12-MEGP-I-1022-0 (Spec For Safety Instrumented System)

VECO Doc. No.
20298-01-EJ12-002
Project Title
MEHAR GAS DEVELOPMENT PROJECT

Area Location Discipline Document No Rev. Page
12
1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.0 3.0 3.1 3.2 4.0 4.1 4.2 4.3 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15
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TABLE OF CONTENTS INTRODUCTION.............................................................................................................4 General ...........................................................................................................................4 Scope ..............................................................................................................................4 Definitions .......................................................................................................................5 Abbreviations...................................................................................................................5 Environmental Conditions................................................................................................7 Device Protection ............................................................................................................7 Units of Measurement ......................................................Error! Bookmark not defined. CODES AND STANDARDS............................................................................................8 VENDORS RESPONSIBILITY .....................................................................................10 Scope of Supply & Services ..........................................................................................11 Conflicts, Discrepancies and Deviations ........................................................................12 MEHAR APPLICATION ................................................................................................13 Gas Processing Facility .................................................................................................13 Gathering Stations.........................................................................................................13 Wellhead Surface Facilities ...........................................................................................13 DESIGN REQUIREMENTS ...........................................................................................13 General .........................................................................................................................13 Logic Controllers ...........................................................................................................14 Inputs and Outputs ........................................................................................................16 Operator Interface .........................................................................................................20 SIS Interfaces................................................................................................................21 SIS Engineering HMI .....................................................................................................21 Critical Controls Panel ...................................................................................................21 Expandability .................................................................................................................22 Reliability.......................................................................................................................23 Diagnostics and Maintenance........................................................................................23 Segregation Philosophy.................................................................................................24 Initiating Devices ...........................................................................................................24 Start-up Bypass.............................................................................................................25 Output Defeat ................................................................................................................25 Output Reset .................................................................................................................25
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5.16 5.17 6.0 6.1 6.2 6.3 7.0 7.1 7.2 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 9.0 9.1 9.2 9.3 9.4 9.5 9.6
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Electrical Requirements.................................................................................................26 SIS System Enclosures .................................................................................................30 SYSTEMS ENGINEERING ...........................................................................................32 Consultation Service......................................................................................................32 Programming Services ..................................................................................................32 System Initialization.......................................................................................................32 SPARE PARTS.............................................................................................................32 Start-up and Commissioning Spare Parts......................................................................32 Operational Spare Parts ................................................................................................33 INSPECTION AND TESTING .......................................................................................33 General .........................................................................................................................33 Pre-Factory Acceptance Test ........................................................................................34 Factory Acceptance Test ...............................................................................................35 IFAT Test ......................................................................................................................35 Site Acceptance Test.....................................................................................................36 Availability Test .............................................................................................................37 Shop Inspection.............................................................................................................37 Certificates of Acceptance .............................................................................................37 DOCUMENTATION.......................................................................................................37 General .........................................................................................................................37 Functional Specification.................................................................................................38 Drawings .......................................................................................................................38 Design Interfaces ..........................................................................................................38 Operation and Maintenance Manuals ............................................................................39 System Log ...................................................................................................................39
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1.0 1.1
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INTRODUCTION General
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PETRONAS CARIGALI (Pakistan) Ltd. (PCPL) is undertaking the development of Mehar Gas Field in Mehar Block (Block 2767-1) located in Sindh and Balochistan Provinces of Pakistan. PCPL intends to develop the Mehar Field by installing a Gathering System, Gas Processing Facility (GPF) and Product Storage & Loading Facilities. The field facilities will be developed in two phases, Phase-I and Phase-2. Phase-1 development will cater to 55 MMSCFD of gas productions and Phase-2 will cater to 80 MMSCFD of gas productions. The expected condensate production rate is 6600 BPD for Phase-I and 7000 BPD for Phase-2. From GPF, treated sales gas will be exported through a new pipeline to existing SSGCL/SNGPL gas pipeline. Stabilized condensate and produced LPG will be exported by road tankers. Mehar Block is located in the Kirthar Fold belt area, in the Middle Indus Basin. Mehar field is located about 190 km west of Sukkur and 400 km north of Karachi in Sindh province. The environment is arid and the terrain is mountainous. Mazarani gas field, operated by PPL is situated about 25 km to the north, while Zamzama gas field operated by BHP is situated about 70 km to the north of Mehar Field. Mehar field consists of Pab and Ranikot formations. The wells will be connected to the new GPF through a Gathering System. There will be a total of 8 wells (4 in Pab & 4 in Ranikot) in Phase-1 and 3 additional wells (2 in Pab & 1 in Ranikot), totaling 11, in Phase-2 of the Mehar field development. 1.2 Scope This Specification, together with all reference documentation, defines the minimum technical requirements for the design, fabrication, configuration, testing, documentation and preparation for shipment of a microprocessor based Safety Instrumented System (SIS) for Mehar Gas Development Project. The SIS shall be a single integrated hardware platform used for Emergency Shut Down functions for all plant facilities. Normal plant monitoring, regulation and data acquisition will be by means of the PMCS. The VENDOR shall supply a standard field-proven fully integrated SIS system that exceed the requested functions or performance are acceptable provided the system is made up of field-proven hardware and software modules. The VENDOR shall clearly identify any design which is nonstandard or does not have a history of at least six fieldinstalled systems which have been in similar service for two years or longer. SIS, FGS and PMCS can be manufactured and supplied by same vendor and shall be interfacing on same network. Physically the systems shall be separate from each other.
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Definitions COMPANY
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Petronas Carigali Pakistan Limited (PCPL) or any Third Party assigned by the COMPANY. Party which carries all or part of the design, engineering of the PROJECT. VECO Engineering, Abu Dhabi is the ENGINEER. Party which carries out all or part of the design, engineering, procurement, construction, commissioning or management, of the PROJECT. EPCC CONTRACTOR includes his approved, MANUFACTURERS, SUPPLIERS, VENDORS and SUBCONTRACTORS.
ENGINEER
EPCC CONTRACTOR
MANUFACTURER/SUPPLIER/VENDOR Party/ies, which manufacture and/or supply materials, equipment and services to perform the duties as specified by the CONTRACTOR in the scope of supply. PROJECT 1.4 Abbreviations DCS FAT IFAT TLAS FGS GPF GUI HART ICS IER I/O LAN Distributed Control System Factory Acceptance Test Integrated Factory Acceptance Test Truck Loading Automation System Fire & Gas Gas Processing Facility Graphical User Interface Highway Addressable Remote Transducer Integral Control System Instrument Equipment Room Input Output Local Area Network MEHAR GAS DEVELOPMENT PROJECT
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LED MCC MOS MTU PLC PMCS PSD RTU SAT SDS SLD SIS UHF USD DC SSV
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Light Emitting Diode Motor Control Centre Master Override Switch Master Terminal Unit Programmable Logic Controller Process Monitoring and Control System Process Shutdown Remote Terminal Unit Site Acceptance Test Shutdown System Single Line Diagram Safety Instrumented System Ultrahigh Frequency Unit Shutdown Direct Current Safety Surface Valve Surface Controlled Subsurface Safety Valve Triple Modular Redundant Safety Integrated Level Digital Input Digital Output Analog Output Analog Input Central Control Room
SCSSV TMR SIL DI DO AO AI CCR
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Environmental Conditions
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Wellhead facilities, Gathering stations and GPF area has been tentatively selected at a location about 190 km west of Sukkur and 300 km north of Karachi in Sindh Province. The environment is arid the terrain is mountain. The Environmental conditions are: Maximum Ambient Temperature Minimum Ambient Temperature Wet bulb temperature (design) Relative humidity (max / nor /min ) Direction of prevailing wind Wind Velocity (max / normal) Elevation above mean sea level (GPF) Average barometric pressure Ice / Snow Seismic zone : : : : : : : : : : 55C 0.5C 30C 90 / 65 / 20 % From south to north Hold / 2.9 knots 54m (Site-IV) / 56m (Site-l) 1001.2 mbara (29.56 inches of Mercury) None Zone 2B, moderate with acceleration of (Hold) 63.3 mm (year 2006) 139.9 mm (year 2005) upper ground 0.2
Annual rainfall min. Annual rainfall max. 1.6 Device Protection
: :
All instruments shall be certified as EExi IIA/IIB per ATEX Directive. Suitable isolators shall be provided in control room. EExd protection shall be used for solenoid valves & where not available. Detector & device enclosures, in field, shall be dust proof, weather proof to IP 65, as a minimum. All external surfaces shall be suitably painted for corrosion protection. Instruments shall be selected based on Area classification drawings by Electrical.
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CODES AND STANDARDS
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Codes, specifications and standards referred to within this specification, form a part of the requirements of this specification in a manner and to the extent specified within those codes and standards. Unless otherwise specified, the latest edition or revision to these codes specifications, and standards in force at the time of Request for Quotation (RFQ) and/or Purchase Order (PO) shall apply. No deviations from the Codes and Standards listed in this document will be allowed unless such deviations are clearly identified in the bids, with the reasoning. In addition, they must be approved in writing by COMPANY. PTS 00.00.05.05 PTS 32.37.20.10 PTS 32.80.10.10 Index to PTS publications and standard specifications Instrument signal lines Classification and implementation instrumented protective functions Management functions of instrumented of
PTS 32.80.10.12 PTS 32.80.10.30 API/RP 501 API/RP 502 API/RP 520
protective
Instrumented protective systems Process Measurement Instrumentation Signal Transmitters and Air Supplies Recommended Practice for Design & Installation of Pressure Relieving System in Refineries (Part 1) Manual on Installation of Instruments and Control Systems Fire Protection in Refineries Refinery
API/RP 550 API/RP 2001 BS 7671
Wiring Regulation Requirements for Electrical Installations Microcomputers in Safety Techniques Safety Related Instrumentation Systems for the Process Industries National Fire Alarm Code
DIN V 19250 EEUMA 160
NFPA 72
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NFPA 101 NFPA 325
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Guide to Fire Hazard Properties of Flammable Liquids, Gases and Volatile solids Standard for Purged and Pressurized Enclosures for Electrical Equipment Interface Between Data Terminal Equipment (DTE) and Data Communication Equipment (DCE). Employing serial binary data Interchange Balanced Serial Interchange Data Communications
NFPA 496
EIA 232
EIA 422
IEC/CISPR11
Limits of Electromagnetic Interference for Electrical Appliances and Equipment Electrical Apparatus for Potentially Explosive Atmosphere-General Requirement Electrical Apparatus for Potentially Explosive Atmosphere-Increased Safety EExe Electrical Apparatus Atmospheres for Explosive Gas
IEC 50014
IEC 50019
IEC 60079
IEC 60364 IEC 60446
Electrical Installation of Buildings Basic Safety principle for Man Machine Interface Classification of Degrees of Protection Provided by Enclosures (IP Code) Electrical Installation Guide Programmable Controller Functional Safety: Safety Related Systems Functional Safety Instrumented Systems for Process Industry sector Guide for Surge withstand Capability Tests
IEC 60529
IEC 61000 IEC 61131 IEC 61508 IEC 61511
IEEE 472
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ISA RP 12.1
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Hazardous
Electrical Instruments Atmosphere. Alarm Annunciation Hardware Testing Computers of
ISA RP 18.1 ISA RP 55.1
Digital
Process
ISA S5.1 ISA S5.2
Instrument Symbols and Identification Binary Logic Operations Diagrams for Process
ISA S5.3
Graphic Symbols for Distributed Control / Shared Display Instrumentation, Logic and Computer System Instrument Loop Diagrams Graphic Symbols for Process Display Application of Safety Instrumented Systems for the Process Industries Federal Occupational Safety and Health Standards Electromagnetic Susceptibility of Process Control Instrumentation
ISA S5.4 ISA S5.5 ISA-S84.01
OSHA
SAMA PMC-33.1 3.0 VENDORS RESPONSIBILITY
The VENDOR shall have responsibility for complete engineering approach to the SIS design, fabrication, engineering, staging, testing, documentation, shipment and commissioning this shall include but not be limited to the integration between Well Head facilities, Gathering Stations and Gas Processing Facilities. SIS programming shall be conducted as a joint exercise between the VENDOR and the EPCC CONTRACTOR. The EPCC CONTRACTOR should inform the COMPANY in writing well in advance before the exercise begins; the COMPANY shall advise the EPCC CONTRACTOR if it desires to be a part of the exercise. The VENDOR shall supply engineering documentation, which shall include appropriate SIS input to the COMPANY'S CAD generated instrument loop diagrams. The COMPANYS approval of the manufacture and model number of equipment and approval of the VENDOR'S drawings/documents does not in any way affect the VENDOR'S full responsibility to supply strictly in accordance with project specifications, codes and standards.
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This Specification shall not relieve the VENDOR of any responsibility to provide equipment and services that are suitable for the intended duty. 3.1 Scope of Supply & Services The Vendor shall supply, but is not limited to, the following: Project management & reporting; Factory assembled SIS including system cabinets, marshalling cabinets, DC power for system and field supplies and all other peripheral equipment as called for by this Specification and the Purchase Order, fully tested and ready for installation; Open book pricing valid for 12 months for additions or deletions of hardware; All necessary interconnecting cables, with plug-in connections at each end, between system cabinets. Connectors (only) shall be provided for all peripheral equipment; Plant SIS LAN connectors, splitters, taps, etc. as required by the system and the application, including the SIS LAN cable; All serial communication interfaces and associated software as called for by this Specification (Refer Section 5.5) and the Purchase Order including a system integration specification for each serial interface, the SIS instruments will be hardwired to the system by the EPCC CONTRACTOR; Nameplates for equipment cabinets, individual devices, terminal strips for groups of input/output terminals, individual tagging of signal pairs and terminals and tag destinations of plug-to-plug cables; The SIS programming activity shall be executed in the VENDOR'S premises using the VENDOR'S configuration tools and assisted as necessary by the COMPANY; All operating and application software with licenses as called for by this Specification and the Purchase Order. This shall be the latest revision of all proprietary software and all software revisions and manual upgrades, which may be released during the first year after Purchase Order award; All necessary interfaces required to run the operating, Windows GUI and the SIS PLC application software; All SIS testing services including the pre-FAT, FAT and IFAT (with PMCS, TALS, FGS & RTUs.) test. All tests shall be conducted in the VENDOR'S premises using the VENDORS utilities and test equipment;
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A complete staging test shall be conducted at the SIS VENDORS premises in order to verify the correct operation of all interfaces between the FGS, PMCS, TALS and RTUs.; Complete documentation as called for by this Specification and the Purchase Order up to and including "As-Builts"; Spare parts for commissioning and two years operation; Packing of the SIS in readiness for shipment in accordance with VENDOR standards unless otherwise specified in Purchase order. The point of demarcation between the VENDOR'S and the COMPANY'S responsibility will be after packing and loading onto transport after the staging tests at the VENDOR'S premises; Site services such as installation supervision, Loop checking commissioning assistance, the SAT, etc. as deemed necessary by the COMPANY and/or the VENDOR; Training for company design engineers, programmers, operators and technicians; Commitment to support the hardware supplied with diagnostics, testing and replacements for 25 years (i.e. the life of the project).
3.2
Conflicts, Discrepancies and Deviations Any conflicts or discrepancies found in the COMPANY design documentation shall be referred in writing to the COMPANY for clarification. No deviations shall be made from design documentation without prior approval in writing by the COMPANY. Where conflicts or discrepancies occur, the order of precedence shall generally be: Government and Statutory regulation; I/O List; System Block Diagrams; This specification; Project Specifications; Company Standards (PTS); International Codes and Standards.
Every deviation from design documentation must be brought to the attention of the COMPANY, whose written approval must be obtained before any work can commence. If no exceptions are stated, or the COMPANY'S approval of a deviation is not given, then full compliance will be assumed and required.
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MEHAR APPLICATION
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Under this Project, following facilities are being considered: 4.1 Gas Processing Facility; Gathering stations. Wellhead surface facilities;
Gas Processing Facility Following are the key functional requirements for the Gas Processing Facility SIS. Overall Plant shutdown; Train 1 and 2 shutdown; Local Shutdown of package unit and/or equipment.
4.2
Gathering Stations Gathering Station manifold are un-manned and will be monitored and controlled by an RTU. The RTU will be the integrated control system of the Gathering Station manifold and is not included in this specification.
4.3
Wellhead Surface Facilities Wellhead Surface Facilities are un-manned and will be monitored and controlled by an RTU. The RTU will be the integrated control system of the wellhead facilities and is not included in this specification.
5.0 5.1
DESIGN REQUIREMENTS General The overall availability of the SIS (Logic Solver central parts, I/O cards and communication cards) shall be based on TUV SIL 3 certified Redundant programmable logic controller technology and shall have hardware architecture such that it is capable of being certified to DIN V 19250(TUV) class 6 (or higher) and comply with the requirements of IEC 61508. The overall availability of the SIS shall be > 99.999%. The proposed system shall use VENDOR standard field proven product lines. No product development shall be undertaken during the length of the contract. The projected life of the installation is 25(twenty-five) years. The SIS must be capable of sustaining an equivalent operational life and be guaranteed by the VENDOR to be capable of being supported for at least this period of time. This may be achieved by the VENDOR guaranteeing product development and supply for five years followed by upgradeable development and support for a further twenty years.
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The SIS shall be chosen for its simplicity, its use of established proven components, and its use of techniques that minimize the need for maintenance and its overall design such that the integrity of the installation is enhanced. Only new equipment shall be supplied. No second hand or obsolete equipment shall be supplied. All hardware items shall be standard modules from existing product ranges. No prototype equipment shall be utilized. The SIS shall incorporate precious metal plating of component lead wiring, connectors, etc. Construction shall not use techniques which are prone to damage by corrosive atmospheric pollutants or vibration (e.g. wire wrapping). The SIS shall be provided with integrated sequence of event recorder capability for system maintenance and shutdown. System shall have capability to retrieve, display and print information about events from dedicated SIS work station and any of the network printers. After any trip, the user can review event data in Event log displays on the HMI screen. Sequence of event recorder stores data in a History file for 60 days minimum before and after a trip of the controlled process. The user can create displays and printout to help evaluate system behavior before during and after the trip in order to determine the cause of the problem. Sequence of event recorder display formats include Bar, Chart, Trend line, Tabular, Static position and profile. The automatic backup and restart features shall be provided which enables Sequence of event recorder to automatically save the trip database. After auto backup takes place, Sequence of event recorder is ready to restart collection of historical data without human intervention. 5.2 5.2.1 Logic Controllers Hardware The SIS shall incorporate a TUV SIL 3 certified Redundant rack mounted construction in which various electronic cards are inserted into a card chassis. The various chassiss are to be located within the SIS cabinets. Card addresses shall be software selectable (i.e. any card in any slot). No external backplane or piggy-back methods shall be used. A figure of less than 100 milliseconds between an input state change and a corresponding output state change shall be achievable by the offered system. Controllers shall be sized to meet the project requirements in the form of available slots or algorithms, points and address plus 10 percent to allow for the project growth. In addition there shall be 30 percent capacity for future growth. Scan time shall not be more than 300 msec.
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Software and Programming
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The SIS shall, as a minimum, perform the logic as shown on the C&E diagrams. All logic programs shall reside in password protected battery backed memory (VENDOR to use latest devices) in order to maintain logic security. Interrogation from the engineering HMI shall be available, but shall have 4 levels of passwords plus key switch security. The SIS shall be simple and flexible with regards to programming of logic connections. The SIS shall only be able to be programmed off-line from a Pentium PC and Microsoft Windows GUI. The SIS programming software package shall conform to IEC 61131: 13 and shall also provide the facility for automatically documenting and annotating logic program. The logic program shall be liberally commented throughout, to assist with fault-finding and maintenance. The software-programming package shall produce logic diagrams in function block format. TUV certification shall be provided for the logic generated in the system. As a minimum but not limited to, the following logic operators and algorithms shall be available in the SIS: Equal to; Not equal to; Greater than; Greater than or equal to; Less than; Less than or equal to; Minimum value of x and y; Maximum value of x and y; AND operation; OR operation; NAND operation; NOR operation; XOR operation; Logical negation; Rise and fall;
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Time delays - delay initiation, delay termination and pulse outputs; Memory operators - set/reset (memory maintained and/or lost upon removal of power); Latch toggle; Timers and counters; Sequencers.
Facilities shall be provided for majority voting techniques to be applied to multiple input, logic or output paths, with discrepancy and trip actuation indication alarms as appropriate. This shall include standard system modules, an extensive library of standard proven function blocks and application specific function blocks. A change control procedure that leaves an audit trail of approved logic programming modifications shall be implemented. This shall include paper records and identification of version within application code. 5.3 5.3.1 Inputs and Outputs General The I/O cards shall utilize modular mount construction. All I/Os shall be point isolated, failure of single point shall not fail whole card. All digital I/O cards shall provide LED indication of the status of each I/O point, independent of any bypass, override or latch function. All I/O cards shall provide LED identification of card status (faulty, healthy, etc). All I/O circuits shall include a current limiting transformer to prevent damage upon short-circuiting of I/O field circuit conductors. All I/O circuits shall provide transient suppression in accordance with IEEE 472 and undergo surge withstand capability testing. Lightning suppression devices are required. As a standard, all I/O circuits shall be individually isolated, utilizing integral solid-state optical or transformer isolators. In addition, all 240V AC I/O circuits shall incorporate external interposing relays. Each I/O circuit shall be individually fused with automatic blown fuse monitoring. This shall be in the form of resetable electronic fuses. For all I/O circuits, the negative terminal at the I/O card in the system cabinet shall be at the clean instrument earth level. All other points in the circuits shall be isolated from earth. All I/O shall be time stamped by the controllers and have a resolution of at least 100 milliseconds. All inputs shall be self resetting, however, alarms will latch. This alarm latching will be performed by the PMCS. The SIS shall use / implement a pulse extension to ensure
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that all alarms are seen by the PMCS. Interlocking shall be configured such that outputs cannot be reset prior to the associated inputs becoming clear. 5.3.2 Digital Inputs There shall be three types of DI point: Field devices with normally-closed in the normal process condition (fail-safe) voltage-free contacts. Multiple field devices may be connected in series by the COMPANY as a single DI point. These shall be powered at 24V DC by the SIS via individually fused circuits at 0.5A (maximum). These will be used for the majority of DI points; Field devices with normally-open (non fail-safe) voltage-free contacts. Multiple field devices may be connected in parallel by the COMPANY as a single DI point. These shall be powered at 24V DC by the SIS via individually fused circuits at 0.5A (maximum). An end-of-line device shall be provided by the SIS VENDOR suitable for its input card to be installed in parallel with the field devices. Three circuit conditions shall be monitored; normal loop resistance (normal condition), high loop resistance (fault condition or open-circuit) and low loop resistance (alarm condition or short-circuit). These will be used for multiple detection devices in a single zone for the F&G system; A clock synchronization signal from the PMCS to the SIS. This shall be powered and fused at 24 VDC, 1A by the PMCS.
Note: Time synchronization may be achieved by network time protocols (NTP) or equivalent. The field devices shall be coupled to the signal conditioning circuits of the logic system. Signal conditioning shall include galvanic isolation, non-integrating input filters and time delays to isolate field equipment from system logic and to prevent operation of the system by any mechanical vibration. All DI points shall be latched in their latest driven state until scanned or read into the SIS. To compensate for possible hardware failure on testing, a maintenance override function shall be provided to allow forcing of the measurement associated with selected DI points. These points are shown on the SIS I/O schedule. Actuation shall only defeat the input to the shutdown functional logic; input status indication shall remain operable. A limited number of overrides may be in place at any one time. This will typically be two per process system and will be defined in the functional logic technical note (by the COMPANY) and in the functional design specification (by the VENDOR). In addition, a single key switch at the SIS system cabinet in the auxiliary room shall enable all points, which may be in override status. A start-up bypass function shall be provided for selected DI points, which may be in an abnormal state prior to process start-up (eg. pressure low-low). These points are shown on the SIS I/O schedule. The start-up bypasses shall be manually activated.
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The operator shall, at any time, be able to cancel a start-up bypass. This shall cause a trip to occur unless the normal state of the field device has been reached. The bypass shall be self-cancelling either by the field device transferring to its normal state or after a pre-determined time delay. If cancelled automatically by the field device transferring to its normal state, the SIS shall avoid nuisance trips caused by oscillation of the field device around the reset value. Attempted operation of the start-up bypass with the field device in its normal state shall have no effect. Activation of the start-up bypass shall only defeat the input to the shutdown functional logic; input status indication shall remain operable. Bypasses shall be time limited to an adjustable period defined on the SIS I/O schedule. Re-operation of an enabled start-up bypass shall have no effect on this bypass time period. The maintenance override and start-up bypass functions shall be implemented as a system of key switch controlled soft-buttons available from a faceplate within the SIS operator interface. The SIS shall maintain a log of these overrides and bypasses. Override and bypass status indication and common alarming shall be provided. Any flow trips should be initiated via a delay-off timer (adjustable 0 to 10 seconds) to remove the problem of nuisance trips caused by transient dips in the flow rate. 5.3.3 Smart Transmitter Interface Smart transmitters using the HART protocol shall be used to sense abnormal process conditions use of switches is not permitted. The SIS shall provide communication interfaces to HART field devices (transmitters, transducers and actuators). These interfaces shall give the host processors access to the digital information encoded with the 4 to 20mA analogue process variable signal. The digital information shall be passed to and from the host processor using a remote I/O. The SIS software shall enable transfer of HART field devices status information to the PMCS, thus enabling remote transmitter programming and remote diagnostic from the PMCS. 5.3.4 Digital Outputs There shall be three types of DO point: Normally energized (fail-safe) 24V DC outputs. These shall be powered by the SIS via individually fused circuits at 2A (maximum). These will be used to drive solenoid valves and relay coils. Surge suppression will be provided when driving such inductive loads. Surge suppression devices will be supplied and installed by the supplier of the field device; Dry contacts rated at 4A for 24V DC or at 2A (hold-in)/8A (in-rush) for 240V AC. These shall be selectable as normally-open or normally-closed, momentary or maintained. The voltage will be supplied externally from the SIS (including individual fuse protection where required) by the COMPANY'S panel. These will
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be used to trip motor control circuits, or other control panels. Segregation of voltage levels (24VDC from 240V AC) shall be maintained; Normally de-energized (non fail-safe) 24V DC outputs. These shall be powered at 24V DC by the SIS via individually fused circuits at 2A (maximum). An end-ofline device shall be provided by the SIS VENDOR suitable for its input card to be installed in parallel with the field device. Three circuit conditions shall be monitored; normal loop resistance (normal condition), high loop resistance (opencircuit) and low loop resistance (short-circuit). These will be used to drive status lights, alarm horns, and to trip shunt-trip coils on circuit breakers.
Each DO circuit shall incorporate an output driver to activate the field device and a logic protection device to guard against field generated interference. Output defeats shall not be incorporated into the SIS. The design of multiple path logic systems shall allow testing of the SIS electronics without the use of output defeats. 5.3.5 Analogue Inputs AI points shall be 4 to 20mA DC with a maximum input resistance of 250 ohms. The following is the type of AI point: The 24V DC loop power shall be supplied by the SIS and the current shall be sourced by the SIS. These will generally be used where a single field transmitter will be signal conditioned within the SIS to generate both high-high and low-low trip points;
All events where AI points move through an alarm point shall be latched until scanned or read into the SIS. All AI points shall be automatically monitored for short-circuit (above a threshold over 20mA) and open-circuit (below a threshold under 4mA) faults. The thresholds shall be fully programmable. All AI points shall be individually isolated and individually fused on the high (supply) side. The fuse rating shall be 250mA. All AI points shall have an individual power regulator to provide field transmitter power. Maintenance override and start-up bypass functions shall be provided for selected AI points. These points are shown on the SIS I/O schedule. Maintenance override and start-up bypass functions shall be implemented after signal conditioning and alarm generation has occurred. 5.3.6 Analogue Outputs AO points shall be 4 to 20mA DC capable of driving up to 600 ohms total loop resistance. All AO points shall be two-wire field devices. The 24V DC loop power shall be sourced by the SIS.
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All AO points shall be automatically monitored for short-circuit (above a threshold over 20mA) and open-circuit (below a threshold under 4mA) faults. The thresholds shall be fully programmable. All AO points shall be individually isolated and individually fused on the high (supply) side. The fuse rating shall be 250mA. All AO points shall have an individual power regulator to provide field transmitter power. Output defeats shall not be incorporated in the SIS. The design of multiple path logic systems shall allow testing of the SIS electronics without the use of output defeats. 5.4 Operator Interface The preferred mode for data exchange with the PMCS and their related amount is that the SIS is interfaced to the PMCS bus as a system node, thus also allowing a common time basis between PMCS and SIS. This way of interfacing is required to be a catalogue product and not a project application, allowing the best performance both for data transfer to operator interface. If not otherwise possible a standard serial interface will be provided. The SIS operator interface shall be available from the PMCS operator HMI by way of interactive graphics (by others). A peer to peer Ethernet link shall be established between the SIS and the PMCS in the Auxiliary Room in order to provide this operator interface. The following functions, described elsewhere in this Specification, shall be available from the operator interface: Status of all SIS I/O, including, as applicable, field status, maintenance override status, start-up bypass status, latch status, logic status, etc.; ESD faults and status, including discrepancy alarms on multiple path logic systems, power supply faults, etc.; Soft-button SIS functions, including output latch resets, maintenance overrides, start-up bypasses, manual test initiation, automatic test enable/temporary disable, acknowledge test failure, etc. These shall be subject to standard PMCS keyswitch security; PSD/ESD operator interface panel integral to the PMCS operator HMI on which a number of manually operated devices shall be installed. These are the covered SIS zone pushbuttons, covered Blowdown pushbuttons, SIS indication lights and SIS Output Zone Reset pushbuttons.
The PMCS will co-ordinate alarm handling of process pre-alarms and process shutdown alarms transferred from the SIS. These will be interleaved on common alarm lists in the PMCS. In order to synchronize alarm time stamping, the PMCS shall periodically reset the SIS clock via a hardwired digital output from the PMCS to the SIS (eg. at 1 am every morning, as determined by the PMCS master clock). Note: this may be achieved by use of network time protocols NTP or equivalent. Alarm points shall be
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transferred from the SIS to the PMCS via a dual-redundant Ethernet network. If the PMCS can manipulate externally time-stamped alarm points, the PMCS shall receive time-stamping information with the relevant alarm points (e.g. tenths of a second after 1 am). Alternatively, the PMCS may time-stamp the occurrence of alarm points when they enter the PMCS. If this second option is taken up, the PMCS will also include the facility to upload at any time a full sequence of events alarm list, complete with timestamping information, from the SIS. Details of alarm co-ordination shall be resolved at the time of functional design specification development. The operator interface shall be designed so that faults on any part of the operator interface or failure of the communication link between the SIS and the PMCS shall not degrade the stand-alone functionality or the reliability of the shutdown actions of the ESD. The operator interface shall be designed so that no information is synonymous with a healthy system. That is, with the process conditions normal, no bypass(s) or override(s) operated, all outputs in the healthy, reset position and no faults on the system, and then all associated alarms will be off. A system integration specification for the interface between the SIS and the PMCS / Transmission interface equipment (for RTUs) shall be produced by the SIS VENDOR for implementation at the PMCS/Telecommunication end of the interface by the VENDORS and at the SIS end of the interface by the SIS VENDOR. 5.5 SIS Interfaces The SIS shall also be capable to communicate with Ethernet/IP (Ethernet Industrial Protocol) capable of handling large amounts of data at speeds of 100 Mbps or better. At GPF it shall be connected directly to ICSS data highway. Peer to Peer communication shall be provided between PMCS, FGS and SIS. The communication between these systems shall be provided on the common PMCS data highway. SIS system shall provide voltage free relay contact for a hardwired connection to TLAS for safety requirements. The VENDOR shall be responsible for the programming, testing and performance of the interfaces. The COMPANY will provide technical assistance and input where applicable. 5.6 SIS Engineering HMI Common EWS for PMCS, SIS and FGS shall be provided. For details of engineering HMI refer Doc 12-MEGP-I-1021 sec 10. 5.7 Critical Controls Panel For manual CCR shutdown purposes, and to provide back-up indication of SIS status, a hardwired ESD emergency panel will be provided with the SIS for installation within
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the operator console in the CCR. The operator console will be supplied within the PMCS scope. The Critical Controls Panel shall include as a minimum the following SIS functions: ESD and PSD shutdown pushbuttons; ESD and PSD status lamps; Master MOS enable switch; Group MOS enable switches; ESD Reset pushbutton; PSD Reset pushbutton; Lamp Test pushbutton.
The panel shall have 20% space for additional electrical devices to be installed by others where rewired. In addition, 20% spare wiring terminals shall also provided for future wiring in the control panel. The design emphasis shall be to provide a simple facility, easily operated under emergency conditions. The PMCS VENDOR has the responsibility for the construction of the operator console. The SIS VENDOR has the responsibility of the critical controls panel and shall coordinate all integration and design issues with the PMCS VENDOR to ensure the critical controls panel is integrated within the operator console design. However, it is the intention of this PROJECT that the SIS and the PMCS will be supplied by a single vendor. 5.8 Expandability The capacity of the SIS is defined by the SIS I/O list. In order to allow for expansion, a minimum of 20% installed backplane spare capacity shall be provided, in addition to 20% installed I/O capacity. The 20% spare shall be abover the overall capacity of the SIS for both Train 1 & 2, Phase 1 & 2. The SIS shall be designed such that input/output and logic module expansion by modular addition is possible without impacting the current system operation. Expansion shall be able to be implemented with the SIS fully powered and operational. Expansion shall be achieved by straight addition, not modification, of hardware and with a minimum of software and programming changes.
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5.9 5.9.1
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The SIS shall tolerate a power interruption time of 1 second without disrupting its operation. Loss of power to the SIS, (beyond the power ride-out period) shall, upon subsequent restoration of power, result in automatic reboot of the system to full operation within five minutes. However, the system logic shall revert to its fail safe state after automatic reboot. 5.9.2 Availability and Redundancy The VENDOR shall state the availability of the proposed SIS as a whole. This should exceed 99.999% based upon a modular change-out maintenance philosophy utilizing held spares. It is critical that single point component failure shall not result in the loss of availability of the entire ESD. Availability, A%, is calculated as A% = (MTBF-MTTR) / MTBF * 100 Mean Time between Failure (single component) Mean Time to Repair (assume one hour based on time to diagnose the fault and make an on-line card replacement)
MTBF = MTTR =
MTBF and MTTR data shall be based upon field installed equipment data and not theoretical data. 5.10 Diagnostics and Maintenance The SIS shall be designed so as to require minimum maintenance and minimum routine calibration. All I/O points shall incorporate extensive fault monitoring facilities as standard. This shall include open circuits, short circuits, and over loads. Diagnostics shall be provided to the individual circuit level. Comprehensive SIS status information and control of the diagnostic routines shall be available at the SIS engineering HMI which shall include, as a minimum, the following functions: Fault and status indication, including discrepancy alarms on multiple path logic systems; Soft-button functions, including manual test initiation, automatic test enable/temporary disable, acknowledge test failure, etc. These shall be subject to password or keylock type security.
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To minimize downtime and assist maintenance personnel, stand-alone diagnostic software, running on Microsoft Windows GUI, shall be provided with the SIS to monitor system operation and the status of all hardware throughout the SIS and LAN. In case of a hardware fault occurring, the diagnostic software shall display on the PMCS / SIS engineering HMI and PMCS operator HMI time stamped address location information and provide a graphical presentation of the faulty card location together with descriptive fault repair instructions. All SIS shutdown paths shall be tested from input to output automatically with a new test being initiated at least every thirty minutes. The diagnostic routines shall involve the generation and monitoring of test pulses which are fast enough to not affect electro-mechanical output devices. If a test shows that the expected change at the output is not in accordance with the known C&E relationship (held in a diagnostic map) then an alarm shall be generated. This testing shall be overridden by an input changing into the shutdown state. The automatic test system shall have a watch-dog to monitor its own operation. If this fails, an alarm shall be generated. Tests shall be able to be manually initiated at any time. The design of the SIS shall be on a modular basis to simplify fault finding, with maintenance being by replacement of complete cards so as to minimize down-time. All controller, communication, non-volatile memory, and I/O circuit cards shall have multiple red and green LED indicators to facilitate the identification and repair of failed cards. The SIS shall provide the capability to replace a failed part with a spare, on-line and under power without affecting the existing SIS operation. The SIS shall be designed to provide maximum ease of equipment servicing. All necessary hardware, software, drawings and test equipment required to execute fault identification shall be provided by the VENDOR. 5.11 5.11.1 Segregation Philosophy Field Inputs The initiating field input devices for the PSD & ESD functions shall be unique to each function. 5.11.2 Field Outputs Output devices for the actuation of isolation / battery limit valves or electrical drive control circuits are the same for both the PSD and ESD functions (if required by both). Segregation of these two functions is only at the logic level, i.e. outputs; marshalling, field cables, field termination panels and end element field devices are common. 5.12 Initiating Devices The initiating field input devices for the PSD and ESD functions shall be coupled to the SIS I/O signal conditioning circuits.
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Each SIS digital input card, to which a field mounted switch is connected, shall have the capability to monitor cable short circuit or cable break by means of an end of line resistor. In addition, each DI card shall contain over-voltage protection. 5.13 Start-up Bypass This facility shall be provided on a per instrument basis, for selected inputs which may be in an abnormal state prior to process start-up (e.g. pressure low-low) as specified on the relevant PSD input/output list or C&Es. Activation of a start-up bypass shall be a protected manual operation carried out on the operators console and only defeat the PSD function. The operator shall, at any time, be able to cancel a start-up bypass. This shall, unless the normal or healthy state has been reached, cause a trip to occur. The bypass shall be self-cancelling either by the initiating device transferring to the normal or healthy state, or after a pre-determined time delay. If cancelled automatically by the initiating device the input circuitry shall prevent nuisance trips being caused by oscillation of the input around the reset value. Attempted operation of the bypass with the process in the normal or healthy state shall have no effect. Indication of the status of the bypass shall be provided on the operators console. 5.14 Output Defeat Output defeats shall not be incorporated into the SIS function. The design of multiple path logic shall allow testing of the SIS function hardware. 5.15 Output Reset In order to minimize the level of operating personnel required to run the plant facilities, the following SIS reset philosophy shall be adopted. 5.15.1 PSD Reset Once a PSD has been initiated, manual intervention shall be required to reset the shutdown function. This will involve a common reset of the PSD function from the control room operator console, which shall remotely reset the emergency shutdown valves, shutdown valves and blowdown valves and restart motors. This shall either be on a one-by-one reset basis or on a process group reset basis. The reset facilities on the control room operator console for the PSD function shall be for the whole function. 5.15.2 ESD Reset Once an SIS has been initiated, manual intervention shall be required to reset the shutdown function. This will involve a reset of the SIS zone from the control room SIS operator interface panel, forming part of the PMCS operator console furniture, as well
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as manual reset of the latched solenoids on the shutdown and blowdown valve actuators and the manual restart of motors from the control room operator console. 5.15.3 Emergency Shutdown Valves, Shutdown Valves and Blowdown Valves Where sequential operation is required for safe shutdown or blowdown, the interlocking shall be performed within the ESD. Interlocking of shutdown valves and blowdown valves shall be as follows: Blowdown prevented unless the blowdown sectional shutdown valves close command has been given; If blowdown valves are not confirmed closed then an alarm shall be generated. However, there shall be no automatic emergency shutdown initiated by this condition; If a blowdown initiation is attempted prior to an emergency shutdown being initiated, then the system will automatically initiate an appropriate process sectional shutdown/blowdown sequence.
5.16 5.16.1
Electrical Requirements Codes and Standards The electrical portion of the ESD, including all wiring, shall be in accordance British Standard Wiring Rules. The VENDOR shall bring to the attention of the COMPANY all deviations from this standard for clarification and final ruling. Exposure of personnel to voltages greater than 24V (AC or DC) shall be prevented. This shall be accomplished by complying with the requirements of BS 7671, in particular, by ensuring adequate safety earthing, by segregation of different voltage levels and by covering and labeling of equipment at voltages greater than 24V DC.
5.16.2
EMI & Radio Frequency Interference (RFI) The ESD, as offered, shall be supplied with provisions for protecting against system errors and hardware damage resulting from electrical transients on power or signal wiring. These transients include those generated by switching large electrical loads, by power line faults and due to lightning strikes which induce surges on power or signal cables. The IEEE Standard 472 shall apply to all SIS power inputs and signal inputs from field devices. The most common sources of electromagnetic radiation are portable VHF hand-held radio transceivers with 5 watts of power and portable UHF hand-held radio transceivers with 4 watts of power. Other sources are fixed radio stations, vehicle radio transmitters, commutator type electrical devices and spurious sources such as from welders and contactors. The SIS shall be immune from these EMI/RFI interferences in accordance with SAMA PMC 33.1. Particular attention shall be given to the immunity
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of the SIS to RFI from hand-held radios potentially transmitting at a distance of one meter from the cabinets whilst the cabinet doors are open. Errors caused by RFI shall not exceed 0.1% of span for exposure to field strength of 10 volts/meter over the frequency range of 10 to l000MHz. A certified test report shall be required in the proposal to verify this performance. The VENDOR'S equipment shall meet all applicable RFI emissions standards. The VENDORS equipment shall not cause RFI interference to the COMPANY'S hand held radios. The VENDOR shall provide a hand held radio (preferably Motorola Saber I Handie Talkie or equivalent of 5W RF output and VHF 450 - 520 MHz frequency band) to be used for the factory acceptance test (FAT) of RFI susceptibility. 5.16.3 Power Requirements AC Voltage and Frequency Tolerances The SIS equipment shall be designed to operate on a 240V AC 50Hz power. SIS equipment shall be powered from two separate UPS feeders from different distribution boards. UPS shall be supplied by others in accordance with the power requirements as determined by the SIS VENDOR and the COMPANY. The vendor shall design and install power buses in such a manner as to accept individual UPS feeders and distribute individual branch feeder to SIS chassis and redundant field I/O power supply loads. Voltage will be 2% with a maximum transient voltage depression of 20% and frequency regulation will be 1%. This is the only power that will be provided to the SIS equipment. Power Supply Systems The VENDOR shall provide power supply systems for the SIS equipment mounted in the system cabinets and all field devices associated with the ESD. At least 30% spare capacity shall be provided. Power supply sizing should assume the following power loading for field devices; Analogue output devices: 0.5 Watts; Interposing relays: 1 Watt; Solenoid valves for SDV : 6.5 Watts; Solenoid valves for BDV & CV : 11.2 Watts;
The power loading for all other field devices (i.e. system powered DI and AI) shall be based upon the SIS VENDORS standard power loading figures. Parallel redundant power supplies with automatic change-over to protect against power supply failure shall be provided for SIS equipment mounted in the system cabinets. Each power supply shall be capable of supplying power to the entire ESD. Both power supplies must be on line at all times, each supplying power to the load. Failed power supplies shall be removable without disconnecting power from any part of the SIS or affecting operation.
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Each power supply shall be provided with primary and secondary overload protection. Each power supply shall be provided with a pilot light and with a fault detector. Failure of any power supply, including incoming power feeders, fuses and circuit breakers, shall be alarmed by the SIS through the use of a common SIS unit alarm digital input. Output current on power supplies shall be locally indicated in order to confirm that supply capacity exceeds current usage. 24VDC power required for internal SIS components and to power field instruments including relays shall be from the SIS cabinet supplied by VENDOR. 5.16.4 Earthing and Shielding BS7671 Electrical Installations shall govern the earthing requirements of any equipment supplied and must be adhered to in all respects. All metal enclosures supplied shall have a minimum of one 6mm x 20mm copper safety earth bus bar across the full width of the panel. All metal racks, internal panels and fabrications, cable tray, doors and detachable panels shall be earth bonded together to this safety earth with a flexible copper braid strap of at least 2.5mm2 to ensure effective earthing. The safety earth will also be used to connect the earth core from the multi-core plus earth field control cables being used for solenoid valves. Each system cabinet and marshalling cabinet shall be provided with one 6mm x 20mm copper galvanically isolated instrument earth bus bar across the full width of, and insulated from the panel. The instrument earth shall be used for earthing system electronics, the negative terminals of DC power supplies and field circuits, and the electrostatic screens from multi-pair field instrument cables. All system and marshalling cabinet earth bars shall be clearly labeled. 5.16.5 Wiring and Connections All wiring shall comply with the requirements of BS7671 Electrical Installations and shall be carried out using not less than 1mm flexible stranded, annealed copper conductors and PVC insulation. Insulation resistance shall be 500 Volts. The VENDOR shall connect to one side only of the incoming and outgoing terminal blocks. A terminal shall be allowed for each incoming and outgoing wire. No more than one wire is to be connected to each side of any one terminal. Where more than one wire is to be connected on one side for looping purposes, a preformed link or comb between adjacent terminals shall be provided. All wiring shall be fitted with PVC insulated crimp pins or lugs. These shall be wire pins for 1mm2 conductors and lugs for 24V DC power distribution conductors. Separate pins or lugs, as applicable, shall be used for each conductor. The size of pin or lug shall be suited to the size of conductor to be terminated and crimped with the pin or lug manufacturer's approved crimp tool. A method of stripping insulation which does not damage the wire shall be employed.
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Wires shall not be jointed or teed between terminal points. An allowance shall be made on the length of wire at each terminal to permit cutting and remaking of the wire termination at least once without interference with the main run of the wire and loom. Terminal blocks shall be Klippon type SAKR polyamide type test/disconnect knife terminals (or COMPANY approved equivalent) of a size suitable for the particular size wiring being used. Terminal mounting shall be Klippon terminal rail type TS32 (or COMPANY approved equivalent). Each terminal shall be clearly tagged with terminal number. Terminals shall be arranged in groups as per their service. All spare cable cores shall be terminated into terminal blocks and connected to the instrument earth. Terminal strips shall be designed so each incoming and outgoing cable can be terminated such that all cores of the cable fan out in a logical sequence onto a single uninterrupted section of the terminal strip. The terminal strips shall be fixed such that terminal screw slots are accessible from outside the compartment to facilitate ease of wire termination. All terminated wiring shall have individual alpha-numerical identification in the form of Grafoplast (or COMPANY approved equivalent) push-on sleeves. No equipment or terminal block/rail in the system cabinets shall be mounted less than 400mm above the floor. No equipment or terminal block/rail in the marshalling cabinets shall be mounted less than 200mm above the floor. A minimum of 50mm shall be allowed between each terminal row and any plastic slotted trunking to permit sufficient clearance to facilitate fanning of conductors whilst providing easy access for terminations and identification markers. Terminals shall be mounted on rails that are attached to a back pan/support and not directly to the surface of the enclosure. Removable engraved cover plates of transparent insulating material shall be provided over all terminals carrying greater than 24V (AC or DC). Terminals carrying mains supply voltages (240V AC) shall be covered identified with a lightning symbol and the voltage level clearly identified on a label. Wiring of voltages greater than 24V (AC or DC) shall be separated from instrument signal wiring. All wiring shall run such that it is accessible, neat and tidy. All wiring shall be run in trunking and loomed with cable ties. Trunking shall be installed in accordance with the approved layout drawings and shall allow for 30% spare capacity. Where cabling or looming is required to bridge to a hinged panel the installation arrangement shall be so that the opening of the hinged panel will cause the wiring loom to twist longitudinally and not bend or rub on a panel edge or face. At no point shall any undue stress be placed upon the wires. The loom shall be protected with PVC spiral wound wrap or flexible conduit or equivalent. Wiring colour coding shall be in accordance with BS7671 Electrical Installations.
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The VENDOR shall propose its own wiring colour code for all other wiring provided that it complies with BS7671 Electrical Installations and the termination diagrams. 5.16.6 Circuit Protection and Fusing The SIS power supply shall have conditioning/filtering and voltage regulation for immunity against switching surges, as required. Each field circuit shall be individually fused and a SIS alarm shall be generated in the case of fuse failure. These shall be in the form of reset table electronic fuses or indicating cartridge style. All items shall be selected, sized, constructed and specified with a power rating of sufficient magnitude to withstand short circuit conditions associated with the application. 5.17 5.17.1 SIS System Enclosures General The VENDOR shall supply SIS system cabinets and marshalling cabinets. Cabinets shall be the VENDORS or third party standard modular construction. Choice of cabinet type (if there is more than one VENDOR standard) shall be such as to limit weight and dimensional size consistent with good operational and maintenance practices. An overall maximum height limit of 2200mm (including the plinth) applies. All cabinets shall be sized to allow for the installation of all equipment as identified in the Purchase Order, plus 20% spare. In particular the SIS system cabinets in the auxiliary room shall have reserve space for at least two additional I/O racks. Cabinets shall be identical to what the PMCS, FGS are providing for uniformity. Any deviations from these requirements shall be brought to the COMPANY'S attention for approval. 5.17.2 Structural The SIS system and marshalling cabinets will be located in a non-hazardous area and shall be ingress protected to IP54 as defined in IEC 60529. The SIS system and marshalling cabinets shall have sufficient structural members and panels shall be stiffened as necessary to prevent deformation/distortion due to equipment weight and/or from dynamic loads experienced during transportation. (Shipping dynamic loads/vibration defined as 0.5g vertical, 0.5g longitudinal, 0.25g lateral). All SIS cabinets shall be designed to provide adequate heat dissipation. Where forced ventilation is required, fans and air filters that are easily accessible for maintenance shall be provided by the VENDOR. Where forced ventilation is required, the VENDOR
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shall include a fan failure alarm built into each cabinet. This shall be alarmed by the SIS through the use of common SIS unit alarm digital input. 5.17.3 Access Doors Access to the SIS system and marshalling cabinets shall be from front and back vertically hinged doors. Hinged doors shall be mounted on lift-off type hinges and shall be capable of being swung through an angle of not less than 100o from the closed position. The lift-off hinges shall have unequal length pins to enable the door to be refitted with ease. Doors shall be secured in position by a lockable three point locking mechanism and locks shall have identical keys. Drawing holders (A3 size) with paper access slots shall be provided on the inside of all doors. 5.17.4 Panel Lifting Suitable removable lifting lugs (pad eyes, complete with bolt hole plug) shall be provided at the top of all SIS system and marshalling cabinets to enable them to be lifted as complete sub units. It is the VENDORS responsibility to ensure that the panel construction takes account of the loads and stresses imposed by such lifts. Four lift points shall be provided. 5.17.5 Threaded Fasteners The threads of all nuts, bolts, screws and studs of 5mm diameter and above on cabinets supplied in accordance with this Specification shall comply with British Standards. Where possible, all nuts shall be of the captive type in order to prevent loss upon dismantling and to aid reassembly. 5.17.6 Painting and Coating The VENDORS standard shop paint finish for equipment will be acceptable if good industry practices are followed in surface preparation and cleaning. COMPANY shall be consulted for the final color. Damage to paintwork of material transported, handled or assembled by the VENDOR, or incurred during such transport, handling or assembly on behalf of the VENDOR, shall be made good at the VENDORS expense. This shall be achieved by thoroughly cleaning the damaged portion and applying the full number of coats of matching paint that has been applied before the damage was caused. The VENDOR shall supply one liter of each paint type used in surface preparation and painting for use by the COMPANY for site touch-up work.
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The VENDOR shall include the provision of the services of a system/applications engineer who shall be responsible for providing technical guidance and direction during the execution of the project. This engineer shall also be available to assist in the finalization of the plant shutdown strategies and to address any questions regarding performance specifications, programming, installation and field wiring of the ESD. 6.2 Programming Services The VENDOR shall include the provision of programming services. The programming activity shall be executed in the VENDORS premises using the VENDORS programming tools and assisted as necessary by the COMPANY. Programming shall be performed on a lump-sum basis to the scope of work as identified on the I/O schedule, P&IDs, SLDs and C&E tables at the time of Purchase Order award. The VENDOR shall allow for up to 15% additions and/or changes to the SIS system SIS program. Additional work beyond this scope, including additions and/or changes, shall be performed at rates per the contract. Development of the graphics shall be the responsibility of the PMCS VENDOR. However the SIS VENDOR shall provide the necessary input and assistance as required. At the completion of the staging test, the VENDOR shall update the final approved SIS program. This program shall be generated from the operating software and shall be free from software patches. The final approved program shall be delivered on a fully tested and verified system program tape or disk. These shall be supplied complete in a compartmented storage case with suitable labeling. The VENDOR shall also retain a copy of this program revision. 6.3 System Initialization The VENDOR shall include the provision of the services of a qualified field service representative to assist with the installation of circuit cards, peripheral devices and software in addition to the initialization of SIS power. This service shall also include a functional test and verification of the SIS power distribution and earthing. 7.0 7.1 SPARE PARTS Start-up and Commissioning Spare Parts The Vendor shall supply spare parts for start up and commissioning. These will be required in order to avoid using any of the operational spare parts. The Vendor must take into consideration the remoteness of Site when deciding which spares and what quantities are offered. Spare parts will generally be held by the COMPANY on the shelf at the Mehar Gas Development Facilities, not as hot running spares. All spare parts shall be clearly
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marked and identified by the VENDOR using a concise tag or serial and type number. Spare parts shall be adequately protected and packaged by the VENDOR to prevent deterioration of components and contact surfaces during prolonged storage in the environmental conditions as defined in the Specification for Site Data and Utilities. 7.2 Operational Spare Parts The Vendor shall submit a spare parts quotation for two years continuous operation. The Vendor must take into consideration the remoteness of Site when deciding which spares and what quantities are offered. 8.0 8.1 INSPECTION AND TESTING General The SIS shall be subject to rigorous QA and testing programs at all stages of manufacture. Quality assurance and testing shall be designed to simulate as closely as possible local conditions. The testing programs shall be based on ISA RP55.1 and outline methods, procedures and simulation facilities proposed. All equipment will be subject to inspection by the COMPANY'S appointed Inspector as itemized in the Purchase Order. The VENDOR shall afford full facilities to the Inspector during the course of manufacture and shall arrange access to any SubVENDOR'S works where necessary. Details of this requirement will be resolved in preinspection meetings. The VENDOR shall ensure that adequate notice (a minimum of fifteen working days, in writing) is given to the COMPANY and the Inspector to enable them to arrange their visits to suit the manufacturing program in accordance with the conditions of the requisition documents. The acceptance of the work by the Inspector and/or his release of the equipment for shipment shall in no way release or relieve the VENDOR from any responsibility for carrying out all of the provisions of this Specification and/or relevant documentation, nor does the COMPANY by such approval and/or release, assume any responsibility whatever for such provisions. All test and inspection data shall be legible including the name and signature of the VENDOR and, where applicable, the Inspector. All defects in materials detected as a result of testing shall be repaired or replaced by the VENDOR at no cost to the COMPANY. If the correction of any error or defect involves serious alterations requiring replacement of parts, the approval of the COMPANY shall be obtained before proceeding with such corrections. Also, if the correction of the error requires witnessing by the Inspector or a change in certificates issued by the Inspector the correction shall be properly corrected and signed by the Inspector. If any part of the equipment is damaged after tests have been completed, retesting of the affected parts is mandatory. The method of repair shall be in accordance with the VENDORS standard procedures.
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All formal testing will be conducted in accordance with a written test procedure. The VENDORS standard test procedures will be forwarded to the COMPANY at least two months prior to the factory acceptance test for approval. Each formal acceptance test must be signed by the VENDORS and the COMPANY'S representatives at the successful completion of the test. The VENDOR shall supply supervision, specialist personnel and all necessary materials to support the inspection and testing. This shall include all the equipment and signal generation gear adequate to simulate all inputs simultaneously on a loop containing multiple inputs. Testing shall be carried out by the VENDOR and may or may not be witnessed by the COMPANY or the COMPANY'S representative (the Inspector) at various stages as the SIS equipment is manufactured and assembled. Locations are detailed below: Pre-Factory Acceptance Test Conducted at the original point of manufacture of the ESD. Conducted at the original point of manufacture of the ESD. Conducted at the IFAT facility nominated by the VENDOR and approved by the COMPANY. Conducted at the Mehar Gas Development Facility. Conducted at the Mehar Gas Development Facility.
Factory Acceptance Test
Integrator FAT
Site Acceptance Test Availability Test
All power supplies shall be checked for correct voltage and frequency and all cables shall be checked for insulation resistance (Megger checked at 500V AC) before any testing is initiated. Test equipment shall be connected to field connection terminals only. 8.2 Pre-Factory Acceptance Test The QA and testing program for printed circuit boards (PCBs) and electronic components should include as a minimum: Physical inspection after initial assembly; Initial functional test under power (100% of all PCBs); Burn-in cycle (powered environmental cycling to protect against failure due to infant mortality); Unit assembly and coating (inspection); Final test and inspection (signed off by test engineer).
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The QA and testing program for modules and sub-assemblies shall include as a minimum: Physical inspection after assembly; Test under power.
These tests need not be witnessed by the Inspector, but certification along with a detailed report on the tests shall be provided. On completion of testing the serial numbers of all equipment shall be recorded for checking on arrival at Site. The results of the pre-FAT shall form part of the Manufacturers Data Report. 8.3 Factory Acceptance Test The FAT shall be conducted in accordance with the VENDOR'S standard QA procedures. The VENDOR shall supply a 5 Watt hand-held UHF radio for use in the vicinity of the SIS to demonstrate that RFI does not affect the system. No other nonstandard tests are required. The VENDOR shall be responsible for generating the FAT procedures. The pass/fail criteria shall be 100% correct performance otherwise the faulty item shall be rectified or replaced at the VENDOR'S cost. The FAT shall include the testing and acceptance of both hardware and proprietary system software. All proprietary system software shall be complete and resident in the SIS prior to the start of FAT. All documentation and listings must be free of markups. All hardware diagnostic programs shall be run at the start of FAT. These shall be the diagnostic programs which have been used for processing the system in the VENDORS factory. During the FAT, the SIS shall be made available to the Inspector for sufficient periods to verify satisfactory performance. The Inspector will reserve the right to witness the entire FAT as a nonparticipating observer. The FAT procedure will be signed off by the VENDOR and the Inspector and a copy of the signed off FAT procedures and related printouts shall be furnished to the Inspector at the successful conclusion of the FAT. However, the FAT is not an inspection and test hold point. 8.4 IFAT Test The IFAT test will be carried out after the entire SIS equipment has been shipped to the nominated staging test site. The staging test of the SIS will be conducted in conjunction with the staging tests of other equipment with which it must interface in order to verify the correct operation of all interfaces. The VENDOR shall be responsible for generating the staging test procedures that shall include pass/fail criteria. All system HMIs shall be hooked up to the data highway and the whole of the final configuration data base shall be loaded, tested and signed off by the Inspector. System diagnostics shall be exercised, and failure modes shall be demonstrated.
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All equipment shall be energized and remain energized for the duration of this test. This includes any externally powered equipment. Dummy loads shall be fitted in all loops where this is necessary for observing the correct functioning of a loop. These dummy loads shall remain fitted to all circuits except the circuit under test. To allow for cable resistance, the circuits under test shall include resistance to the maximum value permissible by the VENDORS specification. Outputs shall be connected to a device as similar as possible to the final field element (e.g. relay coil, I/P converter, etc.). The VENDOR shall provide test sets for checking sequential control circuits. These shall simulate all interlocks and time delays in the system. All loops in the system shall be tested by applying a simulated signal (or signals in the case of complex loops) at the terminal strip in the marshalling cabinet and observing the effect on the screen, including alarms. Alarms shall not be simply tested by adjusting the alarm setting. Outputs should also be manipulated and the result measured again from the marshalling cabinet. All equipment associated with a loop shall be tested as a system. Circuits shall generally be tested one at a time. However, where cascade or similar controls are involved, these shall be tested as one complete system. These tests are not required for calibration purposes. 8.5 Site Acceptance Test Prior to the commencement of the SAT, the following activities will have been performed by the COMPANY with optional technical assistance provided by the VENDOR: An audit and inspection of equipment received; A deficiency report written and appropriate action taken to rectify any problems; The SIS powered up and functionally tested with the appropriate test equipment.
The process controllers, operator HMIs and peripherals powered up and tested with diagnostic routines. Communications established among all components of the system and tested using the appropriate test equipment. All alarm status, analog and pulse inputs, control outputs of each processor module checked with simulated input and output loads; Each analog device calibrated, the system function verified, followed by the interrogation of each analog point and the operation of each final control element.
The VENDOR shall make available, as an option on day-rates, the services of personnel to assist in the performance of the SAT. The VENDOR shall supply all standard and special tools, test and calibration equipment necessary for the SAT. The SAT procedure will be derived from the FAT and the staging test. The FAT procedure shall be modified to take account of the field environment.
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The SAT will be performed as a joint effort between the VENDOR and the COMPANY. The SAT will demonstrate the functionality of all hardware, field inputs/outputs and configuration. The SAT will be witnessed and signed off by the VENDOR, the COMPANY and possibly third party and statutory representatives. 8.6 Availability Test After the completion of the SAT, each system will be subject to an availability test for a continuous sixty day period. The availability test will be conducted by the COMPANY and will consist of monitoring the system availability during the sixty-day period. The SIS provided by the VENDOR shall have an overall availability of 99.999%. If the system does not meet the 99.999% availability requirement during the availability test conducted by the COMPANY, the VENDOR shall be responsible for repairing or upgrading the SIS (at the VENDORS expense) in order to meet the requirement. The COMPANY will then repeat the availability test and the sixty-day period will begin again following the repairs and upgrades. The availability test will be conducted concurrently with normal plant operations. 8.7 Shop Inspection The Inspector will periodically visit the VENDOR shop facilities and inspect system progress from a hardware and software perspective in accordance with Inspection and Test Plan. 8.8 Certificates of Acceptance At the satisfactory conclusion of the FAT the staging test and the SAT, an appropriate certificate of acceptance shall be provided by the VENDOR. Attached to these certificates shall be all test records and other pertinent documentation. These shall form part of the Manufacturer's Data Report (MDR). The COMPANY will review and approve these certificates. Final acceptance of the SIS shall be on satisfactory completion of the warranty period. 9.0 9.1 DOCUMENTATION General The VENDOR shall provide hard copies of drawings and other appropriate documents developed on his system, with the data stored on either floppy disks or tapes, in a format compatible with AutoCAD, for future use and modification by the COMPANY as required. All documents shall be in the English language, with the data stored on CDs, in format compatible with Microsoft Word.
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The VENDOR shall produce a Functional Specification for approval by the COMPANY. This Functional Specification shall detail all hardware and miscellaneous materials to be supplied against the specification, full details of the exact functionality, performance and self-checking which will be available from the SIS and full definition of the interface to all peripheral equipment. The emphasis of the functional specification shall be on the functionality of the ESD. 9.3 Drawings All SIS drawings shall be prepared and submitted in accordance with recognized standards. Wherever practicable, every effort shall be made to minimize the total number of drawings prepared by use of common drawings wherever practicable without loss of clarity. Prior to start of manufacture, the VENDOR shall submit all drawings for the COMPANYS approval. As-built revisions shall be prepared and final issue. Any information or data revised during staging tests or SAT shall be provided before the commencement of the availability test. Each drawing shall be clearly marked As-built and dated. VENDOR and EPCC CONTRACTOR shall also comply with the requirements of documentation specified in PCPL procedure CSP-03. 9.4 Design Interfaces The VENDOR shall make allowances for 3 issues of COMPANYS documents nominally at 75% (Review), 90% (Approved for design) and 100% (Approved for construction) at completion of detailed design. The COMPANY will provide the VENDOR with the following information: ESD I/O schedule including, but not limited to, the following information for each loop: Tag number; Service description; I/O type; I/O range; I/O units; Alarm settings and alarm messages; Control algorithms and initial tuning parameters;
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Piping and instrumentation diagrams (P&IDs);. Single Line Diagrams (SLDs); Process Flow Diagrams (PFDs); Cause and Effect Diagrams (C&E); The COMPANY'S requirements for graphic displays, report format details, tabular displays, etc.; Earthing, power supply and other interface details.
The VENDOR shall supply complete SIS data for inclusion in the COMPANY's instrument loop diagrams. This data shall include, but not be limited to, the following: 9.5 ESD cabinet termination details; Block interconnections and system cables between components of the ESD; Hardware addresses including cabinet, rack, card slot and point in the VENDORS standard notation; Clear, concise and understandable (by an operator/maintenance technician) configuration software listings including graphic display building software.
Operation and Maintenance Manuals Operations and maintenance manuals shall be provided and shall include, but not be limited to, the following documents: A complete set of the VENDORS standard manuals for site preparation and installation, operation, configuration, maintenance and troubleshooting as applicable to the SIS hardware and software supplied; Drawings and data sufficiently detailed to permit diagnostics.
The VENDOR shall follow its standard practice provided this meets the intent of the above requirements. 9.6 System Log A system log shall be maintained by the COMPANY and the VENDOR from the time the staging tests start, through the SAT and on through the warranty period. The system log shall note all software, hardware and configuration changes and log the following: Date of occurrence of a problem;
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Who reported the problem; Summary of a problem; Problem report number; Action taken to correct the problem; Confirmation that the correction has been tested and accepted.
This system log shall be kept in chronological order.

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