No.

S10332300-3004 Rev.0
DISTRIBUTED CONTROL
SYSTEM Date Page
(DCS) 18 JAN 2013 1 3

SUPPORT TO : S10332300-2001 Instrument Design and Cost Estimation

DISTRIBUTED CONTROL SYSTEM (DCS)

S10332300-3004
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TABLE OF CONTENT
SECTION DESCRIPTION PAGE
1.0 SCOPE 4
2.0 CODES AND STANDARDS 4
3.0 CONTRACTOR RESPONSIBILITIES 5
4.0 GENERAL REQUIREMENTS 5
5.0 EQUIPMENT SPECIFICATION 8
6.0 DESIGNED SPECIFICATION 9
6.1 System Cabinet, Power Distribution 9
Cabinet and Electronic Cabinet
6.2 Marshalling Cabinet 10
6.3 Ground Bars 11
6.3.1 Protective Earth 11
6.3.2 Instrument Earth 11
6.4 NAME PLATES 12
6.5 WIRING, CABLING AND WIRE TAGGING 12
6.5.1 Wiring 12
6.5.2 Cable Ducts 12
6.5.3 Terminal Blocks 12
6.6 MAJOR SYSTEM ALARM 14
6.7 OPERATOR INTERFACE STATION SYSTEM RESPONSE TIME 14
7.0 SYSTEM OVERVIEW 14
8.0 CONTROL SYSTEM FUNCTION AND SPECIFICATION. 15
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9.0 INTERFACING 32
10.0 DISPLAY 36
11.0 PRINTING 41
12.0 ALARMS 41
13.0 RECORDING 44
14.0 SYSTEM WORKING ENVIRONMENT 45
15.0 EARTHING AND LIGHTNING PROTECTION 45
16.0 SYSTEM ATTRIBUTES 46
17.0 SPARE CAPACITY 47
18.0 SYSTEM PERFORMANCE 48
19.0 FACTORY ACCEPTANCE TESTING 48
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TABLE OF CONTENT (CONT.)

SECTION DESCRIPTION PAGE
20.0 SHIPMENT PREPARATION 49
21.0 SITE ACCEPTANCE TESTING 50
22.0 CHECKOUT AND INSPECTION 51
23.0 COMMISSIONING 53
24.0 DOCUMENTATION 53
25.0 TEST EQUIPMENT 56
26.0 THE DCS MATERIAL REQUISITION 56
27.0 MASTER CLOCK SYSTEM 57
28.0 AUTHOR COMMITTEE 58
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1.0 SCOPE
1.1 This document defines the procedure by which the minimum functional specifications and
technical requirements for the design, supply, installation, testing and commissioning of a
Distributed Control System (DCS) shall be determined.
1.2 All hardware directly associated with the DCS other than field cable and final elements
(e.g. trip amplifiers etc.) are considered to be part of the requirements of this document.
1.3 This document shall be used together with the Project specifications and/or Engineering
Data sheets for the design of Distributed Control Systems. Deviations must be specified in
writing as a supplement and shall be approved by OWNER.
1.4 DCS shall conform to related IRPC specifications.

2.0 CODES AND STANDARDS

All referenced National, International and OWNER Standard Specification shall be referenced
and defined as applicable by CONTRACTOR.
The DCS shall be designed to comply with the latest issues of the international standards listed
below:

API – American Petroleum Institute

API RP 554, Part 2 : Process Control Systems - Process Control System Design

IEC - International Electro-Technical Commission

IEC 61131, Part 3 :Programming Language
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ISO – International Organization for Standardization (for DCS design)

ISO 9241, Ergonomic Requirements for Office Work with Visual Display Terminals (VDTs)
Part 3 : Visual Display Requirements
Part 5 : Workstation Layout and Postural Requirements

The International Society of Automation

ISA SP 88 Part1 : Batch Control Part 1: Models and Terminology

Other Standards
EEMUA 191 : Alarm Systems - A Guide to Design, Management and Procurement
ISO/IEC27033 Part 1 : Network Security Overview and Concepts
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3.0 CONTRACTOR RESPONSIBILITIES

3.1 The CONTRACTOR shall provide a complete process control and instrumentation system
that functions in accordance with the requirements set forth in this specification. The
CONTRACTOR shall state whether the system offered has been successfully prove by
service in similar operations.
3.2 The CONTRACTOR shall list and explain any exceptions to the specification. By accepting
this specification, the CONTRACTOR agrees to conform fully to the requirements stated
herein except as noted in his list of exceptions. However, the final functional specification
document prepared by CONTRACTOR shall be presented to OWNER for comment and
shall be subject to approval by OWNER.

4.0 GENERAL REQUIREMENTS

4.1 All parts of the New Control System shall have an active life cycle for more than ten (10)
years with certificate.
4.2 Spare parts must be made available as needed for all parts of the New Control System at
least for twenty (20) years from the day of acceptance with certificate.
4.3 The DCS equipment and any control system that are required in this document shall be
designed to enable integration of new DCS equipment for future expansion without any
disturbance, causing damage and trip to the existing DCS.
4.4 Redundant communication port shall be provided spare channels for system expansion in
the future at least three (3) channels (For DCS).
4.5 Redundant communication port shall be provided spare channels for connecting 3Rd party
system in the future at least six (6) channels with 2,500 software license points (For sub
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system).
4.6 The general structure of the DCS will consist of redundant DCS server (the peer to peer
DCS architecture can be arranged to work other function, purpose to increase system
stability), engineering and maintenance workstation (EWS), operator workstations (OPS),
OPC server, asset management server (AMS), alarm management server, automatic
backup server, hardware firewall + IPS, hot standby redundant controllers, redundant
power supplies, redundant interface modules, redundant communication modules, master
clock system, input modules, output modules and communication linked by fully redundant
main bus and information network (TCP/IP). CONTRACTOR shall propose the system
configuration for OWNER approval.
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4.7 Automatic backup server able to configure fully or partial automatic backup shall be
designed RAID 5 Hard disk with capacity at least 1 TB for backup and restore every
computer node in the control system.
4.8 Historical data able to keep for long time data depend on the hard disk capacity and able to
select the desired historical time by have continuous data.
4.9 Asset management server (AMS) shall be included an engineering software able to get
data from HART devices save to database and perform all task relate to analysis and
diagnostics of HART devices with all parameter values.
4.10 Alarm management Server shall be capable of capturing all alarms on the control system
for analysis according to EEMUA191 standard.
4.11 The DCS shall arrange one pair of redundant server be domain controller for network
management task and user work group security.
4.12 OPC Server shall be able to connect to different vendors such as Plant Information
Management system (PIMS), Advanced Process Control (APC) and 3Rd party system.
4.13 Control System shall have virus protection by anti-virus software and Hardware firewall +
IPS specification as specified in Project specification.
4.14 Programming language of the new control system shall be simplified to understand.
Programming by using the black box and command line are not acceptable.
4.15 The DCS shall be comprised of hardware and software at least according to standard of
the system architecture design.
4.16 The communication link to remote field control workstations or remote I/O units shall be
extended by using two (2) fibre optic cables (FOC) and fully redundant optical
communication units.
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4.17 All DCS equipment including remote I/O units shall be located in air conditioned rooms.
4.18 All DCS controllers shall have same model and capability.
4.19 All software shall be supplied with latest version during installation intervals.
4.20 The DCS controller shall interface with analog and discrete I/O, HART instrumentation and
HART capable smart devices and/or FIELD BUS. The DCS can bi-directional
communicate with HART instruments or full digital technology and devices. The asset
management software shall be also provided with 20% of spare license.
4.21 Each software license shall be applied for at least 10,000 tags (I/Os). The OWNER shall be
able to modify the software in the future.
4.22 Designed shall have spare MCBs as least 20 percent of actual using MCBs.
4.23 Adjustable alarm volume and selectable alarm sound.
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4.24 All cables from field to cabinet room shall have marshalling cabinet before connect to
termination board.
4.25 Connection between field signals and I/O modules shall be system connector.
4.26 The response time for major control loops shall be no longer than 150 msec, and for minor
control loops shall be no longer than 250 msec.
4.27 Designed 2 feeder power distribution cabinet for distribute power to all equipment on the
control system.
4.28 Cable labeling shall be according to the From / To format same as OWNER ‘s standard.
4.29 Power distribution cabinet shall have current and voltage transmitter connects to DCS AI
(Analog Input) for continuous power monitoring and alarm.
4.30 Server cabinet shall have temperature transmitter connects to DCS AI (Analog Input) for
continuous temperature monitoring and alarm.
4.31 DCS system cabinets, power distribution cabinets, and other electronic card cabinets shall
have two (2) cabinet thermostats, one (1) thermostat for fan controlling and one (1)
thermostat for cabinet high temperature alarm generating. Spiral wrapping shall be
provided for the cable connections to the cabinet thermostats.
4.32 The automatic PID tuning software shall be provided on DCS to help OWNER to do control
loop optimization.
4.33 Name plate material for cabinets, consoles, terminal name and etc. are acrylic.
4.34 The Batch/Sequence Control Batch/sequence functions shall be provided in order to
perform complex interlocking, sequencing, recipes, and other batch type applications. The
batch functions may be implemented in ladder logic or other types of batch programming
language according to ISA SP 88.01.
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4.35 All signal/cable interfaces between Control & Instrumentation and Electrical systems shall
take place at an Instrument/Electrical Interface Cabinet. This cabinet shall be located in the
Electrical Substation.
4.36 Any command signals to electrical equipment such as Stop, Start or Trip of electrical
circuits shall be by hardwired command only.
4.37 The critical control loops may be effected on machine and/or unit and/or unit and/or plant
shutdown shall be redundant input and output modules.
4.38 The server computer and the workstation computer shall be installed together in the server
cabinet and shall use Keyboard Video Mouse (KVM) switches / extender technology for
connecting with a LCD monitor, mouse and an operator keyboard.
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4.39 All analog input / output modules shall have density not more than eight (8) channels per
module, if not required to add redundant module.
4.40 All digital input / output modules shall have density not more than sixteen (16) channels per
module, if not required to add redundant module.

5.0. EQUIPMENT SPECIFICATION

CONTRACTOR shall select specification for equipment according to OWNER’s recommendation
for purpose of spare part optimization. The equipment specification shall have minimum technical
specification as following.
5.1 Computer server; Dell, HP; 2U Rack type server; Fault tolerance; CPU as least Quad-
core Intel® Xeon® X5560 processor (or better); Memory as least 16 GB DDR3 up to 1333
MHz; Redundant hot swap power supply; HDD as least SAS 600 GB capacity, hot swap
hard disk, RAID 5; DVD + RW; Microsoft® Windows Server® 2008 R2; All technical
specification shall be a latest certified model of DCS manufacturer.
5.2 Computer Workstation; Dell, HP; Desktop/Tower type; Fault tolerance; CPU as least
Intel® Xeon® Quad-Core X 5647 processor (or better); RAM as least 4 GB DDR3 SDRAM
at 1066Mhz; HDD as least SAS 600 GB capacity, hot swap hard disk, RAID 1; DVD+/-RW;
All technical specification shall be a latest certified model of DCS manufacturer.
5.3 LCD Monitor; Dell, HP; Size 26 inches Flat Panel LCD (Passive Matrix); Native
(Recommended) resolution 1920 x 1080 pixel; Max. viewing angle 178 Deg.; Aspect Ratio
Widescreen (16:9); With flat panel sound bar.
5.4 Large screen LCD; Sharp, Sony; Industrial grade working hour 24x7; Screen size ≥ 65
inches nominal diagonal dimension; Aspect ratio W:H = 16:9; Resolution ≥ 1920 x 1080;
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Contrast Ration ≥ 3000:1; Response time ≤ 4 ms.; View Angle 176 degree.
5.5 Color laser printer size A4; HP, Cannon; Network printer double sides printing; Print
resolution 1200*1200 dpi black/color; Memory 1GB; Print speed up to 40 PPM;
Recommended monthly print volume 2,500 to 10,000 pages; Duplex printing : Automatic
(standard).
5.6 Server cabinets; Dell, HP; cabinet dimension is 605 mm. (W) x 1070 mm. (D) x 1999 mm.
(H) with front and rear access.
5.7 Network equipment; CISCO or equivalent.
5.8 Hardware Firewall; CISCO or equivalent; ASA5510 Firewall or equalize include module
IPS, shall be provided the latest model; Modular type or chassis type which consist of
channel for module installation.
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5.9 CCTV camera; Pelco, Bosch, Axis, Sony; Outdoor PTZ camera; 35x High resolution with
wiper, weatherproof with an IP65 outdoor housing.
5.10 Switching Power Supply; Nemic Lambda, Phoenix Contact.
5.11 Barrier and Isolator; P&F, MTL; Mother board type.
5.12 Terminal block; Weildmuller, Phoenix Contact; Fuse terminal with LED for power
distribution; Disconnect terminal with fuse for positive polarity; Feed though terminal for
negative polarity
5.13 Annunciator; Ronan, Idec; LED type.
5.14 Relays; Omron, Finder; With LED indicator; Mother board type.
5.15 MCBs; ABB, Siemens; Industrial type.
5.16 Switches and Lamps; Idec, Telemecanique
5.17 Panel and Cabinets; RITTAL, HOFFMAN; shall be RAL7035 (Light gray) color or
Vendor’s standard. In case of Vendor’s standard shall be submitted for OWNER review
and approval.
5.18 Chairs; Moflex, Modern Form.
5.19 Other equipment need to follow the IRPC’s Approved Manufacturer Lists before proceed.

6.0 DESIGNED SPECIFICATION

6.1 System Cabinet, Power Distribution Cabinet and Electronic Cabinet
The following describes the general features and key design criteria for all system
cabinets, power distribution cabinet and all electronic cabinets.
(1) Cabinet size 800 mm. (W) X 800 mm. (D) X 2000 mm. (H) with color RAL 7035
(2) Cabinet Plinth of height 100 mm. with color code RAL7022.
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(3) Single leaf front and rear steel doors (opening from left to right).
(4) Opening angle of the doors shall be at least 90 degrees.
(5) Cabinet doors fitted with nameplates (front and rear).
(6) Cabinet doors shall have the comfort handle, lock and push-button insert.
(7) Inlet filter for front and rear doors.
(8) 1 set (left and right) cabinet side panel.
(9) Cabinet designed for bottom entry cables with gland plates installed
(10) Removable eye bolts fitted on top of the cabinet (4 pieces per cabinet)
(11) Cable clamp rails shall be positioned to firmly clamp incoming and outgoing cables.
(12) 2 sets cabinet thermostat 1 set for control fan and 1 set generate cabinet high
temperature alarm.
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Spiral wrapping shall be provided for the cable connections to the cabinet
thermostat.
(13) Circuit breakers and terminals that carry 220VAC (50 Hz) power shall be covered
with protection covers.
(14) Heat extraction fans (4 Units) mounted at the top of every cabinet.
(15) 220VAC and 24VDC power shall be routed separately. Spiral-wrap shall be used for
clusters of wires leaving the ducting.
(16) 2 sets cabinet light (front and rear) with door switches.
(17) 2 pcs. (front and rear) divider panels.
(18) 2 pcs. (front and rear) A3 size document pocket

6.2 Marshalling Cabinet

The following describes the general features and key design criteria for all Marshalling
cabinets.
(1) Cabinet size 800 mm. (W) X 800 mm. (D) X 2200 mm. (H) and with color RAL 7035.
(2) Single leaf steel front and rear doors (opening from left to right).
(3) Opening angle of the doors shall be at least 90 degrees.
(4) Cabinet Plinth of height 100 mm. with color code RAL7022.
(5) Cabinet doors fitted with nameplates (front and rear).
(6) Cabinet doors shall have the comfort handle, lock and push-button insert.
(7) Inlet filter for front and rear doors.
(8) 1 set (left and right) cabinet side panel.
(9) Cabinet designed for bottom entry cables with gland plates installed.
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(10) Removable eye bolts fitted on top of the cabinet (4 pieces per cabinet).
(11) Cable clamp rails shall be positioned to firmly clamp incoming cables.
(12) 2 sets cabinet thermostat 1 set for control fan and 1 set generate cabinet high
temperature alarm. Spiral wrapping shall be provided for the cable connections to the
cabinet thermostat.
(13) Spiral-wrap shall be used for clusters of wires leaving the ducting.
(14) Cable ducts to route internal, incoming and outgoing field cable.
(15) Heat extraction fans (2 Units) mounted at the top of every cabinet.
(16) 2 sets cabinet lights (front and rear) with door switches.
(17) 2 pcs. (front and rear) divider panels.
(18) 2 Pcs. (front and rear) A3 size document pocket.
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6.3 Ground Bars

Ground bars are not individually numbered. They only bear labels describing the type of
Ground in the system cabinet, there will be have 2 ground bars.
(1) Protective Earth.
(2) Instrument Earth.

In the marshalling cabinet, there will be 2 ground bars.

(1) Protective Earth.
(2) Instrument Earth.

Instrument shield shall be terminated to Instrument Earth.

6.3.1 Protective Earth

(1) Each enclosure panel is electrically bonded to the Panel Earth Bus bar located
within the cabinet by a wire size equivalent of 16 mm2 (minimum). The Earth
buss consists of a copper bar that is suitably drilled and tapped for screw
terminals and wire lugs. The AC earth terminals are wired to the Panel Earth
buss located at the bottom of each cabinet. In addition, all frame earth is wired
to the Panel Earth.
(2) In case cabinets are bayed together in rows and earth bars are looped using
16 mm2 earth wire. The end cabinets in each row are suitable to accept
customer supplied 35 mm2 earth wire.
(3) Panel Earth bar is labeled as "PROTECTIVE EARTH".
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6.3.2 Instrument Earth

(1) An isolated earth buss is located within the DCS system to wire all signal
earths. The Earth buss consists of a copper bar that is suitably drilled and
tapped for screw terminals and wire lugs. The Instrument Earth bars of bayed
cabinets in the row are looped using 16 mm2 (minimum) earth wire.
(2) Instrument Earth bar is labeled as "INSTRUMENT EARTH" as required.
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6.4 NAME PLATES

(1) Nameplates for cabinets and panels are as per respective General Arrangement &
Details Drawings.
(2) Instruments and accessories mounted inside the cabinet are identified with a
nameplate showing the tag number. Individual rack modules are not provided with
permanent nameplates.
(3) Nameplates are made from acrylic, white-black-white (information engraved using
black color in reverse engraving) with white surface, dull finish.
(4) Each cabinet is identified with a nameplate located on each door. The nameplate
contains the cabinet name/number as given in the cabinet drawings.

6.5 WIRING, CABLING AND WIRE TAGGING

6.5.1 Wiring
(1) 220 VAC power main distribution wiring is minimum 2.5 mm2 stranded copper
Tri-rated PVC insulated, 600 V, 105 degree C minimum. Internal small power
distribution wires are minimum 1.5 mm2 stranded copper types.
(2) Signal wiring is minimum, 250 V/300 V DC when used as single core stranded
and Insulation material is Tri-rated PVC with minimum temperature 105
Degree C.
(3) Electrical connections with voltages greater than nominal 48V AC/DC are
shrouded by transparent, insulating plastic covers.

6.5.2 Cable Ducts

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(1) Cable ducts are sized to accommodate 25% more wiring.

(2) Cable ducts are mounted with screws within the cabinets.
(3) Cable ducts with removable covers are manufactured from PVC material that
meets ASTM D635 standard.

6.5.3 Terminal Blocks

(1) Terminal blocks are rail mounted, non-hygroscope, fire retardant, and halogen
free high strength material such as polyimide, materials shall be according to
standard UL 94 class V-0, standard NF- F 16-101 and related standard for
using in petroleum and petrochemical industry.
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(2) Terminals connected to Field Cable are combination of for positive polarity
signals and disconnected terminal for negative polarity signals
(3) All Terminal blocks shall be used fuse terminal with LED type for power
distribution.
(4) Terminals required for internal/cross wiring are Feed Through Type.
(5) Sizes of terminal blocks are consistent with wire size specified.
(6) All exposed terminal strips above 48 Vdc are identified and have protective
covers.
(7) A minimum of 40 mm. space is provided between electronic component and
terminals to prevent touching when working with terminal blocks.
(8) A minimum of 40 mm. space is provided between terminal blocks and cable
ducts to have proper wiring access and clear visibility of the wire marking.
(9) Panel internal wirings are tagged using tubular PVC sleeves having thermally
inscribed black lettering.
(10) Interconnecting and I/O wiring are tagged at each end with identification tags
which consist of format as explained in this document. Tag closest to the end
of the wire shall identify the terminal number to which the wire is physically
connected and second tag identifies the terminal number to which the
opposite end of wire is connected.
(11) All signal wires are provided with insulated sleeve crimping type wire lugs
suitably sized to match the terminals. The insulating sleeve coloring matches
to that of wire color.
(12) Each bank of terminals is segregated according to the type of signals such
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that multi cores of same cable will be terminated at the same bank.
(13) Terminals are marked on both sides and each terminal strips are provided with
tag holders at the top to hold tag plates.
(14) Cable shieid wires are terminated to the Instrument Earth bars located
adjacent to the core terminals.
(15) The disconnect type terminals are knife-edge type.
(16) The fuse type terminals are fast blown fuse type.
(17) The terminal blocks are arranged in such a way as to group the field wiring.
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6.6 MAJOR SYSTEM ALARM

Major system diagnostic alarm able show on DCS console and annunciator panel. The
following major system alarm shall be provided:
(1) Main 220VAC Feeder 1 Failure.
(2) Main 220VAC Feeder 2 Failure.
(3) Primary DC Power Supply Failure.
(4) Secondary DC Power Supply Failure.
(5) System Cabinet Temp. High.
(6) DCS Controller Failure.
(7) DCS Communication Failure.
(8) DCS I/O Module Failure.
(9) DCS System Power Supply Failure.
(10) DCS Cabinet Temp. High.
(11) Server Cabinet Temp. High.
(12) Network Switches Failure.

6.7 OPERATOR INTERFACE STATION SYSTEM RESPONSE TIME

The DCS operator interface station system response times detailed below shall be based
on manipulating the most complex graphic application available.
(1) Graphic Displays(From call-up to display appearing on screen) 2 second
(2) Alarm Annunciation 2 second
(3) Graphic Display Dynamic Data Update (Time for change in 1 second
Controller to be reflected on graphic)
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(4) Alarm and event resolution 1 second

(5) Resolution Response To Keyboard / trackball Immediate

7.0 SYSTEM OVERVIEW

7.1 The control and instrumentation system shall be an advanced microprocessor-based
Distributed Control System. It will primarily be used to control and monitor the whole plant.
The system will be located in an air-conditioned control and electronic rooms and will have
operator consoles.
7.2 Buses will link up the various components of the system. The CONTRACTOR will prepare a
system block scheme included in this proposal.
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7.3 The control system shall include co-ordinated control of protection and associated plant
systems. The Distributed Control System (DCS) shall provide major and minor modulating
control functions, and sequence/on-off control function. To effect these requirements the
system shall provide control displays, process data acquisition and display, process data
storage and retrieval alarm handling, alarm and event list, historian, trends, process
reporting, control loop configuration and database maintenance.
7.4 All control systems shall be fully and seamlessly integrated with DCS. If PLC is used for
control system for sub system, the proposed PLC shall be of high-end categories and
shall have hot-standby redundant controllers, which possess widely accepted industrial
communication protocol such as Modbus. Communication hardware between the DCS
and PLC shall be TCP/IP on Ethernet.

8.0 CONTROL SYSTEM FUNCTION AND SPECIFICATION

8.1 The system described in this specification shall allow dependable and effective plant
control and shall permit control and data acquisition functions to be distributed to remote
plant locations. A communication system shall link these locations, via redundant and
separately routed communication channels, to a control room with operator workstation
displays.
8.2 The DCS shall be a fault tolerant, self-diagnostic, hot standby redundant microprocessor
based system which shall carry out real time control and monitoring functions of the plant,
interfacing with its electronic measuring instruments and pneumatic actuating devices.
Fully redundant technique shall be applied to get the maximum reliability and availability.
The dual system in a hot standby basis shall be provided as minimum.
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8.3 The DCS shall include all hardware and software required for database configuration, loop
configuration graphics and standard display building facilities.
8.4 Where no requirements are stated for a particular function or attribute, the DCS
CONTRACTOR's Standard shall be subject to approval by OWNER.
8.5 Equipment racks with microprocessor-based control-analogue / digital, input / output
connections to the field instruments. The equipment racks shall be located in air
condition rooms. The system shall perform the functions of conventional analogue and
smart digital instrumentation, including but not limited to:
(1) Process and equipment status display.
(2) Alarm annunciation and display.
(3) Process trending.
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(4) Signal conditioning.

(5) Square root extraction.
(6) Millivolt / Current.
(7) Resistance/Current.
(8) Frequency (Pulse) / Current.
(9) Multiplication, division, addition and subtraction.
(10) Scaling, biasing, and Hi/Lo Selection variables.
(11) Single point indication of analog or digital variables.
The system shall be able to change control schemes via keyboard manipulation and
trackball.
8.6 The system shall be compatible with higher level computer system for supervisory control,
management information and software configuration, modification, engineering, and
maintenance.
The system components shall meet the following requirements:
8.6.1 Operator Consoles
The operator consoles shall present all relevant information and control facilities for
the operator’s particular area of responsibility. The following basic functions shall be
provided:
(1) Indication of controlled and non-controlled variables.
(2) Manipulation of control loops, including set-points, mode and outputs.
(3) Recording by dedicated, real-time trend and historical trend records as well
as trends on the display monitors.
(4) Mutual backup for operator consoles beyond console area group also may
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be acceptable instead of backup within individual console area.

(5) Alarm and event annunciation, display and logging.
(6) Process variable, tabular log display.
(7) Start/stop pushbutton workstation.
(8) System diagnostics.
(9) Historical trends and alarms.
(10) Process graphic displays.
(11) Logic diagram and analog diagram displays.
(12) Group displays.
(13) Face plates.
(14) Permissive condition displays.
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The operator console shall consist of multiple independent microprocessor-driven operator

workstations. The operator workstations shall have identical capabilities, database and
keyboard so that each can perform the tasks of any of the other workstations, and all can
serve as mutual back-up units.
Each console shall have own fan ventilation, power supply circuit breakers, receptacle,
mounting rack for equipment and communication equipment, cable duct and etc.
The operator console will be located in the central control room and shall be the
operations centre of the plant. A number of operator consoles shall be provided to cover
the project particular units. The console shall consolidate all information, provide status
and process information, sort and display data in a standardized format and enable
operators to execute control decisions.
8.6.2 System display shall be of distinctive format to indicate on the display monitor not
only graphical display of process status, but also alphanumerical readout of loop
tagging and process status. Multi-color display shall be provided so that operator
can readily locate desired information.
8.6.3 Keyboard access shall be provided for each display monitor. Each workstation shall
provide full interface capability to process, loop configuration and system check.
8.7 Operator Workstation
8.7.1 An Operator Workstation Shall Be Typically Comprised:
(1) Visual Display Units (VDU).
(2) Keyboards / mouses.
(3) Customised keypads.
(4) Unique processor unit per workstation.
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(5) Data Transport System.

Anti-Virus software shall be supplied to all operator work stations.
Industrial type shall be provided.
Facilities such as tracker ball or joystick for cursor control, are preferred over
‘keyboard only' control arrangements.
8.7.2 Visual Display Unit (VDU)
8.7.2.1 Large Screen
The large screens shall be provided and installed in the Central Control Room. The
screens should be able to display graphics from any of the central control room
operator work stations in a multi-media format using the keyboards of the console
stations. CONTRACTOR shall provide system monitoring multimedia with
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associated equipment for displaying any graphic display available on any operator
workstation. The large screens, interfacing hardware and software applications
shall be installed and specifically designed for graphic display applications.
The Large screens shall have following specification:
(1) LCD monitor wide screen.
(2) Screen size ≥ 65 inches nominal diagonal dimension.
(3) Aspect ratio W:H = 16:9
(4) Resolution ≥ 1920 x 1080
(5) Contrast Ration ≥ 3000:1
(6) Response time ≤ 4 ms.
(7) View Angle 176 degree.
(8) Industrial type 24 x 7 working hour.
Details of how and where this monitor will be installed will be addressed as part of
the detailed design.
8.7.2.2 Operator Workstation VDU
The VDU shall be TFT LCD, not less than 26 inches with aspect ratio W:H = 16 : 9
or bigger monitors. The color screens are capable of displaying mixed alphanumeric
/ graphic information.
The minimum capability and specification of the Operator work station monitor shall
be:
(1) Multi colour.
(2) High resolution graphics screen.
(3) On/off and picture quality controls function and adjustment.
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(4) Desketop mounting VDU's are preferred.

(5) Double Tier LCD monitor per workstation.
(6) Large screen shall be installed where can be visible by all operator work
stations.
8.7.3 Keyboard
The QWERTY keyboard shall be located in front of each VDU, enabling the user to
perform operations, tuning and configuration functions with dedicated function keys.
A keylock shall be provided to lighted pushbuttons shall be able to call-up any one of
the operations groups.
8.7.4 Processor Unit
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The operator workstation shall consist of a microprocessor-based processor unit

permitting to configure the operator workstation, to support the keyboard, to display
alphanumeric and semigraphic information on the screen, to drive a printer or
recorder, to transmit data and to receive data from the process I/O devices via the
communication system.
The performance parameters of the system processors shall be defined by
CONTRACTOR and shall be fast enough to execute application software, operator
actions and critical plant operations. Processors shall have the following features:
(1) Power failure protection.
(2) Automatic restart facilities.
(3) Memory protection.
(4) RAM stack overflow detection.
(5) Real time clock.
(6) Watchdog timer.
(7) Hardware diagnostics.
(8) Operating System Automatic Start-up.
RAM memory shall have battery back-up to protect against loss of memory on
power failure or voltage depression. Batteries shall be of leak proof design.
8.7.5 Data Transport Systems
The systems will be used for:
(1) Load, restore all system configuration and database.
(2) System software back-up.
(3) Historical data recording.
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(4) Storage of system database and configuration.

Data transport shall be done via Main Bus and TCP/IP networks.
8.7.6 Operator Workstation Normal Functions
The operator workstation shall provide facilities required to support the following
functions:
(1) Overview, Unit level, Group level, Drive level displays.
(2) Graphic Displays, Group Displays, Bar chart Display, Face Plates.
(3) SER List and SER Summary.
(4) Equipment Status List.
(5) Alarm and event list, alarm logging and logging, alarm summary, historical
alarms, group alarm.
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(6) Real time and historic trending.

(7) Operational and automatic step sequence control.
(8) Diagnostics and DCS equipment status.
(9) Logic Diagram and Analogue Diagram Displays.
(10) Permissive Condition Displays.
(11) DCS Electronic Documentation/Manual.
(All loop features shall be adjustable from the Process Operator's workstation).
The DCS CONTRACTOR shall define these functions in detail and present to
OWNER for approval.
8.7.7 Access Security
To prevent unauthorised access to databases and configuration data, the system
must support several levels of access under password and keylock control. Access
levels shall include but not be limited to:
(1) Monitor level.
(2) Process Operator level.
(3) Engineering and Maintenance level.
Monitor Level
(1) All operator displays.
(2) Trend selection.
(3) Alarm printout facilities.
(4) Historical information displays.
(5) Reports.
Process Operator Level
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Operator level shall permit normal operator access for:

(1) Loop manipulation.
(2) Start/Stop, open/close and select functions.
(3) Alarm acknowledgement.
(4) Call up of all operator displays.
(5) Trend selection.
(6) Alarm printout facilities.
(7) Historical printouts.
(8) Reports.
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Engineering and Maintenance Level

Engineer level shall permit access to process operator level functions as above and
additionally give access to:
(1) Database facilities for editing, generation and back-up of both global and area
databases.
(2) Loop configuration facilities.
(3) Display building facilities.
(4) Programmable functions.
(5) System network and node diagnostics facilities.
(6) Generation of logs and reports.
The DCS CONTRACTOR shall define these functions in detail and present to
OWNER for approval.
8.8 Engineering Workstation (EWS)
8.8.1 The console shall be an engineering and maintenance workstation (EWS) with
TFT LCD not less than 26 inches monitor with aspect ratio W:H = 16 : 9 or over,
electronic unit with processor, keyboard, mouse, EWS desk and A4 size laser
printers with desk to be located in the CCR. The EWS shall have access to all
points on the control system network (Main bus) and information network (TCP/IP).

The EWS shall be used as data server for the DCS and shall be used for all
database configuration and generation, control logic generation and configuration,
graphic display generation, system configuration and upload/download of data to
system nodes and provide for a range of data processing facilities for building
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reports and logs. The functions and facilities in the EWS shall be defined by the
DCS Vendor.

The EWS software should be through a Graphical Configurator that allows to

represent a point database graphically in the form of logic diagrams positioned on
printable sheets and to make online edits during plant in operation to a point
configuration. The Graphical Configurator should support the following applications
as a minimum:
(1) Create graphical representations of point databases.
(2) Create graphic displays.
(3) Make online edits to configuration during DCS in operation.
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(4) Make offline edits to configuration during DCS in operation.

(5) Edit tag names.
(6) Add and delete configuration software blocks online.
(7) Copy and paste.
(8) Document and print graphical representations of configurations.
(9) Add, remove, and reroute connecting lines (references).
(10) Edit Tag names and Graphics names.
(11) Add and delete control blocks.
(12) Identify the source of fault through the logic diagram.
EWS shall consist of the following software:
(1) DCS system configuration, design tools, builder functions and project builder.
(2) Display Builder, display configuration and display manager.
(3) DCS database.
(4) Equipment and Tag list.
(5) DCS System monitoring and diagnostics.
(6) Network Management.
(7) Alarm Management Tools.
(8) Historian and Trending software.
(9) Library.
(10) Field Device Manager.
(11) Test and simulation functions software.
(12) Operating system software.
(13) DCS electronic document/Manual.
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(14) Anti-Virus software and firewall.

(15) Microsoft Office Professional 2010.
(16) Other software to fulfill, complete requirement.
8.9 Management and Balancing Computer
8.9.1 The DCS shall include computer (such as; DCS server, OPC server and etc.) to
generate operating logs and generate special reports, such as energy balances,
material balances, yield balances and equipment efficiency and a computer (such
as; alarm management server, asset management server and etc.) to collect the
predetermined data from the DCS for further supervisory and diagnostics and to
exchange data with the external computer.
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8.9.2 Operating logs and special reports shall be generated and print out to network
printers.
8.9.3 Each computer shall include a VDU for operator information.
8.9.4 The necessary peripheral software and hardware for programming shall be supplied.
All computers shall consist of the following software:
(a) Front end software, trend, historian, alarm, event and report.
(b) OPC server software including historical database, security functions, alarm and
event data, data access and etc.
(c) Client connectivity.
(d) Anti-Virus.
(e) Operating system software.
(f) Other software to fulfill, complete requirement.
8.10 Controller
8.10.1 Controllers shall be microprocessor-based with integral mode configuration
selectability. The controllers shall be accessible for maintenance via card or control
file. Hot standby redundancy is required for each controller.
8.10.2 Microprocessors shall be non-volatile memory or RAM with backup battery module
for long backup time more than one month which have enough memory capacity be
able to perform their control functions without access to the console or
communication bus. Console and communication bus failure shall not destroy the
process-to-controller interface nor prevent operation of the plant.
8.10.3 The integrated control system shall provide self-check and system diagnostic
capabilities.
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8.10.4 System security shall be maintained by the method selected by Vendor. It must,
however, be automatic and advise the operator on a security failure and location of
the failure.
8.10.5 Controllers in cascade service shall have provision for bump-less transfer from
remote to local to local setpoint control.
8.10.6 Analog automatic back-up devices (PID controller with auto-tracking) shall be
supplied if necessary.
8.10.7 Each controller processor and memory shall not be loaded higher than 50% at final
commissioning.
8.10.8 Controller Functions shall include, but not be limited to the following:
(1) PID control.
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(2) On-off control.

(3) Ratio control.
(4) Lead/lag, dead time compensation.
(5) Calculation control with high level language; such as Basic, Pascal, C and etc.
(6) Analog I/O signal processing.
(7) Digital signal processing including status and pulse signal.
(8) Alarm generation for:
(a) Display monitor.
(b) Contact output.
(c) Analog faced display.
(d) Logging printer.
(e) Sequence control.
The DCS CONTRACTOR shall define the redundancy requirements of the DCS.
Equipment shall be provided to meet the availability target defined later. The
expected levels of redundancy are as follows:

ITEM REDUNDANCY
Communication Network Redundant
RAM Memory-Battery Backup Redundant
Controller Redundant (minimum)
Analogue input card Single (Monitoring) / Redundant
(Critical control loop)
Analogue output card Single (Monitoring) / Redundant
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(Critical control loop)

Discrete input card Single (Monitoring) / Redundant
(Critical control loop)
Discrete output card Single (Monitoring) / Redundant
(Critical control loop)
Video electronics Backed up on Multi-Unit Basis
VDU Keyboard Backed up on Multi-Unit Basis
Power supply Redundant
8.10.9 For items having a redundant unit, it shall be possible to replace the failed unit
without disrupting control of the process. It shall be possible to test the failed unit
on-line without affecting the control of the process.
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8.10.10For non-redundant controllers the system shall 'freeze' on the last signal, or go to
a 'fail-safe' position.
8.10.11Where hard disk are used for mass storage of process and configuration data, a
back-up store shall be provided to minimise loss of data on disc failure. The need
for and use of back-up facilities shall be defined by Vendor.
8.10.12System response time shall be defined by CONTRACTOR and present to
OWNER for approval. With a fully loaded controller subsystem, with its full
complement of I/O and PID control etc, the execution time for PID control shall not
exceed 150 msec. for Major loop control, 250 msec. for Minor loop control.
8.10.13Control system shall be designed and configured with all software necessary to
fulfil the functionality and maintainability of the system. The DCS shall be based on
standard software packages encompassing operating system, application
software, diagnostics and communication software. The need for and use of all
systems software shall be defined by CONTRACTOR.
8.11 Termination, Marshalling and Systems Cabinets
8.11.1 Where DCS, control or monitoring functions are required, then these shall be
achieved via system cabinets within equipment (Electronic) rooms. Field sensors
and actuators will be hardwired to the termination in the cabinets which interface to
the system cabinets. The allocation of racks and equipment cabinets shall be
defined.
8.11.2 The DCS shall be supplied pre-mounted and pre-wired in cabinets or enclosures.
The DCS shall be provided with all necessary termination, marshalling and system
cabinets with all associated accessories, racks, wiring, terminals blocks, and
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intrinsically safe barriers (where required).

The DCS cabinets shall have approximately 2000 (H) x 800 (W) x 800 (D) mm
dimensions, base frame 100 mm, and have steel sheet thickness 2 mm. The
degree of protection (IP) shall be at least IP 42 for cabinets and panels located in
air conditioning room. The cabinets and panels shall be supplied with all necessary
devices including with Fluorescent Lamp (18W), door switch, receptacles,
ventilation fans, louver with filter, circuit breakers for internal power distribution,
signal grounding bus, cable ducts, rail, grommet, cable clamps, and etc.
The CONTRACTOR shall define the system's requirements in respect of the
number of system cabinets, their location and the location of the various major
system components within cabinets.
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Terminal blocks shall be accepted by the OWNER and shall be provided for all
incoming/outgoing field cables with one terminal for every wire. Cable clamping
facilities shall be provided at the bottom of each termination cabinet.
Multi-level terminal block type shall be not accepted.
8.11.3 Hinged doors shall be provided for maintenance access, earth continuity shall be
maintained between the frames of cabinets/consoles/panels by means of braided
wire earth straps.
Termination cabinets shall additionally have their number mounted on the inside
face of the enclosure door.
All cables shall enter control system cabinets, panels and consoles from the
bottom.
8.12 Data Communication Bus
Communication networks for DCS shall consist of control system bus and information
buses. The control system bus shall be separated to information buses.
8.12.1 Control System Bus (Main Bus)
8.12.1.1 The communication subsystem shall be based on redundant industrial-grade
digital communications link, utilizing fiber optic cables that provide a high-
speed data path between all control and I/O devices, multiple operator
interfaces and process computers. The control system bus cable that is not
fiber optic cable shall be shield type control system bus to reduce
electromagnetic interference.
8.12.1.2 Functional Criteria
(1) The communication system shall have multiple branches having
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primary and back-up cables and redundant design. All branches shall
be identical to actual layout conditions.
(2) The minimum transmission speed shall be at least 100 M baud.
(3) The DCS Communication network shall be designed to avoid overload
conditions and accommodate design parameter criteria defined by
Vendor.
(4) The system shall support.
(a) Process controllers.
(b) Data acquisition devices.
(c) Display monitor.
(d) Computer interface.
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(5) All analog input and output devices shall be isolated types.
(6) AC/DC power supply and other devices shall also be isolated.
(7) The system shall be designed for quick and easy connection and
disconnection of devices.
(8) Transfer to the back-up communication channel shall be automatic
without disrupting the system operation.
8.12.1.3 Communication Protocol
All communication system devices shall follow the same communication
protocol, which enables them to perform as follows:
(1) Communication shall be capable of word or block transfer.
(2) Communication shall not be ambiguous; each transmission shall identify
the transmitting and receiving units.
(3) The transmitting device shall receive a reply from the receiving device.
Lack of response shall be considered a receiver’s failure.
(4) A device shall be able to be connected to or disconnected from the
communication system without disrupting other communication devices.
(5) All of the following transmission error detection mechanisms shall be
provided - Error checking on all data transfers.
(6) Automatic re-transmission in the event of errors.
(7) Automatic switchover to alternate link or cable on failure.
(8) Dedicated power supplies for communication electronics.
(9) The system shall alert the operator to malfunction of a device or the
communication link itself, described as follows:
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(a) Failure in one of the devices.

(b) Failure in a standby device.
(c) Loss of communication with a device.
8.12.1.4 Future Expansion
A communication sub-system shall support expandability through
modularized components and provide a common interface to link all devices.
8.12.2 Information Bus (TCP/IP)
A plant information network shall be provided to interconnect all operator
workstations, Supervisor Workstation, the Engineering Workstation, Historians,
Server, computer workstation and etc. The information bus transmission speed
shall be at least 1 G bits per second. The information bus shall support TCP/IP
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protocol compliant. MIS drops shall be made available throughout the plant office
complex. All communication cables and all connectors used in conjunction with the
MIS shall be non-redundant.
The firewalls, routers, switching hubs and etc. network shall be supplied.
8.12.3 FIELD BUS
FIELD BUS means I/O, two way, multi-drop communication cable system for
instruments and other plant automation equipment, instrument, software support,
that use full digital technology. FIELD BUS may be Foundation FIELD BUS,
Profibus, and etc.
Communication of FIELD BUS shall fully digital, high accuracy information with
real-time, multiple data plus alarm/diagnostic messages at every second.
At least but not less FIELD BUS system shall be provided with the following:
(1) Intrinsic safety.
(2) SIL2 approval as standard.
(3) Redundant I/O.
(4) Redundant power supplies.
(5) Redundant shield type cables with robust industrial type cable jacket.
(6) Full digital technology instrumentation for FIELD BUS.
(7) Redundant node/segment that are able to withstand short circuit of not less
than 2 instruments connected to them without affecting to the minimum
operating voltage of the devices.
(8) Cable length shall be designed to maintain the voltage drop of all devices
connected to them at minimum operating voltage with 30% margin.
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(9) Compatibility with existing conventional system.

(10) Ability to work in high noise or strong electromagnetic area.
(11) One device failure will not cause the whole devices in node/segment failure.
(12) Integration with resource management program.
(13) On line software download.
(14) Self-diagnostic.
(15) Advance/ predictive diagnostics.
(16) Ability to replace the devices such as I/O card, communication cable, power
supply, hub, instrument, etc. during normal operation without any shutdown
the process.
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8.13 Power Supplies

8.13.1 The CONTRACTOR shall define the method of power distribution, fusing and
power change over facilities and submit to OWNER for approval.
8.13.2 Sufficient redundancy of power supply units shall be provided to prevent system
disruption in the event of a power supply failure.
8.13.3 The entire control system power will be backed up with an uninterruptible power
supply (UPS) system. The UPS System will be provided. All information necessary
to size the system for a minimum of One (1) hour shall be provided.
(1) The power supply for the DCS shall be 220V 50Hz, single phase and neutral
unearthed supplied from two breakers of redundant UPS.
(2) 24 V dc power packs shall be included in the receiving equipment to change
the incoming from the 220 V 50 Hz UPS to 24 V dc for powering system
components, process transmitter and converter 24 V dc supplies, and for 24 V
dc power for discrete inputs and outputs.
In case of 220 V 50 Hz UPS to 24 V dc converters shall be used, redundant
converters shall be supplied for each DCS cabinet.
(3) Individual loop fusing shall be provided.
(4) The DCS system shall include isolators and over-current protection for all
system components. Sufficient isolation facilities on the DC subsystems shall
be provided to enable maintenance and replacement of components with
minimum disturbance.
(5) Workstations and peripherals shall have internal over-current and isolation
facilities.
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8.14 Printers
Printers shall be connected on common that can be used for all works station. The
printers those supplied by the location of the package systems. shall be located in the
CCR.
8.14.1 Two (2) A4 colour inkjet printer are for:
(1) Alarm/Event printing.
(2) Tabular printouts for hourly average, trends and standard.
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(3) Colour laser printer for screen dumps, reports and displays.
(4) Interface to network via TCP/IP.
(5) System diagnostics, and database configuration.
(6) and etc.
8.14.2 The noise level from printers shall be limited to 55 dBA at 1 m. maximum and if
necessary an acoustic hood shall be fitted. Printer stand and paper handling
facilities shall be provided for each printer.
8.15 Control Console
The control console is designed to comply with accepted Human Factors of Design and
applicable ergonomic standards including ANSI / BIMFA, CSA, and ISO. All ergonomic
standards have been taken into consideration, including view/reach distances, keyboard
height, and knee well space.
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The consoles must accommodate a variety of computer, communication, display,

environmental controls and operator interface devices.
The consoles must be modular, reconfigurable and with an independent steel frame
structure.
Design must facilitate future equipment retrofits and full reconfigurations without requiring
any major modification to the structure or independent exterior cladding.
Control console shall have 48 inches depths and 28 ½ inches highs.
Work surfaces are finished with premium quality High Pressure Laminate (HPL), nominal
thickness 1.2 mm.
The flat panel monitors should be supported on adjustable monitor suspended in a
slatwall system which allows for flexibility in mounting positions. The console must provide
with adjustable monitor system, capable to letting tilt, rotate, raise and lower the flat panel
monitor.
Cold-rolled steel (C.R.S.) is used for structural frame components and sheet metal
stringers. These components ensure square, rigid connection of the frame assembly. All
surfaces are finished with a durable, Electrostatic Powder Coat application.
The console frame shall be constructed using a combination of precision-tooled minimum
14-gauge sheet metal.
Rear slide out shelf for processor compartments – 100 lbs. (45 Kg) load.
Processor shelves – The shelves shall be available in slide-out. The slide out shelves
shall be adjustable in height thus allowing multiple equipment to be mounted vertical with
independent fixed/slide-out shelve.
The control console shall meet the following requirements:
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(1) Pencil drawers.

(2) Under-counter keyboard drawers.
(3) Large monitor Enclosures.
(4) Cable raceways.
(5) Cable Grommets.
(6) Mounting Plates.
(7) Circuit breaker, receptacle.
(8) File drawer pedestals with 5th wheels.
(9) Ventilation Fan (3.62 in x 3.62 in).
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Brushless fan provides extremely quiet operation. It is manufactured with an incorporated

finger guard and is UL, CSA, VDE Listed / Approved. Fan output is 36 CFM @ 0.0 in, 27
dBA.

9.0 INTERFACING
9.1 The DCS shall be capable of interfacing to other related systems such as:
(1) Sub – system and Auxiliary system Controls.
(2) Service air /instrument air control system.
(3) Continuous emission monitoring system.
(4) Master clock system.
(5) Etc.
These interfaces shall be redundant serial data links, fibre optic, hardwired (for protection
and interlocking) and a combination.
9.2 CONTRACTOR shall ensure the function of the DCS's communications with all
subsystems and shall provide successful demonstration of such communications to
OWNER. CONTRACTOR shall ensure the compliance and assistance of both the DCS
and subsystems Vendors in proving these communications.
9.3 CONTRACTOR shall ensure that the provision of the necessary software to display and
provide the required control functions to subsystems from within the DCS shall be
supplied by the DCS CONTRACTOR to the DCS Vendor's standards subject to approval
by OWNER.
9.4 CONTRACTOR shall ensure that the subsystem Vendors provide all necessary hardware
and software to facilitate programming and communication to and control from the DCS at
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the subsystems.
9.5 Plant Interface to Field Instruments.
9.5.1 The DCS's interface to plant instrumentation shall be supplied. The physical
interface to plant sensors and actuators shall be hardwired with smart type HART
Protocol (if applicable) or FIELD BUS, standard open protocol FIELD BUS.
Analogue and/or smart digital inputs/outputs shall be powered from the DCS.
Input modules shall be galvanically isolated from signal sources..
CONTRACTOR shall confirm compliance with this requirement with the DCS
Vendor.
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All inputs shall be filtered and isolated to eliminate noise and provide electrical
input isolation.

Photo-optic isolators or inductive surge protectors shall be provided on analogue

signal leads into and out of each equipment rack and panel in the system to
prevent damage from transient and inductive surges. Inductive surge protectors
shall be used on all power leads into each equipment rack and panel in the
system.

I/O designs shall be modular with keyed quick-connect wiring terminations that
allow replacement of modules without disturbing field wiring. I/O modules shall be
hot swappable.

I/O modules shall be provided with status LED's for each discrete I/O and module
"health" status LED(s) for analogue and specialized I/O.

I/O circuit designs shall be based on 24 VDC.

All I/O shall be protected from inadvertent reverse polarity connection.

All I/O shall be electrically isolated from the system's internal power supply.
All I/O modules shall be designed to prevent inadvertent insertion into the wrong
slot.

All output circuits shall be individually fused with fuse-status indication.

The system shall be able to support HART communications on all analogue I/O
points as standard.
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All analogue I/O cards shall have an individual power regulator to provide isolated
power for AD and isolated transmitter power for AI (where the AI is system
powered).

All calibration constants of the I/O card shall be handled using software without the
need for any potentiometers on the I/O card. As a result, replacement of an I/O
card shall not require recalibration.

Interposing relays will be provided in equipment supplied by others, to ensure that

no 240VAC I/O circuits enter the system cabinets, excepting power supply circuits.
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For intrinsically safe systems, IS barriers will be located in panels adjacent to I/O
modules. Plug-in modular backplane type IS isolating barrier assemblies and
system cables are preferred.
9.5.2 Analogue and Smart Digital Inputs / Outputs (Typical DCS load capability)
(1) Analogue Inputs
Full digital technology FIELD BUS or
4 - 20 mA dc with HART (if applicable) into 250 ohms.
1 - 5V dc into 10 Mega-ohms.
Standard open protocal digital FIELD BUS (Specified by CONTRACTOR).
(2) Analogue Output
4 - 20 mA dc into 600 ohms minimum.
Standard open protocol digital FIELD BUS (Specified by CONTRACTOR)
The DCS shall provide 24 V dc power for process transmitters.
Signals from local panels and process analysers shall be powered from the
DCS.
(3) The ADC and DAC performed by the I/O cards shall meet the minimum
requirements as specified below:
Analogue-to-digital converter (ADC)
• Resolution : 16 bits
• Linearity : ± 1 least significant bit (LSB)
• Repeatability : ± ½ LSB
• Accuracy : ± 0.1 % full scale over entire operating temperature
range
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Digital-to-analogue converter (DAC)

• Resolution : 16 bits
• Linearity : ± 1 least significant bit (LSB)
• Repeatability : ± ½ LSB
• Accuracy : ± 0.25 % full scale over entire operating temperature
range
9.5.3 Discrete Inputs
(1) 24 V dc inputs powered from the DCS for field devices such as pressure and
level switches.
(2) DCS discrete input circuits shall be isolated from earth in all cases and from
each other.
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9.5.4 Discrete Outputs

(1) All DCS discrete outputs shall be single pole changeover contacts (or
equivalent) isolated from earth in all cases and from each other.
(2) 24 V dc outputs powered from the DCS will be used to drive relay coils located
in switch rooms, equipment cubicles etc, for field instrument power supply
interposing contact rating suitable with their loads.
9.5.5 Pulse Inputs
5 V to 24 V dc level pulses at frequencies between 5 and 4000 pulses/second.

9.6 Instrument Interlock and Shutdown System Interface

The DCS's interface to the Instrument for Interlock and Protection System shall be defined
by CONTRACTOR and shall comply with the requirements of IRPC Standard
Specification.
Data shall be provided for display on the DCS operator workstations.
DCS custom displays will relay to the operator the status of the shutdown initiators and
final control /isolation devices.
Communications between the DCS and the Interlocking protection system shall be
Hardwired directional to Field.
9.7 Serial link Interfaces
The DCS shall be required to interface to all control systems that supplied in this project
and supplied by others. The serial interface shall be redundant. The serial I/O interface
shall support either RS-232C, RS-422, or RS-485. This must be accomplished without
the need for a higher level device. The serial I/O interface shall be resident in
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communication/Interface modules, or as a separate multipurpose gateway on the

highway. These interfaces shall be used for communications with other control system
devices such as CEMS PLC, etc.
All data received across serial link interfaces shall be available system-wide and shall be
displayed, integrated into control logic, logged, trended, alarmed, integrated into operator
displays, and communicated to external devices and systems. All data links between non-
DCS Control Systems and the DCS shall be reliable and capable of fast (<1.5 second)
DCS response/update time. DCS interface shall monitor and report the health of the
connected devices. The interface shall include the capability of doing local calculations
and logic, and make all data globally accessible to all DCS functions.
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The DCS interface modules used for serial I/O interface must have twenty percent (20%)
spare capacity (for I/O and memory) at the end of commissioning.

9.8 PLC Interface

The DCS shall provide reliable and redundant communication with all PLC control
systems. All PLC control system shall be stated by the CONTRACTOR after award.
Communication protocol shall be widely common protocol such as MODBUS RTU,
MODBUS TCP/IP and etc.
Main equipment PLC data shall be available system-wide and shall be displayed,
integrated into DCS control logic, logged, trended, alarmed, historian, OPC server,
Reports, integrated into operator displays, and communicated to DCS and external
information systems. The important control functions and any signals that are used in the
BOP control logic (e.g. load set-point, feedback signals, etc.) shall be hardwired to the
plant DCS.
PLCs shall be seamlessly integrated onto the DCS system. Interface shall be done via
communication/Interface modules in order to reducing work load of control processors. No
special/tailor-made hardware modules shall be required to implement the interface. In
addition to the process information diagnostic information from the PLCs shall be available
in the plant DCS. This information shall be derived from standard diagnostic information
available from the PLC. In the event that a connected PLC should malfunction, operating
personnel shall be made aware of the situation via information presented on their
Operator stations.
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10.0 DISPLAYS
10.1 CONTRACTOR shall define the DCS display requirements. All information shall be
presented to the operator via VDU's. Display levels shall be organized into:
(1) Monitor level displays.
(2) Operations level displays.
(3) Engineering and Maintenance level displays.
10.2 Custom graphics showing a schematic representation of plant, equipment, pipework and
valves shall be the primary interface for plant monitoring and control.
Static graphic displays shall be fully displayed on the VDU's within 1 second from the
operator's request. Graphic displays with dynamic data, such as temperature, pressure,
etc. shall be fully displayed on the VDU's within 1 second from the operator's request.
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With a display on view, dynamic points shall be updated within 1 second of the change of
state or significant value change at the measuring device.
Each operator workstation shall include a display menu listing all displays available at the
workstation.
The display access methods used shall permit movement between all displays either on
the same hierarchy levels or between levels with a minimum number of operator actions.
10.3 Operator Displays
The display hierarchy shall be as follows:
Level 1 Custom graphic - System overview
Level 2 Custom graphic - Unit overview
Level 3 Custom graphic - Unit detail
Level 4 Custom graphic - Equipment detail
Level 5 Group display
Level 6 Single Loop display
Level 7 Alarm summary
Level 8 Alarm group
The system shall permit at least sixteen (16) characters to be employed for tag numbers.
10.4 Custom graphic displays shall have the capacity to present a maximum of 50 instrument
tag points on a single display.
Each operator workstation shall be provided with facilities to access and display up to
three hundreds (300) custom graphic displays.
10.5 Overview displays shall allow the display of the status of selected process variables and
discrete points at a glance. The displays shall present to the operator a clear
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representation of the deviation of the process variable from the set point. The variable
shall also be presented in flashing or a changed colour when the variable reaches a
preset value. This value shall be selectable by the operator and shall be individually
selectable for all inputs. The display shall be accompanied by an audible alarm when the
variable reaches a prescribed alarm limit. Overview displays shall be capable of
presenting both controlled and uncontrolled tag points in the above fashion.
10.6 Group displays shall group selected process points in pages of eight or sixteen loops to
provide displays which are representative of the process units. This display shall allow the
operator to select a single process variable and to make changes to certain parameters,
including manual override of the controller, changing set points and the control mode. It
shall not be possible to change any loop parameter unless the loop has been selected.
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Group displays shall include the following data:

(1) Process variable value in engineering units for each loop.
(2) Current set point value in engineering units for each loop.
(3) Control element output value in percent of full scale for each loop.
(4) Tag number for each loop.
(5) Alarms currently active for each loop.
(6) Control mode for each loop (Computer/manual etc).
(7) Loop identification/description for each loop selected within the group.
(8) Time of day and date.
(9) Group display identification number or description.
(10) Graphical representation of the process variable, set point and controller output for
each loop.
(11) Discrete inputs (contact status) indicated by a two position display.
10.7 Either as part of the group display or on a separate display selected from the group
display the system shall provide the following displays and features:
(1) The process variable, set point and controller output as shown in the group display
(2) The loop or variable tag number and description.
(3) All numeric data associated with the loop/variable such as Zero and Span settings
tuning constants and output limits for controllers and alarm settings Configuration
data and data highway addresses of the selected.
(4) When a detail display is shown the following adjustments or changes shall be
permissible under key lock protected access:
(5) Input span and zero.
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(6) Alarm settings.

(7) Controller tuning constants.
(8) Controller algorithm.
(9) Where an alarm condition exists this shall be displayed in the same fashion as per
the group display.
10.8 Logic Displays
Logic display shall be provided at operator workstation . Logic displays assist the user in
visualizing the flow (or status) of information, signals, or decisions. These displays
resemble the traditional documentation provided with system hardware with the additional
advantage of the computer application, which shall provide dynamic aspects such as real-
time sensor inputs.
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Process control system which use complex control systems with numerous feed-forward,
feedback loops, integrators, and similar components shall be also provided. The systems
have systems logic diagrams that use standardized coding to show logic relationships.
Such diagrams may be reproduced on graphic displays with provisions for inputting
commands into active portions of the displayed diagram in order to manipulate
parameters such as set-points and constants.

Although logic displays are designed primarily for use by maintenance personnel in
system tuning and calibration, troubleshooting, or modifying the system configuration,
some users can become highly proficient and may prefer to exercise control over the
process by using such displays interactively.

These displays shall indicate the status of each logic block, the current value of each
associated input and output signal, and pertinent parameters for each logic block (such as
tuning constants and repeats per minute). They also should identify which logic paths are
currently controlling (e.g., when a limit condition causes a change in logic flow). Field
feedback indications from the controlled component (such as valve position, pump speed,
etc.) shall be included on these diagrams as an aid in analyzing system performance.
10.9 User Interaction Requirements
(1) Provide display coding to highlight which items can be selected to be controlled by
the operator; what control is currently active; and what is not controllable. The
differentiation is critical for mimics where some devices are not controlled.
(2) Provide graphic presentation of equipment on graphic display for clear indication of
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control states:
(a) Is item automatically controlled?
(b) Is manual control inhibited?
(c) What is the current operating mode (auto, manual, local control, duty/standby
select, and etc.) of plant areas/units, loops, or equipment?
(d) Condition for indication to be flashing or steady.
• Steady : Condition established
• Flash : Operation in progress. Color is the color of the final
destination. E.g. a damper closing from full open position will
be indicating red and open and will flash green immediately the
closure is initiated.
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Equipment being operated directly via protection or override command.

E.g. sequence closure of modulating dampers prior to plant startup: A/M
symbol flashes.
For 30 seconds following auto start of an item of equipment as part of normal
operation. Indication then becomes steady.
If item of plant starts as result of standby start, a protection operation or
abnormal process condition is flashes continuously until acknowledged.
Flash alarm condition text.
Lock indication flashes when selected but conditions not satisfied.
(e) Show analog signal for feedback signals of valve position and motor current.
(f) Provide a consistent loop-operating philosophy for control of an analog
process variable or a digital state of equipment. This shall include :
• A well-defined act of selecting control (A two step operation shall be
provided for any significant control action including a means of de-
selection).
• A feedback that the control is active.
• A second act of adjusting the active control selected.
• A feedback from the actual control device being controlled (not just a
verification of the demand signal.
• A means to invoke context-sensitive help, if control action is not allowed
(e.g. an interlock) for interlock a selected device.
• A cancel selection target or button to clear the currently elected object.
(g) Provide displays for sequential automatic control functions to include
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displays/windows that :
• List all sequence steps and start/run permissive.
• Indicate the current sequence step.
• Indicate the target sequence step.
• Indicate steps satisfied.
• Indicate steps unsatisfied.
• List inhibit present that prevent further progress.
• Display elapsed time for any time-based hold, and time steps.
• Include controls to start/stop the sequence.
• Provide direct feedback indicating completion of the failure to complete a
selected command.
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(h) Provide analog control adjustments in either of two ways:

• Select and enter a target value that has an acceptable slew rate built into
the firmware which drives the change
• Provide raise/lower keys on a keyboard and displayed on the screen view
and have them accessed with a cursor.

11.0 PRINTING
11.1 The requirements for data printing shall be defined by CONTRACTOR. The system shall
provide facilities for printout of :
(1) The system data base, configuration and programmes.
(2) VDU displays.
(3) Historic trends of process and calculated variables.
(4) Real time trends of selected variables.
(5) Tabular print out of hourly average for a group of variables for a minimum of 24
hours (process or calculated).
(6) Alarm Printout.
(7) Event log (including operator actions).
(8) Change of state of shutdown final elements.
(9) Reports.

12.0 ALARMS
12.1 Alarm Management
Alarm configuration shall be defined by CONTRACTOR. All alarms shall be configured
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into logical groups by:

(1) Unit.
(2) Unit section.
(3) Priority level.
Unit alarm shall be logically created for identify the group of main equipment level alarm.
The graphic shall be presented in tiers of windows. The function and purpose is to replace
the conventional visual alarm hardware.
An indication of a point in alarm shall be provided on every display in an area of each
operational display. It should indicate the current number of active alarms at each priority
level (i.e. unacknowledged alarms).
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Alarm prioritisation levels shall be allocated to enable the operator to discriminate

between critical and non-critical alarms. These levels shall be:
Level 1 - Shutdown pre-alarms
Level 2 - Shutdown alarms.
Level 3 - Operator warning / Deviation alarms.
Level 4 - DCS Diagnostic / Maintenance level .
The system shall provide utilities for sorting alarms. Alarm summaries must indicate time
of alarm, process variable name, process variable description, indication of alarm limit
violated, current value of process variable with quality, value of alarm set point violated,
engineering units of the process variable and whether alarm has been acknowledged. All
plant systems must have alarms that annunciate prior to reaching a shutdown condition.
The system must be able to inhibit alarms based on process groups to avoid alarming
when power block, system or equipment is out of service. DCS diagnostics alarms must
not be inhibited. It shall be possible to print each alarm event at a local Operator station.
All alarm events shall be logged and transferred to the Historian. The Historian shall store
all alarm/events and it shall be possible to query the Historical Alarm Review Program to
display or print alarm event reports.
12.2 Alarm Suppression
The criteria for alarm suppression shall be defined by CONTRACTOR. To avoid alarm
bursts flooding the operator with superfluous alarms due to a process upset or normal
equipment shutdown (e.g. standby equipment), it shall be possible to suppress either
individual or groups of alarms based on the occurrence of a pre-selected alarm or event.
It shall also be possible to defeat individual alarms, or groups of alarms under password
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or keylock control.
12.3 Alarm Handling
The alarm handling philosophy shall be defined by CONTRACTOR. The operator shall be
warned of points in alarm by means of :
(1) Audible alarm.
(2) Illumination of a mini-annunciator keypad or push button lamp dedicated to the unit
or subsystem affected (or functional equivalent).
(3) Display of the highest priority tag or group number, etc. for the first alarm activated,
in an area of each display page.
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12.4 Alarm Acceptance

Alarms shall be accepted both at the graphic level, at the alarm summary and alarm group
page. On acceptance, the alarm tag/text and symbol shall change from flashing to steady
in the specified colour for accepted, uncleared alarms. On the fault clearing the alarm
shall automatically reset and be deleted from the alarm display. The specific details of
alarm acceptance, alarm colour, audible tone etc, shall be defined by CONTRACTOR.
12.5 Audible Alarms
A single common audible alarm with adjustable tone and frequency shall be used for all
levels of alarms priority. Individual alarm tones may be allocated to individual process
operator consoles and areas, the requirements for individual alarm tones shall be defined
by CONTRACTOR.
12.6 Alarm Resolution
The requirements of alarm resolution shall be defined by CONTRACTOR. All alarms shall
be time stamped from the time of occurrence resolution as close to source as possible.
The time of occurrence and the time of acceptance shall be stored for output to the
alarm/event logging printer.
12.7 System Response
The acceptable time parameters of the system's response to alarms shall be defined by
CONTRACTOR and present to OWNER for approval. All alarms shall be reported at the
operator workstation within a half (0.5) second response time of detection. This time
includes the time of when the alarm has been detected together with its transmission to
the operator, and the VDU screen refresh cycle.
12.8 Alarm and Event Logging
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The DCS shall display and printout any system alarm or event configured in the sub-
system databases.
12.9 Alarm and Event History
The system shall store all alarms and event occurrences on mass media. The historic
event file shall be sized to store the events for:
(1) Current shift.
(2) Previous shift.
(3) 1 day operation.
(4) Week operation.
(5) Month, 3 months, 6 Months operation.
(6) 1 year operation.
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13.0 RECORDING
13.1 Data Retrieval
The system shall include the facilities for operator recall to the DCS displays of events
during a time period of specific interest. Custom displays and search facilities shall be
provided for this purpose and shall be defined by CONTRACTOR.
13.2 Real Time Trends
The required trending facilities shall be defined by CONTRACTOR under OWNER
approved during designed state, at least 8 signals/trend, 50 trends shall be provided. It
shall be possible to select any measured or derived variable within an area database for
real time trending on operator and engineering console VDU displays.
Trend displays shall be linegraph representations with the variables magnitude shown on
the Y axis and time on the X axis.
13.3 Historic Trends
The system selected shall have the facilities to store and retain:
All variables (measured and derived)
(1) 1 second snapshots.
(2) 1 minute average for 8 hours.
Selected variables:
(1) One hour averages for 24 hours.
(2) Shift averages for eight shifts.
(3) Daily average for 31 days.
(4) Week.
(5) 1 Month, 3 months, 6 Months.
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(6) 1 Year.
The software shall capability to store all selected historical data at least 3 years.
Historical trends to be stored and archived for a longer period than 31 days should be
backed up on removable media.
13.4 Reports
The required reporting facilities shall be defined CONTRACTOR. The system shall
include the facilities for both pre-formatted and customised reports.
13.5 Pre-formatted Reports
Pre-formatted reports shall use the DCS facilities for :
(1) Hourly report.
(2) Shift report.
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(3) Daily report.

(4) Weekly report.
(5) Monthly report.
(6) Yearly report.
13.6 Customised Reports
The selected system shall provide facilities for two types namely:
(1) Screen dumps of tabular displays.
(2) Free formatted reports.
(3) Microsoft Excel formatted report.
These shall be configured using the report generation facilities provided by the system.

14.0 SYSTEM WORKING ENVIRONMENT

14.1 The environmental operating conditions of the DCS shall be defined by CONTRACTOR.
The DCS will be located in an air-conditioned environment with controlled temperature
and humidity.
14.2 Service Conditions
For the purpose of design the following environmental conditions shall be assumed:
Central Control Room
Heating, Ventilation and Air Conditioning (HVAC) normal operating range
Design temperatures : 22°C ± 2°C
Design Relative Humidity : 50% ± 10%
Rate of change of Temperature : 1oC / minute
H2S : <1 ppm Vol
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SO 2 : <1 ppm Vol

In the event of HVAC failure the temperature could rise to the order of 450C and the DCS
system shall be capable of operating at this elevated temperature without degradation in
system performance.

15.0 EARTHING AND LIGHTNING PROTECTION

The requirements in terms of earthing and lightning protection shall be defined by
CONTRACTOR. System earthing shall comply with the requirements of OWNER Instrument
earthing Philosophy.
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16.0 SYSTEM ATTRIBUTES

16.1 System Availability
The DCS's requirements in terms of availability shall be defined by CONTRACTOR.
Calculations shall be made based on international standard for Electronic Equipment
demonstrating system availability and integrity for the system. The mean time to repair
(MTTR), mean time to detect (MTTD), and mean time between failures (MTBF) used for
these devices in the calculations shall be stated.
Calculations shall be made taking into account the following:
(1) A Controller failure, where failure is the loss of ability to update the Controller online
data, or I/O faults.
(2) Communications link failure, where failure is the condition or conditions causing
changeover to the standby communications link.
(3) Communications system failure, where failure is the condition or conditions
preventing changeover to the backup link.
(4) Data acquisition subsystem failure where failure is the condition or combination of
conditions preventing acquisition of data. This condition also applies to controller
subsystems.
(5) Power supply failure where failure is the condition or conditions preventing full
availability of the DCS.
(6) Operator or engineering workstation failure where failure is:
(a) Total loss of VDU interface.
(b) Total loss of keyboard functions.
(c) Loss of partial facilities due to disc or peripheral failures.
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(d) Total loss due to CPU or resident memory faults.

16.2 Availability Target

The target availability for communications, controllers and operator workstations shall be
99.98%. For data acquisition units an availability of 99.9% shall be the target.

16.3 System Maintainability

The system shall have diagnostics facilities and performance monitoring which will include
self-diagnosis and a standard diagnostics display library giving the status of hardware,
software, communication gateways and all system failure modes. These facilities and
functions shall be defined by CONTRACTOR.
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16.4 Communication Network Expansion

The system provided shall be capable of future expansion by the addition of nodes to the
system communications network. The systems communication network shall be capable
of expansion by 50% in excess of the specified requirement without system performance
falling below that defined in this specification.
It shall be possible to add or remove nodes on the system communications network
without affecting the function of running nodes.
16.5 System Immunity
The DCS shall be immune to the following disturbances :
(1) Variations of UPS power supply: 220 V ac +4% -2% under maximum unbalanced
conditions.
(2) Variation of UPS power supply frequency: 50 Hz ± 2%
(3) Mains transformer by-pass: 220 V ac ± 8%, 50 Hz ± 2%
(4) Power Supply interruptions including :
(a) Total loss for 10 ms.
(b) 50% of nominal voltage for 20 ms or less.
Electrostatic discharge to any conductive surface of up to 10 kV from a source of 150 pF
in series with 50 ohms.
(6) Electromagnetic (EMI) radiation of 15 V/m minimum at frequencies from 10 kHz to
500 MHz.
(7) An intermittent induction field at 60 A/m at 50 Hz laid parallel to external cord sets
and systems cables.
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17.0 SPARE CAPACITY

Space capacity shall be provided as follows: (The percentage figures are nominal)
I/O modules - 20% installed spare for each type of input and output.
(Spare channel shall be reserved on each I/O module)
Controller - 50% installed spare capacity in each controller.
Systems cables - 20% spare cores in each cable.
Power Supplies - 50% Calculated load
Communication Network - 50% installed spare capacity in each network.
All spare I/O shall be completed with wiring and marking at terminals of the cubical.
The above spare capacities relate to the system sizing at the time of order placement and shall
be defined by CONTRACTOR.
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18.0 SYSTEM PERFORMANCE

18.1 Bus Loading
Based upon the final configuration of the DCS, CONTRACTOR shall provide bus loading
calculations for each communication network. These shall be provided to OWNER prior to
the DCS Factory Acceptance Tests.
18.2 EMI/RFI Performance
The EMI/RFI performance of the DCS shall comply with the requirements of IEC 1004
parts 1 through 6 inclusive. Presented with field strength of 10 Volts / metre and frequency
band of 20 to 1000 MHz, the system shall not exhibit a deviation of more than 0.5% of
span on any measure point.
18.3 DCS Controller Loading
Based upon the final configuration of the DCS, CONTRACTOR shall provide controller
loading calculations for each controller. Each controller have not use excess 50% its
capacity (load). If controller loads excess 50% capacity, the additional DCS controllers
shall be supplied without additional cost to OWNER. These shall be provided to OWNER
prior to the DCS Factory Acceptance Test.
19.0 FACTORY ACCEPTANCE TESTING
CONTRACTOR shall produce and issue to OWNER a DCS Factory Acceptance Testing (FAT)
procedure for OWNER approval. The DCS FAT procedure shall be included within the DCS
Material Requisition and it shall be a requirement of the Material Requisition that the DCS
CONTRACTOR shall carry out the FAT in accordance with the approved FAT procedure to
OWNER satisfaction.
It shall be the stated aim of the DCS FAT to determine the compliance of the system with the
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requirements of OWNER Standard Specifications and the Specification defined by

CONTRACTOR. The FAT procedure shall be structured and shall include such tests and
checks so as to achieve this aim.
(1) The DCS FAT procedure shall include the following requirements as a minimum:
(2) All phases of the FAT shall be witnessed by CONTRACTOR and the OWNER.
(3) The Quality Assurance Documentation produced for the FAT shall require the signatures
of designated FAT witnesses from the DCS Vendor, CONTRACTOR and OWNER.
(4) Defects shall be recorded and a log of required corrective actions kept, the FAT shall
require that this system is not accepted until all defects are corrected and the correction
retested in accordance with the FAT procedure.
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(5) No item shall be regarded as accepted unless it has been witnessed by the designated
test personnel from the DCS Vendor, CONTRACTOR and OWNER and these designated
personnel have signed and dated the QA documentation. The system shall be fully
assembled, using heat cycled components and `burned in' under the DCS manufactures
standard procedures.
(6) Each communications network shall be tested separately except for where bus to bus
tests are required.
(7) Continuity test shall be completed 100% on all cores of all cables; point to point resistance
shall be recorded on the test sheet
(8) All spare cards and components shall be assembled to the system and tested during the
FAT
(9) The FAT shall begin with an inventory check and an inspection of all enclosures and
tagging cable identification against the inventory.
(10) The system shall be powered up and loaded with the latest version of both the DCS's
standard and application software.
(11) All DCS I/O shall be checked in accordance with the approved test procedure.
(12) All power supply change over facilities shall be tested by `failing' one of the supplies.
(13) System functionality shall be tested by simulating I/O in accordance with the approved test
procedure.
(14) All keyboards, displays, graphics, logs, reports etc shall be tested in accordance with the
approved test procedure.
(15) Trend functions shall be tested on a selection of 20 points using a simulated cyclical input
over an eight hour period.
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(16) System failure modes shall be tested by simulated failures to ensure the correct system,
software, hardware and alarm responses.
(17) Communications gateways shall be tested by connection to their intended destination
device, internal software shall simulate communication the maximum required rate.

20.0 SHIPMENT PREPARATION

20.1 The instrument consoles and the termination cabinets (or sections) shall be prepared for
shipping by the Vendor.
20.2 In any case, and for shipment to a module fabricator’s yard or warehouse onshore, the
CONTRACTOR shall meet the following requirements:
20.2.1 All open pipes, conduit and enclosure entries shall be securely plugged or capped.
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20.2.2 All components shall have shipping stops to keep them in place and cushioning
installed so as to prevent damage by mechanical shocks during shipment.
20.2.3 The console shall be fully enveloped in a packing material capable of giving
protection against moisture and liquid splash.
20.2.4 The instrument console units shall be protected by framework or crating of heavy
construction arranged to prevent any contact between instruments or component
parts, and frame or crate. Shipping stops, supports, cushioning are to be fitted to
eliminate damage to console face, structure and equipment.
20.2.5 Final dispatch instructions including the prescribed method of transport will be
supplied by the Contract. These instructions will include requirements for marking
and documentation.

21.0 SITE ACCEPTANCE TESTING

CONTRACTOR shall produce and issue to OWNER a DCS Site Acceptance Testing (SAT)
procedure for OWNER approval. The DCS SAT procedure shall be included within the DCS
Material Requisition and it shall be a requirement of the Material Requisition that the DCS
CONTRACTOR shall carry out the SAT in accordance with the approved SAT procedure to
OWNER satisfaction.
It shall be the stated aim of the DCS SAT to determine the compliance of the system with the
requirements of OWNER Standard Specifications and the Specification defined by
CONTRACTOR. The SAT test procedure shall be structured and shall include such tests and
checks so as to achieve this aim.
The DCS SAT procedure shall include the following requirements as a minimum :
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(1) All phases of the SAT shall be witnessed by CONTRACTOR and the OWNER.
(2) The Quality Assurance Documentation produced for the SAT shall require the signatures
of designated SAT witnesses from the DCS Vendor, CONTRACTOR and OWNER.
(3) Defects shall be recorded and a log of required corrective actions kept, the SAT shall
require that his system is not accepted until all defects are corrected and the correction
retested in accordance with the SAT procedure.
(4) No item shall be regarded as accepted unless it has been witnessed by the designated
test personnel from the DCS Vendor, CONTRACTOR and OWNER and these designated
personnel have signed and dated the QA documentation.
(5) The system shall be fully assembled prior to the SAT.
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(6) The SAT shall begin with an inventory check and an inspection of all enclosures and
tagging cable identification against the inventory.
(7) The system shall be powered up and loaded with the latest version of both the DCS's
standard and application software.
(8) All DCS I/O shall be checked in accordance with the approved SAT procedure.
(9) All power supply change over facilities shall be tested by `failing' one of the supplies.
(10) System functionality shall be tested with actual or simulated I/O in accordance with the
approved SAT procedure.
(11) Communications gateways shall be tested by connection to their intended destination
device.

22.0 CHECKOUT AND INSPECTION

The Vendor’s prices shall include the engineering and administration services necessary to fulfill
the requirements of this specification.
22.1 Project Management Service
The CONTRACTOR shall be capable of providing the services of an experienced project
manager to act as overall coordinator during the course of the project. The CONTRACTOR
shall describe in detail the project management provided.
22.2 Configuration/Data Base Generation
22.2.1 The CONTRACTOR shall provide configuration services for incorporating the
OWNER’s configuration and data base information into the control system from
complete CONTRACTOR forms. Plant computer data base generation is also
included.
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22.2.2 The CONTRACTOR shall provide the necessary instruction course or courses to
teach CONTRACTOR and / or OWNER personnel how to configure the control
system and program the computer.
22.2.3 The CONTRACTOR shall be responsible for the initial configuration of the control
system and programming the computer. He shall also supply
CONTRACTOR/OWNER with the back-up documentation used in configuring the
system.
22.2.4 The CONTRACTOR shall be responsible for modifying the configuration and
programming as required during factory test. A 100 % system test will be performed
before start-up of the plant.
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22.3 System Checkout Services

22.3.1 The Vendor’s prices shall include the level of system staging and checkout
performed at the factory. Provision shall also be made for user checkout prior to
shipment.
22.3.2 The system CONTRACTOR shall completely checkout all components of the system
in his shop in order to fulfill quality control and assurance procedures. This will
include loading the CONTRACTOR’s configuration into the system and testing it for
correctness and operability
22.3.3 When the CONTRACTOR is satisfied that this system will perform as required,
CONTRACTOR and OWNER personnel shall then inspect the system at the
vendor’s facility and perform any component, system, or configuration checks.
22.4 Maintenance Training and Spare Parts
The following has to provide :
22.4.1 A list of maintenance training courses available for the OWNER’s personnel
including cost, location, prerequisites, length of course, etc.
22.4.2 Indication what types of maintenance contracts are available along with the details
including cost of each type.
22.4.3 Price list of recommended spare parts.
22.4.4 The nearest source of spare parts for various items and expected time to deliver
them to the plant site or turn around for vendor-repaired items.
22.4.5 The location of the nearest qualified service personnel and normal response time to
the plant site.
22.5 Field Service Support
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22.5.1 Field Maintenance

Define all aspects of field service maintenance organization including :
(1) Availability of field service personnel 24 hours per day at the Plant site during
start-up.
(2) Field service rate for both on-call personnel and full annual maintenance
contract basis.
(3) Availability of spare parts other than at the Plant site with transit time on a
normal and emergency basis.
(4) Availability and number of qualified field service personnel for on-call
assistance.
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22.5.2 Field Applications

Structure and availability of his field service applications organization to be provided,
including:
(1) Availability of system application engineers to assist in evaluating system
performance and possibly recommend system improvement based on operating
experience.
(2) Availability of system software engineers for assistance in optimizing existing
applications software or consultation in the development of new software.

23.0 COMMISSIONING
On completion of the SAT, CONTRACTOR shall commence commissioning activities via the
loop checks. DCS commissioning shall proceed in conjunction with the Plant commissioning
and shall not be deemed complete until the Plant itself is commissioned and producing on
specification product.

CONTRACTOR shall include within the DCS Material Requisition a requirement that the DCS
CONTRACTOR shall be represented by a competent Engineer throughout the DCS
commissioning, the DCS Vendor's Engineer shall witness all commissioning activities and
provide technical support to the commissioning team.

24.0 DOCUMENTATION
The DCS document shall be provided as following items.
24.1 Block Diagrams
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Block diagrams shall be submitted for the complete system. Diagrams shall be arranged so
that the overall operation is easy to comprehend. Block diagrams representing system
configurations detailing number of sub systems, the degree of redundancy and the
interface between sub systems.
24.2 Loop Diagrams
The loop diagram drawings shall be submitted and designed according to ISA 5.4.
Instrument Loop Diagrams.

CONTRACTOR will provide the loop diagrams for all control information and digital type
loops in basic formats. CONTRACTOR shall insert all other information for maintenance
purposes.
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Loop diagrams will be reviewed and approved by the Vendor. Loop diagrams will include
internal information on the microprocessor control and display systems showing how these
systems are to be configured along with the necessary field wiring terminal boxes, etc.
24.3 Wiring Diagrams
System CONTRACTOR shall be responsible for providing complete signal, power and
ground wiring diagrams for the system. These diagrams will be complete from the terminal
rack to the control room and will include all internal wiring of the system. The
CONTRACTOR shall also advise the CONTRACTOR of all requirements for system
grounding including the need for separate grounding rods, etc.
24.4 Manual for Start Up and Maintenance
Manuals shall be supplied for the system, comprising:
24.4.1 A system manual
A manual specific to this system, detailing its scope, method of operation including
start-up, shutdown, paper-changing and the layout of the system. This manual shall
also describe in detail the procedures for changing or adding process point
descriptions or system configuration.
24.4.2 Hardware Manuals
Detailing physical and functional specifications of all items of equipment. These may
be standard literature, supplemented as necessary to form a complete and
consistent specification. This manual also contain maintenance procedures, system
block diagrams and wiring schedules sufficient to cover all maintenance which can
be carried out on the Site by a competent technician.
24.4.3 DCS and Human Machine Interface (HMI) Design Criteria and Manual
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Design criteria shall contain process display color, graphic display symbols,
abbreviation list, Coding for DCS signals, transmitter selection displays, typical
drawings for face plate, I/O connection diagram, report, alarm philosophy, and etc.,
operation philosophy, engineering unit, DCS design and function description,
software list, and etc.
24.5 Standard DCS CONTRACTOR Documentation
The DCS Vendor's standard publications including General Specifications (GS), Technical
Information (TI) and Instruction Manuals (IM) shall be provided. These publications shall
be reviewed and edited as necessary to represent the specific system purchased by
OWNER.
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24.6 System Specific Documents

CONTRACTOR shall provide the documents for any non-standard equipment not covered
by the DCS Vendor's standard documentation. Such documentation shall detail the final
As-Built condition of the equipment.
Documents covered by this category shall include but not be limited to:
(1) Description or narratives to all software including a variables list.
(2) Enclosure and Console layout drawings.
(3) Certified drawings for all special hardware, inclusive of parts list.
(4) Cable schedule listing all cables.
(5) Cabinet/Console interconnection drawing or schedule.
(6) Termination Drawings or schedule to all equipment.
(7) Power supply and grounding drawings for each enclosure.
(8) Inventory of components with approved tags.
24.7 Test Quality Assurance Documentation
The format of all test QA documentation shall be submitted with the FAT and SAT test
procedures for OWNER comment. Typically, it shall detail the tag number of the item
under test, the revision of the item under test, the number and revision of the Material
Requisition under which the item was purchased, the item number on that requisition, a
listing of tested/ inspected points in accordance with the approved test procedure, a listing
of defects, signatures of the approved DCS Vendor's, CONTRACTOR's and OWNER's
inspectors.
24.8 General Arrangement and outline drawings.
24.9 All necessary technical literature for describing the microprocessor based control systems
GFG-002

functions and operation (Hardware and Software).

24.10 Bill of materials or equipment list for all control systems.
24.11 Control device list or data base (Microsoft Access) for all control systems. (Motors, on-off
actuators, modulating actuators, control valves, solenoids etc.)
24.12 Control logic diagram.
24.13 System schematic, wiring and loop diagrams for all instrumentation and control systems
furnished by the CONTRACTOR.
24.14 Detail start up and commissioning procedures for all control systems.
24.15 Control logic and GUI configuration design and technical description.
24.16 Control system I/O database defining hardware and software attributes in Microsoft
Access.
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24.17 Details Performance Calculations.

24.18 Single line diagrams of power supply system and control power distribution of all ac and
dc.
24.19 Recommendation for supply and installation of instrumentation cables including shielding
and grounding recommendations for prevention of noise pick-up.
24.20 Standard schematics and logic for motors, actuators, circuit breakers etc. showing the
Control system interface.
24.21 Internal arrangement for DCS and control system cabinets.
24.22 Backup and restore manual for the control system (Visual guide step by step).
24.23 Start up and shutdown manual for the control system (Visual guide step by step).

25.0 TEST EQUIPMENT

CONTRACTOR shall ensure that all test equipment necessary for the purposes of carrying out
the FAT, the SAT and Commissioning tests is made available by the DCS Vendor.
The CONTRACTOR shall provide a list of the DCS Vendor's recommended maintenance test
equipment, manufactures type and model numbers together with a supplier list.
All test equipment shall be accompanied by a current (in date) test certificate tracing the
calibration of that piece of equipment to an agreed national standard, the test certificate shall
carry the test equipment serial number and the authorised signature or stamp of the test
laboratory. The test certificate shall be in the English language.
The traceability of test equipment to national standards shall be detailed in the DCS Vendor's
FAT and SAT procedures.
GFG-002

26.0 THE DCS MATERIAL REQUISITION

26.1 CONTRACTOR shall issue a Material Requisition specifically for the purchase of the
DCS.
26.2 The DCS Material Requisition shall be submitted to OWNER for review and approval prior
to the placement of order.
26.3 The DCS Material Requisition shall specify as a minimum :
(1) The Scope of Supply and control system configuration.
(2) All relevant Regulations Standards and Codes.
(3) Functional Requirements (by CONTRACTOR).
(4) Material Requirements (with approved Vendor's list).
(5) Equipment Locations.
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(6) Environmental, Hazardous area requirements.

(7) Available Utilities.
(8) Reliability and availability Requirements.
(9) Construction Methods.
(10) Testing and Inspection Requirements.
(11) Documentation Requirements.
(12) System maintenance support requirements.
(13) Start-up procedure, SAT procedure, commissioning procedure and check lists.
26.4 The DCS Material Requisition shall specify a system that fully complies with the
requirements of the OWNER defined by CONTRACTOR.

27.0 MASTER CLOCK SYSTEM.

The Contractor shall furnish the Master clock. The master clock shall be the Plant master clock
and have enough outputs for related control system. All computer equipment and networks that
are available in the DCS shall be time synchronized by the GPS antenna receiver system to be
supplied by contractor.

The Master clock system shall receive time synchronizing signals from the satellite signal. One
master clock shall be provided per block. The contractor shall provide a synchronized time code
generator to be used as a backup to the satellite time source in cases when the satellite feed is
lost for a period of time. The contractor shall provide all hardware and software required to
automatically and manually switch from the satellite time source to the synchronized time code
generator source.
GFG-002

The Contractor shall furnish all required master clock hardware and configuration software,
including master clock time digital indicator. Clock system shall include a synchronized clock
which receives a time signal from master clock. LED type with digit at least 8 cm in height shall
be mounted in main control room.
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28.0 AUTHOR COMMITTEE

Khun Khomkrit Hemhatthaporn
Khun Pornchai Kitwimontakul
Khun Pichet Kongtanakomtunkich
Khun Thanapon Nithithanaphak Prepared (Lead)
Khun Kulrachart Dungukos
Khun Karan Chuaiphikroh Prepared
Khun Somyot Phisarn
Khun Anucha Pinyopornsawat
Khun Jaruvit Audkhammee
Khun Wisit Rienprakasit.
Khun Narong Suphankan
Khun Piriya Piriyayon
Khun Sompas Samnianglam
Khun Monchai Karnjanopas Prepared
Khun Pakorn Bubphasiri
Khun Vorapot Mansatit Prepared
Khun Prayong Supakeeratirot
Khun Suppakit Yenjit
Khun Theera Chananuvong
Khun Pongprapun Huayyai
Khun Chumpol Wongthaiwon Prepared
Khun Tianchai Aramyok
GFG-002