attachment #3. technical specification for i _ c

Attachment #3

Technical Specification for I & C

AL-AMMARA 4 X 125MW 9E Gas Turbine Power Project, IRAQ

Revision A May 27 2012 Page 1 of 28 Issued for Bids

1 Control, Instrumentation and Communications 1.1 Introduction

This Section describes the technical requirements for the supply and installation of

control and instrumentation (C&I) for the gas turbine power plant. All C&I

equipment necessary to allow the safe and efficient operation of the power plant

will be supplied, installed, commissioned and tested.

A consistent control, instrumentation and data acquisition philosophy will be

applied throughout the power plant. The objective will be to standardize all

equipment, wherever possible, throughout the power plant in order to rationalize

operation, maintenance and reduce spare parts. In general, all equipment will be

of modern compact design and incorporating proven technology. C&I will be

provided such that no single failure can cause a forced outage of the power plant.

Triple modular redundant control systems (2 out of 3 voting) will be provided for all

plant safety critical control and protection systems.

.

1.2 Detailed Scope of Supply The extent of supply described will be the minimum necessary to achieve the

required objectives and will consist of, as a minimum, the following:

1) Complete control, protection and monitoring systems for the part of the

switchyard and balance of plant (BOP) equipment systems.

2) The Plant Control System, hereinafter referenced as DCS, will be compatible

with the GTs control system. The DCS will include all hardware, software,

operating licenses and associated equipment to provide integrated control and

monitoring of the switchyard and BOP equipment/systems.

3) Central Control Room equipment including operator desks, chairs, printers,

furniture, etc.

4) Emergency shut-down systems for safe plant running, shut-down and

protection in coordination with GE system.

5) Interfaces between the DCS and field equipment, packaged control systems,

instrumentation, actuators, motor control centers and all associated equipment

and devices.

6) Interfaces to the SCADA (load dispatch), station administration LAN, and GT

control systems.

7) All C&I and telecommunication cabling systems.



8) Instrumentation with accuracy suitable for tariff metering of fuel supplies and

electricity generated with display, trending and log reports of current and

cumulative values in the DCS.

9) Air and water emissions monitoring equipment

10) Local instrumentation, including pressure, temperature, level and flow gauges,

switches, transducers and transmitters, and all associated tapping points, pipe

work, valves, thermowells, local cubicles and racks.

11) Plant control system clock system.

12) Factory and Site testing and inspection

13) Site installation and commissioning

14) Operating and maintenance manuals, including as-built information.

15) Operator and maintenance staff training.

16) Spare parts (commissioning spares and two years operating spares)

17) Special tools and equipment

1.3 Objectives The main objectives of the C&I scheme are as follows:

1) To allow safe start-up, synchronizing, shut-down, emergency tripping,

control and monitoring of all major plant areas.

2) To allow the optimized and efficient use of all plant areas.

3) To maximize the availability of all plant.

4) To provide facilities for comprehensive monitoring, storage and presentation of

information concerning plant conditions.

5) To provide facilities for comprehensive testing and presentation of information

about system and plant performance.

6) To centralize plant monitoring and control facilities.

7) To reduce start-up and shut-down sequence times to a minimum whilst

minimizing mechanical and thermal stresses imposed on the plant.

8) To diagnose and troubleshoot plant operations

9) To include provisions for signals to interface with the National Dispatch Center

to facilitate the control and monitoring functions

1.4 Operational philosophy



The Plant Control System will consist of a set of microprocessor-based controllers

interconnected via a suitable communications network to allow the interchange of

data and control commands. The controllers will be capable of performing data

acquisition, logic, sequential and closed loop control utilizing real time data derived

from plant-mounted instrumentation Control commands will be issued by the Plant

Control System to actuators and final drives located on the plant. The controllers

will be functionally distributed and physically located in suitable plant areas,

particular care being taken to ensure that the equipment is suitable for the

proposed environment.

The control system configuration and associated real time data will be resident in

the system database that will be either distributed throughout the controllers or

resident in a server but accessible to all controllers and operator devices.

The network will also communicate with the Human Machine Interface (HMI) to

allow centralized monitoring and operator control of the plant from the Central

Control Room. This will be based on the use of visual display units (VDUs),

keyboards and other inputting devices.

The Plant Control System will be capable of providing control of individual drives,

of sequencing a functional group of drives to an optimized program of plant

operation, and of sequencing functional groups to provide full automatic plant

operation.

The Plant Control System will incorporate functions for use by the operating,

engineering and management staff including, but not limited to, data historian,

event and alarm handling, engineering and diagnostic tools, software configuration

tools, plant condition monitoring and performance monitoring.

Main items of plant such as fuel systems, water treatment plant, etc may be

supplied with purpose-designed systems for control, monitoring and protection.

Such systems will be designed to function independently of each other but will be

interfaced with the Plant Control System to allow integrated operation of the total

plant. The Plant Control System will be fully integrated with the control,

instrumentation and alarm equipment of the plant being provided, in order to



maximize automation of the power plant and minimize operator manning levels.

Either hardwired data or PLC compatible with the plant control system or

extension of the plant control system will support such a self controlled system.

The Plant Control System will incorporate a high level of availability and be

designed such that a single component failure will not result in the shutdown of

any plant or the reduction in plant load. This will be achieved by the equipment

and component design and the provision of dual redundant power supplies,

control processors and data communications equipment. Where it is applicable,

dual redundant input/output devices will also be provided. For all other plant safety

critical protection systems the redundancy provided will be appropriate to the

hazard being protected against. The Plant Control System will be supplemented

by local controls and instruments necessary for maintenance and commissioning

activities and for performance testing of the plant.

1.5 Control and monitoring of plant 1.5.1 Auxiliary plant

Unless otherwise specified, the manufacturers’ standard packages of control and

instrumentation will be supplied for all auxiliary plant, taking into consideration the

capability for interfacing with other systems’ protocols. Protection systems will be

independent of the control system for that plant. Equipment will be supplied to

interface all auxiliary plant with the Plant Control System to enable normal control

and supervision of the plant remotely from the CCR.

This will be supplemented with local controls, gauges and other devices to allow

local maintenance and testing activities where required. The control and

instrumentation systems for the common systems will be designed, manufactured

and installed to the same standards as that provided for the main plant.

Complete control, instrumentation and protection packages will be provided where

applicable for all systems provided under the contract. This will include but not be

limited to :

1) Water systems (the part of the plant not referring to GE Packaged Electrical



and Electronic Control Compartment (PEECC), e.g. service water and

demineralized water).

2) Compressed air systems (the part of the plant not referring to GE Packaged

Electrical and Electronic Control Compartment (PEECC), e.g. instrument and

service air).

3) Fire Detection and Protection systems (the part of the plant not referring to GE

Packaged Electrical and Electronic Control Compartment (PEECC).

4) Fuel systems (e.g. oil and gas fuel processing and storage systems)

5) Heating and ventilation systems (the part of the plant not referring to GE

Packaged Electrical and Electronic Control Compartment (PEECC)).

6) Black start/emergency diesel generator

7) Emission monitoring systems.

1.5.2 Electrical distribution system All incoming and outgoing feeders, main electrical switchboards, sub-boards and

feeds to main plant auxiliaries will be monitored and controlled at the CCR. The

status and data associated with the electrical distribution system will be displayed

in the CCR via the Plant Control System and will include all systems down to a

voltage level of 400 V.

The controls and indications will include, but not be limited to, the following :

1) Status of circuit breakers, isolators, bus couplers and earth switches on switchboards, including incoming feeders, feeds to main auxiliaries and feeds to sub-boards.

2) Alarms associated with circuit breakers, isolators, bus couplers, earth switches, transformers and electrical protection equipment.

3) Power (MW), reactive power (MVAr), current (A), frequency (Hz) and volt (kV) exported/imported from/to the site.

4) Frequency (Hz), current (A) and voltage (kV) for each main board

Suitable interfaces to the Plant Control System will be incorporated into the

switchgear.

Remote operation of selected switchgear will be by use of the Plant Control

System.



1.6 Plant control system 1.6.1 General system design

A fully integrated Plant Control System will be provided to monitor, control, display,

alarm and record selected physical and electrical parameters associated with all

plant areas.

Where appropriate, the system will have a functionally and geographically

distributed architecture utilizing a number of independent outstations or nodes

containing control processors, power supplies, data communications systems,

marshalling and termination facilities. The Outstations will be capable of

autonomous operation and perform data acquisition, calculation, open loop, and

closed-loop control functions. Communications between the nodes located in

different plant areas and the Operator's or Engineer's Workstations located in the

Central Control Room will be performed over suitably designed, redundant high-

speed serial data highways. The communications system will be designed to

perform at the speed necessary to ensure that all variables are updated and

control commands are issued without loss of system performance. The

communications system will include all control equipment, error detection

correction facilities and cabling. The Plant Control System will be designed to

ensure maximum availability by the inclusion of built-in redundancy for both

hardware and software. This will include duplicated control processors, data

highway and power supplies with automatic changeover to the standby unit upon

detection of a fault or failure of the operating unit. Where appropriate, I/O cards

will also be duplicated. The failure of any single element will not affect the

operation of any item of operating plant. In particular, the duplicated control

processors will be capable of fail over without change to plant status, sequence

status or control actions, at any stage of plant operation.

The Plant Control System will be designed to have an availability of 99.98 per cent

or better by the inclusion of built-in redundancy for both hardware and software.

This will include redundant control processors, data highways and power supplies

with automatic changeover to the standby unit upon detection of a fault or failure

of the operating unit. Redundancy is required for all input and output modules



used for safety critical control or protection functions. The failure of any single

element within the DCS will not affect the operation of any item of operating plant.

Comprehensive system diagnostics will be incorporated to assist in maintenance

and trouble-shooting. These will include memory, control processors, I/O cards,

data highway, and storage devices as a minimum.

The Plant Control System will be synchronized to the plant master clock system.

All necessary hardware for marshalling and terminating incoming and outgoing

plant cabling will be provided. This will include gland plates, glands, terminal

blocks, intrinsic safety barriers, isolation devices, labelling and wiring. Equipment

will be designed to operate in hazardous areas where necessary.

1.6.2 Operator’s facilities Operator’s workstations will be provided in the Central Control Room (CCR) to

allow monitoring, control and adjustment of plant conditions via high resolution

“Windows” style graphics displays. Each of the contractor’s furnished HMIs in the

CCR will be configured to monitor and control the BOP equipment/systems and

the Gas Turbine Generators. All visual display units (VDUs), keyboards, printers,

peripheral devices, and their associated control desks will be supplied. Each

operator workstation will be arranged for an operator to monitor and control each

GT, their auxiliaries, the common auxiliary plant and the electrical systems.

Two operator workstations and one Engineering Workstation will be furnished by

the contractor and located in the CCR. Each operator workstation will consist of at

least two high resolution 20” color VDUs, a single keyboard and a cursor

positioning device. The resolution of the VDUs will be 1280 x 1024 pixels or better.

The workstations will have the capability of being configured as either an

Operator’s workstation or an Engineer’s workstation through different passwords

and will be the main facility for monitoring and controlling the whole plant.

The CCR control desks will be of a coordinated rigid design and of robust

construction.



Surfaces suitable for mounting the VDUs, keyboards, telephones and all other

devices will be included in the design. The control desks will be ergonomically

arranged, suitable for operation by the minimum number of operators and

consistent with the plant operating philosophy. Access must be possible by more

than one operator in the event of special operations and for training purposes.

The control desks will include in their construction, facilities in the desk top and the

base of the units to route cables from VDUs, keyboards, telephones, etc. Lockable

drawer/storage space, leveling and fixing devices will be incorporated into the

design. A suitable number of fully adjustable swivel chairs will be provided (as a

guide, a minimum of one chair per workstation plus one additional chair will be

provided) together with all necessary CCR furniture.

One Engineer’s Workstations (EWS) will be provided for fault finding and software

programming for the DCS. All necessary hardware and software will be provided

to allow engineering staff to trace faults in the system and applications software, to

create control strategies, VDU screens and all other maintenance activities.

Software configuration and modification will be done off-line and with the capability

for testing before downloading to the control processors.

Engineer’s workstation

The EWS will consist of a high resolution VDU, keyboard, input device (e.g.

mouse, trackball etc) mounted on a suitable desk matching the Operator‘s

Workstation in appearance. A color laser printer will also be provided. The EWS

will be connected to the Plant Control System via a data highway to allow access

to system and applications software and to live plant data.

1.6.3 System response times The response times for the Operator’s Workstations under normal conditions will

be as follows :

1) The time between selection and display of a VDU, fully updated, from the

database will not exceed 2 seconds with a typical workstation loading.



2) The time between execution of a control function on an Operator’s workstation

and the command reaching the output terminations of the outstation will not

exceed 2 seconds.

3) The time between the occurrence or change of a signal at the origin and the

change of state, value or alarm showing on the VDU will not exceed 2 seconds.

1.6.4 Spare capacity The Plant Control System will be supplied with all hardware, system and

applications software (VDU displays, alarms, etc) fully developed, tested,

debugged and installed for all analogue and digital I/O’s. An overall further 20 per

cent spare equipment will be provided including all necessary hardware and

associated wiring, supplied and tested. Software will be designed so as to ensure

no degradation in the specified performance with the system fully loaded including

the spare capacity.

1.6.5 Software

The latest version of the manufacture’s operating system software will be provided

fully developed, tested and installed.

General

The application software and associated displays, reports, databases, etc, will be

configured and fully tested when installed at site. The creation or modification of

displays, reports, databases or control strategies will be possible with the system

on-line by owner’s engineering personnel without affecting the plant operation.

Modifications to the software will be done in straightforward and logical steps

using, wherever possible, graphic displays. It will not be necessary to have

specialist knowledge of the underlying software in order to carry out modifications.

All necessary software licenses will be included. Software to access, via a

password assigned by owner management personnel, will be provided to facilitate

changes/revisions to the DCS configuration.

Access to software and application programs at various levels will be possible by

operating or engineering personnel using passwords. This will protect the software



from unauthorized access. Any changes to software, either application and/or

operating, will be fully documented in a logical and structured manner in such a

way that the history and nature of the changes can be easily identified.

The operator interface software will enable the Operator to carry out the necessary

actions in a safe and efficient manner. In particular the following features will be

included, as a minimum, but not be limited to :

Operator interface software

1) Software will be structured in such a way so as to provide a hierarchy of

control from automatic sequential plant start-up through to manual control of

an individual item. Each operation station will be configured to accomplish all

operator functions for the entire plant. All operator screens provide with the

Gas Turbine equipment will function the same when used from the operator

stations provided with the DCS, this includes features such as manual

synchronization.

2) During manual intervention by the Operator (sequence initiation and individual

device control under normal and failure conditions), all software derived,

hardwired permissive and overrides will be visible to the Operator.

3) Where process measurements have been duplicated for improved reliability,

the signals will automatically switch to the good signal in the event of a fault.

The Operator should have, for the purposes of maintenance, the on-screen

facility to select either signal or the average, as the measured variable for

control.

A philosophy will be developed to define the action of the sequence logic in the

event of a step failure, Operator intervention or the initiation of a sequence with

not all plant conditions satisfied. It will be possible to bypass a required plant

condition but this action will be alarmed and logged. The philosophy of operation

will be to owner’s approval.

The Plant Control System will be capable of presenting to the Operator, pre-

defined reports. The information on the reports may be either in tabular form or in

a pre-formatted report form and may be automatic at specific times or on request.

Reports



Reports will include periodic logs, daily logs and group logs, balance of energy

and efficiency log.

All plant (gas turbine and BOP equipment) and system generated alarms will be

prioritized, logged and displayed by the Plant Control System in a fully integrated

manner enabling troubleshooting and tracing of the Plant (BOP, Turbine and

Generator) Alarms from the DCS HMI. The alarms generated will be accessible

from each of the HMIs. There will be a dedicated alarm display, which will show all

the plant alarms or groups of alarms. The Operator’s attention will be drawn to the

occurrence of an alarm by a suitable audible and visual alarm at the CCR desk.

Alarms will also be printed on the alarm/event printer.

Alarm management

The Operator will have the facility to select optional alarm displays, summary of

alarms, historical alarms on global or point based, unacknowledged alarms,

alarms by priority, alarms by predefined system groups.

There will be a facility to suppress an alarm or groups of alarms as a result of a

particular alarm or other plant condition in order to minimize the number of alarms

under transient conditions.

All alarms generated from either analogue or digital I/O will be configured with an

adjustable dead band. The value of the dead band will form part of the

configuration software.

The Plant Control System will incorporate long term data logging facilities for all

analogue, digital, serial data, alarms, condition monitoring and other internally

generated points including the overall extension capacity specified. Data will be

stored for up to 12 months on a suitable storage medium and an alarm generated

to inform the Operator when the storage medium approaches 75 per cent of its

maximum capacity. All data will be automatically archived and retained for future

reference in either optical or magnetic medium. The data logger/ historian will a

prior demonstrated integration history with the DCS.

Data logging and trends



The operator will have the facility to display real time data, recall data held in the

data logger memory or from archives over a specified period of time. The

requested information may be displayed on the Operator’s workstations either in

tabular form or as selected variables on a trend display. It will be possible to

compare on the same display, multiple trends of real-time data or historical data

from the data logger or archives. It will be possible to seamlessly go from the real-

time trending to historical data trending from the same graphical interface.

The format and content of the reports for data retrieval from the logging facility will

be subject to approval by the owner. All the plant data including the Gas Turbine

control system will be available for data logging and trending.

A sequence of events (SOE) recording system will be supplied to allow analysis of

the causes of trips or plant disturbances. The SOE recorder may be either

integrated within the Plant Control System or a standalone item of equipment. Any

digital point from the gas turbines or DCS will be capable of being recorded in a

common database. The same digital input card will be used for SOE or non-SOE

digital inputs. The SOE recorder will scan all agreed digital inputs continuously

with a resolution of 1ms.

Sequence of events

The status of each point will be time tagged and stored in a database together

with other relevant information for a specific time period. Data will be continuously

deleted from the database on a first-in, first-out basis after the specified time

period has elapsed. Facilities will be provided for the data to be archived for future

reference, and for easy retrieval for viewing and analysis.

On the occurrence of a nominated event e.g. turbine trip or manual initiation from

the DCS, all data for a specified time period before the event will be retained and

continue to be recorded for a period after the event.

The SOE recorder will automatically reset after the elapsed time period and

continue to monitor the Plant in the normal way.



SOE reports will be generated and printed using the stored data and will be used

for post trip review and analysis. The report will be presented in a clear and logical

format and clearly indicate the “first cause” of the event. SOE reports containing

Gas Turbine and BOP Points will be available.

The DCS control system supplier will have available the service to remotely

diagnose and troubleshoot system problems. Provisions will be made for a single

point access via telecommunication or satellite link for Remote Monitoring and

Diagnostics when required by the plant for matters of diagnostics, troubleshooting

or performance monitoring.

Remote diagnostic Support

The equipments to facilitate interface with the National Dispatch Center Reference

will be supplied and made to owner standards.

Interface with National Dispatch Center

1.7 Metering Metering will be provided for process monitoring, performance monitoring and

emissions monitoring. Data will be derived from plant instruments designed and

installed to measure actual values and will be corrected where necessary for

variations in pressure, temperature, density etc.

All measurements will be displayed locally and monitored, displayed and logged

by the Plant Control System. Facilities will also be provided for integrating the

instantaneous values over a pre-defined time period.

Metering will be supplied to include but not be limited to the following :

1) Volumetric, mass and energy flow of fuel onto site

2) Raw water flow

3) Total electrical power (active and reactive) imported and exported from/to the

Grid

4) Effluent discharge flow



1.8 Plant performance monitoring Facilities will be provided to enable the performance of the plant to be continually

monitored based on real time data derived from the Plant Control System. The

equipment will be HMI or EWS based, running software designed to calculate,

display and report on the performance of the gas turbine and overall plant and

specific plant areas. The system will generate reports for analysis by management,

engineering and operating staff identifying specific plant values such as MW, MVAr,

fuel usage, etc and calculated values such as heat rate, efficiencies etc.

The facility will be computer-based and will include all necessary hardware,

software, data-inputting and interconnection with other plant equipment to form a

complete and working system.

It will utilize real-time data derived directly from the Plant Control System via

suitable data communications medium and will employ non-linear optimization

techniques.

Additional facilities will be provided to allow operating, engineering and

management staff to carry out on-line and off-line optimization of the power plant.

Use of this facility will not directly affect the operation or control of the power

station. The optimizer will be complete with its own printer for generating reports,

data schedules, diagrams etc as required

Performance monitoring system will provide on-line performance information on

the plant and will advise how to operate the plant cost effectively based on

thermodynamic models. Facilities will be provided to enable the overall equipment

efficiencies of the plant to be continually monitored based on real time data

derived from the DCS or Historian. The performance monitoring system will run

automatically and continuously online, no matter whether the plant equipment are

at base-load or at part-load. The system will consist of a suitable desktop

computer and printer running necessary software to enable On-line Heat Balance,

Performance Monitoring, On-line Optimization and Compressor Wash Advisories

for Gas Turbines. The system will include all necessary hardware, software, data

inputting and interconnection with other plant equipment to form a complete and

working system. The system will also generate reports that allow the users to



quickly understand the plant’s current status and to diagnose problems. The

system will be designed to generate reports for analysis by management,

engineering and operating staff identifying specific plant values such as MW, MVAr,

fuel usage, cooling water usage etc. and calculated values such as heat rate,

plant efficiencies etc.

The system will have a data validation module or On-Line Heat Balance module to

reconcile measured data from the plant, and ensure that mass and energy around

each of the major components are conserved. This module will also produce a

review of the plant sensor equipment. Sensor accuracy will be evaluated on-line

by comparing sensor readings against validated data.

The system will include an online optimizer, as well as an off-line “what-if” analysis

tool, to enable operators and performance engineers to perform off-line analyses

of operational scenarios for different operational choices as well as different power

and ambient/cold-end conditions. Use of this facility will not directly affect the

operation or control of the power station but will be used to advise the Operators

of the current state of the plant and provide them with operational alternatives. The

selection of the operational alternative will be the responsibility of the Operator or

engineering staff. The Optimizer will advise the operator, how to distribute the load

between the individual generators to produce the required plant output of

electricity. The Operator facilities provided will be suitable to allow the Operator,

engineering or management staff to access all necessary items of data and to

generate reports as required.

The package will have a gas turbine Compressor Wash Advisor tool capable of

advising the operator on the optimal time for an off-line compressor wash based

on an economic analysis of the cost of degradation and cost of compressor wash.

The toll will have internal input filtering routines make sure that the extrapolation

for the optimal time of the wash will not be impaired by bad data or shut-down

periods.

1.9 Emissions monitoring Continuous emission monitoring equipment will be provided to monitor the plant



stack emissions and waste water discharged from the site.

Indication and recording of the corrected concentrations of gases in the stack will

include, as a minimum :

1) Flue gas O2

2) Flue gas CO

3) Flue gas SO2

4) Flue gas NOx

5) Flue gas opacity (dust)

Chlorine and halogen residuals will also be monitored in the water sent to waste

after treatment. The flow, temperature and pH levels of the wastewater will be

continuously monitored and displayed by the DCS. Alarm levels will be presented

to the operator for action.

The instruments for stack and water discharges will be complete and will display

the instantaneous value of the measurements to the operator in the CCR via the

DCS. Local indication will also be provided for each measurement at the

respective measuring meter. Fault alarms for each instrument will be raised in the

CCR.

The measurements will be displayed by the instruments in a format suitable for

submission to the appropriate environmental agency. The PCS will display and

record the measurements in the same way. All measurements will be

compensated, where necessary, for variations in temperature, atmospheric

pressure, humidity etc and the correcting values made available for display by the

DCS.

The Plant Control System will be capable of performing hourly and daily averages

for all measurements and give early warning alarms of measurements

approaching their maximum limits.

The equipment will be of proven reliability and will be subject to the approval of

owner. Details of other sites where the equipment has been installed will be

provided.



1.10 Station clock system A station clock system will be provided to synchronize the Plant Control System

and other plant control systems, for the purposes of synchronizing data acquisition,

data logging, alarm and trip events, etc, for all systems employed in such a

manner on the site.

The station clock will be set from an appropriate radio time signal (e.g. GPS

signal). The system will be capable of monitoring the grid system time, and display

to the Operator in the CCR, the time difference and GMT.

The equipment will be supplied with sufficient outputs of the correct type to meet

the operating requirements of the plant. Station clocks synchronized to the system,

will be supplied and installed in locations to be approved during the detailed

design stage.

1.11 Load dispatch A communications interface for the transfer of data to and from a central load

dispatch facility will be provided within the DCS. The communication protocol

details will be defined at the time of the placement of Purchase Order.

1.12 General requirements 1.12.1 Introduction

The following section describes the general requirements for the supply and

installation of the communication, control and instrumentation (C&I) systems for

the plant. All C&I equipment necessary to allow the safe, reliable and efficient

operation of the plant will be supplied.

1.12.2 Environmental requirements In general, equipment supplied will conform to the environmental classes defined

in EN 60654 or equivalent international standard. The internal air in and

equipment cubicle will, at least in some parts, be higher than the defined ambient

temperature. For design purposes the internal air will be taken as 15°C higher

than defined maximum ambient given in EN60654 or equivalent international



standard. The PCS will be installed in an environmentally controlled area.

In operation, during installation and maintenance, and during transit, the

equipment may be subjected to continuous vibration and shock loads. The

mechanical design will take account of these conditions to minimize the risk of

failure.

Instruments will be mounted in heated or protected locations wherever possible in

order to minimize the effects of ambient weather conditions.

All field mounted instruments will be weatherproof to IP65 or equivalent and

suitable for the local operating conditions. Field mounted instruments will be

provided with a suitable shade to protect them from direct sunlight. All instruments,

instrument tapping points and controls will be accessible from floor level or

permanent platforms.

Instruments will be resistant to corrosion.

1.12.3 Hazardous areas All C&I equipment will be suitable for the specific area in which it is located. If

equipment is expected to operate in the presence of flammable or explosive

materials either explosion proof construction or the use of barriers to obtain

intrinsic safety will be acceptable. All equipment offered for use in such areas will

have the necessary certification by the appropriate Certification Bureau and its

proposed application will fully comply with all conditions of the certificate.

The design and installation of the equipment will take into account fully the

appropriate sections and requirements of IEC 60079.

1.12.4 Insulation and isolation All circuits intended to be electrically isolated from external circuits will be

designed to withstand the following voltage levels :

1) All circuits requiring isolation (including contacts of switches, relays or

contactors) will have an insulation resistance across the isolating barrier of not



less than 20 Mega ohms when measured at 500 V dc.

2) A circuit intended for connection to 110 V ac or 125 V dc and above will

withstand 2 kV 50Hz rms between itself and all other points for one minute.

Connections to the external power sources will normally be made via switches and

fuses or via miniature circuit breakers.

1.12.5 Electromagnetic compatibility (EMC) No equipment provided under the contract will generate electrical or

electromagnetic interference at a level detrimental to the performance of other

equipment or to a hazard or of discomfort to personnel. The equipment will meet

the requirements of EN 55011 Class A Group 1 or equivalent international

standard.

1.12.6 Identification Each item of equipment will be durably and legibly labeled, indicating the purpose,

plant identification number and where necessary any operating position functions.

Labels will be provided on front and rear access doors of all cubicles. Labels will

also be provided inside cubicles to assist the identification of apparatus and

terminals. Instruments, valves, actuators and all other field mounted equipment

will similarly be identified with suitable labels.

The material of all labels and the dimensions, legend and method of printing will

be to approval. Surfaces of labels for cubicles and control equipment will have a

matt or satin finish to avoid dazzle. Colors will be permanent and free from fading.

Danger labels will have red lettering on a white background.

1.12.7 Installation All instrumentation will be installed in compliance with BS 6739 or international

equivalent standard and the recommendations of the manufacturer. Only one

instrument will be fitted to each tapping point. Separate instruments will be

provided for control/indication and protection systems.

Connections to instruments after the primary isolating valve will be made using

steel or a material corresponding to the piping class of the line to which it is



connected. Stainless steel (316) will be used in certain atmospheres to prevent

erosion or corrosion problems. Instrument isolating valves, vent/test valves and

instrument manifolds will be provided for all devices where appropriate.

Instrument vent and drain points will be routed to a safe position away from site

personnel.

All indicating instruments and controls will be readable and accessible from floor

level or permanent platforms. Local gauge glasses will be visible from any control

valve that controls the vessel level. Instrument ranges will be such that normal

working indication lies between 60 and 75 per cent of the span.

Post or bracket mounts for instruments will not be attached to pipe work,

removable flooring, and handrails or be directly affixed to machinery and

equipment subject to vibration

1.12.8 Control & Monitoring of the field instruments, actuators And positioners All the transmitters, actuators and positioners will support at least HART protocol

in order to allow the following operations :

1) Control

2) Monitoring

3) Setting

4) Collection of data for predictive maintenance

The above mentioned items will with an accuracy ±0,15% in analogue

measurements and ±0,075 in HART measurements. In both case the above

values are intended to include the effects of non-linearity, hysteresis and

repeatability.

The local control unit of each auxiliary system will be programmed in to issue

predictive maintenance warnings to the operator using the data collected by the

field instruments.

The protocol Fieltbus, Modbus or equivalent can be used to implement the above

mentioned functions.



1.12.9 Flow measurements Flow measurement devices operating on differential pressure principles will be

designed in accordance with the requirements of BS 10421 or equivalent

international standard.

For high pressure applications, the carrier for the primary device will be of similar

material to the pipeline in which it is to be mounted, and will be connected into the

pipeline by butt-welding. Other applications will use flanged connections wherever

possible. For line sizes below 50 mm, a precision pipe assembly will be utilized

with a minimum line size of 50 mm. All differential pressure devices will be

provided complete with tapping point isolation valves, 3-valve manifolds and drain

valves or 5-valve manifolds, as required.

Ultrasonic and Coriolis meters will be used for custody transfer flow

measurements. The accuracy of the flow devices will be better than 0.25% of

reading for custody transfer meters. Minimum rangeability for Custody transfer

meters will be greater than 20:1.Ultrasonic sensors will be explosion-proof, metal

encapsulated of robust construction, and removable under operating conditions.

Installation of transducers should be possible on existing pipe under operating

conditions. Material will be titanium or SS. Ultrasonic gas meter will operate under

atmospheric conditions for verification purposes and capable of bidirectional

service. Transmitter will be in Epoxy Coated Aluminium housing with infrared

keypad or touch buttons. Digital interface will be via RTU MODBUS, Foundation

Field-Bus and Ethernet Coriolis meter’s tubes will be Omega shaped and of

minimum 316Ti SS construction. Mass bar and torsion rod for should be part of

the meter’s construction. Coriolis meters will be used for all batching applications.

For lines below 50 mm, Vortex meters with dynamic compensation for temperature

and pressure changes will be used.

The flowmeters will in all cases be suitable for the process conditions applicable to

the measurement location and the environment in which it is mounted. Meters

used for energy, tariff or metering purposes will be supplied, complete with



adjacent pipe sections, where necessary, with calibration certification from an

approved laboratory. Displacement flowmeters will be capable of accuracies to

within ±0.25 per cent.

Where density, temperature or pressure corrections to tariff metered performance

monitoring signals are required, then such measurements will be made close to

the flowmeter location or within the flowmeter body.

Flowmeters employing alternative measurement principles may be utilized for

appropriate applications subject to the approval of owner.

1.12.10 Level measurements Level measuring devices may be of the direct measurement, differential pressure

or electrical/electronic type as appropriate to the application. For local indication of

level, direct measuring devices will be used. Level measuring equipment will be

capable of being removed without the vessel or other instruments being taken out

of service.

Level gauges will be of the reflex type made from stainless steel bar and fitted with

toughened borosilicate glass and marked with their safe working pressure and

temperature, except on low temperature and pressure application when

transparent types may be used. Each gauge will be fitted with top and bottom

isolation valves with full bore drain valve at the bottom and plugged vent at the top.

Gauges will be arranged so that the visible length is in excess of the maximum

operating range.

Differential pressure transmitting devices will preferably be used on all services

other than slurry.

Displacement type instruments and switches will be mounted in external cages

with flanged connections rated the same as the vessel. This type of instrument will

not be used for applications involving viscous, corrosive or flashing liquids.

Direct measurement of level by means of internally mounted floats etc, will only be



used when the switch point is either well defined in advance or if it is adjustable in

service, if the vessel can be emptied and/or depressurized for the removal of the

switch without affecting the normal operation of the plant, or where choking of

extended connections is likely to occur.

Float switches will be glandless with magnetic coupling.

1.12.11 Pressure measurements In general, local pressure gauges will operate on Bourdon tube principles and will

comply with EN 837 or equivalent international standard. Low pressure gauges

may employ manometer or barometer devices to indicate small gauge, differential

pressures or vacuums.

Sensing element materials will be selected to resist corrosion by the process

medium.

When gauges or transmitters are to be used for duties where the process medium

temperature exceeds 70°C, siphon loops will be utilized. A Hastelloy C276

diaphragm and 316L stainless steel pressure port should be standard for

compatibility with a wide range of hostile media. For severe or hygienic process

conditions, remote diaphragm seals should be used.

Gauges measuring low ranges that can be exceeded by a higher containment

pressure will be fitted with over-range protection. Gauges will be fitted with

vent/test valves. Blow-out devices will be provided for high pressure applications.

Pressure switches will only be provided with the approval of owner. If used,

pressure switches will be such that under normal process operating conditions the

contact in the switch will be closed unless otherwise approved by owner.

1.12.12 Temperature measurements The method of temperature measurement to be employed will be selected for the

particular application bearing in mind requirements for accuracy and reliability.

Sensing elements for air, inert gas and radiant temperature measurements will be



complete with suitable protective sheath. For steam, water and hazardous

applications, thermowells will be utilized.

Resistance thermometer detectors (RTDs) will be used only where they can be

readily replaced without loss of plant capability. RTDs will be to EN 60751 Grade II

using 3-wire connections for applications up to 450°C or equivalent international

standard. On differential temperature measurements RTDs to EN 60751 Grade I

or equivalent international standard will be used.

Thermocouples will be used in accordance with the requirements of EN 60584 or

equivalent international standard.

Careful consideration will be given to the design and installation of thermocouple

systems to ensure that inaccuracies are not introduced into the measurement due

to the use of unsuitable materials or by incorrect installation. Cold junction

compensation will be provided as well as compensating cables of suitable size

and material where required. Thermocouples will be installed in such a way as to

be capable of replacement with the plant in operation.

Local temperature indicators will be supplied with a thermowell and will preferably

be of the bimetallic type and of the multi-angle variety.

No temperature measuring system will use mercury as its sensing medium.

1.12.13 Position measurements Position measuring devices or switches (e.g. limit switches, proximity switches etc)

will be remote from sources of heating or leakage of process, gases or liquids.

Where vibration-free locations are not possible, the mounting arrangement will

incorporate flexibility in the coupling between the device and the point of

measurement and the transducer mountings.

For position instruments in high temperature applications the calibration of position

transducers and the setting of limit switches will be unaffected by the hot/cold

operating temperatures of start-up and shutdown.



1.12.14 Quality measurements Quality measuring instruments monitoring chemical or physical properties of

process fluids and substances may be installed either directly in the process line

or vessel or via a sampling system. Sensors will be of rugged construction and will

not require frequent maintenance or recalibration.

Where sensors require the use of calibration solutions or gases, then a minimum

of one year’s supply at normal usage will be supplied. Where sensors require

replacement or removal for re-calibration or rejuvenation at regular intervals, then

an adequate number of spare sensors will be supplied for one year’s normal

usage.

1.12.15 Control valves and actuators Control valves will be supplied with suitable actuators matched to the operational

and environmental requirements of the plant. All actuators will be provided with a

means of local control, which will be capable of being utilized without the use of

tools. Loss of remote/automatic operation of an actuated valve will be alarmed to

the operator.

All control valves will have local and remote indication to show the actual position

of the valve. For remote control or indication purposes a suitable position

transmitter will be provided (e.g. based on a linear variable differential transducer).

Where it is only necessary to provide a limited number of discrete position

indications, then position actuated switches will be used. Switch settings will be

adjustable.

1.12.16 Motorized valves Motorized valves will be used for isolation purposes and will consist of self-

contained actuator units with motor, gearbox, contactor, controls, limit/torque

switches and all auxiliary equipment installed in each housing actuator. A lockable

local/remote selector switch with open/close controls will be located on the

actuator. The actuator will be designed such that it may be disengaged from the

valve if a fault has occurred and the valve operated normally by using the hand



wheel.

Each end of the actuator travel will be fitted with suitable limit and torque switches

for preventing over-travel and consequential damage to the actuator. Limit

switches will be installed also to provide remote indication of the valve position.

Local valve position indication will be provided on the actuator.

1.12.17 Pneumatic actuators/positioners Pneumatic actuators/positioners will be supplied suitably matched to the

operational and environmental requirements of the valve or driven unit. Pneumatic

actuators/positioners will cause the valve or driven unit to operate over its full

stroke, from a 0.2 to 1 bar signal by means of any of the following :

1) Pneumatic signal Pneumatic the actuator

2) Pneumatic signal to a positioner

3) Electrical signal to electro/pneumatic converter

4) Electrical signal to solenoid pilot valve.

Pneumatic actuators and drive units will automatically return to a safe/pre-

determined position upon signal and/or air supply failure unless the process

operating requirements or the Specification dictates a “stay put” response. “Lock

up” devices will be provided where necessary to ensure the actuator remains in

the operating position prevailing immediately before an air failure.

Volume boosters will be provided on loops where fast-response is required (e.g.

pressure) to enhance stability.

All positioners and electro/pneumatic converters will be furnished with three

pressure gauges, air supply, signal input and control air output, and an air filter

regulator set with a lubricator.

Position transducers and limit switches will be provided to give remote indications

of the valve positions at the PCS.

1.12.18 Cubicles and racks Unless otherwise stated all equipment will be accommodated in suitable cubicles



or racks. Cubicles, cabinets, racks and control panels will all conform to applicable

IEC 60297 standards. The general design of racks and cubicles will be subject to

approval. They will be free standing, fabricated steel construction and will not

exceed 2300 mm in height. The lowest mounting point, plug-in group or terminal

block will be not less than 400 mm above floor level. The methods used for cubicle

mounting, including the provision of anti-vibration mounts, will be to approval. The

welding of cubicles, cabinets, racks and panels to support steelwork is prohibited.

Internal lighting and maintenance power sockets will be provided within the

cubicles. All enclosures containing electrical equipment will be provided with

thermostatically controlled anti-condensation heaters.

Cubicle doors will be provided and arranged to lie flat back when open so as not

restrict access to the cubicle. The doors will be of the lift-off type secured with 3-

point locking system.

Cubicles and doors will be structurally stiff and braced to withstand twisting without

distortion flush fitting and sealed with a gasket of rubber or other approved

material to prevent the ingress of dust and vermin.

Cubicles and racks will be complete with all necessary terminal blocks, cable

glands, gland plates and earth bar with earthing connection. These items will be

located in an approved, easily accessible, position and so arranged that the

terminals face the access direction for convenience during maintenance. The

design will be suitable for either top or bottom cable entry for all cables. The gland

plates will be removable and in the case of floor mounted bottom entry cubicles,

will be not less than 200 mm above the base of the cubicle to allow access for

applying the cable gland. Where cable glands are not used then provision must be

made to seal the cable entry to ensure that the cubicle is dust proof, vermin proof

and has a suitable fire rating. In addition provision for adequate cable support

within the cubicle must be made.

Forced ventilation will not be used without the approval of owner. Where forced

ventilation is approved, fans will be duplicated to provide 100 per cent standby

capacity and will initiate remote alarms in the event of failure. Ventilation systems



will comply with noise limitations imposed by the international standards.

Replaceable dust filters will be provided.

Terminal boards will include 20 per cent spare terminals after all external cables

have been terminated including the screens and spare cores.

All C&I cubicle wiring will consist of copper wires of not less than 1 mm2 cross-

section except for wiring associated with switchgear control and protection and CT

and VT secondary circuits which will not be less than 2.5 mm2.

attachment #3. technical specification for i _ c

Documents

installation of control

packaged control systems

gt control systems

complete control

integrated control

consistent control

gts control system

associated equipment