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PT.

Petrokimia Gresik

GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER

Project / Job No: 32-RKAP-2011 Document No: 34-JI-01-04-2000-10

Revision 3

Sheet No : 38 Sheets (w/ Cover)

Job/Project Title : RETROFIT SYSTEM CONTROL CCR PABRIK III WITH PLC SYSTEM Client : DEPARTEMEN JASTEKON Location : PABRIK III

3 2 1 0 REV.

Issued Issued Issued Issued

For Construction For Construction For Construction For Approval

29 April 2011 10 Maret 2011 1 Maret 2011 1 Februari 2011 DATE

RWY RWY RWY PREPARED

SOL SOL SOL CHECKED

AF AF AF APPROVED

DESCRIPTION

Engineering Department PT Petrokimia Gresik

PT Petrokimia Gresik

GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER

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Revision 3

LIST OF REVISION
General Revision
Revision No. 0 1 2 3 Revision Date 1 Februari 2011 1 Maret 2011 10 Maret 2011 29 April 2011 Issued Issued Issued Issued Remarks For Approval For Construction For Construction For Construction

Detail Revision
Revision No. 1 2 Page/sheet 3, 5, 13, 14, 22 and 23 of 27 3, 13, 31 and 32 of 37 3, 13, 32 and 37 Revision Date 1 Maret 2011 14 Maret 2011 Remarks Sesuai Risalah Rapat Aproval no: 014/01.02/32/RR/2011 tgl 21 Februari 2011 Sesuai surat Kakomp Pabrik III no. 26/PR.00.01/47/MI/2011 tanggal 14 Maret 2011 Sesuai Risalah Rapat Aproval no: 019/04/TK.00.04/38/RR/2011 tgl 19 April 2011.

29 April 2011

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GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER

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CONTENTS

PARAGRAPH

PAGE

1 2 3 4 5 6 7 8

GENERAL CODE AND INDUSTRY STANDARD DESIGN AND MATERIALS MMI (MAN MACHINE INTERFACE) TEST AND INSPECTIONS PAC & MMI TRAINING COMMISSIONING SPARE PARTS SYSTEM CONFIGURATION

3 4 4 17 34 35 36 36

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1.

GENERAL 1.1 This specification covers the common and fundamental technical minimum requirements for the supply, design, programming, configuration, materials fabrication, and testing of the Programmable Automation Controller (PAC) for the RETROFIT SYSTEM CONTROL CCR PABRIK III DENGAN PLC SYSTEM project. 1.2 The Contractor must provide a complete and operable control, interlock and shutdown system in accordance with this specification including all accessories for erection, commissioning, maintenance and spare parts. 1.3 The PAC including all hardware and softwares to meet the requirements detailed in this specification and/or specified in the instrument data sheet is the Contractor responsibility. 1.4
3 2

Programmable Automation Controller (PAC) must be applied to control, interlock, shutdown system and start/stop sequence of the PA and CR plant.

1.5

The CPU (Central Processing Unit), Communication Module and Power Supply Module must be Redundant System. The I/O module for loop control and critical equipment must be redundant. The critical equipment shall be decided on I/O list document.

1.6

The PAC vendor must design, configure, program, install, start up assistant and supervise the PAC and MMI for control dan interlock plant operation. The memory capacities, software licenses, CPU scanning time, CPU load and others for these requirements shall be PACs vendor responsibility.

1.7

The total amount I/Os must be subject to these approved P&ID, control loop, interlock system, sequence and monitoring.

1.8

The PAC Vendor must configure the PAC System. Instrument engineer, process engineer and maintenance must be involved in the configuration work.

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2.

CODE AND INDUSTRY STANDARD 2.1 The document listed below is referenced herein and form part of the order. Applicable issues of Codes and Industry Standards are indicated below: a. b. c. d. National Electrical Manufacturer Association ( NEMA ) NEMA ICS 6-83 : Enclosure for Industrial Control and System NFPA 70-87 IEC 61131-1/2 : National Electrical Code : Programmable Controllers General Information,

Equipment Requirements and Tests. e. IEC 61508 : Functional safety of electrical / electronic /

programmable electronic safety-related systems. f. g. h. i. ISA S 5.1 ISA S 5.2 ISA S 5.5 ISA S 71.04 : Instrumentation Symbols and Identification : Binary Logic Diagrams for Process Operation : Graphic Symbols for Process Display : Suitability of Electronic Equipment in Corrosive Gas Environment j. k. l. m. n. 3. ISA S 72.1 : LAN Industrial Data Highway

National Electrical Code (NEC) Instrument Society of America (ISA) American National Standards Institute (ANSI) Industrial Electronic Control (IEC)

DESIGN AND MATERIALS 3.1 General 3.1.1 Dual modular fully redundancy Programmable Automation Controllers must be applied for particular control system and supervision tasks. The Controller must be capable of executing the following command functions:
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GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER


a. Latches b. Logic functions c. Timer functions d. Counter functions e. Comparison functions f. Totaliser
1

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h. Sequencing j. Limit value functions k. Arithmetic functions l. Proposal, Integral & Derivative. m. Advanced Proportional, Integral & Derivative

3.1.2

The system must be designed for fail safe operation and maximum reliability, flexibility and serviceability. All the module of the PAC must be able to be replaced online without shutdown and

disturb performance of the system. All modules must be possible to be replaced without interfering with the external wiring. 3.1.3 The PAC must have the features below but not limitted to: a. Bumpless-balanceless transfer (Controller must not be Hot Standby System) b. Anti reset windup c. Auto manual switching

d. Cascading with process variable tracking e. Initialisation are contained in standard algorithms 3.1.4 The PAC must be multiple input and output arrangement, immunity to electrical noise and resistance to vibration and impact. 3.1.5 The CPU, Communication modules and I/O must be able to be removal and insertion under power. 3.1.6 PAC Central Processing Unit (CPU) and I/O must be suitable for mounting in non hazardous control room environment. Ambient temperature range is 25 to 45 C at 60 to 95 % relative humidity. The PAC modules must be corrosive coated and if required for outdoor usage must be covered with dust proof enclosure.
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3.1.7

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Power Supplies must be self cooled and be provided with indication of proper operation of the system. The PAC inside temperature must be indicated and alarmed on MMI.

3.1.8

Power is available at 110 VAC, 50 HZ from UPS, unless otherwise specified in the Individual Specification for Programmable

Automation Controller. 3.1.9 The PAC must have screw terminations for the wiring connections. Terminal must be marked for polarity, test connection, etc., and must be protected against accidental contact. The controller located in the control cabinets racks and with to must be

be mounted in expansion

manufacture's

standard

size

modular

capabilities. The control cabinet must house the power supply unit, CPU, interfaces and I/O modules. The cooling fans must be provided in the system cabinets. 3.1.10 Design and materials not specified must be in accordance with manufacturers standard suitable for the operating and design conditions specified on the Instrument data Sheet. 3.2 Central Processing Unit (Redundant) 3.2.1 The Redundant CPU modules must be of the plug-in type. The processor must be mechanically and electrically isolated. Each module must provide protection against overload current and line voltage spikes. 3.2.2 The CPU must retain memory in the event of power failure or internal malfunction. 3.2.3 The RAM must have their own battery backup with lithium batteries with the backup time must not less than 30 days.
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3.2.4

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The PAC Systems CPU memory must be provided with minimum 64 MB and PAC System User Flash Memories must have minimum 64 MB, or higher for future requirements.

3.2.5

Permanent self-monitoring functions must be included in case of failure of CPU, memory module, I/O module and etc.

3.2.6

In case of power supply interruption, automatic restart of the CPU must be provided without operator interference.

3.2.7

The system must include diagnostic capability for identifying the failure down to the card level, communication bus, module level and monitoring workstation.

3.2.8

The controller must perform the error checks such as bus structure, memory and power supply modules.

3.2.9

Sufficient logic inside the I/O module must be provided to diagnose the component or communication failure and also able to shutdown the I/O module independently.

3.2.10 The PAC must be capable of executing the user logic minimum in 10 times per second. 3.2.11 The CPU load conditions must be as follows: a. Peak load condition : : less than 50% of available capacity less than 40% of available capacity

b. Normal load conditions

3.2.12 The processing time of particular controller must be dedicated to the requirement of controlled technological process and maximum

processing time including input operation, logic or function processing and output operation must not be exceed the following limits: a. Closed loop control: 250 msec 150 msec

b. Open loop control :

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3.2.13 Full system synchronization. Link module synchronizes CPU (Primary & Secondary) at beginning and end of each logic scan execution to keep all variable data in the same-providing rapid and bumpless switchover. 3.2.14 PAC systems high-speed memory sharing enables multiple device to transfer up to 20 times faster than Ethernet (2.12 Gbit/s). The use of fiber optic connections allows to easily operate in high-noise areas and cover large distances in real time; a manual toggle switch enables to easily change control between primary and secondary units. 3.3 I/O Module Requirements 3.3.1 In general, inputs and outputs of particular technological process system must be grouped. The I/O modules must be plug-in type with easy module removal without disturbing field wiring. 3.3.2 The I/O module must be configured, replaced or added in online (without shutdown the system) or disturb the current system 3.3.3 The failure of one particular I/O module must be kept isolated to that technological process system and must not cause any

disturbances to the other systems. 3.3.4 The spare inputs and outputs must be provided minimum 20% of I/O type installed or at least 1 (one) of each kind of types. 3.3.5 All individual I/O channel must be electrically isolated from the main frame CPU and the internally used circuits. 3.3.6 The I/O Module must be provided with protection against overload current and line voltage spikes. 3.3.7 The I/O type, operating voltage and quantity must be specified on the Instrument data Sheet. 3.3.8 All individual I/O channel and CPU must be grounded external to PAC.
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3.3.9

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Total amount of the I/O point capacity must be subject to the approved P&ID, interlock system, tripping system and its equipment protection system.

3.3.10 The minimum noise rejection capability for the digital inputs must be as follows: 3.3.10.1 120 dB from DC to 50 Hz and 1000 ohms unbalance for Common Mode. 3.3.10.2 60 dB at 50 Hz for Normal Mode.

3.3.11 The equipment must be immune to electro-magnetic and radio frequency interference from devices operating 1.2m away and at frequencies up to 470 MHz and with power outputs up to 5 watts. 3.3.12 Redundant I/O LAN must be provided to connect each I/O backplane. Each I/O backplane must be completed with redundant power supply, redundant communication module and redundant hub switch LAN. 3.3.13 The following I/O modules must be provided but not be limited to: 3.3.13.1 Analog input module 3.3.13.1.1 The standard analog input signal must be 4-20 mA DC corresponding to the range of 0-100%. 3.3.13.1.2 The system must be capable of accepting 100 ohm Platinum RTDs, Type E (chromel-Constantan) and type K (chrome-Alumel) thermocouples, contact closure and pulse input. 3.3.13.1.3 The analog input signal must be monitored on the life-zero, which means that alarm must occur if

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GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER


21 mA.

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the input signal is less than 3.9 mA or more than

3.3.13.1.4 The particular analog input must be isolated from the others and from ground in order to avoid erroneous signals caused by ground loops. 3.3.13.1.5 The resolution of analog to digital (A/D)

conversion must be minimum 12 bits. 3.3.13.1.6 Each of analog input module must be automatically calibrated using multiple reference voltage. 3.3.13.1.7 Input signal from the field must be 4 to 20 mA DC at nominal 24 VDC power and fully isolated as defined in ISA S 50.1. Controller must be capable of driving output above 20 mA and below 4 mA. 3.3.13.1.8 Line Fault Detection, each channel can be

configured to sense both open and short circuit conditions on inputs. On detection, the actions are those for the high/low alarms. 3.3.13.2 Digital input module 3.3.13.2.1 In general, 24 Vdc must be used for digital input signal voltage. The input module must be noiseproof and the external signal voltage must be insulated from the internally used voltages. 3.3.13.2.2 The input modules must also be provided with over voltage protection. 3.3.13.2.3 The input status must be indicated with LED on the front face of modules.

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3.3.13.2.4 The input voltage range corresponding to binary 0 signal must be 0 Vdc. 3.3.13.2.5 The input voltage range corresponding to binary 1 signal must be 24 Vdc. 3.3.13.2.6 Each channel must have line fault detection, this shall cause a flag to be set to indicate a short or open circuit fault. 3.3.13.3 Digital output module 3.3.13.3.1 In general, 24 Vdc must be used for digital output signal voltage. The output modules must be shortcircuit protection and the external signal voltage must be insulated from the internally used voltage. 3.3.13.3.2 The output modules must also be provided with over voltage protection for induced surge voltage caused by the switching of inductive loads. 3.3.13.3.3 The rated output current must not less than 24 Vdc and output status must be indicated with LED on the front face of modules. 3.3.13.3.4 Each channel must have line fault detection. This shall cause a flag to be set to indicate a short or open circuit fault even when channel output is in OFF state. 3.3.13.4 Analog output module 3.3.13.4.1 The standard analog output signal must be 4-20 mA DC corresponding to the range of 0100%. The particular analog output shall be
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isolated from the others and from grounding order to avoid erroneous signals coursed by ground loops. 3.3.13.4.2 The resolution of digital to analog (D/A)

conversion shall be minimum 12 bits. 3.3.13.4.3 I/O module must be fully isolated as defined in ISA S 50.1. 3.3.13.4.4 Line Fault Detection, each channel can be

configured to sense both open and short circuit conditions on inputs. On detection, the actions are those for the high/low alarms. 3.4 Diagnostic 3.4.1 The PAC shall employ continuous diagnostics in order to verify the system status and to revert to back-up systems without delay. Diagnostics shall be capable of identifying a degradation or failure in the following items as a minimum: a. Rack backplane data bus

b. Rack power supply modules and power rails c. Battery failure or low voltage (as applicable)

d. Processor hardware (including memory cards, EEPROM, etc.) e. Communications module hardware f. g. I/O card (module) failure I/O point (channel) failure

h. Incorrect card type inserted (I/O card) i. j. Program halt Control network failure (inter rack communications)

k. Data Highway failure including switches


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3.4.2

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All monitored faults shall be reported to the HMI wherever possible assuming that a means of communication remains viable, as a minimum, a common failure alarm shall be generated at the HMI regardless of the nature of the fault or component.

3.4.3

The system shall be configured such that a total failure of the system shall automatically initiate a Process Shutdown (PSD) via the ESD System.

3.5

Overall System 3.5.1 The PAC must have minimum listed as below: 3.5.1.1 3.5.1.2 3.5.1.3 3.5.1.4 3.5.1.5 3.5.1.6 3.5.1.7 Redundant CPU (Central Processing Unit) Redundant Backplane Mounting (For Redundant Module) Redundant Power Supply Module electrically isolated. Redundant Regulated Power Supply for PAC Redundant Network Module Redundant Communication Bus (Remote I/O) Buffer Relays operated at 24 Vdc for all Contact Inputs and Outputs.

3.5.1.8 3.5.1.9 3.5.1.10 3.5.1.11 3.5.1.12 3.5.1.13

Fuse block for all Analog Signal Input and Outputs. Analog Input Module Analog Output Module Digital Input Module Digital Output Module Redundant I/O Module for loop and critical process and equipment

3.5.1.14 3.6 Software Requirements

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3.6.1

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The PAC must provide configuration software which allows process control strategy development for Function Block Diagrams (FBD), Instruction List (IL), System Function Calls (SFC), Structure Text (ST) and Ladder Diagram (LD) complying. The development, testing and documentation software must be complied with IEC61131.

3.6.2

The system must be capable of adapting to program changes without affecting the hardware. Programs must be protected from accidental changes by use of passwords or keylock switches.

3.6.3

The Logic Programming and I/O Configuration printout capability must be provided, unless otherwise specified.

3.6.4

Software must be provided to record the user logic programming on DVD or CD.

3.6.5

Software Revision 3.6.5.1 All software must be the latest version. Prior the shipping, if the manufacturer has released a new version/revision, the software provided must be replaced with the new one.

3.6.6

Advanced PID 3.6.6.1 PAC software must have PID controller function types as below but not limited to: 3.6.6.1.1 P control, I control, PI control, PD control and PID control algorithm. 3.6.6.1.2 ON-Off Control Action, Linier Output Control, Closed Loop Valve Control, Open Loop Valve Control, PID with Feed Forward, etc.

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3.6.6.2

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PLC software must accommodate all continuous process control, monitoring, recording, alarm, report, interlock, sequence, shutdown system and etc.

3.6.6.3

Auto tuning PID facility must be included and be standard PAC software itself. Auto tuning facility must not be as added software/program (from other brand software). It must be proprietary by PAC system.

3.6.6.4

Auto tuning PID must have some essential qualities: 3.6.6.4.1 The auto-tuning PID is easy to use. The

parameters that the user must entered are selfexplanatory. 3.6.6.4.2 The auto-tuning sequence is not too long and does not disturb too much the production. During this time, the process must remain in closed-loop control. 3.6.6.4.1 The auto-tuning PID is able to deal with different types of dynamics: processes with and without a delay, processes with zeros (minimal and nonminimal phase), integrating processes, etc. 3.6.6.4.2 The performances of the loop are improved by the use of the auto-tuning. The loop must also be robust to process behavior changes. 3.7 Communication Interface 3.7.1 The following interfaces must be provided but not be limited to: 3.7.1.1 Data gateway interface 3.7.1.1.1 In case of particular controller is part of the plant control system, the complete duplicated

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data gateway interface must be provided for signal exchange with the communication speeds of 10/100 Mbps/sec. 3.7.1.1.2 RS 232 / RS 485 interface must be provided for off-line configuration, reprogram and

troubleshooting of the PAC. 3.7.1.1.3 The standard RS 232 / RS 485 interface module must generally be provided including all necessary hardware and software with D type connector. 3.7.1.1.4 The Local Area Network (LAN) must be a high speed, bi serial communication bus. 3.7.2 A Network Communication Module must be available to transfer data, which is capable of peer-to-peer communication with system PACs and external hosts over IEEE 802.3 networks as well as supporting TCP-IP/UDP-IP protocol. 3.8 System security 3.8.1 A method of securing access to the operating and system engineering functions of the plant systems / sub-systems must be provided. The objective of this method must be to safeguard plant operation, prevent unauthorized and unqualified personnel from accessing the plant systems / sub-systems. 3.8.2 3.8.3 Operator access must be through the use of user ID and password. Operator access through key from the Operator Keyboard must also be provided. 3.8.4 Key access must have privilege to the user login through User ID and password.
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3.8.5 have distinct key.

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Two access levels must be provided with the key. Each level must

3.9

Power Supply 3.9.1 Available Electric Power Supply from source must be nominal 110 VAC 50 Hz from UPS. 3.9.2 Connection from the MCB panel the instruments must be made with no. 14 AWG stranded Copper, or bigger size as required. 3.9.3 Each instrument must have individual disconnect switch. The contractor must prepare Power Distribution Panel and be placed in CCR.

3.10 Logic Programming 3.10.1 Vendor must provide all necessary hardware, cables, and software necessary for the maintenance to implement the user logic

programming. 3.10.2 Programming Software must be furnished on Floppy Disks and Compact Disk. 4. MMI (MAN MACHINE INTERFACE) 4.1 Display/Graphic System Requirements 4.1.1 General The HMI shall be configured to provide many types of displays and schematics for the process, shutdown, start-up, control, indicator, etc, dependent on which display is selected. 4.1.2 Operating Displays The system shall make available to the operator at least two (2) categories of displays - process displays and system displays. Process
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displays shall be those displays used to monitor and control the process. System displays shall be those displays used to view system status and assignments, and make limited changes to the system, such as starting or stopping a node or process connected box. All displays shall be available for display on any HMI. 4.1.3 Process Displays 4.1.3.1 Group Displays - shall be a single page display showing the values and status of the primary operating parameters in both numeric and graphic (bar) form for up to eight (8) display points. 4.1.3.2 Any data point shall be capable of being assigned to one or more groups. A minimum of 400 usable groups shall be

available per operator console. 4.1.3.3 The operator shall be able to make process changes to any of the points assigned to this display (e.g., setpoint, mode, output, etc.) based on their configured scope of

responsibility. Additional group displays shall be accessible by depressing forward and backward display keys. 4.1.3.4 Point Detail Display - A unique, operator viewable, detail display shall exist for every point in the system, This

automatically built as a byproduct of point building.

display shall consist of one or more pages, and shall characterize every parameter and attribute of the data point. The individual data point shall be capable of being manipulated from this display. The detail display shall include an automatic link to a dynamically updating graphical view of the control configuration for the point.
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4.1.3.5

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Trend Displays - shall supply a graphical presentation of historical process data, for up to 32 point parameters simultaneously on an x-y axis. Additionally, the following

trend functions/types shall be available: 4.1.3.5.1 X-Y plot any two analog point/parameters configurable. 4.1.3.5.2 Numeric history shall be optionally viewed with the real-time trend. 4.1.3.5.3 Trend with Events event data shall be available on the real-time trend to allow for analysis of process events. 4.1.3.5.4 A legend shall be available to provide detail on a configured point parameter. The legend shall be able to be hidden to provide maximum screen real estate for the trend. 4.1.3.5.5 Auto scaling feature for a selected point

parameter or for all point parameters configured for a trend. 4.1.3.5.6 4.1.3.5.7 Standard and user-configurable time ranges. Seamless review of historical data (even when pulled from archived data) on the same trend used for real-time data. 4.1.3.6 The following history sample intervals shall be userselectable for all trend types: 4.1.3.6.1 1 second, 30 second, 1 minute, 1 hour, 8 hour and 24 hour snapshots 4.1.3.6.2 6 minute, 1 hour, 8 hour and 24 hour averages

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4.1.3.7

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The range for each trended parameter, normally the Y-axis (but also the X-axis for X-Y plots), shall be operatorselectable. The value shall be displayed as a percent of range (0-100%) or as fixed engineering unit values, either unipolar or bipolar. Each trend trace shall have a user-selectable color.

4.1.3.8

Trends shall support hairlining to accurately determine the value of a particular trace at a specific point in time.

4.1.3.9

It shall be possible to scroll the Y (usually time) axis forward and backward. It shall also be possible to scroll the X (usually parameter value) axis up and down.

4.1.3.10

Trends shall support rubber-band zooming and simple zooming (clicking on a button to zoom in and out in steps) with the ability to return to normal size by selecting a screen target.

4.1.3.11

The operator shall be able to configure trends on line and save them by name, so that they may be attached to a trend menu or recalled by name.

4.1.3.12

It shall be possible to call up a Group Trend display directly from a Group display, automatically trending each point in the group with the point PVs automatically selected as the trended parameter. It shall be possible to revert back to the original Group display with a single screen target action or menu selection.

4.1.3.13

It

shall

be

possible

to

add,

delete

or

modify

point/parameters, trace colors, displayed value range, time range, with an immediate update and redrawing of the trend by the HMI.
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GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER


4.1.3.14 the changes. 4.1.3.15

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User changes to any trend require a specific action to save

Hourly Averages - shall display the last 10 hourly averages for the points of the selected group display in tabular form, including the corresponding clock times. The points shall be easily identified by both point ID and descriptor.

4.1.3.16

Help Displays - shall be displays that provide detailed operational information to the operator about a particular function. These displays shall be context sensitive, and be preconfigured for standard engineering functions; or defined by owner and built for custom or configurable displays (e.g. custom schematics). Vendor shall state the number of help displays available. The user shall have the capability of

defining a specific "help" display to be called whenever any custom graphic is on the HMI and the help key is pressed. 4.1.3.17 Schematics shall be provided detailing a particular area of the process or overviews of the generating unit and all its subsystems. 4.1.3.18 Values shown on schematics shall normally be updated on a four (4) second interval to optimize the ergonomic interface to the operator (e.g. minimize eye strain and fatigue). However, it shall be possible to modify the update rate of each object on the schematic from 1 second to every 24 hours. 4.1.3.19 Schematic displays shall be built as HTML pages that are based on the Web-standard Document Object Model (DOM), suitable for calling up in the meeting room Dept.Pemeliharaan
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GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER

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III or Internet Explorer Web browser on any networkconnected PC that has the proper network security access to view process data. 4.1.3.20 Schematic displays shall support the following display objects: 4.1.3.20.1 Text, lines and solids - geometric and free-form 4.1.3.20.2 Live parameter values -- numeric, status and enumerated (or text) 4.1.3.20.3 Bitmap objects created in the display builder or imported 4.1.3.20.4 Static shapes pre-built and saved in a shape library 4.1.3.20.5 Dynamic shapes which can change their

properties (color, line parameters, etc.), move around on the screen or rotate in place by the execution of a display script 4.1.3.20.6 Fill levels configurable for a rectangle or freeform object, driven by an analog parameter such as a tank level 4.1.3.20.7 ActiveX documents and ActiveX controls. 4.1.3.20.8 Standard Alarm and Event tables 4.1.3.21 Any display object shall have the ability to be a screen target, selectable by the operator to call up point-specific or associated displays, or to execute a programmed script. 4.1.3.22 Schematics shall support VBScript or JScript to allow for event-based, user-defined functionality at runtime. 4.2 System Displays
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GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER


4.2.1

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System Status Display - shall show the status of every hardware component in the system. From this display, targets shall be invoked to access additional displays showing individual modules or nodes. From these displays, nodes and modules shall be capable of being started, stopped, switched (for those nodes with primary and backup) or checked for status and operability. Detailed maintenance

information and history shall also be available from this status display. 4.2.2 Channel (Process Network) Status Display - shall show the status of any and all data highways, process networks and system interfaces, as well as all devices attached to these networks, such as process controllers. 4.2.3 Console (Station) Status Display - shall show the status of each operator and engineering station 4.2.4 4.2.5 Printer Status - shall show the status of all system printers. Workstation Status - shall show the status of all process

workstations, including the status of all server redundancy and distribution. 4.2.6 The operator shall be able to launch any station display in the system (in his/her area of responsibility) from any of the HMIs in the console using one of the system displays or a desktop icon. 4.2.7 It shall be possible to automatically launch system modules with a single keystroke. 4.3 PAC & MMI Configuration 4.3.1 The Main contractor must configure the PAC system. 4.3.1.1 Configuration must be based user friendly type.
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GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER


4.3.1.2 4.3.1.3

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The system must enable for On-line Configuration. The control system must have ability to alter or configure loops without affecting other loops on automatic control. Likewise, the modification or creation of graphic display must not affect loops on automatic.

4.3.1.4

System must be provided to accept eight alpha numeric characters as tag numbers.

4.3.1.5

After performance Test all system configuration must be back up on CD or DVD Compact Disc as the latest backup included MMI program.

4.3.2

Alarm Management 4.3.2.1 Alarm Logic 4.3.2.1.1 When a point goes into alarm, it shall cause a dedicated on-screen indicator and a dedicated alarm summary keyboard pushbutton to enter a flashing mode. When the operator acknowledges the alarm, the indicator and pushbutton shall cease flashing. The system shall support the

capability to configure whether the operator shall, by acknowledging the alarm(s) from any of the operator keyboards in an operator console, cause the alarm(s) to cease flashing on one or all HMIs. 4.3.2.1.2 When the alarm summary display is invoked, the most recent alarms shall appear on the screen. Alarms shall remain on the alarm summary display until they are both acknowledged and cleared (e.g. return to normal). Pressing the acknowledge alarm
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GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER

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key or an alarm acknowledge target shall only acknowledge the alarms that can be seen on the display page. The operator shall have to scroll down to see and acknowledge. 4.3.2.1.3 It shall be possible to perform alarm management functions from within a custom graphic. 4.3.2.1.4 The system shall time stamp for each alarm the time of occurrence, time of acknowledgment, and time of return-to-normal. The time stamp shall have a resolution of one second for all alarms except sequence of events alarms, which shall have a resolution of one millisecond. 4.3.2.1.5 All analog inputs shall have an assignable alarm deadband value. Before an input is defined as

returned to normal, the input must have returned into the normal operating range by the deadband value. The deadband value shall be selectable as either a percentage of span or engineering units. 4.3.2.2 Alarm Priority 4.3.2.2.1 The system shall be capable of at least three (3) levels of process alarm priority. Any points high and low alarm limits shall be capable of being assigned a different priority during database configuration. These priorities shall distinguish

between low, high and emergency alarms. 4.3.2.2.2 The system shall provide a separate relay contact for each of the three alarm levels.
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These

PT Petrokimia Gresik

GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER


devices.

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contacts may be used to drive external audible It shall be possible to momentarily

suppress the audible annunciation of a HMI. 4.3.2.2.3 The system shall support at least four (4) lower levels of priority that shall be assigned to any point during database configuration. These

additional priorities shall allow for control over alarm logging and/or printing, but are not audibly nor visually annunciated on the HMI. 4.3.2.2.4 The system responses to each priority of alarm shall be specified. 4.3.2.3 Alarm Suppression 4.3.2.3.1 Under predefined conditions, the user shall have the option to suppress alarming from selected points. This shall prevent alarms from being reported when alarming would be obvious (such as preventing a low pressure alarm when the

associated pump is off).

This "intelligent"

alarming shall be configurable and modifiable by an engineer without the need for programming knowledge. The system responses to a point in

this alarm state are:


Display No Print No Journal Yes

4.3.2.3.2

Additionally,

when

the

operator

desires

to

temporarily change the alarm enable status to prevent nuisance alarms, the system shall be
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GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER


alarms.

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capable on a per point basis to enable or disable These changes shall be made from the This

point detail and alarm summary displays.

action shall override the response as defined by the alarm priority and alarm configuration. All operator actions that change a points alarm status shall be recorded in the operator process change journal. 4.3.2.4 Alarm Summary Display 4.3.2.4.1 As a minimum, the following alarm information shall be displayed:
Analog Alarms Time Point ID Process Area Alarm Type Alarm Priority Point Description Alarm Limit Current Value Engineering Units Digital Alarms Time Point ID Process Area Alarm Type Alarm Priority Point Description Current Value

4.3.2.4.2

The alarm summary display shall contain a readily visible means of distinguishing acknowledged from unacknowledged alarms (e.g. blinking field). If an alarm returns to normal prior to being

acknowledged, it shall remain on the screen with a unique identifying characteristic (e.g. reverse field). Upon being acknowledged, the alarm shall be removed from the screen. 4.3.2.4.3 The number of alarms displayable on one page shall only be limited by the display resolution and
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GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER

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the size of the display window. Only the total number of concurrent alarms configured for the system shall limit the number of alarms and alarm summary pages. Each alarm summary page shall The

have a prominently displayed page number.

total number of active alarms for each priority shall be displayed in a taskbar by process area and on the page being viewed. 4.3.2.4.4 The alarm summary display shall support the ability to sort alarms based upon any alarm information available, in ascending or descending order. (For example: sort all alarms by

alphanumeric description, in descending order.) 4.3.2.4.5 It shall be possible to pause the alarm summary display, allowing the operator adequate time to respond to alarm information. 4.3.2.4.6 The system shall allow the engineer to configure the colors assigned to each of the three (3) alarm priorities (emergency, high, low) when they are displayed on the system alarm summary. 4.3.2.4.7 It shall be possible to customize the alarm summary display columns, choosing which

information to display. It shall also be possible to adjust the width of the display columns using drag and drop techniques. The operator shall be able to save any customized view of the Alarm Summary for easy call up at a later time.
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4.3.2.5 including: 4.3.2.5.1 4.3.2.5.2 4.3.2.5.3 4.3.2.5.4 4.3.2.5.5 4.3.2.5.6 4.3.2.5.7 4.3.2.5.8 4.3.2.5.9 4.3.3 Popup Faceplates Alarms

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Event Summary lists events that occur in the system,

Alarm Acknowledgements Return to Normal Operator Control Actions Operator Login & Security Level Changes On-line Database Modifications Communications Alarms System Restart Massages etc

Integrated popup faceplate windows support is standard in the EWS and OWS. Faceplates are launched with a single click from process graphic display. No engineering is required. All standard point types are delivered complete with faceplates, and if required, the user can build their own custom popup faceplates. The faceplates provide advanced features including: 4.3.3.1 Up to 32 popup faceplates of tag number can be opened at once. 4.3.3.2 The 32 faceplates of tag number can be opened at 4 windowing. Each windowing consist of 8 tag numbers of faceplates. 4.3.3.3 Faceplates operate in round-robin scheme, unless a specific faceplate is push-pinned. 4.3.3.4 Push pinning preserves the faceplate from closure when new display pages are called. As a result, the operator can call a
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trend display, view an alarm display and then return to process display while maintaining process control from the faceplates. 4.3.4 Trending 4.3.4.1 The standard trend must include single bar graphs, dual bar graphs, triple bar graphs, multi-plot trends, multi-range trends, X-Y scatter plots, Numeric tables, and Group trends. 4.3.4.2 Functions providing data analysis must include Combination real-time/historical trending, trend zooming, panning and scrolling, hairline readout, declutter, Configurable trend density, simple recall of archived history, trend protection and smart clipboard for copy/paste of data. 4.3.5 Group Displays The Standard Group Displays are provided to allow configuration of panel board-like displays. By grouping related points into a Group Display, operators can more easily interpret process activity. Each group contains up to eight points, and each point has its own faceplate that displays the values of the major parameters. 4.3.6 Reporting Reports must be generated periodically, or on an event-driven or demand basis and may be configured on line. Report output must be directed to screen, printer, file, or directly to another computer for analysis or viewing electronically. 4.3.7 Alarms and indicators must be grouped operationally and must be visible to the operator to allow access to operational devices.

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4.3.8

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All emergency alarm indicators, push buttons and selector switches must be visible to the operator and labeled clearly. They must be protected to avoid inadvertent actuation.

4.3.9

All control functions must be grouped for accessibility and in proximity to their associated alarm and indication devices. Where video display units (VDUs) are used, data must be displayed on monitor screens in a logical, operational grouping to minimize the number of keystroke operations needed to respond to system upsets. Alarm functions must be prioritized to appear on the monitor screen upon being sensed, regardless of any information already displayed.

4.4

Central Control Room & Marshalling Room 4.4.1 The equipment of control system must be supplied and located on the CCR and Marshalling Room consist of: 4.4.1.1 SA, SU Plant and Boiler B-6203

Operator Workstation with dual monitor Engineering Workstation Workstation Console Alarm Printer (dot matrix, or equal ) Report Printer A3 (DeskJet Color or equal) Printer Console Marshalling Cabinet (double access/door) Marshalling Cabinet (single access/door) Power Distribution Panel Junction Box

- unit - unit - unit - unit - unit - unit - unit - unit - unit - unit


4.4.1.2

PA Plant

Operator Workstation with dual monitor


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PT Petrokimia Gresik

GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER

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Engineering Workstation Workstation Console Alarm Printer (dot matrix, or equal ) Report Printer A3 (DeskJet Color or equal) Printer Console Marshalling Cabinet (double access/door) Marshalling Cabinet (single access/door) Power Distribution Panel Junction Box

1 unit 2 unit 1 unit 1 unit 2 unit 2 unit 4 unit 2 unit 4 unit


4.4.1.3

Cement Retarder

Operator Workstation with dual monitor Engineering Workstation Workstation Console Alarm Printer (dot matrix, or equal ) Report Printer A3 (DeskJet Color or equal) Printer Console Marshalling Cabinet (double access/door) Marshalling Cabinet (single access/door) Power Distribution Panel Junction Box

1 unit 1 unit 2 unit 1 unit 1 unit 2 unit 1 unit 4 unit 2 unit 4 unit


4.4.1.4

Purification Plant

Operator Workstation with dual monitor Operator Workstation with single monitor Workstation Console Alarm Printer (dot matrix, or equal ) Report Printer A3 (DeskJet Color or equal)
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4.4.2

Printer Console Marshalling Cabinet (single access/door) Power Distribution Panel Junction Box

2 unit 4 unit 2 unit 4 unit

The size of marshalling cabinet is 2200 (H) X 800 (W) X 880 (D) and have double and single access windows.

4.4.3

Control Room layout as shown in CCR Layout no: 34-I-32-04-200001.

4.5

Specifications 4.5.1 The Industrial PC must be prepared with the following minimum specification: 4.5.1.1 Rugged enclosure designs with high electromagnetic

compatibility (EMC) and degrees of protection up to IP 55 / NEMA 4. 4.5.1.2 The processor must be at least Dual Quad Core

Intel Xeon Processor X5677, 3.46 GHz 12M L3, 6.4 GT/s. 4.5.1.3 Windows operating system must be Genuine Windows 7 Ultimate, 32 bit with the latest SP or the latest technology. 4.5.1.4 The dual hard drives must be installed with each capacity 600 GB SAS 3.0 Gb/s, 3.5 inch, 15 K RPM. 4.5.1.5 Random Access Memory (RAM) shall be DDR3, 1333 MHz, ECC (4 DIMM), capacity 2 x 4 GB system memories. 4.5.1.6 4.5.1.7 Communication network from/to PAC must be redundant. Expandability with cards must be 1 x PCI and 1 x PCI Expressx4. T

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4.5.1.8

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The graphic card must have minimum 1 GB NVDIA Quadro, with dual monitor, 2 DP and 1 DVI.

4.5.1.9 4.5.1.10

As Optical drive must be provided DVD +/-R/RW. Optical Mouse and Keyboard must be provided with USB connection.

4.5.1.11

Engineering tool for develop program and reinstallation must be provided.

4.6

Engineering and Maintenance Tool 4.6.1 The 1 (one) licenses for each plant (hart key/dongle (if any) and Serial Number) for engineer and maintenance to configure program,

process parameters, system data, download, upload and etc to the MMI and PAC must be provided. 4.6.2 Maintenance tool must be engineering specification. They must have serial port RS-232C and parallel port LPT. 4.6.3 Communication Cable and connector must be included.

5.

TEST AND INSPECTIONS 5.1 General 5.1.1 The entire instrumentation must be tested and/or calibrated prior to the installation. 5.1.2 All electronic components and circuit board must be tested and burned-in before installation into electronic assemblies. 5.2 Shop Test 5.2.1 The PAC vendor must perform a complete system functional test before advising the purchaser that the system is available for witnessed testing.
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GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER


Factory Acceptance Test (FAT) 5.3.1

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5.3

The PAC & MMI must be Factory Acceptance Tested prior to the shipping.

5.3.2

The FAT must consist of a loop by loop functional test of each input / output, alarm and control function for proper operation and display. The test must be performed using simulated input / output.

5.3.3

The PAC System (Hardware and Software) must be 95% ready for installed before FAT.

5.3.4

The contractor must be submit the documents, drawings, test procedure and PACs photos for FAT invitation.

5.3.5 5.4

The FAT must be witnessed by PT. Petrokimia.

Site Acceptance Test (SAT) 5.4.1 Site Acceptance Test for the PAC & MMI must be conducted only after performance test of the plant.

6.

PAC & MMI TRAINING 6.1 PAC & MMI Training 6.1.1 The PAC Vendor must conduct a set of training in the manufacturer facilities/workshop as follows: 6.1.1.1 6.1.1.2 6.1.1.3 Engineering (5 persons, 5 days) Maintanance Training/plant (6 persons, 5 days) Operator Training/ plant (8 persons, 5 days)

The Vendor must prepare training tools at least simulator and personal computer for each person.

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GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER

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7.

COMMISSIONING SPARE PARTS 7.1 PAC (Programmable Automation Controller) 7.1.1 The contractor must provide commissioning spare part for each plant as follows:


8.

1 (one) module for each I/O PAC module type. 20 % (twenty percent) of installed Buffer Relays. Ink for each printer and color. Paper (A4 dan A3 Size).

SYSTEM CONFIGURATION PA PLANT

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GENERAL SPECIFICATION FOR PROGRAMMABLE AUTOMATION CONTROLLER

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9.

SYSTEM CONFIGURATION CR PLANT

Purifikasi Plant is outside of battery limit project

General Spec PAC/82944 K Bytes

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