PREPARED BY CHECKED BY APPROVED BY CERTIFIED (PTT) REV. DATE NO.

D1 14-Feb-08 D2 11-Jun-08

NA

PTT PUBLIC COMPANY LIMITED ONSHORE COMPRESSOR STATION 4 PROJECT

NA REVISED BY APPROVED BY NA NA DESCRIPTION ISSUED FOR ITB REVISION ISSUED FOR ITB

PHILOSOPHY FOR CONTROL SYSTEMS

PHC-0804.02-60.01 REV.D2
TOTAL 10 PAGES

AREA CODE OF SITE LOCATION GENERAL AREA: 010 PTT PLC. CONTRACT NO.

PTT PLC. PROJECT NO. 0804.02

PHILOSOPHY FOR CONTROL SYSTEMS

PTT PUBLIC COMPANY LIMITED PHILOSOPHY

PHC-0804.02-60.01 PAGE 2 OF 10 REV: D2

CONTENTS SECTION 1.0 2.0 3.0 4.0 5.0 6.0 7.0 OVERVIEW .............................................................................................. 3 DCS ........................................................................................................ 3 SAFETY INSTRUMENTED SYSTEM ............................................................. 4 UNIT CONTROL PANELS FOR MOTOR DRIVEN COMPRESSOR PACKAGE........ 5 MASTER PERFORMANCE, ANTI SURGE AND LOAD SHARING CONTROLLERS. 6 FIRE AND GAS CONTROLLERS................................................................... 7 MACHINE MONITORING SYSTEM............................................................... 7

PHILOSOPHY FOR CONTROL SYSTEMS 1.0 Overview

PTT PUBLIC COMPANY LIMITED PHILOSOPHY

PHC-0804.02-60.01 PAGE 3 OF 10 REV: D2

This document describes the design philosophy for the development of the specification, detail design and system implementation for the control systems. The control systems in this document will be limited to the systems which are related to THE ONSHORE COMPRESSOR STATION 4 (OCS# 4). The control systems for the OCS# 4 shall include at least DCS, Safety Instrumented System, Unit Control Panel for compressor package, Master performance/Anti surge/load sharing controller and Fire&Gas and Machine Monitoring System. 2.0 DCS The DCS system shall consist of a network of Field Control Stations (FCS) to provide the core plant control and monitoring functions and the Human Machine Interface (HMI) workstations for operators to operate the facilities. The DCS shall be designed to execute all process controls which are not related to safety functions. PTT operators shall be able to initiate the command to start/stop the compressor trains, switch over the trains of equipment, change the set points for any process control and perform any other control functions via the DCS HMI workstations. The DCS shall also acquire the information from all utilities and equipment packages, such as motor driven compressor packages, electrical, instrument air, fire fighting, and machine management system etc., in the facilities for monitoring and control. The control signals from DCS to other package equipments (and vice versa) shall be hard wired while the soft link shall be used for monitoring only. The DCS displays and console shall be ergonomically designed to allow PTT operator to fast access the desired information and to operate the facility without fatigue. The position of key switch, push button, alarm indication and communication systems in the DCS console shall also be orderly located for easy access. The DCS shall utilize a fully redundant Bus system, CPU, power supply, process and communication to the external system controllers with automatic bumpless switchover between the hot and standby controllers. The DCS FCS shall comprise of redundant CPUs, power supplies, Field control units (FCU) and communication controllers. All DCS Field Control Units (FCU) shall be foundation field bus for field transmitters and final elements directly connected to DCS. The arrangement for the Field Control Stations (FCS) shall prevent the common cause of inoperability for the equipment trains when the FCS/ its part fail or are under maintenance. All field process devices of different compressor trains shall not be connected to the same FCS and the same principal shall be applied to the inlet scrubber trains and communication between DCS and the compressor control systems.

PHILOSOPHY FOR CONTROL SYSTEMS

PTT PUBLIC COMPANY LIMITED PHILOSOPHY

PHC-0804.02-60.01 PAGE 4 OF 10 REV: D2

All sequential process control, related to the operation of the compressor train and station, outside the motor driven compressor packages shall be performed by the DCS system. The DCS shall execute the program based on the input command from the related compressor unit control panel for the required actions from the field devices. The DCS system shall be designed to allow the data exchange with the existing PTT DCS, LNG terminal DCS and the existing PTT SCADA system. The Sequence Of Event (SOE) in the DCS shall be provided to handle all of the events related to filed devices connected to the DCS, SIS, other equipment package control and utility systems. The DCS shall be equipped with the Plant Information System (PIMS) to manage all related facility historical operating data for reporting and process/operation analysis. In addition the Plant Resource Management (PRM) shall be provided to collect data from all field devices for maintenance planning and other related activities. These two systems shall be equipped with the DCS package. The DCS shall function as a systems master clock for the all equipment package control systems. DCS shall receive the clock data from GPS and then synchronize with other systems once per day. The programming for the logic control in the DCS shall utilize function block. 3.0 Safety Instrumented System The Safety Instrument System (SIS) refers to the field input devices, logic solver and final element as defined by IEC 61511. It is imperative that the Safety Life Cycle (SLC) documents as required by IEC 61511 shall be implemented beginning from SLC analysis up to operation phases. All required functions and configuration related to the SIS shall be thoroughly defined in the Safety Requirement Specification (SRS) before the system implementation. In addition the SIL calculation and SIS equipment selection shall be based on MTTR of 8 hours and 1 year testing interval. The SIS shall execute only functions related to the safety for the facility operations such as over pressure protection, process shutdown, and emergency shutdown with/without blowdown etc. For the shutdown of the motor driven compressor packages due to process condition, the SIS shall send the hard wire signal to the required unit control panels (UCP) to execute theirs own shutdown logic. In the case that the trip of compressor come from its internal causes, the SIS shall receive the hard wire signal from UCPs to execute related process shutdown. The status of the final elements, if not required for the safety functions, shall be sent to the DCS only. All of the equipments used in the SIS shall be certified by TUV for the safety application. For logic solver, it shall be certified for SIL 3 application.

PHILOSOPHY FOR CONTROL SYSTEMS

PTT PUBLIC COMPANY LIMITED PHILOSOPHY

PHC-0804.02-60.01 PAGE 5 OF 10 REV: D2

All of the field input devices connected to the logic solver shall be 2oo3 voting configuration. All field input to the SIS logic solver shall be 4-20 mA HART transmitter. The DCS shall perform the transmitter integrity check function by comparing the value of three transmitters in the same loop and shall initiate alarm when the difference is higher than the preset value. The DCS shall also set the pre-trip alarm to alert the operators before the process condition reach the trip set point by using the values from the SIS transmitters. The SIS logic solver shall be based on 1oo2D configuration. It shall comprise of the network of Safety Control Stations (SCS). Each SCS shall comprise of redundant CPUs, power supplies, Safety Control Units (SCU) and communication controllers. The arrangement for the Safety Control Stations (SCS) shall prevent the common cause of inoperability for the equipment trains when the SCS/ its parts fail or are under maintenance. All field process devices of different compressor trains shall not be connected to the same SCS and the same principal shall be applied to the inlet scrubber trains. The Sequence Of Event (SOE) shall be fully integrated with that of DCS in order to allow the efficient analysis of the shutdown with related process information. The design of the SIS shall allow the on line testing for the system from the field inputs up to the final elements with less human intervention. 4.0 Unit Control Panels for Motor Driven Compressor Package The compressor station control system shall comprise of the Unit Control Panels (UCP), anti surge and load sharing controllers. Each motor driven compressor shall be provided with its dedicated PLC based Unit Control Panel. This PLC shall be redundant in all aspects such as CPUs, power supplies, I/O cards etc. The UCP shall perform all required functions for the operation of compressor such as speed control, start/normal stop and emergency shut down. The UCP shall receive hard wire signals from the DCS for start/normal stop and the SIS for emergency shutdown due to process condition. When the compressor package trips by its own condition, the UCP shall send the hard wire signal to the SIS to execute the process shutdown functions outside the compressor package. The UCP shall also send the operating data to the DCS for monitoring via soft link. The UCP shall send hard wire command to the related switch gears/MCCs for the operation of lube oil pumps, lube oil coolers, and any other auxiliary devices in both normal and emergency case. For the emergency case, the UCP shall send command to the emergency shut down relays in the related switchgears/MCCs.

PHILOSOPHY FOR CONTROL SYSTEMS

PTT PUBLIC COMPANY LIMITED PHILOSOPHY

PHC-0804.02-60.01 PAGE 6 OF 10 REV: D2

The field transmitters connected to these systems shall be 4-20 mA HART and the information for each transmitter shall be sent to the PRM. The UCP shall have its dedicated vibration monitoring systems. All data from these systems shall be transferred to the Machine Monitoring System Server. The HMIs shall be provided locally at the UCP and remotely at the DCS consoles. These two HMI shall have similarly functionalities. The remote and local HMI shall be equipped with the database server to store all historical operating parameter for the compressor packages. 5.0 Master Performance, Anti surge and Load Sharing Controllers The master performance, anti surge and load sharing controllers shall be separate system from the PLC used for the UCP of the compressor train. These controllers shall be the dedicated systems to serve the desired purposes and mounted into the unit control panels The master performance controller shall receive the hard wire process set point from the DCS, and input from the load sharing/ anti surge controllers, process the inputs and send the command to the related controllers. The anti surge and load sharing controllers shall receive the speed , process data and other required compressor status from the UCP of operated compressors to perform the anti surge and load sharing functions. The anti surge controller shall also be able to receive the hard wire command from the DCS for manual operations of the anti surge control valve with anti surge override function. The anti surge and load sharing controllers shall be equipped with the fall back strategy to manage the failure of their input signals in order to minimize the unnecessary shutdown from this cause. As same as the UCP, these controllers shall send all operating data to the DCS for monitoring via soft link in order to allow the DCS HMI workstation to show the same information and displays as those on the local monitors for the compressor station control system. The master performance, anti surge and load sharing controllers shall be fully redundant in all aspects of the system with bumpless transfer between the hot and standby units. The field transmitters connected to these systems will be 4-20 mA HART and the information for each transmitter shall be sent to the PRM. The remote HMI workstation for these controllers shall be provided in the DCS console. This remote HMI workstation shall display all related process data, alarm and event log and healthy of the systems. The remote HMI workstation shall also be equipped with the engineering and maintenance software for these controllers.

PHILOSOPHY FOR CONTROL SYSTEMS 6.0

PTT PUBLIC COMPANY LIMITED PHILOSOPHY

PHC-0804.02-60.01 PAGE 7 OF 10 REV: D2

Fire and Gas Controllers The fire and gas controllers shall be separated from each other and mounted in the separate control panel. The fire controller panels shall include the master fire controller panel and dedicated fire controller panel for each building. The fire controller panel for each building shall receive the signal from the detectors, perform voting function and actuated the fire suppression system. The master fire controller panel shall handle the detectors and manual call points in the field. The master fire control panel shall also acquire the information from the fire controller panel in each building. All information related to the system shall be displayed at the local and remote HMI workstation. The gas controller panel shall include at least controllers, local and remote HMI workstations, and push button for the required functions. The gas controller panel shall handle the gas detectors and the fire suppression systems in the field/process areas. The gas control panel shall be equipped with the dedicated push buttons for each fire suppression systems, such as fire monitors and deluges, in the field. The operator shall be able to initiate the action of these devices via these push buttons. In addition, the reset and horn interrupt push buttons shall also be mounted on this panel The fire and gas systems shall utilize the common remote HMI installed in the DCS control. The remote and local HMIs shall contain the graphical displays for all areas. The graphical displays design shall be in hierarchy from the overview to the detail graphical displays. The graphical display shall clearly show the location of the detectors and fire suppression system. The detectors and fire suppression systems shall be flashed out on the related displays when the abnormal situation is detected or the fire suppression systems are actuated. The local HMI workstations at the master fire and gas controller panels shall be equipped with the engineering and maintenance software for each system.

7.0

Machine Monitoring System The Machine Monitoring System shall include server, vibration controllers and detectors/sensors. The server shall acquire the data from vibration controllers included those provided by package vendors and store for further vibration analysis. The server shall be equipped with the software to allow PTT maintenance personnel to analyze these vibration data in all aspects. The vibration controllers shall receive the data from vibration detectors/ sensors and transfer them to the DCS for monitoring via soft link. In case that the controller detects the vibration of connected equipments, it shall send the hard wire signal to SIS to shutdown the related process units. All alarm from the vibration controllers shall also be transferred to the DCS.

PHILOSOPHY FOR CONTROL SYSTEMS

PTT PUBLIC COMPANY LIMITED PHILOSOPHY

PHC-0804.02-60.01 PAGE 8 OF 10 REV: D2

For the purposes of machine condition monitoring, machines are classified into four categories as shown in the following table and the system shall designed and provided accordingly.
TYPE OF MACHINE CONTINOUS CRITICAL MACHINE Compressors YES ONLINE NON CONTINOUS WITH PROTECTION YES OFFLINE (Portable)

Generators

ELECTRIC MOTORS WITH JOURNAL BEARINGS GEARBOXES VOITH VARECON COUPLINGS Machines With Journal Bearings

ESSENTIAL MACHINE1 Fans Fan Motor

YES

YES

YES

ESSENTIAL MACHINE2 OTHER PROCESS MACHINES UTILITY MACHINES >= to15KW SUBSYSTEMS OF CRITICAL MACHINERY

YES

NO

YES

NON ESSENTIAL MACHINE UTILITY MACHINES < 15KW

NO

NO

NO

YES

Table 2. Types of Machines

PHILOSOPHY FOR CONTROL SYSTEMS

PTT PUBLIC COMPANY LIMITED PHILOSOPHY

PHC-0804.02-60.01 PAGE 9 OF 10 REV: D2

Transducer arrangements per type of machine are indicated in the following table TYPE OF MACHINE CRITICAL MACHINES All Proximity probes 2-X, 2-Y, for each radial bearing, 2-Z for each thrust bearing and key phasor. Three accelerometer measuring point per casing. TRANSDUCER ARRANGEMENT

ESSENTIAL MACHINE 1 Air coolers 1 accelerometer for the fan bearing, 1 accelerometer for the motor casing Accelerometers, 1-X for the motor casing, 1-X for the pump casing. Where the machine is a "between bearings" design an additional probe shall be provided on the driven machine. No permanent probes.

ESSENTIAL MACHINE 2

NON ESSENTIAL MACHINES

Table 3. Transducer arrangements Critical Machines The contractor shall provide the Bentley Nevada 3500 rack system segregated on a machine by machine basis, to interface to field transducer. The Bently Nevada system shall interface to the machinery control system (local PLC, DCS or SIS) to provide the required indication, alarm and trip functions. If the Bentley Nevada system is connected directly to a local machinery control PLC then all vibration and monitoring signals shall be repeated to the DCS for indication. The Bently Nevada 3500 system shall be interfaced via Bently Nevada TDXnet modules to form the machine monitoring network. The TDXnet modules shall be linked to the DCS via dual redundant serial cable to give the necessary indication. Each of the TDXnet modules shall be networked using a 10 Base T hub/switch connection.

PHILOSOPHY FOR CONTROL SYSTEMS

PTT PUBLIC COMPANY LIMITED PHILOSOPHY

PHC-0804.02-60.01 PAGE 10 OF 10 REV: D2

Essential Machines category 1 These machines shall be monitored continuously by accelerometers connected to a Bently-Nevada 3500 system. The 3500 system shall send trip signals to the SIS system for machinery protection purposes and to the System 1 server for machinery analysis. Transducers shall be installed to monitor the fan bearing housing and the motor casing vibration. Additional data may be collected using a Bently-Nevada Snapshot portable data collection and analysis unit.

Essential Machines category 2 Each machine in this category shall be fitted with permanent vibration transducers to monitor pump and motor casing vibration. These transducers shall be connected to the SPA cards on the System 1 server in a multi-drop configuration. Additional data may be collected using a Bently-Nevada Snapshot portable data collection and analysis unit.

Non Essential Machines Vibration measurements shall be taken by a Bently-Nevada Snapshot portable data collection and analysis unit. This data shall be downloaded to the System 1 server for machinery analysis purposes. The machinery monitoring network shall be connected to the ESP DCS ethernet network via a network switch to allow data to be transferred between the two systems. The contractor shall provide a Bently-Nevada System 1 data acquisition and management system located at instrument rack room to provide full analysis of all machinery data. This system shall be provided with the following modules: Data Acquisition, Display and Configuration, Database (SQL Server) DDE Exporter/Importer, OLE Automation Exporter.