Urhoud: Specification For Integrated Control System

COMPANY’S DOC. NO.

URHOUD-Organisation Ourhoud

JOB No.

0-1800

DOC. NO.

REV.

S-000-1371-102

DATE 31-July-2014

PROJECT SPECIFICATION

7461-ORH-SP-J-87001

2

SHEET 1 OF 43

Name

ORGANISATION OURHOUD REALISATION DES INSTALLATIONS DE PRODUCTION D’HUILE OURHOUD, ALGERIE CT-99-010-040

SPECIFICATION DIST’N

FOR

CLIENT OY OM OH OS

INTEGRATED CONTROL SYSTEM J G C / I N I T E C

PJ-PMT PJ-CONST PJ-ENG PJ -CONTROL PROCESS PIPING PLINE CIVIL INST ELEC ROTARY FIRE HSE EQUIP PAINT/INSU

SOLID-H PKG FUR BLDG/HVAC

ACOUSTIC OPER’T LABO EN-IT EN-IT(MAT’L)

LEGAL PPM P- EQUIP P- PIPING P- INST P- ELEC EXPED’G SHIPPING QA QC JPC JGCSITE JM (INITEC) JUS JEB TELECOM YEC

Rev.

Date

Page

Description

Prep’d

Chk’d

App’d

0

8-Aug-‘00

ALL

Issue for Information

Y. S

Y.T

H. M

0a

17-Jul-01

ALL

Issue for Approval

SGJ/NA/YS

Y.T

H.M

1

07-Aug-01

ALL

2

18-Mar-03

For Construction

N.A

Y.T

H.M

As-built

Y.T

Y.T

-

H.M

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

7461-ORH-SP-J-87001

DOC. No.

0-1800

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

CONTENTS 1.

General

2.

Outline 2.1 Definition 2.2 Document Format 2.3 Project Communications 2.4 Approvals 2.5 International Codes and Standards 2.6 Project Document

3.

System Overview 3.1 Installation Condition 3.2 Scope 3.3 Operating Principles

4.

Process Control and Shutdown 4.1 Definition 4.2 System Scope and Configuration 4.3 Operator Interface – CCR 4.4 Operator Interface – LTRs (CTR and OTR) 4.5 Operator Interface – Satellite and Wellheads 4.6 Engineering Work Station 4.7 Functional Requirements – PCS 4.8 Functional Requirements – PSD 4.9 Supervisory Control and Data Acquisition (SCADA) System 4.10 Management Information System 4.11 System Input / Output (I/O) Facility 4.12 Alarm Handling 4.13 Data Logging and Printers 4.14 Communication Facilities 4.15 Satellite Station Control Nodes 4.16 Wellheads Remote Terminal Units (RTUs) 4.17 Leak Detection System

SHEET

2 OF

43

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

5.

ESD and F&G System 5.1 Definition 5.2 General Requirement 5.3 System and Functional Requirement for ESD System 5.4 System and Functional Requirement for F&G System

6.

Software Requirement 6.1 Application Software 6.2 On-line Self-diagnosis 6.3 Power-up Checks 6.4 Software Security

7.

System Cubicles and Field Termination Cabinets 7.1 Components and Wiring 7.2 Year 2000 Compliance 7.3 Radio Interface 7.4 Electromagnetic Compatibility (EMC) 7.5 Earthing 7.6 Power Supplies 7.7 Interconnecting Cables 7.8 Hazardous Area Certification 7.9 Ingress Protection 7.10 Future System Extension

8.

ICS Interface into Package Plant 8.1 General 8.2 Fully Integrated Packages 8.3 Partially Integrated Packages 8.4 Stand Alone Packages 8.5 Instrumentation Sub-system Packages

9.

System Inspection and Testing 9.1 General 9.2 Test Procedure 9.3 Communication Interface 9.4 Site Acceptance Test

SHEET

3 OF

43

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION SHEET

Specification for Integrated Control System

4 OF

43

10. System Engineering 10.1 General 10.2 Pre-Order Documentation 10.3 Post-Order Documentation 10.4 Development 11. Operator Training 11.1 Training Facilities 11.2 Training Program 12.

Guarantee

APPENDIX-1

ACCEPTANCE TESTS AND ACCCEPTANCE

APPENDIX-2

PRELIMINARY PROCESSING

FUNCTIONAL

DESCRIPTION

OF

DATA

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

1.

GENERAL

1.1

Definition

SHEET

5 OF

43

This document specifies the requirements for an Integrated Control System (ICS) for REALISATION DES INSTALLATIONS DE PRODUCTIN D’HUILE. This document should be read in conjunction with the specifications, codes, standards and supporting documentation as specified in Control Philosophy 7461-ORH-TP-J-87001 (S-000-1371-101). 2.

OUTLINE

2.1

Definition The ICS shall comprise integrated but functionally separate Process Control (PCS), Emergency Shutdown (ESD), Fire, and Gas (F&G) sub-systems. The component parts of the ICS will be distributed throughout the CPF, the satellites, the wellheads and CSF to form an overall control and protection facility. The ICS supplier shall be responsible for the detail design, manufacture, assembly, testing, shipment and installation supervision of the control systems and equipment as detailed in this Specification and as required by the relevant design codes for safe, efficient, reliable and accurate operation of the system. The ICS supplier shall demonstrate a successful field record of at least two years with the same type of components and architecture and with an installed capacity greater than 15000 I/O’s.

2.2

Document Format This document initially provides a general overview of the functional and operational requirements of the ICS. Further design detail is then provided for the PCS, including operator interface facilities, and the required functional interfaces into the ESD and F&G systems. Specific design detail is then provided for the functionally separate ESD and F&G systems. Refer to section 2.6 “project document” for support documentation.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

7461-ORH-SP-J-87001

DOC. No.

0-1800

REV.

S-000-1371-102

2

PROJECT SPECIFICATION SHEET

Specification for Integrated Control System

2.3

6 OF

43

Project Communications Verbal agreements between Supplier and Purchaser shall not be official until confirmed in writing by the Purchaser. All post-order Project communications and technical documentation shall be in French and English.

2.4

Approvals The Purchaser reserves the right to approve, prior to construction, the following :  Supplier’s documentation, e.g. drawings and design specifications  Materials of construction  Manufacturers and Model numbers of sub-contracted equipment  Test procedures Any approvals given by the Purchaser shall not release the Supplier from his contractual responsibilities.

2.5

International Codes and Standards Refer to the “Control Philosophy”, 7461-ORH-TP-J-87001 (S-000-1371-101)

2.6

Project Document Doc. No (Company)

Doc. No. (JGC)

Document Title

ORH-TP-J-87001 S-000-1371-101 Control Philosophy ORH-SP-J-87002 S-000-1371-103 Specification for Emergency Shutdown System ORH-SP-J-87020 S-000-1371-104 Specification for Fire And Gas System ORH-SP-J-87021 S-000-1371-105 Specification for Instrument/Electric Interface Cabinet ORH-SP-J-87022 S-000-1371-106 Functional Specification for Field Termination Cabinet ORH-SP-J-87073 S-000-1371-107 Architectural And Operational Requirement for Integrated Control System ORH-SP-J-87023 S-000-1371-111 Functional Specification for Process Control System And Process Shutdown System ORH-SP-J-87024 S-000-1371-112 Specification for Human Machine Interface Of Integrated Control System ORH-SP-J-87027 S-000-1371-115 Functional Specification for Serial Interface ORH-SP-J-87028 S-000-1371-116 Functional Specification for Leak Detection System ORH-LJ-J-87001 S-000-1371-121 Alarm/Trip Setpoint List ORH-LJ-J-87002 S-000-1371-122 ICS Input/Output List ORH-SP-J-87065 S-000-1371-123 Specification for Push-Button Matrix

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

7461-ORH-SP-J-87001

DOC. No.

0-1800

REV.

S-000-1371-102

2

PROJECT SPECIFICATION SHEET

Specification for Integrated Control System

Doc. No (Company)

Doc. No. (JGC)

7 OF

43

Document Title

ORH-SP-J-87066 S-000-1371-124 Specification for F&G Mimic Panel ORH-SP-J-87063 S-000-1371-201 Specification for Auxiliary Panel ORH-SP-J-87011 S-000-1372-001 Specification for Simulator ORH-SP-J-87010 S-000-1372-002 Specification for Management Information System ORH-SP-J-87067 S-000-1372-003 Specification for Management Information System Tag List ORH-SP-J-87068 S-000-1372-004 Specification for Management Information System Reports ORH-DX-J-87001 D-000-1370-200 General Safety Logic Diagram Overview ORH-DX-J-87002 /87020 ORH-DX-J-87101 /87160

D-000-1370-201/ General Safety Logic Diagram for ESD & PSD System 219 D-000-1370-301/ Safety Logic Diagram for Fire & Gas PLC 360

3.

SYSTEM OVERVIEW

3.1

Installation Condition Refer to “Control Philosophy” 7461-ORH-TP-J-87001 (S-000-1371-101), closure 1.3.

3.2

Scope The design objective for the Integrated Control System shall be to provide a fully integrated monitoring, control, protection and safety system for all production, processing, and utility facilities throughout the Ourhoud development. The basis on which to achieve this objective shall be the selection of a single supplier for the entire system, such that common control and protection system hardware and software is provided wherever practical, and a common operator interface is presented throughout the installation. In addition to the operational and maintenance efficiencies achieved by the above approach, the safe operation of the facility will be enhanced by common equipment and procedures for all control and safety related actions.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

SHEET

8 OF

43

The Integrated Control System for this Project comprises the following control and safety sub-systems :       Note:

Process Control System (PCS) Process Shutdown System (PSD) Supervisory Control and Data Acquisition System (SCADA) Fire and Gas Detection/Protection System (F&G) Emergency Shutdown System (ESD) Leak Detection System The SCADA and the PSD functions will be incorporated into the PCS. The above listed systems will include inter-system and external communication facilities.

The operator interface facilities for the above systems will be within the Central Control Room (CCR) and Local Technical Rooms (LTRs) at the CPF. The control and protection system cubicles will however be distributed into the Central Equipment Room (CER) adjacent to the CCR, the Compressor Technical Room (CTR), the Oil Technical Room (OTR), and to the satellite stations, wellheads and CSF. In all cases the design objective shall be simplicity of control system design, instrument hardware, and interfaces. Proven principles and equipment shall be used, with avoidance of “advanced” controls or prototype components or software. The design shall be “fit for purpose”.

3.3

Operating Principles The overall operating philosophy for the installation, as relevant to the control and protection system, is outlined below. The overall production facility, including the satellites and wellheads, will be normally controlled and monitored by a minimum number of operators at the CPF CCR. These operators will be assisted by mobile field operators. These personnel, operating on a 24 hour basis, would be backed-up by additional technicians for fault diagnosis. The satellite stations and wellheads will be normally un-manned, except for maintenance and the following operating procedures:   

Multi-phase flow meter at the satellite stations Well start-up at the wellheads Local resetting of ESD trip actions

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

SHEET

9 OF

43

The following operational scenarios have been selected to provide an overview of the operating philosophy: 1) Start-up Start-up actions for individual wells will initially comprise manual opening of the required valves. Isolation valves at the wellhead will then be opened from the local wellhead panel, and production rate controlled by local operation of the wellhead choke valves. Start-up of a separation train at the CPF will normally be possible from the CCR, although certain manual actions by the field operators may be required during system pressurisation, etc. Start-up of major mechanical plant, e.g. gas compressors, will normally be undertaken at the related Unit Control Panel (UCP) in the associated LTR with operation interlock in PSD safety bar. Machine start facilities will however be provided at the CCR operator stations, for use at operator console. In all cases it is envisaged that local operators will be required for compressor casing drain, etc., operation during compressor start-up. Automated casing drains will not be provided. The compressor UCPs will contain the machine vibration monitors displaying all vibration amplitudes, and providing full vibration diagnostic facilities. The vibration signal that is trigger of Compressor trip will be connected to Compressor Trip by hardwire, and monitoring signal will be transmitted to PCS and PSD via serial link. Compressor start-up in the Compressor Technical Room (CTR) will be assisted by use of an ICS operator station in the CTR to monitor or manipulate the gas process stream during machine start-up. Full information shall be transmitted from the UCP to the CCR operator interface (via the PCS) such that essential pre-start criteria can be ascertained, and that acceptable running status confirmed. The data transmitted to the CCR shall provide full graphic displays of machine lube oil and seal systems, etc. Start-up of stand-by process and utility pumps, air compressors, etc., shall be possible from the CCR without local operator actions.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

SHEET

10 OF

43

2) Normal Running Under normal operating conditions the operator interface facilities for the PCS/PSD, ESD and F&G systems within the CCR shall enable functional monitoring of the process, utility and personnel protection equipment throughout the installation. Certain auxiliary plant items however, typically air compressor oil systems, may require the inspection of local indicators, pressure gauges, etc., for detailed status information. All key variables, common alarms and trip alarms, shall be transmitted to the CCR. 3) Upset Conditions Any condition throughout the production facility requiring operator attention or action, and all trip alarms, shall be annunciated within the CCR. In certain instances, specifically where the resultant operator action is entirely local, a package “common alarm” may dictate that an operator is required to examine a locally mounted annunciator to ascertain the exact cause of the fault. Typically, the air compressor package will operate on the common alarm principle. Alarm system “cascade groups” shall operate on the first-up principle, with time stamping, to define the originating alarm. In a “non-critical” plant trip situation, where full plant status is known to the CCR operator, the trip action may be reset at the CCR operator station. However, in a “critical” ESD trip situation or where plant damage may have occurred, it is essential that the operator can reset the trip action only locally. 4.

PROCESS CONTROL AND SHUTDOWN

4.1

Definition The definition “PCS” within this document refers to the combined Process Control System (PCS), Process Shutdown (PSD), and Supervisory Control and Data Acquisition (SCADA) facility, which covers the following functionality:  The modulating control of flows, pressures, temperatures, levels, etc., for process and utility fluids throughout the production facility.  The process shutdown (PSD) of plant in the event of process upset.  The centralised monitoring of all wellheads and satellites.  Sequence logic control for start-up or auto changeover, etc., of process and machinery units.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

   4.2

SHEET

11 OF

43

The presentation of process and safety information and alarms to the operator, and facilities for the operator to issue control commands. The logging of selected events and operator actions, together with all warning and trip alarms. Blowdown system

System Scope and Configuration The following is a summary of the component parts and configuration of the PCS : CCR operator console containing VDU/keyboard Operator Stations (OS), Management Information System (MIS) interface facility, and a pushbutton matrix for key shutdown actions and blowdown operation.  CCR wall mounting “wide screen display” facility for dynamic process control graphics.  Printing and data storage facilities.  Engineering Work Station (EWS) for location in a maintenance office  LTR operator interface facilities, in the form of cubicle or desk mounted VDU/keyboard units.  Distributed control cubicles, containing control, logic and communication hardware for the PCS, PSD and SCADA functions. These will be distributed into : - CER - Compressor Technical Room (CTR) - Oil Technical Room (OTR) - Satellite stations  Field Termination Cubicles (FTCs). These will be distributed to the CER and LTRs in conjunction with the system control cubicles.  System plug/socket cables for interconnections between control cubicles, FTCs, operator console, ESD/F&G systems, etc.  Interface racks for PCS/motor control interfacing, located in the related electrical sub-station.  A distributed PCS/PSD control node at each satellite, communicating with the SCADA node in the CER.  Remote Terminal Units (RTUs), located at each wellhead, communicating with the SCADA node in the CER via the satellite station nodes.  A computer only for monitoring in Security Control Room (SCR) in Fire Station.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

4.3

SHEET

12 OF

43

Operator Interface - CCR Operator interface to the wellheads, satellites, and CPF process/utility plant throughout the Ourhoud development shall be primarily by CCR console mounted Operator Stations (OSs), comprising VDU, purpose-built keyboard, and an activating. The operation keyboard for OSs shall be of water-proof, semi-stroke or pressure sensitive type; access to control and display functions shall be possible through dedicated control and function keys. The function keys shall include dedicated keys for most often used functions, such as; confirm/delete, open/close, next/previous, alarm/buzzer acknowledge, tune, trend and mimics/groups of mimics direct access. An industrial type trackball shall be added to the keyboard. It is envisaged that four process operator station assemblies will be required for the overall Ourhoud process and utility plant. A total of six (6) identical operator stations shall however be supplied with the PCS to provide redundancy, with each station having full PCS/PSD/SCADA/ESD/F&G operating capability. In normal circumstances it is envisaged that four (4) stations would be allocated to process plant duty, and two (2) to F&G duty. Note that a separate Engineering Work Station (see Section 4.6) will be located in an office adjacent to the CCR and a visual display unit of a Management Information System (see Section 4.10) will be provided in the CCR. The Operator Stations will provide as a minimum the following features :  Reference display, listing application and required key codes for all facilities available to the operator, engineer or supervisor as appropriate.  Graphic displays with control and alarm details, providing operator information and guidance on all process and utility plant.  Group displays arranged such that interactions between control loops can be ascertained.  Single loop displays detailing full process status and instrument calibration parameters.  Alarm and plant status listing in order of initiation, detailing class of alarm, e.g. trip, pre-trip, information, etc.  Real-time trends and short term historical trends on all analogue process variables, with selectable long term historical trends.  Flow rates, hourly and daily averages of fiscal process flows.  Operator control input, via activating device, providing the facility to: - amend controller set points

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

-

SHEET

13 OF

43

select manual/remote/auto control stop/start pumps and drives make duty/standby selections acknowledge alarms open/close remote operated valves reset alarms and process shutdowns initiate start-up overrides and inhibits.

With regard to historical trending, the ICS memory capacity shall allow the followings,  Gas Lift Wells : 5 samples each 30s during 10 days for 50 wells  Regulators : 5 samples each 10 s during 24 hours for 500 loops  Supervision and security : 1 sample each 30 s during 3 days for 5000 points Alarm and event log for 10 days Graphic displays, using French descriptors, shall be developed by the ICS Supplier in conjunction with the Purchaser. For the purpose of the Bids, Suppliers shall allow for 600 pages of graphic display of average complexity. Any OS shall have the possibility to access any display in the system. The display facility shall allow for at least three levels (overview, system, sub-system). Additionally the system shall allow for object displays. It shall be possible to move directly between display levels. During detail design the Operator Station package shall be subject to a detailed operability study covering all operating scenarios, with particular emphasis on alarm and trip situations. Design personnel undertaking this study must have relevant (and recent) operating experience. The OSs shall be desktop type. In additions to the OSs, the operator console shall be sized to allow for:  ESD/F&G push button matrix (Refer to “Specification for Push Button Matrix” 7461-ORH-SP-J-87065 (S-000-1371-123))  Management information facility (see Section 4.10)  Communication facilities (see Note below).  Two document worktop areas, each 1.5m long

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

SHEET

14 OF

43

In addition to the console mounted displays, the ICS scope shall include for a dynamic wide screen display facility. This wall mounted facility shall have the capability to display all graphics available on the PCS operator stations, with display selection possible from any operator station keyboard. It is envisaged that display facility size will be approximately 3m wide, such that it will be visible by a seated console operator (viewing distance approximately 4m). Note: Communication equipment for console mounting will comprise PA control panel, CPF intercom control panel, 3 telephone handsets, trunk radio handset, CCTV control panel, and HF radio unit with handset. A console length of 1.5m shall be allowed for this equipment. 4.4

Operator Interface - LTRs (CTR and OTR) In general, the operator interface for normal operation of the process plant shall be in the CCR. The gas compressors, and certain other special purpose mechanical packages, will however be supplied with LTR located UCPs (complete with local operator interface facilities) for the control of the package skids. A local PCS operator interface assembly shall be supplied for location in each LTR to provide a facility for the operator to determine status of the related process system during local package start-up. The operator station assembly shall comprise two (2) operator stations with VDU/keyboard units in each LTR for redundancy. The local operation station shall be desktop type. The assembly shall provide the full range of facilities described for the CCR operator station, although it shall not be possible to insert operator commands into the LTR operator station unless a permissive has been given from the CCR. The CCR operator will be provided with an overview of all actions being undertaken in the LTR.

4.5

Operator Interface - Satellite and Wellheads There is no requirement for permanent PCS operator interface facilities at either the satellite stations or the wellheads. All measurements, including multi-phase flows, will be provided with local indicators for operator information. The ICS supplier shall provide the facilities as required to enable maintenance activities on PCS components at the satellites and wellheads.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

4.6

SHEET

15 OF

43

Engineering Work Station The CCR shall contain one Engineering Workstation (EWS). The EWS shall be supplied as a separate dedicated unit, but with the facility to display the full range of process data. The station shall, as a minimum, be able to perform the following tasks:   

Configure the system and point database Undertake loop optimisation Build Operator displays Save and load configuration data.

The EWS shall be capable of both on-line and off-line configuration of the system, and shall be fully key or password protected. The keyboard shall be standard stroke type and a mouse shall be provided as a pointing devise. Reporting facilities for the EWS shall include user configurable trending functions to assist in loop optimisation. In addition, the EWS shall provide read only access to all engineering documentation for the entire ICS, with the facility to undertake selective printing in at least 20 configurable formats. 4.7

Functional Requirements - PCS The PCS shall allow dependable and effective control of the plant and shall be designed for maximum integrity and reliability by use of dual redundant control processors, communication sub-systems and power supplies. The hardware and software configuration for the PCS shall be such that each processor shall check the control action of the other, and failure of one processor shall not affect the operation of the other. The ICS Supplier shall advise, in his bid, the expected availability (in % terms) of his proposed PCS configuration. The design of the PCS, I/O racks and cabling shall permit selective shutdown of duplicated processing facilities without prejudicing the control of the rest of the plant. Typically, it shall be possible to undertake hardware component replacement on compressor train A while compressor train B is operational. The controller functions shall be executed by microprocessor based multi-loop controllers. System configuration shall be achieved easily with the use of function software block techniques. System Suppliers shall employ wherever possible a library of proven system configuration “modules” directly applicable to oil and gas production facility applications.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

SHEET

16 OF

43

The controllers shall provide algorithms necessary to implement all required control strategies, sequencing and logic functions. Where practicable, controller algorithms should always reside at the lowest level of the control system hierarchy. All control loops shall be arranged to fail safe, typically by cascade controllers reverting to local set point in the event of failure of the master or supervisory controller. Although the design objective is to minimise system complexity, customised software based facilities shall be provided within the PCS for certain applications. Typically these facilities shall include start sequence logic for gas compressors, gas mass flow computations, etc. The response time for controllers (passing time between the change of a status or of inlet value or the threshold crossing and the activation of the corresponding outlet) is, 1. Analogue functions (ex. Regulations.) : 500 ms 2. Discrete functions (ex. Logic of security, sequences.) : 500 ms 3. Rapid functions (ex. Load Shedding.) : 50 ms The critical input status shall be displayed on the operator station within 1 second of scanned sensing. A graphic refresh shall be undertaken within 1 second, and generation of a new graphic page within 2 seconds. These times are to include the display of both the background and live data. The detail control system configuration will be determined from the Piping and Instrument Diagrams (P&IDs) and supporting documentation as developed during the detail design of the process and utility facilities. Input/Output count shall be referred to “ICS Input/Output List” ORH-LJ-J-87002 (S-000-1371-122). The PCS controllers shall be sized to allow at least 50% expansion of computational capability on factory completion of the system. For reference ICS Functional Specification (preliminary) is attached as Appendix-2.

4.8

Functional Requirements - PSD The logic facilities for Process Shutdown (PSD) actions shall be incorporated within the PCS, shall be based on identical hardware, but shall be functionally segregated and fully redundant. The hardware and software configuration for the PSD shall be such that each processor shall check the control action of the other, and failure of one processor shall not affect the operation of the other.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

SHEET

17 OF

43

As an option, however, the Supplier may propose combined PCS/PSD hardware, provided the Supplier can demonstrate functional segregation between the PCS and PSD software, and an adequate level of reliability for the PSD actions. PSD loops on redundant process equipment, e.g. duty/standby pumps, should be allocated to different I/O cards and controller files to minimise the impact of control system hardware failure. Trip actions initiated via the PSD may be reset at the PCS operator station, and no local reset in the field will normally be required. Overrides and inhibits for start-up and maintenance may be undertaken within the PCS/PSD system, using the PCS operator station. The operation of overrides or inhibits shall be monitored and controlled by alarms and time-out circuits. The PSD controllers shall be sized to allow at least 50% expansion of computational capability on factory completion of the system. 4.9

Supervisory Control and Data Acquisition (SCADA) System In this project, Supervisory Control and Data Acquisition (SCADA) system shall be used for long distance data transmission system via optical communication link as a part of ICS. The PCS control and monitoring facility shall include a “node” at the CPF dedicated to the Supervisory Control and Data Acquisition (SCADA) sub-system, monitoring the satellite and wellhead. This stand-alone node of the PCS shall be configured to provide a communication link with the control nodes at the satellites, and the Remote Transmission Units (RTUs) at the wellheads. The SCADA node shall communicate with the other PCS nodes, and the CCR operator interface facilities, via the common redundant communications bus. Where applicable, hardwired I/O interfacing may be considered between the SCADA node, and other nodes of the PCS (typically the gas injection compressor PSD node) where high integrity of signal transmission is required. The optical communication between CPF and Satellites is defined as the extension of ICS system communication facility.

4.10

Management Information System A PC based Management Information System (MIS) shall be provided as a separate data management and storage facility for the ICS. The MIS shall continuously gather selected plant data from the ICS via the data highway.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

SHEET

18 OF

43

For detail, refer to the “Specification for Management Information System, 7461-ORH-SP-J-87010 (S-000-1372-002). 4.11

System Input/Output (I/O) Facilities The redundancy of Input/Output facility shall be determined in accordance with the results of RAM study. System I/O modules shall be rack mounted. Each individual I/O channel per card shall have status indication for healthy and fault. There shall be at least 20%, 50% at satellite, spare hardwired I/O capacity available, for each signal type, on factory completion of the system. The number of Process I/O shall be referred to ICS Input/Output List. Where the PCS/PSD system is required to provide digital output to solenoid valves, the solenoids shall be powered 24 Vdc, via 24 Vdc coil interposing relays, using the UPS power system supply. The required interposing relays shall be within the ICS Supplier scope, and shall be located within a segregated section of the Field Termination Cabinets (FTCs).

4.12

Alarm Handling A comprehensive alarm handling facility shall be included within the application software package for the complete ICS. The system Supplier shall develop this package during system configuration to ensure that no alarms are “standing” on the operator displays under normal operation. Typically, discharge low pressure alarms on 2 x 100% pump sets shall be configured to be automatically cancelled when the related pump is selected to be in the standby mode. The alarm handling facilities shall include time stamped alarm and status logging within each controller node to a resolution better than 500 msec.

4.13

Data Logging and Printers A data logging facility shall be provided for status changes and general operational data. A minimum of two CCR located printers shall be provided to record all alarms. In addition, a separate colour printer shall be provided for hard copy from trend displays etc., off any operator station VDUs. Additional printer(s) shall be provided if required to ensure redundancy.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

4.14

SHEET

19 OF

43

Communication Facilities Dual redundant communication facilities, operating at a speed of at least 10 Mb/sec, shall be provided for communications between the main components within each node of the ICS, e.g. between I/O facilities and control processors. A dual redundant bus facility shall be provided to link the various PCS nodes, the operator stations, ESD system, F&G system. The Optical communication between CPF and satellites shall be defined as the extension of ICS system communication facility. Single communication interface shall be provided for satellite station communication to the wellhead RTUs. Interfaces between the PCS and the ESD/F&G systems shall be designed to ensure that the integrity of these systems is not compromised by any fault in the PCS. Interfaces to other control systems, e.g. UCPs, shall be designed to ensure that the PCS is fully protected from corruption and invalid commands emanating from such sub-systems. Serial interfaces shall be provided to interface between the major process package UCPs and the relevant nodes of the PCS to enable full remote control and monitoring of the packages from the CCR operator stations. The serial interfaces shall be fully redundant for each application, and should standardise on a single protocol for commonality, e.g. RS485 using Modbus RTU protocol. Interface between the PCS and the MCCs for motor stop/start and status monitoring shall be via redundant link. This link shall also transmit PSD signals to relevant electrical drives where applicable. The status of the power distribution system can also be monitored via the serial link. ESD trip of electrical drives, where required, shall be hardwired from the ESD system, via interposing relay racks located in the relevant sub-station, to the relevant contactor. The relay coils shall be powered 24 Vdc from the ESD system, with volt free contacts for the motor control circuit. All communication facilities, including serial interfaces, shall be sized to allow at least 100% expansion of signal transfer capability on factory completion of the system.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

4.15

SHEET

20 OF

43

Satellite Station Control Nodes The use of PCS/PSD control stations, communicating with the SCADA node of the PCS in the CPF, is proposed for the satellite stations. These units shall be capable of processing linear and non-linear signals, such as square root for d.p. flow measurement, etc. In addition, a limited number (up to 20) PID controller functions will be required at each satellite station, together with approximately 32 PSD functions. It should be noted that no operator interface facilities are required for the satellite station PCS/PSD nodes, as all required local operator information will be provided by local gauges or milliammeters. Signal transmission from the satellite control node shall include node fault alarms for display in the CCR. The fault monitoring functions shall include individual card faults, power failure, high ambient temperature etc, and alarms to indicate local room door open. The ICS Supplier shall include within his bid for portable facilities, which can be readily taken between satellite stations, to undertake detailed fault diagnosis of the satellite station nodes. The Supplier shall advise any alternative to the use of a portable facility for fault diagnosis. The satellite station nodes shall interface ICS system bus communication via dual multi-core fibre-optic cables. The CPF/Satellite communication facility shall be fully redundant, via redundant modems and the dual fibre optic cables. The ICS Supplier shall advise on the possible use of redundant controllers at the satellite station. The ICS Supplier shall provide all components (excluding cable) and software as required for both ends of this link (note: the fibre optic cables will include spare cores for telephone connection to the satellites). The field telephone system (supplied by others) will use additional cores within the CPF to satellite fibre optic cable, and will include the provision of a telephone multiplexer unit at each satellite station. The instrument room maintained by a small HVAC shall be provided in the satellite substation for the satellite station control node, and associated equipment.

4.16

Wellheads Remote Terminal Units (RTUs) Remote signal terminal units, generally located within the wellhead hydraulic control panels, are proposed for the monitoring and control of the wellheads. The RTUs shall interface, multiplex and transmit analogue and digital signals to and from the SCADA node of the PCS at the instrument room in the satellite substation.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

SHEET

21 OF

43

The wellhead RTUs will be required to undertake simple, but high integrity, closed loop PSD logic actions, typically the sensing of high oil flowline pressure and consequent closing of wellhead valves. The design objective is to provide a logic system at the wellhead with an availability of 99.99%. The ICS Suppliers shall make proposals within their Bids to achieve this level of availability. Various analogue process parameters, e.g. wellhead pressure and temperature, shall also be transmitted via the RTU. In addition, the RTU facility will be required to monitor choke position feedback. No PID control actions are required at the wellhead. Facilities shall be provided within the PSD logic for local manual override of low pressure trip inputs, to enable well start-up. Manual override functions shall include time-outs, and local manual input to the logic for this purpose will be from pushbuttons (by others) located on the wellhead control panel (WCP). No indication facilities are required on the RTU for normal operation or routine testing. Simulation of analogue and digital inputs to the RTU for test purposes will be undertaken by use of pressure test facilities and milliammeters supplied by others. Logic outputs for local shutdown action will be verified by solenoid valve initiation. Signal transmission from the RTU shall include fault alarms for display in the CCR. The fault monitoring functions shall include communication failure and common alarm of other failure for card faults, etc. The ICS Supplier shall include within his bid for portable facilities, which can be readily taken between wellheads, to undertake detailed fault diagnosis of the RTUs. The Supplier shall advise any alternative to the use of a portable facility for fault diagnosis. The RTUs shall include the single optical communication interface facilities as required to enable communication with the related satellite, and hence the SCADA node of the PCS. The logic within the RTU shall initiate well closure if communication is totally lost for more than 15 minutes (adjustable). It is proposed that the RTUs, optical communication unit, etc., should be mounted in an enclosure and free-issued to the WCP Supplier, for location within his ventilated local panel. The RTUs shall include facilities suitable for termination of the field cables. The ICS Supplier is required to confirm that the equipment proposed is suitable for location in a hydraulic oil based WCP. The WCPs will be located adjacent to the wellheads, in a safe open desert area. WCP and RTU are required for oil production wellheads and gas injection wellheads. In other wellheads, WCP and RTU are not required.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

4.17

SHEET

22 OF

43

Leak Detection System Export oil leak detection shall be realised by specialised software in a dedicated computer reporting to the ICS. Necessary process data of export side shall be gathered by remote I/O unit in CSF and transmitted to calculation unit in CER via RTU with optical communication function. One PC shall be provided in CSF as leak detection monitor communicating to calculation unit via RTU with optical communication function. Installation space for Remote I/O unit, RTU and monitoring PC with HVAC and electricity will be provided in CSF by Company. Refer to the “Functional Specification for Leak Detection System” 7461-ORH-SP-J87028 (S-000-1371-116).

5. 5.1

ESD AND F&G SYSTEM Definition The purpose of the functionally separate ESD and F&G systems is to provide a reliable means for monitoring, and safely closing down, the total or critical portions of the process and utilities plant throughout the installation.

5.2

General Requirement The ESD and F&G systems shall be functionally separate, and shall operate in stand-alone mode wherever practical. If appropriate, the two systems may however be built as an integrated protection facility, mounted within a single cabinet or suite of cabinets. The ESD and F&G systems shall use identical hardware components and functional principles. In order to maintain a degree of standardisation of hardware, the hardware manufacturer shall be subject to Client Approval. The ESD and F&G systems shall include facilities for interfacing into the PCS, and the communications systems, for the initiation of detail displays and alarms.

5.3

System and Functional Requirement for ESD System Refer to the “Specification for Emergency Shutdown System”, 7461-ORH-SP-J-87002 (S-000-1371-103).

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

5.4

SHEET

23 OF

43

System and Functional Requirement for F&G System Refer to the “Specification for Fire and Gas System”, 7461-ORH-SP-J-87020 (S-000-1371-104).

6. 6.1

SOFTWARE REQUIREMENTS Application Software The application software shall employ the principles of diversity to minimise common mode failures of the system. As a minimum, application software shall be divided into operational logic and auto-test programs. The operational logic shall be produced by a separate group of programmers to that producing the auto test programmes.

6.2

On-line Self-diagnosis The ESD and F&G systems shall be designed to ensure that the whole system is fully operational at all times, and that any faults are clearly defined to the operator. In order to meet this criteria and to reduce spurious trips, a comprehensive self diagnostic facility shall be included. The self diagnostic facility shall provide the following as a minimum:  Two hardware watchdogs shall be provided to detect hardware or software system failure. As a further safeguard the two watchdog programs shall run in separate memory areas. Action to be taken on fault detection within a redundant system shall be to raise an alarm and revert to non-voting operation on the second channel or unit by automatic removal of the faulty equipment from service.  The ability of each I/O module to communicate with CPU. The self check routine shall also detect any module not being updated. Outputs shall be de-energised on communication failure and indication of the failed module shall be detailed on the ESD status/services display as a module fault.  All serial communications with the ESD and associated systems shall be subjected to exhaustive error detection procedures. Provision for communication of detected failure to the display systems and local indication of failed sub-assemblies is required.  Each PLC shall have the ability to monitor the other PLC during diagnostic and self check routines and annunciate any failure or discrepancy.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

6.3

SHEET

24 OF

43

Power-up Checks When primary power is applied to the PLC the following checks shall be carried out as a minimum:  RAM checked in its entirety for read/write ability  Stored user software to be checked for corruption  Internal high speed data buses to be checked for integrity of data transfer  Logic and arithmetic manipulation ability of the PLC CPU as a whole to be verified  Ability of the CPU to operate with the I/O modules and the integrity of all interconnecting circuits to be verified including backplane conductors.  I/O module complement to be checked.

6.4

Software Security The Supplier shall advise in the Bid his standard procedure for the protection of software package during design development. A QA procedure shall be incorporated within the QA manual for the secure development and storage of all software. On completion of the final 'as built' software package, the Supplier shall place a dedicated project copy within a secure storage area. This copy shall not be revised, and any further amendments shall be undertaken on additional copies.

6.5

Functional Specification Refer to Section 2.6 for the detail specification of ICS.

7. 7.1

SYSTEM CUBICLES AND FIELD TERMINATION CABINETS Components and Wiring The control system cubicles, located in the CPF CER and LTRs, shall contain the electronic components for the ICS, and shall be located adjacent to the associated Field Termination Cabinets (FTC) for the field cabling. The CCR and CER will be provided with computer type suspended flooring, and the partly raised LTRs provided with floor slots. In all cases, system cubicles and FTCs shall be suitable for bottom entry of cables.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

SHEET

25 OF

43

The ICS Supplier shall supply, install and wire all components, racks, power supplies and accessories within the ICS cubicles and FTCs. All assemblies shall be complete and ready for site connection of power inputs, earthing and field cabling. Wiring shall be on cable trays or in trunking so designated as to produce a neat and accessible layout, properly supported and wherever necessary, loomed up. Separate wire-ways and terminals shall be provided for intrinsically safe signals (if used), non-intrinsically safe signals and power wiring. Minimum conductor size for internal panel wiring shall be 0.5 sq mm except for special purpose and ribbon cables. All insulating material shall be flame retardant, low halogen content. Identification sleeves shall be fitted to each end of wiring runs, and shall be inscribed with instrument tag number (where applicable) and terminal number. All terminals in Junction Boxes, FTCs and System cubicles will use “cage-clamp” type terminal. Terminals and gland plates shall be provided for incoming and outgoing field and interconnecting cables. Field and interconnecting cables shall enter from the bottom of the cubicles. 40% spare capacity is required at all entries into the cubicles unless agreed otherwise in writing by the Purchaser. This spare capacity shall also be provided within the cable trunking. A separate terminal shall be provided for each conductor and shall be suitable for a minimum of 2.5 sq mm copper conductors. Sufficient terminals shall be provided for the termination of all spare cores within the field cables. Terminals for field cables shall be test/disconnect type to enable circuit isolation or test. The field cables will comprise individually screened pairs, hence facilities shall be provided in the FTCs for the termination and grounding of these screens. The Supplier shall install means of isolating power supplied to the panel.

7.2

Year 2000 Compliance The ICS components and systems shall be Year 2000 Compliant. The term “Year 2000 Compliant” means that the system, when configured and used according to the documented instructions, will, without manual intervention or interruption:

Correctly handle and process date information, before, during and after January 1st, 2000, accepting date input, providing date output and performing calculations, including but not limited to sorting and sequencing, on dates or portions of dates.



Function according to the design documentation during and after January 1, 2000 without changes in operation resulting from the advent of the new century.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

 

7.3

SHEET

26 OF

43

Where appropriate, respond to two-digit date input in a way that resolves any ambiguity as to the century in a disclosed, defined and predetermined manner. Store and provide input of date information in ways that are unambiguous with regard to the century.

Radio Interface The ICS equipment shall be immune to interference from hand-held radio transceivers in the immediate vicinity with signal strength of 10V/m over the range 27 to 500 MHz, and shall not affect the operation of other equipment.

7.4

Electromagnetic Compatibility (EMC)

In order to comply with the requirements of IEC 61000 all electrical equipment shall meet the current applicable levels of “emission” and “immunity”. All applicable equipment shall be designed so that the Electromagnetic disturbance it generates does not exceed a level allowing telecommunications equipment and other relevant apparatus to operate as intended. The design of equipment should be of an adequate standard to maintain its performance during its operational life in its installed environment. For the purpose of EMC the performance of apparatus which must comply, is taken to be degraded if permanent or temporary loss of function occurs. 7.5

Earthing Reference should be made to the Instrument Installation Specification for general instrument earthing requirements. Two separate instrument earthing systems shall be provided within the system cubicles and FTCs as follows : Electrical earth:

Connection to installation earth of all electrical equipment, for personnel safety. The electrical earth shall be used for panel steel, and power supply earth.

Instrument earth:

Used for termination of instrument cable screens at the FTC. The instrument earth bar must be insulated from steel or any other earth system.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

7.6

SHEET

27 OF

43

Power Supplies The power supply of ICS shall be dual separated supplies 230Vac from individual Uninterrupted Power Supply (UPS) with 30 min backup (2 hours for F&G), on 100% system load. UPS fault alarm shall be transmitted to ICS. All CPF and satellite station UPS facilities will be supplied by Purchaser. The power supply circuits shall be redundant by individual dual power supply line 230 Vac / 24 Vdc with isolating diode units so that if one of the supplies fails the supply to the system is maintained, and the faulty unit initiates an alarm. The power supply to the RTU at each oil production and gas injection wellhead will be 230 Vac from the electrical feeder to the wellhead. The RTUs for these wellheads shall include a small battery, and charging facility, to enable continued wellhead monitoring for a period of 15 minutes following mains power failure.

7.7

Interconnecting Cables It is a requirement to make maximum use of system cabling to minimise site installation work. The ICS Supplier shall provide system cables for all interconnections within rooms between FTCs and system cabinets, system cabinets to operator console, and to mimic/matrix facilities, etc. System interconnections shall comprise multicore cables, with plug and socket assemblies. The connectors shall be of robust construction which, when connected, are locked in place with anti vibration screws. The Supplier shall propose and give details of his recommended type. For the purpose of this Specification the Supplier shall allow 20 metres of cable ready made up between cabinets, cubicles, console, and CCR matrix. The lengths shall be more accurately defined during the detail design. Conductors shall be stranded annealed copper of 0.5 sq mm suitably insulated for the specified voltage. Cabling shall be flame retardant PVC insulated, twisted pairs with overall screens. The ICS Supplier shall include for the required fibre optic core termination facilities for both ends of the CPF to satellite communication link.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

7.8

SHEET

28 OF

43

Hazardous Area Certification For the purpose of the ICS enquiry, it shall be assumed that electrical instrumentation located in hazardous areas will be certified flameproof (EEx’d’). Where suitable EEx’d’ equipment is not available, intrinsically safe (EEx’i’) equipment may be used, subject to Purchaser approval. If EEx’i’ equipment is selected, galvanic isolators (rather than Zener barriers with dedicated IS earth bars) shall be used within the FTCs. All ICS components, except possibly the wellhead RTUs, will be located in safe areas.

7.9

Ingress Protection Field mounted equipment at the wellheads and satellites shall have an ingress protection to IP56 (protected against dust and strong jets of water) to EN 60529. Control room equipment shall be protected to a minimum of IP21.

7.10 Future System Extension The separate PCS, ESD and F&G subsystems shall each be capable of future expansion. In addition to the I/O, terminations, etc., sparage detailed previously including MGF spare, all control PLCs or microprocessors, and operational condition (air conditioning power supply ,cable route, etc.) shall have the capability of handling an additional 50% control and monitoring functions. 8. 8.1

ICS INTERFACE INTO PACKAGED PLANT General Packaged plant, typically gas compressors, air compressors, etc., will be interfaced into the ICS to enable monitoring and control (where applicable) of the equipment from the operator interface facilities in the CCR. In general, this interface will be one of the following three forms: 

Fully Integrated

 

Partially Integrated Stand Alone

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

8.2

SHEET

29 OF

43

Fully Integrated Packages These Packages, typically water treatment filters with auto-changeover and backwash facilities, will be supplied as skid mounted process plant units, generally with instrument cabling wired to skid edge junction boxes. All control and monitoring functions will be undertaken within the PCS/PSD, to a design (typically sequence logic functions) by the Package Supplier.

8.3

Partially Integrated Packages These Packages, typically gas compressors, will be supplied as fully cabled skids, with skid edge junction boxes. The total Package will be controlled and monitored in two forms: 

The machine driver, compressor bearings, lube oil systems, etc., will be monitored and controlled from the Package Supplier’s Unit Control Panel (UCP), which will be located in a safe area LTR. The UCP will also contain surge protection and load control systems as required for the compressor.



The gas side of the compressors (excluding surge protection and load control) will be generally monitored and controlled by the PCS/PSD system, using a node of the PCS located adjacent to the compressor machine UCP in the LTR.

The compressor UCP shall communicate via redundant serial link with the dedicated PCS node to enable monitoring of the compressor from the CCR operator work stations. The scope of the signals communicated to the PCS shall be sufficient to enable development of VDU displays, with alarms and indications, for the machine and the supporting lube oil systems, etc. Although vibration alarms and amplitudes will be transmitted to the PCS for CCR display, vibration analysis (shaft position against vibration amplitude) will only be made available on the Package Supplier’s UCP. Sequence interlocks and PSD functions between the gas side PCS node and the machine UCP shall be undertaken by hardwired signals. In general, ESD functions will be external to the compressor Package, undertaking isolation of the gas stream and fuel gas supply. There will, however, be an ESD signal to gas turbine drivers where applicable. Although F&G detection/protection facilities will generally be external to the Package, gas turbine hoods will be supplied with F&G detectors, which shall be wired to F&G logic within the UCP. Control outputs will be taken to the Package Supplier’s extinguishant system, HVAC dampers, etc.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

8.4

SHEET

30 OF

43

Stand Alone Packages These Packages, typically air compressors, will be supplied with on-skid control panels, incorporating local annunciators and indicators. A simple hardwired interface will be cabled into the relevant distributed PCS node, providing a small number of status signals and common alarms for CCR display.

8.5

Instrumentation Sub-System Packages In addition to mechanical plant Packages, the control/instrumentation scope for the Ourhoud project will include certain instrumentation sub-systems. The following paragraph outlines a typical unit: A dedicated tankage monitoring system will be provided to monitor level and temperature of the various water and oil storage tanks. This system will include for special purpose volume computations in accordance with inserted tank data, and will be located in a separate cubicle within the OTR. The tankage monitoring system shall interface into the ICS via serial link to enable transfer of tankage data to the operator and the MIS.

9. 9.1

SYSTEM INSPECTION AND TESTING General After final system assembly, the Supplier shall carry out his own comprehensive testing procedures to ensure full functionality of the complete system prior to offering the equipment for witnessed Factory Acceptance Test (FAT). The overall testing and commissioning procedure is envisaged to be in at least four stages as follows :  Supplier’s tests.  Supplier shall confirm the heat soak test as card by card to be done during assembling period. Then the global 72 hours test can be suppressed.  Witnessed FAT (including FATs at sub-contracted suppliers’ works as appropriate), with Client and Third Party present, to demonstrate functionality of the equipment and system using simulated inputs. Overload test shall be carried out during FAT also, with reference to the Appendix-1.  Site Acceptance Test (SAT) to confirm full functionality of the system following installation.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

SHEET

31 OF

43

The Supplier should note that the Client and Third Party require three weeks’ notice for attendance at witnessed tests. The scope of the tests shall fully demonstrate the capability of the ICS to meet the requirements of Statutory Regulations, this Specification, and all supporting documentation. 9.2

Test Procedure Full test procedures shall be developed by the Supplier and provided for Client/Third Party comment/approval, prior to FAT and SAT. These procedures shall define all test criteria, and shall contain an acceptance column for all systems, sub-systems and components that have to meet specified functional or integrity criteria. The procedures shall also include the Supplier’s proposals for presentation and control of a ‘deviation report’ and ‘outstanding items’ system to provide a historical record of problems encountered during testing and means used to overcome them. The preliminary test procedure shall be shown in Appendix-1 as “ACCEPTANCE TESTS AND ACCEPTANCE”. Detail procedure shall be discussed and determined in detail engineering stage.

9.3

Communication Interface All inter-system bus and serial links within the ICS shall be fully verified, and simulations undertaken to verify the communication loading is within the specified limits. The ICS Supplier shall also include for the functional verification of all serial and bus links into related systems, e.g. machinery Package Supplier UCPs. The ICS Suppliers scope shall include for a minimum of two portable serial link test units, comprising hardware and software identical to that used for the delivered PCS/PSD systems. These units shall be made available for use by the packaged plant Suppliers during UCP tests. Complete communication test (retrieval of tables and sending / receiving of commands with the final application) shall be done before the FAT to allow for the latter to be run with the final configuration. It is the ICS Supplier’s responsibility to liase with the UCP suppliers as necessary to ensure full compatibility between the various systems. Communication between PCS/PSD and wellhead RTUs via SCADA node with optical communication way shall be tested with a minimum one (1) complete set of RTU.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

9.4

SHEET

32 OF

43

Site Acceptance Test

The complete inventory of ICS components including spare parts and consumable items shall be inspected at site. All ICS functions including application software and Sub-system communication shall meet the applicable specifications. The ICS Supplier has the responsibility to confirm above tests at site as Site Acceptance Test (SAT).

10.

SYSTEM ENGINEERING

10.1 General The Supplier shall include for an engineering documentation package in accordance with the Supplier’s Documentation Requirements Schedule (SDRS) incorporated in the Technical Requisition. Where practicable, documentation shall be provided in electronic as well as hard copy format. 10.2 Pre-Order Documentation The Supplier shall provide, with his Proposal, adequate documentation to demonstrate that the proposed design satisfies the requirements of this Specification and other documentation referred to herein. This shall include, but not necessarily be limited to:  System topology diagrams  Separate Outline Specifications for the separate PCS, PSD, SCADA, ESD and F&G parts of the system.  I/O card counts and sparage calculations  Initial reliability calculations for PCS, ESD and F&G systems  Supplier proposals, and analysis, for satellite and wellhead control units  Proposals on use of computer based design techniques  Preliminary electrical load list for individual items of equipment  Spare parts lists for commissioning, and for 2 years’ operation  Insurance spares

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

7461-ORH-SP-J-87001

DOC. No.

0-1800

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

SHEET

33 OF

43

10.3 Post-Order Documentation The Supplier shall provide the documentation in accordance with the Supplier Documentation Requirements Schedule (SDRS). All Supplier documentation shall be made available in both paper and electronic format. The ICS Supplier shall allow for the following documentation:  Functional design specification for the overall ICS, and the separate PCS, PSD, SCADA, MIS, ESD and F&G systems  Overall and system dedicated topology diagram  Bills of material for separately definable hardware components within each system  Cubicle and console internal and external layouts, including card locations  Power distribution and earthing schematics  Field cable termination diagrams  Interconnecting cable schedule, connection details, and block diagram  Listing and details of serial links to external systems  Tagged system databases, one for each system, recording configuration details for each tagged signal.  Load and heat emission calculations for electrical components  System manuals containing, as a minimum, procedures for the following: - System start-up and shutdown - System maintenance - System test and fault diagnosis - On-line and off-line loop configuration - Sequence logic configuration The Supplier shall propose procedures for the following engineering actions:  The receipt of ICS design data from the Purchaser in database format, and the direct transfer of this core data into the configuration of the system.  The configuration of loops, sequence and shutdown logic.  The development of graphic displays.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

SHEET

34 OF

43

10.4 Development An architecture study shall be done to implement the results of the RAM study and may lead to ICS architecture simplification. Application Development shall be done directly in French (programming and Human Interface); all application specific documents shall be in French. Some standard Manufacturer’s Technical Documentation may be accepted in English, pending COMPANY Approval. Provisions shall be made for two Sonatrach employees to actively participate in application development and FAT on ICS vendor premises. Prior to full application development a series of “typicals” (programming and HMI) shall be developed for basic functions in co-operation with COMPANY; only after “typicals” have been subjected to a successful FAT by COMPANY, shall they be used as elementary building blocks for the development of the complete application. A preliminary non-exhaustive list: Analog input, Analog input with 4 thresholds, Triad of analog inputs with voting, Discrete input, Discrete output, Discrete output with line monitoring, Analog output, Regulator, Control valve, SDV simplex, / ROV, SDV duplex, ESDV, LV pump, HV pump, LV electric starter, HV electric starter, Monowell, Multiwell, Safety bar, Normal / Helper / Spare 3 pumps @ 50%, Normal / Helper / Spare 2 pumps @ 100%, Normal / Spare 2 pumps @ 100% The content and hierarchy of Graphic displays on ICS Operator station shall have to be approved by COMPANY before implementation. IEC-61131 (Programming method) and ISO-12207 (Guideline for development of application) shall be applicable for engineering development and programming. 11.

OPERATOR TRAINING

11.1 Training Facilities An operator station assembly, which consists of three operator stations, one instructor console, simulator computer and communication bus, shall be provided 3 months prior to on-site commissioning, and shall be supplied complete with a software package enabling training of operators on the control and monitoring facilities provided by the Project system. The software package shall simulate all control and protection functions which will be available on the supplied equipment. The required simulator function is shown in Project Specification ORH-SP-J-87011, (S-000-1372-001) “Specification for Simulator”.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION SHEET

Specification for Integrated Control System

35 OF

43

The “Training” portion of the simulator must be operational three month before the beginning of the commissioning operations; the “Optimization/Tuning” portion of the simulator must be operational from the beginning of the start-up.

11.2 Training Program The supplier will be required to provide the Training Courses on total ICS for operating and maintenance personnel as detailed in Table 11.1 below: However, this program shall be integrated into the general project training program for Sonatrach personnel. Table 11.1

Scope 1 week at Supplier’s works on software procedures 1 week systems training during FAT of overall system 1 week application training on site during commissioning. 4 weeks for configuration and system maintenance

12.

Number of Persons Maintenanc Operating e 16 16

4 4

16

4

-

4

GUARANTEE The supplier shall guarantee the integrity, workmanship, engineering ability and the materials of hardware. The supplier shall guarantee the equipment for the warranty period and the conditions stated in the enquiry/purchase order documents (as applicable).

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

SHEET

36 OF

43

APPENDIX – 1 ACCEPTANCE TESTS AND ACCEPTANCE 1.

Application software Each application shall be the subject of acceptance tests. The software shall comprise an assembly of copies of standard software modules (assumed correct) and/or validated, custom software modules. The objective of acceptance testing is to verify the connections between the software modules and the parameter settings of the copies (names, message texts, colour coding, threshold values, etc). The tests should be easily reproducible to ensure that any modifications made are consistent with their specifications and have not affected the satisfactory operation of the parts assumed unaffected ("non-regression" check).

2.

Non-standard software The aim of acceptance testing is to check that the non-standard software modules are compliant with their specification. 1) Each typical module shall be the subject of an acceptance test based on the acceptance test procedure for the related standard function. The supplier shall propose a procedure, a platform and the tools for acceptance testing all types of software modules involved in implementing the standard function. 2) With each change of version of a typical module, the acceptance test of the standard function ought to be repeated. 3) The acceptance test shall be applied to an identified version of the software and its documentation. 4) The documentation must therefore be available at the time of acceptance testing. 5) It would be desirable for the supplier to submit the results of his own inspections prior to acceptance testing.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

3.

"System" acceptance test specification

3.1

Objectives

SHEET

37 OF

43

1) To measure specified performance levels under maximum load conditions. 2) To measure, under such maximum load conditions, the loading on the machines and the networks. The acceptance criteria shall be the value supplied in the design documentation. 3) To check out operation of the system display and level 1 service procedures (fault locating and identification). 4) To check that system operation in degraded situations is in accordance with specifications: redundancy arrangements, management of communication link faults; shutdown, restarting and initialisation of subsystems. 5) To check that a total shutdown, battery-based data backup time and restarting of the entire system are all carried out correctly. 6) To check that the system's administration and maintenance procedures are correct. 3.2

Procedure (principles) 1) Measurement and reading of machine loads (PLC and controller cycle times, CPU and disk load, etc) and network loads in "normal" situation. 2) Simultaneous startup of test generators in normal situation and recording of loads. 3) Determination of the maximum load supported by the system supplied and recording of specified characteristics. 4) Verification or steady-state operation of the system in degraded situations, of the system display and of the redundancy mechanisms. 5) Verification of steady-state operation of partial restarts. 6) Verification of operation under load (generators running) of the system in degraded situations, of the system view and of the redundancy mechanisms. 7) Verification of operation under load of partial restarts. 8) Verification of the simultaneous restart of all of the system after a general power supply failure for a specified time. 9) Verification of administration and maintenance procedures and tools,  Failures - Fault tracing based on information from the system display and/or the administration and maintenance system. - Identification of the type of failure. - Return to service after rectification.  Modifications

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

0-1800

7461-ORH-SP-J-87001

DOC. No.

REV.

S-000-1371-102

2

PROJECT SPECIFICATION SHEET

Specification for Integrated Control System

3.3

38 OF

43

Implementation, commissioning and backing up of changes to each type of software. System configuration management.

Resources 1) System design documentation:  A map of the applications and the information flows (see ... ).  A map of the system: communication networks, architecture of machines / firmware / software (see ...).  Administration and maintenance procedures. 2) Load generators (principles):  Periodic flows 100% signal sent signal returned

0% figure 1







The test signals shall include signals of modifiable frequencies (for example, sawtooth wave signals, easy to produce). The generation, recording and display of these signals, the operator interfaces required for implementing these functions and modifying the parameters shall be constructed using the system's technical functions. The principle is to inject a test signal and record the signals sent and received. The phase difference represents the group delay time and the distortion of the signal transmitted reveals how the software modules through which the signal has passed are operating. Injection of signals of variable frequencies on different paths in the system in operation is used to determine performance levels, given the loading of the system at the time of the test, and to explore the "reliable" operation of the system, still under the same load conditions. Since the systems are non-linear, the limit on the acceptable region represents the frequencies beyond which the transmitted signal is highly distorted.

URHOUD - Organisation Ourhoud

COMPANY’S DOC. NO. JOB No.

7461-ORH-SP-J-87001

DOC. No.

0-1800

REV.

S-000-1371-102

2

PROJECT SPECIFICATION Specification for Integrated Control System

 

SHEET

39 OF

43

The repetition of these measurements for different system loading provides a means of exploring all of the acceptable operating range. This test shall be used to measure the performance levels of the following technical functions:  Display of analogue measurements and MMI.  Operator commands.



 Execution of processes, machine performance and communication network performance.  History load and trend. Event flows

 The test signals shall comprise generators specially developed for this purpose and for which the labels provide a rapid indication of which events have been lost or transposed, and/or shall be based on application alarms.  This test shall be used to measure the performance levels of the alarm process (logging, sorting).  The file transfer function shall be tested using files of maximum size and the protocols that are to be used. 3) Machine and network load measurement tools:  Communication protocol analyzers ("sniffer" type from Network General).  

Machine loading analyzers (CPU, disk, swap zone, queues), "HP-Glance" type for HP-UX. SNMP administration tools (MIB, supervisor).

4) System display and DCS and network administration tools. 5) Test procedures. These will need to be prepared in detail by the supplier and/or the systems integrator, and shall be designed to achieve the objective.