENDOR in their proposal.
PCS/SIS hardware shall be capable of hot swappable change-out to facilitate on line

maintenance without disruption to any other system component or application.
Redundancy/reliability requirements for control system integrity shall be the goal of the
control system design. Equipment and software design criteria shall be such that no
single failure can cause deficient operation. Reliability shall be provided through the
use of quality components throughout the system. All system components shall be
new components unless directed otherwise by the Owner. The selection of redundancy
for the shutdown system shall be determined by analysis of the involved process and
equipment (per ISA 84.01 and IEC 61511).
VENDOR shall provide PCS/SIS with standard and field-proven design which can
meet the requested functions and performance. All components, both hardware and
software shall be of field proven respectively. The VENDOR shall supply the latest
release of all hardware and software applicable at the time of bid presentation, no
obsolete or superseded releases of hardware or software shall be offered.
The VENDOR shall have responsibility for applying a professional engineering

methodology to the design, fabrication, testing, documentation and preparation for

shipment of the PCS. Configuration shall be conducted as a joint exercise between the
VENDOR and the PURCHASER. The VENDOR shall supply engineering
documentation, which shall include appropriate PCS input to the PURCHASER’s loop
diagrams.
7.3. System Integration

PCS and SIS shall be integrated by means of redundant Control Network, in form of
Ethernet TCP/IP or VENDOR proprietary protocol. Hence each system shall be
provided as independent functional system which is linked and integrated by the
redundant Control Network. The redundant Control Network shall be provided as
dedicated network which is capable to perform all data exchanges among PCS, SIS
and GPS Clock as well as enable common operator interface for all systems through
Operator Work Station (OWS)/Human Machine Interface (HMI). It is not allowed to have
common network for process control and office/administration purpose.
The interface will use industrial and robust standard communication protocol. In case of
failure of both links and/or the PCS, the SIS must not be affected and shall run
idependently.
Communication to 3rd party systems shall be performed as communication

interface (non- redundant) utilizing Ethernet and Modbus TCP/IP protocol. Other
protocol shall be approved by COMPANY. VENDOR shall be responsible for the
integration among systems and 3rd party systems. VENDOR shall request, during
bidding stage, any additional information which is required concerning interfaces with 3rd
party control systems, in order to ensure complete and successful integration of with the
control & safety system.
7.4. VENDOR Responsibility

The VENDOR shall supply a standard field-proven fully integrated PCS and SIS that
exceed the requested functions or performance are acceptable provided the system is
made up of field-proven hardware and software modules. The VENDOR shall clearly
identify any design which is non standard or does not have a proven field history; details
of installed systems, including length of time in service shall be supplied by the
VENDOR for the PURCHASER’s review. The VENDOR shall supply the latest
release of all hardware and software applicable at the time of bid presentation, no
obsolete or superseded releases of hardware or software shall be offered.
The VENDOR shall have responsibility for applying a professional engineering

methodology to the design, fabrication, testing, documentation and preparation for
shipment of the PCS & SIS. Configuration shall be conducted as a joint exercise
between the VENDOR and the PURCHASER. The VENDOR shall supply engineering
documentation, which shall include appropriate PCS & SIS input to the PURCHASER’s
loop diagrams. The VENDOR shall also be responsible for the integration of all
peripheral equipment interfaced with the PCS & SIS as listed in this specification.
The VENDOR shall ensure that maximum use is made of Standardised Fixed/Limited
Variability Programme System software. The use of Full Variability Systems software
should be minimised and restricted to those cases where it is necessary to develop
bespoke software for a particular application. Where used, an established method
for controlling and validating software development and subsequent modification
shall be available.
The VENDOR shall be responsible for configuration of gateways, switches, nodes,

routers and other applicable network hardware and software configuration to establish
the redundant PCS & SIS communications bus.
The VENDOR shall prepare detailed procedures for the installation of equipment and
software at site where applicable. These procedures shall include estimates of the
time and resources required for executing each operation and conforming to the
PURCHASERs work-pack format.
The VENDOR shall request, at the tender stage, any additional information he requires
concerning interfaces to foreign systems (metering system), in order to ensure
complete and successful integration with the PCS & SIS.
The PURCHASER’s approval of the manufacturer and model number of equipment and
approval of the VENDOR’s drawings/documents does not in any way affect the
VENDOR’s full responsibility to supply strictly in accordance with project specifications,
codes and standards.
This specification shall not relieve the VENDOR of any responsibility to provide
equipment and services that are suitable for the intended duty.
8. PCS/SIS HARDWARE AND SOFTWARE REQUIREMENTS
8.1. PCS/SIS Hardware Design Requirements

For the purpose of the bid proposal the VENDOR shall base the hardware design on the
Instrument I/O List in the referenced document SNBP2-00-INS-LST-002.
The PCS & SIS shall be provided as a microprocessor-based PLC comprising

redundant control processors, redundant power supply, redundant control network (for
communication with ESD and F&G), redundant communication interfaces with 3rd party
control system, all hardware, all software, all pheriperal and accessories as required to
perform safe and reliable control and monitoring of the facility. No redundant I/O
configuration for PCS & SIS are required.
In general, the PCS & SIS shall be installed in the CRS Control Room located in
Senipah and RU- V Balikpapan facility. PLC hardware shall be suitable for indoor
operation and powered from UPS backup power feeder to ensure no interruption during
power failure.
The design of system must be such to maximize reliability of PCS & SIS. Failure of one
processor shall result in take over of the control by other processor without process
upset or loss of control/data archiving functions. Transfer to the standby shall be
automatic, shall be alarmed and should have no effect on the operation of the control
system. The system shall also have automatic cross-checking, integral self-test and
failure indication. The self-test shall include input circuit, output circuit, processor and
any voting circuit.
The “health” of the processor shall be continuously monitored by a configurable

watchdog timer. Any hardware or software problem in the processor subsystem,
including CPU, memory, power supply, communication interface, etc. shall be
reported as failures. The health of application program and communication interface
shall be available for monitoring in HMI.
The processor shall have the capability to implement all the control functions and PID
controller blocks required to implement the logic schemes. The size of the memory
shall be sufficient for storage of the program instructions required by the logic schemes.
In addition spare memory space is also required.
The processor shall continuously scan the programs and all inputs and execute
commands to appropriate outputs. Input scan, program execution and output state
transition time shall be as low as possible and not greater than 200 ms. It will be
assumed that the execution rate for 80% of the control functions will be set at once per
second while the execution rate for 20% of the control functions will be set at four times
per second. It will also be assumed that the execution rate for all calculations,
sequences and logic functions will be set at once per second. VENDOR shall confirm the
scan time.
The control logic shall have the capability of implementing Ladder Logic or Function
Block Diagram and shall include the use of register, arithmetic functions, block functions,
latched and momentary contacts, counters and timing functions. The VENDOR shall
state any system limitation for these functions. The programming software shall be
compliant to IEC 61131. It shall be possible to create user defined function blocks.
The system shall be modular in construction and expandable in future by adding

additional modules. Modules shall be easily accessible for maintenance and repair. The
different types/ models of modules shall be rationalized in order to promote
interchangeability and common spares inventory. All unused card locations shall be
fitted with cover plates.
Online replacement of any redundant module shall be possible in such a way that the
removal and addition of the module shall be possible without de-energizing the system
and without interruption of process control. Further, there shall not be any interruption in
the system while replacing a faulty module except for the inputs/outputs which interface
to that module.
Suitable battery back-up shall be provided to protect volatile program memory. Auxiliary
batteries shall maintain memory for at least 24 months on loss of power supply. The
type of memory provided shall be clearly identified in the Bill of Material along with the
offer. The life of the battery i.e. in powered off condition shall be minimum 5 years. Hot
replacement of battery shall be possible without interruption of PLC operation or loss of
process control.
It shall be possible to synchronize the PLC and EWS & OWS clock to package control
system. The time synchronization is done from a digital output PCS given at a preset
time. Hardwired time sync signal shall be provided once in 24 hours at preset time from
PCS to package control system.
The PLC system shall also have protection of the electronic components from static
electricity and electromagnetic radiation; when exposed to field strength of 15
V/meter or less over a frequency range of 27 MHz up to 2.6 GHz. All hardware
components of the PLC shall be immune to High Frequency Communication tools
such as handheld radios. EMC emission of PLC equipment shall meet IEEE 518
requirements.
The VENDOR shall provide protection for the PCS & SIS equipment against surges
and transient over-voltage/currents that may be induced via the power supply,
communications and signal cabling systems. Protection shall be provided in accordance
with IEC 801.5 “Surge Immunity Requirements”.
The PURCHASER shall be responsible for the joint development of the serial interfaces
with the VENDOR, and external package equipment suppliers. This will include, but
not limited to, the design of the physical interface, specification of protocols,
definition of data to be transferred, redundancy philosophy, and testing and
documentation.
Where a serial link or ethernet communication facilities is required between the PCS and
a third party, this shall be a fully tested and proven installation design prior to
incorporation into facility detailed design.
The interface will use industrial and robust standard communication protocol. In case of
failure of both links, the SIS must not be affected and can run fully independently
8.1.1. Input / Output Module

The PLC shall accept all the process signals listed below without additional devices
converting them to milliamp or voltage signals.
 Due to the varying requirements, a wide variety of I/O modules for common
PLC are shown below :
 Analog Input Module : Reads in analog voltages, converts them into digital
values and sends the information to the control unit.
 Analog Output Module : Takes in digital values and produces an appropriate
analog voltage level.

 ASCII Input Module : These modules take in character information usually via
serial links (RS-485) and convert it into a form the PLC controllers can
understand.
 ASCII Output Module : Takes PLC information converts it to an character
representation and sends it out via RS-485.
 BCD Input Module : This module reads in inputs from devices that output
binary-coded decimal (a method of representation where each decimal digit is
represented by four bits). An example of such device is a thumb wheel.
 BCD Output Module : Essentially does the reverse of the input module,
usually used for compatibility when devices expect data in BCD format.
 Discrete Input Module : This is isolated digital input.
 Discrete Output Module : This is isolated digital output module.
 Encoder Counter Module : Keeps track of angular positioning of shafts.
 Grey Encoder Module : Receives grey-code signals from a device that produces
grey-code.
 High-Speed Counter-Encoder Module : This type of module allows counting and
encoding at a much faster rate than is normally possible inside a PLC program.
 PID Module : These modules enable the user to perform closed loop automatic
control based on proportional integral and derivative values. If properly tuned the
module can hold a process at the desired set point.
 Thermocouple Modules : These modules allow the PLC to read temperatures of
a process and will output usually with Celsius or Fahrenheit.
 TTL Input Module : Allows reading inputs from TTL devices such as most
integrated circuits.CCTV Camera
The I/O modules shall be capable of removal and replacement under power, without
affecting the other I/O modules or interrupting the facility operation (hot swappable).
PLC shall be able to accommodate various types of input and output shown below:
Inputs
Analog Input : 4 to 20 mA DC (sinking and sourcing)
Digital Input : Contact (Volt free)
Digital Input : 1 to 5 VDC Input
Digital Input : 24 VDC Input
HART Module Input : 2-wire digital signals
Outputs
Digital Output : Contact (Volt-free)
Digital Output : 24 VDC ±5% Output
Analog Output : 4 to 20 mA DC (system powered or external powered)
Note : Appropriate interposing relays shall be provided in PLC system by VENDOR if

interfacing with MCC or package system is necessary.
The following spares shall be built into the PLC system unless specified otherwise:
 The system shall be delivered with 30% installed and pre-wired spares, to
include terminals, barriers, gland plates, trunking, cables, power supplies, I/O
cards. This 30% spare are non- engineered I/Os and pre-wired for future use.
 Spare I/Os shall be fully wired from marshalling panel level till the last system
component (I/O channels).
 In addition, 10% additional terminal (unwired) and 20% panel space shall be
provided to allow a further 30% future expansion without the requirement to
install additional cabinets. All elements of each PLC system (controller,
processor, memory, power supplies, network equipment, etc.) shall be sized to
accommodate all installed, spare, and future expansion I/O, including meeting
the maximum allowable loading and performance requirements.
8.1.2. Controller Modules

Each processor module shall have microprocessor based components capable of
performing data acquisition, regulatory controls, and sequential controls in the
CRS Control Room. Minimum hardware, peripheral and functional requirements and
capabilities shall be as described below :
 The process module shall utilize a standardized modular rack construction in
which various electronic cards (modules) are inserted into the rack card file.
Module addresses shall be switch or software selectable; i.e., any card in any
slot. No external back plane methods may be used.
 All processor modules shall be designed and supplied as redundant.
Processor fail-over shall be without loss of data or control function.
 Each module shall have an onboard diagnostics, with onboard LED
indicators, defining status.
 Each processor module shall have flash memory for memory retention
feature to keep configuration for minimum of 365 days with no power
supplied.
 The control module processor shall have the capability of being configured and
tuned from either fixed or transportable console.
 System loading refers to the use of memory, CPU time, and communication
capacity. The loading shall consider the worst-case of high system
activity. During this case, no degradation of system performance is allowed.
 Controllers shall be provided with sufficient memory and processing capability
for the initial I/O plus 40% additional for future expansion. With the fully
developed application software loaded and also with a spare capacity for 40%
future I/O expansion, Controller loading shall not exceed 60%.
8.1.3. Communication Interface

Communications interface modules shall be capable of communicating with
Ethernet and RS - 485 redundant interfaces. The PCS shall be capable of driving the
interface link with modules that are built into the processor or that plug directly into the
processor module card files. Serial interfaces shall have a redundant hardware
configuration. The PLC shall be capable of interfacing with the following :
 Other PLC systems : ControlNet or Modbus link
 PC-based operator interface : Ethernet
 PC-based program I monitoring terminals : Ethernet
For detailed requirement of interface communication between PCS & SIS to other
system, refer to “Control & Safety System Architectural Diagram”, drawing no. SNBP2-
00-INS-DRW-002.
Data Communication Network Interfaces
Data communications network interface devices shall be available with the capability of
interfacing various devices with the Data Communications Networks. Process related
and control functions shall utilize ControlNet network communications or equal. HMI
operator workstations shall utilize Ethernet. Examples of such interfaces are:
 Remote I/O via redundant ControlNet, Ethernet or fibre optic media
 Communication with other PLCs via redundant ControlNet, Modbus, or Ethernet
 Data communications via redundant Ethernet network to HMI operator
workstations and Communication router
 Engineering workstation computer for programming or maintenance on
serial link or ControlNet/Ethernet network interfaces
 Poll other control systems in a standard protocol for connection to data network
 Ethernet extended to communications network
Communication Bus
Communication buses shall have redundant cables, routed in separate paths to avoid a
single incident causing simultaneous failure of both buses. Separation of paths shall
extend all the way to the bus interface and control devices on the I/O racks,
operator/engineering interfaces, and any other type of unit connected to the
communication buses.
VENDOR shall provide dual internal communication buses for the Human Machine
Interface (HMI), controllers and I/O buses and historian. Redundant cables of each
communication bus shall alternate at regular intervals, as recommended by the
VENDOR.
The PCS shall be capable of interfacing with other commercially available process
computers, personal computers and microprocessor based process control equipment
with serial communication interfaces using OLE for Process Control (OPC), TCP/IP or
Modbus.
Data Communications Networks
The ControlNet and Ethernet data communications networks shall be dual redundant
capable of data transmission over a distance of a minimum of 500 metres. The
redundant highway shall be continually checked for availability and any fault shall be
alarmed. The system shall switch to the redundant highway on failure, without
interruption of service or loss of signals.
The system redundancy shall extend to the processor module bus interface level. The
following features shall be provided, as a minimum :
 Two (2) data communications networks shall both be active at all times but can
be operated as a single highway for an indefinite period with no system
degradation
 Communications diagnostics are to be continuous such that a failure is
alarmed in the minimum amount of time
 Each network shall accommodate up to a minimum of 32 active devices
(addressed nodes)
 Each node shall have message checking capability. Detection and alarm of
node failure shall be in a minimum amount of time.
 There shall be no single point of failure
 Data communications network shall be redundant with automatic node (drop)
bypass
 Any measured or calculated variable in one part of the system shall be available
to any other node in the system without hardware
 All communication error shall be alarmed, logged on a printer and stored in a
history file
The data protocol used shall safeguard against false data transfers. Under operational
conditions, any single event occurring at the processor module level shall be displayed
at an attached operator console with 1 second after occurrence. Similarly, any
command given at any HMI keyboard shall complete its action within 1 second.
VENDOR shall demonstrate this capability during FAT test.
Data transfers shall be made by either change in status or by exception; i.e., contact
change or analogue value change, etc., and by operator console request.
8.2. Software Firmware

Software for programming shall be supplied by VENDOR. PLC shall be supported with
various programming languages. Preferred programming languages for PLC
programming are Ladder Logic Diagram, Function Block Logic Diagram, Sequential
Function Logic Chart, Instruction Lists and Structured Text.
Standard operating system software, with full documentation, shall be provided by

VENDOR. VENDOR shall provide configuration software to meet PURCHASER /
COMPANY's specific requirements. The following control and calculation algorithms
shall be provided, as a minimum:
 Timer and counter function
 Comparison logic & arithmetic function
 PID instruction/control modes & change control parameter

 Self-diagnostic
 File management
The operating system software shall permit expansion of input and output data without
requiring program revision, reorganization, regeneration or reassembly up to the limits
defined at the time of system generation.
The software shall be designed to respond to all interrupts (either external or internal).
All interrupts shall store registers and program counters of the working program, process
the interrupt, and restore the working program. Sufficient hardware interrupts shall
be furnished to service all input/output equipment. The priority structure shall be
adequate to handle all interrupts within a time period that does not degrade the system
in worst case conditions.
The operating system software shall be upgradeable. VENDOR shall supply software
for programming, antivirus, and HMI graphic display complete with licenses.
9. HUMAN MACHINE INTERFACE (HMI)

The PCS & SIS shall be provided with Human Machine Interface (HMI) with the purpose
of Operator Work Station (OWS) and Engineering Work Station (EWS) for each PCS
& SIS, event & alarm printer and report printer.
The HMI shall be designed to permit operator to control and monitor the facility during
normal, process upset, start-up and shutdown operation, as well as to handle data and
generate report.
An Operator Work Stations (OWS) of desktop style shall be provided in CRS Metering
Operator Room as common operator interface/HMI for all systems, i.e. PCS, SIS and
3rd party sub-systems. Another dekstop style PC function as Engineering Work Station
(EWS), shall also be provided to be used for PCS and SIS system configuration,
program development and system maintenance (include diagnostic & monitoring). The
EWS shall be capable to support both online and offline programming.
VENDOR shall indicate requirement for other servers during the bid, include but not
limited to, historian, sequence of event and alarm recorder, application and SCADA/OPC
host. VENDOR shall also indicate storage capability of the Historian server part of the
offered system during the bid.
9.1. Pcs / Sis Graphic Requirement

The OWS & EWS shall be provided with graphic display which is organised in a logical,
hierarchical manner. Links to graphic pages shall be furnished to enable ease and
simple ‘user friendly’ operation.
Graphic display in OWS & EWS shall be provided in the following levels:
 Overview page
 Area or Unit view

 Equipment view
 Details of the process and parameters, include set points
 Supervisory data from package equipments (3rd party system)
OWS & EWS shall be also provided with graphic displays for the following purposes:
 Trending page
 Alarms and events list page
 System status
The trend display shall present the data in the format of a strip chat on the screen. The
trend display shall consist of two types:
 Real time trend
 Historical trend
All trend data shall be stored on non-volatile memory (hard disk) of the system so that
the trend data can be archived and subsequently recalled.
9.2. Alarm Management System

The following types of alarms shall be provided in the system for both control
and data acquisition points:
 Absolute and deviation from set point
 Rate of change alarm (high and low)
 System diagnostic alarms
 Transducer limit alarm
 Thermocouple open circuit
 System utility alarms
 Communication failure alarm with wellhead panels and packaged panels
9.3. System Configuration and Database

The system configuration and data base generations are the responsibility of
VENDOR.
Display graphics shall conform to ISA 5.3 and ISA 5.5, unless otherwise directed by the
PURCHASER. Display graphics will be configured based on P&ID's that follow ISA 5.1
symbol or similar.
The following shall be provided by CONTRACTOR towards the PCS configuration:

 Selection of control strategies
 Selection of control algorithms
 Providing custom graphic sketches and color scheme
 Instrument data including tag numbers, range, engineering units, and service
description
 Requirements of logs and reports
 Grouping of points in various displays like group, trend, overview, etc.
System modification/re-configuration for, control/monitoring loops and/or graphic

display shall be enabled to be performed online without affect in the operation and
performance of the PCS.
PCS & SIS shall be designed to accept at least 25 alphanumeric characters for loop
name tags and 26 bit minimum RAW data.
All system configuration files (loops and displays) shall be stored on high integrity hard
drives within the system and can be backed up using removable mass storage devices
like DVD’s or flashdisks. The harddrive minimum capacity shall be 500 GB.
VENDOR shall clearly indicate at what time which data are required and confirm the
data provided by CONTRACTOR.
VENDOR shall also request CONTRACTOR for the data required from package
equipment suppliers for configuring the serial interface to PLC.
9.4. Logging and Reporting

A report generator shall be supplied to build and change report. Reporting function shall
be initiated by a control program, by operator demand or on schedule. All points in the
system shall be capable of being logged.
The reports shall comprise VENDOR'S standard logs and reports formatted by the
engineer. The standard logs shall mainly consist of alarm summary and event summary
report to be printed out at the end of each shift. The event summary report shall consist
of the operator actions like auto/manual change over, manual overrides, resets, etc.
A daily report shall be provided to log the important process parameters. The report
shall be printed at 12 hourly intervals. Format of the daily report will be provided by
COMPANY.
Apart from the reports and logs mentioned above approximately, five free additional
formatted reports are envisaged to be configured in the system. The free formatted
report software shall allow the engineer to decide the layout and content of the report,
which may involve mathematical calculations like summing, efficiency calculations, etc.
Alarm and return to normal shall be printed as they occur. Alarm messages shall contain
time, tag number, service description, process data and the type of alarm. Operator
action i.e. set point change, auto manual changeover etc., shall be logged as they occur.
Alarms associated with PCS equipment shall be logged as they occur.
All alarms and operator action printed in the log report shall have date and time printed
alongside the action.
9.5. Engineering Work Station & Operating Work Station

The exact hardware specifications for the engineering workstation and clients shall be
determined by the PURCHASER during detailed design. This will minimise the risk
of obsolescence in the rapidly changing computer hardware technology field.
An Operator Work Stations (OWS) and Engineering Work Station (EWS) shall be
provided as common HMI for PCS & SIS. OWS & EWS shall be provided as desktop
work station of industrial grade PC embedded with the latest revision of the VENDOR
proprietary software that support Ethernet TCP/IP protocol and the latest revision of
the Microsoft Windows operating system software.
At the time of writing, the minimum hardware specification of the EWS & OWS shall be
as follows:
 Processor : Intel core i7, 3.2 GHz or fastest available at time of purchase
 RAM : 8 GB or better
 Hard Drive : 1 TB HDD or more
 Optical Drive : DVD combo or DVD – RW
 Wired Network Card : Gigabit Ethernet card 10/100/100 MBPS
 Keyboard, mouse or operational keyboard
 22” LED wide screen monitor
 USB flash drive support, serial port, parallel part, surge arrester
 Latest antivirus
 Licensed Microsoft Windows OS (latest version)
 All software and operating system version shall be of the latest version available
at the time of purchase that are required for system programming,
diagnostic, and maintenance complete with lifetime license
Display Monitor
OWS & EWS shall be provided with 22” LED wide screen monitors with a minimum
resolution of 1680 x 1050 pixel matrix of 32 bit true colour.
Keyboards & Pointing Devices or Operational Keyboard

OWS & EWS shall be provided with keyboard and mouse or operational
keyboard. These peripherals shall be industrially hardened and be impervious to
ingress of dust, smoke and liquids. Accidental depression or failure of a single key on
any keyboard or trackball shall not cause a control action to occur. Control actions
shall require a minimum of a two key sequence.
Data Storage
The VENDOR shall provide a proposal for the number and capacity of the hard disk
units required to facilitate efficient and secure data historian, alarm/event logging and
archiving capabilities. The proposal shall satisfy the following :
 Utilize optical disk or other high resolution storable media
 Minimum capacity of 1 TB
 Disks shall be redundant synchronised mirror disks
 Archiving to be an automatic scheduled background activity

 Function to monitor disk drive space and performance and alarm when drive
space < 5% total capacity
 Support for off-line data retrieval (i.e. via a PC)
The PCS & SIS programs and database shall be key and/or password (from HMI
workstation) protected to prevent accidental or unauthorized program or data changes.
The access rights shall be in the following three (3) levels with sublevels :
 Operator
 Supervisor
 Engineer
A database back-up and historian data upload medium shall be provided. The file
and the associated memory allocation shall be based on the back-up and upload not
being more frequent than once per 94 (31 x 3 + 1) days.
9.6. Event and Alarm Logging Printer

Event and alarm printer shall be provided for SOE data logging. The printer shall be of
dot matrix printer. The PCS/SIS must be able to support both local and LAN based
printing for alarms, reports, screen prints, and engineering functions.
Each Operator and Engineering workstation shall have access to and dot matrix printer
for logging alarms, system events, and other information. Event and alarm logging shall
be initiated by either automatic program or operator request. The standard logs shall
mainly consist of alarm and event summary to be printed out periodically. Template and
format of print out logs shall be verified during detail engineering.
The VENDOR shall provide dot matrix printer and its software as required.
10. OTHER REQUIREMENTS
10.1. System and Marshalling Cabinet Requirements

PCS & SIS shall be provided with combined system and marshalling cabinets. The
cabinets shall be installed in CRS Control Room which is climate controlled and
considered as non-hazardous area.
Power to system and marshalling cabinets shall be provided from UPS (by
CONTRACTOR), rated of 230 VAC, 1-phase, 50 hz. VENDOR shall provide power
distribution internal cabinet.
System and marshalling cabinet shall be freestanding and made from Rittal or equal.
The cabinet shall be IP 41 (as minimal) and provided with swing rack configuration.
The finish of cabinets shall be smooth and cabinet colour shall be RAL 7035. One liter
of finish paint will be shipped with the system for field touch-up for each color used.
Lifting lug shall be provided at the top of the cabinet.
System and marshalling cabinets shall be designed to accommodate 20% installed

spare of I/O, 20% uninstalled spare (of rack with uninstalled module) as well as 20%
spare space. Power supply shall accommodate power consumption of these 20%
installed spares. All unused card locations shall be fited with cover plates.
All terminals carrying more than 24 VDC shall be protected againts accidental contact
by means of removable cover and shall be labelled accordingly. Signals of different
voltage levels shall be run in separate trunking and shall be segregated on the terminal
boards.
Access to the cabinet may be front and rear access or double door with front access
only, using double leaf hinged lift off doors. Door openings shall not be obstructed by
center posts. Doors shall be easily removable. All doors shall be provided with the
same lock and key combination. A document pocket shall be provided in each
enclosures door for storage of documentation. Seals shall be fitted for dust exclusion.
Cabinet layout shall be provided in such a manner to enable maintenance access.

Cable entry shall be from the bottom side. All cable entering the cabinet shall be
properly clamped with armour grounding. Cable support system shall be located at the
bottom of each cabinet.
All cabinets shall be provided with ventilation fan (noise < 55 dba) and louvers backed
by dust filter, to maintain temperature and humidity inside the cabinet. The fan shall be
furnished with fault status alarm and high temperature alarm.
All cabinets shall be provided with internal illumination activated by door switch.
All cabinets shall be provided with dedicated protection against radio frequency
interference (RFI) with door open in accordance to IEC 61000-4.
All cabinets shall be provided with protection against system errors and hardware
damage resulting from electrical transients on power or signal wiring. These transients
include those generated by switching large electrical loads, power line faults,
lightning strikes, power surges and radio frequency interference (RFI).
Contact of dissimilar metals shall be avoided wherever possible. Where contact

unavoidably occurs, the VENDOR shall state what precaution against action are
proposed.
Internal wiring within the cabinets shall be as per VENDOR’s standard. However signal
segregation shall be provided in accordance to the following:
 I/S and non-I/S
 Analogue, digital, RTD, T/C
 Voltage level
Wiring terminal block shall be of Klippon make, SAK 2.5 or equal.

All cabinets shall be provided with earthing system. Earthing system for power and
signal shall be segregated.
Overall dimensions of cabinets and peripheral devices indicating all clearances
required for access shall be provided. Proposed system layout drawing showing all
components of the system shall be also provided by VENDOR for COMPANY
approval.
VENDOR shall indicate the weight of all subdivided items of equipment, and the
weight & dimensions as crated for transport.
10.2. Electrical Requirements
All electrical components supplied by the VENDOR shall be completely wired and
tested prior to shipment. All work shall meet IEC and OSHA requirements and
applicable electrical codes.
Power distribution in the cabinets shall be VENDOR’s responsibility. All power circuits
shall be fed from molded case circuit breakers, using separate breaker for each circuit.
Field device I/O power shall be provided from the respective system and sized to feed
only the devices and field I/Os associated with their processor unit.
Incoming power supply feeders to the PCS/SIS cabinet shall be connected to

thermal/magnetic circuit breakers of adequate current carrying and breaking capacity,
with manual isolation facility. The associated circuit breakers and feeders shall be
sized for full load. Daisy chaining of power supplies and signal wires on terminals shall
not be used. Instead, combing bars shall be used.
Power distribution within and also out of PCS & SIS cabinet shall be equipped with
sufficient breakers, fuses, isolators and other protective devices such that the
possibility of a fault affecting a significant amount of equipment avoided and each
component is protected from undesirable power surges. The VENDOR shall ensure
that each circuit and sub-circuit shall be individually protected and capable of being
isolated for maintenance or replacement.
Main power interruptions of up to 100 ms shall not affect operation.
10.2.1. Power Supply

PCS & SIS shall utilize 230 VAC, 1-phase, 50 Hz from UPS. The system shall be
provided with all required internal power supplies, bus bars, and power wiring within it.
Redundant feeders shall be provided to each system cabinet from the UPS
distribution board. A suitable backup power for volatile memory cards shall be provided
also, if used.
VENDOR shall provide all filters, transformers, rectifiers, etc to convert the above
power supply to the level acceptable to the various PCS requirement.
The maximum static transfer time of UPS which the PCS should tolerate is 100 ms.
The power distribution and individual protection shall be furnished for all field input and
output devices for ease of field mounting and accommodation of signals powered from
other sources.
AC Power
The PCS & SIS shall be equipped with AC distribution panel with circuit breakers. The
VENDOR shall define the following for the proposed system based on the 230 VAC, 50
Hz power to be provided by the COMPANY:
 Voltage tolerance
 Start-up inrush currents including start-up sequencing or delays, if applicable
 Running current
 Frequency tolerance
 Requirements (if any) for isolation from the COMPANY’s AC power source
 Power factor
DC Power
The PCS & SIS shall be provided with DC power supplies and DC distribution panel
with circuit breakers within the instruments system for all power required by two/three
wire analog inputs, two wire analog outputs, dry contact inputs, digital outputs, etc.
Each loop shall be individually isolated to prevent a ground fault in one loop from
effecting other loops.
Earthing
There shall be three separate earthing systems in PCS & SIS system : Safety Earth
All metal enclosures supplied shall have a minimum of one M10 brass earth stud,
complete with nuts and washers, dedicated for safety earthing. All metal racks, internal
panels and fabrications, cable tray, doors and detachable panels shall be earth bonded
together to this safety earth with a flexible copper braid strap of at least 10 mm2 to
ensure effective earthing.
Instrument Earth
Each system cabinet/marshalling cabinet shall be provided with one 5 mm x 15 mm
copper galvanically isolated instrument earth busbar across the full width of, and
insulated from, the panel for earthing system electronics and electrostatic screens of
field cables.
In general, field instrument shields will be grounded to instrument earth within the
marshalling cabinet.
Intrinsically Safe Earth – I.S. Earth
Marshalling cabinets with passive I.S. equipment (eg zener barriers) circuits shall be
supplied with an additional galvanically isolated IS earth busbar clearly labelled as such.
10.2.2. Cabling
The PCS & SIS shall be supplied with all required system cabling.
All control wiring shall be carried out using not less than 1 mm² flexible multi-stranded,
annealed copper conductors and shall be flame retardant to IEC 60332 Cat. C and
insulated in accordance with document no. SNBP-00-INS-SPC-004 “General
Instrument Specification” and document no. PTG-00-ELE-SPC-002 “Electrical General
Specification - Electrical & Instrument Cable”.
Segregation of any IS circuits, terminals, earthing and screening connections to be

carried out in accordance with EN 50020.
Wiring of voltages greater than 24 V (AC or DC) shall be separated from instrument
signal wiring.
All wiring shall run such that it is accessible, neat and tidy. All wiring shall be run in
trunking and loomed with cable ties. Trunking shall be installed in accordance with the
approved layout drawings.
Segregation of any IS circuits, terminals, earthing and screening connections to be

carried out in accordance with IEC 60079.
10.3. NAME PLATES

All cabinets, console, push buttons, lamps shall be provided with laminated plastic
nameplates. The nameplates shall be fixed to the cabinets/consoles with stainless steel
screws. Nameplate engraving details shall be provided by VENDOR and approved by
COMPANY.
In addition all equipment shall be identified with the manufacturer type and serial
number to facilities future references.
11. PROJECT MANAGEMENT

The VENDOR shall provide all of the following project management services.
11.1. Project Personnel

The VENDOR shall ensure that sufficient qualified personnel are at all times allocated to
the project. The VENDOR shall utilise a project team structure to achieve continuity
and quality of project implementation.
The VENDOR shall produce an organisation structure for the project team proposed for
this project (engineering and project management). Curriculum Vitae of key personnel
are to be included.
The project manager shall be the nominated representative of the VENDOR with
responsibility and authority to fully implement the project with technical correctness, on
schedule and within budget. This project manager shall function as the single point
interface for any project issues, which arise.
11.2. Project Schedule

The VENDOR shall produce a detailed project schedule showing major schedule
milestones.
The project schedule shall clearly show any freeze dates required by the VENDOR and
major milestones for equipment design and manufacture and delivery. The schedule
shall clearly indicate required dates for all PURCHASER supplied design data.
The project schedule shall be used as the basis for progress reporting, schedule
controlling and schedule forecasting. At regular intervals, the VENDOR shall revise the
project schedule to include the effect of any changes and to reflect actual project
progress.
11.3. Progress Reporting

The VENDOR shall submit to the PURCHASER a fortnightly progress report with
associated bar chart or critical path analysis sheet, which addresses the following details
in particular:
Engineering progress and manpower involved against the project schedule, highlighting
the amount of float or delay.
 Any proposed specification changes
 Equipment purchase status
 Fabrication/assembly status
 Software and programming status
 Any problems encountered or foreseen shall be reported immediately to the
PURCHASER and then reiterated on the progress reports
11.4. Coordination Meetings

Shortly following Purchase Order award, an initial kick off meeting shall be scheduled to
review the total project scope, to verify project schedules, and to identify any key issues,
which need to be addressed. This meeting shall take place at the PURCHASER’s
premises and require the attendance of key members of the VENDORs nominated
project team.
Regular coordination meetings between the PURCHASER and the VENDOR shall be
carried out on a monthly basis at the PURCHASER’s premises and attended by
members of the VENDORs nominated project team agreed by both parties at the kick-
off meeting. The agenda for each coordination meeting shall be prepared by the
VENDOR prior to each meeting. Detailed meeting minutes shall be taken by the
VENDOR and submitted to the PURCHASER for concurrence. An action item log shall
be prepared and continuously updated by the VENDOR.
11.5. System engineering
11.5.1. Consultating Service

The VENDOR shall include the provision of the services of a suitably experienced Lead
System/Applications Engineer who shall be the focal point responsible for providing
technical guidance and technical interface with the PURCHASER during the execution of
the project. This engineer shall also be available to assist in the finalisation of the plant
control and operating strategies and to address any questions regarding performance
specifications, configuration, prototyping, installation and field wiring of the PCS & SIS.
11.5.2. Configuration Services

The VENDOR shall include the provision of configuration services. The configuration
activity shall be executed in the VENDOR's or PURCHASER’s premises using the
VENDOR's configuration tools and assisted as necessary by the PURCHASER.
Configuration shall be offered on a lump sum basis to the scope of work as identified on
the Instrument Index, Instrument I/O List, functional definition documents and P&ID’s at
the time of tender.
At the completion of the integration test, the VENDOR shall update the final approved
configuration. This configuration shall be generated from the operating software and
shall be free from software patches. Three copies of the final approved configuration
shall be delivered on a fully tested and verified system configuration DVD-ROM. These
shall be supplied complete in a compartmented storage case with suitable labelling.
The VENDOR shall also retain a copy of this configuration revision.
12. INSPECTION AND TESTING

The PCS & SIS the hardware and software, will have formal testing at the following
points:
 During manufacture according to manufacturer standard test procedures. A test

certificate shall be supplied with each sub-assembly/module.
 Prior to delivery from factory (FAT) and
 Following installation at site (SAT)
100% I/O and logic checks shall be carried out prior to the start of FAT. VENDOR to
include effort for testing prior to start-up FAT. All electronic modules shall have been
subjected to a heat soak during manufacture prior to assembly into the overall system.
12.1. Test Procedures

The Test Procedures and Plan covering FAT and SAT shall be submitted for COMPANY
approval. The test plan should be a list of all the tests necessary to prove the system
and should be arranged to show:
a) The sequence in which the tests are to beundertaken
b) The interdependencies between tests
c) The project personnel involved Test specifications

d) Acceptable performances
The test plan should include all tests necessary to satisfy the correct operation of the
PCS & SIS before the system is commissioned. The test plan will provide for negative
testing, as well as for positive testing.
Negative testing is required to prove that the PLC will reject false data or instructions
and will not perform functions it is supposed to prevent.
12.2. Test Equipment
All necessary test equipment shall be provided by VENDOR, the accuracy of which
shall be at least one order of magnitude better than the equipment under test.
Equipment shall be made available for online analysis of the PLC network.
All of the equipment supplied shall be subjected to a series of tests, which shall
include, but not be limited to:
a) Hardware inventory
b) Visual examination of main equipment and PC boards for mechanical and
electrical integrity
c) On line testing of peripheral equipment in final configuration
d) Earth integrity checks
e) Power consumption recording, which shall include a recorded oscillograph
showing switching and steady state operating conditions and also measurement
of waveforms and harmonic distortion
f) Power supply test.
g) Environmental test.
All spare items supplied under the contract shall be subject to similar test.
12.3. Function Test

The Integrated System shall be subjected to a series of tests, which shall include but not
be limited to:
a) Final functional tests of operating system facilities including load, dump,
initialization and recovery. These tests shall be carried out using the appropriate
storage media.
b) Demonstration of configuration development facilities
c) Functional tests of connected peripheral devices such as disc drives, printers,
etc.
d) 100% I/O check using simulator panels
e) Logic and sequence controls and complex control strategies
f) 100% functional testing of PLC inputs and outputs
g) Testing of data links including display of information, alarm generation using
simulator. A protocol analyzer shall be inserted into each data link and link
performance monitored for the test duration. Logs of the analyzed data shall be
provided as part of the integrated system testing records.
h) Synchronization of all associated equipment and other system, if any i.
i) Integrated test with 3rd party system
Functional tests shall be carried out on all modules of system. These tests shall
demonstrate that all requirements in each area have been met. Tests shall be included
to demonstrate the correct operation of all communication protocols used in the system.
The test procedure shall define the database to be used for FAT.
VENDOR shall provide a suitable configuration for the test, which shall be capable of
providing the processor(s) loading figures. If a software simulator is to be used, the
output shall be subject to review by COMPANY. All inputs to the PCS/SIS shall be
simulated and all outputs shall be provided with a means of easy verification. Tests shall
be included to demonstrate the correct operation of all data links to external systems.
A series of tests will be required to demonstrate the degeneration and recovery of the
system following different possible hardware and software failures. This shall include
detection of communication errors, the operation of the self-diagnostic facilities.
The capability of the system to remain in operation during corrective maintenance work
shall be demonstrated. Testing recommendations by the COMPANY shall be carried out.
13. QUALITY CONTROL

A complete summary of the proposed quality assurance program shall be submitted to
COMPANY for review and approval. This program should include provision for
COMPANY to have access to the manufacturing and test facilities by prior arrangement
with VENDOR.
14. TRAINING
Training shall be presented towards people who have a very basic understanding of PLC
system, controllers and HMI, no training on communication network and a limited
understanding of Windows environment.
COMPANY expects that the proposed process control system is easy to learn, easy to
operate and maintain, thus should require only minimal training of COMPANY’s
personnel.
All proposed courses shall be developed by the VENDOR or others. Course contents
Lesson Plans and Written Training materials shall be presented for COMPANY’s
approval 3 months prior to the scheduled courses.
VENDOR’s responsibility includes course materials, course fee, transportation, meal,

board and lodging and per diem allowance of the instructor. VENDOR shall also include
any recommended special training and/or any special training capabilities beside these
training below.
Trainings shall be provided by VENDOR dedicated for System Engineer, Maintenance

Support, and Operator as per the following:
14.1. System Engineer Training

The objective is to enable System Engineer to understand the overall system, modify the
control system and upload program/setup configuration upon hardware or memory
media failure. It shall cover also topics such as database maintenance, documentation,
screen development. Functionally, it shall be similar to the training offered by HMI and
PLC manufacturer as its basic training, except it shall be tailored specifically for the
control system under this contract.
14.2. Maintenance/Support Training

Dedicated training for the system maintenance shall include PLC, Controllers, HMI, Bus
Protocol Plus Network. The training shall focus on the troubleshooting of hardware
problems, but it shall also include the training on the PLC programming, basic
instructions, how to get in and out of the PLC/Controller programming environment and
how the PLC/Controller and HMI interacts (e,g. how PLC/Controller controls the PID
loops, how the set-points are changeable from the HMI).
14.3. Operator Training

The Operator courses objective is to enable the participants to operate facility under the
control system This course should include general information about HMI, PLC,
Controllers and the system as a whole. The course content consist of at least: how to
start and shutdown the facility or equipment, change set-point, change configurable
parameters, print reports, understand and handle alarms message. VENDOR shall
schedule the Operator Training prior to the facility start- update.
15. SPARE PARTS & SPECIAL TOOLS
15.1. Spares
The VENDOR shall identify the following spares:
 Pre-commissioning, commissioning and start-up spares
 Recommended spares list for two years operation Spares shall be itemized and
priced with the Tender. Special Tools
The VENDOR shall identify all necessary standard and special tools, test software, and
test and calibration equipment required to perform routine maintenance and any other
recommended tools for specialised procedures.
Standard equipment includes items available from standard catalogs. The list of the
standard tools and testing and calibration equipment required shall state the following:
 Description of its service or simulation application
 Manufacturer and catalog number
 Quantity recommended
Special tools shall be itemized and priced with the Tender. The Purchaser shall agree
the Special Tools to be included in Purchase Order.
The VENDOR shall provide design and performance specifications for all special
tools, test software, and calibration equipment.
16. PREPARATION OF SHIPMENT

Equipment shall be prepared for export shipment and shall be crated in a manner to
provide maximum protection during shipment and extended outdoor storage. All
exposed machined surfaces shall be protected by means of easily removable rust
preventives.
None of the equipment specified herein shall be prepared for shipment or shipped
before COMPANY has either inspected the equipment or waived inspection in writing.
All openings shall be provided with substantial wood, plastic or metal closures.
All tapped openings, not otherwise closed shall be plugged.
Major equipment components shall be securely bolted to substantial skids for

shipment. Small and easily damaged parts shall be removed, tagged with the
description of the major item to which it belongs, and adequately protected during
shipment.
Tools and spare parts shall be packed in metal boxes suitable for long term storage.
The boxes shall be galvanized or coated.
17. GUARANTEE
Material and equipment shall be guaranteed by VENDOR/Manufacturer to perform in
accordance with specification requirements and to be free of defects and poor
workmanship including, but not limited to, those caused by inadequate preparation for
shipment, as per Section 15.0 of this document, for a period of one (1) year after
material and equipment is placed in service, but not exceeding eighteen (18) months
following delivery to the contracted destination.
VENDOR shall repair or replace all defective items during the guarantee period at
no cost to COMPANY.
18. VENDOR DATA

The VENDOR shall furnish data as required on the VENDOR Data Requirement List
with the number of copies and in the number of days indicated following receipt of the
purchase orders.
As minimum, following documents shall be included:

 General Arrangement Drawing (System/Power Supply/ Network/
Marshalling Cabinet, Mimic Panel, Operator Consoles)
 Detail Drawing (System/Power Supply/ Network/ Marshalling Cabinet,

Mimic Panel, Operator Consoles)
 Bill of Material
 I/O allocation detail for each module and rack
 Power Distribution Diagram
 Overall Block Diagram
 Serial Link Block Diagram
 Detail Wiring Diagram
 Typical Earthing Drawing
 System Cable Termination Schedule
 Communication Diagram
 Detailed Functional Design Specification for PCS
 Network Loading Calculation
 Network IP allocation
 System CPU Loading Calculation
 MTBF, MTTR, SIL Verification (as applicable)
 Power Consumption and Heat Dissipation List
 Operator station HMI graphic display (per page)
 Inspection and Test Plan
 Factory Acceptance Test Procedure and Reports
 Site Acceptance Test Procedure
 System Integration Work Pack
 Start Up and Commissioning spare part list
 Two-years operation spare part list
 PCS program Configuration (including ladder logic)
 Operating and Maintenance Manual
 Networking System Design and Specification
 Hardware Design and Specification
 Alarm Management System Design and Specification
 Database Configuration Design and Specification
Vendor shall submit complete draft for review and agreement by PURCHASER/
COMPANY.
The design specification shall be approved by PURCHASER/COMPANY prior to

commencement of equipment procurement and software works.
The drawings and documents shall be considered part of the order. The order shall
not be considered complete for payment until all items are received.

Control & Safety System Specification

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Control & Safety System Specification

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CONTRACT NO.

B 06/05/2022 Issued For Approved SW ASW EFC

TABULATION OF REVISION SHEET

10.2. Electrical Requirements........................................................................................................... 29

Tabel 2-1 List of Definitions........................................................................................................................ 7

1.1. Project Overview

HMI Human Mechine Interface

4. CODES AND STANDARD

Indonesia Codes & Regulations

5.1. Environmental Condition

Parameter Unit Data

5.2. Standard Condition

Parameter Unit Data

5.3. Electrical Power Supply

Meanwhile, the power for RU V Balikpapan shall be taken from RU V power

Conversion to other voltage levels (e.g. 24 VDC) as deemed necessary shall be

5.4. Hazardous Area Classification

requirement, the electronic instrument device shall be follow stringent

5.5. Ingress Protection

 For indoor area : minimum IP 42 as defined in IEC 60529

Electronic components of instrumentation shall be tropicalized. Appropriate measures

6. DESIGN LIFE AND RELIABILITY

All components which for practical, safety or cost-efficiency reasons are

7. CONTROL & SAFETY REQUIREMENT

7.1. General requirement

interconnection respectively. Other protocol shall be approved by COMPANY.

The PCS shall be engineered to perform the following functions:

7.2. Design Criteria

The PCS/SIS shall be engineered to meet the Availability (A) as follows:

PCS/SIS hardware shall be capable of hot swappable change-out to facilitate on line

The VENDOR shall have responsibility for applying a professional engineering

methodology to the design, fabrication, testing, documentation and preparation for

7.3. System Integration

Communication to 3rd party systems shall be performed as communication

7.4. VENDOR Responsibility

The VENDOR shall have responsibility for applying a professional engineering

The VENDOR shall be responsible for configuration of gateways, switches, nodes,

8. PCS/SIS HARDWARE AND SOFTWARE REQUIREMENTS

8.1. PCS/SIS Hardware Design Requirements

The PCS & SIS shall be provided as a microprocessor-based PLC comprising

The “health” of the processor shall be continuously monitored by a configurable

The system shall be modular in construction and expandable in future by adding

8.1.1. Input / Output Module

analog voltage level.

Note : Appropriate interposing relays shall be provided in PLC system by VENDOR if

8.1.2. Controller Modules

8.1.3. Communication Interface

8.2. Software Firmware

Standard operating system software, with full documentation, shall be provided by

 PID instruction/control modes & change control parameter

9. HUMAN MACHINE INTERFACE (HMI)

9.1. Pcs / Sis Graphic Requirement

 Area or Unit view

9.2. Alarm Management System

9.3. System Configuration and Database

The following shall be provided by CONTRACTOR towards the PCS configuration:

System modification/re-configuration for, control/monitoring loops and/or graphic

9.4. Logging and Reporting

9.5. Engineering Work Station & Operating Work Station

Keyboards & Pointing Devices or Operational Keyboard

 Archiving to be an automatic scheduled background activity

9.6. Event and Alarm Logging Printer

10. OTHER REQUIREMENTS