815.301 scada specification rev0

THU DUC III Specification for Supervisory Control And Data Acquisition (SCADA)

810-301-PR-930-E-XXX Rev 0

29-Oct-2014

THU DUC III

INSTRUMENT SPECIFICATION FOR DISTRIBUTED CONTROL SYSTEM (DCS)PLC – SCADA SYSTEM

CONTENTS

1. INTRODUCTION............................................................................................................ 1

1.1 Scope of Specification........................................................................................... 1

1.2 Description of Plant ............................................................................................... 5

1.3 Scope of Supply ................................................................................................... 6

1.4 Project Specifications ...........................................................................................10

1.5 Definitions & Abbreviations ...................................................................................10

1.6 Vendor Exceptions ...............................................................................................11

1.7 Order of Precedence............................................................................................12

1.8 Language ............................................................................................................12

2. REGULATIONS, CODES & STANDARDS .....................................................................13

2.1 Codes and Standards ..........................................................................................13

2.2 Regulations .........................................................................................................14

3. GENERAL REQUIREMENTS ........................................................................................15

3.1 Operation & Design Life .......................................................................................15

3.2 Environmental Conditions .....................................................................................15

3.3 Utility Data...........................................................................................................15

3.4 Materials .............................................................................................................15

3.5 HSE Requirements ..............................................................................................15

3.6 Hazardous Area/ IP Rating ....................................................................................16

3.7 Transportation Loads ...........................................................................................16

3.8 Certifying Authority ..............................................................................................16

3.9 Units of Measurement ..........................................................................................17

4. TECHNICAL REQUIREMENTS .....................................................................................18

4.1 Statement of SCADA Vendor’s Responsibility ........................................................29

4.2 SCADA System Topology ....................................................................................31

4.3 Instrument System Interfaces ...............................................................................31

4.4 SCADA Hardware Design Requirements ...............................................................34

4.5 Field Signal Characteristics ..................................................................................38

4.6 System Performance ...........................................................................................41

4.7 SCADA Communications .....................................................................................43

4.8 SCADA Software .................................................................................................45

4.9 Power Supply Arrangements ................................................................................56

4.10 Earthing ..............................................................................................................56

4.11 Cabinet, Wireways, Termination, Cabling and Tagging...........................................58

5. TESTING......................................................................................................................60

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5.1 Factory Acceptance Testing .................................................................................60

5.2 Site Acceptance Tests .........................................................................................60

5.3 System Initialisation, Commissioning and Start-up .................................................61

5.4 Site Support ........................................................................................................61

6. PROTECTIVE COATINGS ............................................................................................62

7. NAMEPLATE DETAILS ................................................................................................63

7.1 Primary Nameplate ..............................................................................................63

7.2 Tag Plates ...........................................................................................................63

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1. INTRODUCTION

1.1 Summar y for System:

ICA PANEL AT CONTROL ROOM – HOA AN

SUMMARY FOR 800 ICA 01

SUM SPARE TOTAL SELECTED Remark

PLC S7 300 2 0 2 2

HMI 2 0 2 2

Tough HMI, 10” color (1 for MV

and 1 for LV system)

DI 204 40.8 244.8 16 Sixteen DI card (16 nodes type)

DO 103 20.6 123.6 8 Eigh DO card (16 nodes type)

AI 45 9 54 7 Seven AI Card (8 nodes type)

AI HART 9 8 17 2 Two AI Hart Card (8 nodes type)

AO 7 8 15 2 Two AO Card (8 nodes type)

ET200M 10

OPTICAL LINK 6

Power supply 24

VDC 1

UPS 230VAC

1

Cable for

connection 1

ACCESSORIES 1

ICA PANEL AT CONTROL ROOM - CWPS



HMI 2 0 2 2

Tough HMI, 10” color (1 for MV and 1 for LV system)






ET200M 10

OPTICAL LINK 6

Power supply 24 VDC

1

UPS 230VAC 1

Cable for

connection 1

ACCESSORIES 1

THU DUC III


ICA PANEL AT ELECTRIC ROOM - WTP



PLC S7 412 H 2 0 2 2 Redundancy

HMI 1 0 1 1 Tough HMI, 10” color

DI 100 20 120 8 Sixteen DI card (16 nodes type)


AI 4 0.8 4.8 1 Seven AI Card (8 nodes type)

AI HART 0 0 1 Two AI Hart Card (8 nodes type)


ET200M 4

OPTICAL LINK 6

Power supply 24 VDC

1

UPS 230 VAC 1

Cable for connection

1

ACCESSORIES 1

ICA PANEL – LME 1+2

SUMMARY FOR 151.1 ICA 01








ET200M 4

OPTICAL LINK 4

Power supply 24 VDC

1

UPS 230 VAC 1


1

ACCESSORIES 1

THU DUC III



SUMMARY FOR 151.3 ICA

01








ET200M 4

OPTICAL LINK 4

Power supply 24

VDC 1

UPS 230 VAC 1

Cable for

connection 1

ACCESSORIES 1


SUMMARY FOR 151.5 ICA

01








ET200M 4

OPTICAL LINK 4

Power supply 24

VDC 1

UPS 230 VAC 1

Cable for

connection 1

ACCESSORIES 1

THU DUC III


ICA PANEL – FILTRATION BUILDING









ET200M 12

OPTICAL LINK 8

Power supply 24 VDC

1

UPS 230 VAC 1


1

ACCESSORIES 1

ICA PANEL – LIME MILK + FERIC



HMI 1 0 1 1






ET200M 6

OPTICAL LINK 6

Power supply 24 VDC

1

UPS 230 VAC 1


1

ACCESSORIES 1

THU DUC III


ICA PANEL – SLUDGE DEWATERING BUILDING



HMI 1

DI 2 Sixteen DI card (16 nodes type)

DO 1 Eigh DO card (16 nodes type)

AI 1 Seven AI Card (8 nodes type)

AI HART 1 Two AI Hart Card (8 nodes type)

AO Two AO Card (8 nodes type)

ET200M 2

OPTICAL LINK 4

Power supply 24 VDC

1

UPS 230 VAC 1


1

ACCESSORIES 1

1.2 Scope of Specification

This document defines the minimum requirements for design, materials, fabrication, configuration,

inspection, testing and painting for the Supervisory Control and Data Acquisition hereafter in this

document referred to as the SCADA, to be installed as part of the THU DUC III Project.

The supplier should draw upon his existing, pre engineered or standard designs to saisfy the

requirements on the basis of scope of supply, P&ID, layout and block diagrams.

1.3 Description of Plant

1.3.1 Thu Duc III Project Control Philosophy

This section provides an overview of the Control Philosophy to assist the Vendor in assessing the

requirements of this functional specification.

The Thu Duc III Project is a new phase, is designed to be able to process 300,000 water m3/day. Beside

that, the system is also designed to connectable to next phase. As such there is a requirement for a

process control system, and in compliance with various international codes and standards, a

functionally segregated Safety Shutdown System. All of these systems will be new and stand alone at

Thu Duc. There are, however, required interfaces between phase III and Phase IV which are discussed

later in this document.

SCADA is used for controlling, monitoring and collecting data for all devices in factory via controlling

screen with command buttons, data box, etc. After that, system sends controlling signals to PLC. Signal

processing programs in PLC will process received signal and generate commands to control devices. In

return, PLC will send back status signal as well as value (analog) of device’s operating parameters to

display in the user interface.

1.3.2 Extent of Automation & Control

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The extent of automation and or remote control of the plant shall be as follows:

Thu Duc III Project Plant HMI shall be centralised, in the existing CCR.

Equipment used in the control or safeguarding of the plant shall be connected to the SCADA, ESD or

F&G systems as appropriate, and monitored / controlled using the SCADA HMI. In addition, matrix

panels are provided for critical HMI to ESD & F&G.

Start-up and shutdown of the plant will be largely automatic, although equipment requiring visual/local

checking will still require manual operator intervention at stages in the start up sequence. Normal plant

operation in the steady state shall be completely automatic.

Water quality, process and power system will be fully monitored on HMI in the CCR.

1.4 Scope of Supply

A standalone SCADA is required in the following locations:

- Thu Duc Water Treatment Plant

- Hoa An Pumping Station

The SCADA shall consist of a complete factory assembled unit. The unit shall be configured for Process

Control, and monitoring of all THU DUC III defined in this specification document and in the list of

referenced documents herein.

The Process Control I/O summary referenced in the Instrument I/O List, 815.301.PRxxx provides an I/O

count estimate and shall be used in conjunction with P&ID as the basis for sizing the THU DUC III

SCADA system.

The Vendor shall furnish all components and ancillary equipment necessary to make the SCADA

package complete, safe and ready for trouble free operation.

Each unit shall be complete with, but not limited to the following equipment and requirements

Main supply list at Thu Duc:

Operator interface workstations, each consisting of a 21“ Flat Screen LCD colour monitor,

membrane keyboard and Vendors standard VDU interface device, the preferred screen pointing

device is a trackball, the Vendor may offer an equivalent for the Purchasers approval. HMI Touch

Screen interface technology shall be used.

One (1) lot SCADA system and marshalling cabinets complete with controllers, I/O card,

Communication card and communication network units, power supply modules, terminal blocks,

Optical link modules, etc.

Two redundancy PLC S7-410H or equivalent at CCR are connected ot OS Servers via Industrial

Ethernet.

One (1) unit colour laser jet printers (A4 and A3 size) –nominally for printing alarms and printing

reports & graphics dumps.

Two (2) OS server with backup system completed with all required application software. The

server shall be provided with RAID 5 (Hard disk redundancy) configuration.

UPS 230VAC, 20A for each ICA panels;

One (1) Destop Engineering Workstation completed with all required software and application

programs – at Central Control Room (CCR)

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Two (2) Destop Operator Interface Station completed with all required software and application

programs - at Central Control Room (CCR)

One (1) Destop for camera control completed with all required software and application programs

at Central Control Room (CCR)

One (1) Historian server and one (1) Webserver.

One (1) lot routers/FOs converter (support VPN with static IP address to connect to Hoa An

Pumping Station) and Industry Ethernet Switches/Hub;

One (1) lot of GPRS module.

One (1) lot cables (system cables, optical fibre cable, profibus dp cable, Ethernet CAT6 cable,

printer cable

Full package for accessories

List of Instrument Control Automation (ICA) panel:

- Equipment/componet at CCR (admin room)

- 801 - ICA – 01: Electrical room WTP

- 151.1 - ICA – 01: LME 1+2;

- 151.3 – ICA – 01: LME 3+4;

- 151.5 – ICA – 01: LME 5+6;

- 143 – ICA – 01: Filtration Building;

- 179 – ICA – 01: Feric + Lime Milk

- 802 – ICA – 01: CWPS

Main supply list at HOA AN:

One (1) lot SCADA system and marshalling cabinets complete with controllers, I/O card,

Communication card and communication network units, power supply modules, terminal blocks,

Optical link modules, etc.

Two redundancy PLC S7-300 or equivalent at RWPS are connected ot OS Servers via Industrial

Ethernet.

One (1) unit colour laser jet printers (A4 and A3 size) –nominally for printing alarms and printing

reports & graphics dumps.

UPS 230VAC, 20A for each ICA panels;

One (1) Destop Engineering Workstation completed with all required software and application

programs

One (1) Destop Operator Interface Station completed with all required software and application

programs

One (1) Destop for camera control completed with all required software and application programs

at Central Control Room (CCR)

One (1) lot routers/FOs converter (support VPN with static IP address to connect to Thu Duc) and

Industry Ethernet Switches/Hub;

One (1) lot of GPRS module.

One (1) lot cables (system cables, optical fibre cable, profibus dp cable, Ethernet CAT6 cable,

printer cable

Full package for accessories

List of Instrument Control Automation (ICA) panel:

THU DUC III


- 800 – ICA – 01: RWPS

Other:

- Equipment/componet at CCR (admin room)

Process Control System Marshalling Cabinets for field cabling terminations, patch wiring,

termination boards and associated electronic components.

Communication bus, and serial data link interface equipment, modems, etc for interconnection to other systems

System software and licences as required for full functional operation of the process control system.

Application software including configuration and programming services as required for full

functional operation of the process control system.

HMI graphics development / testing, including ESD / F&G logic HMI graphics

Project Management, Engineering, Consultation & Programming Services.

All Hardware required interfacing between the component parts of the SCADA system and third

party interfaces detailed in this document.

All operating system, application and software licensing as called for by this specific ation. This

shall be the latest revision of all proprietary software. In addition, the Vendor shall include any

and all software revisions and manual upgrades which may be released for a period of two (2)

years after purchase order award.

All cabling between SCADA system components.

Engineering configuration services. The configuration activity shall be executed in the Vendor’s

premises using the Vendor’s configuration tools and assisted as necessary by the Purchaser.

Engineering design services and provision for testing for joint development of interfaces to 3rd

party systems, as listed in this specification, including ergonomic input to the design of both the

operator station furniture and the human machine interface.

Fabrication design services.

All testing services including the Vendor’s Factory Acceptance Test, System Integration Tests,

Site Acceptance Test. The integration tests where possible will be coordinated with the delivery of

packaged sub-system equipment in order to verify the correct operation of all interfaces without

the requirement for simulation.

Server, hub/switch for SCADA system as indicated in this document and “PLC AND SCADA

OVERVIEW”, 815.301.PR.941.E.011.00.

Terminal Administration System (TAS) - software for management system.

Verified and checked Equipment layout in control room.

Transportation of equipment to the site, unloading and storage.

Calculated the actual power consumption and power distribution

System integration specifications for all serial interfaces with peripheral equipment as listed in this

specification. This shall be the responsibility of the SCADA vendor to jointly develop the interface

specifications with 3rd party vendors.

Documentation

Special Tools

Preservation and packing of the SCADA in readiness for shipment to the site. The point of

demarcation between the Vendor’s and the Purchaser’s responsibilities will be after packing and

loading onto transport after the staging tests at the Vendor’s premises.

Training

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Laptop PC and all operating and application software and licences for configuration and

diagnostics of subsystems etc during commissioning.

Recommended spares for start up, commissioning and two (2) years operation.

Optional rates for site support

1.4.1 Work Excluded

The Purchaser will provide the following:

VENDOR’s scope shall be as minimum include design, engineering, perform system

configuration, manufacture, fabricate, assemble, test, supply and deliver the complete system,

installation and connection, calibration, precommissioning and commissioning.

Installation of all SCADA equipment in the site.

Connect to all low voltage control panel (MCC) to send/receive command/signal, data.

Connect to all medium voltage switch gear to send/receive command/signal, data.

Connect to all instrument such as flow meter, pressure transmitter, temperature transmitter, pH

sensor, Turbidity sensors, switches, control unit, protection unit to receive the signal and data.

All field equipment, including cabling beyond marshalling cabinets.

Documentation required to enable the Vendor to proceed with the project requirements.

THU DUC III


1.5 Project Specifications

Equipment shall be designed and installed in accordance with the latest edition of the following project

specifications:

Project Documents

Consumer List Including I/O for electrical, Instrument and

measurement

PLC and SCADA Overview

Process xxxx

1.6 Definitions & Abbreviat ions

Definitions

Certifying Authority Nominated Third Party Verifying Body

Company PASSAVANT ENERGY AND ENVIRONMENT

Inspector Nominated Third Party Inspection Agency

Project Data Sheets Governing technical documents for the specific item(s)

Project Drawings Reference drawings for the specific item(s)

Purchaser SWIC

Vendor Vendor of Equipment, including Sub-Vendors(s) appointed by the Vendor to

carry out part or all the work

THU DUC III


Abbreviations

CCR Central Control Room

CED’s Cause and Effect Diagrams

SCADA Distributed Control System

DDFS Detail Design Functional Specification (Vendor deliverable)

DFS Design Functional Specification (Purchaser deliverable)

EPC Engineer, Procure and Construct (form of contract)

ESD Emergency Shutdown System

F&G Fire and Gas

HART Highway Addressable Remote Transducers

HAZOP Hazard and Operability Analysis

HMI Human Machine Interface

HSE Health Safety and Environment

IS Intrinsically Safe

ITP Inspection and Test Plan

OPC Object linking and embedding (OLE) for Process Control

OS Operator Station

P&ID Process & Instrumentation Diagram

PLC Programmable Logic Controller

RTU Remote Terminal Unit (telemetry outstation)

SCADA Supervisory Control And Data Acquisition

SIL Safety Integrity Level as defined by standard IEC 61508

SUB Start Up Bypass

TCP/IP Transmission Control Protocol / Internet Protocol

TUV Technische Überwachungs-Verein - a German based international standards authority

UCP Unit Control Panel

UPS Uninterruptible Power Supply

VDRL Vendor Data Requirements List

1.7 Vendor Exceptions

The Vendor shall be responsible to submit, together with the Tender, a list of deviations or exceptions to

this Specification. In the absence of any exceptions, it will be construed that the Vendor fully complies

with this Specification.

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1.8 Order of Precedence

In the event of any conflict arising between this Specification and other documents listed herein, refer

comments to the Purchaser for clarification before design or fabrication commences. The order of

precedence that applies is as follows:

1. Purchase Order and Purchase Requisition

2. Project Data Sheets

3. This Specification

4. Project Drawings

5. Project Specifications

6. International Codes and Standards

1.9 Language

All documentation and communications shall be in the English language.

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2. REGULATIO NS, CODES & STAND ARD S

2.1 Codes and Standards

All equipment shall be in accordance with the latest edition of the following codes and standards:

Vietnamese Codes and Standards

TCVN 5334 Electrical apparatus for petroleum and petroleum products terminal.

Requirements on safety in design, installation and operation

TCVN 3254 Fire safety-General Requirements

TCVN 3255 Explosion safety-General Requirements

TCVN 5738 Fire detection and alarm systems-Technical Requirements

TCVN 5760 Fire Extinguishing Systems-General Requirements for Design,

Installation and Use

American Gas Association

AGA Report No. 8, 1994

Compressibility and Super-Compressibility for Natural Gas and

Other Hydrocarbon Gases

American Petroleum Institute (API)

API RP 551 1993 Process Measurement Instrumentation

API RP 552 1st Ed,

Oct 1994

Transmission Systems

API RP 554 1st Ed,

Sept 1995

Process Instrumentation & Control

CENELEC – Centre for European Normalisation

EN 54 Fire detection and fire alarm systems

The Instrumentation, Systems and Automation Society (ISA)

ISA S5.1 July 1992 Instrument Symbols and Identification

ISA S51.1 May 1993 Process Instrumentation Terminology

International Standards Organisation (ISO)

ISO 9001 3rd Ed,

2000

Quality Management Systems – Requirements

International Electrotechnical Commission (IEC)

IEC 61000 6-2 Ed 1.0 b

(1999)

Electromagnetic Compatibility (EMC) – General Standard –

Immunity for Industrial Environments

IEC 60079-0 Ed 3.1 B Electrical Apparatus for Potentially Explosive Atmospheres – Part 0

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(2000) General Requirements

IEC 60079-1 Ed 4.0 E

(2001)

Electrical Apparatus for Potentially Explosive Atmospheres – Part 1

Flameproof Enclosures ‘d’.

IEC 60079-11 Ed 4.0 b

(1999)

Electrical Apparatus for Potentially Explosive Atmospheres – Part

11 Intrinsic Safety ‘i’.

IEC 60947-5-6 1999 Low Voltage Switchgear and Control Gear Part 5-6: Control

Devices and Switching Elements – DC Interface for Proximity

Sensors and Switching Amplifiers (NAMUR) First Edition.

IEC 60331 Ed. 1b Tests for Electric cables under Fire Conditions (Fire Resistant

cables)

IEC 60332-3 2000 Tests on Electric Cables Under Fire Conditions - Test for Vertical

Flame Spread

IEC 60529 Ed 2.1 B

(2001)

Classification of Degrees of Protection Provided by Enclosures (IP

code)

IEC 61131 Programmable Controllers

Health and Safety Executive

89/391/EEC Display Screen Equipment Regulations 1992

Institute of Petroleum

IP-15, 2nd Ed., 1990 Model code of Safe Practice Part 15: Area Classification Code for

Petroleum Installations

National Fire Protection Authority (NFPA)

NFPA 72 National Fire Alarm Code

2.2 Regulations

All equipment shall comply with the relevant Vietnamese and international recommendations, and

relevant codes and standards. The Vendor shall determine what equipment requires type approval by

the local Vietnamese Authority and shall provide type approval equipment where necessary.

THU DUC III


3. GENERAL REQUIREMENTS

3.1 Operation & Design Life

The SCADA shall be designed for minimum life duration of 30 years.

3.2 Environme ntal Conditions

The SCADA will be installed on THU DUC III Project.

The SCADA shall be designed suitable for the site conditions:

Maximum Temp: 40C

Minimum Temp: 13.8C

Annual Average: 27.2C

Maximum Humidity: 87%

Height relative to MSL: <1000m

Maximum Wind speed: 20m/s

3.3 Utility Data

The following electrical power supplies and instrument air system shall be made available for use by the

Vendor.

Normal Power supplies: 400 V AC, three phase 4 wire, 50 Hz - solidly earthed

230 V AC, single phase 2 wire, 50 Hz

UPS Power supplies: 230 V AC, single phase 2 wire, 50 Hz (1)

24 V DC (Loop power for instruments only)

Instrument air: Operating min / norm / max: 5 / 10.0 / 13.0 barg

Design max: 14.3 barg

Note (1) Voltage should be updated to the latest electrical specification and finalized in

detail design

3.4 Materials

All materials shall be as detailed on the Project datasheets and referenced specifications. When

materials are not specified the Vendor may offer his standard material suitable for the environment and

operating/design conditions.

All materials shall be new and free of defects.

The Vendor shall use only non-asbestos products.

3.5 HSE Requirements

3.5.1 Noise Limits

Maximum noise emissions shall be in accordance with Vietnamese legislation, Noise in Public and

Residential Areas, Standards for (TCVN 5949).

THU DUC III


The design of the facility shall minimise the noise levels to the lowest practicable. Maximum noise level s

for external areas shall be 85 dB (A) measured at 1m.

The equipment located within instrument rooms shall not generate a noise level exceeding 45 dB (A) at

1m, laterally, from the source and 1.5m, vertically, from the floor.

3.5.2 Emission Limits

Instrument design shall minimise fugitive emissions.

3.6 Hazardous Area/IP Rating

All equipment shall be suitable for the Hazardous Area and Ingress Protection Rating as detailed below:

Non Hazardous Area – Indoor : IP42

All SCADA equipment for THU DUC III Refrigerated Storage Project will be installed in non-hazardous,

air conditioned, and indoor locations.

3.7 Transportat ion Loads

The SCADA shall be designed to withstand both dynamic and static loading and transportation

accelerations.

If required the Vendor shall provide transportation supports for loading and transporting the assembled

and completed packages from Vendors works by either road and/or sea.

3.8 Certifying Authori ty

The Purchaser shall ensure that all applicable technical, documentation or inspection requirements

specified by the Certifying Authority are included in this Specification or associated Project Data Sheets.

Equipment shall be certified to CENELEC or IEC standards only.

THU DUC III


3.9 Units of Measurement

The units of measurement on all documentation and equipment shall be in accordance with SI Units of

Measurement.

Variable Symbol Unit

Temperature 0C Degree Celsius

Pressure Bar Bar

Vacuum kPaa Kilopascals absolute

Weight (mass) Kg Kilograms

Volume (liquid) m3 Cubic meters

Volume (gases) Sm3 Standard cubic meters

Flow (liquid) m3/h Cubic meters per hour

Flow (gas) sm3/d Standard cubic meters per day

Heat kJ Kilojoules

Power kW Kilowatts

Viscosity cP Centipoises

Heat Transfer

coefficient kJ/m2.oCh Kilojoules per square meter per degree Celsius per hour

Dimensions mm Millimetres

Level (storage) mm Millimetres

Level (miscellaneous) 0-100% Percent

Velocity m/s Meters per second

THU DUC III


4. TECHNICAL REQUIREMENTS

SCADA should have following main functions:

- Monitoring and Controlling: user interface will display technological screen for arranging devices in the

factory. On these screens, device’s real status and analog value, e.g. pressure, flow, temperature,

current, etc, will be displayed. In addition, there are command buttons, parameter board for operator to

enter controlling parameters and send commands.

- Connecting to datalogger

- Connecting to power meter by ProfiBus/ Modbus protocol.

- Accessible via Web.

- Able to warn system administrator and higher management level via SMS.

- Providing central database and single station’s database. All data must be accurately synchronized

about time as well as value. Data is not lost when ADSL/GPRS connection is down.

- Easy to backup and restore.

- Flexible and expandable.

- Distributed Client Server

- Support many connecting protocols (connect to many types of PLC as well as devices) following

industrial standard OPC.

- Support charts as SPC chart, XY chart, etc.

- Suport timing chart and configuration user defines

- Support tags such as Event, Alarm Calculation, etc. Easy to calculate and set up PID on Scada

without accessing to PLC (to avoid dependence on the Contractor).

- Database of Scada must be able to import, export and query easily. It also has independent user

interface.

- Can cretate and change tag online without affecting system.

- Database must support communication among nodes and can be easy and

independently developed.

- Alarm event trend will be stored by file for easily backup and restore. There is no limit of time to store

alarm event as well data.

- Alarm must support many speed level (>7 levels). Alarm and event must define directly on tag

definition.

- Support VBA in each object on picture as well as global function.

- Suppport win vista 2008 server, win 2003 server.

- Support tag group for easy maintance.

- Support connection to many servers and clients (256 nodes)

THU DUC III


- Database of Scada must be able to connect with other system such as wheatstone bridge, cameras,

fire-fighting system, sound system, etc.

- Scada in Hoa An and central Scada in Thu Duc must support exchanging data.

- Support security mode 21CFR11 for digital signature to use in the future.

- Easy to connect to other databases via ODBC or OLE DB.

- Can support 256 servers/clients for developing in the future and exchanging data with water factories

and branches in the city.

- Easy to upgrade into new version in the future but still be compatible with old version.

- Graphic supports multi-layer, allows people to view in detail for complicated picture (Graphic has layer

function).

- No limit on number of picture.

- Support security and assigning user.

- Support playback function (simulate device’s timing activities for system’s maintance and

troubleshooting)

- Support creating specific tags of process.

- Configuration of Scada system in Thu Duc and Hoa An: follow attached configuration table.

- Warning and error: alarm screens have display functions of error status of devices, signals. Error

statuses are display in two different forms.

- Security function and right of system access

- Modifying online: Scada must have functions of modify program (online) when it is running without

interrupt producing process (devices don’t have to stop when modifying SCADA).

- Monitoring via internet based on Web browser foundation: Scada must have function of monitoring via

internet based on web browser foundation like directly monitoringin factories with roles which are

assigned in server for security.

- Characteristics and size of software:

Base Scada must have license. This software must be able to manage PLC of different developers.

Controlling (I/O) size of Scada including devices which are investigated in the investigating reports and

in article III: project implementing range of phase 1 and preparation for future development is 20%

12.2. Historian and analysis database

Database of Scada must meet following requirements:

- Be able to store in 20 years and this ability must be proved clearly.

- Storage data must support timestamp and quality to ensure system’s accuracy. Database must be

exclusive for industry and easy to use.

- Be able to connect to OSI_PI collector.

- Storing must support compressing.

- Be able to exchange data among servers.

THU DUC III


- Scada’s computers in Thu Duc and Hoa An must have database and, at the same time, there is

another central database in Thu Duc for backup in case computers are down.

- When connection is lost and restored after a period of time, data in this period must be sent to central

node so that collecting data can happen continuously.

- Allow connecting excel directly to central database in order to easily access any data without

modifying scada (to avoid dependence on the Contractor)

- Provide tools such as calculating average, min – max, total, deviation, standard deviation, etc. so that

reporting can be done easier.

- Historican data must be stored into files. These files are easily back up and restored.

- Support collecting data from csv, xml, data logger.

- Support collecting alarm and event.

- Suport saving (at least 20000 record/s).

- Suport digital signature 21CFR11.

- Support collecting, calculating for server.

- Support collecting data from Scada as well as other system in the future via OPC.

- Suport collection time to 1ms.

- Suport collecting, sending data from nodes to central database to synchronize data among nodes and

central node (especially 64-bit data).

- Support synchronizing time among data in nodes.

- Support data scaling and calculation

- Support data analysis.

12.3. Web:

WEB of Scada must meet following requirements:

- Web must be able to inherit Scada for easy modifying (copy data from Scada to web easily).

- Support at least 5 users connecting at the same time.

12.4. Sms:

SMS of Scada must meet following requirements:

- Support group alarm

- Define group user and priority

- Suppport working schedule

- Allow defining delay time.

12.5. Requirements of newly installed plc:

- Have redundance function for further upgrade in the future.

- Have Ethernet port and easily transmit data to Scada.

THU DUC III


- Programming language follows IEC 1131 standard.

- Boolean calculation speed is at least 0.15ms/k.

- Minimum logic memory is 10MB.

- Realtime clock.

- I/O is compatible with the attached I/O table, list number xxx

- Analog is compatible with the attached I/O table, list number xxxx

- Support Ram Flash

- Processor is at least 300Mhz

- Support communication standards such as Modbus, Profibux, EGD, Hart, SRTP

- Support programming language C.

12.6. Hardware

12.6.1. PLC network,…

Industrial Ethernet: standard network which is very popular in industry, has less responding time, is

expendable and highly stable with following

functions:

- PLC is connected as ring structure to guarantee that the network still work when there is one PLC

failed.

- Network is easily expanded by adding PLC.

- Network’s events are always checked regularly and alarmed when there is accidents such as cable

parting, PLC failure, etc.

- Can easily expand redundancy.

12.6.3. Transmitting system

Private internet channel or ADSL/GPRS with static IP address is used from Thu Duc Water Plant to Hoa

An Pumping Station

Requirements of system displaying standard: in the programming progress, the Contractor should give

common regulations – following consistent standards of Europe or US (depend on the Contractor and

the vigilance of the Investor) for alarm, alarm lamp, siren, color of operation level. For example: red –

run, green – stop, yellow – alarm, etc. Moreover, report and format will be provided by the Investor.

2. Technical solution

12.7. Solution:

Solution is designed following Redundancy PLC.

General map of SCADA system in Thu Duc Water Plant

12.8. Assessing the solution:

THU DUC III


This solution meets requirements of the project’s scope table in the agreement about “Consulting,

investigating and implementing SCADA project in Thu Duc Water Plant”. The system is designed

without using Redundancy. However, Redundancy still can be installed in the future.

Therefore, this solution has following advantages:

- Meet financial requirements, can be easily upgraded with redundancy if needed.

- Have simple design, can connect to many devices: data logger, warning via mobile phone.

- Safety level of this system is high, can guarantee safe and continuous water supplying.

The solution that CATIC center proposes meets almost requirements of designing, maintaining, building

and expandability in the future.

12.9. Describe the solution

According to the investigation and technical requirements that are mentioned in previous articles, the

technical solution suits SCADA system of the existing factory and can be expanded in the future. The

SCADA system includes 2 main groups (from the left to the right on the attached drawing “WATER

SUPPLY SCADA CONFIGURATION”):

12.9.1. Central server system and nodes in Thu Duc Water Plant

Server is installed respective program:

- 02 sets of industrial switch: 1 for controlling department and administrating house which are connected

to each other via fiber cable system in the factory. In the other hand, 1 set for PLC.

- Central controlling department includes: 2 servers with backup system, 1 computer for database, 1

computer for web.

- 02 controllers include: 1 controller is put in central controlling house, 1 in

deposit tank. These set controls remote I/O as unit group as divided in configuration map. Controllers

are connected to SCADA system via industrial Ethernet.

- 01 router Internet (support VNP) to connect to Hoa An station and 1 router to transmit to headquarter.

- 01 internet line with static IP address.

- Printer to print reports and UPS for energy saving (quantity is listed in the estimation table).

- Communication method: monitor SCADA system via internet or LAN using web server with at least 5-

user license.

12.9.2. System in Hoa An pumping station

The system includes:

- 01 Controller receives signal of monitored and controlled devices.

- 01 router Inter to connect to Thu Duc Water Plant via Internet with static IP.

- 01 Internet line with static IP.

- 01 computer to data controlling and monitoring is put in administration department.

- 01 printer connected to server for printing reports and charts.

- Moreover, there should be a UPS for energy saving (quantity is listed in the estimation table)

THU DUC III


12.10. Technical attribute of the design

Devices used for controlling system are designed following international standards.

12.10.1. PLC

- Can be upgraded with redundancy in the future.

- Have Ethernet port and transmit data to Scada easily.

- Programming language follows IEC 1131-3 standard.

- Boolean calculating speed is at least 0.15ms/k.

- Minimum logic memory 240kb.

- Have realtime clock.

- I/O is compatible with I/O table, list number P.1006-LT-0701-01 in investigation documents that are

approved by the Investor.

- Analog is compatible with I/O table, list number P.1006-LT-0701-01 in investigation documents that

are approved by the Investor.

- Support Ram Flash.

- CPU speed (Processor) at least 133 Mhz.

- Support communication standards Modbus, Profibus, EGD, Hart, SRTP.

- Ethernet module should build switch function in module.

- Support C.

12.10.2. Computer, Printer and accessories

- For CPU, the processor must be at least Core4 Duo with high speed. RAM and HDD capacity should

be high capacity (counted at the constructing time) to avoid being behind the times. There are also DVD

write drive and other peripheral devices.

- For monitor, 21” LCD is recommended. Moreover, there should be another

50” LCD monitor for observing. Computers in central department, operation department and Hoa An

pumping department should use dual display monitors.

- Laser parallel printer (color printing for charts, mono printint for reports): printing speed is at least 20

ppm.

- Switch, cable and cable contactors, LAN card, Industrial Ethernet card.

12.10.3. Electric cabinet, intermediate relay and accessories

- Electric Cabinet:Vietnamese design. Imported steel frames. Thickness depends on provider. Minimum

protection level IP54 satisfies following factors:

substituted. So the working life

can be longer and the system is more reliable.

THU DUC III


-circuit current, power light, warning light.

equipped with switch to change mode

Local/Remote.

- Intermediate relay:

NC and NO.

12.10.4. Other additional materials

- A terminal connects the signal cable with domino: use European or Japanese type.

- Signal cable and controlling cable for controlling system in PLC cabinet.

- Screws, bolts, etc. use Vietnamese products

- Cable box in the controlling cabinet… use Vietnamese products.

12.10.5. Technical documents

- The Contractor must provide in English or Vietnamese technical documents which are supplied by the

producers. Main parameters must meet (or more)

requirements. Other things such as attributes, technical design and working principles of devices must

be described cleary in these documents.

- Provided programs must have license and must be fully transferred to the Investor.

12.10.6. Instructing, training and transferring technoloty

The Contractor must commit to organize activities of instructing, training and transferring technology for

the factory’s technical employees about the whole system after technical acceptance. The content must

at least include:

- Introduce about map and principles of the system.

- Introduce about communication network, SCADA program and programming tool PLC.

- Introduce configuration and method to connect to the sytem of PLC.

- Introduce program, monitor and operate in computers.

- Instruct to use and program the monitoring and controlling software in computers (the instructor must

have certification for instructing and training Scada from provider).

- Operating process of the system.

12.10.7. Warranty conditions and after-sale service

THU DUC III


The warranty must be at leat 12 months since the construction is takingover and is brought into

operation. The warranty includes all errors of designing and devices, may not include errors of wrong

operating and other accidents (e.g. flood, natural calamity, etc.).

The Contractor is in charge of all expenses to repair and recover the construction that is still under

warranty.

SCADA FUNCTIONAL AND OPERATIONAL REQUIREMENT

No Location, Devices &

Requirement Monitoring

Mode Collecting

Mode Warning

Mode Controlling

Mode Note

Remark

A. HOA AN STATION

1 Raw Water Pumps

Start/Stop/Speed Command x

Running/Stopped Status x

Trip/Fault Status x x

Local/Remote Status x

Auto Transfer Pumps x x

Speed x x x

Temperature x x x

Pressure x x x

Vabration x x x

Current (A) x x x

Real Time x

2 Penstock

Close/Open/Stop Command x

Closed/Openned Status x


Fault/Trip Status x x

Current (A) x x

Real Time x

3 Air Compressor

On/Off Command x

Run/Stop status x


Auto Transfer x

4 Butterfly Valve





Current (A) x

Real Time x

THU DUC III


5 MV Switch Gear Incomer

Incomer Open Command x

Incomer Close via ATS

Command x x x

Incomer Open/Close Status x x

Incomer Trip/Fault Status x x

Protection x x x

5 MV Switch Outgoing

Open/Close Command x

Open/Close Status x


Protection x

Inter Trip to downstream x x

Current (A) x

Real Time x

6 Measuring System

Voltage, Current, Frequency,

Cos ø, KWH, KVARh,… x x x

7 Transformer

Controlling On/Off x

Working condition and failure x x x

8 Sensors:

Flow, Temperature, Pressure,

Level, pH, Vibration, Turbidiry, Leakage, weigh, gas detector, smoke, fire.

x x x

9 Solenoid Valve


Open/Close Status x

10 VCB, ACB, MCCB, CB

Open/Close Status x

11 Pumps, Fans


Open/Close Status x

Trip/Fault Status x x x

B. THU DUC

12 Clear Water Pumps

Start/Stop/Speed Command x

THU DUC III


Running/Stopped Status x x

Trip/Fault Status x x x

Local/Remote Status x x

Auto Transfer Pumps x x x

Temperature x x x

Pressure x x x

Vabration x x x

Current (A) x x x

Real Time x x

13 Penstock





Current (A) x x

Real Time x

14 Air Blower

On/Off Command x

Run/Stop status x


Auto Transfer x

Softstarte Start Command x

Softstarter bypassed Status x x


15 Butterfly Valve





Current (A) x x

Real Time x x

16 MV Switch Gear Incomer

Incomer Open Command x

Incomer Close via ATS Command

x x x

Incomer Open/Close Status x x

Incomer Trip/Fault Status x x

Protection x x x

17 MV Switch Outgoing


Open/Close Status x


THU DUC III


Protection x x

Inter Trip to downstream x x

Current (A) x

Real Time x

18 Measuring System

Voltage, Current, Frequency,

Cos ø, KWH, KVARh,… x x x

19 Transformer

Controlling On/Off x

Working condition and failure x x x

20 Sensors:

Flow, Temperature, Pressure, Level, pH, Vibration, Turbidiry,

Leakage, weigh, gas detector, smoke, fire.

x x x

21 Solenoid Valve


Open/Close Status x

22 VCB, ACB, MCCB, CB

Open/Close Status x x

Trip Status x x x

23 Sludge Pump

Open/Close/Speed Command x


Trip Status x x x


Temperature x x x

Current (A) x x x

Real Time x

24 Mixer Chamber



Trip Status x x x


Temperature x x x

Current (A) x x x

Real Time x

25 Paddle Mixer Chamber

THU DUC III




Trip Status x x x


Temperature x x x

Current (A) x x x

Real Time x

26 Schludge Scraper LME



Trip Status x x x


Current (A) x x x

Real Time x

Torque Switch x x x

27 AUMA

Open/Close/Stop Command x


Fault Status x x x


Current (A) x x x

Real Time x

28 System of measuring at Lab’s Room

x x x

4.1 Statement of SCAD A Vendor’s Responsibi li t y

The Vendor shall supply a standard field-proven fully integrated SCADA. The Vendor shall supply the

latest release of all hardware and software applicable at the time of bid presentation, no obsolete or

superseded releases of hardware or software shall be offered.

The Vendor shall have responsibility for applying a professional engineering methodology to the design,

fabrication, testing, documentation and preparation for shipment of the SCADA. Configuration shall be

conducted as a joint exercise between the Vendor and the Purchaser. The Vendor shall supply

engineering documentation, which shall include appropriate SCADA input to the Purchaser’s loop

diagrams. The Vendor shall also be responsible for the integration of all peripheral equipment interfaced

with the SCADA as listed in this specification.

The Vendor shall ensure that maximum use is made of Standardised Fixed/Limited Variabilit y

Programme System software. The use of Full Variability Systems software should be minimised and

restricted to those cases where it is necessary to develop bespoke software for a particular application.

THU DUC III


Where used, an established method for controlling and validating software development and

subsequent modification shall be available.

The Vendor shall be responsible for configuration of gateways, switches, nodes, routers and other

applicable network hardware and software configuration to establish the redundant Process Control

System communications bus.

The SCADA Vendor is responsible for total SCADA performance, including communications to foreign

interfaced systems.

The Vendor shall prepare detailed procedures for the installation of equipment and software at site

where applicable. These procedures shall include estimates of the time and resources required for

executing each operation and conforming to the Purchasers work-pack format.

The Vendor shall request, at the tender stage, any additional information he requires concerning

interfaces to foreign systems, in order to ensure complete and successful integration with the SCADA

The Purchaser’s approval of the manufacturer 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.

This specification shall not relieve the Vendor of any responsibility to provide equipment and services

that are suitable for the intended duty.

Verify the loop wiring diagram and design the whole loop wiring diagram from field instruments to

marshalling cabinet (SCADA system).

THU DUC III


4.2 SCAD A System Topology

The SCADA system design topology selected consists of an I/O sub-system and data processing

equipment, located in the Instrument room.

All field I/O shall be hardwired via junction/marshalling boxes to the Instrument room.

System hardware will be optimised by process units, reducing the potential for impact of any hardware

failures on production.

For a more detailed description of the SCADA topology selected the Vendor is referred to, XXX

The normal operation for THU DUC III Project control shall be centralised from the SCADA operator

interface stations located in the CCR.

All SCADA operator interface stations shall be configured to boot-up into ‘viewer’ privilege mode on

power up, and default from any higher security privilege level to ‘viewer only’ mode when the operator

interface station remains unused for a period of >20 minutes.

.

4.3 Instrument Syste m Interfaces

4.3.1 SCADA, ESD and F&G Interface Philosophy

The SCADA, ESD and FGS shall be designed to operate on a stand-alone basis.

The ESD/F&G operator interface station shall be capable of providing display and control functionality of

the ESD/F&G system.

In the event of a ESD/F&G operator interface station failure or for performing particular high integrity

tasks, hard wired console mounted ESD & F&G Matrix Panels, situated in the CCR, will be used to

monitor and control the ESD & F&G system. The ESD and F&G alarms shall be time stamped by the

ESD and F&G system prior to communication to the SOE and shall be printed on a process control

system printer.

The ESD/F&G systems will be capable of external bi-directional and redundant communication to the

SCADA Control Network.

The interface will use industrial and robust standard communication protocol. In case of failure of both

links and / or the SCADA, the ESD/F&G Systems shall not be affected and can run fully independently.

4.3.2 Existing SCADA System Integration

The SCADA system is connectable to any party to send/receive signal also connect able to next phase

4.3.3 Controlled Packages

The SCADA shall have the facility to interface with other sub-system microprocessor based PLC

systems or intelligent devices via single or redundant networks or serial data links. The SCADA shall

carry out control and monitoring of the package via a serial interface to the package local control panel.

The package unit field instruments shall interface directly to the local control panel control system.

The SCADA interface to the local control panel shall via a bi-directional serial interface.

THU DUC III


The package Vendor, under the control of the Purchaser, shall be responsible for the specification of

the control functionality of the package. The SCADA Vendor shall be responsible for designing an

appropriate SCADA HMI user interface and for the joint development of the interface with the package

Vendor. Ultimate responsibility for the correct operation of the interface shall be with the SCADA Vendor

to ensure interface commonality and to optimise the data transfer between systems.

The required interfaces into sub-systems, and the required communication principles, are outlined in the

following sections.

4.3.4 MV-LV panel System Interface:

The SCADA shall have the facility to interface with all panel incl MV and LV panels System via serial

data links. The SCADA shall carry out monitoring some of equipment parameters specified by P&ID via

IP.

The MV-LV panel System Vendor, under the control of the Purchaser, shall be responsible for the

specification of the functionality of the MV-LV panel System that specified by P&ID. The SCADA Vendor

shall be responsible for designing an appropriate SCADA HMI user interface and for the joint

development of the interface with the Tanks Gauging System Vendor.

4.3.5 SCADA Emergency Shutdown and Fire & Gas Interface

The ESD / F&G systems shall interface to the SCADA system utilising redundant system

communications bus architectures.

This shall be achieved utilising separate dedicated redundant profibus network communications links

between the ESD / F&G and SCADA system.

THU DUC III


4.3.6 Electrical System Interfaces

All status signals of the majority of electrical equipment at LV switch board is display on SCADA

operation station. Similarly, commands to start or stop drives operable by the Operator are transmitted

from the SCADA to the LV switch board.

Motors will be capable of being started and stopped from the SCADA Control Network to individual

motor control protection units. The SCADA will also receive status information about the motor from the

motor control protection unit. The control for small motors will be hardwire

Hardwired safety related trip signals to the individual motor control drives shall be generated from the

ESD/F&G system.

A subset of the total amount of detailed information available in the Electrical System is presented to the

Operator on the SCADA and will typically include only the following:

Drive Operation status (Running or Stopped)

Drive selected for remote operation (Remote or Local)

Drive fault status (Fault or Healthy, Trip)

Drive Commands from SCADA (Start, Stop,Speed)

Drive Operation time, Off time

Drive/Transformer temperature, Pressure;

Drive current, Voltage (receive signal from SIMOCODE, VFD, CT,VT);

Valve command from SCADA (Close, Open, Stop);

Valve status (Close, Open, Fault);

Temperatur, pH, Flow, Pressure, .. (Show on SCADA by table, Curve, export to print, excel,

picture file…)

For drives set-up as duty / standby pairs, a further control shall be provided within the SCADA

Drive Duty Selector (Duty, Standby)

This signal is used by the SCADA logic to determine the required action on failure of the duty pump.

On an individual basis, further data that may be required on SCADA will be identified and configured as

required.

4.3.7 Package Time Synchronisation

Larger Vendor packages will be equipped with their own control systems inclusive of alarming & HMI

functionality, the time stamping of which operates relative to their local clock. These external s ystems

may be interrogated to establish the cause of faults or shutdowns.

To allow an accurate comparison of alarm summaries from these packages with the main process

SCADA alarm summary, it is necessary to ensure that each package’s time of day is synchronised with

the SCADA time of day.

This synchronisation shall be achieved by the use of a hard-wired digital output. The outputs shall be

pulsed at predetermined times and the package UCP correct its internal time value based on this signal.

Only the minutes and seconds counters will normally require synchronisation.

THU DUC III


4.4 SCAD A Hardware Design Requirements

4.4.1 System Design

The SCADA hardware system detailed design shall be carried out during the detail design stage by the

Purchaser.

For the purpose of the bid proposal the Vendor shall base the hardware design on the SCADA I/O

summary tabled in the Consumer List and PLC SCADA Review, P&ID and Electrical Drawings.

The Vendor shall take into consideration the following requirements when carrying out hardware system design.

Allocation of control functions shall be allocated within the system hardware with due regard to:

Processor & network loading

Plant integrity,

Common mode failure,

Cable marshalling,

Efficient use of equipment,

Segregation for maintenance,

Calculation of heat load and distribution,

4.4.2 System Redundancy

To provide a high level of integrity, the SCADA shall be implemented on a redundant basis. Thus all

main system components, including but not limited to, the system bus, microprocessor control units,

interface stations, network communications interfaces, gateways, routers, switches, multiplexers, power

supplies, and rack back-planes shall be segregated and duplicated by an on-line hot standby, which

maintain full control in the event of a failure. Transfer to the standby shall be automatic, shall be

alarmed and should have no effect on the operation of the control system.

The system shall be designed to ensure continuous operation with redundancy PLC controllers, two

CPUs on the same rack, in the event of a fault, changeover takes place from the master system to the

standby station. The method of event driven synchronization supports fast and bumpless changeover to

the redundant CPU in the event of a fault. It resumes processing at the point of interruption without any

loss of information or interrupts.

All components can be replaced during normal operation (Hot swapping). When a CPU is replaced, all

the current programs and data are automatically reloaded.

Central processing unit for the upper performance range of central and decentralized control, Used in

fault tolerant plants, programming using FBD, LAD, STL in accordance with IEC 61131-5, SCL, CFC,

GRAPH, Passward protection, supply voltage 24 VDC. Minimum work memory 1MB, support RAM and

EPROM external memory. Processing times for bit operation is at least 31.25 ns.

PLC must have at least 5 interfaces: (1) Ethernet/Profinet for programming, (2) Ethernet/Profinet

interface with 2 port switch for SCADA connection, (3) profibus interface for remote I/O,

(4&5)2xinterfaces for sync-modules.

4.4.3 Controller Processor Loading

THU DUC III


The loading of the system processors shall not exceed 60%, including an allowance of 40% for the

installed spare capacity. The application software and firmware cycle times to meet this loading capacity

shall be set to ensure optimum control of all loops and fast process response (Refer to section 4.6.5 for

details).The system shall require a minimum of maintenance and shall have comprehensive watchdog,

self-checking and self-diagnostic fault detection capabilities, to monitor the system hardware and

software. System failures shall be reported as system alarms. The VENDOR shall provide details of the

redundant operating schemes and the consequences of loss of any functionality in back up mode.

THU DUC III


4.4.4 I/O Capacity & I/O Spare

The capacity calculations of the SCADA I/O processor shall be based on the figures defined by the

SCADA I/O. In order to allow for expansion, the system shall have the minimum installed spare capacity

above the actual I/O and future allowance.

The capacity of the SCADA is defined by the SCADA I/O summary detailed in the “SCADA Instrument

I/O List” – document number: xxxx. With quantities tabulated separately for with, and without, spare

quantities. In order to allow for expansion, the system shall have a minimum of 20% installed spare

capacity above the actual I/O and future allowance defined in xxxx. This should include I/O facilities,

racks, power supplies and distribution, software and bus capacity. 50% spare capacity is required at all

entries into the cabinets and shall also be provided within the cable trunking.

Terminal rails shall be furnished with approved anti vibration screwed terminals. 30% spare installed

capacity shall be provided for each type of terminal fitting.

4.4.5 Hot Spare Capacity

The SCADA system shall be capable of supporting the installation of Hot Spares where specified by the

Purchaser. It shall be capable of enabling removal of installed hot spares from the equipment rack

without risk of adversely affecting adjacent equipment.

4.4.6 SCADA Server Specification

The exact hardware specifications for the engineering servers and clients shall be determined by the

Vendor during detailed design. This will minimise the risk of obsolescence in the rapidly changing

computer hardware technology field.

At the time of writing: The minimum hardware specification of the Engineering servers and workstations

shall be as follows:

Engineering Servers & Workstations

Intel @ Processor Minimum 3.5Ghz Processor.

2048 MB DDR SDRAM.

3MB/1GHz Cache

Automatic Server Recovery Function.

500 GB 10000RPM Hard Disk.

3.5" FD Drive.

8 X DVD +RW/+R Drive.

Dual Embedded Gigabit 10/100/1000 MHz Ethernet / NICs with Fail-Over & Load Balancing.

Keyboard & Cordless Mouse.

THU DUC III


4.4.7 Human Machine Interface

OPERAT I NG CONSOL E S & PERIP H E RAL S

The operator console layout shall be reviewed and agreed with the Purchasers client operations team at

an early stage of console design, this practice helps to establish timely receipt of the clients preferred

layout and engenders client ownership of design minimising the risk of subsequent rework.

The preferred design shall be based around a curved console layout utilising a two tiers approach for

screen placement as this maximises the operator’s overview capabilities.

All Operator interface station hardware shall be mounted remotely from local Instrument room to

minimise noise and & heat in the Instrument room. The CCR console shall contain the OS display,

keyboard, CPU and pointing device.

The SCADA Vendor shall supply ergonomically designed transportable operator consoles as defined in

section 1.4 of this document - Scope of Supply, to house the operator interface station LCD monitors,

ancillary and communications equipment. The operator console design will also incorporate facilities for

seamless fitment of two matrix panels to house a dedicated ESD matrix and a dedicated F&G matrix

supplied by ESD/F&G vendor.

The design shall incorporate sufficient additional space for operator’s documentation along with a

suitable writing area.

The design of the operator console shall comply with the HSE Display Screen Equipment Regulations

1992 (EEC directive 89/391/EEC). Including:

Display screen with stable image, adjustable brightness and free of glare.

Minimisation of reflection, noise, heat and radiation.

Adequate lighting and humidity.

OPERAT OR D ISPLAY M ONITORS

The operator interface workstations as detailed in the scope of supply shall consist of 21” LCD Flat

Screen Monitor computer display devices, with a minimum resolution of 1280 x 1024 pixel matrix of 32

bit true colour.

KEYBOA R DS & POINTI NG DEV ICES

All keyboards shall be industrially hardened, and be impervious to ingress of dust, smoke and liquids.

Accidental depression or failure of a single key on any keyboard or trackball shall not cause a control

action to occur; control actions shall require a minimum of a two key sequence.

PRINT ER S

The SCADA shall perform day to day production reporting.

Two printers shall be supplied for alarm, event and report duties. Both printers shall be high resolution

colour laser type. One shall normally be configured to cover all alarm and event printing functions. One

shall normally be configured for printing reports, screen dumps etc. In the event of printer failure, either

printer should be able to be selected to take over the failed printers function.

The printer shall be connected to the Process Control System LAN and shall include a self-contained

print server for standalone operation. Sufficient memory shall be provided to support full page graphics

printing.

THU DUC III


The printers shall have a maximum noise level of 48Dba at 1 metre; this may be achieved by the use of

acoustic hoods.

Colour Laser Printer Minimum Requirements:

Minimum Print Speed - 5 pages per minute.

Image captures time to be < 10 secs.

Print colours – choice of 256.

Print resolution > 1200DPI.

230V AC 50 Hz UPS supplies.

Supplied on mobile stand, with fresh and used paper storage facilities attached.

Provide as a minimum, On-line / Off-line / Paper Out / Print Job Failed fault diagnostic alarms to

SCADA.

A4 Stationary feed – 500 sheet magazines.

Self Test Facility.

SCADA communication to be via LAN connection

4.4.8 Change, Repair & Test On-Line

The SCADA hardware supplied must be capable of hot swappable change-out to facilitate on line

maintenance without disruption to any other system component or application.

The SCADA hardware supplied must be on-line addressable and configurable through the supplied

engineering workstation package without disruption to any other system component.

The SCADA hardware supplied must support on-line testing of the hardware through the supplied

engineering workstation package without disruption to any other system component.

4.5 Field Signal Characterist ics

4.5.1 Analogue to Digital Conversion

The ADC and DAC performed by the I/O cards shall meet the minimum requirements as specified

below:

Analogue-to-digital converter (ADC)

Resolution: 16 bits.

Linearity: ± 1 least significant bit (LSB).

Repeatability: ± ½ LSB.

Accuracy: ± 0.1% full scale over entire operating temperature range.

Common mode rejection @ 50Hz: 98dB

Digital-to-analogue converter (DAC)

Resolution: 16 bits.

Linearity: ± 1 LSB.

Repeatability: ± ½ LSB.

Accuracy: ± 0.25% full scale over entire operating temperature range.

THU DUC III


All analogue I/O points shall be individually isolated and individually fused on the high (supply) side

through the use of fused terminals. The fuse rating for all analogue I/Os shall be 100 mA. Fuse health

shall be able to be monitored visually (e.g.: Socket Board LED indicators or pop-up tag type fuses).

The system shall be able to support HART communications on all analogue I/O points as standard.

All analogue I/O cards shall have an individual power regulator to provide isolated power for AO and

isolated transmitter power for AI (where the AI is system powered).

All calibration constants of the I/O card shall be handled using software without the need for any

potentiometers on the I/O card. As a result, replacement of an I/O card shall not require recalibration

4.5.2 Analogue Inputs

The SCADA shall support the following types of Analogue Input (AI)

The SCADA will be capable of interfacing to 2, 3, and 4 wire devices. The 24 VDC loop power for two

wire devices shall be supplied by the SCADA and the current shall be sourced by the SCADA. The 3

wire devices shall be supplied 24 VDC from the SCADA. The 4 -20 mA DC signal shall sink at the

SCADA. The device shall not be grounded.

In particular, 4-20 mA DC 2 wire transmitters supplied at 24VDC from the system and suitable for a

maximum input resistance of 250 ohms, with HART communication capabilities, both I.S and non I.S,

Individually fused. Where Hart devices are used the SCADA shall provide access to the full range of the

transmitter’s intelligence from the operator and/or engineering workstation.

Alarming of out of-range signals,

Dual Redundant Capable,

Selectable isolation from ground,

Intrinsically safe as standard,

Support “HART” protocol,

Common and differential mode surge protection,

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4.5.3 Analogue Outputs

Alarming of open or short circuit loads,

Standard sourcing 4 -20 mA signal capable,

Supply of 24VDC power to the load (current limited),


Support “HART” protocol,

Common and differential mode surge protection,


Capable of driving an output load of 1000 ohms (Non-I.S.) or 600 ohms (I.S.),

Capable of programmable selection of fail state action on communications failure,

4.5.4 Digital Inputs

The SCADA shall support the following types of Digital Inputs

All digital I/O points shall be individually isolated and fused. Fuses shall be able to be replacing without

removing the I/O card. All digital I/O cards shall provide loop status LED indication. Specifications on

digital I/O shall be as follows:

24VDC as input “1” (logical “true”) and open circuit as input “0” (logical “false”). The sense voltage to

field contacts shall be supplied from the SCADA via individually fused circuits.



Incorporate surge protection,

Provide contact “de-bounce” circuitry,

4.5.5 Pulse Inputs

Suitable for 3 wire connection.

Compatible with a received signal that is square wave, unipolar, of 8-24 VDC peak magnitude, 10Hz -20

kHz frequency. Exact pulse rates and levels will be defined during detailed design.

Intrinsically safe as standard.

Incorporate surge protection.

4.5.6 Digital Outputs (24 VDC)

The SCADA shall support the following types of Digital Outputs

Dry contacts rated at 4A (24VDC). These shall be selectable as normally open or normally

closed, momentary or maintained. The voltage to outputs shall be supplied by the SCADA

(including individual fuse protection) for 24VDC outputs.

24VDC, I.S. powered digital outputs, 45ma load minimum, individually fused (with out the use of

interposing relays).

24Vdc, non-IS powered digital outputs, 1amp load minimum, individually fused (with out the use

of interposing relays).

Incorporate surge protection,

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Capable of programmable selection of fail state action on communications failure,


4.5.7 Intrinsically Safe Circuits

The SCADA system shall support interface to intrinsically safe circuits through intrinsic safety isolation

achieved through the use of appropriately certified, galvanically isolating intrinsically safe interface units.

The barriers may be either inherent in the system I/O cards, termination assemblies or field cable

termination blocks within the marshalling cabinets.

The SCADA Vendors intrinsically safe equipment shall be capable of interfacing to high frequency pulse

transmission to enable connection of HART devices.

4.5.8 Smart Field Device Interfaces

The SCADA shall be capable of interfacing to the following smart device protocols to enable

interoperability and competitive selection of smart field devices.

The SCADA shall interface to all HART analogue transmitter inputs, HART multiplexers are not acceptable.

This will enable incorporation of HART parameters into the SCADA Asset and Maintenance Management

System.

4.6 Syste m Performance

4.6.1 Input Conditioning

The SCADA shall provide the capability to apply analogue input point, process variable filtering to

prevent signal noise degrading the system and communications performance. Filter time constants shall

be configurable from the SCADA engineering workstation on an individual input point basis.

4.6.2 System Diagnostics

The SCADA VENDOR shall state clearly the tools and methods available for system health monitoring,

system performance statistics and proactive failure analysis for all SCADA components.

The SCADA shall have extensive self diagnostic capabilities running on-line as a background function.

The SCADA shall generate alarms and log internal errors/faults to the system log files for archiving.

The SCADA shall provide graphic displays dedicated to providing diagnostic and system performance

overviews to enable clear identification of system component failures including both primary and backup

in the case of redundant nodes.

4.6.3 Controller Failure

The SCADA controllers provided must incorporate a designed inherent redundant architecture that

provides a demonstrable availability figure of > 99.99% in accordance with section 4.6.10. Redundancy

features shall include

Synchronous operation of redundant CPU’s,

Uninterruptible switching of control on master controller failure, (< 1ms),

Fault diagnostics generation & alarming on CPU failure.

4.6.4 SCADA Memory Retention

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All SCADA devices or components containing volatile memory shall employ a means of battery back -up

in order to preserve memory contents for not less than 28 days subsequent to interruption of power to

the system, and so avoiding the need to re-load software.

The SCADA Vendor shall fully describe where all software resides in the system and identify where

volatile memory cannot be preserved for the specified time.

4.6.5 Processing and Scan Rates

CONTROL L ER ANALOG UE PERFORM A NC E

Controller analogue performance based on system execution speed, under the stated loading

conditions, shall facilitate loop execution speed as described below. Where execution speed refers to

the computation period for the cycle of reading all inputs, executing analogue algorithms and writing the

results should be referred to the analogue output registers.

Based on I/O loading of 100% actual I/O + spare requirements identified in section 4.4.4.

20% for 1.0 second updates

60% at 0.50 second updates

20% at 0.25 second updates

CONTROL L ER DIGITAL PERFORM A NC E

Controller digital performance based on system execution speed, under the stated loading conditions,

shall facilitate loop execution speed as described below. Where execution speed refers to the

computation period for the cycle of reading all inputs, executing digital algorithms and writing the results

should be referred to the output registers.

Based on I/O loading of 100% actual I/O + spare requirements defined in section 4.4.4. 100% for 200

ms updates

4.6.6 Operator Interface Station System Response Times

The SCADA operator interface station system response times detailed below shall be based on

manipulating the most complex graphic application available.

Graphic Displays 2 seconds

Alarm Annunciation 2 second

Graphic Display Dynamic Data Update 1 second

Alarm and event resolution 1 second

Sequence Of Events Resolution 1 millisecond

Response to Keyboard/Trackball Immediate

4.6.7 Loading

Loading of operator interface stations, controllers, data communications devices and networks shall not

exceed 60% of total capacity under maximum loading conditions including all spares capacity defined in

this document, maximum loading conditions is to be based on the heaviest alarm load possible.

The SCADA Vendor shall provide calculations for the estimation of the data loading for all

communications circuits, in his tender.

4.6.8 Alarm Flooding

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The SCADA system shall provide inherent alarm handling capabilities to prevent/minimise alarm floods

on the SCADA. The alarm handling package shall be capable of automatically disabling alarm

annunciation both audible, and visual on the alarm summary displays under prescribed operating

conditions. The alarm handling package shall also support manual selection of alarm disabling by the

process operator. The disabled alarm states shall still be visible to the operator on the applicable

process graphic and be logged in the alarm/event log.

The alarm handling package should automatically identify the operating conditions to initiate alarm

disabling from a set of criteria based on measured operating parameters defined by the Purchaser in

the detailed design documentation.

4.6.9 SCADA System Re-Boot Time

The Vendor shall state and guarantee the time that the entire SCADA system, including all controllers,

servers, gateways, switches, hubs, interface stations, software applications, historizing & archiving

functions take to conclude their re-start routines and return to normal status.

This value is to be based on the actual system hardware and software proposed in the Vendors

proposal, not on a typical installation.

The figure guaranteed will be subject to verification during the FAT procedures.

4.6.10 Availability/Reliability Requirements

GENERAL

The SCADA System is required to have an overall availability of 99.99% or better with a Mean Time to

Repair (MTTR) of no more than one hour. The Vendor shall submit the availability calculation for the

system proposed along with the system reliability figures for all SCADA sub components. Equipment

reliability figures used in the calculations shall be based on proven field performance or similar

installations. The overall design of the system shall be such that the failure of any component of the

system shall have minimal affect on the process operation.

SYSTEM RELIABILI TY F IGURES

The reliability figures to be achieved by the system are summarized below:

MTBF : *

Minor Failure : *

Significant Failure : *

Major Failure : * > 10 Years

Total Failure : * > 50 Years

* Indicates value to be calculated by SCADA Vendor.

Data used in the calculations shall be supplied and the source of the data shall be identified. All

assumptions shall be clearly explained with justifications.

4.7 SCAD A Communicat ions

4.7.1 Data Communications

The control system network shall provide real time performance. The control system shall be based on

“open” system architecture and protocols. That is, the system shall have inherent capability to integrate

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and exchange information with other brand system devices and platforms via industry standard

communications, platforms and protocols.

4.7.2 Gateways

The SCADA shall be capable of interfacing to third party systems via gateways. Where proposed by the

Vendor the gateways shall satisfy the following requirements:

Provide within the gateway a resident image table of all data blocks written to or read from this device,

such that the SCADA accesses only the image data so reducing downstream network congestion.

The gateway image table shall be updated asynchronously to SCADA operations with configurable

update times.

Provide error checking and diagnostics on data transfer.

Ability to assign tag names and descriptors to gateway addresses.

Provide translation of data protocols.

The Vendor shall fully describe the ability of the system proposed to integrate with the third party

systems detailed in section 4.3 and his methodology for doing so. The resulting inter-operability of the

SCADA with the third party packages shall be fully described.

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4.7.3 Ethernet Interfaces

The SCADA shall provide as a minimum, Ethernet interface capability to the ProfiBus DP

4.7.4 Serial Interfaces

The SCADA shall provide as a minimum, /RS-485 Serial interface capability to the Modbus

RTU/ProfiBus DP.

4.7.5 Fibre Optic Links

The SCADA Vendor shall supply details of proposed fibre optic link interface devices required to

integrate the SCADA distributed control network

4.7.6 SCADA Network Loading

Loading of data communications devices and networks shall not exceed 60% of total capacity under

maximum loading conditions including all spares capacity defined in this document, maximum loading

conditions is to be based on the heaviest alarm load possible.

The SCADA Vendor shall provide calculations for the estimation of the data loading for all

communications circuits, in his tender.

4.7.7 Network Diagnostics

The SCADA Vendor shall state clearly the tools and methods available for sys tem health monitoring,

system performance statistics and proactive failure analysis.

The SCADA shall have extensive self diagnostic capabilities running on-line as a background function.

The SCADA shall generate alarms and log internal errors/faults to the system log files for archiving.

The SCADA shall provide graphic displays dedicated to providing diagnostic and system performance

overviews to enable clear identification of system component failures including both primary and backup

in the case of redundant nodes.

The SCADA shall display the number of re-tried transmissions resulting in non-fatal communications

errors to enable advance warning of network issues.

4.7.8 Network Error Handling

The SCADA Vendor shall state clearly the tools and methods utilised to manage transmission error

detection and elimination. These shall include but not be limited to:

Error checking on all transmissions.

Automatic re-transmission on error detection.

Automatic switching to standby data path in the event of primary link critical fault or failure.

4.8 SCAD A Software

4.8.1 General

The Vendor shall supply clarification of the standard system software release version that is proposed in

the bid, and his expected software updates for the coming 3 years. The migration path for future

software upgrades shall be clearly specified by the Vendor.

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The SCADA Vendor shall provide as part of the system all system and application software (fully

configured & documented) necessary to implement the functionality described in this specification and

the Equipment Specification for SCADA Functional Requirements.

The software shall be designed and programmed to facilitate maintenance, modification and future

expansion of facilities and be of modular structure. For standard supervisory control, monitoring,

sequential and interlocking the software coding shall be provided through the Vendors standard function

block oriented application programming techniques.

Maximum use shall be made of standard application logic macros for all commonly used functional

requirements, this maximises programming efficiency allowing parallel manpower development, and

results in standardised application logic which simplifies operation, long term maintenance and

development requirements for the client.

Where the Vendor proposes the use of industry standard high level programming languages, eg

FORTRAN 90, PASCAL, VB, C/C++ to satisfy functional requirements the Vendor must submit in

advance of any programming being carried out his reasons for requesting this variation and request the

approval of the Purchaser.

4.8.2 Controller Functionality

The SCADA, as offered, shall utilise a single global distributed system database structure distributed to

the controller level. All algorithms, tags, loop descriptors, and calculated or actual values shall reside in

the controller card cage. All information in the controller, all digital and analogue data, whether it be field

or system calculated, all system alarms, and all diagnostic information shall be globally accessible by

every node on the SCADA Control Network.

The SCADA, as offered, shall accept and manipulate, as a minimum, sixteen character tags.

The SCADA Controllers shall be mounted in Instrument rooms and shall be fully pre-programmed with a

wide selection of control and data acquisition algorithms. Configuration shall be maintained in RAM (or

non volatile memory) and shall have battery power back up. In the event of a link failure between the

controlling device and the SCADA Control Network, the controller shall continue to monitor and control

the process without interruption.

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4.8.3 System Functionality

REGUL AT OR Y CONTROL

The SCADA as offered shall provide as a minimum the following regulatory control functions:

PID control

Input Indication

Manual loaders

Signal selectors(High/middle/low)

Signal setters

Sequence Function Control (SFC)

Function Block Diagrams (FBD)

Structured Text (ST)

Batch Control

Controller Bump-less Transfer

Gap controller

Internal Cascade Control

Error squared controller

Integral with Bias Controller

Split Range Control

Lead Lag Function

Dead Time Compensation Function

Ratio/Bias Controller

Adaptive Control

Mass Flow Computation

Velocity Limiter Function

Rate of Change Calculation

User Selectable Math and Logic Functions

Piecewise Linear Interpolator

Discrete Motor Controller

Auto Sequencing Motor Controller

Dual Speed Motor Controller

Dual Direction Motor Controller

Discrete Valve Controller

Auto Sequencing Valve Controller

Motorised Valve Controller

Configured Moving Average

ADV ANC E D CONTROL

The SCADA as offered shall provide as a minimum the following advanced control functions:

Fuzzy Logic Controller

Multivariable Control

Neural Control

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Multivariate Statistical Control

Real Time Optimization

Auto Self-Tuning controllers

4.8.4 Alarm Management

Process and system alarms shall be annunciated audibly and displayed at appropriate workstations.

They shall be printed on appropriate alarm printers and logged in alarm history files.

An audible signal shall sound each time an alarm occurs. A visual signal shall indicate plant section

in which the alarm has occurred. Audible sound shall have different, configurable, priority tone

levels.

It shall be possible to alarm any point in the system.

It shall be possible for an operator to acknowledge any alarm configured at his workstation by no

more than two actions. The operator shall be able to acknowledge a single alarm, a group of alarms

or all alarms on current page.

ALARM SUM M ARY D ISPLAY

It shall be possible to provide separate alarm summary displays for each plant section in the following

format:

Multi-page displays may be used for alarm summaries. It shall be possible to access these pages

sequentially (forward or backward) by a single operator action.

The alarm summary display shall list alarms in tabular format in order of occurrence with most

recent alarm at the top. An option shall be available to list alarms by priority with the highest priority

alarms starting at the top of the page.

Accessing alarm summary displays from any other display shall require no more than two operator

actions.

Alarm display format shall be one line of 80 characters minimum. The alarm message shall contain

the following information as a minimum:

1. Time of alarm in "hours:minutes:seconds" in a 24-hour format

2. Tag ID

3. Tag descriptor

4. Type of alarm

5. Engineering units

6. Alarm priority

7. Alarm limit and actual value or desired state and actual state

Colours for different alarm states shall be configurable for graphics.

PROC ES S ALARM ING TYPES

The following types of alarms shall be provided as a minimum:

Process input high/low warning value

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Process input high/low absolute value

Process input excessive rate of change

Process input out of range high/low failure

Process input setpoint deviation from control and computational point high/low warning value

Process input setpoint deviation from control and computational point high/low absolute value

Process input high/low deadband deviation

Contact input change of state

PROC ES S ALARM LOGGI NG

For each process alarm that is configured to be logged, the alarm printer shall be activated

automatically upon any alarm condition.

Alarms shall be logged only on the alarm printer associated with workstations that are configured for the

plant section in which alarm occurred.

The following information shall be logged as a minimum:

Alarm tag ID

Alarm description

Type of alarm

Time of alarm, time acknowledged and time returned to no alarm expressed in

"hours:minutes:seconds" in a 24 hour format (day and month shall also be logged)

Process value at alarm

Alarm priority

Log entries shall be generated for tags going into alarm state and for tags returning to normal. Tags

going into alarm shall be indicated by red colour or by some other easily recognized characteristic. Tags

returning to normal shall be indicated by black colour or some other easily recognized charact eristic.

Alarm printer shall be the Laser type.

ALARM DEACTIV ATI ON AND INHIBI TI N G

It shall be possible to manually inhibit alarms on a point-by-point, group or system-wide basis. This

capability shall be protected by system access control. These actions shall be logged. A list of

suppressed alarms shall be available at the operator station.

An alarm cutout function shall be provided to automatically suppress alarms upon occurrence of

another alarm.

An alarm cutout function based on logic shall be provided to deactivate groups of alarms for

equipment that is out of service.

SYSTEM ALARM S

All devices connected to the communications network shall be monitored for failure.

An alarm indication shall be generated for each failure detected.

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It shall be possible for system alarms to be logged on a printer separate from the process alarm

printer.

4.8.5 Historical Data and Trends

This Section details the minimum requirements for historical data collection, trending, event history and

sequence of events.

GENERAL

There shall be configurable real-time and historical data collection package to support trending.

It shall be possible:

For operators to trend tags as needed

To store the value of any analogue point or calculated value in history files

To record the change of state of any discrete point in one of the event histories

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H ISTORI CA L DATA

The Operator system shall provide a complete historical subsystem providing the user the capability to

capture and analyse historical data. The system shall allow selection of any point in t he system to be

added and configured for archiving.

The archiving system shall ultilize a Microsoft SQL real time relational database for storage of all

process related data. Flat file or internal proprietary databases will not be accepted. The archiving

system shall be configured using standard tools provides by the system to facilitate the display and

editing of archive rates, archive types, etc. from graphical and tabular data displays.

The system shall support the online addition of new tags to the historical database without interrupting

operations.

The historical subsystem shall promote the visualization of historical data in both tabular and graphical

form. The historical system shall provide the ability to define archiving rates in increments of

millisecond, seconds, minutes, hours, or days. The historical system shall allow an individual archive

rate to be systematically modified and/or utilized as part of the control logic/Scripting requirements

specified above.

A high speed back up device with removable media, such as streaming tape cartridge or optical disk,

shall be provided for each, suitable for backing up the whole system on a weekly basis. At least one

double DVD write/rewrite/read with +R and –R capacity in addition to the historical data storage device

in the operator station should be provided.

It shall be possible to transfer data to removable media for historical data storage and/or archiving. The

historical device shall not support any type of data compression algorithm that is not 100 percent

recoverable. Following are minimum requirements for historical storage:

Eight hours of five second snapshots

Ninety-six hours of one minute snapshots

Hourly averages for last 168 hours

Eight hour averages for last 168 hours

Daily averages for last 30 days

Monthly averages for last 12 months

TRENDI NG

A configurable trend package shall be provided to fulfil the following real-time and historical trending

requirements:

Historical data collection rates shall be configurable between five seconds and one hour, inclusively.

When an analogue point is not available (point off scale, out of range, etc.), an unavailable code

shall be entered in history.

Standard reports shall be provided to print history values.

TREND H ISTORY CAPACITY

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It shall be possible for the system to be configured to support online trends for at least the following data

collection rates and retention times:

One minute snapshot and/or average values for four days

Five or six minute average values for a month

TREND D ISPLAYS

Both real-time trends and historical trends shall be provided.

All operator workstations shall be capable of displaying trends.

Each trend display shall consist of plotted trend graph(s) and a table showing trend parameters.

It shall be possible to call up real-time trend displays for any process point. The trending facility shall not

allow any display exception reporting, i.e., all raw data shall be displayed as it is collected or stored.

It shall be possible to incorporate trends in graphic displays.

Consecutive trend data points shall be connected by straight lines.

In full screen format, resolution of the graph shall be equal to or better than 210 value points on the

process value axis for at least 60 tag data points.

If only one point is on the trend display, the vertical axis shall be used for engineering units and

engineering units for that point shall be shown. If multiple points are on trend display, then the

vertical axis shall be in percent of engineering units for each point shall be listed in a table if they

are not shown on the vertical axis.

Time period and scale available for a trend display shall be adjustable. As a minimum, time periods

between 15 minutes and four days shall be available. Auto scaling and timebase changes of the

trend shall be available to the operator through a simple action (e.g., one or two keystrokes).

Trend display parameter table shall show the tag ID, minimum scale value, maximum scale value

and engineering units for each point, in the same colour as the tag graph.

REAL-TIM E TREND S

A real-time trend feature shall be provided to make it possible for an operator to initiate a real -time trend

for any analogue point.

EV ENT H ISTORY COLLECTI ON

Each event history file entry shall contain time and date of occurrence, tag ID, tag description and

value/state and type of event.

The following events as a minimum shall automatically be stored in history files for later reporting and

analysis:

Process Events

Operator Events

Engineer Events

System Events

EV ENT SUM M ARY DISPLAY

The event summary shall display all events described in Section 16.7 of this section.

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4.8.6 Reports and Printers

The system shall have utility packages to generate report formats using a conversational, fill -IC-the-

blank approach.

Software programming shall not be required to generate reports.

It shall be possible to use any variable in the system in a report.

It shall be possible to activate a report on the following basis:

On demand (operator's request)

Shift, daily and monthly

Event driven

Reports to the same device are to be queued.

It shall be possible to configure a report to accept manually entered data for specified fields.

The system shall provide facilities to program user defined reports using a configurable and flexible

report writing package.

The package shall be provided with necessary system calls and access to generate a report from the

real-time database and event history collection files. It shall be possible to print user-defined reports to a

report printer and at least one bulk storage device.

4.8.7 Application Language

The Vendors application language shall be a user-friendly, intuitive tool that facilitates ease of use for

operations, maintenance and engineering. The system shall be based on a windows based architecture

utilising modular function block architecture in accordance with IEC 61131-3 from the Vendors standard

system library incorporating extensive parameter selection help menus and on line documentation and

configuration manuals.

A tagged instrument database, in an agreed format to facilitate configuration will be issued to the

SCADA Vendor as a basis for system configuration. Simple loops shall be configured by the Vendor

directly from the P&ID’s. More complicated loops, such as sequence logic, will be configured by the

SCADA Vendor, from the Specification for SCADA Functional Requirements, and logic block diagrams,

as supplied by the Purchaser.

The SCADA Vendor shall be responsible for the preparation of all application software and configuration

for the system.

The system configuration software package shall be structured such that data entry is required only for

detailed engineering fields, these shall be accessed from pull down options menus and configured with

smart default settings to minimise data entry.

The system configuration shall support cut, copy, and paste control strategy development built to the

IEC 61131-3 standard for control strategy development.

The SCADA shall support concurrent system configuration by multiple PC’s on a single system

database to facilitate productive engineering.

The resulting application software shall provide complete safe and efficient control of the facilities, with

logical and interactive operator control via the operator interface workstations. The software shall be

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backed up and stored on non-volatile media such as CD-ROM/DVD, such that it can be loaded into the

system simply and quickly.

The SCADA system shall be capable of modifications to the application software in the online mode

without the need to stop or interrupt a controller from the engineering terminal. There shall be no impact

on any other control functions other than the portion being modified. Online application changes must

be distributed throughout the network in real time.

The SCADA system shall support creation of simultaneous multi-user “virtual system” databases to

enable emulation of control interface stations and allow development and testing of application software

on standard PC’s without the need for interface station hardware.

4.8.8 Functional Specification

The Vendor shall produce a Detailed Functional Design Specification (DFDS) for the Purchaser’s

approval, in accordance with the request for engineering documents issued by the Purchaser.

The DFDS shall detail all hardware and miscellaneous material to be supplied, full details of exact

functionality, performance and self-checking which will be available from the system, and full definition

of the interfaces between the SCADA, the ESD, the FGS and all other package interfaces defined in

this document and shown on the “Instrument System Architecture Block Diagram” – 00023-IC-DBD-

0001.

A full analysis shall be included of the reliability and availability of the system supplied, complete with

source data as detailed in section 4.6.10 of this document.

4.8.9 Engineering Programming Facilities

The Vendor shall provide a dedicated engineering workstation to be situated in the CCR as detailed in

the scope of supply. The engineering workstation shall be desk mounted and consist of a 21” LCD flat

screen monitor, keyboard and pointing device. The engineering workstation shall be the dedicated point

for all maintenance and analysis of SCADA performance and should be furnished with all licensed

software applications and maintenance tools necessary to maintain, diagnose, modify, tune, document

and configure the system. All tools shall operate under the same environment and be Windows XP

driven.

Additionally the system shall be capable of enabling modification, save, and loading of configuration

data from any of the operator interface workstations under software security access control.

The system shall be capable of self documenting configuration data in English format directly to a

printer for hard copy,

A full list of all software, engineering tools, together with details of all licensing agreements and

restrictions shall be submitted by the Vendor.

The Vendor shall also supply the original software media and licences.

4.8.10 Audible Alarm Annunciation

The SCADA shall be used to initiate audible alarms for the process control system, ESD/F&G systems

to alert the operator of plant disturbances and conditions. The SCADA shall support generation of a

minimum of four (4) different alarm tones, which shall be assigned on an alarm priority basis to enable

audible discrimination of incoming alarm priorities.

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Generation of the alarm signals shall be from redundant sources so no single component failure can

disable the generation of alarms. Alarm generation speakers shall incorporate redundancy in there

design.

The alarm volume levels shall only be adjustable from the SCADA engineering workstation and their

access controlled through software security access. No external volume controls are permitted.

4.8.11 Access Security

The SCADA functionality shall provide for application of user configurable access securit y control via

software password recognition. This shall be used to limit the access rights of personnel to the SCADA

system functionality into the following user defined groups as a minimum.

Viewer - Allows any process or system graphic display to be accessed from the interface

station and view only privileges apply.

Operator - Allows any process or system graphic display to be accessed from the interface

station and normal operator privileges apply.

Supervisor - Allows all operator privileges plus the addition of a selected number of additional

privileges (Custom selected).

Engineer - Allows only for maintenance purpose

Admin - Allows unrestricted access to all process and system privileges.

4.8.12 SCADA System Clock

The SCADA shall support a Master clock and calendar function synchronised by a GPS interface

receiver within the SCADA system. This function shall be available for access by all devices connected

to the SCADA Control Network including:

Controllers

Interfaces

Operator's and Engineer's Stations

Trends

Reports

Event logs

Disk drives

Host computer

Third party interfaces

The Master clock and calendar must be immune to failure of the device which is currently responsible

for its maintenance. If that device is unable to continue support, responsibility must be passed

automatically to another device without interruption. The transfer must be recorded in the event log and

enunciated. The master clock/calendar function shall generate an audible alarm if corrupted (e.g. restart

from total system power outage).

The clock function shall incorporate the following features:

24 hour display format

1 second resolution

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4.9 Power Supply Arrange me nts

The SCADA equipment shall be designed to operate on 230VAC 50Hz power from two reliable

uninterruptible power supply (UPS) sources. Voltage will be +5/-10% with a maximum transient voltage

depression of 15%, and frequency regulation will be ±2%. Total harmonic distortion of less than 5%.

This is the only power that will be provided to the SCADA equipment.

The SCADA power is to be provided from pairs of redundant 100% feeders derived from the UPS

230VAC distribution boards (Purchaser Supplied). The power shall be reticulated within the SCADA

system cabinets as required. Redundant 24VDC switch mode power rectifiers shall be supplied by the

Vendor for power distribution to all parts of the process control system, where required.

Isolation, fusing, DC rectifiers, filters and distribution for all parts of the system shall be included in the

SCADA package. The facilities within the SCADA cabinets shall include power required by the system,

all remote I/O units and system supplied field instruments. Power distribution cabling between the

control cabinets and any remote I/O will be covered by Purchaser.

The Vendor shall provide power supply systems for the SCADA and all field devices associated with the

SCADA. At least 20% spare capacity shall be provided over actual requirements and future capacity.

Input will be from two independent feeders of 110VAC 50 Hz. Non volatile memory shall be backed up

for a minimum of 28 days.

Parallel redundant (n & 1) power supplies with automatic change-over to protect against power supply

failure shall be provided. Each power supply shall be capable of supplying power to the entire SCADA

failure of 1 power supply shall not cause SCADA disruption. Both power supplies shall be on line at all

times, each supplying power to the load. Failed power supplies must be removable without

disconnecting power from any part of the system or affecting control and operation.

The power supply shall be sized such that no power supply shall be loaded at more than 75% of its

maximum continuous rating, even when its dual redundant twin, has failed.

Each power supply shall be provided with primary and secondary overload protection. The secondary overload

shall be self-resetting or have a time overload delay to prevent a momentary fault from tripping the system off.

Over voltage protection shall be provided if it is necessary for the protection of the connected loads.

Each power supply shall be provided with a pilot light and with a fault detector. Failure of any power

supply including loss of voltage, under voltage, incoming power feeders, batteries, fuses and circuit

breakers shall be alarmed by the SCADA through the use of a common SCADA unit alarm digital input.

Output current on power supplies shall be locally indicated in order to confirm that supply capacity

exceeds current usage.

The SCADA Vendor shall recommend the rating of the upstream circuit breakers to be installed on-site

(Supplied by the Purchaser contractor). The Vendor is to include in his submission the total number of

normal and emergency AC supplies required by his system.

The SCADA Vendor shall produce a total summary and detailed list of all component AC power

consumption in (VA) and heat dissipation levels in (Watts), for all system and marshalling cabinets and

monitors supplied.

4.10 Earthing

There shall be three separate earthing systems within the SCADA system.

4.10.1 Safety Earth

THU DUC III


All metal enclosures supplied shall have a minimum of one M10 brass earth stud, complete with nuts

and washers, dedicated for safety earthing. 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 10mm2 to ensure effective earthing.

4.10.2 Instrument Earth – Non-IS Earth

Each system cabinet and marshalling cabinet shall be provided with one 5mm x 15mm copper

galvanically isolated instrument earth busbar across the full width of, and insulated from, the panel for

earthing system electronics and electrostatic screens of field cables.

In general, field instrument shields will be grounded to instrument earth within the Marshalling Cabinet.

4.10.3 Intrinsically Safe Earth – I.S. Earth

Marshalling cabinets with passive I.S. equipment (eg zenner barriers) circuits shall be supplied with an

additional galvanically isolated IS earth busbar clearly labelled as such.

THU DUC III


4.11 Cabinet, Wireways, Termination, Cabling and Tagging

4.11.1 Cabinet

This Section covers minimum requirements for cabinet construction.

All cabinets ingress protection shall be as indicated in section 3.6, the cabinets shall be free standing

and constructed to withstand moving, installation and normal plant vibration and use.

Doors on cabinets and workstations shall be fitted with seals for dust exclusion. All holes or openings

that are not used shall be suitably covered or sealed.

Finish of cabinets and workstations shall be smooth and have manufacturer's standard colours.

Access to all equipment within cabinets and workstations shall be provided without the need to disconnect

wires or shut down system power. Equipment shall be installed so that connectors are easily accessible.

All doors shall be lockable. All door locks shall be provided with the same lock and key combination

unless otherwise specified.

Each PCS cabinet shall have the earthing system as indicated in section: 4.10.

A cable support system shall be located at the bottom of each cabinet.

All PCS cabinets shall be equipped with cooling fans for heat dissipation. Each cabinet shall be

equipped with a cooling-fan-failure or high-temperature alarm.

4.11.2 Ducts and Wireways

Wiring inside cabinets shall be run in dedicated plastic ducts or wireways, or neatly loomed and secured

with plastic spiral wrapping or tie-wraps and anchors. Spare space shall be provided in the wireways

and where wiring is placed to accommodate 25 percent more wiring. All cables shall be adequately

supported and shall be provided with a strain relief mechanism for cable connectors.

Segregation of power and signal wiring shall be accomplished by separating wireways or loomed cable

bundles by a minimum of 75 mm. Where intersections between power and signal wiring occur, care

shall be exercised to make intersections at right angles, with maximum possible separation.

4.11.3 Wiring Termination

All terminal blocks shall be constructed on non-brittle polyamide 6.6mm material (or equal)

No more than two wires shall be connected to a single terminal block connection.

Adequate space and/or barriers shall be provided to prevent the touching of electronic hardware when

working at terminal blocks.

If field wiring terminates directly on I/O circuit boards, then intermediate terminal strip assemblies shall

be provided and wired to the I/O cabinet. This does not apply to thermocouple input wiring or printed

circuit board assemblies especially designed for field terminations.

4.11.4 Cabling

The SCADA Vendor shall supply all system cabling, including the SCADA System network up to the

fibre optic break-out terminals.

THU DUC III


All control wiring shall be carried out using not less than 1mm² flexible multi -stranded, annealed copper

conductors and shall be flame retardant to IEC 60332, halogen free, low smoke emission and EPR

insulated. Insulation resistance shall be 250 Volts.

Segregation of any IS circuits, terminals, earthing and screening connections to be carried out in

accordance with EN 50020

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.

Segregation of any IS circuits, terminals, earthing and screening connections to be carried out in

accordance with IEC 60079

4.11.5 Tagging

Each cabinet, card, device, terminal strip, terminal and interconnecting cable end shall be clearly

marked with proper identification.

Cabinet and device labels shall be permanently affixed to the assembly with fasteners or bonding,

labels shall be Graphoplast or equal. Each cabinet shall have a cabinet identification label on the front

and a nameplate listing all major items within the cabinet, their function and location (Hiway address,

Box number & so on). All PCS nameplates and labelling schedules should be in accordance with project

specifications.

All wires connected to terminal block terminals, including I/O module termination panels, shall be tagged

with two identification tags. The first tag (closest to the end of the wire) shall identify the terminal

number to which the wire is physically connected. The second tag shall identify the terminal or devic e

number to which the opposite end of the wire is connected. Wire markers shall be slip-on, heat-shrink,

permanently embossed, sleeve types. Wrap-around, self-adhesive type markers are not acceptable.

Each terminal block shall be labelled with a sequential terminal identification number for input or output

signal wires.

Each row or column of terminal blocks shall be labelled with a unique identification name or number.

Each circuit breaker shall be tagged with a permanently mounted nameplate that identifies its service

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5. TESTING

All testing shall be carried out at the manufacturer’s test facility. Test equipment shall be supplied by the

manufacturer and shall be calibrated within six months of the test date. The minimum scope of testing is

summarised below. The Vendor shall supply ITP with the Tender.

5.1 Factor y Acceptance Testing

The Vendor shall be responsible for generating the FAT procedures; the Vendor should submit the

proposed FAT procedures to the Purchaser 3 months before scheduled date of FAT commencement.

The pass/fail criteria shall be 100% correct performance otherwise the faulty item shall be rectified or

replaced at the Vendor's cost. On identification of a testing fault, the Purchaser shall have the authority

to stop all testing until satisfactory remedies have been implemented. Resumption of testing will be on

approval from the Purchaser.

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 SCADA prior to the start of FAT. All

documentation and listings must be free of mark-ups.

All equipment shall be energised and remain energised 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. Outputs shall be connected to a device as similar as possible to the final field

element (eg. 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 on a marshalling panel 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 a marshalling panel. 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.

The Purchaser will reserve the right to witness the entire FAT as a non-participating observer.

5.2 Site Acceptance Tests

The SAT shall be based on a sub-set of the FAT procedures supplemented by tests which can be

carried out only at site, for location, logistical or technical reasons.

The tests shall be carried out in accordance with a FAT procedure specification prepared by the system

Vendor and agreed by the Purchaser in advance of commencement.

The SCADA Vendor shall be responsible for maintaining detailed test records for all inspection and

testing carried out in the format agreed in the SAT procedures documentation.

The SAT test specification shall reflect the structure and the phasing of the testing starting with

inventory checks and hardware tests through software testing to final testing of a fully integrated system

of hardware and software. Test scripts shall be produced to cover all testing.

The SAT test specification shall be developed to cover all testing to be carried out. The specific ation

shall state clearly the objectives of testing and contain test pre-requisites, test scripts, programme

procedures for fault rectification and the means for documenting the tests.

THU DUC III


The purpose of the SAT is to establish that the SCADA equipment has been shipped without damage,

has been correctly installed, and operates reliably to specification in its final environment.

5.3 Syste m Initialisat ion, Commissioning and Start -up

The Vendor, in their tender, shall identify any special requirements or recommendations for Vendor

support during offshore commissioning and start up of the equipment supplied. The Purchaser's final

acceptance of the equipment will be subject to a performance test once the equipment has been

installed and commissioned offshore.

The Vendor shall make available the services of experienced start-up engineers to assist with the

installation of I/O cards, peripheral devices and software in addition to the initialisation of SCADA power

and provide direction during the commissioning of the SCADA and also provide general SCADA

troubleshooting assistance.

5.4 Site Support

The Vendor shall fully describe the local support he is able to provide. They shall fully disclose:

Number and type of maintenance personnel employed and where they are based.

Workshop and repair facilities.

Spare parts holding details (Quantity & Location).

Time guaranteed to mobilise personnel and spares.

Availability of 24 hour support.

Availability of remote dial-in maintenance support.

Site support field service agreements, detailed as follows, shall be available as an option.

Factory trained specialists in the Vendor's employ shall be available on a 24-hour-a-day basis. The

Vendor shall advise of the availability and locations of service personnel for the SCADA and service and

parts distribution centres.

The Vendor shall advise details and costs of all standard maintenance services available, which are

suitable for the proposed SCADA (hardware, firmware and software). The Purchaser shall be under no

obligation to select all or any of the agreements detailed and shall be free to negotiate a unique

maintenance agreement with the Vendor.

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6. PROTECTIVE COATINGS

All surface preparation, painting and protective coatings shall be in accordance with vendor standard

Painting Specification.

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7. NAMEPLATE DETAILS

7.1 Primar y Nameplate

In addition to any International Code nameplate requirements, SCADA equipment shall be equipped

with a permanently attached primary nameplate manufactured from 316 stainless steel. Text and

numbering shall be clearly engraved, paint filled and a minimum of 12mm high.

The primary nameplate shall be mounted in a prominent location secured by stainless steel screws or

rivets. The nameplate shall contain the following information:

Client name

Project name

Purchase order number

Equipment title

Equipment tag number

Manufacturer’s Name

Serial number

Year built

Certified Weight (kg)

Major sub equipment shall be provided with individual nameplates in accordance with applicable Project

Specifications and/or the manufacturer’s standard nameplate.

7.2 Tag Plates

SCADA minor sub-components and electrical equipment shall be fitted with a tag plate identifying their

individual tag number only. Tag numbers shall be issued by The Purchaser during Detail Design.

Tag plates shall be manufactured from laminated, engraved plastic. Text and numbering shall be clearly

engraved, paint filled and a minimum of 6mm high.

Tag plates shall be secured by stainless steel nuts and bolts.

815.301 scada specification rev0

Engineering

nodes type do10320

nodes type do234

nodes type do176

nodes type ai40

nodes type ai163

nodes type ao78152two

nodes type ao1231two

nodes type ao5381two