12-MGDP-I-1046-0 (Spec for Remote Terminal Unit)

7/30/2019 12-MGDP-I-1046-0 (Spec for Remote Terminal Unit)

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MEHAR GAS DEVELOPMENT PROJECT

Area Location Discipline Document No. Rev. Page

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TABLE OF CONTENTS

1.0 INTRODUCTION............................................................................................................... 41.1 General .............................................................................................................................41.2 Scope................................................................................................................................4 1.3 Definitions ......................................................................................................................... 51.4 Abbreviations ....................................................................................................................51.5 Environmental Conditions .................................................................................................61.6 Device Protection..............................................................................................................71.7 Codes and Standards .......................................................................................................72.0 SCOPE OF SERVICES .................................................................................................... 83.0 TECHNICAL REQUIREMENTS OF THE RTU CAbinet ..................................................93.1 Scope of Supply................................................................................................................93.2 Functional Requirements ................................................................................................103.3 Design Requirements......................................................................................................114.0 RTU HARDWARE .......................................................................................................... 124.1 General ...........................................................................................................................124.2 MOS and POS ................................................................................................................134.3 CPUs...............................................................................................................................13 4.4 Modules...........................................................................................................................13 5.0 SOFTWARE.................................................................................................................... 166.0 COMMUNICATION......................................................................................................... 166.1 Overview.........................................................................................................................166.2 Technical Requirement...................................................................................................176.3 Communication with Laptop............................................................................................ 17


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6.4 Other Modules or Devices...............................................................................................177.0 RTU PROGRAMMING, CONFIGURATION AND MONITORING LAPTOP................... 177.1 Functional Requirements ................................................................................................177.2 Technical Requirements .................................................................................................188.0 POWER SUPPLIES........................................................................................................ 199.0 SYSTEM PERFORMANCE ............................................................................................ 1910.0 CABINETS...................................................................................................................... 1910.1 General ...........................................................................................................................1910.2 Labeling...........................................................................................................................20 10.3 Equipment Grounding.....................................................................................................2010.4 Cabling and Wiring..........................................................................................................2110.5 Terminations ...................................................................................................................2111.0 SPARE PARTS............................................................................................................... 2112.0 SPECIAL TOOLS ........................................................................................................... 2213.0 MARKING AND PACKING............................................................................................. 2214.0 DOCUMENTATION ........................................................................................................ 2214.1 General ...........................................................................................................................2214.2 Functional Design Specification (FDS) ...........................................................................2314.3 Inspection & Testing........................................................................................................2415.0 TRAINING.......................................................................................................................25 16.0 SITE SERVICES............................................................................................................. 2517.0 QUALITY ASSURANCE/QUALITY CONTROL .............................................................2618.0 GUARANTEE ................................................................................................................. 26


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1.0 INTRODUCTION

1.1 General

PETRONAS CARIGALI (Pakistan) Ltd. (PCPL) is undertaking the development of MeharGas Field in Mehar Block (Block 2767-1) located in Sindh and Balochistan Provinces ofPakistan.

Mehar Block is located in the Kirthar Fold belt area, in the Middle Indus Basin. Meharfield is located about 190 km west of Sukkur and 400 km north of Karachi in Sindhprovince (distances by road). The environment is arid and the terrain is mountainous.Mazarani gas field, operated by PPL is situated about 25 km to the north, whileZamzama gas field operated by BHP is situated about 70 km to the north of Mehar Field.

Mehar field consists of Pab and Ranikot formations. The wells will be connected to thenew GPF through a Gathering System. There will be a total of 6 wells (3 Wells from theNorth and 3 Wells from the South). 3 Wells will be producing in Phase-1 and 3 Wells inPhase-2 (future). ME-1 well is from PAB reservoir. ME-2 wells is from Ranikot reservoir.Wells, ME-3, ME-4, ME-5 and ME-6 are dual completion.

PCPL intends to develop the Mehar Field by installing a Gathering System, GasProcessing Facility (GPF) and Product Storage & Loading Facilities. The field facilitieswill be developed in two phases, Phase-I and Phase-2.

Phase-1 development will cater for 55 MMSCFD of gas production and Phase-2 willcater to 80 MMSCFD of gas production. The expected condensate production rate is6600 BPD in Phase-I increasing to 7000 BPD in Phase-2.

1.2 Scope

This specification covers the basic minimum requirements for design, manufacture,configuration, testing, documentation, and preparation for shipment of PLC basedWellhead and Manifolds RTU for the MEHAR Gas Development Project.

Integration of RTU with PMCS shall be part of EPCC CONTRACTOR.

This specification shall not be considered all-inclusive. The VENDOR shall submit fulltechnical details of his standard equipment, which meet the requirements herein.Aspects of the requirements, which cannot be met, shall be identified and variancesexplained. This specification shall be read in conjunction with other specifications anddocuments indicated in the material requisition. The order of precedence of thedocuments shall be the following:

Government Legislation;

Material Requisition;

Project Specification; Basic Design Drawing;


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International Codes & Standards;

Company Specifications.

The Control System shall be complete, tested, pre-commissioned, and commissioned sothat it shall ensure a trouble-free start-up and operations of the new facilities.

1.3 Definitions

COMPANY Petronas Carigali Pakistan Limited (PCPL) orany Third Party assigned by the COMPANY

ENGINEER Party which carries all or part of the design,engineering of the PROJ ECT. VECOEngineering, Abu Dhabi is the ENGINEER.

EPCC CONTRACTOR Party which carries out all or part of thedesign, engineering, procurement,construction, commissioning or management,of the PROJ ECT. EPCC CONTRACTORincludes his approved, MANUFACTURERS,SUPPLIERS, VENDORS andSUBCONTRACTORS.

MANUFACTURER/SUPPLIER/VENDOR Party/ies, which manufacture and/or supplymaterials, equipment and services to performthe duties as specified by the CONTRACTORin the scope of supply.

PROJ ECT MEHAR GAS DEVELOPMENT PROJ ECT

1.4 Abbreviations

PMCS : Process Monitoring and Control System

ESD : Emergency Shutdown System

EWS Engineering Work Station

F&G : Fire & Gas

PLC : Programmable Logic Controller

RTU : Remote Terminal Unit

MTU : Master Terminal Unit

WHCP : Well Head Hydraulic Control Panel


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SCSSV : Surface Controlled Sub-Surface Safety Valve

SSV : Surface Safety Valve

WV Wing Valve

POS : Process Override Switches

MOS : Maintenance Override Switches

FAT : Factory Acceptance Testing

SAT : Site Acceptance Test

SPIR : Spare Parts Interchangeability Record

1.5 Environmental Conditions

Wellhead facilities, Gathering stations and GPF area has been tentatively selected at alocation about 190 km west of Sukkur and 300 km north of Karachi in Sindh Province.

The environment is arid the terrain is mountain.

The Environmental conditions are:

Maximum Ambient Temperature : 55C

Minimum Ambient Temperature : 0.5C

Wet Bulb Temperature (design) : 30C

Relative Humidity (max / nor / min) : 90 / 65 / 20%

Direction of Prevailing Wind : From South to North.

Wind Velocity (max / normal) : Hold/ 2.9 knots

Elevation Above Mean Sea Level (GPF) : 54m (Site-IV) / 56m (Site-l)

Average Barometric Pressure : 1001.2 mbara (29.56 inches ofMercury)

Ice/Snow : None

Seismic zone : Zone 2B, upper moderate withground acceleration of 0.2 (Hold)

Annual rainfall min. : 63.3 mm (year 2006)

Annual rainfall max. : 139.9 mm (year 2005)


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1.6 Device Protect ion

Instruments shall be selected based on area classification drawings by Electrical (12-MGDP-E-4000)).

All instruments shall be certified as EExi IIA/IIB, T3. Suitable isolators shall be providedin RTU cabinet. EExd protection shall be used for solenoid valves & where EExi notavailable.

Instruments enclosures, in field, shall be dust proof, weather proof to IP 65, as aminimum. All external surfaces shall be suitably painted for corrosion protection.

RTU cabinet shall be weatherproof to IP-65 with increased safety as will be installedinside passive cool shelter.

Intrinsically safe barriers, independent or integrated within I/O modules, shall be TVcertified SIL 2 minimum, when used for ESD or F&G functionalities and shall allow linemonitoring facilities.

All external surfaces shall be suitably treated to provide an anti-corrosion protectionagainst the plant atmosphere.

1.7 Codes and Standards

Codes, specifications and standards referred to within this specification, form a part ofthe requirements of this specification in a manner and to the extent specified withinthose codes and standards but not limited to below.

Unless otherwise specified, the latest edition or revision to these codes specifications,and standards in force at the time of request for quotation and/or Purchase Order shallapply.

No deviations from the Codes and Standards listed in this document will be allowedunless such deviations are clearly identified in the bids, with the reasoning. In addition,they must be approved in writing by COMPANY.

EN 50081 European Harmonized Generic Standard for Electro-MagneticEmissions

EN 50082 European Harmonized Generic Standard for Electro-MagneticImmunity

EN 50014 Electrical apparatus for potentially explosive atmosphere General requirements

EN 50018 Electrical Apparatus for potentially explosive atmosphere Flameproof "EEx(d)"


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EN 50020 Electrical Apparatus for potentially explosive atmosphere Intrinsically Safe "EEx(i)"

ISA - S5.1 Instrumentation symbols and identification

ISA - S5.2 Binary Logic Diagrams for process operations

ISA - S5.4 Instrument Loop Diagrams

ISA-S84.01 Application of Safety Instrumented System for the ProcessIndustries.

IEC 60079-14 Electrical Installation in Explosive gas atmospheres

IEC 60529 Classification of degrees of protection provided by enclosures

IEC 60801 Electromagnetic Compatibility for industrial processmeasurement and control equipment

IEC 61000 Electro-magnetic Compatibility

IEC 61131 Programmable Logic Controllers Part 2

IEC 61131 Programming Languages (Part 3) Guidelines for theapplication and implementation of programming languages(Part-7)

IEC 61508 Safety Instrumented Systems

IEEE 802.3 Ethernet TCP/IP

PTS 32.30.20.11 Fire, Gas and Smoke detection Systems

PTS 32.31.00.34 Instrumentation documentation and drawings

PTS 32.80.10.30 Instrumented Protective Systems

PTS 62.10.08.11 Inspection and Functional Testing of Instruments

PTS 70.10.90.11 Spare parts

NFPA 72 National Fire Protection Code

2.0 SCOPE OF SERVICES

The scope of services provided by the VENDOR shall include the following as a

minimum:


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Project management and reporting;

Functional design specification (participation, endorsement, finalization);

Design, sizing and engineering studies of the well and manifolds RTU cabinet;

Coordination with third parties (in particular TV);

Procurement of the necessary components and software, with related licenses;

Configuration and programming of the system, including I/O assignment,database, user application, SOE, communication;

Integration and wiring of the RTU cabinets;

Preparation of the documentation including final documentation;

Internal tests and FAT;

Packing, transportation and delivery;

On site assistance for installation, pre-commissioning, commissioning, SAT,including all necessary adaptation of the hardware and application software, and

start-up of systems; COMPANY personnel training.

3.0 TECHNICAL REQUIREMENTS OF THE RTU CABINET

3.1 Scope of Supply

3.1.1 RTU (PLC)

For each well, the RTU cabinet shall include the following components as a minimum:

Racks;

CPUs;

Power supply modules;

Communication modules;

I/O modules;

I/O field termination assemblies;

Utilities i.e. lightning, electrical outlet etc;


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Cables and connections between components;

Solar array, batteries, charge controller and accessories for Solar Panel.

3.1.2 Cabinet

The RTU shall be provided housed in a cabinet in a passive cool shelter with all itsinterfaces for field instruments, Wellhead Hydraulic panel and other sub-systems.

The RTU cabinet shall also contain the following:

Intrinsically safe barriers for all field devices that provide intrinsically safe

protection mode. These barriers may be independent or integrated inside I/Omodules;

Interfacing relays certified TUV AK6 for safety trips if required.

3.1.3 Configuration Device

Configuration in all RTU shall be done by Laptop EWS. EWS shall be provided withlicensed operating & engineering software required for RTU configuration. RTU shallhave provision for monitoring and modifications through PMCS in CCR.

The laptop shall be loaded with TUV certified software and procedure.

3.1.4 Solar Panel and Passive cool shelter

VENDOR shall provide Solar Panel to power the RTU and other electrical loads atwellhead. For details requirement of solar panel specification document no. 12-MEGP-E-1008 shall be followed.

Pre-engineered Passive cool shelter shall also be provided to house the RTU atwellhead and manifolds with all systems ( air conditioners, lighting and power supplysystems) in place and tested before shipment.

Shelter shall be rain proof and dust proof and shall be designed to withstand theenvironmental conditions specified in sec 1.5.

The shelter floor shall be sealed to prevent the ingress of gas or vapor.

3.2 Funct ional Requirements

The RTU shall have combined operation sequence and safety functions including:

Wellhead operation and shutdown;

F&G alarm and shutdown;

Well open / close sequence.


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Each RTU cabinet shall perform the following integrated function, as a minimum:

Emergency Shutdown (ESD), to avoid personal injuries or major damage to theenvironment, equipment, personnel, etc. by setting wellhead equipment into asafe predetermined shutdown state, in case of abnormal condition;

Fire and Gas (F&G) detection, to allow intervention of relevant personnel tocontain and prevent the spread of fire, and extinguish it in the early stages, ifpossible. Confirmed fire shall shutdown the wellhead through CCR operatorintervention;

Process monitoring and control of the well;

Wellhead valves shall be able to remotely operated from PMCS through the RTUvia WHCP;

Choke valves shall able to adjust remotely from PMCS through the RTU.

3.3 Design Requirements

The system shall be designed to meet the requirements of this specification and otherrelevant international codes and standards. However, in general this shall meet thefollowing specific requirements listed below.

RTU shall be designed for IOs as per IO list 12-MGDP-I-7102.

3.3.1 Segregation Rules

RTU modules and associated accessories, if any, shall be segregated as follows:

Process I/Os;

ESD I/Os and F&G I/Os shall be connected to different modules though allowedon the same rack.

CPU and communication modules shall be installed in the rack dedicated to ESD andF&G.

3.3.2 Redundancy

Redundancy shall apply according to TV certificate to meet the required level (SIL 2minimum). For this purpose, all common parts of RTU shall be redundant including butnot limited to:

CPU, bus, power supplies, etc.;

Communication module.

ESD and F&G I/O modules, though being compliant with SIL 2 requirements, may not benecessarily redundant.


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Some ESD and F&G I/Os do not need safety requirement (lights, lamp-test, and pushbuttons). Those I/Os can be connected to standard I/O modules.

Process I/O modules do not need SIL 2 compliance.

3.3.3 Spare Capacity

As a general rule, quantities used to size individual components shall be easilyexpandable with I/O variation. All these components, mainly the I/O sub-system shall beprovided with equipped spares capacity of 20% for each type of signals and for eachfunction (ESD, F&G and Process). For this purpose, additional I/O modules shall beprovided wherever the sum of all unused I/O for a type of module used for a given

function does not reach this 20% spare. Addition of new instruments into these limits of20% shall only require soft configuration.

Quantities used to size all common components, either hardware or software (CPU load,communication modules, rack, power supply, and memory capacity) shall provide sparecapacity of 20% for each type of I/O signals plus additional spares as follows:

30% for CPU load, communication modules and memory capacity;

20% for racks. Each type of rack shall allow addition of a minimum of 20% I/Omodules, without the addition of a new rack. If necessary, additional racks shallbe provided to comply with this requirement.

In any case, CPU load shall not exceed 60% of maximum capacity.

RTU cabinet shall be provided with 20% spare space to accommodate future extension.

4.0 RTU HARDWARE

4.1 General

RTU shall be implemented on high reliable fail-safe and fault tolerant architecture. Fail-safe is defined as the capability of a system to go to a predetermined safe state when it

is de-energized in the event of one or more failures. Fault tolerance is of primeimportance. In particular, the system shall be able to continuously operate without anyplant disturbances during modules failure and replacement.

RTU shall be designed to allow hot replacement of any failed component without loss ofsystem performance and plant safety level. Re-initialization of newly installed moduleshall as per TV requirement requiring manual reset.

RTU shall be certified SIL 2 minimum as per DIN V19250 (TV approval). Auto-test andinternal diagnostic of major parts (I/O modules, processors, buses, memory and powersupply) shall be considered as being of primary importance, as well as RTU faultsmonitoring.


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RTU modules shall be provided with LEDs for normal and fault indication. Systemcomponents design shall be modular with rack mounting and plug-in type assemblies.

RTU shall restart automatically after a power supply restoration without extensive timeconsuming for system rebooting procedures (VENDOR to define maximum time) andwithout system qualified technician (to be performed by operator or maintenancetechnician).

4.2 MOS and POS

MOS and POS shall be provided in CCR as required by the operation procedure.

4.3 CPUs

Each processor shall be provided with battery backup to retain its memory for two (2)months. Low battery level alarm shall be provided 3 months before as part of thediagnostic alarm. The processor shall be capable for performing both logic andsequence functions. Also, VENDOR to note that RTU may have to perform processfunction such as integration, counting, etc. The VENDOR shall state the list of availablestandard functions and algorithms in his proposal.

The programmable controllers shall be programmed and configured to meet thefunctional requirements. At start-up, the system shall be immediately and automaticallyavailable without human intervention.

Watchdog function shall be available. Logic functions, timing data and operatingsubroutines shall be loaded and tested into the RTU at the VENDORs premise and shallbe stored in non volatile memory.

It shall be possible to configure the RTU using easy-to-use language. VENDOR shallspecify which programming languages are available on the configuration software, and ifit complies with the requirements of IEC 61131. The logic shall be TUV certified.

RTU shall be protected from unauthorized configuration modification by key lock and/orpassword. All facilities needed for any modification of the configuration shall be providedon the programming console.

4.4 Modules

4.4.1 Principle

All I/O modules dedicated to ESD or F&G functions shall be suitable for safetyapplication; except for non-critical I/Os such as push buttons, lights, etc. These non-critical I/Os shall be indicated in the input/output list. All other modules shall be designedso that, in no case, they may reduce the safety level of the overall system or of othersafety I/Os.

Safety I/O modules shall be SIL 2 compliant, as a minimum. They shall support line-monitoring facilities, allowing open and short circuit detection and alarming.


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All I/O modules dedicated to F&G functions shall be compliant with NFPA 72.Alternatively, VENDOR shall indicate compliance to any other national fire protectionregulation.

All field mounted sensors or actuators shall provide intrinsically safe (EExi) protection,except for solenoid valves and motors. Intrinsically safe barriers may preferably beintegrated in I/O modules. As an alternative, they may be supplied as independentcomponents.

RTU components shall be of modular design, with rack mounting and plug-in typeassemblies. Each RTU module shall be equipped with light indicators for fault and statusdisplay, and shall provide error and alarm status for group alarm indication in the PMCS.

It shall be possible to replace I/O modules without switching off the power. All modulesshall be on-line replaceable without degrading the system performance, affecting othercomponents or causing a system failure. Re-initialization of newly installed I/O moduleshall be automatic.

All printed circuit boards shall be protected against corrosion and humidity by means ofappropriate varnish coating and gold plated contacts of connectors or equal.

4.4.2 Analogue Input

Standard signal will be 4-20 mA, 24 V DC, 2 wires, floating for passive transmitter.

Passive transmitter means that RTU module will deliver power supply for 4-20 mA inputsignal. However, it shall be able to accept passive inputs, i.e. powered by the fielddevices.

Analogue inputs shall incorporate monitoring function. Signal range shall be softwareconfigurable per input channel.

RTUs shall be able to perform and generate as a minimum the following facilities foreach type of detection loop:

Detection loop fault (auto-test, beam block, over range, etc.);

Open and short circuit line monitoring with generation of fault;

Inhibit facilities for maintenance operation;

Detection loop alarm reset.


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4.4.3 Analogue Output

Each analogue output shall be standard 4-20 mA DC signal. Output channels shall beisolated, independent and individually protected by fuse.

Analogue output shall be powered by RTU internal 24V DC supply.

The negative and positive sides of the circuit output shall be wired to independentterminals (common supply or return is not allowed). Each output channel shall be able todrive an external load up to 750 ohms.

4.4.4 Digital Input

Sensors shall be volt-free contacts. RTU shall provide the power for each type of switch.For volt-free contacts, power will be 24V DC.

Input modules shall include circuitry (filtering, etc.) to ensure that any "chatter" or"bounce" encountered during contact closure does not initiate erroneous information.Filter time may be software configurable. Dielectric strength for digital input shall betested between I/O terminals and ground for 2 seconds. VENDOR shall state therequired voltage test.

4.4.5 Digital Output

Digital outputs shall use either solid state or relay technology, and be voltage free.Output circuits shall be short circuit proof. Short-circuiting of one output shall not affectany other channel. Electronic fuse shall be part of output module.

Each output contact shall be individually configurable to allow the following actions:

Latched;

Pulse;

Normally open;

Normally close.

The output contacts shall be powered by the internal 24 V DC power supply. Interfacingoutput relays will be used when output load requires any other voltage.

The following outputs shall be supported:

Solenoid valves with 24 VDC coil voltage;

Motor starting commands, if any, with interfacing relay powered by RTU.


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For safety trips (ESD or F&G), VENDOR shall provide minimum SIL 2 TV certifiedrelays.

These relays shall be hermetically sealed and fitted with LEDs.

5.0 SOFTWARE

RTU software shall allow:

Function block diagram programming and editing compliant with part 3 ofIEC 61131, which defines requirements of programming languages. The

programming software shall preferably allow use of ladder logic as well asfunction blocks, Boolean logic and structured text for building the control logic;

Offline and online programming;

Define system and hardware configuration;

Tag name definition to assign Owners tag name to individual hard wiredinput/output points and other software/memory resident points;

Test and debug program execution which allows software testing before actualprogram downloading;

Download configuration software and application program;

Monitor the real time program execution with program variable updates on thefunction block logic diagrams;

Manual forcing;

Password security to define users and their privileges with regard to editing,manual forcing, download and other operation;

Automatic documentation and report generation for documenting programs, audittrail of program changes and user actions.

6.0 COMMUNICATION

6.1 Overview

Each of the RTU shall communicate via fiber optic link with the PMCS at GPF forprocess monitoring, alarming and remote control (open/close valves, start wellopening/closing sequence) etc. and other signals through FO cabling system. RTU shallhave Ethernet port for connection to FO equipment.


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6.2 Technical Requirement

Communication interface shall have internal self-diagnostics to ensure data integrity andoperational security. Identification and location of faults and status shall be automatic.Faults and failures of the communication link or module shall not degrade the RTUreliability. Communication module shall be rated interference free.

It shall be possible to replace communication module without switching off the power.Re-initialization of newly installed module shall be automatic. Each communicationmodule shall be equipped with light indicators for fault and status display, and willprovide error and alarm status at the operator station.

Loss and restart of communication shall not result in trips or status changes of thecommunication ports. Recovery of communication shall be automatic.

6.3 Communication with Laptop

VENDOR shall provide communication facilities to allow connection of a laptop directlyto the RTU, for local maintenance activities.

6.4 Other Modules or Devices

VENDOR shall specify in his proposal the different types of modules.

7.0 RTU PROGRAMMING, CONFIGURATION AND MONITORING LAPTOP

7.1 Funct ional Requirements

Both laptop and EWS in CCR shall allow development and maintenance operations.

RTU shall be able to support both on-line and off-line programming. The laptop softwareshall have on-line help facility. It shall include the following minimum functionalrequirements:

I/O assignment and database configuration (module type location, tag name,

description, type, etc.);

User program implementation for sequences, logic diagrams, etc.;

Upload and download application program;

Cross-reference list between database and user program;

RTU maintenance and diagnostic facilities;

Off-line testing facilities of the control program, including full emulation ofprogram and monitoring of the emulated program;

On-line monitoring of the program execution in the RTU;


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Several passwords will prevent unauthorized access to the different operatoraccess levels (loading, programming, monitoring, etc.) as defined in TV report.

User program shall be self-documented. Database, I/O assignment and sequences shallbe issued through printouts reports to allow engineering or maintenance staff to controlthe whole configuration.

7.2 Technical Requirements

The laptop shall be of the following minimum configuration:

Pentium microprocessor (latest available model at order awarding date);

4 GHz;

2 GB RAM;

160 Gbytes HDD;

CD ROM / DVD RW drive;

3 1/2 high density floppy;

Real time clock;

14 TFT SVGA color monitor for QWERTY keyboard;

Mouse or track-ball;

IEEE 802.3 port;

USB port;

Batteries and battery charger for laptops;

Operating system: Windows Vista, according to the supplied version of thedevelopment software. Operating system will be of the latest available version atorder awarding date;

Anti-virus software;

Programming and maintenance software (latest available version at orderawarding date);

All necessary cables and easy fitting devices.

VENDOR shall provide all software components needed to implement any modification

of the application software. The VENDOR shall provide the necessary quantities oflicenses. The VENDOR shall clearly indicate the purpose and the limits of the different


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licenses provided. VENDOR shall submit type and characteristics of the laptop at bidstage for COMPANY approval.

8.0 POWER SUPPLIES

24 VDC power supply shall be provided through the solar power system. For each RTUcabinet, VENDOR shall provide all the equipment necessary to generate the differentpower supplies needed by the RTU cabinet components and in particular the powersupply for I/O powering (taking into account equipped spares). These power supplies willbe 100% redundant. Special attention will be paid to transient suppression.

Power consumption and heat dissipation of each RTU cabinet shall be calculated.Diagnostic and signaling facilities such as LEDs shall be provided to identify that apower supply unit requires service or replacement. It shall be possible to isolate,disconnect, remove and replace a faulty power supply unit withoutloss of operation.

9.0 SYSTEM PERFORMANCE

RTUs minimum performances shall be as follows:

RTU execution time (input acquisition + program execution + output writing +communication): 0.5 sec maximum;

Analog signal scan rate (signal used for safety loop): 50 ms;

Digital signal scan rate: 50 ms.

10.0 CABINETS

10.1 General

For the cabinet refer to PTS 32.80.10.30 chapter 6 and the following are the minimumrequirement:

1. One or more cabinets are required at each wellheads / manifolds to house thesystem equipment, termination strips and wiring.

2. Cabinet construction shall be convection ventilated with readily accessible,removable filter screens inserted behind slotted louver inlets. Louvers and filtersinstalled within cabinet doors are acceptable provided that adequate ventilationarea is allocated to avoid hot spots within the cabinet.

3. Cabinets will be installed in a passive cooled shelter, located in an unclassifiedarea, but the cabinet shall meet IP 65.

4. Cabinet sizes shall be standardised as much as possible, preferably free standingtype for all plants. The number and size of cabinets shall be provided by RTU


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vendor. The preferred dimensions are 800x800x1800mm, keeping in view theavailable clear space.

5. Cabinets shall have two eye hooks centred at either end at the top of the cabinet.Eye hooks shall be of sufficient size to accommodate lifting hooks to lift the fullyloaded cabinet into place. Blanking plugs shall be provided and installed toreplace the eye hooks once the cabinets have been installed.

6. The front of the cabinet shall be provided with full-length access, swing-outdouble door. Double door arrangement is required, considering the availablespace in the existing passive cooled shelter. Rear access to cabinets shall not beprovided. Swing-out doors shall be removable and gasketed. All doors shall be

reinforced against buckling and provided with lockable door handles. All doorsshall be provided with the same lock and key combination. Each swing out doorshall have at least three hinges. Each door cabinet shall be electrically bonded tothe main cabinet by braided ground strap (wire size 10sq.mm. or mm2 orequivalent).

7. The front door shall have a pocket sized to contain drawings and documents andshall contain a folding shelf to accommodate a laptop computer.

8. Cabinets shall contain internal light.

9. Cabinets shall be painted grey RAL 7032.

10. Cabinets shall be designed and constructed to meet EMC requirements;

11. Cabinet shall be SS 316 suitable for harsh environment.

10.2 Labeling

Each cabinet and all major system components shall be clearly labeled and identified.Nameplates shall be made from laminated plastic, white-black-white (informationengraved into black core with white surface, dull finish).

In addition, all equipment shall be identified with the manufacturer type and serial

number to facilitate future reference.

10.3 Equipment Grounding

1. Cabinets shall incorporate two (2) separate, isolated ground bus bars. Separateground buses shall be provided for the following sub-systems:

a) Safety ground bus for all exposed metal surfaces of cabinets, racks etc.(individual ground wiring interconnections to be minimum 1.5 mm (16AWG, copper wire, green/yellow insulation).

b) Shield connection bus for connecting signal cables and wire shields,

(individual cable/wire shield interconnections to be minimum 1.5 mm (16AWG, copper wire, green insulation).


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2. The VENDOR shall provide a specification of the grounding requirements for theRTU cabinet.

10.4 Cabling and Wiring

For the system cabling following are the minimum requirement:

1. All cable entries shall be through the bottom of the cabinets through suitablemulti-cable transits.

2. All multicore cables shall be fully terminated.

3. Sufficient free space shall be available for accommodating all terminal wires for afully loaded system, i.e. modules etc.

4. Cable clamps and supports shall be provided for all incoming cables.

5. All internal cabinet wiring shall run in suitably sized PVC ducts with removablecovers. Sizes shall accommodate all wiring required for a fully loaded system.

6. Minimum conductor for internal cabinet wiring to be PVC insulated 1.0 mm2 solidor stranded tinned copper. When stranded wire is used they shall be connectedwith crimped on connectors.

7. Instrument cables and individual signal cores shall be fitted with identificationferrules.

8. System cables shall be to VENDORs standard.

10.5 Terminations

1. All terminals shall be of the SAKR Klippon type.

2. All sockets terminals and wiring shall be clearly identified in strict accordancewith the system documentation.

3. For all fused inputs, knife disconnected terminals shall be used.

4. Outputs to solenoids shall be provided with circuit breaker of suitable rating.

11.0 SPARE PARTS

Commissioning spares and consumables shall be included in scope of work;

Price list of spare parts for 2 years operation.

Lists shall include pieces item numbers, each referenced to the relevant drawings.

These drawings shall be supplied with the VENDOR documents.


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Each part shall be properly tagged with a weatherproof label, showing the:

MESC number;

Manufacturer's unique part number;

Description of the part;

Expiry date for parts having a limited shelf life;

Small items with the same part numbers shall be tagged and packed together in a plasticbag or box, and the tag shall also be shown on the outside of the bag or box.

The VENDOR shall provide with the initial offer a price escalation formula for spare partsorders, binding for a 5 years period after warrantee expires. The warranty period for allmaterials and equipment to be provided shall be "24 months from delivery (exVENDOR's Works) or 12 months from the Plant in-service date, whichever occurs first."

12.0 SPECIAL TOOLS

The VENDOR shall supply all special tools necessary for the main and auxiliaryequipment for installation, pre-commissioning and commissioning.

13.0 MARKING AND PACKING

Marking and packing of VENDOR equipment shall be done according to requirementsindicated in material requisition. Marking and packing will be defined during EPC phase.

14.0 DOCUMENTATION

14.1 General

The documentation requirement shall be in accordance with the project documentation

requirement and as provided in the requisition.

The VENDOR shall produce a Functional Design Specification (FDS), which forms thebasis of the RTU system. The project documentation shall cover the FDS and also thefollowing engineering drawings & documents as a minimum.

System architecture diagram;

System configuration (slot & module configuration);

Logic narratives;

Cabinet General Arrangement & Module layout diagrams;


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Power consumption and heat dissipation calculations;

Reliability and Availability calculations;

Communication and system loading calculations;

Loop diagrams;

I/O database with rack, slot and channel assignments;

Termination details;

Diagnostics logic.

As far as possible all the above documents shall be taken from the system itself, usingthe self-documentation facilities. For compiled programs, they shall be obtained fromprogram source files.

Detailed listings of point assignments (with rack, slot, channel etc.) and point usage shallalso be provided. Point usage listings shall identify each display and computing deviceor interface device application that has been assigned to each tag in the system.

The loop diagrams with file details shall be developed by the VENDOR and submitted tothe COMPANY. The loop diagrams shall be in accordance with ISA standards.

Vendor shall also comply with the requirements of documentation specified in PCPLprocedure CSP-03.

14.2 Funct ional Design Specification (FDS)

The VENDOR shall prepare detailed Function Design Specification, which covers thedesign of both the hardware and software. The FDS shall clearly define all standardsoftware modules developed for implementation of typical SCADA functionalitys.

All documents, drawings, correspondence, operating, installations and maintenanceshall be in English.

It shall clearly define the following design criteria, as minimum,

System architecture;

Signal flow within the system;

Fail safe feature;

Reliability and availability;

Redundancy;


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System and software security;

Basis of hardware selection;

Basis of software selection;

Basis of communication facility;

Power consumption and heat dissipation calculations;

Reliability and Availability calculations;

Communication and system loading calculations.

The above indicates only the basic minimum requirements. However the FDS shallconsist of all the relevant information regarding the design and functions of the RTUsystem.

System cabinet, sub-components shall be tagged as per COMPANY procedurementioned above.

14.3 Inspect ion & Testing

The inspection and testing requirement shall be in accordance with the approved"Inspection and Test Plan. It shall cover the following as a minimum:

Physical / dimensional checks, bill of material including spare parts.

Inspection of all test record performed by VENDOR prior to FAT.

100% Functional checks for hardware, logic.

Calibration checks.

The Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) shall be as

per procedures provided by the VENDOR and approved by COMPANY.The FAT shall be an integrated test which includes RTU and Solar Panel System.

The FAT will be witnessed by COMPANY or their representative and theCONSTRUCTION CONTRACTOR. A minimum of fifteen (15) days intimation shall begiven by the VENDOR to COMPANY before the FAT.

The installation and pre-commissioning of the RTU system, field detectors and cablingbetween them are in the scope of CONSTRUCTION CONTRACTOR. TheCONTRACTOR shall provide assistance during commissioning to the COMPANY.

VENDOR shall provide the services of an experienced Engineer to assist theCONTRACTOR/COMPANY with pre-commissioning & commissioning.


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All items shall be suitably protected against damage during shipment and storage.

On completion of inspection and testing equipment shall be properly packed andprepared for shipment.

15.0 TRAINING

Selected personnels shall receive specialized training at site and at VENDOR premises.Training topics shall include the following:

Overall description and illustration of RTU capacities and functionalities (control,

communication, I/O types, programming);

RTU major components: racks, CPUs, power supply, communication modules,I/O modules of each type;

RTU cabinet;

Programming functionalities: I/O and database configuration, control program,communication, SOE;

Maintenance functionalities: On-line running monitoring, component replacement,diagnostic alarm analysis;

All software and standard program blocks used definition;

Spare parts ordering, coding, care of spares;

Running and workshop testing.

16.0 SITE SERVICES

VENDOR shall provide on site assistance for the following periods:

Mechanical completion: assistance for system installation and site preliminarytests;

Pre-commissioning and commissioning;

Start-up.

The expected time for each of these periods will be estimated by the VENDOR andindicated in the proposal for information with the required qualification of personnel andrelated day costs.


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17.0 QUALITY ASSURANCE/QUALITY CONTROL

Vendor proposed quality system shall fully satisfy all the requirement of ISO9001/9002/9003/9004. The VENDOR and the Sub-vendors shall be ISO certified.

VENDOR shall provide a specific Quality Control Plan (QCP) within 2 weeks of orderaward for COMPANY review and approval.

VENDOR shall provide the following to COMPANY for approval:

1. Coordination procedure to coordinate the manufacturing of all materials, partsand components in different places.

2. The source of material supply for all parts and components including the countryof origin and place of manufacturing, assembly and testing.

3. Material certificates for all parts and components before assembly.

4. Sub-vendors and contractors list and these shall be from COMPANY approvedlist.

18.0 GUARANTEE

The VENDOR shall ensure that the material and accessories provided shall be hisstandard product which is regularly manufactured, tested and serviced in accordancewith the Codes and Standards defined above.

Any material or part thereof covered by this specification that shows evidence ofdeterioration, contamination or corrosion within the guarantee period shall be consideredthe result of failure to comply with the requirements and the intent of this specificationand shall be replaced on site at no extra cost to the Owner.

12-MGDP-I-1046-0 (Spec for Remote Terminal Unit)

Documents

Transcript of 12-MGDP-I-1046-0 (Spec for Remote Terminal Unit)