1

CLIENT:

SYLHET GAS FIELD LIMITED CONDENSATE FRACTIONATION PLANT & ASSOCIATED FACILITIES

CAPACITY 4000 BBL/DAY

AT RASHIDPUR, BAHUBOL, HABIGANJ, BANGLADESHCONTRACTOR :

SPECIFICATION FOR DISTRIBUTED CONTROL SYSTEM

PAGE 2 of 38

CLIENT:

SYLHET GAS FIELD LTD. CONDENSATE FRACTIONATION PLANT & ASSOCIATED FACILITIES

CAPACITY 4000 BBL/DAY

AT RASHIDPUR, BAHUBOL, HABIGANJ, BANGLADESHCONTRACTOR :

SPECIFICATION FOR DISTRIBUTED CONTROL SYSTEM

PAGE 3 of 38

CONDENSATE FRACTIONATION PLANT & ASSOCIATED FACILITIES

CAPACITY 4000 BBL/DAY

AT RASHIDPUR, BAHUBOL, HABIGANJ, BANGLADESH

SYLHET GAS FIELDS LIMITED

SPECIFICATION FOR DISTRIBUTED CONTROL SYSTEM

A05-NOV-2014ISSUED FOR REVIEWMMPAMDOCCS

REV.DATED E S C R I P T I O NPREP.ENGEMPM

CHECKEDAPPROVED

TOTAL OR PARTIAL REPRODUCTION AND / OR UTILIZATION OF THIS DOCUMENT ARE FORBIDDEN

WITHOUT WRITTEN AUTHORIZATION OF THE OWNER

Client Job No. : CONTRACTOR :

Contractor Job No. : C-222

Client Document No. :

Contractor Document No. : 222-X-XX-XXX

Page No. : 1 of

TABULATION OF REVISED SHEETS

SHEETREVISIONSSHEETREVISIONS

A

139

240

341

442

543

644

745

846

947

1048

1149

1250

1351

1452

1553

1654

1755

1856

1957

2058

2159

2260

2361

2462

2563

2664

2765

2866

2967

3068

3169

3270

3371

3472

3573

3674

3775

3876

NOTE : X : PREVIOUS ISSUE : CURRENT ISSUEContents

61.INTRODUCTION

62.DEFINITIONS

63.SCOPE

74.REFERENCE DOCUMENTS

85.CONDITION OF SERVICE

86.GENERAL REQUIRMENTS

86.1General

86.2Vendors Responsibility

97.SYSTEM ARCHITECTURE

108.CONTROL SYSTEM REQUIREMENTS

108.1Regulatory Controls

118.2Discrete Control

118.3Sequential Controls

128.4Non Controller Input

128.5Control System Software

139.DATA ACQUISITION AND PROCESSING

139.1Generals

139.2Alarms

149.3Logs and Reports

149.4Historical Database

1510.PROCESS INTERFACE

1510.1I/O Rack

1510.2I/O Cards

1610.3I/O Summary

1610.4Noise Immunity Requirements

1710.5Cable Segregations

1710.6Interface with Others Device

1811.OPERATOR INTERFACE AND DISPLAYS

1811.1General

1911.2Operator Stations

2011.3Engineering Station

2011.4Control Stations Electronics

2111.5Keyboard and Security Feature

2211.6Video Display

2311.7Alarm and Event Printer

2411.8Screen Copier

2411.9Report Printer

2412.COMMUNICATION SYSTEM

2412.1Requirement

2512.2Highway Redundancy

2512.3Systems Capability

2512.4Network Topology and Access methods

2612.5System Loadings

2612.6Systems Response Time

2713.POWER SUPPLIES

2713.1General

2713.2Power Supply Tolerance Limit

2713.3Power Distribution Information Required with Quotation

2713.4Fault Discrimination

2713.5Power Supplies

2813.6System Grounding

2914.SYSTEM SECURITY AND RELIABILITY

2914.1General

3014.2Basic Reliability

3014.3Operator Security

3014.4Regulatory control Reliability

3114.5Diagnostics

3114.6System Software and Database Back up

3214.7System Redundancy

3215.ENVIRONMENT

3215.1General

3215.2ENVIRONMENT AREA CLASSIFICATION

3315.3Heat Load

3316.MECHANICAL REQUIREMENTS

3316.1Dimension and Layout

3416.2Flooring

3416.3Finishing

3417.MATERIALS

3418.SPARE PARTS

3519.INSPECTION AND TESTING

3519.1Quality Assurance

3519.2Quality Assurance Testing

3519.3Factory Acceptance Test Preparation

3619.5Field Test

3619.6Performance Guarantee Test

3720.EQUIPMENT / MATERIAL IDENTIFICATION

3721.PREPARATION FOR SHIPMENT AND STORAGE

3822.GUARANTEE

1. INTRODUCTION

This specification defines the minimum technical requirements for the design, material procurement, fabrication, inspection, testing, and painting, preparation for shipment and delivery of Distributed Control System (DCS) for The Project CONDENSATE FRACTIONATION PLANT & ASSOCIATED FACILITIES CAPACITY 4000 BBL/DAY AT RASHIDPUR, BAHUBOL, HABIGANJ, BANGLADESH2. DEFINITIONS

Terms used in this specification are defined as follows:

Companymeans SYLHET GAS FIELDS LIMITEDSupplier/Vendormeans the party selected to supply the equipment and service detailed in this specification. This is the entity having unit responsibility as defined in the industry codes and standards.

Purchaser/Contractormeans PT ISTANA KARANG LAUT.3. SCOPE

This specification covers the minimum requirements governing the design, material, fabrication, inspection, testing, painting and preparation for shipment of Distributed Control System (DCS) complete with spare parts and VENDOR data.This specification and referenced documents listed in Section 4 below are not intended to be all-inclusive. The requirements set forth do not relieve VENDOR of his responsibility to perform all services in a safe manner, to meet applicable codes and standards to supply a product capable of performing its intended service.

This specification, together with the attached Instrument Data Sheets, and / or sketches and purchase documents, covers the Company's minimum requirements for the supply, design, materials of construction and fabrication of DCS. The DCS furnished according to this specification shall conform to the requirements contained herein, unless modified in writing by the Instrument Data Sheets, sketches or addendum to this specification

4. REFERENCE DOCUMENTS

The requirements and recommendations of the latest revisions of the following listed codes, standards, PURCHASER general specifications and project documents shall apply. The latest revision number and / or date of each referenced industry code or standard applied shall be applicable. VENDOR's proposal shall clearly state and list exceptions to this specification and all referenced codes and standards.

Codes and standards referenced in, and / or pertinent to, and applicable to this document are listed below. The latest revision number and / or date of each referenced industry code or standard applicable.

ANSI-C3.9.5Safety Requirements for Electrical and Measuring and Control Instrumentation.

ANSI-C37.90Relays and Relay Systems associated with Power Apparatus.

ICEA-S-66-524Insulated Power Cable Engineer Association cross-linked thermosetting polyethylene insulated wire and cable for transmission and distribution of electrical energy.

IEEE-Std 446Emergency and Standby Power systems for Industrial and Commercial Applications.

IEEE-Std 488.1Standard Digital Interface for Programmable Instrumentation.

IEEE-Std 488.2Standard Codes, Formats, Protocols, and Common Commands for Use with IEEE Std 488.1, Standard Digital Interface for Programmable Instrumentation.

IEEE-Std 730.1Software Quality

ISA.S5.1Instrumentation Symbols and Identification

ISA-S5.2Binary Logic Diagrams for Process Operations

ISA-S5.4Instrument Loop Diagrams

ISA-S5.5Graphic Symbols for Process Displays

ISA-S50.1Compatibility of Analog Signals for Electronic Industrial Process Instruments

ISA-S51.1Process Instrumentation Terminology

ISA-RP55.1Hardware Testing of digital

5. CONDITION OF SERVICE

All equipment shall be designed for installation and operation on shore and be suitable for the climatic and site conditions described in this specification and equipment Data Sheets

6. GENERAL REQUIRMENTS

6.1 General

a) This specification, together with the Attachments and purchase documents, covers the Company's minimum requirements for the supply, design, materials and fabrication of a Distributed Control System (DCS).

b) The scope of this Specification is to define a DCS that shall be factory tested and ready to function as soon as it is connected to electrical power supply and field input / output signal wiring. Included in this Specification are performance requirements, which will be delineated by function, and general requirements for system reliability, integration and packaging

c) The equipment furnished according to this specification shall conform to the requirements contained herein, unless modified in writing by the attachments or an addendum to this specification.

d) Deviations from this specification must be approved in writing by the Company prior to implementation.

6.2 Vendors Responsibilitya) The Vendor shall accept full system responsibility for all supplied hardware, operating and application software and provide necessary training, supervision, spares and site support for the construction, testing, installation and pre-commissioning phases of this contract until successful hand-over to the Company.

b) The Vendor shall provide the equipment required for this function on a loan basis. The equipment shall include all consumables for its use in the project for the time frame indicated on the schedule.

c) The Vendor is responsible for transportation, crating / uncrating, and setup/testing the development system when moving to / from the designated location. The Vendor shall also provide on-call maintenance for this equipment, including replacement parts and maximum response time as part of this quotation to cover the duration of the lease. d) The Vendor shall supply sufficient equipment to fully prepare, load, and test user information (database). This equipment is expected to include the components listed below, as a minimum but not limited to :

1. Operator Station Consoles and Engineering Work Station complete with printer.

2. Data Highway.

3. Regulatory Controller Cards

4.Analog I/O card (approximately 16 analog in and 16 analog out)

5.Discrete I/O cards (approximately 32 inputs and 32 outputs)

6.History

7.DCS terminal to enter database, build displays, etc.

8.All required software

9.All required interconnecting cables

10.Foreign device for each type of foreign device included in the proposed system.

7. SYSTEM ARCHITECTURE

1. The DCS shall utilize microprocessor based devices which are configured by the Vendor to perform in real time such essential functions as:

a).Data acquisition

b).Regulatory control

c).Sequential and batch control

d).Operator interface

e).Interactive graphic displays

f).Data base for data collection, archiving, and reporting

g).Process alarms and system diagnostic alarms

2. The DCS shall utilize a modular architecture to permit a wide range of system configurations and facilitate system flexibility and expandability.

3. The DCS shall be capable of protecting the system integrity and security by implementation of redundancy for both communication links and system hardware. In case of failure, the switchover shall be automatic and in no way affect the control operation.

4. The DCS hardware and system architecture shall be reliable and field-proven. The Vendor shall inform the Company in writing if any hardware, system architecture, or software proposed has not been field-operational for a period of twelve months.

8. CONTROL SYSTEM REQUIREMENTS

8.1 Regulatory Controls

a. The regulatory control system shall consist of a flexible set of tasks that can be executed interactively via the stations and require no programming skill by the user. Vendor's system shall be able to perform, as a minimum, the following functions with one or more algorithms and programming in the regulatory control system. All regulatory control features shall be Vendor's standard. Vendor shall identify and price those that are not standard in his proposal.1.PID control

2.Cascade and ratio control

3.Hand control (HIC) which can accept a cascade set point

4.Square root extraction

5.Computational function (addition, subtraction, multiplication, division)

6.Lead/lag

7.Time delay

8.High/low select

9.Switches10.Digital filter

11. Mass flow computation (temperature, pressure, molecular weight compensation)

12.Totalizing/integration

13.A general equation block to perform other calculations

14. Signal characterization

15.Ramp function

16.Set-point tracking

17.Adaptive / self-tuning including adaptive gain.

b. The process controller must be able to communicate with other controllers and other elements in the system (peer-to-peer communication) without interconnecting hardwires or a separate communication network.

c. The control configuration shall be programmed by a high level language and / or function blocks.

d. Control configuration and programming shall be permissible while the system is online. The remainder of the controllers (including those executing in the same processor) shall be decommissioned by this procedure.

8.2 Discrete Control

Discrete control functions are required at the regulatory level. Vendor's system shall be able to perform, as a minimum, the Boolean Logic based on discrete variables, controller modes and alarm states, and to produce a digital output to another continuous or discrete algorithm or to the field.8.3 Sequential Controls

a. The sequential controls will allow the creation of custom software. The program shall be able to access data from any location in the regulatory controls and input modules. Also, the operator will interact via the operator's station with the sequential controls in the same manner as with the regulatory controls.

b. The standard sequential control software shall contain special processing instructions to provide such functions as:

1.Batch control

2.Motor start/stop and shutdown

3.Interlock logic (and, or, not, etc)

4.Recipe transfer

5.Emergency procedures

8.4 Non Controller Input

There are a number of analog and discrete inputs that will be used in the system only for display and logging. These points maybe input through controller modules or multiplexer modules.

8.5 Control System Software

a. The process control software must allow for a wide range of process control application and require no special programming skills from the user.

b. The system software shall permit the user to configure the system interactively via interfaces such as the keyboard, mouse, track-ball, touch-screen, and HMI. The language shall be any combination of the following forms :

1.Functions blocks

2.Problems-oriented languages that are customized for specific types of control applications, such as fill-in-the-form approach for PID controller or batch control language.

3.High-level language that offers the user some degree of flexibility in designing his own control algorithm while maintaining compatibility with function block or problem-oriented applications in the system.

c. The system software shall use a control-oriented approach and permit the user to select one or more functions in the form of dedicated modules and to implement them in a desired control strategy. The control function library shall include, as a minimum, the following modules :

1.Data acquisition and signal conditioning modules, such as input scanning, linearization, and conversion to engineering units

2.Limit checking and alarming modules

3.Continuous control modules for regulatory control

4.Sequential control modules for implementing Boolean logic.

5.Communication modules to allow signal transmission between the controllers and other devices in the DCS, indicating interfaces with foreign devices, such as PLC's or other computer.

9. DATA ACQUISITION AND PROCESSING

9.1 Generals

Data acquisition is applicable to all process data input to the system and is not limited to non-controlled variables. The data may be from various sources which include, but are not limited to the following devices:

a).Controllers

b).Non-controlled input

c).Operator input devices, keyboards, etc.

d).Communication (Redundant) links with other devices.

9.2 Alarms

Alarm monitoring shall be performed for system failures and process alarms.

1. All alarms generated must be able to be displayed on an operator's HMI via a color change or reverse video. The system must alert the operator to each alarm with an audio and a visual signal, regardless of the current display on the screen.

2. The following alarm types shall be available within the system:

a).Absolute high-high, low, and low-low and high-low deviation from set point alarms for each point.

b).Rate of change alarms, high and low, for each point

c).System diagnostic alarms

e).Transducer out-of-range limit alarms, to identify a transducer operating outside its range for analog input

f).Thermocouple open circuit for each point with millivolt input

g).First-out alarm to indicate a sequence of events as they occurred. The Vendor shall state time resolution of sequence of event reporting within which events are reported as simultaneous.h).Priority alarms which rank the current alarms by their importance to process operation.

i).Alarms shall be able to be assigned to groups.3. The operator shall have the facility to suppress alarm points individually, by plant, or by unit.

4. Alarms shall be time tagged to 1 second resolution.

9.3 Logs and Reports

1. A report generator shall be supplied to build and modify logs. Logging and reporting functions shall be initiated by a control program, by operator demand, or on schedule. All points in the system shall be available for logging and reporting. Logs and reports shall be capable of being printed on the printers, stored on disk, and / or displayed for viewing on any operator or engineering station HMI.2. The system shall be capable of generating the following logs with events, time, and date stamped as they occurred:

a).Process alarms and return-to-normal status

b).Operator control actions, i.e., set-point changes, control mode, logic command, manual output.c).Alarms associated with equipment failure, status, or performance

d).Short-term and long-term trending of process variables

e).Periodic or on-demand log of process information.9.4 Historical Database

1. The system shall have a mass storage device which saves an historical database for graphical trending.2. Any process variables should be selectable for graphical trending.

3. The graphical trending shall display a minimum of four process variable on an X-Y graph. The data should be sampled at a rate according to the table below as a minimum requirement.

4. The graphical trend display modes shall include:

a).Single rate mode: a plot of real-time values at a pre-selected sampling rate.

b).Average mode: a time compression of the average values of points. The degree of time compression shall be selectable.

c).Minimum / Maximum mode: the minimum and maximum values of the selected points are displayed according to the selected intervals of time compression.

5. Any point shall be capable of being configured in the Historical Database implemented by the software system.10. PROCESS INTERFACE

10.1 I/O Rack

1. I/O racks shall be of free-standing type with hinged access door on front or both front and back sides. All fields wiring shall enter the rack from the bottom and terminated inside the I/O rack directly on disconnect marshalling terminals. Terminals shall be provided including 20% spare cores in the field cable on I/O card connectors or on termination panels. Inter-rack wiring shall enter via the top of the rack. Thermocouple cables shall be terminated directly on the I/O termination card. Terminals shall be provided for 10% spare cores.

2. Any field-mounted rack shall be equipped with a weatherproof housing and with IP 55 rating as a minimum. If located in a classified hazardous environment area, the equipment shall satisfy the requirements for such areas and be approved by a certifying body to be in accordance with IEC Std. 79.10.2 I/O Cards

1. The I/O cards shall be able to handle discrete signals and a wide variety of analog signals.2. Malfunction of a particular channel shall not affect the operation of other channels on the card.

3. Each card shall have status indication light and each I/O shall be provided with a non board indicator which lights when the associated voltage is present or contacts are closed.

4. All of the I/O circuits must be provided with galvanic or optical isolation. The Vendor shall clearly state the type of isolation provided. Separate galvanic / optic isolator may be used, if necessary.

10.3 I/O Summary

1. I/O Count

A summary of the field I/O count and spares is provided in Requisition.

2. Field I/O types

The system shall be able to support standard signals such as:

a). Analog inputs : 4-20mA, (self-powered 4-wire and loop-powered 2- wire).b). Analog inputs: thermocouple type J, K, E, T, R, S, and 100 ohm platinum RTD.c). Analog outputs: 4-20 mA. d). Discrete inputs: +24 VDC (220 VAC by exception)

e). Discrete outputs: +24 VDC (220 VAC by exception)3. The discrete outputs shall select and operate latched relays, momentary relays and solenoid valves and shall include output interposing relays if the contact rating does not meet the requirement.4. Momentary contact closures, when activated, shall stay closed for an adjustable time interval and then release automatically. The minimum technical requirements are :

a).Contact rating 0.5 Amp, 125 VDC,

b).Contact closure time of 0 to 10 sec. Adjustable

c).Insulation: IEEE-STD-472

5. Discrete inputs will detect field dry contact with interrogating voltage supplied from the DCS system.10.4 Noise Immunity Requirements

1. The electronic components must be isolated from power line transients, electromagnetic interference (EMI), and radio frequency interference (RFI) as demonstrated in accordance with IEC 801 or SAMA PMC 33.1.2. The Vendor shall state the performance specifications for all types of 1/0 cards contained within the bid:

a).Common and normal mode voltage rejection levels

b).Voltage isolation requirements between 1/0 terminals and system electronics

c).Input impedance requirements

d). Requirements on ability to drive output load

10.5 Cable Segregations

1. The rack layout shall ensure clear and adequate segregation between termination panel, I/O modules, and cables in the following categories:

a).High Level I/O

b).Low Level I/O

c).Analog I/O

d).Power cable2. The Vendor shall use within practical limits, plugs and sockets between all separable pre-wired units, e.g., shipping breaks, processor racks and card racks. All cables shall be clearly, permanently, unambiguously marked at both ends.

10.6 Interface with Others Device

1. The system offered shall be capable of interfacing with foreign control systems. These systems normally utilize microprocessors. Therefore, the interface will be digital and is expected to be a serial link e.g., EIA/RS-232C, EIA/RS-485 standards. The preferred protocol is MODBUS RTU.2. The Vendor is responsible for the hardware and software to communicate with foreign devices. The suppliers of the foreign equipment are required to cooperate fully with the Vendor in this development through parallel purchase agreements.3. The system interface protocols shall permit the bi-directional transmission of analog and discrete signals, and integrate their data into the process control database.4. The typical foreign devices are programmable logic controllers (PLC), process analyzers, compressor anti-surge controllers, gas-turbine generator controllers, etc.

11. OPERATOR INTERFACE AND DISPLAYS

11.1 General

1. Operator interfaces shall be provided at workstation which shall permit the operator to control and monitor the plant during normal, startup and shutdown operation, and process upset conditions.2. Multi-window type displays are acceptable provided the monitor's size and resolution are suitable.3. The system shall provide conversational and interactive modes to the process via video display units and functional keyboards. The DCS system shall include typically two types of interface stations: OPERATOR STATION and ENGINEERING STATION.4. The Operator Stations shall be able to view all information required to operate the plant and change all parameters except those specifically reserved for changing by the engineers (such as alarm set-points, controller tuning and configuration).5. Each station shall be capable of indicating and controlling any particular loop of the process in any area of the plant.6. Engineer interface shall be provided by Engineering Station which shall permit system configuration, graphics development, report generation, and log generation, in addition to normal operator functions. Detailed maintenance information shall be available at the engineer station and general maintenance information available at the operator station.7. Printers shall be provided for printing logs, process and system alarms and reports on operator actions, suppressed alarms and all loops off scan and other messages programmed by the user. In systems where a common processor is used to drive a group of HMI Stations, the printers shall be switchable between the processor in operation and redundant processor.8. For identification and display, every configured loop shall be assigned a unique point tag. Each point tag field shall have a minimum of 10 alphanumeric characters prefixed with a 3-digit plant identifier. There shall be no restriction to the use of letters or numbers in any of the 10 positions. In addition, each point shall have an unrestricted service description field of a minimum of 30 characters.

11.2 Operator Stations

1. The Operator (Work) Station shall present all relevant information and control facilities for the Operator's particular area of responsibility.2. The basic functions shall be provided:

a).Indication of control and non-control of analog and digital variables.

b).Manipulation of control loops, including set-point, and controller mode selection

c).Hard copy of real time and historical trends via recorders, printers or video copiers

d).Alarm annunciation and display

e).Process variable tabular log display if part of Vendor system

f).Start / Stop pushbutton station motor operation, motor operated valves, pumps, and switches

g).Status indication

3. The Operator Station shall consist of a grouping of multiple independent microprocessor driven HMI operator stations. In all cases, the operator stations, each with its own keyboard (and if applicable, mouse or track-ball) shall provide a means for centralizing the tasks of monitoring and manipulating the process while using distributed devices to perform the actual process interface and control functions.

4. Each Operator Station shall have one HMI, out of each pair of HMI's for the operator status that incorporates a touch sensitive screen. This shall allow the operator to perform cursor selection function by touching or nearly touching the designed object on the HMI screen. Graphic objects shall be provided to allow the operator to completely control the plant in this manner.

5. During normal operation, each station shall be assigned a specific task; e.g., overview display, point display, or alarm display. The operator stations shall be redundant and interchangeable within a Station grouping.6. As a minimum, the following types of operator displays are required:

a).Single point display

b).Group display

c).Overview display

d).Graphic/ schematic

e).Trend graphic11.3 Engineering Station

1. The Engineer's Station is mainly used for configuring system database and graphics.2. The Engineer's station must be able to emulate an operator's station. Thus, it must have the same database as an operator's station. However, it is not required that the engineer's station have both operator and engineer databases simultaneously, i.e., loading data bases via a floppy or hard drive is acceptable.3. Engineer's facilities shall be available at a Operator Work Station by Password access, and if required, via a plug in an QWERTY keyboard. The station shall include a desk to mount the Engineers workstation.

11.4 Control Stations Electronics

1. The station electronics shall consist of a microprocessor-based system that will configure the control station to support the keyboard, display alphanumeric and semi-graphic information on the screen, drive a printer or recorder, and transmit data to and receive data from the process 1/0 devices other station via the communications system.2. Where common electronics are used to drive multiple HMI's, redundant electronics must be provided.11.5 Keyboard and Security Feature

1. The keyboards shall have cursor controls and tactile feedback pushbuttons. The system shall provide operator and engineer keyboards. Engineering stations shall have a "QWERTY" type keyboard, as a minimum, in addition to any other type of keyboard.2. The Operator's keyboard shall have at least the dedicated functions listed below:

a).Auto / Manual / Computer / Cascade

b).Set-point Up / Down (2 speeds) and numeric

c).Controller Output Open / Close (2 speeds)

d).Change Digital State

e).Pump and Motor Start / Stop

f). Motor Operated Valve Open / Close

g).Alarm Acknowledge

h).Print Screen

i).Sequence Start / Override

j).Log and Trend Select / Assign

k).Report Initiation 1). Manual Entry of Data for Storage (e.g., Laboratory Data)

m). Calling Displays

3. The engineer's keyboard shall have at least the following functions:

a).Configuring / programming all features in the system for control, data acquisition, report generation, graphics building, and requesting all documentation printouts.

b).Changing tuning constants, process variable zero and span values, alarm set-points

c).System status and maintenance

d).All of operator's keyboard functions4. The preferred type of keyboard is tactile feedback, spill-proof membrane protection. The Vendor shall state clearly the type offered.

5. All keyboards shall be protected against unauthorized access by means of a key-lock. Password or equivalent method. The Vendor shall describe the security method provided.

11.6 Video Display

1. Each Video Display Unit (MMI) shall have a 21-inch, high resolution, color monitor capable of displaying mixed alphanumeric /semi-graphic information. The Vendor shall describe in detail the HMI to be provided including character display formats, colors available, resolution, and any special features. The user shall have the option of defining colors from a pre-defined set for alarms, operation functions, and programmer's functions. The Operator Work Station shall provide the operator with capability to demand and utilize the following displays as a minimum in accordance to the Vendor's standard software. Use of a "Windows Interface" is preferred.2. An overview display shall enable the operator to determine the overall operation of a large segment of the plant. The condition of every point shall be displayed through alarm conditions, deviation from set-point, or analog display of set-point and process variable. The minimum number of variables displayed on one screen (i.e., 1 page) is 100 and the maximum is 256. The operator must be able to call up directly any group display covered by the overview screen.3. A group display shall show a limited number of points, i.e., analog or digital inputs or outputs. Each point shall be displayed as a faceplate with analog-type (bar) display of variables such as the measured process variable, set point and controller output. The point identification, description, alarm status, controller mode, engineering units, and digital values for process variable and set-point are also to be displayed.

The operator shall be able to quickly address any point a make appropriate changes to mode, set-point, output and so forth. The Vendor shall describe any limitations regarding adding the same point in several different groups.4. An individual point detail display shall show all relevant information for only a single point on a screen. This information shall include configuration parameters group display. The operator shall be able to change parameters from this display, and the engineer shall be able to tune the loop with the security clearance (e.g., key-lock). 5. An overview graphical trend display shall present data in the format of a strip chart on the screen. A minimum of 20 variables are to be displayed simultaneously on one screen or Vendor's standard. The data to be displayed is stored in the historical database.6. A custom graphic display shall have the ability to present process and control schematics, alphanumeric text, real-time digital data, and analog faceplates on one screen. The layout of each screen can be designed by engineers using user-friendly interactive software. The graphic builder shall have a minimum of seven user-selectable colors and a basic library of symbol shapes to which engineers can add shapes. 7. A standard alarm display shall show the standing alarms with time of occurrence, priority, current process variable, and alarm set-point.

8. As a minimum, the operator shall be able to operate the control strategies, i.e., change set-points, control modes, manual outputs, and so forth, from the group, individual point, and graphic displays.

11.7 Alarm and Event Printer

1. Low speed printers shall have a minimum of 132 characters per line and a printing speed of at least 120 characters per second.

2. Alarm and event line printers shall have a minimum of 132 characters per line and a printing speed of 60 lines per minute. They shall have continuous tractor feed paper.3. The Vendor shall include in his proposal one text printer dedicated to printing alarm and operator events. Should the Vendor offer two speed options for text printers, Vendor shall quote the higher priced unit as the base and the lower priced unit as an alternate to the base. It shall be possible to reassign the alarm / event printer to printing shift reports and daily logs through the station electronics or station software. The alarm & event printer shall utilize continuous tractor feed paper and be an impact type dot matrix printer. It shall be high speed and low noise.

11.8 Screen Copier

1. One screen copier shall be provided with the system. Copying is to be accomplished by one pushbutton operation associated with the screen involved. The use a standard color laser printer is preferred.2. The screen copier shall be able to print display by connecting it to any station. I.e., operator's station, engineer's station, and development station.

11.9 Report Printer

1. Report printers shall be standard high capacity sheet feed laser printers, HP LaserJet or better.2. The Vendor shall include in his proposal one text laser printer dedicated to printing daily reports and shift logs. The use of a high capacity sheet feed laser printer is preferred.3. The Vendor shall include in his proposal one text printer dedicated to printing alarm and operator events. Should the Vendor offer two speed options for text printers, Vendor shall quote the higher priced unit as the base and the lower priced unit as an alternate to the base. It shall be possible to reassign the alarm / event printer to printing shift reports and daily logs through the station electronics or station software. The alarm & event printershall utilize continuous tractor feed paper and be an impact type dot matrix printer. It shall be high speed and low noise.

12. COMMUNICATION SYSTEM

12.1 Requirement

1. The communication system shall be based on a dual path industrial grade digital communication link, utilizing a coaxial cable or fiber optic, to provide a high speed data transfer between I/O modules, control modules, and operating stations. Fiber optic cable shall be used between buildings with more than 200 meters distance.

2. The communication facility shall provide essential functions such as:

a).Transmission of process variables, control variables, and interlock status between regulatory controllers, operator stations, and supervisory computers

b).Communication of set-point commands, operating modes, and control variables from operator stations and supervisory computer to regulatory controllers for the purpose of regulatory and supervisory control.

c).Up/Down loading of control configuration, turning parameters, and user program between operator stations and regulatory controllers

d).Transfer large block of data (e.g., station displays, historical trends and logs), programs, or control configuration among system components.e).Synchronization of real time among all of the elements in the system. The time stamping between the DCS and HMI shall be provided to manage time of alarm and event for all HMIs.f).Provide plant to plant and DCS-system to system communications for future enhancements on a global basis.12.2 Highway Redundancy

The dual redundant data highway shall have automatic fail-over and generate a system diagnostic alarm. No loss of data or control shall occur due to fail-over. The total time to diagnose and switch the full functionality shall be a maximum of 2 seconds. Highway functionality shall be continuously tested by the system operating software.

12.3 Systems Capability

1. The Vendor shall specify with his proposal the maximum number of devices that the system can address and support without affecting the total system scan time and performance or requiring an additional highway.2. The Vendor shall specify with his proposal the maximum electrical cable distance allowed between main devices and sub-devices.

12.4 Network Topology and Access methods

The Vendor shall provide with his proposal a full description of the standard communication system, including the network topology (star, ring, multi-drop), the communication protocol, structure, security checking, and access method (broadcast, baton passing, polling, etc.).

12.5 System Loadings

1. The Vendor shall determine the equipment and architecture of the system to meet all requirements in this specification and at the same time observe the maximum loading defined in this section. Loading here refers to the use of memory, CPU time, and communication capacity. 2. The maximum loading for various equipment are given below:80 percent

- Regulatory Control

-Non-controller Input - Stations

-History

50 percent

-Highway traffic (transmission)

- RS-232/RS-485 Interfaces to foreign devices

12.6 Systems Response Time

The entire system shall respond rapidly enough to control a quick acting continuous industrial plant. The following are maximum values for the responses of key elements of the system:

1.Controller (inputs, calculation, and output) 1 second for 10% of loops. Vendor shall calculate standard response and indicate the worst case response for all loops to respond.

2.Non-controller input 2 seconds

3.Operator set point change until signal is sent to the valve 2 seconds

4.Build MMI display (including graphic with 20 percent of pixels used and 10 real time data) 2 seconds

5.Update real-time data on a HMI display 5 seconds.13. POWER SUPPLIES

13.1 General

The Vendor shall specify with his proposal the voltage level, capacity and power requirement for the proposed system. The power distribution shall be designed to accommodate 2 independent circuits to be provided by the Company.

13.2 Power Supply Tolerance Limit

The Vendor shall state with his proposal power supply tolerance limits of the system without a UPS attached, the degree of immunity of the system to power-line noise and interference system, and the system response under brownout and transient over-voltage conditions.

13.3 Power Distribution Information Required with Quotation

The Vendor shall provide with his proposal a preliminary sketch of the power distribution scheme for the quoted equipment. In addition, the Vendor shall provide an estimate of the power requirements for each major component and for the total system.

13.4 Fault Discrimination

The fault discrimination shall be such that minimal equipment shall be affected by any individual fault. Power distribution to control devices shall be arranged such that the loss of an individual circuit does not result in complete loss of control capability or create unsafe operating conditions. An alarm shall be generated to alert the operator to loss of power to a device.

13.5 Power Supplies

1. All the 24 VDC power supplies for the system shall be supplied mounted on system racks and made redundant. Both primary and backup power supplies shall be continuously active. It shall be possible to remove at least one power supply for maintenance without affecting the overall load requirements of the system.2. All 2-wire transmitters shall be powered from the Vendor's 24 VDC system. Process Plant units shall not share power supplies with other process plant.

3. The system shall have a power supply monitoring facility that checks that internal power output voltages are within tolerance. The monitoring facility shall be fed into the system diagnostic facilities. Appropriate alarms shall occur on any power supply failure.4. The operator shall, by means of a system alarm, be informed of the failure and switchover. No loop shall be lost by the failure of a single power supply.5. Internal power supplies shall be fused for short circuit protection. Outputs shall be provided with electronic current limiting and with over-voltage protection. Every power failure shall generate a system alarm plus a local indicator (LED or flag).

13.6 System Grounding

1. The Vendor shall provide an installation layout of the grounding plan for the purposed system.2. The Vendor shall consult the relevant electrical codes for specifics on the grounding requirements and adhere to local installation codes and regulations.3. The stations, cabinets, and other components of the DCS may be geographically located throughout the plant area. It is important that the DCS shall be designed to eliminate ground loops, electrical noise, and other ground-related problems. 4. The power system must have a provision for an equipment safety ground conductor to be connected at the power entry point. The cabinet structure is connected to this ground point through the power system within the cabinet. The conductor shall be 10 mm2 Copper as minimum.5. If a power subsystem in one cabinet also provides power to components in other cabinets, there must be a mechanism for connecting the structures of the latter cabinets to the safety ground point in the former cabinet.6. Within each cabinet, a separate grounding system (system common) must be provided to allow the common terminals of the DC power supplies, the shields of the process 1/0 signal wiring, and the signal grounding points to be tied together at a common ground bus. DC power supplies shall have the PE earthed. It must be possible to connect this bus to site ground through a single conductor that is separated from the safety ground connection. In the case of multiple cabinets powered by a single electrical supply, there must be a means to interconnect the common bus in each of the cabinets and in such a manner so as to maintain single point ground integrity.

14. SYSTEM SECURITY AND RELIABILITY

14.1 General

1. The system shall be designed so that any failure can be eliminated as quickly as possible. The repair policy shall be based on replacing printed circuit boards or subsystems from a small quantity of spares backed up by prompt exchange of high quality replacement parts from a factory parts depot.2. Each individual card and power supply shall be fitted with an LED or similar flag to denote failure of the card or power supply.3. The hardware shall be modular in construction and replacements and adjustments can be made as far as possible with the system online.4. The Vendor shall describe the methodology used to ensure that the cards cannot be put into incorrect card frame slots or incorrectly oriented.5. All fan units for cooling shall carry a vane switch which shall indicate fan failure and generate a system diagnostic alarm. All rotating parts shall be adequately screened and guarded.6. Wherever redundancy is specified, it shall be possible to replace the failed part online without affecting the system performance.

14.2 Basic Reliability

1. The Vendor shall supply with his proposal reliability data for all equipment supplied and shall include as a minimum component and system MTBF (Mean Time Between Failure) and MTTR (Mean Time to Repair), stating the basis for calculation, and enclose a copy of the calculation with the quotation. It shall be preferred that the Vendor use documented installed data for the basis.2. All equipment supplied shall be based on proven hardware and software. Special hardware and software shall be acceptable only when it is shown to be absolutely necessary for the application.3. The equipment and system shall be so designed, engineered and produced to give a total availability of critical equipment (highways, controllers, and station processors) or 99.99 percent.

14.3 Operator Security

All operator requests shall be checked for validity of access. Format and syntax checks shall be made to ensure that control parameters entered are within defined limits for the system.

14.4 Regulatory control Reliability

1. The Vendor shall describe fully the action of redundancy, including the diagnostics involved in fault detection and the method and rate of data update of the redundant system.2. The Vendor shall recommend the best method of configuration to ensure maximum reliability, availability and safety of the regulatory control system.

14.5 Diagnostics

1. The system shall include a library of programs to detect on-line component failures. The diagnostic tests shall be executed at system startup, continuously during operation, and / or on a periodic basis and on a demand basis.2. Once a diagnostic test has detected a failure, a descriptive alarm is generated and a bumpless transfer of control to a redundant component is triggered.3. The minimum requirements for system diagnostic test are as follows:

a).Input diagnostics: sensor out of range, open thermocouple, open or shorted loop, analog to digital converter check.

b).Output diagnostics: open or shorted loop, digital to analog converter check

c).Configuration diagnostics: checking the compatibility and availability of selected 1/0 hardware and software

d).Memory diagnostics: Processor compares the computed sum of the contents of memory with the pre-stored value

e).End-to-end processor / memory diagnostics : Processor executes as test control or arithmetic algorithm, then compares results with pre-stored answer

f).Peripherals and foreign devices diagnostics : watch dog timer to confirm proper operation

g). Power system diagnostics: monitor the availability of supply voltages.

14.6 System Software and Database Back up

1. The system shall have an automatic and on-demand data protection scheme for the preservation of all data during a planned or unplanned outage. The entire control software shall be backed up including vendor software, control database, user-built programs, source code, data files, and graphic development.2. Data backup copies on bulk devices shall be removable to remote storage. Backup during normal operation shall not degrade performance. To recover from an outage, any component of the system must be able to be reloaded from bulk.14.7 System Redundancy

1. The Vendor shall describe in detail with his proposal the offered redundancy system and propose the best and cost effective approach to suit the particular control process.2. Critical equipment of the DCS system shall be fully redundant so that neither hardware or a software failure shall not disturb the process.3. Controller redundancy shall be provided in the form of redundant controllers.4. The operator stations shall be split with two processors dividing of the screens and keyboards, i.e., two operator stations. Interface with the highway shall be redundant. No redundancy is required for the engineer station.5. Controller and station memory must be protected against short term power loss or interruptions in power. Non-volatile memory shall be used. Volatile memory with battery backup shall not be allowed.

15. ENVIRONMENT

15.1 General

1. The Vendor shall specify in his proposal the environmental requirements to protect the proposed system components from typical industrial plant atmosphere which contains airborne and biological contaminants and temperature and humidity variations. 2. The airborne contaminants may include dust, oil, sea salt, chlorine compounds, sulfur compound, sulfur oxides, nitrogen oxides, hydrogen fluoride, etc. The biological contaminants may include flora (mold fungus) and fauna (birds, insects, rodents, etc.).3. The Vendor shall describe in his proposal the required or supplied methods (i.e., system packaging, sealed enclosure, filtering system) in order to meet the following environment area specification.15.2 ENVIRONMENT AREA CLASSIFICATION

1. Generally the control room shall be considered a benign environment since it is designed for the comfort of the operators and housed equipment such as stations, computer hardware and associated peripherals. The typical conditions are as follows:

a).Temperature 27 to 38C without HVAC, 23C with HVAC.

b).Relative humidity 20 percent to 80 percent, non-condensing with HVAC; up to 95 percent without HVAC

c).Small amount of dust and contaminants.2. All circuit boards shall be coated to protect against the effects of condensation and prevent corrosion.3. The rack room is designed to provide a central location suitable for housing the bulk of the control and data acquisition equipment such as I/0 cabinets, field termination panels. The typical conditions are as follows:

a).Temperature 27 to 40C

b).Relative humidity 10 percent to 95 percent, non-condensing

c).Small amount of dust and contaminants

4. Field-mounted equipment is designed to be geographically distributed around the plant in the sever environment. The typical worst-case conditions are as follows:

a).Temperature 27 to 44C

b).Relative humidity 5 percent to 95 percent, non-condensing

c).Significant amount of dust, contaminants, and vibration

15.3 Heat Load

1. The Vendor shall specify with his proposal the heat load of each separate equipment unit.2. In the event of control and equipment room air-conditioning failure, the Vendor shall recommend the maximum operating time of the equipment under such environmental conditions, and the maximum safe operating temperature of each equipment unit. Equipment cabinets shall have high temperature alarms to protect against this condition.

16. MECHANICAL REQUIREMENTS

16.1 Dimension and Layout

1. The Vendor shall provide with his proposal the maximum overall dimensions of all desks, cabinets, peripheral devices, furniture, and indicate all clearances required for access.2. The Vendor shall provide with his proposal a preliminary system-layout drawing showing how all component parts of the system fit into the control room, and lengths and routes of all interconnecting cables. For guidance a sketch of the control building is provided in the requisition. (The cabinet shall be provided with rear lockable doors)16.2 Flooring1. The Vendor shall indicate the weight of all subdivided items of equipment, and the weight and dimensions as created for transport.

2. The Vendor shall indicate floor loading for all equipment supplied.3. The Vendor shall identify all shipping breaks and provide plug and socket connections across all such breaks.16.3 FinishingThe color of all equipment supplied shall be Vendor's standard color. The Vendor's standard finish is acceptable but shall be specified within the quotation..17. MATERIALS

1. Material construction for DCS shall be as specified in the data sheets and shall be new and free from defects.

2. Material for DCS shall be suitable for full range of metal temperatures to be encountered. Standard materials for tropical location shall be considered for those items not covered in data sheet.

3. Material specifications for the DCS shall be furnished for approval by CONTRACTOR/ COMPANY.18. SPARE PARTS

1. The Contractor shall provide sufficient spare parts and consumables necessary for testing, pre-commissioning, commissioning and two years continuous operation of the equipment, units and its associated facilities.2. Details of spare parts, consumables, materials, plant equipment and special tools to be supplied for eventual hand-over to the Employer shall be catalogued and submitted for the approval of the Employer.

3. All spare parts shall comply with the same specifications and tests as the original equipment and shall be fully interchangeable with original parts without any modifications at site. The availability of spare parts shall be guaranteed for 15 (fifteen) years.4. The Vendor shall quote the supply of spare parts for 2 years of operation. These spare parts should include allowances for normal maintenance. The quotation must include an itemized list of equipment to be provided.

19. INSPECTION AND TESTING

19.1 Quality Assurance

The Vendor shall submit a complete summary of the proposed quality assurance program to the Company for review and approval. This program should include provision for the Company nominated inspectors to have access to the manufacturing and test facilities by prior arrangement with the Vendor.

19.2 Quality Assurance Testing

The Vendor shall agree with Client on Factory Acceptance, Field and Performance Guarantee Tests which shall indicate that the intent of this Specification has been fully carried out. This will be witnessed by the Company engineers.19.3 Factory Acceptance Test Preparation

1. System testing. The entire system shall be assembled and configured at the vendor factory prior to shipping. The test shall be with all interfaces to foreign devices.2. Test Equipment. The Vendor shall supply all test software, labor required to implement the Factory Acceptance Test, and all assembly and wiring drawing necessary to verify system compliance to specification requirement. This will include handling and test installation of foreign devices during the factory test period.19.4 Factory Acceptance Test

1. The Company will provide engineers to participate full time in the Factory Acceptance Test (FAT). It is proposed that the following sections will form a minimum starting point describing what is to be tested in general terms. The Factory Acceptance Testing shall be progressive and integrated with the Vendor's own testing where possible.

2. Since FAT will be an integrated test and will include testing of interfaces to foreign devices, access shall also be provided for other vendor representatives as necessary for testing.3. During the test, the Vendor shall prepare a maintenance log in which the following items will be entered: failed components, effect of failure, cause of failure and length of component service prior to failure. FAT shall be suspended upon failure of any component. The Vendor may replace a component (e.g., board) to repair the system, but if this action is not quickly successful, the Vendor must provide a fully functional subsystem (e.g., station processor) to restart the test.

19.5 Field Test

The field test is a modified acceptance test to ensure that the integrated system operates properly after shipment. It is proposed that the following sections will form a minimum starting point for the Field Test definition. The Company will provide an engineers to participate full time in the Field Test. 19.6 Performance Guarantee Test

1. The test shall take place within the first six months of plant operation. A Performance Guarantee Test will be performed after the plant start up and within the Warranty period. The Vendor shall provide a representative during the period. The Company shall provide 2 weeks prior notice.

2. The test shall be 72 hours in duration.3. During the test, all hardware and software shall operate without failure. Failures shall be detected by system diagnostics and status indications such as LEDs and recorded on a test log.4. During the test, no plant disturbance shall be caused by failure of Vendor-supplied hardware or software or Vendor services.5. During the test, the system will perform as required by this Specification. The Vendor shall provide monitors to determine the performance of the system with respect to the loading and response time requirements. Actual system loading shall be measured and recorded for documentation purposes.

20. EQUIPMENT / MATERIAL IDENTIFICATION

Each major equipment component shall have a permanently attached, impression stamped, 316 stainless steel name plate. The name plate shall include the following information:

a).COMPANY Name

b).PURCHASER Name

c).Project Name

d).Equipment Tag Number

e).Equipment Title D. Manufacturer Name

g).Model & Type

h).Serial Number

i).Code

j).Purchase Order Number

21. PREPARATION FOR SHIPMENT AND STORAGE

Equipment shall be prepared for export shipment and shall be crated, accordance with Packing, Marking and Shipment Instruction to provide maximum protection during shipment and extended outdoor storage. Following shop testing, the equipment shall be drained, evacuated, dehumidified, etc as applicable and sealed prior to leaving the VENDOR's works. Any items which are liable to be damaged during shipment shall be removed, packed separately and shipped with the unit.

22. GUARANTEE

Material and/or equipment shall be guaranteed by VENDOR to perform in accordance with specification requirements and to be free of defects and poor workmanship including, but not limited to, those caused by inadequate preparation for shipment, as per of this document, for a period of one (1) year after material/ equipment is placed in service, but not exceeding eighteen (18) months following delivery to the contracted destination.