Untitled

J3 Program 10080-1-SS-CI-017
Distributed Control System Date: 30/07/2012, Rev. 0
RECORD OF REVISIONS
Date Revision Details Revision

Number
30/07/2012 Issued for implementation 0

Contents
1. Purpose............................................................................................................................. 1
2. Scope ................................................................................................................................ 1
3. Cost competitive engineering and design ........................................................................ 1
4. Conflicts and Deviations ................................................................................................... 1
5. Terms and Definitions ...................................................................................................... 1
6. Abbreviations ................................................................................................................... 2
7. Codes and Standards ........................................................................................................ 4
8. Environmental .................................................................................................................. 6
9. Scope and Responsibilities ............................................................................................... 8
10. DCS Hardware .................................................................................................................. 8
11. DCS Functional Requirements ........................................................................................ 20
12. System Performance ...................................................................................................... 61
13. System Reliability and Availability.................................................................................. 63
14. DCS System Requirements ............................................................................................. 64
15. Time Synchronization ..................................................................................................... 68
16. DCS Engineering Workflow ............................................................................................ 68
17. Inspection and Testing ................................................................................................... 70
18. Control and Technical Buildings ..................................................................................... 74
19. Field Technical Buildings ................................................................................................ 75
20. Warranty and Post-Warranty Maintenance .................................................................. 76
21. Quality ............................................................................................................................ 77
22. Drawing and Documentation ......................................................................................... 78
23. Installation ...................................................................................................................... 80
24. Packing and Shipping...................................................................................................... 80
Attachment-1: Scope of work .................................................................................................. 81
Attachment-2: Documentation Required ................................................................................ 91
Attachment-3: Functional Design Specifications ................................................................... 103
Attachment-4: Display and Graphics Requirement ............................................................... 110
Attachment-5: Instrument Asset Management System (IAMS) ............................................ 147

Attachment-6: Alarm Management System (AMS) ............................................................... 167
Attachment-7: Project Execution ........................................................................................... 184
Attachment-8: Third Party Integration Test........................................................................... 187
1. Purpose
This document provides the general technical specifications for Distributed Control
System (DCS) and associated equipment’s.
2. Scope
This specification provides minimum technical requirements for design, performance,
reliability, inspection, testing, delivery, installation and operation of a Distributed
Control System (DCS) and associated equipment’s.
The function of these systems is to provide the operator with the ability to perform
all process control functions, such as discrete, analog, and logic, etc., as well as data
acquisition functions and all other operator process interface and control functions.
In addition, the system will provide the facilities for the retrieval of data used for
management reporting, process engineering analysis, process modeling, trouble
shooting and advance controls.
All equipment and accessories covered by this specification shall comply with all
Project Specifications.
3. Cost competitive engineering and design
The MANUFACTURER/SUPPLIER engineering team shall maintain the cost focus
throughout all phases of the project. This should be done without compromising any
specification and design requirements.
4. Conflicts and Deviations
MANUFACTURER/SUPPLIER shall be responsible to inform any conflicts between this
specification and other applicable specifications, industry standards and codes to
MANAGING CONTRACTOR/OWNER. MANUFACTURER/SUPPLIER shall proceed
further in the concerned matter only after conflicts are resolved in writing by
MANAGING CONTRACTOR/ OWNER.
In general, order of priority of the documents shall be as follows,
Local regulatory and statutory requirement,
Project specification, including datasheets where applicable
This specification and relevant equipment/system specification,
Codes and Standards,
MANUFACTURER/SUPPLIER shall be required to obtain prior approval from
MANAGING CONTRACTOR/OWNER for any deviation from this specification.
5. Terms and Definitions
MANAGING CONTRACTOR: The party responsible for Design, Engineering,
Procurement, Construction and Commissioning of
10080-1-SS-CI-017 Page 1 of 203

the project on behalf of OWNER.

MANUFACTURER/SUPPLIER: The party that manufactures or supplies equipment
and services to perform the duties as per project
specifications.
OWNER: Reliance Industries Limited
The word "shall" indicates a requirement.
The word "should" indicates a recommendation.
6. Abbreviations
APC and OPT Advanced Process Control and Optimization
AC Alternating Current
BOM Bill of Material
CCTV Closed Circuit Television
CMRR Common Mode Rejection Ratio
CPU Central Processing Unit
CRCA Cold Rolled Commercial Anneal
DC Direct Current
DCS Distributed Control System
DD Foundation Fieldbus Device Descriptions
ESD Emergency Shutdown System
ECS Electrical Control System
EWS Engineering Work Station
Increased Safety (Explosion protection
Ex-e
technique)
Ex-i Intrinsic Safety (Explosion protection technique)
FAT Factory Acceptance Test
IFAT Integrated Factory Acceptance Test
FDS Functional Design Specification
FF Foundation Field Bus
FIFO First In First Out
FISCO Field Intrinsic Safety Concept
FGS Fire and Gas System
10080-1-SS-CI-017 Page 2 of 203
FNICO Fieldbus Non-Incendive Concept

GPS Global Positioning Satellite
HVAC Heating Ventilating and Air Conditioning
HMI Human Machine Interface
IFC Issued For Construction
I/O Inputs / Outputs
IP Internet Protocol
IS Intrinsically Safe
ISAT Integrated Site Acceptance Test
ISBL Inside Battery Limit
LAN Local Area Network
MIS Management Information System
MTK Master Time Keeping
MCC Motor Control Center
NMRR Normal Mode Rejection Ratio
P and ID Piping and Instrumentation Diagram
PIMS Plant Information Management System
PLC Programmable Logic Controller
PSU Power Supply Unit
PCC Power Control Center
PAC Pressurized Air Conditioning
PCS Package Control System
pps Parameters Per Second
RFI Radio Frequency Interference
RFQ Request for Quotation
RMS Remote Maintenance System
RTD Resistance Temperature Detector
SAT Site Acceptance Test
SCSI Small Computer System Interface
10080-1-SS-CI-017 Page 3 of 203

SDS Software Design Specification

SIS Safety Integrated System
SPI Smart Plant Instrumentation
STP Spanning-Tree Protocol (IEEE 802.1d standard)
T/C Thermocouple
TCP/IP Transmission Control Protocol/Internet Protocol
TÜV Technischer Überwachungs Verein
UHF Ultra High Frequency
UPS Uninterruptible Power Supply
VDU Visual Display Unit
VHF Very High Frequency
7. Codes and Standards

All design, materials, construction and performance shall conform to the latest issues
of relevant internationally recognized codes and standards including, but not limited
to, the following:
IEC 60079 Installations and Maintenance of Electrical Apparatus
for Use in Potentially Explosive Atmospheres
IEC 60529 Degrees of Protection of Enclosures
IEC 60617 Graphic Symbols for Electronic Diagrams.
IEC 801.4 Electromagnetic Compatibility for Industrial Process

Measurement and Control Equipment
IEE 4 Guidelines for Documentation of Computer Software
for Real Time and Interactive Systems
ISA S5.1 Instrumentation Symbols and Identification
ISA S5.2 Binary Logic Diagrams for Process Operations
ISA S5.3 Graphic Symbols for DCS Display Information, logic and
computer system
ISA S5.5 Graphic Symbols for Process Displays
10080-1-SS-CI-017 Page 4 of 203

ISA 71.01 Environmental Conditions for Process Management

and Control System, Temperature and Humidity
ISA 71.04 Environmental Equipment Conditions for Process
Management and Control System, Air-borne
Contaminants.
ISA 50.02 Part-2 Fieldbus Standard for Use in Industrial Control Systems,
Part 2: Physical Layer Specification and Service
Definition
ISA 18.2 Management of Alarm Systems for the Process
Industries
ISO 9001 Quality Management Systems Requirements.
FF-569 Foundation™ Fieldbus Host Interoperability Test

Procedures
FF-816 Foundation™ Specification 31.25 kbits/s Physical Layer
Profile
FF-890 Foundation™ Specification Function Block Application
Process
AG-181 Rev. 3.1 FF System Engineering Guidelines
ANS/ISA RP55.1 Recommended Practice – Hardware Testing of Digital

Process Computers
ANSI/ISATR99.00.01 Security Technologies for Manufacturing and Control
Systems
OPC Object Linking and Embedding for Process Control
ANSI/ISA R99.00.02 Integrating Electronic Security into the Manufacturing

and control Systems Environment
EEMUA 191 Alarm System, a guide to design, management and
procurement
NE-107 Self-Monitoring and Diagnosis of Field Devices
NE-43 Standardization of signal level for the breakdown

information of digital transmitters
IEC 61000-4 Electromagnetic Compatibility (EMC) Part 4: Testing
and measurement Techniques
10080-1-SS-CI-017 Page 5 of 203

IEC 61158 Digital data communications for measurement and

control - Fieldbus for use in industrial control systems
IEC 61508 Functional Safety of
Electrical/Electronics/Programmable Electronic Safety
Related Systems
IEC 61151 Functional Safety- Safety Instrumented Systems for the
Process Industry Sector
IEEE Institute of Electrical and Electronics Engineers
IEEE 802.3 Communication Standard: Defines carrier sense

multiple access with collision detection (CSMA/CD)
access method and physical layer specifications.
IEEE 802.3ab Defines a media access method and physical layer
specifications for 1000Base-T Gigabit Ethernet.
IEEE 802.3u Defines a media access method and physical layer
specifications for 100Base-TX Fast Ethernet over CAT5
cable
IEEE 802.3x Defines Ethernet frame start/stop requests and timers
used for paused flow control on full-duplex links
IEEE 802.3z Defines a media access method and physical layer
specifications for 1000Base Gigabit Ethernet
CENELEC EN-50039 Electrical Apparatus for potentially explosive
atmospheres - Intrinsically safe electrical systems
10080-1-ENGG-DBD- Control and Instrumentation Design Basis
CI-001
8. Environmental
8.1. Control Room/PIB Condition
The System will be located in an air conditioned environment which will be to ISA
S71.01 G1.
Normal operating conditions will be:
22 ± 2 °C and 50% ± 6% non-condensing Relative Humidity.
Air flow shall be from bottom to top for cabinet design.
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All the electronic components / cards for controllers, I/O's, data acquisition systems,
operator interface, engineering interface subsystem and gateway interface
subsystem for DCS shall be ISA S71.04 G3 compliant.
Control room/PIB temperature, pressure, corrosion level shall be monitored and its
high alarm shall be provided in DCS. Measurement instrument shall be in
MANUFACTURER/SUPPLIER scope of supply.
8.2. Short Term
However, in case of failure of air-conditioning system the Panels and the components
in it shall be capable of operating for a minimum period of 48 hours (continuous),
without any damage or degradation in the performance, when the panels and the
Components will be subjected to extreme temperature and humidity conditions
Specified.
Temperature: 0 to 50 °C (32 to 122 °F)
Relative humidity: 10 to 90% @32°C non-condensing
8.3. Vibration
Maximum 0.2G 20 - 300 Hz
Maximum displacement 0.01", 5-20 Hz
8.4. Dust Contamination
OWNER shall provide the required air conditioning for this project. Air conditioning
filtration shall be capable of filtering 95% of 5 microns particle size for re-circulated
air and 0.5 microns fresh air. The air shall be free from corrosive contaminants.
Dust contamination shall be kept to a minimum. The system and environment shall
be thoroughly cleaned before operation.
8.5. Shock
Below 10 G vertical direction only.
8.6. Static
Precautions shall be taken to guard against discharge.
8.7. Component Protection
All components, equipment and cable shall be resistant to bacterial, fungal attack
and airborne chemical attack. MANUFACTURER/SUPPLIER shall specify acceptable
level of such contaminants.
8.8. Heat Load
The MANUFACTURER/SUPPLIER shall specify the heat load of each separate
equipment unit separately and total for the system. The MANUFACTURER/SUPPLIER
shall specify if the equipment requires forced or convection cooling. It is preference
that all printed circuit boards are mounted in vertical planes.
10080-1-SS-CI-017 Page 7 of 203
8.9. Ambient Lighting

The MANUFACTURER/SUPPLIER is to recommend the ambient lighting level within
the control room, for optimum clarity and minimum glare of the VDUs. The figure is
to be quoted in Lux. MANUFACTURER/SUPPLIER to recommend suitable lux level in
marshaling rack room also.
9. Scope and Responsibilities
The MANUFACTURER/SUPPLIER shall accept total responsibility for the overall
system as specified. This includes system design, procurement, fabrication,
assembly, configuration, programming, building of displays such as dynamic graphics
and reports/logs, FAT, IFAT packing, shipment, supervision for site installation, SAT,
ISAT, pre-commissioning and commissioning assistance.
The MANUFACTURER/SUPPLIER shall supply all hardware, system and application
software, configuration, cabinets, termination facilities, work stations, consoles,
power supply units, peripherals, systems cables, communication cables,
documentation, licenses, dongles and other equipment required for a fully
functional, operable, reliable and maintainable system.
DCS MANUFACTURER/SUPPLIER shall include a complete set of furniture for the
Control Rooms of ergonomic design, especially designed for computer peripherals
from OWNER approved reputed manufacturer. The set of furniture shall include but
shall not be limited to Control Operator’s, console, chairs, tables for mounting
printers, PCs, cabinets for storage of manuals/booklets/recorder charts, storage racks
for special tools/ diskettes/DVD’s/CD’s etc.
Refer Attachment-1 for detail scope of work.
10. DCS Hardware
The DCS shall be the MANUFACTURER/SUPPLIER’s field proven standard product
using standard configurable software. Hardware shall consist of the following as
minimum.
Control and data acquisition modules.
Process Input / Output modules (Type as per project requirement).
Serial Communication Modules.
Communication interface modules between the DCS and other systems such as
ESD, package PLC’s and package control systems.
Engineering Station.
Operator stations.
Servers.
Communication network.
10080-1-SS-CI-017 Page 8 of 203

Interconnecting cabling between various DCS equipment in the Control Room.

Serial link cables between DCS and package control system along with associated
Network switches (package vendor shall supply up to communication module).
Hardwired console complete with hardwired push-buttons, switches and
communication equipment.
Historian and Storage Devices.
Alarm Management PC with software.
Asset Management PC with software.
System cabinets.
Marshalling Cabinet.
Server Cabinets.
Interposing Relay Panel.
Fiber optic Patch Panel.
Fiber Optic Patch card and all necessary accessories.
Control Room and Engineering room Console.
Applicable Network Devices and Cables.
All Panel internal Hardware like terminal strips, fuses, relay, barrier etc.
All communication Interface module or Network Device for integration with MIS
(Management Information System)
Network Laser Printer with colour and black and white print facility (capability of
printing 12 pages per minute in case of colour printing and 22 pages per minute
in case of black and white printing or better
Printer paper and consumables for a minimum period of 6 months consumption
from the start-up.
Time synchronizing equipment for DCS, ESD and package control systems,
including GPS server.
Network management system (including switches and servers)
Display wall server (Video Wall-Large Screen Display)
Network Switches
WEB server with software (Minimum 5 premier concurrent users)
Remote Maintenance facility with server (RMS)
Firewall
10080-1-SS-CI-017 Page 9 of 203

OPC server with software.

Documentation server PC.
10.1. System Cabinet
DCS cabinets shall be free standing type of dimension 800mm wide x 800mm
deep x 2100mm high (includes 100mm plinth) with cable entries from the
bottom.
All free standing cabinets shall have front and rear access with double leaf hinged
lift off doors. Front and Rear access shall be considered subject to MANAGING
CONTRACTOR/OWNER review and approval.
The system cables shall be plug in type and shall be terminated at sockets to
MANUFACTURER/SUPPLIER’s standard.
Each DCS system cabinet shall have its own independent protection against Radio
Frequency Interference (RFI) with door open in accordance with IEC 61000-4.
For panel baying, proper isolation (Side Plates) shall be provided between two
groups of panels like Analogue In/Output and FF etc.
Ventilation fans and louvers backed by dust filters shall be provided in each
cabinet.
All electronic cards shall have unique serial number and node number (where
applicable) which shall be indicated on the hardware test report.
All unused card locations shall be fitted with cover plates.
20% spare space shall be provided in all DCS cabinets.
Cables entering the DCS cabinets, auxiliary console shall be properly clamped
with armour grounding.
All terminals carrying more than 24 VDC shall be protected against accidental
contact by means of removable cover and shall be labeled accordingly. Signals of
different voltage levels shall be run in separate turnings and shall be segregated
on the terminal boards
10.2. Marshalling Cabinet
The marshalling cabinets shall be free standing cabinets of dimension 1200mm
wide x 400mm deep and 2100 mm high including a plinth of 100 mm.
The marshalling cabinets shall be provided with front and rear access with double
leaf hinged lift off door.
Cable entry to the marshalling cabinet shall be from the bottom. All cables shall
be clamped.
All Digital Output signal cables to be terminated by fuse link terminal with LED
indication for fuse blowing.
10080-1-SS-CI-017 Page 10 of 203
Blue terminals shall be provided for the intrinsically safe field cables. Grey
terminals shall be provided for the non-intrinsically safe field cables.
For panel baying, proper isolation (Side Plates) shall be provided between two
groups of panels like Analogue In/Output and FF etc.
Intrinsic safety barriers or galvanic isolators shall be installed inside the
marshalling cabinets for the IS field signals. All barriers shall be galvanically
isolated type of approved make. Adequate space shall be kept between barriers
for heat dissipation and easy replacement without affecting other connection.
Intrinsic safety wiring shall be blue in colour.
Conductor size of internal signal wiring shall be 1.0 sq. mm. minimum.
Conductor shall be stranded type terminated with crimped wire lugs.
IS and non-IS wiring shall be adequately segregated according to CENELEC EN-
50039.
Isolated earth bus bars (safety earth, IS earth and instrument earth) shall be
provided in the marshalling cabinet.
All the terminals in termination panel shall be independently accessible.
All thermocouple signals shall be directly terminated to the barrier.
MANUFACTURER/SUPPLIER to follow the Design philosophy of marshalling cabinets
as following (Detailed out later during Function Design specification) for quotation:
Marshalling cabinets shall be provided for each individual unit.
Separation of Marshalling cabinets will be Analog (IS), Digital (IS), Analog /Digital
(NIS) and Foundation Fieldbus.
In Marshalling cabinets, all incoming cable unused core/pairs shall be connected
to spare terminals.
Plastic wire ducts with removable covers shall be installed in cabinets as required
to provide a means of routing and organizing wiring. A minimum of 50 mm shall
be maintained between the duct and terminal strips. Wire markers shall be
completely presented without being obscured by the duct.
In addition to the above, the maximum plastic wire duct fill (including spare
capacity) shall not exceed 75% of its depth.
All spare entries shall be closed with SS blind plugs.
MANUFACTURER/SUPPLIER to advice with the bid for any deviation from above
spec.
The following shall be applicable to both System cabinets as well as marshalling
cabinets:
10080-1-SS-CI-017 Page 11 of 203

MANUFACTURER/SUPPLIER’s equipment cabinets, consoles and termination

cabinets will be installed within Control Room / Equipment Rack Room. A
computer type floor will be provided with an under floor void approximately 0.8
meter deep. Suitable under floor steel support framework will be provided by
OWNER.
Cable gland plate with mesh arrangement shall be used. Cable entry to cabinets
will be from below. All opening remaining after entry of all cables shall be sealed.
The seals shall be easily removable to enable entry of cables for future use.
All cabinet colors shall be
 Outside: Powdered coated in textured Grey RAL 7035.
 Plinth : Dark Grey RAL7022
The 110-VAC power distribution to DCS cabinets shall include a main circuit
breaker. Individual breakers shall be provided for the following circuits: 24-VDC-
power supply, rack power supply, output modules. Each output shall be
individually fused.
Panel lighting and receptacles for maintenance shall be of universal type provided
with normal 230 VAC, 50 Hz electrical distribution board. Each panel shall be
provided with separate incoming breaker for 230 VAC and 110 VAC incoming
power isolation.
All the bus bars to be protected with Acrylic sheets against accidental contact
with hazard/danger symbols/tags.
Cabinets shall be supplied completely wired, assembled, tested, and ready for
installation.
Terminal shall be spring loaded type. Terminals for field cable termination shall
be knife-edge disconnect type, hinge on the field side. Terminals shall preferably
Phoenix/Wago or equivalent.
Conductor size of internal signal wiring shall be 1.0 sq.mm whereas all power
cabling inside the cabinet shall be minimum 2.5sq.mm. Conductor shall be
stranded type terminated with crimped wire lugs. Maximum number of wires per
terminal shall be only one.
Equipment and enclosures shall be constructed to withstand vibration as per
clause 8.3 in addition to vibration encountered in plant environments. The
equipment shall not become loose or damaged in any way due to vibration.
Panel temperature rise calculations shall be provided by the
MANUFACTURER/SUPPLIER to determine if supplemental cooling is required to
protect the components within the enclosure. Cooling fans shall be provided
wherever required. Cooling fan noise level shall not be higher than 65 dBA
measured at a distance of 1 meter from source with cabinet doors closed. Filters
10080-1-SS-CI-017 Page 12 of 203

associated with cooling mechanisms should be readily and easily accessible and
replaceable.
Each panel with a power supply shall provide a temperature alarm, a ventilation
fan failure alarm in DCS and In the case of FF System Cabinet an alarm from the
power conditioning module in the DCS. All hardware for above alarm should be
included by Vendor.
A common key shall be provided for all locks. No equipment / components shall
be mounted on doors or side panels.
Separate ducts shall be used for System, Power and Signal cable with segregation
between different types of signals.
The cabinet layout shall be such as to provide clear access to the internals for
maintenance.
Ventilation fans and louvers backed by dust filters shall be provided in each
cabinet.
Each cabinet shall be provided with internal illumination activated by door
switch.
All unused card locations shall be fitted with cover plates.
20% spare space shall be provided in all cabinets.
Cables entering the DCS cabinets, auxiliary console shall be properly clamped
with armour grounding.
All terminals carrying more than 24 VDC shall be protected against accidental
contact by means of removable cover and shall be labeled accordingly (Warning
Text). Signals of different voltage levels shall run in separate turnings and shall be
segregated on the terminal boards.
The indoor cabinets shall have an ingress protection of IP54 as raw panel and
minimum IP33 after cutout.
All cabinets shall be provided with removable lifting lugs.
The cable entry for all instrumentation cables from field to control equipment
room and to control room shall be with the help of Multi Cable Transit (MCT)
blocks. There shall be 50% spare entry available in these MCT systems. Proper
segregation shall be maintained in groups of various signal level cables MCT
block.
MANUFACTURER/SUPPLIER to advice with the bid for any deviation from above
specifications.
10.3. Identification
Each cabinet shall have an identifying nameplate fixed on the front and rear with
screws. OWNER tagging system shall be used. The format of which will be advised to
10080-1-SS-CI-017 Page 13 of 203
the MANUFACTURER/SUPPLIER. Internally mounted equipment shall be clearly

identified as to the device or function they serve by name plates using Traffolyte type
W/B/W labels.
All electronic cards shall have unique serial number and node number (where
applicable) which shall be indicated on the hardware test report.
10.4. Wiring
The internal wiring of the DCS system will be as per MANUFACTURER/SUPPLIER’s
Standard.
System cabling between marshalling cabinet and system cabinet, cabling
between DCS cabinets and operating consoles, between DCS cabinets and ESD
cabinets shall be according to MANUFACTURER/SUPPLIERs Standard.
Channel mounted terminal blocks of make Phoenix or Wago SAK 2.5 or equal
shall be used for termination of signal cables in the system cabinets. Larger size
terminals shall be provided, if necessary for power cables.
All System cables, Communication cables including fiber optic cables, ribbon
cables, serial interface cables, DCS data highways, printer cables etc. shall be
within MANUFACTURER/SUPPLIER’s scope. The length shall be calculated based
on final rack room and control room panel layout drawing.
System cables between equipment cabinets, termination cabinets and
peripherals shall utilize plug and socket techniques to the maximum extent
possible. Each cable shall be supplied with a unique cable marker at both ends.
Cable schedules / block diagram shall be provided to enable quick hook-up at
site. As far as possible the design of pre-formed cables and sockets should be
used after first marshalling rack.
All wires shall be tagged using slip on heat shrink type markers / Printed Type.
Tag numbering shall be subject to approval by OWNER/Managing Contactor.
Terminals shall be clearly identified. Group header shall be used to identify rows /
groups of terminals. Preference is for different colored terminals for various
voltages.
10080-1-SS-CI-017 Page 14 of 203

Panel internal wiring colour coding shall be as below
Power Distribution
Brown
240V AC Utility (N)
240V AC Utility (L)

Blue
110V AC (Live)
Brown
110V AC (Neutral)
White
24V DC (Positive)
Red
24V DC (Negative)
Black
Signal
24V DC(Analogue and Digital) Light Grey
Wiring between terminal block and IS

barrier Blue
Wiring for non-IS signals

Grey
Earthing
Yellow(where
Intrinsically Safe Earth
applicable)
Instrument Earth
Green
Protective Earth
Green/Yellow
10080-1-SS-CI-017 Page 15 of 203

10.5. All Hazardous area field instrumentation connected to DCS will be either intrinsically
safe or flame proof. The use of Foundation Fieldbus shall be maximised. However, in
addition, SMART field devices using 4-20mA signal for control and HART data for
diagnostic shall be used. For Safe area IS protection is not required and isolators as
required shall be used.
10.6. Power supply
OWNER shall provide 110VAC ± 5%, 50 Hz ± 3 % redundant single phase, grounded
uninterrupted power supply (UPS) to power distribution cabinet of DCS.
Switchover to redundant power supply in case of failure of one should be less
than 0.5 ms. DCS Power Distribution cabinet is under MANUFACTURER/SUPPLIER
scope of supply. Further distribution to all DCS components shall be in scope of
MANUFACTURER/SUPPLIER.
MANUFACTURER/SUPPLIER shall provide UPS consumption initially during
quotation stage and during detail engineering. In case of increase in UPS
consumption later, MANUFACTURER/SUPPLIER shall provide his own UPS system
to take care of same.
All necessary cabling, glanding, termination and further distribution / conversion
to different power levels including isolation transformers if required shall be in
the scope of MANUFACTURER/SUPPLIER. Size of the UPS shall be arrived after
considering system and user loads.
The system load shall be calculated considering
Expandability of I/O’s including installed spares 20% and future spare of 20%.
Inrush current and Power Factor for system / user load shall be considered
The MANUFACTURER/SUPPLIER to state power supply tolerance limits of the
system without a UPS attached the degree of immunity of the system to mains
born noise and interference without a UPS system and the system response
under “burnout” and transient over voltage conditions without a UPS system.
AC power connection for the equipment requiring such power is made, using
three conductors: AC (live), AC (neutral) and ground. Protected access and over
current protection of the AC (live) is required.
MANUFACTURER/SUPPLIER shall provide all filters, transformers, rectifiers, etc.,
to convert the above power supply to the level acceptable to the various DCS
equipment.
All electrical terminals inside the system racks and consoles shall be clearly
numbered and permanently identified on the terminals and the system wiring
drawings.
Electrical wiring shall be in accordance with applicable electrical standards.
Wiring diagrams shall be complete with grounds in recommended wire sizes,
10080-1-SS-CI-017 Page 16 of 203

type, and shielding required for the electrical circuits between components that
are to be wired.
The MANUFACTURER/SUPPLIER shall include miniature circuit breakers for AC
supply to each power supply unit and sub-distribution within the system.
Sufficient isolation facilities on the DC sub-system shall be provided to enable
maintenance of components with minimum disturbance to healthy devices.
The fault discrimination shall be such that minimal equipment will be affected by
any particular fault. Power distribution to control devices shall be arranged such
that the loss of an individual circuit does not result in complete loss of control
capability or create unsafe operation conditions. An alarm shall be generated to
alert the operator to loss of power to a device.
Utility power supply shall be provided for lighting equipment and convenience
outlets. Each convenience outlet shall be wired to an individual breaker (non-UPS
Power) and shall be fed independent of instrument power supply breaker (UPS
Power). Utility power socket should be identified with different connections or by
colour.
All the 24 V DC power supply units for the system shall be supplied and mounted
on system racks by MANUFACTURER/SUPPLIER and made redundant with both
continuously active. 24VDC Power supply shall be with appropriate diode-OR-
ring. Each power supply unit should be able to cater to 120% of design load and
at the same time this demand shall not exceed more than 60% of the power
supply unit capacity during normal operation i.e shall be loaded upto 60%
maximum. In normal operation there will not be any load sharing between two
bulk power supplies.
It shall be possible to remove at least one power supply for maintenance without
affecting the overall load requirements of the system. The power supplies shall
have separate fusing and diode isolation. For easy access and maintenance, DIN
rail mounting provision for Bulk Power Supply is preferable.
There shall be provision to power all field transmitters, analogue outputs, digital
inputs and digital outputs from the 24 volt system. MANUFACTURER/SUPPLIER
shall state the current rating for each power supply.
The system shall have a power supply monitoring facility that checks the internal
power output voltages are within tolerance. The monitoring facility shall be fed
into the system diagnostic facilities. Appropriate alarms shall occur on any power
supply failure.
The operator shall, by means of a system alarm, be informed of the failure and
switch-over. No loop shall be lost by the failure of a single power supply.
Internal power supplies shall be fused for short circuit protection and shall have
thermal overload self-resetting protection unit. Every power failure shall
generate a system alarm plus a local indicator (LED or flag).
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All internal power supplies shall be mounted at the top (preferably) or bottom of
the racks.
MANUFACTURER/SUPPLIER shall mention maximum static transfer time of UPS
which the DCS system shall tolerate without affecting plant operation.
10.7. Earthing
Each DCS equipment shall be provided with protective and signal earth.
10.7.1. Protective Earth
All metal components must be connected to a protective earth system.
Flexible conduits, soldered joints or door hinges are not accepted as earth
returns.
All earth connections must be made direct to the earth point for all system
cabinet. Looping is acceptable in case of marshalling cabinets.
10.7.2. Signal Earth
Signal earth must be totally separate from the protective earth and must be of very
high integrity.
IS/Instrument earth bar, mounted on insulators shall be provided in each
equipment and termination cabinet. It will be used to ground zero volt
references and signal cable screens
Signal cable screens of all multipair (including shield of spare pairs) cables shall be
terminated on the IS/Instrument earth bars via terminals.
The MANUFACTURER/SUPPLIER shall provide all earth continuity links required
for his equipment.
Provision shall be made for terminating 35mm2 stranded copper structural and
IS/Instrument earthing conductors supplied by the MANAGING CONTRACTOR
Segregation between different voltage levels must be achieved using barrier
strips between terminals connected to different voltage levels.
MANUFACTURER/SUPPLIER shall specify any separate / additional earthing
requirement for his system. MANUFACTURER/SUPPLIER shall indicate the
maximum earth resistance value separately for the system supplied.
10.7.3. General
Generally following points shall be considered:
Dedicated noise free earth of less than 1 ohm
Shall be away from any heavy plant or high noise.
The earth shall be as short and straight as possible via a heavy cable preferably a
flat copper strap.
10080-1-SS-CI-017 Page 18 of 203
The environment shall be such as to reduce the likelihood of static build up and
discharge by using antistatic materials for floors, chairs and other surfaces.
10.8. Electrical System Interface
The electrical equipment shall be provided with their own controls and Safeguarding
equipment. However, there shall be interface between instrumentation and
electrical comprising the following:
Automatic / manual control of selected electrical motors by DCS.
Monitoring of status of selected electrical equipment from DCS.
It is envisaged that interfaces between instrument and electrical shall be via
hardwired signals. MANUFACTURER/SUPPLIER shall provide a dedicated interposing
relay cabinet for all hardwired signals to the MCC/PCC/ECS. The Interposing Relay
Cabinet shall be located in the substation. Its construction shall comply with
requirements of clause 10.2.
The provision of serial link between MCC/PCC/ECS and DCS shall be kept for
monitoring the information required from MCC/PCC/ECS.
Vendor to ensure segregation between AC and DC voltage relay (based on coil
voltage) and Segregation between Different Voltage level relays. Relays shall have on
LED indication.
10.9. Galvanic Isolation
Galvanic isolation shall be provided for all field signals for Hazardous area. All the I/O
cards of DCS shall have individual channel to channel as well channel to field
isolation.
10.10. Barriers and Relays:
Active barriers shall be used for all intrinsically safe instruments. Minimum voltage
required for instrument operation also should be taken into consideration for barrier
selection. Adequate space shall be kept between barriers for heat dissipation and
easy replacement without affecting other connections. Relays with LED shall be used
for isolating discrete digital inputs / outputs from electrical circuits. Relay coil power
and contact should be on different side of relay base. For High Power motor, either
relay with higher contact rating to be used or contactors to be used.
10.11. Spare Philosophy and Spare Parts
Sparring philosophy shall be as follows:
Installed spares:
I/O level (Wired) : 20%
Spare space
I/O racks : 20%
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Marshalling rack : 20%

Mandatory spares : 5 % or minimum 1 no. of each type of module
Spare cores of all field cables shall be terminated in the marshalling cabinets.
MANUFACTURER/SUPPLIER shall recommend and provide hardware/software for
desired functionality of the system.
All bought items shall be as per OWNER approved make.
11. DCS Functional Requirements
The DCS system can be divided into following major sub-systems based on functional
distribution.
System Architecture and Network.
Input / Output subsystem.
Foundation Field Bus subsystem.
HART subsystem.
Wireless subsystem.
Controller subsystem.
Data acquisition subsystem.
Human Machine Interface (HMI) system.
History subsystem.
Asset Management subsystem.
Alarm Management subsystem.
Network Management subsystem.
Communication subsystem.
Serial Interface subsystem.
The functional requirements of these sub-systems are described in the following
sections.
11.1. System Architecture
The MANUFACTURER/SUPPLIER shall provide the system architecture drawing. This
drawing shall include operator workstations, engineering workstations, controllers,
I/O sub-system, bulk storage devices, third party/package system interface, historian,
web-server, asset management system, alarm management system, control network,
plant interface network, firewall, remote maintenance server, documentation server
and output devices etc.
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The system architecture shall provide the necessary hardware and software to satisfy
the needs of following major functions:
Operator station for man machine interface
Interface to process shall be through distributing control modules. Each module
shall be standalone unit capable of performing full data acquisition and can
control of the process via I/O modules.
The Engineering work station shall be high performance workstation capable of
engineering and configuring any DCS device linked to network.
A high speed network connecting all the components of DCS and third party
devices to perform real time information transfer between various components.
All electrical components shall be completely wired and tested. All works shall
confirm to all applicable codes and standard as per project specification.
11.2. DCS System Network
DCS System Network shall be divided into three main networks:
Control Network
Plant Information Network
Safety Network (For ESD Interface not a part of this specification)
These three networks shall be independent and not connected to each other. There
will be Plant interface building (PIB) in ISBL of a plant housing all the Control System
racks and operator stations for local operation and control room common for cluster
of plants housing common high level application servers (Engineering Station, Alarm
Management Server, Asset Management Sewer, Terminal Servers etc).
Architecture and Network Design shall be based on following criterion:
Availability
Reliability
Scalability
Speed
Security for North bound IT applications enabled infrastructure
Centrally managed and administered
11.2.1. Control Network
The core control network shall be dedicated redundant Ethernet network that will
allow single failure to occur without affecting the overall functionality of the system.
Control network shall contain Operator Workstations, Application Workstations, and
Engineering Workstations. and Control Processors. Network traffic shall not affect
controller or server performance. Network shall be deterministic type.
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The control network shall be switched Fast Ethernet network fibre optic based on
lEEE 802.311 (Fast Ethernet) and IEEE 802.32 (gigabit Ethernet) standards. The DCS
control network shall consist of a number of Ethernet switches connected in a
redundant fault tolerant configuration. The flexibility of the architecture shall allow
designing a network configuration that fits the needs of the control system.
Control network shall consider- following topologies:
Standard Configuration
Linear
Ring
Star
Inverted tree
Modified inverted tree
Mesh
Security Enhanced Configuration
Linear
Star
Inverted tree
Modified inverted tree
Mesh
Each configuration topology listed has unique features and one shall be chosen for a
particular network depends on the specific requirements of the project.
System Architecture shall be based on Layer 2 switches (IP based System) and shall
be able to handle the large integrated network.
Layer 2 based system network shall support following features:
IP, IPX, and IP multicast routing and forwarding between Ethernet ports
All standard Routing Protocols
CMF (constrained multicast flooding)
Support for up to 128 IP multicast groups
QoS-based forwarding based on IP precedence based forwarding
Load balancing among equal cost paths based on source and destination IP and
IPX
addresses
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It shall be possible to utilize standard commercial off-the-shelf Ethernet switches to

configure the system to meet functional, performance and plant requirements.
11.2.2. Plant Information Network
As an integral complex, data from all plants shall be correlated for a complete
information management solution. This shall include data from operators as well as
different network that are external to DCS.
Plant Information Network shall be an information network with a redundant fibre
optic backbone between Central Control Building and Plant Information Buildings.
This shall be parallel network to the main control network and it shall not be directly
connected to main control network. This PIN network and main control network shall
be connected together to main control network through common non-bridging or
non forwarding devices such as Engineering workstation, Application Workstations
and operator workstation.
The Plant Information Network is primarily used to access historian data from control
network through application workstation or operator workstation. Other functions
are data recording, printing and file transfer. For security, PIN is protected from
direct corporate network access via a firewall, so only trusted sources are allowed
access. The firewall shall sit at the junction point between the PIN and the corporate
network.
11.2.3. Control Network Considerations
The physical location of equipment at the site influences the control network design.
To choose equipment and cabling appropriate to the requirements for the specific
site, the distances between the ends of control network may determine what kind of
Ethernet switches are used and what kind of cabling is used between those switches.
If individual cable runs are greater than 100 (hundred) meters, it is necessary to use
fiber optic cable, due to its capability for transmitting signals over longer distances.
All hardware must be considered when the network requires multiple hops; no low
end standalone switches shall be used in the network core.
The total network delays between two end devices shall not exceed 100 ms.
There shall not be duplicate MAC addresses across control network VLANs. No VLAN
Port shall exceed 50% loading.
No end devices with transfer (Tx) and receive (Rx) speeds greater than 100 Mbs are
supported. The number of control stations and workstations influences how many
Ethernet switches and separate cables are included in the control network. A plan for
expansion and growth when arriving at this number shall be considered. The physical
distribution of control stations and workstations can have a bearing on the type and
number of Ethernet switches, as well as the type of cabling used.
If the control stations and workstations are clustered together, two larger capacity
switches may be able to accommodate them all. If they are dispersed, several smaller
switches may be a better solution. For large distances and noise protection, fiber
10080-1-SS-CI-017 Page 23 of 203
optic cable between switches or between switches and control stations, workstations
shall be used. Cable routing between devices must also be considered. Control
network with redundant paths is recommended for control systems.
Network switches shall be mounted in cabinet with specifications similar to system
cabinet. Thermal requirements shall be taken into consideration and adequate
ventilation shall be provided.
High or moderate electromagnetic noises sources, for example, machinery,
switchgear, high voltage lines, and so forth, in close proximity must be avoided to
ensure reliable operation.
Ethernet switches with additional ports shall be considered so that control stations
or workstations can be easily added in the future. Running extra copper or fiber optic
cable will allow for network expansion later.
11.2.4. Traffic Considerations
It shall be possible to group control stations or workstations according to
department, process, or other criteria that is important to the site or organization to
reduce traffic through the root/main switches.
It is recommended that each control station or workstation from a particular group
be connected to two separate switches. If one switch were to fail, these control
stations or workstations can access the network through the redundant switch.
Workstations shall have two Ethernet ports to access the network.
11.2.5. Network Loading
DCS system network shall be designed such that sufficient network bandwidth will be
available between the network components. A load prediction shall be achieved by
approximating the environment, modeling the network components and analyzing
the interrelations. Maximum 50 % network load shall be considered.
A network stress test shall be performed for finding the inter switch link load. Based
on this Load calculation shall be performed and network shall be designed.
11.2.6. Network Reliability and availability
The DCS network configuration shall allow high availability by providing redundant
data paths and eliminating single points of failure caused by component link failures.
Failure of any component in network shall not cause system failure.
Network component MTBF shall be high and it shall be hardened for industrial
application standard.
Control, PIN and safety network shall he isolated with each other and not connected
to corporate network. For corporate connectivity firewall shall be considered.
11.2.7. Network Monitoring
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Dedicated software shall be considered for monitoring the control and PIN network.
Monitoring software shall give details such as network component failure, network
loading and route of network path. In a Network with multi layer switches and multi
locations switches Network Management system is recommended, which will
provide network-wide monitoring and troubleshooting, such as device discovery,
topology mapping, and event management. Software shall also have graphical
representation capabilities for network monitoring. Network Monitoring shall also
provide following as a minimum:
Create map of network layout.
Set SNMP (Simple Network Management Protocol) port traps for link loss
detection to be displayed on network map and shall be logged.
Set events to display on network map and logged if loss of switch is detected.
Monitoring broadcast muticast traffic thresholds on each port e.g if 300pps for
100Mbps or 1000pps for 1Gbps is exceeded then the set alarm to show port
exceeding threshold.
Switch Configuration:
Use Console to push configuration changes to switch
Save all switch configurations locally at console to push back down in case of
switch replacement.
11.2.8. Network Design Rules
When designing the physical layout of a large network, the following guidelines
apply:
Switch-to-Switch connections (uplink ports) should be made using 1 Gbs uplink
ports to allow enough bandwidth for network traffic of equipment
There should be a primary and backup switch on the network.
There should be no horizontal connections between switches on the same tier
except the root and backup. This minimizes the number of switch
interconnections in order to facilitate faster network responding of the network
tree. This also reduces the likelihood of a loop occurring.
Each tier should contain an even number of switches.
Each switch should be connected to two different switches in the tier above it
There should be two connections between the primary root and the backup root.
11.2.9. Network Cable
Following are the different types of cables:
11.2.9.1. Ethernet Cable:
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Two basic configurations of Ethernet cables shall be used:

Straight-through cables: cables used to connect workstations to Ethernet
switches, and media converters to Ethernet switches.
Crossover cables (also called a null hub): cables used to interconnect Ethernet
switches.
11.2.9.2. Fiber Optic Cable:
Fiber optic cable shall be used to connect workstations to Ethernet switches and to
make connections between Ethernet switches. The fiber optic cable's electrical
isolation characteristics shall provide protection from voltage differentials and
ground loops and permit communication installations to pass through areas where
intrinsically safe operation is required. Fiber Optic Cable shall be installed even in the
following cases:
Areas containing rotating machinery, arc welders, and so forth
Cable trays containing high voltage power lines
Outdoor areas exposed to lightning hazards (with appropriately rated cable).
Areas containing strong magnetic fields
Longer distances than twisted pair cable limitation
Control Network shall use two different types of fiber optic cable:
Single mode cable
Multimode cable
FO cable’s are preferred to be used for networking.
Refer 10080-1-SS-EL-012 for Fiber Optic cable detail specifications. Fiber Optic Cable
installation guidelines given by cable MANUFCTURER/SUPPLIER shall be followed as
this document scope is limited to Engineering and Design. FO connectivity shall be
preferred for networking.
11.3. Input / Output subsystem
The input/output system shall consist of I/O modules located inside the DCS system
cabinets in PIB’s. The possibility of installing Remote I/O cabinets in the plant area
shall be reviewed and implemented if found economical and shall meet the
hazardous and ambient environment conditions.
The input/output system shall be microprocessor based and shall consist of different
modules for different types of input and output signals like analogue, contacts, etc.
Self configuring I/O system shall be preferred.
The I/O modules shall be on-line replaceable with the system energized without
disturbing field wiring and without causing spurious effects on other modules in the
system.
10080-1-SS-CI-017 Page 26 of 203
The I/O modules shall be capable of accepting the following types of inputs and
outputs:
Analogue inputs (4-20 mA DC) (HART pass through),
Thermocouple inputs,
RTD inputs,
Pulse input (frequency input),
Digital inputs (volt free contacts),
Analogue outputs(4-20 mA DC),
Digital outputs (volt free contacts),
Digital outputs (24 VDC to drive relays and other similar output devices),
24V DC input,
Proximity Switches ( Namur Contacts),
Digital communication with FF / HART / Provirus,
Temperature Multiplexers (Mainly FF).
The digital outputs activating relays shall have 24V DC power supply with minimum
contact rating of 2.0 amps at 24V DC. Digital output cards for Intrinsically Safe type
solenoid valves shall be capable of driving 12W solenoids.
Discrete output modules shall have visible LED indicators on a per channel basis to
indicate the current state of the output.
Discrete output modules shall have the following configurable fail-safe options:
Drive to either energize or de-energize output
Hold last output
The fail-safe actions listed above shall be taken upon processor halt or
communication break between the controller and the I/O module. This shall be
decided during detail engineering stage and licensor recommendation.
The digital inputs shall sense volt free contacts of field switches with 24V DC
interrogation voltage supplied from the DCS system. The input interrogation voltage
shall be 24 V DC for all points coming from hardware auxiliary console. Contact
interrogation voltage shall be 24 VDC.
Discrete input modules shall have visible LED indicators on a per channel basis to
indicate the current state of the input.
The system shall be capable of detecting discrete input transitions with duration of
50 millisecond.
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The input / output sub-system shall be capable of providing software

characterization of inputs like Thermocouple characterization and Thermocouple
cold junction compensation.
Each input shall be provided with digital filter with adjustable time constant.
The analogue input cards shall provide 24 VDC power supply to field transmitters.
Each transmitter power supply shall be protected against short circuit.
Analog Input cards shall also be able to accept powered 4-20 mA signal from field
devices and other modules (4-Wire Devices) Selection of 2 wire and 4 wire shall be
available on I/O cards.
Analog output modules shall have the following configurable failsafe options:
Drive to zero output or full-scale output
Maintain last good output value
The fail-safe actions listed above shall be taken upon processor halt or
communication break between the controller and the I/O module. This shall be
decided during detail engineering stage and licensor recommendation.
Output modules shall be provided with individually fused outputs or current limiters.
The Foundation Field Bus I/O card's shall be capable of carrying out diagnostics and
remote calibration of transmitters from the engineering station and Asset
Management System.
Digital I/O shall be configured with dead band filters to prevent chattering.
Input / output modules shall be capable of supporting process signals from all types
of process sensors and contact closure devices without external or auxiliary signal
conditioning devices.
All Input/output modules shall provide a status LED which indicates the health or
operational condition of the module. The status of the module shall also be
communicated to the system diagnostics software.
Analog input/output cards shall be galvanically isolated and digital input/output
cards shall be optically isolated. This isolation shall be inbuilt feature of each type of
cards and it is in addition to the isolations achieved by active safety barriers to be
used for I/Os of hazardous areas Group isolated type or bulk I/O cards shall not be
used
Analogue input:
Analogue to Digital conversion shall have (minimum):
Resolution - 12 bits minimum
Linearity - Least significant bit
Repeatability - ½ least significant bit
10080-1-SS-CI-017 Page 28 of 203
Accuracy - 0.1% of full scale

CMRR - 120 DB from DC TO 60Hz
NMRR - 60 dB at 50Hz
The system shall be able to detect bad measurements on both open circuits, short
circuit, off limit values of input and on thermocouple / RTD burnout’s. Up –scale or
downscale for Thermocouple / RTD burnout shall be selectable.
Digital to analogue conversion minimum shall have:
Resolution - 12 bits minimum
Linearity - Least significant bit
Repeatability - ½ least significant bit
Accuracy - 0.25 % of full scale
Calibration of the A/D converters shall be automatically checked by the system on a
periodic basis. An indication of calibration error shall be provided by the system.
For inputs and outputs, which cannot be provided by means of standard input /
output cards, option shall be quoted (relay converters).
Minimum required channel density for each AI, AO, DI, DO module shall be specified.
(E.g.: AI-16, AO-8, RTD input-16, DI-32, DO-16 etc.)
11.3.1. Fault Handling
Analog 4-20 mA input cards shall be capable of differentiating between an out of
range measurement signal and a failed transmitter signal.
Upon detection of either high or low transmitter failure alarm signal, the DCS shall
generate a critical alarm (visual and audible).
Invalid value status shall be generated for inputs and calculated variables.
A value shall be declared invalid if any of the following conditions are true:
If a value is out of range.
If a value cannot be measured or calculated.
If a value is declared invalid by an application program.
If a value is declared invalid by the source instrument.
On loss of communications to the data source, invalid value status shall be
propagated through control schemes.
It shall be possible to inhibit the detection and propagation of an invalid value status.
This selection shall be available on a per tag basis. It shall be possible for an invalid
value status to be used as a logical input to initiate control algorithm changes.
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When a control algorithm's input is declared invalid, it shall be possible to configure

the output to take any of the following actions, on a per point basis:
Hold last good value,
Zero output signal,
Full-scale output.
The term control algorithm refers to instructions executed within function blocks
where an output is calculated based on the value and status of inputs to the function
block.
11.4. Foundation Field Bus subsystem
Foundation Fieldbus implementation can be considered for following cases.
In general FF signals shall be considered for all control and monitoring purpose
except for following cases
Licensor requirement for fast or critical control loops.
Anti-surge control loops for compressors.
FF compatible input/output devices are not available.
Small package unit instruments supplying conventional devices.
General monitoring signals.
However, above shall be decided during detail engineering. Vendor to consider 55-60
% FF inputs for design purpose.
FF is implemented by using hybrid technology that allows high power trunks to field
and barriers are located in field junction boxes. Use of Ex-i for the field termination is
preferred. For details refer document “Foundation Fieldbus Philosophy / Guidelines:
AG-181, Rev. 3.1
FF testing tools such as 475, FBT3, FBT6, NI bus monitors etc. or latest shall form part
of this spec.
Foundation Fieldbus Design and Configuration shall be in line with design basis
document “10080-1-ENGG-DBD-CI-003”.
11.5. HART subystem
System shall support communication to HART devices using Universal and Common
practice command sets using HART I/O module as the interface.
The system shall be capable of receiving, displaying, and storing diagnostic data and
device alerts from HART devices using HART I/O module interface.
The system shall be capable of displaying configuration data resident in HART devices
on the DCS workstations.
11.6. Wireless subsystem
10080-1-SS-CI-017 Page 30 of 203
Wireless Instrumentation shall be considred for non critical open loops.

MANUFACTURER/SUPPLIER Shall offer proven wireless technology for all selected
monitoring signals.
Following wireless protocols shall be considred for the project
ISA-100
Wireless HART
Final selection of the protocol shall depends on proven track record of the offered
system. MANUFACTURER/SUPPLIER shall provided information of projects executed
on similar scale (100+ instruments). MANUFACTURER/SUPPLIER shall be responsible
to ensure complete connectivity between field adevices and wireless gateway
located in PIB. Redundant gateway shall be offered to ensure bumpless tranasition
on failure of one of the Gateways.
Gateway interface with DCS shall be industrial standard protocol such as MODBUS.
MANUFACTURER/SUPPLIER shall clearly specify this inferface details.
As a mimimum monitoring signal values, field device diagnostics, gateway
diagnostics, signal strength at each device and battery status of field devices shall be
made available on DCS.
Batteries used in wireless filed instruments shall have long life and shall be easly
replacable. MANUFACTURER/SUPPLIER shall mention the relation between the
expected battery life and update time of signals. Update time shall be in the range of
5 sec to 60 sec selectable.
11.7. Fault Handling
Analog 4-20 mA input cards shall be capable of differentiating between an out of
range measurement signal and a failed transmitter signal.
Upon detection of either high or low transmitter failure alarm signal, the DCS shall
generate a critical alarm (visual and audible).
Invalid value status shall be generated for inputs and calculated variables.
A value shall be declared invalid if any of the following conditions are true:
If a value is out of range.
If a value cannot be measured or calculated.
If a value is declared invalid by an application program.
If a value is declared invalid by the source instrument.
On loss of communications to the data source, invalid value status shall be
propagated through control schemes.
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It shall be possible to inhibit the detection and propagation of an invalid value status.
This selection shall be available on a per tag basis. It shall be possible for an invalid
value status to be used as a logical input to initiate control algorithm changes.
When a control algorithm's input is declared invalid, it shall be possible to configure
the output to take any of the following actions, on a per point basis:
Hold last good value,
Zero output signal,
Full-scale output.
The term control algorithm refers to instructions executed within function blocks
where an output is calculated based on the value and status of inputs to the function
block.
11.8. Controller Subsystem
The Controller system shall consist of microprocessor based multi-loop controllers,
which will receive data from process through input / output system, execute control
functions and send output signals to process via input / output system.
The controller system shall provide pre-programmed algorithms to achieve various
regulating control functions.
Following is a list of minimum control algorithms to be provided in the controller sub-
system:
Input Monitoring
PID, PID with cascade, PID with ratio, PID with adaptive gain.
Hand control (HIC) which can accept a cascade set point.
Addition / Subtraction, Multiplication / Division.
Lead / Lag, Time delay.
High / Low select, High/low limiter.
Switch.
Digital Filter.
Mass flow computation.
Totalizing / integration.
Ramp function.
General equation block to perform other calculations.
Proportional plus integral control.
Proportional only control.
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PID with dead time.

Computer backup / manual / auto or supervisory set point.
Set-point / Output limiter.
Reset limiting.
The option to have derivative action act on the process measurement rather than
the error.
Output alarms high / low.
Rate of change alarm.
Deviation alarm.
Measurement alarms high-high / low-low and high/low.
Summer.
Square root extractor.
Linearization based on X-Y table.
High / low / mid selector.
Auto / manual station.
Characterizer.
Two position ON/OFF control.
Pulse duration ON/OFF control.
Dual transmitter scaling / selection.
User definable calculations.
Motor Control Block.
Valve Control Block.
FF Configuration Block.
Comparator.
7th order polynomial.
User defined algorithms.
Boolean functions: AND, OR, NAND, NOR, XOR and NXOR.
Scaling.
Compensation and conversion (characterization, pulse counter, accumulator,
high/low clamp, rate of change, clamps, etc.).
Program set function (generate function of time).
10080-1-SS-CI-017 Page 33 of 203
The points in the regulatory control must able to access values from and send values
to other regulatory control points and data acquisition points.
Controllers shall be able to operate in manual, auto, cascade or remote mode. Mode
changeover shall be bump less in either direction.
It shall be possible to change controller set points, tuning constants, operating mode
and controller configuration from the operator station through operator’s keyboard
and engineer’s keyboard.
The controller shall have facility for fast and slow ramping of set point and output.
The PID algorithm shall have integral wind up protection and initialization.
It shall be possible to reconfigure any particular control loop on line and without
disrupting any other control loop in the system. Remainder of the controllers,
including those executed in the same module, shall not be decommissioned by this
procedure. The control module shall have logic functions based on logics, alarm
states and sequence control functions, which shall be used for inputting and
outputting discrete variables to and from the control modules.
All these logic and sequence control functions shall be configurable on line without
disturbing the rest of the system.
The execution period for the control functions shall be within the limits specified. It
shall be possible to assign different execution periods to different control loops.
In cascade loops, the primary controller shall able to track the set point of the
secondary controller when secondary controller is not operating in cascade mode.
The system shall be capable of implementing automatic sequence logic involving
control and monitoring functions during start-up and shutdown situations.
11.8.1. Complex loops
Functional Descriptions
11.8.1.1. Any logic function and loops beyond simple PID execution are defined as complex
loops. Complex loops shall be documented and include any controls with special
settings and limits configured.
11.8.1.2. The functional descriptions of control functions are intended to provide detailed
descriptions of how a control configuration functions. Particularly how a complex or
non standard loop functions and operates, where the input and output signals
originate or go to, how constants, or coefficients used in the function were
developed and how the control functions are implemented requires detailed
documentation. MANAGING CONTRACTOR shall provide functional description to
11.8.1.3. The following must be described in detail by Seller for each complex loop:
Definitions (process area, control system nodes, modules related, application
name, the tags affected by the application and parameters used for each point)
10080-1-SS-CI-017 Page 34 of 203
General Description (Overview of application, a sketch of the application with all

inputs, outputs, and addresses associated with the application)
Operating Instructions (Instructions, procedures or other information required
for operating the application and shall identify the displays associated to operate
the application and fallback arrangement in case of failure of the application)
Implementation (How the application is implemented, the algorithms and logic
used shall be identified)
Equations and Scaling (All equations used in developing the application shall be
identified. This includes all the pressure, temperature correction, inferred
variable computation, and signal scaling for manipulation
Related Information (This may include the data sheets of all equipment,
instruments, and valves involved in the application, reference drawings, and
other pertinent material)
11.8.2. Controller Redundancy:
To ensure control strategy integrity, a reliable means of controller redundancy shall
be provided. Any active-controller failure shall cause the failed controller to switch
over to the redundant controller without upsetting the process or causing
interruption or loss of control within minimum possible time.
MANUFACTURER/SUPPLIER shall clearly specify the switch over time. The power
supplies to controllers shall also be redundant. The controller redundancy shall be 1
to 1.
11.8.3. Controller availability:
Availability of control shall be ensured by providing internal, failure protection
circuitry, such that continuous uninterrupted control is ensured in the event of any
controller or communication failure.
Failure of any controller module shall cause an alarm to be generated on the
associated operators console and the failure shall be logged.
Loss of the active controller or, in case of application of redundant controllers, both
the active and redundant controller, shall cause system outputs to “freeze” at their
last position or drive to pre-defined fail-safe condition. In addition, all alarm shall be
generated on the associated operators console and the alarm shall be logged.
11.8.4. Controller Configuration:
Configuration of the process controller shall be accomplished at Engineers console,
using a ‘fill-in-the –blanks’ or conversational technique.
Configuration shall be in an on-line fashion and shall not require more than one VDU
display for the configuration process. Off-line configuration shall also be possible.
It shall also be possible to update an individual loop configuration in the multiple
loop controllers, including the addition of functional elements, without disrupting the
10080-1-SS-CI-017 Page 35 of 203
normal operation of other loops resident in that controller. Unit wise segregation at
controller and I/O level is to be considered.
Also if their are two or more devices for same function e.g pump A and B. Then signal
related to pump A and B shall be in segregated in different I/O cards and Controller.
This will ensure that overall plant availability will not be jeopardized on failure of one
component.
11.8.5. Initialization:
Initialization is the process by which initial values of the mode, setpoint and output
of a control block are set.
It shall be possible to initialize a control block or control strategy when any of the
following conditions exist:
The control block is turned from off to on.
The control block mode is changed from manual to automatic, from manual to
cascade, or from automatic to cascade.
The control block output is cascaded to the remote set point of a downstream
control block which is being switched from manual to automatic, from automatic to
cascade, or is being initialized.
Variables that are being initialized shall be subject to the following:
Calculations involving time-based data shall be reset.
Initialization shall not cause an audible alarm.
Function blocks which have a setpoint shall offer the option of either initializing the
setpoint to the process value (PV) or of maintaining the last valid setpoint upon
algorithm initialization.
Function blocks which write their outputs to field devices, shall initialize their output
to the current state or position of the field device during initialization.
11.8.6. Data Acquisition subsystem:
The primary function of the data acquisition system is to display and log the inputs
from analogue and discrete open loops.
The data acquisition system shall receive process inputs via the input/output sub-
system and display these inputs on the operator console.
The data acquisition system shall be capable of providing output signals to other
non-DCS system or field instruments. The output signals may be analogue (4-20mA
DC) or 24V DC outputs (for relays / solenoids) or serial.
The data acquisition sub-system shall have the following computational capabilities:
Square root extraction,
Flow computation (pressure and temperature compensation),
10080-1-SS-CI-017 Page 36 of 203
Thermocouple linearization,
Addition / subtraction,
Multiplication / Division,
Totalisation,
High / low selection ,
Auto ranging of dual transmitters,
In addition to the above, this system shall also have binary logic functions for
implementing pump start/stop logics, etc.
Input filtering and signal conditioning shall be performed before alarms are checked
and control calculations are made
The data acquisition system may be a part of the controller system in order to utilise
the capacity of the controller sub-system.
11.9. HMI subsystem
The function of the HMI system is to provide the following information to the plant
operator / engineer at a centralised location,
Display plant graphics in dynamic mode showing status of selected parameters
and valves etc.
Display of all information related to open and closed loops of analogue and digital
process variables,
Manipulation of control loops, e.g. changing set point, mode, output,
configuration and tuning,
Display and Acknowledgement of alarms,
Display of plant dynamic graphics,
Logging and report generation,
Trend recording,
Providing self-diagnostic messages,
Providing system diagnostic messages.
Further the operator interface software shall be capable of acting as Dynamic Data
Exchange (DDE) or OLE (Object Linking and Embedding) for Process Control (OPC)
Client or Server to share real-time data with DDE or OPC compliant applications.
HMI with touch screen facility shall be offered as an option.
The HMI shall be provided by operator stations and engineering workstation, which
shall permit the operator to control and monitor the plant normal operation as well
as during start-up, shutdown and process upset conditions.
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Standard system software shall not be modified to meet any of the specific
requirements. Application software shall be designed in a manner that requires no
modification to the operating software.
There shall be various access levels provided at the operator consoles with password
protection to ensure security of operation. Broadly the operator Console shall have
four main category of access level as briefed below:
OPERATOR: Lowest level, access to view and browse through all able to
acknowledge alarms, but will not have the authority to tune loops and change
alarms limits.
SUPERVISOR: As OPERATOR level but with additional access and manipulating
privileges such as system building, configuration and tuning functions in additions
to normal operation tasks.
MAINTENANCE:As SUPERVISOR level but with additional access and
manipulations privileges such as system building, configuration, detailed system
diagnostic displays, intelligent transmitter detailed displays, and tuning functions.
ENGINEER: As SUPERVISOR level but additional rights for configuring, installing,
and maintaining a database.
Each Operator workstation shall have the capability of printing the information
displayed on the screen. The workstation operating system shall be latest version
Microsoft ™ Windows, independent of the hardware. The workstation operating
system (OS) + service packs shall be a revision which is currently supported by the OS
vendor and has been verified by the vendor for application software compatibility.
Each of the operator stations shall consist of the following hardware as minimum:
PCs with Latest processor and Microsoft ™ Windows latest version operating
system.
Dual Monitor OS with high resolution 22” LCD/LED monitors
Engineers keyboard (detachable type)
Membrane type Operator key boards with assignable function keys
One Hard Disc Drive(500 GB Minimum)
DVD R/W drive or latest available media.
Mouse / track ball (Optical)
Minimum 4 GB RAM
Dual power supply
Dual redundant network interface card. Network card shall be as per system
design, copper/fibre optics.
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Each of the Engineering work stations/Server Grade Machine shall consist of the
following hardware:
Server Grade PCs with Latest processor and Microsoft ™ Windows latest version
operating system.
High resolution 22” LCD/LED
Engineers keyboard,
RAID 5 or latest
HDD (500 GB Minimum) qty as per RAID-5, Hot Pluggable
DVD R/W or latest available media,
Mouse
Minimum 4 GB RAM
Redundant hot-swap power supplies ,
Dual redundant network interface card. Network card shall be as per system
design, copper/fibre optics.
The engineering station shall incorporate configuration software, which shall be
windows based supporting drag and drop configuration. Standard user definable
templates shall be supported to allow for rapid application development. The
engineering configuration software shall support on-line monitoring of control loops.
On-line changes of control parameters, as well as creation, loading, activation,
deactivation and deletion of control strategies shall be possible. Existing control
loops and I/O modules shall continue to operate while configuration changes are
being made.
Engineering work station shall provide minimum following functions:
Configuration and Backup.
Database generation.
Graphics display generation and modification.
Control algorithm generation and modification.
Report generation and modification.
Generation and Modification of tags assigned to history
System access configuration.
File access.
Diagnostics.
Workstation/monitors and keyboard plant area assignments Document.
10080-1-SS-CI-017 Page 39 of 203

Utility program access.

PID list.
Alarm list.
It shall be possible to embed objects spreadsheets, graphics etc into control charts
for documentation. Access to the engineering workstation shall be controlled by
password protection. The control strategies built in the engineering workstation shall
be capable of being directly loaded into the system.
Also following software will be loaded if required:
Valve Link software or Vendor specific valve signature software or equivalent for
Partial stroke testing and Full Stroke testing.
Alarm and Event Management Software ,
SOE software with 1 mill sec resolution for SOE inputs.
Software packages for study of process dynamics and auto-tuning shall be provided.
Removable storage media either DVD-RW shall be provided at each engineering
workstation.
All operator stations and Engineering Stations shall have the same database and
displays. Engineering workstations shall contain all the functionality of an operator
workstation and be capable of being used as an operator workstation when required.
Electronic documentation facility should be available in engineering workstation or
dedicated documentation server. This should be provided for the following:
System documents generated by system MANUFACTURER/SUPPLIER e.g. FDS,
SDS, Loop schematics, Loop wiring drawings, GA drawings etc.
System hardware and software Manuals for operations and maintenance.
Input data provided by engineering contractor like P&IDs, Cause and Effect
diagram, I/O details, specifications etc.
Useful technical data for operation and maintenance (Datasheets, Calculations
etc.)
MANUFACTURER/SUPPLIER shall provide a separate maintenance facility along with
accessories for remote maintenance. The web terminal should be able to provide
view only remote access to graphics, trend and reports via intranet or internet.
All real time clocks of the system including those in the third party systems shall be
synchronised with each other. The system shall be capable of accepting GPS clock
signals and synchronize the entire DCS, ESD and Subsystems (major packages)
network with the same.
Colour capability of LCD/LED shall be 256 colour/ True colour or better.
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Each point in the system shall be designated by a tag number consisting of minimum
twelve alpha-numeric characters.
Operator’s keyboard shall be touch sensitive membrane type. Each keyboard entry
shall be registered with an audio beep. Spilled liquids shall not damage the keyboard
and it shall be easily cleanable.
The operator shall be able to take following actions through the key board as a
minimum,
Calling up of all displays.
Acknowledgement of alarms.
Changing parameters.
Control of cursor.
Initiating printouts of logs, alarm history, event history.
Changing of controller mode.
All control room alarms shall be connected to the DCS. The DCS shall have an audible
alarm. High Priority and equipment protection related alarm shall be configured for
first out and subsequent alarm sequencing. All alarms and events shall also go to
Alarm and Event Management System.
The operator keyboard shall include special keys to enable the following additional
functions to be performed,
Control loop call-up from graphic, alarm page or any other page or tag entry,
On/off command to controller outputs such as valve solenoids, rotating
equipment and ESD systems,
Graphic paging access,
Return-to-last-page access,
System status access,
Print screen,
Change digital state,
Manual entry of data for storage,
Sequence start / override.
The operator’s keyboard shall contain minimum 48 annunciator keys which can be
assigned to call up specific important displays with a single keystroke. Each of the
annunciator keys shall be provided with a LED to indicate alarm status of particular
sections of the plant.
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The operator shall also be able to use optical mouse to control the cursor, change
controller mode, directly access a particular display from another display, etc.
Engineer’s keyboard shall be QWERTY type and shall enable the plant engineer to
take the followings actions through the keyboard,
Changing data base configuration,
Inhibiting alarms during plant maintenance,
Changing of alarm settings,
Changing of tuning constants,
Changing of displays,
Changing of clock settings.
Production system Simulator
The plant model shall be provided by Purchaser and the control system will be
provided by MANUFACTURER/SUPPLIER. This shall be included under production
system simulator.
DCS shall have a Production System simulator with features like:
Dynamic simulator model for process plant,
Real time model system for online monitoring of process,
Look ahead predictive model,
Instrumentation conditioning monitor,
Offline planning / training simulator,
Operational planning,
Optimization.
11.10. Process and System Alarms Audible Annunciation
Alarms shall cause audible annunciation at, and only at, workstations configured
for those alarms.
The annunciation shall occur within 1 second of the initiating event.
The audible annunciation shall continue until a "Horn Silence" command is issued
by the operator.
There shall be at least three audible alarm tones available and these shall be
assignable to any priority level.
Volume of the audible tones shall be adjustable.
10080-1-SS-CI-017 Page 42 of 203

If an audible alarm is on and another alarm of higher priority is initiated, then the
tone of the higher priority alarm shall immediately sound. The lower priority
audible tone may either continue or cease.
Return-to-normal state shall not cause audible annunciation.
There shall be a "Horn Silence" command available regardless of which display is
in use.
When the "Horn Silence" command is given at a workstation, it shall silence the
current audible alarm sound at all workstations within that console only and
without acknowledging the alarm itself.
It shall be possible to display the following information, as a minimum, for each
alarm in the alarm summary display:
Tag ID of item in alarm.
Tag Description.
Alarm Type (HI/LO/HH/etc).
Alarm Limit value.
Engineering units (if applicable).
Actual process value at time of alarm.
Time of occurrence.
Alarm description.
Alarm priority.
Alarm state (whether into-alarm state or return-to-normal state).
Acknowledgment state.
It shall be possible to filter or sort entries in the alarm summary display based on Tag
ID, time of occurrence, priority, alarm type, and process area or unit number. The
alarm summary display shall clearly indicate when filtering or sorting is active.
System shall provide the list of all the alarms which are
inhibited/suppressed/bypassed with the date, time and role. The list fields shall be
user configurable.
System shall capture and store all the alarms and events. The list shall be list fields
shall be user configurable.
Storage capacity shall be of three months.
Alarms shall be defined according to four level of priority.
First Level - Emergency
Second Level - High Priority
10080-1-SS-CI-017 Page 43 of 203
Third Level - Normal Priority

Fourth Level - Low Priority
11.11. Displays
All displays and graphics that show real time data shall update automatically when
the display is resident on the screen. Updates shall not require operator initiation.
Special indication with different colour shall be used to indicate that a value is
invalid.
Call-up-time for display and process graphics shall be a maximum of one (1) second.
This requirement applies to all displays and graphics including ones which have fully
active dynamic elements for up to one hundred (100) fields.
The update frequency for real time data, displayed alphanumerically and symbolically
(shape change, color change, etc.), shall be at least one second for all displays and
graphics.
The following displays shall be provided as a minimum in the displays,
Overview display.
Group display.
Point display.
Faceplate display.
Graphic display.
Trend display.
Alarm display.
Diagnostic display.
System Status display.
Cause and Effect display.
Networking and Serial link status display.
FF power supply display.
etc.
Display and Graphics requirements shall be as per the Attachment-4.
11.12. Historical Data, Reports and Logs
A report generator shall be supplied to build and change reports. Reporting function
shall be initiated by a control program, by operator demand or on schedule.
It shall be possible to activate a report by:
Demand (operator request) ,
10080-1-SS-CI-017 Page 44 of 203
Scheduled (shift, daily and monthly) ,

Triggered by an Event ,
Through automation or scripting.
All points in the system shall be capable of being logged.
The reports shall comprise MANUFACTURER/SUPPLIERs standard logs and reports
formatted by the MANAGING CONTRACTOR/OWNER.
The standard logs shall mainly consist of alarm summary and event summary reports
to be printed out at the end of each shift.
Alarm summary report shall be printed out of the historical alarm summary at the
end of each shift.
The event summary report shall consist of the operator actions like auto / manual
changeover manual overrides, resets, etc.
A daily report shall be provided to log the important process parameters. The report
shall be printed at 12 hourly intervals or user defined interval. Format of the daily
report shall be provided by OWNER.
It shall be possible for the operator to modify/update certain fields in a report prior
to printing.
The free formatted report software shall allow the OWNER to decide the layout and
content of the report, which may involve mathematical calculations like summing,
efficiency calculations, etc.
It should be possible to retrieve this data and be able to manipulate it to produce
displays and reports.
Alarm and return to normal shall be printed as they occur. Alarm message shall
contain time, tag number, service description, process data and the type of alarm.
Operator actions i.e. set point change, auto/manual changeover etc., shall be logged
as they occur.
Alarms associated with DCS equipment shall be logged as they occur.
All alarms and operator actions printed in the log report shall have date and time
printed alongside the action.
Trip Report
11.12.1. Historical data storage and trend display
All process variable values, controller set point values and controller output
values shall be stored digitally on non-volatile memory or hard drive either within
the control system equipment, or in auxiliary systems communicating with the
control system. No distinction shall be made between direct process variables
(e.g. flow, temperature, pressure, level, etc.) or indirect calculated process
10080-1-SS-CI-017 Page 45 of 203
variables (e.g. velocity, density, ratio, concentration, etc.). The stored information
is used for the following purposes:
 Determination of plant material balances.
 Trend analysis of equipment performance.
 Troubleshooting and analysis of malfunctions.
 Monitoring the day to day operation.
The actual (uncompensated) measured process variable values shall also be
saved, when process variable values are modified by the control system to
compensate for process conditions.
For the purpose of trouble shooting and analysis of malfunctions, the ability to
retrieve and display the actual instantaneous sampled process data, rather than
the averaged or maximum/minimum values, is essential.
All process variables, controller set points and controller outputs shall be
sampled and the instantaneous values shall be stored at intervals of one second.
Storage capacity shall be sufficient to store process variable data, controller set
point data, and controller output data for at least the immediately previous 7 day
period. Only "lossless" data compression techniques may be used during this
period. The control system equipment shall be able to access and display the
stored data at the operator station console and/or other console on demand at
any time. The control system equipment shall be capable of selecting for display
the instantaneous values stored in any 1 hour period within the 7 days of data.
Stored data shall not be erased by display. Update of data shall be on a point-by-
point basis to ensure that the immediately previous 7 days of data are available
at any time. When data compression techniques are an integral feature of the
historical data storage package, the data discrimination delta value shall be set to
the minimum setting.
The DCS shall have the capability of archiving to removable storage media and
shall be capable of playing back the stored data in the same formats e.g. trends,
reports etc. The MANUFACTURER/SUPPLIER shall clearly describe how the data
base are backed up including an estimate of total time and number of copying
media required to back up the entire history data base.
Storage capacity that is capable of retaining daily averages and weekly averages
of the process variable values for a period of one year shall also be provided.
Storage capacity shall be capable of storing process parameters for 6 months
with a sampling rate of one second. The control system equipment shall able to
access and display the stored data at the operator station console and/or other
console on demand at any time.
Data stored for historical review shall be accessible in grouped trend display
format. The grouping of the process variables shall be logical with respect to the
10080-1-SS-CI-017 Page 46 of 203

process. Configuration of trend displays shall have the capability for operators to
set up additional trend displays of selected variables for specific troubleshooting
activities. Different colours shall be used for each variable trended. Additional
trend display capacity shall be available for at least 10 percent of the historical
trend display groups.
History stations shall be sized on the basis of 5% analogue inputs being trended at
one (1) second, 15% of the analogue inputs being trended at two (2) seconds and
remainder (80%) is being trended at five (5) seconds intervals for 90 days without
any backups as a minimum. The sizing shall include 20% extra capacity at 70%
loading of Historians which shall be dual redundant (mirror image).
The MANUFACTURER/SUPLIER’s capabilities with respect to the subject of data
storage and retrieval shall be thoroughly reviewed by the OWNER/operator of
the process unit before deciding to accept a particular system.
The control system must be capable of archiving historical data onto removable
media.
11.12.2. Controller Tuning Display
Each loop controller shall have a trending display for tuning. This tuning display shall
show the loop controller tuning values and include the capability to change the loop
controller tuning values while trending. Different colours shall be used for each
parameter trended. The minimum controller parameters trended shall be:
Set point
Process variable
Controller output signal
Trending intervals shall be user selectable between 0.25 second to 5 seconds. The
overall trend display must show as a minimum between 1 minute and 20 minutes of
trending per Table:
Table
Minimum Duration of
Sample Interval
Screen Trend
0.25 seconds (4 times per second) 1 minute

0.5 seconds (2 times per second) 2 minute
1 second (1 time per second) 4 minute
2 seconds (0.5 times per second) 8 minute
5 seconds (0.2 times per second) 20 minute
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The DCS shall have a historical data base which can be accessed for trending, report
generation, alarm history retrieval and event history retrieval to both printer and
HMI. All alarms and events shall be historised.
It shall be possible to configure the database through the engineer’s keyboard.
11.13. Diagnostics
The DCS shall have extensive off-line and on-line diagnostics. The self diagnostics
shall as minimum detect the fault in the following.
Data highways and communication lines,
Power supplies,
All cards (I/Os, controllers, CPU, etc.),
Wherever fault tolerant/redundant paired equipment is provided, the equipment
shall continue functioning in case of failure of one of the pair.
The diagnostic alarm message for any failure shall appear on the operators console
irrespective display on the HMI.
It shall be possible to get accurate and detailed diagnostic information through
system status displays which can be called from operators keyboard.
The self diagnostic software shall be capable of detecting and reporting fault to an
I/O level.
The operator stations shall have the same capability in respect of displaying
diagnostic messages.
In addition to the above, all modules shall be provided with diagnostic LEDs to
indicate their status at a local level.
The off-line diagnostic programs shall consist of a library of programs used to verify
operation of a device or to aid in the troubleshooting of a device.
Off-line diagnostics shall be provided for every device in the system.
NAMUR NE-107 “Self-Monitoring and Diagnosis of Field Devices” shall be followed
for different field device status indication, implemented as a function in DCS, to help
the operator and service personnel to trigger various different actions. There are four
types of status signal output:
Failure (F),
Function check(C ),
Out of specification(S),
Maintenance required (M).
10080-1-SS-CI-017 Page 48 of 203

Status signal output changes irrespective of the transmission media used (type of
bus, HART, contacts…) when the device status change or individual measurement in
case of multi-variable device.
The device diagnostics shall meet NAMUR 107 classification with 4 levels of
diagnostics are available namely:
Maintenance Required The output from the device is valid

but the wear reserve is nearly exhausted or function will be
restricted due to operational conditions.
Colour: Blue
Out of Specification Measurement uncertainty, or output
position deviation, is greater than expected due to
deviations in ambient or process conditions.
Colour: Yellow
Function Check Output invalid due to ongoing work on

the device
Colour: Orange
Failure Output is invalid due to a malfunction in the field

device
Colour: Red
11.14. System back-up

MANUFACTURER/SUPPLIER shall provide a complete automatic backup. The entire
control software including control database, system software, source code,
schematics, etc. shall be backed up on system hard disk automatically at a regular
interval. All configurable entries should be automatically reloaded on restart of the
system in case of loss of database.
It shall be possible to have a complete back-up of the system including the historised
data without interrupting the system normal function.
It shall be possible to have a back-up on demand.
It shall be possible to have back-ups on removable storage media like DVD-RAM or
DVD-RW or latest available media. Also back-up shall be on one or two servers and
with facility for restoration online.
Any failed device of the system shall be capable of being reloaded from the back-ups.
Batteries shall be avoided as much as possible, however, if provided for unavoidable
10080-1-SS-CI-017 Page 49 of 203

reasons the controller memory shall have a battery back-up of minimum 72 hours to
save the controller configuration in case of power failure.
MANUFACTURER/SUPPLIER shall provide a list of all batteries used within the DCS
system, indicating battery type, rated shelf life, location within the DCS and renewal
frequencies.
Immediately after the SAT, DCS MANUFACTURER/SUPPLIER shall replace all batteries
within the DCS system with new ones.
The maximum time acceptable for reloading a component (e.g., a console) is five
minutes, which includes the time to mount disks. The MANUFACTURER/SUPPLIER
shall quote the maximum time required to reload the system from backup bulk
storage.
11.15. Serial Interface system
The Serial interface system shall consist of the redundant Serial interface modules
and the Protocol converters as required, to suit the serial interface communication.
Generally redundant ETHERNET/Modbus TCP/IP, RS 232/485 (Modbus/ASCII) shall be
used for all serial interfaces. The redundant serial links shall be connected to
separate modules so that failure of one module does not affect the serial
communication. The transmission of data shall be bi-directional with read/write
capability.
The Serial Interface shall be able to handle all types of I/Os of Third Party System.
After selection of DCS vendor, data capture form will be created and given to all
PACKAGE UNIT MANUFACTURER/SUPPLIER for serial interfaces to have both
hardware and software compatibility.
MANUFACTURER/SUPPLIER shall indicate limitations if any in connecting number of
serial interface per controller.
11.16. Interface with other applications/systems
The system shall be capable of interfacing other applications of any hardware and
software combination. Other applications/systems can be one or more of following:
Advance process control.
Process Optimization.
Laboratory Management.
Warehouse Management.
Logistic Optimization.
Tankfarm Management.
Asset Management System.
ATG (Automatic Tank Gauging).
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Tanker Loading System.

Package Unit control systems/PLC.
Alarm management system.
SAP/ERP/OPC connectivity.
ESD, BMS, Analyzer System and MCMS.
Compressor control system.
Analyser system.
Integrated motor control system.
CCTV.
Note:
Communications error shall be alarmed.
Failures of external systems shall not degrade the performance or functionality of
the DCS.
List of interface signals shall be provided by PU through OWNER/MANAGING
CONTRACTOR. Communication and testing shall be established jointly by PU
MANUFACTURER/SUPPLIER and DCS vendor/OWNER.
OPC connectivity shall be used for APC, IP21 and any other process application
connectivity. Connectivity shall be through firewall. Software required for
connectivity like CIMIO OPC (Aspen Software) is not included in the scope of this
specification.
11.17. Control Software Requirement
The software control languages shall demonstrate a high level of integration by
providing the ability to perform data reads and writes to each other.
The software control languages should be capable of running simultaneously in the
same Controller CPU to allow for efficient data and communications management.
11.17.1. Configurable Block Structured Language
The primary means of process control and monitoring shall be accomplished via a
predefined set of block-structured algorithms which can be chained together to form
various configurations of control, calculation, and loops.
The configurable block structured software shall support a full range of functions
including but not limited to:
Input (analogue, digital, pulsed input, pulse input time derivative, etc.)
Output (analogue, digital, pulse train, pulse duration, etc.)
Calculation (linearization, compensation, filtering, square root, logic, etc.)
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Controller (P, PI, PID, Discrete Devices, etc.)

Extended processing (standard deviation, periodic total, max, min, avg., etc.)
User defined algorithms.
The standard controller algorithm shall include provision for bumpless mode
transfers, anti-reset windup, and tracking functions.
The configurable block structured software shall provide a means of establishing a
unique I/O name and descriptor for a collection of algorithms which form a control,
indicating, or calculation loop. Once defined, the I/O name shall be available for use
system wide by all system application software packages without the requirement
for knowing its physical address or location.
The configurable block structured software shall include provisions for setting the
execution rate (scan) and phase individually for each loop to allow processor load
distribution. It shall be possible to execute loops of different scan rates within the
same Controller CPU.
The configurable block structured software shall be configurable by means of fill in
the blank menus or other user friendly approach that allows the user to easily create
and modify control strategies by merely software linking the predefined algorithm
blocks.
Provision shall be included for adding user defined custom algorithms to the
standard predefined set of algorithms for cases where standard algorithms do not
meet the project requirements.
Algorithms for device control shall be provided to handle a wide variety of devices
requiring multiple input/output channels and states.
The DCS software shall as a minimum be able to map all serial I/O data into the DCS
real-time relational database so as to provide:
Loop Tag and Descriptor
Linearization
Engineering Units Conversion
Alarm Limit Checks
Trend Data Collection
Historical data storage
Display at operator Stations
Inclusion in DCS reports
11.17.2. Programming Language
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A high level programming language directed to process control shall be provided to

perform control, calculating and supervisory functions. The programming language
shall support a protective environment to provide safety from disturbing crucial
parameters or system code.
The programming language shall have the ability to be executed in the Controller.
The MANUFACTURER/SUPPLIER shall state the capability of where the programming
language can be executed and what restrictions, if any, apply.
The programming language shall have free format capability so the user need not be
concerned with text position or line numbering.
The programming language shall use high level commands (keywords) and easy to
read English-like code.
The programming language shall have provision for performing read/write functions
directly to any configurable block structured software loop by I/O name and
descriptor without regard to the physical address.
Program variables shall consist of user defined English syntax words.
The programming language shall have a hierarchical structure and full provision for
scheduling, parallel task execution, emergency handling, event detection, and
program execution priority setting.
The programming language shall also have intrinsic math functions and logical and
relational operators.
The programming language shall be comprehensive enough to perform the following
functions at a minimum:
Sequential operations
Process monitoring
Automatic startup/shut down control
Process Optimisation
Process modeling
Mathematical computations
Emergency condition processing
Store program data and initiate execution of program reports.
Operator message generation
Serial interface drivers
The commercial programming language shall be capable of running on console
connected directly to the control network without the use of gateways.
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The generation and editing of the programming language program source code shall
be performed on any of the DCS consoles. Additionally, the user shall have the ability
to monitor, control program execution, and troubleshoot programs in a runtime
mode from any console without the necessity of creating any of the interactive
program displays.
System utilities shall be provided to allow program source code print out, I/O cross
reference printout, program back up and version control documentation.
11.17.3. Ladder Logic Language
Ladder logic programming language shall be provided with the system.
Ladder logic shall be executable in the Controller CPU.
Ladder logic element data shall be accessible from the other control languages.
The generation and editing of the Ladder logic program source code shall be
performed on any of the DCS console. Additionally, the user shall have the ability to
monitor, control program execution, and troubleshoot programs in a runtime mode
from any Station monitor without the necessity of creating any of the interactive
program displays.
System utilities shall be provided to allow ladder logic program source code print out,
I/O cross-reference printout, and program back up.
11.17.4. Sequence and Batch Control:
The system shall provide a graphical configuration tool which conforms to the IEC
61131-3 guidelines for Structured Text or Sequential Function Chart.
It shall be possible to modify individual program logic for sequential functions
without interrupting the operation of other sequential functions that are active.
The system shall have the ability to monitor and control program flow through
sequential functions in real-time.
11.17.5. Sequential Functions:
The following sequential functions shall be supplied as standard instructions:
Relational expressions: Equal to, Not equal to, Less than, Less than or equal,
Greater than, Greater than or equal, IF / IF Then.
Calculations: Add, Subtract, Multiply, Divide, Exponentiation (whole and
fractional), Square root
Timers: Output true after preset delay, Output false after preset delay
Counters: Count up, Count down
Logical expressions: And, Or, Not, Exclusive Or, Single bit memory elements
(flip/flops)
Hold sequence - Manual or preset time
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Recycle to prior step

Skip 1 or more steps
Restart at beginning
11.18. Antivirus Software:
MANUFACTURER/SUPPLIER shall provide OWNER approved latest antivirus software
for all windows base stations and servers. MANUFACTURER/SUPPLIER will provide
their philosophy of updating the patches/upgrading the software version for OWNER
review and approval. MANUFACTURER/SUPPLIER will provide software patches/
upgrades and services for implementing the same for 3 years from the date of
commissioning and during warranty period.
11.19. Software Revision:
Vendor shall communicate time to time revision (Patches/Updates/Upgrades) of
system software (all supplied software’s like Alarm Management software, Asset
Management software etc.), operating system software’s, and antivirus software
etcs. With release note. Vendor shall also indicate impact of software revision to
system supplied/installed at site. MANUFACTURER/SUPPLIER shall supply, supplied
software’s Patches/Updates and services shall be for implementing the same for 3
years from the date of commissioning and during warranty period. The
Patches/Updates/Upgrades required for reliable and continuous operation of the
system shall be supplied by MANUFACTURER/SUPPLIER free of cost throughout the
life cycle of system/till the system/plant is functional.
OWNER review and approval is required for implementing the software revisions.
Software revisions shall be fully tested and certified by MANUFACTURER/SUPPLIER at
their centre before implementing the revisions at site.
The system shall allow for upgrading of system operating software on all
redundant modules of the system without requiring a shutdown of any process
equipment, without loss of the operator's view to the process, and without the
loss of access to any control function.
Application software shall not require modifications in order to be able to run
under new releases of the system operating software.
11.20. Display Wall Server
MANUFACTURER/SUPPLIER shall provide a central server which shall provide
interface to third party Display wall (Large Screen Display) controller (By OWNER).
The servers shall have scalable vector graphics libraries for all symbols used in
creating DCS graphics.
11.21. System Back-Up
MANUFACTURER/SUPPLIER shall provide a complete automatic backup. The entire
control software including control database, system software, source code,
10080-1-SS-CI-017 Page 55 of 203

schematics, etc. shall be backed up on the system hard disk automatically at a regular
interval. All configurable entries should be automatically reloaded on restart of the
system in case of loss of database.
It shall be possible to have a complete back-up of the system including the historised
data without interrupting the system normal function.
A dedicated backup server sitting on PIN network shall be considered for online
restore and back up.
11.22. System Security:
MANUFACTURE/SUPPLIER at a minimum shall comply with ISA-99 for security
requirements of industrial control system.
System shall be protected from viruses, hackers and they should not have any effect
on controllers and network loading. All tested patches need to be updated in DCS. All
USB ports, media drive shall be blocked. All unused ports on switches shall be
disabled. Accessibility for these ports shall be through authorized permission.
Windows menu shall be disabled and internet access shall not be provided from any
DCS workstations, application servers. As the system is Windows based, virus and
patch management need to be mentioned in spec.
Application integrity is required to ensure the application meets its stated
performance requirements. Application unavailability may impact on facility
production and/or integrity compliance.
An assessment of the required availability should be performed prior to the
deployment of an application. Availability of the application shall consider both
planned and unplanned downtime.
Application shall be sufficiently stable when deployed to minimize the potential
frequency of upgrades and patches to maintain application functionality. Application
deployed shall comply with the security requirements.
Typically, application installed at lower levels will be of a higher availability due to the
increased network/system redundancy, design considerations( such as integration
testing), operating environment, network/system stability, rigidity of change
management processes, etc.
User Groups and User Roles
The system shall be capable of defining user groups or user roles. System access
privileges shall be configurable for each user group or user role. Individual user
privileges shall be determined based on the user group / role to which the user is
assigned.
A minimum of fifteen user groups / user roles shall be configurable. The system shall
be capable of defining the following user roles as a minimum:
View Only
10080-1-SS-CI-017 Page 56 of 203

Plant Operator (Minimum 1 – 10 plant operator roles shall be specifiable)

Process Supervisor
Engineer
System administrator
View Only – This role shall enable viewing of all process values and process graphics
but shall not allow manipulation of any process parameters.
The system shall have the ability to track user login activity and maintain records of
user login activity.
The system shall have the ability to monitor and detect failed login attempts. The
system shall automatically notify the system administrator when the number of
failed login attempts exceeds a threshold value. The threshold shall be configurable
by the systems administrator.
Passwords
Each user shall have a separate password required for login to the system.
Management and administration of passwords shall be done from a central location
within the system. If a user updates his password on one station in the system, every
station connected to the system shall have access to the updated password. Separate
passwords for individual workstations on the system shall not be permitted.
The system shall be capable of enforcing password policies for administration of user
passwords.
The following policies shall be capable of being configured as a minimum:
Password Aging – the system shall be capable of configuring and enforcing a
maximum password age. Users shall be required to change their password within
the password aging period. Users shall be notified during login when the current
password is about to expire. Users whom do not change their password within
the password aging period shall be locked out of the system.
Password Complexity – The system shall be capable of configuring and enforcing
the policies for password construction. As a minimum, passwords shall be
required to meet a minimum length requirement.
Password Uniqueness – The system shall be capable of configuring and enforcing
a minimum number of unique passwords be used prior to a password being re-
used. This prohibits the user from entering the same password.
Supplier shall submit a detail specification specially covering system and network
security features available in the offered system. The specification shall include as
minimum following requirements:
11.22.1. SYSTEM HARDENING
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Removal of Unnecessary Services and Programs

Host Intrusion Detection Systems
Changes to File System and Operating System Permissions
Hardware Configuration
Heartbeat Signals
Installing Operating Systems, Applications, and Third-Party Software
11.22.2. PERIMETER PROTECTION
Firewalls
Network Intrusion Detection System
Canaries
11.22.3. ACCOUNT MANAGEMENT
Disabling, Removing, or Modifying Well-Known or Guest Accounts
Session Management
Password/Authentication Policy and Management
Account Auditing and Logging
Role-Based Access Control for Control System Applications
Single Sign-On
Separation Agreement
11.22.4. CODING PRACTICES
Coding for Security
11.22.5. FLAW REMEDIATION
Notification and Documentation from Vendor
Problem Reporting
11.22.6. MALWARE DETECTION AND PROTECTION
Malware Detection and Protection
11.22.7. HOST NAME RESOLUTION
Network Addressing and Name Resolution
11.22.8. END DEVICES
Intelligent Electronic Devices
Remote Terminal Units
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Programmable Logic Controllers

Sensors, Actuators, and Meters
11.22.9. REMOTE ACCESS
Dial-Up
Dedicated Line Modems
TCP/IP
Web-based Interfaces
Secure Virtual Private Networks
Serial Communications Security
11.22.10. PHYSICAL SECURITY
Physical Access of Cyber Components
Physical Perimeter Access
Manual Override Control
Intra-perimeter Communications
11.22.11. NETWORK PARTITIONING
Network Devices
Network Architecture
11.23. Printers
Each operator and engineering workstation shall have access to a networked
printer for printing of reports, process graphics, and other information.
Black and white and color printers shall be supported.
It shall be possible to send multiple requests to a printer without having to
reboot it or its interface or its associated workstation.
All printers provided shall be the latest commercially available models at the time
of FAT.
The color printers shall be commercially available high quality laser-type printers.
The capability to generate a hardcopy of any active display shall be available.
Generation of a hard copy shall not freeze the monitor display for longer than 2
seconds.
The system shall support both full color and black and white copies for all
displays.
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It shall be possible to save an image of the current operator window to file in

either .jpg or .bmp format.
11.24. Training Hardware
One set of training hardware to be installed in training room consisting of following:
Engineering station,
Operator station with LCD/LED screen,
Controller with minimum configuration,
I/O cards 2 nos. of each type,
Representatives hardware in the Main system,
Required software licenses for functionality
Training hardware shall be utilised as:
Hot standby for main system,
Training of engineers / operators,
Off-line configuration,
Data backup and validation,
Graphic addition / changes etc.,
Spares.
Training Hardware shall be in the scope of supply of DCS MANUFACTURER/SUPPLIER.
11.25. Auxiliary Consoles:
MANUFACTURER/SUPPLIER shall provide hardwired console for mounting of
hardwired devices which include hardwired push buttons for initiating ESD, starting
firewater pumps, opening deluge valves, opening isolation valves, releasing
extinguishant, key operated maintenance override enable switch, VHF radio and PA
access unit, etc. Also a dedicated LCD/LED screen/workstation for soft alarm
annunciation shall be provided per unit.
MANUFACTURER/SUPPLIER shall provide all engineering inputs for interconnecting,
to console MANUFACTURER/SUPPLIER.
The console shall be fabricated from minimum 2.5 mm thick cold rolled sheet steel.
The CCTV monitors, VHF radio and PA access unit shall be free issued to DCS
MANUFACTURER/SUPPLIER. The CCTV Monitors shall be identical to the DCS Monitor
and shall be LCD/LED type.
The signal wiring of the hardwired console shall be done with 1.0 sq. mm 300/500V
PVC insulated, PVC jacked cable. Power supply wiring shall be done with minimum
2.5 sq. mm conductor 600/1000 V PVC insulated and PVC jacketed cable.
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Interconnection between the hardwire console and other equipment, ESD cabinet,
DCS cabinet, etc. shall be done with the help of plug in type system cables.
VENDOR shall provide all plugs and sockets for termination of system cables at both
ends.
Push Buttons and Switches
Up to 20 Hardwired push buttons and switches shall be provided for various ESD
and other critical functions.
To prevent inadvertent operation, Emergency push buttons shall be provided
with a guard. All push buttons shall be back lit type.
Push button Colour coding:
Start-Green
Stop-Red
Reset-Yellow
Bypass-Amber (Two position- illuminated)
Selector switch-Black (Two position)
Emergency Stop-Red (Mushroom stay-put with key lock + Protection cover)
Lamps shall be green for running and red for stop/trip.
Note: For CPP Auxiliary console will also have Electronic water level indicators (EWLI)
of HRSG and Auxiliary/utility system boiler drums.
12. System Performance
12.1. System Loading
The loading refers to the use of memory, CPU time and communication capacity. The
loading shall consider worst case system activity.
The maximum loading allowed are as follows considering installed and future spare
inputs and outputs:
Control processor : 60%
History data base : 60%
Serial : 50%
Network Loading : 50%
MANUFACTURER/SUPPLIER shall submit system loading calculation for each of the
above. In case loading increases above the indicated values, Vendor shall supply
required hardware to meet the above requirement without time and price
implication to client.
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12.2. RFI Immunity

Standard commercial UHF and VHF band hand-held telecommunications equipment
for all frequency bands will be used within the control building housing the
equipment supplied, as close as 3 feet distance from the equipment with doors
closed. The System shall have total immunity from the UHF/VHF radios used for
plant communications in accordance with IEC 61000-4.
MANUFACTURER/SUPPLIER shall ensure that suitable precautions are taken to
render the installed controllers immune to interference from such radio equipment.
MANUFACTURER/SUPPLIER shall certify that the supplied equipment shall not be
affected in any way by the use of these radios.
12.3. System Response Time
Controller Scan Time / Controller Response Time
This is the total time required for read and process input, perform control functions
and update output for the final control element for all the loops connected to a
particular controller. This scan time for critical loops shall not exceed 500 millisecond
for multi loop controller.
12.3.1. Controller Scan Time
In case of an automatic control scheme, maximum allowable control response period
is shown in following Table:
Process Control Parameter Scan Time

Flow, Pressure 250 millisecond
Differential Pressure 1000 millisecond
Level/Temperature 1000 millisecond
Designated fast process control loops 100 millisecond
All other (Analysis, Density, pH etc.) 1000 millisecond
Scheme includes Read inputs, perform the configured control algorithm and update
control output.
MANUFACTURER/SUPPLIER shall assume all analogue outputs are associated with
controllers and give the basis of sizing for the controller and also specify how the
scan time affects the loading of the CPU.
MANUFACTURER/SUPPLIER shall also clearly mention whether different control
loops in one controller, can be assigned different scan times.
12.3.2. Data Acquisition Time
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This is the total time required for controller for read and process input and perform
computations (as required) for all open loops connected to a particular data
acquisition sub-system. This time shall not exceed 1 second.
12.3.3. Alarm Response
Within 1 second after a new alarm has occurred, the system shall annunciate the
alarm and have the alarm ready for display.
12.3.4. Command Action Response
Command from the operator shall result in an output to the control device within 1
seconds following the command to execute.
12.3.5. Display Call-up Time
This is time that elapses between operator’s command and appearance of the display
on the screen. This time shall not exceed 3 seconds including graphic display.
New screen call-up time - 1 secs.
Screen updates time - 1 sec.
(Refreshment of process data on a display screen)
12.3.6. Miscellaneous
PLC, Compressor Control Interfaces – 1 sec.
The MANUFACTURER/SUPPLIER shall verify the following
System Performance of similar system in service based on record of actual tests
and stated conditions.
13. System Reliability and Availability
The DCS shall be subjected to careful component level subsystem and system testing,
prior to factory acceptance tests. The availability of the DCS shall then be part of the
guarantee of the system.
The system availability is usually expressed in terms of two factors:
Mean Time Between Failures (MTBF).
Mean Time to Repair (MTTR).
The system availability shall be guaranteed 99.99% or greater all times.
Calculation is based on:
System availability = MTBF
MTBF + MTTR
(Assuming average MTTR = eight hours).
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MANUFACTURER/SUPPLIER shall furnish an availability calculation clearly specifying

the methods how it is achieved. MTBF of all the modules quoted/supplied shall be
made available
Where fault-tolerant/redundant modules are provided, it shall be possible to replace
the faulty module on-line without interrupting the process.
It shall be possible to replace I/O cards without powering down the I/O racks. The
real time operating system must provide, without failure, a response to process
events within a specified time window (typically the response time shall be within
scan time for control loops and display update time).
The response must be predictable and independent from other activities undertaken
by the operating system.
Control System internal communications shall be designed so that no single failure
shall degrade the performance of Control System. This requirement applies to all
Control System communications.
Any single failure of DCS LAN shall not compromise or degrade in any way control or
monitoring functions.
MANUFACTURER/SUPPLIER shall identify during design review the areas affecting
controls and shutdown actions that are susceptible to single point failure.
It shall be possible to operate the units (risk area) from their assigned control
building utilizing the local Maintenance Console.
Any failure in Operator Console located in Control Building or in communication
network, shall not compromise or degrade in any way the control and / or
monitoring functions available in Maintenance Console in control building or any
other Consoles/Workstations.
14. DCS System Requirements
14.1. Redundancy
The following parts of the system shall be redundant:
Controller system - 1:1
Data acquisition and Control Configuration - 1:1
Communication system - 1:1
Power supply - 1:1
Interfaces - 1:1
Serial link between DCS and package units (e.g. compressor panel) shall be redundant
and shall be MODBUS TCP protocol, Object Linking and Embedding for Process
Control (OPC) protocol or equivalent.
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All servers such as ES, Asset management, alarm manager, historian should be rack
mounted and installed in racks.
I/O used in critical control loops and logic (these to be decided on a case by case
basis) shall use dual redundant field interface cards. The requirements will be
determined during detailed engineering.
14.2. Installed spare capacity
The offered system shall have a 20% installed spare I/O capacity for each type of I/O
listed in the I/O list. The spare capacity shall be evenly distributed over various
cabinets. The spares shall also be uniformly distributed in all cards instead of
complete spare cards. Installed spares shall be wired into terminal blocks. All the
spare cores of the incoming filed multicore / multipair cable shall be wired up to the
marshalling cabinet. All process input / output racks shall have 20% usable spare
space for installing additional modules in the future.
In addition 20% spare space shall be provided in the cabinets for future expansion of
DCS. Sufficient additional software capacity shall be available in the system to take
care of spare requirement as required above.
Start-up Spares: Average failure rates and availability of parts from the closest repair/
MANUFACTURER/SUPPLIER support facility shall be used in determining the quantity
(not less than one) of each type. Additional spare parts that may be required during
start-up shall be guaranteed to be available from the DCS
MANUFACTURER/SUPPLIERs support facilities in India.
Long-term Spares (Two Years Operation): These spare parts include normal
maintenance as well as failures. MANUFACTURER/SUPPLIER shall provide complete
Spare Parts and interchange ability records (SPIR) forms for all parts of the DCS in his
supply. These shall be sent to OWNER / MANAGING CONTRACTOR at least six (6)
months before delivery to site, in order to allow time for purchase / delivery with the
DCS equipment. The DCS MANUFACTURER/SUPPLIER should maintain optimal
number of spares at its local office at site.
MANUFACTURER/SUPPLIER shall provide Project spare philosophy document
covering commissioning spares, two years maintenance spares, mandatory spares
and insurance spares and quote for the same.
14.3. Consumables
The MANUFACTURER/SUPPLIER shall ship the system with six months supply of
consumables, with the exception of printer paper.
MANUFACTURER/SUPPLIER shall provide a complete list of consumables with the
Design Review.
For all units, spare fuses and consumable items shall be provided as individual
packages.
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14.4. Expandability
System shall be configured to no more than 50% of the system capabilities and be
expandable to 50% future capabilities without reduction in system performance.
Control System shall be expandable to meet future growth, without requiring
changes to equipment supplied. Control System shall be designed such that future
expansion and addition of future DCS Areas shall not require any replacement /
upgrade of equipment, and shall not in any way impact Operations.
MANUFACTURER/SUPPLIER shall provide capacity, loading and performance
calculations for Integrated DCS System components during design review. These
calculations shall take into account limitations due to gateways, routers, bridges and
system internal firewalls.
MANUFACTURER/SUPPLIER shall state the constraints for potential expansion of the
proposed system as part of critical design review documents.
Potential expansion features addressed shall include the following:
Addition of application engineering functions
Addition of controller functions
I/O and controller expansion
Addition of operator Workstations
Expansion capacity of the database
Maximum communications throughput
Addition of third-party systems
Addition of process control computers
Addition of future Operating Groups
Addition of Future Risk Areas
Additions of Network components for expansion of DCS/ESD network
14.5. Accessibility and Maintainability
Control System shall be designed to allow easy access and maintainability, without
compromising packaging density or floor space requirements.
Front access to cabinets or front / rear access where applicable, shall be used for
Maintenance. Terminal blocks and all components shall be installed so to permit
accessibility for maintenance.
Top or side access to cabinets are not acceptable for maintenance.
14.6. Manageability
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Applications should be designed to utilize standard hardware, standard protocols,

Standards interfaces, etc. to assure ready coexistence with other applications and
services.
Applications should be easy to understand and maintain with built in procedures for
such as update patching, backups, etc.
14.7. Remote Maintenance System
A remote maintenance shall be supported by the DCS system. It shall consist of PC
and latest network security appliance. The RMS shall connect to DCS system for the
purpose of establishing diagnostics and monitoring system health. It shall able to
remotely view and troubleshoot issues such as displays, system management and
system application by experts. Remote access shall be made via Router to Modem or
ISDN line or internet access through firewall with password access. Remote
connection to RMS will remain disconnected physically and only be made when
desired by user.
14.8. Integration / Optimization
The applications and systems already in place should be considered and new
applications should be integrated with them to optimize systems and costs.
14.9. Transient/Surge and Fault Protection
All electrical equipment shall incorporate electrical transient protection on the power
input and on the all interfaces to inputs and outputs.
As a minimum the system shall be able to withstand applied surges without damage
to components and without operating errors.
The system shall be internally protected against system errors and hardware
resulting from connecting and disconnecting device or removing or inserting cards.
14.10. Electrostatic discharge protection
The system shall be capable of withstanding electrostatic discharge test. This
assumes that the system is properly grounded as per project specification.
14.11. Office Network Applications
Office Network applications are outside the scope of this document, but a summary
is included here.
Applications that utilize data can only be installed in the Office Network if they do
not meet the criteria for becoming a process control application.
These types of applications are generally used by technical specialists, engineers and
other supporting staff to perform calculations and supply values to specific
supporting groups such as:
Financial /Management
Environmental
10080-1-SS-CI-017 Page 67 of 203
Production
Forecasting
Reservoir Management
Laboratory Applications
15. Time Synchronization
A dual GPS based integrated time synchronization system shall be supplied. Time
Synchronization system shall consist of GPS Antenna, Receiver, Time Strobe
Generator, Time Keeper, Network Time protocol server.
The DCS control Network shall be the primary distribution media for time
synchronization. The DCS MTK Workstation shall receive GPS time and distributes it
to control processors and workstations across the DCS control Network.
NTP servers shall be located in the control room and provide time synchronization
across the Plant Interface Network. Servers, Workstations, PLC, etc that connect to
the PIN can subscribes to the NTP service for time synchronization. The exact type
frequency of outputting time signals for time synchronization of various systems shall
be decided during detail engineering.
Time synchronization redundancy shall be considered by having a Primary Master
Time Keeper and Backup Master Timer Keeper workstation. Each MTK workstation
sources its GPS signal from its own GPS Antenna /Receiver. In the event of failure of
the Primary MTK the Backup MTK shall take over. Failure of master clock system
shall not affect operation of all connected control system. Time synchronization shall
be considered for the following:
DCS Workstations
DCS Control Processors
ESD system including SOE station.
Alarm Management System Servers
Instrument Asset Management System Servers and Clients
Historian Servers
Third Party Systems - Package PLCs and Workstation/Server based Microsoft ™
Windows latest version based systems connecting to the Plant Interface Network
16. DCS Engineering Workflow
The Engineering inputs for the configuration of the DCS system includes the Process
and Instrument Diagrams (PID's), Process Flow Diagrams (PFD's), Cause and Effect
Diagrams, logic diagram, Graphics, Cable Block Diagrams, Process Schematics,
Instrument Plot Plans, Instrument Data Sheets, Motor Coordination Sheets, FF
segment design and, most importantly the SPI Database. SPI database shall be
10080-1-SS-CI-017 Page 68 of 203
generated by considering selected DCS system configuration fields. Related SPI Rule
book shall be given to all MANAGING CONTRACTOR's
All listed engineering deliverables shall be generated by MANAGING CONTRACTOR.
Each engineering input shall be issued as IFC (Issue for Construction).
Inputs such as the SPI Database, FF segment design shall be validated for their
correctness and completeness by MANUFACTURER/SUPPLIER. In addition, Process
and instrument teams from Site shall be involved in the validation. Operations
validate I/O allocation, alarm rationalization and segment validation with FMEA. In
this phase MANUFACTURER/SUPPLIER will generate the technical queries for missing
such as information such as missing tag, cable modification, alarm value, range value
missing etc.
MANUFACTURER/SUPPLIER shall generate complete system design of Network,
hardware and software for DCS. MANUFACTURER/SUPPLIER shall do submission for
early interface engineering like Final BOM, Power calculations, Heat Loads, Panel
Foot Prints, Weight of the Equipment, Grounding and Earthing Scheme, Foundation
Details, Space Requirement, floor cut out dimensions, UPS/batteries-chargers, Power
distribution from separate feeders etc.
MANUFACTURER/SUPPLIER shall submit Functional Design Specifications, Software
Design Specifications, Graphics and HMI development specifications, Detailed Design
Specifications (DDS).
Functional Design Specifications shall be reviewed and approved by MANAGING
CONTRACTOR and OWNER for MANUFACTURER/SUPPLIER to start engineering.
MANUFACTURER/SUPPLIER shall submit all engineering deliverables as per details
provided in the specifications, interface engineering details for all third party
interfaces.
System configuration of all equipment, databases, interfaces, graphics, screen
displays, reports etc.
Engineering deliverables by MANUFACTURER/SUPPLIER shall be reviewed and
approved by MANAGING CONTRACTOR and OWNER.
16.1. Functional Design Specifications
MANUFACTURER/SUPPLIER shall prepare the functional design specification (FDS)
giving system specific technical guidelines which shall be used during
implementation. It will be mandatory to be followed by all MANAGING
CONTRACTORs and any waiver has to be approved jointly by OWNER and initiator.
FDS shall be reviewed and approved jointly by MANAGING CONTRACTOR and
OWNER.
Following is the minimum but not limited list of FDS to be prepared:
System Hardware and software
10080-1-SS-CI-017 Page 69 of 203

SPI Rulebook
Foundation Field Bus
Alarm Philosophy, Management and reports
Historian Reports
DCS cabinets
System Networking
Third Party Interface
Serial Link
OPC
Time Synchronization
HMI
Asset Management
System Security
The purpose of FDS document shall be to define accurately and clearly the scope of
supply for the DCS System and therefore quantify the agreed scope of work. FDS shall
be the primary MANUFACTURER/SUPPLIER document used for the design and
implementation of DCS system. For details refer Attachment-3.
17. Inspection and Testing
17.1. The MANUFACTURER/SUPPLIER shall be responsible for the inspection and quality
assurance of materials and equipment and for the standard of the workmanship. A
quality dossier shall be submitted after testing, complete with certificates and test
results.
17.2. MANUFACTURER/SUPPLIER shall allow MANAGING CONTRACTOR/OWNER’s
representatives to review the System and documentation at any stage of design and
assembly.
17.3. The MANUFACTURER/SUPPLIER shall be responsible to conduct the pre-FAT and FAT
for DCS system and associated equipment in accordance with written FAT
procedures. MANUFACTURER/SUPPLIER shall submit the procedures for MANAGING
CONTRACTOR's approval at least six weeks prior to commencement of testing.
17.4. MANUFACTURER/SUPPLIER shall advise the heat soak tests that the electronic cards
have been subjected to after manufacture/assembly. If adequate proof is not
available then a heat soak test shall be included as part of the FAT.
17.5. MANUFACTURER/SUPPLIER Test
All system inputs and outputs shall be fully tested by the MANUFACTURER/SUPPLIER
prior to the FAT in accordance with agreed test plan and procedure. The
10080-1-SS-CI-017 Page 70 of 203
MANUFACTURER/SUPPLIER shall generate the procedures used for these tests,

including the "pass/fail" criteria.
The system shall be inspected by managing contractor's representatives prior to the
MANUFACTURER/SUPPLIER test for satisfactory quality and workmanship. The entire
test shall be successfully completed by the MANUFACTURER/SUPPLIER prior to the
FAT.
17.6. FAT Requirements
The MANUFACTURER/SUPPLIER shall provide all standard and special tools, test and
calibration equipment necessary for FAT.
MANUFACTURER/SUPPLIER shall carry out FAT as per approved FAT procedure
MANUFACTURER/SUPPLIER shall comply with following requirements.
MANUFACTURER/SUPPLIER shall conduct Pre-FAT for internal tests which shall
include cabinet visual inspection, configured loops check and graphics check.
MANUFACTURER/SUPPLIER shall offer the FAT schedule after working on the
comments of Pre FAT.
MANUFACTURER/SUPPLIER shall have previously successfully completed a dry
run test of all equipment and services to be demonstrated before the OWNER
witnesses the test. A pre-FAT report of 100% of all the test carried out by
MANUFACTURER/SUPPLIER shall be submitted minimum one month prior to FAT
date.
MANUFACTURER/SUPPLIER shall carry out functional testing of accurate time
synchronization as defined in Project specifications prior to FAT which shall be
witnessed by MANAGING CONTRACTOR/OWNER.
Prior to FAT, MANUFACTURER/SUPPLIER shall offer Pre-FAT in which complete
system functionality (Including Package units Interfaces) on simulator/testing
software shall be witnessed by MANAGING CONTRACTOR/OWNER.
17.7. Performance Approval Criteria’s
DCS system minimum shall comply with below mention perform criteria's
Criteria Requirement
Availability
• Availability 99.99%
• MTTR figure 8 hour
Scan Time
Closed loops Inputs 15% at 100ms & 25% at 250ms

• 60% at 500ms
10080-1-SS-CI-017 Page 71 of 203
• Digital 100ms
• Time stamping resolution Vendor to define
FF
• FF Segment Ideal Time 50% of Macrocycle
• Device Diagnostic templates As per NAMUR NE-107
Loading
• Controller 60%
• Network 50%
• Serial Link 60%
• Historian 70%
Response time
• Alarm Response 1 sec
• A/D 12 bit Minimum
• Security 3 Levels
• Command to Output 1 sec
30 real time trend points with 60
samples
Trend
each, time interval 1sec to 15
• minutes
• New Screen Call Up time 1sec
• Graphic Update rate 1sec
• Network access Not more than 600ms
History Data call up time
• maximum 5 sec
Operator Interface
• Operator logging 1 sec
• Response to mouse/trackball 0.5 sec
• Alarm summary display Minimum 300 alarms

• Alarm Priorities 4
• User Graphics access Minimum 500 Graphics
• Access to tags Minimum 5000 Tags
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Network Switches Management

• Network Switches Managed Type
17.8. Factory Acceptance Test (FAT)

All hardware must be installed and connected and all software functionalities must
be configured prior to the start of the FAT. The FAT shall include the testing and
acceptance of both hardware and software systems individually followed by
integrated testing with DCS.
The serial interface I/O shall also be tested. The test shall be carried out with the
actual system to be installed at site or prototypes.
As an option DCS MANUFACTURER/SUPPLIER shall offer portable mini DCS system
with necessary hardware and software to test package unit/third party serial
interfaces at their respective locations. MANUFACTURER/SUPPLIER approved
procedure for interface shall also be provided for ease of operation/interface. The
parameters checking, Graphics checking and other data checking for successful
testing of interface shall be provided by MANUFACTURER/SUPPLIER for MANAGING
CONTRACTOR/OWNER approval one month before planned testing schedule.
MANAGING CONTRACTOR/OWNER personnel will witness the entire FAT. This will
involve 100% testing of hardware and software configurations including loop testing,
logic testing, graphics, system tests, system generated displays, alarms, historian
test, network test, reports, logs, control logic, system performance, loops,
redundancy, time synchronisation, interface test, power supply testing, cabinet test
etc.
One month prior to proceeding with the testing, the MANUFACTURER/SUPPLIER
must submit for review the system log, pre-test records, and show certificates for
test equipment to be used. The MANUFACTURER/SUPPLIER shall also submit a
detailed schedule of FAT showing assigned personnel and location to enable the
MANAGING CONTRACTOR/OWNER to plan their personnel requirement.
The FAT will be signed off by MANUFACTURER/SUPPLIER and MANAGING
CONTRACTOR/OWNER personnel at the successful conclusion of FAT.
Unstructured tests may be performed by the MANAGING CONTRACTOR/OWNER
personnel to further ensure that all the functional requirements are met.
All hardware diagnostic programs shall be run at the start of the FAT. The
MANAGING CONTRACTOR/OWNER shall include steps in the FAT procedure to
demonstrate all system features including performance requirements such as control
network and controller loadings including scan times etc.
It will be mandatory to witness and followed the tests by all
MANAGING/CONTRACTOR's and any waiver have to be approved jointly by OWNER
and initiator.
10080-1-SS-CI-017 Page 73 of 203
MANAGING CONTRACTOR's shall give dispatch clearance after inspection, review and
approval of engineering documents, BOM with reference to Cabinet and other
hardware.
17.9. Site Acceptance Test (SAT)
Detail SAT procedure shall be submitted by MUNUFACTURER/SUPPLIER for review
and approval of MANAGING CONTRACTOR/OWNER one month prior to
commissioning.
The SAT procedures for both the systems will be derived from the FAT and will be
developed by the MANUFACTURER/SUPPLIER in consultation with the
MANAGING/CONTRACTOR. The SAT will be performed upon completion of
MANUFACTURER/SUPPLIER hardware installation and tests. Site Acceptance Test
shall be held on site to verify the correct operation of all hardware and software, the
validity of all programs, guaranteed accuracy, and the proper functioning of all
components as an integral system.
All the System functions shall be checked thoroughly for proper functioning.
OWNER will take over the system from the MANUFACTURER/SUPPLIER after the final
acceptance test, which is defined as successful uninterrupted operation of the
integrated System for one month for all units of the Plant.
MANUFACTURER/SUPPLIER personnel shall be present during the test. Any
malfunctioning of the system components shall be replaced/repaired as required
free of cost. Once the System failure is detected, the acceptance test shall start all
over again from the beginning.
SAT will be witnessed and signed off by the MANUFACTURER/SUPPLIER and
MANAGING CONTRACTOR/OWNER’s personnel.
18. Control and Technical Buildings
Control Building is the nerve centre of the DCS system. Following buildings shall be
considered while designing the DCS System. Other buildings such as Admin,
Laboratory shall be considered but not covered under this document.
18.1. Control Building
Control Building will be designed to facilitate the efficient and safe operation of the
plant by taking into account both the ergonomic needs of the operators and the
plant work processes. Issues such as lighting, console layout, furniture, display
configuration, traffic flow, noise levels, communications and work environment shall
be taken in due consideration.
The Control System operating interface will be located in this building and shared
between a certain numbers of operator consoles. Each console consists of several PC
based DCS workstations (OWS), F and G monitors, process CCTV monitors,
telecommunication equipments, auxiliary panels fitted with hardwired devices such
as ESD and FGS activation buttons, network printers, etc.
10080-1-SS-CI-017 Page 74 of 203
Project specific Design Basis will be prepared for Control room based on location,
operation philosophy, functions and population and facility requirement meeting
OISD (Oil Industry Safety Directorate) norms.
18.2. Engineering Room
The engineering rooms will house engineering workstations for DCS, ESD and other
system with network printers, telecommunication equipment etc. Engineering
workstations will be loaded with all control system engineering configuration, HMI
building software and any other specific engineering software tools, to provide
remote engineering, testing, diagnostic and troubleshooting capabilities.
Engineering Room shall have access controlled doors to ensure security of DCS
configuration.
18.3. Server Room/Rack Room
The server rooms will house all servers/stations and associated networking
components connected to the Control System such as Alarm Management System,
Historian, Asset Management, Web, OPC, Remote Diagnostics, Backup, Network
servers etc, as well as servers of all centralized engineered systems such as PLC,
MCMS, ATG, CCC, Analyzers and advance control system etc a KVM switch shall be
considered where multiple connectivity considered from one application server. Also
KVM extender shall be considered for installing HMI of above mentioned
stations/servers in engineering room.
Server room shall have minimum 600 mm raised floor of adequate load bearing
strength and antistatic floor surface. Server room shall deploy under floor cable/Fibre
management system using composite Fibre/copper patch panels, structured cabling
design, and hinged cable raceway systems to protect patch cords.
Under floor cable/fibre management system plays important role in reliability and
availability of DCS and should be carefully designed in consultation with vendor.
Raised floor cavity will be used for HVAC using Precision air conditioning units to
provide control environment. It shall be protected with Dry type fire suppression
system.
19. Field Technical Buildings
19.1. Process interface Buildings
Process Interface building shall be blast resistant and constructed as a rectangular
box type reinforced concrete structure. False flooring shall be provided. Down
through type Precision A/C units shall be considered. HVAC shall have corrosion filter
for protection of electronic components and connectors. The room shall have a
cavity floor system to facilitate the air conditioning process. Installation of HVAC and
UPS equipment shall be segregated from the Control System Equipment.
The HVAC and UPS shall be provided by OWNER.
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Field instrumentation interfaces, control system equipment, system and marshalling

cabinets and power distribution cabinets shall be located in normally unmanned
Process interface Buildings.
DCS System workstations, connected to Control network will be provided inside PIB
with PIB operational capabilities with password protection during initial plant
commissioning and start-up, emergency situations and during maintenance
operations. MANUFACTURER/SUPLIER shall consider all extra stations/servers with
necessary software licenses and other requirements (like special software's, tools
etc.) which are required for timely commissioning of the system as per project
schedule.
PIB shall have minimum 600 mm raised floor of adequate load bearing strength and
antistatic floor surface.
PIB shall deploy under floor cable/Fiber management system using composite
Fiber/copper patch panels, structured cabling design, and hinged cable raceway
systems to protect patch cords.
Under floor cable/fiber management system plays important role in reliability and
availability of DCS and should be carefully designed in consultation with vendor.
19.2. Electrical Substations
Normally there will be no instrumentation related equipment installed in electrical
substation, except for:
Electrical Control System (ECS)
110 VAC, 50 Hz UPS equipment
Electrical / Instrumentation interposing relays cabinets for interface between DCS
/ESD termination cabinets and MCC panels. (Interposing relay's are in
MANUFACTURER/SUPPLIER scope of supply)
Remote I/O equipment
Fire and Smoke detector
20. Warranty and Post-Warranty Maintenance
20.1. Warranty
The warranty period shall be 2 years after the plant start-up and cover all parts of
DCS provided by MANUFACTURER/SUPPLIER. The warranty shall include periodic
maintenance, on-call maintenance, replacement of failed components and software
upgrades. In case of failure of any hardware or software, DCS service engineer shall
be available at site within 24 hours of notification.
Provision shall be made for remote maintenance facility, during the warranty period
to carry out maintenance from any part of the world, where system experts can log
in to system for Remote diagnostics.
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20.2. Post-warranty Maintenance

The MANUFACTURER/SUPPLIER shall enter in to a post-warranty maintenance
contract and shall provide the following:
Fully qualified and experienced maintenance engineers to carry out the following
services:
Scheduled routine preventive maintenance on a 3 monthly basis for software
checks and hardware inspection,
24 hours hot-line for urgent advice by telephone, email and fax in the event of
problems occurring with the system,
Unscheduled site visit on the first available flight in the event that verbal
instructions cannot solve the problems.
Essential software upgrade shall be implemented by the
MANUFACTURER/SUPPLIER at the earliest mutually convenient opportunity with
all costs borne by the MANUFACTURER/SUPPLIER, non-essential releases may be
bought by OWNER.
Remote maintenance of system from MANUFACTURER/SUPPLIER works/Global
Centre.
20.3. Record
MANUFACTURER/SUPPLIER shall maintain a record of site specific data of the DCS
configuration, installed hardware and software revision levels, history of problems
and their recommended solution regarding system, spares consumption history etcs.
21. Quality
21.1. General
The hardware and software supplied shall be standard production quality
components following the MANUFACTURER/SUPPLIER’s standard Quality Assurance
Program for software development, manufacturing and inspection.
MANUFACTURER/SUPPLIER shall submit a Quality Program Plan, which provides a
description of the policy with respect to item quality and defines the means by which
quality assurance shall be implemented. Product will not be accepted unless it is free
of defects and poor workmanship.
21.2. Quality Requirements for Drawings
21.2.1. General Drawing Requirements
All design computations, drawings, procedures, and reports shall be checked and
signed as checked for accuracy, clarity, completeness, and compliance with the
applicable codes, standards, and specifications before they are submitted for
approval. Drawings shall be by CAD software and submitted in a hardcopy and
10080-1-SS-CI-017 Page 77 of 203

editable electronic format. All subsequent revisions shall be clearly highlighted with
revision mark.
21.2.2. Drawing Identification
Each drawing shall be provided with a title block in the bottom right hand corner. The
title block shall incorporate, apart from the official trade name of the manufacturer,
the DCS MANUFACTURER/SUPPLIER's drawing number and title, giving the
description of contents, the DCS MANUFACTURER/SUPPLIER's model or type
number, a symbol or letter indicating the latest issue or revision, and item's
equipment number. All drawing shall be reviewed and approved as per
MNUFACTURER/SUPPLIER quality requirements.
21.2.3. Risk Management
The risk management shall be conducted from the stage of kick off meeting to
identify key risks to the project. Area of Risk pertained to engineering, hardware,
logistics and other general heads shall be considered. These shall be highlighted in
the Risk register and shall be discussed during risk review meetings. A plan shall be
considered to mitigate the risk, which shall be approved by OWNER / MANAGING
CONTRACTOR and shall be implemented during project execution stage.
22. Drawing and Documentation
OWNER intends to use SMART Plant Instrumentation (SPI) for the generation of
drawings and documents. OWNER will provide remote access through Citrix server to
the DCS MANUFACTURER/SUPPLIER. DCS MANUFACTURER/SUPPLIER shall generate
minimum following document from SPI.
Cross wiring details
Configuration details
Loop drawings
A detail procedure for transfer and import/export of SPI data to DCS database shall
be prepared by and submitted by DCS MANUFACTURER/SUPPLIER in consultation
with MANAGING CONTRACTOR/OWNER.
Drawings and Documentation of the complete System shall be provided in
accordance with, but not limited to, the requirements stated in the project
specification. Documentation of the DCS systems shall be provided in accordance
with the requirements as specified below.
In general, the requirements can be categorized as below:
Full technical specifications of all hardware and software, Project
Drawings and specific documentation, Proven track record.
Documents with
System blocks diagrams and Earthing requirements.
Quotation
A completed Table of compliance
10080-1-SS-CI-017 Page 78 of 203

Project Management Documents, Engineering Documents which

comprise design and manufacture, Application engineering
documents which comprise software configuration details of
Drawings and
system
Documents
After Order Cabinet details (physical layout and hardware MTO), UPS/Non
Placement UPS Power requirements, Heat dissipation data (with all
supported back-up documents).
Operation and maintenance manuals
Document submission, approval methodology, number of copies during approval,

after final approval, requirement of soft copies and manufacturing record book shall
be as per the project specification.
Within four weeks after completion of the FAT, the MANUFACTURER/SUPPLIER shall
issue (hard copy and soft copy) a complete set of updated drawings reflecting any
modifications made during the FAT.
An updated set of documents shall also be issued by the MANUFACTURER/SUPPLIER
reflecting any changes made during site installation and commissioning.
MANUFACTURER/SUPPLIER shall provide completely filled SPIR (Spare Parts
Interchangeability Record) form, detail specification for recommended spares to be
given for facilitating to SAP codification
For list of documents refer Attachment-2
22.1. Loop Drawings
Loop drawings are required for the DCS. The MANUFACTURER/SUPPLIER shall
provide complete loop drawings for all input/output from the field instruments up to
the System displays. The drawings shall include intermediate connections including
field junction boxes, termination cabinet barriers and isolators and system cable
details, input/output card slot and sub-slot numbers, control processor identity and
the control blocks involved in the processing.
The loop drawings shall contain all the necessary information in order to perform
complete maintenance on all inputs and outputs associated with the DCS such as: PID
values, Alarm values, Controller action, Output limits, notes for critical /cascade
controls etc.
Automatic generation of loop drawings using valid SPI database is proffered to avoid
errors and omission in drawings.
22.2. Design Drawings
Prior to start of hardware assembly the system MANUFACTURER/SUPPLIER shall
submit all relevant drawings for approval.
10080-1-SS-CI-017 Page 79 of 203

After completion of FAT the system MANUFACTURER/SUPPLIER shall issue a

complete set of updated documents reflecting any modifications made during the
FAT.
An “as built” set of documents shall also be issued by the
MANUFACTURER/SUPPLIER after site installation and commissioning.
22.3. Design Interface
The MANUFACTURER/SUPPLIER shall develop/define the system configuration in
consultation with the OWNER / MANAGING CONTRACTOR. All configuration work,
when requested shall be provided to OWNER / MANAGING CONTRACTOR for review
and comment.
The DCS displays such as groups, trends, alarms, graphics and logs/reports,
configuration details and drawings of all complex schemes shall be engineered.
MANAGING CONTRACTOR will provide P and IDs, logic diagrams / cause and effect
diagram for complex schemes and other information such as Smart Plant
Instrumentation (SPI) I/O database for preparation of the System database. Graphic
input shall be provided in form of P&ID markups.
23. Installation
Transportation to site and installation of the System will be by the MANAGING
CONTRACTOR. The MANUFACTURER/SUPPLIER shall supervise site installation. The
MANUFACTURER/SUPPLIER shall provide details of any special equipment required
for the installation.
24. Packing and Shipping
MANUFACTURER/SUPPLIER shall submit his packing specification to MANAGING
CONTRACTOR for approval.
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Attachment-1: Scope of work

1. Purpose
Attachment-1 describes the scope of work that the Distributed Control System (DCS)
MANUFACTURER/SUPPLIER is required to provide for the hardware, software and
System design specified in DCS Specification 10080-1-SS-CI-017
The MANUFACTURER/SUPPLIER shall take single point responsibility for the work
detailed in this and all referenced documents.
2. Scope of Work & Supply
The MANUFACTURER/SUPPLIER shall design, procure equipment, build, develop
and implement the software and hardware configurations, write application
software as required, factory test the systems, supervise unloading and site
installation and perform MANUFACTURER/SUPPLIER tests prior to site
acceptance tests, assist in commissioning as requested and provide all
documentation.
The MANUFACTURER/SUPPLIER shall accept total responsibility for the work
detailed in this document. This includes project management and engineering
associated with all configuration work, all programming requirements, building
displays such as graphics and reports / logs etc., Factory Acceptance Test,
packing, supervise unloading and movement of equipment at site installation,
MANUFACTURER/SUPPLIER Test, Site Acceptance Test, pre-commissioning and
commissioning assistance.
The MANUFACTURER/SUPPLIER shall accept total project management
responsibility for the interface of the DCS with the ESD and other third party
equipment’s.
2.1. Design and Engineering
Complete system design of hardware & software for DCS.
Submission for early interface engineering like Final BOM, Power calculations,
Heat Loads, Panel Foot Prints, Weight of the Equipment, Grounding and Earthing
Scheme, Foundation Details, Space Requirement, floor cut out dimensions,
UPS/batteries-chargers, Power distribution from separate feeders etc.
Submission for proceeding with detail engineering work like Functional Design
Specifications, Software Design Specifications, Graphics & HMI development
specifications.
Submission of all engineering deliverables as per details provided in the
specifications.
Submission of interface engineering details for all third party interfaces.
10080-1-SS-CI-017 Page 81 of 203

System configuration of all equipment, databases, interfaces, graphics, screen

displays, reports etc.
Application Engineering
Drawings and termination schedules as agreed in Material Requisition(MRQ)
Documentation sets as agreed in MRQ
To furnish final Bill of Material (BOM)
2.2. Project Management
Shall includes but not limited to the following
To supply all hardware and software as per agreed BOM.
To supply a functional, Operable, Reliable and Maintenance friendly System in
accordance with the referenced specifications.
Project administration and reporting
Kick off meeting
MANUFACTURER/SUPPLIER to provide sufficient man power at MANAGING
CONTRACTOR Office for Conceptual Engineering & FDS development. Also
adequate manpower shall be provided at all the execution centers as required.
Technical co-ordination meetings – monthly or as required, alternatively at
MANAGING CONTRACTOR’S office & MANUFACTURER/SUPPLIER’s works
Scheduling, monitoring and regular reporting to MANAGING CONTRACTOR.
Procurement & Management
Warranty/Guarantee for equipment hardware, software and integrated system
for 2 years from the date of SAT.
Private office space for up to Ten (10) MANAGING CONTRACTOR and OWNER.
The MANUFACTURER/SUPPLIER shall provide access to office support facilities
such as Telephone, copiers, office stationary, etc. to MANAGING CONTRACTOR
and OWNER Engineers.
The MANUFACTURER/SUPPLIER shall have communication facility for extending
project (Managing contractor) networks to MANUFACTURER/SUPPLIER’s works.
2.3. Hardware, Software and Staging
Interoperability Tests for up to 50 devices and generation of detailed report. The
scope of tests shall be agreed prior to its commencement with MANAGING
CONTRACTOR.
Application Engineering
10080-1-SS-CI-017 Page 82 of 203
Supply of Systems to meet the functional requirements defined in this and all
referenced documents.
All software licenses required for operation of System
Consoles for all workstations, Auxiliary consoles for Alarm window, Hardwired
Push buttons, Switches, Lamps etc.
Assistance in Segment design and checking at Managing Contactor Office and at
all Execution centers.
Assistance in Foundation Field Bus related design.
Any item, which is not in BOM but required for commissioning/operation of the
system, shall be supplied free of cost
Staging at MANUFACTURER/SUPPLIER’s works
Standard & customised (Application) software including any source code
generated
Configuration and test of the systems
Supply of all interconnecting cables including Fibre optic cable and wiring &
termination between all components of system. This also includes FO cable
laying, Splicing and testing.
Integrated Factory Acceptance Test shall be performed; in addition separate
Foundation Fieldbus FAT with devices shall be tested as loop typicals. All the
fieldbus loops shall be tested at site.
Integration of Display wall Supplied by MANUFACTURER/SUPPLIER.
Integration of Operator console (if supplied by purchaser) with
MANUFACTURER/SUPPLIER supplied equipment’s on the console.
Packing & Shipping to site
Provide hardware support for quoted hardware for a period of 15 years from
date of declaring the same as obsolete
Provide software upgrades for 2 years free of cost and software support for 15
years free of cost.
Spare parts planning / supply (required during commissioning/ start-up and
warranty period with main equipment.
Software License shall be functionally unlimited for each license purchased.
2.4. Scope of Site Services
Supervision of unloading & unpacking.
10080-1-SS-CI-017 Page 83 of 203

Shifting material to relevant location.

Base frame fabrication and mounting including holes, fasteners, etc.
Installation of all Equipment (panels, racks, consoles and other hardware)
Fabrication of support for equipment
Scaffolding or any such facility which is required for system commissioning.
Supply and installation of interconnection of cables and cabling & termination up
to marshalling racks
Installation of Fibre Optic Network
Distribution of AC/ DC Power within racks and consoles etc.
Obtaining relevant Permits and Approvals for Site Work.
Obtaining Entry passes and completing all the formalities for Manpower (Includes
Contractor Manpower)
24 hrs vehicle for Site Support
Power up to complete commissioning of system.
Loading/Checking of system configuration
Establish communication in all relevant systems
Hardware/Software additions / deletion / changes
Site Acceptance Test
Assistance in Loop checking
Integration of various sub-systems, third party system, Telephone, PA System &
Radio System etc.
Assistance for Loop Tuning of the process system
Establish service centre at site
Availability of Hardware/Software Engineers during Warranty period
Generation of Over, Shortage & Damage (OS&D) reports as required and
providing further necessary assistance to OWNER for Insurance claims.
Issue final reconciliation report for all the material used.
After installation, check all drawings for correct installation in accordance with
the relevant drawings. Modify the site changes in drawings & bring all drawings
to as built level. All changes to be documented and countersigned by the relevant
engineer.
Submit final As-Build documentation.
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2.5. Support in terms of Spares, Maintenance Contracts, Manpower, Training

Provide complete details for commissioning spares, insurance spares etc. to
justify availability of system more than 99.99% with MTBF & MTTR considered.
Provide complete details of comprehensive maintenance contract.
Training : Provide complete details of training facilities available for following:
System engineering
Hardware maintenance
Application software
Configuration
Operator training
Interface/Networking training
System Diagnostics training
2.6. Facilities to be provided by OWNER
Storage space for all hardware items at site
230 V AC/ 50 Hz Single phase power at one point for erection purpose as well for
lighting & maintenance sockets in racks / cabinets
110 V AC/ 50 Hz, UPS power in one cabinet for further distribution by
Grounding system at required one location for each type of earth.
Crane & manpower for unloading at manned locations only.
Cable Trays and Trenches for FO Cable.
2.7. Input to be provided by MANAGING CONTRACTOR
MANAGING CONTRACTOR shall supply the following documentation from which
the MANUFACTURER/SUPPLIER shall extract the information required for system
configuration.
Segment design rules and typicals
Input / Output signal count and details (Hardwired and Serial)
Control Strategy Diagrams
Grouping of tags for control
Display Definition
Control Building floor plans
Console floor plans
10080-1-SS-CI-017 Page 85 of 203
Control room and auxiliary room floor plans

Transmitter/Valves select logic
P & IDs
Trip and control logic system diagrams
Cause and effect diagrams
Process definition
Instrument index including ranges, controller actions and alarm/trip settings in
form of SPI database
Control logic and sequential diagrams
Data for configuring interfaces to all Packages and Third party Systems
Reports requirement
Cable Schedule
JB Wiring Diagram/marshalling rack termination details
3. Design Engineering, Drawings and Documentation
Documentation of the DCS systems shall be provided in accordance with, but not
limited to, the requirements in this document and the DCS specifications and other
related documents included as part of this requisition.
3.1. Design Drawings
Refer Attachment-002 of this specification for details of Design Documentation.
3.2. Design Interface
The MANUFACTURER/SUPPLIER shall develop/define the system configuration in
consultation with the MANAGING CONTRACTOR. All configuration work, when
requested shall be provided to MANAGING CONTRACTOR for review and comment.
The DCS displays such as groups, trends, alarms, graphics and logs/reports,
configuration details and drawings of all complex schemes shall be engineered in the
MANAGING CONTRACTOR’S office with assistance from the
MANAGING CONTRACTOR will provide P & IDs, logic diagrams for complex schemes
and other information such as I/O databases to assist in the preparation of the
System database. The database will be supplied on an optical media or through
import/export of SPI database f and will include details such as tag numbers,
descriptive texts, Engineering scale ranges and alarm settings.
10080-1-SS-CI-017 Page 86 of 203

4. Administration
Design review meetings shall take place regularly and formally at least once per
month. These meetings will alternate between the MANUFACTURER/SUPPLIER’s
Office and the MANAGING CONTRACTOR’S/OWNER Office. The agenda for each
meeting shall be prepared in advance by the MANUFACTURER/SUPPLIER. The
MANUFACTURER/SUPPLIER shall be responsible for publishing minutes resulting
from such meetings.
MANUFACTURER/SUPPLIER shall issue monthly progress reports describing progress
made against the mutually agreed project schedule. MANUFACTURER/SUPPLIER
shall identify any actual or anticipated slippage in the performance of work with
corrective actions to be taken.
MANUFACTURER/SUPPLIER shall provide office facilities for MANAGING
CONTRACTOR /OWNER. The private lockable offices shall be suitable for up to ten
(10) MANAGING CONTRACTOR and owner engineers. The office shall be supplied
with:
Lockable filing cabinets
Desks and chairs
Book/file shelves
Telephones
Fax
Access to photo copiers / bulk printing
Access to office stationary
The assigned project team shall work on this project until the final SAT.
5. Inspection and Testing
The MANUFACTURER/SUPPLIER shall be responsible for a high standard of
workmanship, inspection of the equipment and quality assurance of all materials
used including items supplied by third parties. A quality dossier shall be submitted
after testing, complete with certificates and test results.
MANUFACTURER/SUPPLIER shall allow MANAGING CONTRACTOR /OWNER’S
representatives to review the Quality plan, systems and documentation at any stage
of design and assembly.
The MANUFACTURER/SUPPLIER’s Test and the Factory Acceptance Tests for the DCS
systems shall be conducted by the MANUFACTURER/SUPPLIER in accordance with
approved test procedures. MANUFACTURER/SUPPLIER shall submit the test
procedures for approval at least six weeks prior to commencement of internal tests.
5.1. MANUFACTURER/SUPPLIER Test
10080-1-SS-CI-017 Page 87 of 203

All system inputs and outputs shall be fully tested by the

MANUFACTURER/SUPPLIER prior to the FAT in accordance with agreed test plan
and procedure. The MANUFACTURER/SUPPLIER shall generate the procedures
used for these tests, including the "pass/fail" criteria.
The system shall be inspected by MANAGING CONTRACTOR’S representatives
prior to the MANUFACTURER/SUPPLIER’s Test for satisfactory quality and
workmanship. The entire test shall be successfully completed by the
MANUFACTURER/SUPPLIER prior to the FAT.
5.2. Factory Acceptance Test (FAT)
All hardware must be installed and connected and all software must be
configured prior to the start of the FAT. The FAT shall include the testing and
acceptance of both hardware and software systems individually followed by
integrated testing of both the DCS together with other systems which are serially
interfaced to the DCS.
The I/O associated with serial interfaced systems supplied by others shall also be
tested. The tests may be carried out with the actual system to be installed at site
or proto type system. The MANUFACTURER/SUPPLIER shall be responsible for
unpacking and packing of the third party systems before and after the FAT.
MANAGING CONTRACTOR/OWNER personnel will witness the entire FAT. This
will involve testing 100% of the hardware and software configurations including
graphics, system generated displays, reports, logs, control logic, alarms, system
performance, loops, redundancy, data exchange between other systems etc.
One month prior to proceeding with the testing, the MANUFACTURER/SUPPLIER
must submit for review the system log, pre-test records, and show certificates for
test equipment to be used. The MANUFACTURER/SUPPLIER shall also submit a
detailed schedule of FAT showing assigned personnel and location to enable the
MANAGING CONTRACTOR/OWNER to plan their personnel requirement.
The FAT will be signed off by MANUFACTURER/SUPPLIER and MANAGING
CONTRACTOR /OWNER personnel at the successful conclusion of FAT.
Unstructured tests may be performed by the MANAGING CONTRACTOR / OWNER
personnel to further ensure that all the functional requirements are met.
All hardware diagnostic programs shall be run at the start of the FAT. The
MANUFACTURER/SUPPLIER shall include steps in the FAT procedure to
demonstrate all system features including performance requirements such as
control network and controller loadings including scan times.
5.3. Site Acceptance Test (SAT)
The SAT procedures for both the systems will be derived from the FAT and will be
developed by the MANUFACTURER/SUPPLIER in consultation with the MANAGING
CONTRACTOR. The SAT will be performed upon completion of
10080-1-SS-CI-017 Page 88 of 203
MANUFACTURER/SUPPLIER hardware installation and tests. The SAT will include a

selection of random I/O which will be checked on all the associated displays and will
cover selected portions of the hardware tests carried out during the FAT. Integration
with all third party systems shall be checked during SAT. SAT will be witnessed and
signed off by the MANUFACTURER/SUPPLIER and MANAGING CONTRACTOR /
OWNER’s personnel.
6. Storage and Site Installation
The MANUFACTURER/SUPPLIER shall be responsible for supervision of unloading
and movement of equipment within site, personnel, materials, tools and
instruments required for site installation of the DCS systems.
If required, the MANAGING CONTRACTOR/OWNER shall provide one or more
storage facilities at site for temporary storage of the equipment.
Service and Associated Equipment
The MANUFACTURER/SUPPLIER shall be responsible for site installation, power
distribution, grounding and rack mounting of all his equipment.
Site Installation
The installation includes un-crating, moving equipment, wiring and start-up of all
components supplied as part of this requisition.
The services include all internal DCS rack wiring and wiring between the racks and
the marshalling racks including intrinsically safe isolators. The services include all
cabling between DCS equipment and other third party serial interfaces to the
DCS.
The MANUFACTURER/SUPPLIER shall include any special equipment required for
the installation.
Power Distribution
The MANUFACTURER/SUPPLIER shall provide all equipment and wiring for power
distribution for all equipment specified in this requisition.
Grounding
The MANUFACTURER/SUPPLIER shall provide grounding for all equipment and
wiring inside the Plant Control Centres / Plant Interface Buildings for all
equipment supplied under this requisition including any third party equipment, if
used.
Rack Mounting
In addition to other equipment racks, the MANUFACTURER/SUPPLIER shall
mount, in their standard racks, the equipment provided by third parties.
10080-1-SS-CI-017 Page 89 of 203

7. Training
MANUFACTURER/SUPPLIER shall be responsible to provide training to operation,
maintenance and engineering personnel during project execution period at
MANUFACTURER/SUPPLIER’s location and also at site.
MANUFACTURER/SUPPLIER shall submit details of training modules for various skill
levels and schedules for the training for OWNER’s approval. It is expected that total
of 100 engineers will required to be trained by supplier.
10080-1-SS-CI-017 Page 90 of 203

Attachment-2: Documentation Required

1. General
As part of the MANUFACTURER/SUPPLIER’s responsibility, complete and accurate
documentation detailed in this Attachement-2 form MANUFACTURER/SUPPLIER
Document Requirements and elsewhere in the requisition shall be provided on the
following key milestones of the project:
MANUFACTURER/SUPPLIER selection
After Order placement
During engineering phase
Factory Acceptance Tests
After installation and Site Acceptance Tests
2. Documentation
1.1. The documentation shall cover the following categories:
Technical manuals and instructions

Planning and reporting
Hardware drawings and data
Software
1.2. The MANUFACTURER/SUPPLIER shall provide the following as a minimum with his
bid
Compliance matrix showing compliance, non-compliance or alternative to each

paragraph of the base specification, annexures and referenced documents.
Technical description and Specifications with supporting drawing of the proposed
system and its functionality.
Technical description and Specifications with supporting drawing of the proposed
system modules, buyout system/items and their functionality.
Proposed cabinet arrangement drawings with dimensions.
System Architecture in detail
Key design features of the offered system
Project execution plan as per Attachment H
System loading calculations (Network loading, Controller loading, Heat load,
Power Load and their basis)
10080-1-SS-CI-017 Page 91 of 203

Preliminary power requirements/estimated UPS consumption and heat

dissipation figures.
Field bus segment loading calculations
Reliability & Availability calculations
Detailed Bill Of materials with Makes & Model nos.
List of software’s required with tag handling capacities.
Reference list of similar large projects handled in last 3 years along with FF
experience.
General arrangements, panel design for marshalling panels, system panels, power
distribution panels & how panel count is arrived at by vendor.
System catalogues and data sheets (Product data sheets)
Bought items data sheets (Product data sheets) & catalogues
Proposed lay out of consoles
Typical of FDS, Loop Drawings, FAT procedure etc. for large Foundation Fieldbus
project
1.3. The MANUFACTURER/SUPPLIER shall issue the following four weeks prior to the FAT:
Two (2) copies of Factory Acceptance Test forms to be used during the tests.
Two (2) copies of all software documentation, including configuration, program
listings, loop drawings and ladder/logic diagrams.
1.4. All changes resulting from Factory Acceptance Test shall be updated and issued by
the MANUFACTURER/SUPPLIER within four (4) weeks after FAT.
After Site Acceptance Test and hand-over of the DCS all the afore mentioned
documents shall be issued ‘as-built’ within four (4) weeks of acceptance by OWNER
or appointed representatives.
This shall include six (6) sets in Electronic Format of system configuration and utility
software.
One (1) set shall be retained by the MANUFACTURER/SUPPLIER and one (1) set by
PROJECT MANAGER as back-up copy, while the balance shall be carried to site.
3. List of Documentation
The documentation list enclosed represents the typical documentation expected
from DCS MANUFACTURER/SUPPLIER by OWNER.
The documents are divided into the following categories:
1.5. Project Management Documents.
10080-1-SS-CI-017 Page 92 of 203

1.6. Engineering Documents which comprise of hardware details of:
Control room requirements

Process Interface Building room requirements
1.7. Application engineering documents which comprise of software configuration details
of DCS.
1.8. System manuals which comprise of printed manuals of:
DCS
1.9. Control room instruments data sheets
1.10. Loop Drawings

Loop drawings for DCS shall be generated through SPI (Smart Plant Instrumentation).
The MANUFACTURER/SUPPLIER shall provide complete loop drawings for all
input/output from the field instruments up to the System displays. The drawings
shall include intermediate connections including field junction boxes, termination
cabinet barriers and isolators and system cable details, input/output card slot and
sub-slot numbers, control processor identity and the control blocks involved in the
processing.
The loop drawings shall contain all the necessary information in order to allow the
MANAGING CONTRACTOR to perform complete maintenance on all inputs and
outputs associated with the DCS.
To assist the MANUFACTURER/SUPPLIER in production of the full loop diagrams
MANAGING CONTRACTOR will provide a database with all the details on the field
side up to the termination cabinets. This information shall take the form of
termination drawings
1.11. Control room instruments instruction manuals
e-Room facility shall be used by MANUFACTURER/SUPPLIER for documents

submission. e-Room access and procedure for use shall be provided by OWNER.
Following type documents are require for submission in e-Room.
TYPE e-Room
FI = For
= Information Yes
FFA = For
= Approval Yes
A
FC = For
= Construction Yes
AB = As
= Built Yes
10080-1-SS-CI-017 Page 93 of 203

In addition to e-Room submission of documents, optical media are required for some
of the documents. Three sets of documents in such ELECTRONIC media will be
required wherever mentioned in addition to e-Room documents. Hardcopy of final
approved document shall be submitted by MANUFACTURER/SUPPLIER.
LIST OF DOCUMENTS
3.1 Project Management Document
DOCUMENT NAME TYPE OF DOCUMENT ELECTRONIC MEDIA
Project Organisation FI -
Project Schedule FA Yes
Document Issue Schedule FA Yes
Standard Documentation List for FA Yes

the System
Training Schedule FA -
Progress Report FI -
FAT Procedure FA Yes
SAT Procedure FA Yes
Quality Plan FI Yes
Functional Design Specification FA + FC Yes
Software Design Specification FA + FC Yes
10080-1-SS-CI-017 Page 94 of 203

3.2 Engineering Documents

Control Room Equipment Drawings
DOCUMENT NAME TYPE OF DOCUMENT ELECTRONIC

MEDIA
Required Control Room Lighting Design FI -

Arrangement
Required Channel Frame Drawings FI -
C/R Layout Drawing FA + AB Yes
System Installation Diagram FA + FC + AB Yes
System Definition Drawing & System Writeup FI + FC + AB Yes
System Architecture Diagram FA + FC + AB Yes
GA drawings for panel internals FA + FC + AB Yes
Signal Interconnection Diagram for Operators FA + FC + AB Yes
Stations/Peripherals
Power Consumption and Heat Load Table FI + AB -
AC/DC Power Distribution Single Line Diagram FA + FC + AB Yes
System Grounding Diagram FA + FC + AB Yes
Communication Cable Connection Diagram FC + AB Yes
Operator Station Dimensional Drawing and FI + AB Yes
Internal Module Layout Drawing
ESD Auxiliary Console FA + AB Yes
Dimensional Drawing with Front Layout
(Indicating Typical Layout of Components
(e.g. Lamp, Switch, etc.)
Internal wiring Diagram
Terminal Assignment
Power Distribution Diagram
Certificates Hazardous Area Approvals FC Yes

Test Certificates FC Yes
10080-1-SS-CI-017 Page 95 of 203

PIB Room Equipment’s Drawing

MEDIA
Typical System Cabinet/Internal Layout FA Yes

Diagrams (If the Cabinet has marshalling also).
Typical Internal Layout Diagram for Marshalling, FA Yes

Rack, PDB Electrical Inst. Interface
Cabinet/Pump.
Typical Loop Wiring Diagram FA Yes
Typical Network/Segment Diagrams FA Yes
Aux. Room Layout Drawing FA + AB
Installation Drawing FA + FC + AB
1) System Cabinets
Internal Layout Diagram with System Module FC + AB Yes

Listing
Internal Wiring Diagram/TB Assignment
Power Supply Distribution Diagram
2) Marshalling Cabinet
GA Drawing/Base Drawing -
Barrier/Terminal Assignment FA + FC + AB Yes
Power Supply Distribution Diagram Yes
Wiring Diagrams Yes
2) Network Cabinet
Network diagram for all networks FA + FC + AB Yes
Detail of port connection for all switches Ye
4) Power Distribution Cabinet
10080-1-SS-CI-017 Page 96 of 203


MEDIA
Internal Wiring Diagram Yes

Terminal Assignment Yes
Power Distribution Diagram FA + FC + AB -
5) Electrical - Instrument Interface Cabinet
Internal Wiring Diagram FA + FC + AB Yes
Terminal Assignment Yes
Power Supply Distribution Diagram Yes

6) FF System Cabinet
Terminal Assignment FA + FC + AB Yes
Power Supply Distribution Diagram FA + FC + AB Yes
Cross- Wiring diagrams FA + FC + AB Yes
Interconnection Diagrams for FBM FA + FC + AB Yes
Panel Interconnection Details

PDB’s to electrical/inst. interface cabinet pump and valve
trip/DCS/PLC/maintenance override panels etc.
Electrical/inst. interface cabinets to DCS, PLC, pump and valve logic.
Pump and valve trip logic to DCS
10080-1-SS-CI-017 Page 97 of 203

3.3 Application Engineering Documents

DOCUMENT NAME TYPE OF ELECTRONIC
DOCUMENT MEDIA
Document for DCS
Detailed software BOM along with details of FA + FC + AB Yes

Media
Comm. network Configuration FA + FC + AB Yes
Operator Station Console Configuration FA + FC + AB Yes
Area/Unit Philosophy FA + FC + AB Yes
Graphics Philosophy FA + FC + AB Yes
Graphics FA + FC + AB Yes
Alarm Messages Listings FA + FC + AB Yes
Trend point grouping FA + FC + AB Yes
Logs/report implementation philosophy FA + FC + AB Yes
Functional Design Specification (FDS) FA + FC + AB Yes
Control Strategy (Indicating which Control FC + AB Yes

Resides Where)
Details regarding software block configuration FA + FC + AB Yes

and their interconnection (Software Design
Specification)
I/O Assignment Tables FA + FC + AB Yes
List of default values/parameters to be used for FA + FC + AB Yes

configuration
Operation philosophy of interlocks (motor/ FA + FC + AB Yes

valves/bypass switches etc.)
Specification for special software/ FA + FC + AB Yes

requirements/interface
10080-1-SS-CI-017 Page 98 of 203


DOCUMENT MEDIA
Software Testing Documents FA + FC + AB Yes
Factory Acceptance Test (FAT) Procedure FA + FC + AB Yes
Site Acceptance Test (SAT) Procedure FA + FC + AB Yes
Field bus segment design calculation FA + FC + AB Yes
Gateway communication point listing for: FA + FC + AB Yes

Compressor Control
PSA
Gas Chromatograph
Gateway configuration details FA + FC + AB Yes
Loop Diagram FA + FC + AB Yes
10080-1-SS-CI-017 Page 99 of 203

3.4 System Manuals

DOCUMENT MEDIA
1) For DCS
A) Hardware Manual FI Yes
Operation and Maintenance manual for all system

components.
Installation Manuals
Fault Diagnostics Manuals
Preventive Maintenance Spare Parts Lists
Laser Colour Printer
B) Software Manual
Details of all Software Blocks FI Yes

Configuration Manuals
Self-Documentation Manuals
Graphics/Logging Builders
System Initialisation Guide
Communication with PLC/CC/GC etc. guide
10080-1-SS-CI-017 Page 100 of 203

3.5 Control Room Instrument Datasheets

DOCUMENT MEDIA
Barriers Data Sheets FI Yes
FF Power Conditioner Data Sheets FI Yes
10080-1-SS-CI-017 Page 101 of 203

3.6 Control Room Instruments (Instruction Manual)

DOCUMENT MEDIA
Barrier Instruction Manual FI -
FF Power Conditioner Instruction Manual FI -
PB, Lamps, Relays etc. Leaflets with specs. and part FI -

Nos.
10080-1-SS-CI-017 Page 102 of 203

Attachment-3: Functional Design Specifications

1. Scope
MANUFACTURER/SUPPLIER is required to submit detail Functional Design
Specification structured as defined below and covering the following topics as a
minimum.
2. Project Overview
2.1. Introduction
2.2. Purpose
2.3. Scope of Supply
2.4. Project Implementation Plan
2.5. Quality Assurance
2.6. Change Control Procedures
2.7. Glossaries/Abbreviations/Definitions
2.8. Definition of Nodes
2.8.1.1. Communication Network
2.8.1.2. Operator Console
2.8.1.3. History
2.8.1.4. Engineering Workstation
2.8.1.5. Computer Gateway
2.8.1.6. Controller Sub-System
2.8.1.7. Data Highway and Interface
2.9. Summary of I/O
2.9.1. Hardwired I/O
2.9.2. Interfaces to Third Party Equipment
2.9.2.1. ESD System
2.9.2.2. Package Unit Control Systems (PLC, MCMS, Anti-Surge controller etc.)
2.9.2.3. Custody Transfer System
2.9.2.4. Turbine Speed Governor System
2.9.2.5. Burner Management System
2.9.2.6. Multiplexer System
2.9.2.7. Turbine Control System
10080-1-SS-CI-017 Page 103 of 203

2.9.2.8. Analyser Management System

2.9.2.9. ATG System
2.9.2.10. Terminal Automation System
2.9.2.11. Any Other System
3. System Overview
3.1. Introduction and System Topology
3.1.1. Overview
3.1.2. Foundation Fieldbus
3.1.3. Profibus
3.1.4. Conventional
3.2. Subsystems (Nodes)
3.2.1. Controller Subsystems
3.2.1.1. Controller and I/O Hardware
2.2.1.1.1 Controller Cardfile
2.2.1.1.2 Controller Modules
2.2.1.1.3 Controller Interface Modules
2.2.1.1.4 Serial Interface Links
2.2.1.1.5 I/O Modules
2.2.1.1.5.1 I/O Block Types

3.2.1.2. Controller and I/O Software
2.2.1.2.1 Controller Software
2.2.1.2.1.1 System Software
2.2.1.2.1.2 Programmable Control Functions

(Blocks)
2.2.1.2.2 I/O Software
2.2.1.2.3 Serial Interface Links and Software

3.2.1.3. Controller and I/O Housing
3.2.2. Work Stations
3.2.2.1. Engineering Station
10080-1-SS-CI-017 Page 104 of 203
2.2.2.1.1 Basic Hardware Options
2.2.2.1.2 Software Option

3.2.2.2. Operator Station
2.2.2.2.2 Software Options

3.2.2.3. MIS Station
2.2.2.3.2 Software Options

3.2.3. Interface Gateways
3.3. Communications
3.3.1. The Communication Network
3.3.2. The Field Bus
3.3.3. Profibus
3.4. Power Supplies
3.4.1. Controller Power Distribution
3.4.1.1. AC Power Distribution Panel
3.4.1.2. Redundant 24V Power Supply
3.4.2. Marshalling Rack I/O Power Supply
3.5. Bought-Out Items
3.5.1. PLC
3.5.2. Trip Amplifiers/Current Repeater
3.5.3. Proximity Amplifiers
3.5.4. Multiplexers
3.5.5. PCS
3.5.6. Push Buttons/Switches
3.5.7. Printers
3.5.8. Barriers/Isolators
3.5.9. Relays
3.5.10. Any Special Instruments
3.6. System Security
10080-1-SS-CI-017 Page 105 of 203

4. System Configuration
4.1. Introduction
4.2. Communication Network
4.2.1. Console
4.2.1.1. Hardware Configuration
4.2.1.2. Software Configuration
3.2.1.2.1 Console Resident Packages
3.2.1.2.2 Configurable Packages

4.2.2. MIS/History
3.2.2.2.1 MIS Resident Packages

4.2.3. Engineering Workstation
3.2.3.2.1 EWS Resident Packages

4.2.4. Host Computer Gateway
3.2.4.2.1 EWS Resident Packages

4.2.5. Controllers
3.2.5.1.1 Controller
3.2.5.1.2 I/O
3.2.5.1.3 Controller I/O Allocation

10080-1-SS-CI-017 Page 106 of 203
4.2.6. Communication Network Interface

3.2.6.2.1 Resident Package
3.2.6.2.2 Configuration Package

4.2.7. Interface Gateways
4.2.8. Communications
4.2.9. Power Supplies
5. Software Configuration
5.1. Introduction
5.2. Database
5.2.1. Database Hierarchy
5.2.2. I/O Allocation
5.2.3. Loop Specification
5.2.4. Process Control
5.2.5. Logic/Sequencing
5.2.6. Data Storage
5.2.7. History Recorders
5.3. Custom Graphics
5.3.1. Design
5.3.2. Conventions
5.3.3. Building
5.3.4. Symbols
5.4. Control Language
5.4.1. General
5.4.2. Block Structured
5.4.3. Programming Language
5.4.4. Ladder Logic Language
5.5. Alarm/Event Logging
5.6. Console Environment
5.6.1. Hierarchy
10080-1-SS-CI-017 Page 107 of 203
5.6.2. Access Levels

5.6.3. Tag Allocation
5.6.4. Units
5.6.5. Standard Displays
5.7. Operator Interface
5.7.1. Operating Philosophy
5.7.1.1. Schematics
5.7.1.2. Use of Colour, Symbols and Symbols Action
5.7.1.3. Page Linking
5.7.1.4. Windowing
5.7.1.5. Operational Procedures
5.8. Reports
5.8.1. Production Report
5.8.2. Efficiency Reports
5.8.3. MIS Reports
6. System Attributes
6.1. Introduction
6.2. Redundancy
6.2.1. General
6.2.2. Controller Subsystem
6.2.3. I/O Redundancy
6.2.4. Communication Network Redundancy
6.2.5. Gateway Redundancy
6.2.6. History Redundancy
6.2.7. Power Supply
6.3. System Security
6.4. System Performance and Reliability
6.4.1. Quantitative assessment of Performance requirements
6.4.2. Reliability and Availability Calculations.
6.5. Database Management
6.6. Communication Services
10080-1-SS-CI-017 Page 108 of 203

6.7. Diagnostics
6.7.1. General
6.7.2. System Diagnostics
6.7.3. Controller Power-up
6.7.4. Console Power-up Diagnostics
6.7.5. Run-Time System Diagnostics
6.7.6. Diagnostic Displays
6.7.7. Diagnostic Alarms
6.7.8. Diagnostic Lights
6.7.9. Status - Error Indicators
6.7.10. Operational Indicators
6.7.11. Replacement Indicators
6.8. Failure/Recovery Modes
6.8.1. Subsystem Start-up
6.8.2. Resumption of Plant Control
6.8.2.1. Console
6.8.2.2. Controller Subsystem
6.8.2.3. Gateways
6.8.2.4. I/O Blocks
6.9. System Expandability/Up gradation
6.9.1. Hardware Expansion/Up gradation
6.10. Remote Maintenance
7. System Environment
7.1. Introduction
7.2. Electrical Supply
7.3. Physical Environment
7.3.1. Equipment Room
7.3.2. Control Room
7.3.3. Engineering Room
10080-1-SS-CI-017 Page 109 of 203

Attachment-4: Display and Graphics Requirement

1. Scope
Attachement-4 describes the minimum requirements for the DCS Operator Interface
which will enable fully integrated, automatic control with minimal operator
interaction.
ASM consortium guidelines for Effective Operator Display Design shall also be
followed.
2. Operational Philosophy
Control Building contains DCS workstations and IMS with ability to access and
monitor all plant areas. In addition to control room DCS workstations will also be
located in PIB (Process Interface Building).
The quantity and locations of operator workstations in the Building and the PIB
will be defined in the MR.
In general, no more than 100 control loops shall be operated from a single
operator workstation. System with more than 100 control loops per operator
shall be analysed carefully to ensure that the operator workload is manageable.
The Control Building and PIB shall have communication equipment, together with
the relevant equipment such as printers, colour video copiers and emergency
shutdown facilities dedicated to plant areas.
The Process, Utilities and Offsites Units for the plant shall be controlled and
monitored primarily from Control Building. Operator workstations will be
available in the Building for control and monitoring and in some PIB for local
start-ups, shutdowns, maintenance and emergencies. Additional workstations
can be added in future in any desired location as the need arises.
3. Display Requirements
3.1. HMI shall be high performance
Task With Traditional With High Performance Result
HMI HMI
Detecting abnormal
situation before alarm 10% of the time 48% of the time A 5X increase
occur
Success rate in handling 37% over base
70% 96%
abnormal situation case
Time to complete
18.1 min 10.6 min 41% Reduction
abnormal situation
10080-1-SS-CI-017 Page 110 of 203

Figure-1 High Performance HMI Benefits

Figure-1 indicates benefits of High performance HMI.
3.2. Operator Interface
Operator Interface functionality shall include advanced features for communication
with the user such as:
Presentation of user defined graphic displays, standard displays, reports and
various lists
Effective Operator dialogue for manual control
Alarm and Event Management and display
System self diagnostics and display of system status
System shall make use of the latest technology in Man-machine interaction to
offer the
The Status of the process shall be presented on the following different types of
display:
3.2.1. Overview and Group Displays provide a standard way of presenting cursory
information about the process. The basis layout shall be standardised, but the user
defines which objects to show where.
3.2.2. Object Display contains all the information there is about single objects. These
displays shall not require configuration but are automatically available for all objects
defined within the system database.
3.2.3. Trend Display shall provide multiline display of up to 16 loops on a single x-y plot.
3.2.4. Process Graphics Displays shall be application specific displays consisting of a
combination of text and shapes to mimic the process. The values and states of
objects such as PID controller, Sequences, measurement points, etc shall be
presented dynamically.
3.2.5. Historical Trend Displays shall present historical data in graphic form. The time range
of the trend displays will be selectable.
3.2.6. Alarm and Event Lists contain messages about process alarm and events in
chronological order.
These displays cover the format used to describe the system's operational
parameters and status to the operators. Each page shall display tile, the date and
time, together with the relevant operating data ranging from system overview to
individual process equipment display.
The following capabilities shall be available as a minimum:
The user shall be capable of building a library of shapes for use in configuring
displays. All shapes shall be capable of being rotated and scaled.
10080-1-SS-CI-017 Page 111 of 203
As operator control function shall be at least two steps i. e. no single operator

action can initiate a control change. Access to specify displays and pick points is
restricted by password.
Key lock or password protection shall be provided to allow features such as loop
tuning to be performed by only authorised personnel.
Display configuration shall be accomplished utilising a menu driven CAD like
package which requires no knowledge of computer programming. Display builder
that require only programming of characters or pixel locations are unacceptable.
The capability shall exist at an Engineer's Console to configure, upload and
download configurations of database, control and graphic displays.
Graphic display shall be stored in each Operator Console in non-volatile memory.
Each Operator Console shall have its own dedicated memory, as opposed to a
central storage area for graphic display
Display data shall be updated at least one second interval. The
MANUFACTURE/SUPPLIER shall guarantee that no value or status on any display
shall be more than one second old regardless of where in the DCS, or any PLC
connected thereto, it originates.
A display hierarchy shall be built by allowing the user to target points, page up,
down, left and right as well as recall the last display.
Each Operator Console shall be able to access all historical trend data for all
points in the system.
The Keyboard, mouse and trackball shall be available for cursor control.
3.3. Standard Display
3.3.1. Overview Display
The overview display shall enable operator to have overall information of the
process.
The overview display shall consist of a single page of display which will be divided
into a number of groups. Each group shall consist of a number of instrument tags.
Information related to analogue inputs shall be represented by deviation bars
with alarm limits and setpoint value.
Information related to discrete inputs shall be shown with tag numbers.
Any tag number on the overview display, which in alarm shall be identified by
flashing.
The operator shall be capable of directly calling up the group display,
corresponding to a tag number, which is in alarm, from the overview display by
single click of mouse
10080-1-SS-CI-017 Page 112 of 203

The minimum number of variables displayed on the overview display shall be

100.
3.3.2. Group Display
Each Group Display shall contain up to 8 loops (nos. shall be user configurable) of
analogue control, digital control or indicator loops. The loops shall be grouped by
related operation. For example, in a cascade control loop, the primary and secondary
controllers will both appear on the same group display. Any system point shall be
configured in any group and displayed in as many groups as desired. There shall be
no limit on the number of group displays available at a particular Operator Console.
Group Display shall be called up from the associated Process Graphics displays. The
group display catalogue shall also permit call up of individual group display. The tags
shall be grouped together by related operation.
At the Group Display, the Operator shall be able to perform the following:
View a bar indication of controller process variable, set point and output.
Shall display Instrument tag number, description, alarm status controller mode,
engineering units and digital values of process variable and set points in
engineering units.
Select a control loop or device for control action.
Change the mode of the control loop selected (manual/auto mode, remote/local
selection, Advanced Process Control).
Change the set-point of a loop while in automatic.
Alarm acknowledges, toggle value, ramp value, value direct entry.
Change the output of a controller while in manual.
Issue commands to Start/stop Motors or Open/Close valves.
The control valve failure position shall be incorporated in the bar graph display.
The bar graph display of output signal shall always move upwards when the valve
opens.
The discrete input/output shall be represented by on/off software lamps and
alphanumeric description of status.
It shall be possible to assign a particular point to more than one group with
control being possible from only one group.
Each point in the group shall be displayed as an instrument face plate with bar
graph display. The number of bar graphs per point shall be based on the function
of the point i.e. control or data acquisition.
3.3.3. Object Display (Single loop)
10080-1-SS-CI-017 Page 113 of 203

The Object Display shall allow for the capability of viewing all algorithms that are
associated with a particular control loop strategy. This display depicts a faceplate and
associated trend of a single object. These displays are automatically available for all
objects without the requirement for configuration. The display shall allow the user to
view on-line a control strategy in the same format as which it has been configured.
The following capabilities shall exist from this display:
Select a control algorithm and display a faceplate. The point display shall provide
a separate detailed display for each of the points in the system.
Display the tuning constants of a control loop.
Display a trend of process variable, set-point, and output to facilitate controller
tuning.
Display the configuration parameters of a specific control algorithm.
Display alarm limits of a particular process point.
Loop Scan rate and phase shall be displayed.
All operator adjustment modes such as set-point, manual/auto mode,
remote/local selection, Advanced Process Control.
3.3.4. Faceplate Display
Faceplates provide detailed, dynamic process and status information for a single
control loop. They also provide the ability for the operator to manipulate process
parameters for the loop.
Faceplates shall be constructed from templates such that the layout and
operational characteristics of an individual faceplate shall be inherited from the
template. Changes to the template shall be automatically propagated to all
faceplates built from the template.
The system shall have standard pre-configured faceplate templates for all
standard Functions. Faceplates shall be moveable on the screen after being called
up for display on a workstation.
The system shall have standard pre-configured faceplate templates for all
standard Functions.
3.3.5. Trend Display
The Trend Display shall allow the user to interact with minimum up to 16 control
loops or devices via a multi-line display. This display shall include all the capabilities
of the Group Display with the exception of bar indication of variables.
The trend display shall present the data in the format of a strip chart on the
screen.
The trend display shall consist of two types:
10080-1-SS-CI-017 Page 114 of 203

Real time trend

Historical trend
The real time trend package shall be capable of storing and displaying real time
data for at least 300 variables with a time base of 30 minutes and sampling rates
of 2/10 seconds.
It shall be possible to assign any tag number including third party equipment tag
numbers to real time trend.
It shall be possible to assign any variable like process variable set point, output,
calculated parameters, digital values etc., to real time or historical trending. It
shall be possible to trend either instantaneous or average date for a particular
variable. It shall be possible to histories all analogue parameters including those
received from third party equipment.
All trend data shall be stored on non-volatile memory (hard disk) of the system so
that the trend data can be archived and subsequently recalled.
The selection of trend tag number and time base shall be possible from the
operator’s keyboard. The user shall have the ability to select a sample frequency
of a minimum 1 second and to select a number of samples to be displayed along
with top and bottom scales in engineering units.
The detail trend display shall contain the information on tag number, engineering
unit, span, present value of the point being trended, alarm status, etc.
Capability shall exist to save and play back historical trends on demand by means
of internal and removable storage media.
By selection with the cursor or numeric entry of time and date, the operator shall
have the capability of retrieving a “snapshot” of the process variable or status in
direct digital value. Scrolling of the trend shall be possible.
The DCS shall also be capable of generating X-Y plots containing two variables
which are plotted against each other rather than against time.
The DCS shall have ability to perform data reduction on sampled raw data.
A minimum of 90 days data at the rate of one second sample period should be
available on internal hard disk drive and there shall be provision to automatically
back-up it on High density media device at a frequency recommended by
OWNER. Back-up media shall be scope of supply of MANUFACTURER/SUPPLIER.
4. Custom Graphic Display
4.1. General
Full Custom Graphic Display capability shall exist such that the user can combine
shapes, text, and process variables to mimic the actual process based upon the
P&ID's.
10080-1-SS-CI-017 Page 115 of 203
The ability to build graphic displays at a central location and download tiles to
individual operator consoles.
The graphic display shall support dynamic display symbols, dynamic values, control
targets, page link targets and dynamic bars. The display symbols shall be capable of
changing to reflect process data status as follows:
The graphic display shall be multi-page display with each page providing a flow
diagram of a certain section of the plant in a dynamic fashion.
Colour change (colour of the display element changes)
Display blinking (displayed image blinks)
Text character string change (e.g., NORMAL message is substituted by WARNING
message)
Dynamic display functions shall be used for depicting electrically controlled
conveyers, level changes in vessels etc.
Ability to setup a graphic display hierarchy for navigating efficiently through the
process.
The graphic displays shall be capable of being configured from engineer’s
keyboard by using standard graphic symbols of process equipment and valves to
be available in graphic symbols library, which will be part of graphic builder
software. It shall also be possible to develop user defined symbols in the graphics.
The graphic building software shall be user friendly and interactive.
The graphic display shall show the tag numbers of important analogue / digital
variables at their respective locations on the process and shall display their
dynamic behavior through instantaneous values, alarm status, control modes,
etc. Position of control valves and pump running status shall also be shown.
Operator shall be able to control the process from graphics display in a similar
fashion as the group or point displays.
The graphic display shall have a minimum 256 colours / True colour capability.
MANAGING CONTRACTOR/OWNER will provide marked up PID’s or static graphic
sketches for generation of graphic displays by MANUFACTURER/SUPPLIER.
The detailed graphic drawings for approval, graphic building, page linking and
visualization linking, shall be the responsibility of the MANUFACTURER/SUPPLIER.
Linking shall be possible to:
Group loop display;
Loop display;
Alarm and event summaries;
10080-1-SS-CI-017 Page 116 of 203

Tabular listings;
Plant protective system displays;
(In some cases) maintenance displays.
The console subsystem shall have a facility of viewing multiple windows one
screen enabling the operator to conveniently access and control all the necessary
factors at the same time.
The plant graphics shall consist of the following types and overall content;
Loop display;
Plant profile;
Maintenance displays;
System alarm / status displays;
Tabular listing (data matrix) displays:;
Plant sequence displays (operator guidance).
Balance of graphics (not included above). The symbols and colours to be followed
for the graphics shall be as per MANAGING CONTRACTOR’s standard formats,
which will be furnished to MANUFACTURER/SUPPLIER after the placement of the
order.
4.2. Process Graphics
Process graphics shall show process equipment, piping and the instrumentation and
control. They shall closely follow the project PFD's and P&ID's. They shall be arranged
in five hierarchy levels:
Plantwide (Level 1)
Complex (Level 2)
Unit (Level 3)
Detailed (Level 4)
At each of these levels, the graphics shall provide the means to move up and down
the graphic hierarchy, as also sideways.
The Plantwide Level graphic shall shows an overview of the Complex. It shall display
the main plant areas, their statuses and primary plant data. There shall be no control
or process information at this level. The main purpose of this display shall for
navigation to other displays.
The Complex Level graphics shall show overview of each complex. Only the major
flows and other important data specific to each area shall be shown. There shall be
no process control from this level. Additionally, the Complex Level graphic shall
10080-1-SS-CI-017 Page 117 of 203

indicate when a fault occurs at any point within the process which will allow the
operator to choose to display a more detailed graphic.
The Unit Level graphics shall show most process equipment and major piping and
instrumentation. All controllers, important process variables and general monitoring
parameters shall be indicated at this level. ESD trips shall also indicate. Facilities shall
be provided for operator actions such as alarm acknowledgement, manipulation of
control loops, operation of valves, pumps, etc. Each plant area is represented by
several unit level graphics. The graphics at this level shall follow the project PFD's and
P&ID's. The level of detail is between PFD's and P&ID's. Unit Level graphics are
intended to be the ones that will be used most of the time for plant operations.
The Detailed Level graphics shall show all instrument functions implemented
indicating loops, monitoring functions, equipment statuses, trips, ESD's, etc. Facilities
shall be provided for alarm acknowledgement; access to all control loops, faceplates,
groups and trends. ESD's shall be indicated on these graphics. The graphics at this
level shall closely follow the project P&ID's and indicate almost all P&ID level
information. It is expected that operators will use this level of graphics only when
pursuing detailed information on the process and the instrumentation. The Detailed
graphic shall be a representation of some elements of the Overview graphic but ]nay
spread over several graphics with a finer degree of detail.
The system shall be capable of presenting the graphics in the following formats:
Standard full size graphics.
Quarter-size and half-size based window graphics overlays providing mol-e
detailed information pertaining to the standard full size graphics.
Half-size and windows based graphics which enable simultaneous viewing of
multiple graphics on the same screen.
Over-size large graphics in which the users can scroll vertically or horizontally to
view the entire graphic.
Where several graphics display the same plant information, a consistency of layout
between graphics shall be maintained. This will help reinforce operator learning,
improve recognition of the graphic information, reduce the likelihood of errors and
reduce training times.
DCS system shall include following:
The graphic display shall be multi-page display with each page providing a flow
diagram of a certain section of the plant in a dynamic fashion.
The graphic displays shall be capable of being configured from engineer’s
keyboard by using standard graphic symbols of process equipment and valves to
be available in graphic symbols library, which will be part of graphic builder
software. It shall also be possible to develop user defined symbols in the graphics.
10080-1-SS-CI-017 Page 118 of 203

The graphic building software shall be user friendly and interactive.

The graphic display shall show the tag numbers of important analogue / digital
variables at their respective locations on the process and shall display their
dynamic behavior through instantaneous values, alarm status, control modes,
etc. Position of control valves and pump running status shall also be shown.
Operator shall be able to control the process from graphics display in a similar
fashion as the group or point displays.
The graphic display shall have a minimum 256 colours / True colour capability.
MANAGING CONTRACTOR/OWNER will provide marked up P&ID’s or static
graphic sketches for generation of graphic displays by
The detailed graphic drawings for approval, graphic building, page linking and
visualization linking, shall be the responsibility of the SELLER.
Linking shall be possible to:
Group loop display;
Loop display;
Alarm and event summaries;
Tabular listings;
Plant protective system displays;
(In some cases) maintenance displays.
Any Graphics or display.
The console subsystem shall have a facility of viewing multiple windows one
screen enabling the operator to conveniently access and control all the necessary
factors at the same time.
The plant graphics minimum shall consist of the following types and overall
content;
Loop display;
Plant profile;
Maintenance displays;
System alarm / status displays;
Tabular listing (data matrix) displays;
Plant sequence displays (operator guidance);
System Diagnostic;
Network status;
10080-1-SS-CI-017 Page 119 of 203
Serial communication link status

Cause and Effect;
CPU loading, Power Supply Health FF as well as system, panel health etc
It shall be possible to place a new graphic in service without interrupting an
operator's ability to control the plant. Auto synchronization of graphics shall
be possible.
The graphics builder utility shall have the capability to make a copy of an
existing graphic in order to build a new graphic that is similar.
The graphics builder utility shall use the same tag IDs that are used in the
process database to access real time variables from any database. No
intermediate index numbers or addressing shall be required.
The graphics builder utility shall be subject to system access protection.
Graphic elements shall have the following capabilities:
Graphic elements shall be maintained in a specific library or folder on the
system.
Properties of graphic elements (such as visibility, color, fill level, etc.) shall be
capable of being linked to process values.
An automated tool shall be provided to update graphic elements inserted into
process graphics when a change is made to a graphic element in the library.
It shall be possible to create a minimum of 100 user define graphic elements.
It shall be possible for each state of a multi-state device to be indicated by a
unique foreground/background color combination.
It shall be possible to display numeric data and other text on process graphics
with multiple fonts and different character sizes.
Each graphic shall be capable of handling any mix of 200 calculated, analog,
and / or discrete dynamic display elements, including graphical symbol
representation of process status for real time data display.
4.3. Special-function Displays
Special-function operating displays including primary operating displays not fitting
into the overview operating display, or detailed graphic display categories. They
contain the complete operating information relating to a given application or
function. This includes provision to initiate control actions and acknowledge alarms
where required.
4.4. Advanced Process Control Application Displays
Advanced process control displays shall be selectable from targets on related
detailed graphic displays. Targets on advanced control displays shall allow the
10080-1-SS-CI-017 Page 120 of 203
operator to return to the calling display. All information relating to the application
shall be contained within a single display as far as possible.
4.5. Equipment Shutdown Displays
Equipment shutdown displays shall contain information relating to the automatic or
manual shutdown of a given piece of equipment. This shall includes trip status signals
associated with the control logic, bypass trips active associated with the control logic,
as well as soft shutdown and reset signals initiated from the DCS. Cause and Effect
display for understanding and de-bugging of logic.
4.6. Overlays
Overlay-type displays shall provide an alternate window to process and equipment
information. They are generally used to provide ancillary monitoring and/or control
operations in a quarter-screen or half-screen window. The overlay shall be called up
from the main display or equipment display.
Any or all of the process and equipment displays mentioned in the sections above
might be created as overlays. The most common use of overlays will be to provide
faceplate-type operation for I/O monitoring and control action. The basis for I/O and
controller overlay design will be the quarter-screen overlay, with the right half of this
window containing the standard Object display (e.g., showing block tag, descriptor,
set-point, inputs/outputs, controller modes and alarm status) and the left half
containing function keys associated with, the software block (e.g. alarm
acknowledge, auto/manual selection, local/remote selection, toggle value, ramp
value, etc.).
Each overlay shall be called up to occupy a predetermined quadrant or half the
screen, so not to overlap relevant information. A target shall be configured on the
overlay to close the overlay.
Additional targets on each analogue I/O and controller shall allow access to trend
overlays and standard Object displays associated with the point. Trend overlays shall
be directed to appear in any selected quadrant of the screen at the time of call-up.
4.7. Symbols and graphic elements
Symbols shall be unambiguous and conform to common electrical, instrument, and
mechanicals symbol conventions wherever possible.
The number of symbols or shapes that can be used shall be highly dependent on the
quality of the graphic and information to be conveyed. Provision shall be made for a
library of symbols that can readily be used for constructing a graphic.
All symbols shall have additional labeling, where required to indicate item name or
code, rate of flow, capacity etc. If a symbol has some dynamic quality, such as tank
filling with liquid, show both the changing liquid level and the numerical equivalent
(overlaid on the symbol) to allow exact readings to he taken from it.
The following guidelines shall he used when constructing detailed graphics:
10080-1-SS-CI-017 Page 121 of 203
Local instruments such as orifice plates, temperature and pressure gauges, relief
valves self regulating valves etc. shall not be shown.
All instrumentation associated with the DCS including all inputs and outputs from
subsystems such as PLC's shall be shown.
Equipment and instrument (such as control valves and pumps) symbols will be
the same as on P&ID's. Complex symbols may he simplified as necessary.
Where space does not permit otherwise, the alarms associated with equipment
such as tanks may be shown within the equipment.
Control loop control lines to be shown in a dashed format depicting PID controller
and final control element e.g., valve or motor, but not the sensor. Intermediate
elements such as Low/High selectors, split range functions, etc., should also be
shown.
Pumps, valves etc., should have their equipment number shown, but description
of pump service should not be shown. Tag numbers of valves can be left out if it
is part of a control loop and has the same number as the controller.
If necessary certain instruments may he shown on more than one graphic to
enable information to be more meaningful.
All graphics shall be numbered and headers shall be 32 characters maximum
Place directional arrows where process lines enter equipment and at each line
tee.
Do not join lines where four lines meeting at one point.
Place boxes/borders around text in such a manner that the boxes/borders shall
not touch other lines or symbols.
Place level indicating bar graphs inside vessels. Each bar graph will be one
character wide and boxed to indicate 0 to 100 % signal range. The bar will change
colour depending on the alarm status.
Optionally, the use of trends inside vessel symbols to provide level indication
shall be considered in place of a level bar graph.
Place the process measurement value below the loop tag for control loops and
indicators.
Use bar graphs for comparative data displays such as temperature profiles.
4.8. Data Representation
Data representation shall be consistent from display to display. To accomplish this at
the custom display level, display library elements are created and standards for
configuration of these elements are provided. All applicable configurable attributes
are written into the library element whenever possible.
10080-1-SS-CI-017 Page 122 of 203

Data representation in custom displays will conform to the following guidelines:

Analogue values shall be displayed as real numbers, with numeric formatting left
as "automatic".
Each process variable or control element shall appear on the process operating
display with the relevant tag (e.g., "LIC100"), process or controlled value, and
engineering units contained within a single "box".
Analogue controller data fields shall contain a bar graph showing the output
signal in percent of full range.
Bar graphs for vessel level indication and for comparative data displays, such as
temperature profiles, shall be additionally shown where helpful.
Overlays for I/0 and controllers shall use the standard Object display as far as
Engineering units for analogue data values will be read into displays directly from
the control database.
4.9. Display Lines
Lines play an important factor in process control interfaces. It is important, for
instance, to distinguish between the flow or non-flow of materials through a pipeline.
The use of colour is one method of indicating these states but other means of coding
e.g., thickness and intensity or a combination of both.
Process lines shall be horizontal or vertical. Where these cross, the Horizontal line
shall be continuous and vertical line broken.
The following priority (from highest to lowest) should be followed:
Equipment Outlines
Horizontal Process Lines
Vertical Process Lines
Instrument lines shall be provided with arrow heads to illustrate cascade, feed
forward, lead/lag, or ratio connections wherever necessary.
Process line descriptions shall be kept to a minimum and shall not exceed 20
characters if possible. The description may be split above and below the line.
4.10. Display Colours
Display colours will be used to distinguish the contents of lines and vessels and to
distinguish instrument signal lines from process lines. Alarms shall be shown by a
background colour change when an alarm condition exists.
In general terms red should be associated with danger and is an appropriate colour
for alarm conditions. Yellow is associated with caution and is to be used for alerting
messages or to denote changed data. Green is associated with normal conditions.
10080-1-SS-CI-017 Page 123 of 203

White is a colour with neutral association and shall be used for data display
purposes.
All display colours will be finalised with OWNER during the Project Application
Specifications development phase.
4.11. Graphic Navigation
This section describes requirements of the Operator for navigational aids within DCS
applications. As an aid to the Operator- his/her position within the system should he
clear and unambiguous at all times. Where appropriate the system shall provide
information relating to past screens.
The following features shall be available, on graphics to assist navigation:
A meaningful title on each graphic indicating its function shall be provided
Dynamic page link screen buttons shall be provided on each screen for fast access
around the system. These screen buttons shall be selectable by a pointing device
and should be clearly labeled as to their function.
The following type of screen buttons shall be provided:
Go back one screen (i.e. to the screen the system displayed previous to the
current one). This facility is useful because it allows the operator to remain on
one central screen to carry out a particular task, and then return to the central
screen
Page back - Return to the immediate preceding graphic in the chain.
Page ahead - Go forward to next immediate graphic in the chain.
Recall - Return to start (i.e. graphic that displays the first step in the process).
Return to top level (i.e. the overview screen in the hierarchy).
5. Pattern Recognition Object (PRO)
HMI shall have capability of providing properly implemented and enhanced “radar
plot” type of diagram. This element is designed to provide a graphical pattern
recognition overview of a complex multivariable processes. The process shape
changes dynamically as the process values change. This method of data presentation
offers an extensive amount of dynamic information in a single display element.
The PRO element produces a polygon shape obtained by plotting each parameter's
present value on a separate plane with a common time axis, which is then viewed
laterally. The concept is depicted in below Figure-1.
10080-1-SS-CI-017 Page 124 of 203

Figure-1 Time Varing MultivariableDisplay Mapped into 2-D space

A traditional trend displays process measurements against time. It quickly becomes
difficult to simultaneously display and trend many different parameters in a cohesive
way. More than four to SIX traces on a single trend usually become confusing rather
than informative.
Figure-2 twelve different, but associated, process parameters are displayed
simultaneously (Seventeen is a practical Limit). By plotting the values simultaneously
and building a polygon, a shape results. Each such shape becomes a distinct pattern
the user will begin to identify as a specific plant state.
Bars on each axis indicate proper operating range for the current plant state. The
current value of each parameter is shown at the edge of the polygon.
Figure-2 PRO Display Element

The PRO type of data presentation has many benefits
Provides effective graphical overview of simultaneous process conditions
Includes multiple process values
10080-1-SS-CI-017 Page 125 of 203

Provides consistent patterns for normal operations and at-a-glance recognition of

abnormal situations
Maximizes use of space on a display since it is compact
Captures and saves plant process condition patterns for future retrieval
Recalls pre-captured patterns and superimposes them under real time data
Shows either process values or deviation from a predefined "normal operation"
set or from a current "snapshot." In deviation mode, any change will become
quickly apparent.
Display of Alarms - When any of the included measurements goes into alarm, the
shape changes color based upon the highest alarm priority in effect. The
particular reading(s) in alarm are highlighted.
Value Identification -The name of each individual sensor can be shown, hidden,
or appear as a "tool-tip" manner, as in Figure-2.
Rate-of-Change Indication - When values begin changing rapidly, an arrow is
displayed indicating the magnitude and direction of the change.
Variability Indication - Range bars indicate the extent each parameter has varied
in a predefined time period.
The values can be scaled so normal operation produces a circular shape. Humans
recognize shapes and colors much faster than complex set of numbers.
Figure-3 PRO Display Element with Alarms, Range Bars and Rate of change
indicators
10080-1-SS-CI-017 Page 126 of 203

Figure-4 PRO Display in Deviation Mode

Desirable features for this type of display element include:
Configurable component colors
Indication of Alarm colors by priority
Configurable line thickness
Configurable labeling of chosen parameters (on-off toggle or tooltip)
Configurable value movement arrows with deadband
Configurable variable range and range bars
A properly implemented radar plot or enhanced PRO element shall be in the
toolkit of High Performance HMI designer.
6. Alarm Display
The DCS shall provide capability to display all process, shutdown, and system alarms
on all Operator Workstations.
The following types of alarms shall be provided as a minimum
Absolute (high high, high, low, low-low) and deviation from set point.
Rate of change alarms (high and low).
Status input change of state
System diagnostic alarms (Hardware/Software).
Transmitter out of limit (bad PV), burnout condition.
10080-1-SS-CI-017 Page 127 of 203
Thermocouple open circuit.

RTD open/short circuit.
System utility alarms.
Invalid data.
Communication and networking alarms.
Internally derived alarms
6.1. Alarm Display
The DCS shall include a comprehensive Alarm System to advise the operator of
process and system upsets in a concise and orderly fashion. The Alarm System
shall be capable of the following features as a minimum:
 Alarm checks shall be made at each scan by the system.
 Alarms shall be originated and time stamped.
Alarms shall be prioritised to allow the operator to make judgements about
relative importance of alarms. The operator shall have the capability to segregate
alarms by process area at each operator workstation. Separate priorities shall be
available for each value's emergency, high, normal low alarm. A minimum of four
alarm priorities shall be available. Alarm priority display shall be colour
segregated, with a separate colour for each alarm level.
The resolution of alarms shall be at least 1 second.
All alarms generated shall be displayed on operator’s console for which they are
configured by a flashing colour change and audio signal. The audible alarm signal
shall have multiple different tones to distinguish between alarms of different
priorities.
Colour Schemes for all type of alarm shall be proposed by
MANUFACTURER/SUPPLIER and approved by MANAGING CONTRACTOR/OWNER.
All alarms shall latch until acknowledged individually by the operator, after which
they will change to “steady mode" until the alarm condition no longer exists.
The system shall provide a current alarm summary and a historical alarm
summary, which may be displayed and printed by the operator.
The current alarm summary display shows all points in the system which are in
alarm. The historical alarm summary shall contain minimum 500 alarms. This
summary shall be updated on FIFO basis. The degree of information for each
alarm point shall be similar to the current alarm summary but with additional
details like time of acknowledgement and time of return to normal. The display
shall list the following for each alarm:
 Time and Date of Alarm
10080-1-SS-CI-017 Page 128 of 203
 Tag Name of point in Alarm

 Text description of Alarm
 Current value of point in Alarm
 Alarm limit exceeded value for the point
 Alarm Limit
 Alarm type and priority;
 Units
It shall also be possible to filter or sort entries in the alarm history summary.
When an alarm occurs, an audible signal shall be generated together with a
screen display banner to indicate the group or area in which the alarm has
occurred. This initial advice of an alarm shall be displayed on the screen,
irrespective of the current display, in the Alarm summary display.
The Operator shall have the ability to directly access from the Alarm summary the
faceplate or custom graphic associated with any alarm entry. An area on the
screen shall allow for display of alarms when the alarm is not displayed.
The Alarm displays shall make use of pulsating symbols and/or distinctive colours
to attract Operators attention to new unacknowledged alarms.
Each type of alarm, whether acknowledged or unacknowledged, shall be listed in
the alarm summary. Removal of the alarm from the system shall take place
automatically after it has been acknowledged and has returned to normal status,
however the operator shall be able to access history of cleared alarms.
New alarms shall be displayed at the top of the screen and as the screen fills the
alarms should scroll down onto the next page.
Ensure that any keystroke to acknowledge or clear an alarm is only associated
with a single alarm (e.g. do not have a repeat key facility on alarm
acknowledgement
It shall be possible to suppress alarms on a point-to-point basis or alarms on a
group basis. The system shall capability and allow alarms to be suppressed and
unsuppressed automatically by applying specific rules.
The capability to suppress alarms shall be protected by keyswitch or password
operation and shall be logged. The list of such alarms shall be available from the
system with tag, description, date, time reason and role as a minimum.
The system must alert the operator to each alarm regardless of the current
display on the screen. The operator shall be able to call up the relevant display
with maximum two key strokes.
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The system shall also provide detailed alarm displays resulting from self
diagnostics of the DCS system.
The system diagnostic alarms shall be displayed to the operator irrespective of
the display on the screen and will help pinpoint fault in any sub-system to the I/O
level.
The system utility alarms shall consist of cabinet power supply failure alarms,
cabinet ventilation fan failure alarm and cabinet high temperature alarms. These
alarms shall be derived from volt-free contacts inside the cabinet, which will be
monitored by the digital input cards.
MANUFACTURER/SUPPLIER shall specify the time resolution for the alarms.
High priority and equipment protection related alarms should be configured for
first out and subsequent alarm sequencing as per ISA-18.2.
It shall be possible to acknowledge alarms only from operator station for which
they are configured, in not more than two operator actions.
DCS shall histories and play back on demand (from internal and external back-up
media), all alarms and events.
Alarm and event history shall be available for 90 days on internal hard disk and
system shall auto back-up alarm and event history to removable media at user
recommended frequency.
DCS shall have capability to print the resulting alarm displays to a printer or to
export the data to text files or Microsoft ™ Office compatible file format.
The following types of alarms shall be provided in the system for both control
and data acquisition points:
 Absolute (high high, high, low, low-low) and deviation from set point.
 Rate of change alarms (high and low).
 Status input change of state
 System diagnostic alarms (Hardware/Software).
 Transmitter out of limit (bad PV), burnout condition.
 Thermocouple open circuit.
 RTD open/short circuit.
 System utility alarms.
 Invalid data.
 Communication and networking alarms.
 Internally derived alarms
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6.2. Preventing and Responding to Abnormal Situations

MANUFACTURER/SUPPLIER shall provide system details for achieving risk reduction
due to abnormal conditions. Abnormal conditions shall be recognised by DCS to
prompt operator to take timely necessary action for preventing risk. Following shall
be considered for preventing and responding abnormal conditions.
6.2.1. Abnormal Situation
An abnormal situation is a disturbance or series of disturbances in a process with
which the control system is unable to cope and which requires operator intervention.
The disturbance may cause the plant operations to deviate from their normal
operating state. The nature of the abnormal situation may range from a minimal to a
catastrophic consequence. The job of the operations team is to identify what the
situation is, determine what might have caused the situation, and execute corrective
or compensating actions in a timely and efficient manner. A disturbance may cause a
reduction in production or, in cases that are more serious, it may endanger human
life. Abnormal situations develop, extend, and change over time in the dynamic
process control environments, thereby increasing the complexity of the intervention
requirements.
6.2.2. Anatomy of a Catastrophic Incident
An important aspect of understanding the management of abnormal situations is the
interrelationships among root causes and interventions by plant systems and plant
personnel. Specifically, Figure-5 below illustrates the anatomy of a catastrophic
incident. Figure below depicts the evolution of an abnormal situation from some
initial cause producing an operations upset to a catastrophic disaster involving
serious destruction and harm to the plant and/or the surrounding community. In an
abnormal event sequence, the modes of the plant progress from normal, to
abnormal and can eventually escalate to an emergency.
The role of plant personnel (operations and technical) is to intervene to prevent a
process upset from escalating to a plant shutdown when the control system cannot
cope.
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Figure-5 Anatomy of a Catastrophic Incident

6.2.3. Response activities
The ASM (Abnormal Situation Management) supervisory control model is depicted in
Figure below. From the left-hand side of the drawing, operations team members
receive the inputs from the process from the field sensors and transmitters,
analyzers, radio communications, and other inputs via their five senses. The
operations teams mentally process this information in four major ways:
Orienting-Sensing, perception, or discrimination
Evaluating-Information processing (thinking or interpretation)
Acting-- Physical or verbal response
Assessing-Information processing (thinking or interpretation)
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Figure-6 Response activities

The framework was constructed to support the concept of an operator that
proactively monitors a stable process for potential deviations and proactively
responds to disturbances before they escalate into unplanned loss conditions.
6.2.4. Intervention paths
Figure-7 Intervention Paths

DCS shall be able to alert, for operator action, before start of abnormal condition.
7. Operator Event Logging
The DCS shall be capable of generating messages as a result of changes made by an
Operator or Engineer any other defined role in the system e.g supervisor. These shall
include as a minimum the following features:-
Scan Removal/Return
Alarm inhibit/suppress/enable
Limit (sensor) Check Removal/Return
Alarm limit changes
Deadband changes
Tuning parameter changes
Failures to perform changes
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Operator workstation security keylock position changes

Controller Mode changes
Controller Set point changes
Change made to Controller Configuration
Output change
Device Start/Stop or Open/Close changes
Soft bypass/inline from DCS for ESD point
Configuration changes to any loop (including FF)
Configuration changes for applications and associated equipment (e.g Network
switches, Serial card etc.)
Station online/off-line
Event messages shall be logged on designated printers. Additionally, capability shall
exist to store messages on disk for recall at operator workstations.
The event summary shall include:
 Date and time.
 Tag and service.
 Event (open, stop, etc.).
 Role.
8. Report Configuration and Generation
The system shall have the capability to generate or modify report formats using
standard character set in an off-line mode, the defined report being loaded into
the operating system.
The Report Generator shall build and schedule reports based on current and
historical data. The Report Generator shall consist of a builder and scheduler
which can be implemented separately.
Configuration of reports shall involve selecting of desired types of information
from a pop-up scrolling menu and then specifying how that information is to be
presented and used. Software expertise shall not be necessary to generate
custom reports.
The system shall be capable of generating reports automatically based on process
alarms or events. These alarms or events shall be based on process alarms, or
user defined logic. Complete scheduling of the reports by time of day, elapsed
time, event occurrence, or manually on demand shall be provided. Demand for
immediate generation of a report will not affect any schedules that have been set
up previously
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Access to real-time controller data and system data such as alarm lists, event lists
and operator logs. Math functions shall be a standard part of the report package.
The software package shall be easy to use and not require programming.
A variety of data types shall be capable of being integrated into a report. These
shall include the following types:
 Process data extracted from Historian or direct from system database.
 Hardware addresses recorded in system controllers.
 Functional Block types residing in the database (e.g PID block).
 Block descriptors associated with Functional Block.
 Engineering units of a value residing in a Functional Block.
Any report shall be viewable from the Operator console by requesting the report
by file name, selecting the report from the report file or linking the report to a
target field on a graphic display.
The system shall be able to print a specified report after it is run and saved to the
hard disk. A report shall be printed by specifying a screen print from the Operator
workstation, requesting a report print, or configuring it to print automatically
upon generation.
Trip report shall be configured to collate alarms, messages, and historical data
into a single report. The report shall be configured for initiation by a predefined
event.
Trip reports shall include SOE, Alarm History, Operator Actions, and analog data
over a configurable time span around a trip. For each process unit, one or more
triggers may be defined.
9. System Diagnostics
The DCS shall include as a standard feature a comprehensive diagnostic package that
allows the user to diagnose faults.
9.1. System Status Display:- The system status display shall graphically display the
"health" or status of all nodes on the data highway. Should a problem develop, an
alarm is sounded a message is displayed and logged and the device that has a
problem will change to red on the status display.
9.2. Device Module Level Display:- The Device Module level display presents a graphic
representation of all modules attached to a particular node. Should a module have a
problem, it will be indicated in red, allowing the user to identify problems to a Device
Module level to facilitate maintenance. Shall include power system supply system
and bulk status.
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9.3. Fault Display: - The Fault Display allows the user to determine the specific cause for a
Device Module level fault and determine the nature of the fault whether it is
hardware or software related.
9.4. I/O Card Diagnostic Display:- An I/O Card Display shall be available to isolate I/O and
sensor failures to an individual point basis. By accessing this display, the user may
determine if any field instrument or DCS I/O problems exist and take measures to
correct them.
9.5. System Performance Display:- This display shall provide both digital and bar graph
representation of the following parameters:-
CPU Loads: current, average, and peak.
Memory Utilisation: current, average and peak.
System Performance displays for devices running configurable control loops shall
provide information on the current, average and maximum number of loops being
processed.
9.6. Network display: Network display provide the health status of network switches and
ports. Shall also provide traffic on ports (current, average, and peak). Generate alarm
if traffic crosses threshold limit. Limit shall be defined with approval of MANAGING
CONTRACTOR/OWNER.
9.7. FF Display: Shall include FF segment status, FF power supply status and FF
communication status
9.8. Other Display: Shall include Serial link status, Cause and Effect status overview and
detail
10. DCS Access Level
There shall be various access levels provided at the operator consoles with password
protection to ensure security of operation. Broadly the operator Console shall have
four main category of access level as briefed below:
OPERATOR: Lowest level, access to view and browse through all able to
acknowledge alarms, but will not have the authority to tune loops and change
alarms limits.
SUPERVISOR: As OPERATOR level but with additional access and manipulating
privileges such as system building, configuration and tuning functions in additions
to normal operation tasks.
MAINTENANCE: As SUPERVISOR level but with additional access and
manipulations privileges such as system building, configuration, detailed system
diagnostic displays, intelligent transmitter detailed displays, and tuning functions.
ENGINEER: As SUPERVISOR level but additional rights for configuring, installing,
and maintaining a database.
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Users will be given access rights to areas containing the loops that they have access
rights to. Therefore loops will be grouped accordingly, depending on which users will
be able to take control of which loops.
Users of the system shall log on by either security key or password methods.
SUPERVISORS, MAINTENANCE, and ENGINEERS will use security keys and
OPERATORS will use passwords. For those using security keys, on insertion of the key
into the security key interface the system verifies the user information programmed
on the key and automatically logs on the user. To log out, the key is removed from
the security key interface and system automatically logs out the user
Each Operator workstation shall have the capability of printing the information
displayed on the screen and SOE for ESD.
11. Assessing HMI Performance
The assessment of HMI performance involves both quantitative and qualitative
measures. Operator and engineer questionnaires are quite useful. It is necessary to
tailor questions so they reflect the type of operation you have, such as batch,
continuous, continually-staffed, and so forth. The operator's span of control, the
process complexity, and the use of advanced process control methodologies are also
a factor.
11.1. General Graphic Factors
MANUFACTURER/SUPPLIER HMI shall comply with several quantitative and
functional measures mentioned in this clause. MANUFACTURER/SUPLIER shall
provide following as minimum for a High Performance HMI.
An overview display summarizing the key factors of each operator's entire span
of control.
Special graphics, specifically designed for the support of startup and shutdown.
Special graphics, specifically designed for the support of making different
products or using different feedstocks or operating at significantly different rates.
All controllers shall be shown on a graphic.
All system modules shall be shown on a graphic.
All cabinet status, power supply status shown on a graphic.
All alarms shown on a graphic.
FF power supply, segment, and communication graphic.
All interlocks shown on graphics clearly indicating their inputs, status, and
outputs which shall clearly tell operator from these displays the actions needed
to clear the interlock.
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Animation used on any graphic only for the purpose of indicating an abnormal
situation and even then, in only very limited ways. (There should be no spinning
agitators and pumps, moving conveyors, splashing liquids and sprayers, and other
such animation elements.)
Alarm colors designated by priority and used only for alarm functions and no
other graphic elements shall be preferred.
Process vessels and equipment rendered simply in 2-D line drawings, without
bright colors or 3-D shadowing and shading or detailed depiction of non-changing
internals.
No attempt to color code process piping with its contents.
Measurement units (Kg/cm2, m3/hr, 0C etc.) displayed with consistent
abbreviations and only in small, low-contrast lettering.
Analog liquid levels in vessels displayed in narrow strips rather than in bright
colors the full width of the vessel.
Embedded trends of important values placed in the appropriate graphic so
operators do not have to configure trends "on-the-fly".
Line-crossings shall be minimized in the graphics.
Process flow consistently shown in a left-to-right pattern, with gases flowing up
and liquids down.
Graphics shall have gray backgrounds to minimize glare. (Control Rooms should
be brightly lit.)
Process lines shown as black, with major lines shown slightly thicker.
Very limited use of color and all use is consistent.
Ambient flammable and/or toxic gas detectors shown on a geographic layout
with wind direction and velocity depicted.
Equipment layout on a graphic consistent with the operator's mental model of
the process. For example, Tank Farm diagrams should match the physical layout,
not a P&ID layout.
Techniques used to minimize the possibility of operator data entry mistakes,
inadvertent trip actuation, and to provide validation and security measures.
Analog-type indicators used for process measurements where appropriate, rather
than the common practice of simply putting numbers on a screen.
There are a variety of methods for operator action in such things as adjusting
controllers (setpoints, modes, and outputs) and digital (On-Off) points. It is
usually worthwhile to test several operators on a standard list of tasks on the
amount of keystrokes/mouse-clicks it takes them to accomplish the needed
10080-1-SS-CI-017 Page 138 of 203

action. Wide variation will often be found, indicating training needs and HMI
deficiencies. Tests shall be performed during FAT or training.
11.2. Navigation Factors
It is possible to navigate to any screen, within 5 seconds, using only three
pushbutton and/or mouse-click actions. The navigation should be logical and
straightforward.
Graphics shall have a hierarchy in which progressive exposure of detail is logically
made.
Proper and logical use and arrangement of soft-keys made for the assignments of
certain pushbuttons to certain graphics.
DCSs shall have the capability to associate a predetermined graphic with each
alarm. When the alarm comes in, a one-key jump can be made to display the
particular graphic. It shall be configured for every alarm.
11.3. Workstation Factors
The operator shall have four DCS screens plus a DCS overview screen. If fewer,
justify why there is no need. If more, justify why there is a need.
The operator shall have a PC with corporate intranet access for procedures, work
requests, etc.
The up-to-date electronic copy of documentation shall be available.
If any one physical display screen is lost, the information on it shall be displayed
on other screens at the workstation without problems.
11.4. Control Room and Work Practice Factors
There shall be a separate workstation for engineers and maintenance use, so the
operator's workspace does not have to be shared.
For multi-console, multi-operator control rooms, operators should be placed
adjacent to the other operators with whom they must communicate the most.
Off-site backup copies of the source files of all HMI elements.
11.5. Alarm Management Factors
All alarms configured so they indicate situations for which specific and known
operator action is required.
All alarms occur only for abnormal situations and never for expected, normal
situations.
The alarm system shall be capable to be used of alarms for miscellaneous status
indication.
The priorities of alarms set in a meaningful and consistent manner.
10080-1-SS-CI-017 Page 139 of 203

All alarms unique, where the same situation does not generate multiple alarms.
There shall be a monitoring system to detect nuisance alarms (chattering,
fleeting, long-standing, and so forth) and those detected are promptly dealt with
so they operate properly.
The rationale for the selection and priority of each alarm shall be documented.
The operator shall have on-line access to this alarm documentation.
The HMI have the ability to display any and all alarm suppression currently in
effect, in one easy-to-get-at list. (Shall be tested and audited)
The alarm system configuration protected from inadvertent and inappropriate
change.
The alarm system performance shall be monitored and action steps taken based
on known Key Performance Indicators. MANUFACTURER/SUPPLIER shall
recommend parameters for monitoring system performance.
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12. Graphics Display (For Reference and Compliance):

Minimum following graphics shall be provided beside Process and System Graphics
FF Segment Alarms Graphic
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FF Communication Status Graphic
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Power Monitoring of FF Graphic
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ESD Cause & Effect overview Graphic
10080-1-SS-CI-017 Page 144 of 203

ESD Cause & Effect Graphic
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Serial Link Status Graphic
10080-1-SS-CI-017 Page 146 of 203

Attachment-5: Instrument Asset Management System (IAMS)

1. Introduction
The intent of Attachement-5 is to provide clear guidelines to
MANUFACTURER/SUPPLIER for the Instrument Asset Management System
requirements. The MANUFACTURER/SUPPLIER shall develop a detailed Instrument
Asset management system Functional Design Specification based on these guidelines
and submit it to MANAGING CONTRACTOR/OWNER for approval for the project. As a
minimum, the requirements of these guidelines shall be incorporated in the
Instrument Asset Management System (IAMS). The MANUFACTURER/SUPPLIER shall
ensure that the Instrument Asset Management System is designed, built and tested
to meet these requirements.
The Instrument Asset Management System shall be based on a high specification
server(s)/client(s) configuration which shall form an integral part of the DCS network
running a recognized third party or specialist Instrument Asset Management
packages.
2. Purpose
This document outlines how IAMS will be implemented for the project.
The goal of the Instrument Asset Management System shall be to provide system
wide real-time alert monitoring for predictive maintenance rather than preventive
maintenance practice. Also configuration/ parameterisation of field devices through
central maintenance PC. These shall make the best use of the new busses
technologies used. These shall in turn reduce the life cycle cost of running the plant.
This document covers the minimum requirements for the Instrument Asset
Management System. The MANUFACTURER/SUPPLIER shall be responsible for the
supply of all Hardware, Software, Interface(s) with DCS, ESD, Interface(s) with
Package Control Systems, System Design, Documentation, Delivery, Installation
Supervision and Field Support for the as defined within this specification. The
MANUFACTURER/SUPPLIER shall carry out all system testing for system, including
FAT, SAT, communication tests and integration tests.
3. Functional Requirements
Instrument Asset Management System (IAMS) is based on open communication
standards and will provide a single integrated software application to perform device
configuration, calibration, documentation, and predictive diagnostics of FF, HART,
wireless and conventional field instruments and valves (instruments). The System will
operate on either a standalone or a distributed system. IAMS shall have following
capabilities:
Management of configuration data for intelligent instrumentation including
integration with mobile hand-held intelligent instrument configuration and
diagnostic tools.
10080-1-SS-CI-017 Page 147 of 203
Automatic recording of Events for Audit purposes of intelligent instrumentation

configuration changes and diagnostic status changes.
Diagnostic interrogation of intelligent instruments.
Preventative maintenance alerts for intelligent instruments that support this
function.
The System shall be a standard commercially available station having latest software
package running on the latest Windows operating system.
The System shall be dedicated to the function of Instrument Asset Management and
will function independently of control system or instrument vendor model. However,
the System Windows station will be available for other uses such as common desktop
packages like Microsoft Office, subject to suitable station sizing.
The System shall be part of an integrated family of software applications for
predictive diagnostics and performance monitoring on all major industrial plant
assets such as steam and combustion turbines, engines, generators, compressors,
pumps, motors, petrochemical process trains, and similar mechanical and process
equipment.
The System will include an option to aggregate multiple Systems into a single system
using a web-based portal. The portal will provide the ability to monitor asset details,
active alerts and historical events from multiple plants across the country or around
the world. The portal will include the ability to design custom information
dashboards for preferential display of high priority asset information.
The System will have modular software units that allow the selection of specific
functions pertinent to a user’s requirements and for the future addition of new
functionality as it becomes available.
4. System Design Requirements
4.1. General
DCS MANUFACTURER/SUPPLIER shall provide independent Instrument Asset
Management System (IAMS).
AMS shall able to support/integrate HART, FF, WirelessHART, wireless(As per ISA)
Profibus DP and conventional devices using one software application.
AMS shall have capability to configure, re-range, upload, download and calibrate
HART, FF, WirelessHART, wireless(As per ISA) Profibus DP and conventional
devices remotely using one software application. AMS shall able to provide trend,
report and email of test results for complete test traceability and data
management.
AMS shall fully implement predictive diagnostics to improve plant availability and
reduce maintenance costs.
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Monitoring of device (Transmitters/Positioners/Control Valves etc) status on-line.

All maintenance related data like device diagnostics alarms, transmitter range,
settings etc. shall be available on IAMS and shall be possible to change from
IAMS.
Data for all devices can be trended.
Data on predictive maintenance such as list of transmitters experiencing drift,
control valves loosing as-shipped characteristics etc.
The IAMS shall provide an audit trail for all Instruments &
maintenance/engineering operations (e.g Configuration, calibration and
Instrument alerts)
The IAMS shall be a server / client application supporting access by remote
clients.
All DCS ES (Engineering Station) shall be provided with an IAMS client licenses.
The IAMS shall support the following configuration and diagnostic requirements
as a minimum.
Tag
Device
Serial Number
Descriptor
Date
Real time alert record with time and date stamp
Calibration location
Revision Level
Valve Characterization
Configuration change flag
Write protect password
High & Low valve travel Assets
Actuator travel positions
Actuator pressure
Configurable 4-20 mA input range if applicable
Configurable valve travel range limits
Step response Test ( Multiple Position Set point Changes to gauge valve tuning
and stroking speed)
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Valve signature (Actuator pressure versus stroke position)

Other configurable FF/ HART parameters
Drive output signals
Partial and Full Stroke Test
Some of the above information will only be available through a special package
(Plug-in) provided by the device MANUFACTURER/SUPPLIER. The DCS
MANUFACTURER/SUPPLIER and MANAGING CONTRACTOR shall ensure that
these plug-in / associated packages are fully compatible with the Instrument
Asset Management System provided by MANUFACTURER/SUPPLIER. Any non-
compatibility shall be brought to OWNE'S attention for approval.
DCS MANUFACTURER/SUPPLIER shall include a list of device alerts that shall be
configured to be automatically sent to maintenance personnel. IAMS shall have
capability to route alerts on mobile phone.
IAMS shall be designed for import and export information to/from Microsoft
Excel file. Alternatively, the IAMS shall be capable of performing bulk import for
all device data by plug and play functions.
For all valves containing HART or FF positioners, valve diagnostics tests (signature
curves, Dynamic error band, Drive signal, output signal and step response) shall
be loaded into the IAMS database and verified during FAT.
FF transmitters and valve positioners, for control and emergency isolation valves
shall be provided by MANAGING CONTRACTOR for all field measurement and
control. DCS SUPPLIER shall provide FF host Interface for these devices.
MANAGING CONTRACTOR shall provide SMART (HART) devices when FF devices
are not available. DCS MANUFACTURER/SUPPLIER shall provide smart host
interface for these devices.
The IAMS shall include local and remote analysis, trending, diagnostics and
predictive maintenance on the valve and smart positioners utilizing a standard or
specialized software package.
An IAMS shall manage and display real-time and historical diagnostic and
maintenance information.
MANAGING CONTRACTOR shall coordinate with the selected valve
MANUFACTURER/SUPPLIERs to provide the valve diagnostics data to DCS
MANUFACTURER/SUPPLIER for entry into IAMS prior to FAT.
Device MANUFACTURER/SUPPLIER to provide both EDDL (IEC-61804 compliant)
and FDT/DTM devices compatibility and to deliver complete graphical user
interface that plugs in to form seamless integration in the host asset manager
and operator interface.
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The asset manager hardware and software to be designed to take diagnosis from
the Device blocks, if available.
NAMUR NE-107 Self-Monitoring and Diagnosis of Field Devices shall be followed.
Any revision in operating system or DD of device should not require change in the
configuration of DCS system.
Documentation like various trend reports, Diagnostic report predictive
maintenance reports, audit reports, historical data and device specification
sheets in addition to those available with selected software as stand-alone.
Definition engineering configuration loading and compilation of all reports
whether specifically indicated in this specification or available as standard with
the selected software.
Advance diagnostics of valves shall be available in IAMS for monitor the health of
valve.
IAMS shall provide graphically view of communication path and their health for
wireless network.
IAMS shall able to integrate third-party software application like Valvelink,
ValVue, Samr’s valid, Flowserve’s, PACTware etc.
IAMS shall be capable of partial and full valve stroke of valves and document and
maintain the record for the same. Testing result shall be mailed to concerned
maintenance personal.
4.2. Presentation of Information
The System will provide displays in the following format:
A hierarchy of all instruments in the database.
By Plant/Area/Unit/Equipment/loop layout
By Manufacturer / Model Number / Revision number
By Assigned to Plant / Spare / Decommissioned status
A hierarchy of instruments with on-line data connections between the System PC
and the instrument.
Via control system I/O and communications bus wiring structure (if supported by
the control system)
Via modem network
Via multiplexer network
A hierarchy of instruments with off-line data connections between the System PC
and the instrument via a mobile hand-held instrument configuration and
diagnostic tool.
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A tabular display for each instrument of its configuration data.

A tabular display showing all instruments with their active diagnostic alarms.
The user interface will have a common “look and feel” for the user with other
Windows packages and across instrument types. Comprehensive on-line help
shall be available for all functions. The System will be able to support multi-client
/ multi-server networking if required.
4.3. Wireless
IAMS shall provide graphical interface that allows users to import an image of their
plant, drag and drop devices and validation against best practice planning
parameters. It shall also graphically display wireless network advisories and the
parent-child communication pathways between devices. This functionality shall help
troubleshoot the network and shall also display the power and robustness of the self-
organizing network. The following functionality should be provided:
STATUS ICONS:
Good
Pinchpoint (e.g. single point of communication failure)
Low battery - sensor operating
Pinchpoint has low battery - sensor operating
Critical battery - sensor not operating
Pinchpoint has critical battery - sensor not operating
Device not communicating
REPORTING SCREEN
Default Parameters:
Device Tag
Status
Number of Neighbors
Average reliability
Battery voltage
Update rate
Gateway
4.4. Maintenance Management Functions
Instrument Asset Management Tools (Minimum Requirement)
Field Device Manager for FF devices
10080-1-SS-CI-017 Page 152 of 203
PACT ware and Device Type Managers (DTMs) for DCS & ESD HART devices.
Remote desktop services provided by Microsoft Windows Operating System
4.5. IAMS Maintenance Management Functions:
DCS hosted ART, FF, WirelessHART, wireless(As per ISA) Profibus DP and
conventional devices device failures shall be detected and communicated
maintenance personal. In addition FF devices block errors shall also be detected
and notified by System. System shall generate messages on the DCS HMI and
routed to the associated historian for archiving.
The following standard FF block errors shall generate alarm:
Block configuration error
Link configuration error
Simulate active
Local override
Device fault state set
Device needs maintenance soon
Sensor failure
Output failure
Memory failure
Lost static data
Lost Vs data
Readback check failed
Device needs maintenance now
Power up
Out of service (OOS)
Intelligent devices using HART communications may include a "More Status
Available" (MSA) bit. The MSA bit indicates the existence of a range of operating
problems that fall short of device failure. The range of conditions that drive this bit
are defined by the device MANUFACTURER/SUPPLIER. Based on this indication of a
device malfunction, further investigation and maintenance on the device can be
performed using the PACT ware/DTM application.
The DCS system shall monitor parameter(s) from intelligent devices using
Foundation Fieldbus communications using standard blocks. Parameters will vary
with individual devices, as defined following device selection. Maintenance
10080-1-SS-CI-017 Page 153 of 203

alarms from these blocks shall be passed to the plant area historian and to the
Engineering Workstations in the control building engineering room.
4.6. Diagnostics (Minimum Requirement)
A primary objective of the System shall be to improve maintenance processes.
Particular emphasis shall be placed on alerting the user of potential problems with
plant assets before they become serious problems. To accomplish this goal, the
System shall provide the following preventative and predictive diagnostic
capabilities.
4.6.1. Valve Diagnostics
The System will include a Predictive Valve Diagnostic Capability that can perform as a
minimum the following diagnostic checks:
Generate a complete valve signature
Perform a dynamic error band test
Drive signal test
Step response analysis and overlay
Valve Stroke test
Partial and full valve stroke test
I/P and relay integrity test
Travel deviation test
Supply Pressure test
Relay Adjustment
Air Mass Flow test
Valve friction test
4.6.2. Transmitter Diagnostics
The System shall be capable of reporting and displaying all transmitter diagnostic
conditions detected by every transmitter connected to the System. The diagnostic
conditions available for each transmitter shall be listed.
For pressure transmitters the System shall include the ability to detect and report
plugged impulse lines. This capability shall be provided in the System regardless of
whether this plugged impulse line detection is included in the transmitter.
4.6.3. Loop Diagnostics
The System will include the ability to monitor complete flow and level regulator
control loops and alerts the operator of the root cause of a particular loop problem.
As a minimum, this predictive diagnostics will be capable of detecting and reporting
the following loop conditions:
10080-1-SS-CI-017 Page 154 of 203
Control Wound Down

Control Wound Up
Measurement Sensor Drift
Valve Problem
Liquid Leak
Head Loss
These conditions will present an alert to the user and record the condition in the
Instrument Event Audit Record.
4.6.4. Diagnostics Event Reporting
All diagnostic conditions detected by the System shall be presented as alert
conditions to the maintenance and operations personnel. Each of these alert
conditions will be capable of being directed to the operations console, the
maintenance console, or both. In general, more serious diagnostic events will be
reported to both the operator and the maintenance person while more routine
diagnostic conditions will be presented to the maintenance person only. Diagnostic
conditions from all devices will be organized into the following three categories:
FAILED – The device is not able to perform it primary function and is probably
affecting the process.
MAINTENANCE – The device is impaired and may be affecting the process.
ADVISORY – The device is in need of preventative maintenance or has
information that needs to be recorded.
When these alerts are presented to the operations or maintenance personnel, it will
be possible to access a more detailed display that provides complete status of the
device, along with specific recommendations on how to resolve the diagnostic
condition.
An enhanced polling feature will be provided to ensure fast identification of device
status changes and alerts.
4.7. Device Maintenance Alarm Philosophy
For devices HART, Profibus DP, wireless and FF real-time maintenance
management alerts will be provided by alarms generated within control
processors from resource, transducer and function blocks.
Field device maintenance alarms are separate from process alarms and shall be
sent to the Engineering Station. Alarm Display on Engineering Workstations used
for maintenance functions. Maintenance alarms will not be sent to Operator
Workstations.
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Maintenance alarms shall provide alerts to advise maintenance personnel that

further investigation is required using the IAMS diagnostic tools.
The transducer and function block parameters that generate maintenance alarms
shall also be historised by the plants Historian from where they will be sent to the
plant Instrument Asset Management Server.
For HART devices connected to the Triconex ESD system via multiplexers, IAMS
shall provide maintenance alerts.
IAMS shall also provide predictive notification for HART/FF DVC positioners and
maintenance record keeping.
4.8. Web Based Display of Information
The System shall also able to act as a Web Server so that instrument configuration,
diagnostics, and calibration data from the System can be made available via standard
PC Web Browser applications. The System Web Services will provide data to a Web
Based Instrument Asset Management System (WBIAMS) such that data from multiple
data sources are consolidated and viewable in one place. Data sources supported by
the WBIAMS will include field devices, rotating equipment, and performance
monitoring information. The WBAMS will include the following capabilities:
A summary of all Assets monitored by the WBIAMS shall be presented on its
home page. This summary will include the following:
A summary of assets by type
A summary of active alerts by severity
A summary of alerts by duration
A summary of the event rate over the last 12 months
Also included on the home page shall be a list of the ten most serious alerts from all
data sources monitored by the WBIAMS.
Every asset displayed in the WBIAMS shall include a health index from 0 to 100
indicating the overall health of the device. It will be possible to display assets and
alerts from any or all data source prioritized by health index
In addition to alert information, it shall be possible to display all configuration
and calibration data for any asset from any data source monitored by the
WBIAMS.
It shall be possible to display an entire event history of any asset monitored by
the WBIAMS.
The WBIAMS shall be capable of displaying work procedures, manuals, drawings,
or images for any asset.
4.9. Remote Desktop Services
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Remote desktop services are a standard Microsoft Windows component which

allows the desktop of a Workstation to be remotely invoked and used on another
Workstation connected to the PIN as if the user was physically present at the remote
Workstation.
Desktop services shall allow configuration and diagnostics to be performed from the
Engineering Workstation located Control building Engineering Room. Similarly
functions hosted by Engineering Workstations located in the control building
Engineering Room can be used in the PIB.
Access to Remote Desktops will be limited by password and network security.
4.10. Instrument Event Audit Record
All configuration and calibration changes to smart instruments shall automatically
record the following:
Tag of Instrument
As found / as left value
Client / Server workstation from which the change was made
Date & time of change
Logon Account name of the Person performing the change
Reason for change
Changes to Instrument diagnostic status will automatically record the following:
Tag of Instrument
Date & time of change
Detail of diagnostic status change
The System will be able to roll back to a given date and restore previous
configurations to the instrument. Configurations from one instrument will be able to
be transferred to another instrument.
4.11. Notification
IAMS shall proactively notify the user off new alerts. These alerts shall latch, be
filtered and configurable across all stations. It can be viewed, printed, acknowledged
or cleared, mailed (as per requirement). System shall monitor detailed device alert
type. IAMS shall able to capture minimum following:
Tag of instrument
Count
Date and Time
Severity
10080-1-SS-CI-017 Page 157 of 203

Description
Device Group
Plant location
Station
Manufacturer
Device type
Device Revision
Protocol
Acknowledged
The System shall have the ability to define the monitoring process by setting the
following parameters:
Audible Alert
Device Group
Automatic acknowledge of new alerts
Show desktop alerts
HART Device Defaults
 Polling Rate (Days/Hours/Minutes)
 Polling Factor
(default HART) Alert Conditions
 Non PV out of limits
 PV out of limits
 PV analog output saturated
 PV analog output failed
 Cold start
 Configuration changed
Additional feature of the System shall allow customization of notifications that may
be consolidated for single view of issues to identify valve performance, root causes
and improve equipment life. Notices can also be sent to email or mobile phone.
4.12. User Security
The System shall provide privileges with password protection for User Accounts that
allow definable access for the following:
Writing to online Instruments
10080-1-SS-CI-017 Page 158 of 203
Adding/deleting/renaming Instruments in the database

Changing Calibration Management settings
Adding Calibration Records.
Separate levels of user security will be assignable for devices connected to Safety
Instrumented System (SIS) logic solvers
4.12.1. User Access Control
IAMS shall provide access control to selected individuals at many different levels of
permission. This is accomplished by defining Security Profiles and assigning them to
individual employee's role.
Further, personalized desktops can be assigned to an individual's security profile.
Minimum three levels of security shall be assigned to individual entities or values list
with in IAMS including:
No access
View only
Edit
Using the security profiles and levels of security, controlled access can be granted to
various individuals within the maintenance organization.
The definition of the selected individuals and their level of access shall be defined
during detailed design. Thirty concurrent users shall be supported by IAMS.
4.13. Reports
Any requested view can be directly printed. The reporting software shall allows each
of these reports to be custom formatted and modified to include visual elements
such as headings and logos. In addition, the information presented in views can be
transferred to Excel spreadsheets for further processing and analysis. These reports
provide documentation for the maintenance management functions.
4.14. Time Synchronisation
The IAMS shall be time synchronised with GPS, to maintain common time reference.
This ensures that the time and any work order of instruments for calibration and
maintenance will have the same and common global time reference.
4.15. Automatic Device Registry Generation
The IAMS shall have the ability of the Instrument Asset Management software to
auto-generate the device registry by examining the underlying DCS whenever
available.
Device information shall be extracted from the project SPI database and for creating
instrument registry database.
10080-1-SS-CI-017 Page 159 of 203

SPI database that shall be used to generate the I/O configuration in the DCS and ESD
system, ensuring consistency between the configuration of the registry and the
commissioned DCS and ESD systems.
These devices will be organized in an equipment hierarchy as an aid to locating the
device information within the software to address its functionality. This hierarchy will
utilize the asset hierarchy provided MANAGING CONTRACTOR/OWNER to identify
each device. The levels shall:
Level 1 - Project
Level 2 - Complex
Level 3 - Unit
4.16. Custom Views
IAMS shall have capability of SQL queries into the relational database, and can
present information relating to any aspect of the maintenance function in a
spreadsheet format. IAMS shall be provides a variety of standard, pre-configured
Custom views. For the purposes of IAMS and the Asset Registry, these include:
System administration view
Equipment information view
Device type information view
In addition, the user is free to create any desired custom views by selecting any
desired set of entity columns available in the Asset Registry, or by copying and
modifying the contents of any of the existing pre-configured views. Views
requirement shall be detailed in the Detail Design Specification.
4.17. DCS Control Processor Scan Periods and Phases
Control blocks that provide device parameter alarms shall run at 30 second intervals.
All detection and alarm block shall be phased across the 30 second interval to
minimize the load on the communications network. MANUFACTURER/SUPPLIER shall
take prior approval from MANGING CONTACTOR/OWNER for implementation.
The System shall be able to scan up to 10 concurrent devices. It shall be modal
network scanning that will allow user to do other tasks while processing. The System
shall show progress to let user know if devices haven’t scanned successfully. Finally,
it can print or/and mail results of the scanning for troubleshooting.
Number of Instrument
Tag of Instrument
Progress
Failure Notice
4.18. Data Transfer Operation
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The System shall have the capability to move data from one system to another. It
shall allow user to choose to copy either the entire database or just selected
elements of the database. This capability shall be available via standard
methodologies like .csv or .xls files, or via a system database file.
4.19. Device Configuration
IAMS maintains a database for the devices within its scope. This database supports
all interactions with the device. Configuration information on the device can be
transferred in both directions to and from the devices to ensure that the information
in the database is identical to the information in the devices.
This database can be backed up to secure locations and restored as necessary.
Multiple instances of the database can be stored and a selected backup copy can be
restored to the workstation.
4.20. Commissioning and Startup
4.20.1. IAMS shall have capability of uploading and downloading complete configuration of
the devices. Individual parameters can be verified and adjusted as necessary to
download to devices. Final configurations shall be are uploaded to coordinate the
instruments and IAMS databases.
4.21. Data Storage and Archiving
The IAMS shall allow archiving at least 6 months storage of Asset data on the hard
drive. The system shall have multiple hard disk drives interfaced in a way so that any
drive can be added to or removed from the system while it is operational (hot
standby).
All Asset data must be archived automatically in removable state-of-the-art media.
Removable archival media and system back-up media shall be latest model and
technology at the time of system detailed engineering. The archiving shall be carried
out on a 24 Hour Cycle. The system shall provide an alarm/alert for changing of
archive media when it reaches 80% of its capacity.
5. System connectivity and Interfacing Requirements
5.1. Connectivity of the System
The preferred method of connecting the System to the instruments will be to utilize
the control system’s I/O infrastructure, with the System station connected as a node
on the control system’s communication bus. Messages to/from the instruments shall
pass through the control system from/to the System station with NO EFFECT on the
control system’s process control capability.
In addition, the System will provide connectivity to the following types of I/O
Systems:
Remote I/O Systems
Multiplexers Using HART Protocol
10080-1-SS-CI-017 Page 161 of 203
Multiplexers Using FOUNDATION fieldbus Protocol

Modems Using HART Protocol
HART over profibus
Router DTM
FF high speed Ethernet
Wireless
Handheld Intelligent Instrument Configuration and Diagnostic Tool
Diagnostics for Rotating Machinery
The System will provide complete compatibility and full diagnostic support for
monitoring the health of rotating equipment such as motor/pump combinations and
similar equipment through the use of FOUNDATION fieldbus communications
protocol. Support for Remote Operations Control
The System will provide an Ethernet interface to a Remote Operations Controller for
use at remote field installations where monitoring, measurement, and control of
processes and equipment is required.
Support for Safety Instrumented Systems
The System shall be classified as non-interfering by a recognized authority on Safety
Instrumented Systems (SIS), and shall support an integrated, two-tier security
scheme that enables field instrument configuration changes when the logic solver is
set in the correct mode. The System shall detect configuration changes made to SIS
instruments with handheld field communicators, and shall also detect any SIS
instruments left in loop test mode. The System shall automatically record within the
System Audit Trail all SIS instrument loop tests performed.
Integration with Other Functions
The System will provide data links at both the System package level and the
individual instrument level to common PC software packages such as Word, Excel,
AutoCAD and their files. Data files, such as Calibration Records, P&ID Drawings, Loop
Drawings, Instrument Vendor’s product documentation etc., from other software
packages will be able to be assigned to individual instruments in the System
database.
The System will support interface to and integration with other plant management
functions such as Computer Based Maintenance Management packages and Process
optimization packages.
Support and User Training
Details of the System’s Service Support capabilities will be provided, including the
following:
10080-1-SS-CI-017 Page 162 of 203

System design, installation and commissioning support

Advanced Diagnostic interpretation Support
Support for integration with other systems (PCS, Computerized Maintenance
Management System, Documentation etc.)
The System will support connections to off-site users over internet/intranet to allow
remote interrogation and diagnosis of instruments by specialist personnel. The
remote users’ connection will be a fully functional interface to the System package
and associated instruments in order to support preventative maintenance and fault
diagnosis.
A self-paced user training package will be included with the System, plus details of
the Manufacturer’s scheduled training courses.
Vendor will demonstrate the long-term support intentions for the System plus the
history of System product releases and user data migration.
5.2. Interfaces
The interfaces to the Instrument Asset Management System will include, but not be
limited to, the following systems:
Compressor Control System
Custody Transfer System
Turbine Speed Generator System
Vibration Monitoring System
Burner Management System
Multiplexer Systems not connected to the ESD
Turbine Control System
5.2.1. Distributed Control System (DCS)
The Instrument Asset Management System shall have a high level, high-speed
interface to the DCS. The data transfer interface shall be TCP/IP. All Process data and
diagnostic data shall be collected from the DCS.
5.2.2. Emergency Shutdown (ESD) System
The ESD system shall communicate basically via DCS for process data and diagnostic
data through PC connected to the Multiplexers in Plant Interface Building. System
shall provide two-tier security scheme that enables field instrument configuration
changes for ESD instruments. The System shall detect configuration changes made to
ESD instruments with handheld field communicators, and shall also detect any ESD
instruments left in loop test mode and generated alert for the same. The System
shall automatically record within the System Audit Trail all ESD instrument loop tests
performed.
10080-1-SS-CI-017 Page 163 of 203
5.2.3. Machine Condition Monitoring system (MCMS) interface

5.2.4. The System shall provide complete compatibility with MCMS and full diagnostic
support for monitoring the health of rotating equipment such as compressor’s
motor/pump combinations and similar equipment's. MANUFACTURER/SUPPLIER
shall suggest connectivity for the same. Implementation shall be with the approval of
MANAGING CONTRACTOR/OWNER.
5.2.5. Third-party package units control system
5.2.6. The System shall provide complete compatibility with Third-party package units
control system and full diagnostic support for monitoring the health of instruments
MANUFACTURER/SUPPLIER shall suggest connectivity for the same. Implementation
shall be with the approval of MANAGING CONTRACTOR/OWNER.
5.2.7. Support for Remote Operations Control
The System will provide an Ethernet interface to a Remote Operations Controller for
use at remote field installations where monitoring, measurement, and control of
processes and equipment is required.
5.2.8. OPC Interface
IAMS shall be capable of OPC connectivity as a server as well as acting as a client with
other hosts and sub-systems. The OPC link shall be fully redundant hardware
configuration with automatic switchover to the redundant link.
The option shall enable an OPC client application to access HART and FOUNDATION
fieldbus device data and interact with connected devices through the System. The
OPC client will utilize the Windows station user account information for security
purposes. The System username and Windows username must correspond when
Device Write permission is needed, otherwise the user can only view information.
The OPC client application will be able to access live devices, and it will be able to
directly or indirectly change device configuration or parameter information.
5.2.9. For Profibus interface
Profibus devices shall communicate to DCS via Profibus Interface Card.
MANUFACTURER/SUPPLIER shall load necessary software in system in PIB and
Central Control building. Tag parameters pulled through shall be also available to the
maintenance management functions in the Instrument Asset Management software.
In this software, device data can be used in the condition monitoring tests which
support maintenance alerts and notifications and logging. Profibus interface shall
comply with all the requirements mentioned in this specification.
5.2.10. Integration with Other Functions
The System shall provide data links at both the System package level and the
individual instrument level to common station software packages such as Word,
Excel, AutoCAD and their files. Data files, such as Calibration Records, P&ID Drawings,
Loop Drawings, Instrument MANUFACTURER/SUPPLIER’s product documentation
10080-1-SS-CI-017 Page 164 of 203
etc., from other software packages will be able to be assigned to individual

instruments in the System database.
The System shall support interface to and integration with other plant management
functions such as Computer Based Maintenance Management packages and Process
optimization packages.
6. Scope of Supply and Services:
The Instrument Asset Management System shall be supplied as a field proven and
latest software package complying with above mention specifications, loaded on
latest windows operating system. This shall include, but not be limited to, the
following:
Maintenance station in Central Engineering Services area
High specification redundant Servers system with storage and archiving facility
Required Licenses
Direct HART interface to the ESD multiplexer.
Associated peripherals as required.
Compatibility test between IAMS FDT and unique instruments
Antivirus software and management
Windows operating software and management
Manuals
Training
For Workstation grade machines base document, Operator Station requirements and
For Server Grade machine base document, Engineering Station requirements shall be
followed.
Functional specifications for Instrument Asset Management server and system shall
be subject to OWNER review and approval 6 months before FAT date. The work
station/server supply shall include all required operating system and application
original licenses.
The hardware/software used shall be latest and filed proven. All software licenses
shall be multi-user (10 concurrent users) with multi-level password for monitoring,
access, editing, etc.
6.1. Power Supply System
Redundant 110 VAC 50 Hz UPS system power to system shall be provided by
MANUFACTURER/SUPPLIER. All equipment shall be supplied to operate from these
earthed neutral, UPS derived power supplies.
10080-1-SS-CI-017 Page 165 of 203

The MANUFACTURER/SUPPLIER shall state the total load requirements, for each
location of equipment, at an agreed key date to permit the sizing of the UPS system.
6.2. Communication system
The communication link between PIB and the control building shall use fibre optic
cables (supply by the DCS MANUFACTURER/SUPPLIER).
Ethernet 100/1000 Base –T workgroup switches with Gigabit Ethernet 1000 base-SX-
LX backbone connections should be used.
7. Support and User Training
Details of the System’s Service Support capabilities shall be provided, including the
following:
System design, installation and commissioning support
Advanced Diagnostic interpretation Support
Support for integration with other systems (Computerized Maintenance
Management System, Documentation etc.)
The System shall support connections to off-site users over internet/intranet through
firewall and system security measures, to allow remote interrogation and diagnosis
of instruments by specialist personnel. The remote users’ connection will be a fully
functional interface to the System package and associated instruments in order to
support preventative maintenance and fault diagnosis.
A self-paced user training package shall be included with the System, plus details of
the MANUFACTURER/SUPPLIER are scheduled training courses.
MANUFACTURER/SUPPLIER shall provide 15 years for the System and System
product releases and user data migration support.
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Attachment-6: Alarm Management System (AMS)

1. Purpose
The intent of Attachement-6 is to provide clear guidelines to
MANUFACTURER/SUPPLIER for the Alarm Management System (AMS). The
MANUFACTURER/SUPPLIER shall develop a detailed alarm management system
Functional Design Specification (FDS) based on these guidelines and submit it to
MANAGING CONTRACTOR/OWNER for approval for the project. As a minimum, the
requirements of these guidelines shall be incorporated in the Alarm Management
System. However, MANUFACTURER/SUPPLIER shall add and implement any
applicable industry standards for the project during detailed design based on the DCS
system selection. The MANUFACTURER/SUPPLIER shall ensure that the alarm
management system is designed, built and tested to meet the requirements of the
Electrical Equipment Manufacturers and Users Association (EEMUA) guide number
191, and ISA-18.2, ASM consortium guidelines for Effective alarm management
practice and Alarm philosophy requirements.
2. Scope
This document covers the minimum requirements for the Alarm Management
System (AMS).
The MANUFACTURER/SUPPLIER shall be responsible for the supply of all AMS
Hardware, Software, Interface(s) with DCS, Interface(s) with package control
systems, System Design, Documentation, Delivery, Installation Supervision and Field
Support for the AMS as defined within this specification. The
MANUFACTURER/SUPPLIER shall carry out all system testing for AMS system,
including FAT, SAT, IFAT, ISAT, communication tests and integration tests.
3. System Design Requirements
3.1.1. General
The required Project Alarm Management System shall be based on a high
specification server(s) /client(s) configuration. It shall form an integral part of the DCS
network, running recognised third party or specialist Alarm Management packages.
The AMS and software package supplied shall form part of a complete DCS
automation solution. The AMS system will employ the latest field proven technology,
enabling the functionality required in this specification to be met.
The AMS shall include all required hardware, software and system programming to
provide a complete and operational system. This shall comprise the AMS and alarm
analysis workstations, with the required operating system software, and the full set
of the system application software to provide the required features, meet industry
guidelines, protect personnel safety and reduce the risk of plant accidents.
The AMS shall include all required hardware, software and system programming to
provide a complete and operational system. This shall comprise the AMS and alarm
10080-1-SS-CI-017 Page 167 of 203
analysis workstations, with the required operating system software, and the full set
of the system application software to provide the required features, meet industry
guidelines, protect personnel safety and reduce the risk of plant accidents.
The MANAGING CONTRACTOR, in conjunction with the MANUFACTURER/SUPPLIER,
will define all Alarm Management System interface points, and shall submit to
OWNER for review and approval.
3.1.2. Hardware Requirement
The software shall run on commercially available station. Operating System shall be
Microsoft ™ Windows latest version for the Server and Client software. In case the
requirement for the hardware differs, it shall be clearly specified by the
3.1.3. Software Functionality minimum requirement
AMS software shall be proven and latest and shall be loaded on latest windows
operating system. The operating system should have import/export capability for MS
Office suite of applications.
MANUFACTURER/SUPPLIER shall provide latest verified version of operating and
application system software at Project’s Provisional Acceptance Test. The package
shall be complete for user to upgrade the system at a suitable future time during
shutdown.
The AMS shall be supplied with all the required software/hardware to:
Accurately capture with timestamp all alarms.
Help Operations identify and rectify nuisance Alarms, therefore reducing the
number of Alarms the operator has to deal with.
Help Operations to find the cause of Process Shutdowns.
Analyse and present Alarm Data in a Simple Easy to understand format.
The AMS software shall be subject to OWNER approval.
3.1.3.1. Storage
The alarm / event / log messages shall be stored for future accessibility.
MANUFACTURER/SUPPLIER shall supply AMS having storage capacity capable of
archiving 6 (Six) months of data on internal hard drive. The system shall have
multiple hard disk drives interfaced in a way so that any drive can be added to or
removed from the system while it is operational (hot standby). After the maximum
limit of event is stored, the oldest messages shall be deleted on FIFO basis. All Alarm
data must be archived automatically in removable state-of-the-art media. Removable
archival media and system back-up media shall be latest model and technology at the
time of system detailed engineering. The auto archiving shall be carried out on a 24
Hour Cycle. OWNER will have the right to choose the equipment needed at the time
10080-1-SS-CI-017 Page 168 of 203

of purchase order. The system shall provide an alarm for changing of archive media
when it reaches 80% of its capacity.
3.1.3.2. Message segregation / Search Report
The software shall support segregation of the message on the basis of following:
Type of message, e.g. Alarm Messages; or Acknowledgement Messages, or Event
Messages, Log report or by System etc.;
Time slots: Type(s) of Messages within given time slot;
Tag-wise: Messages for the given Tag or Group of Tags;
Alarm Priority: Messages of the given priority type;
Outstanding Alarms: Alarm Messages, which exist at a given time not normalized.
3.1.3.3. Frequency Analysis
The software shall scan all the messages during the given time period and generate
report giving frequency of each messages with which it has occurred. It shall be
available as a summary report during the given time.
Remark Column Against Message
The software shall support insertion of additional columns against messages for
either automatic entering on predetermined text / value or ‘manual remarks by
reviewer’.
3.1.3.4. Log Time
The software shall support to find time between specific messages.
3.1.3.5. Data Export
The software shall support data / analysis export to Microsoft ™ Office applications
as well as to other database such as Oracle, MS Access etc.
3.1.3.6. Printing
Though the software is intended to replace the alarm / event printer, the software
result shall be printed on a network printer ‘as desired’ or ‘when a certain predefined
message arrives’.
3.1.3.7. Backup
The software shall support backup on removable storage media such as Floppy Disk,
Write-able DCD’s, Tapes, Optical Disks etc. The same backup shall be retrieved
whenever required. This shall make every messages archival possible till the desired
period irrespective of storage / licensed capacity.
3.1.3.8. Voice Notification
Upon receipt of a specific alarm/event, the system shall dial phone/mobile, output a
recorded message corresponding to the alarm and wait for an acknowledgement
10080-1-SS-CI-017 Page 169 of 203
typed in the telephone/mobile keypad. It shall be possible to dial into the software to
listen to the play back of all unacknowledged alarms over the telephone.
3.1.3.9. DTMF (Dial Tone Multi Frequency) tones to Paging Systems
When an alarm occurs the software shall dial up a mobile/pager and if applicable,
send DTMF tones corresponding to the alarm.
3.1.3.10. Text Messages to Paging System
On occurrence of an alarm the software shall dial up a TAP compliant mobile pager
or cell phone and if applicable, send text messages.
When high priority alarm arrives, it shall be possible to extract a telephone number
form a roster of personnel, which can change automatically to reflect shifts or
weekends. It shall then dial them, wait for a security code and speak the alarm. If it
does not get the required response it shall dial the next entry in the list.
3.1.3.11. Reporting
Reports: Reports shall be available in windows office files. Automatic Generation of
e-mail on stated time shall be offered.
Shift Report: This report shall be generated once every 8 hours (shall be user
configurable). The report shall comprise of ‘Frequency analysis’ and ‘Outstanding
Alarms’.
AMS shall generate alarm history report for detail alarm analysis purpose. Also report
format shall be editable.
AMS shall be able to capture the Log/production Report and export in excel format
with scheduled email facility.
AMS shall have feature to have operator guided messages and critical alarms pop up
on operator screen
3.1.3.12. Day Report
This report shall be generated once a day at specified time. The report shall comprise
of ‘frequency analysis’ and ‘statistical data of the outstanding alarms giving statistics
based on priority, tag group etc.’.
3.1.3.13. Reports on e-mails
The software shall trigger transmission of e-mail to predefined group of e-mail
addresses. The trigger shall be provided by either of the following
Messages: Appearance of Particular Alarm / Event, Appearance of Periodic
Production Report. The e-mail content shall be appeared alarm / event message or
Production Report or attachment of report in office format.
3.1.3.14. Real Time and Historical Analysis
10080-1-SS-CI-017 Page 170 of 203

The analysis tools and client software shall work on both Real time data and
historical data.
3.1.3.15. Control System Independent
The software and hardware shall be independent of and separate from any control
system.
3.1.4. Reliability
The system shall be designed to avoid unrevealed failures.
The MANUFACTURER/SUPPLIER shall supply a list of all single points of failure, which
will affect other systems receiving outputs generated by the AMS. Any device that
cannot be replaced while the system is running must be explicitly identified. For
system components that can be replaced while the system is running, the necessary
steps to bring the components to full functional operation shall be described in the
maintenance manuals furnished with the AMS.
3.1.5. Events and Data Analysis
The AMS system shall collect events in real time from the sub-systems distributed
across the site, archive the data in a central server and provide client applications to
view and analyse the data. The functionality of the Alarm Analysis System should
include at least the following:
Event Capture
Data Collection, Storage and Archiving
Data Analysis
Event data shall be captured by a control system or sub-system such as DCS, ESD, and
Package Control System etc. These events shall be transmitted to AMS, where they
shall be collected and stored in a central server location for easy retrieval during a
trip analysis exercise. The data shall be stored in a structured, normalised format.
The system shall have provision for data tracking and validation.
Client workstations for alarm analysis shall also be provided at Control Room. Tools
shall be available for sorting, filtering and analysing the data such that a shutdown
root cause can be identified. The analysis package shall also have following
capabilities as a minimum:
Analysis to identify and eliminate nuisance alarms
Monitor, record and register standing alarms
Monitor, record and register operator interventions
Identify problem alarms (per unit, frequency)
Identify chattering, redundant alarms
The following areas are the kinds of data that will typically be required:
10080-1-SS-CI-017 Page 171 of 203
Process
Utilities
System diagnostics / health
Device health
Operator actions
Plant maintenance (Software changes etc)
3.1.5.1. Alarm Prioritisation
Alarm prioritisation refers to a scheme used to cause some alarms to appear more
compelling to the plant operator than others. This is often accomplished by using a
combination of colour coding, audible tones and symbols. Consideration of different
priority in different displays could be used, in order to assist Operator in dealing with
the type of alarms presented.
The alarm prioritisation and suppression control logic shall be implemented within
DCS. Suppression, inhibition and limit adjustment of alarms shall be subject to
password authorisation. Alarms can either be suppressed entirely, or their limits
adjusted, according to the process situation (e.g. train offline, filter stream in
regeneration, device failure, etc). One of the features of alarm management is the
ability to automatically inhibit or disable alarms or groups of alarms, for example
those that are currently not in service on a piece of equipment that is shut down for
maintenance. The current operating status of the plant should be inferred from
various inputs and secondary alarms should be suppressed. For example, a low flow
alarm might be suppressed when the associated pump is not running. The particular
prioritisation scheme used depends upon the particular DCS selected as well as upon
system design. However, a typical 4-level prioritisation scheme might be as follows:
Priority 1: personnel, environmental or equipment hazard or plant trip
Priority 2: other equipment failure or partial trip condition
Priority 3: call for maintenance but no immediate danger or trip potential
Priority 4: status information, events with no operator action required
The alarms shall be prioritised considering following two factors: -
Severity of consequence and criticality (in safety, environmental and economic
terms) the operator can prevent by taking the corrective action associated with the
alarm.
The time available compared with the time required for the corrective action to be
performed and to have desired effect
The relative frequency of occurrence of alarms of different priority should reduce
with increased priority summarized below in table 1.
10080-1-SS-CI-017 Page 172 of 203

Table 1
Priority band Target Maximum Occurrence
rate
Safety related/critical very infrequent
High less than 5 per shift
Medium less than 2 per hour
Low less than 10 per hour
If there are very few high priority alarms, say one per month, then the ones that do
occur will get very special attention by the operator. By relaxing the criteria of what
constitutes a high priority alarm further, such that 2 or 3 high priority alarms occur
per shift then these will still be effectively discriminated by the operator. This
argument implies that the allocation of priority should be an iterative process and
should be adjusted with operator experience.
During detailed design, alarms should be configured in the approximate ratios as
shown below in Table 2. However MANUFACTURER/SUPPLIER & MANAGING
CONTRACTOR shall carry out detailed ‘alarm reviews’ and prioritisation for OWNER
review, approval and submittal prior to implementation.
Table 2
Priority band Alarms configured during system
design
Critical About 50 altogether
High 5% of total
Medium 15% of total
Low 80% of total
It is emphasized that the figures in tables 1 & 2 should be taken as approximate

indicators of effective discrimination between priorities rather than exact figures.
The implementation of alarm prioritisation shall be achieved using DCS
MANUFACTURER/SUPPLIER specific alarm management system software.
3.1.5.2. Alarm Acknowledge
This function changes the appearance of an alarm, so that new alarms (not
acknowledged) can be readily distinguished from old ones. The acknowledge action
(mouse click) may apply to a single alarm or multiple alarms. If the acknowledgment
of multiple alarms is required, care shall be taken to ensure that all alarms that are
10080-1-SS-CI-017 Page 173 of 203

being acknowledged are easily visible and understood by the operator. Multiple
alarm acknowledgements should not be provided for critical and high priority alarms.
The Alarm Acknowledge function shall be initiated through the DCS operator
workstation only. Alarm Acknowledge events shall be recorded by the AMS.
3.1.5.3. First-Out Sequences
The first-out alarm sequence shall be assigned to a defined set of alarm points, and
provides indication of which point in the group received its alarm initiation signal
“first”. AMS shall be able to implement logic to capture the first-out alarms shall be.
The first out alarms shall be registered and can be printed as ‘FO’.
3.1.5.4. Alarm Groups
Alarms shall be arranged in a hierarchical series of groups. Alarm groups shall be
used to modify the behavior of alarms related to the same piece of equipment or
process area. Alarm groups will define first out boundaries, group acknowledge
(where required) and secondary or consequential alarm suppression.
Consequential alarm suppression shall be applied to minimize the number of alarms
needing operator attention and acknowledgement, and to reduce the possibility of
an alarm “avalanche”.
3.1.6. Features
As a minimum the supplied Alarm Management System package shall provide tools
to identify, analyse and display the following functions:
Frequency of Alarm
Frequent Alarm
Time of alarm
Time for a particular alarm is remained in alarm state
Time to acknowledge
Alarms per alarm type
Alarms per time period
Alarms per unit
Chattering Alarms
Duplicated Alarms
Standing Alarms
Consequential Alarms
Controller Mode Changes
Controller Set point Changes
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Analogue Output Changes

Discrete Output Changes
Alarm Enable State Changes
Return to Normal Changes
Alarms change of state (e.g. Spurious)
Alarm Priority Changes
Priority Distribution
Alarm Disable/Inhibit/Enable and their listing
Setpoint Change
Group Change
Range Changes
Tuning Constant Changes
Other Process Changes
Alarm Configuration Analyses
Alarm Flood
The supplied AMS System shall be able to:
Analyse Alarms from all Main Systems, e.g. DCS, ESD, MCMS, Analysers and any
Package Control Systems
Supply the Analysis in a Standard or Customised format to a suitable medium,
e.g. Monitor, Printer, and Disk Media.
The AMS shall also have the following features:
Efficient Archiving to allow straight forward retrieval of reports/alarm analysis
Analysis of Alarm information with tools such as Frequency Analysis
Frequency Breakup, Frequency Monitoring
Time elapsed between two alarms/events
Alarm severity and Consequences frequency along with analysis
Export Alarm information to other applications, e.g. Excel or Access
AMS shall support programmatically masking facility upon defined criteria.
Analysis results shall be graphically represented.
AMS shall generate Frequency analysis chart e.g. maximum alarm generation
report in pie and bar chart format.
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All alarm trip setting messages shall be stored in a system wide database.
Database shall include information on when data item within it are changed?
Back up important information on-line to optical disk or a networked drive
Client/Server design to allow Remote Access over a network
Use Trigger Words to highlight Important Alarms as high, medium, or low priority
by displaying them in different colours
Use of an advanced diagnostic system to analyse the cause of a plant shutdown
Log the time between specific messages
Different user levels and Password Security
Support of multiple clients displaying different screens simultaneously from the
same AMS database
Automatic or Demand output to a printer, disk file or file.
Disk Shadowing over a network.
Automatically trigger Alarm Reports and/or Screen Dumps.
SQL type search facility.
Alarm Sort facility.
AMS shall generate deviation report w.r.t standards database settings
Facility of Alarm Banner based on priorities i.e. High, medium, Low for LVS is
preferred
Alarms received over communication lines shall have time tagged at source.
AMS connectivity with Sound Module and PA System shall be there.
Cyber Security Features shall be implemented.
Wherever possible events shall be time stamped by the initiating device. The AMS
shall maintain the original time stamp and shall only time stamp events that cannot
be time stamped by an initiating system. The AMS shall be synchronised by a GPS
master clock. Where available, time stamp correction algorithms shall be used.
3.1.6.1. Alarm Displays
As a minimum, the following displays shall be made available on the AMS:
Alarm Displays sorted/grouped by:
Priority
Type
Frequency
10080-1-SS-CI-017 Page 176 of 203

Unit/Equipment
Area
Operator Console
Process/System
SQL Alarm Search Display
3.1.7. Architecture and Communication:
The AMS will be connected to the all the main systems and subsystems, DCS, ESD,
MCMS and Analysers. There will also be links to all the Package Control Systems, e.g.
Gas/Steam Turbine controls, Anti surge controls etc
The MANUFACTURER/SUPPLIER shall describe in detail the possible interfaces and
functionality.
The MANUFACTURER/SUPPLIER shall describe in detail the proposed Architecture for
the Project.
3.1.8. Scope of supply:
The AMS will be supplied as a field proven and latest working package. This shall
include, but not be limited to, the following:
Client Workstation for AMS System
High specification redundant Servers System with storage and archiving facility
AMS Supervisory System (configuration and maintenance workstation) in Control
Room.
Associated Hardware and Peripherals: e.g. Redundant Servers and client
workstations complete with 21” LCD/LED monitors, keyboards and tracking
devices and all other necessary equipment plus at least one colour laser printer.
All network interfaces to the DCS and other subsystems
Associated System Software e.g. Operating System latest windows based.
Associated Applications Software e.g. Alarm Management Software,
Configuration Software and Interface Software
Licenses for the Software
Redundant Interface to main systems and any Package Control Systems
Associated peripherals, e.g. mouse, printer (one dedicated for AMS) etc.
Manuals
Training
10080-1-SS-CI-017 Page 177 of 203

All workstations and servers shall be offered from MANUFACTURER/SUPPLIER’S

standard product range but complying with the following minimum specifications:
As a minimum, all operator workstations and servers shall have 21" LCD/LED display
monitor with DVD R/W drive, keyboard and mouse. However, final specifications for
AMS server and system shall be subject to OWNER review and approval 6 months
before FAT date. The work station/server supply shall include all required operating
system and application original licenses.
Printers for the project shall be standardized by MANAGING CONTRACTOR. OWNER
approved MANUFACTURER/SUPPLIER shall be used for printers supply. For any
bought out items, the system MANUFACTURER/SUPPLIER should identify such
products and seek written approval from MANAGING CONTRACTOR/ OWNER during
the bid stage.
The latest hardware/software shall be used to ensure that the AMS is field proven
and up-to-date. All AMS software licenses shall be multi-user (5 concurrent users)
with multi-level password for monitoring, access, editing, etc.
The AMS shall be capable of OPC connectivity as a server as well as acting as a client
with other hosts and sub-systems. The OPC link shall have a fully redundant
hardware configuration with automatic switchover to the redundant link.
3.2. Interfaces
The interfaces to the AMS will include, but not be limited to, the following systems:
3.2.1. Distributed Control System (DCS)
The AMS shall have a high level, high-speed interface to the DCS. The data transfer
interface shall be OPC/LAN/Serial Link. All Process, Operator Action, diagnostic alarm,
and event data shall be collected from the DCS.
3.2.2. Emergency Shutdown (ESD) System
The ESD system shall have a high level, high-speed interface to the AMS. The data
transfer interface shall be OPC/LAN/Serial. All alarm and diagnostic data shall be
collected from the ESD.
3.2.3. Machine Control Monitoring System (MCMS)
The MMS Interface shall have a high level, high-speed interface to the AMS. The data
transfer interface shall be OPC/LAN. All alarm, event and diagnostic data shall be
collected from the MMS.
3.2.4. Package Unit Control System (Anti surge controls, BMS, UPS etc)
The package unit interface shall have a high level, high-speed interface to the AMS
System. The data transfer interface shall be OPC/LAN (emulator)/Serial Link. All
Process and diagnostic alarm data shall be collected from the package unit control
system.
10080-1-SS-CI-017 Page 178 of 203

Systems that generate an internal alarm/event log and are incapable of supporting
an OPC server themselves. These Systems shall supply data to a PC-based printer
emulator (Data logger). The AMS shall access alarm data from the data logger.
Systems that cannot meet the time stamping requirements themselves shall be
hardwired to the DCS or ESD system, to provide fault and common alarms for very
basic analysis.
3.2.5. Supervisory Control and Monitoring System (SMC)
The SMC system shall have a high level, high-speed interface to the AMS. The data
transfer interface shall be OPC/LAN/Serial Link. All alarm and diagnostic data shall be
collected from the SMC.
3.2.6. Analysers
The Analysers shall have a high level, high-speed interface to the AMS. The data
transfer interface shall be OPC/LAN/Serial Link. All alarm and diagnostic data shall be
collected from the Analysers.
3.3. Supervisory System (for configuration and maintenance)
3.3.1. General
The supervisory system shall be Windows families operating system (2003 or later)
based and shall include independent workstations, with dedicated keyboards and
cursor positioning devices. The workstation shall have continuous and simultaneous
access to AMS servers. These servers shall act as a central database for the AMS,
archiving alarms and events and shall provide system diagnostics.
The system database shall use the OWNER tag numbers allocated to devices as the
unique basis for point reference.
The system shall include diagnostics displays with detailed status information
concerning network communications performance, status of each node and server.
Operations at the Supervisory system shall not cause any adverse effects on the
system operation; this includes, but is not limited to, communications, alarms,
logging, time stamping, time synchronisation etc.
The Supervisory system shall have password protected access levels for different
functions.
Complex wide enterprise AMS shall be provided. Enterprise AMS shall able to collect
alarms from plant AMS's. Interface and software requirement for the same shall be
in MANFACTURER/SUPPLIER scope of supply with approval from MANAGING
CONTACTOR/OWNER.
3.3.2. Time Synchronisation
The alarm analysis and management system shall be time synchronised with GPS, to
maintain common time reference. This ensures that the time and order of sequence
10080-1-SS-CI-017 Page 179 of 203

of events data, and the recorded data from all process control systems will have the
same and common global time reference.
Any device that trips the process or utility shall be connected to a system which time
stamps it to millisecond level. All time stamping systems shall be synchronised by
GPS.
This requirement includes but is not limited to DCS, ESD, anti surge control, electrical
switchgear, BMS etc.
3.3.3. Data Storage and Archiving
The AMS shall allow archiving at least 6 months storage of alarm data on the hard
drive. The system shall have multiple hard disk drives interfaced in a way so that any
drive can be added to or removed from the system while it is operational (hot
standby).
All Alarm data must be archived automatically in removable state-of-the-art media.
Removable archival media and system back-up media shall be latest model and
technology at the time of system detailed engineering. The auto archiving shall be
carried out on a 24 Hour Cycle. The system shall provide an alarm for changing of
archive media when it reaches 80% of its capacity.
3.4. Alarm Management System
3.4.1. Power Supply System
Redundant 110 VAC 50 Hz UPS system power to the system will be provided by
MANUFACTURER/SUPPLIER. All AMS equipment shall be supplied to operate from
these earthed neutral, UPS derived power supplies.
The MANUFACTURER/SUPPLIER shall state the total load requirements, for each
location of equipment, at an agreed key date to permit the sizing of the UPS system.
3.4.2. Fault Alarms
System fault alarms shall report individually and shall at least be provided for:
System crash and Software Failures
Application Software Failures
Interface/Network Failures
Communication link Failures
Power supply/fuse failures
Common fault alarms shall be reported to the DCS through communication link
for operator information and action.
3.4.3. AMS communication system
The communication link between PIB and the Control Room shall use fibre optic
cables (supply by the DCS MANUFACTURER/SUPPLIER).
10080-1-SS-CI-017 Page 180 of 203
Ethernet 100/1000 Base –T workgroup switches with Gigabit Ethernet 1000 base-SX-
LX backbone connections should be used.
3.5. Alarm Monitoring System
In addition to the detailed specifications stated above, following further features
are required:
The system shall be capable of expansion and able to accommodate other inputs
for future expansion.
The system will allow analysis of equipment start-up, shutdown and any other
transient phenomena.
Necessary hardware, software and configuration shall be provided to achieve the
above functionality.
The requirement for prediction and anticipation of plant deterioration with sufficient
lead-time for operator action shall be fulfilled as follows:
The system will monitor Alarms, i.e. Alarm data processed, using well-proven
analysis techniques, directly related to specific faults, which are trendable.
The system will include an advanced diagnostic system. This advanced diagnostic
system shall be both easy to start up and expandable with new symptoms and
new diagnosis.
The central computer / workstation of the system will be multi-tasking to allow
simultaneous operation of the Alarm functions, advanced diagnosis function, and
visualisation on remote terminals etc, without perturbing the AMS function.
The network components such as switches, hubs, routers etc shall be installed in a
separate cabinet / junction box.
Functional Design Specifications shall be subject to OWNER approval 6 months
before FAT date.
3.5.1. AMS Advanced Tools
The AMS system should have advanced, rule-based, specialised, diagnostics
functionality, including the latest abnormal condition management tools, or
equivalent. The system shall have additional functionality for real-time root cause
analysis of process upsets or inefficiencies with the aim of identifying prospective
problems early enough so they do not result in off-spec production or unscheduled
plant shutdown. The AMS acts as an operator’s assistant, continually monitoring the
process, looking for potential process excursions before they necessarily become
apparent in the form of direct process alarms. The AMS will assist the operator into
making certain decisions based on detailed analysis carried out by AMS.
The system can be represented as shown in Figure 1.
10080-1-SS-CI-017 Page 181 of 203

Alarms Alarm & Event Alarms &

& Events
Capture/Storage Events
Process
Alarm Analysis
Controls
(OFFLINE)
(DCS, ESD, PLC)
Intelligent Alarm Rules

Supression
Modes Manager
Limits
3.6. Other Requirements

MANUFACTURER/SUPPLIER shall carry out the following requirements:
Chair/manage a detailed ‘alarm analysis and review’ that shall be carried out
during detailed design to check that sufficient process and utility monitoring
points have been included for event gathering and trip analysis, as well as the
safety issues and prioritisation. A detailed report is to be produced as a project
record. Typical determination matrix for priorities is attached in appendix B.
If the relevant control sub-system (e.g. DCS, PLC or proprietary) is not capable of
resolving a particularly fast sequence of events, or is unable to pass on the time-
stamped information to an event server, then the data should be hard wired in
parallel to a system that can. The dynamics of each process or package unit
should be studied during detailed design to establish the required event capture
resolution.
Detailed health monitoring to identify component failure should be included on
all sub-systems
4. AMS Proposal
As a minimum, the following criteria shall be used to evaluate the proposed AMS:
User friendliness
Database Administration
Alarm Processing, Storage and Archiving
Alarm Reporting
Graphic displays
System software feature
Alarm Analysis feature
Notification and alerts communication method support
10080-1-SS-CI-017 Page 182 of 203
Interfaces and Networking facility

Alarm Access and Retrieval
Other related packages such as Diagnostic Package, Configuration Package
Customization
Hardware requirements (platform, files server size, back-up system)
Experience and references world wide, and installed bases
Special features
Package Control System Integrated Instrument Interfacing Capabilities
MANUFACTURER/SUPPLIER shall provide an itemised list of hardware and software
required to cater for the architecture of the system identifying the mandatory and
optional items.
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Attachment-7: Project Execution

1. Purpose
The purpose of Attachement-7 is to define minimum requirements for project
execution and planning by MANUFACTURER/SUPPLIER.
2. Project Execution and Planning
The DCS MANUFACTURER/SUPPLIER shall submit detail Project Execution Plan
covering the following topics.
2.1. Project Execution Concept
2.2. Project delivery schedule taking the Managing Contractors information flow dates
into consideration
2.3. Project Execution Centers
2.4. Command and control of remote execution centers (if applicable)
2.5. Project Organization
Organization structure,
Engineering strength,
Resource Allocation & loading plan
Team member training,
Team staffing,
2.6. Roles & Responsibilities
2.7. Resume of Key personnel
2.8. Work Integration, Work Planning, Work authorization, Work Execution
2.9. Project Execution Cycle
Scope
Functional design specification development
Approved FAT Procedures
Configuration plan
In house testing
2.10. Subsystem interface
Interface handling (ESD, PLC, Analysers, Automatic Tank Gauging, Custody Transfer
Metering, Machine Conditioning Monitoring, Motor Control Centre, MOV System,
Turbine Control System, Burner Management System, Partial Stroke Test Devices,
10080-1-SS-CI-017 Page 184 of 203

Valve Link, Compressor Control System, Turbine Speed Governor System & any other
System bought by OWNER) & Testing.
2.10.1. FAT
Prior to FAT, DCS MANUFACTURER/SUPPLIER shall carry out interoperability test as
per latest ITK Standard for maximum instruments & submit the detailed reports to
the MANAGING CONTRACTOR/OWNER. MANUFACTURER/SUPPLIER shall also
demonstrate the same performance to the OWNER at it’s workshop.
2.10.2. Shipment
2.10.3. Installation
2.10.4. Commissioning
2.10.5. SAT
2.10.6. As Built Documents
2.10.7. Training
2.10.8. Life time support
2.11. Risk Management & Mitigation Plan
Identification of major risks & mitigation plans
Project critical path reviews
Status of Product development for new products, if any
Fall back strategy & recovery plan.
2.12. Reports & Analysis
Progress Report - Planned v/s Actual
Engineering Progress Report – Planned v/s Actual
Drawing, Documents issued etc – Planned v/s Actual
Material Report – Planned v/s Actual
Staffing curves – Planned v/s Actual
Performance Report – Planned v/s Actual
2.13. Interface matrix – OWNER / MANAGING CONTRACTOR / DCS
MANUFACTURER/SUPPLIER
2.14. Value engineering
2.15. Change management (Applicable post-FAT)
2.16. Documentation Management
2.17. Integrated FAT requirement
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Manpower
Tools & Tackle
Space
Amenities (HVAC / UPS)
2.18. Quality Assurance Plan Installation schedule
2.19. Training & Certification for all users as per Spec
2.20. Foundation field bus devices – Pre testing & testing criteria
2.21. Software upgrades for 10 years
2.22. Hardware support for 15 years
2.23. Spare parts
Comprehensive Annual Maintenance Contract spares
Support Commissioning spares / Warranty spares to be stored at site
MANUFACTURER/SUPPLIER to provide 02 years operation and maintenance
spares
MANUFACTURER/SUPPLIER to provide 6 months consumables
Vendor to prepare interchangeability spares list (SPIR) indicating installed
quantity, part no. & recommended spares.
2.24. Annual Maintenance Contract
2.24.1. Comprehensive:
Comprehensive Annual Maintenance Contract Support for 3 years after 2 years of
warranty (Total 5 years)
Commissioning spares / Warranty spares to be stored at site.
MANUFACTURER/SUPPLIER to provide the details considered under Comprehensive
Annual Maintenance Contract.
2.24.2. Non-Comprehensive
MANUFACTURER/SUPPLIER to provide the details considered under Non-
Comprehensive Annual Maintenance Contract.
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Attachment-8: Third Party Integration Test

1. Purpose
Attachemnt-8 details the Third Party system IFAT Test procedure for project.
Interface tests that may be deemed necessary for the Project will be performed at
the DCS MANUFACTURER/SUPPLIER’s facilities. Any requirement for interface tests
shall be identified and agreed during the Interface kick-off meeting.
2. Abbreviation
INT Internal Test by MANUFACTURER/SUPPLIER
3. Scope and Purpose of Tests
The scope and purpose of this test is to validate the Third Party system integration
with the DCS. The tests check and validate the correct operation for the system
communication modules, network equipment and software application.
Device Integration Serial Interface Tests are focused on verification of graphics,
database, power, communications, and alarms/trip and other system integration
features and functions. The purpose of Third Party system device testing is to
support the host system (DCS) tests.
This test procedure consists of Failure Mode tests that verify all Network equipment
is configured and functioning correctly in accordance with the design. With all I/O
modules installed and functioning, the downloaded program in each device will
simulate a normal operational state of the system before commencing the test.
A pre-requisite for these tests is that all the test procedures detailed in FAT test
procedure and any fault and/or remedial issues have been fully resolved.
The software configuration in each Third Party system and the interface to the DCS
(serial interface and graphical HMI) shall be tested separately.
Document used in this test procedure shall be Approved/Final document revisions. If
subsequent issued revision of Approved/Final documents are to be used, it must be
incorporated with all requested changes/comments and must be agreed at the
discretion of the responsible persons. Such agreement shall be recorded without
dispute.
All approved/final documents shall be verified using the latest revision as per
document register.
DCS MANUFACTURER/SUPPLIER shall provide Serial Protocol Data Capture Forms to
Third Party System MANUFACTURER/SUPPLIERs. Third Party System
MANUFACTURER/SUPPLIER will complete the forms and transmit it to DCS
MANUFACTURER/SUPPLIER. Sample forms are attached herewith in Section 7.
In coordination with Third Party system supplier, DCS MANUFACTURER/SUPPLIER
shall submit his own testing and acceptance procedure for OWNER’s approval 6
10080-1-SS-CI-017 Page 187 of 203
weeks before testing. Hardware test shall include purpose of test, test definition of
input, procedure, results expected and acceptance criteria. Software test shall
include details of the method, list of tests, sequence of execution, results expected
and acceptance criteria.
DCS MANUFACTURER/SUPPLIER shall ensure the availability of adequate number
(minimum 3 sets), of all test equipment, tools & tackles, simulators, documentation
etc. before commencement of test.
For integration and testing interface with DCS:
DCS MANUFACTURER/SUPPLIER shall ask OWNER/Third Party system supplier to
arrange to provide each type of devices with required auxiliary
hardware/software at DCS MANUFACTURER/SUPPLIER’s place.
Third Party MANUFACTURER/SUPPLIER shall provide all the details (serial
interface details, serial database, format for serial database, etc.) for interfacing
their system with DCS.
During test, any non-conformance, addition or modification shall be brought to
notice of OWNER.
DCS MANUFACTURER/SUPPLIER shall supply communication cables to interface
with Third Party Systems.
As an option DCS MANUFACTURER/SUPPLIER shall offer portable mini DCS
system with necessary hardware and software to test package unit/third party
serial interfaces at their respective locations.
Rigorous Third Party system device tests shall be performed during Site Acceptance
and Integration Tests.
4. Staging
It is not possible to stage all devices and perform a full functional test on all devices.
Therefore a focused and limited test with representative testing shall be conducted.
At least one of each Third Party system device types should be available at the
staging facility. This is dependent on the functionality testing requirements in the
specification. The test shall address the following items:
Communication checks
Functionality checks
Data reconciliation checks
Communication/Network loading check
Redundancy test
10080-1-SS-CI-017 Page 188 of 203

5. Test Procedure
MANUFACTURER/SUPPLIER minimum shall perform following:
5.1. Communication Module Redundancy check
Step
No. Procedure Pass / Fail Criteria INT FAT IFAT TISAT
1 Removal of Verify Alarm on chassis of
Communication module Third party system.
Verify the Link failure

alarm notification on DCS
2 No change in operation of Verify No change in IO

the system module’s normal
operation state.
No change in IO module’s
normal operation state Verify Data transfer is
through redundant
communication module
& thus communication is
maintained.
3 Re-insert communication Verify Alarm on chassis is
module cleared and
communication module is
normal.
Verify DCS reports Link

recovery.
Verify that the

communication is OK and
Data transfer is re-
established through
communication module.
4 Repeat steps 1, 2 and 3 Verify the identical
for other remaining results as per steps 1,2,3
module. Ensure the
testing results are
identical to the original
communication module
test.
10080-1-SS-CI-017 Page 189 of 203

5.2. Protocol Converter Redundancy check
Step SAT/I
No. Procedure Pass / Fail Criteria INT FAT IFAT SAT
1 Removal of power from Verify the Link failure
one of the protocol alarm notification on DCS.
converter or disconnect
the serial
communication cable
from one of the
converters.
2 No change in operation Verify No change in IO
of the system by loss of module’s normal operation
communication path. state after loss of the
communication path.
No change in IO
module’s normal Verify Data transfer is
operation state after through remaining
the network has (redundant)
degraded to simplex communication path &
operation. thus communication is
maintained.
3 Re-insert serial Verify DCS reports Link
communication cable recovery.
into the converter /
power up the Verify that the
deactivated converter. communication is OK and
established through
communication module .
4 Repeat steps 1,2 and 3 Verify the test results are
for other remaining identical to the loss of
converter. Ensure the communication on other
testing results are path, communication link
identical to the original failure reported by DCS.
converter test. System operation and
communication was
maintained.
10080-1-SS-CI-017 Page 190 of 203

5.3. Network Switch Redundancy check
Step SAT/I
No. Procedure Pass / Fail Criteria INT FAT IFAT SAT
1 Remove the power from Verify the Link failure
one of the network alarm notification on
switch. DCS.
2 No change in operation Verify No change in IO
of the system by loss of module’s normal
communication path. operation state after loss
of the communication
No change in IO module’s path.
normal operation state
after the network has Verify Data transfer is
degraded to simplex through remaining
operation. (redundant)
communication path &
thus communication is
maintained.
3 Power up the deactivated Verify DCS reports Link
switch. recovery.
Verify that the

communication is OK and
established via
communication module.
4 Repeat steps 1, 2 and 3 Verify the test results are
for other remaining identical to the loss of
switch. Ensure the testing communication on other
results are identical to path, communication link
the original switch test. failure reported by DCS.
System operation and
communication was
maintained.
10080-1-SS-CI-017 Page 191 of 203

5.4. Peer to Peer Failure Application Configuration check
Step SAT/
No. Procedure Pass / Fail Criteria INT FAT IFAT ISAT
1 Remove the power from Verify the Link failure
both of the network alarm notification on DCS.
switch.
2 System loops requiring Verify that the system

immediate shutdown. loops requiring immediate
shutdown are initiated to
shutdown within
approximate time (decided
during detail engineering)
and de-energised in
accordance with the C&E
for each system.
3 System loops requiring Verify that the system

time delayed shutdown. loops requiring time
delayed shutdown are
initiated to shutdown
within approximate time
(decided during detail
engineering) and de-
energised in accordance
with the time delay and
C&E for each system.
4 System loops not Verify that the system

requiring shutdown on loops not requiring
both the network switch shutdown on both the
failure. network switch failure
remain in the normal state
in accordance with C&E for
each system.
10080-1-SS-CI-017 Page 192 of 203

Note: Independent and redundancy of communication link(s) for each third party
system configured on network and Confirmation of data transfer will be carried out
during these tests.
Data Integrity & Functionality check
Data Read/Write bidirectional check shall be done for few tags of each controller &
serial interface. Testing shall be done for all possible modes of controller (open and
close loop) as applicable.
6. Test Verification
This section is to be signed off after all applicable tests have been completed.
Test Verification & Signature Log
OWNER/
DCS
Third Party MANAGING
Test Type Date MANUFACTURER/SUPPLIER Date Date
Acceptance CONTRACTOR
Acceptance
Acceptance
Internal
test
Factory
Acceptanc
e Test
Integrated
FAT
Site
Acceptanc
e Test
Integrated
SAT
10080-1-SS-CI-017 Page 193 of 203

7. Serial Protocol Data Capture Forms

7.1. Data Capture Form – MODBUS/MODBUS TCP/IP
The MANUFACTURER/SUPPLIER Details
Package Name
Plant Name
PIB Number
Unit Area in Plant
Address
Contact Engineer
Telephone No.
Email address
Modbus Interface Details
Information Required Project settings Details from PLC

PLC make
PLC model
Interface module model
Is the PLC redundant Yes No
Does the PLC run in a Yes No
Duty/Standby configuration?
Is the PLC interface redundant? Yes No
Does the PLC/Server support a Yes No
heartbeat
Is the link with the DCS peer-to- Peer-to-peer Multi-
peer or multi-dropped? dropped
Is a Local/Remote (PLC/DCS) Yes No
selection flag mapped on the
serial link
10080-1-SS-CI-017 Page 194 of 203


Any Interface converter e.g. RS232 to RS485 Yes No
required?
What is the Interface standard? e.g. EIA-485 232 422 485
What is the Interface protocol? e.g. Modbus RTU
State the Communications e.g. D-Type, male, 9 pin,
Connector Type for the PLC. RJ-45
Supported Baud Rates e.g. 9600, 19200 Baud 50 300 600 1200 2400
4800 9600 19200 38400
57600 115200
Modbus Register Types /Function 01, 02, 03, 04, 05, 06, 08,
Codes used 15, 16
Register Formats Integers, Floats,
Unsigned, Signed, etc.
Slave IDs (Modbus) Starts at 1
IP Address (Modbus TCP)
Parity None Odd Even
No of start bits
No of data bits 8 bits 7 bits
No of stop bits 1 bit 2 bits
Error checking Yes No
Transmission mode e.g. Serial asynchronous,
bi-directional, duplex
Line support e.g. 2 wire twisted pair 2 wire 4 wire
Signal Cabling Details Pin number details
Copper /Single Mode
Fiber
heartbeat
HeartBeat Implementation E.g. register will be
Details incremented periodically
to indicate healthy
communication.
10080-1-SS-CI-017 Page 195 of 203


No. of Slaves connected
Function code used 5,6,15,16 or any other
Are all Boolean inputs are packed
in integer?
Total number of digital inputs
transferred to the DCS
Total number of analogue inputs
Total number of digital outputs
Consecutive Registers Used Consecutive Registers
All Digital Data is Packed Digital Inputs and
Outputs are Packed
Does the Package PLC support
the viewing of its HMI remotely
using Microsoft Windows
Terminal Server or equivalent
10080-1-SS-CI-017 Page 196 of 203

7.2. Data Capture Form-OPC

The MANUFACTURER/SUPPLIER Details
Package Name
Plant Name
PIB Number
Unit Area in Plant
Address
Contact Engineer
Telephone No.
Email address
OPC Client and Server Interface Details
Information Required Project Settings Details from PLC

Is the Server compliant to OPC Yes No
Data Acquisition (DA) Ver. XXX
using asynchronous interfaces?
Is the Client compliant to OPC Yes No
Data Acquisition (DA) Ver. XXX
using asynchronous interfaces?
Is the Client compliant to OPC Yes No
Historical Data Acquisition (DA)
Ver. XXX using asynchronous
interfaces?
Is server compliant to OPC Alarms Yes No
and Events Ver XXX or higher?
Is the OPC Server simplex or Simplex
redundant ? Redundant
serial link
10080-1-SS-CI-017 Page 197 of 203


Does the Server support OPC
Group names in Upper Case only
and limited to 19 characters?
Does the Server support and
export OPC Item names in Upper
Case only and limited to 32
characters?
heartbeat
Does the Server export data in Single Array Non Array
single / non array data types;
Device IP address
DCS can accept/send only the
following variant types
Data Types Supported by DCS
OPC Client
VT_BSTR (Limited to 80 Yes No
characters)
VT_I2 (16 Bit Signed Integer) Yes No
VT_I4 (32 Bit Signed Integer) Yes No
VT_R4 (Real) Yes No
VT_R8 (Internally, DCS converted Yes No
to 32Bit IEEE Float)
VT_BOOL Yes No
Data Types Supported by DCS
OPC Server
VT_EMPTY (Default / Empty Yes No
(Nothing))
VT_I2 ( 2 byte signed integer ) Yes No
VT_I4 ( 4 byte signed integer ) Yes No
VT_R4 ( 4 byte real ) Yes No
VT_R8 ( 8 byte real ) Yes No
10080-1-SS-CI-017 Page 198 of 203


VT_CY ( Currency ) Yes No
VT_DATE ( Date ) Yes No
VT_BSTR ( Text ) Yes No
VT_ERROR ( Error code ) Yes No
VT_BOOL ( Boolean [ TRUE = 1, Yes No
FALSE = 0 ] )
VT_I1 ( 1 byte signed character ) Yes No
VT_UI1 ( 1 byte unsigned Yes No
character )
VT_UI2 ( 2 byte unsigned integer Yes No
)
VT_UI4 ( 4 byte unsigned integer Yes No
)
VT_ARRAY ( Array of values (i.e. Yes No
8200 = array of text values)
Does the PLC Support Yes No
10/100BASE-T
All OPC items are grouped Yes No
logically?
Outputs are Packed
10080-1-SS-CI-017 Page 199 of 203

7.3. Data Capture Form- Profibus

MANUFACTURER/SUPPLIER Details
Package Name
Plant Name
PIB Number
Unit Area in Plant
Address
Contact Engineer
Telephone No.
Email address
Profibus Interface Details

Profibus Version
Device make and model
Supply GSD File for Device
Is the Device Modular, if yes
supply configuration of modules
Repeaters Used, supply make and Yes No
model
What is the Interface standard? e.g. EIA-485
serial link
Slave ID or Address
Supported Data transfer rate e.g. 9600, 19200
Baud
Data Types Used Integers, Floats,
Unsigned, Signed,
10080-1-SS-CI-017 Page 200 of 203

etc.
What Topology is used
Watchdog Supported Yes No
Signal Cabling Type Copper /Single
Mode Fiber
Signal Cabling Details RS485
Outputs are Packed
10080-1-SS-CI-017 Page 201 of 203

7.4. Data Capture Form- Ethernet IP

MANUFACTURER/SUPPLIER Details
Package Name
Plant Name
PIB Number
Unit Area in Plant
Address
Contact Engineer
Telephone No.
Email address
Ethernet IP Interface Details

Model of PLC
Is the Model of PLC simplex or Simplex Redundant
redundant
Are there any sub-ordinate
controllers that are accessed via a
PLC acting as a gateway?
Does the PLC support and export
Tag Name names in Upper Case
only and limited to 32
characters?
heartbeat
PLC IP Address
serial link
Does the Server export data in
single / non array data types;
10080-1-SS-CI-017 Page 202 of 203

DCS can accept/send only the Confirm All
following variant types
Real Input RIN (Float)
Real Output ROUT (Float)
Binary Input BIN (Binary Digit in
LSB of a byte)
Binary Output BOUT (Binary Digit
in LSB of a byte)
Packed Input PAKIN (Signed
Integer 32 bit)
Packed Output PAKOUT (Signed
Integer 32 bit)
Integer Input IIN
(Signed/Unsigned Integer 32 bit)
Integer Output IOUT
(Signed/Unsigned Integer 32 bit)
Does the PLC Support
10/100BASE-T
Outputs are Packed
10080-1-SS-CI-017 Page 203 of 203

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J3 Program 10080-1-SS-CI-017

Distributed Control System Date: 30/07/2012, Rev. 0

Date Revision Details Revision

30/07/2012 Issued for implementation 0

Attachment-5: Instrument Asset Management System (IAMS) ............................................ 147

10080-1-SS-CI-017 Page 1 of 203

the project on behalf of OWNER.

FNICO Fieldbus Non-Incendive Concept

10080-1-SS-CI-017 Page 3 of 203

SDS Software Design Specification

7. Codes and Standards

IEC 60617 Graphic Symbols for Electronic Diagrams.

IEC 801.4 Electromagnetic Compatibility for Industrial Process

ISA S5.2 Binary Logic Diagrams for Process Operations

10080-1-SS-CI-017 Page 4 of 203

ISA 71.01 Environmental Conditions for Process Management

FF-569 Foundation™ Fieldbus Host Interoperability Test

ANS/ISA RP55.1 Recommended Practice – Hardware Testing of Digital

ANSI/ISA R99.00.02 Integrating Electronic Security into the Manufacturing

NE-43 Standardization of signal level for the breakdown

10080-1-SS-CI-017 Page 5 of 203

IEC 61158 Digital data communications for measurement and

IEEE 802.3 Communication Standard: Defines carrier sense

22 ± 2 °C and 50% ± 6% non-condensing Relative Humidity.

Air flow shall be from bottom to top for cabinet design.

10080-1-SS-CI-017 Page 6 of 203

8.9. Ambient Lighting

10080-1-SS-CI-017 Page 8 of 203

Interconnecting cabling between various DCS equipment in the Control Room.

10080-1-SS-CI-017 Page 9 of 203

OPC server with software.

10080-1-SS-CI-017 Page 11 of 203

MANUFACTURER/SUPPLIER’s equipment cabinets, consoles and termination

10080-1-SS-CI-017 Page 12 of 203

the MANUFACTURER/SUPPLIER. Internally mounted equipment shall be clearly

10080-1-SS-CI-017 Page 14 of 203

Panel internal wiring colour coding shall be as below

240V AC Utility (L)

24V DC(Analogue and Digital) Light Grey

Wiring between terminal block and IS

Wiring for non-IS signals

10080-1-SS-CI-017 Page 15 of 203

10080-1-SS-CI-017 Page 16 of 203

10080-1-SS-CI-017 Page 19 of 203

Marshalling rack : 20%

10080-1-SS-CI-017 Page 20 of 203

10080-1-SS-CI-017 Page 22 of 203

It shall be possible to utilize standard commercial off-the-shelf Ethernet switches to

10080-1-SS-CI-017 Page 24 of 203

10080-1-SS-CI-017 Page 25 of 203

Two basic configurations of Ethernet cables shall be used:

10080-1-SS-CI-017 Page 27 of 203

The input / output sub-system shall be capable of providing software

Accuracy - 0.1% of full scale

10080-1-SS-CI-017 Page 29 of 203

When a control algorithm's input is declared invalid, it shall be possible to configure

Wireless Instrumentation shall be considred for non critical open loops.

10080-1-SS-CI-017 Page 31 of 203

10080-1-SS-CI-017 Page 32 of 203

PID with dead time.

General Description (Overview of application, a sketch of the application with all

10080-1-SS-CI-017 Page 38 of 203

10080-1-SS-CI-017 Page 39 of 203

Utility program access.