spc-0804.02-60.05 rev d2 dcs specification

5/25/2018 SPC-0804.02-60.05 Rev D2 DCS Specification

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PREPARED

BYNA

PTT PUBLIC COMPANY LIMITED

CHECKED

BY ONSHORE COMPRESSOR STATION 4

PROJECT

APPROVED

BY

CERTIFIED

(PTT)NA

REV.

NO.

DATE REVISED

BY

APPROVED

BY

DESCRIPTION

D1 18-Feb-08 NA ISSUED FOR ITB

D2 19-May-08 NA REVISION ISSUED FOR ITB

SPECIFICATION FOR

DISTRIBUTED CONTROL SYSTEM SPECIFICATION

SPC-0804.02-60.05 REV.D2

TOTAL 31PAGES

AREA CODE OF SITE LOCATION

GENERAL AREA: 010

.

PTT PLC. CONTRACT NO. PTT PLC. PROJECT NO.

0804.02


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ENGINEERING SPECIFICATION

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CONTENTS

SECTION

1.0 SCOPE OF SERVICE .............................................................................. 3

2.0 SYSTEM OVERVIEW ............................................................................. 3

3.0 DEFINITIONS AND ABBREVIATIONS ....................................................... 4

4.0 APPLICABLE SPECIFICATIONS, STANDARDS AND DRAWINGS ................. 5

5.0 GENERAL REQUIREMENTS .................................................................... 6

6.0 HARDWARE REQUIREMENTS................................................................10

7.0 FUNCTIONAL REQUIREMENTS ..............................................................18

8.0 ENGINEERING, DETAILED DESIGN AND IMPLEMENTATION ......................25

9.0 INSPECTION AND TESTING ..................................................................26

10.0 INSTALLATION AND COMMISSIONING ..................................................29

11.0 DELETED. ...........................................................................................30

12.0 DOCUMENTATION REQUIREMENT ........................................................30


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1.0 SCOPE OF SERVICE

1.1 This Specification defines the minimum technical and functional requirementsfor the Distributed Control System (DCS) to be installed for the Onshore

Compressor Station 4 (OCS# 4). It also covers the requirements for the

supply, installation, testing, and commissioning of the DCS system for the

OCS# 4 project.

1.2 The Vendor shall furnish all labor, material, equipment, transportation, and

facilities necessary to perform all work as defined in this specification and on

the related drawings.

1.3 The work required of the Vendor includes design, engineering, procurement,

transportation, installation, commissioning, and start-up of DCS hardware andsoftware required for the monitoring and control of the OCS# 4 and FTPP

facilities.

1.4 The DCS vendor shall be the single source of supply, engineering, installation

and testing for the Safety Instrumented System logic solver, Plant Information

Management System and Plant Resource Management System

2.0 SYSTEM OVERVIEW

2.1 The functions of the DCS are to control and monitor the OCS#4 and FTPP

facilities to continuously produce on-specification products.

2.2 The OCS# 4 shall be controlled and monitored by the Yokogawa Centum CS

3000 R3 DCS system or the latest Yokogawa Centum series.

2.3 The system shall consist of a network of the Field Control Stations and

Human Machine Interface work stations (HMI) which shall be located at the

new Control Building. They shall provide the core DCS functions of:

Acquiring data from field instrument devices via Field Control Units

(FCU) located locally at the instrument rack room in the new control

building.

Acquiring data from the SIS logic solver, compressor control system,

electrical system, FTPP SIS logic solver, DCS systems provided by the

FTPP and LNG contractors, and other package equipments.

Processing the field data to detect alarms and other significant

process/data changes.

Performing process and sequence control functions

Presenting the data to the user via easy to understand graphical

displays and reports

Performing system monitoring and diagnostics to detect failure of


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hardware and/or software and take appropriate actions.

2.4 The control and data acquisition equipments shall be housed at the instrument

rack room in the new control building and/or other remote equipment rooms

distributed throughout the facilities. A redundant fibre optic communication

network shall link the various equipment rooms to the new control building.

2.5 The DCS system shall utilize a dual redundant Fast Ethernet LAN as the core

communications backbone of the system. Each FCS and HMI workstations

shall be connected to both system LANs.

2.6 Industrial type PC-based Operator workstations shall be used to access the

process information in the FCSs. Each Operator workstation shall be

connected to both DCS LANs and shall allow the user to interact with the

information in the DCS system.

2.7 The Operator workstations shall function as the main interface for the DCS

and SIS provided by both OCS# 4 and FTPP contractors, the compressor

control system, the fire & gas system, the machine monitoring system and

other package equipments. The functions of these work station shall include

at least;

Graphical displays showing the process and equipment conditions of

the FTP facilities

Trends of selected process variables

Alarm / Event management including alarm acknowledgment

Commands and controls to change the operating state of the FTP

facilities

Summaries and reports

2.8 The DCS system shall support open interfaces with other systems such as

higher level management information systems and other business systems.

The system shall support TCP/IP based links to these external systems. The

DCS system shall support the use of standards commonly used in the

Microsoft environment, including OPC and COM.

3.0 DEFINITIONS AND ABBREVIATIONS

AMS - Asset Management System

PRM - Plant Resource Management

CCR - Central Control Room FTP facilities

DCS - Distributed Control System

EMC - Electromagnetic Compatibility


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IS - Intrinsically Safe

MTTR - Mean Time To Repair

MTBF - Mean Time Between Failures

RTD - Resistance Temperature Detector

SER - Sequence Of Events Record

UPS - Un-interruptible Power Supply

VDU - Visual Display Unit (LCD TFT Type)

HMI Human Machine Interface

FTP Faculties The PTT facilities including the OCS# 4 and

facilities provided by the FTPP contractor

4.0 APPLICABLE SPECIFICATIONS, STANDARDS AND DRAWINGS

4.1 Project Specification

PHC-0804.02-60.01 Instrument and Control Philosophy

SPC-0804.02-60.01 Instrumentation General Specification

SPC-0804.02-60.02 Safety Instrumented System Logic Solver

Specification

4.2 International Standards

IEC 79 - Electrical Apparatus in Explosive Atmosphere

IEE - Guidelines for the documentation of software in

industrial computer systems

89/336/EEC - European Union EMC Directives

EN 50081-2 - Emission, Industrial Environments

EN 50082-2 - Immunity, Industrial Environment

IEC 61000-4 - Electromagnetic Compatibility

MIL-STD-217E - Military Handbook - Reliability Prediction of

Electronic Equipment

ISO 11064-3 - Ergonomic Design of Control Centres


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ISO 9241-3, -5 - Ergonomics requirements for office work with

Visual Display Terminals (VDTs)

4.3 Project Drawings60-3-0804.02-6000-001 OCS 4 Control System and Interface Block

Diagram

60-3-0804.02-6000-002 to 004 OCS 4 Control System and Interface

Architecture

5.0 GENERAL REQUIREMENTS

5.1 System Environment

The DCS equipments shall be installed in the control building, where the

temperature and humidity are climate controlled, i.e. air-conditioned.

However, in the event of failure of the air-conditioner, the system is expected

to continue normal operation. Therefore, the system shall be designed for

continuous operation under the following conditions:

20 to 50 Celsius operating temperature range

10% to 95% relative humidity, non condensing

5.2 System Architecture

5.2.1 The system shall comprise of a distributed architecture with a microprocessor-

based control system consisting of discrete types of functional hardware

elements interconnected to provide overall system functionality, i.e.

distributed architecture.

5.2.2 The system shall also be geographically distributed with the control and data

acquisition functions performed at a remote location within the OCS# 4 area

and the control and monitoring of these functions from the new Control

Building..

5.2.3 The DCS shall be based on an open architecture where the system has

inherent capabilities to integrate and exchange information with other systems

and/or platforms via industry standard protocols.

5.2.4 The DCS network system shall be based on fast dual redundant Ethernet LAN

network. The failure of one network cable shall not have any impact to the

operation of the DCS system.

5.2.5 The arrangement for the Field Control Stations (FCS) shall prevent the

common cause of inoperability for the equipment trains when the FCS/ its

part fail or are under maintenance. All field process devices of differentcompressor trains shall not be connected to the same FCS and the same

principal shall be applied to the inlet scrubber trains and communication

between DCS and the compressor control systems.


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5.3 System Spare Capacity, Loading and Expansion Requirements

5.3.1 The DCS system shall be designed such that after the completion of

commissioning the following evenly distributed spare capacity shall be

available:

I/O Modules - 30% installed, wired and fully functional

I/O of all types used

I/O Racks - 30% fully wired spare rack

Terminal Blocks - 30% spare terminal blocks shall be

provided in cabinets containing terminal

blocks

System Cabling - 30% spare pairs over and above the I/O

module/rack spare requirements

Fibre Optic Cables - 100% spare Fibres

DCS Communication Port - 100% spare

5.3.2 The system shall be designed such that, after the completion of

commissioning, no more than 60% of processing capacity and/or memory is

utilised (Spare capacity to be included).

5.3.3 The system communication network shall also be design so as not to exceed

60% loading after the completion of commissioning (Spare capacity to be

included).

5.3.4 The system power supply units shall include 30% spare capacity over the

required loading (including the spare capacities).

5.3.5 The system shall be designed such that 30% future expansion can beaccommodated without any modification or replacement of existing

equipment, communication systems or software.

5.4 System Availability and Redundancy

5.4.1 The system shall be designed to achieve an availability of 99.99999% with

an assumed Mean Time To Repair (MTTR) of eight hours or less and a Mean

Time Between Failures (MTBF) of 5,000,000 hours or more. This shall be

demonstrated by calculations as defined in US Military Handbook Standard

217E.

5.4.2 In order to meet the required system availability, redundant and/or fault

tolerant technology shall be incorporated.


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5.4.3 As a minimum the following equipment shall be redundant:

- Communication Network including fibre optic cabling

- Control Processors

- Mass data storage devices

- Power Supplies

- I/O cards for control loops

- Redundant network cards for the operator workstations

- Network Hubs

5.4.4 The system database shall be bi-weekly backed-up.

5.4.5 The redundant system shall be designed such that, on failure, automatic

bumpless changeover to the other unit shall take place. It shall also be

possible to replace and test the failed unit without disrupting the control of

the process.

5.5 System Protection Requirements

5.5.1 The system shall support at least three different levels of access control either

via the use of a removable key and/or by entering a pre-configured password.

It shall also be possible to configure user-specified functions to the following

levels.

Operator Level This level shall include typical operator functions

and not require a key or password.

Supervisor Level This level shall include all the operator functions

as well as the pre-configured supervisory

functions and shall require a key or password.

Engineering Level This level shall include all functions and

require a key or password.

5.5.2 Different type of keys shall be used for the supervisory and engineering levels.

Once removed, access will revert to the operator level.

5.5.3 The system shall be provided with the firewall to protect the unauthorized

access from outside. The firewall shall be Nokia or equivalent.

5.5.4 The system shall be provided with Synmatec anti virus software. The anti

virus server shall be provided to receive the update version of anti virus

software via the internet and then distribute to the DCS and PIMS system.


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The supplier shall configure the antivirus server to prevent unauthorized

access from outside.

5.5.5 The Plant Information Resource Management System shall be connected to

the DCS network via firewall.

5.6 System Electrical Requirements

5.6.1 The DCS equipment shall be installed in the new control building and auxiliary

equipment rooms, which shall be considered as safe areas. Equipments

connected to the DCS, normally situated in areas classified as hazardous,

shall be connected to the DCS via approved interfacing equipment.

5.6.2 The preferred method of hazardous area protection is intrinsically safe. The

use of IS certified I/O modules shall be preferred to discrete IS barriers. Insuch cases, the DCS VENDOR shall provide the certified I/O termination units

for installation into the Clients marshalling cabinets.

5.6.3 The DCS shall comply with all relevant European Union Electromagnetic

compatibility (EMC) directives and, in particular, compliance with IEC 61000-

4.

5.6.4 The DCS shall be powered by two A.C. feeders connected to two

independent 230 volts 50 Hz Uninterruptible Power Supplies (UPSs). The DCS

power shall be derived from these including all necessary distribution and

protection. Each cabinet/system shall be provided with redundant powersupply units, each sized and networked such that a system shutdown shall

not be caused by the failure of one of these units. Any power supply unit

failure shall generate both local and control room alarms.

5.6.5 Where possible, field devices, connected to the DCS and operating at 24 volts

DC, shall be powered by the DCS with all necessary protection of the field

circuits such as surge protection etc.

5.7 Standard Hardware and Software

5.7.1 The system shall comprise standard hardware and software configured to

meet the stated requirements.

5.7.2 The systems standard operating software shall not be modified to meet the

project requirements.

5.7.3 The system software shall be the latest commercially released version at the

time of order placement.

5.7.4 All necessary software licences shall be provided, enabling the right to

exercise the use of all relevant and applicable software.


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6.0 HARDWARE REQUIREMENTS

6.1 Operator Console

6.1.1 The DCS Operator Workstations shall be housed in a purpose made console

designed specifically to be used as a control console for the DCS and control

systems, such as Evans Consoles or equivalent.

6.1.2 The consoles shall provide five operating positions, each with space for 2

display units, vertically arranged, of at least 21 viewable area in size. Three

spaces shall be used for the DCS display units. The fourth space shall be used

for the remote compressor control display units. The last one shall be for the

Fire & Gas and CCTV display units, Fire & Gas on the bottom and CCTV on

the top.

6.1.3 The space between operating position shall be wide enough to prevent the

congestion of the operator position.

6.1.4 Console shall be modular in design and construction, capable of being

expanded in the future to add additional modules and positions.

6.1.5 Each module shall be approximately 36 inch in width and shall accommodate

two vertically arranged 21-inch display units. An enclosed type design shall

be used where the display units and all components of the PCs are enclosed

under removable panels. The panels shall be easily removable without tools.

6.1.5 For the modules that house auxiliary equipments, the width for each model

shall be suitable for its application.

6.1.6 The overall DCS console shall consist of at least 10 modules to be used as

follows:

5 display units, each for vertical arranged dual display units (Five operator

positions) and be equipped with telephone mount.

1 communication units of communications equipment such as the UHF

radio based station and PAGA controller

2 auxiliary units for the key switches, the push buttons, annunciators and

the indication lamps.

2 storage units/work surface at each end to provide additional space for

operating manual storage and office space.

6.1.7 The arrangement for the module shall allow the easy access to the push

buttons and the indicator lamps are clearly visible for each operating position.

6.1.8 The console shall be specifically designed to work with flat panel displays.

The display modules shall be equipped with a non-glare glass protective cover

for the LCD display panels.


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6.1.9 Non-glare area task lighting shall be provided for the console by a hidden

lighting strip at the top edge of the console. Intensity of the lighting shall be

user controllable.

6.1.10 The console system shall be designed to provide adequate ventilation to

equipment inside through the use of ventilation grills (and fans, if necessary).

6.1.11 Hardware, such as CPUs and networking equipment, mounted inside the

console shall utilize pull out drawers or shelves to allow easy access for

maintenance and service of the equipment.

6.2 Operator and Engineering Workstations

6.2.1 The total of 6 operator workstations shall be provided as follow.

Three DCS operator workstations, each equipped with dual screens.

These workstations shall be used for the monitoring and control of the

FTP facilities.

Two operator workstations, each equipped with one screen. One

workstation shall be used as the remote compressor unit control panel

HMI. The other shall be for the remote HMI of the compressor master

performance, anti surge and load sharing controllers. The screens of

these workstations shall vertically mount in the DCS console.

One operator workstations, equipped with one screen. Thisworkstation shall be for the remote HMI of the Fire & Gas systems

The contractor shall ensure that the DCS vendor hands over one dual screen

DCS operator workstation to the FTPP contractor and the other single screen

workstations to the related system vendors during the engineering phase.

From the pre commissioning phase, these workstation shall be housed in the

same DCS consoles.

6.2.2 The DCS operator workstations shall be the latest industrial grade PC from

the reliable and proven manufacturer. The performance and specification for

these workstations shall meet the intended purposes.

6.2.3 Where dual screens (stacked) are specified, only one keyboard and pointing

facility are required to access both screens.

6.2.4 Each operator workstation shall be powered from a redundant power supply

arrangement and also have dual redundant network connections to each of

the networks to which it is connected.

6.2.5 The screen display units shall be as a minimum 21" diagonal screens with

high resolution graphics (minimum 1600 x 1200 pixels), with minimum 8

control (increment / decrement) key built-in with optical mouse. The LCD shall

be flicker-free and glare-free. Standard screen controls such as brightness,etc., shall be accessible to the operator.


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6.2.6 The typical computer keyboard shall be provided for each operator

workstation which is not for the DCS system.

The following requirements are for the operator workstations dedicated to the DCS

system.

6.2.6 Each workstation shall be capable of storing all particular graphics assigned to

that workstation and any other workstation graphic once transferred from the

data storage medium without the need for cartridges, disks, etc.

6.2.7 Upon failure of a workstation, all its functions, that are not otherwise

accessible, shall be assigned automatically to another workstation in that

particular console.

6.2.8 Operator keyboards shall be spill proof membrane type keyboards with aminimum of 64 dedicated and/or variable function keys (configurable).

6.2.9 A separate engineering workstation shall be provided. It shall be a desktop

style industrial type PC and include all the functionality as specified for the

DCS operator workstation. In addition it shall provide all of the engineering

tools necessary to configure the system database, include a cartridge drive for

loading or storing software, an alpha/numeric keyboard and any other

enhanced hardware features as required by the system VENDOR.

6.2.10 A detachable engineering keyboard shall be provided, and shall be used for

connection to any of the operator consoles.

6.2.11A Plant Resource Management System (PRM) shall be provided. This system

shall be installed in the control room.

6.3 Printers6.3.1 Two A3 colour laser printers shall be provided. One printer shall be connected

to the main DCS hub to allow each operator or engineering workstation to

print out the selected logging of alarm, events, reports, system configuration

and any other information in colour. Another printer shall be connected to the

auxiliary hub to allow the PIMS, PRM, Bently Navada System 1 and APC

server (provided by the FTPP contractor) to print out the reports and other

information as required by the users.

6.3.2 The operator shall be able to print out any graphical display in colour from any

operator workstation.

6.3.3 The printer shall be equipped with the hot-stand by redundant network cards

and be connected to both LAN of the redundant DCS network.

6.3.4 Both printers shall be equipped with 512 MB RAM as minimum.


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6.4 System Control Processor Requirements

6.4.1 Control and data acquisition functions shall be performed by fully redundant

microprocessor-based controllers, capable of supporting multiple loops via a

flexible array of I/O options.

6.4.2 These control processors shall be able to support multiple I/O processors.

6.4.3 Deleted.

6.4.4 The overall system performance shall, as a minimum, provide the following

response times based on the actual system I/O loadings:

Analogue and digital control loops execution frequency of 50 mS

configurable up to 1 second

Operator workstation command execution within 1 second

Operator workstation command to the field equipment within 1 second

Operator workstations refresh rate of 1 second or less for the update

information from the field equipment

6.4.5 The control processors together with the I/O processors shall provide

independent control and monitoring of the OCS# 4.

6.4.6 In the event of total communication system failure, the controllers shall

continue to operate with the last valid information received. In addition, each

output shall be configurable to either maintain its current value or be driven to

a predefined state on input or processor failure.

6.5 System I/O Requirements

6.5.1 The Field Control Station (FCS) shall be allocated such that independent

process units/trains can be operated and maintained without affecting the

other units upon the failure of the FCS. As minimum, three FCSs are foreseen

for the OCS# 4.

6.5.2 The critical I/O within a particular FCS shall be separated to minimise the

effect of common mode failures. The required segregation shall be confirmed

during detailed engineering.

6.5.3 System I/O shall be selected such that the requirement for separate signal

conversion and/or protection shall be kept to a minimum. The use of I/O with

signal processing and/or protection facilities built-in shall be preferred.

6.5.4 If discrete signal converters and/or IS barriers are essential, they shall be

supplied and installed in the marshalling cabinets.

6.5.5 All field measurements shall utilise Foundation fieldbus transmitters. This

will enable full digital communication with the DCS, and transmitter access

directly from the Plant Resource Management System. (PRM)


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6.5.6 Maximum 8 number of Foundation Fieldbus transmitters per one segment

shall be utilised.

6.5.7 All analogue inputs and outputs shall be short circuit proof and individually

fused or isolated to provide electrical input isolation.

6.5.8 All digital inputs and outputs shall be individually fused or isolated to provide

electrical input isolation. Digital outputs shall also be short circuit proof.

6.5.9 All system I/O shall be local to the controller equipment (within 50 metres).

The use of remote I/O shall only be employed when specifically called for.

6.5.10 In addition to Foundation Fieldbus signals, the system shall support the

following analogue input signal types:

4 - 20 mA (Self powered)

4 - 20 mA (Externally powered, floating or grounded)

1 - 5 volts

Thermocouple

Resistance Temperature Detector (RTD)

The overall accuracy of the analogue signals shall be better than 0.1% of

span and 0.5% of the maximum range for the selected type of

thermocouple.

6.5.11 Input isolation shall be provided for all I/O devices with external AC supplies

or with grounded 4 - 20 mA signals.

6.5.12 All analogue outputs shall be 4 - 20 mA, fully isolated from ground and be

capable to drive resistive loads of 750 ohms. The overall accuracy shall be

0.25% of full scale and a resolution of 0.1%.

6.5.13 The analogue input and output systems shall provide a means of stripping

the HART data signal from the analogue signal to make the data available tothe PRM. Preferably this functionality shall be included in the DCS analogue

input/output module.

6.5.14 Digital inputs. The system shall support both normally open and normally

closed contacts with circuitry to ensure that chatter or bounce,

encountered during contact closure, does not initiate an erroneous signal.

6.5.15 External contacts shall be voltage and ground free and shall normally be

powered from the system.

6.5.16 Digital outputs. The system shall support both solid state and relay contacttype outputs.


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6.5.17 Solid state outputs shall be capable of supplying a 1 amp non-inductive load

at 24 volts DC and be isolated from ground.

6.5.18 Relay contact type outputs shall be voltage free, isolated from ground, and

fully independent from each other, with a minimum contact rating of 2

amps.

6.5.19 The system shall support pulse type inputs of rectangular and/or sine waves

with pulse frequencies up to 10 KHz and levels of between 12 and 24 volts

dc.

6.5.20 The system shall support hardwired sequence of events record (SER) digital

inputs which shall, generally, conform to the same requirements as normal

digital inputs although the maximum event resolution shall be 10

milliseconds (time from event to the time stamping thereof).

6.6 Foundation Fieldbus

6.6.1 For the Fieldbus field devices, the system shall be Foundation Fieldbus

compatible devices. Communication with intelligent transmitters shall be bi-

directional allowing read / write procedures.

6.6.2 Vendor shall supply the software tools in the Engineering Workstation to

create Fieldbus-based database and device parameters reference / setting,

trend / message display and basic data acquisition for diagnostics and

analysis.

6.6.3 The tools shall provide schedule generation for communication of each

fieldbus segment.

6.6.4 Each Fieldbus I/O Module shall be able to support more than one segment and

each segment should support no more than 32 blocks.

6.6.5 Each Fieldbus I/O module shall be able to support 1:1 redundancy I/O module.

6.6.6 Redundant I/O module shall be used for all Foundation Fieldbus I/O.

6.6.7 Database documentation function shall support the Fieldbus configuration.

6.6.8 DCS shall support PID algorithm implanted in the DCS control module as well

as PID algorithms embedded in Fieldbus devices.

6.6.9 DCS shall provide standard faceplate for PID algorithm embedded in

Fieldbus devices. The faceplate shall have same look and feel of standard

DCS based PID block.

6.6.10 Virtual test function for the Fieldbus loops shall be available to check the

integrity of the configured Fieldbus function blocks without the presence of

actual field devices.

6.6.11 DCS shall also support Plant Asset Management software that can

integrate with the DCS system.


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6.6.12 Diagnostic software packages for Foundation Fieldbus devices should be

able to plug-in to the Plant asset management software for maintenance

diagnostic functions.

6.7 System Communication Requirements6.7.1 The DCS system communication network shall be fully redundant with

automatic changeover upon failure of the active path. Manual changeover

facilities shall also be provided.

6.7.2 The redundant/secondary communication path shall either be used

continuously or checked at least once per minute to ensure correct operation.

Status changes shall be alarmed at the operator workstations.

6.7.3 The system shall support Fast Ethernet and/or fibre optic communicationcables. However, all outdoor communication cables shall be fibre optic via

diverse routes.

6.7.4 Differences between the primary and secondary communication cable lengths

shall be minimised so as not to affect the DCS communication system

operation. The vendor shall advise maximum allowable length discrepancy.

6.7.5 The system shall support redundant Modbus serial and TCP/IP based links.

6.8 Data Storage, Backup and Restoral Requirements

6.8.1 The data storage system shall be fully redundant and sized sufficiently to

cope with all historical data collection requirements. The storage system shall

be RAID 5 configuration.

6.8.2 Data on the RAID storage array that has aged sufficiently, shall be

automatically archived onto optical disk media. Upon the successful data

archive, the system shall clean up the data in the storage disk.

6.8.3 Data archiving and clean up shall be completely automated with no need for

user interaction except for media replacement.

6.8.4 The system shall perform an incremental backup monthly for entire disk

system, including program files and system files for all operator workstations,engineering workstation, and Long time trend and log server to Optical media.

6.9 System Cabinet Requirements

The system cabinets shall be used Rital or equivalent and comply with the

following requirements:

- Cabinets to be free standing and constructed taking into account

delivery and installation requirements (multi-pin plug and sockets shall

be used between shipping breaks e.g. Elco plugs)

- Cabinets to be mounted on sub-floor mountings suitably designed to

withstand normal plant vibrations


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- Overall cabinet dimensions to be 2100mm high x 800mm wide and

800mm deep with double front and rear removable and lockable hinged

doors

- Cabinet protection class IP 30 minimum

- Cabinet finish to be smooth and follow the colour table below;

Description Muncell code RAL colour Finish

Exterior 7.5GY 7/2 7032 Semi gloss

Panel Interior 7.5GY 7/2 7032 Semi gloss

Channel base 7.5GY 7/2 7032 Semi gloss

- Separate and isolated cabinets earthing connections shall be provided

as follows:

Safety earth (cabinets and steelwork)

Signal earth (cable screens and signal common)

- The cabinet layouts are to allow full and easy access for installation and

maintenance requirements

- Cable access shall be bottom entry via suitable cable clamping

mechanisms

- Utility power supplies shall be provided separated from UPS such as

conventional type receptacles, fluorescent Lighting.

6.10 System Wiring Requirements

6.10.1 All wiring inside cabinets shall run in dedicated plastic ducts or wireways, or

neatly loomed and secured with plastic spiral wrapping or tie-wraps and

anchors.

6.10.2 All discrete wiring shall be single core with sufficient current carrying

capacity. A minimum core size of 0.5 mm shall be used unless otherwise

stated.

6.10.3 Wireways/ducting shall be routed to provide sufficient segregation between

AC and DC wiring and will be able to accommodate 30% more wiring.

6.10.4 System card bins shall be interconnected with plug and socket type system

cables or ribbon type cables and edge connectors. The sockets and both


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ends of the cables shall be labelled with the Origin and Destination

tags.

6.11 Other System Requirements

6.11.1 Marshalling cabinets shall be provided with an identical outward

appearance to the system cabinets.

6.11.2 Within the marshalling cabinets the incoming field multi-pair cables shall

terminate either sequentially onto terminals or directly onto the IS barrier

terminals. The output side shall be connected to the system I/O termination

units or to Elco sockets where no I/O termination units are available.

6.11.3 The DCS VENDORs system cabling or pre-made and tested system cables

with Elco plugs shall be used to connect to the DCS system cabinets.

6.11.4 The Plant Information Management System (PIMS) shall be configured to

record all Operation Logs, reports, process/system alarms and shall have

the facility to print any of the logs, reports or alarms on demand using a

Network Laser printer also supplied with the System. The PIMS shall be

equipped with Alarm and event analysis software. This software shall

provide the tools and be configured to allow PTT to analyze the alarm and

event in the system in all aspects. The detail requirements for the PIMS are

specified in the related specification

6.11.5 Long Term Historical Data Recording Package and server.

The DCS vendor shall provide the server connected directly to the DCS

network to store the historical long term trend and alarm/event log for 14

days

The System as a minimum shall be able to keep data such as PV, MV, SV,

Operator actions, System alarms, Process Alarms etc in the Long term

historical data recording package. The System shall have the facility to

select the data required to be put in the Long term historical package and

to display their trending in any selective time span. Any Operator station

can access this database via System data highway and intuitive graphical

interface displays.

7.0 FUNCTIONAL REQUIREMENTS

7.1 Process Control and Data Acquisition Requirements

7.1.1 The system process control functions shall be performed by predefined

algorithms with configurable parameters and shall, as a minimum, include the

following:

- Control algorithms such as PID, ratio control, gap control, etc.

- Computational algorithms such as addition, subtraction, etc.


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- Logic algorithms such as AND, OR, Set/Reset, etc.

7.1.2 Sequential, timed and computational control programmes shall be supported

via a high level programming language. The following typical functions shall

be supported:

- Expressions such as Equal To, Not Equal To, etc.

- Mathematical functions

- Timer related functions

- Counter/Pulse related functions

- Logic type functions

7.1.3 The system shall also support logic control programmes where the

grouping/linking of various logic functions shall provide the required

functionality. The programming shall be done via function block. The

following typical functions shall be supported:

- Logic functions such as AND, OR, etc.

- Timer related functions

- Counter/Pulse related function

7.2 Graphic Display Requirements

7.2.1 Graphic displays can be divided into standard and custom types. The

custom graphic display details a schematic presentation of the station at

different levels, from overview level right through to equipment detail level.

The standard graphic displays provide the operator with a standard format for

displaying information and are configurable and normally accessible from

dedicated function keys.

7.2.2 The graphic displays, together with the keyboards shall provide a complete

window to the station for all control and monitoring requirements.

7.2.3 The real time data within these displays shall be automatically updated

without the need for operator action with a configurable refresh rate of four

seconds or less.

7.2.4 The following standard type of graphic displays shall be provided and

accessible from dedicated function keys:

- Loop (Faceplate) Displays. The loop display shall contain, in engineering

units and bargraph format, the process variable, set point and loop

output values. In addition, all control and configuration parametersincluding tuning constants shall be displayed. All adjustable parameters

shall be changeable from within the display.


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- Group Displays. Predefined and operator configurable group displays

shall consist of approximately eight loops displayed in similar format as

in Loop Displays. Configuration parameters shall not normally bechangeable from within this display.

- Trend Displays. Both historical and real time trend displays shall be

available for any variable point. Trend displays shall be able to

accommodate at least eight different points simultaneously in different

colours.

- Alarm Displays. Alarm displays shall contain the alarm summary in

chronological order and alarm groups for the configurable plant

area/group.

- System Diagnostic Displays. Diagnostic displays shall be specially

designed to facilitate system maintenance and shall, as a minimum, list

all the system devices, including communication systems and their

associated status. System maintenance functions such as module

restarts/switchovers, accepting errors, etc. shall be actioned from this

display.

7.2.5 The system shall support a powerful and flexible custom graphic display

capability which shall include, as a minimum, the following:

- Hierarchical display relationship for ease of movement

- Display capacity of at least 200 dynamic elements per graphic including

calculated values

- Symbolic presentation of data by means of change in colour/shape

and/or flashing

- Configurable data/numeric format including colour

- Unique colour combination display capability for multi-state devices

- Suppression of inactive status messages and/or alarms

- At least two different text/data sizes

- Movement of displays from one screen to another

7.2.6 The system shall contain custom graphic pages to display the status of all

inputs and outputs to / from the SIS system and package equipment control

systems such as compressor train etc., in the ESD hierarchy format for the

shutdown. These graphics shall include a first out alarm display such that the

first in a series of trip initiators can be easily identified.

7.2.7 The system shall contain custom graphic pages to display the status of allinputs and outputs to / from the package equipment control systems, such as

compressor train in the sequential format for the compressor start up

sequence or the other operation.


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7.2.8 The system shall support X-windows technology which shall, as a minimum,

provide the following added features:

- Displaying data from other X-window devices connected to the

DCS/workstation

- Displaying multiple sets of data on a single screen

- Display resizing, repositioning including reduction to icon size

- Running other standard software packages such as Microsoft Office

etc.

7.2.9 The customized graphic displays shall include the displays and interface for all

process, SIS, package equipments, Fire& gas, utilities, Fire suppression,electrical systems and any other systems interfacing to the DCS.

7.3 Alarm and Event Management Requirements

7.3.1 The alarm management system shall be a fully configurable system capable of

processing all alarms in an appropriate manner to maximise the information

provided, but to minimise the number of alarms displayed.

7.3.2 In order to minimise the number of alarms, grouping, suppression and/or

filtering techniques shall be available. Suppressing and/or filtering of alarms

shall include:-

- Automatic suppression of individual and/or groups of alarms based on

the occurrence of a preselected alarm or event.

- Automatic disabling of alarms based on the associated equipment

running status.

7.3.3 Each alarm point shall be capable of being configured to at least three

different alarm priority levels in order to discriminate between critical and non-

critical alarms.

7.3.4 Each alarm shall activate an audible and visual alarm at the configuredoperator console. The alarm shall be displayed on the alarm summary and on

the respective graphic displays. In addition, each workstation screen shall

display a warning that a point is in an alarm state including the number of

unacknowledged alarms.

7.3.5 Once the alarm has been acknowledged :-

- The alarm shall change from flashing to steady state.

- The audible alarm signal shall be silenced at all the assigned consoles.

7.3.6 Once the alarm returns to the normal state:-

- The alarm shall be removed from the alarm summary (if acknowledged).


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- The displays shall return to normal.

7.3.7 All alarms and first out alarms from other machinery packages, Safety

instrumented System, electrical systems, machine monitoring system, and fire

and gas systems shall be time stamped with a resolution of at least one

second. Both the alarm occurrence and acceptance times shall be recorded.

7.3.9 All alarms and associated information shall be stored on the mass data

storage medium for historical purposes.

7.3.10 Deleted

7.3.11 The system shall support a sequence of event capability either as part of the

alarm management system or in a similar format and/or presentation. The

sequence of event shall acquire the event from the SIS, packageequipments, electrical systems, machine monitoring system and Fire & Gas

system. The time stamping of the sequence of event signals shall be carried

out in the DCS when hardwired directly to the system or when time

stamping is carried in another system, the signals, with the time stamping

information, shall be transmitted to the DCS and/or sequence of events

recorder. In either way, the time stamping resolution shall be 1 milliseconds

or less.

The contractor shall purpose in his bid how the time stamp for the package

equipment will be achieved.

7.3.12 The system shall automatically record the following events information and

store in the historical database in long term trend and historical server and

PIMS.

period of occurring

tag name

tag description

event type

system generating alarm/event

Process Events : Points going in and out of alarm, Points changing state, ,

Sequence of event records

the action of the operator,

command from the systems/logic

configuration changes

response from the filed devices whether commanded or uncommanded state

change


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other events generated by the systems interfacing with the DCS system.

The information for the event generated by other system shall contain the

same information as generated by the DCS.

7.3.13 The system shall provide the capability for the alarm and event filtering. The

operator shall be able to filter the interested alarm and event list based on

the following

period of occurring

tag name

tag description

event type

system generating alarm/event

The intuitive graphical displays shall be provided for the filtering operation.

7.3.14 The sequence of event facility shall allow reports to be displayed or printed

automatically and/or on demand.

7.4 Data Collection and Trend Requirements

7.4.1 All measured and calculated variables shall be stored as follows:

- 1 second snapshots for 14 days

- 1 minute average for 14 days

7.4.2 The system shall perform the data aggregation for the data mention in 7.4.1

and store in the per the following

- 1 hour averages for 1 month

- Daily averages for 1 year

- Monthly averages for 2 year

The vendor may purpose to PIMS to perform this functions.

7.4.3 The system shall support both real time and historical trend facility at any

workstation. Each trend shall consist of the plotted trend graph and a table

containing the trend parameters. The points engineering units shall be

displayed on the vertical axis and the time scale on the horizontal axis. If

more than one point is displayed, the vertical axis shall be in percentage or

displayed in the multiple vertical axis.

7.4.4 Real time trends shall be available for all measured and calculated variables in

similar time scales with a 1 second sampling time. This is expected to cater

for approximately 2000 points.


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7.4.5 Historical trends shall be available for any of the recorded variables at the

specific sampling time per 7.4.2.

7.4.6 The system shall provide the intuitive graphical display for the operators to

customize the required trend set. The operator shall be able to select the

following the parameters to be display in the trend.

Tag name/ID

Type of data such as second, 1 minute average, hourly average, daily

average,

Period of data

The operator shall be able to save the new configured trend set in the system.

7.5 Deleted

7.6 Deleted

7.7 System Diagnostic Requirements

7.7.1 The system shall include a full diagnostic facility which shall intelligently

identify all system faults and failures to ensure a fully operable system is

maintained.

7.7.2 The system shall generate the alarm and log the event when detecting the

faults.

7.7.3 The system shall display the location of the fault components in the graphical

displays.

7.8 System Clock and Synchronization

7.8.1 The clock source shall be a GPS based clock source. This shall be provided by

a GPS receiver and all necessary software and interfaces to retrieve the GPS

clock data into the DCS system.

7.8.2 The DCS shall then distribute the clock information to the SIS, Fire & Gassystem, utility control systems, Electrical systems, Compressor Unit Control

Panels, Master performance, Load sharing and Anti surge controllers and any

other system controllers connected to the DCS.

7.8.3 The DCS shall distribute the clock to the DCS and SIS systems provided by

the FTPP contractor.

7.8.4 Clock updates shall be performed a minimum of once per day and shall not be

scheduled during or near end of day rollover times or other critical periods in

the day.


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8.0 Engineering, Detailed Design and Implementation

8.1 General

3.1.1 The contractor and vendor shall be responsible for the engineering, detailed

design and configuration of the DCS system.

3.1.2 The engineering, detail design and implementation shall be performed by the

DCS vendor in Thailand.

3.1.3 Work included shall be configuration and customization of all DCS databases

(real-time and historical) and HMI displays and reports.

3.1.4 Custom programming required to implement functional requirements that are

not available in the core DCS system package shall be included. The result of

all custom programming specific to the project shall belong to PTT and sourcecode shall be included.

3.1.5 Detailed design shall be an interactive process involving working closely with

PTT engineering and operations team. The contractor and vendor shall make

allowances for performing the work in this manner and shall allow for multiple

iterations of design submittal, review, comments for changes and redesign.

The vendor shall provide the office space for three PTT personnels during the

engineering, detail design and Factory Acceptance Test phases.

8.2 Database Configuration and Population

8.2.1 Detailed design shall include complete configuration of each of the DCS

databases and populating them with data based on the information on the

project P&ID and process / instrument datasheets.

8.2.2 This work shall include configuration of alarm limits, alarm actions and data

archiving rate for each DCS database point.

8.2.3 The DCS database point shall also include the data of the other systems

which interface with the DCS.

8.3 Graphical Displays

8.3.1 The contractor and vendor shall design and implement all DCS graphical

display screens

8.3.2 The displays shall be designed to allow simple and efficient maneuvering from

one display to the next in a structured hierarchical flow.

8.3.3 The DCS system is expected to be supplied with a number of vendor standard

displays (such as database summaries, system status summaries, etc.) shall

serve as the starting point for customization, as required based on PTT

requirements.

8.3.4 The contractor and vendor shall allow for creation of at least 500 displays.

8.3.5 PTT shall be consulted regarding the conventions for the use of colors and

other attributes for denoting the various states of a signal.


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8.3.6 CONTRACTOR shall choose simple to understand icons and symbols that are

sufficiently large to be clearly visible.

8.3.7 Screens shall be kept as uncluttered as possible

9.0 INSPECTION AND TESTING

9.1 General

3.1.6 PTT reserve the right to carry out inspections at any time during construction

of the Contractor's or Sub Contractor's work.

3.1.7 The Contractor shall supply all calibration, test, and simulation equipment that

are required to demonstrate correct operation of the system. Certificates ofthe test equipment shall be traceable to National Standards.

3.1.8 Calibration, test, and simulation equipment shall be used at pre-

commissioning, commissioning, and site testing. During the commissioning

and testing period the Contractor shall ensure that all equipment is maintained

in calibration.

3.1.9 All calibration, test, and simulation equipments, used during the Site Accept

Test and commissioning, shall be handed over to PTT after the completion of

the commissioning and testing period. Current test certificates for all

calibration equipment shall be supplied and included as part of the official test

results.

3.1.10If, for any reason, PTT waives any part of the inspection, this does not relieve

the Contractor and vendor of the responsibility to effect repairs at their own

expense to any defects found later, including within the guarantee period.

3.1.11The Contractor and vendor shall submit to PTT a complete test schedule and

procedure for the Factory Acceptance Test and the Site Acceptance Test at

least two months prior to each test being performed.

3.1.12The Contractor and vendor shall provide two copies of hand-written test

reports at time of inspection. Four copies of typewritten official certificatescomplete with all necessary details shall be supplied to PTT for approval

within one week after test completion. The results of all tests and checks are

to be recorded in the form of a Test Certificate, copies of which shall be

supplied to PTT.

9.2 Factory Acceptance Test (FAT)

9.2.1 The FAT procedures shall be submitted to PTT for approval at least two

months in advance of any testing. The FAT procedure must be agreed in full

by PTT prior to commencement of any testing.

9.2.2 The Contractor and vendor shall supply all test, simulation, and otherequipment necessary to perform the FAT. The simulation equipment shall be

able simulate the AI, DI, and the status of the output from the DCS such as

AO and DO.


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9.2.3 The test and simulation equipments shall allow the test of all provided Field

Control Stations simultaneously. This means that the FAT shall be able to

demonstrate the functions and performance of the DCS system as the realoperating conditions.

9.2.4 The Contractor shall perform the following tests as a minimum during FAT:

Visual Inspection: All equipment shall be checked for conformity

with the approved drawings and with the contract/vendor

documents.

Hardware Functional Tests: Sub-system tests shall be

performed on any equipment provided by the vendor. The

equipment shall be tested for correct configuration,

functionality, and fault handling.

Software Testing: Software tests shall be performed to

demonstrate the satisfactory operation of the software. Testing

shall include:

i) Telemetry I/O processing, speed, and accuracy

ii) Display operation and performance

iii) Application software

iv) Alarm handling

v) Database configuration

vi) Logging facilities

viii) System utilities

ix) Historical data collection

x) Logic

xi) Links to the other systems interfacing with the

DCS

xii) Any other test required to demonstrate that the

provided DCS system complies with this

specification.

9.2.5 The vendor shall perform the system integration test with the OCS# 4 SIS,

FTPP DCS& SIS, all operator workstations, PIMS and PRM online.

9.2.6 The vendor and contractor shall use the emulator to simulate the interfacebetween the DCS and other package equipments and electrical system for the

FAT.


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9.3 Site Acceptance Test (SAT)

9.3.1 The SAT procedures shall be submitted to PTT for approval at least two

months in advance of any testing. The SAT procedure must be agreed in fullby PTT prior to commencement of any testing.

9.3.2 The Contractor shall supply all test, simulation, and other equipment

necessary to perform the SAT.

9.3.3 In general the SAT shall follow the same procedure as the FAT except the I/O

signals shall be live.

9.3.4 The vendor shall perform total system integration test which includes the

interface and function with the following systems online.

FTPP DCS

FTPP SIS

Motor Driven Compressor UCP

Compressor Master Performance, Load Sharing and Antisurge

controllers

Instrument Air Package

Fire Water Pump Package

Fire and Gas Control Panels

Emergency Diesel Generator

Deluge Skid

Machine Monitoring System

Electrical switchgear and MCC

9.4 Performance Test

9.4.1 The system shall undergo a thirty day performance test after completion and

acceptance of all SATs and correction of any deficiencies noted. This thirty

day performance test shall be in line with the 30 day continuous run of the

OCS# 4 station,

9.4.2 The performance test procedures shall be submitted to PTT for approval at

least two months in advance of any testing. The procedure must be agreed in

full by PTT and all punch list items must be satisfactorily completed prior to

commencement of any testing.

9.4.3 During the thirty day performance test the system shall operate without a

major error. Should a major error occur, the test will be stopped, the error

corrected, and the thirty day test restarted at day one.


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9.4.4 The Contractor shall notify PTT in writing when the repairs have been

completed, along with a detailed explanation identifying the problem and

corrective action taken.

9.4.5 PTT shall have full access to the system during the thirty day test, and all

normal operations shall be performed. Normal operations include polling,

calculations, display of data, trends, and reports, as well as the addition or

modification to any of the above.

9.4.6 Should any abnormal event occur during the thirty day test the contractor and

vendor shall immediately investigate the event to determine a cause , correct

the problem and submit a report to PTT. The report shall state whether in the

opinion of the contractor the event is a major error or not, and the reasons for

such a conclusion.

9.4.7 During investigation of any abnormal event the Contractor shall continue to

make all tests and measurements as required by the performance test

procedure. The report shall be submitted to PTT within three calendar days of

the event. Failure to submit a report within the allotted time shall result in the

event being declared a major error.

9.4.8 PTT will respond to an abnormal event report within three days; either

accepting the report, requesting additional information, or rejecting it.

Rejection of a report shall result in the event being declared a major error.

10.0 INSTALLATION AND COMMISSIONING

10.1 A minimum of thirty days prior to commencement of any installation work the

Contractor shall provide a schedule detailing the dates work will be

undertaken to PTT.

10.2 The Contractor shall provide a written plan detailing the work to be performed

for the installation of the system. The site installation plan shall be submitted

for approval by PTT a minimum of thirty calendar days prior to the

commencement of any work.

10.3 No installation of commissioning work shall be started at any site until the

Contractor has obtained PTT approval for the FAT results and PTT approvalfor the applicable issued for construction drawings.

10.4 The Contractor shall be responsible for obtaining all necessary permits and

permission to perform the required installation work.

10.5 The Contractor shall check the system as soon as it is installed at site to

confirm the system is still fully calibrated and functional after shipment and

installation.

10.6 The Contractor shall be required to maintain the commissioning team of the

vendor on site to cover any failures during the commissioning period.

10.7 The Contractor shall supply on site software and hardware support expertise

during commissioning of the system and during the complete thirty day

performance test period from the DCS system vendor.


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11.0 Deleted.

12.0 Documentation Requirement

The Contractor and vendor shall provide the following documents in both

hardcopy form (five copies) and electronic form on Compact Disk (three

copies). The format of the document files shall be complied with the related

PTT specification. The table of contents for each document shall be submitted

to PTT for approval.

(a) Basic Data

(b) Design formulae and calculations

(c) Overall accuracy or uncertainty in measurement

(d) Outline of calibration and verification methods

(e) Network setup setup and troubleshooting

(f) Reliability details of all equipment

(g) Equipment details / drawings for all components

(h) Full software documentation

(i) Wiring diagrams, including loop drawings

(j) Terminal schedule including tag identifier and point description

(l) System or component installation drawings and details

(m) Equipment lists and data sheets

(n) Drawing index

(o) Factory acceptance test procedure


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(p) Site commissioning plan

(q) Site installation plan

(r) Site acceptance test procedure

(s) Thirty day performance test procedure

(t) System technical manuals

(u) Utility consumption data

(v) Comprehensive operation and maintenance manual which will

enable PTT personnel to operate and service the equipment

without reference to the Contractor

(w) Comprehensive spare parts list and priced quotation for three

years operation

(x) Functional design specification which shall describe the system

hardware and software from the users point of view

(y) Complete and revised version of the detailed design manual

which provides details on the implementation and configuration

of each software component

The contractor and vendor shall submit the mentioned documents from item

(a) to (n) and (x) to PTT for review and approve during the engineering phase.

For the item (y), the vendor shall consult PTT for the document developing.

The rest of document shall be submitted to PTT for review and approval

according to the specification and the related system implementation phase.

spc-0804.02-60.05 rev d2 dcs specification

Documents

rev d2 dcs specification

dcs vendor

distributed control

system overview2

specification products

hardware requirements

general requirements

installationand testing