A== oo vwr- REV.: B PAGE 1 OF 47 BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 SPECIFICATION FOR STATION CONTROL SYSTEM B__ | REASSUED FOR APPROVAL | pec. 20, 2018} HuangH.M. | Tang J.D. wus. Wang Y.B. A ISSUED FOR APPROVAL | 2016.8.15 | ShenH. UXH. wus. weiZ.R. REV. DESCRIPTION DATE PREP'D cHK’D REVD APP'D= _ os «< = I BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 2 OF 47 Revision History Revision A is completed on 15" Aug. 2016. The purpose of Revision B is updating some requirements based on the engineering & practice in Halfaya projects in the latest two years, and commented by PCH on transmittal of HFY3- 3030-PCH-CPE-T-0015" on 5” Aug. 2018. Detail modification shall be as per revision marker in the documents. Major changes as following: ‘Chapter Revised to 7.3.3 | Add: “Manufactured date of equipment and accessories provided by vendor shall not be 7 year earlier than Purchaser Order date.” 32__[ Add 1EC-61643-11/12/21722 3.3 | Add SCADAIDCS/SIS/F&G system documents number. 44.3 _ | Add: “SCS Architecture shall be provided during detailed design accordingly Vendor shall size the System.” 447 | Revise “20kA" to “1kA” for SPD Nominal discharge current 45 | Revise “terminal board—module” to "Module with terminal board” Revise “terminal with fuse" to “terminal with fuse and LED” 45__[ Add: "Panel internal wiring shall be used cable Lug” “Cabinet main cable duct size shall be minimum 100Hx100W mm and other duct size can be 4100Hx50W mm for sufficient space for cable maintenance.” FB |Add: “Vendor is also responsible to upgrade the existing system software to meet project requirement during executing the tie-in work to the existing system. All software licence shall be genuine and on end user name” 47.2.1 | Add: “active and standby CPU" 47.23 | Add: “active and standby" 7.0 _ | Add: "Site changes design RED MARK UP duly signed by COMPANY representative, As Built drawings and documents”BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 3 OF 47 CONTENT 1.0 GENERAL 4.1 Purpose... 1.2 Definitions and Abbreviations 1.3 VENDOR’s Responsil 1.4 Company Access 4.5 Language and Units. 2.0 SITE CONDITIONS. 2.1 Environmental Conditions Outside Building 2.2 Environmental Conditions Inside Bullding. 2.3 Standard Reference Conditions 3.0 APPLICABLE REGULATIONS, CODES, STANDARDS AND SPECIFICATIONS.......11 3.1 General W 3.2 International Standards and Codes ........2..2.00++ . cece ld 3.3 Applicable Project Specifications. 12 3.4 Conflicting Requirements, Deviation and Substitution 13 3.5 Order of Precedence for Documents... cece eee, . . . 13 4.0 TECHNICAL REQUIREMENT.. 4.4 General .. 4.2 Work scope of supplier 215 4,3 Environmental conditions. 18 4.4 Design basis. . 4.6 Panel, box, cabinet. .BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 4 OF 47 4.7 System setting requirements. 4.8 SCS Configuration .. 5.0 TEST AND INSPECTIONS 5.1 Basic Test.......2......00cceeeeeeeceeeeeeeeeeeeee . ceeeeeeees 40 5.2 Pre-Testing In Factory... 5.3 Factory Acceptance Test (FAT). 5.4 Site Acceptance Test (SAT) ........... ceeeeee . ceeeeeeeee AD 5.5 Operational Availability Test (System Commissioning) ....... ceceeeeeee AD 6.0 ON SITE ASSISTANCE. 6.1 On-Site Service . 6.2 Training... 7.0 DOCUMENTATION= _ os «< = I BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 5 OF 47 1.0 GENERAL 1.1 Purpose This specification defines the minimum technical requirements for the engineering, design, manufacture. testing, delivering and after sale service support for the OIL Pipeline Station Control System (SCS). It also defines the minimum scope of work. Any items and activities not covered in this specification but which are required to achieve a fully functional Station Control System (SCS) will remain the responsibility of the VENDOR The documents and parameters necessary for Station Control System (SCS) design and configuration shall be prepared by VENDOR and approved by PURCHASER. Therefore, the VENDOR shall implement the OIL Pipeline SCS construction and configuration in accordance with the above. 1.2 Definitions and Abbreviations 1.2.1. Definitions WORD MEANING COMPANY. PetroChina Intemational Iraq FZE Iraq Branch The organization selected and entrusted by COMPANY to perform the CONTRACTOR Engineering, Procurement, Construction, Start-up, pre-Commissioning and Commissioning of the Project. The party who is in charge of awarding agreement on behalf of PURCHASER COMPANY / CONTRACTOR for the supply of goods and services in connection with the work. The party to the contract andlor purchase order which has undertaken the obligation to supply the goods andlor services which are ordered VENDOR’ SUPPLIER/ SUBCONTRACTOR | ana Specified herein. Shall Indicates a mandatory requirement ‘Should Indicates a strong recommendation to comply with the requirements of this document 1.2.2 Abbreviations ‘ACRONYM MEANING ANSI ‘American National Standards Institute API ‘American Petroleum Institute ISA) Instrument Society of America IEC International Electrotechnical Commission ASME ‘American Society of Mechanical Engineers Iso International Standardization Organization= _ os «< = I BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV.:B PAGE 6 OF 47 EEMUA Engineering Equipment And Materials User Association aC Alternating Current ccR Central Control Room ccs ‘Compressor Control System CER Central Equipment Room CPF Central Production Facilities PU Central Processing Unit RC Cyclic Redundancy Check ‘PMS Cathodic Protection Monitoring System cis Custody Transfer Metering System De Direct Current ces ‘Compressor Control System cTms Custody Transfer Metering System DPDT Double Pole Doutle Throw EPC Engineering & Procurement & Construction ESD Emergency Shut Down EMC Electro Magnetic Compatibility EP Electro-pneumatic converter Ews Engineering Work Station FGMP Fire & Gas Matrix Panel FGs Fire and Gas FAT Factory Acceptance Test FEP Front End Processor FDS Functional Design Specification HVAC Heating Ventilating and Air Conditioning= _ os «< = I BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 7 OF 47 wo Inputs/Outputs uP Current to Pneumatic LAN Local Area Network LsD Local Shut Down LER Local Equipment Room mec Motor Control Centre Mos Maintenance Override Switch PA Pneumatic to Current Paid Piping and Instrumentation Diagram PLC Programmable Logie Controller POS Process Overnde Switch PPcs Power Plant Contiol System PsD Process Shut Down Psu Power Supply Unit RA Quantitative Risk Analysis RTD Resistance Temperature Detector RTU Remote Terminal Unit SAT Site Acceptance Test ‘scs Station Control System SCADA ‘Supervisory Control and Data Acquisition system ‘SOE ‘Sequence Of Event SER ‘Sequence of Event Recorder sis Safety Instrument System Sov Solenoid Operated Valve ‘SPDT Single Pole Double ThrowBASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 8 OF 47 SXGA ‘Super Extended Graphics Array UPS Uninterruptibie Power Supply vou Visual Display Unit 1.3 VENDOR’s Responsi 1.3.1 Vendor Qualification Vendor shall have at least 5 years’ experience of similar engineering applications where the system has been in use. Vendor shall provide user list included user name, site location, running time, and brief project summary in the bid. Vendor shall provide the licence and certification to prove that the application of the provided equipment shall be appropriate and legal for the project. 1.3.2 Vendor Responsibility Vendor shall be responsible for system designing, material procurement, manufacture and assembly, testing, and inspection, delivery to site, installation, pre-commissioning and commissioning of the system. Vendor will also be responsible for the coordination and management of any sub-contraction appointed during the course of design and manufacture and will also offer after sales service support. Vendor shall be capable to provide service for site. 1.3.3 Standard Products ‘The SCS system should be of a comprehensive integrated flexible configuration employing a standard design utilizing systems and equipment which have a proven history of operation Ay Manufactured date of equipment and accessories provided by vendor shall not be 1 year earlier than Purchaser Order date, Equipment manufactured before this date should not be considered. They shall also be of an intemationally recognised brand. Equipment from Non internationally recognised brands or product ranges will not be accepted. The system shall be composed of manufacturer's standard hardware, software, and firmware, which can be configured to meet the stated requirements. (If it isn’t based on Windows, this issue must be approved by COMPANY.) Software design shall ensure that future revisions or updates of the system operating software shall not affect the successful operation of the system. Standard software shall be used as far as possible to guarantee safety on delivery. Vendor's standard system operating software can be modified to meet Purchaser's requirements. 1.3.4 Field ProvenBASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 9 OF 47 All hardware and software to be provided shall have been installed for at least 5 similar applications, within the last 5 years with a proven history of operation and reliability. Previous examples of where the hardware, firmware and software being offered in the proposal have been installed and are in current operation should be cased referenced. 1.3.5 Planning ‘A milestone schedule shall be set-up by Vendor and approved by Purchaser before system execution. This schedule shall show all target dates for SCS system implementation. Any deviation to the established schedule must have the Purchaser's approval. The Vendor shall report job progress in writing on a monthly basis. 1.4 Company Access COMPANY andior authorised representatives shall have free access and the right to inspect and/or witness any of VENDOR'S activities, operations, reports and certificates in connection with the equipment purchased to this specification. COMPANY and/or his authorised representative may, at no extra cost to COMPANY, reject any work failing to ‘mect the purchase order requirements 1.5 Language and Units The governing language shall be English language. All notices, correspondence, information, literature, data, manuals and other documents required under the Contract shall be in the English language. Technical units, quantities, etc. shall be expressed, used and abbreviated according to the SI system. Preferred units of measure are as for: Flow Rate mi/hr, MMSCFD (gas), BPD (condensate), BWPD (Water) Power, Duty 2 kW Area 2m Length £ meter (m), km, mm Pressure : Bar (g), Bar (a), kPa (g) Temperature 1c Volume 2m Weight kg= o_o wi r — BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV.:B PAGE 10 OF 47 2.0 SITE CONDITIONS 2.1 Environmental Conditions Outside Building Altitude mAsL, 05-6 ‘Atmospheric Pressure kPa 102 Max. Temp. c 55 Wet Bulb Temp c 22.2 (GPSA 11-3b) Dry Bulb Temp. c 42.2 (GPSA 11-30) Max. Metal temp. by sun shine c 80 Min. Temp. c 2 Max. Speed Wind mis 40 Prevailing Direction Wind (winter) NW-SE Prevailing Direction Wind (eummer) NW-SE Max. Relative Humidity 80% Min. Relative Humidity 25% Rainfall mnva 1774 ‘-hour Rainfall mm. a 415 in winter (1.2-1.6 m) Under Ground Temp. c - 33.6 in summer (1m) Seismic Zone 28 Evaporation Rate mnva 3054.4 2.2 Environmental Conditions Inside Building ‘SCS will be installed in non-classified area (CCR or LER), under HVAC atmosphere - ISA $71.04 & $71.01 The System shall be suitable to operate in a room with the following ambient parameters: Maximum: T = 40°C Relative Humidity = 90% Minimum: T = 10°C Relative Humidity = 20% The system shall be suitable to be stored in a warehouse with the following limit ambient parameters: ‘Temperature from 0 to + 50°CBASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 11 OF 47 Relative Humidity from 20% to 95% 2.3 Standard Reference Conditions In the project, the standard reference conditions shall be as following: Absolute Pressure: 101.325kPa; ‘Standard Temperature: 15.56°C 3.0 APPLICABLE REGULATIONS, CODES, STANDARDS AND SPECIFICATIONS 3.1 General The Station Control Syste (SCS). shall meet or exceed requirements specified in the latest editions or the equivalent ones of the following standards and specifications. If any requirements are specified in more then one standard or specification at the same time, the most stringent shall be followed. In addition, Station Control System (SCS) shall also comply with laws and regulations approved by local government. Before design and manufacture of Station Control System, if any contradiction between this Technical Specification and relevant technical specifications or correspondences, the PURCHASER shall be consulted and written confirmation from the PURCHASER shall be obtained before any further work starts. 3.2 International Standards and Codes The following codes and standards, to the extent specified herein, form a part of this specification. When an edition date is not indicated for a code or standard, the latest edition in force at the time of VENDOR's proposal submitted shall apply. lec 60529 Classification of degrees of protection provided by enclosure 61000-4-3 Electromagnetic compatibility (EMC) - Testing and measurement techniques — Radiated radio frequency, electromagnetic field immunity test 61000-4-4 Electromagnetic compatibility (EMC) — Testing and measurement techniques — Electrical fast transient/burst immunity test Ay 1643-11 Low-voltage surge protective devices - Part 11: Surge protective devices connected to low-voltage power distribution systems - Requirements and test methods 61643-12 Low-voltage surge protective devices - Part 12: Surge protective devices connected to low-voltage power distribution systems - Selection and application principles 61643-21 Low voltage surge protective devices — Part 21: Surge protective devices connected to telecommunications and signalling networks = Performance requirements and testing methods - Edition 1.2BASIC DESIGN DOG. NO.: GEN-INT-SPC-0014 REV..B | PAGE 120F 47 Consolidated Reprint 61643-22 Low-voltage surge protective devices - Part 22: Surge protective devices connected to telecommunications and signalling networks - Selection and application principles - Edition 2.0 Isa RP55.1 Hardware Testing of Digital Process Computers RP 60.3. Human Engineering for Control Centres, RP 60.6 Nameplates, Labels and Tags for Control Centres S64 Instrument symbols and Identification. $52 Binary logic diagrams for process operation. $53 Graphic symbols for distributed control system display instrumentation, logic and computer system. S54 Instrument Loop Diagrams $5.5 Graphic eymbole for proceee dieplay 810.4 Annunciator sequences and specifications. $20 Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves S614 Process instrumentation Terminology $71.04 Environmental Conditions for Control Systems: Airborne Contaminants IEEE 472 Electrical Surge Protection AGA AGA Report No.3 AGA Report No.8 APL RP 554 Process Instrumentation and Control RP 1119 Training and Qualification of Liquid Pipeline Operators ‘Standards and codes that are quoted in the above standards and codes shall also be complied with: The vendors are obligated to provide other standards and codes relevant to these equipments that are not included within, 3.3 Applicable Project Specifications VENDOR shall design, fabricate, assemble, test, paint, and ship the equipment in accordance with the following project specifications:BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 13 OF 47 A HFY-GEN-INT-SPC-0008 Specification for General instrumentation HFY-GEN-INT-SPC-0001 ‘Specification for PLC System based PCS HFY-GEN-INT-SPC-0002 ‘Specification for Safety Instrument System HFY-GEN-INT-SPC-0003 ‘Specification for SCADA System for OCC HFY-GEN-INT-SPC-0005 ‘Specification for Fire & Gas System HFY-GEN-INT-SPC-0007 Specification for Distributed Control System HFY-GEN-INT-SPC-0012 ‘Specification for CPF SCADA System ‘Some requirements in this specification may be modified by special requirements in the Purchase Requisition. In case of conflict, the special requirements supersede this specification 3.4 Conflicting Requirements, Deviation and Substitution In the event of a conflict between this specification and other specifications or correspondence, VENDOR shall consult with the COMPANY’s designated representative and a ruling, in writing, shall be obtained before any work is started. Where Provincial or National Codes conflict with this specification, the more rigid requirement shall govern ‘Any deviation from this specification must be approved, in writing, by the COMPANY's designated representative. Alternatives may be offered for materials and fabrication, if technically or economically justified and provided that they meet the requirements of the applicable codes, standards and specifications. 3.5 Order of Precedence for Documents. All conflicts between the requirements of this specification, related contract documents, national / international documents, codes, engineering practices and the requisition shall be referred to COMPANY/PURCHASER for clarification. Should any conflict occur in the application of these specifications, the order of precedence shall be as follows: 1) PURCHASER order (including attachments) and variations thereon; 2) Data sheets and drawings; 3) This Technical Specification; 4) Project Specification in conjunction with native standard; 5) International codes and standards. 4.0 TECHNICAL REQUIREMENT 4.1 General The SCS scope shall include provision of all marshalling & system cabinets, server & power cabinets (details should refer to detail design phase’s integration), interconnecting cables,BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 14 OF 47 workstation, printers and control desks, plus generation of the system database & software, controls and displays. The SCS systems should be a comprehensive, integrative, flexible configuration and standardization process control system, and should adopt the late developed and improved new technique; new equipment and new system but they must be the practicable and mature system in the world. Vendor shall be able to supply parts for SCS hardware and provide upgrade for SCS software for at least 12 years. The selected SCS shall be having a history of reliable operation in pipeline station process facility type applications of similar architecture, size and complexity. All requirements of the project shall be met by software packages and by hardware in service at the time of supplier's bia. The technical specification is revised with the work progress and can ultimately become a part of the supply contract. SCS is an integral part of the SCADA system, which is invited tender together with SCADA system. For any content not mentioned in this technical specification but necessary for forming a complete set of SCS, the supplier should also take into account. The supplier should be familiar with the pipeline system requirements, and bear work expericnees on similar project, and can configure and complete the whole system on basis of information provided. so that the system fully meets the needs of this project. The supplier must have sound reputation and after- sales service capabilities, strong technical strength, system integration capabilities, and technical capabilities for completing this project, adequate human resources, and work achievements on similar project in recent years. The project manager, technical leader and key technical members of the project team assigned by the supplier must have work experience on similar project within recent years and be major ‘management staffs and technicians on those projects. The main management and technological personnel of supplier's project team can not be casually replaced before the construction completion. All the software, hardware and other auxiliary equipment of the SCS system provided by the supplier enjoy powerful after-sales service ability in abroad. Besides, it has to provide the guarantee letter to meet the Purchaser's demend for after-sales service. The automatic control system is applied wth SCADA system. The system will reach the automation level for monitoring, scheduling and management the entire line in the Control ‘Center. Each manned process station along the pipeline is installed with SCS, SCS as a remote control unit is the basis for ensuring normal operation of SCADA system, remote execution unit for scheduling, management and control command of the control center, and also the most important supervision level in SCADA system. SCS can not only independently complete the data acquisition and control for process station, and will send the information to the control center and receive the order issued by the center. SCS mainly consists of the computer network system, PLC, operator workstations and communication equipment for data transmission.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 15 OF 47 SIS is an integral part of SCS, and must make timely response in case of emergency situations with the station, or failure with the safety instrumented system failures, and also produce a correct output to the site to avoid any occurrence of danger or mitigate consequence. Failure of the system to respond will ultimately lead to or increase the consequence of risk. SIS system uses independent logic control system in compliance with IEC61508 SIL 2 requirements to handle emergency situations endangering personal safety, pipeline safety and equipment safety. Combustible gas detectors and flame detectors shall be hardwired to SIS. ‘The security level certification for Safety Instrument System requires design as per SIL2, and the specific security level requires determination upon safety assessment. The marshalling panel shall be used for interconnection of field instruments with PLC&ESD cabinet. The external wiring terminal of marshalling panel shall be the interface for vendor with contractors. 4.2 Work scope of supplier The eupplier’e work ecope includee (but not limited to) the following contente: Perform system design as per this technical specification and other related documents, and provide detailed design documents for SCS system (design document should be approved by the Purchaser and the design before implementation). The design documents should at least include: = System design, detailed technological plan and functional specification; = System configuration block diagram and logic diagram; = Network topology; = System connection diagram - Detailed specification of various equipment and materials adopted in the system and relevant catalogues; = Detailed equipment and materials list; - Detailed structure design for various cabinets, equipment layout and wiring diagram; = Power supply & distribution system; = Setup of surge protector and all technical data of the selected surge protector device; = Grounding system; - System reliability and availabilty analysis (the availability level shall be 99.99%); - Training contents and pian; = Project implementation plan; = Detailed contents and plan of FAT and SAT:BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 16 OF 47 = On-site debugging plan and implementation plan; = Production plan and implementation plan; = Operating Manual; = Users instruction manual; = Proposal. * * ‘System integration; Provide software and hardware training for the Purchaser and the designer; Training of on-site operator; Application software programming configuration and debugging; in order to enable the relevant technicians of the Purchaser and the designer ‘command the software in comprehensive and in-depth way, and further develop the software in light of demand during actual operation, the preparation and configuration of application software are under responsibility of and enlirely completed by the supplier. The Purchaser and the designer shall supervise work during lhe slage. Il has lo complete the compilation of applicable software in the supplier's plant. Design and production of Human - Machine Interface (HMI- Human/Machine Interface) dynamic picture based on the marked up P&ID's with SCADA MRO; Communication interfaces and testing with third party software and intelligent devices; Provide technical documents; Factory Acceptance Test (FAT) and all related procedures to apply FAT and certificates after finish tests; Packing and delivery; Site installation and power supply test; On-site supervision and guidance and SCADA system associated instrumentation and equipment wiring: ‘On-site commissioning; Pre-operation; Site acceptance test (SAT) and all related procedures to apply SAT and certificates after finish tests; Operation; 72 hours operation and monitoring as integrated system; To provide completion documents;BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 17 OF 47 * To provide spare parts for commissioning and start-up phases and any special tools shall be needed to complete proper commissioning, start-up and system running; * _ After-sales service and long-term technical support; * Project management. 4.2.1 Minimum documents to be provided in technical bid —Detailed system technological plan and specification; = Detailed Analytical System Configuration; Calculation of SCS power consumption: —Item-by-item response to tender technological documents; = Detailed work contents and implementation plan; —Needed qualifications; —Power of attomey and quality and after-sales guarantee letter of third party's products; Quality guarantee manual: —Submit all detailed technical documents, catalogues for all componets shall be used in this system for review and approval; ~After-sales service guarantee letter; —Systems and major equipment MTBF (Mean Time between Failure) and MTTR (Mean Time to Repair); — Characteristics and product manuals for detailed system and its hardware and software; —Work performance of recent years similar to the project; —Detailed equipment and materials list; List of spare parts and fittings (list out according to the selective items); =Ithas to provide the list of technologicel documents; List of key personnel responsible for and involved in the project list and their resumes and job performances; —Detailed introduction, qualification and performance of personnel belonging to the subcontractor and participating in the project; = List of adopted standard and code; — Arrangement of training plan and course; —Contents and implementation plan of Sat and FAT; On-site debugging plan and implementation plan; —Production plan and implementation plan; ~Existent problems and suggestions;BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 18 OF 47 — Other requirements mentioned in the document. 4.2.2 External interface of SCS Interfaces between SCS and related systems are as follows (not limited to): + Various measurement instruments, actuators, and control valves in each station through 1/0 cards; + Third-party monitoring systems or intelligent devices through serial communication; ‘Telecommunication systems through communication cards; Power supply system through serial communication; Catholic protection system through hardwire; %* Data exchange with superior monitoring system and management information system. 4.3 Environmental conditions 4.3.1 Building Conditions Control building shall include control room and local equipment room (LER-RIO room). All control building shall be compliant with the relevant specification and standard. Control and equipment rooms, will be air-conditioned dust proof. However, the plants are required to continue to operate without failure, without error and without incurring long or short- term damage to the equipment when the HVAC is out of commission at the conditions indicated hereinafter All electric/electronic equipment within the buildings must operate satisfactorily in an air- conditioned environment, which will be maintained at the following conditions:222°C and 50~ 60% Relative Humidity The system shall continue to operate in HVAC upset conditions for at least 2 hour, In order to minimize maintenance and the requirement for spares, the equipment shall be designed to operate in the worst ambient conditions to which it will be exposed. (Eg temperature fluctuations: 0-52°C, humidity levels 26%-76%, severe dust) Vendor shall specify the requirements for air contamination. Therefore Purchaser has to design the HVAC system in accordance with the above. 4.3.2 RFVEMI Susceptibility The installed SCS shall guarantee an EMC for an electromagnetic environment of level 2 as per the IEC 61000 4-3 and IEC 61000 4-4. 4.3.3 Equipment Noise The noise level for all equipment shall be less than: 50 dBA for equipment installed in continuously manned areas 60 dBA for equipment installed in other areas,BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 19 OF 47 Vendor shall specify the max noise level of printers. Noise measurements shall be based on type tests carried out in accordance with any of the methods detailed in international standards and expressed in terms of dBA sound levels 4.4 Design basis 4.4.1 Automation Level The automatic control system of the XXX project is applied with SCADA system. The control center is located in KXX and XXX. The system will complete the automation level of monitoring, scheduling and management of the whole line in the Control Center. After the system is put into operation, the operator can complete the pipeline monitoring and operation management in the Control Center, and realize unmanned operation mode in each process station along the line. 4.4.2 Design Principles 4.4.2.1 General Ine design principles ot the system require as tollows: Strictly comply with laws and regulations of Iraq. This design applies internationally recognized, latest version of codes and standards. ‘TWe Control Centers are installed along the line. The automatic control system will automatically and continuously monitor and control the operation of pipeline, to ensure physical, pipeline and equipment safety. Under the premise of guaranteed safety, ensure continuous oil supply for downstream users. Meet environmental protection requirements. To make the pipe run normally at the lowest operating costs and optimal work condition. The adopted equipment, control systems and materials should be technologically advanced, high performance-price ratio, and meet their environment and process conditions, proven mature products in industrial applications. 4.4.2.2 Design principles for SCS ‘The CPU and power supply for control equipment (system) in SCS adopts the redundant hot standby mode. The communication interface for data communication in local area network and Control Center are set in mode of redundant and hot standby. The SIS controller in SCS is used with relatively independent control devices in compliance with IEC61508 SIL2. The safety instrumented system is designed asBASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 20 OF 47 fail-safe type, namely the control loop of safety instrumented systems under normal state should be excited; The hardware should be modular in performances, and allow future upgrade of capacity and functionality. The system should be easy to increase disk drive, memory, terminal and external devices, and does not interrupt the operation of other online network devices. SCS system hardware and software availability rate (availability) should reach 99.99%. When the system must complete the printing, programming and screen display, the real-time acquisition system may not be interrupted. The design and configuration of hardware and software should meet the said indicators. The network structure used by the system should feature advanced technology and reliable performances. SCS shall be installed with well-established surge protection measures at interface locations where possible high voltage generated from lightning (direct lightning flash, induction lightning flash) can be imported into the computer system. At least the following substances should be installed with surge protection measures: — Connection with satellite communications; — Connection with power supply system; — Communication interface with other systems; — Analog instrument input/output interfaces inside station; — All /O interfaces for safety instrumented system; 4.4.2.3 Input and output signal types The main signal types of measurement instrument and control devices in each process station along the line are as follows: 4~20MADC or 1~SVDC; HART protocol Passive contact (24VDC); pulse; Serial communication interface (such as RS-232 or RS485, etc.) 4.4.3 Principle for type selection of equipment and materials Equipment is selected in principles of advanced technology, stable performance, high reliability, high performance-price ratio, satisfaction to required accuracy requirements, and satisfaction to requirements for site work conditions. The type of equipment should be selected preferably of the same series, specification and type and minimized number of manufacturer. Ay SCS Architecture shall be provided during detailed design accordingly Vendor shall size the System.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 21 OF 47 4.4.4 Communication XXX project is adopted with the mode of network telecommunication. Two Control Centers are connected respectively to SCS via fiber optic cable, and meanwhile installed with satelite ‘communication system as a backup communication line. When the primary communication channel fails, it should automatically switch to the backup communication channel. The switching shall be automatically completed by SCADA system and recorded in files. SCS is connected to 100M/1000M bandwidth Ethemet interfaces provided by optical transmission devices, and SCS accesses to satellite communication system via backup port of router. Communication system bit error rate should be smaller than 10°. TCP/IP protocol is used between Control Center and each station, of which communication rate is 64kbps. The data scanning cycle for SCADA system shall be smaller than 4 seconds. ‘Communication software for both server and client functions which shall be required shall be provided by the system vendor at the same time. The system shall be capable of handling multiple protocols such as OPC (DA HAD A&E Security), MODBUS, TCP/IP, and IEC 60870-5- 104 etc as SCADA system required. Cables for communication with EGADA shall be in the scope of XXX ECADA vendor. 4.4.5 Power supply Uninterruptible power supply system (UPS-Uninterruptable Power Supply) is used for the station control room. The UPS is not included in the supply scope of SCS. UPS supplies power to system at voltages of 230VAG, 50Hz. If the electrical equipment requires other levels of power, such as 24VDG, the supplier shall provide by itself. In case of external power failure, the UPS can backup power supply for normal working time of 2 hours for main equipment in the station control room, and backup 2 hours normal working time for computer systems and instrumentation. The UPS for SCS adopts hot backup redundant configuration. The power distribution as required for SCS and power supply for site instrument shall be provided by the SCS supplier. The DC power supply used should be in redundancy configuration. The 24VDC power supply circuits shall be installed separately for on-site transmitter, passive contact input, contact output, and equipped with circuit breaker. 230VAC power supply circuit breaker should be used with type of double-knife (phase, in) circuit breaker. 24VDC power supply circuit should be used with double-knife circuit breaker. The system supplier shall bring up precise requirements for power load within 30 days after signing the contract. UPS input and output voltage and current, operating status, battery low voltage alarm, fault alarm and other parameters shall be transmitted to SCS via RS232 or RS485 serial communication port. 4.4.6 GroundingBASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 22 OF 47 The in-station electrical grounding, automatic control, and telecommunication protection grounding and work grounding, anti-lightning and anti-static grounding share the same grounding device. Typically, the work and protection of automatic control equipment share the same grounding, of which grounding resistance is not greater than 40. ‘System supplier should provide detailed grounding requirements and data for the system. Regardless of whether the grounding requirements for the system provided is higher or lower than the above conditions, the system supplier should provide truthful data as basis for detailed design of the design unit. 4.4.7 Lightning ‘SCS should set the perfect lightning and surge protection measures at interface locations where Possible high voltage generated from lightning (direct lightning flash, induction lightning flash) can be imported into the computer system The equipment for lightning and surge protection should be imported products with good application performances on domestic large oil and gas project, and the original imported products’ inspection report issued by state-level anti-ightning test center. The basic requirements for power surge protector are as follows: Single channel shall be adopted; Built-in overcurrent and overheating fuse protection; Heat trip protection devices when degraded; Comply with the UL 1449 safety certification, or have certificate of conformity for test report issued by lightning protection product test center authorized by state. The surge protectors should be installed in a standard 35mm DIN rail, of which grounding method is to connect to the rail through its metal base, and realize Teliable grounding through rail. External connection conductor grounding should not be used. The performance parameters should conform to the requirements in the following table. The requirements for performance parameters for signal surge protector are as listed in the following table. 2av 1 24V digital | Thermal S485 | analog | resistance _and Pulse signals signal | signal 1 0) thermocouple UD signals cavaoy_|4 Ay| Nominal aischarge current | eq (in) (8/20us) »BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 23 OF 47 Voltage rotection < tevelp) a sttoviso0 | <1tovi600 | <1 10/600 P 6oviLin | 6OViLin |\)" “(ine -|V (Line -|V(ine - Test Waveform: 6k] @ Line }@ Line) ine 7 Line-| Line / Line-| Line/ Line - 1.2G0us, SHA, 8204 oF trosnd) ground) ground) | ground) | ground) Higher than | Higher than the loop the loop working | working current current Load current capability When the digital output in process control system is relay output, due to greater current, the load current capability for surge protector should be higher than the loop working current. 4.4.8 Working interface SCS will be connected with the communication system, each station's measurement instrument, actuators, and other monitoring systems (eg power transformation and distribution monitor system, inverter, UPS and other detection systems), intelligent instruments (such as flow meter computers, etc.) for data exchange. 4.4.8.1 Telecommunication systems; ‘SCS supplier shall provide communication interface and cable for communication system optical termination device terminal equipment. 4.4.8.2 Field instrumentation and equipment The field instruments, actuator and SCS shall be connected by cable. The data exchange between SCS and other monitoring systems (such as the power transformation and distribution system, inverter, UPS, and other detection and control systems) and intelligent instruments are in form of serial communication. Bordered by physical interfaces of serial communication The said terminal blocks (cabinet), serial communication interface and communication protocols conversion programs are provided by the SCADA system supplier. The supplier should provide | / © module channel allocation of PLC to the user and design unit on basis of /O datasheet, and be responsible for wiring from each channel to the terminal block The low voltage systems for all stations are used with 230V system to maintain consistency with the local system in Iraq. The power distribution for SCS is provided by the SCS system suppliers. The power distribution and power supply for field instrument is the responsibilty of SCS supplier and the power devices are supplied by the station control supplier, among which the fieldBASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 24 OF 47 instruments include (but not limited to) the transmitter, connection point, drive (command) and communication interfaces (devices). Usually the power voltage grade should be 24VDC. ‘The supplier should bring up the requirements for system or devices associated with SCS, e.g. requirements for communications, power supaly capacity and quality, control room layout and grounding system. The power supply for all devices in SCS shell be connected with anti-lightning power socket. The anti-lightning power socket is provided by SCS supplier. 4.5 Panel, box, cabinet The provided cabinets shall include the following as minimum: > Power distribution cabinet; > System cabinets; Marshalling cabinets; Remote I/O station cabinets in the local equipment room; > InstrumenvElectrical interface and interposing Relay cabinets in the MCC or electrical substation; > Other cabinets as requirement such as server cabinets. The size of cabinets shall be 800mm(width)x800mm(depth)x2100mm(height, with 100mm support). The cabinets shall be painted with standard RAL7036 (colour). Protection of cabinet shall be of IP-41 as minimum. The cabinets shall be made of steel sheet with a minimum thickness of 3 mm for internal plates. Cabinets shall be self-standing, standard RITTAL type or equivalent. Wiring relevant to all /O signals shall be terminated to suitable marshalling cabinets. The interconnecting cables (completed of pre-wired connectors at both end) between marshalling cabinets and VO cards, and between SCS panel and /O cards, shall be included in the supply. All electrical devices, connection circuits, cabling and installation practices shall be complied with the requirements of the relevant statutory authorities. For SCS cabinets, wiring shall be arranged in such a way which will not interfere with maintenance operations (i.e. card removal or insertion, etc.). > The cabinets shall be double access and provided with front and rear access doors, opening on hinges and with handles for easy access to all internal devices.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 25 OF 47 > One key with standard profile shall be used for all locking doors. Each cabinet shall be supplied with two keys. Each cabinet shall be provided with internal lighting, complete with. door switch and outlet socket. > Cabinets shall be of painted sheet ste! > Marshalling and equipment cabinets shall also have bottom entry/clamping. (But will be supported on sub-floor mounted supports stools’ supplied by others). > Marshalling cabinets shall provide terminations and cross connection facilities for all the plant instrumentation systems. > Multi-pair cables will include approximately 30% unused pairs which shall be connected in ‘sequence to spare terminals along with the used pairs. in addition approx. other 10% spare terminals shall also be included for future use. All spares shall be grounded. Incoming cables shall be connected to ‘knife-fuse switch’ type terminals. > Connections lo the SCS processors hardware from termination cards shall be by seller's system cables (cord sets), » Cabinets shall be fitted with ground lugs so that all metallic enclosures can be connected to AC safety ground for personnel protection. Isolated ground bars shall also be provided ‘where required to meet Vendor's recommended grounding practices. > Cabinets shall be provided with hook-eyes to allow easy transport and handling. insulating plate, bushing and anchor bolts shall be provided. > Power supply units shall have on the cabinet front a lamp indicating power supply failure, a voltage free contact with the same function shall be provided for remote monitoring (system alarm). > For AVAO/DI: blade terminal without fuse—SPD—terminal with fuse and LED—module A\ with terminal board > For DO: blade terminal with fuse—Relay—terminal without fuse—module with terminal board > Other signal type similar to the above > Panel internal wiring shall be used cable Lug. > Cabinet main cable duct size shall be minimum 100Hx100W mm and other duct size can be 100Hx50W mm for sufficient space for cable maintenance.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 26 OF 47 4.6 System setting requirements SCS automatically completes specific operations as per the on/off command, pressure/fiow settings. Either switches to control on each single device. ‘SCS consists mainly of the following components: Process Control system sis > Operator Workstation > Network equipment > Data communications equipment > SCS Software The time marker for each kind of data for SCS shall be based on the computer clock where the data source is located. In the event of communication failure, the local computer can store the data in this period of time in memory until the trouble is eliminated, and then sends them all to the Control Center and supplement the data in time sequence. GPS clock is provided by SCADA system contractor in complete set. The time synchronization of PLC and SIS should be achieved by means of GPS receiver provided with SCADA, The control circuit and protection parking control loop for all SIS should be excited under normal state and non-excited under abnormal state, i.e. non-exciting parking. Vendor is also responsible to upgrade the existing system software to meet project AX requirement during executing the tie-in work to the existing system. All software licence shall be genuine and on end user name. 4.6.1 Process station automatic control system Under normal circumstances, the operation of the Pump unit is controlled by PLC in Pump control unit, and the Control Center issues corresponding regulation instructions through SCS; ‘when the operating unit fails, the Control Center issues corresponding instruction on shutdown and startup of backup units to meet the oil transmission requirements. The station process control unit of process station can automatically monitor, control and protect the technology process of the whole station, and perform monitor and sequential starl/stop under operating state of pump unit. The task of SCS is to monitor and control the whole process station, to ensure their safety and reliable operation, while providing the necessary information to the Control Center, and receiving the commands issued by the Control Center (when controlled by the Control Center), Main functions of process station (not limited to): = Monitor the operating state of process equipment for this station;BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 27 OF 47 = Upload the selected data and alarm information to the Control Center; Accept and execute the control command of the Control Center, and perform control and adjust the settings end can work independently; = Oil transmission process control, including the pressure or flow control; - Collect and process variable data for technology and auxiliary systems, and provide real time display, alarm, storage, recording and printing; Provide operating status, process, dynamic data picture or graphic display, alarm, storage, recording and printing; - Exchange information with inteligent instrument of third party via communication interface: ~ Station safety interlock protection control; = Make fault self-diagnosis, and transfer information to the control center; Monitor safety conditions of the process station and the station control room e.g. fire, combustible gases; = Monitor the status of power Wansformation and distribution system of each station, = Data communications management; = Make fault self-diagnosis, and then transfer the information to the Control Center. 4.6.2 Instrument measurement and regulation systems Set the pressure control system at the station, as per the requirements for pipeline operation. The regulated parameters for pressure control system are the revolution speed of pump or opening of adjustment valve of pump outlet. To prevent overiow pressure of pump inlet and avoid overhigh pressure of pump outlet, the pump inlet pressure control system and the outbound station pressure control system form into a set of automatic selective control system, The pressure setting can be given either by the Control Center or the SCS. The pump rotation speed is regulated by SCS in accordance with the output of pressure control system. Install temperature measurement, pressure testing, flow testing, combustible gas detection, flame detection and other instruments on process pipeline of each process station, used for controlling technology process and monitoring of safety on station. All information on measurement instruments requiring remote signal shall be transmitted to SCS, and uploaded to the Control Center via SCS, and used as important parameters for operation of SCADA system For details on setting of measurement and control system, refer to the process piping and instrumentation process diagram of each process station. 4.8.3 other control system Pump control unit (UCS) shall be provided with pump unit. The UCS will be interconnected to ‘SCS via Ethemet with Modubus TCP/IP communication protocol and the physical interface shall be RJ45 redundant,BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 28 OF 47 Metering system in Halfaya pump station will be interconnected to SCS via Ethernet with Modubus TCP/IP communication protocol and the physical interface shall be RJ45 redundant. 4.6.4SCS 10 The estimated | / O statistics (the spare shall be 40%) are as shown in IO List. Notes: The /O statistics is estimated. It shall be confirmed according to final information of Pump station contractor. 4.7 SCS Configuration SCS js the remote monitoring station of SCADA system, as well as the basis for ensuring normal operation of the SCADA system. SCS jis installed in the station control room in the process stations. Each set of SCS is installed with PLC for controlling crude oil process equipment, and respectively installed with independent SIS as emergency cutoff system of crude oil process station. The fire control system of initial station is installed with independent control system, and connected into relatively independent I/O templates. SIS is used with independent control unit to deal with emergency situations and ensure personal and equipment safety, SIS meets IEC61508, and the safety integrity level is designed as per SIL2. The SIS actuator also has its corresponding safety level certificate ‘SCS mainly consists of process control units, operator workstations, data communication server and interfaces. The process control unit is used with highly reliable PLC. The operator ‘workstation used as human-machine interface is recommended to be PC machine. PLC consists mainly of processor, JO system, network communication system, power supply, and installation accessories. The SIS of each station uses relatively independent control devices, to connect these systems in form of network. To ensure reliability of the system, the PLC processors, /O network and LAN are designed as hot standby redundancy. The communication server is used as the communication center for SCS, responsible for completing tasks such as communication protocol conversion, communication management, data processing and storage and communication and communication in the control center. 4.7.4 Hardware for process control system The template selected for use by PLC should be hot plug type template, and each piece of ‘template should have self-diagnostic function. The PLC processor should be able to accept and process subroutines copied from other stations, and transplant some functional routines of the very station to the stations requiring such routine, to reduce the workload of repeated programming. The version of processor should be upgraded in form of FLASH, instead of replacing processor. The PLC system should be able to meet the requirements for hot standby configuration. The hardware address allocation assignment setting and /O quantification are completed by configuration.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 29 OF 47 4.7.1.1 Processor module PLC processor should be 32bit CPU or more based. The Control loop processing time, which includes the input scan rate, the loop processing at microprocessor level and the output scan rate, shall not be more than 0.5 seconds (throughput time). When the power fails and is restored, the processor should automatically restart instead of manual intervention. Processor should use hot standby redundancy configuration, the hot standby redundancy processor can switch automatically, and equipped with communications interfaces, network interfaces and programming interfaces satisfying performances and quantity in this system. The memory should be Lithium battery supported CMOS (storage time less than six months) or other type of memory unsusceptible to failure. Memory should be able to be partitioned by software, respectively used in storage control programs and data sheet. Memory should have considerable margins, of which extension should be modular, instead of replacing the original equipment and change procedures. The PLC processor memory should not be smaller than 8M. (The extended memory card is not included). Dual machine hot standby system with dual-rack dual CPU configuration is used. The two racks should have identical configurations e.g. power supply, CPU and communication modules, to form into host PLC and backup machine PLC, and the two systems realize hot standby communication through dedicated hot standby optical fibers. In case of unexpected failure with the host PLC, the backup machine PLC automatically switches to the main machine and the dual-machine hot standby system can ensure realization of smooth and seamless switching between main and standby machines. The switching is transparent for the system so that the process monitoring by system will not be interrupted. The switching time is not longer than 50ms. The station-controlled PLC can transmit the additional millisecond time value for analog and switch to the host computer for use in analysis. No processor shall be loaded at more than 60% of its processing capacity (including all kinds of load index about PLC processing capacity).System memories and clocks shall be protected against power loss by batteries sufficient to maintain these items for at least 72 hours. The Vendor shall specify with the bid the maximum length between the communication network and the remote units. 4.7.1.21/ 0 module The PLC input module and output modules should have self-diagnostic functions, and should have function of protection against power surges. I/O module input and output ends should have automatic diagnosis functions identifying short circuit or open circuit connection with field instrument or device, and generate alarms. The output module should be the safety output value kept or placed at preset level for failure output. The I/O module should be multi-channel, but the number of channels should not exceed the following requirements: = 16-channel analog input module;BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 30 OF 47 = 16-channel analog output module; - 32-channel digital input module: = 16-channel digital output module; = Communication module uses only 1 communication port. (1) Analog input module AND converter at least 16 bits, common mode rejection ratio greater than 804B, inputs isolated from each other. Analog input template should be set with alarm limit. The 24V DC power supply to site two-wire system transmitter is provided by PLC system. Optional input signal 4 ~ 20mADC or 1 ~ SVDC, optional active or passive input. The scan rate for analogue inputs, ‘which are part of control loops, shall not be more than 0.25 seconds. All analogue input cards shall have an individual power regulator to provide isolated power for transmitters.As a standard, all analogue input points shall be individually either optically or galvanic isolated. The maximum resistance and the maximum loop length for the analogue inputs shall be clearly stated. The system shall provide out-of-calibrated-range alarms for all analogue inputs. Failure on input cards shall be indicated with an error status on each card and an additional error indication on a system status display on Control Room. Each analog input card shall be individually fused and equipped with blown fuse LED indication. Each input point shall be individually protected against over-current, analog input card circuits should be isolated channel-to-channel and channel-to- ground, The analogue input modules shall accept transmitters working with HART protocol if necessary (confirmed in detail design), provided that the communication between them and the PLC. (2) Analog output module The D/A converter is at least 12 bits, output 4 ~ 20mADC or 1 ~ SVDC signal, with output isolation, short circuit protection and circuit alarm functions. The scan rate (output update) for analogue outputs, which are part of control loops, shall not be more than 0.25 seconds. All analogue output cards shall have an individual power regulator to provide isolated power for loop outputs. As a standard, all analogue output points shall be individually either optically or galvanic isolated. The control system shall perform an integrity check on the entire output loop. The system shall provide out-of-calibrated-range alarms for all outputs. All calibration constants of the output cards shall be handled using software without the need for any potentiometers on the output cards. The maximum resistance and the maximum loop length for the analogue outputs shall be clearly stated. Analogue output cards shall be capable of driving minimum 700 ohm loop resistance. Analogue output cards shall have the function of direct output and reverse output signals Isignals.Failure on output cards shall be indicated with an error status on each card and an additional error indication on a system status display on Control Room. Each analog output card shall be individually fused and equipped with blown fuse LED indication. Each output point shall be individually protected against over-current. analog output card circuits should be isolated channel-to-chennel and channel-to-ground.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 31 OF 47 (3) Digital Inputs The system shall accommodate both normally open and normally close contacts. The digital input modules shall include circuitry to ensure that any “chatter” or "bounce" encountered during contact closure does not initiate an erroneous alarm. The input contacts, generally, will be free of voltage and ungrounded; it shalll be powered by the digital input modules using 24 V DC. The scan rate for digital inputs, which are part of sequential control loops, shall not be more than 0.25 seconds. The scan rate for digital inputs not involved in sequential control loops shall not be more than 0.5 seconds. As standard, all digital input points shall be individually either optically or galvanic isolated. Each digital input card shall be individually fused and equipped with blown fuse LED indication Each input point shall be individually protected against over-current. Digital input card circuits shall be isolated channel-to-channel and channel-to-ground. Each digital input card can not have more than 32 inputs.(4) Digital Outputs Solid state of digital outputs shall be 24 VDC and be capable providing at least 300 mA to the external coil The sean rate (output update) for digital outputs, which are part of sequential control loops, shall not be more than 0.25 seconds. The scan rate (output update) for digital outputs not involved in sequential control loops, shall not be more than 0.5 seconds. Each digital output card shall be protection for the switching Each channel of digital outputs cards shall be equipped with interposing relay. Relays shall be complied with the following requirements (as minimum): Maintained latching contact Normally open/normally closed outputs selectable fail-safe position for each channel shall required Relays shall be suitable for inductive field devices with 24 VDC coil, like solenoid valves. Relay contacts shall be SPDT available free of voltage, and each contact set shall be totally independent of any other contact set. Relay contact rating shall be 230V AC BA. Relays shall be plug-in type with socket, hermetically sealed with heavy silver contact. Mercury switches are not acceptable (4) Communication module The module should be able to complete the conversion between different communication protocols. The module has the capacity for communication with third-party intelligent device, or at least support the BASIC or C language programming. Communication interfaces should be RS-232C or RS-485 serial communication interfaces, of which communication rate can be optional within the range of 300 ~ 19200bits, and the communication protocol should be MODBUS RTU or other.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 32 OF 47 (8) Pulse input module The pulse input module accepts the pulse signals of transient flow from site flow meter. The pulse input module should be able to receive multi-channel pulse signals, allowing input ‘frequency and voltage to meet the requirements of flow meter. (6) Network Network connection is used between PLC's CPU rack and PLC's VO rack. The network should comply with IEC standards, and the network rate should not vary with change of node and length of network. Communication rate not lower than 5M. Communication link between PLC's CPU and upper level PC should be made with redundant International Standard Industrial Ethernet. 4.7.1.3 Redundant Requirement Redundancy capability shall be provided. Where redundancy is required, no additional identification character shall be needed to identify primary/secondary cards. The failure of one card shall be reported with clear alarm identification. No additional external wiring shall be necessary for such a purpose. Processors and CPU, power modules, and communication modules shall be 1:1 redundant with hot back up configuration. For process control loops, I/O modules shall be 1:1 redundant with hot back up configuration. The bus connected CPU, I/O modules, power modules and communication modules shall be 4:1 redundant. Operator stations shall be duplicated to split plant operations between the stations, but either station can take full control. Data communications bus shall be duplicated with an adequate methodology of redundancy. Power feeders and power supply units shall be redundant. The power supply unit will be either in hot back up or with “n+2" configurations. 4.7.2 Hardware for SIS The template selected for use by PLC should be hot plug type template, and each piece of template should have self-diagnostic function. The PLC processor should be able to accept and process subroutines copied from other stations, and transplant some functional routines of the very station to the stations requiring such routine, to reduce the workload of repeated programming. The version of processor should be upgraded in form of FLASH, instead of replacing processor. The PLC system should be able to meet the requirements for hot standby configuration. The hardware address allocation assignment setting and /O quantification are completed by configuration. 4.7.2.1 Processor module PLC processor should be 32bit CPU or more based. 100MHz, fail-safe and self-testing, composed by Triple Modular Redundant (TMR) or Quadruple Modular Redundant (QMR)BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 33 OF 47 processor (active and standby CPU) with suitable components and functions adequate to Ad achieve a high reliability and high integrity. CPU shall employ 2 out of 3 or 2 out of 4 voting. The failure of one CPU processor shall resutt in a degraded availability, fail-safe mode of operation, maintaining at the maximum possible extent the system's safety performance. ‘The CPU shall continuously scan the control program, along with the status of all inputs and execute specified command to appropriate outputs. Each CPU shall be capable of scanning the VO and executing specified application program a minimum 4 times per second (overall throughput time). When the power fails and is restored, the processor should automatically restart instead of manual intervention. Processor should use hot standby redundancy configuration, the hot standby redundancy processor can switch automatically, and equipped ‘with communications interfaces, network interfaces and programming interfaces satisfying performances and quantity in this system. Any failure in the communication system shall not affect control unit functions. The CPU shall continuously monitor its own status and indicate both normal operation and error via LED status indicators on each CPU faceplate. The monitoring watchdog for the CPU processors should be a separate part of the system that is dedicated to this function only. The memory should be Lithium battery supported CMOS (storage time less than six months) or other type of memory unsusceptible to failure. Memory should be able to be partitioned by software, respectively used in storage control programs and data sheet. Memory should have considerable margins, of which extension should be modular, instead of replacing the original equipment and change procedures. The PLC processor memory should not be smaller than 4M. (The extended memory card is not included). The station-controlled PLC can transmit the additional millisecond time value for analog and switch to the host computer for use in analysis. Each processor shall not be loaded at more than 60% of its processing capacity.(including all kinds of load index about SIS processing capacity) The Vendor shall specify with the bid the maximum length between the communication network and the remote units. 4.7.2.2] O module The Processor cards and relevant I/O cards shall be capable of being removed and inserted into the SIS system rack under power, without affecting any other cards in the rack. It shall be possible to replace any faulty system module without degrading the safety of the system. The transition to the healthy module shall be bumpless (ie. no loss of control). No operator action shall be required to restore the system to normal operation other than simple mechanical replacement of modules. It shall be possible to remove the I/O modules and replace them without disconnecting the field wiring from the I/O module termination assembly.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 34 OF 47 | 1 O module should have self-diagnostic functions, and should have function of protection against power surges. VO module input and output ends should have automatic diagnosis functions identifying short circuit or open circuit connection with field instrument or device, and generate alarms. The output module should be the safety output value kept or placed at preset level for failure output. The VO module should be multi-channel, but the number of channels should not exceed the following requirements: - 46-channel analog input module; = 16-channel analog output module; ~ 32-channel digital input module; = 16-channel digital output module: = Communication module uses only 1 communication port. — The /O cards shall have fault diagnostics and signalization (local and remote on DCS/PLC VDU's). The digital input and digital output signals from or to the electrical equipments powered by 230V or above such as pumps, compressors and bumers’ status or trip/stop commands, shall be equipped with relays for isolation, = Channel isolation shall be applied to all /O modules. = JO cards shall be of dual or triple redundancy it's vendor’s responsibility to ensure the integrated system's voting system integrity. (1) Analog input module AID converter at least 16 bits, common mode rejection ratio greater than 804B, inputs isolated from each other. Analog input template should be set with alarm limit. The 24V DC power supply to site two-wire system transmitter is provided by PLC system. Optional input signal 4 ~ 20MADC or 1 ~ SVDC, optional active or passive input. The scan rate for analogue inputs, ‘which are part of control loops, shall not be more than 0.25 seconds. All analogue input cards shall have an individual power regulator to provide isolated power for transmitters.As a standard, all analogue input points shall be individually either optically or galvanic isolated. The maximum resistance and the maximum loop length for the analogue inputs shall be clearly stated. The system shall provide out-of-calibrated-range alarms for all analogue inputs. Failure on input cards shall be indicated with an error status on each card and an additional error indication on a system status display on Control Room. Each analog input card shall be individually fused and equipped with blown fuse LED indication. Each input point shall be individually protected against over-current. analog input card circuits should be isolated channel-to-channel and channel-to- ground. Each analogue input channel shall be testable type (self-testing). (2) Analog output module All 4~20mA analogue output cards shall have an individual DA converter for each analogue output All analogue output cards shall have an individual power regulator to provide isolated power for loop outputs. As standard, all analogue output points, when used, shall be individually either optically or galvanic isolated. The SIS shall perform an integrity check on the entire output loop.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 35 OF 47 The system shall provide out-of-calibrated-range indication for all analogue outputs. The maximum resistance and the maximum loop length for the analogue outputs shall be clearly stated. Each analogue output channel shall be testable type (self-testing). Each analog output card shall be individually fused and equipped with blown fuse LED indication. Each output point shall be individually protected against over-current. analog output card circuits should be isolated channel-to-chennel and channel-to-ground. (3) Digital Inputs The system shall accommodate both normally open and normally close contacts. The digital input modules shall include circuitry to ensure that any “chatter” or “bounce” encountered during contact closure does not initiate an erroneous interlock or alarm. The input contacts, generally, will be free of voltage and ungrounded; they shall be powered by the digital input cards using 24 V DC. As standard, all digital inputs shall be individually either optically or galvanic isolated. Each input peint shall be individually protected against over- current. Each digital input card shall be individually fused and equipped with blown fuse LED indication. All digital process input circuits shall be designed so that accidental connection of up to 300 VACIDC for an unlimited period of time shall not cause any damage other than to the input module to which it is connected. Digital input card circuits shall be isolated channel-to-channel and channel-to-ground. Each digital input channel shall be testable type (self-testing) (4) Digital Outputs The output shall comply, but not be limited to, with the following requirements: Maintained powered output for normal condition Output shall be suitable for field devices with 24 VDC coil, like solenoid valves. Each output shall be individually protected against over-current Each digital output card shall be individually fused and equipped with blown fuse LED indication. All digital process output circuits shall be designed so that accidental connection of up to 300 VACIDC for an unlimited period of time shall not cause any damage other than to the output ‘module to which itis connected. Digital output card circuits shall be isolated channel-to-channel and channel-to-ground. Output cards shall normally be solid state type, able to drive field SOV's. Solid state outputs shall be 24 volts DC and be capable providing at least 17W to 20W to the external coil. Each output shall be independent from other outputs. Each digital output channel shall be testable type (self-testing). Interposing relay shall be used and installed for each digital output channel. The system shall perform an integrity check on the entire output loop. Digital output circuits shall be provided with protection for the switching of inductive loads. (5) Communication moduleBASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 36 OF 47 The module should be able to complete the conversion between different communication protocols. The module has the capacity for communication with third-party intelligent device, or at least support the BASIC or C language programming. Communication interfaces should be RS-232C or RS-485 serial communication interfaces, of which communication rate can be optional within the range of 300 ~ 19200bit/s, and the communication protocol should be MODBUS RTU or other. (6) Network Network connection is used between SIS's CPU rack and SIS's I/O rack. The network should comply with IEC standards, and the network rate should not vary with change of node and length of network. Communication rate not lower than 5M. Communication link between PLC's ‘CPU and upper level PC should be made with redundant International Standard Industrial Ethernet. 4.7.2.3 Redundant Requirement Redundancy capability shall be provided. Where redundancy is required, no additional identification character shall be needed to identify primary/secondary cards. The failure of onc card shall be reported with clear alarm identification. No additional external wiring shall be necessary for such a purpose. ‘Ay Processors and CPU shall be of active and standby TMR or QMR. 110 modules shall be of dual or triple redundancy. Power modules and communication modules shall be 1:1 redundant with hot back up configuration Power feeders and power supply units shall be redundant. The power supply unit will be either in hot back up or with “n#2" configurations. The following requirements shall be applied to those parts of the system supplied in a redundant configuration. Imposed switchovers shall not have effect on system operation Redundant equipment shall be continuously monitored for error diagnostics ‘Automatic switchover to back up equipment shall take place on detection of failure of the primary equipment. The switchovers shall not have effect on system operation. Failure of back up equipment shall be alarmed as a system alarm. Current operating parameters shall be continuously updated and synchronized on backup equipment. ‘Switchback to repaired equipment shall be by manual command. There shall be no single failure point that could affect more than one channel. Failure of any single component supplied within the system shall not cause a shutdown action, and during such a failure, the system shall remain on-line and shall maintain the process safety protection Additionally, the system shall accommodate a means for alarming the fault 4.7.24 Auxiliary OperationBASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 37 OF 47 ‘Auxiliary operation device shall be connected to system modules via hard wiring, it is important to remind Vendor that the required /O points, relevant cables and power shall be considered by Vendor additionally Vendor shall furnish all pushbuttons and switches completed with LED individual status indication to show if the pushbuttons and switches are actuated. Pushbuttons and switches shall be suitable for industrial application, heavy-duty, and dust-tight 50% of pushbuttons and switches shall be reserved for spare use. 4.7.3 Network equipment The network device mainly consists of network switch, router, and connecting cables and accessories. The network device adopts hot standby redundant structure. SCS internally forms into redundant industrial Ethernet 100MB Ethemet TCP / IP via connection with network devices. Each set of SCS is installed with 2 routers in accordance with requirements for configuration of SCS. Each router is required to configure 2 piece of 4-port R45 Ethemet card. The induetrial Ethernet ued for SCS chould be intemationally renowned brand of induetrial Ethernet switches suitable for industrial environment application and featuring technologically mature high performance and high reliability. The main indexes are as follows: = SCS switches are generally provided with 24 ports, recommended use of modular design, and the port density for each module is not greater than 4 ports. All switch ports should support single, multi-mode optical fiber interfaces SC/LC or RJ45 electrical interface. - Supports standard TCP / IP protocol, satisfies relevant industry certification, including, for example: safety certificate for industrial control equipment: CUL 508, certification for use in hazardous locations: cUL1604 Class1 Div2 certification. CUL 60950 (E168643) certification. Rack mounting or rail mounting, supporting redundant power supply mode (24VDC), no-fan cooling, mean time between failures (MTBF) greater than 30 years; — Application software should be able to support the network management functions. 4.1.4 Operator Workstation Operator workstation is the human machine interface between operator and SCS, and the site operator can learn more about the operating conditions via the interface, and can issue the operate control command so as to complete the monitoring and management of the station in question. The operator workstation should at least have functions such as the data acquisition and processing, real-time and historical data management, dynamic process, and other graphic displays, alarm / event management, report generation and printing. Under control mode of the Control Center, the operator station for closing SCS should not have any influence on signal transmission and operation of system. Minimum hardware configuration requirements > Intel ® Xeon ® (Quad-Core CPU) 3.3 GHz, > 16 GB RAM DDR3 mini expendable to 64 GB; 1333MHzBASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 38 OF 47 > 2.Gb graphics memory expandable to 4 Gb; Utilize the Windows 7 or later operating system; S00GB (or larger) of Hard Disk storage for Historical Data, storing programs etc. 7200 RPM ; > Soundcard and built-in speakers > DVD-RW Archiving device for backup of system and historical data, etc. Device shall be of the latest manufacture product and highest operating speed available at the time and be readily upgradeable > Power fail/auto restart > Dual LCD monitors - Minimum 27-inch colour IPS display, in a suitable enclosure for ‘mounting on the control console > Keyboards - Consynventional alphanumeric keyboards. > Trackball or mouse - Consoles shall have an alternate input device besides the keyboard for operator issued commands. > Redundant Network cards 4.1.5 Printer ‘SCS equipped with 1 printer. A3 format laser printer is used for printing statement and reports. 4.7.6 Software The following software shall be configured as a minimum to complete the SCS tasks: > Operator workstation operating system software. The software should use the standard English Windows running stably and of the latest version. > Server operating system software and application software > PLC programming software Programming software should support the IEC61131-3 in all 5 languages, such as step ladder diagram, and function block, and can use multi-level subroutine calls, and have functions of logic operations, mathematical operations and string operations, complete the configuration of input-output signals by configuration mode, have ability of configuring multiple complex control systems, and multiple PID computation modules and other commonly used funciion blocks. In short, PLC programming software should be software featuring powerful function, flexible and convenient use and user- friendly. The software should run on standard Chinese Windows platform. The software can be installed in the notebook computer as @ programmer, or installed in the operator ‘workstation, both of which can complete programming and configuration of PLC. > PLC user application software Execution program prepared by the system supplier. v HMI configuration software. HMI is the dialog window between operator and the station control computer system, which provide information for relevant persons and receiveBASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 39 OF 47 operation commands by relevant persons. The software should run on standard Chinese Windows platform. It should have powerful functions of graphic editing and display, and capability in supporting 3D figure editing and display. Support multi-window screen display and dynamic menu display. HMI software should at least have function modules e.g. communication management, database management, dynamic and static image editor, text editor, online help, real-time editing trend display, historical trend edit display, alarm ‘management, event management, report management and printing, ‘System supplier uses the software as development tools, configure and prepare various display, operation and online help menus as required for operation and running, and provide convenient, intuitive, flexible, friendly dialog window to the operators, ‘SCS Configuration of MOEP is as listed in the following table No. | Station Name __| Equipment Quantity Containing: Redundant CPU, Process Control Unit ‘Aset Redundant power supply, /O. system etc. Containing: Redundant CPU, sis ‘set Redundant power supply, /O. system etc. Operator Workstation 2set Switch 2set 1 | Xpump Router, 2set Station Laser Printer (A3) Aset Cabinet Aset configured as | / O statistics Operation console ‘1Oset Containing chairs Containing: operating system software, application software, Software PLC programming software, HMI configuration software etc OPC server Aset 4 Containing: Redundant CPU, Process Control Unit set Redundant power supply, VO 2 XXX Station m etc. Containing: Redundant CPU, sis Aset Redundant power supply, VOBASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 40 OF 47 system etc. Operator Workstation 2set ‘Switch 2set Router 2set Laser Printer (A3) Aset Cabinet Aset configured as | / O statistics Operate console AWWset | Containing chairs Containing: operating system software, application software, ‘Software PLC programming software, HMI configuration software etc. 5.0 TEST AND INSPECTIONS This paragraph indicates the minimum tests to be applied to the SCS system and ‘Automation sub-system (integrated test). The purpose of this paragraph is to supply the guidelines for tests, in order to ensure that the SCS system meets all functional requirements. The tests will be developed in different phases based on the procedure approved by the Purchaser. These phases are defined hereinafter. 5.1 Basic Test A system register shall be prepared et the beginning of the test period to be used for annotating the successful completion of each test and any corrective action requested All components (including printed circuits, subassemblies and modules) shall be factory tested and documented in accordance with national or international standards. The component test shall comprise 100 % inspection as per manufacturer's quality control procedure. All electronic modules or components utilized within the system shall be functionally tested and burned-in by the Manufacturer prior to system assembly. 5.2 Pre-Testing In Factory The test is performed and their Vendor and not necessarily witnessed by the Purchaser. The Purchaser reserves the right to make inspections to ensure the application of the procedures listed below. This test shali be certified by exhaustive documentation, which, if approved, shall constitute the “PRE-TESTING CERTIFICATE”. The test listed below shall be considered an integral part of the pre-testing in factory Environmental test ‘Combined system test 24 hours system running test Tests required at FATBASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 41 OF 47 5.3 Factory Acceptance Test (FAT) ‘The intent of this test is to confirm that the system meets all user requirements. This test shall take place, prior to delivery, at the Vendor's factory. The FAT shall be done with the SCS system completely assembled, including the engineering workstations, printers, control processors, etc. The test is performed and their Vendor and witnessed by the Purchaser. Accommodation and transport costs for purchaser's attendance at the FAT will be covered by vendor. The FAT shall consist of loop by loop test of each input, ‘output, alarm, and control function for proper operation and display. Test shall be performed using simulated inputs and outputs. During the Factory Acceptance Test at Vendor's facility, simulated 1/0 granted by the Vendor for the test, shall be wired to the system and labelled with wire number and I/O identification prior to the test. Vendor shall furnish clerical and technical support, including troubleshooting equipment and Purchaser personnel's working space such as desk, telephone and fax. The SCS system may comprise some products not supplied by the SCS system Vendor. The products specified for integration shall not jeopardize the user requirements and shall be installed, wired and tested together with the SCS system, according to the quality standards required from Vendor for SCS system components. The FAT activities will be carried out based on the procedure approved by the Purchaser. The vendor shall supply to the Purchaser the FAT procedure and relevant planning at least 3 months before the starting date of the FAT in order to receive the approval for the same. The Vendor shall confirm to the Purchaser the starting date of the FAT at least one month prior to commence the test. Before to commencing the testing, reference contractual documentation (including specifications, normative and Codes) and supplied equipment shall be available, listed in a dedicated report and checked for completeness 5.3.1 FAT testing This paragraph defines the minimum tests to be carried out to test the SCS system. Visual inspection Cabinetry inspection AC and DC circuit test Diagnostics (operational) Control processors and workstations test (operational) ‘Communication links test Functional test Module replacement test Power supply failure and reset Redundancy test Application SW test with 100% /O simulated SER and SOE test 5.3.2 FaultsBASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 42 OF 47 ‘On FAT any component of the system found defective due to hardware shall be replaced and retested. If the defective component can be repaired, it shall be demonstrated subsequently during the FAT. Any operational defect due to the software configuration shall be corrected as soon as possitle within the FAT period and the validity of the correction demonstrated subsequently during the FAT. A minor fault found during the operational test will not hold up the testing. However, any fault or lack of design shall be solveditepaireditested before FAT completion. Any impact to the planning of the FAT due to any deviation from Purchaser requirements will be at Vendor's care and cost. The FAT approval by Purchaser will be a pre-condition for the authorization to delivery the system at site. 5.4 Site Acceptance Test (SAT) ‘On reaching the site, and after the system installation, the system shall be subjected to the SAT. The objective of the SAT is fo demonstrate the correctness of installation and that the system maintains all the requirements of the technical specifications after being installed in field and with system elements/cables connected within the SCS system. The SAT shall basically be the repetition of FAT procedures without field instruments check. Vendor and their Vendor's personnel employed for the test shall be appointed prior to the commencement of the same. Vendor and their Vendor shall be responsible for carrying out the test and solving any problems that may arise during the SAT, under the supervision of Purchaser appointees. Before starting the SAT, Vendor and their Vendor shall have identified and transported to site all the equipment and associated documentation. All spare parts deemed necessary for test performance shall be made available at site. No modification shall be made to system hardware andlor software without the prior agreement with the Purchaser. The SAT activities will be carried out based on the procedure submitted by the Vendor and approved by the Purchaser. The Vendor shall supply to the Purchaser the SAT procedure at least 2 months before the starting date of the SAT in order to receive the approval. During SAT, 100% V/O points shall be tested. 5.5 Operational Availability Test (System Commissioning) The operational availability test (OAT) shall be conducted after the SAT and upon completion of the plant loop check. The OAT shall be performed to demonstrate the availability of the system to carry out the functions required in this specification, once it is in operation with the plant running. The duration of the OAT will be the same of Plant ‘commissioning; it means that the system commissioning has to be considered as integral part of the commissioning relevant to the whole plant. The system availability shall be calculated considering the following definitions. Operating Time (OT): the period of time during which all the functions are operable or may be operated within the required response times. Operating time can be calculated starting from the overall test period and subtracting the inactive periods requested by Vendor and their Vendor and granted by Purchaser, utilized for making any modifications to methodologies and test equipment found necessary only during the performance of the test itself. Outot-service time (OST): the period of time during which at least one function is inoperable or cannot be operated within the required response times.BASIC DESIGN DOC. NO.: GEN-INT-SPC-0014 REV. B PAGE 43 OF 47 The formula utilized for calculating the availability is as follows: or OT + OST The Vendor shall demonstrate the following availability values for the system 99.99 %. If the demonstration fails, the Vendor shall be required to make the necessary ‘modifications and replace any part deemed inappropriate, at its complete expense, after that the demonstration shall be repeated. The OAT shall be conducted in compliance with the test plans and procedures previously submitted by Vendor and approved by the Purchaser, and implemented in accordance with the technical specifications, Availability = 6.0 ON SITE ASSISTANCE 6.1 On-Site Service In order to provide rapid response for services or part replacement, the Vendor shall maintain regional field service centres for the plant location. The location of these centres shall be indicated in the Vendor's proposal. Vendor shall guarantee support for all system hardware and firmware with spare parts and service for ten (10) years from the placement of order. 6.2 Training ‘Two training courses shall be provided Classroom training conducted prior the Plant pre-commissioning (On-the-job training conducted at site during the Plant pre-commissioning The training course will be organised for: Operators ‘System Engineers (including Software Design and System Configuration) Maintenance Engineers (including System Configuration) All work under the training programme shall be completed prior the commencement of the Plant Commissioning. An outline of the training course shall be submitted with the bid. 7.0 DOCUMENTATION All drawings and specifications shall be supplied with both paper printout and electronic files. Source files shall be implemented by means of AUTOCAD 2008 or later version and Microsoft Office suite. Where standard drawings and documentation, which cannot be produced with AUTOCAD, the souree files provided to the Purchaser shall be Acrobat. The form, the contents and relevant details and extent of description/representation of each document shall be subject to specific Purchaser approval. The vendor shall be responsible for supplying documentation revisions or changes due