Professional Documents
Culture Documents
Contents
1 Scope ................................................................ 2
2 Conflicts and Deviations .................................... 2
3 References ........................................................ 2
4 Definitions and Terms ........................................ 4
5 General .............................................................. 7
6 Environmental Conditions ................................ 10
7 Hardware and Assembly.................................. 11
8 Electrical Requirements ................................... 18
9 Tagging and Nameplates................................. 20
10 Functionality .................................................... 20
11 Architecture ..................................................... 22
12 Software .......................................................... 24
13 Maintainability .................................................. 24
14 Communications .............................................. 25
15 RTU Cabinet .................................................... 26
16 Documentation ................................................ 30
17 Inspection and Testing..................................... 30
Revision Summary .................................................. 31
1 Scope
This specification defines the minimum mandatory requirements for Remote Terminal
Units (RTUs) for oil & gas and utility applications.
1.1 This specification and explicitly referenced Saudi Aramco specification applies
to all RTU equipment, RTU cabinet, accessories, power distribution, process
instruments power supplies and associated software required to remotely control
and monitor a process area.
1.2 This specification excludes non-integrated network switches and radio modems
that are covered by other existing specification documents.
1.5 The RTU Specific Requirement Sheet (Attachment 1) lists only items that are
optional. It is not intended to list design parameters. The parameters have to be
supplied by the design office or the proponent.
Any conflicts between this document and other applicable Mandatory Saudi Aramco
Engineering Requirements (MSAERs) shall be addressed to the EK&RD Coordinator.
Any deviation from the requirements herein shall follow internal company procedure
SAEP-302.
3 References
Material or equipment supplied to this specification shall comply with the latest edition
of the references listed below, unless otherwise noted.
Two methods widely accepted for calculation of predicted MTBF are; MIL-
HDBK-217 and Bellcore TR-332.
Electronic Industries Association
TIA EIA/TIA-232 Interface between Data Terminal Equipment and
Data Circuit - Terminating Equipment
Employing Serial Binary Data Interchange
EIA/TIA RS485 Electrical Characteristics of Generators and
Receivers for Use in Balanced Digital
Multi-point Systems
4 Definitions
This section contains definitions for acronyms, abbreviations, words, and terms as they
are used in this document. For definitions not listed, the latest issue of the
“Comprehensive Dictionary of Measurement and Control,” International Society for
Measurement and Control, shall apply.
Marshalling Cabinet: A cabinet containing wiring ducts, DIN rails, terminal strips
and/or wire terminations only. Cabinets: Generically used within this specification;
refers to all of the above. Module: An assembly of interconnected components
that constitutes an identifiable device, instrument, or piece of equipment. A
module can be disconnected, removed as a unit, and replaced with a spare. It
has definable performance characteristics that permit it to be tested as a unit.
Mean Time between Failure (MTBF): A statistical value equal to the mean or
average time expected between failures of a given device which is used in the
determination of system reliability. MTBF figures can be “predicted” or
“observed.” Observed MTBF for a given component is calculated using actual
failure rate data collected for the population of the component while in-service.
Predicted MTBF is a figure which is calculated based on failure rate models of
Resolution: The least value of the measured quantity that can be distinguished.
RTU Operating Software: The vendor's standard software that performs the
basic functions of the RTU.
5 General
5.1.2 The vendor shall not supply Non-Standard version of the RTU
operating software to meet any of Saudi Aramco's requirements.
5.2.1 The RTU vendor shall guarantee support of all system hardware,
firmware, and software with spare parts and services for a period of
twenty five (25) years from the hardware freeze date as defined in the
contract purchase order or the Preliminary Design Review (PDR),
whichever is the latter. Vendor shall submit the product support during
PDR. The RTU vendor shall guarantee support for all workstations,
servers, networking equipment and any commercial off-the-shelf
(COTS) products supplied as part of the RTU for a minimum period of
ten (10) years from the hardware freeze date as defined in the contract
purchase order or the Preliminary Design Review (PDR), whichever is
the later. Support shall include spare parts and technical support. This
support shall not be contingent on the customer upgrading to later
releases of software
Commentary Note:
It is not the intent of Saudi Aramco to require RTU vendors to service
commercially available products which they did not manufacture. The vendor
shall, however, guarantee that this equipment can be replaced with a similar
component for the period specified without loss of functionality and without
requiring software upgrades.
The RTU cabinet design shall be engineered and implemented to allow
easy hardware components replacement of aged, obsolete, and
unsupported components without impacting the RTU system hardware.
5.3.1 All RTU and I/O subsystem hardware and/or firmware and other
vendor proprietary hardware shall be the latest revision level, approved
by Saudi Aramco, at the time of the hardware freeze date as defined in
the contract purchase order or the Preliminary Design Review (PDR);
whichever is the latest.
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Document Responsibility: Process Control Standards Committee 23-SAMSS-030
Issue Date: 9 October 2018
Next Planned Update: 10 October 2021 Remote Terminal Unit
Commentary Note:
Application software that is written for project specific control and monitoring
strategies cannot be field proven prior to the hardware freeze date. The exclusion
of application software is not intended to provide exclusion for software written to
perform standard functions.
Application software shall be backward compatible and shall be able to run the
same features under new releases of the system operating software. Re-compiling
of application software to integrate with new software release is acceptable. It is
acceptable if the vendor provides a translator.
Each RTU shall be supplied with the following minimum spare expansion
capability for all elements of the RTU configuration. However, the Project FSD
shall be followed if higher spare capacity is specified for a specific project.
5.6.1 10% expansion capability for all elements of the RTU configuration.
The base RTU is defined as the hardware and software needed to meet
the project requirements. Hardware communication modules and
modems are excluded from this requirement.
5.6.2 A minimum spare capacity of 5% for each I/O type in the base RTU
shall be installed and wired to termination points.
5.6.3 The RTU processor shall have 50% spare processing capacity after
downloading RTU IO configuration, all applications and
communication interfaces to the master and subsystems.
5.6.4 One Spare communication port of each type. For compact RTU, spare
communication channels can be provided by TCP/IP connection on the
same port.
6 Environmental Conditions
6.1.1 Temperature
6.1.1.1 The RTU and all components installed within the RTU
cabinet shall be rated for a maximum continuous operating
temperature of 65°C.
Commentary Note:
Cabinet lights that operates when the door is open, are excluded from the above
requirement.
6.1.1.4 Cabinet fans may only be used to dissipate internal heat when
RTU cabinets are installed in air-conditioned buildings or
shelters. Where fans are used, redundant fans shall be
supplied for each cabinet and credit may only be taken for the
air-flow volume of a single fan.
6.1.2 Humidity
6.2 Equipment which is not enclosed or hermetically sealed, but is situated outdoors
offshore or outdoors near-shore shall be protected against corrosion and
operational failure due to wind-borne sea water spray and the accumulation of
wetted salt (sodium chloride).
Commentary Note:
Near-shore is defined as within one kilometer from the shoreline of the Arabian
Gulf, all of the Ras Tanura refinery and terminal, and within three kilometers from
the shoreline of the Red Sea.
7.1 General
7.1.1 The RTU shall support a local programming interface via a laptop
computer.
7.1.2 The RTU shall support analog and smart wired field devices as specified
in the attached RTU Specific Requirement Sheet (Attachment 1),
e.g., transmitters, positioners. Communications to the smart field
devices shall be HART or Foundation Fieldbus.
7.2.1 The CPU utilization at peak load shall not exceed 60% of the processor
capacity. This requirement shall be demonstrated during FAT.
7.2.2 The RTU execution cycle time shall not exceed 500 msec (this
includes I/O scan and execution of diagnostics and application
program).
This requirement shall be demonstrated during FAT.
7.2.3 The RTU program/application design and execution shall make use of
real-time operation system supporting multiple threads and processes
and inter process communication. The application execution
environment shall run asynchronously to the communication and
database support processes. No process waiting on communication
response shall block another independent process.
7.3 Memory
7.3.1 The RTU memory shall be sized such that 50% of total memory
supplied is available after all memory requirements for system and
application software are utilized at peak load conditions.
7.3.2 Configuration data shall be retained for a minimum of sixty (60) days
upon loss of power supply to the RTU.
7.4.1 General
7.4.1.2 All input and output points shall incorporate internal short-
circuit or overload protection. Fuses shall only be used for
Discrete Output points and any loop which utilizes an
external power source for loop power (ie. not powered from
the I/O card). Where fuses are required, they shall be
integral, fused terminal blocks which are hinged, quick
disconnect or equivalent, shall have blown fuse indication,
and it shall be possible to replace the fuse without disturbing
signal wiring or the IO module.
7.4.2.1 The nominal input range shall be 4-20 mA DC, 1-5 VDC,
and 0-10 VDC.
7.4.2.2 The total number of analog inputs or outputs shall not affect
minimum program execution time constraints and the way
they are monitored and processed.
7.4.2.6 In case of bad field input the RTU shall report Bad input,
e.g., ????, and not the last good value.
The RTU shall support pulse input modules that shall be capable of
measuring pulse inputs with the following characteristic:
a) Square wave or sine wave
b) 0 to 10 kHz
c) 5, 12 or 24 Volt
7.4.5.1 The signal voltage range shall include 24 VDC, 125 VDC,
and 120 VAC.
7.4.6.2 The following solid state or relay board output ratings shall
be available:
a) 24 VDC, 80 mA, non-inductive load
b) 125 VDC, 1 A, non-inductive load
c) Each Digital Output module shall be capable to support
2A per output (8A max. per common) loads.
7.4.7.15 Relays shall be used when the RTU relay board is incapable
of meeting signal isolation specifications. Electric relays
shall be dust-tight when installed indoors and hermetically-
sealed when installed outdoors.
7.4.8.4 The RTU shall support Pass through communication port for
Instrument Asset Management Systems for RTU that do not
offer HART enabled IO.
7.4.9.1 The RTU shall support built-in modules which are capable
of communicating to HART ™ registered devices using the
latest HART protocol version.
7.4.9.4 The RTU shall provide the capability to pass HART device
diagnostic data from the IO card to an Instrument Asset
Management System using industry standard protocols such
as EDDL or FDT/DTM.
8 Electrical Requirements
When required, the RTU system shall be suitable and certified for use in
hazardous locations as defined in Article 500 of the National Electrical Code
(NEC). The panel/cabinet and all components within the panel shall be suitable
for the electrical area classification where the panel will be installed. All RTUs
intended for operation in locations classified under requirements of NFPA 70,
Article 505, shall have a certification from organizations that is approved to
operate within the IECEx Certified Equipment Scheme. The classification of the
area in which the panel will be used, shall be specified in the Purchase Order.
RTU equipment shall carry CE Mark for compliance with European EMC
Directive 2004/108/EC or shall comply with immunity levels stated in
IEC 61000-6-2. Alternatively, the vendor shall provide testing results to
confirm that the equipment will operate without disturbance when energized and
subjected to an electromagnetic field from a radiating source equivalent to a
level 3 disturbance as detailed in IEC 61000-4-3. In particular, RF sources such
as hand-held radio transceivers operating at 5 Watts within the frequency ranges,
50-174 MHz, 406-470 MHz, and 800-870 MHz and held at a distance off
1.0 meters from the equipment shall not cause any malfunction, data corruption,
or damage to the equipment.
Commentary Note:
It is not the intent to dictate to RTU vendors of interconnecting and mounting
their standard proven equipment. However, the wiring for system power,
lighting, convenience outlets, field terminal wiring and input/output wiring
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Document Responsibility: Process Control Standards Committee 23-SAMSS-030
Issue Date: 9 October 2018
Next Planned Update: 10 October 2021 Remote Terminal Unit
between intermediate terminal strips within these cabinets shall adhere to this
specification.
8.3.2 The need and type of internal cabinet lighting for outdoor cabinet shall
be determined in the project FSD and provide improved LED or DC
operated lighting. The selected lighting shall meet the temperature and
environmental spec for outdoor installation.
8.3.3 All provided I/O points shall be terminated to Terminal Blocks within
the RTU.
8.3.4 All requested spare I/O points by the standard and the project FSD
shall be terminated to Terminal Blocks within the RTU.
8.3.5 The RTU shall be able to tolerate a loss of power for at least 100 msec
without damage, mis-operation, or data corruption. A power supply
buffer module shall be used to provide voltage stability during voltage
dips.
8.3.6 Power supply unit external to the RTU and RTU internal power supply
modules shall incorporate over current/voltage protection schemes for
input and output power circuits.
8.3.7 The RTU shall comply with the surge withstand capability tests as
defined in IEEE STD C37.90.1 or IEC 61000-4 without damage,
mis-operation, or data corruption.
8.3.8 Power supply shall never be mounted below the CPU. Power Supply
unit shall be installed in the upper section of the cabinet.
8.3.10 The RTU shall be capable to support standard power supply input
voltage ranges including 24 VDC and 120/230 VAC at 60 Hz.
8.3.11 If required in the project FSD, the RTU vendor shall provide lightning
protection for all incoming and outgoing circuits to/from the RTU.
This shall include the power supply, communication circuit, and I/O
circuits.
9.1 All RTUs shall be identified with tag number and service description.
The nameplates shall be permanently attached in accordance with
34-SAMSS-820.
9.2 RTU shall comply with ISA RP60.6, Nameplates, Labels, and Tags for
Control Centers
9.6 The type of card in each slot shall be indicated either by labels on the card slots
or a drawing or a table securely attached to the inside of the cabinet door.
10 Functionality
10.1 General
10.1.1 The RTU shall support PID closed loop control, open loop control, and
logic & sequence functions.
10.1.2 The RTU shall be capable to support flow calculations using AGA3,
AGA7, AGA8 for gas and API Chapter 14.3 Part 1, equation 1-2, mass
measurement equation for orifice meters.
10.1.3 The RTU shall automatically upload data to the Master station upon
receiving a poll request.
10.2.1 The RTU shall support remote configuration, remote down loading,
remote uploading of stored data, and remote data base modifications.
10.3.2 In case of a communication failure with the master, the RTU shall be
capable of archiving data points. The number, type of data points that
to be archived and the archive frequency shall be specified in the RTU
FSD. The archived data points shall utilize the memory specified in
section 7.3.3.
10.4.1 The RTU shall be provided with initialization functions at power up,
such as initial self-checking, and controlled start-up.
10.4.2 Upon RTU power up, all initial data shall be re-stored equal to the
values prior to predetermined safe values.
10.6.2 The RTU shall generate an alarm or diagnostic message when it fails to
respond to a request from the Master station within a specified number
of retries. This requirement shall be demonstrated during FAT.
10.6.3 The RTU shall use a secure communication protocol for accessing and
managing the RTU. SSH shall be used instead of telnet and HTTPS
instead of HTTP.
10.7.1 For RTUs with redundant configuration, the fail over to a redundant
module shall be automatic upon detection of a failure. A diagnostic
message/alarm shall be generated.
All connections shall be authorized with role based security. The RTU shall
employ access restriction for configuration and for operation. There shall be a
minimum of one password layer.
11 Architecture
11.1 General
11.1.1 It shall be possible to upgrade the RTU CPU and/or IO Hardware and
firmware to newer release.
11.1.2 Hardware and firmware changes shall not impact the supplied system
architecture.
11.2 Scalability
11.2.1 The RTU shall be modular in design such that the same hardware is
used for small or large system configurations, with expansion being
based on plug-in modules.
11.2.2 For applications requiring a maximum of two (2) control loops and a
maximum of sixteen (16) I/O points, single board RTUs may be
considered. The justification to consider single board RTU is to reduce
power consumption and reduce back up battery size.
Commentary Note:
Single board RTU refers to single Module with built in CPU and limited
number of IO support of different types. It shall be noted that certain
standard requirement such as scalability/expansion my not be
applicable for this type of RTU.
11.3 Flexibility
11.3.1 For modular RTUs, flexible I/O configuration shall be supported such
that I/O cards can be physically located within any I/O slot without
restriction.
11.4 Reliability
Mean Time between Failures (MTBF) of all RTU Modules shall not be less than
200,000 hours. Power supplies MTBF not be less than 100,000 hours.
11.5 Redundancy
11.5.3 External switches and/or 3rd party hardware shall not be used to meet
redundancy requirement.
11.5.4 Internal failures that would impact successful switchover shall generate
system alarm and shall be configured in the operator screen.
11.5.6 Switchover from active to the standby RTU shall be bumpless transfer.
Switchover shall not cause loss of data or any upset to the analog /
digital input or output signals.
11.6 Expandability
Expanding the RTU's I/O shall be based on adding chassis and modules as required
in conjunction with required software changes to system I/O configuration.
12 Software
The RTU shall support local programming tools and on-line program debugging
utilities to modify and develop application software. The RTU operating system
and application programs shall be stored in non-volatile memory.
12.2.1 The RTU programming language shall comply with IEC 61131, Part 3.
12.2.2 The RTU shall have the necessary software to enable local interface
and uploading of historical data.
13 Maintainability
13.1 Diagnostics
13.1.1 The RTU configuration package shall have on-line help screens.
13.1.3 The diagnostics shall be to the channel level. Diagnostic alarms shall be
mapped into the SCADA database and shall be available to the operator.
13.1.4 All diagnostic functions that can be performed via a locally accessed
port on the RTU shall be executable via remote functionality.
13.1.5 The RTU remote on line diagnostic routines shall not affect normal
RTU operations or functionality.
13.2.1 It shall be possible to install wires into I/O card connections without
disassembling the RTU or powering it down.
13.2.2 Vendor installed cables shall be designed and installed in such a way
as to allow cable disconnection in order to service the equipment.
Cables shall not interfere with circuit board removal.
13.2.3 It shall not be necessary to remove field or terminal panel wiring when
replacing an I/O module.
When RTU CPU and/or IO redundancy is specified in the project FSD, The
RTU shall support hot replacement of I/O cards. This requirement shall be
demonstrated during FAT.
14 Communications
14.1 Software
The RTU shall support DNP 3.0 level 3 Master and Slave with Secure
Authentication, Modbus Master and Slave and optionally other Open industry
standard communication protocols as defined in the RTU Specific Requirement
Sheet (Attachment 1).
Commentary Note:
14.2 Hardware
14.2.3 The RTU shall support communication data transmission rates of 9,600
bits per second or higher.
14.2.4 The RTU shall provide minimum of two Ethernet ports. IEEE 802.3
14.2.6 The RTU shall support two (2) communication ports which can be
configured to communicate with two different nodes.
15 RTU Cabinet
15.1.3 When multiple cabinets are required, the cabinets shall be identical in
construction and external appearance.
15.1.6 The cabinet fabricator shall supply detailed drawings for review and
approval.
15.2.2 If specified in the Purchase Order, above items shall be issued with
proponent drawing numbers and completed in format convertible or
compatible to Saudi Aramco Drawing Format as specified in the PO.
15.2.4 All Vendor literature and drawings shall be of sufficient size and
quality to be clearly legible.
15.3.4 Fans may be used within indoor cabinets to assist in heat removal and
cabinet ventilation. If the fans are required to dissipate heat when the
HVAC is running, redundant fans shall be provided. If the fan(s) are
only required to dissipate heat when the HVAC is not running, a single
fan is adequate. In both cases, fan failure and over-temperature
detection and alarm are required in the SCADA.
15.3.5 Where two or more front sections are required for the RTU cabinet, the
interior shall be an open-frame construction. Cabinet support bracing
shall not restrict maintenance access to chassis, modules or components.
The cabinet shall be properly sized to have easy access to all installed
components and wires. Accessing any of the installed components or
wiring shall not require the removal of other components.
15.3.7 Cabinet doors shall be full-height. All doors shall be dust-tight and
reinforced against buckling. The maximum door width shall be
900 mm (36 inches) unless otherwise specified in the Purchase Order.
15.3.9 When front and rear access is required by the FSD, the following
requirements shall be fully complied with:
a) Cabinet vendor standard mounting plate sizes shall be used.
b) Top and side gaps around the mounting plates SHALL not be used
to run wiring and or system cables between the two sides of the
cabinets exception for front lamp to rear lamp connection.
c) Internal wiring and/ or system cables shall be routed from the
bottom of the mounting plats using approved duct or equivalent.
15.3.10 RTU and marshalling cabinets if required, may have double door
access on each side (front and rear) subject to site conditions and final
mounting location.
15.3.11 All doors shall be provided with integral lockable door handles with
the same lock and key combination, unless otherwise specified in the
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Document Responsibility: Process Control Standards Committee 23-SAMSS-030
Issue Date: 9 October 2018
Next Planned Update: 10 October 2021 Remote Terminal Unit
15.3.12 Equipment that are installed within cabinets or panels and are normally
used by the operator shall be readable and operable with the operator in
a standing position.
15.3.13 The inside of each door shall be equipped with a pocket suitable for
holding A4 documents and/or cabinet drawings.
15.3.14 Cabinets intended for bottom cable entry shall be provided with a
gland plate at the bottom of the cabinet.
For indoor and outdoor locations, cabinet finish shall be unpainted grained
stainless steel. If specified in the Purchase Order cabinets may be painted
internally and / or externally.
15.6 Nameplates
15.6.1 All Cabinets and the equipment therein shall have a nameplate
permanently attached indicating the service description. Nameplates
shall comply with the relevant sections of 34-SAMSS-820 specific to
Nameplates.
Unless otherwise specified in the Purchase Order, each cabinet shall be provided
spare capacity to allow for future system modifications in accordance with the
relevant sections of 34-SAMSS-820 specific to Spare Requirements.
16 Documentation
16.1 The following standard documents shall be provided as part of the RTU
documentation package: installation, operating instructions, maintenance
instructions, test records, complete schematics/logic diagrams, and the RTU
application software.
16.2 Electronic documentation shall be supplied with the RTU. The document
management system shall include graphics, and text string search as defined in
the PO.
17.1 FAT criteria shall be developed by the vendor and approved by Saudi Aramco.
17.2 The vendor shall supply a list of any required test tools.
17.3 Each RTU and/or Integrated systems shall be tested at the RTU vendor's staging
facilities according to the project Factory Acceptance Test (FAT) and in
accordance with Saudi Aramco FAT procedure in SAEP-750.
Revision Summary
21 January 2013 Major revision to include Value Engineering Recommendations and defined RTU cabinet
requirements.
31 December 2015 Minor revision to clarify various requirements:
1. Revised section 5.2 to define new life cycle support requirement,
2. Revised section 6.1.1, temperature rating and cabinet sizing / heat dissipation
requirements based on PMT feedback,
3. Revised section 7.4.1.1 to define Process I/O circuit protection against common mode
transient surges of up to 500 V RMS,
4. Revised section 8.3 to clarify requirement of Power Supply and Distribution,
5. Revised section 10.5 to clarify output command integrity requirements,
6. Revised section 11.5 to clarify redundancy requirements, and
7. Revised section 15.4 to clarify RTU cabinet construction requirements.
14 March 2017 Editorial revision deleting the reference to the canceled procedures (SAEP-1630,
SAEP-1634, and SAEP-1638) and adding procedure SAEP-750 as a reference.
Also, deleting reference to cancelled SAES-J-905 and 34-SAMSS-911.
1 January 2018 Editorial revision to delete "without prior written approval from General Supervisor, Process
Automation Systems Division, P&CSD, Dhahran" in paragraph 7.4.9.8.
9 October 2018 Major revision