Sie sind auf Seite 1von 27

G

XXXXXXXXXX

SPECIFICATION FOR
TURBINE CONTROL SYSTEMS

Rev Date Prep’d by Checked BY App’d by Reason for Issue

XXXXX

XXXXX

XXXXX
TABLE OF CONTENTS
1.0 GENERAL.................................................................................................................................................3
PROJECT OVERVIEW.....................................................................................................................3
SCOPE...............................................................................................................................................4
DEFINITIONS AND ABBREVIATIONS.........................................................................................4
CODES AND STANDARDS, REFERENCE DOCUMENTS............................................................5
CODES AND STANDARDS...............................................................................................................5
ENGINEERING PRACTICES.............................................................................................................5
REFERENCE DOCUMENTATION....................................................................................................5
ORDER OF PRECEDENCE................................................................................................................5
COMPLIANCE.....................................................................................................................................5
ENVIRONMENTAL CONDITION..............................................................................................6
UNITS OF MEASUREMENT............................................................................................................7
EXISTING SYSTEM DETAILS......................................................................................................................8
ASAB................................................................................................................................................8
BAB...................................................................................................................................................9
3.0 TECHNICAL REQUIREMENTS..............................................................................................................10
GAS TURBINE CONTROL SYSTEM.............................................................................................10
FUEL GAS VALVES.......................................................................................................................16
VIBRATION MONITORING..........................................................................................................16
FIRE AND GAS DETECTION SYSTEM........................................................................................16
TURBINE EMERGENCY SHUTDOWN.........................................................................................16
INTERFACE TO THE PROCESS COMPRESSOR ANTISURGE CONTROL SYSTEM................17
HARDWARE CONFIGURATION..................................................................................................17
CLASSIFIED AREAS......................................................................................................................19
OPERATOR INTERFACE REQUIREMENTS................................................................................19
4.0 SPECIFIC REQUIREMENT.....................................................................................................................19
TAGGING.......................................................................................................................................20
5.0 IMPLEMENTATION................................................................................................................................20
5.1 TECHNICAL REQUIREMENT.................................................................................................21
5.2 SCOPE OF WORK.....................................................................................................................21
5.3 TESTING & INSPECTION........................................................................................................21
SITE SERVICES.............................................................................................................................23
SITE INSTALLATION AND COMMISSIONING ..........................................................................23
COMMISSIONING ENGINEER.......................................................................................................23
COMMISSIONING.............................................................................................................................24
SPECIAL TOOLS, SPARE PARTS...................................................................................................24
SPECIAL TOOLS...............................................................................................................................25
DOCUMENTATION.......................................................................................................................25
6.0 TRAINING...............................................................................................................................................25

ATTACHMENT 1 : Serial I/O count– preliminary

SUMMARY OF REVISION HISTORY

Section or Pages,
Rev. No. Date Description of Change
Revised
A 20.09.03 - Original Issue

B 08.11.03 All Sections Reissue for Comments

0 08.12.03 - Final Issue

1.0 GENERAL

PROJECT OVERVIEW

XXXXX Gas Industries Ltd (XXXXX) has NGL extraction facilities at Asab & Bab,
located at 190 KM south & 150 KM south west of XXXXX city respectively. The
facilities consist of the following plants which are:

Gas Gathering (Booster area).


Gas compression
Gas Treating (Bab only)
Propane Refrigeration and Extraction
Utilities, relief and blowdown.
Power Generation
Acid gas recovery (Bab only)
Lean gas station

The facility has been operational since 1981. The process control system is pneumatic
and safeguarding logic is by means of relays based system. Separate fire & gas panels are
provided for the fire & gas detection & protection of the plant and main equipment.
These systems are very old and have become obsolete.

The Company, XXXXX, will replace and upgrade the existing control system by new
integrated control system (ICS) comprising of the following main components.

• Distributed Control system (DCS)


• Instrumented Protective System (IPS)
• Fire & Gas system (FGS)

Associated with the above, interfaces to subsystems or the subsystems will also be
upgraded.

SCOPE

This specification covers the minimum requirements for the design, manufacture,
inspection and testing of the upgraded Turbine control systems and the interface for new
ICS.

DEFINITIONS AND ABBREVIATIONS

The following definitions are used in this specification:

VENDOR The Supplier with whom the purchase order will be placed for
the supply of the specified equipment.

OWNER XXXXX

CONTRACTOR The EPC Contractor

ICS VENDOR The supplier of the main ICS components comprising of DCS,
IPS & FGS.

The following abbreviations are used in this specification:

DEP : Design and Engineering Practice from Shell International Oil


Product B.V.
ICS : Integrated Control System
DCS : Distributed Control System
MCR : Main Control Room
AR : Auxiliary Room
GTCS : Gas Turbine Control System
MPU : Main Processor Unit
CODES AND STANDARDS, REFERENCE DOCUMENTS

CODES AND STANDARDS

The following codes and standards shall be applied. Any deviations or conflicts shall be
reported in writing and shall require prior approval by the Company.

IEC : International Electro Technical Commission


IEC 79 : Electrical Apparatus for Explosive Gas Atmospheres
IEC 529 : Degree of Protection of Enclosure
IEC 331 : Fire Resisting Characteristics of Electrical Cables

NEMA : National Electrical Manufacturer’s Association

ICS 1-1978 : General standards for industrial control system


ICS 6-1978 : Enclosures for Industrial Control and Systems
ICS 2-230 : Electromagnetic Interference

CENELEC standards
EN 50018 : Electrical Apparatus for Potentially Explosive Atmospheres
API : American Petroleum Institute
API 670 : Machinery Protection System
ANSI : B 1.20.1

Vendors shall indicate in their proposal the codes and standards, which have been
applied in the manufacture of the material required under this specification

ENGINEERING PRACTICES

The following Shell DEP’s of latest issues shall be applied.

DEP 32.37.20.31-Gen System Cabling

REFERENCE DOCUMENTATION

The following documents are applicable for reference:

P5223-30-A-0004 I/O list for Asab


P5223-30-B-0004 I/O list for Bab

Note :Bulk I/O count attached is preliminary and for reference only. EPC contractor
to finalize the actual I/O requirement for system upgrade requirement.

ORDER OF PRECEDENCE

In the case of conflict, the following order of precedence shall apply,


1. Contract Specifications
2. SHELL Design and Engineering Practice (DEP)
3. International Codes and Standards

COMPLIANCE

The VENDOR shall notify the CONTRACTOR or OWNER of any apparent conflict
between this specification, equipment or software functional detailed
specifications/drawings, the Codes and Standards and any other specifications noted
herein. The VENDOR is to prepare a tabulated list of discrepancies between any of these
documents for review with CONTRACTOR. Resolution and/or interpretation precedence
shall be obtained from the CONTRACTOR or OWNER in writing before proceeding
with the design/manufacture.

In case of conflict or ambiguous possible interpretation of documents, the vendor shall


notify Contractor and seek clarification during the tender period.

The Vendor may propose alternative improved performance features as long as the
system is made up of field proven hardware and software modules.

The Vendor shall ensure that the design complies with the requirements of this
specifications and it’s referenced standards and work practices.

Vendor shall submit with his quotation a completed “Table of compliance”. Vendor shall
confirm compliance to the specifications and the referred standards by section by section
An example of the table of Compliance is given below:

TABLE OF COMPLIANCE

Date :
Project :
Vendor :

Paragraph Enhancement Conforms Alternative Exception Noted Clarification


Number Note
2.0
2.1
2.1.1
2.1.2
2.1.3
2.1.3.1

Definitions of the column headings are as follows

Enhancement: Feature fully complies with the specifications and offers more
functionality. Vendor to give full description.

Conforms: Feature fully complies with the specification.


Alternative: Feature does not meet the specification, however the functional
requirements can be met in different way. Vendor to give full description.

Exception: Vendor cannot meet the specification.

Noted: The relevant paragraph in the specification contains information only. By


checking this paragraph as “noted”, Vendor confirms that the information is understood
and that the supply will be in compliance with this information.

Clarification Note: To be detailed by Vendor item wise.

ENVIRONMENTAL CONDITION
The plants are located at ASAB & BAB, approximately 190 km south and 150 km south
west of XXXXX City respectively.
The atmosphere is laden with dust and contains traces of hydrogen sulphide (Bab only),
sulphur dioxide and chlorides. All selected equipment including indoor equipment,
modules and PCBs shall be suitable for the above mentioned condition for the severe
Arabian Gulf environment.
Site elevation
- Elevation 95 m (BAB) and 134 (ASAB)
Wind
- Prevailing direction NW quadrant
- Design velocity (basic) 144 km/hr
Air temperature
- Average ambient temperature 27°C (BAB)30°C (ASAB)
- Maximum temperature in direct sunshine 86°C for BAB and ASAB
- Maximum temperature in shade 55°C (BAB)59°C (ASAB)
- Minimum ambient temperature 06°C (BAB)4°C (ASAB)
Relative humidity
- Relative humidity (average 54°C) 60 % BAB and ASAB
- Maximum relative humidity (43°C) 95 % BAB and ASAB
Rainfall
- Average rainfall Extremely rare
Indoor conditions
- Air conditioned environment.

Normally the complete monitoring equipment will operate in the aforesaid indoor
conditions at a temperature of 26°C.
However, while being transported to site or during a malfunction of the air conditioning
system the ambient temperature may vary between 5 and 55 °C. At all times, the relative
humidity may vary between 30 and 96%, and the air may contain sand dust particles as
small as two microns.
In case of air conditioning failure, the vendor shall advise the duration for, which the
equipment shall be capable of sustained, un-degraded operation in the above mentioned
conditions.

UNITS OF MEASUREMENT

The instrument ranges and display variables shall be in S.I. units.


Ex:
Length : mm, m
Flow : m3/h
Temperature: ºc
Mass : kg
Density : kg/m3
Pressure : bar, mbar
EXISTING SYSTEM DETAILS
The details of the existing Turbine control panels various locations of the plant are
elaborated in the following sections. The turbine control panels are used for the
monitoring, control & safeguarding of the power turbines, generator or compressor units
and their associated auxiliaries.

ASAB

2.1.1 MCR

The details of the existing Turbine control system in the MCR are given below.

Sl.No Panel Description System Description


.
1 22-K-101 One Netcon 5000 F/T system along with Woodward
(LP Compressor) speed controller, HMI interface equipment including
Compac PC monitor, HP LaserJet Printer and a
separate event printer. Also Bently Nevada Vibration
Monitoring system along with Vibrometer system &
F&G linked with Netcon system.

2 24-K-401 General Electric (GE Mark II) control panel, used for
(Propane) monitoring and control associated with Feed gas
compressor. Also Bently Nevada for Vibration and
temperature monitoring along with F&G linked to this
system.
Total there are three panels:
• Turbine GE MK2 control panel
• Compressor control panel (including BN
monitors)
• HOW-R3 F&G panel

3 24-K-101 General Electric (GE Mark II) control panel used for
(HP gas) monitoring and control associated with feed gas
compressor. Also Bently Nevada for Vibration and
temperature Monitoring along with F&G linked to this
system.
Total there are three panels:
• Turbine GE MK2 control panel
• Compressor control panel (including BN
monitors)
• HOW-R3 F&G panel

Note : Control systems for 24-K-401, 24-K-101 are being upgraded and relocated to SS
4 and SS 5 respectively (under a separate project).

2.1.2 SUBSTATION-1

The details of the existing Turbine control system in the Substation-1 are as follows:
Sl.No Panel Description System Description
1 Power generator control One GE Speedtronic control (GE Mark II) control panel
panels –3 No. used for monitoring and control each power generator.
One for each 26-V-101, Vibration monitoring along with F&G is also linked to this
26-V-102, 26-V-103 system.

Note : Control system for 26-V-101, 26-V-102 & 26-V-103 are being upgraded (under
a separate project).

2.1.3 LEAN GAS STATION

The details of the existing Turbine control system in the Lean gas station are as follows:

Sl.No Panel Description System Description


1 Compressor control panel One Netcon 5000 F/T system complete with a HMI
for Lean gas train A unit, printer and a separate event printer. Vibration
Monitoring from Bently Nevada along with Vibrometer
system, with Netcon system. F& G has its own panel
and monitor however linked to Netcon & HMI for alarm
and trip only
2 Compressor control panel One Netcon 5000 F/T system complete with a HMI
for Lean gas train S unit, printer and a separate event printer. Vibration
Monitoring from Bently Nevada along with Vibrometer
system, linked with Netcon system. F& G has its own
panel and monitor however linked to Netcon & HMI for
alarm and trip only.

BAB

2.2.1 MCR

The details of the existing Turbine control system in the MCR are given below.

Sl.No Panel Description System Description


1 14- K-101 HP One Netcon 5000 F/T system complete with a HMI unit
Compressor and a printer. Vibration monitoring along with vibrometer
system and F&G is also linked with Netcon system.

2.2.2 SUBSTATION-1

The details of the existing Turbine control system in the Substation-1 are as follows:

Sl.No Panel Description System Description


1 Power generator control One GE Speedtronic control (GE Mark II) control panel
panels –3 No. used for monitoring and control each power generator.
One for each 16-V-101, Vibration monitoring along with F&G is also linked to this
16-V-102, 16-V-103 system.

Note : Control system for 16-V-101, 16-V-102 & 16-V-103 are being upgraded (under
a separate project).

2.2.3 LEAN GAS STATION

The details of the existing Turbine control system in the Lean gas station are as follows:

Sl.No Panel Description System Description


1 Compressor control panel One Netcon 5000 F/T system complete with a HMI
for Lean gas train ‘A’ unit, printer and a separate event printer. Vibration
Monitoring from Bently Nevada along with Vibrometer
system, Vibration Monitoring system linked with Netcon
system. F& G has its own panel and monitor however
linked to Netcon & HMI for alarm and trip only
2 Compressor control panel One Netcon 5000 F/T system complete with a HMI
for Lean gas train ‘S’ unit, printer and a separate event printer. Vibration
Monitoring from Bently Nevada along with Vibrometer
system, Vibration Monitoring system linked with Netcon
system. F& G has its own panel and monitor however
linked to Netcon & HMI for alarm and trip only

3.0 TECHNICAL REQUIREMENTS


Since the plant control’s is being upgraded to a new ICS system, it is necessary to
integrate monitoring of machine parameters in ICS, which require communication
between machine control and ICS. Presently the Netcon 5000 F/T control systems have
become obsolete and many of the cards are not supported by M/s Woodward. Similarly
the GE Mark II systems also have become outdated. In view of this it is necessary to
upgrade the systems and establish communication to ICS.

GAS TURBINE CONTROL SYSTEM

3.1.1 GAS TURBINE SYSTEM DESIGN REQUIREMENTS

The new Control and Protection system will be used to provide all control and
protection functions currently performed by the existing system, with the addition of the
new features that will improve the reliability, availability and maintainability (greater
than 99,99%) of the Gas Turbine.

3.1.2 SYSTEM HARDWARE

The new system shall be a fully programmable gas turbine controller with its own
power supply, processor, communications, and I/O for turbine control and protection.
Critical functions, such as emergency overspeed, exhaust over-temperature protection;
ESD and backup synchronous check protection shall be provided by an independent
protection system as per API 670.

3.1.2.1THE MAIN PROCESSOR UNIT (MPU) shall have the following requirements:

a) All Algorithms and Human Machine Interface (HMI) tasks shall be executed by the
MPU
b) Real time clock with a 1m seconds resolution shall be available for time dependent
functions such as rate calculations as well as time stamp process variables, alarms
and events generated by the controller.
c) The microprocessor shall be capable of scanning and updating the I/O and
executing user-defined logic a minimum of 40 times per second.
d) Communication facility with DCS via Modbus RTU protocol or OPC

3.1.2.2 I/O INTERFACE

Input Modules
The GT Control System must have input modules capable of accepting input signals
directly from all the following categories as required:

a) Field switches-volt-free contacts and solid state


devices with 1msec time stamp for sequence of events monitoring.
b) Analog 4-20ma, 0-5VDC or 0-10VDC signals
from 2 or 4 wire transmitters.
c) Low-level analog signals from J, K, T, or E
thermocouples.
d) Pulse Inputs (for rate measurement)
e) RTD inputs.
f) Vibration inputs for the casing vibration probes.

Digital input signals shall be conditioned by a low pass filter, typically up to 15 ms, to
reduce the effects of noise and bounce. A minimum of 1000 VDC opto-isolation shall
be provided between each input signal and microprocessor. Each individual input signal
path on the input module shall be automatically tested for proper operation at least
every 10 minutes. Analog and pulse input signals shall have a minimum of 150VDC
input over range protection

Digital inputs shall not be fused

Input modules shall have test circuitry to detect “stuck-on” and stuck-off” conditions to
ensure safe operation.

Output Modules
The Gas turbine control system must have output modules capable of driving output
signals for all the following categories:

a) Analogue signals 4-20mA (500 ohms max.) or 0-200 mA (50 ohms max.)
b) Solenoid valves, relays, motors and LVDT valve position feedback (24 VDC,
125VDC, 240 VAC)
c) Alarm annunciators and DCS interface I/O

Output modules shall fail to open state upon microprocessor failure.


Digital outputs shall be current rated for an inductive load with a minimum of 1 amp
per point at 60 degrees Celsius.

Each individual output point shall be automatically tested for proper operation at least
every 10 minutes.

Digital output modules shall operate properly with a +/- 10% signal voltage, provide a
minimum of 1000 VDC opto-isolation between each output signal and microprocessor
and accept surge current on each point of 12A per cycle for AC voltage and 2.5A per
second for DC voltage.
Digital output modules, which support line fault monitoring, shall also be available.
The modules shall be capable of detecting and alarming open or shorted field circuits as
well as power monitoring. Line monitoring shall be required if any energize to trip
signals are specified.

Each digital output shall be individually fused with blown fuse indication and knife
disconnect terminals for complete isolation capability.

Analog I/O
The Gas turbine control system shall be capable of accepting both high level and low
level analog signals directly through an input module without the use of external
monitor switches.

Thermocouple inputs shall have built in automatic cold junction compensation and
linearization. A single module shall accommodate type J, K, T and E thermocouples.

Analogue outputs shall be capable to be configured to provide a 4-20 mA signals


through 500 ohms load or 200 mA through 50 ohms load. Each output shall be
automatically calibrated. Analog inputs shall be automatic calibrated.

Analog I/O shall have 12 bit minimum analog to digital or digital to analog conversion.
Accuracy shall be at least +/- 0.25% of full scale over the entire operating range.

The vendor shall provide any dropping resistors necessary for analog modules operating
with 4 to 20 mA DC

3.1.2.3 AUTOMATIC TESTING AND DIAGNOSTICS

The system shall incorporate self-diagnostics such that permanent and transient faults
are identified, alarmed and reported. The reporting shall be up to and including the
individual channels in modules and the system shall have the first-out alarm facility.
The diagnostics shall be capable of identifying locating and reporting the following
faults as a minimum:

Scan failure of main or I/O processors.


Memory faults.
Communication faults.
I/O Interface or addressing faults.
Application program and layout consistency.
I/O module faults.
Load power or fuse faults on field circuits.
Power supply faults.
Over temperature conditions.
I/O forcing status.
System cabinet high temperature.

Minimum test period for all logic circuits shall be once every 10 minutes. Fault
information shall be available and displayed for maintenance staff in a manner that
enables fault diagnosis to at least the module level.

All testing described shall be performed automatically on-line and without disturbing
the process or reducing the reliability of the GTCS. The diagnostics described above
shall be built into the operating system of the GTCS hardware and not located in the
application program.

3.1.2.4 INTERNAL SEQUENCE OF EVENTS RECORDER for logging of (but not limited
to):

a) System alarms
b) Diagnostic alarms
c) System events (turbine operation monitoring).
d) Turbine trips (including a real “first out” alarm facility of signal condition that
caused a turbine trip, and freeze frame feature for key parameters just before and
after the trip). 5 minutes pre trip and 2 minutes post trip data shall be available.

3.1.2.5 ALARM LOG

1) The alarm logging shall be available to the operator on the Operator Interface
display and on the printer.

2) The alarm management screens shall list the alarms in the chronological order of
their time tags.

3) The alarm line must show (color highlighting) whether the alarm has been
acknowledged or not and whether the alarm is still active.

4) When the alarm condition clears the alarm can be reset. If reset is selected and the
alarm has not cleared, the alarm shall not clear and the original time shall be
retained.

5) An audible alarm shall be initiated when a new alarm occurs, and will be
maintained until the operator manually silences the alarm.

6) A status field on the alarm display showing the current status on the origin of each
alarm regardless of whether the alarm has been acknowledged shall be made
available.

7) Facility to change or add alarm messages in the alarm status field shall be
provided.

8) Lock out feature to enable the operator to lock out the logging of a nuisance alarm
such as contact inputs continuously changing state must be provided.

9) The locked out alarm shall be highlighted on the alarm display to provide
continuous record that it locked out.

10) Separate queues shall be maintained for the turbine system alarms and internal
control equipment diagnostics.

11) All contact inputs to the new control system will be included in the events log and
will be logged on the printer with individual time tags. Facility to add or delete
individual contact inputs from the event log shall be provided.

12) Separate queue for trip contacts shall be provided, and any logic forcing of these
contacts, shall be highlighted on the alarm display by continuous flashing.

3.1.2.6 TRENDING
Signal trending facilities shall include:

a) Real time trending


b) Short term trending
c) Long term trending (Historian), to be quoted as an option

High resolution trends (1sec) shall be provided

For Real time trending purposes the Operator Interface Station shall have the facility to
display up to six points (user defined) of data simultaneously.

3.1.2.7 COMMUNICATIONS

DCS Interface
The new control system shall be capable of interfacing to a DCS via RTU Modbus
protocol or OPC (preferred). The vendor shall provide details of successful interfaces to
DCS systems, stating client and location of the project. The vendor shall supply in the
proposal a list of services and hardware necessary to provide a complete working DCS
interface. All data must be upgraded in the ICS every one second or faster.

The information to be transferred to and from the DCS via this data link shall include,
but not limited to the following:

a) All operational and control signal.


b) System diagnostic, alarms and status.
c) Field I/O status
d) Shutdown signals and first out indication
e) DCS generated signals
f) System maintenance override status conditions
g) GT accessories status

3.1.2.8 APPLICATION SOFTWARE

The application software shall be specifically designed for the turbines listed in the
specification.

The vendor shall be fully responsible for all the programming and configuration of the
proposed system and will fully describe his proposed system, including in detail the fail
safe operation of the control system, referring to resets, condition of valves, lube oil,
fuel supply system etc. in the proposal.

Software shall be protected from unauthorized changes by the use of both passwords
and key lock switches. Vendor shall state with proposal methods available in his system
for such protection.

3.1.2.9 HUMAN MACHINE INTERFACE

A separate operator interface shall be provided as a back up for any failure of the panel
operator interfaces. This operator interface shall have all the functionalities of any of the
local operator interfaces, which can be selected and identified through software buttons
located in the corner of each screen. The location of this equipment shall be located
inside the same building as the GTCS panels (exact location yet to be decided but no
more than 30 meters from the referred panels)

Note: The operator interfaces hardware requirements are described under 3.9.

Control
1) Unit control display (Operational command screen)
2) Start up sequence display
3) Turbine wash display
4) Unit test display
5) GCV and IGV calibration and stroke check.
6) Mechanical and Over speed tests

Data
1) Exhaust temperatures and spread display.
2) Lube oil temperatures and pressures display.
3) Lube oil and hydraulic oil system display
4) Wheel space temperatures display.
5) Vibration monitoring display (generator, gas turbine).
6) Timers and event counters display.
7) Fuel system display.
8) Start check display
9) Bearing temperature displays
10) Air temperatures display (Accessory compartment, turbine compartment, compressor
discharge)
11) Flame monitoring display.
12) Ventilation system overview display

Administrative
1) Annunciation of Trips display
2) Annunciation of alarms and fault conditions display
3) Ladder logic display
4) Logic forcing display
5) Diagnostic alarms display

Trending
1) Standard and user defined trend displays

Note: All screens must have a window preferably at the bottom of the screen to display
the most recent alarm and trip events. The size of the window shall be enough to
display at least five alarms. From the same window alarms can be scrolled through the
complete list of alarms. The listed alarms shall be displayed with its date, time, alarm
identification, device, acknowledge state and message. Software buttons shall be
available on the top of this alarm screen to acknowledge, silence, lock, unlock, see
comments and set up the alarms.

Display print out samples (from the above list) shall be submitted along with quotations
for evaluation and complete set of print out displays shall be submitted by the
successful bidder before FAT for review and comments.

3.1.2.10TURBINE CONTROL SYSTEM ACCESSORIES HARDWARE

The vendor shall have the capability of furnishing any control system accessories
hardware, which may be required to complement the Gas Turbine Control System. The
vendor shall fully describe his proposed accessory system in the proposal with the block
diagram to explain functionality. The installation of these accessories shall be the
responsibility of the contractor.

3.1.2.11SPARE CAPACITY/EXPANDABILITY

At least 15% wired spares and 20% spare capacity shall be made available within each
system. The spares shall be distributed all over each system. This includes marshalling
cabinets, terminations, I/O, etc. Processor utilization shall be no more than 70%.

FUEL GAS VALVES

Vendor shall quote for the upgrading / replacement (if required) of the control valve,
servo hydraulic to suit the new control system requirements.
Any new servos shall be compatible with existing valve actuator assembly.
Redundancy should apply for the actuators commands and valve position feedback.

3.2.1 FUEL GAS MEASUREMENT

The turbines fuel gas flow is measured through an orifice plate, and the measurement
loop includes the differential pressure, pressure and temperature transmitters. Using the
existing mentioned signals (4 to 20 mA), the vendor shall be responsible to interface and
provide the necessary computation and display graphics to ensure that the corrected flow
rate and totalized flow, pressure and temperature will be displayed in the new control
system.

VIBRATION MONITORING

The vendor shall quote for the required hardware and software interface to the vibration
system (Bently Nevada 3500 & vibrometer) to provide monitoring, alarm and trip.

Bently Nevada system shall be installed on separate cabinet. Vibrometer may also be
replaced and interfaced with new Bently Neveda System

FIRE AND GAS DETECTION SYSTEM

The Gas turbine / Compressor unit is protected by a dedicated fire and gas detection
system, located in the main control room.

Vendor shall interface/connect the Fire & Gas panel signals to the new control system.
The interface/connection to the new control system will be limited to the alarm and trip
signals, which will be available at the Fire & Gas panel as voltage free contacts.

TURBINE EMERGENCY SHUTDOWN

Dedicated ESD push buttons (red color) shall be provided with spring loaded
transparent covers, clearly marked as Turbine ESD in the following places:

a) In the new control system panels.


b) In the Main Control Room (location to be advised)
c) In the turbine area (two numbers) one on each side of the
turbine (location to be advised).

The ESD push buttons will be hardwired to the new control system panel through
individual input channels.
INTERFACE TO THE PROCESS COMPRESSOR ANTISURGE CONTROL
SYSTEM

A unit and run trip contact (free of voltage), shall be provided from the control system
for interface with the latest C.C.C. anti-surge control system.

HARDWARE CONFIGURATION

3.8.1 LOCATION / SUPPORT

a) The room where the new control equipment is to be installed is air-conditioned and
the temperature is maintained between 20°C and 25°C, with approximately 60%
RH. However the system shall be designed to meet a satisfactory performance
without any kind of disturbance or malfunction up to temperatures of 50°C, and RH
of 95% approximately. Which may occur as a result of air-condition malfunction.

The supplier equipment cabinets shall be installed as given below:

22-K-101 - in auxiliary room (Asab)


Lean Gas Train A&S - in Lean Gas station CR (Asab)
14-K-101 - in auxiliary room (Bab)
Lean Gas Train A&S - in Lean Gas station CR (Bab)

b) Suitable support framework shall be provided by the supplier to support all


equipment cabinets. Blank floor plates shall be fitted to open areas.

3.8.2 MECHANICAL DESIGN

a) Construction and finish for the cabinets and consoles shall be to industry accepted
standards so that durable, high quality cabinets that facilitate operation and
maintenance are provided. Cabinets shall be fitted with removable eyebolts.

b) Cable entry to cabinets, console and racks shall be from below.

c) Ventilation is not required through the bottom of the enclosure, consequently all
holes remaining after the entry of the cables shall be sealed against entry of dust.
The dust seal shall be easily removed to enable entry of future cables. Supplier
shall identify his means of achieving this requirement.

d) Equipment cabinets shall have front access. Each door shall include a locking latch
with integral locks and common keys.

e) Louvers, filters and exhaust fans shall be provided as required to maintain


Electronic Instrumentation within manufacturers/supplier’s specified operating
range.

f) Cabinet interior lighting shall be provided.

3.8.3 ELECTRICAL DESIGN

a) Supplier shall employ industry-accepted practices in cabinet and wiring design.


b) All equipment installed inside the cabinet shall be easily accessible and secured in
position to prevent any possibility of a loose contact.

c) The power supply available for the panel will be 240v AC ±10%, 50Hz ± 4%
single phase and neutral.

d) Nevertheless supplier shall provide in the quotation the power supply requirements
of the proposed system, (HMI, printers, control panel, ignition transformers, etc.).
Main power ELCB shall be provided by vendor.

e) All terminals shall be clearly identified.

f) All field I/O shall be terminated at knife edge terminals (widemuller or Klipon).

g) Care shall be taken to minimize interference between signals and power supply
wiring. Separate trunking shall be used with appropriate space between.

h) Field power supply shall be floating and monitored for low voltage and earth fault

i) Joints in internal wiring are prohibited. All jumpering shall be done at terminal
strip, using proprietary cross-links.

j) A minimum of 20 % installed spare terminals shall be provided.

3.8.4 EARTHING

a) An A.C. safety earth bar, bonded to framework, shall be provided in each


equipment cabinet. It shall be used to provide earthing for power supply modules,
metal equipment enclosures and doors.

b) An instrument earth bar, mounted on insulators shall be provided in the equipment


cabinet. It will be used to provide 0V reference (where required) and grounding of
signal cable screens.

c) Provision shall be made for terminating earth continuity cabinet links (by supplier)
and main earthing conductors.

d) Supplier shall specify his system grounding requirements.

Note : Control system to include earthing detection

3.8.5 RFI / EMI Immunity

a) Radio Frequency Interference


Standard U.H.F and V.H.F personal radio equipment will be operated at down to
one-meter distance of system equipment. Provision shall be made to render the
control system immune to interference from such radio operation with cabinet
doors open.
Field devices shall also be immune to R.F.I. (i.e. valve servos, LVDTs, etc.). The
supplier’s equipment shall not cause R.F.I. to the radios.

b) Electromagnetic Emissions
Care shall be taken to ensure that signal lines susceptible to interference are not
affected by power wiring.

CLASSIFIED AREAS

All equipment under the scope of this specification shall be supplied and installed in
accordance with the defined standards (see section 11.0) for the following Hazardous
Area classification:

a) Within turbine enclosures:


Hazardous area: Zone 1; Gas group: IIA; Temperature class: T3

b) Outside turbine enclosures:


Hazardous area: Zone 2; Gas group: IIA; Temperature class: T3

c) Within substations and the main control room: Safe

OPERATOR INTERFACE REQUIREMENTS

As a minimum, the operator interface stations shall include the following:

a) Industrial Colour LCD monitor 21” high resolution and shall be easily readable
under normal fluorescent conditions.

Note: For the panel monitors vendor shall propose alternatives for flat screens, which
he may find more suitable for the application.

b) Industrial grade PC Pentium 4, 1GHZ, 30 GB Hard disk, 1 GB RAM

c) Back up devices such as CDRW and DAT tape drive.

d) Wireless keyboard and mouse, shall be mounted in drawable type in the panel.

Note: The available power supply for the operator interface units and printers is 240v,
50 Hz.

4.0 SPECIFIC REQUIREMENT


As mentioned in section “2.0” panels for turbine control systems of GE Mark II are
being upgraded to new control system under different project scope of work which
include HP and propane along with turbine control of power generators at ASAB and
BAB.

Hence scope of this specification is to upgrade stand alone Woodward Netcon control
system only for compressors mentioned as below:

Asab
22-K-101 (LP)
29-K-501 – A (Lean Gas Train A)
29-K-501 – S (Lean Gas Train S)
Note : Each package consists of :
• Starter
• Rolls Royce gas generator
• Gas turbine
• Compressor
• Oil system
Existing control system for each package includes:
• WW Netcon F/T
• BN vibration system
• Vibrometer
• F&G system

Bab
14-K-101 (HP)
401-ME-104 (Lean Gas Train A)
401-ME-105 (Lean Gas Train S)

Note : Each package consists of :


• Starter
• Rolls Royce gas generator for HP and Solar for Lean Gas train ‘A’ & ‘S’
• Gas turbine
• Compressor
• Oil system
Existing control system for each package includes:
• WW Netcon F/T
• BN vibration system
• Vibrometer
• F&G system

In each of the stand-alone WOODWARD Netcon control system shutdown signals from
the existing Vibration monitoring system (BN 3300 series & Vibrometer) and Fire &
Gas system (HOW panel) are hardwired. These signals will be now re-routed from the
new Vibration monitoring system and Fire & Gas system (PLC based), to the upgraded
system but the functions will remain unchanged.

For the monitoring of the analogue, alarms, faults and status signals, a communication
link must be established between the upgraded system and the ICS as mentioned earlier.

The following shall be done for Netcon System.

♦ Upgrade the existing system to the new system.


♦ Add communication links as indicated earlier in the sub sections for each system to
new ICS.

TAGGING

Data issued from the Turbine Control Systems will be tagged in accordance with the
general tagging convention defined in the Project. Tag numbers will be made available
during Detailed Engineering.

5.0 IMPLEMENTATION
5.1 TECHNICAL REQUIREMENT

♦ Provide total turbine control.


♦ Provide Turbine protection system.
♦ Shall be expandable to meet future needs.
♦ Communication with ICS.
♦ Hot replacement of modules should be possible.
♦ All different type of I/O interface modules.

5.2 SCOPE OF WORK

VENDOR shall be responsible for:

♦ Supply of new upgraded Turbine Control system.


♦ Site survey to establish the current functionality and system spec for upgrade and
interface to the new ICS.
♦ Establishing the serial link or OPC communication at the new system end and
required configuration.
♦ Verification of hardware with those existing at site which includes provision of
appropriate devices fully compatible and the same revision as that of the hardware
existing at site.
♦ Ensuring proper data exchange between ICS and the Turbine control systems.
♦ Modification & loading of program in the new system including consideration of
tag number changes, Control Commands from ICS, monitoring signals to ICS and
other changes.
♦ Connect Power Supply alarms to ICS

Necessary OPC/MODBUS software licences shall be provided for each communication


link.
Vendor shall note that all the necessary software modifications & changes should be
done at their works and shall not leave any work to be done at site.

The following are out of the scope of supply of the VENDOR. This is the scope of
supply of the ICS VENDOR.

♦ Communication modules at ICS end


♦ Cables and connectors, to ensure the communication between ICS and sub-system.
♦ Configuration for the ICS side.

However the Turbine system supplier shall be responsible providing full support to the
ICS supplier for the development & testing of the interface. Such support to include
engineering services, hardware for development and testing at an early stage of project
implementation.

5.3 TESTING & INSPECTION

5.3.1 GENERAL

The interface shall be fully tested at the ICS vendor’s premises to ensure that the
requirements of the specification are met. The vendor will provide necessary interface
devices (model control system) in line with the new system to be installed at site for
interface testing at ICS Vendor’s facility with the turbine control system program.

5.3.2 ACCEPTANCE TESTS


a) Vendor shall be responsible for performing all tests, and shall supply all necessary
test and simulation hardware and software.

b) Equipment shall comply with any Health and Safety type regulations in force in
XXXXX.

c) Before the start of formal acceptance tests, supplier shall perform such tests as
necessary to ensure that the system is in fit condition to commence acceptance
testing. Such tests shall include the component testing and burn-in tests. 100%
internal tests shall be performed by vendor.

5.3.3 FACTORY ACCEPTANCE TEST (FAT)

a) The FAT shall include the testing and acceptance of both hardware and software
systems. The supplier shall generate the FAT procedures used for these tests
including the “pass / fail“ criteria used and submit them for Casco’s approval at
least one month in advance.

Note: All software must be completed prior to the start of the FAT.

The test plan shall include the following:

1) Hardware physical inspection for completeness; safety; finish; correct labeling;


conformity with arrangement and lay out drawings.

2) Electrical testing to confirm correct system operation under marginal power supply
situations.

3) Demonstration of correct operation of all inputs and outputs.

4) Demonstrations of correct control algorithms and communications.

5) Demonstration of all configured graphic displays.

b) XXXXX personnel will witness the entire tests at the vendor’s premises. Prior to
proceeding with test, the supplier must submit his system log, pre-test records and
demonstrate any certified test equipment. The FAT procedure will be signed off by
supplier and XXXXX personnel at the successful conclusion of testing, and will
formally accept satisfactory completion of FAT, when all test certificates have been
signed.

c) All hardware diagnostic programs shall be run at the start of the FAT.

d) The supplier shall allocate adequate time, space, facilities, test equipment,
engineering, and support personnel to permit testing to the satisfaction of XXXXX.
If the system is not ready for testing upon arrival of XXXXX team, the supplier
will be liable for costs for any extra time required to complete the testing.

e) All components of the system, including cables supplied as part of the system, shall
be connected in operating configuration.

5.3.4 SITE INSPECTION TEST


a) Site inspection tests shall be carried out to verify that the system did not suffer
damage during shipment to the site.

b) The contractor shall include for travel to site to carry out the unpacking and
installation of the equipment and site inspection tests.

The interface shall be fully tested at the ICS VENDOR’s premises to ensure that the
requirements of the specification are met. The VENDOR will provide necessary
interface devices in line with the new system to be installed at site for interface testing at
ICS VENDOR’s facility with the modified Turbine Control system program.

All tests, both hardware and software, shall be documented, with specimens of test
sheets and certificates submitted to the CONTRACTOR and OWNER for prior
approval.

SITE SERVICES

SITE INSTALLATION AND COMMISSIONING

Vendor will be responsible for the site installation(supervision) and commissioning of


all equipment in his supply.

In particular, this shall include:

a) Locating and fixing new panels and equipment (supervision only).

b) Interconnecting cables between supplier’s equipment.

c) Connecting power supplies.

d) Cross-wiring to the existing panels.

e) Pre-commissioning, including verification of correct cabling.

f) Full commissioning of the system to XXXXX`s satisfaction.

In order to carry out this project in a professional and safe manner, the vendor shall
supply the services of a dedicated team, who will be fully acquainted and familiar with
this project and its requirements, and shall comply with all safety rules and regulations
prevalent in XXXXX sites.

Vendor is requested to estimate and indicate in his proposal the number of


engineers/technicians required and their categories.

The vendor shall be responsible to provide all working tools, equipment and instruments
necessary for job execution, (unpacking of new panels, installation and connection of
new system and consoles, cable laying, installation of new instruments and devices,
testing and measurement instruments and equipment…. etc.).

The supplier shall indicate in his offer all the required lifting equipment necessary for
the job execution.

COMMISSIONING ENGINEER
a) The vendor shall supply the services of a system start-up commissioning engineer
with very good experience in the installation and commissioning of similar systems
and fully acquainted with the requirements of this particular project.

b) The vendor-commissioning engineer shall be responsible for on-site pre-start-up


checks and a full system and peripherals functional test in order to satisfy a
nominated XXXXX engineer of the correct system operation prior to on-line
commissioning.

c) The vendor-commissioning engineer shall provide an approved pre-test and


commissioning check list detailing the above procedure.
The compliance to this shall be witnessed and accepted by a nominated XXXXX
engineer.

d) To satisfactory, complete the on-site testing. The commissioning engineer shall be


in possession of all necessary manufacturer’s documentation and standard test
equipment.

e) The vendor-commissioning engineer shall be fully responsible for taking all the
precautions for safe commissioning and start-up of the gas turbine.

f) Commissioning shall be regarded as complete if the system can successfully satisfy


at least the following operations:

1) Full start-up from cold conditions.


2) Normal stop.
3) Full start-up from hot conditions.
4) Emergency stop.
5) Another hot start-up.
6) Redundancy function checks for all devices.(where applicable).
7) Trip by simulating a process trip condition.
8) Another cold start-up (e.g. 2 hours after the trip).
9) Continuous operation of the machine for 48 hours under the control of the new
control system, subjected to speed and load changes as per process
requirements.
10) Overspeed and synchrocheck protection tests.

The VENDOR shall provide qualified personnel to connect the communication modules
inside the existing Turbine Control systems equipment, software changes and to verify
the cabling prior to power-up.

COMMISSIONING

VENDOR’s qualified personnel shall carry out implementation of corrected program in


the new system, which will include requirements called for in this specification.

VENDOR’s personnel will co-ordinate with ICS Vendor personnel and establish link.

Test the interface requirements like executing control commands from ICS to Turbine
control system.

SPECIAL TOOLS, SPARE PARTS


Any special tool needed for the commissioning and/or for the troubleshooting of the
communication links must be supplied.

SPECIAL TOOLS

The VENDOR shall supply all software programs (including licenses) as well as any
special tools, programming tools and calibration equipment deemed necessary for the
correct installation and testing of the control system equipment for use either in the
workshop, or on site.

DOCUMENTATION

In addition to the information required in this specification, the VENDOR shall furnish
the information indicated in the material requisition documents.

VENDOR shall provide documentation:


♦ In English
♦ Complete, accurate and internally consistent.
♦ Clearly indexed.
♦ Easily updated.
♦ Mounting instructions clearly detailed.

The VENDOR’s documents shall include:


♦ The standard documentation on the interface modules.
♦ The as-built documentation for the hardware, the software and the specific
configuration for each communication link.
♦ The connection drawings on both ends of the communication links.
♦ Listing with Tag No., Valve and description.
♦ Complete software documentation (hard and electronic copies).
♦ Operator Manual.
♦ Configuration Manual.
♦ Installation Manual.
♦ Maintenance and troubleshooting manual.
♦ Logic diagram for the interlocks and sequences control logic.
♦ Loop drawings.
♦ Cable core assignments.
♦ Overall system shielding and grounding schems indicating all components and
ground paths.

6.0 TRAINING
Vendor shall provide site training by competent engineers from supplier’s Head
Quarters. Training by commissioning engineers is not acceptable. Training shall be
specific to supplied system for the project. The trainers shall have total familiarity with
both project hardware and software and shall be able to answer queries during training.
The proposed Trainer’s CV and course material shall be submitted for company
approval 8 weeks before start of training. Supplier shall arrange required training
equipment (demo kits, simulator, etc.). Since training will be required for operating and
maintenance personnel, vendor shall specify different type of training sessions for each
system, which will include: system familiarization, operation, troubleshooting and
maintenance.
The training shall be planned to be conducted immediately after the commissioning of
the first system.
ATTACHMENT # 1

Bulk I/O COUNT