Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Asset Management System (AMS) Document No.: 192-YER-PE-I35-0009 Revision No.: FF Issue Date: 24 April 2008

TABLE OF CONTENTS 1.0 2.0 2.1 2.2 3.0 3.1 3.2 3.3 3.4 4.0 4.1 4.2 5.0 6.0 7.0 PURPOSE................................................................................................................... 3 SCOPE........................................................................................................................ 3 General........................................................................................................................ 3 Deliverables................................................................................................................. 4 REFERENCE DOCUMENTS & STANDARDS ........................................................... 4 Conflicting Requirements ............................................................................................ 4 YERP Reference Documents...................................................................................... 5 Saudi Aramco Engineering Standards ........................................................................ 5 Project Specification and Drawings............................................................................. 5 DEFINITIONS & ABBREVIATIONS ............................................................................ 5 Definitions.................................................................................................................... 5 Abbreviations............................................................................................................... 6 OPERATING AND RISK AREAS ................................................................................ 7 FUNCTIONAL REQUIREMENTS ............................................................................... 7 MAINTENANCE SHOP SYSTEM & TOOLS............................................................... 8

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Asset Management System (AMS) Document No.: 192-YER-PE-I35-0009 Revision No.: FF Issue Date: 24 April 2008

1.0

PURPOSE The purpose of this specification is to provide technical requirements for an Asset Management System (AMS) for the Yanbu Export Refinery Project (YERP), Saudi Arabia. The Yanbu Export Refinery Project (YERP) is the development and installation of a new Grassroots full conversion refinery in the Kingdom of Saudi Arabia that will process Arabian Heavy Crude into gasoline, diesel, and LPG products. As currently defined, the refinery will also modify existing terminal facilities for import of crude feed and export of products. The refinery will be located in Yanbu Industrial City on the west coast of Saudi Arabia on the Red Sea. The entire project includes refinery process units, utilities and interconnecting piping, associated feedstock and refined product storage/logistics facilities, as well as the offsite services necessary to support the safe and efficient operation of the refinery. The selected configuration is a Full Conversion scheme with a Hydrocracker Unit and a Delayed Coker Unit. The plant life or project life is assumed to be 25 years. The facility is designed for 92% Plant-wide uptime (availability) with 95% unit availability for defined areas. Process units within the refinery may be designed for up to a 5 year turnaround cycle.

2.0 2.1

SCOPE General An Asset Management System (AMS) shall be provided by the Main Automation Contractor (MAC) for device configuration, documentation, calibration, and diagnostics. The AMS shall continuously monitor the status, events and operating conditions of all field connected devices to provide an efficient condition-based maintenance solution. AMS is sometimes also referred to as a Plant Resource Manager (PRM). The AMS shall be an integral part of the Process Automation System (PAS) provided by the MAC. MAC is responsible to fully furnish the AMS including, but not limited to, design, engineering and configuration of the database. Field Instruments shall be purchased by EPC CONTRACTOR(s) and shall include Foundation Fieldbus and Smart/HART type instruments. The selected PAS and AMS Solution must support FDT/DTM based device diagnostics. The MAC will provide Asset Management System (AMS) for field instrumentation diagnosis, as well as predictive maintenance (failure prevention) of process equipment related to the PAS. AMS Solution must be able to access and
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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Asset Management System (AMS) Document No.: 192-YER-PE-I35-0009 Revision No.: FF Issue Date: 24 April 2008

monitor the DCS, ESD, FGS, VMS, ENMCS and CMS systems. EPC Contractor(s) shall provide the details of third party systems for MAC to check the feasibility of integration. The AMS shall offer a configurable environment to provide alarms and messages based on combinations of sensed conditions including device errors etc. Running hours and time in service to be implemented in DCS or DAHS. The MAC shall comply with AMS requirements specified in YERP-SAES-J-904. 2.2 Deliverables The Asset Management System shall manage all of the Smart Field Device assets in the plant and shall ensure that all parts of the system are included. The system shall include the following as a minimum: Centralized AMS server for Engineering Room in CCB. AMS clients in each Engineering Workstation All required hardware and software, including transmitter diagnostics. MAC shall quote following plug-ins for control valves as an option: o o o o VALVELINK FF/HART Plug-in Application for Fisher Valve Positioners ValVue FF Plug-In Application for Dresser Valves Positioners ValVue HART Plug-in Application for Dresser Valves Positioners ValveNavi FF Plug-in Application for YVP Positioners

Generic configurator for all smart devices to allow end user access to diagnostic functionality over and above what is defined by the FF or HART Foundations.

The MAC shall ensure that AMS database is fully populated with device data for all devices in the PAS during site pre-commissioning. A list of all MACs AMS compatible third party applications allowing for enhanced AMS functionality in the host system shall be supplied by the EPC Contractor(s). 3.0 3.1 REFERENCE DOCUMENTS & STANDARDS Conflicting Requirements Any conflict between this document and any other project specification, or Saudi Aramco standards/specifications, shall be brought to the attention of the YERP PMT for resolution.

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Asset Management System (AMS) Document No.: 192-YER-PE-I35-0009 Revision No.: FF Issue Date: 24 April 2008

3.2

YERP Reference Documents The design, materials and construction of the equipment described herein shall comply with references listed below which are considered part of this specification.

3.3

Saudi Aramco Engineering Standards YERP-SAES-J-904 FOUNDATION Fieldbus (FF) Systems

3.4

Project Specification and Drawings 192-YER-PE-I35-0001 192-YER-PE-I35-0002 192-YER-PE-I35-0003 192-YER-PE-I35-0011 192-YER-PE-I35-0015 192-YER-PE-I35-0023 Main Automation Definition Contractor (MAC) Scope

Project Specification For Process Automation System Project Specification For Contractor Supplier Services Main Automation

Project Specification For Foundation Fieldbus Project Specification For Wireless Infrastructure and Applications Process Automation System Architecture Drawing

4.0 4.1

DEFINITIONS & ABBREVIATIONS Definitions Company Project Management Team (PMT): The Company Project Management Team (PMT) is the group responsible for the management of the entire project and is dedicated to the overall success, development and execution of the work and to ensure alignment across the numerous project interfaces. The PMT consists of Aramco Services Company and ConocoPhillips team members, partner(s), agency personnel, and contractors. These project management resources will form a cohesive, seamless team responsible for the project execution.

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Asset Management System (AMS) Document No.: 192-YER-PE-I35-0009 Revision No.: FF Issue Date: 24 April 2008

Saudi Aramco (SA): Saudi Aramco as used in this procedure shall mean Saudi Arabian Oil Company and its affiliated companies, including, but not limited to Aramco Services Company. ConocoPhillips (COP): ConocoPhillips as used in this procedure shall mean ConocoPhillips Company and its affiliated companies, including but not limited to ConocoPhillips Yanbu Ltd. Yanbu Export Refinery Project (YERP): The Yanbu Export Refinery Project (YERP) as used in this procedure, shall also mean the Yanbu Export Refinery Company and its affiliated companies. It is also named as the COMPANY. Contractor or Contractors: Any Design, Construction or Service Contractor(s); Manufacturer(s); Vendor(s); Government Agencies; and other similar organization(s) having a contractual relationship or a prospective contractual relationship with the Company. When used in this or referenced documents the following words are used in the manner described below: Shall and must are used in the imperative sense. Will is used in the preferred sense. May is used in a permissive sense to state authority or Permission to do the act prescribed or provide the function being defined in the prescribed manner, and the words no person may. Or a person may not. mean that no person is required, authorized, permitted to do the act prescribed, and the words a may not . mean that the item being described is not required, authorized, or permitted in the prescribed manner. Includes means includes but not limited to.

4.2

Abbreviations AMS CCB CDR CMS DCS DTM ENMCS ESD Asset Management System Central Control Building Critical Design Review Condition Monitoring System Distributed Control System Device Type Management Electrical Network Monitoring and Control System Emergency Shut Down (also referred to as a Safety Instrumented System SIS)
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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Asset Management System (AMS) Document No.: 192-YER-PE-I35-0009 Revision No.: FF Issue Date: 24 April 2008

FDT FF FGS HART MTS PAS PRM RFID SAT VMS 5.0

Field Device Tool Foundation Fieldbus Fire and Gas System Highway Addressable Remote Transducer Maintenance Training System Process Automation System Plant Resource Manager Radio Frequency Identification Site Acceptance Test Vibration Monitoring System

OPERATING AND RISK AREAS Operating and Risk Area segregation shall be as defined in the Main Automation Contractor (MAC) Scope Definition (192-YER-PE-I35-0001). The operational philosophy for the YERP facilities shall be based on operating areas for monitoring, control and alarm management, with each area operated by a dedicated board operator. For the purpose of maintaining plant production during maintenance periods and to mitigate against loss of production due to a major incident or catastrophic failure of equipment; the plant process and utility equipment has been divided on a plant geographical basis known as Risk Areas.

6.0

FUNCTIONAL REQUIREMENTS The MAC shall ensure full functionality of the Foundation Fieldbus and Smart/HART parameters to the AMS during site pre-commissioning instrument monitoring system with the various types of the devices supplied by the EPC Contractor(s). EPC Contractor(s) shall obtain a list of devices that have been successfully tested with the host system/AMS (HIST TEST) from the MAC before selecting devices. The Asset Management System shall be integrated with the PAS and shall collect diagnostics data from the Smart devices. All diagnostic information shall be available at each AMS client station.

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Asset Management System (AMS) Document No.: 192-YER-PE-I35-0009 Revision No.: FF Issue Date: 24 April 2008

The AMS shall be capable of managing wireless operator tablet and RFID device information. Configuration shall be done at any client workstation with proper password protection. The AMS system shall be capable of providing an audit trail for all Smart device maintenance operations. The Asset Management System shall be a server/client application supporting access by remote thin clients. Alarm and status messages shall be individually configurable to where they are directed (operations, maintenance) via e-mail or paging. YERP PMT and MAC shall define, prior to CDR, a list of device alerts that shall be configured to be automatically sent to operations and maintenance personnel. AMS shall be designed for import and export of information to/from SmartPlant Instrumentation. Alternatively, the AMS 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), which will be provided by EPC contractor(s), shall be loaded into the AMS database and verified during SAT. The Asset Management System shall support local and remote analysis, trending, diagnostics and predictive maintenance on the smart positioners. 7.0 MAINTENANCE SHOP SYSTEM & TOOLS This shall form part of the Maintenance Training System (MTS) covered under 192-YER-PE-I35-0013. The MAC shall be responsible for supplying a complete AMS maintenance system. The intent of this maintenance system is to allow AMS instrument troubleshooting, calibration, and setup in the Instrument Maintenance shops. The Maintenance AMS system will include all system hardware, software, and auxiliary equipment required to connect and maintain the AMS system and devices in the shop. Equipment shall include a sample of all AMS related PAS hardware and software with Operator/Engineering workstations, control network with appropriate switches, chassis with controller & power supplies, power supplies. The I/O chassis, power supplies, wiring and terminal blocks will be prewired and installed in an easy to access, caster mounted cabinet. EPC Contractor(s) shall supply device FF Device couplers for mounting by MAC.

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Asset Management System (AMS) Document No.: 192-YER-PE-I35-0009 Revision No.: FF Issue Date: 24 April 2008

The MAC shall supply, as required, all standard, test software, and test and calibration equipment required for the AMS system. EPC Contractor(s) shall supply special tools or testers special to the devices. A list of the above tools, test and calibration equipment shall be submitted to YERP PMT for review and approval. Standard maintenance tools and equipment, defined above, are available from standard catalogs. The list of the standard tools and testing and calibration equipment required shall identify the following: Description of its service or simulation application. Manufacturer and Catalog No. Quantity recommended.

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