Remote I/O Panel Specification

MEJI GGCP DEBOTTLENECKING PROJECT
Detailed Engineering
REMOTE I/O PANEL SPECIFICATION

Contract No: FAC-2015-CW1362182
Work Authorization: WA-002
Document No: MDP-M028-ICS-SPC-IES-0000-00190-00
U01 01-Dec-16 Issued for Construction OMM SCA SVB

K01 14-Sept-16 Issued for Review OMM SCA SVB
REV DATE ISSUE PURPOSE ORIG CHK APPR
Project Area Discipline Type Originator Package Sequence-Sht Revision

Document Control No.
MDP M028 ICS SPC IES 0000 00190-00 U01
Meji GGCP Debottlenecking Project Remote I/O Panel Specification
MDP-M028-ICS-SPC-IES-0000-00190-00 Rev No.: U01
REVISION HISTORY
REVISION DESCRIPTION OF REVISION DATE REMARK
K01 Issued for Review 14-Sept-16
U01 Issued for Construction 01-Dec-16
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TABLE OF CONTENTS
1.0 ACRONYMS .................................................................................................................................. 5
2.0 INTRODUCTION ........................................................................................................................... 6
2.1 GENERAL ......................................................................................................................... 6
2.2 DEFINITIONS OF TERMS AS USED IN THIS SPECIFICATION ............................ 7
2.3 PURPOSE ......................................................................................................................... 8
3.0 APPLICABLE CODES AND STANDARDS ............................................................................. 9
3.1 CODES AND STANDARDS ........................................................................................... 9
4.0 REFERENCE ............................................................................................................................... 10
4.1 COMPANY SPECIFICATIONS .................................................................................... 10
4.2 PROJECT SPECIFICATIONS ..................................................................................... 10
5.0 HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS ...................................... 11
5.1 ENVIRONMENTAL CONDITIONS .............................................................................. 11
5.2 AREA CLASSIFICATION.............................................................................................. 11
5.3 HEALTH, SAFETY AND ENVIRONMENTAL REGULATIONS .............................. 11
6.0 GENERAL DESIGN REQUIREMENTS .................................................................................. 12
6.1 SCOPE OF SUPPLY ..................................................................................................... 12
6.2 OPERATING REQUIREMENTS .................................................................................. 13
6.3 DESIGN LIFE.................................................................................................................. 14
6.4 STANDARDISATION .................................................................................................... 14
7.0 EQUIPMENT DESIGN AND MANUFACTURING ................................................................. 14
7.1 SYSTEM OVERVIEW ................................................................................................... 14
7.2 REDUNDANCY .............................................................................................................. 15
7.3 AVAILABILITY ................................................................................................................ 15
7.4 SYSTEM DIAGNOSTICS ............................................................................................. 15
7.5 COMMUNICATION ........................................................................................................ 16
7.6 FIELD INPUTS / OUTPUTS ......................................................................................... 16
7.7 CONVERSION ACCURACIES .................................................................................... 18
7.8 SPARE CAPACITY ........................................................................................................ 19
7.9 POWER SUPPLIES & GROUNDING ......................................................................... 19
8.0 SYSTEM CONFIGURATION .................................................................................................... 21
8.1 APPLICATION SOFTWARE ........................................................................................ 21
8.2 HUMAN MACHINE INTERFACE................................................................................. 22
8.3 ALARMS .......................................................................................................................... 23
8.4 SYSTEM INTERFACES................................................................................................ 24
8.5 CABINETS ...................................................................................................................... 24
8.6 FUTURE EXPANSION. ................................................................................................. 29
9.0 TESTING AND INSPECTION ................................................................................................... 30
9.1 GENERAL ....................................................................................................................... 30
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9.2 TESTING ......................................................................................................................... 30

9.3 QUALITY ASSURANCE ............................................................................................... 32
9.4 INSPECTION .................................................................................................................. 33
10.0 SHIPMENT, PRESERVATION, STORAGE AND HANDLING ........................................... 33
10.1 PACKAGING, SHIPPING AND HANDLING .............................................................. 33
10.2 PRESERVATION AND STORAGE ............................................................................. 33
11.0 WEIGHTS ..................................................................................................................................... 34
12.0 INSTALLATION, SITE TESTING AND COMMISSIONING ................................................. 34
12.1 INSTALLATION .............................................................................................................. 34
12.2 SITE ACCEPTANCE TEST (SAT) .............................................................................. 34
12.3 SITE INTEGRATION TEST (SIT) ................................................................................ 35
12.4 COMMISSIONING ......................................................................................................... 35
13.0 MAINTENANCE REQUIREMENTS ......................................................................................... 35
13.1 REGIONAL MAINTENANCE SUPPORT ................................................................... 35
13.2 MAINTENANCE DURING WARRANTY..................................................................... 36
13.3 MAINTENANCE AFTER WARRANTY ....................................................................... 36
14.0 SPARE PARTS AND SPECIAL TOOLS ................................................................................ 36
14.1 GENERAL ....................................................................................................................... 36
14.2 START-UP AND COMMISSIONING SPARES ......................................................... 37
14.3 OPERATIONAL SPARES ............................................................................................. 37
14.4 CONSUMABLES ............................................................................................................ 38
14.5 SPECIAL TOOLS ........................................................................................................... 38
15.0 DOCUMENTATION AND DRAWINGS ................................................................................... 38
15.1 GENERAL ....................................................................................................................... 38
15.2 REQUIRED FOR TECHNICAL EVALUATION .......................................................... 39
15.3 FUNCTIONAL DESIGN SPECIFICATION ................................................................. 39
15.4 DESIGN DRAWINGS .................................................................................................... 40
15.5 DETAILS AND DATA SHEETS ................................................................................... 41
15.6 OPERATION AND MAINTENANCE MANUALS ....................................................... 41
15.7 AS BUILT DRAWINGS.................................................................................................. 42
15.8 SELF DOCUMENTATION ............................................................................................ 42
16.0 TRAINING .................................................................................................................................... 42
16.1 TRAINING PHILOSOPHY ............................................................................................ 42
16.2 TRAINING COURSE DOCUMENTATION ................................................................. 42
16.3 OPERATOR AND MAINTENANCE TRAINING COURSE ...................................... 43
16.4 SYSTEM CONFIGURATION COURSE ..................................................................... 43
16.5 TRAINING AIDS ............................................................................................................. 43
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1.0 ACRONYMS
ASME American Society of Mechanical Engineers

API American Petroleum Institute
C&I Control and Instrumentation
CSA Canadian Standards Association
CSI Control System Integrator
C&E Cause & Effect Chart
ºC degrees Centigrade
ESD Emergency Shutdown
FAT Factory Acceptance Test
FGS Fire and Gas System
I/O Input / Output
IP Ingress Protection
ISA Instrument Society of America
JB Junction Box
LSB Least Significant Bit
MTTR Mean Time to Repair
MTBF Mean Time Between Failure
NEMA National Electrical Manufacturer’s Association
PA/GA Public Address/General Alarm
PCS Process Control System
P&ID Piping and Instrumentation Diagram
SAFE Safety Analysis Function Evaluation
SDV Shutdown Valve
SS Stainless Steel
SSS Safety Shutdown System
SAT Site Acceptance Test
SIT Site Integration Test
SOE Sequence of Events
UPS Uninterrupted Power Supply
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2.0 INTRODUCTION
2.1 General
This specification defines the minimum requirements for the design, procurement,
assembly, configuration, programming, integration, documentation, inspection and
testing of the Remote I/O Process control and safety cabinets to be installed for Chevron
Nigeria Limited Meji GGCP Debottlenecking project.
The project scope of work is based on data acquisition and control of all the signals
associated with process and safety equipment to be installed at the Meji RP facility.
For the process control signals, a new PCS Remote I/O Panel will be installed at the
Meji RP facility.
For the safety signals, a new SSS Remote I/O will be provided and installed besides the
new PCS remote I/O Panel.
A new PLC FG panel located on RP shall be provided completely assembled and

installed to monitor all F&G devices. A set of hardwired interlocks will be provided
between the SSS Remote I/O and the new F&G panel at the Meji RP facility.
For further details about the overall control system architecture and integration
philosophy reference is made to: MDP-M035-ICS-BLK-IES-0000-09324-00 - Control
System Architecture as well as to: MDP-M035-ICS-PHL-IES-0000-09204-00 -
Instrument Control Philosophy and Fire & Safety Layout – MDP-M028-ICS-LAY-IES-
0000-90007-00.
This specification shall be used in conjunction with other project documents and
applicable standards.
Any exceptions to the requirements of this specification or conflicts between this

specification and other project documents shall be submitted in writing to the COMPANY
/ CONTRACTOR for resolution.
The new PLC based systems shall incorporate in its architecture data communication
capabilities to integrate the PCS, SSS and F&G signals through ControlNet/Ethernet
with the existing PCS and SSS systems installed at the Meji GGCP Control room .
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The SUPPLIER shall notify COMPANY of any conflicts between this specification and
other project documents or referenced industry standards.
Scope of work includes provisions of all the computer network hardware and
communication cables required to provide an integrated and functional system as per
this specification and reference documents.
2.2 Definitions of Terms As Used In This Specification

Company – affiliated companies of Chevron Corporation including subsidiaries and
divisions, thereof CO or CNL)
Concession Request — A deviation requested by the Subcontractor or Supplier,

usually after receiving the contract package or purchase order. A Concession Request is
subject to written Company approval
Contractor - The party which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of this Project.
Project – Meji GGCP Debottlrnecking Project
Shall - Indicates a Mandatory Requirement
Should - Indicates a Recommendation
CSI - The party which manufactures and/or supplies equipment, technical

documents/drawings and service to perform the duties specified by the Company
Central Control Room (CCR) - contains the essential equipment required to operate
the plant optimally and safely.
Configuration -The process of setting up the system using predefined software of the
PCS
Process Control System (PCS) – A configurable microprocessor-PLC based control

system that performs the real time closed loop control of processes, and provides the
interfaces between the different system and human operators. This system integrates
and contains two or more PLC based controllers and associated software required to
accomplish the regulatory control and monitoring of a process plant.
Safety Shutdown System (SSS) – A configurable PLC microprocessor based system

that provides the safeguarding of the process and equipment to protect personnel,
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assets and environment. The SSS exchanges information with PCS system via the
control network. The SSS functions as the main overriding safety system for the whole of
the Meji facility.
Fire & Gas System (FGS) – A system that incorporates fire & gas sensors/detectors
and a Redundant PLC based logic solver to provide fire, flammable and combustible gas
detection and response in the event of a loss of containment or other hazardous
conditions. Outputs may be executed by the system directly, or via the SSS.
Peer-to Peer – A messaging hierarchy used where no single unit in the message chain
is a master. Each unit can request information to and from other units in the
communications chain and issue command as well as acknowledge the command.
Single Window - A single-window approach shall be implemented for the Plant Control
and Safety systems monitoring and package controls. The single window approach shall
be provided by the PCS Operator Workstations via interfaces with other systems.
Smart Field Devices - Transmitters that incorporate advanced diagnostics and data
transmission that may allow the information to be transferred for analysis and remote
intervention.
2.3 Purpose
2.3.1 The SUPPLIER shall engineer the PCS, SSS and FGS design, procure
materials, fabricate, assemble, test, and deliver to the job site a complete and
functionally proven system.
2.3.2 The SUPPLIER shall design the PCS, SSS and FGS systems for consistency in
details with regard to modularity and for commonality of spares.
2.3.3 The SUPPLIER shall provide information about components, system failure rates
and reliability data for the proposed equipment.
2.3.4 The SUPPLIER shall perform a system configuration and performance evaluation
to ensure that the optimum system components are selected for the intended
application.
2.3.5 Where the SUPPLIER considers that an alternative would improve the level of
performance or reduce costs, the SUPPLIER shall provide written notification of
the recommendation to the COMPANY. Costs for all services to implement the
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alternatives shall be provided at the SUPPLIER’s proposal. Alternatives must

meet the base specification and shall have the written approval of the
COMPANY.
2.3.6 The SUPPLIER shall respond to Company in writing for any of the exceptions in
this specification.
2.3.7 The SUPPLIER shall provide manufacturing schedules for this proposed PCS,
SSS and FGS Remote systems.
2.3.8 The SUPPLIER shall take responsibility for following and expediting the progress
to deliver systems as per this specification and under the expected and defined
project schedule.
2.3.9 The SUPPLIER shall review the overall project schedule and determine schedule
requirements for control systems. The schedule shall be incorporated into this
specification.
3.0 APPLICABLE CODES AND STANDARDS

Instrumentation shall be based upon Chevron Project Standards. The existing CES
standards are developed from international standards (ISO) and should be used de facto
otherwise international standards will be referred to.
Instrument Systems and Equipment supplied shall have certificates of conformance and
industrial safety in accordance with Nigerian legislation. Supplier shall ensure that the
equipment supplied complies with this requirement, and obtain certification from the
relevant authorities when they are currently not certified.
The list of codes and standards proposed is given below. The list is not exhaustive and
will be subject to review during the project.
In the event of a conflict or interpretation between CES and the international codes, the
most stringent shall apply.
3.1 CODES AND STANDARDS

API 552 Transmission Systems
API 551 Process Measurement
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API 14C Recommended Practice for Analysis, Design, Installation and

Testing of Basic Surface Safety System for Offshore Production
Platforms.
IEC 60331 Tests on Electrical Cables under Fire Conditions-Circuit Integrity
IEC 60332 Tests on Electrical Cables under Fire Conditions
IEC 61000 Electro-magnetic compatibility – Generic emissions Standard
IEC 60529 (1989-11) Degrees of Protection Provided by Enclosures (IP Code)
IEC 61131-3 Programmable Controllers – Part 3: Programming Languages
IEC 61508 Functional Safety of
(Parts 1 to 7) Electrical/Electronic/Programmable Safety- Related Systems
IEC 61511 Functional Safety Instrumented Systems for the
Process Industry Sector.
4.0 REFERENCE
4.1 COMPANY SPECIFICATIONS
ICM-DU-5144 Rev B Process Automation System Design

Basis
ICM-DU-6025 Rev B Safety Instrumented Systems
ICM-DU-6036 Nov. 2012 Fire and Gas Systems
ELC-SU-1213 Wire and Cable
ICM-SU-11.06 Instrument Control Panels
4.2 PROJECT SPECIFICATIONS

MDP-M035-ICS-BLK-IES-0000-09324-00_K01 Control System Architecture
MDP-M035-ICS-PHL-IES-0000-09204-00_K01 Instrument Control Philosophy
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5.0 HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS

5.1 ENVIRONMENTAL CONDITIONS
Equipment and system cabinets shall be specified and designed to be mounted in the
process area in a Non-Hazardous area. The cabinets shall meet environmental
protection level IP65 as a minimum as defined in IEC 60529, ‘Degrees of Protection
Provided by Enclosures (IP Code)’, equivalent to NEMA 4X.
All the electronic instrumentation shall comply with Electromagnetic Compatibility (EMC)
and Radio Frequency Interference (RFI) requirements in standard IEC 61000 or similar
applicable standard. Compliance shall be demonstrated by way of testing and/or
certification.
5.2 AREA CLASSIFICATION

The PCS, SSS & FGS will be installed in a non-hazardous area however careful
consideration will be done by the vendor / supplier that such equipment shall adhere to
the general standard application as defined on the API-RP 500 and art. 500 of the NFPA
70 code of practice.
5.3 HEALTH, SAFETY AND ENVIRONMENTAL REGULATIONS

The systems and equipment shall be designed, selected, engineered and configured to
provide the highest possible standard of personal safety, protection of assets and
environment, and ergonomics and shall conform to Nigerian Health, Safety and
Environmental regulations.
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6.0 GENERAL DESIGN REQUIREMENTS

6.1 SCOPE OF SUPPLY
The SUPPLIER shall be responsible for supply of the following items of equipment to be
installed at Meji RP, as a minimum, in accordance with the criteria defined within this
specification;
 System hardware, including I/O modules, racks, power supplies and power
distribution, system racks, terminal blocks and system functional wiring within a
NEMA 4X Rittal type panel, defined by this specification to provide a functional
PCS and SSS Remote I/O systems to be installed at Meji RP and linked through
ControlNet to the existing PCS and SSS at the Meji GGCP Control Room.
 System hardware, including I/O modules, racks, power supplies and power
distribution, system racks, terminal blocks and system functional wiring within a
NEMA 4X Rittal type panel, defined by this specification to provide a functional
remote PLC based Fire & Gas System (FGS) to be installed at Meji RP and
linked through ControlNet.
 Additional PCS and SSS panels for redundant controllers at Meji GGCP Control
room
 All 24Vdc power supplies for the PCS, SSS and FGS cabinets, galvanic isolators
and any other device required for the present scope of work and company
specifications.
 All cabling of power supply and control cables to cabinet and into the field
terminal blocks and shall be identified by means of wire marks.
 System Hardware and Software
 System cabinets to house the required hardware, RittalExpress type.
 Engineering, configuration, design and programming required to integrate the

new PCS, SSS and FG cabinets to the existing PCS and SSS at the Meji GGCP
control room. SUPPLIER shall make provisions to configure and program all the
hardwired interlock signals between the fire and gas panel and the SSS.
 SUPPLIER shall use as reference all project P&IDs, I/O lists and other
engineering documents provided to meet present specifications.
 PLC programming and application software
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 Human Machine Interface software
 Redundant HMI Servers, Monitoring station and an engineering station
 Network routers and/or switches
 Internal wiring between components provided
 Development and testing of operational templates.
 Engineering and maintenance Documentation
 Recommendation of Spare Parts and Consumables
 Supervision of Site installation
 Site pre-commissioning assistance
 System Site Commissioning and Start-up assistance
 FAT
 SAT
 SIT
 Shipping
All supply of ControlNet cables between the PCS Remote I/O cabinet and Meji GGCP
PCS; SSS Remote I/O cabinet and Meji GGCP SSS and remote FGS will be provided by
CSI.
All cabling works between cabinets and field instruments, electrical cabling from the site
power supply to the cabinet will be done by construction contractor.
The new PCS shall be linked to the existing PCS in Meji GGCP Tech. Office; process
and safety data will be updated in the existing HMI at Meji GGCP Tech. Office and PCS
and SSS shall work as a complete unit. For details refer to Control System Architecture
– MDP-M035-ICS-BLK-IES-0000-09324-00.
6.2 OPERATING REQUIREMENTS

All process control and monitoring operations shall be carried out through the existing
operator screens. The SUPPLIER shall use equipment that has been used and is proven
in the COMPANY’s fields. All Digital electronics systems shall employ standard
hardware and software. Customisation beyond the user level shall be minimised.
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The Control System Integrator shall offer a cost-effective solution and shall be designed
for ease of operation as well as minimize errors by operators / maintenance personnel
as well as meet safety needs of the process operation.
The Control System Integrator shall supply a list of previous projects utilising the
equipment proposed and clients for Company’s review.
6.3 DESIGN LIFE

The design life of the PCS, SSS and FGS shall be 20 years minimum. This shall be
based on the following prerequisites:
 Maintenance and support of the system shall be available for this duration.
 The entire system, including all sub-components, shall facilitate upgrade and are
selected from recognised manufacturers with a proven track record of system
maintenance and essential upgrades.
6.4 STANDARDISATION
As far as practically possible, variations in the selection of instruments and systems for
these offshore facilities shall be kept to a minimum. This is to reduce engineering,
procurement, commissioning, maintenance, training, spares holding and operations
costs.
7.0 EQUIPMENT DESIGN AND MANUFACTURING

7.1 System Overview
The process transmitters shall be hard wired to the PCS and SSS Remote I/O systems
via the field terminal blocks installed in the junction boxes. The Remote I/O systems will
communicate with the existing PCS and SSS systems in Meji GGCP via Controlnet
cables.
The Process Control System shall be designed to generate Alarms when

devices/circuits/loops are faulty. Failure of any one component shall diminish the
capability of the system.
The FGS shall be designed under the same specifications of the SSS.
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7.2 Redundancy
The SUPPLIER shall design, engineer and configure the systems so that all critical
components are redundant and that failure of one unit shall not result in the total loss of
control, data transfer or operator interfaces. The following components shall have
redundancies incorporated, as a minimum:
 Data Highway,
 Power Supplies,
 PCS third parties interface gateways
 Critical External system interface units.
Failure of any unit shall be made known on the operator workstation by alarm, and
internal diagnostics provided to aid troubleshooting and rectification.
For the FGS, the AB ControlLogix CPU and power supplies shall be redundant.
Minimum CPU version shall be L7x.
7.3 Availability
The system shall be designed such that failure of a single component shall have a
minimum impact on the operation of the system. The system shall contain diagnostic
routines to alert the operator of such a component failure.
Equipment redundancy shall be used where high availability is demanded. Henceforth,

the Control System Integrator shall provide a redundant Process Control System thus
maintaining high availability of the system at all times.
The SSS RIO and FGS shall be rated SIL-2.
7.4 System Diagnostics

The PLCs processors on the Meji GGCP facility shall be capable of providing continuous
full diagnosis of its internal operations, and inform operations personnel of the status of
the diagnostics. Any failures, faults, or predicted failure conditions shall be annunciated
to the operator via the PCS workstations. Examples of faults include:
 Data Highway Faults
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 Controllers Faults
 Data Link Faults
 Internal Memory Failures, etc
 Cabinet Common Alarm
 Power Supply Faults
The faulty units shall be highlighted on LEDs located on each module and the fault
logged via the Sequence of Event (SOE) Recorder and the information updated on
dedicated autodiagnostic screens at the HMI. The alarms shall only be cleared after the
faults have been rectified. Transient faults shall also be recorded and logged. Once the
number of transient faults has exceeded a preset limit, the device shall be marked as
faulty.
In the event of failure of a redundant component, the faulty unit shall be marked as
‘failed’ and an alarm indication shall be shown on the PCS Workstations.
7.5 COMMUNICATION
The Remote I/O shall be connected with other systems via secure redundant highways.
Data transfer for monitoring purposes from the SSS and PCS shall be via the
CONTROLNET.
Interconnection of the PCS / SSS system within control building shall be hardwired.
Extension of the highway to remote locations shall be via ControlNet cables. The
ControlNet cables shall be supplied and installed by others. Switches / routers and vice
versa to couple the cables to the communications modules shall be supplied by others.
The communication between the PCS modules shall be achieved via a fiber optic
redundant cable, this is also obtainable in the SSS modules.
Interconnections of the PCS and SSS signals to the 10 Mb Ethernet network shall be
through routers and switches in dual array. (Refer to Control System Architecture –
MDP-M035-ICS-BLK-IES-0000-09324-00).
7.6 Field Inputs / Outputs

The Input/output modules shall interface to the following types of field inputs/outputs.
Critical inputs may require the use of redundant modules.
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Analog Input
 4-20 mA DC with maximum input resistance to be 250 ohms.
 24 VDC loop power for the 2 wire transmitters to be furnished by the PCS
system.
 1-5 VDC input option to be provided, input resistance equal to 250 ohms or
greater.
 The negative terminal to be at isolated signal ground level. The inputs shall be
capable of sourcing or sinking the current.
 Input faults such as open circuit, short circuit, and earth fault are to be detected
by the I/O module.
 The analogue modules shall also accommodate transmitter powered inputs

which have a grounded common at the transmitter, i.e. signal isolated from earth
at the I/O module.
Analog Output
 4-20 mA DC
 24 VDC loop power for the 2 wire contact initiators to be furnished by the PCS
system.
 1-5 Vdc input option to be provided
 The negative terminal to be at isolated signal ground level. The inputs shall be
capable of sourcing or sinking the current.
Digital Input
 24 VDC as input “1” and open circuit (infinite resistance) as “0”.
 Negative terminal to be at isolated ground level.
 Sense voltage (24 VDC) to field contacts and inputs for proximity switches shall
be provided by the PCS system.
 Inputs shall be individually isolated.
 Inputs shall have ‘de-bounce’ filtering to eliminate spurious effects.
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 The input modules shall include line monitoring function to detect open and short
circuits.
Digital Output
 Dry contacts rated at 5 A @ 24 VDC, and 2 A @ 120 Vac
 Selectable as normally open or normally closed, momentary open or momentary

closed,
 Maintained to activate relays, alarms, solenoids, or other similar devices.
 Voltage to output contacts shall be provided by an external source.
 Momentary contacts shall have closing time of 200 msec.
 Individually isolated 120 Vac TRIAC, 24 V / 125 V DC outputs shall also be

available.
 The output modules shall include line monitoring function to detect open and
short circuits.
To compensate for possible hardware failure or testing, a software “override function”

shall be available to allow “forcing” of the measurement associated with a specific input
point (analog, digital or software) or to ‘force’ changes to an output (analog, digital or
software).
7.7 Conversion Accuracies

The analog-to-digital conversion (ADC) performed by the I/O module electronics for
digital transmission shall meet the minimum requirements as specified below:
Resolution 10 bits
Linearity 1 Least Significant Bit (LSB)
Repeatability 1/2 LSB
Accuracy 0.1% full range over entire operating range
Common Mode Rejection @ 50/60 Hz 65 db
Normal Mode Rejection @ 50/60 Hz 58 db
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7.8 Spare Capacity

The system shall be capable of catering for the additional I/O and configuration
requirements. The PCS and SSS Remote I/O shall be supplied with an additional 20%
spare capacity for each I/O type installed. Additionally it shall be sized to cater for an
additional 30% without procurement of any additional I/O chassis.
7.9 Power Supplies & Grounding
The PCS and SSS Remote I/O Cabinets shall be powered from the existing 24VDC
Battery charger and an alternative120VAC/ 24VDC power supply from 25KVA dry type
transformer. PCS, SSS and FGS power supplies shall be redundant for the field
instruments and other essential equipment. The PCS, SSS and FGS power supplies
shall be such that will not result in degradation of the system performance and/or trip of
the plant in the event of the loss of one power unit.
The PCS and SSS Remote I/Os and the FGS are required to derive all its internal power
requirements, as well as the 24 VDC required to power the I/O modules of the
PCS/SSS/FGS and field devices connected to the I/O cards and modules from the raw
power that comes from the distribution Panel and UPS in Meji GGCP facility. The PCS is
also required to power short-haul modems / network switches / routers for
communication with sub-systems that interfaces with the PCS systems for data transfer.
The PCS and SSS Remote I/O Panels and FGS shall be furnished with a circuit breaker
for each incoming mains supply to isolate the supply for maintenance purposes. Isolation
on one of the redundant power supplies shall not result in the shutdown of system .
24 VDC Power Supply for field devices shall be linked together via dropper diodes to
provide the necessary redundancies. Power supply modules shall be installed to provide
easy access for maintenance purposes. If critical back-up batteries are employed, they
shall be easily accessible for maintenance purposes.
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Inputs and outputs of 24 VDC Power Supplies shall be protected from over-currents by
fuses or other protective devices or circuits.
24 VDC Power supply outputs shall be diode protected and connected in parallel.
24 VDC Power supplies shall have normally open, energized closed alarm contacts
wired to the PLC system to monitor and alarm on power supply failure or fault.
The SUPPLIER shall present to the Contractor a listing and detailed schematics of the
number of electrical feeders, their termination points and respective loads.
The SUPPLIER shall include in the quotation a calculation of the estimated power
consumption of the system (volts, amps, watts and heat dissipation).
Mains power interruptions of up to 100 ms shall not affect operation. The Supplier shall
state in the quotation the maximum mains power surge that may occur when the system
is switched on.
The Supplier shall indicate in the quotation the maximum allowable mains voltage spikes
(amplitude and duration) that the system can withstand without affecting operation.
The Supplier shall indicate in the quotation the procedures to be followed and the
features of the system which allow system recovery after power failure.
A groundbar shall be provided to terminate ground wires from instrument chassis,

console, frames, console doors, other device grounds, and the user’s ground cable.
Groundbar shall be copper, 1 inch by 0.25 inch (25 mm by 6 mm) wide with a minimum
length of 12 inches (300 mm).
Cabinet doors, sidewalls, roofs, gland plates, and internal fabrication shall be electrically
bonded together.
Cabinet ground bars shall be connected to the corresponding plant grounding systems.
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8.0 SYSTEM CONFIGURATION

8.1 Application Software
8.1.1 GENERAL
Programmable systems shall be programmed with languages that comply with IEC
61131-3, in either Functional Block or Ladder logic manner.
Configuration and logic programming of the PCS and SSS shall be with ‘point, click, drag
and drop’ software, and fill-in-forms for data entry. Programming using text based
languages shall not be acceptable.
The maximum PLC scan time shall not exceed 100 milliseconds. Scan time is defined as
the time taken by the system to read input, executing logic, update control outputs and
self-diagnostics of the system.
The system shall be capable of implementing and displaying up to 16 alphanumeric

characters for tag numbers.
The application option should have analog signal processing capabilities. In the bid the
SUPPLIER shall detail what are the standard capabilities of the proposed system.
8.1.2 SPARE CAPACITY

The system software shall be capable of catering for an additional 30% I/O and the
associated configuration requirements without affecting performance or requiring any
additional hardware.
8.1.3 SYSTEM SOFTWARE REQUIREMENTS
8.1.3.1 SEQUENCE OF EVENT RECORDING (SER)

The system supplied shall have a Sequence of Event Recording facility. The event shall
be recorded, time-stamped and stored in internal memory for later archiving or printing.
The system shall be capable of providing recording to a resolution of 100 milliseconds or
better.
Memory allocation of the SSS SOE recorder shall be specified to ensure that at least 3
months of data is retained. It shall be acceptable for the SOE to commence overwriting
data after this time.
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The signals monitored shall not be required to be wired to special Input cards/modules.
The SOE recorder shall meet the following requirements:
a. Accurate time and date stamping of key SSS events that shall include but not be
limited to the following:
1) Pre-trip alarms
2) Trips
3) First-out indications
4) Bypass status changes
5) Resets
6) Manual shutdown related events
7) Bad process variables
8) Out-of-range alarms
9) Partial stroke related events
10) Change of state of discrete input and output
11) Transition of threshold of analog signal past alarm or top threshold.
b. Time stamping resolution that is less than 50 milliseconds.
c. Event sorting capabilities by SSS safety sequence function.
8.1.3.2 TIME SYNCHRONIZATION

The PCS shall accept/provide time-synchronization signals via the peer-to-peer link. The
PCS suppliers/manufacturers shall ensure and suggest how time synchronization is
carried out. The synchronization shall be done once a day, every day.
8.2 HUMAN MACHINE INTERFACE

The normal Human Machine Interface shall be via the existing operator workstations.
The Operators shall have the capability to initiate soft manual over-rides on certain
safety interlock during start-up via the Operator Workstations with the data being
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electronically transferred to the SSS for execution. Likewise the entire status of the PCS
can be viewed on the operator’s workstations.
Communication between these Remote I/O Panels and Meji GGCP control room will be
by Controlnet network.
8.3 ALARMS
Alarm configuration shall follow ICM-DU-5144 and ICM-DU-5088. During development of

the alarm philosophy, detailed design guidelines for the alarm system shall be
documented.
Alarm management software in the PCS system shall provide displays for operations
and maintenance personnel to build instructions for rectifying an alarm condition and to
log the resolution for an alarm.
Alarm detection and generation shall be implemented within the originating PLC
controller under the following conditions:
a. The alarm condition initiates an executive or control action.
b. The alarms and associated setpoints are utilized by multiple HMI systems and the
local controller is a common system (e.g., the PCS host and a local panel HMI
independently read the alarm status and associated setpoints).
8.3.1 ALARM PRIORITIES
Four PCS alarm priorities shall be available. For the purpose of this document, the
priorities shall be designated as follows:
a. Most Urgent
b. Medium
c. Least Urgent
d. Logging
Logging priority shall be available to capture events that do not require operator
intervention.
Logging priority alarms shall not be displayed on the alarm overview screen.
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8.3.2 ALARM TONE

Unique alarm tones shall be assigned to Most Urgent, Medium, and Least Urgent
priorities.
Critical alarms shall be assigned a unique alarm tone that is easily distinguished from
other alarm tones.
No alarm tone shall be assigned to the logging priority.
8.4 SYSTEM INTERFACES
8.4.1 F&G INTERFACE

All the Fire and Gas detection devices will be connected to the PLC based Fire & Gas
System (FGS) at Meji RP.
8.4.2 SSS INTERFACE

The new SSS Remote I/O cabinet at Meji RP shall communicate with the existing SSS
via ControlNet network. The capacity of the Data Highway shall cater for the
requirements identified in this specification, including the future expansions considered.
Additionally a set of interlock shall be provided between the existing SSS, the new
redundant controller at GGCP facility and the new SSS for emergency shutdown
conditions.
8.4.4 ENGINEERING WORKSTATION

There are not requirements for additional engineering workstations. Existing HMI will be
used to monitor the Meji RP signals.
8.5 CABINETS
8.5.1 CABINETS DESIGN REQUIREMENTS

System shall be sized as per the Instrument Index Listing – MDP-M028-ICS-LST-IES-
0000-00154-00, and the I/O listing for the PCS and SSS respectively – MDP-M035-ICS-
LST-IES-0000-09203-00.
Enclosures are required, defined below as System and I/O cabinets, and shall be
RittalExpress standard units, or equivalent. The size of the cabinets shall be appropriate
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for the Allen Bradley equipment to be housed, and shall be selected from a standard
range.
The panel section shall be bolted to a 100 mm high plinth.
The enclosures shall be of sheet steel, weatherproof to IEC 60529, degree of protection
IP 65 as a minimum (NEMA4X equivalent).
Stiffeners shall be provided as necessary to ensure a rigid structure and prevent

warping.
Front access is required via lockable and detachable steel doors. Offshore panels shall
be front access only.
Where required by the Supplier’s design, the side panels between adjacent panels may
be removed for internal cable access.
Equipment shall not be mounted on swing frames for front access cabinets.
The equipment shall be installed in such a manner as to allow easy access and removal
for maintenance operations.
No equipment shall be mounted, inside the panel, within 150 mm of the gland plates
Blanking plates shall be provided for all unused slots in any card file chassis.
Cooling fans are not accepted. Vendor will design all the cabinets with mechanical
ventilation. Vendor shall explicitly detail if design proposed requires use of cooling fans
for Customer acceptance. If fans are provided at Vendor’ recommendation, fan failure
alarm and indication shall be provided.
Louvers shall only be provided if necessary.
All labels shall be in English. Panel shall be provided with a permanently fixed Traffolyte
nameplate detailing Panel number and function.
A drawing pocket shall be attached to the inside of each door, capable of holding a
folded A1 size drawing.
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All cabling to cabinets shall be bottom entry. Split gland plates shall be provided fitted
with metal brush seals. Cables shall be clamped within the panel base utilising the
standard Rittal cable clamp system.
Certified removable lifting lugs/eyes shall be provided for both Cabinets. Blanking plugs
shall be provided for lifting eye bolt holes.
Cabinets shall contain sufficient terminal blocks, wire ducts and raceways to
accommodate all assigned wiring, plus spares.
A 24V dc Power Supplies shall be provided and installed inside the cabinets and power
will be distributed within the cabinet they service.
All Internal cabinet components including Power Supplies, stabilisers, relays, fuses and
terminals shall be clearly labelled with engraved traffolyte labels. Labels shall not be
obscured by wiring or components, nor should they be fitted to cable trunking covers.
All panels shall be equipped with internal lights powered from the 120V 60Hz Non UPS
supply. The light shall be switchable from within the cabinet and segregated from other
panel wiring.
Functionally, the field terminal blocks shall be physically installed on the bottom half of
the PCS cabinet, it shall include interposing relays, fuse terminals and power supplies
facilities for field instrument, ferrules, panel wiring, etc.
Panels shall be delivered completely assembled, wired, configured, programmed and

tested to the site destination as defined by Company.
8.5.2 MISCELLANEOUS
PCS cabinet shall provide additionally:
 Panel wiring of field terminations and signal converters.
 Panel wiring of signal converters and plug and socket connector mother boards.
 Plug and socket connectors to permit the interconnection of the Signal I/O to the
field terminal blocks.
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All equipment shall be mounted and connected in accordance with the equipment
manufacturer’s recommendations. Panel / Cabinet construction, wiring etc. shall be in
accordance with this Specification.
8.5.3 CIRCUIT PROTECTION

All panel and field wiring shall be protected by suitably rated devices as follows:
Power distribution: Over-current and short-circuit protection shall be by means of double

pole miniature circuit breakers
Sub-distribution: Over-current and short-circuit protection shall be by means of fused

terminals
All miniature circuit breakers shall have visible “tripped” indication and auxiliary contacts
for remote fault annunciation. All 24VDC and 120 VAC power supplies inside the system
cabinet shall be provided with miniature circuit breakers. Sizing of this breakers shall be
the responsibility of the control system integrator.
The sizing criteria for MCBs and fuses shall be submitted to Contractor for review. Digital
outputs shall be individually fuse protected.
The analog and digital input/output signals shall be protected against surge and
lightning. MTL IOP series of terminal block shall be used for this type of protection.
8.5.4 EARTHING
Cabinets shall be equipped with:
 Protective (safety) earth bar, bonded to the metal work of the panel and to which
all metallic parts and equipment earth terminal shall be connected with
green/yellow PVC-insulated 4 mm2 cores.
 Isolated instrument reference earth bar, insulated from all metallic parts of the
panel, which shall be the 0V dc reference point for the panel and to which all 0V
dc instrument and power supply terminals shall be connected.
8.5.5 WIRING
a. Signal core, except those forming part of the CSI / Supplier’s standard ribbon
cable within the panel shall not be less than 0.75 mm2.
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b. Wiring from field instrumentation shall utilize stranded conductors.
c. Power wiring for 120 VAC 60Hz circuits within the panel shall not be less than
1.5 mm2, but otherwise shall be rated for the duty.
d. Crimped lugs and ferrules, for identification, shall be fitted to all cables prior to
termination.
e. All cores shall be clearly marked in accordance with the project standards.
f. All wiring shall be run in non-flammable plastic cableway which shall not be more
than 70% full at the time of shipment.
g. All connections within panels shall be made using Weidmuller terminal

blocksmounted on DIN rails.
h. Signal wiring shall be screened within the Panel where necessary to avoid pick-
up of electrical noise. For input/output signal wiring, screens shall be electrically
continuous and the screen shall be connected to the panel screen earth bar.
i. No splices shall be made in cables at any point.
j. Network wiring / interconnection cabling shall be furnished by the vendor

supplier. The cables shall conform to applicable industry standards for data
transmission. Redundant network cables outside the MCC building shall be
routed in two geographically different routes separated by at least 10 meters.
k. Connection wiring from the I/O modules shall be prewired using ribbon cables
into the field terminal blocks located inside the I/O & system cabinets.
l. The following cable colours shall be used:
All system wiring shall be flame retardant as per references IEC 60331 and IEC 60332.
8.5.6 TERMINALS
Terminals shall meet recognized international IEC standards, and carry UL and CSA
ratings and shall mount on standard DIN rail. It shall be tin plated terminal and zinc
chromate screws in order to withstand corrosion. Terminal shall also have flexibility for
installation and maintenance.
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Duty Terminal Type

120Vac Mains supply terminals Weidmuller – Pin Crimp/Lug
High Current 24Vdc supply Weidmuller – Pin Crimp/Lug
terminals
Incoming/outgoing low voltage Weidmuller – Pin Crimp
/low current signals
Internal fuse terminals Weidmuller – Pin Crimp
Internal connections Weidmuller – Pin Crimp
a) Each terminal shall hold only one wire on each side.
b) Jumper wire straps especially designed for the terminal blocks shall be used if
more than one wire requires to be common.
c) All terminals shall be numbered.
d) Terminal numbers shall be shown on the Supplier’s panel wiring diagrams.
8.6 FUTURE EXPANSION.

The PCS and SSS Remote I/O and FGS shall be capable of being expanded to cater for
additional input/output modules and communication interface units by way of the
installation and connection of standard modular components and units.
As specified, Remote I/O’s shall have 20% additional spare capacity in input and output
modules installed on delivery to cater for plant modifications. Consequently, 20% spare
space shall be provided in the system cabinets and enclosures to add input/output
modules without having to increase the number of equipment enclosures. The final
equipment capacity, sizes and layouts shall be reviewed and approved before
construction. See section 8.1.2 spare capacity.
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9.0 TESTING AND INSPECTION

9.1 GENERAL
The Supplier and his sub-Suppliers shall operate quality systems satisfying the
applicable requirements as defined in the requisition.
9.2 TESTING
8.2.1 FACTORY ACCEPTANCE TESTING (FAT)
The FAT shall include the testing and acceptance of both hardware and software
systems, including system redundancy. Supplier shall develop and produce a FAT
procedure covering all aspects of the hardware, operating software, application software,
communications, redundancy testing and interface testing with the SSS and other
specified systems. The FAT procedure shall be submitted to the Contractor / Company
one month prior to the commencement of the FAT for review / approval. The FAT
procedures shall include “pass/fail” criteria. Company and Contractor representative
shall witness the entire FAT. The FAT procedure shall be signed off by the Supplier,
Contractor and Company representative at the successful conclusion of testing.
Functionality shall be fully tested via potentiometers to simulate current sources and
Ampere-meters used to indicate output signals; lamps shall be used to indicate On/Off
output conditions.
The Supplier shall notify the Company 4 weeks in advance of the start of the FAT, in
order to enable mobilization of personnel.
Prior to the start of the FAT, the Supplier shall conduct a pre-FAT inspection and testing
of the cabinets to ensure that it is ready for FAT. The results of the inspection and review
shall be forwarded to the Company to assess the state of readiness for FAT.
All system programs must be complete, free of patches and resident in the systems prior
to the start of FAT. All hardware diagnostic programs shall be run at the start of FAT.
These must be the diagnostic programs, which have been used for processing the
system in the Supplier’s factory.
During FAT the system shall be made available to Company for sufficient periods to
verify satisfactory performance.
All inputs and outputs must be simulated during the FAT. Supplier shall be responsible
for rectifying any faults/mistakes/omissions discovered during the course of the FAT.
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Backups of the system software and configurations shall be made during and at the end
of the FAT. After FAT, Supplier shall uninstall all the PLC cards in order to ship them
apart in boxes properly protected.
A copy of the signed off FAT procedure, punch-list and related printouts shall be
furnished to Company representative.
Following test shall be conducted / carried out during the FAT:
 Complete Bill of Material Check
 Check with purchasing specification or the vendor’s specification/drawings

approved by the purchaser.
 Appearance and construction check
 Outline and dimensional check
 System Power on check
 Hardware check – Functionality of all electronics, cards, power supplies etc
 Software Check – configuration, graphics, database, other standard displays
 I/O simulation test – 100% I/O shall be simulated and tested
 Systems communication Test
 Redundancy Test – Processors, power supplies, communication modules, etc
 Interface with SSS system / F& G / PAGA, and third party system
 Checking of scan time for controllers and data acquisition system
 Checking of controller loading
 Checking various log formats, shutdown report, alarm report, I/O mapping
 Simulation of power failure and re-starts
 Grounding
 Power variation
8.2.2 CERTIFICATES OF ACCEPTANCE

At the satisfactory conclusion of the FAT, a factory Certificate of Acceptance shall be
provided by the Supplier for signature by the Company.
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9.3 QUALITY ASSURANCE

The supplier shall maintain an effective quality system that complies with the
requirements of the vendor quality requirements, specifications and BS EN 9001.Quality
systems: Model for Quality assurance in Design, Development, Production, Installation
and Servicing.
The vendor shall supply a concise description of vendor’s quality system and its
proposed application to the scope of work, including references where applicable to a
Quality Manual or similar authorized company document.
A Quality plan, indicating the verification activities that will be applied in order to achieve
the required quality shall be submitted with the Bid. The quality plan will also include
monitoring performance of the supplied system.
The vendor must be able to demonstrate the existence of effective Software Quality
Procedures addressing as a minimum, the following:
 Hierarchical Design Documentation Structure
 Documentation Control.
 Design and Programming standards.
 Fault tolerance features.
 Design Review.
 Verification and validation.
 Test & Integration Strategy.
 Defect recording and Analysis.
The vendor software package shall be identified by Revision and Date. All software
loading and changes from the commencement of the project shall be only such identified
software and all activities shall be entered in a Project logbook, signed.
A complete record will be kept for all software errors and corrections carried out during
the development and testing of the system. The software problem report will record the
description of the problem, any diagnostic and supporting data, software modules
affected and the corrective action undertaken.
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9.4 INSPECTION
The Contractor/ Company, at its discretion, may choose to utilize the services of a 3rd
party Inspection House(s) to validate witness or hold as detailed on an agreed and
approved Supplier Inspection and Test Plan.
10.0 SHIPMENT, PRESERVATION, STORAGE AND HANDLING
10.1 Packaging, Shipping and Handling

Preparation for shipment shall be in accordance with the Supplier's standards and as
noted herein. Supplier shall be solely responsible for the adequacy of the preparation for
shipment provisions with respect to materials and application, and to provide equipment
at the destination in ex-works condition when handled by commercial carriers.
Adequate protection shall be provided to prevent mechanical damage and atmospheric

corrosion in transit and at the jobsite. Preparation for shipment and packing shall be
subject to inspection and rejection by Company’s inspectors. All costs occasioned by
such rejection shall be to the account of the Supplier.
Equipment shall be packed, securely anchored, and case mounted as required.

Bracing, supports, and rigging connections shall be provided to prevent damage during
transit, lifting, or unloading. PLC cards shall be shipped apart and carefully boxed.
Separate, loose, and spare parts shall be completely boxed. Pieces of equipment and
spare parts shall be identified by item number and service and marked with Company's
PO number, tag number, and weight, both inside and outside of each individual package
or container. A bill of material shall be enclosed in each package or container of parts.
One complete set of the installation, operation, and maintenance instructions shall be
packed in the boxes or crates with equipment. This is in addition to the number called for
in the Purchase Order.
10.2 Preservation and Storage

Equipment and materials shall be protected to withstand ocean transit and extended
period of storage at the jobsite for a minimum period of 18 months without adverse
effects:
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Temperature minus 10 OC to 50 OC
Relative Humidity zero to 100% (non-condensing)
Equipment shall be protected to safeguard against all adverse environments, such as:
humidity, moisture, rain, dust, dirt, sand, mud, salt air, salt spray, and sea water.
11.0 WEIGHTS
The dimensions and weights of the individual completed cabinets shall be advised by the
Supplier in his documentation.
12.0 INSTALLATION, SITE TESTING AND COMMISSIONING
12.1 Installation
Supplier shall provide experienced and competent personnel to assist in the final hook-
up, pre- commissioning and support of start-up of the onshore and offshore facilities.
Technical assistance shall be provided from support bases via telecommunications in
the event that problems encountered cannot be resolved by the site personnel.
Installation of complete cabinets shall be done by others under Supplier’s supervision.

Installation of loose shipped items in cabinets shall be performed by Supplier. Installation
of field instruments shall be performed by the Installation/Fabrication Contractor. Any
special tools required for installation shall be provided by the Supplier.
12.2 Site Acceptance Test (SAT)

Supplier shall develop and produce a SAT procedure covering all aspects of the system
that have not been tested in the FAT, specific to the site, or included as a punch list item
from the FAT. The SAT procedure shall be submitted to the Company for review /
approval prior to commencement of SAT.
The SAT shall include all the interfaces to the actual sub-systems, system redundancy,
configuration, physical installation and` interfaces, data links settings and testing of data
transfer from each data point.
During SAT all field devices shall be tested from the field device through to end element.
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At the satisfactory conclusion of the SAT (Site Acceptance Test) a final Certificate of
Acceptance shall be prepared by the Supplier. Attached shall be all testing results
records, software backup media, and receipt for documentation and spare parts plus any
other pertinent records regarding the Supplier’s delivery. The document becomes a
Certificate of Final Site Acceptance with Company approval.
12.3 Site Integration Test (SIT)

Supplier after installation of all Remote I/O components & hardware and after successful
completion of the SAT shall conduct a Site Integration Test to ensure that all control and
communication in between PCS, SSS and FG cabinets installed in the different locations
are fully functional and operational.
12.4 Commissioning
Supplier shall prepare a pre-commissioning procedure for the Contractor/Company to
review and approve, prior to the start of the pre-commissioning activities.
Pre-commissioning shall include, but is not limited to, the following:
 An audit and inspection of equipment received. A deficiency report shall be

written and appropriate action taken to rectify any problems.
 Each system shall be powered up and functionally tested with appropriate test
equipment.
 The logic solvers, engineering workstations, and sub-systems shall be powered

up and tested with diagnostic routines.
 Field instruments shall be powered up and checked out with diagnostic routines
 Communications shall be established between all components of the system and

tested.
13.0 MAINTENANCE REQUIREMENTS

13.1 Regional Maintenance Support
Preventive and breakdown maintenance activities shall be carried out by regional
maintenance support teams who shall conduct maintenance activities in accordance with
the Maintenance/Support Agreement.
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On notification of breakdown or preventative maintenance service requirements, the

Supplier’s maintenance support team shall be mobilized to site to rectify the fault and
conduct preventative maintenance services. Technical assistance shall be provided from
support bases via telecommunications in the event that problems cannot be resolved by
the site personnel.
13.2 Maintenance during Warranty

During this period the Supplier shall provide qualified service personnel for periodic
preventative maintenance, fault finding, repair and replacement of all equipment,
firmware and software, supplied in accordance with this specification.
The Supplier may utilize the recommended spare parts to maintain the system however;
supplier shall replace all such spare parts used, at no cost to Company.
13.3 Maintenance after Warranty

The proposal shall include the details and costs of all standard maintenance services
available from the Supplier which are suitable for the proposed system (hardware,
firmware and software). Company shall be under no obligation to select all or any of the
agreements detailed and shall be free to negotiate a unique maintenance agreement
with the Supplier, or other maintenance service providers, as appropriate.
14.0 SPARE PARTS AND SPECIAL TOOLS

14.1 General
The Supplier shall be requested to complete a Spare Parts and Interchangeability
Record (SPIR) form to identify commonality in spares. Any spare parts utilized in
rectification of faults on the Remote I/O or any integrated systems used during the
Warranty Period shall be replenished at the Supplier’s expense.
The time scale and procedure for repair and/or replacement of parts shall be stated in
the Supplier’s bid. The Supplier shall provide ordering information for consumables and
spare parts as required.
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The spare part lists shall detail:
 Model and/or figure number of the main equipment being quoted.
 Part number and identification name.
 Drawing or sketch number.
 Source of the part. When a part is not manufactured by the Supplier, the original
supplier’s identification must be given.
 Price of spare parts.
 The lead time for supplying additional spares shall be quoted, (e.g., ex. stock, 30
days, subject to quotation, etc.).
 The Supplier shall indicate whether compete units or modules are recommended
for the peripheral equipment.
 For all units, spare fuses and consumable items shall be provided as individual
packages.
 All spare parts shall be clearly marked and identified using a concise tag number.
 Original spare parts shall be guaranteed available for a period of 15 years from
the date of delivery and equivalent spare parts guaranteed available for a further
20 year period.
 Standard quantities recommended for start-up and normal operation.
Spare parts shall be adequately protected and packaged to prevent deterioration of

components and contract surfaces during prolonged storage under condition set forth in
Project Preservation specification.
14.2 Start-Up and Commissioning Spares

The Supplier shall supply start-up and commissioning spares. The cost of start-up and
commissioning spares shall be quoted separately. The time scales and procedure for
repair and/or replacement of parts shall be stated in the Supplier’s bid.
14.3 Operational Spares

The Supplier shall review the equipment (including tools, testing and calibration
equipment) offered in his proposal and shall include a comprehensive recommended
spare parts list sufficient for two (2) year’s continuous operation of the equipment.
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The costs of the recommended spares shall be quoted separately.
14.4 Consumables
Supplier shall ship a six-month supply of consumables with the hardware. Supplier shall
list in his bid proposal the consumable items for the system.
14.5 SPECIAL TOOLS

The Supplier shall provide equipment required to test, calibrate, service and generally
maintain the system equipment to its maximum reliability and accuracy. The Supplier
shall supply all standard and special tools, test and calibration equipment necessary for
site installation, pre commissioning and SAT.
The Supplier shall provide his standard items of test equipment to perform the following
functions:
 Signal injector to test the proper operation of the input and output point functions.
This unit shall be portable for local testing of I/O cards
 Multi-meters, laptop and/or any other equipment recommended by the Supplier.

The Supplier may use the above equipment in the course of the pre-
commissioning and the SAT. At the completion of these activities the equipment
shall be handed over to Company in good condition.
Supplier shall provide a full list of test equipment with the proposal.
15.0 DOCUMENTATION AND DRAWINGS

15.1 General
The Remote I/Os shall be supplied complete with full documentation from the Supplier to
enable the systems to be maintained, enhanced and updated on the entire life of the
facilities, through to final decommissioning.
Supplier shall submit the type and quantity of drawings and documentation for
Contractor's authorization or information as listed in the individual Purchase Orders.
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Comments made by Contractor on drawing/document submittal shall not relieve Supplier

or Sub-suppliers of any responsibility in meeting the requirements of the specifications.
Such comments shall not be construed as permission to deviate from requirements of
the Purchase Order unless specific and mutual agreement is reached and confirmed in
writing.
Documentation and drawings shall be produced and stored on paper as well as in

computer readable media. All final system design documentation shall be provided in
electronic format. Additionally, it is desired to have as much system documentation as
possible available on CD-ROM with search and retrieval capabilities. Documentation
specifically developed for the Project shall be provided in CD-ROM read/write format
while Supplier standard documentation may be provided in read only format.
15.2 Required for Technical Evaluation

Supplier shall provide complete documentation for the Remote I/O in sufficient scope
and detail for review and evaluate by the COMPANY. This shall include but not be
limited to:
● System architecture block diagrams

● Dimensional outline drawings showing cabinet layout
● Bill of material for main PCS hardware and software proposed
● Hardware/software specifications
● Availability calculation
● Power and grounding requirements
● Project execution plan
● Drawing index
● Equipment catalogs on CD for Hardware proposed
Supplier shall structure their proposal in the same form of the present specifications.
Supplier shall provide an exception list with all the deviations to the present
specifications.
15.3 Functional Design Specification

Following purchase order, the Supplier shall respond to this specification with a
Functional Design Specification (FDS) five (5) weeks after purchase order award,
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detailing the proposed design for the PCS and SSS Remote I/O and FGS. This
document shall be analysed and approved by the Company before any procurement of
PCS and SSS components. Technical review meetings shall be held to resolve the
outstanding issues.
With the FDS, the supplier shall provide:
 Detailed PCS and SSS Remote I/O cabinets layouts and General Arrangement
 PCS and SSS configuration
 Memory map distribution
 Programming logic design criteria
 Preliminary wiring drawings
 Internal Wiring and interconnection diagrams
 Design calculations, (including power consumptions, heat dissipations, weights,

Mean Time Between Failure (MTBF) and Mean Time To Repair (MTTR)
 System self-generated documentation
15.4 Design Drawings

All project specific system design drawings shall be provided in AutoCAD 2007 or later
format file.
Every effort shall be made to minimize the total number of drawings prepared by use of
common drawings, where practicable without loss of clarity.
Each drawing shall be provided with a title block in the bottom right-hand corner
incorporating the following information:
 Official trade name of the Supplier.
 Supplier's drawing number whereby the drawing can be identified
 Drawing title giving the description of contents.
 A symbol or letter indicating the latest issue or revision.
 PO number and item tag numbers.
 Chevron logo.
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Revisions to drawing shall be identified with symbols adjacent to the alterations, a brief
description in tabular form of each revision shall be given, and if applicable, the authority
and date of the revision shall be listed. The term "Latest Revision" shall not be used.
15.5 Details and Data Sheets

The Supplier shall supply the following documents:
 Lists of all equipment items giving type, manufacturer, etc.
 Equipment Data Sheets
 Equipment layout drawings.
 Equipment dimensions and weights.
 Cabling and hook up drawings.
 Interface specifications and input/output summaries.
 Communications requirements.
 Definition of operation procedures, lists of commands, pages and printouts.
 Lists of all applications modules (descriptions and basic flow charts).
 List of all spare parts, tools, test equipment and installation materials.
 List of preliminary maintenance requirements.
 The packing and transportation specification with preliminary quantities

dimensions and weights.
 Approvals and certificates for equipment supplied
 Spare parts and Interchangeability records
15.6 Operation and Maintenance Manuals

A Project Manual shall be provided which shall include, but not be limited to the following
documents:
 Supplier’s standard manuals for operation, configuration, installation, and

maintenance as applicable to the system.
 The approved COMPANY supplied Project Specification(s).
 Drawings and schematics sufficiently detailed to permit diagnostics.
Page 41 of 43
15.7 As Built Drawings

The Supplier shall continuously update drawings and documents to reflect the latest
status of the equipment. In particular, documents and drawings shall be updated to
reflect current status for FAT and SAT.
When the equipment has been fully accepted following the SAT, the Supplier shall issue
a complete set of updated drawings incorporating all modifications, additions or other
changes that have taken place during manufacture and site commissioning
15.8 Self Documentation

The Remote I/O shall have self-documentation facilities to generate information on the
control loop diagrams/configurations, batch/sequence control schemes, and system
configurations.
The system shall have comprehensive facilities to enable on-line searching of the
control, cross references for specific Tag Numbers, and other free format searches to
aid maintenance of the control and inputs/outputs.
The control logic and selected parts of it shall be capable of being printed on the hard
copy printers supplied as part of the system.
16.0 TRAINING
16.1 Training Philosophy
Supplier shall provide formal training both on site and at the Supplier’s facility for
nominated personnel.
The course structure and syllabus shall be submitted to the Company for review and
approval. The course pre-requisite experience and technical expertise shall be advised
to the Company prior to the start of the course.
16.2 Training Course Documentation

For each trainee who shall attend a training course, a copy of the complete training
course, notes, and drawings shall be provided to the trainee eight weeks prior to the
commencement of the training course. The copies shall be retained by the trainees on
completion of the training course and shall be the property of COMPANY.
Page 42 of 43
In addition, five copies of the training course documentation shall be available on site
prior to the installation and pre commissioning for reference purposes.
16.3 Operator and Maintenance Training Course

The course shall be aimed to make the attendees familiar with the main components of
the system, (including field devices supplied), to train the technicians for first line fault
diagnosis, and repair by replacement. Operator manuals shall be made available to
Company prior to this course.
16.4 System Configuration Course

The purpose of this course is to enable Company Engineers to be able to modify system
configuration.
Typical course content shall be:
 Basic System Introduction.
 Analogue Control, Batch/Logic sequence
 PCS and SSS Peripherals.
 Engineering Workstation
16.5 Training Aids

The Supplier shall bid and provide all necessary training aids required for the above
courses.
Page 43 of 43

Remote I/O Panel Specification

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Remote I/O Panel Specification

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MEJI GGCP DEBOTTLENECKING PROJECT

REMOTE I/O PANEL SPECIFICATION

Document No: MDP-M028-ICS-SPC-IES-0000-00190-00

U01 01-Dec-16 Issued for Construction OMM SCA SVB

Project Area Discipline Type Originator Package Sequence-Sht Revision

REVISION DESCRIPTION OF REVISION DATE REMARK

K01 Issued for Review 14-Sept-16

U01 Issued for Construction 01-Dec-16

9.2 TESTING ......................................................................................................................... 30

ASME American Society of Mechanical Engineers

A new PLC FG panel located on RP shall be provided completely assembled and

Any exceptions to the requirements of this specification or conflicts between this

2.2 Definitions of Terms As Used In This Specification

Concession Request — A deviation requested by the Subcontractor or Supplier,

Project – Meji GGCP Debottlrnecking Project

Shall - Indicates a Mandatory Requirement

Should - Indicates a Recommendation

CSI - The party which manufactures and/or supplies equipment, technical

Process Control System (PCS) – A configurable microprocessor-PLC based control

Safety Shutdown System (SSS) – A configurable PLC microprocessor based system

alternatives shall be provided at the SUPPLIER’s proposal. Alternatives must

3.0 APPLICABLE CODES AND STANDARDS

3.1 CODES AND STANDARDS

API 551 Process Measurement

API 14C Recommended Practice for Analysis, Design, Installation and

IEC 60331 Tests on Electrical Cables under Fire Conditions-Circuit Integrity

IEC 60332 Tests on Electrical Cables under Fire Conditions

IEC 61000 Electro-magnetic compatibility – Generic emissions Standard

IEC 60529 (1989-11) Degrees of Protection Provided by Enclosures (IP Code)

IEC 61131-3 Programmable Controllers – Part 3: Programming Languages

IEC 61508 Functional Safety of

(Parts 1 to 7) Electrical/Electronic/Programmable Safety- Related Systems

IEC 61511 Functional Safety Instrumented Systems for the

Process Industry Sector.

ICM-DU-5144 Rev B Process Automation System Design

ICM-DU-6025 Rev B Safety Instrumented Systems

ICM-DU-6036 Nov. 2012 Fire and Gas Systems

ELC-SU-1213 Wire and Cable

ICM-SU-11.06 Instrument Control Panels

4.2 PROJECT SPECIFICATIONS

MDP-M035-ICS-PHL-IES-0000-09204-00_K01 Instrument Control Philosophy

5.0 HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS

5.2 AREA CLASSIFICATION

5.3 HEALTH, SAFETY AND ENVIRONMENTAL REGULATIONS

6.0 GENERAL DESIGN REQUIREMENTS

 System Hardware and Software

 System cabinets to house the required hardware, RittalExpress type.

 Engineering, configuration, design and programming required to integrate the

 PLC programming and application software

 Human Machine Interface software

 Redundant HMI Servers, Monitoring station and an engineering station

 Network routers and/or switches

 Internal wiring between components provided

 Development and testing of operational templates.

 Engineering and maintenance Documentation

 Recommendation of Spare Parts and Consumables

 Supervision of Site installation

 Site pre-commissioning assistance

 System Site Commissioning and Start-up assistance

6.2 OPERATING REQUIREMENTS

6.3 DESIGN LIFE

7.0 EQUIPMENT DESIGN AND MANUFACTURING

The Process Control System shall be designed to generate Alarms when