VECO Doc. No.

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TABLE OF CONTENTS 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.0 3.0 3.1 3.2 3.3 4.0 4.1 4.2 4.3 4.4 5.0 6.0 6.1 6.2 6.3 INTRODUCTION............................................................................................................... 4 General ............................................................................................................................. 4 Scope ................................................................................................................................ 4 Definitions ......................................................................................................................... 5 Abbreviations .................................................................................................................... 5 Environmental Conditions ................................................................................................. 6 Device Protection .............................................................................................................. 7 Codes and Standards ....................................................................................................... 7 SCOPE OF SERVICES .................................................................................................... 8 TECHNICAL REQUIREMENTS OF THE RTU CAbinet .................................................. 9 Scope of Supply ................................................................................................................ 9 Functional Requirements ................................................................................................ 10 Design Requirements...................................................................................................... 11 RTU HARDWARE .......................................................................................................... 12 General ........................................................................................................................... 12 MOS and POS ................................................................................................................ 13 CPUs............................................................................................................................... 13 Modules........................................................................................................................... 13 SOFTWARE.................................................................................................................... 16 COMMUNICATION ......................................................................................................... 16 Overview ......................................................................................................................... 16 Technical Requirement ................................................................................................... 17 Communication with Laptop............................................................................................ 17

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6.4 7.0 7.1 7.2 8.0 9.0 10.0 10.1 10.2 10.3 10.4 10.5 11.0 12.0 13.0 14.0 14.1 14.2 14.3 15.0 16.0 17.0 18.0

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Other Modules or Devices............................................................................................... 17 RTU PROGRAMMING, CONFIGURATION AND MONITORING LAPTOP................... 17 Functional Requirements ................................................................................................ 17 Technical Requirements ................................................................................................. 18 POWER SUPPLIES ........................................................................................................ 19 SYSTEM PERFORMANCE ............................................................................................ 19 CABINETS...................................................................................................................... 19 General ........................................................................................................................... 19 Labeling........................................................................................................................... 20 Equipment Grounding ..................................................................................................... 20 Cabling and Wiring.......................................................................................................... 21 Terminations ................................................................................................................... 21 SPARE PARTS............................................................................................................... 21 SPECIAL TOOLS ........................................................................................................... 22 MARKING AND PACKING............................................................................................. 22 DOCUMENTATION ........................................................................................................ 22 General ........................................................................................................................... 22 Functional Design Specification (FDS) ........................................................................... 23 Inspection & Testing........................................................................................................ 24 TRAINING....................................................................................................................... 25 SITE SERVICES ............................................................................................................. 25 QUALITY ASSURANCE/QUALITY CONTROL ............................................................. 26 GUARANTEE ................................................................................................................. 26

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1.0 1.1

INTRODUCTION General PETRONAS CARIGALI (Pakistan) Ltd. (PCPL) is undertaking the development of Mehar Gas Field in Mehar Block (Block 2767-1) located in Sindh and Balochistan Provinces of Pakistan. Mehar Block is located in the Kirthar Fold belt area, in the Middle Indus Basin. Mehar field is located about 190 km west of Sukkur and 400 km north of Karachi in Sindh province (distances by road). The environment is arid and the terrain is mountainous. Mazarani gas field, operated by PPL is situated about 25 km to the north, while Zamzama gas field operated by BHP is situated about 70 km to the north of Mehar Field. Mehar field consists of Pab and Ranikot formations. The wells will be connected to the new GPF through a Gathering System. There will be a total of 6 wells (3 Wells from the North and 3 Wells from the South). 3 Wells will be producing in Phase-1 and 3 Wells in Phase-2 (future). ME-1 well is from PAB reservoir. ME-2 wells is from Ranikot reservoir. Wells, ME-3, ME-4, ME-5 and ME-6 are dual completion. PCPL intends to develop the Mehar Field by installing a Gathering System, Gas Processing Facility (GPF) and Product Storage & Loading Facilities. The field facilities will be developed in two phases, Phase-I and Phase-2. Phase-1 development will cater for 55 MMSCFD of gas production and Phase-2 will cater to 80 MMSCFD of gas production. The expected condensate production rate is 6600 BPD in Phase-I increasing to 7000 BPD in Phase-2.

1.2

Scope This specification covers the basic minimum requirements for design, manufacture, configuration, testing, documentation, and preparation for shipment of PLC based Wellhead and Manifolds RTU for the MEHAR Gas Development Project. Integration of RTU with PMCS shall be part of EPCC CONTRACTOR. This specification shall not be considered all-inclusive. The VENDOR shall submit full technical details of his standard equipment, which meet the requirements herein. Aspects of the requirements, which cannot be met, shall be identified and variances explained. This specification shall be read in conjunction with other specifications and documents indicated in the material requisition. The order of precedence of the documents shall be the following: Government Legislation; Material Requisition; Project Specification; Basic Design Drawing;

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International Codes & Standards; Company Specifications.

The Control System shall be complete, tested, pre-commissioned, and commissioned so that it shall ensure a trouble-free start-up and operations of the new facilities. 1.3 Definitions COMPANY ENGINEER Petronas Carigali Pakistan Limited (PCPL) or any Third Party assigned by the COMPANY Party which carries all or part of the design, engineering of the PROJECT. VECO Engineering, Abu Dhabi is the ENGINEER. Party which carries out all or part of the design, engineering, procurement, construction, commissioning or management, of the PROJECT. EPCC CONTRACTOR includes his approved, MANUFACTURERS, SUPPLIERS, VENDORS and SUBCONTRACTORS. Party/ies, which manufacture and/or supply materials, equipment and services to perform the duties as specified by the CONTRACTOR in the scope of supply. MEHAR GAS DEVELOPMENT PROJECT

EPCC CONTRACTOR

MANUFACTURER/SUPPLIER/VENDOR

PROJECT 1.4 Abbreviations PMCS ESD EWS F&G PLC RTU MTU WHCP : : : : : : :

Process Monitoring and Control System Emergency Shutdown System Engineering Work Station Fire & Gas Programmable Logic Controller Remote Terminal Unit Master Terminal Unit Well Head Hydraulic Control Panel

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SCSSV SSV WV POS MOS FAT SAT SPIR 1.5

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: :

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Surface Controlled Sub-Surface Safety Valve Surface Safety Valve Wing Valve

: : : : :

Process Override Switches Maintenance Override Switches Factory Acceptance Testing Site Acceptance Test Spare Parts Interchangeability Record

Environmental Conditions Wellhead facilities, Gathering stations and GPF area has been tentatively selected at a location about 190 km west of Sukkur and 300 km north of Karachi in Sindh Province. The environment is arid the terrain is mountain. The Environmental conditions are: Maximum Ambient Temperature Minimum Ambient Temperature Wet Bulb Temperature (design) Relative Humidity (max / nor / min) Direction of Prevailing Wind Wind Velocity (max / normal) Elevation Above Mean Sea Level (GPF) Average Barometric Pressure Ice/Snow Seismic zone Annual rainfall min. Annual rainfall max. : : : : : : : : : : : : 55C 0.5C 30C 90 / 65 / 20% From South to North. Hold/ 2.9 knots 54m (Site-IV) / 56m (Site-l) 1001.2 mbara (29.56 inches of Mercury) None Zone 2B, upper moderate with ground acceleration of 0.2 (Hold) 63.3 mm (year 2006) 139.9 mm (year 2005)

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Device Protection

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Instruments shall be selected based on area classification drawings by Electrical (12MGDP-E-4000)). All instruments shall be certified as EExi IIA/IIB, T3. Suitable isolators shall be provided in RTU cabinet. EExd protection shall be used for solenoid valves & where EExi not available. Instruments enclosures, in field, shall be dust proof, weather proof to IP 65, as a minimum. All external surfaces shall be suitably painted for corrosion protection. RTU cabinet shall be weatherproof to IP-65 with increased safety as will be installed inside passive cool shelter. Intrinsically safe barriers, independent or integrated within I/O modules, shall be TV certified SIL 2 minimum, when used for ESD or F&G functionalities and shall allow line monitoring facilities. All external surfaces shall be suitably treated to provide an anti-corrosion protection against the plant atmosphere. 1.7 Codes and Standards Codes, specifications and standards referred to within this specification, form a part of the requirements of this specification in a manner and to the extent specified within those codes and standards but not limited to below. Unless otherwise specified, the latest edition or revision to these codes specifications, and standards in force at the time of request for quotation and/or Purchase Order shall apply. No deviations from the Codes and Standards listed in this document will be allowed unless such deviations are clearly identified in the bids, with the reasoning. In addition, they must be approved in writing by COMPANY. EN 50081 EN 50082 EN 50014 EN 50018 European Harmonized Generic Standard for Electro-Magnetic Emissions European Harmonized Generic Standard for Electro-Magnetic Immunity Electrical apparatus for potentially explosive atmosphere General requirements Electrical Apparatus for potentially explosive atmosphere Flameproof "EEx(d)"

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EN 50020 ISA - S5.1 ISA - S5.2 ISA - S5.4 ISA-S84.01 IEC 60079-14 IEC 60529 IEC 60801 IEC 61000 IEC 61131 IEC 61131

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Electrical Apparatus for potentially explosive atmosphere Intrinsically Safe "EEx(i)" Instrumentation symbols and identification Binary Logic Diagrams for process operations Instrument Loop Diagrams Application of Safety Instrumented System for the Process Industries. Electrical Installation in Explosive gas atmospheres Classification of degrees of protection provided by enclosures Electromagnetic Compatibility for measurement and control equipment Electro-magnetic Compatibility Programmable Logic Controllers Part 2 Programming Languages (Part 3) Guidelines for the application and implementation of programming languages (Part-7) Safety Instrumented Systems Ethernet TCP/IP Fire, Gas and Smoke detection Systems Instrumentation documentation and drawings Instrumented Protective Systems Inspection and Functional Testing of Instruments Spare parts National Fire Protection Code industrial process

IEC 61508 IEEE 802.3 PTS 32.30.20.11 PTS 32.31.00.34 PTS 32.80.10.30 PTS 62.10.08.11 PTS 70.10.90.11 NFPA 72

2.0

SCOPE OF SERVICES The scope of services provided by the VENDOR shall include the following as a minimum:

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Project management and reporting; Functional design specification (participation, endorsement, finalization); Design, sizing and engineering studies of the well and manifolds RTU cabinet; Coordination with third parties (in particular TV); Procurement of the necessary components and software, with related licenses; Configuration and programming of the system, including I/O assignment, database, user application, SOE, communication; Integration and wiring of the RTU cabinets; Preparation of the documentation including final documentation; Internal tests and FAT; Packing, transportation and delivery; On site assistance for installation, pre-commissioning, commissioning, SAT, including all necessary adaptation of the hardware and application software, and start-up of systems; COMPANY personnel training.

3.0 3.1 3.1.1

TECHNICAL REQUIREMENTS OF THE RTU CABINET Scope of Supply RTU (PLC) For each well, the RTU cabinet shall include the following components as a minimum: Racks; CPUs; Power supply modules; Communication modules; I/O modules; I/O field termination assemblies; Utilities i.e. lightning, electrical outlet etc;

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Cables and connections between components; Solar array, batteries, charge controller and accessories for Solar Panel.

Cabinet The RTU shall be provided housed in a cabinet in a passive cool shelter with all its interfaces for field instruments, Wellhead Hydraulic panel and other sub-systems. The RTU cabinet shall also contain the following: Intrinsically safe barriers for all field devices that provide intrinsically safe protection mode. These barriers may be independent or integrated inside I/O modules; Interfacing relays certified TUV AK6 for safety trips if required.

3.1.3

Configuration Device Configuration in all RTU shall be done by Laptop EWS. EWS shall be provided with licensed operating & engineering software required for RTU configuration. RTU shall have provision for monitoring and modifications through PMCS in CCR. The laptop shall be loaded with TUV certified software and procedure.

3.1.4

Solar Panel and Passive cool shelter VENDOR shall provide Solar Panel to power the RTU and other electrical loads at wellhead. For details requirement of solar panel specification document no. 12-MEGP-E1008 shall be followed. Pre-engineered Passive cool shelter shall also be provided to house the RTU at wellhead and manifolds with all systems ( air conditioners, lighting and power supply systems) in place and tested before shipment. Shelter shall be rain proof and dust proof and shall be designed to withstand the environmental conditions specified in sec 1.5. The shelter floor shall be sealed to prevent the ingress of gas or vapor.

3.2

Functional Requirements The RTU shall have combined operation sequence and safety functions including: Wellhead operation and shutdown; F&G alarm and shutdown; Well open / close sequence.

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Each RTU cabinet shall perform the following integrated function, as a minimum: Emergency Shutdown (ESD), to avoid personal injuries or major damage to the environment, equipment, personnel, etc. by setting wellhead equipment into a safe predetermined shutdown state, in case of abnormal condition; Fire and Gas (F&G) detection, to allow intervention of relevant personnel to contain and prevent the spread of fire, and extinguish it in the early stages, if possible. Confirmed fire shall shutdown the wellhead through CCR operator intervention; Process monitoring and control of the well; Wellhead valves shall be able to remotely operated from PMCS through the RTU via WHCP; Choke valves shall able to adjust remotely from PMCS through the RTU.

3.3

Design Requirements The system shall be designed to meet the requirements of this specification and other relevant international codes and standards. However, in general this shall meet the following specific requirements listed below. RTU shall be designed for IOs as per IO list 12-MGDP-I-7102.

3.3.1

Segregation Rules RTU modules and associated accessories, if any, shall be segregated as follows: Process I/Os; ESD I/Os and F&G I/Os shall be connected to different modules though allowed on the same rack. CPU and communication modules shall be installed in the rack dedicated to ESD and F&G.

3.3.2

Redundancy Redundancy shall apply according to TV certificate to meet the required level (SIL 2 minimum). For this purpose, all common parts of RTU shall be redundant including but not limited to: CPU, bus, power supplies, etc.; Communication module.

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

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Some ESD and F&G I/Os do not need safety requirement (lights, lamp-test, and push buttons). Those I/Os can be connected to standard I/O modules. Process I/O modules do not need SIL 2 compliance. 3.3.3 Spare Capacity As a general rule, quantities used to size individual components shall be easily expandable with I/O variation. All these components, mainly the I/O sub-system shall be provided with equipped spares capacity of 20% for each type of signals and for each function (ESD, F&G and Process). For this purpose, additional I/O modules shall be provided wherever the sum of all unused I/O for a type of module used for a given function does not reach this 20% spare. Addition of new instruments into these limits of 20% shall only require soft configuration. Quantities used to size all common components, either hardware or software (CPU load, communication modules, rack, power supply, and memory capacity) shall provide spare capacity of 20% for each type of I/O signals plus additional spares as follows: 30% for CPU load, communication modules and memory capacity; 20% for racks. Each type of rack shall allow addition of a minimum of 20% I/O modules, without the addition of a new rack. If necessary, additional racks shall be provided to comply with this requirement.

In any case, CPU load shall not exceed 60% of maximum capacity. RTU cabinet shall be provided with 20% spare space to accommodate future extension. 4.0 4.1 RTU HARDWARE General RTU shall be implemented on high reliable fail-safe and fault tolerant architecture. Failsafe is defined as the capability of a system to go to a predetermined safe state when it is de-energized in the event of one or more failures. Fault tolerance is of prime importance. In particular, the system shall be able to continuously operate without any plant disturbances during modules failure and replacement. RTU shall be designed to allow hot replacement of any failed component without loss of system performance and plant safety level. Re-initialization of newly installed module shall as per TV requirement requiring manual reset. RTU shall be certified SIL 2 minimum as per DIN V19250 (TV approval). Auto-test and internal diagnostic of major parts (I/O modules, processors, buses, memory and power supply) shall be considered as being of primary importance, as well as RTU faults monitoring.

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RTU modules shall be provided with LEDs for normal and fault indication. System components design shall be modular with rack mounting and plug-in type assemblies. RTU shall restart automatically after a power supply restoration without extensive time consuming for system rebooting procedures (VENDOR to define maximum time) and without system qualified technician (to be performed by operator or maintenance technician). 4.2 MOS and POS MOS and POS shall be provided in CCR as required by the operation procedure. 4.3 CPUs Each processor shall be provided with battery backup to retain its memory for two (2) months. Low battery level alarm shall be provided 3 months before as part of the diagnostic alarm. The processor shall be capable for performing both logic and sequence functions. Also, VENDOR to note that RTU may have to perform process function such as integration, counting, etc. The VENDOR shall state the list of available standard functions and algorithms in his proposal. The programmable controllers shall be programmed and configured to meet the functional requirements. At start-up, the system shall be immediately and automatically available without human intervention. Watchdog function shall be available. Logic functions, timing data and operating subroutines shall be loaded and tested into the RTU at the VENDORs premise and shall be stored in non volatile memory. It shall be possible to configure the RTU using easy-to-use language. VENDOR shall specify which programming languages are available on the configuration software, and if it complies with the requirements of IEC 61131. The logic shall be TUV certified. RTU shall be protected from unauthorized configuration modification by key lock and/or password. All facilities needed for any modification of the configuration shall be provided on the programming console. 4.4 4.4.1 Modules Principle All I/O modules dedicated to ESD or F&G functions shall be suitable for safety application; except for non-critical I/Os such as push buttons, lights, etc. These noncritical I/Os shall be indicated in the input/output list. All other modules shall be designed so that, in no case, they may reduce the safety level of the overall system or of other safety I/Os. Safety I/O modules shall be SIL 2 compliant, as a minimum. They shall support linemonitoring facilities, allowing open and short circuit detection and alarming.

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All I/O modules dedicated to F&G functions shall be compliant with NFPA 72. Alternatively, VENDOR shall indicate compliance to any other national fire protection regulation. All field mounted sensors or actuators shall provide intrinsically safe (EExi) protection, except for solenoid valves and motors. Intrinsically safe barriers may preferably be integrated in I/O modules. As an alternative, they may be supplied as independent components. RTU components shall be of modular design, with rack mounting and plug-in type assemblies. Each RTU module shall be equipped with light indicators for fault and status display, and shall provide error and alarm status for group alarm indication in the PMCS. It shall be possible to replace I/O modules without switching off the power. All modules shall be on-line replaceable without degrading the system performance, affecting other components or causing a system failure. Re-initialization of newly installed I/O module shall be automatic. All printed circuit boards shall be protected against corrosion and humidity by means of appropriate varnish coating and gold plated contacts of connectors or equal. 4.4.2 Analogue Input Standard signal will be 4-20 mA, 24 V DC, 2 wires, floating for passive transmitter. Passive transmitter means that RTU module will deliver power supply for 4-20 mA input signal. However, it shall be able to accept passive inputs, i.e. powered by the field devices. Analogue inputs shall incorporate monitoring function. Signal range shall be software configurable per input channel. RTUs shall be able to perform and generate as a minimum the following facilities for each type of detection loop: Detection loop fault (auto-test, beam block, over range, etc.); Open and short circuit line monitoring with generation of fault; Inhibit facilities for maintenance operation; Detection loop alarm reset.

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4.4.3

Analogue Output Each analogue output shall be standard 4-20 mA DC signal. Output channels shall be isolated, independent and individually protected by fuse. Analogue output shall be powered by RTU internal 24V DC supply. The negative and positive sides of the circuit output shall be wired to independent terminals (common supply or return is not allowed). Each output channel shall be able to drive an external load up to 750 ohms.

4.4.4

Digital Input Sensors shall be volt-free contacts. RTU shall provide the power for each type of switch. For volt-free contacts, power will be 24V DC. Input modules shall include circuitry (filtering, etc.) to ensure that any "chatter" or "bounce" encountered during contact closure does not initiate erroneous information. Filter time may be software configurable. Dielectric strength for digital input shall be tested between I/O terminals and ground for 2 seconds. VENDOR shall state the required voltage test.

4.4.5

Digital Output Digital outputs shall use either solid state or relay technology, and be voltage free. Output circuits shall be short circuit proof. Short-circuiting of one output shall not affect any other channel. Electronic fuse shall be part of output module. Each output contact shall be individually configurable to allow the following actions: Latched; Pulse; Normally open; Normally close.

The output contacts shall be powered by the internal 24 V DC power supply. Interfacing output relays will be used when output load requires any other voltage. The following outputs shall be supported: Solenoid valves with 24 VDC coil voltage; Motor starting commands, if any, with interfacing relay powered by RTU.

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For safety trips (ESD or F&G), VENDOR shall provide minimum SIL 2 TV certified relays. These relays shall be hermetically sealed and fitted with LEDs. 5.0 SOFTWARE RTU software shall allow: Function block diagram programming and editing compliant with part 3 of IEC 61131, which defines requirements of programming languages. The programming software shall preferably allow use of ladder logic as well as function blocks, Boolean logic and structured text for building the control logic; Offline and online programming; Define system and hardware configuration; Tag name definition to assign Owners tag name to individual hard wired input/output points and other software/memory resident points; Test and debug program execution which allows software testing before actual program downloading; Download configuration software and application program; Monitor the real time program execution with program variable updates on the function block logic diagrams; Manual forcing; Password security to define users and their privileges with regard to editing, manual forcing, download and other operation; Automatic documentation and report generation for documenting programs, audit trail of program changes and user actions.

6.0 6.1

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

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Communication interface shall have internal self-diagnostics to ensure data integrity and operational security. Identification and location of faults and status shall be automatic. Faults and failures of the communication link or module shall not degrade the RTU reliability. Communication module shall be rated interference free. It shall be possible to replace communication module without switching off the power. Re-initialization of newly installed module shall be automatic. Each communication module shall be equipped with light indicators for fault and status display, and will provide error and alarm status at the operator station. Loss and restart of communication shall not result in trips or status changes of the communication ports. Recovery of communication shall be automatic. 6.3 Communication with Laptop VENDOR shall provide communication facilities to allow connection of a laptop directly to the RTU, for local maintenance activities. 6.4 Other Modules or Devices VENDOR shall specify in his proposal the different types of modules. 7.0 7.1 RTU PROGRAMMING, CONFIGURATION AND MONITORING LAPTOP Functional Requirements Both laptop and EWS in CCR shall allow development and maintenance operations. RTU shall be able to support both on-line and off-line programming. The laptop software shall have on-line help facility. It shall include the following minimum functional requirements: I/O assignment and database configuration (module type location, tag name, description, type, etc.); User program implementation for sequences, logic diagrams, etc.; Upload and download application program; Cross-reference list between database and user program; RTU maintenance and diagnostic facilities; Off-line testing facilities of the control program, including full emulation of program and monitoring of the emulated program; On-line monitoring of the program execution in the RTU;

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

User program shall be self-documented. Database, I/O assignment and sequences shall be issued through printouts reports to allow engineering or maintenance staff to control the whole configuration. 7.2 Technical Requirements The laptop shall be of the following minimum configuration: Pentium microprocessor (latest available model at order awarding date); 4 GHz; 2 GB RAM; 160 Gbytes HDD; CD ROM / DVD RW drive; 3 1/2 high density floppy; Real time clock; 14 TFT SVGA color monitor for QWERTY keyboard; Mouse or track-ball; IEEE 802.3 port; USB port; Batteries and battery charger for laptops; Operating system: Windows Vista, according to the supplied version of the development software. Operating system will be of the latest available version at order awarding date; Anti-virus software; Programming and maintenance software (latest available version at order awarding date); All necessary cables and easy fitting devices.

VENDOR shall provide all software components needed to implement any modification of the application software. The VENDOR shall provide the necessary quantities of licenses. The VENDOR shall clearly indicate the purpose and the limits of the different

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licenses provided. VENDOR shall submit type and characteristics of the laptop at bid stage for COMPANY approval. 8.0 POWER SUPPLIES 24 VDC power supply shall be provided through the solar power system. For each RTU cabinet, VENDOR shall provide all the equipment necessary to generate the different power supplies needed by the RTU cabinet components and in particular the power supply for I/O powering (taking into account equipped spares). These power supplies will be 100% redundant. Special attention will be paid to transient suppression. Power consumption and heat dissipation of each RTU cabinet shall be calculated. Diagnostic and signaling facilities such as LEDs shall be provided to identify that a power supply unit requires service or replacement. It shall be possible to isolate, disconnect, remove and replace a faulty power supply unit without loss of operation. 9.0 SYSTEM PERFORMANCE RTUs minimum performances shall be as follows: 10.0 10.1 RTU execution time (input acquisition + program execution + output writing + communication): 0.5 sec maximum; Analog signal scan rate (signal used for safety loop): 50 ms; Digital signal scan rate: 50 ms.

CABINETS General For the cabinet refer to PTS 32.80.10.30 chapter 6 and the following are the minimum requirement: 1. 2. One or more cabinets are required at each wellheads / manifolds to house the system equipment, termination strips and wiring. Cabinet construction shall be convection ventilated with readily accessible, removable filter screens inserted behind slotted louver inlets. Louvers and filters installed within cabinet doors are acceptable provided that adequate ventilation area is allocated to avoid hot spots within the cabinet. Cabinets will be installed in a passive cooled shelter, located in an unclassified area, but the cabinet shall meet IP 65. Cabinet sizes shall be standardised as much as possible, preferably free standing type for all plants. The number and size of cabinets shall be provided by RTU

3. 4.

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vendor. The preferred dimensions are 800x800x1800mm, keeping in view the available clear space. 5. Cabinets shall have two eye hooks centred at either end at the top of the cabinet. Eye hooks shall be of sufficient size to accommodate lifting hooks to lift the fully loaded cabinet into place. Blanking plugs shall be provided and installed to replace the eye hooks once the cabinets have been installed. The front of the cabinet shall be provided with full-length access, swing-out double door. Double door arrangement is required, considering the available space in the existing passive cooled shelter. Rear access to cabinets shall not be provided. Swing-out doors shall be removable and gasketed. All doors shall be reinforced against buckling and provided with lockable door handles. All doors shall be provided with the same lock and key combination. Each swing out door shall have at least three hinges. Each door cabinet shall be electrically bonded to the main cabinet by braided ground strap (wire size 10sq.mm. or mm2 or equivalent). The front door shall have a pocket sized to contain drawings and documents and shall contain a folding shelf to accommodate a laptop computer. Cabinets shall contain internal light. Cabinets shall be painted grey RAL 7032. Cabinets shall be designed and constructed to meet EMC requirements; Cabinet shall be SS 316 suitable for harsh environment.

6.

7. 8. 9. 10. 11. 10.2

Labeling Each cabinet and all major system components shall be clearly labeled and identified. Nameplates shall be made from laminated plastic, white-black-white (information engraved into black core with white surface, dull finish). In addition, all equipment shall be identified with the manufacturer type and serial number to facilitate future reference.

10.3

Equipment Grounding 1. Cabinets shall incorporate two (2) separate, isolated ground bus bars. Separate ground buses shall be provided for the following sub-systems: a) Safety ground bus for all exposed metal surfaces of cabinets, racks etc. (individual ground wiring interconnections to be minimum 1.5 mm (16 AWG, copper wire, green/yellow insulation). Shield connection bus for connecting signal cables and wire shields, (individual cable/wire shield interconnections to be minimum 1.5 mm (16 AWG, copper wire, green insulation).

b)

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

Cabling and Wiring For the system cabling following are the minimum requirement: 1. 2. 3. 4. 5. 6. All cable entries shall be through the bottom of the cabinets through suitable multi-cable transits. All multicore cables shall be fully terminated. Sufficient free space shall be available for accommodating all terminal wires for a fully loaded system, i.e. modules etc. Cable clamps and supports shall be provided for all incoming cables. All internal cabinet wiring shall run in suitably sized PVC ducts with removable covers. Sizes shall accommodate all wiring required for a fully loaded system. Minimum conductor for internal cabinet wiring to be PVC insulated 1.0 mm2 solid or stranded tinned copper. When stranded wire is used they shall be connected with crimped on connectors. Instrument cables and individual signal cores shall be fitted with identification ferrules. System cables shall be to VENDORs standard.

7. 8. 10.5

Terminations 1. 2. 3. 4. All terminals shall be of the SAKR Klippon type. All sockets terminals and wiring shall be clearly identified in strict accordance with the system documentation. For all fused inputs, knife disconnected terminals shall be used. Outputs to solenoids shall be provided with circuit breaker of suitable rating.

11.0

SPARE PARTS Commissioning spares and consumables shall be included in scope of work; Price list of spare parts for 2 years operation.

Lists shall include pieces item numbers, each referenced to the relevant drawings. These drawings shall be supplied with the VENDOR documents.

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Each part shall be properly tagged with a weatherproof label, showing the: MESC number; Manufacturer's unique part number; Description of the part; Expiry date for parts having a limited shelf life;

Small items with the same part numbers shall be tagged and packed together in a plastic bag or box, and the tag shall also be shown on the outside of the bag or box. The VENDOR shall provide with the initial offer a price escalation formula for spare parts orders, binding for a 5 years period after warrantee expires. The warranty period for all materials and equipment to be provided shall be "24 months from delivery (ex VENDOR's Works) or 12 months from the Plant in-service date, whichever occurs first." 12.0 SPECIAL TOOLS The VENDOR shall supply all special tools necessary for the main and auxiliary equipment for installation, pre-commissioning and commissioning. 13.0 MARKING AND PACKING Marking and packing of VENDOR equipment shall be done according to requirements indicated in material requisition. Marking and packing will be defined during EPC phase. 14.0 14.1 DOCUMENTATION General The documentation requirement shall be in accordance with the project documentation requirement and as provided in the requisition. The VENDOR shall produce a Functional Design Specification (FDS), which forms the basis of the RTU system. The project documentation shall cover the FDS and also the following engineering drawings & documents as a minimum. System architecture diagram; System configuration (slot & module configuration); Logic narratives; Cabinet General Arrangement & Module layout diagrams;

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Power consumption and heat dissipation calculations; Reliability and Availability calculations; Communication and system loading calculations; Loop diagrams; I/O database with rack, slot and channel assignments; Termination details; Diagnostics logic.

As far as possible all the above documents shall be taken from the system itself, using the self-documentation facilities. For compiled programs, they shall be obtained from program source files. Detailed listings of point assignments (with rack, slot, channel etc.) and point usage shall also be provided. Point usage listings shall identify each display and computing device or interface device application that has been assigned to each tag in the system. The loop diagrams with file details shall be developed by the VENDOR and submitted to the COMPANY. The loop diagrams shall be in accordance with ISA standards. Vendor shall also comply with the requirements of documentation specified in PCPL procedure CSP-03. 14.2 Functional Design Specification (FDS) The VENDOR shall prepare detailed Function Design Specification, which covers the design of both the hardware and software. The FDS shall clearly define all standard software modules developed for implementation of typical SCADA functionalitys. All documents, drawings, correspondence, operating, installations and maintenance shall be in English. It shall clearly define the following design criteria, as minimum, System architecture; Signal flow within the system; Fail safe feature; Reliability and availability; Redundancy;

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System and software security; Basis of hardware selection; Basis of software selection; Basis of communication facility; Power consumption and heat dissipation calculations; Reliability and Availability calculations; Communication and system loading calculations.

The above indicates only the basic minimum requirements. However the FDS shall consist of all the relevant information regarding the design and functions of the RTU system. System cabinet, sub-components shall be tagged as per COMPANY procedure mentioned above. 14.3 Inspection & Testing The inspection and testing requirement shall be in accordance with the approved "Inspection and Test Plan. It shall cover the following as a minimum: Physical / dimensional checks, bill of material including spare parts. Inspection of all test record performed by VENDOR prior to FAT. 100% Functional checks for hardware, logic. Calibration checks.

The Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) shall be as per procedures provided by the VENDOR and approved by COMPANY. The FAT shall be an integrated test which includes RTU and Solar Panel System. The FAT will be witnessed by COMPANY or their representative and the CONSTRUCTION CONTRACTOR. A minimum of fifteen (15) days intimation shall be given by the VENDOR to COMPANY before the FAT. The installation and pre-commissioning of the RTU system, field detectors and cabling between them are in the scope of CONSTRUCTION CONTRACTOR. The CONTRACTOR shall provide assistance during commissioning to the COMPANY. VENDOR shall provide the services of an experienced Engineer to assist the CONTRACTOR/COMPANY with pre-commissioning & commissioning.

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All items shall be suitably protected against damage during shipment and storage. On completion of inspection and testing equipment shall be properly packed and prepared for shipment. 15.0 TRAINING Selected personnels shall receive specialized training at site and at VENDOR premises. Training topics shall include the following: 16.0 Overall description and illustration of RTU capacities and functionalities (control, communication, I/O types, programming); RTU major components: racks, CPUs, power supply, communication modules, I/O modules of each type; RTU cabinet; Programming functionalities: I/O and database configuration, control program, communication, SOE; Maintenance functionalities: On-line running monitoring, component replacement, diagnostic alarm analysis; All software and standard program blocks used definition; Spare parts ordering, coding, care of spares; Running and workshop testing.

SITE SERVICES VENDOR shall provide on site assistance for the following periods: Mechanical completion: assistance for system installation and site preliminary tests; Pre-commissioning and commissioning; Start-up.

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

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QUALITY ASSURANCE/QUALITY CONTROL Vendor proposed quality system shall fully satisfy all the requirement of ISO 9001/9002/9003/9004. The VENDOR and the Sub-vendors shall be ISO certified. VENDOR shall provide a specific Quality Control Plan (QCP) within 2 weeks of order award for COMPANY review and approval. VENDOR shall provide the following to COMPANY for approval: 1. 2. 3. 4. Coordination procedure to coordinate the manufacturing of all materials, parts and components in different places. The source of material supply for all parts and components including the country of origin and place of manufacturing, assembly and testing. Material certificates for all parts and components before assembly. Sub-vendors and contractors list and these shall be from COMPANY approved list.

18.0

GUARANTEE The VENDOR shall ensure that the material and accessories provided shall be his standard product which is regularly manufactured, tested and serviced in accordance with the Codes and Standards defined above. Any material or part thereof covered by this specification that shows evidence of deterioration, contamination or corrosion within the guarantee period shall be considered the result of failure to comply with the requirements and the intent of this specification and shall be replaced on site at no extra cost to the Owner.