RUTENBERG POWER STATION, UNITS 1- 4 … - IEC - Specification... · UPGRADING OF THE SIEMENS AND MODICON PLC BASED ... develop, engineer, manufacture, preserve, assemble, tune, shop

THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B"

Engineering Division SPEC.: ZE-85701

ISSUE: FOR PROPOSAL

August 2015 B - 1

RUTENBERG POWER STATION, UNITS 1- 4

SPECIFICATION FOR

PLC BASED CONTROL SYSTEMSIEMENS AND MODICON UPGRADING OF THE

FOR COAL HANDLING SYSTEM

1. PURCHASER: The Israel Electric Corporation Limited (I.E.Co).

2. NAME OF ITEM: Upgrading of Coal Handling Control System.

3. LOCATION OF ITEM: Rutenberg Power Station, near Hadera at the

Mediterranean seashore, Israel.

4. SCOPE

The scope of work includes Engineering, Equipment and services for the

upgrading of the existing control system, based on Siemens S5 and MODICON

QUANTUM PLC, for Coal Handling System at the Rutenberg Power Station,

Units 1-4, by a new unified single control system based on new Siemens or

MODICON PLC (hardware and software).

4.1 Project description

Upgrading of the existing control system, based on Siemens S5 and MODICON

QUANTUM PLC, which are outdated and no more supported for Coal Handling

System at the Rutenberg Power Station, Units 1-4, by a new unified single

control system based on new Siemens or MODICON PLC (hardware and

software).

4.2 Scope of supply

The scope of work shall include, but shall not be limited to the following:

Within the scope of engineering and supply the contractor shall, as applicable,

design, develop, engineer, manufacture, preserve, assemble, tune, shop test,

pack and furnish the following:

THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: ZE-85701 ISSUE: for Proposal

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4.2.1 Basic Scope of Engineering, supply and services:

a.1 A Hot Redundant Programmable Logic Controller (PLC) Type Siemens

S7-400 or MODICON UNITY QUANTUM type 140CPU67260 with all

necessary hardware in order to replace the existing Siemens S5 CPU (S5

I/O will be not replaced) and MODICON QUANTUM PLC including 4 (four)

existing remote I/O cabinets with all the existing functions, parts,

appurtenances and accessories. All the new cabinets prewired and tested

will be installed on site. All replaced cabinets will be dismantled by

Contractor except field wiring (as per item 4.5.1).

a.1.1 The I/O that will be replaced will be according to the chosen type of PLC

Siemens or MODICON. For Siemens the I/O will be S7-400 RIO series

type. For MODICON the I/O will be QUANTUM RIO series type. The

Contractor must submit the details about the PLC type selected and RIO

type selected within the technical stage.

a.1.2 The PLC will support Ethernet IP Protocol as Native Port , in order to

provide a national brand free standard .

a.1.3 The System Switches will be from same brand as PLC Manufacture and will

be supplied with network Management System in order to provide a full

diagnostic of Communication system and to manage all switches.

The supplied Switches will support a Redundancy Loops and Closed FO

loops to provide full redundancy.

a.1.4 The Contractor will supply an automatic backup of PLC Software.

a.2 Dust Elimination:

a.2.1 Transferring all the Dust Elimination System of Units 1&2 (today on a

separate MODICON PLC with MODBUS+ communication) to the new PLC.

The I/O cabinet will be replaced too by a prewired cabinet checked and

tested in the factory (FAT).

a.2.2 In Dust Elimination System Units 3&4 the timer cabinets will be deleted and

the functions will be in PLC.

a.3 All necessary racks, mounting rails, connectors and power supplies.

a.4 Preparing, checking, debugging, uploading and commissioning of the

software for entire Coal Handling Control System (CHCS).


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a.5 All necessary provisions (including hardware and software) for assuring all

the specified below communication levels.

a.6 All appropriate licenses for the programming language.

a.7 All necessary updates of the Coal Handling HMI based on former WIZCON,

today CONTROL MAESTRO.

a.8 One complete package of language software for the training of IEC

personnel.

a.9 Two (2) Laptops with licenses for maintenance and one (1) Laptop for

engineering purposes.

a.10 All the hardware and software which provide the implementation of

Embedded Cyber Security (ECS) requirements, as stipulated in paragraph

6 and throughout this Specification.

4.2.2 Optional scope:

Future replacement of S5 I/O's (see supplement 8.6.3.4 for details).

4.2.3 The Equipment shall be supplied complete with appurtenances and accessories

as specified herein, to form a complete system which will achieve and assure

safe and reliable operation with best overall performance at all loads and modes

of operation. All components, appurtenances and accessories shall be of proven

design, verified by Power Plant Operation.

4.2.4 The Equipment shall meet the following essential requirements:

a. This upgrade work shall ensure normal Coal Handling operation without

interruption during the entire erection and commissioning period. In order to

achieve this goal the Contractor will propose the intermediate stages

program, which will be submitted during Bid period with the proposal and

will be subject of IEC approval.

b. The erection and commissioning activities shall be completed within 12

weeks (as further detailed in Annexure "D") - delays in Provisional

Acceptance shall be penalized per each week of delay (as set forth in

Annexure "A" par. 11.3).


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c. The number of cabinets and their capacities, the location and distribution of

the cabinets and I/O's shall remain unchanged due to existing cabling and

wiring limitation.

d. The Contractor will state a minimum time of spare parts supply of any kind.

This will be subject of IEC approval.

e. The erection and commissioning staff will be authorized for low voltage live

work (acc. to Israeli Law requirements).

4.2.5 Components that are herein specified in regard to manufacturer brand and

model or type shall be considered the standard of supply. It is not intended that

the Contract be limited solely to such characteristics. The Contractor may make

an appropriate substitution, but all substituted Components offered shall be

noted as EXCEPTIONS to this Specification and are subject to review,

comment, and approval by the Purchaser.

Additionally, while everything else being equal and without derogating from

Contractor's responsibilities under the Contract, the Contractor shall endeavor to

include in the scope of design and supply, components and accessories

manufactured in Israel.

4.2.6 Contractor shall provide, in the required format and form and in a timely manner,

all documentation required by this Specification and/or required by applicable

Standards and Codes and/or as specifically detailed in the Documentation

Submission Schedule (DSS), Annexure "J". A consistent nomenclature shall be

used project-wide in naming all component parts within the Scope of Work. This

shall apply to all drawings, Instruction Books, Bill of Materials, special

instructions, etc. Engineering design shall commence immediately after Contract

award. The cost of correcting inconsistent nomenclature shall be borne by the

Contractor.

4.2.7 Changes in design already approved by the Purchaser are normally unaccepted.

However, should such changes become necessary on an exceptional basis, the

Contractor shall obtain the Purchaser's approval prior to introducing any such

change.


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4.3 Special Equipment, Tools and Instruments

4.3.1 Contractor shall provide all special equipment, tools and instruments required for

safe and secure transport of all components from ex works to final destination,

and for test and maintenance of Equipment provided under this Contract. Said

equipment, tools, and instruments should be listed in Contractor's Proposal

where it should be clearly stated which are provided on a loan basis and which

are included in the Contract Price.

4.3.2 The Contractor shall furnish all necessary special tools, instruments and/or test

equipment which are required to fulfill the approved test procedure for equipment

tested by Purchaser.

4.3.3 Maintenance equipment and tools provided under this specification shall be new

and of best quality. They shall be shipped to the job site in a suitable separate

box, clearly marked with the name of the equipment they are intended for.

4.4 Contractor Services

The Contractor shall provide the services listed in the following sub-articles as

part of the basic Scope of Work or as Purchaser’s option, at the per diem or

lump sum rates, all as stated in the Summary of Prices and Delivery Schedule,

Annexure “C1”. Field personnel provided by the Contractor shall be capable and

qualified to perform the required duties to the satisfaction of the Purchaser. They

shall be vested with authority to make decisions that could affect the status of

the Equipment and which are binding on the Contractor.

4.4.1 Erection Services:

Contractor shall provide the services for erection, including, without limitation,

identifying the equipment, unpacking, intermediate storing, erection sequencing

and erection checking as may be required to assure proper and successful

erection and installation of the Equipment provided under this Specification.

4.4.2 Commissioning and Start-Up Services:

Contractor shall provide the services for successful commissioning, starting,

combustion tuning and placing into service of the Equipment provided under this

Contract with the balance of equipment at the related power station Unit(s).


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4.4.3 Training:

Contractor's personnel shall conduct a thorough training course pertaining to the

equipment furnished under this Specification, for Purchaser's personnel,

covering, without limitation, correct start-up, safe operation at all modes of

operation, safe shutdown and maintenance. The Contractor shall verify that the

trainees are completely familiar with all phases of such procedures and are

capable of operating and maintaining the equipment successfully.

Training course will be at Contractor's training Center.

Training of the maintenance staff shall be prior to commissioning in order to

provide in time the necessary skills for successful assisting and taking part in the

commissioning process.

Syllabus of the course will be provided with the proposal for IEC approval.

4.4.4 Performance Tests

4.4.4.1 Factory Tests:

The performances of the following components shall be verified by a shop test

as a precondition for delivery in accordance with the applicable standard

requirements:

a. PLC – functional simulation

b. HMI simulation

4.4.4.2 Site Tests:

Contractor shall delegate at its own cost, qualified test engineer(s), to witness

Equipment field performance tests necessary to establish compliance with this

Specification, and to satisfy that the Equipment fulfills the performance

guarantees, and other Contract requirements.

Field performance tests shall be carried out by the Purchaser, using procedures

provided by the Contractor and approved by the Purchaser according to ASME

PTC and EPA codes, all as further detailed in Annexure "D" – Equipment

Performance Guarantees.

4.5 Work by Others (Facilities and Services to be provided by the Purchaser)

In performing its duties the Contractor shall not be required to provide facilities,

services and equipment as detailed below [further details with respect to

Purchaser's undertaking regarding qualifications, quality, quantities and

scheduling should be stated in Contractor’s proposal]:


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4.5.1 On site and Engineering Services

4.5.1.1 Erection Services

Purchaser shall provide all the necessary labor force, general purpose tools and

facilities in order to dismantle, erect and install the field wiring related to this

Specification, following Contractor’s instructions and according to Contractor’s

plans, procedures and supervision.

4.5.1.2 Commissioning, Start-up and Performance Test Services

Purchaser shall provide all the necessary general purpose tools and facilities in

order to allow Contractor to perform commissioning and start-up of the Unit and

to perform performance tests.

4.5.1.3 Work by others related to interfacing and adjacent systems

Purchaser (Engineering Division) shall provide all necessary updates and

revisions in the relevant drawings, this shell be based of the Contractor

drawings.

5 TERMINAL POINTS AND TERMINAL CONNECTIONS

Contractor shall terminate the Equipment provided under this Specification in

accordance with the attached drawings (Supplements, item 8.6.3 below).

Contractor shall include in the proposal a detailed definition for all terminal points

and terminal connections not specified in the Supplements..

6 CYBER & INFORMATION SECURITY

6.1 Embedded Cyber Security (ECS)

6.1.1 General

Cyber security is a highly dynamic field, in continuous change and adaptation

to new threats. The Contractor / supplier shall propose adequate solutions, in

pace with global trends at the delivery time.

Particular methods or technologies are mentioned below only for the sake of

clarity.

Specific project security requirements are presented in:


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Supplement mentioned in item 8.6.1.3: 'Project system security standard

specification'. This document sets physical and logical security requirements the

purpose of which is to ensure the proper management of security in the project

phases i.e. during design, development, production, FAT, transportation,

delivery, SAT, commissioning and turnover. Supplier shall indicate in the

proposal all specific solutions for the requirement in the a.m. annexure.

6.1.2 The purpose of cyber security:

a. To ensure the safety of IEC personnel.

b. To prevent damage to IEC equipment.

c. To ensure the full operational capabilities of IEC computerized control and

information systems.

d. To maintain full system capabilities in the control and monitoring of IEC

facilities.

e. To ensure the regular supply of high quality electricity to IEC’s clients.

f. To ensure the availability, integrity, authenticity and confidentiality of IEC

data.

6.1.3 IEC’s specific terms and definitions

Communication networks hierarchy

IEC’s communication infrastructure is divided into four functional levels:

a. field level (data collection, commands, feedback between controllers and

field devices);

b. control and monitoring system Data Highway (communication between

controllers, controllers and operators / engineers / supervisors' stations etc.);

c. process – managerial level (real time process data transfer at the managerial

level);

d. corporate level - IEC’s LAN / WAN (organizational, commercial, personnel

etc. data).

6.1.4 Applicability

The cyber security requirements shall apply to:

a. Computer and microprocessor based systems/installations/

devices/embedded devices (hardware and software, both off-the-shelf and

customized applications).

b. Communication networks (hardware and software, both off-the-shelf and

customized applications).


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c. Real time or off-line systems.

d. Software above refers to Operating System, Application software (either off-

the-shelf or proprietary) and firmware.

6.1.5 General requirements

Contractors / suppliers shall carefully address the following points:

a. Compliance with NERC-CIP-002-1 through CIP-009-2, when not otherwise,

explicitly, specified in this document.

b. Compliance with IEC’s general policy and rules of data security defined

throughout this document. Some aspects or nuances, specific to a particular

project, will be decided during contract negotiations.

c. Both external (from outside IEC) and internal (from inside IEC)

vulnerabilities.

d. Security measures on manufacturer’s production floor and during

transportation.

e. Use of properly trained and skilled personnel (with respect to security

aspects) both in production and support phase.

f. Clear identification of existent system vulnerabilities (still unsolved).

g. Detailed documentation regarding proposed security provisions (including

the above mentioned vulnerabilities).

h. The security provisions shall not prevent the system from performing in all

aspects according to the performance demanded by the technical section of

the specification.

i. Prevention is preferred to post-intrusion detection.

j. When sub-contractors are involved, the main contractor still has the full

responsibility for overall compliance with security requirements. Furthermore,

regardless of where any component of the system was manufactured, coded, or

processed, the main contractor has, as above, full responsibility for compliance

of the component with the requirements described in these data security

guidelines.

k. Security provisions should be in accordance with generally accepted security

trends within computer community.

l. Use of state-of-the-art technologies.

m. Provide means for user-friendly periodical upgrades.

6.1.6 IEC’s policy

Some of the aspects referred to in item 6.1.5 a. are covered below:


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a. “One point of contact” per site between operational and management /

organizational networks.

b. Use of a highly secure gateway (hardware and software) at the above

mentioned point of contact; for new facilities this gateway shall be part of the

site Main Control / Monitoring System contract. Present and foreseeable

needs for data transfer between other DCS, SCADA, DPMS etc. systems on

the site should also be taken into account. For retrofit projects in existing

facilities the best purchase strategy shall be adopted, but the principle of

implementation remains the same.

c. There should be no connections of the system (on operational stations and

servers) to Internet, e-mail or other servers running any kind of public service.

d. The cyber security structure will be multi-tiered (“in depth” layers of different

protection) and “broadly applied”, that is, every piece of equipment complying

with the definitions in item 4 above will have at least one type of protection.

6.1.7 Physical security

In accordance with the project size and importance, the following points shall

be considered and assessed:

a. Use of physical means of security (such as smart cards, tokens etc.) for user

identification and authentication.

b. Seals and locks to avoid component theft (such as hard disk).

c. Protection of removable media. (CD, floppy etc.) by software/hardware.

d. Use of fiber optic cables whenever appropriate (enhanced security

protection).

6.1.8 Logical security

Refers mainly to the gateway mentioned above, but some items are relevant for

points of interconnection between two or more Control / Monitoring Systems

and other ones cover all the computer-based components:

a. (Network) address filtering.

b. Content filtering.

c. Intelligent filtering (rules).

d. Access Control Lists (ACL).

e. Concealment of the structure and nature of the data systems or networks

within the site.

f. Intrusion prevention/detection (IPS/IDS)

-Security audits


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-Logs

-Monitoring of unusual events (anomalies detection)

-Automate response (in case of intrusion)

g. Means for vulnerability analysis / assessment.

h. O.S. and proprietary programs hardening (definitions, options and

parameters shall be configured for the minimum, strictly necessary environment

to successfully perform the required tasks).

i. Complex rules for passwords (shall complement the physical means for user

identification and authentication).

j. Encryption – wherever applicable (e.g. wireless data transmission etc.).

k. DoS / DDoS prevention.

l. Encryption of control protocol data transfer (advantageous option).

m. Use of field device level Fire Wall.

n. Port-based Network Access Control, according to IEEE 802.1X standard (or

an equivalent technology at delivery time).

o. Intensive use of VLAN's architecture.

6.1.9 Protection against viruses / worms / vandals / Trojan horses

a. Provision for compatible, efficient programs for online protection (on all system

computers, even when not explicitly exposed to such threats).

b. Detection, cleaning and logging of executed actions.

c. Methodology for secure and frequent updates, such as built-in

process for installing/updating security updates - antivirus, operating

system patches, control system patches whenever necessary

firmware patches, etc.

d. White Listing

6.1.10 Management of cyber security means

6.1.10.1 It is highly recommended that the provided cyber security will be managed

through the same, integrated HMI, to the maximum possible extent.

6.1.10.2 Contractor / supplier shall provide friendly means (e.g. GUI) for:

a. Configuration

b. Monitoring

c. Testing

d. Updating / upgrading

6.1.10.3 Complex identification and authentication (at least two factors, such as e-token

and password) to access the control of cyber security means.

6.1.11 DCS-SCADA-DPMS systems interconnection


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6.1.11.1 Security safeguards (such as dedicated electronic appliances, protective

Gateways, FW's with DPI and preferably in a back to back architecture, etc.) shall

be used, whenever appropriate, at the interconnection point between systems.

6.1.11.2 Different suppliers of interconnected systems have to cooperate by providing the

necessary information and taking part in inter-systems tests or start-ups.

6.1.12 Cyber security on application level

The control / monitoring application software has to provide protection against

unintentional or hostile access to process data. While each manufacturer has its

own approach (subject of decision during contract signing), there are common

guidelines to be followed:

6.1.12.1 Implementation of secure programming rules, such as:

a. Input validation – whenever the input origination may constitute a threat.

b. Data base lock against "SQL injection".

c. Use of secure libraries throughout the code.

d. Well filtered error messages to prevent unveiling the code internal

structure.

6.1.12.2 Minimal privilege (which still allows proper work environment).

6.1.12.3 Segregation of responsibilities (roles), e.g.: a) technicians, b) operators,

c) engineers, d) supervisors, e) system administrators, f) communication network

administrators, g) security manager etc.

6.1.12.4 Different groups (classes) of security for writing (changing) process database

points, e.g.: a) manual data update (lab data), b) alarm limit, c) alarm

acknowledgement, d) command / set point, e) mode of operation, f) tuning,

g) configuration etc.

6.1.12.5 Predefined scenarios for “which roles are permitted to do what tasks”.

6.1.12.6 Control-field-level in-depth communication recording/analyzing

6.1.12.7 SIEM- Security Information & Event Management-for Plant/Site level.

6.1.13 Means for disaster recovery

If a disastrous shutdown happens, the system has to facilitate a rapid, easy and

accurate recovery through:

a. Configuration data backup (automatically).

b. Key process data backup (automatically).

c. Mechanisms and predefined procedures for quick restoration.

6.1.14 Remote Control / Maintenance / Support

Remote connections shall be avoided. When absolutely necessary, they shall

follow the guidelines below:

6.1.14.1 From a technical point of view, the proposed connection –subject to IEC's

approval– shall be implemented securely, complying with IEC's corresponding


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procedures, and based on secure identification / authentication, authorization,

encryption.

6.1.14.2 The connection shall be established for the shortest pre-specified period of time

and only from pre-specified system(s) / location(s).

6.1.14.3 The connection shall be under the permanent supervision of authorized IEC

personnel; IPS and / or IDS are recommended to monitor the connection.

6.1.14.4 Remote logins shall be logged in detail (who, when, for how long, from where, what actions have been performed etc.); providing adequate tool(s) for logs analysis shall be weighed.

6.1.15 Information exchange between IEC and Contractors / Suppliers

After contract award and through the startup period and site acceptance test there is an intense exchange of design data, documentation, software etc. between the Contractor / Sub-Contractors and IEC.

Contractor's proposal shall detail all the hardware & software, methods and procedures for safe data exchange. Known, proven technologies, adapted to IEC’s infrastructure, are preferred. Guidelines are as follows: a. Data encryption – decryption (optional). b. Data source certification. c. Data integrity certification. d. Data receiving confirmation (at its destination). e. Clear definition of IEC’s and other parties’ obligations for implementing the safe information exchange.

6.1.16 System Test

a. A test proving the implementation of cyber security requirements should be run both on FAT and SAT. b. Prior to test execution, a plan will be prepared by Contractor and then discussed with and approved by Purchaser.

6.1.17 Abbreviations Glossary

ACL – Access Control List DCS – Distributed Control System DDoS – Distributed Denial of Service DPMS – Data Processing and Monitoring System DoS – Denial of Service FAT – Factory Acceptance Test GUI – Graphic User Interface HMI – Human Machine Interface IEC – Israel Electric Corporation Ltd. IPS/IDS – Intrusion Prevention / Detection System LAN – Local Area Network OS – Operating System (e.g. Windows, Unix, Linux etc.) SAT – Site Acceptance Test SCADA – Supervisory Control and Data Acquisition WAN – Wide Area Network


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7 QUALITY ASSURANCE AND QUALITY CONTROL

a. Without derogating from the provisions of the General Conditions, Contractor's

quality system shall meet the requirements of Purchaser's Standard Q-APP-02-

PR, "Quality Requirements", and of the requirements of the Inspection and Test

Plan, all as further detailed in Annexure "M" to the Contract.

b. The Contractor and the main subcontractors shall be certified to ISO-9001-2000

by a certification body qualified to EN-45004 levels A or C or otherwise as may

be acceptable to the Purchaser.

c. The Contractor shall submit upon request a copy of its Quality Assurance Manual

including Quality Procedures.

d. The choice of main subcontractors shall be subject to Purchaser's approval and

the Contractor shall be responsible for assuring that their quality

assurance/quality control programs, including their organizations, procedures,

personnel qualifications, etc., meet Purchaser’s quality requirements. Contractor

[also Suppliers at the first stage of proposal evaluation] may propose additional

possible sub-suppliers by submitting to the Purchaser a formal request for

approval with sufficient details for evaluation including country of origin for

design and manufacturing, proven experience with respect to equipment of the

same size and functionality, quality assurance, catalogues, functional

parameters and technical data.

8 STANDARDS AND SUPPLEMENTS

8.1 Standards and Codes referenced in this Specification and in the Supplements to

this Specification form an integral part of this Specification - to the extent their

requirements are consistent and conform with the requirements specifically set

forth herein. All such Standards and Codes are to the issue, including all

amendments, supplements, etc., current as of the date of the Contract, unless

indicated otherwise. In the event of a variance between the requirements of the

Standards and Codes and the particular requirements set forth in the

Specification, the requirements specifically set forth in the Specification shall

take precedence.


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8.2 The Equipment to be provided under this Specification, including all

appurtenances and accessories, shall be designed, fabricated, inspected,

tested, stamped and preserved to the extent indicated in said referenced

Standards and Codes. Where this Specification does not include such reference,

The Equipment, or any of its components, shall be designed, fabricated,

inspected, tested and preserved, as applicable, to comply with currently

recognized International and/or Contractor's Standards, whichever are tighter

and more restrictive.

8.3 The Contractor may propose Standards and Codes as alternates for, or

additions to those specified herein. A copy of each proposed Standard and

code, if any, shall be submitted (in English) for Purchaser's approval. In case

Purchaser's approval is granted, the Contractor shall remain responsible for the

compatibility of the design and the physical interfaces between the supplied

Equipment and the equipment supplied by others.

8.4 The Purchaser shall assist Contractor in identification of Israeli codes and

standards applicable to the Work. In all cases Contractor shall adhere to and

comply with the requirements of Israeli official standards found to be more

restrictive than those specified herein.

8.5 Subject to the provisions stated above, the equipment shall be designed,

manufactured, erected, tested operated and maintained in accordance with the

standards, regulations, directives and publications of the following agencies and

organizations:

ANSI: American National Standards Institute, Inc.

ASME: American Society of Mechanical Engineers.

NEMA: National Electrical Manufacturer's Association.

NFPA: National Fire Protection Association.

IEC: International Electrotechnical Commission.

IEEE: Institute of Electrical and Electronics Engineers

NEC: National Electrical Code

8.6 Supplements

The following supplements are attached hereto and their requirements form an

integral part of this specification - to the extent they are consistent and conform

with the requirements specifically set forth herein. In the event of a variance

between the requirements of the Supplements and the particular requirements

set forth in the Specification, the requirements specifically set forth in the

Specification shall take precedence.


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8.6.1 Purchaser's general documentation, quality assurance, quality control:

8.6.1.1 Standard 01-1E Standard Specification for Contractor’s Drawing

and Data Transmittal.

8.6.1.2 Q-APP-02-PR: Quality requirements from suppliers.

8.6.1.3 Project system security standard specification

8.6.2 Purchaser's standard electrical requirements and data sheets:

8.6.2.1 EPD-A.14/04 PLC Based Control Systems

8.6.2.2 EPD-A.03 Control Cubicles – Electrical Wiring Requirements

8.6.2.3 EPD-A.05 Low Voltage Switchgear and Controlgear Assemblies of Fixed-

Mounted Design

8.6.3 Purchaser's drawings:

8.6.3.1 Control Cabinets: A, B, E, F, DE, Legend.

8.6.3.2 Sketches: 5.2, 5.3, 5.4, 5.5.1, 5.5.2

8.6.3.3 Handling Routes (in Hebrew)

8.6.3.4 S5 I/O Map (Optional scope)

9. TECHNICAL DOCUMENTATION

Without derogating from Contractor's obligation to provide any other document

called for by the Contract, the Contractor shall submit technical documentation in

accordance with the provisions of Annexure "J" – Documentation Submission

Schedule.


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10. TECHNICAL REQUIREMENTS

10.1 Environmental considerations & Site Conditions

10.1.1 Noise

The noise level of the supplied Equipment shall not exceed an A-weighted sound

level of eighty (80) dB(A) at a distance of one (1) meter from any major surface.

10.1.2 Environmental Data

Should the equipment to be furnished by the Contractor have discharge points to

the environment and/or generate waste materials that must be discharged to the

environment, the Contractor shall provide, upon Purchaser's request, a plan for

the treatment of the discharge/waste to meet current regulations of the U.S.

Environmental Protection Agency (EPA).

The Contractor shall submit, within thirty (30) days of demand, additional

information on noise and/or other environmental data. All information shall be

prepared in a manner acceptable to Israeli licensing authorities.

10.1.3 Wind Load

The calculation of wind loads in Israel is governed by the provisions of the Israeli

Standard 414 (latest edition at contract signing) “Characteristic Loads in building:

Wind Load”.

The calculation shall be accomplished using the basic design wind velocity,

defined below.

According to this Israeli Standard, the basic design wind velocity is defined as

the average velocity for ten (10) minutes, with an average return period of fifty

(50) years, at an altitude of ten (10) meters above ground level, and in an open

terrain with only a few obstacles.

The maximum upper gust velocity (three (3) seconds average) can be calculated

by multiplying the basic design wind velocity (ten (10) minute average) by a

factor of 1.50.

The basic design wind velocity shall be taken from the velocity map which forms

an integral part of the standard.


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10.1.4 Earthquake Loads

10.1.4.1 General

The seismic design of buildings and structures in Israel is governed by the

provisions of the Israeli Standard 413 “Design Provisions for the Earthquake

Resistance of Structures” (amendment 3 / 2009).

According to this Standard, the seismicity of the site is expressed by the

expected horizontal ground acceleration coefficient Z.

The expected horizontal ground acceleration coefficient Z expressed as:

Z = ah,max/g.

The maximum expected ground acceleration ah,max has the meaning of peak

horizontal ground acceleration, expressed in m/sec2, with a 90% probability not

to be exceeded over a 50 years period. The gravity acceleration g = 9.81 m/sec2.

The expected horizontal ground acceleration coefficient (Z), per provisions of the

Amendment 2 (2004) to the Israeli Standard 413 is 0.09 for Rutenberg Power

Station.

10.1.4.2 Seismic environment for electrical equipment

The seismic environment is defined according to IEC Publication 60068-3-3

("Seismic Tests methods for equipment"), for "General Seismic class".

1. For the scope of work the peak acceleration of the ground level shall be taken

2 m/sec2.

2. The value of superelevation factor (k) shall be:

K = 1 for equipment mounted on rigid foundation.

K = 1.5 for equipment rigidly connected to buildings.

K = 2 for equipment installed on stiff structure connected rigidly to

building.

3. The equipment shall comply with the relevant qualification criterion, according

to paragraph 4.3 of IEC Publication 60068-3-3, which fulfils the required

functionality statements.


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10.1.4.3 Load Combination

Design wind and design earthquake shall not be considered to act at the same

time and their respective effects on the buildings and structures shall not be

combined.

10.1.5 Environmental conditions

The Power Station is located near the Mediterranean coast. The supplied

equipment shall be installed indoors, in an air conditioned Electrical Room.

Nevertheless, the items shall be suitable for operation without any restriction at

the following conditions of the surrounding air:

Temperature: between +0ºC and +45ºC.

Humidity: less than 95%

10.2 Operational requirements

10.2.1 The upgrade shall include hardware, software, engineering, soft and hard

connections of parts that will be upgraded/ added/ replaced and will ensure a

similar automation and technical level with the existing ones.

10.2.1.1 Description of the existing Coal Handling Control System

10.2.1.1.1 The coal handling system is functionally comprised of the following

systems/equipment:

a) Two (2) ship unloaders.

b) Three (3) stacker/ reclaimers.

c) Coal supply to power units 1-4.

d) Auxiliary systems.

The equipment specified under paras a) & b) is operated independently (by operators

who are permanently on the working machines), but interlocked and supervised by

the coal handling main control system. All other items/systems are fully controlled by

the operator of the control system (from the coal handling control room), by means of

former Wizcon HMI system today Control Maestro.

The control is based on hot redundant PLC's (programmable logical controller), as

shown in Sketch No. 5.2 (item 8.6.3.2).


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The CPU's located in the Coal Handling Control Room (CHCR) controls, supervises

and monitors the Remote I/O's distributed in the site and located in control cabinets

as shown in Sketch No. 5.3 (item 8.6.3.2).

10.2.1.1.2 The existing main control system located in CHCR includes:

- Front control desk housing five (5) personal computers (P.C.'s) operating

and displaying the coal handling process.

- Back side control desk housing P.C.'s for lighting, air-conditioning and binary

system.

- Four (4) large screens for process display.

- T.V. closed loop for coal handling site overview and monitoring

- Two (2) hot redundant QUANTUM PLC's manufactured by MODICON-SCHNEIDER.

- Two (2) hot redundant SIEMENS-made PLC's, type 155H.

10.2.1.1.3 Heavy and auxiliary equipment control

- Two (2) ship unloaders, with local PLC based control & HMI, inter-

connected to the CHCR by communication, as shown on

sketches 5.2, 5.4 (item 8.6.3.2).

- Three (3) stacker/reclaimers with PLC based local control & HMI

inter-connected with CHCR by communication, as shown on

sketches 5.2, 5.4 (item 8.6.3.2).

- Two (2) sampling systems with PLC based control inter-connected

with CHCR, as shown on sketches 5.2, 5.4 (item 8.6.3.2).

- Dust elimination and suppression systems are included in the main coal handling

control system (CHCR).

10.2.1.1.4 There are three (3) communication levels via fiber-optic media (as shown on

Sketch No. 5.4 (item 8.6.3.2))

- ETHERNET TCP/IP communication between PLC's and P.C.'s on this

network hangs 9 PLC's, 5 PC's and 4 large screens.

- DUAL PROFIBUS-FMS Communication between PLC's for signal

exchange, including interlocks.


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- MODBUS + (for MODICON) and PROFIBUS-DP (for SIEMENS)

communication between PLC's and their remote I/O's.

10.2.1.1.5 The CHCR operator activates the coal handling process by means of

HMI screens.

The selection of coal routes is based on source - target method, as exemplified on

the attached Sketches Nos. 5.5.1 - 5.5.2 (item 8.6.3.2), Handling Routes (item

8.6.3.3)

The following settings are necessary:

* Choosing the destination.

* Choosing sources.

* Choosing flow rates.

- If the line consists of one source and one destination (not Surge

Bin):

the coal rate is to be determined on source.

- If the line consists of one source and two destinations:

the coal rate is to be set on source and one constant flow

rate is to be set for one destination.

- If the line consists of two sources and one destination:

the coal rate on destination and ratio between sources is to be

determined on source.

10.2.2 The Programmable Logic Controller (PLC) shall be supplied with all necessary

hardware in order to replace the existing PLC with all the existing functions, parts,

appurtenances and accessories. The equipment shall be designed in accordance

with the seismic environment for electrical equipment specified in para. 10.1.4.2.

The performance of the components and of the whole control system shall comply

with requirements of EPD-A.14 (item 8.6.2.1 above)

10.2.3 The number of racks and their capacities, the location and distribution of the

racks and I/O's shall remain unchanged due to space limitation and in order to

use the existing cabinets with minimal rewiring works.

10.2.4 The Contractor shall supply all the necessary racks, mounting rails, connectors

and power supplies.


B - 22

10.2.5 The scope of supply shall include I/O cards in the following approximate

quantities and types:

Cabinet A:

a. 230 VAC digital inputs (16 points) – DI 16 - 10 cards;

b. 230 VAC digital outputs (16 points) – DO 16 - 2 cards;

c. 230 VAC digital relay outputs (8 points) – DO 8 - 5 cards;

d. Analog inputs 4-20 mA (8 points) - AI 8 - 1 card;

e. Analog inputs 4-20 mA for TC (8 points) –AI 8 - 1 card;

f. At least 15% spare I/O of each type (mandatory requirement).

Cabinet B:






f. At least 15% spare I/O of each type (mandatory requirement).

Cabinet E:






B - 23


f. Analog outputs (4 points) – AO 4 - 1 card.

g. At least 15% spare I/O of each type (mandatory requirement).

Cabinet F:






f. Analog outputs (4 points) – AO 4 - 1 card.

g. At least 15% spare I/O of each type (mandatory requirement).

DE Cabinet:


b. 230 VAC digital isolated outputs (16 points) – DO 16 -9 cards;

or relay outputs (8 points) DO8 - 18 cards

c. At least 15% spare I/O of each type (mandatory requirement).

Note. Slight changes made by the power station staff during the years,

after commissioning, are shown in the control cabinets

configurations.

10.2.6 The Contractor shall supply all the necessary provisions (including hardware and

software) for assuring all the communication levels, as described in above item

10.2.1.1.4.

10.2.7 The Contractor shall provide the programming language with all appropriate

licenses.


B - 24

10.2.8 The Contractor shall be responsible for the upgrade and transfer of the existing

PLC program into one common, unified, completely integrated Coal Handling

Control System and HMI, including all necessary hardware, software and

application programs.

During writing of the program the maintenance staff will have to approve every

segment of the program before forth going to the next segment.

10.2.9 The Contractor will supply one complete package of software language for IEC

personnel training (after signing the Contract but prior to detail design).

10.3 Functional testing, Commissioning and Performance Requirements

The performances of the Equipment shall be verified by a site test in accordance

with the provisions set forth in Annexure “D” to the Contract – Equipment

Performance Guarantees.

10.3.1 FAT (Factory Acceptance Test)

10.3.1.1 Contractor shall perform a complete cyber security test prior to the FAT

according to paragraph 6.

10.3.1.2 Software simulation and hardware FAT will be performed prior shipment and

witnessed by Purchaser's personnel.

10.3.2 Site Acceptance and Performance Tests

10.3.2.1 The Contractor shall be responsible for proper protection of

instruments and devices that may be damaged during commissioning and tests.

10.3.2.2 The Contractor shall inspect board-mounted devices to ensure that

they are securely attached.

10.3.2.3 The Contractor shall inspect terminal blocks and interconnecting wiring.

10.3.2.4 The Contractor shall perform 100% point-to-point continuity tests

and electrical insulation tests. Megger or other high voltage tests shall be

applied to any coaxial and triaxial cables. Solid state components shall be tested

in accordance with Section 1-109.05.-09 of NEMA ICS.

10.3.2.5 The Contractor shall perform control circuit function tests as far as possible by

actuating control switches and push buttons during application of appropriate

signals while observing the functioning of all associated panel and console

devices and checking for proper output signals at terminal blocks.


B - 25

10.3.2.6 Written tests procedures shall be prepared by the Contractor.

The test procedures shall include the records to be taken during the tests. A

written report shall be provided. The owner shall be given the opportunity to

witness all Contractor's activities on site including the performance tests.

10.3.3 Commissioning

The commissioning and tuning of the Equipment shall be conducted in

accordance with the provisions set forth in Annexure “D” to the Contract –

Equipment Performance Guarantees.

10.4 Maintenance requirements

10.4.1 Spare and Renewal Parts

The Contractor shall provide upon purchaser's request as purchaser's option

spare parts at their itemized prices, subject to the applicable terms and

conditions, all as further detailed in Annexure "C1"- Summary of Prices and

Delivery Schedule.

10.5 Reliability, Availability, Maintainability (RAMS)

Reserved.

10.6 Safety

The Equipment supplied under this Specification shall meet the U.S.

"OCCUPATION, SAFETY, AND HAZARD ADMINISTRATION" (OSHA)

requirements or equivalent.

11 TEST AND INSPECTIONS

I&TP (Inspection & Test Plan)

I&TP will be provided by Contractor according to requirements of item 7 above.

12 PACKAGING & DELIVERY

The Contractor shall comply with the requirements for Shipment and Handling of

Equipment set forth in Annexure "R" to the Contract and additionally with the

following supplementary requirements:


B - 26

12.1 All components or accessories shipped detached for field mounting or field

assembly shall be suitably tagged to allow easy identification. Tags shall be

stamped with cross reference data such as Manufacturer's Name, Contract No.,

Power Station, Unit No., reference drawing and Equipment Designation, and

shall be exceptionally durable and securely tied to items by wire or other

methods approved by Purchaser.

12.2 Major pieces of Equipment (such as motors, pumps, fans, valves, actuators)

shall be supplied with securely tied nameplates (Adhesive fastening is not

acceptable) including manufacturer’s name, model number, serial number and

additional information, such as voltage, frequency, etc.

12.3 Unless specially designated, all Equipment and other items shall be packaged

for outdoor storage until erection. Where required by the nature of the

Equipment, the Contractor shall furnish and install necessary covers to protect

the Equipment from sand, rain, hail, wind, dust and salt spray. Equipment shall

be adequately sealed and protected during shipment to prevent corrosion and

entrance of foreign matter. All exposed machined surfaces shall be protected

where required with a suitable antirust compound or covers before shipment, for

shipment and storage until erection.

12.4 The equipment components shall be supplied as large as possible to reduce

field welds and erection time.

13 STORAGE & HANDLING

13.1 Before packing, the equipment shall be cleaned to remove all dirt and waste

material left for fabrication to the extent that it can be put into service without

further cleaning.

13.2 The top, back, ends and bottom of the control panels shall be provided with

temporary enclosure, tightly sealed to prevent entry of foreign matter during

shipment and storage at the job site. The entire panel or console shall be

adequately protected to prevent damage to components during handling and

shipping.

13.3 The control panels and all equipment shall be packaged so that they will arrive at

the plant site undamaged, either by handling and/or due to weather conditions.

13.4 The Contractor shall be responsible for, and shall repair or replace at his expense

damaged equipment where damage was due to improper preparation for

shipment of goods.


B - 27

13.5 Detailed storage requirements for short term (up to 6 months) and long term

(greater than 6 months) shall be provided. Special handling provisions shall be

transmitted to the owner prior to shipment. Storage and handling requirement

data shall be attached to each package when shipped.

13.6 Prior to preparing the system for shipment, all accessories which may be subject

to damage either during shipment or during handling at the job site shall be

removed.

Each item removed shall be clearly labeled as to the equipment with which it is

associated and in accordance with a drawing showing its exact location and

configuration on that equipment to facilitate reassembly in the field. This drawing

shall be placed in a suitably marked envelope and shall accompany the

equipment and disassembled components.

14 NAMEPLATE & MARKING

- The Contractor shall use a nameplate (Manufacturer’s marking) in reference

to an instrument or a device on drawings, correspondence and manuals,

where applicable.

- The nameplate (Manufacturer’s marking) tag shall include the following

identifying data:

* manufacturer’s name,

* model number,

* serial number;

* additional information, such as voltage, frequency, etc.

- Construction of nameplate (Manufacturer’s marking):

For field mounted instruments the Manufacturer’s Marking Data shall be

stamped on a tag fastened permanently to the instrument. Adhesive fastening

is not acceptable.

Name plate material will be stainless steel.

– F I N A L –

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