RLNG-000-IC-SP-0801

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

RLNG-000-IC-SP-0801

CONTRACTOR DOC. REF.

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 1 OF 224

ADNOC GAS

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY Contract No.

4700022871

JV TJN RUWAIS Contract No

215122C

Document Class

Class 2

Document Category (for Class 1)

OPERATING CENTER Contract No.

OPERATING CENTER Doc Ref.

IFC – Issued for Construction

24-Oct-2024

J. El Yazali

ICR – Issued for Client Review

12-Jul-2024

J. El Yazali

K. Michineau M. Joshi R. Ikeya R. Biju

S. Deilles F. Kiyoshi

Rev.

Revision Purpose

Date

Prepared by

Checked by Approved by

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

RUWAIS LNG PROJECT

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REVISION: 1

PAGE 2 OF 224

Table of Contents

Contents

Page

1.0

INTRODUCTION… 5

1.1 Scope of the Document … 5 1.2 Holds List … 5 1.3 References … 6 1.4 Definitions and Abbreviations … 6 2.0 AMENDMENTS TO INSTRUMENTATION FOR PACKAGED EQUIPMENT SPEC. AGES-SP-04-007 7 3.0 AMENDMENTS TO PROGRAMMABLE LOGIC CONTROLLER SPEC. AGES-SP-04-018 … 29 4.0 Appendix … 31 4.1 APPENDIX 1 - AGES-SP-04-007 … 31 4.2 APPENDIX 2 - AGES-SP-04-018 … 31

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

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PAGE 3 OF 224

Table of Changes compared to previous revision

Paragraph

Modification description

Remarks / Origin

All

1.3

This document has been updated from the “359665-0000-070-SP-1500-010_Rev 0” FEED document. Project document references are updated

2.0 AGES 1.3 Definitions and Abbreviations are updated

AGES-SP-04-007

2.0 AGES 2.2 Project document references are updated

2.0 AGES 3 Order of precedence of documents applicable to

2.0 AGES 5.3 Reference of “Project Basis of Design” is

RLNG Project

2.0 AGES 5.3.3 2.0 AGES 5.5 & 5.6 2.0 AGES 7.2.2.c 2.0 AGES 7.2.2.i & 7.2.4.j 2.0 AGES 7.3.5 2.0 AGES 7.4.4.3 2.0 AGES 7.4 & 7.4.7.2 2.0 AGES 7.4.10 2.0 AGES 7.4.12 2.0 AGES 7.4.15

updated Requirement for cable tray/ladder covers

Standardisation of instrumentation within Package equipment Supply and installation of cable trays/ladders within Package skid. Interface between Packaged equipment PLC(s) and Electrical Switchgear / ASD Reference of “Specification for OT Cyber Security

for Vendors” Standard applicable for Electromagnetic Compatibility Specification of version of HART Protocol for ‘Smart’ type instrumentation: HART 7 Reference to “Project Basis of Design” for instrument air supply pressures Solenoid valves: preferred power consumption of 4 W and lower, maximum consumption Reference to “Project Basis of Design” for engineering units

2.0 AGES 7.5 Reference to “Critical Rating Procedure” for

2.0 AGES 7.7.2.2

criticality rating Standardisation of compression fittings (not applicable to tubing)

2.0 AGES 7.11 Reference to “Instrument & Control System

Numbering Procedure” (RLNG-000-IC-PP-0001) for Instrument Numbering and Tagging

2.0 AGES 9 Reference of “Specification for Packaged

Analysers” (RLNG-000-IC-SP-0601)

2.0 AGES 15.2 Removal of the requirement for transparent plastic or toughened glass windows for cabinets/panels in IES

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

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PAGE 4 OF 224

Paragraph

Modification description

Remarks / Origin

2.0 AGES 15.4 Requirement for internal lighting in cabinets /

panels

2.0 AGES 15.4 Common panel alarm to be provided for each

2.0 AGES 18.11.4

panel. Materials for cable trays / ladders / covers: GRP or SS316L

2.0 AGES 27.1 Reference to “Specification for Protective Coating

2.0 AGES Appendix 5

of Equipment, Piping & Structures” (RLNG-000- MT-SP-2301) Update of list of packages based on Equipment new numbering and based on FEED update design

3.0 AGES 2.2 Project document references are updated

AGES-SP-04-018

3.0 AGES 3 Order of precedence of documents applicable to

RLNG Project

3.0 AGES 6.2 Reference to “Project Basis of Design” for RLNG

plant environmental / site conditions HART communication with IAMS

3.0 AGES 7.9.2

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

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PAGE 5 OF 224

1.0

INTRODUCTION

The ADNOC Ruwais LNG Project is a two train, near net-zero electrically driven LNG facility, targeting international markets. The feed gas for the project is supplied from the Habshan Gas Processing Plant via a new export gas pipeline. The plant will have two 4.8 MTPA (nominal capacity) electric driven LNG Trains with associated LNG storage/marine export facilities and utilities.

Figure 1 – Project Context

The ADNOC Ruwais LNG Project foresees the following main components at the facility:

• Onshore LNG Liquefaction facilities for 2 x 4.8 MTPA electrically driven LNG Trains (9.6MTPA total)

• Common facilities including inlet receiving facilities, LNG storage, BOG handling, flare, refrigerant

storage and support buildings.

• Utilities to support the facilities including import power from the national grid.

• Marine facilities for LNG export and bunkering.

1.1

Scope of the Document

This specification amends ADNOC Instrumentation for Packaged Equipment Specification AGES-SP-04-007 which is attached hereto in Appendix 1. Section 4 of this document identifies the amendments to the ADNOC Instrumentation for Packaged Equipment Specification included in Appendix 1.

1.2

Holds List

HOLD

DESCRIPTION

Standardization requirements for PLC, MMS and fitting shall be reviewed and updated in the next revision

HART communication with IAMS

Package List under consolidation

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PAGE 6 OF 224

1.3

References

[1] RLNG-000-PM-BOD-2002 [2] RLNG-000-IC-PP-0002 [3] RLNG-000-IC-SP-0501 [4] RLNG-000-IC-SP-0411 [5] RLNG-000-IC-SP-0431 [6] RLNG-000-IC-SP-0741 [7] RLNG-000-PM-SP-0001 [8] RLNG-000-IC-PP-0001 [9] RLNG-000-PM-SP-2501 [10] RLNG-000-IC-SP-0143 [11] RLNG-000-IC-SP-0102 [12] RLNG-000-IC-SP-0802 [13] RLNG-000-IC-SP-0003

Project Basis of Design Philosophy for Automation & Instrumentation Design Specification for Field Instruments Specification for Control Valves Specification for On/Off valves Specification for Instrumentation & Telecommunication Cables Cyber Security Requirements for Vendors Instrument & control System Numbering Procedure Human Factors Engineering Procedure Specification for Machine Monitoring System Specification for Alarm Management System Specification for Compressor Control System Instrument Data Base Structure and Administration Specification

1.4

Definitions and Abbreviations

COMPANY

CONTRACTOR

EPC ADOC POC YOC SUPPLIER

ABU DHABI NATIONAL OIL COMPANY (ADNOC) P.J.S.C. TJN Ruwais, Joint Venture of Technip Energies France-Abu Dhabi, JGC Corporation and National Marines Dredging Company (NMDC) Engineering Procurement Construction Abu Dhabi Operating center - National Marines Dredging Company Paris Operating Center - Technip Energies Yokohama Operating center - JGC Corporation Supplier of goods or services to CONTRACTOR

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

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PAGE 7 OF 224

2.0

AMENDMENTS TO INSTRUMENTATION FOR PACKAGED EQUIPMENT SPEC. AGES-SP-04-007

Instructions contained below such as “Add”, “Substitute”, “Revised”, or “New” shall be interpreted as follows:

Add: Requirements shall be a continuation of the paragraph in the referenced specification.
Substitute: The requirement of the referenced specification shall be replaced in its entirety by the

requirements below.

Revised: The requirement of the referenced specification shall be revised by the specific wording

below.

New: A new requirement as described below.

The following sections are amended in AGES-SP-04-007, Rev.1

Section A – General

Sub-section 1.3

Add :

BOG

DCS

ECMS

FACP

FGS

HHR

LCP

Boil-Off Gas

Distributed Control System

Electrical Control & Monitoring System

Fire Alarm Control Panel

Fire & Gas System

Gas Chromatograph

Heavy Hydrocarbon Removal

High Pressure

Local Control Panel

Low Pressure

MCHE

Main Cryogenic Heat Exchanger

NRU

OPC

Medium Pressure

Mixed Refrigerant

Nitrogen Rejection Unit

OLE for Process Control

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

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PAGE 8 OF 224

P&ID

Piping and Instrumentation Diagram

Sub-section 2.2

Substitute: The following ADNOC specifications are substituted with Project documents as detailed below:

AGES Reference

Project Document No.

Project Document Title

AGES-PH-04-001

RLNG-000-IC-PP-0002

Philosophy for Automation & Instrumentation Design

AGES-SP-04-002

RLNG-000-IC-SP-0411

Specification for Control Valves

AGES-SP-04-005

RLNG-000-IC-SP-0431

Specification for On/Off valves

AGES-SP-04-006

RLNG-000-IC-SP-0741

Specification Telecommunication Cables

for

Instrumentation

AGES-SP-04-013

RLNG-000-PM-SP-0001

Cyber Security Requirements for Vendors

AGES-SP-04-009

RLNG-000-IC-SP-0601

Specification of Packaged Analysers.

AGES-SP-04-017

RLNG-000-IC-SP-0701

Specification for Instrument Installation & Design

Add:

AGES-SP-04-018 Programmable Logic Controller

Sub-section 3

Substitute:

‘In case of conflict, the order of document precedence shall be:

a. UAE Statutory requirements

b. ADNOC HSE Standards

c. Equipment datasheets and drawings

d. Project Specifications and standard drawings

e. COMPANY Specifications

f. National / International Standards’

with:

‘The order of precedence with respect to codes and regulations that shall be followed for the design of the terminal is as follows in terms of priority:

UAE Statutory Legislation and Regulations

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

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PAGE 9 OF 224

ADNOC HSE Regulations, Standards and Codes of practice
Project Specifications and Standards
ADNOC Engineering Specifications, Standards and Procedures
ADNOC Guidelines, Procedures & Codes of Practice
International Codes & Standards’

Sub-section 5.3

Add: ‘For environmental / site conditions, refer to “Project Basis of Design” (RLNG-000-PM-BOD-2002)’

Sub-section 5.3.3

Substitute: ‘All outdoor cables installed within cable tray or ladder shall be protected by covers.’

with: ‘Cable tray/ladder covers shall be provided where cables are likely to be exposed to direct sunlight or mechanical damage is likely to occur.’

Revise: ‘…switches shall be avoided….COMPANY approval.’

to: ‘Process (e.g. pressure, flow, temperature & level) switches shall be avoided except for switches to be limited to ancillary with COMPANY approval.’

Sub-section 5.5

Substitute: ‘All instrumentation shall be of the same make, model and type as chosen for the project main plant facilities.’

with: ‘All instrumentation within a Package shall be of the same make, model and type, and from a Vendor listed in COMPANY Approved Vendor List. PLC, HMI workstations, servers, MMS and Fittings shall be standardized across the whole Project. [HOLD_1].

Sub-section 5.6

Substitute: ‘All package equipment instrumentation shall be chosen from the same manufacturer and models used within the main project plant facilities to minimize spares, instrument types, and simplify the maintenance operations.’

with: ‘All instrumentation within a Package shall be chosen from the same manufacturers and models to minimize spares, instrument types, and simplify the maintenance operations.

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

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PAGE 10 OF 224

Section B Part I

Sub-sections 7.2.2.c

Add: ‘In both cases, cable trays between skid junction boxes or field instruments up to skid edge boundary shall be supplied and installed by SUPPLIER’

Sub-sections 7.2.2.i, 7.2.3.n & 7.2.4.k

Substitute: ‘The Burner Management System shall be designed and engineered to the same level of integrity as the SIS system.’

with: ‘’

Sub-Section 7.2.3.h

Substitute: ‘SUPPLIER shall provide a Gas Turbine Control System (GTCS) for control of all turbine, associated process compressor related equipment and auxiliaries. SUPPLIER shall refer to Section 14 for further technical requirements.’

with: ‘’

Sub-Section 7.2.4.c

Add: ‘Any alarm or status signal from Package UCP required to be hardwired to ICSS shall be made available as dry contact type output from Package UCP by the SUPPLIER.’

Sub-Section 7.2.4.i

Substitute: ‘Packaged equipment PLC(s) shall use hardwired control signals to Electrical Switchgear / ASD for commands and feedback. ICSS shall monitor status of electrical devices (such as motors, heaters etc.) via dual redundant data link from Electrical Switchgear / ASD. The trips shall be hardwired from ESD.’

with: ‘Packaged equipment PLC(s) shall use hardwired control signals to Electrical Switchgear / ASD for commands and feedback through Interposing Relay Panel (IRP). Communication interface via dual redundant data link may be considered but subject to CONTRACTOR’s approval. ICSS shall monitor status of electrical devices (such as motors, heaters etc.) via dual redundant data link from ECMS and/or Package PLC(s). The trips shall be hardwired from Package Safety PLC or Plant SIS.’

Sub-Section 7.2.4.j

Substitute: ‘For hardwired signals between Electrical Switchgear / ASD and plant ICSS where required, an interposing relay shall be used for safe isolation of different voltage levels.’

with: ‘For hardwired signals between Electrical Switchgear / ASD and Package PLC, an interposing relay shall be used for safe isolation of different voltage levels.’

Sub-Section 7.2.4

Add: ‘SUPPLIER shall implement/configure the software following project Software Typicals and ICSS functional design specification.’

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

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PAGE 11 OF 224

Sub-Section 7.4.7.2.e

Revise: ‘…switches shall be avoided….COMPANY approval.’

to: ‘Process (eg. pressure, flow, temperature & level) switches shall be avoided and used only with COMPANY approval.’

Sub-Section 7.3.5

Revise: ‘SUPPLIER shall refer to AGES-PH-04-001 for Cyber Security (OT Security) technical requirements.’

to: ‘SUPPLIER shall refer to RLNG-000-PM-SP-0001for Specification for OT Cyber Security - for Vendors technical requirements for Packaged equipment.’

Sub-Section 7.4

Revise: ‘Transmitters shall be ‘Smart’ type, unless specified otherwise by COMPANY. ‘Smart’ transmitters shall be based on 4-20 mA DC with the latest version of the HART Protocol.’

To: ‘Transmitters shall be ‘Smart’ type, unless specified otherwise by COMPANY. ‘Smart’ transmitters shall be based on 4-20 mA DC with the HART 7 Protocol.’

Add : IS calculations for Package type C are in Supplier’s scope

Substitute: ‘Transmitters used for PCS can use Foundation Fieldbus where approved by COMPANY.’

with: ‘Foundation Fieldbus shall not be used.’

Substitute: ‘All HART/FF instruments shall be integrated with Instrument Asset Management System.’

with: ‘All HART instruments shall be integrated with Instrument Asset Management System.’

Sub-Section 7.4.4.3

Substitute:

‘All instrumentation, junction boxes and system equipment containing electronics shall satisfy the requirements of EMC immunity and emissions in accordance to IEC 61000-6-2, IEC 61326, NAMUR NE 21, and European EMC Directive 2004/108/EC.

For further Electromagnetic Compatibility requirements SUPPLIER shall refer to AGES-PH-04-001.’

with:

‘The design and installation of all electrical / electronic instruments shall meet the radio frequency interference (RFI) and electromagnetic interference (EMI) (IEC 61000) emission (IEC 61000 6-4) and immunity (IEC 61000 6-2) requirements for an industrial environment.’

Sub-Section 7.4.7.2

Substitute:

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PAGE 12 OF 224

Sensors/transmitters shall be ‘Smart’ type with a communication protocol based on latest HART standard.

Valve electro-positioners shall be ‘Smart’ type with a communication protocol based on latest HART standard.’

‘b.

with:

‘b.

Sensors/transmitters shall be ‘Smart’ type with a communication protocol based on HART 7 standard*.

Valve electro-positioners shall be ‘Smart’ type with a communication protocol based on HART 7 standard*.

For each ‘Smart’ instrument, Hart data (Hart Tag, Hart Descriptor, etc.) shall be set up by SUPLIER and verified during Package FAT. SUPPLIER shall also provide Firmware and Device Description (DD) files required for Plant IAMS configuration.’

Sub-Section 7.4.7.2.e

Revise: ‘…switches shall be avoided….COMPANY approval.’

to: ‘Process (eg. pressure, flow, temperature & level) switches shall be avoided and used only with COMPANY approval.’

Sub-Section 7.4.7.3

Substitute whole section: ‘SUPPLIER shall…………….Instrument requirements.’

with: ‘’

Sub-Section 7.4.10

Revise: ‘Instrument Air Supply: min = 5.5 barg, normal = 7 barg, max = 10 barg,’

to: ‘Refer to “Project Basis of Design” (RLNG-000-PM-BOD-2002) for Instrument Air supply pressure specification for Ruwais LNG Project.’

Sub-Section 7.4.12

Substitute:

‘The use of flameproof or increased safety instruments shall be avoided except for solenoid valves which should be certified Ex db (Flame Proof) or Ex mb eb (combined encapsulation and increased safety), operating on 24 VDC with maximum power consumption, of 12 W.’

with:

Sub-Section 7.4.15

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

RUWAIS LNG PROJECT

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REVISION: 1

PAGE 13 OF 224

Substitute whole section with:

‘For engineering units, refer to “Project Basis of Design” (RLNG-000-PM-BOD-2002)’

Sub-Section 7.4.16

Substitute: ‘In case air intake filter unit is associated with the package, pulse-cleaning system shall have an isolation valve for each solenoid to facilitate removal of the solenoid without isolation of the air header.’

with: ‘’

Sub-Section 7.4.16

Substitute: ‘SUPPLIER shall refer to AGES-PH-04-001 for further Air Supply requirements.’

with: ‘SUPPLIER shall refer to RLNG-000-IC-PP-0002 for further Air Supply distribution requirements.’

Sub-Section 7.4.17

Substitute: ‘Topicalization’

with: ‘Tropicalization’

Sub-Section 7.5

Substitute whole section with:

‘For RLNG Project criticality rating, refer to “Critical Rating Procedure” (RLNG-000-PM-PP-2004) and AGES AGES-SP-13-001’

Sub-Section 7.7.2.2:

Add: ‘All Instrument fittings shall be from a single system from single supplier across the whole project / site [HOLD_1]. Tubing and associated fittings shall use metric sizes and fitting threaded connection shall be NPT type.’

Sub-Section 7.11

Substitute: ‘SUPPLIER shall refer to AGES-PH-04-001 for Instrument Numbering and Tagging.’

with: ‘The instrument tag numbering shall follow the “Instrument & Control System Numbering Procedure” (RLNG-000-IC-PP-0001).’

Sub-Section 7.12

Substitute: ‘SUPPLIER shall refer to AGES-PH-04-001 for Instrument Symbols and Identification.’

with: ‘The instrument symbols and identification shall follow the Ruwais LNG Project philosophy, refer to Project Instrument Symbols and Legends P&IDs.’

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

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REVISION: 1

PAGE 14 OF 224

Sub-Section 9

Add after 2nd paragraph: ‘The design of any analyzer house / shelter if included in SUPPLIER scope shall follow the Project philosophy and “Specification for Packaged Analysers” (RLNG-000-IC-SP-0601).’

Sub-Section 14

Substitute whole section: ‘The Gas Turbine Control System (GTCS)…………….technical requirements.’

with: ‘’

Sub-Section 15.2

Remove the requirement: ‘IES panels provided with lamp indicators on electronic PCBs shall have a transparent plastic or toughened glass windows to allow checking without opening the door.’

Sub-Section 15.4

Substitute: ‘Door switch activated lighting shall be provided for each panel within the IES.’

with: ‘Internal lighting in cabinets / panels within the IES shall be controlled by a door switch or by a movement detector incorporating a manual on/off/auto switch.’

Sub-Section 18.11.4

Substitute: ‘Cable trays / ladders / covers shall be heavy duty, hot dip galvanized and painted.’

with: ‘Cable trays / ladders / covers shall be in Glass Reinforced Polyester (GRP). As alternate316L Stainless Steel can be used but subject to COMPANY approval.’

Remove:

‘Cable trays, ladders and covers shall be heavy duty, hot dipped galvanized after fabrication to 85 microns zinc coating. These shall be painted with one coat of primer and two coats of finishing paint at site before laying cables on them. Thickness of steel used for fabrication of cable tray / ladder / covers shall be 2 mm minimum.

Section C – Other Requirements

Sub-Section 27.1

Add: ‘Field Instrument painting and coating shall comply to “Specification for Protective Coating of Equipment, Piping & Structures” (RLNG-000-MT-SP-2301)’

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

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Section E APPENDICES

Add: Sub-section A5 (APPENDIX 5)

A list of the main packages suggesting package type and interface type is shown in table below:

Item GWBS

Area

Process Unit

Equipment Tags

Equipment type

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

[HOLD]

Jetty Topside

HOLD

42Z-10A

[HOLD]

Jetty Topside

HOLD

42Z-10B

Jetty Berth 1 Tower Gangway [HOLD]

Jetty Berth 2 Tower Gangway [HOLD]

Field LCP

Vendor LCP

JCB-01

Field LCP

Vendor LCP

JCB-01

N/A

Type A

All

A250

LNG train 1 - Substation & Instrument Building

C100

Utility Sub Station (Including Electrical Cable from/to J100)

All

CMS

Corrosion Monitoring System

all

CMS

all

Modbus TCP

Yes

Type C

All

TBD

Building Fire Extinguishing system

[HOLD]

Nearest IES/CCB/JCB

[HOLD]

Type A

088

088-EG-001

Emergency Diesel Generator Package Train 1

Field LCP

Vendor PLC (LCP)

IES-11

Modbus TCP

088

088-EG-001

Emergency Diesel Generator (Utility Area )

Field LCP

Vendor PLC (LCP)

IES-02

Modbus TCP

F100

Industrial Buildings

088

088-EG-403

C600

[HOLD]

088

088-EG-003

D200

BOG Compression

088

088-EG-201

E100

Causeway

088

088-EG-202

Emergency Diesel Generator (Control Building & Administration Area) Emergency Diesel Generator (Chiller Package Unit and Feed Gas Compression)

Emergency Diesel Generator (BOG Substation)

Emergency Diesel Generator (Jetty Loading)

Field LCP

Vendor PLC (LCP)

CCB-01

Modbus TCP

Field LCP

Vendor PLC (LCP)

IES-01

Modbus TCP

Field LCP

Vendor LCP

IES-03

[HOLD]

Type A

Field LCP

Vendor LCP

JCB-01

[HOLD]

Type A

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

Yes

Type C

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Item GWBS

Area

Process Unit

Equipment Tags

Equipment type

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

A250

LNG train 2 - Substation & Instrument Building

088

088-EG-002

Emergency Diesel Generator Package Train 2

Field LCP

Vendor PLC (LCP)

IES-21

Modbus TCP

Yes

Type C

A250

LNG Train 2 - Substation & Instrument Building

088

088-EG-001

Emergency Diesel Generator Package Train 2

Field LCP

IES-11

Modbus TCP

Yes

[HOLD]

A130

LNG Train 1 - General Area

086

086-P-001

Sump Pump

IES-01

ICSS Integrated

N/A

A130

LNG Train 1 - General Area

086

086-P-002

Sump Pump

IES-01

ICSS Integrated

N/A

A130

LNG Train 1 - General Area

086

086-P-004

Sump Pump

IES-01

ICSS Integrated

N/A

A130

LNG Train 1 - General Area

086

086-P-003

Sump Pump

IES-01

ICSS Integrated

N/A

A140

LNG train 1 - Refrigeration Compressors area

A140

LNG train 1 - Refrigeration Compressors area

086

086-P-005 A

First Flush Basin Pump

IES-11

ICSS Integrated

N/A

086

086-P-005 B

First Flush Basin Pump

IES-11

ICSS Integrated

N/A

D100

LNG Tank & Onloading

086

086-P-201A

LNG Impoundment Basin Pump

Field LCP

ICSS Integrated

N/A

D100

LNG Tank & Onloading

086

086-P-201B

LNG Impoundment Basin Pump

Field LCP

ICSS Integrated

N/A

Type A

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

CONTRACTOR DOC. REF.

RLNG-000-IC-SP-0801

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 17 OF 224

Item GWBS

Area

Process Unit

Equipment Tags

Equipment type

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

D100

LNG Tank & Onloading

086

086-P-202A

IES-11

ICSS Integrated

N/A

D100

LNG Tank & Onloading

086

086-P-202B

IES-11

ICSS Integrated

N/A

D200

BOG Compression

086

086-P-203A

IES-11

ICSS Integrated

N/A

First Flush Basin Pump

D200

BOG Compression

086

086-P-203B

IES-11

ICSS Integrated

N/A

E200

Jetty (Trestle and Berthing structure)

086

086-P-204A

E200

Jetty (Trestle and Berthing structure)

086

086-P-204B

E200

Jetty (Trestle and Berthing structure)

086

086-P-205A

E200

Jetty (Trestle and Berthing structure)

086

086-P-205B

Jetty LNG impoundment basin pump

IES-11

ICSS Integrated

N/A

IES-11

ICSS Integrated

N/A

IES-11

ICSS Integrated

N/A

IES-11

ICSS Integrated

N/A

A230

LNG Train 2 - General Area

086

086-P-011

Sump Pump

IES-01

ICSS Integrated

N/A

A230

LNG Train 2 - General Area

086

086-P-012

Sump Pump

IES-01

ICSS Integrated

N/A

A230

LNG Train 2 - General Area

086

086-P-013

Sump Pump

IES-01

ICSS Integrated

N/A

A230

LNG Train 2 - General Area

086

086-P-014

Sump Pump

IES-01

ICSS Integrated

N/A

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

N/A

Type A

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

CONTRACTOR DOC. REF.

RLNG-000-IC-SP-0801

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 18 OF 224

Item GWBS

Area

Process Unit

Equipment Tags

Equipment type

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

A240

LNG Train 2 - Refrigeration Compressors area

A240

LNG Train 2 - Refrigeration Compressors area

086

086-P-015 A

First Flush Basin Pump

IES-11

ICSS Integrated

N/A

086

086-P-015 B

First Flush Basin Pump

IES-11

ICSS Integrated

N/A

HVAC

082

[HOLD]

Building HVAC

All Buildings

Vendor PLC (UCP)

Nearest IES/CCB/JCB

HW/BMS

F200

Non-Industrial Buildings

079

079-P-401A

F200

Non-Industrial Buildings

079

079-P-401B

Sewage Transfer Pump

Local Command

Field LP

N/A

Field LP

N/A

C530

CW Chiller / Sanitary Treatment Plant

079

079-Z-101

Sewage Treatment

N/A

ICSS Integrated

IES-02

F200

Non-Industrial Buildings

079

079-P-404A

Periphery Gate House Sewage Transfer Pump-A

Local Command

Field LP

N/A

F200

Non-Industrial Buildings

079

079-P-404B

Periphery Gate House Sewage Transfer Pump-B

Local Command

Field LP

N/A

F200

Non-Industrial Buildings

079

079-P-402A

Internal Gate Houses Sewage Transfer Pump-A

Local Command

Field LP

N/A

F200

Non-Industrial Buildings

079

079-P-402B

Internal Gate Houses Sewage Transfer Pump-B

Local Command

Field LP

N/A

F100

Industrial Buildings

079

079-P-403A

Warehouse, Workshop and Fire Station Sewage Transfer Pump-A

Local Command

Field LP

N/A

F100

Industrial Buildings

079

079-P-403B

Warehouse, Workshop and Fire Station Sewage Transfer Pump-B

Local Command

Field LP

N/A

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

N/A

Yes

N/A

Type A

Type C

N/A

Type A

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

CONTRACTOR DOC. REF.

RLNG-000-IC-SP-0801

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 19 OF 224

Item GWBS

Area

Process Unit

Equipment Tags

Equipment type

C220

Fire Water

077

077-Z-001B

Main Fire Pump Package - Diesel Drive

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

Field LCP

Vendor PLC (LCP)

IES-02

Modbus TCP

Yes

Type C

C350

Utility & Potable Water Prod

076

076-Z-004

Corrosion Inhibitor Injection

N/A

ICSS Integrated

IES-02

C350

Utility & Potable Water Prod

076

076-Z-002

Potable Water Sodium Hypochlorite Injection

N/A

ICSS Integrated

IES-02

C350

Utility & Potable Water Prod

C350

Utility & Potable Water Prod

076

076-Z-001

Potable Water Treatment

N/A

ICSS Integrated

IES-02

076

076-Z-003

Potable Water Chiller

N/A

ICSS Integrated

IES-02

N/A

Type A

D200

BOG Compression

061

061-Z-001

BOG Flare

[HOLD]

D200

BOG Compression

060

060-E-001A

SS-05

MCC [HOLD]

IES-03

N/A

D200

BOG Compression

060

060-E-002A

SS-05

MCC [HOLD]

IES-03

N/A

D200

BOG Compression

060

060-E-001B

BOG Compressor - Air Coolers

SS-05

MCC [HOLD]

IES-03

D200

BOG Compression

060

060-E-002B

SS-05

MCC [HOLD]

IES-03

D200

BOG Compression

060

060-E-001C

SS-05

MCC [HOLD]

IES-03

N/A

Yes

Type A

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

CONTRACTOR DOC. REF.

RLNG-000-IC-SP-0801

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 20 OF 224

Item GWBS

Area

Process Unit

Equipment Tags

Equipment type

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

D200

BOG Compression

060

060-E-002C

SS-05

MCC [HOLD]

IES-03

N/A

D200

BOG Compression

060

060-K-001A

IES-03

Modbus TCP

D200

BOG Compression

060

060-K-001B

BOG Compressor

IES-03

Vendor PLC (UCP)

IES-03

Modbus TCP

D200

BOG Compression

060

060-K-001C

IES-03

Modbus TCP

C430

Dry Flare systems

059

059-Z-001

Ground Flare

IES-01

Vendor PLC

IES-01

Modbus TCP

Yes

Type A

Type C

C530

Chilled Water Unit

044

044-Z-001

Cooling Water Chiller Package

N/A

ICSS Integrated

IES-01

N/A

Type A

C340

Air & Nitrogen

042

042-Z-001A

IES-02

Vendor PLC

IES-02

Modbus TCP

C340

Air & Nitrogen

042

042-Z-001B

Air Compressor

C340

Air & Nitrogen

042

042-Z-002

Emergency Air Compressor (Diesel Engine Driven)

IES-02

Vendor PLC (UCP)

IES-02

Modbus TCP

IES-02

Modbus TCP

C340

Air & Nitrogen

042

042-Z-003A

Field LCP

ICSS Integrated

IES-02

Modbus TCP

Air Dryer

C340

Air & Nitrogen

042

042-Z-003B

Field LCP

ICSS Integrated

IES-02

Modbus TCP

Yes

Type C

Type A

C340

Air & Nitrogen

042

042-Z-004

Nitrogen Storage and Vaporisation

N/A

ICSS Integrated

IES-02

N/A

Type A

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

CONTRACTOR DOC. REF.

RLNG-000-IC-SP-0801

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 21 OF 224

Item GWBS

Area

Process Unit

Equipment Tags

Equipment type

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

Jetty Topside

024

environnemental management system

023

QRH (Mooring PLC)

environnemental management system

JCB-01

Modbus TCP

[HOLD]

Type C

QRH (Mooring PLC)

JCB-01

Vendor PLC (UCP)

JCB-01

Modbus TCP

[HOLD]

Type C

Jetty Topside

022

BAS System

JCB-01

Modbus TCP

[HOLD]

Type C

E200

Jetty (Trestle and Berthing structure)

E200

Jetty (Trestle and Berthing structure)

E200

Jetty (Trestle and Berthing structure)

E200

Jetty (Trestle and Berthing structure)

E200

Jetty (Trestle and Berthing structure)

E200

Jetty (Trestle and Berthing structure)

E200

Jetty (Trestle and Berthing structure)

E200

Jetty (Trestle and Berthing structure)

021

021-LA-001A

LNG Transfer Arm “A” (Berth 1)

JCB-01

Modbus TCP

021

021-LA-001B

LNG Transfer Arm “B” (Berth 1)

JCB-01

Modbus TCP

Vendor PLC (UCP)

021

021-LA-001C

LNG Transfer Arm “C” (Berth 1)

JCB-01

Modbus TCP

021

021-LA-002

Vapor Return Arm (Berth 1)

JCB-01

Modbus TCP

021

021-LA-003A

LNG Transfer Arm “A” (Berth 2)

JCB-01

Modbus TCP

021

021-LA-003B

LNG Transfer Arm “B” (Berth 2)

JCB-01

Modbus TCP

021

021-LA-003C

LNG Transfer Arm “C” (Berth 2)

JCB-01

Modbus TCP

Vendor PLC (UCP) Future

021

021-LA-004

Vapor Return Arm (Berth 2)

JCB-01

Modbus TCP

Yes

Type C

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

CONTRACTOR DOC. REF.

RLNG-000-IC-SP-0801

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 22 OF 224

Item GWBS

Area

Process Unit

Equipment Tags

Equipment type

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

D100

LNG Tank & Onloading

020

020-T-001

LNG Storage Tank 1 - TGS

IES-03

D100

LNG Tank & Onloading

020

020-T-001

D100

LNG Tank & Onloading

020

020-T-001

D100

LNG Tank & Onloading

020

020-T-001

LNG Storage Tank 1 - Leak Detection

LNG Storage Tank 1 - Cooldown Monitoring

IES-03

LNG Storage Tank 1 - Seismic Monitoring

Field LCP

D100

LNG Tank & Onloading

020

020-T-002

LNG Storage Tank 2- TGS

IES-03

D100

LNG Tank & Onloading

020

020-T-002

D100

LNG Tank & Onloading

020

020-T-002

D100

LNG Tank & Onloading

020

020-T-002

LNG Storage Tank 2 - Leak Detection

LNG Storage Tank 2 - Cooldown Monitoring

IES-03

LNG Storage Tank 2- Seismic Monitoring

Field LCP

Tank Gauging System (TGS)

Leak Detection System

Cooldown Monitoring

Seismic Monitoring

Tank Gauging System (TGS)

Leak Detection System

Cooldown Monitoring

Seismic Monitoring

IES-03

Modbus TCP

IES-03

Modbus TCP

IES-03

Modbus TCP

IES-03

Modbus TCP

IES-03

Modbus TCP

IES-03

Modbus TCP

IES-03

Modbus TCP

IES-03

Modbus TCP

D100

LNG Tank & Onloading

020

020-P-001A

LNG In-Tank Pump (Tank 1 Export)

IES-03

ICSS Integrated

IES-03

D100

LNG Tank & Onloading

020

020-P-001B

LNG In-Tank Pump (Tank 1 Export)

IES-03

ICSS Integrated

IES-03

D100

LNG Tank & Onloading

020

020-P-001C

LNG In-Tank Pump (Tank 1 Export)

IES-03

ICSS Integrated

IES-03

D100

LNG Tank & Onloading

020

020-P-001D

LNG In-Tank Pump (Tank 1 Export)

IES-03

ICSS Integrated

IES-03

N/A

Yes

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

Type C

Type A

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

CONTRACTOR DOC. REF.

RLNG-000-IC-SP-0801

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 23 OF 224

Item GWBS

Area

Process Unit

Equipment Tags

Equipment type

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

D100

LNG Tank & Onloading

020

020-P-002A

LNG In-Tank Pump (Tank 2 Export)

IES-03

ICSS Integrated

IES-03

D100

LNG Tank & Onloading

020

020-P-002B

LNG In-Tank Pump (Tank 2 Export)

IES-03

ICSS Integrated

IES-03

D100

LNG Tank & Onloading

020

020-P-002C

LNG In-Tank Pump (Tank 2 Export)

IES-03

ICSS Integrated

IES-03

D100

LNG Tank & Onloading

020

020-P-002D

LNG In-Tank Pump (Tank 2 Export)

IES-03

ICSS Integrated

IES-03

D100

LNG Tank & Onloading

020

020-T-001

LNG Tank 1

IES-03

ICSS Integrated

IES-03

D100

LNG Tank & Onloading

020

020-T-002

LNG Tank 2

IES-03

ICSS Integrated

IES-03

N/A

Yes

N/A

Type A

B100

Inlet Facilities

010

010-Z-001

Inlet Gas Metering Station

IES-04

Flow Computer PLC(UCP)

IES-01 [HOLD]

Modbus TCP

Yes

Type C

[HOLD]

Chemical Injection Package for Chilled Water Package

[HOLD]

A220

LNG Train 2 - NRU and MCHE area

100

A220

101

A210

102

A210

LNG Train 2 - NRU and MCHE area

LNG Train 2 - Precooling and Propane Cycle wo Compressor LNG Train 2 - Precooling and Propane Cycle wo Compressor

212

212-P-001 A

Cryogenic Centrifugal Pumps

IES-01

ICSS Integrated

N/A

212

212-P-001 B

Cryogenic Centrifugal Pumps

IES-01

ICSS Integrated

N/A

212

212-E-003

NRU Compressor -Air Coolers

MB-24

MCC [HOLD]

IES-01

Modbus TCP

212

212-E-004

NRU Compressor -Air Coolers

MB-24

MCC [HOLD]

IES-01

Modbus TCP

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

N/A

Yes

Type A

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

CONTRACTOR DOC. REF.

RLNG-000-IC-SP-0801

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 24 OF 224

Item GWBS

Area

Process Unit

Equipment Tags

Equipment type

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

103

A210

104

A210

105

A220

LNG Train 2 - Precooling and Propane Cycle wo Compressor LNG Train 2 - Precooling and Propane Cycle wo Compressor

LNG Train 2 - NRU and MCHE area

106

A220

LNG Train 2 - NRU and MCHE area

107

A240

LNG Train 2 - Refrigeration Compressors area

108

A240

LNG Train 2 - Refrigeration Compressors area

109

A240

LNG Train 2 - Refrigeration Compressors area

110

A210

111

A210

112

A210

113

A210

114

A210

LNG Train 2 - Precooling and Propane Cycle wo Compressor LNG Train 2 - Precooling and Propane Cycle wo Compressor LNG Train 2 - Precooling and Propane Cycle wo Compressor LNG Train 2 - Precooling and Propane Cycle wo Compressor LNG Train 2 - Precooling and Propane Cycle wo Compressor

212

212-E-005

NRU Compressor -Air Coolers

MB-24

MCC [HOLD]

IES-01

Modbus TCP

212

212-E-006

NRU Compressor -Air Coolers

MB-24

MCC [HOLD]

IES-01

Modbus TCP

212

212-K-001

NRU Compressor

MB-24

Vendor PLC (UCP)

IES-21

Modbus TCP

Yes

Type A

Type C

212

212-XP-001

MR LNG Liquid Turbine

IES-01

ICSS Integrated

N/A

Type A

211

211-K-201

Propane Compressor

SS-21C

211

211-K-101

LP MR Compressor

SS-23C

211

211-K-102

HP / MP MR Compressor

SS-22C

Vendor PLC (UCP)

IES-21

Modbus TCP

IES-21

Modbus TCP

IES-21

Modbus TCP

211

211-E-201

Propane - Air coolers

SS-T2

MCC [HOLD]

IES-01

Modbus TCP

211

211-E-202

Propane - Air coolers

SS-T2

MCC [HOLD]

IES-01

Modbus TCP

211

211-E-204

Propane - Air coolers

SS-T2

MCC [HOLD]

IES-01

Modbus TCP

211

211-E-105

MR COMPRESSOR - Air coolers

SS-T2

MCC [HOLD]

IES-01

Modbus TCP

211

211-E-106

MR COMPRESSOR - Air coolers

SS-T2

MCC [HOLD]

IES-01

Modbus TCP

Yes

Type C

Type A

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

CONTRACTOR DOC. REF.

RLNG-000-IC-SP-0801

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 25 OF 224

Item GWBS

Area

Process Unit

Equipment Tags

Equipment type

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

211

211-E-107

MR COMPRESSOR - Air coolers

SS-T2

MCC [HOLD]

IES-01

Modbus TCP

Yes

Type A

211

211-XP-101

LNG Liquid Turbine

IES-01

ICSS Integrated

N/A

117

A230

LNG Train 2 - General Area

211

211-P-201

Propane Transfer Pump

IES-01

ICSS Integrated

112

112-P-001 A

Cryogenic Centrifugal Pumps

IES-01

ICSS Integrated

112

112-P-001 B

Cryogenic Centrifugal Pumps

IES-01

ICSS Integrated

N/A

112

112-E-003

NRU Compressor -Air Coolers

MB-14

MCC [HOLD]

IES-01

Modbus TCP

112

112-E-004

NRU Compressor -Air Coolers

MB-14

MCC [HOLD]

IES-01

Modbus TCP

112

112-E-005

NRU Compressor -Air Coolers

MB-14

MCC [HOLD]

IES-01

Modbus TCP

112

112-E-006

NRU Compressor -Air Coolers

MB-14

MCC [HOLD]

IES-01

Modbus TCP

112

112-K-001

NRU Compressor

MB-14

Vendor PLC (UCP)

IES-11

Modbus TCP

112

112-XP-001

MR LNG Liquid Turbine

IES-01

ICSS Integrated

112-E-001

NRU Reboiler

[HOLD]

ICSS Integrated

112-E-002

NRU Condenser

[HOLD]

ICSS Integrated

112

111

111-K-201

Propane Compressor

111

111-K-101

LP MR Compressor

SS-11C

SS-13C

Vendor PLC (UCP)

IES-11

Modbus TCP

IES-11

Modbus TCP

N/A

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

N/A

Yes

N/A

Yes

Type A

Type C

Type A

Type C

115

A210

116

A220

LNG Train 2 - Precooling and Propane Cycle wo Compressor

LNG Train 2 - NRU and MCHE area

118

A120

119

A120

120

A110

121

A110

122

A110

123

A110

124

A120

125

A120

126

A120

127

A120

128

A140

129

A140

LNG train 1 - NRU and MCHE area LNG train 1 - NRU and MCHE area LNG train 1 - Precooling and Propane Cycle wo Compressor LNG train 1 - Precooling and Propane Cycle wo Compressor LNG train 1 - Precooling and Propane Cycle wo Compressor LNG train 1 - Precooling and Propane Cycle wo Compressor LNG train 1 - NRU and MCHE area LNG train 1 - NRU and MCHE area LNG train 1 - NRU and MCHE area LNG train 1 - NRU and MCHE area LNG train 1 - Refrigeration Compressors area

LNG train 1 - Refrigeration Compressors area

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

CONTRACTOR DOC. REF.

RLNG-000-IC-SP-0801

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 26 OF 224

Item GWBS

Area

Process Unit

Equipment Tags

Equipment type

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

130

A140

LNG train 1 - Refrigeration Compressors area

111

111-K-102

HP / MP MR Compressor

SS-12C

Vendor PLC (UCP)

IES-11

Modbus TCP

131

A110

132

A110

133

A110

134

A110

135

A110

136

A110

137

A120

LNG train 1 - Precooling and Propane Cycle wo Compressor LNG train 1 - Precooling and Propane Cycle wo Compressor LNG train 1 - Precooling and Propane Cycle wo Compressor LNG train 1 - Precooling and Propane Cycle wo Compressor LNG train 1 - Precooling and Propane Cycle wo Compressor LNG train 1 - Precooling and Propane Cycle wo Compressor LNG train 1 - NRU and MCHE area

140

141

142

143

144

B220

C550

Refrigerant Storage

Chilled Water Unit

145

C350

Utility & Potable Water Prod

111

111-E-201

Propane - Air coolers

SS-T1

MCC [HOLD]

IES-01

Modbus TCP

111

111-E-202

Propane - Air coolers

SS-T1

MCC [HOLD]

IES-01

Modbus TCP

111

111-E-204

Propane - Air coolers

SS-T1

MCC [HOLD]

IES-01

Modbus TCP

111

111-E-105

MR COMPRESSOR - Air coolers

SS-T1

MCC [HOLD]

IES-01

Modbus TCP

111

111-E-106

MR COMPRESSOR - Air coolers

SS-T1

MCC [HOLD]

IES-01

Modbus TCP

111

111-E-107

MR COMPRESSOR - Air coolers

SS-T1

MCC [HOLD]

IES-01

Modbus TCP

111

111-XP-101

LNG Liquid Turbine

IES-01

ICSS Integrated

138

A130

LNG Train 1 - General Area

111

111-E-203

Propane Reclaimer Condenser

[HOLD]

ICSS Integrated

139

A120

LNG train 1 - NRU and MCHE area

111

111-E-005

Cryogenic Heat Exchanger

[HOLD]

ICSS Integrated

A130

LNG Train 1 - General Area

111

111-P-201

Propane Transfer Pump

IES-01

ICSS Integrated

N/A

035

044

076

035-P-003

Propane Make-Up Pump

N/A

ICSS Integrated

IES-01

044-P-001A

Cooling Water Circulation Pump A

044-P-001B

Cooling Water Circulation Pump B

044-P-001C

Cooling Water Circulation Pump C

076-P-001A

Utility Water Pump A

N/A

ICSS Integrated

IES-01

ICSS Integrated

IES-02

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

N/A

Yes

N/A

Type C

Type A

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

CONTRACTOR DOC. REF.

RLNG-000-IC-SP-0801

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 27 OF 224

Item GWBS

Area

146

C350

147

C350

148

C350

Utility & Potable Water Prod Utility & Potable Water Prod Utility & Potable Water Prod

Process Unit

Equipment Tags

Equipment type

076

076-P-001B

Utility Water Pump B

076

076-P-002A

Potable Water Pump A

076

076-P-002B

Potable Water Pump B

149

C220

Fire Water

077

077-Z-001A

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

N/A

ICSS Integrated

IES-02

ICSS Integrated

IES-02

ICSS Integrated

IES-02

N/A

077

079

150

C220

Fire Water

151

152

C220

153

C540

154

C540

155

C530

156

C530

Fire Water

Sanitary Sewer / Sewage Treatment Sanitary Sewer / Sewage Treatment Sanitary Sewer / Sewage Treatment Sanitary Sewer / Sewage Treatment

Main Fire Pump Package – Electric Drive Main Fire Pump Package – Diesel Drive

Field LCP

Vendor PLC (LCP)

IES-02

Modbus TCP

Field LCP

Vendor PLC (LCP)

IES-02

Modbus TCP

077-Z-001C

077-Z-002A

Firewater Jockey Pump A Package

Field LCP

Vendor PLC (LCP)

IES-02

Modbus TCP

077-Z-002B

Firewater Jockey Pump B Package

Field LCP

Vendor PLC (LCP)

IES-02

Modbus TCP

079-P-101A

079

079-P-101B

Operator Cabin Sewage Transfer Pump-A Operator Cabin Sewage Transfer Pump-B

079

079-P-103A

Treated Water Transfer Pump A

079

079-P-103B

Treated Water Transfer Pump B

N/A

ICSS Integrated

IES-02

ICSS Integrated

IES-02

ICSS Integrated

IES-02

ICSS Integrated

IES-02

157

C220

Opened Drains

086

086-P-101A

158

C220

Opened Drains

086

086-P-101B

159

C430

Opened Drains

086

086-P-102A

160

C430

Opened Drains

086

086-P-102B

161

B130

Opened Drains

086

086-P-103A

162

B130

Opened Drains

086

086-P-103B

163

C350

Opened Drains

086

086-P-104A

164

C350

Opened Drains

086

086-P-104B

First Flush Basin Pump A - Firewater Area First Flush Basin Pump B - Firewater Area First Flush Basin Pump A - Flare Area First Flush Basin Pump B - Flare Area First Flush Basin Pump A - Metering Area First Flush Basin Pump B - Metering Area First Flush Basin Pump A - Utility Area First Flush Basin Pump B - Utility Area

ICSS Integrated

N/A

IES-02 (TBD)

IES-01 (TBD)

IES-04 (TBD)

IES-02 (TBD)

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

N/A

Yes

N/A

Type A

Type C

Type A

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

CONTRACTOR DOC. REF.

RLNG-000-IC-SP-0801

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 28 OF 224

Item GWBS

Area

Process Unit

Equipment Tags

Equipment type

Package Panel Location

System Type

ICSS Interface Location

ICSS Interface Type

Redundant

Package Type

165

B220

Opened Drains

086

086-P-110A

166

B220

Opened Drains

086

086-P-110B

167

B220

Opened Drains

086

086-P-113A

168

B220

Opened Drains

086

086-P-113B

Refrigerant Storage Impoundment Basin Pump A Refrigerant Storage Impoundment Basin Pump B First flush basin pump A for Refrigerant Storage Area First flush basin pump B for Refrigerant Storage Area

ICSS Integrated

N/A

IES-01 (TBD)

169

170

171

172

173

174

175

176

A130

LNG Train 1 - General Area

111

111-H-001 A

Defrost Gas Heater A

A130

LNG Train 1 - General Area

111

111-H-001 B

Defrost Gas Heater B

A230

LNG Train 2 - General Area

211

211-H-001 A

Defrost Gas Heater A

A230

LNG Train 2 - General Area

211

211-H-001 B

Defrost Gas Heater B

A130

LNG Train 1 - General Area

115

115-EH-001 A

Cold Drain Drum Heater

A130

LNG Train 1 - General Area

115

115-EH-001 B

Cold Drain Drum Heater

A230

LNG Train 2 - General Area

215

215-EH-001 A

Cold Drain Drum Heater

A230

LNG Train 2 - General Area

215

215-EH-001 B

Cold Drain Drum Heater

177

D200

BOG Compression

178

179

C400

Dry Flare systems

058

059

058-H-001

Fuel Gas Heater

059-H-001A

Dry Gas Flare KO Drum Heater

059-H-001B

Dry Gas Flare KO Drum Heater

SS-T1

SS-T2

SS-T1

SS-T2

SS-05

SS-01

Thyristor Panel

IES-11

IES-21

IES-11

IES-21

IES-03

IES-01

N/A

Modbus TCP

N/A

Yes

Type A

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

RLNG-000-IC-SP-0801

CONTRACTOR DOC. REF.

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 29 OF 224

3.0

AMENDMENTS TO PROGRAMMABLE LOGIC CONTROLLER SPEC. AGES-SP-04-018

Instructions contained below such as “Add”, “Substitute”, “Revised”, or “New” shall be interpreted as follows:

Add: Requirements shall be a continuation of the paragraph in the referenced specification.
Substitute: The requirement of the referenced specification shall be replaced in its entirety by the

requirements below.

Revised: The requirement of the referenced specification shall be revised by the specific wording

below.

New: A new requirement as described below.

The following sections are amended in AGES-SP-04-018, Rev.1

Section A – General

Sub-section 2.2

Substitute: The following ADNOC specifications are substituted with Project documents as detailed below:

AGES Reference

Project Document No.

Project Document Title

AGES-PH-04-001

RLNG-000-IC-PP-0002

AGES-SP-04-001

RLNG-000-IC-SP-0101

AGES-SP-04-003

RLNG-000-IC-SP-0101

AGES-SP-04-004

RLNG-000-IC-SP-0101

AGES-SP-04-006

RLNG-000-IC-SP-0741

AGES-SP-04-007

RLNG-000-IC-SP-0801

AGES-SP-04-013

RLNG-000-PM-SP-0001

Philosophy for Automation & Instrumentation Design

Specification for Integrated Control & Safety System

Specification Telecommunication Cables

for

Instrumentation

Specification Instrumentation

for

Packaged

Unit

Specification for OT Cyber Security - for Vendors

AGES-SP-07-011

RLNG-000-PM-SP-6006

JV Packing Marking and Shipping Instructions

AGES-SP-13-001

RLNG-000-PM-PP-2004

Critical Rating Procedure

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

RLNG-000-IC-SP-0801

CONTRACTOR DOC. REF.

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 30 OF 224

Sub-section 3

Substitute:

‘In case of conflict, the order of document precedence shall be:

a. UAE Statutory requirements

b. ADNOC HSE Standards

c. Equipment datasheets and drawings

d. Project Specifications and standard drawings

e. COMPANY Specifications

f. National / International Standards’

with:

‘The order of precedence with respect to codes and regulations that shall be followed for the design of the terminal is as follows in terms of priority:

UAE Statutory Legislation and Regulations
ADNOC HSE Regulations, Standards and Codes of practice
Project Specifications and Standards
ADNOC Engineering Specifications, Standards and Procedures
ADNOC Guidelines, Procedures & Codes of Practice
International Codes & Standards’

Sub-section 6.2

Add: ‘For environmental / site conditions, refer to “Project Basis of Design” (RLNG-000-PM-BOD-2002)’

Section B – Technical Requirements

Sub-section 7.9.2

Substitute:

‘The PLC SUPPLIER shall provide all hardware necessary to support the bi-directional communication between SMART field devices (transmitters / positioners) and the Instrument Asset Management System (IAMS) supplied as part of ICSS using superimposed HART communication signals. HART pass-through analogue I/O modules shall be supplied. The use of external HART multiplexers shall be subject to COMPANY approval.’

with:

‘The PLC SUPPLIER shall provide all hardware necessary to support the bi-directional communication between SMART field devices (transmitters / positioners) and the Instrument Asset Management System (IAMS) supplied as part of ICSS using superimposed HART communication signals. HART pass-through analogue I/O modules or external HART multiplexers shall be supplied [HOLD_2].’

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

RUWAIS LNG PROJECT

SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

COMPANY DOCUMENT REF.

RLNG-000-IC-SP-0801

CONTRACTOR DOC. REF.

215122C-000-JSD-1580-0001

REVISION: 1

PAGE 31 OF 224

4.0

APPENDIX

4.1

APPENDIX 1 - AGES-SP-04-007

AGES-SP-04-007 – SPECIFICATION FOR PACKAGED UNIT INSTRUMENTATION

4.2

APPENDIX 2 - AGES-SP-04-018

AGES-SP-04-018 – PROGRAMMABLE LOGIC CONTROLLER

The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.

THE CONTENTS OF THIS DOCUMENT ARE PROPRIETARY AND CONFIDENTIAL.

ADNOC GROUP PROJECTS AND ENGINEERING

INSTRUMENTATION FOR PACKAGED EQUIPMENT SPECIFICATION

Specification

APPROVED BY:

Abdulmunim Saif Al Kindy NAME: Abdulmunim Al Kindy TITLE: Executive Director PT&CS EFFECTIVE DATE:

AGES-SP-04-007

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/7691 All parties consent to this document being signed electronically -UPST/UDR/INT/2021/6591

GROUP PROJECTS & ENGINEERING / PT&CS DIRECTORATE

CUSTODIAN ADNOC

Group Projects & Engineering / PT&CS Specification applicable to ADNOC & ADNOC Group Companies

REVISION HISTORY

DATE

REV.

26-Feb-2021

PREPARED BY (Designation / Initial) Asadullah Malik Sr. Engineer, I&C, TE.

REVIEWED BY (Designation / Initial) Ashwani Kumar Kataria/ A/MIHE,TC-Eng

ENDORSED BY (Designation / Initial) Abdulla Al Shaiba/ VP-GPE

ENDORSED BY (Designation / Initial) Zaher Salem/ SVP-GPE

21/04/2021

Reuben Yagambaram/ SPM GPE

22/04/2021

Group Projects & Engineering is the owner of this Specification and responsible for its custody, maintenance and periodic update.

In addition, Group Projects & Engineering is responsible for communication and distribution of any changes to this Specification and its version control.

This specification will be reviewed and updated in case of any changes affecting the activities described in this specification.

AGES-SP-04-007

Rev. No: 1 Page 2 of 130

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/7691 All parties consent to this document being signed electronically -UPST/UDR/INT/2021/6591

Scanned by TapScannerDigitally signed by Asadullah Malik DN: cn=Asadullah Malik, o=ADNOC, ou=AGP, email=asadullahm@adnoc.ae, c=AE Date: 2021.03.11 16:18:36 +04’00’Digitally signed by Ashwani Kumar Kataria DN: cn=Ashwani Kumar Kataria, o=ADNOC Onshore, ou=ADNOC Onshore, email=akataria@adnoc.ae, c=AE Date: 2021.03.14 08:37:50 +04’00’Reuben YagambaramDigitally signed by Reuben Yagambaram Date: 2021.03.14 12:17:21 +04’00’INTER-RELATIONSHIPS AND STAKEHOLDERS

The following are inter-relationships for implementation of this Specification:

i. ADNOC Upstream and ADNOC Downstream Directorates; and

ii. ADNOC Onshore, ADNOC Offshore, ADNOC Sour Gas, ADNOC Gas Processing. ADNOC LNG,

ADNOC Refining, Fertil, Borouge, Al Dhafra Petroleum, Al Yasat

The following are stakeholders for the purpose of this Specification:

i. ADNOC PT&CS Directorate

This Specification has been approved by the ADNOC PT&CS is to be implemented by each ADNOC Group company included above subject to and in accordance with their Delegation of Authority and other governance-related processes in order to ensure compliance.

Each ADNOC Group company must establish/nominate a Technical Authority responsible for compliance

with this Specification.

DEFINITIONS

“ADNOC” means Abu Dhabi National Oil Company.

“ADNOC Group” means ADNOC together with each company in which ADNOC, directly or indirectly, controls fifty percent (50%) or more of the share capital.

“Approving Authority” means the decision-making body or employee with the required authority to approve Policies & Procedures or any changes to it.

“Business Line Directorates” or “BLD” means a directorate of ADNOC which is responsible for one or more Group Companies reporting to, or operating within the same line of business as, such directorate.

“Business Support Directorates and Functions” or “Non- BLD” means all the ADNOC functions and the remaining directorates, which are not ADNOC Business Line Directorates.

“CEO” means chief executive officer.

“Group Company” means any company within the ADNOC Group other than ADNOC.

“Specification” means this Instrumentation for Packaged Equipment Specification.

CONTROLLED INTRANET COPY

The intranet copy of this document located in the section under Group Policies on One ADNOC is the only controlled document. Copies or extracts of this document, which have been downloaded from the intranet, are uncontrolled copies and cannot be guaranteed to be the latest version.

AGES-SP-04-007

Rev. No: 1 Page 3 of 130

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/7691 All parties consent to this document being signed electronically -UPST/UDR/INT/2021/6563 All parties consent to this document being signed electronically -UPST/UDR/INT/2021/6591

TABLE OF CONTENTS

GENERAL … 10

INTRODUCTION … 10

PURPOSE … 11

DEFINED TERMS AND ABBREVIATIONS … 11

SECTION A - GENERAL … 15

REFERENCE DOCUMENTS … 15

INTERNATIONAL CODES AND STANDARDS … 15

ADNOC SPECIFICATIONS … 18

DOCUMENT PRECEDENCE … 19

SPECIFICATION DEVIATION / CONCESSION CONTROL … 19

DESIGN CONSIDERATIONS / MINIMUM DESIGN REQUIREMENTS … 19

DESIGN BASIS … 19

DESIGN PARAMETERS … 21

ENVIRONMENTAL / SITE DATA … 21

AREA CLASSIFICATION … 23

MINIMUM DESIGN REQUIREMENTS … 23

STANDARDISATION … 23

SECTION B – TECHNICAL REQUIREMENTS … 24

PROCESS SAFETY REQUIREMENTS … 24

SECTION B PART I … 25

DESIGN REQUIREMENTS … 25

GENERAL … 25

INSTRUMENT EQUIPMENT PACKAGE TYPES … 26

CONTROL SYSTEM … 29

DESIGN CONSIDERATIONS … 30

CRITICALITY RATING … 43

ISOLATIONS … 43

MATERIALS … 45

HAZOP, LOPA, SIL REVIEW … 46

PACKAGED EQUIPMENT DESIGN … 48

EARTHING… 51

AGES-SP-04-007

Rev. No: 1 Page 4 of 130

INSTRUMENT NUMBERING AND TAGGING… 52

INSTRUMENT SYMBOLS AND IDENTIFICATION … 52

FIELD INSTRUMENTATION… 52

GENERAL … 52

FLOW MEASUREMENT … 53

LEVEL MEASUREMENT … 53

PRESSURE MEASUREMENTS … 54

TEMPERATURE MEASUREMENT … 54

MACHINERY MONITORING INSTRUMENTS … 56

SOLAR POWERED INSTRUMENTS … 62

MULTI VARIABLE INSTRUMENTATION … 62

ANALYSERS … 62

FIRE AND GAS DEVICES … 63

FINAL ELEMENTS … 63

CONTROL VALVES … 63

ACTUATED VALVES … 63

SHUTDOWN VALVES … 63

BYPASS MANIFOLDS … 63

EMERGENCY DEPRESSURIZING VALVES … 63

MOTOR OPERATED VALVE (MOV) … 63

PRESSURE SAFETY VALVES … 63

MACHINERY MONITORING SYSTEM … 63

GENERAL … 63

FUNCTIONS AND OPERATION … 65

FEATURES … 65

MACHINE ALARM AND SHUTDOWN FUNCTIONS … 66

ARCHITECTURE AND COMMUNICATION … 66

SYSTEM DESIGN … 66

MACHINERY DIAGNOSTICS AND MAINTENANCE PREDICTION SYSTEM … 72

MAIN CONTROL ROOM … 73

ANTISURGE AND PERFORMANCE CONTROL … 73

GAS TURBINE CONTROL SYSTEM … 74

EQUIPMENT PANELS AND SHELTERS … 74

GENERAL … 74

AGES-SP-04-007

Rev. No: 1 Page 5 of 130

INSTRUMENT EQUIPMENT SHELTERS … 74

LOCAL PANEL / GAUGE BOARDS … 75

CONTROL PANELS … 75

ELECTRICAL … 76

HEATING, VENTILATION, AND AIR CONDITIONING … 76

INSTRUMENT INSTALLATION … 76

GENERAL … 76

INSTRUMENT INSTALLATION DETAILS … 77

PACKAGE EQUIPMENT INSTRUMENTATION … 77

INSTRUMENT MOUNTING AND SUPPORTS … 78

INSTRUMENT ACCESSIBILITY … 79

INSTRUMENT PROCESS CONNECTIONS … 80

INSTRUMENT TUBING, FITTINGS AND VALVES … 80

INSTRUMENT PROCESS PIPING … 80

INSTRUMENT AIR PIPING … 80

SUNSHADES … 80

CABLE AND WIRING … 81

JUNCTION BOXES AND ENCLOSURES … 83

CABLE GLANDS … 83

CABLE TRAY AND RACK … 83

CABLE TRUNKING … 83

INSTRUMENT FIREPROOFING … 84

LABELLING … 84

GENERAL … 84

LANGUAGE FOR NAMEPLATES AND TAG PLATES … 85

INSTRUMENTS … 85

JUNCTION BOXES … 86

LOCAL GAUGE BOARDS … 86

LOCAL PANELS … 87

CONTROL PANELS … 88

INSTRUMENT EQUIPMENT SHELTERS … 88

INSTRUMENT TAPPING POINTS … 89

CABLE, WIRING AND TERMINATIONS … 89

INSTRUMENT RECEIVING, STORAGE AND INSTALLATION … 90

AGES-SP-04-007

Rev. No: 1 Page 6 of 130

GENERAL … 90

RECEIVING AND STORAGE … 91

STORAGE OF INSTRUMENTATION … 92

FUNCTIONAL CHECK … 92

SECTION B PART II … 93

CONTROL PHILOSOPHY … 93

GENERAL … 93

PACKAGED EQUIPMENT PANELS FOR START-UP … 93

START-UP INITIATION … 93

CONTROL AND MONITORING … 94

PACKAGED EQUIPMENT SEQUENCING … 94

PACKAGED EQUIPMENT ESD SYSTEM … 94

VIBRATION AND TEMPERATURE MONITORING… 94

ANTI-SURGE, LOAD SHARING, PERFORMANCE CONTROLLERS … 95

TURBINE/COMPRESSOR SEQUENCE CONTROL … 95

SPEED AND FUEL CONTROL (GAS TURBINE)… 95

FIRE & GAS SYSTEMS … 95

ALARM AND SHUTDOWN PHILOSOPHY … 96

INTERFACE REQUIREMENTS … 96

SECTION C – OTHER REQUIREMENTS … 98

SCOPE OF SUPPLY AND ENGINEERING … 98

SCOPE OF SUPPLY … 98

SCOPE OF ENGINEERING … 98

QUALITY CONTROL AND ASSURANCE … 98

GENERAL … 98

QUALITY MANAGEMENT … 98

QUALITY PLAN … 99

SUB-CONTRACTORS / SUB-SUPPLIERS … 100

INSPECTION, TESTING AND CERTIFICATION REQUIREMENTS … 100

SPARE PARTS … 100

SPARES… 100

SPECIAL TOOLS … 101

PAINTING, PRESERVATION AND SHIPMENT… 102

GENERAL … 102

AGES-SP-04-007

Rev. No: 1 Page 7 of 130

SURFACE PROTECTIVE COATING AND PAINTING … 102

PACKING AND SHIPPING … 102

PRESERVATION AND STORAGE … 103

COMMISSIONING … 104

TRAINING … 104

DOCUMENTATION / MANUFACTURER DATA RECORDS … 104

DOCUMENTATION … 104

MANUFACTURING RECORD BOOK … 106

INSTALLATION, OPERATION AND MAINTENANCE MANUAL … 106

SUPPLIER’S RESPONSIBILITIES … 106

MANUFACTURER / SUPPLIER QC DOCUMENT AND CERTIFICATION … 107

GUARANTEES AND WARRANTY … 107

SECTION D – STANDARD DRAWINGS AND DATASHEETS … 108

DATA SHEET TEMPLATES … 108

STANDARD DRAWINGS… 108

SECTION E - APPENDICES … 109

INSTRUMENT PACKAGE EQUIPMENT TYPES - TYPICAL ARRANGEMENTS … 109

INSTRUMENT PACKAGE EQUIPMENT TYPES - TYPICAL SCOPE OF SUPPLY . 113

INSTRUMENT PACKAGE EQUIPMENT TYPES - TYPICAL SCOPE OF

ENGINEERING … 123

INSTRUMENT MANUFACTURING RECORD BOOK REQUIREMENTS … 130

AGES-SP-04-007

Rev. No: 1 Page 8 of 130

LIST OF TABLES

TABLE 1.1 LIST OF ABBREVIATIONS … 13

TABLE 5.1 INDOOR ENVIRONMENTAL / SITE CONDITIONS … 21

TABLE 5.2 OUTDOOR ENVIRONMENTAL / SITE CONDITIONS … 22

TABLE 7.1 INSTRUMENT PACKAGED EQUIPMENT TYPES … 26

TABLE 7.2 INSTRUMENT SCALES AND INDICATORS … 31

TABLE 7.3 SAFETY CLASSIFICATION GUIDELINES … 37

TABLE 7.4 ENGINEERING UNITS OF MEASUREMENT … 39

TABLE 18.1 MOUNTING PLATE SELECTION… 79

TABLE 30.1 DRAWING SIZES … 105

TABLE A4. 1 MANUFACTURING RECORD BOOK REQUIREMENTS … 130

AGES-SP-04-007

Rev. No: 1 Page 9 of 130

GENERAL

Introduction

This specification provides requirements for Instrumentation for Packaged Equipment, including, but not limited to the following sections:

Design Considerations and Requirements.

Instrument Materials and Sour Service.

Instrument Hazardous Area Protection.

Package SUPPLIER HAZOP and SIL assessments.

Package equipment field instruments (flow, level, pressure, and temperature).

Machinery Monitoring Instruments.

Analysers, Fire and Gas Devices and Output Devices.

Instrument Equipment Package Types and integration.

Instrument Enclosures and Shelters (Junction Boxes, Local Gauge Boards, Instrument Equipment Shelters, UCP/SCPs).

Package Equipment Control System Philosophy and Machinery Monitoring Control Systems.

Instrument Installation Design.

Instrument Piping.

Instrument Labelling.

Instrument Receiving, Storage and Installation.

Quality Control and Assurance.

Inspection, Testing and Certification Requirements.

Future capacity and Spare Parts.

Painting, Preservation and Shipment.

Commissioning.

Training.

Documentation and Manufacturers Data Records.

Guarantees and Warranty.

The following Appendices are included within this specification:

Instrument Package Equipment Types - Typical Arrangements.

Instrument Package Equipment Types - Typical Scope of Supply.

Instrument Package Equipment Types - Typical Scope of Engineering.

Instrument Manufacturing Record Book.

This specification does not cover:

AGES-SP-04-007

Rev. No: 1 Page 10 of 130

Development of functional safety documentation.

Integrated Control and Safety Systems.

ICSS Graphics and Displays.

Instrument Control Rooms.

Telecommunications equipment.

Instrument design requirements for subsea installations.

Purpose

The purpose of this specification is to define the minimum mandatory technical requirements for selection, design, manufacturing, inspection and testing, packing, preservation, installation, and commissioning of Instrumentation for Packaged Equipment across the ADNOC Business Units. Unless otherwise stated in this specification, the supplied equipment shall comply fully with the requirements of relevant international standard.

The requirements detailed within this specification apply to both offshore and onshore installations, unless specifically stated to apply for either one or the other, i.e. a requirement starting with “for installations offshore” applies only to equipment to be located on an offshore installation. This specification does not apply to subsea installed equipment.

This specification provides the structure to support standardisation and its associated savings in lifecycle costs.

Defined Terms and Abbreviations

The following defined terms are used throughout this Specification:

‘COMPANY’ means ADNOC, ADNOC Group or an ADNOC Group Company, and includes any agent or consultant authorized to act for, and on behalf of the COMPANY.

‘CONTRACTOR’ means the parties that carry out all or part of the design, engineering, procurement, construction, commissioning, or management its approved MANUFACTURER(s), SUPPLIER(s), SUB-SUPPLIER(s) and SUB-CONTRACTOR(s).

for ADNOC projects. CONTRACTOR

includes

“MANUFACTURER” means the Original Equipment Manufacturer (OEM) or MANUFACTURER of one or more of the component(s) which make up a sub-assembly or item of equipment assembled by the main SUPPLIER or his nominated SUB-SUPPLIER.

‘may’ means a permitted option.

‘should’ means a recommendation.

‘shall’ indicates mandatory requirements.

“SUB-CONTRACTOR” means any party engaged by the CONTRACTOR to undertake any assigned work on their behalf. COMPANY maintains the right to review all proposed SUB-CONTRACTORs; this right does not relieve the CONTRACTOR of their obligations under the Contract, nor does it create any contractual relationship between COMPANY and the SUB-CONTRACTOR.

“SUPPLIER” means the party entering into a Contract with COMPANY to provide the materials, equipment, supporting technical documents and/or drawings, guarantees, warranties and/or agreed services in accordance with the requirements of the purchase order and relevant specification(s). The term SUPPLIER includes any legally appointed successors and/or nominated representatives of the SUPPLIER.

AGES-SP-04-007

Rev. No: 1 Page 11 of 130

“SUB-SUPPLIER” means the sub-contracted SUPPLIER of equipment sub-components software and/or support services relating to the equipment / package, or part thereof, to be provided by the SUPPLIER. COMPANY maintains the right to review all proposed SUB-SUPPLIERS, but this right does not relieve the SUPPLIER of their obligations under the Contract, nor does it create any contractual relationship between COMPANY and any individual SUB-SUPPLIER.

‘[PSR]’ indicates a mandatory Process Safety Requirement.

For the purpose of this AGES, the following Technical Definitions apply:

Term

SIS System

PFD

Reliability

Technical Definitions

Definition

It is an Electrical / Electronic / Programmable Electronic safety-related System that provides the safeguarding of the process and equipment to protect personnel, assets and environment. It comprises of sensors/transmitters, the final control elements, and the logic solver.

A value that indicates the probability that a device or system will fail to respond to a demand in a specified interval of time.

The probability that when operating under stated environmental conditions, the system will perform continuously, as specified, over a specific time interval.

Fail Safe

The capability to go to a predetermined safe state in the event of a specific malfunction.

Fault-Tolerant System

A system incorporating design features which enable the system to detect and log transient or steady-state fault conditions and take appropriate corrective action while remaining on-line and performing its specified function.

MTTF

MTTR

“Mean Time to Failure” is the expected time to failure of a system in a population of identical systems.

Mean Time to Restore” is the statistical average of time taken to identify and repair a fault (including diagnosis) and restore.

Response Time

Total maximum time required to read all field inputs, program execution and change field output state at I/O card channel level.

Safety Instrumented Function (SIF)

Safety function with a specified safety integrity level which is necessary to achieve functional safety, and which can be either a safety instrumented protection function or a safety instrumented control function.

Safety integrity

Average probability of a safety instrumented system satisfactorily performing the required safety instrumented functions under all the stated conditions within a stated period of time.

Safety Integrity Level (SIL)

Discrete level (one out of four) for specifying the safety integrity requirements of the safety instrumented functions to be allocated to the safety instrumented Systems. Safety integrity level 4 has the highest level of safety integrity; safety integrity level 1 has the lowest.

SIL Validation

SIL Verification

Activity of demonstrating that the safety instrumented function(s) and safety instrumented system(s) under consideration after installation meets in all respects the safety requirements specification.

Activity of demonstrating for each phase of the relevant safety life cycle by analysis and/or tests that, for specific inputs, the outputs meet in all respects the objectives and requirements set for the specific phase.

Watchdog

Combination of diagnostics and an output device (typically a switch) for monitoring the correct operation of PES device and taking action upon detection of an incorrect operation.

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The abbreviations used throughout this specification are shown in Table 1.1

Table 1.1 List of Abbreviations

Abbreviations

ASD

BMS

BOM

CIT

Adjustable Speed Drive

Burner Management System

Bill of Material

Communications interface testing

ECMS

Electrical Control and Monitoring System

ELE

ESD

EWS

FAT

FDS

Safety Earth (also called Plant Earth or Protective Earth or Electrical Earth)

Emergency Shutdown System

Engineering Workstation

Factory Acceptance Test

Functional Design Specification

FMEA

Failure Modes and Effects Analysis

FMEDA

Failure Modes, Effects and Diagnostic Analysis

HART

Highway Addressable Remote Transducer

HAZOP

HAzard and OPerability

HMI

Human Machine Interface

HVAC

Heating, Ventilation and Air Conditioning

ICSS

IES

IFAT

INE

ISE

I/O

LAN

LCD

Integrated Control and Safety System

Instrument Equipment Shelters

Integrated Factory Acceptance Test

Instrument Earth (also called Clean Earth or System Earth)

Ingress Protection

Intrinsically Safe Earth (also called Barrier Earth or Zener Barrier Earth)

Input/Output

Intrinsically Safe

Junction Box

Local Area Network

Liquid Crystal Display

LOPA

Layers of Protection Analysis

MCR

MDR

Main Control Room

Master Document Register

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Abbreviations

MMS

MTBF

MTTF

MTTR

NIS

OEM

OLE

OWS

PCS

PFD

PLC

PVC

Machine Monitoring System

Mean Time Between Failures

Mean Time to Failure

Mean Time to Restore

Non-Intrinsically Safe

Original Equipment Manufacturer

Object Linking & Embedding

Operational Technology

Operator Workstation

Personal Computer

Process Control System

Probability of Failure on Demand

Programme Logic Controller

Polymerization of Vinyl Chloride

RAM

Random Access Memory

RFI

SAT

SCP

SFF

SIF

SIL

SIS

SIT

Radio Frequency Interference

Site Acceptance Test

Supplier Control Panel

Safe Failure Fraction

Safety Instrumented Function

Safety Integrity Level

Safety Instrumented System

Site Installation Test

TCP/IP

Transmission Control Protocol / Internet Protocol

TÜV

UCP

UPS

Technischer Uberwachungs Verein

Unit Control Panel

Uninterruptible Power Supply

Ultraviolet

WAN

Wide Area Network

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SECTION A - GENERAL

REFERENCE DOCUMENTS

International Codes and Standards

The following Codes and Standards shall form a part of this Specification. When an edition date is not indicated for a Code or Standard, the latest edition in force at the time of the contract award shall apply.

AMERICAN PETROLEUM INSTITUTE (API)

API STD 520

API STD 521

API STD 526

API STD 527

API STD 610

API STD 612

API STD 616

API STD 617

API STD 618

API STD 670

API STD 2350

API RP 551

API RP 552

API RP 553

API RP 554

API RP 555

Sizing, Selection, and Installation of Pressure-relieving Devices – All Parts

Pressure-relieving and Depressuring Systems.

Flanged Steel Pressure-relief Valves

Seal Tightness of Pressure Relief Valves

Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries

Petroleum, Petrochemical and Natural Gas Industries-Steam Turbines- Special-purpose Applications

Gas Turbines for Petroleum, Chemical, and Gas Industry Services

Axial and Centrifugal Compressors and Expander-compressor

Reciprocating Compressors for Petroleum, Chemical, and Gas Industry Services

Machinery Protection Systems.

Overfill Prevention for Storage Tanks in Petroleum Facilities

Process Measurement.

Transmission Systems

Refinery Valves and Accessories for Control and Safety Instrumented Systems

Process Control Systems – All Parts

Process Analysers

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B1.20.1

ASME B 16.34

ASME B16.5

Pipe Threads, General Purpose (Inch)

Valves - Flanged, Threaded, and Welding End

Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24 Metric/Inch Standard

ASME B31.3

Process Piping

ASME PTC 19.3 TW

Thermowells Performance Test Codes

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BRITISH STANDARDS (BS)

BS 4800

BS 6121

BS 6739

Schedule of paint colours for building purposes

Mechanical cable glands – All Parts

Code of practice for instrumentation in process control systems: installation design and practice

ENGINEERING EQUIPMENT and MATERIALS USERS ASSOCIATION (EEMUA)

EEMUA Publication 133

Specification for underground armoured cable protected against solvent penetration and corrosive attack.

EEMUA Publication 138

Design and installation of On-line analyser systems.

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 60079

IEC 60092

IEC 60228

IEC 60331

IEC 60332

Electrical apparatus for explosive atmospheres. All Parts.

Electrical installations in ships - All Parts

Conductors of Insulated cables

Tests for Electric Cables under Fire Conditions - Circuit integrity – All Parts

Tests on electric and optical fibre cables under fire conditions.

IEC 60364-4-44

Low-voltage electrical installations - Part 4-44: Protection for safety - Protection against voltage disturbances and electromagnetic disturbances.

IEC 60381

IEC 60382

IEC 60529

IEC 60584

IEC 60684-2

IEC 60754

IEC 60770

IEC 60793

IEC 60794

IEC 60811

IEC 61000

IEC 61010

Analogue signals for process control systems – All Parts

Analogue pneumatic signal for process control systems

Degrees of protection provided by enclosures (IP Code)

Thermocouples - All parts

Flexible Insulating Sleeving Method of Test

Tests on Gases Evolved during Combustion of Materials from Cables - All parts

Transmitters for use in industrial-process control systems - All Parts.

Optical fibres - All parts

Optical fibre cables: Generic specification - All parts

Electrical and Optical Fibre Cables - Test Methods for Non-metallic material

All parts

Electromagnetic Compatibility (EMC) - All Parts

Safety requirements for electrical equipment for measurement, control, and laboratory use – All Parts

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IEC 61034

IEC 61131

IEC 61158

IEC 61280

IEC 61281-1

IEC 61282

IEC 61326

IEC 61508

IEC 61511

IEC 62305

IEC 62444

IEC 62591

IEC 62734

IECEx

Measurement of smoke density of cables burning under defined conditions - All parts

Programmable Controllers – All Parts

Industrial Communication Networks - Fieldbus specifications – All Parts

Fibre optic communication subsystem basic test procedures - All Parts

Fibre optic communication subsystems - Generic specification

Fibre optic communication system design guide - All Parts

Electrical equipment for measurement, control and laboratory use - EMC requirements - All Parts

Functional safety of electrical/electronic/ programmable electronic safety related systems - All Parts

Functional safety - Safety instrumented systems for the process industry sector - All Parts

Protection against lightning - All Parts

Cable glands for electrical installations

Industrial communication networks – Wireless communication network and communication profiles – WirelessHART™.

Industrial networks - Wireless communication network and communication profiles - ISA 100.11a

IEC System for Certification to Standards relating to Equipment for use in Explosive Atmospheres (IECEx System)

INTERNATIONAL SOCIETY OF AUTOMATION (ISA)

ISA 5.1

ISA 5.2

ISA 18.1

ISA 71.04

ISA 84.91.01

ISA RP60.1

ISA RP60.3

Instrument Symbols and Identification

Binary Logic Diagrams for Process Operations

Annunciator Sequences & Specifications

Environmental Conditions for Process Measurement and Control Systems: Airborne Contaminants

Identification and Mechanical Integrity of Safety Controls, Alarms, and Interlocks in the Process Industry

Control Center Facilities

Human Engineering for Control Centers

INTERNATIONAL ORGANISATION FOR STANDARDISATION (ISO)

ISO 9000

ISO 9001

Quality management systems — Fundamentals and vocabulary

Quality Management Systems - Requirements

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ISO 10005

ISO 23251

Quality management — Guidelines for quality plans

Petroleum, Petrochemical and Natural Gas Industries - Pressure Relieving and Depressuring Systems

NATIONAL ASSOCIATION OF CORROSION ENGINEERS

NACE MR0175/ISO 15156

Material for use in H2S containing environments in oil and gas production

NACE MR0103/ISO 17945

Petroleum, petrochemical and natural gas industries — Metallic materials resistant to sulphide stress cracking in corrosive petroleum refining environments.

NORMENARBEITSGEMEINSCHAFT FŰR MESS-UND REGELTECHNIK (NAMUR) NAMUR NE 21

Electromagnetic Compatibility of Equipment for Industrial Processes and Laboratory.

NAMUR NE 43

Standardisation of the Signal Level for the Failure Information of Digital Transmitters.

UNDERWRITER LABORATORIES (UL)

UL 1581

Standard for Safety Reference Standard for Electrical Wires, Cables, and Flexible Cords.

ADNOC Specifications

AGES-GL-02-001

AGES-PH-04-001

AGES-SP-01-001

AGES-SP-01-002

AGES-SP-01-003

AGES-SP-01-004

AGES-SP-04-002

AGES-SP-04-005

AGES-SP-04-006

AGES-SP-05-006

AGES-SP-07-003

AGES-SP-07-004

AGES-SP-13-001

AGES-SP-04-007

Electrical Engineering Design Guide

Automation and Instrumentation Design Philosophy

Concrete Supply and Construction Specification

Structural Steel Supply, Fabrication and Erection Specification

Structural Design Basis - Onshore Specification

Anchor Bolt and Grouting Specification

Control Valve Specification

Emergency Shutdown and On Off Valves Specification

Instrument and Control Cables Specification

Rotating Equipment Minimum General Requirements and System Integration Specification

Requirements for Materials in Severe Service

Painting and Coating Specification

Criticality Rating Specification

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DOCUMENT PRECEDENCE

The specifications and codes referred to in this specification shall, unless stated otherwise, be the latest approved issue at the time of contract award.

It shall be the CONTRACTOR’s responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.

The CONTRACTOR shall notify the COMPANY of any apparent conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein.

Resolution and/or interpretation precedence shall be obtained from the COMPANY in writing before proceeding with the design/manufacture.

In case of conflict, the order of document precedence shall be:

UAE Statutory requirements

ADNOC HSE Standards

Equipment datasheets and drawings

Project Specifications and standard drawings

COMPANY Specifications

National / International Standards

SPECIFICATION DEVIATION / CONCESSION CONTROL

Deviations from this specification are only acceptable where the SUPPLIER has listed in their quotation the requirements he cannot, or does not wish to comply with, and the COMPANY / CONTRACTOR has accepted in writing the deviations before the order is placed.

In the absence of a list of deviations, it will be assumed that the SUPPLIER complies fully with this specification.

Any technical deviations to the Purchase Order and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be sought by the SUPPLIER only through Concession Request Format. Concession requests require CONTRACTOR’s and COMPANY’s review / approval, prior to the proposed technical changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.

DESIGN CONSIDERATIONS / MINIMUM DESIGN REQUIREMENTS

Design Basis

Package equipment instrumentation and installation shall comply with the requirements identified within this specification, AGES-PH-04-001 Automation and Instrumentation Design Philosophy and standards and specifications referred within these documents.

SUPPLIER package equipment instrumentation systems, materials and installation design shall be performed in accordance with all statutory requirements of facilities, using the codes of practice, guidance notes and other standards, specifications and technical practices defined within this specification and sound engineering practice.

In general, the design and selection of package equipment instrumentation systems shall consider the following:

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To ensure that the instrumentation provided by the Packaged Equipment SUPPLIER conforms to the

instrumentation design philosophy of the project.

To provide instrument standardisation across the project facility, including the same instrument type,

model and manufacturers as used on the main project units.

To ensure that information on instrumentation items is readily available to all CONTRACTOR’s design

departments.

Instrument range, pressure rating.

Materials of construction based on fluid properties, operating conditions, and mechanical design

constraints.

Application suitability, reliability, maintainability, quality, accuracy, and repeatability.

Safety of personnel and equipment during installation, operation, and maintenance.

Compatibility with the site environment.

System integrity and reliability of hardware and software.

Maximum availability of critical equipment.

Compatibility with existing instrumentation and systems.

Ease of installation, inspection, maintenance, and operation.

Minimise instrument spares and improve availability.

Availability of spares.

Flexibility of use.

Life Cycle.

CONTRACTOR/SUPPLIER’s design shall reflect the highest standards of safety, reliability, operability and maintainability of its equipment and components, consistent with the most advanced proven technological features.

This specification shall always be read in conjunction with the relevant equipment specifications, and/or Project specifications associated with the supply of equipment packages, in order to provide the instrument and controls functional and operational requirements.

SUPPLIER shall review the CONTRACTOR’s P&IDs, control and protection systems for start-up, normal and emergency shutdowns, operating conditions, anti-surge and reverse rotation protection, over-pressure protection, differential pressure protection, and confirm compatibility with SUPPLIER’s furnished control equipment.

Packaged equipment control shall be fully integrated with the plant Integrated Control and Safety System (ICSS). The plant ICSS shall be able to start / stop and receive all alarms / trip signals generated by the package equipment control system or machinery monitoring system.

SUPPLIER shall provide technical assistance to CONTRACTOR in defining control, shutdown, and logic requirements to be incorporated in CONTRACTOR’s control and emergency shutdown (ESD) system.

SUPPLIER shall provide or arrange to provide all required assistance during installation, testing and commissioning activities.

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Design Parameters

All Instrumentation provided by the package equipment SUPPLIER shall conform to the design parameters contained within this specification and associated standards.

SUPPLIER shall only use instruments that are approved by COMPANY and any deviations shall require COMPANY approval.

The Packaged Equipment SUPPLIER shall be responsible as a minimum for the selection of the proper range, pressure rating, materials of construction based on fluid properties, operating conditions, and mechanical design constraints for all instruments contained within the package equipment.

Environmental / Site Data

5.3.1

General

SUPPLIER shall ensure that all package equipment instrumentation and equipment including local panels, junction boxes, UCP/SCPs, cables and instrument accessories shall be designed for continuous operation within the environmental conditions identified in Sections 5.3.2 and 0 and purchase order data sheets. Any discrepancy between documents should be highlighted by SUPPLIER to COMPANY for decision.

SUPPLIER shall ensure that all Offshore and coastal area equipment shall also be suitable for installation in saliferous, marine and corrosive environment combined with high temperature and humidity.

Marine exposure shall be considered for all plants. In addition, islands, or other locations with sea prevailing winds, shall also take marine exposure into consideration. The protection against corrosion shall include special treatment and coating of all exposed surfaces and the use of corrosion resistant materials and protective housings against corrosive dust and fog.

5.3.2

Indoor Conditions

The systems installed indoors shall be suitable for an air-conditioned environment to ISA 71.04, G3 classification. Normal indoor operating conditions shall be as per Table 5.1 below, unless otherwise stated by COMPANY:

Table 5.1 Indoor Environmental / Site Conditions

Environmental Condition

Values

Temperature

Normal operating Temperature

22 °C ± 2 °C

During HVAC upset conditions (See Note 1)

Between 0 ºC to 55 ºC

Relative Humidity

Normal operating Relative Humidity

50 %

During HVAC upset conditions (See Note 2)

between 5 % and 95 %

Notes:

The system shall continue to operate during HVAC upset conditions, during which the indoor

location of installation temperature can range between 0 ºC to 55 ºC.

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1. The relative humidity can vary between 5 % and 95 % non-condensing during HVAC upset

conditions.

Instrument Equipment Shelters (IES) will be air-conditioned and pressurized with air locks.

5.3.3

Outdoor Conditions

In the field, only gauges, transmitters, switches, positioners, transducers, field mounted analysers are permitted, although the use of switches shall be avoided and require COMPANY approval.

All Integrated Control and Safety System cabinets and/or Package Control System Cabinets, shall be installed by CONTRACTOR in climate controlled indoor locations.

Local panels near package equipment shall have only gauges, push buttons, lamps, etc. and all other system components (I/O modules, controllers, monitors etc) shall be located within adjacent functionally relevant IES.

The installation of sensitive electronic components within outdoor panels / use of Smart JBs/panel containing Remote I/Os shall be subject to COMPANY approval.

All instrumentation and equipment mounted inside local panels shall be selected and/or protected so that they function correctly under the project environmental conditions. Consideration shall be given to any temperature rise caused by equipment heat dissipation and/or direct sunshine. Wherever local electronic panels are used, suitable air conditioned (dual air-conditioners rated for the hazardous area classification) panels shall be used.

All outdoor electrical and instrument equipment shall be provided with individual sunshade and installation in direct sun shall be avoided. Where installation in direct sun is unavoidable, it shall be designed for maximum metal surface temperature conditions of 87 °C. All non-metallic materials in direct sunlight shall be UV stabilised.

Refer Section 18.10 for further details of the sunshade technical requirements.

The instruments and accessories shall perform to their design specifications as per the climatic conditions given in Table 5.2.

Table 5.2 Outdoor Environmental / Site Conditions

Environmental Condition

Temperature

Maximum Temperature in shade

Maximum solar metal Temperature in the sun

Minimum ambient Temperature

Relative Humidity

Maximum (at 43° C)

Average (at 28° C)

Design

Notes:

Values

54 °C

87 °C

5 °C

95 %

60 %

100 %

Rainfall is infrequent but may occur with winds of up to 175 m/sec.

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2. Sandstorms are frequent and dust adheres to all exposed surfaces. Heavy salty dews are

frequent.

In general, the environment for outdoor installations shall be considered as high temperatures, high humidity, salty, sulphurous, dusty, and corrosive. Cables shall be suitable for installation and operation over the full range of ambient temperature and humidity specified in the data sheets and in an environment containing trace amount of H2S, CO2 (sour and corrosive atmosphere) and HC gases.

Cables exposed to direct sunlight (outdoor above ground) shall be manufactured using the best suitable UV stabilizers which enables the long life without stress cracking suited to Middle East Environment Conditions. Cables resistance to UV shall meet requirements of UL 1581 art. 1200.

All outdoor cables installed within cable tray or ladder shall be protected by covers.

Note that maximum and minimum temperatures are 58 °C in shade and 4 °C respectively for certain Onshore sites.

Area Classification

All instrument equipment shall be suitable for the area classification, gas grouping, and temperature classes specified within the project area classification drawings. All field instruments installed in both hazardous and non- hazardous areas within the process facility battery limits shall, as a minimum, be certified for operation within a Zone 1, Gas group IIB and ignition Temperature class T3 as per IEC 60079.

All instrument equipment located in a hazardous and safe areas shall fully comply with Section 7.4.12 and IEC 60079.

Minimum Design Requirements

Instrument equipment, including accessories, shall be designed, manufactured, tested, transported and installed to achieve a minimum life duration of 15 years with cabling designed for a life of 30 years to allow for at least one major upgrade of the control and instrumentation systems over the design life of the asset.

All instrumentation shall be of the same make, model and type as chosen for the project main plant facilities. SUPPLIER shall obtain this information from the CONTRACTOR. Any deviation to this shall require COMPANY approval.

Standardisation

All package equipment instrumentation shall be chosen from the same manufacturer and models used within the main project plant facilities to minimise spares, instrument types, and simplify the maintenance operations. SUPPLIER shall obtain this information from the CONTRACTOR. Any deviation to this shall require COMPANY approval.

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SECTION B – TECHNICAL REQUIREMENTS

PROCESS SAFETY REQUIREMENTS

Where listed within this specification, the capitalised term shall [PSR] indicates a process safety requirement.

Sr.No. Description

ESD/SIS Logic Solver shall be highly reliable and certified for safety integrity level of SIL3 as per IEC 61508 and IEC 61511.

ESD/SIS Logic Solver hardware architecture shall be redundant and fault tolerant to provide availability of 99.99 %.

ESD digital output fail-safe state shall be the ‘de-energized’ unless otherwise specified. ESD digital output shall go to a “0” (deenergized) state on shutdown conditions, power failure and on component failure.

CONTRACTOR shall carry a Functional Safety Assessment (FSA) as per IEC 61511-1 clause 5.2.6.1.5 prior to the hazards that the SIF are designed to prevent.

A detailed safety integrity assessment review to establish SIF integrity targets (SIL) shall be completed by CONTRACTOR during FEED and Detailed Design engineering phase.

Once the data is available from selected instrument models, SIL validation reports are to be produced by CONTRACTOR using certified personnel based on the results of the SIL study, demonstrating that the safety instrumented function(s) (SIF)s and safety instrumented system(s) (SIS)s under consideration meet in all respects the safety requirements specification (SRS).

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SECTION B PART I

DESIGN REQUIREMENTS

General

Package equipment design shall be based on the operational requirements and criticality/complexity of the equipment. The primary strategy shall be to protect all packaged equipment against the equipment operating outside of its integrity and performance design envelope.

The Packaged Unit SUPPLIER shall furnish all instrumentation that forms an integral part of the equipment or package to enable the Packaged Units to be operated unattended in a “Fail Safe” manner. This shall include all instruments, controls, interlocks, and shutdown devices as detailed within this document and the equipment specifications. Fire and Gas design for packages shall be as per Corporate HSE Philosophy.

All packaged equipment instrumentation shall comply with:

API RP 551, 552, 553, 554 and 555.

Specifications and standards listed in this document.

Local statutory codes/regulations.

International codes and standards.

Instrumentation and control equipment installed as part of SUPPLIER packages shall be in compliance with the project standards, specifications, philosophies, and standardization. Any deviation shall be listed in the quotation and require COMPANY approval.

The Packaged Unit SUPPLIER shall provide engineering and design for the instrumentation, control, and safety systems for the Packaged Unit. This shall include specifications, data sheets, loop drawings, Cause and Effects, Logic diagram, control narrative etc. and drawings for instruments in the scope of supply and information as required by the CONTRACTOR for the supply of integrated controls.

SUPPLIER shall be responsible for the selection of the required instrumentation to be installed within the package equipment.

The SUPPLIER shall be responsible for co-operating with the selected or existing ICSS SUPPLIER to have package unit control systems implemented within the ICSS (PCS, ESD, and F&G) without any change in the equipment warranty and/or performance requirements. SUPPLIER shall participate in factory testing as required and coordinated by CONTRACTOR.

The Packaged Unit SUPPLIER shall use CONTRACTOR’s specifications, standards, typical hook-ups, and drawings. Formats of these will be provided during Project execution as well as paper copy and electronic media. The same also applies to design instructions.

Package Unit SUPPLIER shall be responsible for reviewing and modifying any typical schemes provided by CONTRACTOR, in order to ensure that the package equipment provided by the SUPPLIER is safe and operable. Any such proposed modification shall be submitted to COMPANY for approval.

The Packaged Unit SUPPLIER shall be responsible for the completed equipment package and for any correction required for a safe and operable unit.

Package Unit SUPPLIER supervision of instrument and control system installation, pre-commissioning, commissioning, and start-up is a requirement for the project.

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SUPPLIER shall refer to AGES-PH-04-001 for the life cycle requirements, total cost of ownership and long-term maintenance agreements.

Instrument Equipment Package Types

7.2.1

General

Instrument equipment packages shall be defined into the following three types, as per Table 7.1 Instrument Packaged Equipment Types, according to the package equipment complexity and instrument scope:

Package Equipment Type

Table 7.1 Instrument Packaged Equipment Types

Description

Package fully integrated into ICSS for Control and Monitoring, no ICSS equipment within SUPPLIER’s cabinets.

Package fully integrated into ICSS for Control and Monitoring, ICSS nodes in SCPs located in remote IES.

Typical Arrangement Drawing

Appendix 1A

Appendix 1B

Complex package with PLC control within SUPPLIER UCPs located in remote IES

Appendix 1C

SUPPLIER shall refer to the following sections for further details regarding instrument package equipment types A, B and C. SUPPLIER shall also refer to the typical arrangement drawings contained within Appendix A1 for each of the instrument packaged equipment types.

Optimizing the use of ICSS (PCS, ESD, and F&G) for package controls shall be considered as a requirement. To minimise lifecycle cost, the requirement is to integrate as many of the packages (including rotary packages) into the ICSS (Type A) with the priority being for Type B if Type A cannot be met, followed by Type C if the criteria for the two other types cannot be met.

SUPPLIER / CONTRACTOR shall seek COMPANY approval for package category selection.

SUPPLIER shall refer to Section 22 and Appendices 2A, 2B and 2C for the scope of supply for instrument packaged equipment types A, B and C. SUPPLIER shall also refer to Section 22 and Appendixes 3A, 3B and 3C for the scope of engineering for instrument packaged equipment types A, B and C.

7.2.2

Package Equipment Type A - Fully integrated into ICSS for Control and Monitoring, no ICSS equipment within SUPPLIER’s cabinets.

Package equipment type A shall be fully integrated within the plant ICSS, as shown in Appendix 1A, and summarised below:

Package equipment type A is fully integrated into the ICSS (PCS, ESD, and F&G) with all control, monitoring and shutdown functions carried out within the ICSS, with no additional SUPPLIER PLC installed.

Control, monitoring, and shutdown hardware resides within the ICSS cabinets outside of the package

equipment scope.

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Field Instruments within the package equipment battery limit shall be wired and terminated into junction boxes located at the package equipment skid edge boundary. Note: Skid edge boundary junction boxes may not be required for some of the small packages with a limited number of field instruments, and this shall be confirmed with CONTRACTOR / COMPANY.

All cabling between package equipment skid edge Junction boxes to ICSS Marshalling Cabinets shall be by the CONTRACTOR. If skid edge boundary junction boxes are not required, CONTRACTOR shall install cables directly from the field instruments back to the ICSS.

For Machinery Monitoring, field devices such as sensors, probes shall be supplied and installed by SUPPLIER. CONTRACTOR shall supply and install Machine Monitoring System (cabinet with monitors, servers, etc).

SUPPLIER shall provide all sequence control and safety interlock logic for operation and protection of

the package equipment.

ICSS shall control and monitor status of electrical devices (such as motors, heaters etc.) via dual redundant data link with Electrical Switchgear / ASD. For critical control applications requirement of hardwired signals instead of using data link to be decided on case by case basis. The trips shall be hardwired from ESD.

For hardwired signals between Electrical Switchgear / ASD and plant ICSS where required, an interposing relay shall be used for safe isolation of different voltage levels. Use of an interposing relay shall take SIL requirements into account.

The BMS shall be designed and engineered to the same level of integrity as the ESD system.

7.2.3

Package Equipment Type B - Fully integrated into ICSS for Control and Monitoring, ICSS nodes in SCPs located in remote IES.

Package equipment type B shall be fully integrated within the plant ICSS with ICSS nodes installed within Control Panels supplied by SUPPLIER (SCPs) located in a remote IES. Package equipment type B arrangement is shown in Appendix 1B and summarised below:

Package equipment type B is fully integrated into the ICSS (PCS, ESD, and F&G).

Package equipment control, monitoring and shutdown ICSS controllers and associated I/O modules and termination shall be installed in Supplier Control Panels (SCPs). The ICSS controllers shall be nodes in the plant ICSS network and supplied as part of the package equipment. The make, model, and design of Package ICSS nodes shall be identical to the Plant ICSS in all aspect.

SCPs cabinets shall be installed within a remote climate-controlled Instrument Equipment Shelter by

CONTRACTOR.

Where specified, anti-surge and performance control system shall be provided.

Where specified, Electrical load shedding shall be carried out within the ECMS.

SUPPLIER shall supply fully configured ICSS controllers installed in SCPs for integration with overall

plant ICSS.

For rotating equipment packages, where specified, a Machinery Monitoring System shall be provided. The MMS may be installed on the package equipment skid if approved by COMPANY or located within the remote Instrument Equipment Shelter.

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SUPPLIER shall provide a Gas Turbine Control System (GTCS) for control of all turbine, associated process compressor related equipment and auxiliaries. SUPPLER shall refer to Section 14 for further technical requirements.

Field Instruments within the package equipment battery limit shall be wired and terminated into junction

boxes located at the package equipment skid edge boundary.

All cabling between package equipment skid edge Junction boxes to the remote IES SCPs shall be by

CONTRACTOR.

SUPPLIER shall provide all sequence control and safety interlock logic for operation and protection of

the package equipment.

The BMS shall be designed and engineered to the same level of integrity as the ESD system.

7.2.4

Package Equipment Type C - Complex package with PLC control within SUPPLIER UCPs located in remote IES

Package equipment type C packages shall be complex packages with SUPPLIER standard PLC control, monitoring and shutdown hardware located within UCPs. SUPPLIER UCPs shall be fully compatible with the plant ICSS (PCS, ESD, and F&G).

Package equipment type C arrangement is shown in Appendix 1C and summarised below:

Dedicated PLC(s) for packaged equipment control, monitoring and shutdown shall be provided by

SUPPLIER where the ICSS cannot accommodate the control requirements.

SUPPLIER Package equipment hardware shall be fully compatible and interface with the ICSS for control, monitoring and shutdown. Package ESD and F&G system shall as a minimum be certified SIL 3. Make, model of PLC shall be approved by COMPANY as part of standardization requirement.

All interfaces between UCP and Plant ESD/F&G system shall be hardwired. All monitoring signals from

the UCP shall interface with the Plant PCS using redundant communication link.

SUPPLIER UCP cabinets shall be installed within a remote climate-controlled Instrument Equipment

Shelter by CONTRACTOR.

Where specified, Electrical load shedding shall be carried out within the Electrical ECMS.

Field Instruments within the package equipment battery limit shall be wired and terminated into junction

boxes located at the package equipment skid edge boundary.

All cabling between package equipment skid edge Junction boxes to the remote IES UCPs shall be by

CONTRACTOR.

SUPPLIER shall provide all sequence control and safety interlock logic for operation and protection of

the package equipment.

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Packaged equipment PLC(s) shall use hardwired control signals to Electrical Switchgear / ASD for commands and feedback. ICSS shall monitor status of electrical devices (such as motors, heaters etc.) via dual redundant data link from Electrical Switchgear / ASD. The trips shall be hardwired from ESD.

The BMS shall be designed and engineered to the same level of integrity as the ESD system.

Control System

7.3.1

General

All Packaged equipment operation, control and ESD safeguarding functionality shall be implemented within the Plant Integrated Control and Safety System for Package Types A and B, which comprises the PCS, ESD and Fire & Gas systems.

Turbine governor control systems shall be of SUPPLIER / OEM standard. Fire & Gas system, Machine Monitoring system, Performance / Anti-Surge and Load Sharing system controllers shall be stand-alone with redundant data communication with the Plant ICSS.

Operator intervention to control the equipment shall be kept to a minimum by maximizing automatic controls with the necessary safety features.

For compressors and machinery where instrumentation and sensors are performing a safeguarding function, the SIS logic solver shall interface with the machinery controller hardware for process related trips and start permissives.

Package control system shall be integrated in the ICSS for operation and monitoring. For interface requirements refer Section 21.13.

Control, MMS and ESD functions that are not implemented within the ICSS shall be synchronized with the plant GPS time synchronized system.

All S/W and H/W diagnostic alarms shall be available in ICSS including all required monitoring graphic pages.

7.3.2

Technical Requirements

All rotating equipment, suction, discharge pressure, temperature and flow measurement transmitters shall be provided with indication to the ICSS, for operation and performance monitoring purposes. Local indication with gauges alone is not acceptable without prior COMPANY approval.

Each rotating equipment system shall be designed such that a trip of upstream and/or downstream equipment will not create unsafe trip conditions for the rotating equipment.

Irrespective of the position of any switch at any location, the remote stop shall be effective wherever triggered.

7.3.3

Proprietary Equipment

Proprietary equipment items shall be identified within the SUPPLIER’s proposal for COMPANY review. The extent to which proprietary items conform to this specification and other referenced specifications shall be subject to COMPANY approval during the proposal evaluation period.

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Proprietary equipment items that do not conform to the requirements of this specification and associated standards, shall require the SUPPLIER to demonstrate that these proprietary items are of equivalent standard and are proven in similar applications.

7.3.4

Proven Design

Instrument package equipment materials and components shall be of the latest field proven design and in current production. SUPPLIER shall not use any unproven designs, materials, or components without COMPANY approval.

7.3.5

Cyber Security

SUPPLIER shall refer to AGES-PH-04-001 for Cyber Security (OT Security) technical requirements.

7.3.6

Time synchronization

A GPS based time synchronization system shall be provided in the Control Rooms and IES to synchronise the ICSS and various sub-systems including Package Equipment Control Systems for time stamping of alarms and events. GPS time synchronisation shall be applied across the whole network and systems so that all alarms and events are time and date stamped at the point of entry into the system, whether that is the ICSS, package or third-party system so that alarm and events can be chronologically synchronised. The time synchronization signal shall be taken from ICSS network and SUPPLIER shall ensure that the system components remains synchronized with the rest of the plant. Time synchronization shall be based on Simple Network Time Protocol (SNTP) whilst meeting OT security requirement.

All third-party systems shall accept time synchronization from the network or a signal provided by ICSS Supplier.

Design Considerations

7.4.1

Selection of Instruments

The preferred method of protection for instruments installed in either hazardous areas or safe areas shall be intrinsically safe (Ex i). The use of flameproof or increased safety instruments shall be avoided and subject to COMPANY approval, as specified in Section 7.4.12.3.

Transmitters shall be ‘Smart’ type, unless specified otherwise by COMPANY. ‘Smart’ transmitters shall be based on 4-20 mA DC with the latest version of the HART Protocol. Exceptional cases such as ESD and anti-surge applications shall be reviewed on a case by case basis as the response time to convert the signal makes the instrument too slow to respond in certain applications.

Transmitters used for PCS can use Foundation Fieldbus where approved by COMPANY.

All HART/FF instruments shall be integrated with Instrument Asset Management System. Refer AGES-PH-04-001 for details.

In general, the package equipment process instrumentation and control system, shall be based on an Integrated Control and Safety System located in air-conditioned pressurized rack and control rooms, and shall be used in conjunction with ‘Smart’ type electronic transmitters and Positioners. Critical loops shall be defined carefully and redundancy up to field equipment shall be considered for high safety and reliability.

All instruments and instrument systems shall be designed to facilitate first level instrument maintenance and testing. Instrumentation shall be suitable for the process and environmental conditions and designed to cover all operating modes such as start-up/shutdown/emergency operation and pressure relief conditions.

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Electronic Transmitters shall be used for all measurements including alarm and trip service, use of process switches shall be avoided. Where standard mechanical package design includes process switches, COMPANY approval for their use shall be obtained.

Diaphragm seal instruments shall be used on pressure and level instruments in sour service applications. When necessary to prevent corrosive or solids bearing fluids from entering instruments or instrument lines, seals or purges shall be provided. Where diaphragm type seals are most applicable, they shall be given first consideration. Seals or purges should be used in place of heat tracing

Transmitters shall be SIL certified based on the requirements of applicable SIL classification.

Transmitters shall include diagnostics covering sensor, impulse pipework, and electronics and the ICSS I/O module configuration shall comply with NAMUR NE43 (Standardization of the signal level for the breakdown information of digital transmitters) requirements.

SUPPLIER shall ensure that all package equipment field instruments are compatible with the Intrinsically Safe (IS) barriers. SUPPLIER shall submit the list of compatible instrument barriers to CONTRACTOR, when required to do so for Intrinsic Safety (IS) calculations when they form part of the ICSS IS loop.

Use of local pneumatic control loops shall be subject to COMPANY approval.

All instrument tubing and fittings used on sour service shall be certified to metallurgical requirements of NACE MR 0175/ISO 15156 or NACE MR0103/ISO 17945 and in accordance with AGES-SP-07-003.

All tube fittings shall be double compression type and SUPPLIER shall refer to AGES-PH-04-001 for Instrument Tubing, Fittings and Valves for use in Sour Service environments.

Unless otherwise specified, the instrument ranges shall be selected such that the normal value will be between 50 and 75 % of scale range taking into account the specified minimum and maximum values. Additional instruments may become necessary for normal minimum and maximum values. In these cases, a single scale and auto-ranging facility shall be provided in the ICSS. Trip setting shall be between 20 % to 80 % of calibrated range.

For Instruments in ESD Service and for special applications (e.g. Compressor interstage flow measurement for Anti-Surge application), a common tapping shall not be used. The exception is for 2oo3 flow measurement using an Orifice assembly where a common tapping is used for multiple DP transmitters, with provision for individual Transmitter isolation and maintenance.

All selected instruments shall have local UAE support for maintenance, spares, testing, training etc.

7.4.2

Scales and Indicators

SUPPLIER shall use the Instrument scales and indicators as defined in Table 7.2 below:

Table 7.2 Instrument Scales and Indicators

Variable

Temperature

Pressure

Flow (Differential)

Scale

Direct Reading

Direct Reading with square root extraction in Control System.

Flow (Linearized)

Direct Reading

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Variable

Level

Analyzer

Signal to Valves

Notes:

Scale

0-100 % Linear

Direct Reading

0-100 %

Local scales for Flow, Pressure, Temperature and Analysers shall be in engineering units and

Level scales shall be in “percent“ units unless otherwise specified.

7.4.3

Instrument Accuracy and Range

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for the Instrument accuracy and range requirements.

For the machinery monitoring system accuracy requirements shall be as per API STD 670 Table 1.

All instruments shall be installed so that accuracy, reliability, or maintainability shall not be impaired due to vibration, pulsation, temperature, contamination, or location.

For Instruments associated with Metering system package, licensor packages and other critical packages, accuracy requirement specified in relevant project specification shall be referred for more stringent accuracy requirement.

7.4.4

Electromagnetic Compatibility (EMC)

General

SUPPLIER shall confirm compliance with Radio Frequency Interference (RFI) and Electromagnetic Compatibility (EMC) during the Factory Acceptance Test (FAT), Site Acceptance Test (SAT) and repeated at the site during commissioning in equipment rooms, switch rooms and control rooms.

Radio Frequency Interference

Unless otherwise specified by the COMPANY, with reference IEC 61000-4-3 and IEC 60364-4-44, for portable radio transmitters/receivers which have an electromagnetic field strength of 10 mV in the frequency range between 20 to 1000 MHz, the total effect of the radio frequency interference shall be equal to or less than +/-0.1 % of the output span with the instrument enclosure (cover) in place, and equal to or less than +/-0.5 % of the output span with the instrument enclosure (cover) removed.

Electromagnetic Compatibility

All instrumentation, junction boxes and system equipment containing electronics shall satisfy the requirements of EMC immunity and emissions in accordance to IEC 61000-6-2, IEC 61326, NAMUR NE 21, and European EMC Directive 2004/108/EC.

For further Electromagnetic Compatibility requirements SUPPLIER shall refer to AGES-PH-04-001.

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7.4.5

Burn-in Test

SUPPLIER shall carry out a burn-in test by operating a system for an extended period to detect any problems. The burn-in test shall be conducted to ensure that a device or system functions properly before being shipped from the SUPPLIER facility and ensures the COMPANY that the equipment is functioning properly. Burn-in test duration shall be 72 hours or manufacturer standard duration whichever is higher.

An end user may use a burn-in process to ensure that new equipment is functioning properly, for example, running a new computer for several days before committing it to serious use. If any of the components are defective the problem will usually show up within this initial testing time frame.

7.4.6

Design for Maintainability

The package equipment design shall include provision for full replacement / component replacement with minimum disruption to the plant operations. This shall include all configuration software packages/hardware platforms required to view, interrogate, and modify the Packaged Equipment software (e.g. Application Software, System Software, Source code, Operating systems, etc.).

Instruments shall be installed to ensure that they can be easily maintained or replaced without the need to modify any existing equipment. The package design shall allow for all aspects of the removal and replacement of instrumentation without the need for further plant shutdown or system de-pressurisation.

7.4.7

Instrument Signal Types

General

SUPPLIER shall implement conventional instrument signal types. as per Section 7.4.7.2, unless instructed otherwise by COMPANY for the use of Foundation Fieldbus or Wireless instrumentation.

All software and firmware configurations within all instrumentation shall be “lockable” or have the ability to disable remote modifications. All Safety related instrumentation shall have local protection for remote write functions.

Conventional Instrument Signals

Instrument signal types shall be as follows:

Analogue signals shall be 4-20 mA, 24 VDC conforming to IEC 60381 and IEC 60382 and NAMUR NE

Sensors/transmitters shall be ‘Smart’ type with a communication protocol based on latest HART standard.

Valve electro-positioners shall be ‘Smart’ type with a communication protocol based on latest HART

standard.

Discrete digital signals shall be 24 VDC nominal.

Switches shall be avoided and used only with COMPANY approval.

Fire and gas detectors shall be analogue ‘Smart’ type with a communication protocol based on HART

standard.

Independent sensing instrumentation / transmitters shall be provided for Safety and Control / Monitoring for the same process measurement, and these transmitters shall be specified with the same range and span, with fully independent process connections using separate tappings and located close together to allow comparison of measurements on vessels, equipment or line. Level transmitter tapping points shall be at the same elevation. The transmitters shall continuously cross check and alarm if a transmitter deviates.

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Foundation Fieldbus

SUPPLIER shall only implement Foundation Fieldbus instrument signal types, after approval from COMPANY. SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for further Foundation Fieldbus Instrument requirements.

Wireless Instruments

SUPPLIER shall only implement Wireless Instrument signal types with prior approval from COMPANY.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed Wireless Instrumentation selection and requirements.

Pneumatic Instruments

Electronic transmitters shall be used for all monitoring, control or shutdown service and Pneumatic instruments shall require COMPANY approval.

7.4.8

Diaphragm Seals

Diaphragm Seal shall normally be integral with the instrument. The application of diaphragm seals with capillary extensions shall be kept to an absolute minimum.

Special attention shall be paid to diaphragm seals on low differential pressure and pressure applications.

Applications of diaphragm seals with capillary extensions require the written approval of the COMPANY.

When a diaphragm seal is required, the largest practical size should be applied as specified in the data sheet. Special coating materials may be considered where these will improve the corrosion resistance of the diaphragm.

The capillary tubing material shall be of 316 type stainless steel and be shielded by flexible stainless-steel tubing, according to MANUFACTURER’s standard.

The length of capillary tubing shall suit the application, but the length should be at least 1.0 metre. For differential pressure applications the capillary tubing shall be the same length.

Refer AGES-PH-04-001 Automation and Instrumentation Design Philosophy for further technical requirements for diaphragm seal.

7.4.9

Electrical Utility Data

Electrical power supply feeds are available from the following sources:

Two independent separate power feeds from separate UPS sources to provide secure power. The two 240VAC UPS feeders shall not be paralleled unless converted to DC via AC/DC converters to one common DC distribution bus.

One feed from the Utility power supply for powering equipment not requiring secure power.

As the ICSS and instrumentation always needs to remain available, the ICSS and instrumentation will be powered from option a. above.

Electrical voltage level, frequency and tolerances shall follow AGES-GL-02-001 Electrical Engineering Design Guide and are identified below:

240 VAC, Single Phase, 50 Hz, earthed.

Steady state Voltage variation ± 5 % nominal voltage.

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Steady state Frequency variation ± 2 %.

The SUPPLIER shall provide a complete detailed power supply system to meet the needs of their own equipment as well as the needs of the field devices. Spare capacity shall be provided to accommodate fully loaded cabinets. The SUPPLIER power supplies shall receive power from UPS systems provided by the CONTRACTOR.

7.4.10 Summary of utility data including air supply, etc.

Instrument utility requirements are identified below:

Instrument Air Supply:

min = 5.5 barg, normal = 7 barg, max = 10 barg,

Water dew point -20 °C at 7.5 barg

Pneumatic signals: 3 –15 psig (0.2 – 1 barg).

Instrument air required for operation of pneumatic instrumentation on a single skid or geographically split multiple skid-based packages shall be provided on each skid at a single location with flanged ends by CONTRACTOR. Further distribution shall be the responsibility of SUPPLIER.

Where several instruments are grouped together, then standardized instrument air manifold (e.g. 12-way, 6-way) shall be used for instrument air distribution. These air manifolds shall be stainless steel with individual ball valves for feeder clearly identified to prevent inadvertent shut off the supply to the wrong user. Air distribution from these manifolds shall be via 12 mm or 20 mm tubing using compression fittings and refer to AGES-PH-04-001 for the tubing and fitting material.

For large skid requirements (air header size requirement higher than 50 mm or 2 in.), SUPPLIER shall install a secondary pressure control and a master filter system at the package battery limit.

7.4.11 Seismic Requirements

The system shall be designed to operate in the presence of a sinusoidal vibration of 2g at 10 - 500 Hz and withstand a shock of 15g for 11 milliseconds.

7.4.12 Hazardous Area Protection

Instrumentation in hazardous areas shall be certified by IECEx or equivalent recognised certifying body. The IECEx directive requires that a register is held of all IECEx certified equipment installed on the facilities and that the equipment is certified to the IECEx 02 scheme in conformance to IEC 60079.

For the UAE, Ex certified equipment also requires an Emirates Conformity Assessment System (ECAS) Ex Certificate of Conformity (CoC) issued by a notified body. Requirement for the ECAS Ex programme utilizes IEC Standards, and qualification of conformity is met by meeting the requirements of the IECEx scheme in full, including mandatory factory site Quality Assessment Reports (QARs).

All field instruments installed in both hazardous and non-hazardous areas within the process facility battery limits shall, as a minimum, be certified for operation within a Zone 1, Gas group IIB and ignition Temperature class T3 as per IEC 60079.

For instrumentation installed in hazardous area, Ex ia or ib (Intrinsically Safe) design is the preferred method for hazardous area protection. The use of flameproof or increased safety instruments shall be avoided except for solenoid valves which should be certified Ex db (Flame Proof) or Ex mb eb (combined encapsulation and increased safety), operating on 24 VDC with maximum power consumption, of 12 W. Ex ia or Ex ib solenoid

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valves shall not be permitted. Use of Ex ia or ib (Intrinsically Safe) solenoid valves is subject to COMPANY approval.

Unless otherwise specified, all system and marshalling cabinets shall be installed within a general purpose, non- classified area.

Equipment located in certified Hazardous Area enclosures shall comply with maximum ambient conditions for continuous operation.

All personnel designing, installing, and inspecting instrumentation are required to demonstrate hazardous area competency.

Hazardous Areas

The Hazardous Area is defined by hazardous area classification drawings and associated documentation developed by HSE.

Hazardous Area Installation

Each electrical instrument or system to be installed in hazardous area shall be built according to IEC 60079 recommendations and corresponding national translations and publications.

The local regulations shall have precedence if they are more stringent than the international corresponding code. For each concerned type of instrument or instrument system, the CONTRACTOR shall obtain from the SUPPLIERs (prior to issue purchase order) a copy of the certificate of conformity to the standards delivered by a certified notified body. ECAS certification will be required for equipment used in the UAE.

For all instrumentation and systems to be installed in hazardous areas, the hazardous area certification shall be as per IECEx and certification requirements.

Instrument Safety Classification

All instrument equipment located in a hazardous and safe areas shall fully comply with latest editions of IEC 60079. SUPPLIER to refer to the project electrical area classification drawings for details of the hazardous and safe area zones.

Unless otherwise specified by COMPANY, the method of protection to be implemented within hazardous areas shall be as follows:

Field Instruments

Intrinsically Safe Equipment (Ex ia or Ex ib)

Instrument analogue field devices and valve positioners.

Instrument digital devices.

Limit switches and valve position transmitters.

ii. Flame Proof Equipment (Ex db)

Solenoid Valves (or dual certified Ex db de).
Gas Detectors.
Fire Detectors.

iii.

Increased Safety Equipment (Ex eb)

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1. Solenoid Valves (Ex mb eb combined encapsulation and increased safety).

Junction Boxes

Instrument junction boxes shall be flameproof Ex db as per IEC 60079-1, or Increased Safety Ex eb as per IEC-60079-7, for installation within a Zone 1 or Zone 2 hazardous area.

ii. Non-incendive Ex n as per IEC-60079-15 shall not be permitted for installation within a hazardous

area.

Local Panels / Smart JBs

i. Local Panels / Smart junction boxes shall be flameproof Ex db as per IEC 60079-1, Intrinsically Safe (Ex ia or Ex ib) as per IEC-60079-11 or Increased Safety Ex eb as per IEC-60079-7 suitable for installation within hazardous area.

ii. Non-incendive Ex n as per IEC-60079-15 shall not be permitted for installation within a hazardous

area.

Approved national authorities shall certify all Instruments, instrument equipment, devices or fittings installed in hazardous areas in which it will be used. Additional ATEX marking shall be applicable for equipment conforming to IEC as per European Union Directive, whereas equipment conforming to North American Practices / NEMA shall carry Ex apparatus marking.

Only Active or Galvanic barriers shall only be provided for all Intrinsic Safety (I.S.) requirements, unless otherwise specified in project documents.

Table 7.3 below provides a summary of the guidelines to be used for the selection of instruments and equipment:

Table 7.3 Safety Classification Guidelines

ZONE 0

ZONE 1

ZONE 2

Type of Protection

Ex ‘ia’

Any type of Protection suitable for Zone 0 and

Any type of Protection suitable for Zones 0 or 1

Ex ‘sa’ (specifically certified for use in Zone 0)

Ex ‘ib’

Ex ‘db’

Ex ‘eb’, ‘ec’

Ex ‘p’, ‘px’, ‘py’, ‘pxb’, ‘pyb’

Ex ‘sb’

IEC Reference

IEC 60079-11

IEC 60079-1

IEC 60079-7

IEC 60079-2

IEC 60079-33

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ZONE 20

ZONE 21

ZONE 22

Type of Protection

Ex ‘ia’

Any type of Protection suitable for Zone 20 and

Any type of Protection suitable for Zones 20 or 21

Ex ‘sa’ (specifically certified for use in Zone 0)

Notes:

Ex ‘ib’

Ex ‘tb’

Ex ‘pD’

Ex ‘sb’

IEC Reference

IEC 60079-11

IEC 60079-31

IEC 60079-2

IEC 60079-33

Instruments suitable for installation within Zone 1/21 shall also be suitable for use in Zone 2/22.

b. The IECEx/EC Directive requires that a register shall be held of all IECEx certified equipment

installed on the project facilities.

c. Selected equipment protection classification shall be stated on the associated instrument

datasheet.

Unless otherwise specified, all instruments as a minimum shall be certified for use in a Zone 1 Gas Group IIB Temperature Class T3 hazardous area.

7.4.13

Ingress Protection

All Instrument equipment and enclosures shall fully comply with IEC 60529 with independent verification provided of the associated IP rating.

Field Instruments

All field instruments shall be protected to IP 65 as a minimum that will meet site environmental conditions, and adequately protected against accident and contact with live or moving parts within enclosure.

Equipment mounted within engine rooms and machinery enclosures shall be IP 66 rated.

Instrument equipment

Unless otherwise specified, all outdoor Instrument enclosures, such as Junction Boxes, shall be IP 65 rated.

Unless otherwise specified, all indoor instrument equipment enclosures shall have the following minimum IP ratings:

Offshore Instrument Equipment

IP 56 for Indoor climate-controlled environments.

Onshore Instrument Equipment

IP 42 for Indoor climate-controlled environments.

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7.4.14

Lightning Protection

Surge protective devices shall be installed by SUPPLIER to protect sensitive electronic equipment. SUPPLIER shall refer to AGES-PH-04-001 Automation and instrumentation Design philosophy for further lightning protection requirements.

7.4.15 Engineering Units

The International System Units (SI) shall be used as the basis for the Engineering Units of measurement. If a conflict occurs between the units listed in Table 7.4 and the units identified in other specifications, the units listed below shall be used for instrumentation purposes. For existing plant facilities, the existing measurement unit shall be followed for consistency.

Table 7.4 Engineering Units of Measurement

Unit Name

Unit

Abbreviation

Ambient Temperature

degree Celsius

Amount of Substance

kilogramme mole

°C

kg-mol or kmol

Area

Square metre or Square millimetre

m² or mm²

Barometric Pressure

Base Pressure

bar gauge

Base Temperature

degree Celsius

Beta Ratio

Concentration

Conductivity

Orifice bore diameter / pipe inside diameter

parts per million

Micro Siemens per centimetre

Control Valve Opening

Percentage

Density

Design Pressure

Diameter (Pipe)

Differential Pressure (Control Valve)

Differential Pressure (DP Instrument)

Differential Range (Flow)

kilogrammes per cubic metre

bar gauge

Inch

bar

Electric Current

Energy

Ampere

Kilowatt hour

Flow - Process Liquid

Cubic metre per hour

Flow - Process Liquid (For small volume)

Litre per hour

Flow - Gas and Vapour

Normal cubic metre per hour

barg

°C

ppm

µS/cm

kg/m³

barg

“

bar

kWh

m³/h (1)

l/hr

Nm3/h (2)

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Unit Name

Unit

Abbreviation

Flow - Boiler Feed Water & Steam Kilogrammes per hour

Force

Frequency

Heat

Length (Vessel Level)

Kilogramme force

Hertz

Kilocalorie

Millimetre

Length (Storage Tank Level)

Metre

Length

Kilometre

Level (General Applications)

1 percent

Mass

Kilogramme

Tone

Molecular weight

Kilogramme per kilogramme mole

Power

Pressure Gauge

Pressure Absolute

Kilowatt

bar gauge

bar absolute

Pressure Differential (high)

bar differential

Pressure Differential (low)

Sound Level

Specific Heat

Temperature

Thermowell Length

Time

Vapour Pressure

Velocity

Millibar

Decibel

Kilojoule per kelvin and kilogramme

degree Celsius

Millimetre

Hour

bar gauge

Metre per second

Vibration (Velocity)

Millimetre per second

Vibration (Displacement)

Micrometres

Viscosity - Dynamic

Viscosity - Kinematic

Voltage

Volume

Notes:

Centipoise

Centistoke

Volts

Cubic metre

Barrel per day (bbl/d) could be also used for condensates.
Normal 1.013 bara and 0 °C.
To denote millions prefix MM shall be used (not mm or 106).
MMSCFD could be also used.

kg/h

kgf

kcal

1 %

Te or T

barg

bara

bar

Mbar

dBA

kJ/kgK

°C

hr or h

barg

m/s

mm/s

µm

m³

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Inch pound system will be used for the nominal bores and rating of pipe, flanges, and valves.

7.4.16 Air Supplies

Package equipment skids requiring instrument air, shall have piping / tubing fully routed and connected to each user installed on the skid, with a single connection at the skid edge boundary labelled “INSTRUMENT AIR SUPPLY”.

Each package equipment instrument requiring an air supply, shall have a dedicated individual air supply block valve on the air supply header.

In case air intake filter unit is associated with the package, pulse-cleaning system shall have an isolation valve for each solenoid to facilitate removal of the solenoid without isolation of the air header.

SUPPLIER shall verify that the maximum and minimum air pressure supplied by COMPANY is adequate for valve actuator performance.

SUPPLIER shall verify that the maximum air pressure supplied by the COMPANY is within the actuator maximum operating pressure limit. Where the maximum air pressure exceeds the design pressure of package equipment, actuator etc, suitably sized pressure reducing regulators and over protection relief valve shall be provided.

Valve stems shall withstand the maximum torque generated by the actuator at the maximum available air supply pressure.

The SUPPLIER shall provide an instrument air consumption calculation for the whole package unit to the Contractor and the Principal.

The metallurgy for instrument air headers shall meet the project piping class specifications as defined by the CONTRACTOR.

SUPPLIER shall refer to AGES-PH-04-001 for further Air Supply requirements.

7.4.17 Topicalization

All Instrument and Instrument items shall be tropicalized to meet the climatic conditions specified within the environmental and site data by suitable epoxy and resin coatings.

All hazardous area Instrument and accessories shall also be weatherproof and suitable for the environmental and site conditions identified in Section 5.3.

Instrument and Instrument item enclosures shall fully comply with the Ingress Protection (IP) requirements identified in Section 7.4.13.

SUPPLIER shall refer to AGES-PH-004-001 for further Topicalization requirements.

7.4.18 Future Capacity and Spare Space

All junction boxes, cables, cable tray/ladder, systems and local panels shall be supplied with the future capacity and spare space requirements identified in the following sections.

Multicore Cables

In each multi-core cable 20 % spare cores shall be provided, a minimum of 1 pair / 2 core. All spare wires in multi- core cables shall be terminated and numbered in junction boxes and Marshalling cabinets. Refer AGES-SP-04-006 for detail.

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Fibre Optic Cable

Fibre optic cables shall have a minimum of 100 % spare fibres left in each multi-fibre cable.

Cable Tray and Ladder

Number of cables in the cable trays and ladders shall be limited to two layers, 25 % space shall be provided in each cable tray/ladder for future use.

Junction Boxes

Each Junction Box (J.B.) shall have 20 % spare capacity of wires, terminal blocks, and cable entrance glands. The Junction box shall be loaded max. 60 % and 40 % empty space capacitance shall be left.

All spare junction box terminals and cables shall be numbered.

Junction boxes shall be provided with 20 % spare cable entries and plugged using hazardous area certified stopping plugs and of same IP rating, and material in line with gland material (brass or nickel-plated brass).

Panels and Cabinets

SUPPLIER shall provide 20 % installed spare terminals for each local panel or UCP/SCPs (minimum 20 terminals) and all spare terminals shall be numbered.

SUPPLIER shall provide 20 % installed spares, I/O modules, I/O channels, and spare terminals for each panel. Due to design constraints, some panels may have less, but the overall total spares shall be 20 %. Where there are very few installations of an I/O card / module type, to meet the 20 % requirement, a minimum of one (1) I/O card shall be installed. 20 % spare space shall be provided for I/O modules.

All spares shall be identified and tagged as SPARE points and evenly distributed, along with all spare terminals shall be numbered.

PLC Systems

Logic System Spare terminals shall be provided as follows for each category: 20 % equipped (minimum 20 terminals) and 25 % spare space (minimum 20 terminals).

20 % of installed spare channels and modules shall be provided in PLC or machinery monitoring rack.

All spare channels and spare cards shall be fully wired up to field terminal of respective cabinet.

Instrument Equipment Shelters (IES)

The IESs and MCRs shall be sized to include 30 % spare space for future use in floor space, power at all levels, grounding, and HVAC.

Power Supplies

A minimum of 30 % spare capacity shall be provided in sizing the power supply system.

7.4.19 Painting

Painting requirements shall comply with Section 27.2 of this specification, unless agreed otherwise with COMPANY.

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Criticality Rating

Criticality Ratings (CR) are comparative indications of the ‘importance’ of a given item with respect to factors relating to service conditions and the consequences of failure. This rating is then used as a guide in determining the level of inspection to be applied to SUPPLIERs and the extent of documentation to be supplied by them.

The CR for a given item is used to define its inspection requirements, test plans, and certification requirements. However, the definition of the inspection requirements, test plans, and certification requirements is outside the scope of this specification.

SUPPLIER shall refer to AGES-SP-13-001 for the Criticality Ratings for the following equipment:

Instrumentation.

Static Equipment.

Rotating Equipment.

Electrical.

Telecommunications.

Isolations

7.6.1

Instruments

All instruments shall be provided with integral manifold. Close-coupled installation shall avoid impulse tubing and accessories. In such cases direct mounted isolation such as mono block valve shall be used. Each tapping point for the instrument shall be provided with isolation valve to isolate the process line. Isolation valve shall be in accordance with piping material specification. Pressure instrument isolation valve shall be provided with 2-way valve manifold, flow instrument and level instruments (DP type) shall be provided with 5 valve manifolds for instrument/ isolation. All drain and vent shall be connected to close/open vent/drain system as appropriate.

Piping take off connections shall always include an isolation valve at the piping tapping point (manifold cannot be used as piping isolation).

All instruments provided within the package equipment shall be identified by a permanent, engraved, metal tag plate (as per Section 19) at the first isolation valves.

If more than one instrument is connected to the same process connection, then there shall be separate isolation valves for each transmitter. Instrument manifolds shall not be considered as an isolation valve.

7.6.2

Overpressure Protection

Techniques to be implemented

The following techniques are to be implemented for the design of overpressure protection systems:

Elimination or reduction in magnitude and frequency of overpressure cases through an inherently safer

design.

Installation of mechanical relief devices to relieve excess pressure and protect equipment from overpressure.

Application of ESD to limit relief loads.

Application of ESD to protect equipment from overpressure.

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Overpressure Standards

Causes of overpressure to be investigated in relief design shall include those listed in the following standards:

API STD 521.

ISO 23251.

Causes of overpressure

The flowing items are to be considered as a minimum, as potential causes of overpressure:

Blocked outlet.

Fire.

Thermal expansion.

Reverse flow.

Inadvertent valve operation.

Tube rupture.

Utility failure (e.g. power, instrument air).

Leaking valve.

Cooling water failure.

Accidental mixing.

Overfilling.

Accumulation of non condensables.

Failure of automatic controls.

Abnormal heat or vapour input.

Internal explosion or pressure surge.

Chemical reaction.

Closed outlet on fired heater.

Loss of heat.

Loss of absorbent.

Abnormal flow, through vent valve and equipment.

Vacuum relief.

Multiphase vapour, or liquid relief.

Gas break through (blowby).

Human factors.

Emergency depressurisation.

Other scenarios identified by Supplier.

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Safety Relief Valves

If safety relief valves or bursting discs are installed to protect pressure vessels, equipment, or piping, they shall conform to API STD 520, API STD 521, 526 and 527, and the pressure equipment design code.

If safety relief devices are installed to protect non-pressure vessel equipment, they shall conform to 7.6.2.3.

Relief devices shall be sized based on the back pressures specified by COMPANY.

Calculations for relief devices and their associated lines shall be submitted for review and approval by COMPANY.

Calculations shall include basis of design, and summary of relief cases evaluated.

Calculations shall include piping and valve pressure drops.

Relief valves shall be mounted in a vertical position.

Acoustic fatigue analysis shall be completed for pressure reducing devices in accordance with COMPANY specifications.

Pilot operated relief valves shall be located and orientated in conformance to the piping detail drawings. Pilot assembly shall be accessible from floor level or permanent platforms. If the valve is inaccessible, pilot assembly shall be remote mounted.

Bursting disc holders shall be located to allow replacement of bursting discs.

For relief valves venting to atmosphere, location will be specified on data sheets.

Relief valves larger than DN 25 (NPS 1) shall be transported upright after calibration.

Overprotection Cases

SUPPLIER shall determine and agree the overprotection cases, the types, sizing, layout, and configuration of over pressure protection system with COMPANY.

Set points of pressure limiting ESD, preceded by alarms, as required, shall be below the lowest design pressure in the system under review.

Materials

7.7.1

Severe Services

As defined within AGES-SP-07-003, Severe services includes cracking mechanisms applicable to “upstream oil and gas production facilities” and “downstream oil refineries”. Since cracking mechanisms are not time dependent, or can be monitored, these services are deemed severe services.

Sour service requirements are further identified for both the oil and gas production environment and refinery environment in the following sections, which are also further detailed in AGES-SP-07-003. SUPPLIER shall refer to AGES-SP-07-003 for the requirements of the remaining Sever Services.

SUPPLIER shall refer to AGES-PH-04-001 for Instrument Tubing, Fittings and Valves for use in Sour Service environments. All instrument tubing and fittings used on sour service shall be certified to metallurgical requirements of NACE MR0175/ISO 15156 or NACE MR0103/ISO17945 as applicable.

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7.7.2

Instrument and Installation Materials

General

Instrument installation materials shall be in accordance with COMPANY Standard(s) and any deviation from this specification shall be noted on the installation drawing.

Instrument Tubing, Fittings and Valves.

Instrument tubing, fittings and valve materials of construction shall be in accordance with AGES-PH-04-001 for Tubing, Fittings and Valve Material Selection.

7.7.3

Positive Material Identification

Positive Material Identification (PMI) testing is a non-destructive testing method used for both material verification and identification.

Positive Material Identification shall be used to identify the following:

Ensure products / components have been manufactured using the correct alloy material.

Find potentially mixed-up alloys within the equipment being tested.

Identify if the wrong material has been used.

Ensure material conforms to the correct standard and specifications.

Ensure welded components have used the correct filler material.

In general, PMI testing is required for all alloy pressure-containing materials, piping components, instrument manifolds and thermowells.

Positive Material Identification (PMI) shall be carried out in accordance with the specified requirements within the relevant COMPANY Business Unit Standard(s).

HAZOP, LOPA, SIL Review

7.8.1

HAZOP

SUPPLIER shall participate and assist CONTRACTOR in HAZOP review meetings. SUPPLIER shall implement any HAZOP decisions and revise accordingly any associated SUPPLIER design / documentation.

7.8.2

LOPA / SIL Assessment

SIL Assessments and LOPA reviews shall be carried out by CONTRACTOR in compliance with the requirements of IEC 61511. SUPPLIER shall participate in LOPA (SIL Study).

The following three main safety / integrity barriers that are applicable for all packaged equipment LOPA and SIL assessment reviews:

Process containment.

Mechanical containment.

Prevention of ignition sources.

Implementation of safeguarding functions shall be designed based on the outcome of the SIL assessment and the category applicable for the package.

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The number of trip instruments required for an application shall be determined using the HAZOP and LOPA processes. HAZOP, LOPA and SIL review process shall take into account the defined process over the lifetime of the plant/asset.

Shutdown settings shall be established to protect against equipment failures that could breach these safety / integrity barriers identified above, and lead to a process safety and/or asset integrity incident.

SUPPLIER shall ensure that all packaged equipment shutdown devices comply with the SIL Assessment requirements. The instrumentation type, level of redundancy, and voting logic selection shall be based on the SUPPLIER Package SIL Reviews and shall be in accordance with HSE specifications, process safety, plant economics and environmental considerations.

Design shall follow AGES-PH-03-001 ESD and EDP System Philosophy.

7.8.3

SUPPLIER Package SIL Assessment

SUPPLIER shall participate and assist CONTRACTOR in SIL validation meetings. CONTRACTOR shall carryout the SIL Assessment based on the Layer of Protection Analysis (LOPA) methodology. Refer to ADNOC HSE Standards for details.

For each Safety Instrumented Function (SIF) operating in Demand Mode, the required SIL levels shall be assigned.

SIL 4 shall not be accepted and the SIF shall be redesigned to reduce the SIL level down to a maximum of SIL 3.

SUPPLIER shall implement any SIL actions and revise accordingly any associated SUPPLIER documentation.

The SIL review meetings shall be recorded and distributed by CONTRACTOR. Actions/recommendations arising from the SIL Assessment study shall be reviewed, finalised, and agreed by the team. All actions / recommendations made will be transferred to the SIL review action tracking register.

7.8.4

SIL Verification Data

For all instrument equipment which forms part of a Safety Instrument Function (SIF), the SUPPLIER shall provide the following documents and data to CONTRACTOR:

Probability of Failure on Demand (PFD).

Safe Failure Fraction (SFF).

Mean Time Between Failures (MTBF).

Mean Time to Repair (MTTR).

Useful Lifetime.

FMEA/FMEDA report third-party approvals body (e.g. Exida, TÜV) or if not available other functional

safety assessment clearly stating the source of data.

Relevant IEC 61508 certificate.

Safety manual.

The independent third-party approval certification plus its associated safety manual(s) shall demonstrate the equipment suitability for use in functional safety applications.

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Packaged Equipment Design

7.9.1

Design for Maintenance and Operability

General

COMPANY operations and maintenance personnel are to be involved during the package equipment engineering and design phase, with regular consultation throughout the instrumentation and control system detailed design. Operations and maintenance personnel provide vital input into the operations and maintenance philosophies and instructions, which will form part of the package equipment documentation.

Operations and maintenance personnel involved during the installation, configuration and testing of the instrument and control systems, will prove extremely valuable during these phases and ensure a successful project.

The following operational requirements shall be considered when specifying instrumentation and data recording deliverables:

Information processing, display, recording and reporting facilities for the presentation of processed measured data in a format suitable for management, operations, technical, commercial, and maintenance personnel. Data links to facility wide management information systems as specified by COMPANY.

The availability of the facility is to be analysed for required reliability and where necessary increase the

redundancy of instrumentation to prevent spurious trips.

Means of recording facility variables for fault diagnosis and for the prevention of unscheduled shutdown.

Record shall include real time information on sequence of events and facility trips.

Means of processing and recording key information for facility operation and for facility efficiency

monitoring.

Measurement, information processing, recording, and automatic sampling for fiscal and accountancy

purposes.

Measurement, information processing, recording, and automatic controls for emissions to atmosphere and discharges of liquid effluents to enable adherence to legislative requirements (including environmental and health monitoring systems).

General evacuation alarms with policy for activation and sound levels and frequencies in relation to the

surrounding facility.

Regulations applicable to drilling areas on offshore platforms.

Field-proven ability for the application. If an updated version is offered and is advantageous, Contractor shall identify a proven fall-back item that is available and compatible with the correct software and hardware version.

Supplier support to meet the safety requirements i.e., MTTR time.

Information to enable early detection of degradation of facility or equipment due to fouling, wear, or another malfunction. This shall be addressed as part of the overall condition monitoring and maintenance policy for the facility.

Operability

Instrumentation shall provide information and control of the process, so facility and utilities meet specified requirements for:

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Safety.

Product quality.

Throughput.

Efficiency.

Economic operation.

Local adjustment of control and bypass valves shall have local indication provided.

Indication of variables required for facility and equipment operation during start-up, shutdown, or emergency conditions shall be provided locally.

Packaged Unit SUPPLIER furnished motor ammeters, prime mover tachometers, discharge pressure gauges of driven machines and other essential indicators required by Operator shall be readable from the local control point. If the instruments cannot be so located, a second remote indicator shall be provided.

7.9.2

Layout

SUPPLIER shall ensure that the package equipment layout of equipment, piping, instrumentation, and components shall provide for safe operation and maintenance.

In general, junction boxes shall be installed at the package equipment skid edge boundary for interconnection with the IES or ICSS Main Control room.

Gauges and indicators shall be positioned on local gauge boards or local panels in a logical order from left to right following inputs to outputs of the associated package equipment.

Package equipment layout shall avoid the following hazards:

Slips, trips, and falls.

Contact with sharp objects or projections.

Contact with hot or cold objects.

Contact with unguarded rotating machinery.

Collection and disposal of spills and accumulated liquids.

SUPPLIER shall reduce size and weight without compromising cost, performance, safety, environmental

impact, operational or maintenance access.

Unless specified otherwise, equipment shall be mounted on a single structural base frame.

Package dimensions shall be kept to a minimum consistent with providing access to equipment for

operation and maintenance.

Package shall conform to dimensional requirements, arrangement or interface locations specified on the

data sheets or Purchase Order.

Package equipment shall be designed and located on the package in conformance to requirements

specified on the data sheets or Purchase Order.

Package dimensions shall be limited by transportation restrictions, if stated in the Purchase Order.

Package equipment, piping, vessels, instruments, and other components shall be within the outer edge

of structural base frame.

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Equipment shall be mounted and installed in conformance to SUPPLIER’s recommendations.

Package equipment shall be designed for equipment to be removed and (or) maintained.

Piping and instrumentation systems design shall enable isolation and removal of equipment without

bending, cutting pipe or hot work, including:

Isolation block valves and spool pieces.

ii. Unobstructed access to relief valves.

Provision for escape routes shall be identified within the design.

7.9.3

Accessibility

General

Access from package equipment skid edge to clear workspaces shall be provided in accordance with project specifications for all equipment requiring operation or maintenance on the package, including:

Manual valves and local field instrumentation.

Isolation points required for operation, maintenance, or emergency shutdown and isolation.

Sample points, manual drains, and vents.

Equipment requiring routine inspection, maintenance, and surveillance (e.g. compressors, pumps).

The arrangement and location of access routes and any clear space adjacent to the package for access to the package, shall be shown in 3D model and on the layout drawings.

Stairs, ladders, cages, platforms, handrails, etc., shall conform to project specifications and statutory requirements.

Items including pipe work, valve spindles and instrumentation, shall not obstruct or protrude into operating and maintenance workspaces or access and egress routes.

Instrument, valve, or equipment item shall not be located in an enclosure or restricted location requiring confined space entry permit unless agreed by COMPANY.

Equipment that requires manual operation shall be within the reach from a clear space around the equipment. Refer Section 18 for accessibility requirement.

Location of Instrumentation

Package equipment instruments shall not be installed in locations where conditions can be detrimental to their operation. Instruments shall be located to provide access for installation, removal, manual operation, and maintenance.

Instruments shall not be located under lines or equipment where leaks from joints, etc., may cause damage.

Instrument locations shall be selected to minimize the effect of vibration from adjacent equipment.

Temperature and pressure gauges shall be close mounted to their sensing point and orientated for viewing.

All other instruments shall be:

Located near to the point of measurement.

Mounted on a 50 mm diameter pipe stand.

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Earthing

7.10.1 General Earthing Requirements

Instrument Earthing systems may comprise of two or three of the following levels:

Safety Earth (ELE) - also called as Plant Earth or Protective Earth or Electrical Earth.

Instrument Earth (INE) - also called Clean Earth or System Earth.

Intrinsically Safety Earth (ISE) - also called Barrier Earth or Zener Barrier Earth.

Notes:

Power supply neutral Earthing for Power supply systems to Instruments or Instrument panels shall be addressed separately as a project practice, since the general practice is to have “floating” mode power supply to Instrument or instrument panels to avoid fault shutdowns due to noise voltages induced in the circuit.

Earthing requirements shall follow IEC TR 61000-5-2 and IEC 60364. COMPANY facilities may include a single integrated plant earthing system with a final single point tie-back of all INE and ISE to ELE(s) or a fully segregated INE and ISE with separate earth pits / rods / insulated structure. A typical earthing diagram is provided in AGES-PH-04-001.

Package SUPPLIER may submit their earthing recommendations consistent with the plant control system.

Package SUPPLIER shall plan for segregation of ELE, INE and ISE as applicable in their scope of supply, but the tieback to the Main Plant Earth system shall be by COMPANY.

7.10.2 Cabinet Earthing Requirements

Earthing requirements for within cabinets are identified below:

The instrument cable screens shall be earthed at one end only at the equipment room marshalling or I/O interface cabinet, while the screens shall be left tied back and insulated at the field end of the measuring element, transducer, or transmitter. The screen continuity shall be maintained from the field instrument to the marshalling or equipment cabinet and shall be continuous through field junction boxes or intermediate terminations.

The equipment room marshalling cabinets shall have the instrument earth bar and intrinsically safe earth bar insulated from the cabinet enclosures. The instrument earth and intrinsically safe earth bars inside the cabinets shall be separately connected back to the main instrument earth and main intrinsically safe earth system using typically 70 mm2 cables.

The cabinet enclosures shall be separately connected to the safety earth bar and then connected back

to the main safety earth system using a 70 mm2 cable.

Each individual and overall screen shall be terminated within the Instrument Earth (INE) or Intrinsically

Safe Earth (ISE) terminal strip.

Separate but linked individual and overall screen terminals are then connected back to either the separate

Instrument Earth (INE) or Intrinsically Safe Earth (ISE) bar.

INE from each cabinet shall be linked to the insulated main instrument earth as per AGES-GL-02-001 Electrical Engineering Design Guideline and Electrical power, control, and earthing cables specification.

Lead sheath (when provided), steel wire armouring and metal wire braiding of signal cables shall at each

termination be connected to safety earth.

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Mounting bolts of instrument housings shall be fitted with two shark rings to ensure a very low resistance

to structure.

Ungrounded Thermocouple screens shall be insulated in the thermocouple head and earthed at the

instrument earth at marshalling cabinet.

Grounded thermocouple (e.g. skin thermocouples) when used, shall be provided with galvanic optical isolator at the control room end before the marshalling cabinet. The earthing of separate screened cable after the isolator shall be at the instrument earth at the marshalling cabinet.

Screened cables for Machinery Monitoring System (MMS) shall follow manufacturer’s guidelines.

Cable armour shall be earthed to metallic enclosures by an earthing ring or bond leading to Safety Earth.

Metal enclosures and junction boxes shall be earthed to their local steelwork support by typically 6 mm2

earthing cable, earth bolt and tag washer.

Metallic sections of a Fibre re-enforced Polyester Junction box shall be earthed to their local steelwork

support by 6 mm2 earthing cable, earth bolt and tag washer.

Gland plates within enclosures and junction boxes shall be linked internally to the local steelwork earthing

connection point.

Notes:

Typically, field instruments do not have insulated connection facilities for the screen. The screen shall be tied back and insulated with a protective sleeve and left (open) unconnected with the same offset length as the screen wires.
Lightning arrestors used for DC signals installed at the transmitter end may also require field safety earthing of the shield. Such transmitters shall also be provided with galvanic optical isolator at the control room end before the marshalling cabinet. The earthing of a separate screened cable after the isolator shall be at the instrument earth at the marshalling cabinet.

Instrument Numbering and Tagging

SUPPLIER shall refer to AGES-PH-04-001 for Instrument Numbering and Tagging.

Instrument Symbols and Identification

SUPPLIER shall refer to AGES-PH-04-001 for Instrument Symbols and Identification.

FIELD INSTRUMENTATION

General

All instruments and instrument equipment shall fully comply with specifications and design considerations specified in this document and reference documents. The instrument make and models provided within the packaged equipment shall be in accordance the COMPANY approved suppliers list and instrument standardisation identified within Section 5.6.

Transmitters shall be supplied with an integral local digital display to provide indication of the process variable. Transmitters located on Lube Oil packages shall have local integral displays mounted on a local gauge board.

Local displays shall have the same scale and units as the transmitter calibrated range.

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Transmitters shall be provided with span and zero calibration adjustment facilities.

Transmitters that are close coupled shall be designed to enable continuous operation at the design temperature of the pipe or equipment on which the instrument is installed.

All Instruments shall be remote mounted if the design temperature of the process is outside of the instrument environmental operating range.

If extremally powered transmitters and analysers are selected, SUPPLIER is advised of the following:

Externally powered transmitters are only to be used where loop powered instruments and analysers are

not available.

External power shall be provided from a dedicated UPS for ICSS control or safety services.

A summary of the field instrument types for use on packaged equipment is summarised in following sections. SUPPLIER shall also refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy and AGES-SP-05-006 Rotating Equipment Minimum General Requirements and System Integration Specification, for the instrument requirements for Rotating Equipment.

Flow Measurement

8.2.1

General

The selection of type of flow measurement shall be made on an individual basis and shall be based on the suitability of the chosen flow meter technology to meet the process and environmental conditions.

The suitability of the flow meter for a given duty shall be determined by, but not restricted to, the following considerations:

Required accuracy / uncertainty of measurement.

Process fluid including contamination and upset conditions.

Ability of the meter to measure process fluid (turbulence, mixed phases, contamination, conductivity,

corrosion, and any other property that may impede the meter performance).

Process conditions (operating and design).

Meter turndown.

Piping arrangement requirements.

Installation and accessibility.

Total life cost.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed flow measurement selection and requirements.

Level Measurement

8.3.1

Transmitters

Level instruments shall be selected to provide the required accuracy and integrity with the emphasis on simplicity of installation and maintenance. The primary level measuring elements shall be Guided Wave Radar (GWR), non-contacting radar, displacers, or differential pressure transmitters.

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SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed level instrument selection and requirements.

8.3.2

Level Gauges

Magnetic float type level gauges shall be provided unless not suitable for the application. Glass tube type gauges shall not be used except in very limited applications and if a magnetic follower type is not suitable, with agreement of COMPANY. In toxic service use of level gauge shall be avoided.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed level gauge selection and requirements.

8.3.3

Level Switches

The use of switches within package equipment is not permitted and can be used only with prior approval by COMPANY. Where use of switch is approved, SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed level switch selection and requirements.

Pressure Measurements

8.4.1

Transmitters

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed pressure instrument selection and requirements.

8.4.2

Pressure Gauges

Pressure gauge ranges shall be selected so that the pointer reads approximately 12 o’clock at normal operating pressure. Maximum working pressure of a gauge shall not exceed 65 % of the full-scale value for fluctuating pressure or 75 % of the full range value for steady pressure. In toxic service use of pressure gauge shall be avoided.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed pressure gauge selection and requirements.

8.4.3

Pressure Switches

Temperature Measurement

8.5.1

Transmitters

Temperature instruments shall consist of an element and transmitter, either head mounted or for local, field mounting, supplied as a complete assembly.

Temperature elements shall normally be installed within thermowells so that they can be removed during plant operations, with the following exceptions:

Embedded mineral insulated sensors used to measure bearing, motor, or generator winding

temperatures.

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On air conditioning systems, unless removable without dismantling equipment.

Skin temperatures of heater, reactor internals or boiler tubes measured by direct contact sensors.

In these exception cases, there is a requirement to seal the process from the environment. This shall be achieved with a compression fitting. In certain applications (for example, reactor bed temperature), it may be necessary to pass the sensor through a special isolating shear valve so that if a compression fitting fails, process isolation can be achieved. In such cases, design to ensure the temperature sensor does not drop into the process. This may require the use of a special probe with a reduced diameter tip.

All temperature circuits shall be IS if sensors are installed without a thermowell and the process fluid is potentially flammable.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed temperature transmitter selection and requirements.

8.5.2

Resistance Temperature Devices (RTD)

All temperature elements shall be provided complete with thermowells fabricated from solid bar stock. The use of welded thermowells is subject to COMPANY approval. If welded thermowells are used in hydrogen service, they shall have full penetration welds to prevent hydrogen (migration) pocketing.

Temperature elements shall be Resistance Temperature Detectors (RTDs) for temperatures up to 500 °C (for indication and control). Any exception requires COMPANY approval.

RTD elements shall be 3 wire unless 4 wire is required for custody transfer measurement. RTDs shall normally be the 3-wire platinum resistance type, 100 Ω at 0 ºC tolerance Class A.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed temperature RTD selection and requirements.

8.5.3

Thermocouples (TC)

Thermocouple extension wires shall conform to IEC 60584, Part 3, or API RP 551.

Thermocouple design shall be a mineral insulated, duplex thermocouple in a 6 mm (1/4 in) nominal OD 316 SS sheath with the junction earthed to sheath unless there is insufficient space in which case a 3 mm (1/8 in) diameter may be used. An earthed junction provides improved response time over an isolated junction. An isolated junction may make both installation and earthing systems easier since multiple earths are less of a problem.

For earthed thermocouples, the input channel of transmitters or input cards shall not be earthed.

For differential temperature measurement, two thermocouples shall be:

The same type connected in opposition into one measuring instrument.

Isolated junction type.

For temperature averaging, two or more thermocouples shall be:

The same type.

Unearthed.

Connected in parallel.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed temperature Thermocouple selection and requirements.

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8.5.4

Thermowells

All Thermowells shall comply with ASME PTC 19.3 TW - 2016, TW for calculations of natural frequency and corresponding frequency limits.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed thermowell selection and requirements.

8.5.5

Temperature Gauges

Temperature gauges shall be of the bimetallic “every angle” type of 150 mm diameter. Bimetal type and filled systems shall not be used for control, alarm or shutdown purposes unless approved by COMPANY.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed temperature gauge selection and requirements.

8.5.6

Temperature Switches

The use of switches within package equipment is not permitted and can be used only with prior COMPANY approval. Where use of switch is approved, the following shall be applied within the design:

Temperature switches shall have adjustable set points or adjustable differential span settings marked

with a reference scale.

Temperature switches shall be activated by either thermocouples or RTDs if:

i. Switch trip point accuracy requirement is ±1 % or better.

ii. Overall control scheme is electronic design.

iii. Power supplies are available.

Temperature switches shall have snap acting type actuation devices. Temperature switches that have snap acting type actuation devices are preferred over switches with lever, volume, or piston type mechanisms. This is because the snap acting type provides better accuracy and repeatability of set points.

All switch enclosures shall be classified intrinsically safe, weatherproof unless otherwise conditions

warrant the use of Ex db enclosures.

Thermal flow switches maybe used for Lube Oil systems.

Machinery Monitoring Instruments

8.6.1

General

Package equipment machinery monitoring will include monitoring of a range of different parameters, depending on API STD 670 requirements and the parameters defined within AGES-SP-05-006.

Monitoring the vibration and shaft position of large rotating equipment, the probes and oscillator/demodulators form part of instrument engineering but are usually supplied by the packaged equipment SUPPLIER. For main package equipment machines, key phasers shall be included. The make and type of these items shall therefore be agreed upon between instrument engineering and mechanical engineering at an early stage of the project.

In general, vibration switches shall not be used as tripping device as the vibration switches does not provide any pre warning or diagnostic details about the machine vibration status.

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Where non-contact vibration probe systems are installed, the SUPPLIER should indicate in their proposal the permissible alarm and trip values for the safe running of the machine.

For the vibration probes, key phasors, etc each element shall have junction box for the sensor termination with the extension cable. The junction box shall be of stainless steel with cover tied with the element casing. The fitting and installation shall be according to the SUPPLIER standards final elements installations. The body material of connectors on cables / sensors shall be 316 stainless steel or other corrosion-resistant stainless steel suitable for the environmental conditions and shall be designed to withstand a minimum tensile load of 225 N (50 lb).

Flying leads from probes, transducers or transmitters are not acceptable and shall be connected to a local junction box by SUPPLIER.

Shaft target material specifications shall be clearly specified in the element data sheet.

The sensors shall have easy access for removal and installation without requiring removal of local equipment.

The machinery monitoring instrument requirements as defined within the following sections, with further information identified within API STD 670 and AGES-PH-04-001 Automation and Instrumentation Design Philosophy shall be complied with.

Voting logic shall be implemented as stated in Section 12.6.14

8.6.2

Position / Proximity Sensors

Bearing vibration is a reliable indicator of the condition of bearings within a package equipment machine and include Position / Proximity sensors that provide an output voltage that is directly proportional to the distance between the probe tip and the observed conductive surface.

The position / proximity sensors shall be able to provide accurate measurement with a stable output over a wide temperature range, in the following applications:

Radial Position.

Axial Position.

A position / proximity sensor system will contain the following items:

Position / Proximity probe.

Extension cable.

Position / Proximity sensor.

Proximity probe transducer system accuracy shall be verified on the actual probe target area or on a target with the same electrical characteristics as those of the actual probe target area. When verifying the accuracy of any individual component of the proximity probe transducer system in the operating range, the components not under test shall be maintained within the testing range.

As a preliminary estimate, vibration and axial displacement probe ranges are 0 - 125 microns and -0.8/0/+0.8 mm respectively. (These ranges shall be subject to verification during detailed engineering). Proximity sensor signals shall be 200 mV/mm. Machine monitoring field circuits shall be suitable for installation within a Zone 1 hazardous areas as a minimum.

The measurement ranges and type of setting (RMS, Peak to peak) shall be finalized based on the machine characteristics, Codes requirement and SUPPLIER recommendations.

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8.6.3

Accelerometers

Package equipment casing accelerometers provide acceleration measurement for equipment located in harsh industrial environments and are also able to be installed with space limitations.

Case mounted accelerometers shall provide acceleration measurements in units of g or m/s2. The accelerometer sensor shall have a standardized output voltage proportional to the level of acceleration which will interface to the machinery monitoring system.

The case mounted accelerometers shall be able to detect a vibration frequency range between 0.2 - 14,000 Hz.

8.6.4

Vibration Probes (displacement)

Vital and essential rotating package equipment shall be provided with vibration measuring devices to monitor the condition of the following package equipment components, as identified below:

Radial Bearing Vibration.

Radial Shaft Vibration.

Depending on the equipment type, these devices can be either non-contacting probes to monitor shaft displacement or velocity/acceleration transducers to monitor casing/bearing housing movement. In both cases, machine vibration data can be monitored continuously on-line from the ICSS or machinery monitoring system. A local read out of the vibration data shall be available from the machinery monitoring system, located within the IES. When a data limit is reached, current vibration data and vibration trends can be evaluated so that operational adjustments can be made to reduce vibration levels, or a plan can be developed to shut down the equipment for required maintenance.

For certain types of failure, vibration levels can increase faster than operators can respond; therefore, automatic shutdown trips are required to protect against loss of containment and major machine damage.

For centrifugal machines, radial vibration probes in X-Y arrangement at each bearing and axial displacement probes identified in Section 8.6.5 shall be configured for automatic shutdown.

Fault tolerance of the system should be evaluated prior to selecting 1oo2, 2oo2 or 1oo4 voting.

It should be noted that, in a 2oo2 logic system, if one signal becomes faulty and does not violate the shutdown setpoint, then the trip protection will not work even if the other signal exceeds the shutdown setpoint. It is important, therefore, to set a high priority status to fault alarms.

If an external system is used for the voting, then the logic in the monitor needs to be set to single.

Set point multiplication shall not be used.

Unless otherwise specified, for monitoring radial shaft vibration, the full-scale range shall be from 0 to 250 micrometres (0 to 10 mils) true peak to peak displacement. This scale range is likely to cover the majority of the radial bearing clearances; but high-speed rotation with tighter bearing clearances might need a smaller full-scale range.

In the event of failure of a single radial shaft vibration channel transducer or circuit, only the circuit-fault alarm will activate [i.e. the shutdown (danger) relay will not activate]. Therefore, if specified, single voting (one-out-of-two) logic shall be implemented.

8.6.5

Axial Displacement

Axial displacement vibration probes with their respective alarms and trip functions protect against serious internal package equipment damage. Shutdown levels are selected to prevent the most serious failures, including loss of

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containment or loss of integrity of main casing / bearing housings, secondary damage to unit facilities from failed machine components, and failures that will keep the machine down for extended periods.

These types of failures would require rotor replacement or refurbishment and would likely entail damage to the casing or stationary components.

Unless otherwise specified the full-scale range for axial position monitoring shall be from –1.0 to +1.0 millimetres (–40 to +40 mils) axial movement.

The monitor indicated “zero” point shall be set to represent the rotor at the mid-point of its axial float within the thrust bearing.

8.6.6

Key phasors

The key phasor system receives input signals from proximity probes and converts these signals into digital Key phasor signals that indicate when the mark on the shaft coincides with the key phasor proximity probe.

Key phasors for both high and low speed shafts shall be installed if a key phasor is identified for use within a gearbox transmission.

8.6.7

Bearing and Motor Temperature Probes

Bearing Temperature

Bearing metal temperature is a reliable indicator of the condition of bearings within a package equipment machine and included the following types:

Radial journal temperature.

Thrust bearing temperature.

Radial journal and thrust bearing temperatures are measured by thermocouples or RTDs embedded in the white metal temperature of the bearing elements. The standard default temperature sensor used is a 100 Ohm, platinum, duplex three lead resistance temperature detector (RTD). Burnout protection shall be provided for thermocouples.

The reliability of RTDs is now comparable to that of thermocouple temperature sensors.

Temperature transmitters are required for all radial and thrust bearing temperature RTDs which shall be mounted in a local Junction Box. One of the duplex bearing temperature RTD elements shall be kept as a spare and shall be connected to the local junction box.

In accordance with the design requirements within API STD 670, these measurements are taken in or near the loaded zone of the bearings. Bearings can run hot for several reasons including high load, high speed, and changes in lube oil supply.

Because the rate of change is typically slow, shutdown functions are not normally provided. However, there are machines where bearing temperature along with elevated vibration levels or excessive axial displacement can serve as a trip function. For example, in aero derivative gas turbines, a shutdown triggered by high bearing sump temperature might indicate distress or failure of the anti-friction bearings.

Motor Winding Temperature

Motor winding temperatures are measured by thermocouples or RTDs embedded in the motor windings. The standard default temperature sensor used is a 100 Ohm, platinum, simplex three lead resistance temperature detector (RTD). Burnout protection shall be provided for thermocouples.

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The reliability of RTDs is now comparable to that of thermocouple temperature sensors. Motor winding temperature measurements shall be taken on each motor phase (2 per motor winding phase) and should be monitored in accordance with the manufacturer’s recommendations, industry standards and practice, and plant experience. SUPPLIER shall refer to AGES-SP-02-002 and AGES-SP-02-007 for further Motor Winding Temperature requirements.

Each motor winding temperature RTD shall be connected back to a temperature transmitter mounted within a local junction box.

An audible alarm shall be activated within the control room to reflect the status of the motor winding temperature.

The motor winding temperature transmitters shall be wired to the Electrical Switchgear and not to the Machine Monitoring System / ICSS.

8.6.8

Velocity sensors

Velocity sensors are designed to measure absolute (relative to free space) bearing housing, casing, or structural vibration. Specialized piezoelectric accelerometers can be used that incorporate embedded integrated electronics in a solid-state design.

Velocity sensors that incorporate solid-state electronics and have no moving parts, will not suffer from mechanical degradation and wear, and can be mounted vertically, horizontally, or at any other angle of orientation.

8.6.9

Piston Rod Drop Monitoring

Piston rod drop monitoring shall be as defined in API 670. Proximity transducers shall be used to measure the drop of the piston rod during operation.

SUPPLIER is advised that Eutectic type piston rod drop detection may be considered for noncritical applications only.

8.6.10 Thrust Position Monitoring

Transducer location is very important for an accurate and reliable thrust position monitoring system. The objective of the system is to measure the actual thrust position. Therefore, care shall be taken to ensure that the system is not observing items such as thermal growth of the shaft.

Thrust position sensors can either be mounted externally or internally to the motor shaft. Advantages of externally mounted thrust position sensors are as follow:

Generally, a good viewing surface.

Gap may be changed while machine is running.

Disadvantages of externally mounted thrust position sensor are:

May not be close to thrust bearing.

Advantages of internally mounted thrust position sensors are as follows:

Generally, good viewing surface.

Close to the thrust bearing.

Disadvantages of internally mounted thrust position sensors are:

No access to transducer while machine is running.

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Cables shall be tied down due to “windage”.

Transducer cable exits shall be provided.

Care shall be taken to avoid oil leakage.

Non-integral thrust collars that require hydraulic tooling to fit and remove from the shaft can be considered a good surface for monitoring thrust position. Loose thrust collars include those that are kept in position with lock nuts and tab washers.

Thrust position monitoring is carried out using two thrust position monitors mounted at each thrust bearing.

8.6.11 Speed Measurement and Protection

Overspeed Protection

Package equipment expanders, gas and diesel engines, gas turbines and steam turbine drivers shall be equipped with an overspeed protection system that is independent of other control systems. Speed-measuring instruments are usually supplied as part of rotating equipment, and their make and type shall be as specified by the COMPANY.

On large rotating equipment, the speed measurement shall have a separate channel in the machine monitoring system.

The equipment OEM shall describe the overspeed design criteria and protection philosophy (including test facilities up to the expander inlet valve, and/or to the fuel gas trip valve and/or to the main steam trip valve).

The required system speed of response shall be determined based on OEM input. The range of the peak hold feature shall be at least 127 % of the rated speed of the driver.

The overspeed system shall respond within these limits to prevent damage to the equipment rotor and potential loss of containment.

A two out of three (2oo3) voting logic shall be applied on electronic overspeed detection systems, unless otherwise stated by SUPPLIER Package SIL Assessment (Section 7.8.3). Time delays are not allowed on any overspeed trip protection systems.

Online and offline Over speed test provision shall be considered (Automatic/Manual).

Speed Tachometer

For package equipment variable speed drives, SUPPLIER shall provide a Speed Tachometer.

The tachometer shall be digital, and its peak speed range shall cover all speeds up to 127 % of rated speed of the driver.

For steam turbine drivers it shall be possible to test the ability of the transducer to generate a speed signal once it has been installed in the machine. This shall be possible without the need to admit steam to the turbine.

This requirement is easily met if the turbine has a turning device capable of turning the rotor at a speed above the minimum threshold of the tachometer transducer. If the turbine does not have a turning device then consider designing, or ordering, a special test rig (e.g. a toothed wheel and a transducer mounting plate) that could test the transducers in the field immediately before their installation in the machine.

The steam turbine protection is at its most vulnerable when the start command has been given to the governor. At this point the tachometer transducer failure input has been overridden in order to allow the rotor speed to reach the minimum detectable by the transducer. Meantime the governor is opening the steam control valves.

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If the transducers fail to send a signal to the governor, then the turbine could start to turn as more steam is admitted. The next trip signal would be from a time delay for the speed signal reaching the governor, but this might be set too long to prevent serious damage or even an overspeed. Testing the speed transducers’ ability to generate a signal when installed would bring confidence in the governing and protection systems.

8.6.12 Process and Dry Gas Seals

Dry Gas Seals

SUPPLIER shall refer to AGES-SP-05-007 Rotating Equipment Auxiliary System specification for the technical requirements.

Process Seals

SUPPLIER shall refer to AGES-SP-05-007 Rotating Equipment Auxiliary System specification for the technical requirements.

Solar Powered Instruments

SUPPLIER shall not provide any solar powered instrumentation or equipment unless approved by COMPANY.

If COMPANY approval has been granted for the use of solar powered monitoring and control instrumentation equipment, then the SUPPLIER shall include this technology within the package equipment design.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed Solar Powered Instruments selection and requirements.

Multi Variable Instrumentation

Proposal to use multi variable instrument devices shall be agreed by COMPANY prior to implementation. Instrumentation able to measure more than one variable is available and continues to develop. For certain applications it may offer benefits, for example mass flow metering where one device may offer differential pressure, pressure, and temperature measurements. A single failure can affect all measurements. Avoid unless a significant benefit can be demonstrated.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed Multi Variable Instrumentation selection and requirements.

ANALYSERS

Analyser systems shall comply with API RP 555 Process analysers and EEMUA 138 Design and installation of On-line analyser systems. As a minimum, the analyser system shall be supplied and designed for unattended continuous operation.

An analyser house or analyser Electronics enclosure shall include, as applicable, signal converter/amplifier system, signal linearization electronics, power distribution, signal output and conditioning electronics, testing and calibration electronics, and diagnostics.

An alarm indication of analyser failure (or out of service), together with an alarm indication of low analyser sample flow should be provided direct wired to the main control system or area.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed Analyser instrument selection and requirements.

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FIRE AND GAS DEVICES

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed Fire and Gas Devices selection and requirements.

FINAL ELEMENTS

Control Valves

SUPPLIER shall refer to AGES-SP-04-002 Control Valve Specification for detailed Control Valve selection and requirements.

Actuated Valves

SUPPLIER shall refer to AGES-SP-04-005 Emergency Shutdown and On Off Valves Specification for detailed Actuated Valve selection and requirements.

Shutdown Valves

SUPPLIER shall refer to AGES-SP-04-005 Emergency Shutdown and On Off Valves Specification for detailed Shutdown Valve selection and requirements.

Bypass Manifolds

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed Bypass Manifold selection and requirements.

Emergency Depressurizing Valves

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed Emergency Depressurizing Valve selection and requirements.

Motor Operated Valve (MOV)

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed Motor Operated Valve selection and requirements.

Pressure Safety Valves

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for detailed Pressure Safety Valves selection and requirements.

MACHINERY MONITORING SYSTEM

General

Machine Monitoring of rotating equipment shall comprise of:

Machine Monitoring Instruments such as sensors, accelerometers, probes, key phasors, speed

tachometers, extension cables, etc.

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Machine Monitoring System consisting of:

i. Monitors with associated modules such as power supply modules, communication modules, relay

modules etc. installed in MMS Cabinet.

ii. First level of Machine Monitoring software with related hardware: computer, printer, and data storage

facility.

iii. High level software to assist reliability engineer in machine analysis and maintenance with related

hardware: computer, printer, data storage facility.

Machine Monitoring Systems shall be state-of-the-art and physically and functionally independent. The Machinery Monitoring Systems shall accomplish as a minimum the following:

Monitor the health of package equipment to detect and identify faults before they could potentially lead

to a shutdown state.

Hardwired machine trip outputs to ESD System for machine protection.

Machine condition data extracted from machine monitoring system to display data for reliability group.

A redundant communications interface for alarms and event signals.

Rotating machinery with drive units rated in excess of 500 kW, or where the machinery is judged to be ‘critical’, shall be continuously monitored by Machine Monitoring System for excessive vibration, axial displacement, over- temperature, over speed or degradation of performance over time etc.

Machinery of less than 500 kW shall not be continuously monitored. However, provision for connection of temporary hand-held monitoring equipment shall be provided (e.g. by the provision of ‘Flat Spots’ for inserting sensors), to allow the Reliability Engineering staff to obtain performance ‘snapshots’. This function shall be carried out using a portable data connector and data to be downloaded to the MMS server system. CONTRACTOR shall develop the proposed equipment list to be considered for Off-line condition monitoring and the list will be subject to review and agreement with COMPANY.

Machinery monitoring instrument and systems shall be in accordance with this document, AGES-SP-05-006, AGES-PH-04-001, API STD 670 and shall be subject to COMPANY inspection and approval. Machinery probes, devices and transmitters shall be interfaced to the MMS conditioning modules within the IES or locally installed on the packaged equipment if Local MMS is approved by COMPANY.

Unless otherwise specified by COMPANY, all new project facilities shall be provided with a Machinery Monitoring System (MMS) with reliability monitoring, performance and condition monitoring and diagnostic configuration. The latest proven MMS hardware and software configurations available in the market shall be from a supplier approved by COMPANY.

All machine monitoring related data from the machine monitoring racks shall be available on ICSS. In addition, all relevant process data on the ICSS shall be transferred to the MMS for the purpose of Advanced Machinery Analysis by Reliability Engineers using advanced software.

Analysis Software / Hardware required for monitoring diagnosing configuration shall be in accordance with the MMS SUPPLIER standards.

The proposed MMS computers shall be in accordance with CONTRACTOR specification and shall be approved by COMPANY. MMS servers shall have Ethernet port for connecting to networked printer facilities.

The MMS shall meet the highest Safety Integrity Level (SIL) specified for each of the functions in accordance with SIL Assessment. The MMS SUPPLIER shall supply a list of all single points of failure, which will affect other systems receiving outputs generated by the MMS.

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For system components that can be replaced while the system is running, the necessary steps to bring the components to full functional operation shall be described in the maintenance manuals furnished with MMS. Any device, which cannot be replaced while the system is running, shall be explicitly identified.

Functions and operation

The MMS shall provide, but not be limited to, the following functions and operations:

To protect the equipment machinery by providing predictive analysis methods using the SUPPLIER standard analysis hardware / software requirements that will determine the need for remedial action.

To assist reliability engineers in predicting and anticipating deterioration in rotating equipment with

enough lead time to permit corrective action prior the failure.

To assist reliability engineers in detecting deterioration of performance and efficiency using the latest SUPPLIER proven hardware/software requirements in order to take remedial action before unnecessary energy resources are consumed and equipment is subject to undue distress.

To provide machine trips to the ESD system on high vibration / axial displacement through individual dedicated hardwired contact. Implementation of the safeguarding functions associated with the MMS shall be through SIL certified modules (minimum SIL 2). However, to provide first out alarm in the ICSS operator screen, the individual analogue values and the corresponding alarm limits with time stamped data shall be interfaced with ICSS.

To provide system diagnostic alarms such as probe failure, module failure, rack fault, power supply fault

etc.

As a minimum, one pair of non-latching relays, alarm (alert) and shutdown (danger), shall be provided for

each transducer signal monitoring.

De-energise to alarm and de-energise to trip shall be the standard relay outputs.

The MMS System shall be able to, as a minimum:

Automatically acquire, analyse, monitor, and diagnose data obtained directly from field transducers or

other protection monitors.

Accept and off-load data collected by portable data collectors for further analysis.

The MMS shall be designed to allow transient analysis when equipment starts and stops.

SUPPLIER shall refer to AGES-SP-05-006 Rotating Equipment Minimum General Requirements and System Integration Specification for the required voting logic to be implemented.

Features

The MMS shall have the following features:

Interface with lower level monitoring equipment which will be interfaced to the ICSS by a redundant communication link.

Simultaneous acquisition of all data from an equipment train in order to be able to correlate and trend the

data unambiguously.

Real time transient and steady state data collection and analysis.

Adaptive monitoring capability, meaning that the monitoring parameters change automatically with

respect to machine states and machine operating condition.

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Ability to dynamically compare baseline and current signatures during run up and coast down operation.

Acquire process data from ICSS for high level analysis through a redundant communications interface

link.

Retransmit all data in conditioned as well as raw format for advance digitisation or third-party applications.

Machine Alarm and Shutdown Functions

Package equipment safeguarding shutdown functions (Trip functions), are required on rotating package equipment to prevent serious failures, which may result in either potential hazards to personnel, environment hazards or extended process unit downtime.

Package equipment machine trip functions shall be applied if there is insufficient time and/or opportunity for an operator to take corrective action to prevent a failure and consequential damage.

All package equipment trip functions shall be provided with a pre-alarm prior to a shutdown, in order for the appropriate pre-alarm action to be carried out. Package equipment pre-alarms alert the operators that a measured parameter is exceeding its value, indicating that corrective action is required. If this action does not restore acceptable conditions, operators can then initiate a manual shutdown before the equipment is automatically shutdown by the trip function.

Shutdown function design shall be based on the SUPPLIER Package SIL Review identified in Section 7.8.3.

Shutdown function design shall incorporate the recommendations of the original equipment Manufacturer (OEM) during the SUPPLIER Package SIL Review.

In cases where it is safer to keep the package equipment machine running to allow a process shutdown, the shutdown system should be sequenced to do so automatically so that the process is returned to a safe situation before the machine is shut down.

Package equipment alarm and trip settings are defined within AGES-PH-04-001 Automation and Instrument Design Philosophy.

Architecture and Communication

The machinery monitoring system shall interface with the ICSS network to enable the display of machinery monitoring data and trends on the operator workstations.

An off-line data collector shall also be supplied.

As a minimum, each EWS / configuration tool shall be based upon a current PC Notebook design meeting the OT security requirements.

However, final specifications shall be subject to COMPANY approval 6 months before FAT date. The supply shall include required operating system original license, configuration license and any other material with licenses to make it a fully functional system.

The MMS shall be able to interface with the ICSS to gather process values from the ICSS.

System Design

Instrument equipment, including all ancillary components, shall be installed within the IESs to interface to probes, or within the package equipment skid. The quantities shall be provided to the MMS Supplier when specific rotating equipment SUPPLIER information becomes available and shall be reviewed and confirmed by the MMS SUPPLIER to ensure the full functionality of the MMS system.

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Separate machine monitoring cabinets shall be provided in each IES on a process subsystem Basis for each group of rotating equipment within a unit and shall contain the following:

System Monitor Module.

Redundant Power Supply Module.

Redundant ICSS Communication Interface.

Vibration Monitoring.

Temperature Monitoring.

12.6.1 Measured Variables

Rotating equipment variables are to be measured by the MMS and will be derived as a minimum from the following devices:

Position / Proximity sensors.

Accelerometers.

Radial displacement (Vibration).

Axial displacements.

Key phasors.

Bearing and motor winding temperature probes.

Case expansion sensors.

Velocity sensors.

Thrust/valve position, rod drop.

Speed measurement and protection.

Process and gas seals.

All package equipment variables shall be derived using the machinery monitoring instrumentation identified within Section 8.6.

All machine and motor bearing temperature measurements shall be wired to MMS for data collection and trending analysis.

Motor winding temperature RTDs shall be wired to Switchgear for motor over temperature protection. Motor winding temperature analogues signals shall be made available to ICSS over the communication link from intelligent switch gear to ICSS and ultimately be available at MMS system via a redundant communications interface.

12.6.2 Monitors

The monitors shall be able to:

transmit monitoring data (such as shaft speed, differential expansion, bearing temperature, vibration, axial displacement) to a ICSS via suitable redundant (MODBUS) link, for display in the control room.

transmit monitoring data, via dedicated network to the MMS.

provide hardwired trip relay from the local monitor as inputs to the Emergency Shutdown System.

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12.6.3 Power Supply System

240 VAC, UPS, Single Phase, 50 Hz power supply from two independent separate power feeds from separate UPS shall be feed to the machinery monitoring system.

Redundant Power supplies modules shall convert 240 VAC 50 Hz power into voltage levels required by the system components. All systems shall be capable for accepting dual power supply feeds.

The redundant power supplies shall provide automatic switchover from one power supply to the other without affecting the operation or the integrity of the protection system.

Each power supply shall be capable of supplying 100 % power to the full system. Both power supplies shall be online at all times, each supplying power to the full system. Upon failure of a power supply, the load shall automatically shift to the other power supply. Faulty power supplies shall be able to be removed without removing power from the system or affecting control.

Each power supply shall be provided with primary and secondary overload protection. The secondary overload shall be self-resetting or have a time overload delay to prevent an instantaneous fault from tripping the system off. Over voltage protection shall be provided if it is necessary for the protection of the connected loads.

Each power supply shall be provided with a pilot light and with a fault detector. Failure of any power supply shall be signalled via a dry normally closed contact (opens on power supply failure) which shall be wired to a discrete input point for alarm indication on the ICSS console.

Spare power capacity shall be provided within the SUPPLIER power supply system to accommodate fully loaded cabinets and equipment installed in all bays, including all modules to be installed in future free slots and instruments connected to all channels.

12.6.4 Monitor Rack Layouts

Separate monitor racks shall be supplied for each large machine such as Turbine, Compressor or Turbo expander. Probes of redundant equipment of such machinery are assigned to separate racks so that any card failure will not affect more than one machine. However other machines were only few probes are used can be located in a single rack; however redundant machine probes shall not be connected in the same monitor. Probe assignment shall be submitted to COMPANY for approval, before proceeding for the manufacturing. Monitor racks shall be suitable for standard 19-inch EIA installations. Monitors shall be arranged in a logical arrangement. Internal arrangement of cabinets shall insure that sufficient access for maintenance shall be available.

12.6.5 MMS Cabinet

Refer Section 15.4 for MMS cabinet construction requirements.

12.6.6 Pre-Alarm and Trip Alarm Outputs

SUPPLIER to confirm the alarm and trip functionality identified within the appendices of AGES-SP-05-006, for the associated package equipment type. All pre-alarms for all points shall be generated from the machinery monitoring system and shall be configured and displayed in the ICSS.

Relay modules shall be provided for normally closed potential free trip contacts to hardwire to the ICSS where specified.

12.6.7 Display

As a minimum, the following plots shall be made available on the MMS:

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Spectra (Fast Fourier Transform, Zoom).

Spectrum histogram.

Trend plots.

Bode plots.

Polar plots.

Cascade plots.

Waterfall diagrams.

Nyquist plots.

Multiple spectra.

Orbit plots.

Digital displays shall be specified for shaft vibration axial position channels and temperature with the display updated at a minimum rate of once every two seconds.

12.6.8 Software

All machine monitoring system software shall fully comply with the Cyber/OT security requirements.

Operating Systems shall be based on the latest approved COMPANY standard, such as MS Foundation classes using OLE/ActiveX or equivalent. Operating systems shall have import / export capability of MS Office suite applications.

MMS shall be provided with the latest version of the operating and application system software and the Project’s Provisional Acceptance Test time. The package shall be complete to enable the user to upgrade the system at a suitable future time during a scheduled shutdown.

As mentioned above, the MMS shall be supplied with all the required software/hardware to:

Assist the COMPANY reliability engineer in detecting all incipient faults at an early stage.

Assist the COMPANY reliability Maintenance Engineers in evaluating the date when maintenance

operations are needed.

Assist the COMPANY reliability engineer to diagnose the origin of the detected faults, using a diagnostic

software.

To evaluate and monitor the performances of the equipment.

The MMS shall allow archiving at least 6 months of data on the machinery monitoring system such as a local or networked hard drive.

All machinery monitoring system files and historical plant data shall be archived automatically in a removable state-of-the-art medium. Removable archival media and system back-up media of latest technology shall be provided. COMPANY shall have the right to choose the equipment needed at the time of purchase order. The system shall provide an alarm for changing of the machinery monitoring media when the internal or external storage is 80 % full.

Performance monitoring shall include the following as a minimum:

Power Calculations.

Plot of Operating point on the performance map.

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Efficiency.

12.6.9 Time Delays

In order to prevent significant package equipment damage and plant exposure, overspeed trip functions, axial position trip functions, surge shutdown on axial compressors and manual trip buttons shall have no time delays in instrument package equipment system design.

All proposed time delays shall be subject to the approval of the COMPANY, prior to being implemented within the design. Time delays shall not be provided on any overspeed trip protection systems.

Typical package equipment shutdown PLCs, vibration monitoring systems, surge control systems and other instrument package systems can have built-in time delays as a standard feature, usually intended to prevent spurious trips caused by signal noise or fast transients.

The default shutdown time delay settings from the instrument MANUFACTURER/SUPPLIER shall be reviewed during system commissioning phase.

The default settings provided by the instrument MANUFACTURER/SUPPLIER will potentially already include a few seconds time delay. These individual time delays can add-up during the design phase and can ultimately exceed the specified Process Safety Time.

Start-up overrides and temporary start-up time delays shall be subject to approval of the COMPANY. There are some equipment packages where automatic start-up overrides (time and/or condition limited override during machine start-up) are necessary to enable equipment start up.

Depending on the facility/plant, time delays on selective trip points can be justified to prevent false trips from adversely rough weather conditions or other factors unrelated to equipment failure. In such cases, time delays should not be limited to just rotating equipment.

Before time delays are including within the package equipment machine trip functions, it shall be confirmed that the shutdown system design does not already include a system delay with the associated plant shutdown hardware.

If a machine trip time delay is required, the time delay plus the time to trip shall [PSR] not exceed the calculated Process Safety Time.

Time delays should be evaluated during the HAZOP process identified within Section 7.8.1.

12.6.10 System Fault Alarms

System fault alarms shall report individually and shall at least be provided for:

Field circuit/probe failures.

Monitor circuit failures.

Signal transmission faults (communication link).

Power supply failures.

Faults shall be reported to the ICSS through communication link for operator information and action.

12.6.11 Signal Isolation and safety

Hardwired analogue and the communication links outputs shall be fully isolated from the MMS power supply in order to prevent power supply interactions between transmitting and receiving systems.

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Intrinsic Safety active barriers shall be provided for all field inputs to the monitors.

For protection against EMI and RFI, all cables shall be shielded individually.

12.6.12

ICSS Communication Interface

The MMS shall include a redundant data communication interface to the ICSS. One redundant interface module shall be provided in each monitor rack for the purpose of communicating with the plant ICSS.

The communication interface shall allow multiple rack systems to communicate with the ICSS.

As a minimum it shall be possible to transmit the following signals from the MMS to the ICSS via communication link:

Analogue values representing monitor inputs (vibration, displacement, bearing temperatures).

Pre-alarm status including probe gas alarm if applicable (shut down alarm status shall be transferred from

ESD system).

System fault alarms (power supply station, self-check status channel bypass status, hardware, software

and communication link diagnostic alarms, probe/transducer health status).

The ICSS communication interface shall allow a one second response time for pre-alarms at the ICSS workstation.

A redundant communications interface to the ICSS shall be provided for process data transfer from ICSS to MMS to enable high level analysis, based on MMS SUPPLIER standards. The detail of the implementation shall be finalized by the CONTRACTOR.

A Communication Interface Test (CIT) shall be carried out by the SUPPLIER for review and approval by CONTRACTOR / COMPANY.

Analogue outputs for all measured variables shall be made available for ICSS display via system monitor communication interface, provided that the information on the link can be updated without reasonable transmission delays. The system data transmission rates shall be calculated by the SUPPLIER for approval by the CONTRACTOR.

All signals shall have individual alarm with clear description that reflects the status and the detector location. Common alarm is not acceptable in all MMS interfaces.

12.6.13 MMS communication system

The communication link between the IES (or from the MMS installed within the package equipment boundary) and the MCR backbone shall use fibre optic cables (supplied by CONTRACTOR).

There shall be dual redundant, diversely routed, multi-fibre optic cables for communication between MCR, IES and Substation. The dual redundant links are identified as follows:

Control Systems.

Information Systems.

Hardwired ESD and Electrical machine protection interfaces shall be provided between the following systems:

ESD Safety System.

Electrical Switchgear / ASD System.

Shared media Hubs with 24 Ethernet ports RJ45 and fibre backbone ports should be used, These Hubs shall be interconnected with the existing network over fibre Optic Links.

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Fast Ethernet switches should support / meet COMPANY LAN/WAN configuration and shall be provide with a minimum of 48 ports.

All the network components shall be fully compliant with the latest international standards from the following organizations: IEEE, ITU, IETF, EIA/TIA, OSI, ATMFORUM, and ANSI.

All Equipment shall be mounted in a 19-inch cabinet within a dedicated UCP/SCP or dedicated control panel, per COMPANY specifications.

The equipment shall be provided with adequate patching management units (troughs) to allow the routing of the patching cords.

For implementing System Time Synchronization, the SUPPLIER shall be responsible for setting the MMS time using GPS. This is to ensure that the MMS time is synchronized with the ICSS and all other relevant sub-systems.

12.6.14 Voting Logic

SUPPLIER shall refer to AGES-SP-05-006 Rotating Equipment Minimum General Requirements and System Integration specification for the required voting logic for the associated type of packaged equipment.

Machinery Diagnostics and Maintenance Prediction System

In addition to the detailed general requirements identified in Section 12.1, the following additional requirements shall be provided:

The system shall be capable of expansions and able to accommodate other inputs for future expansions.

The system will allow analysis of equipment start-up, shutdown, and any other transient phenomena. The data collection will be automatically triggered at start-up and shut down; data will be automatically uploaded to the hard disc drive of the main acquisition computer to facilitate post-transient analysis.

All necessary hardware, software and configuration shall be provided to achieve the above functionality.

The requirement for prediction and anticipation of deterioration with enough lead time shall be fulfilled as follows:

The system will monitor symptoms, i.e. data processed using well proven analysis techniques, directly

related to specific faults, allowing to trend.

The system will include a diagnostic expert system. This expert system shall be both easy to start up and

expandable with new symptoms and new diagnosis.

Compatibility of the MMS as a minimum with state-of-the-art specialized software packages for Electrical machinery, operation deflection shape, reciprocating compressor monitoring. SUPPLIER to give the list of such software with which their software is compatible.

The central computer / workstation of the system will have to be multi-tasking in order to allow simultaneous operation of the monitoring functions, diagnosis expert system, visualization on remote terminals etc, without perturbing the condition monitoring function.

The network components such as switches, hubs, routers, etc shall be installed in a separate cabinet/ junction box.

As a minimum, all workstations and servers shall have 21-inch LCD display monitor, 512 GB SSD hard disc, 8 GB RAM, USB port, DVD R/W drive, keyboard, and mouse. However, final specifications shall be subject to COMPANY approval 6 months before FAT date. The PC shall have wired keyboard, mouse, and the peripherals. This also applies to system monitor for servers. The workstation / server supply shall include required operating

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system original license. Workstation / server license shall be the Microsoft Windows 10 family and any other materials with licenses to make it a fully functional system.

The global architecture will include as a minimum:

An interface to monitors.

An interface to off-line data collector.

An interface to a computer or server, with display, streamer, network connection, printer etc, installed

with:

i. Multi-tasking operating system.

ii. Condition monitoring and prediction software. The maintenance prediction system shall be able to differentiate between different load condition, including start up and shut down and monitor machine characteristics accordingly, without creating any false.

iii. Diagnostic expert system.

iv. Performance monitoring software.

v. Reliability Engineers’ PCs.

All hardware including servers and computers shall be based on COMPANY approved Functional Design Specification (FDS).

Main control room

The following instrument equipment shall be supplied and installed within the main Control Room (MCR).

Human Machine Interface (HMI).

Communication interface.

Fibre optic interface if required.

Computer/workstation communication interface.

Interconnecting cables and wiring.

Data servers.

On-line condition monitoring hardware shall be provided in offices such as, Reliability Engineers’ Office (Rotating equipment) and the Maintenance Workshop Building, depending on the project facility which shall be confirmed with COMPANY. Equipment required for this purpose shall be supplied by the CONTRACTOR. MMS system shall have the capability of supporting the remote monitoring displays, as required.

ANTISURGE AND PERFORMANCE CONTROL

The anti-surge and performance control devices shall be of the latest proven technology and capable of advanced compressor protection and optimization. A fully functional serial communication link between the anti-surge control system and ICSS shall be provided.

For anti-surge control applications, attention shall be paid to the response time of the transmitters, valve actuators and associated positioners. For control valves used on anti-surge applications that are also used as a recycling line, careful consideration shall be given to selection of the trim and characteristic of the valve to meet the process requirements.

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SUPPLIER shall refer to the Corporate Specifications for anti-surge and compressor performance controller integration and technical requirements.

GAS TURBINE CONTROL SYSTEM

The Gas Turbine Control System (GTCS) shall include in its control all turbine, associated process compressor related equipment and auxiliaries. The GTCS shall be of the latest proven technology along with a proven track record of successful operation within similar applications.

SUPPLIER shall refer to the Corporate Specifications for gas turbine control system technical requirements.

EQUIPMENT PANELS AND SHELTERS

General

Wherever possible, instrument equipment panels shall be designed to avoid the use of local field control panels, with the preference for UCP/SCPs located in climatically controlled Instrument Equipment Shelter.

These shall be subject to COMPANY inspection and approval.

Instrument equipment panel materials of construction shall be as follows:

Outdoor - 316L Stainless Steel.

Indoor – As per COMPANY Specification.

The following Earthing Bars shall be provided:

Safety Earth (ELE).

Instrument Earth (INE).

Intrinsic Safety Earth (ISE).

Refer Section 7.10.2 for panel earthing requirement.

Cable entry shall be from the bottom wherever possible.

Panel terminal type shall be with test socket screw type Knife Edge terminals.

Active barriers shall be used in IS circuits.

All instrument panels, junction boxes and shelters shall comply with the future spares and capacity requirements identified in Section 7.4.18.

Panel height, width and depth shall be standardized as per project standard, unless deviations are approved by COMPANY. Packaged equipment SUPPLIER to advise the panel size dimensions in mm (L-W-H) along with the panel weight.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy, Instrument Panels section, for further Instrument Panel technical requirements.

Instrument Equipment Shelters

CONTRACTOR shall be responsible for the Instrument Equipment Shelters (IES), whilst the SUPPLIER shall be responsible for the associated package equipment panels and equipment to be installed within the IES.

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SUPPLIER and CONTRACTOR shall work closely together to ensure that all required information is available to both parties and that regular meetings and discussions are held during all phases of the project.

CONTRACTOR shall install climatically controlled Instrument Equipment Shelters at convenient places within the project facility and near to the packaged equipment wherever possible. Instrument Equipment Shelters may be located inside the blast pressure zones, depending on the location of packaged equipment.

Panels and equipment within the IES shall be painted so that the dominant type of equipment will determine the colour scheme for the rest of the equipment.

IES panels provided with lamp indicators on electronic PCBs shall have a transparent plastic or toughened glass windows to allow checking without opening the door.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for further Instrument Equipment Shelter technical requirements.

Local Panel / Gauge Boards

Local Gauge Boards shall be furnished by the Packaged Unit SUPPLIER including for auxiliary systems, such as lube oil consoles, seal gas modules, etc. Auxiliary systems shall have individual local gauge boards.

If the packaged equipment SUPPLIER contractually requires local start-up at the packaged equipment, start-up may alternately be from the packaged equipment Local Gauge Board / Local Panel. However, all input / output signals from the packaged equipment shall be repeated remotely to the ICSS.

In addition, for major equipment the Packaged Unit SUPPLIER shall provide local start/stop panels where specified. The local start/stop panels shall have essential monitoring gauges/lamps and push buttons for start/stop/emergency stop operations.

Local gauge boards / local panels shall be located on the skid edge of the packaged equipment easily accessed from the back and front, away from vibration and heat sources (steam outlets, steam traps etc.) and water sprays and shall be supplied complete with sunshades.

Control Panels

Control Panels shall typically house the following equipment, depending on the Instrument Package Equipment Type:

The Package control system (ICSS PCS controllers or SUPPLIER Controllers).

The Package safety system (ICSS ESD controllers or SUPPLIER Controllers).

The Package F&G system when applicable (ICSS F&G controllers or SUPPLIER Controllers).

The Vibration and Temperature Monitoring System racks when applicable.

The Anti-surge controllers when applicable.

Load sharing and performance controllers when applicable.

Gas Turbine Control System when applicable

The Package marshalling cabinets when applicable.

Modules for interface with ICSS

The signalling lamps, switches, push buttons, display screens, etc.

All panels (e.g. UCP/SCP/MMS) shall be designed and fabricated as per project specification.

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All panels shall be free standing, straight faced with sub-frame support and design approved by COMPANY. All panels shall have front and rear access (or both) as required. Mounting of modules/chassis on the swing frame is not acceptable.

Door switch activated lighting shall be provided for each panel within the IES.

Panel colour shall be COMPANY standard. Panels shall be painted in according with Section 27.2 of this specification. Panels shall be painted with a white interior colour regardless of their exterior colour. Panels shall be shipped with each colour of topcoat paint for field repair or any minor damage sustained during installation.

Individual fan failure alarm and high temperature alarm shall be provided for each panel. Cooling fans shall be designed as (n+1) nos. for each single panel. Instrument panels shall have a temperature switch with continuously adjustable set point range. Fans shall be replaceable on-line without shutting down the panel equipment or affecting the plant operation. Noise due to running fan(s) shall be less than 85 dBA with the cabinet doors open.

All panels shall be supplied fully assembled and wired and shall be provided with dust guards. Panel wiring shall meet the requirements of IEC 60332 for flame retardancy.

If COMPANY approves installation of electronic devices and instruments in field installed Control Panels / Cabinets, then such cabinets / panels shall be provided with dual air conditioners. Air conditioners shall not be mounted directly on the panel to avoid effects associated with vibration. They shall be mounted adjacent to the panel on a suitable rigid support or foundation. The supply and return air circuit of air conditioner shall be connected using suitable non-corrosive, UV rated medium and the its length shall be as short as possible.

Drawings such as the layout, wiring termination, power supply distribution drawing shall be provided specific for each panel.

ELECTRICAL

SUPPLIER shall refer to the Electrical details identified within this specification and refer to AGES-GL-02-001 Electrical Engineering Design Guideline for further Electrical technical requirements.

HEATING, VENTILATION, AND AIR CONDITIONING

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrument Design Philosophy for the technical requirements of the heating, ventilation, and air conditioning systems.

INSTRUMENT INSTALLATION

General

All packaged equipment instrumentation shall follow the installation requirements identified within this specification, AGES-SP-05-006 and associated API standards, AGES-PH-04-001, and standard installation drawings.

It is the CONTRACTOR responsibility to ensure that the installation requirements are strictly applied without any deviation. The CONTRACTOR shall do this by reviewing SUPPLIER documents, instrument specifications, installation and hook-up drawings and skid / package layout drawings.

Field instrumentation, instrument junction boxes and local gauge boards shall be easily accessible and installed so that accuracy, reliability, or maintainability shall not be impaired due to vibration, pulsation, temperature, contamination, or location.

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The measurement effect due to vibrations on all field instrumentation shall be less than ± 0.1 % of Upper Range Limit (URL) when tested in accordance with IEC 60770-1 Transmitters for use in industrial-process control systems - Part 1: Methods for performance evaluation.

Junction boxes, gauge boards and field instrument panels, are to be located on the skid edge in a safe place, easily accessed from back and front, away from vibration and heat sources and shall be fitted with sunshades.

All instrument and electric cables, sample lines and grounding cables shall be routed inside dedicated trays fully covered and protected against heat dispassion, oil splashing or leakage, mechanical shocks, vibrations or damage and shall not obstruct the access of any other equipment or instruments or obstruct human access either for operation or maintenance.

For future capacity and spare in instrument installation design refer Section 7.4.18.

CONTRACTOR shall carefully review the location of instruments and instrument equipment panels with regard to the package equipment skid and to the framework to ensure enough space is available to comply with all the above requirements.

Instrument Installation Details

The complete installation for each instrument will follow one of the typical installation detail drawings. These typical installation detail drawings will capture the instrument process piping, air piping, electrical connections, and mounting requirements. The applicable typical installation detail drawings for each instrument will be shown on an instrument index.

The installation details shall show the approximate configuration of the impulse piping and the instrument location relative to the process connections. The exact placement of the instrument and routing of impulse piping shall be determined in the field. However, the location of the instrument with respect to the process connection shall be as shown on the associated instrument location drawing. Each instrument typical installation detail drawing shall contain a list of applicable instruments and material required for each installation.

Package Equipment Instrumentation

Transmitters shall not be directly installed on the machine and shall have their own impulse lines up to transmitters. The impulse line shall have a primary isolation valve at the start of the line close to the machine or to the pipes as well as a secondary isolation valve at the other end close to the instrument item itself. A valve manifold shall always be used, and will either be 2, 3 or 5 way-valve as per Section 7.6.1 and shall not be considered as the secondary isolation valve mentioned above. Whenever one impulse line is used for more than one instrument, each instrument shall have its own independent secondary isolation valve to enable removal of each one complete with its manifold without interrupting the other instrument.

Temperature, vibration detectors shall be directly mounted on the machines or lines. These detectors shall have wide, safe, and easy access to maintain, calibrate, or remove them online without tripping the machine / equipment. For removal, enough space shall be considered to easily manipulate any required tools or loading equipment without the need to remove or shift any other pipes, cables, lines, instruments, or cable trays. Although the detector is directly mounted but its receiver / monitor shall be far installed on the control panel or in the control building.

If installation of the machinery monitoring probes is at a remote, unpopulated location, armoured extension cable shall be specified.

For final control elements, such as control valves, actuated shutdown valves, motor operated valves, and solenoid vales, the same accessibility rules as mentioned in Section 18.5 shall be applied. For ESD instruments, their

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primary and secondary isolation valves as well as their valve manifold shall be marked with red colour to differentiate them from other instruments.

Instrument Mounting and Supports

18.4.1 General

Support structures for following items shall conform to project standard drawings and AGES-SP-01-002.

Instruments.

Cable tray.

Filed installed local gauge boards / local panels.

Junction Boxes.

Instrument Air Headers and tubing

In general, Instruments and field enclosures may be mounted on pipe stands, building walls, steel columns, masonry structures of non-load bearing (of main structure) and offset from the surface to avoid collection of debris and water. Instrument pipe stands shall not be attached to grating, deck plate, handrails, or ladders.

Instrument stands shall be installed ensuring that they do not hinder removal of gratings or platforms to attend maintenance works beneath them.

They shall be located so that they will not interfere with aisle, space on platforms, or catwalks or tube bundle removal areas, overhead crane passage path etc. Instruments shall also be located so as to maintain clearances required for walkways, accessways and operation and maintenance of valves and equipment.

Sufficient space shall be left around the instrument for applying heat tracing, where required, and for removing the protective shades. The minimum clearance between any part of the instrument mounting system and surrounding structures or equipment shall not be less than 0.3 m to allow for insulation, painting, etc.

Instrument impulse, hydraulic, pneumatic and air supply lines shall be installed so as to maintain the clearances required for walkways, accessways, operation and maintenance.

Instruments and enclosures shall be provided with sunshades as defined within Section 18.10.

Instrument removal and reconnection shall be possible without disconnecting other fixtures and connections etc.

All panels such as UCP/SCPs shall be floor mounted in the Instrument Equipment Shelters (IES). SUPPLIER shall provide support requirements. UCP/SCPs or other equipment that is designated as floor mounted in IES shall be securely mounted to the supporting structure by CONTRACTOR in conformance with the project requirements.

18.4.2

Instrument Supports

Instrument process piping details are described as “close-coupled”, “semi-remote”, or “remote”.

Close-coupled instruments shall be supported by the primary valve and the primary valve shall be readily accessible. Close coupled instruments shall be supported from the associated process piping, and occasionally from adjacent structural members. The use of line-mounted supports shall be considered but requires the approval of the COMPANY / CONTRACTOR.

The semi-remote instrument is mounted from 1 to 2 metres from the primary valve and the primary valve is readily accessible.

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Remote instruments are mounted more than 2 metres from the primary valve.

Instruments shall not be line mounted when temperature or vibration from hydraulics or operating equipment will affect the operation of the instrument, or cause damage to instrument piping.

The manifold block, which forms part of the impulse line arrangement, shall be bolted to a mounting plate. Selection of the type of mounting plate depends upon the various components required and is shown in Table 18.1 below:

Table 18.1 Mounting Plate Selection

Mounting Plate

Description

When a sunshade is required

L-shape

When a junction box is required (in combination with a requirement for a protective housing for transmitter)

Rectangular

All others

Instrument piping shall be supported from pipe supports, pipe and any other permanent structure, except as follows:

Instrument piping shall not be supported from uninsulated pipes 51 °C and above or 4 °C and below, pipe or pipe supports, handrails etc., that would be subjected to above normal vibration.

Instrument piping supports shall not be welded to stress relieved equipment or internally line equipment. Instrument piping supports shall be sufficient to maintain the instrument piping in a neat manner

All applicable details for each installation shall be examined before work on mounting or piping is started. This is particularly important when sealing or purging is shown on the detail, and when heat tracing or special insulation is indicated.

Sufficient clearance shall be provided for the removal of the instrument cover or the instrument enclosure and for access to external adjustments.

All packaged equipment shall be piped and instrumented so that on-stream performance verification can be made.

Instrument Accessibility

Field instruments shall be accessible and ergonomically located within 500 mm arm sweep from an accessible height. The accessible height shall be between 1200 mm to 1600 mm from grade, a fixed platform, or specially constructed step for operability and maintenance.

Instruments shall be oriented so that electronics are accessible for maintenance. Field drive selections (start, stop, Hand-Off-Auto etc.) shall be located close to equipment for functional operation check from grade, a fixed platform, or specially constructed step.

Control points, electrical push buttons, switches, control panels and junction boxes shall be located at optimum height between 850 mm to 1300 mm without need to use ladders, scaffolding or to remove any piping, doors or floor plates and without need to enter the enclosure or to have a shutdown.

Heavy instrument items such as Control valves and Relief valves shall access space to use hoists, cranes etc. for lifting and moving to workshops for maintenance or testing. The installation shall provide access for maintenance for both valve and actuator.

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Tube fittings (connectors, unions, and tees) shall be staggered and offset when making multiple runs to provide maintenance access and save space.

Facilities for in-situ calibration or frequent withdrawals of instruments for maintenance shall be accessible from fixed platform or grating.

All solenoids shall be easily accessed from grade or a platform without opening the filter compartment or utilizing any ladder or scaffolding.

Instrument Process Connections

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for instrument process connection requirements. In the event that it is impractical or unreasonable to apply these process connection sizes due to application or access constraints; the package SUPPLIER shall request COMPANY approval to deviate from these requirements stating alternative connection method.

Instrument Tubing, Fittings and Valves

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for the Instrument process and pneumatic tubing, Fittings and Instrument Valve materials and technical requirements.

Instrument Process Piping

SUPPLIER to shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for the Instrument Process Piping requirements.

Instrument Air Piping

SUPPLIER to shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for the Instrument Air Piping requirements.

Sunshades

18.10.1

Instrument Sunshades

All electronic instruments, instrument junction boxes and local gauge boards located in an open area shall be protected against solar radiation and flare radiation with sunshades. Displacer type level instruments shall be protected with custom - made sunshade.

The instrument sunshade shall be fixed to the instrument equipment such that quick installation, removal and replacement is guaranteed.

Instrument sunshades shall be solar heat insulating UV resistant electrostatic-free fibre re-enforced polyester with 316 SS fastenings. The dimensions of the sunshade shall be approved by COMPANY.

Instrument and instrument junction box sunshades are not intended for dropped object protection of any nature.

Where instruments require shades which are not available as standard equipment or require specially made supports/brackets such as for tank gauges, etc., these shall be shown on detailed construction drawings, and a decision shall be taken whether these can form part of the installation activities or whether they should be requisitioned for prefabrication.

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18.10.2 Equipment Sunshades

Outdoor panels shall be engineered to meet requirements for weatherproofing and with rain/sunshade hood section (with a gutter) and outer lighting.

Cable and Wiring

18.11.1 General

All package equipment instrument cables and wiring shall comply with AGES-SP-04-006, AGES-GL-02-001 Electrical Engineering Design Guideline and Electrical power, control, and earthing cables specification.

All power, lighting, control, and earthing cables shall comply with AGES-GL-02-001 Electrical Engineering Design Guideline and Electrical power, control, and earthing cables specification.

All cables shall be installed in one unbroken length between two termination points. Cable splicing is not permitted.

Single cable runs from the junction box to the instrument in the field shall be routed, supported, and protected against mechanical damage with cable trays, steel angles, channels etc. as appropriate. These shall not be supported by process piping. The use of conduits is only permitted within the package equipment where small sections of conduit can only be used. In general, all cables shall be installed using cable tray, cable ladder or trunking within enclosures.

Instrument cables shall not be clamped to equipment, process piping, handrails, structural steel etc.

Near the instrument, a cable slack of at least 0.5 m shall be provided, to facilitate termination/disconnection. This portion of the cable shall be protected against mechanical damage by a flexible metal conduit if the cable is unarmoured.

In order to prevent galvanic corrosion, direct contact of trunking, trays, supports etc. to non-ferrous metal shall be avoided by applying proper insulating methods.

Cables connected to instruments which have the possibility of an internal release of flammable medium shall be provided with a sealing fitting to prevent liquid/gas transport.

For embedded sensors (e.g. bearing RTDs or load cell censors), cable sealing system shall be provided prior to cable gland to avoid oil seepage along the individual sensor cables.

Cable passages/ducts shall be designed such that cable laying and cable pulling is possible within the allowable mechanical properties of the cable. Cable manufacturers’ specifications shall be followed with respect to the minimum bending radius and pulling strength of the cables.

Cables shall enter the gland from below to avoid the ingress of water.

Instrument cables shall not be routed along with power cables.

All redundant cables shall be routed in diverse routes within different cable ladders or trays and shall not cross each other.

Where practical all cables shall be supported in hot dipped galvanized and painted steel trays. Cable tray installation will not obstruct access. Sunshades are required.

All cable ties shall be stainless steel with PVC coating treated to be resistive for ultraviolet radiation. Nuts and bolts shall be SS316 / SS316L.

Installation of cable on cable tray shall be restricted to 1 bank high.

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Cabling between the skids and the Packaged Unit SUPPLIER’s panels located in the IES shall be supplied by the CONTRACTOR (unless specified otherwise in the project Purchase Order / Material Requisition).

All field instruments shall be pre-wired to equipment boundary junction boxes at the edge of the skid(s) by the Packaged Unit SUPPLIER.

All wire entries into the equipment casings or bearing housings shall be provided with proper sealing against leakage. Stranded wires shall be crimped.

Field cable shield to be stripped at top of panel and shields terminated to earthing bar at the top. Field cable to be routed in a metallic tray not exceeding 60 % loading.

Maximum number of wires per terminal is one.

Extension wires or cables shall be installed with suitable environmental and mechanical protection.

18.11.2 Cable Separation Requirements

Separate cables and junction boxes shall be used for different systems like PCS, ESD, F&G, MMS, etc. Mixing the signals for different systems in one JB is not allowed. Also, within one system, separate junction boxes shall be used for different types signals e.g. Analogue (4-20 mA) and 24 VDC, thermocouple, RTDs, Machine Monitoring Instruments, IS and NIS, etc. In any case, mixing of AC and DC, low voltage, and high voltage in one JB is not allowed. Redundant signals shall be wired to different JBs.

Instrument cable routing shall be segregated as follows:

Low level signals mV; RTD; mA and 24 VDC Analogue and digital signals.

Power cables 110 VDC 240 VAC.

IS and non-IS cables.

Fibre Optic cables.

Instrument signal cables shall be separated from power cables and electrical equipment to minimize interference.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for further segregation requirements for junction boxes, cables, and cable routing.

18.11.3 Underground Cable Installation

CONTRACTOR shall be responsible for installation of underground cables between the package equipment skid edge junction boxes and the IES, ICSS Main Control Room or other remote building.

18.11.4 Above Ground Cable Installation

Cable tray or ladder racks supported from structures shall be used for overhead cable runs. Cable trays/ladders shall be laid in horizontal formation supported at a distance of not more than 2m (6ft) interval for rack and 1m (3 ft) intervals for tray. Mechanical and electrical continuity of all cable trays/ladders shall be maintained.

Cable trays / ladders / covers shall be heavy duty, hot dip galvanized and painted. Cable tray/ladder covers shall be provided where cables are likely to be exposed to direct sunlight and mechanical damage is likely to occur during plant maintenance. All cable trays up to a height of 1800 mm from ground level or working platform level shall be provided with cable tray cover irrespective of tray location. The covers arrangement shall allow free ventilation. Rungs for the cable ladders shall be welded to the side rails. Thickness of steel used for fabrication of cable tray/ladder/covers shall be 2 mm minimum.

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Cable trays if laid in multi-tier shall have sufficient maintenance access throughout the cable length.

Fibre Reinforced Plastic (FRP) material may be applied to marine installations only where high corrosion is a determinant factor. Material original colour shall be retained in this application.

All cable ties shall be of stainless-steel insert and PVC coating.

Where specified by ‘process safety discipline’, fire protection coating shall be applied to cable installation to enhance the temperature withstand to 1000 °C for one hour.

A minimum spacing of 300 mm shall be maintained between cables and high temperature surfaces.

Cable trays, ladders and covers shall be heavy duty, hot dipped galvanized after fabrication to 85 microns zinc coating. These shall be painted with one coat of primer and two coats of finishing paint at site before laying cables on them. Thickness of steel used for fabrication of cable tray / ladder / covers shall be 2 mm minimum.

Cables will be protected from the sun and mechanical damage (likely to occur during plant maintenance activities) with a stainless-steel (SS316 / SS316L) cover clip and bolting. Rungs for cable ladders shall be welded to the side rails.

Junction Boxes and Enclosures

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy for Instrument junction box, enclosure, and Smart junction box design requirements.

Cable Glands

SUPPLIER shall refer to AGES-PH-04-001 Automation and AGES-GL-02-001 Electrical Engineering Design Guideline for the Cable Gland requirements.

instrumentation Design Philosophy and

Cable Tray and Rack

SUPPLIER shall refer to AGES-PH-04-001 Automation and instrumentation Design Philosophy for the Cable Tray and Rack requirements.

Cable Trunking

Instrument cables shall be installed within cable trunking systems as follows:

The trunking shall be safely and easily accessible for maintenance purposes.

Vertical sideway position of cable trunking shall be preferred.

The trunking shall not obstruct traffic, nor interfere with accessibility or removal of process equipment. Main trunking shall be sized such that on completion of the project, cables will occupy only 70 to 75 % of the capacity.

The trunking should be routed away from hot environments and places with potential fire risks such as hydrocarbon process pumps, burner fronts of furnaces and boilers. Those parts of the trunking which will be laid in places where they are liable to damage by plant fires shall be provided with fireproofing.

The trunking shall be located away from places where they are subject to mechanical damage, spilt liquids, escaping vapours and corrosive gases. Where trunking riser points are liable to damage by traffic, they shall be protected by free standing and sturdy mechanical structures.

IS and non-IS cables shall be separated.

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The trunking shall be firmly supported. Wherever possible the supports shall be arranged such that

cables can be laid sideways into the trunking instead of pulling them through consecutive openings.

The trunking shall be internally smooth; bolts shall be installed with the head inside and the nut outside.

The trunking material to be hot dipped galvanized carbon steel and painted as per project specification.

Instrument Fireproofing

If fireproofing is specified by CONTRACTOR for the packaged equipment instrumentation, SUPPLIER shall:

Install any fireproofing materials supplied with the valve.

Ensure fireproofing is installed with access for maintenance.

Ensure fireproofing covers cable and tube entries.

Fire proofing shall be removal box type design considering removal and re fixing of all associated

equipment during maintenance.

SUPPLIER shall refer to AGES-PH-04-001 for further Fireproofing requirements.

LABELLING

General

SUPPLIER shall be responsible for ensuring that every item of equipment is identified by an accurate and legible permanent label(s) showing tag number and description.

A master tag list detailing all equipment to be labelled shall be prepared by SUPPLIER and approved by the CONTRACTOR prior to the making and fixing the package equipment labels.

As a minimum, the following devices shall be labelled by the SUPPLIER:

Instruments.

Cable, wiring and terminations.

UCP/SCPs.

Local Gauge Boards.

Local Panels.

Junction Boxes.

Instrument Equipment Shelters.

Instrument Tapping Points.

Permanent label fixings provided by SUPPLIER shall not affect the IP rating or hazardous area certification of the instrument or equipment the tag label is attached to. SUPPLIER shall rectify any instrument or equipment that is affected by an incorrectly attached label.

All labels shall have no sharp edges. Twisted wire which may result in skin puncture points shall not be used. i.e. labels and installation method shall be finger and hand cut proof.

All nameplates shall be manufactured with materials giving long service life within an aggressive environment.

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Abbreviations shall be standardised and agreed with COMPANY and then used consistently on all labelling nameplates and tag plates as specified in following sections.

Sources of energy shall be labelled with service and function at the point of distribution.

SUPPLIER shall follow the guidelines in the sections below regarding the labelling requirements to be followed.

Language for Nameplates and Tag Plates

All tag labelling shall be in English unless otherwise approved by COMPANY.

Instruments

The Packaged Unit SUPPLIER shall tag all instruments with a 316 stainless steel name plate, engraved with the following information as a minimum, except for local pressure and temperature gauges where the SUPPLIER’s standard nameplate shall be submitted to the COMPANY for approval:

Instrument Tag No.

MANUFACTURER’s name.

Model No.

Serial No.

Certifying Authority Markings.

Pressure/Temperature rating of pressure retaining parts.

Operating Range.

Calibrated Range.

Materials of Construction of all process wetted parts.

Project Purchase Order No.

The following information shall also be listed on the nameplate, where applicable:

Operating / max. voltage.

Operating / max. frequency.

Operating max power consumption.

Exceptions for using the MANUFACTURER’s standard nameplate shall be submitted to the COMPANY for approval, these may be, for example, local pressure and temperature gauges.

A separate instrument tag plate shall be mounted on Instrument Stand (in addition to the tag plate on instrument body) so that information on location of instrument is available even in case of removal of instrument. The tag plate shall be a laminated Traffolyte tag plate with tag number and service. The minimum height of lettering or numbering shall be 5 mm (1/4 in).

Instrument tag plates shall be coloured as follows:

Non intrinsically safe services shall be white / black / white.

Safeguarding and emergency shutdown service non-IS shall be red / white / red.

intrinsically safe services shall be blue / white / blue.

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Emergency and shutdown IS services shall be blue red blue.

Warning labels shall be yellow black yellow.

In case of the mounted instrument tag nameplate not being available on the instrument body, a tie-on tag plate shall be tied onto the equipment with a stainless-steel wire. The tie-on tag plate shall be installed in such a way so as not to allow water to collect behind the tag plate.

Junction Boxes

The Packaged Unit SUPPLIER shall tag all Junction boxes with a 316 stainless steel nameplate, engraved with the following information as a minimum:

Junction Box Tag No.

MANUFACTURER’s name.

Model No.

Serial No.

Certifying Authority Markings.

Materials of Construction.

Project Purchase Order No.

Junction boxes shall be provided with separate laminated Traffolyte labels installed on the front of the junction boxes, secured by stainless steel screws. Adhesive fastenings, stickers or temporary fixings shall be prohibited. The Traffolyte label shall contain the Junction Box number and the minimum height of lettering or numbering shall be 10 mm.

Separate Traffolyte labels shall also be provided within each junction box secured by stainless steel screws, to allow for panel identification when the doors are opened or removed. Traffolyte labels within the junction boxes shall contain the Junction Box Tag Number.

Junction box Traffolyte tag plates shall be coloured coded as follows:

Non intrinsically safe services shall be white / black / white.

Safeguarding and emergency shutdown service non-IS shall be red / white / red.

intrinsically safe services shall be blue / white / blue.

Emergency and shutdown IS services shall be blue red blue.

Warning labels shall be yellow black yellow.

Local Gauge Boards

The Packaged Unit SUPPLIER shall tag all Local Gauge Boards with a 316 stainless steel nameplate, engraved with the following information as a minimum:

Local Gauge Board Tag No.

MANUFACTURER’s name.

Model No.

Serial No.

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Certifying Authority Markings.

Materials of Construction.

Project Purchase Order No.

Local gauge boards shall be provided with separate laminated Traffolyte labels installed on the front of the local gauge board, secured by stainless steel screws. Adhesive fastenings, stickers or temporary fixings shall be prohibited. The Traffolyte label shall contain the Local Gauge Board tag number and the minimum height of lettering or numbering shall be 10 mm.

Local Gauge Board Traffolyte tag plates shall be coloured coded as follows

Non intrinsically safe services shall be white / black / white.

Safeguarding and emergency shutdown service non-IS shall be red / white / red.

intrinsically safe services shall be blue / white / blue.

Emergency and shutdown IS services shall be blue red blue.

Warning labels shall be yellow black yellow.

Local Panels

The Packaged Unit SUPPLIER shall tag all Local Panels with a 316 stainless steel nameplate, engraved with the following information as a minimum:

Local Panel Tag No.

MANUFACTURER’s name.

Model No.

Serial No.

Certifying Authority Markings.

Materials of Construction.

Project Purchase Order No.

Local Panels shall be provided with separate laminated Traffolyte labels installed on the front of the Local Panels, secured by stainless steel screws. Adhesive fastenings, stickers or temporary fixings shall be prohibited. The Traffolyte label shall contain the Local Panel tag number and the minimum height of lettering or numbering shall be 10 mm.

Separate Traffolyte labels shall also be provided within each local panel secured by stainless steel screws, to allow for panel identification when the doors are opened or removed. Traffolyte labels within the Local Panels shall contain the Local Panel tag number and the minimum height of lettering or numbering shall be 10 mm.

Local Panel tag plates shall be coloured coded as follows

Non intrinsically safe services shall be white / black / white.

Safeguarding and emergency shutdown service non-IS shall be red / white / red.

intrinsically safe services shall be blue / white / blue.

Emergency and shutdown IS services shall be blue red blue.

Warning labels shall be yellow black yellow.

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Control Panels

The Packaged Unit SUPPLIER shall tag all UCP/SCPs with a 316 stainless steel nameplate, engraved with the following information as a minimum:

UCP/SCP Tag No.

MANUFACTURER’s name.

Model No.

Serial No.

Certifying Authority Markings.

Materials of Construction.

Project Purchase Order No.

UCP/SCPs shall be provided with separate laminated Traffolyte labels installed on the front of the panels, secured by stainless steel screws. Adhesive fastenings, stickers or temporary fixings shall be prohibited. The Traffolyte label shall contain the tag number and the minimum height of lettering or numbering shall be 10 mm.

Separate Traffolyte labels shall also be provided within each UCP/SCPs secured by stainless steel screws, to allow for panel identification when the doors are opened or removed. Traffolyte labels within the panels shall contain the tag number and the minimum height of lettering or numbering shall be 10 mm.

UCP/SCP Traffolyte tag plates shall be coloured coded as follows

Non intrinsically safe services shall be white / black / white.

Safeguarding and emergency shutdown service non-IS shall be red / white / red.

intrinsically safe services shall be blue / white / blue.

Emergency and shutdown IS services shall be blue red blue.

Warning labels shall be yellow black yellow.

Instrument Equipment Shelters

All Instrument Equipment Shelters shall be tagged with a 316 stainless steel nameplate, engraved with the following information as a minimum:

Instrument Equipment Shelter Tag No.

MANUFACTURER’s name.

Model No.

Serial No.

Certifying Authority Markings.

Materials of Construction.

Project Purchase Order No.

Instrument Equipment Shelter shall be provided with separate laminated Traffolyte labels installed on the front of the Instrument Equipment Shelters, secured by stainless steel screws. Adhesive fastenings, stickers or temporary fixings shall be prohibited. The Traffolyte label shall contain the Instrument Equipment Shelter tag number and the minimum height of lettering or numbering shall be 10 mm.

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Separate Traffolyte labels shall also be provided within each panel in Instrument Equipment Shelter secured by stainless steel screws, to allow for panel identification when the doors are opened or removed. Traffolyte labels within the junction boxes shall contain the Instrument Equipment Shelter tag number and the minimum height of lettering or numbering shall be 10 mm.

Instrument Equipment Shelters tag plates shall be coloured coded as follows

Non intrinsically safe services shall be white / black / white.

Safeguarding and emergency shutdown service non-IS shall be red / white / red.

intrinsically safe services shall be blue / white / blue.

Emergency and shutdown IS services shall be blue red blue.

Warning labels shall be yellow black yellow.

Instrument Tapping Points

Instrument tapping points shall be provided with a tie-on tag plate indicating the instrument tag number destination, that is installed onto the equipment tapping point with a stainless-steel wire. The tie-on tag plate shall be installed in such a way so as not to allow water to collect behind the tag plate and shall not interfere with the operation of the instrument or equipment. Adhesive fastenings, stickers or temporary fixings shall be prohibited.

Instrument tapping point tags shall be coloured coded as follows

Non intrinsically safe services shall be white / black / white.

Safeguarding and emergency shutdown service non-IS shall be red / white / red.

intrinsically safe services shall be blue / white / blue.

Emergency and shutdown IS services shall be blue red blue.

Cable, wiring and terminations

19.10.1 Cables

All cables shall be tagged at both ends and on both sides of the terminal block. Tagging of cables shall indicate the instrument tag to which it is related. When cables / wires are used for interconnection, wire ferruling at each end shall have source / destination reference and terminal no. where it is to be terminated.

SUPPLIER to refer to AGES-SP-04-006 Appendix 1 for the cable datasheet and Appendix 2 for the cable designation / numbering requirements.

19.10.2 Wiring and Terminations

All cable cores shall be marked with core number / terminal number in accordance with the SUPPLIER’s Termination drawings.

Wiring shall be fitted with interlocking numbered identification ferrules in line with the SUPPLIER’s Termination drawings. The allocated ferrule number shall be unique for each wire or cable core within a panel. Ferrules shall be indelibly marked and fitted at both ends of each wire using printed heat shrink PVC sleeve wire marker. Paper ferrules and split ferrules shall not be used.

Markers of the “adhesive band” type shall not be used.

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The following describes the cross-ferruling philosophy to be used for instrument cable cores:

At instrument side: Instrument Terminal details + Field JB and its terminal number

If no markings exist at Instrument terminals, the cores are identified by “+” and “-“, except in the case of switches when “C” and “NO” or “NC” shall be used.

At JB side for instrument cable: JB TB (Terminal block) number + Instrument Tag number

At JB side for main cable: JB TB number + Marshalling cabinet tag and its TB number.

At Marshalling cabinet side: TB number of marshalling cabinet + Field JB number and its Terminal

number

INSTRUMENT RECEIVING, STORAGE AND INSTALLATION

General

Packaged equipment instruments and equipment items are designed for continuous operations in an outside atmosphere within the site environmental conditions. However, before they are in continuous operation, instruments are prone to potential damaged during storage and whilst waiting for commissioning and start-up.

Potential instrument and instrument equipment damage is caused by moisture, heat, corrosion, dirt, dust, fungus, manhandling, and aging. When an instrument is installed and operating within its design conditions, instruments and equipment generally require only minimum routine maintenance.

It is preferable for all package equipment instrumentation and equipment, to be received, installed, checked, commissioning and operational in as short as time as possible. However, there are limits to achieving this, due to other site construction and commissioning constraints. Therefore, during storage and installation, instruments and instrument equipment require adequate protection and storage to be carried out. Additional protection is required during longer term storage at site, where longer term storage is considered to be six months or more.

Instruments shall remain installed on the package equipment as much as possible and are to follow the SUPPLIER’s recommendations for storage, including if they are to be routinely powered. This will help to reduce any instrument component aging process. If the received instrument components cannot withstand the ambient environmental site conditions, as stated in the purchase order, SUPPLIER rectify the instrumentation or instrument equipment so that they are suitable for continuous operation in the environmental site conditions.

CONTRACTOR shall check any SUPPLIER special instructions on electronic instruments that are in an unpowered state with ambient environmental site conditions stated within Section 5.3, including temperature and relative humidity requirements.

Complete instruments and parts shall be stored in dust-free area at a controlled temperature environment. Sensitive parts such as a I/O cards and electronic components are to be covered in anti-static sheets.

Proper and careful storage and handling of package equipment instrumentation and instrument equipment is vital for ensuring that the equipment remains functional, operational and above all undamaged. The following are examples of package equipment instrumentation and instrument equipment:

Electronic instrument transmitters and local control instruments.

Machinery monitoring instruments.

Instrument cases for electronic components, relays, or switches.

Pressure, temperature, and flow switches, if approved by COMPANY.

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Temperature gauges (dial thermometers), pressure gauges, level gauges, flow rotameters and gauge

glasses.

Control valves, relief valves, solenoid valves and displacement level instruments.

Float switches, if approved by COMPANY.

Analyzer instruments.

Junction boxes

UCP/SCPs.

Local panels.

Local gauge boards.

Main control boards and racks.

ICSS equipment, computer, and peripherals.

Miscellaneous items.

SUPPLIER shall refer to the sections below and AGES-PH-04-001 for further receiving, storage and installation requirements.

Receiving and Storage

CONTRACTOR shall be responsible for checking and storage of the Instrumentation and equipment as they are received at the project facility, against the project specifications. CONTRACTOR shall examine the instrumentation and equipment to determine the following:

Taking delivery of equipment and material.

Secure storage of all items in environmentally controlled, vibration free conditions in conformance to

CONTRACTOR’s procedure.

Continuous stores monitoring and reporting equipment and material usage.

Advising COMPANY of any anticipated shortages to avert delays.

Compliance with the purchase specifications in relation to type, range, materials of construction, appropriate scales, and tags. A copy of the instrument specification shall be marked to record receipt and compliance with specifications.

Correct instrument and equipment tagging.

Identifying any shipping damage.

Relevant documentation provided such as installation and handling instructions.

Free of defects, possible damage, or shortage of parts. Any defects, deficiencies, damage, and shortage

shall be immediately reported for replacement or repair to new condition.

Orifice plates shall be identified by tag number and checked for nameplate data versus instrument data sheet. The bore shall be measured to ensure data sheet compliance and visually checked for physical defects (nicks and scratches). Orifice plates shall be stored to prevent physical damage to the bore. This procedure shall be applicable to other instruments as well, such as flow nozzles, venturi tubes, etc.

Receipt shall be marked on the project facility Field Receiving Report.

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Storage of Instrumentation

After receipt and inspection, all instruments shall be clearly marked with engraved tag numbers. Items shall be stored in accordance with the SUPPLIER guidelines for instrument equipment protection during field storage. The place of storage shall be recorded in permanent warehouse records so that each item can be easily located.

Instruments, instrument fittings, tubing, and bulk installation material shall be stored in a closed warehouse building protected against weather, flooding, entry of water or wind, and free of airborne dust, oil, and objectionable vapours. All instrument openings shall be sealed to prevent ingress of dirt and moisture whilst in storage.

Relief valves shall be palletized and stored and handled in an upright position.

At all times, the air shall be kept at a temperature well above dew point. Delicate instruments shall be stored well away from outside walls, undersides of roofs, off floors, and corrosive chemicals.

If space does not allow for all instruments to be in a warehouse, such items as control valves, relief valves, and other large valves may be stored outdoors, providing precautions are taken to protect them from the weather, flooding, entry of water or wind, and free of airborne dust, oil, and objectionable vapours. Control valves and other valves end flanges shall be covered with suitable covers.

Control panel storage shall be in a closed building with proper air cooling.

Meters and Meter provers shall be palletized. Openings shall be covered with suitable covers while under storage. If these devices could not be stored in a covered building they may be stored outdoors, providing precautions are taken to protect them from weather, flooding, entry of water or wind, and free of airborne dust, oil, and objectionable vapours.

Instruments that require storage under nitrogen conditions shall be connected to nitrogen cylinders provided with pressure gauges and regulators. Pressure regulator shall be set to provide a pressure inside the instrument higher than atmospheric to prevent ingress of air into the instruments.

Consideration shall be taken for the storage of electronic equipment, junction boxes, UCP/SCPs, local control panels, etc. An air-conditioned room shall be available for the equipment to protect against the environmental conditions.

Functional Check

Instruments such as transmitters, controllers, control valves, and relief valves, will undergo a functional check to confirm the calibration and operating range. Any deficiencies shall be rectified or replaced by the SUPPLIER.

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SECTION B PART II

CONTROL PHILOSOPHY

General

SUPPLIER shall insure that all software and communication links shall match and compare with other equipment/systems without any problems.

Switching from Manual to Auto shall be feasible from the following locations:

Local panel – SUPPLIER shall provide a permissive signal from the local panel, i.e. Auto position selected

in Hand-Off-Auto selector switch at Local Motor or Driver.

Remote local panel – provided there is a permissive from the local Hand-Off-Auto selector and also at

the remote local panel Hand-Off-Auto selector switch.

Packaged Equipment Panels for Start-Up

If required by the SUPPLIER in addition to the control from the ICSS located within the MCR, local start/stop panels will normally be located in the Field. The Packaged Equipment SUPPLIER shall indicate if there are any cable length limitations for equipment supplied.

SUPPLIER is advised that Instrument Equipment Shelters will be generally be in the vicinity of the equipment. The location of electronic instrumentation within the IES shall not require an operator to be in the IES for start-up or operational activities, and all required signals and commands should be provided to the ICSS located within the Main Control Room.

Start-Up Initiation

Remote start-up shall be from the ICSS located within the Main Control Room. The Packaged Equipment SUPPLIER shall ensure that all required signals for start-up, permissive and shutdown are made available at the equipment boundary junction boxes. If the Packaged Equipment SUPPLIER contractually requires local start-up at the Packaged Equipment, start-up may alternately be from the Packaged Equipment Local Gauge Board / Local Panel. However, all Instrument input/outputs of package Equipment shall be repeated remotely.

Whether the package control system is independent or configured within the ICSS system, the following shall be considered:

Start-Up Permissive Conditions:

A display page in ICSS shall indicate all the permissive signals with dynamic status whether they are healthy status or not. Timer bar shall display to show % of completion or remaining time to complete.

If all signals are OK, a “ready for start” message shall be displayed. If the package has its own control system same display contents shall be communicated and presented in ICSS to standardize operation from all package Equipment.

Start-up Sequence:

A display page in ICSS shall indicate all the start-up steps dynamically either it is completed nor not. After all steps are completed a message shall display indicating successful start-up. Timer bar shall also be available to indicate the time completion %.

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Under certain conditions, warm start of operations from local panels is acceptable provided monitoring at the local panel is pursued, during transfer of control.

Control and Monitoring

Irrespective of the package equipment type identified within section 7.2, package equipment and its auxiliaries shall be possible to operate from the ICSS. Accordingly, the package equipment control system shall be fully integrated with plant ICSS. The control, monitoring, start up and shutdown shall also be possible from the package equipment HMI in the IES and ICSS.

SUPPLIER shall refer to AGES-PH-04-001 Automation and Instrumentation Design Philosophy, Graphic Hierarchy section, for further HMI and graphic requirements.

21.4.1 Stand-by Equipment

Duty and stand-by pumps shall be designed such that any pump can be selected as duty or stand-by. Necessary selector switches and alarms shall be provided. Stand-by pump design shall be suitable for simultaneous operation during testing of stand-by pump.

I/O cards, power supply, cabling, Standby equipment shall not share any of instrumentation/controls, auxiliary equipment, or isolation valving of the main equipment. Pressure differential control valve (PDCV) and pressure safety valve (PSV) on pump discharge shall be installed in individual pump discharge lines. PDCV and PSV shall not be located in common discharge line.

the control system

Packaged Equipment Sequencing

As per the applicable package category, sequencing shall be integrated as part of the plant ICSS. The Packaged Equipment SUPPLIER shall provide sequence matrices and review CONTRACTOR and ICSS SUPPLIER designs and participate in testing of the sequence dynamic logic display at the ICSS FAT and Package Equipment SAT as required by COMPANY / CONTRACTOR.

Dynamic power flow logic display in ICSS shall be provided for sequence and cause & effect diagrams. These shall be developed in accordance with IEC 61131 Programmable Controllers – Programming Language.

Packaged Equipment ESD System

The packaged equipment ESD system shall be integrated as part of the plant wide ESD system. The package equipment SUPPLIER shall provide cause and effect diagrams of the shutdown ESD requirements for review and approval by CONTRACTOR / COMPANY.

SUPPLIER shall participate in the package equipment FAT and SAT as required by CONTRACTOR / COMPANY.

SUPPLIER shall refer AGES-SP-04-004 Emergency Shutdown (SIS) System Specification for further technical requirements.

to AGES-PH-04-001 Automation and

instrumentation Design philosophy and

Vibration and Temperature Monitoring

Proximity probes, proximeters and RTD temperature sensors as required shall be provided and shall be wired to equipment boundary junction boxes. Monitoring equipment shall interface to the plant ICSS and to the plant-wide machine condition and performance monitoring system.

All Vibration Probes fittings shall be of the same manufacturer as probes, unless specified otherwise by COMPANY.

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All Vibration, temperature elements shall have their own built-in housing box. Housing box shall be 316L. Stainless steel cover shall be tied with the body via a stainless-steel chain.

Anti-Surge, Load Sharing, Performance Controllers

Anti-surge and load sharing control implemented in the integrated Turbine or Compressor control system is acceptable. The control system shall meet the scan time requirements for the anti-surge loop.

If separate system is considered, the Anti-surge and Performance Control shall be the latest proven model from a supplier approved by COMPANY. All controllers shall be provided with an interface to the plant ICSS System. The Packaged Equipment SUPPLIER shall provide machine operating parameters, machine curves and other information required by the CONTRACTOR for interfacing with their equipment.

For simple compressors and blowers, the anti-surge controllers can be incorporated into the ICSS after COMPANY approval, if compressor/blower SUPPLIER approves such implementation based on a proven track record.

EWS shall be provided with engineering diagnostics and tools such as trending, alarming, compressor maps etc.

Turbine/Compressor Sequence Control

Control and safeguarding functions shall be implemented in the turbine/compressor control system. Start up, shutdown shall be carried out from the plant ICSS/ESD and shall also be possible from package HMI located within the IES.

Dynamic power flow logic display shall be provided for sequence and cause and effect diagrams.

Speed and Fuel Control (Gas Turbine)

Speed and Fuel control shall be integrated into the Gas Turbine Control system. The Packaged Equipment SUPPLIER shall provide an approved electronic governor system which shall be interfaced to the ICSS.

Fire & Gas Systems

F&G sensors shall be supplied based on COMPANY / CONTRACTOR recommendation in line with other plant F&G sensors. Proven sensors shall be supplied. Consideration for open/closed path continuous gas detectors shall be given in combination with point detectors.

F&G Detector for Package Equipment shall be connected to Plant F&G System. However, SUPPLIER shall be responsible for supplying the redundant Fire and Gas Detection System for any SUPPLIER supplied equipment enclosures e.g. Gas Turbine Enclosures. Common Alarm and Status signals, as agreed by the COMPANY, will then be hard-wired to the plant F&G System.

SUPPLIER shall refer to AGES-PH-04-001 Automation and instrumentation Design philosophy for further technical requirements.

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Alarm and Shutdown Philosophy

The shutdown of package equipment shall be from MCR and field. The alarm and shutdown systems shall be designed to be fail-safe. Alarm and shutdown systems shall be normally energized in normal running conditions and de-energized to alarm and shutdown.

Alarm system shall be designed in compliance with ISA 18.1. A lamp test facility shall be provided for the unit control panel.

3-way universal type solenoid type valves shall be used for trips and interlock functions. Solenoid capacity, port, and connections shall be sized according to valve stroking requirements. Solenoid coil shall be designed to be a permanently energized (hot coil).

Local ESD push buttons shall be provided with alarm/light at the local panel and be repeated into the ICSS alarm logging systems. Push button shall be back lighted and guarded with cover and a flap.

Alarms for all shutdown initiators shall alarm into the ICSS alarm logging system and shall be repeated at the local panel. Alarms from the packaged equipment which are to be annunciated on the local panel, ICSS and ICSS+Local panel are to be identified during HAZOP and P&ID reviews.

If the SUPPLIER provides a packaged equipment control system, a remote acknowledge and reset facility from the ICSS shall be provided.

Pre-Alarms, where remedial action can be taken, shall alarm into the ICSS alarm logging system.

Recording of sequential events shall be done in the ESD / Package control system through a first out event identification.

First out alarm shall be clearly identified and reported in the machine control system (in case stand-alone system is approved by COMPANY) with a time stamp. This first-out alarm shall be communicated to ICSS system with time stamp of package Equipment control / ESD system in case of stand-alone system.

SUPPLIER shall participate in Alarm Management Workshop.

Interface Requirements

All packages and associated control systems shall interface directly and as seamlessly as possible with the ICSS. The interface shall enable full monitoring and control of these packages from the ICSS with total integration of the package control systems (e.g. MMS, Anti-Surge, GTCS, PLC system)

Interfaces with third-party systems shall utilize well proven and reliable interface protocols. All Interfaces shall have redundant hardware configuration with automatic bump less switch-over to the redundant link.

Interface protocols include the following:

Modbus over Ethernet (TCP) shall be utilized where:

Native timestamp data is not required

Possible logic execution is expected

Driving the interface link with dedicated module that becomes part of a ICSS controller

All Modbus over Ethernet (TCP) interfaces shall be redundant

OPC shall be utilized where:

Native time stamp involving bulk process data transfer is required

No executive actions are required through the interface

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Data used for information and further analysis/processing purpose only

The ICSS shall be capable of OPC connectivity as a server as well as a client with other hosts and sub-systems. The OPC link shall be fully redundant hardware configuration with automatic switch-over to the redundant link.

OPC servers shall conform to the necessary standard for the data being transferred (Alarm and Events,

Data Access, Historical Data Access, Data Exchange).

OPC servers shall not use more than 60 % of any resource (memory, CPU processing time) at commissioning. Ethernet communications shall not use more than 20 % of the available bandwidth at any point on the network.

All OPC interfaces including the servers shall be redundant.

The design of all interfaces shall be subject to COMPANY approval.

The Electrical Switchgear / ASD interface shall terminate at the Junction boxes at the edge of the Packaged Equipment skid. CONTRACTOR shall provide implementation up to Switchgear / ASD and ICSS including data interfaces. SUPPLIER shall also refer to AGES-GL-02-001 Electrical Engineering Design Guidelines and with the requirements specified within the relevant COMPANY Business Unit Standard(s).

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SECTION C – OTHER REQUIREMENTS

SCOPE OF SUPPLY AND ENGINEERING

Scope of Supply

SUPPLIER shall refer to Appendices 2A, 2B and 2C for the packaged equipment scope of supply for the three defined instrument packaged equipment types A, B and C.

The packaged equipment scope of work shall be based on the following unless approved otherwise by COMPANY.

CONTRACTOR shall be responsible for all interface connections between the package equipment skid edge junction boxes (or directly from the instruments on some of the Type A packages) to either the IES or directly back to the ICSS system.

Equipment located within the package equipment boundary, including field instruments and panels shall

be supplied and installed by SUPPLIER.

Scope of Engineering

SUPPLIER shall refer to Appendices 3A, 3B and 3C for the packaged equipment scope of engineering for the three defined instrument packaged equipment types A, B and C.

QUALITY CONTROL AND ASSURANCE

General

Instrument package equipment shall only be purchased from SUPPLIERs and SUB-SUPPLIERs approved by COMPANY. This approval indicates that the SUPPLIER has an approved Quality Management System and a proven track record in supply of this equipment type.

The SUPPLIER shall submit a proposed list of SUB-SUPPLIERs for all major components to COMPANY for approval prior to order placement.

Quality Management

The SUPPLIER shall operate a quality management system established for the supply of products or services which shall conform to ISO 9001 or equivalent quality management system standard agreed with the purchaser.

The SUPPLIER’s quality management system shall always have in effect a QA/QC program which clearly identify the established lines of authority and responsibility of those responsible for the SUPPLIER’s quality management system. Those persons responsible for quality management shall have ultimate authority to enforce quality assurance within the SUPPLIER’s organisation and to identify, assess and implement corrective actions (CA) to deficiencies identified in the quality management system and to monitor the continued effectiveness of all corrective actions.

The SUPPLIER shall submit a copy of their corporate Quality Plan and valid ISO 9001 or equivalent certificate to the CONTRACTOR / COMPANY with their quotation for review prior to award. If SUPPLIER’s QA/QC program and facility, where the work is to be performed, is ISO 9001 certified and still valid, then only a copy of the SUPPLIER’s valid ISO 9000 certificate is required. If the SUPPLIER’s facility is not ISO 9001 certified, the CONTRACTOR may at their discretion conduct a QA audit in accordance with ISO 9001 audit requirements,

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unless the SUPPLIER can provide evidence that he is operating a quality management system in accordance with ISO 9001 or equivalent quality management system international standard.

ISO 9001 Clause 8.1 and ISO 10005 may be used as a basis for the development of quality plans for specific applications, processes or products may be used as a basis for the development of Service Quality Plans.

Quality control and associated inspection activities by the SUPPLIER on their SUB-SUPPLIERs will address both internally and externally sourced processes, products, and services.

The SUPPLIER’s inspection and test plan(s) shall include provisions for COMPANY / CONTRACTOR inspection; as per Section 25, and contained within the purchase order.

Irrespective of the Inspection Class defined within the purchase order, the SUPPLIER shall remain fully responsible for the operational planning and control of the supplied documentation, material sourcing, fabrication, manufacturing, inspection and test activities in order to ensure full conformity of the supplied products and services with the specified requirements. Refer to ISO 9001, sub-sections 8.1 and 8.2.

The SUPPLIER shall ensure that all applicable QA/QC, inspection, and test requirements specified by the CONTRACTOR are included within the sub-orders to their SUB-SUPPLIERs to ensure full compliance to the purchase order requirements. If requested by COMPANY / CONTRACTOR, the SUPPLIER shall provide clear evidence of the required QA/QC surveillance of SUB-SUPPLIER activities.

The SUPPLIER shall submit certified reports of production tests as soon as the tests are completed satisfactorily.

The COMPANY / CONTRACTOR reserves the right to inspect materials and workmanship at all stages of manufacture and to witness any or all tests at the SUPPLIER’s and/or SUB-SUPPLIER’s premises. A dedicated inspection and test plan (ITP) shall be developed by the SUPPLIER as outputs to operational planning and to ensure quality control of the products or services to be provided by the SUPPLIER and their SUB-SUPPLIERs.

The SUPPLIER shall provide the CONTRACTOR with a copy of the manufacturing Inspection and Test Plan (ITP) for review and inclusion of any mandatory COMPANY / CONTRACTOR required witness points no less than 30 days after contract award or prior to the Pre-Inspection Meeting (PIM), whichever comes first. The inspection and test plan (ITP) shall specify the individual tasks to be performed, the procedures used and associated acceptance criteria to be applied by the SUPPLIER, SUB-SUPPLIER and/or MANUFACTURER to ensure that the materials or services are delivered in full conformity with the specified requirements.

Quality Plan

The SUPPLIER’s Quality Manual shall provide details for the preparation of a Quality Plan, which shall include provisions for the QA/QC of services activities. The Quality Plan shall be submitted to COMPANY for approval. Moreover, in case of any revision in the Quality Plan due to change in Quality Management System, then the revised Quality Plan shall be submitted for COMPANY approval before initiating any service activities.

The level of detail required in the Quality Plan shall be commensurate with the scope of services provided.

The quality of works is an essential factor in carrying out all services and activities covered by this Document.

During services/activities, Quality Assurance / Quality Control issues are the responsibility of the SUPPLIER and shall be approved and certified by a Third-Party Authority.

All conflicts among CONTRACTOR, SUPPLIER and Third-Party Authority shall be reported in writing to COMPANY for resolution.

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SUB-CONTRACTORS / SUB-SUPPLIERS

The packaged equipment SUPPLIER shall assume full responsibility and overall guarantee for the equipment package and associated equipment.

The packaged equipment SUPPLIER shall transmit all relevant Purchase Order documents including Specifications to their SUB-SUPPLIERs and SUB-CONTRACTORs.

It is the packaged equipment SUPPLIER’s responsibility to enforce all Purchase Order and Specification requirements on their SUB-SUPPLIERs and SUB-CONTRACTORs.

The packaged equipment SUPPLIER shall submit all relevant SUB-SUPPLIER and SUB-CONTRACTOR drawings and engineering data to the CONTRACTOR / COMPANY.

The packaged equipment SUPPLIER shall obtain and transmit all SUB-SUPPLIER and SUB-CONTRACTOR’s warranties to the CONTRACTOR / COMPANY, in addition to the system warranty.

INSPECTION, TESTING AND CERTIFICATION REQUIREMENTS

SUPPLIER shall refer to AGES-PH-04-001 for Inspection, Testing and Certification requirements.

SPARE PARTS

Spares

26.1.1 General

CONTRACTOR shall be responsible for obtaining recommendations for spares holdings from the package equipment SUPPLIERs and where requested, make recommendations based on the project operations and maintenance philosophy to meet the desired level of plant availability.

Spare parts recommendations shall be based on data from suppliers, experience with equipment and parts use in similar applications, and requirements of the operating unit.

Spares required for commissioning shall be part of scope of supply, but operational and maintenance spares will not.

The following factors and their impact on facility operations shall be taken into account in making recommendations:

MTTR.

Spared or single train unit.

Critical nature of service.

Severity of application, including jobsite environment.

Availability of qualified craft maintenance personnel.

Accessibility of jobsite to qualified service engineering.

Availability of local stock at jobsite.

Long delivery / lead items.

Deterioration in storage.

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Economics of ordering high cost items with original equipment such as rough machined forgings, spare

rotor assemblies, complete spare units, and subassemblies.

Proactive obsolescence management strategies need to be developed, particularly for subsea hardware.

Instrument spares shall be readily usable by replacing the faulty item within the packaged equipment. If special jumpers or address switches made to be changed, those shall be made ready for the specific application and shall be listed clearly on the spare part, packing documents with reference to the project number and machine contract number.

SUPPLIER shall provide order preparation services for spare parts and consumables during the warranty period and for 2 years operation. This cost assumes that the procurement service will be executed within a period such that the order to the SUPPLIER is placed before the corresponding SAT is carried out. COMPANY will place the order directly to the SUPPLIER. All cost of material, packing, shipping, clearing, custom duties. If applicable, delivery to site will be paid directly by COMPANY.

26.1.2 Start-Up and Commissioning Spares

The SUPPLIER shall supply start-up and commissioning spares, as required in order to avoid using any of the recommended spares. The cost of start-up spares shall be quoted separately in advance for review. The time scales and procedure for repair and/or replacement of parts shall be stated in the SUPPLIER’s bid.

26.1.3 Operational Spares

The SUPPLIER shall review the equipment (including tools, testing and calibration equipment) offered in their proposal and shall include a comprehensive recommended spare parts list enough for two (2) years continuous operation of the equipment and one-year consumable spares.

Special Tools

SUPPLIER shall furnish, all special tools required for installation, commissioning, dis-assembly, and re-assembly of their equipment. These shall include but not limited to the following per equipment package.

Software (including any third-party software) configuration devices for all controllers, I/O modules.

Software (including any third-party software) for reconfiguration of operator interface.

Diagnostic software and hardware for all electronics.

CONTRACTOR as well as technician level diagnostic software for all machine condition/performance

monitoring, machine condition/performance evaluation.

Any special instrument tools to dismantle impeded instrument items.

Special test clamps or leads for electronic/instrument checks, if any.

SUPPLIER shall provide with their proposal a list of special tools included in their offer. For multi-unit installation of three and more than three identical units, two sets of special tools shall be provided. For two identical units, one set of special tools shall be provided. Tools required for use during normal operation shall be suitable for the specified area classification. All special tools shall be packaged in metallic containers.

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 their standard items of special tools and test equipment.

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PAINTING, PRESERVATION AND SHIPMENT

General

All painting and coating systems shall meet the performance requirements and the coating systems identified within AGES-SP-07-004 Painting and Coating specification with a minimum environment of Category CX, ISO 12944-9.

The SUPPLIER shall guarantee performance of the paint and / or lining (shop and field) as follows:

External blasting / painting - 5 years.

Internal blasting / lining - 6 years.

TSA - 10 years

Surface Protective Coating and Painting

Instruments and the following items shall be protected against paint used on equipment and process units:

Glass fronts.

Moving parts, i.e., control valve stems and positioners.

Vents and drains.

Name/data plates.

Tube fittings and cable glands.

Isolation and vent valves.

Panels and equipment in Control Rooms and Instrument Equipment Shelters (IES) shall be painted so that the dominant type of equipment will determine the colour scheme for the rest of the equipment.

Painting shall be to MANUFACTURER’s standard for items not addressed in COMPANY specification or undefined within this specification, in such case SUPPLIER shall furnish their standard painting procedure for approval prior to manufacturing for approval. Colour and finish shall be to MANUFACTURER’s standard for items not identified by COMPANY.

Instrument cases shall be corrosion resistant Stainless steel. Non-stainless-steel metallic cases when approved by COMPANY shall have marine painting. Marine coating finish is required on both materials.

Colour Finish Schedule (to BS 4800 or approved equal by COMPANY).

Packing and Shipping

Preparation for shipment shall be in accordance with the COMPANY Standard(s) for Preservation and Export Packing. 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.

All material shall be packed/covered with suitable material to provide physical protection during transit, ordinary storage, and handling operations. Packing shall ensure that material will be protected from water/humidity/dust. Adequate protection shall be provided to prevent mechanical damage and atmospheric corrosion in transit and at the jobsite.

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Preparation for shipment and packing will be subject to inspection and rejection by COMPANY’s / CONTRACTOR’s inspectors. All costs occasioned by such rejection shall be to the account of the SUPPLIER. Special precautions required during transport and handling shall be clearly marked externally on packings of all materials.

Packing shall be road-worthy, sea-worthy (open deck storage) and air-worthy as per transportation basis.

After inspection and test, equipment shall be completely free of water and dry before start of preparation for shipment.

Equipment shall be packed, securely anchored, and skid mounted when required. Bracing, supports, and rigging connections shall be provided to prevent damage during transit, lifting, or unloading. All temporary bracing / supports shall be marked “REMOVE BEFORE EQUIPMENT COMMISSIONING AND START-UP”.

Cabinets and instrumentation shall be packed separately; other loose or small parts shall be properly packed and protected to prevent loss or damage to equipment. The cabinet shall be braced or strengthened to avoid distortion. The Vendor shall be liable to make good any damage during transit.

Flanged openings shall be protected with metal cover plates to prevent damage and ingress of foreign matter during shipment. Covers shall be a minimum of 6 mm thick and shall be installed with a full-size gasket using a minimum of 4 full diameter bolts. Large diameter flanges will require enough full diameter bolts to seat the cover all around. The cover and flange shall be taped for waterproof protection.

Open ends of tubes and pipe shall be capped for protection and to prevent ingress of foreign matter. Female threaded connections shall be plugged with solid metal pipe plugs, and male threaded connections shall be protected with full metal pipe caps.

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 CONTRACTOR ‘s order 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.

Exposed finished and machined surfaces, including bolting, shall be given a coating of rust inhibiting compound. Internal metal surfaces shall be sprayed or coated with a suitable rust preventative prior to shipment. Openings shall be suitably tagged to indicate the rust preventative applied.

Heavy-duty plastic foil and silica gel shall be used for safeguarding and sealing of all parts sensitive to moisture. Provide additional external reinforcing against mechanical damage. Mechanical seal assemblies shall be fully protected from rusting and entry of moisture and dirt.

Each consignment shall be clearly marked with the complete Purchase Order, requisition number, description of its contents and its intended project name.

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.

Construction site and CONTRACTOR shall be notified in advance of the delivery date and time of transport.

The SUPPLIER shall be fully responsible for supplying all necessary documentation to ensure smooth and rapid transportation/customs clearance of the equipment.

Preservation and Storage

Preservation/Storage methods shall follow MANUFACTURER’s recommendations. Instructions shall be provided listing special requirements for long-term storage. All equipment and material shall be preserved, and export packed in accordance with COMPANY Standards(s).

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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. Control panels, racks, cabinets, and equipment containing electronics shall be stored in a warehouse whose environment is artificially controlled to prevent dew point condensation.

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.

SUPPLIER shall provide clear instructions for the type of storage required at site after receipt of the material.

COMMISSIONING

SUPPLIER shall refer to AGES-PH-04-001 for Commissioning requirements.

TRAINING

SUPPLIER shall refer to AGES-PH-04-001 for Training requirements.

DOCUMENTATION / MANUFACTURER DATA RECORDS

Documentation

The CONTRACTOR shall define the requirements for the MANUFACTURER / SUPPLIER drawings and documentation for CONTRACTOR’s and COMPANY’s approval or information as listed in the associated Manufacturing Record Book.

The Packaged Unit SUPPLIER shall provide all documents needed to allow engineering and design of the package, the installation, start-up, and maintenance of all instrumentation. All references to any instruments on any SUPPLIER document or drawing shall be by Tag Number.

Comments made by CONTRACTOR on drawing submittal shall not relieve the Packaged Unit SUPPLIER or SUB SUPPLIER 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 by COMPANY.

All drawings and documents shall be submitted in COMPANY approved software and electronic formats for the project as well as hard copies. CONTRACTOR shall ensure SUPPLIER utilizes the same drawing format, contents style, presentation, electronic format, as per the Project procedures.

The Packaged Unit SUPPLIER shall provide a legend within the documents or drawings detailing all the symbology employed.

Each drawing shall be provided with a project standard drawing title block in the bottom right-hand corner incorporating the following information:

Official trade name of the Packaged Unit SUPPLIER.

The Packaged Unit SUPPLIER’s drawing number.

Drawing title giving the description of contents whereby the drawing can be identified.

A symbol or letter indicating the latest issue or revision.

Purchase Order number and item tag numbers.

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Revisions to drawings 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.

Documents and drawings shall be provided only in the following sizes, as shown in Table 30.1:

Drawing Size

Table 30.1 Drawing sizes

Dimensions

210 mm X 297 mm

297 mm X 420 mm

420 mm X 594 mm

594 mm X 841 mm

841 mm X 1189 mm

No handwritten documents or drawings shall be accepted.

All SUPPLIERS’ documents and drawings shall strictly follow revision marking (vertical line in right border) along with (strikethrough) for deletion and (underlined) for addition and modifications in hard copy as well as in electronic copy. All documents/drawings shall be submitted showing the last revision and changes/additions made along with a list of item-by-item SUPPLIER response to COMPANY comments. When COMPANY approves a document with “No Comments”, SUPPLIERs shall issue such documents/drawings as “COMPANY approved issue”. In this issue, the document shall be same as previous submission except that it will only show revised/added version without any revision marks.

CONTRACTOR shall thoroughly review SUPPLIER’s documents to ensure compliance to Project documents / drawings and shall submit only the marked-up copy of SUPPLIER documents.

All instrument and electrical schematics shall be drawn with the power off and any switches in the absence of process parameter (level, temp. pressure…etc.).

Instrument Loop diagrams for local control and monitoring shall be generated by the Packaged Unit SUPPLIER as defined on the CONTRACTOR forms. For integrated controls supplied by the CONTRACTOR, the Packaged Unit SUPPLIER shall provide drawings indicating interface to package instrumentation and equipment boundary junction boxes to enable the CONTRACTOR / ICSS SUPPLIER to complete all other loop diagrams.

The Packaged Unit SUPPLIER shall provide functional logic diagrams in ISA 5.2 symbology for special and/or proprietary systems in their supply. Detailed write-ups for start-up, sequence control and safeguarding and (emergency) shutdown procedures shall be prepared by Packaged Unit SUPPLIER for the entire package. The CONTRACTOR shall prepare functional logic (Cause and Effect Charts) diagrams for the integrated controls based on information provided by the Packaged Unit SUPPLIER.

If applicable, the Packaged Unit SUPPLIER shall provide trip relay listing with detailed information for maintenance (Tag Numbers, Terminals, Set Point, Range, Location, etc.).

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Manufacturing Record Book

30.2.1 Deliverables

The SUPPLIER MRB requirements are defined within Appendix A4. The listed documentation shall be considered to be the minimum requirements. Additional requirements shall be discussed and agreed with COMPANY where specifically required by individual projects. All drawings and documents shall be written in the ENGLISH Language.

30.2.2 Specific Requirements

The Manufacturing Record Book for each packaged equipment item shall be compiled in accordance with the following requirements and the applicable codes:

Documents shall be written in English.

Documents shall be in a legible, reproducible form.

The number of MRBs to be supplied shall be specified in the request for quotation (RFQ) and the

Purchase Order (PO) documents.

Drawings and other data shall be based on the A4 series sizes, and all drawings larger than A4 size shall be folded to A4 size so that title box and status decal are visible from the front and inserted into pre- punched plastic sleeves.

The contents of the MRB shall be collated into a logical sequence in accordance with the Purchase

Order/Contract requirements. Tabbed dividers shall be provided to separate the sections of data.

MANUFACTURER / SUPPLIER shall submit a detailed MRB index/contents list for CONTRACTOR

approval within 8 weeks of order placement unless stated otherwise in the Purchase Order.

The reports shall be provided in loose leaf form with numbered pages in 2.5inch hard cover A4 size binders (MANUFACTURER / SUPPLIER can use narrower binders if appropriate subject to COMPANY / CONTRACTOR approval). Binder mechanism shall be four pillar interlock type. The colour and finish of the binder will be advised by CONTRACTOR / COMPANY during a pre-production meeting.

Multiple binders shall be clearly referenced i.e. “1 of xx”, and each contains an index detailing how many

volumes and the contents of each volume.

Installation, Operation and Maintenance Manual

SUPPLIER shall refer to AGES-PH-04-001 for the Installation, Operation and Maintenance Manual requirements.

SUPPLIER’s Responsibilities

As manufacturing of the packaged equipment progresses, the MANUFACTURER / SUPPLIER shall compile the MRB with all the design, manufacturing, inspection, tests, and certification information on a per tag item number basis. Documents that are common to more than one item shall be duplicated in each report.

The MANUFACTURER / SUPPLIER shall present the MRBs to the nominated inspector at each inspection visit. It is also their responsibility to ensure that Inspection and Test Plans are signed and dated by the nominated inspector on the day of any Inspection / Test. The spine and cover of each binder shall indicate the following as a minimum:

Manufacturing Data Report.

Project Name.

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MANUFACTURER / SUPPLIER Name.

Purchase Order No.

Equipment No.

Equipment Description.

MANUFACTURER / SUPPLIER Order Ref. No.

MANUFACTURER / SUPPLIER Doc. No.

Date of Issue and Revision.

Alterations, deletions, or additions to certification are not normally permitted, and a new document shall be prepared. However, where this is not possible the alteration shall be approved, signed, and dated. Additions and revisions shall be added to the documentation, not as a replacement but as an addition to the existing records.

The Manufacturing Data Report shall, after being accepted by clear endorsement of each page by stamp,

date, and signature of the nominated inspector, be submitted to the CONTRACTOR.

MDR documents that are already approved by CONTRACTOR with a signed and dated endorsement do not require additional endorsement by the nominated inspector at the MANUFACTURER / SUPPLIER works. The nominated inspector shall endorse the index as correct with reference to documents embodied within the MRB. For multi-page documents the first page (used for approval) shall clearly state the document total number of pages and each page shall be numbered. CONTRACTOR can use dated stamps, subject to COMPANY approval (without requirement for signature endorsement) providing stamp is uniquely identifiable to individual inspectors.

The original and the required number of copies shall be forwarded promptly after the completion of the equipment in accordance with the terms and conditions of the purchase order. If the order is subject to inspection by COMPANY / CONTRACTOR, the release note for the acceptance of the equipment shall only be issued when the manufacturing report, including the required number of copies, is presented.

The use of coloured markers to highlight certificates shall not be permitted.

The use of correction fluids is not permitted.

When test / material certification is called for, these certificates are to be countersigned by COMPANY /

CONTRACTOR.

MANUFACTURER / SUPPLIER QC Document and Certification

SUPPLIER document and deliverables shall be updated with the required document submission times according to the project schedule requirements.

GUARANTEES AND WARRANTY

The SUPPLIER shall guarantee, in accordance with the general conditions, that the provided equipment shall meet the performance conditions specified in this specification, the purchase order, associated documents and Data Sheets.

The SUPPLIER will provide warranty services for a minimum period of 18 months from purchase date or 12 months after has been installed, whichever is later. The warranty services shall comprise any diagnostic services, on-site repairs or replacements, and technical support required to ensure that the control valves operate as specified during the defined warranty period and shall be provided at no additional cost to COMPANY.

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SECTION D – STANDARD DRAWINGS AND DATASHEETS

DATA SHEET TEMPLATES

Project Standard.

STANDARD DRAWINGS

Project Standard.

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SECTION E - APPENDICES

INSTRUMENT PACKAGE EQUIPMENT TYPES - TYPICAL ARRANGEMENTS

Instrument package equipment typical arrangements are defined within Appendices 1A, 1B and 1C. SUPPLIER shall review and confirm these requirements with CONTRACTOR / COMPANY for each project

Typical instrument package equipment types are defined within the following Appendices:

Appendix

Instrument Package Equipment Type

Appendix 1A

Instrument Package Equipment Type A - Typical Arrangement

Appendix 1B

Instrument Package Equipment Type B - Typical Arrangement

Appendix 1C

Instrument Package Equipment Type C - Typical Arrangement

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A1.1.

APPENDIX 1A: INSTRUMENT EQUIPMENT PACKAGE TYPE A - TYPICAL ARRANGEMENT

Package fully integrated into ICSS for Control and Monitoring, no ICSS equipment within SUPPLIER’s cabinets.

SUPPLIER’S PACKAGE EQUIPMENT SKID BOUNDARY

INSTRUMENT EQUIPMENT SHELTER

ICSS Cabinets

Field Devices

PCS Junction Box

Note 1

Junction Box

Note 1

MMS Junction Box

Note 1

Machinery Protection Monitoring Sensors

Motors

ESD Field Devices

F&G Field Devices

ESD Junction Box

Note 1

F&G Junction Box

Note 1

Notes:

Package equipment skid edge boundary junction boxes may not be required for some of the small packages with a limited number of field instruments, and this shall be confirmed with CONTRACTOR / COMPANY.
Can either be a dual redundant data link and / or hardwired.
Electrical Switchgear dual redundant data link.
F&G mitigating devices can be hardwired from the ICSS Controller F&G.
All cabling between package equipment skid edge Junction boxes to ICSS Cabinets and Panels shall be by the CONTRACTOR. If skid edge boundary junction boxes are not required, CONTRACTOR shall install cables directly from the field instruments back to the ICSS.
Cabinets shall be installed remote in IES. Local System may be provided by the SUPPLIER on the package equipment skid if approved by COMPANY.

Anti-Surge, Performance & Load Sharing Controllers

Note 6

ICSS Controller PCS

Note 2

Machinery Monitoring System

Note 6

Rack Data

SUBSTATION

Electrical Switchgear / ASD

Note 3

ICSS Controller ESD

ICSS Controller F&G

Note 4

Legend:

Where required on Rotating Equipment Packages

Package Equipment Skid Edge Boundary Junction Boxes

Hardwired connection

Data Link connection

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A1.2.

APPENDIX 1B: INSTRUMENT EQUIPMENT PACKAGE TYPE B - TYPICAL ARRANGEMENT

Fully integrated into ICSS for Control and Monitoring, ICSS Nodes in SCPs located in remote IES.

SUPPLIER’S PACKAGE EQUIPMENT SKID BOUNDARY

INSTRUMENT EQUIPMENT SHELTER

MAIN EQUIPMENT ROOM

SUPPLIER CONTROL PANEL

ICSS Cabinets

Field Devices

PCS Junction Box

Note 7

Note 1

Junction Box

MMS Junction Box

Note 1

Machinery Protection Monitoring Sensors

Motors

ESD Field Devices

F&G Field Devices

ESD Junction Box

Note 1

F&G Junction Box

Note 1

Notes:

Package equipment skid edge boundary junction boxes.
ICSS controllers (PCS, ESD and F&G) shall be installed within SCPs. SCP cabinets shall be installed within a remote climate-controlled Instrument Equipment Shelter by CONTRACTOR.
Can either be a dual redundant data link and / or hardwired.
Electrical Switchgear dual redundant data link.
F&G mitigating devices can be hardwired from the ICSS Controller F&G.
All cabling between package equipment skid edge Junction boxes to the remote cabinets and panels located in IES shall be by CONTRACTOR.

Legend:

ICSS Controller PCS

ICSS Network Comms

ICSS Network Comms Note 2

Anti-Surge, Performance & Load Sharing Controllers

Note 3

Machinery Monitoring System

Server Data

Rack Data

SUBSTATION

Electrical Switchgear / ASD

Note 4

INSTRUMENT EQUIPMENT SHELTER

SUPPLIER CONTROL PANEL

ICSS Network Comms

ICSS Controller ESD

Note 2

SUPPLIER CONTROL PANEL

ICSS Controller F&G

Note 5

ICSS Controller F&G

ICSS Network Comms

Note 2

Where required on Rotating Equipment Packages

Hardwired connection

Data Link connection

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A1.3.

APPENDIX 1C: INSTRUMENT EQUIPMENT PACKAGE TYPE C - TYPICAL ARRANGEMENT

Complex package with PLC control within SUPPLIER UCPs located in remote IES

SUPPLIER’S PACKAGE EQUIPMENT SKID BOUNDARY

INSTRUMENT EQUIPMENT SHELTER

MAIN EQUIPMENT ROOM

Field Devices

PCS Junction Box

Note 1

SUPPLIER UNIT CONTROL PANEL

ICSS Cabinets

Controller PCS

Notes 2 & 3

ICSS Controller PCS

Motors

SUBSTATION

Electrical Switchgear / ASD

Note 4

ESD Field Devices

ESD Junction Box

Note 1

INSTRUMENT EQUIPMENT SHELTER

SUPPLIER UNIT CONTROL PANEL

Controller ESD

ICSS Network Comms

ICSS Controller ESD

Notes 2 & 3 SUPPLIER UNIT CONTROL PANEL

F&G Field Devices

F&G Junction Box

Controller F&G

ICSS Network Comms

Note 1

Notes 2 & 3

ICSS Controller F&G

Note 5

Notes:

Package equipment skid edge boundary junction boxes.
Dedicated PLC(s) for packaged equipment control, monitoring and shutdown shall be provided by SUPPLIER within the SUPPLIER UCPs. SUPPLIER Package equipment hardware shall be fully compatible and interface with the ICSS (PCS, ESD and F&G) for control, monitoring and shutdown.
SUPPLIER UCP cabinets shall be installed within a remote climate- controlled Instrument Equipment Shelter by CONTRACTOR.
Electrical Switchgear dual redundant link.
F&G mitigating devices can be hardwired from the ICSS Controller F&G.
All cabling between package equipment skid edge Junction boxes to the remote cabinets and panels located in IES shall be by CONTRACTOR.

Legend:

Data Link connection

Hardwired connection

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INSTRUMENT PACKAGE EQUIPMENT TYPES - TYPICAL SCOPE OF SUPPLY

Typical instrument package equipment scope of supply is defined within Appendices 2A, 2B and 2C. SUPPLIER shall review and confirm these requirements with CONTRACTOR / COMPANY for each project

Typical instrument package equipment type scope of supply is defined within the following Appendices:

Appendix

Instrument Package Equipment Type

Appendix 2A

Instrument Package Equipment Type A - Typical scope of supply

Appendix 2B

Instrument Package Equipment Type B - Typical scope of supply

Appendix 2C

Instrument Package Equipment Type C - Typical scope of supply

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A2.1.

APPENDIX 2A: INSTRUMENT EQUIPMENT PACKAGE TYPE A – TYPICAL SCOPE OF SUPPLY

Package fully integrated into ICSS for Control and Monitoring, no ICSS equipment within SUPPLIER’s cabinets.

Legend:

S = SUPPLIER

C = CONTRACTOR

Description

Design Supply

Install

Instrument & Accessories

Instruments

Impulse lines, fittings, isolating valves & manifolds

Cable Glands

Sunshades

Supports & fixings and painting

Labels on instruments and supports

Junction Boxes (if applicable) [1]

Junction boxes

Terminals & internal wiring

Cable glands including outgoing multicore cable glands

Supports & fixings and painting

Labels

Local Panels (where required)

Local Panels

Terminals & internal wiring

Cable glands including outgoing multicore cable glands

Supports & fixings and painting

Labels

Local Gauge Boards (where required)

Local Gauge Boards

Terminals & internal wiring

Cable glands

Supports & fixings and painting

Labels

Plant ICSS [6]

Marshalling cabinets

System cabinets

Application software (programming, configuration)

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Description

Design Supply

Install

6 Machinery Monitoring System (where applicable) [3] [6]

MMS sensors and probes such as vibration, temperature, etc.

Local MMS cabinet [5] containing items such as MMS Monitor racks and associated components such as Power Supply Modules, Communication Modules, Relay modules, HMI, terminals, internal wiring, labels, cable glands, etc.

Remote MMS cabinet [5] containing items such as MMS Monitor racks and associated components such as Power Supply Modules, Communication Modules, Relay modules, HMI, terminals, internal wiring, labels, cable glands, etc.

Server, desk mounted OWS, EWS, Printer for MMS

Operating System, Programming & application software, and their licenses for servers and workstations

Labels

Anti-surge and performance Control System (where applicable) [4] [6]

Anti-surge sensors and control valve [4]

Controller and associated components such as Power Supply Modules, Communication Modules, HMI, terminals, internal wiring, labels, cable glands, etc.

Local Anti-surge controller cabinet [5] containing items as mentioned above

Remote Anti-surge controller cabinet [5] containing items as mentioned above

EWS, desk mounted OWS, Printer for Anti surge and Performance Control System

Operating System, Programming & application software, and their licenses for workstations

Cables

Instrumentation cables from/to instruments up to skid junction boxes

Instrumentation cables from/to junction boxes up to remote panels in IES (e.g. ICSS cabinets, MMS / Anti-surge cabinets [2])

Instrumentation cables from/to instruments up to local panels (including any Local MMS / Anti-surge cabinets [5])

Instrumentation cables from/to instruments up to remote panels in IES (e.g. ICSS cabinets, MMS / Anti-surge cabinets [2])

Interface cables between MMS / Anti-Surge Cabinets and ICSS

Electrical cables from/to package equipment up to Electrical Switchgear / ASD / power distribution boards

Special cables (metering, serial, FO, etc.)

Cable Trays

Cable trays & supports from instruments up to skid battery limits

Cable trays & supports out of skid battery limits

10 Others

F&G detectors for package enclosures

F&G detectors other than package enclosures

S/C

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Description

Design Supply

Install

Instrument air distribution within the Package

Supports & fixings, painting of supports & fixings for Local Cabinets such as MMS cabinet / Anti-Surge Control System [5] Supports & fixings, and painting of supports & fixings for Remote Cabinets in IES such as MMS cabinet / Anti-Surge Control System [5]

Notes:

Skid edge boundary junction boxes may not be required for some of the small packages with a limited number of field instruments. SUPPLIER shall confirm with CONTRACTOR / COMPANY if skid edge junction boxes are required.

If skid edge junction boxes are not provided (subject to COMPANY approval) for a package, CONTRACTOR shall be responsible for the design, supply, and installation of the instrumentation cables from/to the field instruments up to the ICSS.

Machinery Monitoring System shall be provided for applicable packaged equipment.
Anti-surge and Performance Control System shall be provided for applicable packaged equipment. SUPPLIER shall design the anti-surge sensors and control valves for the required packaged equipment. Scope of supply and installation of anti-surge valves and sensors shall be agreed upon between SUPPLIER and CONTRACTOR based on package boundary limits and approved by COMPANY. For anti-surge valves purchased by CONTRACTOR, SUPPLIER shall review and approve selected valve design.
MMS / Anti-surge Controller cabinets shall be installed remote in IES. Local cabinets may be provided by the SUPPLIER on the package equipment skid if approved by COMPANY. For Local cabinets, SUPPLIER shall also design, supply, and install cabinets, supports and fixings, all cables from field instruments to the local cabinets. CONTRACTOR shall design, supply, and install all interface cables between the local cabinets and cabinets / systems located in IES.
System OEMs (e.g. ICSS, MMS, Anti-surge and Performance Control System) in conjunction with Package SUPPLIER and CONTRACTOR shall be responsible for all design and engineering activities of the System (such as hardware and software design, configuration, testing, etc.). OEMs shall also be involved in site installation and commissioning activities.
For local motor control station requirements refer to AGES-GL-02-001 Electrical Engineering

Design Guide.

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A2.2.

APPENDIX 2B: INSTRUMENT EQUIPMENT PACKAGE TYPE B – TYPICAL SCOPE OF SUPPLY

Package fully integrated into ICSS for Control and Monitoring, ICSS nodes in SCPs located in remote IES.

Legend:

S = SUPPLIER

C = CONTRACTOR

Description

Design Supply

Install

Instrument & Accessories

Instruments

Impulse lines, fittings, isolating valves & manifolds

Cable Glands

Sunshades

Supports & fixings and Painting

Labels on instruments and supports

Junction Boxes

Junction boxes

Terminals & internal wiring

Cable glands including outgoing multicore cable glands

Supports & fixings and Painting

Labels

Local Panels (where required)

Local Panels

Terminals & internal wiring

Cable glands including outgoing multicore cable glands

Supports & fixings and Painting

Labels

Local Gauge Boards (where required)

Local Gauge Boards

Terminals & internal wiring

Cable glands

Supports & fixings and Painting

Labels

Plant ICSS [5]

Marshalling cabinets

System cabinets

Application software (programming, configuration)

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Description

Design Supply

Install

Supplier Control Panels (SCPs) [5]

ICSS (PCS, ESD, and F&G) controllers and associated components such as I/O Modules, Power Supply Modules, Communication Modules, Marshalling, terminals, internal wiring, labels, cable glands, etc.

SCP cabinets containing items as mentioned above

ICSS programming for Package Unit

Graphic Displays for Package Unit

EWS, OWS, Printer for ICSS Nodes

Operating System, Programming & application software, and their licenses for workstations

7 Machinery Monitoring System (where applicable) [1] [5]

MMS sensors and probes such as vibration, temperature, etc.

MMS Monitor racks and associated components such as Power Supply Modules, Communication Modules, Relay modules, HMI, terminals, internal wiring, labels, cable glands, etc.

Local MMS cabinet [4] containing items as mentioned above

Remote MMS Cabinet [4] containing items as mentioned above

Server, desk mounted OWS, EWS, Printer for MMS

Operating System, Programming & application software, and their licenses for servers and workstations

Labels

Anti-surge and performance Control System (where applicable) [2] [5]

Anti-surge sensors and control valve [2]

Controller and associated components such as Power Supply Modules, Communication Modules, HMI, terminals, internal wiring, labels, cable glands, etc.

Local Anti-surge controller cabinet [4] containing items as mentioned above

Remote Anti-surge controller cabinet [4] containing items as mentioned above

EWS, desk mounted OWS, Printer for Anti surge and Performance Control System

Operating System, Programming & application software, and their licenses for workstations

9 Gas Turbine Control System (where applicable) [3] [5]

GTCS controller and associated components such as Power Supply Modules, Communication Modules, HMI, terminals, internal wiring, labels, cable glands, etc.

Local GTCS cabinet [4] containing items as mentioned above

Remote GTCS cabinet [4] containing items as mentioned above

EWS, desk mounted OWS, Printer for GTCS

Operating System, Programming & application software, and their licenses for workstations

S/C

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Description

Design Supply

Install

10 Cables

Instrumentation cables from/to instruments up to skid junction boxes

Instrumentation cables from/to junction boxes up to remote panels in IES (e.g. SCPs, MMS, Anti-Surge, GTCS Cabinets)

Instrumentation cables from/to instruments up to local panels (including any Local MMS / Anti-surge / GTCS cabinets [4])

Interface cables between SCPs / MMS / Anti-Surge / GTCS Cabinets and Plant ICSS

Electrical cables from/to package equipment up to Electrical Switchgear / ASD / power distribution boards

Special cables (metering, serial, FO, etc.)

10 Cable Trays

Cable trays & supports from instruments up to skid battery limits

Cable trays & supports out of skid battery limits

11 Others

F&G detectors for acoustic enclosures (e.g. gas turbines)

F&G detectors other than acoustic enclosures

Instrument air distribution within the Package

Supports & fixings, and painting of supports & fixings for Local Cabinets such as MMS cabinet / Anti-Surge Control System / GTCS Cabinet [4] Supports & fixings, and painting of supports & fixings for Remote Cabinets in IES such as SCP / MMS cabinet / Anti-Surge Control System / GTCS Cabinet [4]

Notes:

Machinery Monitoring System shall be provided for applicable packaged equipment.
Anti-surge and Performance Control System shall be provided for applicable packaged equipment. SUPPLIER shall design the anti-surge sensors and control valves for the required packaged equipment. Scope of supply and installation of anti-surge valves and sensors shall be agreed upon between SUPPLIER and CONTRACTOR based on package boundary limits and approved by COMPANY. For anti-surge valves purchased by CONTRACTOR, SUPPLIER shall review and approve selected valve design.
Gas Turbine Control System shall be provided for control of all turbine, associated process

compressor related equipment and auxiliaries.

MMS / Anti-surge Controller / GTCS cabinets shall be installed remote in IES. Local cabinets may be provided by the SUPPLIER on the package equipment skid if approved by COMPANY. For Local cabinets, SUPPLIER shall also design, supply, and install cabinets, supports and fixings, all cables from field instruments to the local cabinets. CONTRACTOR shall design, supply, and install all interface cables between the local cabinets and cabinets / systems located in IES.
System OEMs (e.g. ICSS, MMS, GTCS, Anti-surge and Performance Control System) in conjunction with Package SUPPLIER and CONTRACTOR shall be responsible for all design and

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engineering activities of the System (such as hardware and software design, configuration, testing, etc.). OEMs shall also be involved in site installation and commissioning activities.

For local motor control station requirements refer to AGES-GL-02-001 Electrical Engineering

Design Guide.

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A2.3.

APPENDIX 2C: INSTRUMENT EQUIPMENT PACKAGE TYPE C – TYPICAL SCOPE OF SUPPLY

Complex package with PLC control within SUPPLIER UCPs located in remote IES

Legend:

S = SUPPLIER

C = CONTRACTOR

Description

Design Supply

Install

Instrument & Accessories

Instruments

Impulse lines, fittings, isolating valves & manifolds

Cable Glands

Sunshades

Supports & fixings and painting

Labels on instruments and supports

Junction Boxes

Junction boxes

Terminals & internal wiring

Cable glands including outgoing multicore cable glands

Supports & fixings and painting

Labels

Local Panels (where required)

Local Panels

Terminals & internal wiring

Cable glands including outgoing multicore cable glands

Supports & fixings and painting

Labels

Local Gauge Boards (where required)

Local Gauge Boards

Terminals & internal wiring

Cable glands

Supports & fixings and painting

Labels

Plant ICSS [2]

Marshalling cabinets

System cabinets

Application software (programming, configuration)

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Description

Design Supply

Install

Unit Control Panels [1] [2]

Controllers (PCS, ESD, and F&G) [1] and associated components such as I/O Modules, Power Supply Modules, Communication Modules, terminals, internal wiring, labels, cable glands, etc.

UCP cabinets containing items as mentioned above

EWS, desk mounted OWS, Printer for UCP

Operating System, Programming & application software, and their licenses for workstations

Supports & fixings, and painting of supports & fixings

Cables

Instrumentation cables from/to instruments up to skid junction boxes

Instrumentation cables from/to junction boxes up to remote UCP in IES

Instrumentation cables from/to instruments up to local panels

Interface cables between UCP and ICSS

Electrical cables from/to package equipment up to Electrical Switchgear / ASD / power distribution boards

Special cables (metering, serial, FO, etc.)

10 Cable Trays

Cable trays & supports from instruments up to skid battery limits

Cable trays & supports out of skid battery limits

11 Others

F&G detectors for package enclosures

F&G detectors other than package enclosures

Instrument air distribution within the Package

Notes:

SUPPLIER shall design, supply, and install dedicated UCP controllers (PCS, ESD, & F&G) fully

compatible with the Plant ICSS.

System OEMs (e.g. ICSS, PLC System) in conjunction with Package SUPPLIER and CONTRACTOR shall be responsible for all design and engineering activities of the System (such as hardware and software design, configuration, testing, etc.). OEMs shall also be involved in site installation and commissioning activities.
For local motor control station requirements refer to AGES-GL-02-001 Electrical Engineering

Design Guide.

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INSTRUMENT PACKAGE EQUIPMENT TYPES - TYPICAL SCOPE OF ENGINEERING

Typical instrument package equipment scope of engineering is defined within Appendices 3A, 3B and 3C. SUPPLIER shall review and confirm these requirements with CONTRACTOR / COMPANY for each project

Typical instrument package equipment type scope of engineering is defined within the following Appendices:

Appendix

Instrument Package Equipment Type

Appendix 3A

Instrument Package Equipment Type A - Typical scope of engineering

Appendix 3B

Instrument Package Equipment Type B - Typical scope of engineering

Appendix 3C

Instrument Package Equipment Type C - Typical scope of engineering

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A3.1.

APPENDIX 3A: INSTRUMENT EQUIPMENT PACKAGE TYPE A – TYPICAL SCOPE OF ENGINEERING

Package fully integrated into ICSS for Control and Monitoring, no ICSS equipment within SUPPLIER’s cabinets.

Legend:

I = ISSUE

R = REVIEW

DESCRIPTION

SUPPLIER CONTRACTOR COMPANY

Design Engineering

P&IDs

Instrument tagging

Instrument data sheets

Instrument specifications

Equipment list

Instrument index

I/O list

Cable Schedule

Cable Block diagrams

Instrumentation loop diagrams

Junction box wirings

Earthing connection diagrams

Calculation notes (control valve, flow element, thermowell stress, etc …)

IS loop calculations

SIL calculations & Verification Report

MMS drawings (Cabinet layouts, BOM, wiring, interface signals, serial link exchange, loop diagrams, etc …) – if MMS cabinet is included in SUPPLIER’s scope

MMS drawings (Cabinet layouts, BOM, wiring, interface signals, serial link exchange, loop diagrams, etc …) – if MMS cabinet is included in CONTRACTOR’s scope

Anti-surge control drawings (Cabinet layouts, BOM, wiring, loop diagrams, interface signals, serial link exchange, etc …)

Package control Narrative / Description

Package safety logic diagram / Cause and Effect matrix

Utilities list & consumptions

Inspection & calibration

Certificates (material, IECEx, SIL, etc.)

FAT procedure

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DESCRIPTION

SUPPLIER CONTRACTOR COMPANY

IFAT procedure

SAT procedure

Installation Engineering

Field instrument, junction box, air header, local panels etc. - layouts & location plan

Field instrument hook ups

Field instrument, junction box, cable tray, air header, local panel supports

Main & secondary routings (Cables, cable trays, air headers etc) within skid battery limits

Main & secondary routings (Cables, cable trays, air headers etc) out of skid battery limits

Junction box General Arrangement Drawings & BOM

Material take off

Pre-commissioning documents

Commissioning documents

Notes:

All documents shall be submitted to COMPANY for review / information as per Project specific,

approved document distribution matrix.

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A3.2.

APPENDIX 3B: INSTRUMENT EQUIPMENT PACKAGE TYPE B – TYPICAL SCOPE OF ENGINEERING

Fully integrated into ICSS for Control and Monitoring, ICSS nodes in SCPs located in remote IES.

Legend:

I = ISSUE

R = REVIEW

DESCRIPTION

SUPPLIER CONTRACTOR COMPANY

Design Engineering

P&IDs

Instrument tagging

Instrument data sheets

Instrument specifications

Equipment list

Instrument index

I/O list

Cable Schedule

Cable Block diagrams

Instrumentation loop diagrams

Junction box wirings

Earthing connection diagrams

Calculation notes (control valve, flow element, thermowell stress, etc …)

IS loop calculations

SIL calculations & Verification Reports

SCP drawings (Cabinet layouts, BOM, wiring, interface signals list, communication link data exchange list, etc …)

MMS drawings (Cabinet layouts, BOM, wiring, interface signals list, communication link data exchange list, etc …)

Anti-surge control drawings (Cabinet layouts, BOM, wiring, interface signals list, communication link data exchange list, etc …)

GTCS drawings (Cabinet layouts, BOM, wiring, interface signals list, communication link data exchange list, etc …)

Package control narrative description

Package safety logic diagram / Cause and Effect matrix

Utilities list & consumptions

Inspection & calibration

Certificates (material, IECEx, SIL, etc.)

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DESCRIPTION

SUPPLIER CONTRACTOR COMPANY

FAT procedure

IFAT procedure

SAT procedure

Installation Engineering

Field instrument, junction box, air header, local panels etc. - layouts & location plan

Field instrument hook ups

Field instrument, air header, junction box, cable tray, local panel supports

Main & secondary routings (Cables, cable trays, instrument air headers etc.) within skid battery limits

Main & secondary routings (Cables, cable trays, instrument air headers etc.) out of skid battery limits

Junction box General Arrangement Drawings & BOM

Material take off

Pre-commissioning documents

Commissioning documents

Notes:

All documents shall be submitted to COMPANY for review / information as per Project specific,

approved document distribution matrix.

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A3.3.

APPENDIX 3C: INSTRUMENT EQUIPMENT PACKAGE TYPE C – TYPICAL SCOPE OF ENGINEERING

Complex package with PLC control within SUPPLIER UCPs located in remote IES

Legend:

I = ISSUE

R = REVIEW

DESCRIPTION

SUPPLIER CONTRACTOR COMPANY

Design Engineering

P&IDs

Instrument tagging

Instrument data sheets

Instrument specifications

Equipment list

Instrument index

I/O list

Cable schedule

Cable Block diagrams

Instrumentation loop diagrams

Junction box wirings

Earthing connection diagrams

Calculation notes (control valve, flow element, thermowell stress, etc …)

IS loop calculations

SIL calculations & Verification reports

UCP drawings (Cabinet layouts, BOM, wiring, interface signals list, communication link data exchange list, etc …)

Package control functional narrative / description

Package safety logic diagram / Cause and Effect matrix

Utilities list & consumptions

Inspection & calibration

Certificates (material, Ex, SIL, etc.)

FAT procedure

IFAT procedure

SAT procedure

Installation Engineering

Field instrument, junction box, air header, local panels etc. - layouts & location plan

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DESCRIPTION

SUPPLIER CONTRACTOR COMPANY

Field instrument hook ups

Field instrument, junction box, cable tray, air header, local panel supports

Main & secondary routings (Cables, cable trays, air headers etc.) within skid battery limits

Main & secondary routings (Cables, cable trays, air headers etc.) out of skid battery limits

Junction box General Arrangement Drawings & BOM

Material take off

Pre-commissioning documents

Commissioning documents

Notes:

All documents shall be submitted to COMPANY for review / information as per Project specific,

approved document distribution matrix.

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INSTRUMENT MANUFACTURING RECORD BOOK REQUIREMENTS

Table A4. 1 Manufacturing Record Book Requirements

Package Equipment

Document Number

Title

CENTRIFUGAL PUMPS (API 610)

Appendix 3 - AGES-SP-05-001

CENTRIFUGAL COMPRESSORS (API 617)

Appendix 3 - AGES-SP-05-002

RECIPROCATING COMPRESSORS (API 618 and ISO 13631)

Appendix 3 - AGES-SP-05-003

STEAM TURBINES (API 611&612)

Appendix 3 - AGES-SP-05-004

GAS TURBINES (API 616)

Appendix 3 - AGES-SP-05-005

SPECIAL PURPOSE GEARS (API 613)

Appendix B2 - AGES-SP-05-007

LUBRICATION OIL SYSTEMS (API 614)

Appendix B2 - AGES-SP-05-007

PUMPS- SHAFT SEALING SYSTEMS (API 682)

Appendix B2 - AGES-SP-05-007

DRY GAS SEALING SYSTEMS (API 692)

Appendix B2 - AGES-SP-05-007

GENERAL (UTILITY) and FIREWATER SERVICES

Appendix B2, C2, D2 – AGES-SP-05-008

PACKAGED INTEGRALLY GEARED PACKAGED CENTRIFUGAL AIR COMPRESSORS

Appendix 2 – AGES-SP-05-009

ROTARY TYPE POSITIVE DISPLACEMENT COMPRESSORS AND PUMPS (API 619 and API 681)

Appendix B2, C2 – AGES-SP-05-010

INFORMATION REQUIREMENTS FOR CENTRIFUGAL PUMPS (API 610) SPECIFICATION Appendix 3 - AGS-SP-05-001

INFORMATION REQUIREMENTS FOR CENTRIFUGAL COMPRESSORS (API 617) SPECIFICATION Appendix 3 - AGS-SP-05-002

INFORMATION REQUIREMENTS FOR RECIPROCATING COMPRESSORS (API 618 and ISO 13631) SPECIFICATION Appendix 3 - AGS-SP-05-003

INFORMATION REQUIREMENTS FOR STEAM TURBINES (API 611&612) SPECIFICATION Appendix 3 - AGS-SP-05-004

INFORMATION REQUIREMENTS FOR GAS TURBINES (API 616) SPECIFICATION Appendix 3 - AGS-SP-05-005

INFORMATION REQUIREMENTS FOR SPECIAL PURPOSE GEARS (API 613) Appendix B2 - AGES-SP-05-007

INFORMATION REQUIREMENTS FOR LUBRICATION OIL SYSTEMS (API 614) Appendix C2 - AGES-SP-05-007

INFORMATION REQUIREMENTS FOR PUMPS- SHAFT SEALING SYSTEMS (API 682) Appendix D2 – AGES-SP-05-007

INFORMATION REQUIREMENTS FOR DRY GAS SEALING SYSTEMS (API 692) Appendix E2 – AGES-SP-05-007

INFORMATION REQUIREMENTS FOR GENERAL (UTILITY) and FIREWATER SERVICES Appendix B2, C2, D2 – AGES-SP- 05-008

INFORMATION REQUIREMENTS FOR PACKAGED INTEGRALLY GEARED PACKAGED CENTRIFUGAL AIR COMPRESSORS Appendix 2 – AGES-SP-05- 009

INFORMATION REQUIREMENTS FOR ROTARY TYPE POSITIVE DISPLACEMENT COMPRESSORS AND PUMPS (API 619 and API 681) – Appendix B2, C2 – AGES-SP-05- 010

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THE CONTENTS OF THIS DOCUMENT ARE PROPRIETARY AND CONFIDENTIAL.

ADNOC GROUP PROJECTS AND ENGINEERING PROGRAMMABLE LOGIC CONTROLLER

Specification

APPROVED BY:

NAME: Abdulmunim Al Kindy TITLE: Executive Director PT&CS EFFECTIVE DATE:

AGES-SP-04-018

All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/1840724/11/202124/11/2021 GROUP PROJECTS & ENGINEERING / PT&CS DIRECTORATE

CUSTODIAN ADNOC

Group Projects & Engineering / PT&CS Specification applicable to ADNOC & ADNOC Group Companies

REVISION HISTORY

DATE

REV.

27 Sep 2021

PREPARED BY (Designation / Initial) Annamalai Kulandaivel Sr. Eng. I-C

Annamalai K Digitally signed by Annamalai K

Date: 2021.10.05 09:13:26 +04’00’

REVIEWED BY (Designation / Initial) Mahmoud Abdel Hakim / HOD Pipelines Eng. - GPE

Mahmoud Abdel Hakim

Digitally signed by Mahmoud Abdel Hakim Date: 2021.10.11 08:34:28 +04’00’

ENDORSED BY (Designation / Initial) Najem Qambar / VP Group Eng. - GPE

ENDORSED BY (Designation / Initial) Ebraheem AlRomaithi/ SVP- GPE

Reuben Yagambaram/ Mgr, Offshore Portfolio - GP&E

Ali AlBreiki/ VP Upstream Projects – GPE

Group Projects & Engineering is the owner of this Specification and responsible for its custody, maintenance, and periodic update.

In addition, Group Projects & Engineering is responsible for communication and distribution of any changes to this Specification and its version control.

This specification will be reviewed and updated in case of any changes affecting the activities described in this document.

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23/11/2021All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/1840723/11/202123/11/2021 INTER-RELATIONSHIPS AND STAKEHOLDERS

The following are inter-relationships for implementation of this Specification:

ADNOC Upstream and ADNOC Downstream Industry, Marketing & Trading Directorate.

ii. ADNOC Onshore, ADNOC Offshore, ADNOC Sour Gas, ADNOC Gas Processing. ADNOC LNG,

ADNOC Refining, Fertilisers, Borouge, Al Dhafra Petroleum, Al Yasat

The following are stakeholders for the purpose of this Specification:

ADNOC PT&CS Directorate

Each ADNOC Group company must establish/nominate a Technical Authority responsible for compliance with this Specification.

DEFINITIONS

“ADNOC” means Abu Dhabi National Oil Company.

“ADNOC Group” means ADNOC together with each company in which ADNOC, directly or indirectly, controls fifty percent (50%) or more of the share capital.

“Approving Authority” means the decision-making body or employee with the required authority to approve Policies & Procedures or any changes to it.

“Business Support Directorates and Functions” or “Non- BLD” means all the ADNOC functions and the remaining directorates, which are not ADNOC Business Line Directorates.

“CEO” means chief executive officer.

“Group Company” means any company within the ADNOC Group other than ADNOC.

“Specification” means this Programmable Logic Controller Specification.

CONTROLLED INTRANET COPY The intranet copy of this document located in the section under Group Policies on One ADNOC is the only controlled document. Copies or extracts of this document, which have been downloaded from the intranet, are uncontrolled copies and cannot be guaranteed to be the latest version.

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All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/18407

TABLE OF CONTENTS

GENERAL … 8

INTRODUCTION … 8

PURPOSE … 8

DEFINITIONS AND ABBREVIATIONS … 9

SECTION A – GENERAL … 13

REFERENCE DOCUMENTS … 13

INTERNATIONAL CODES AND STANDARDS … 13

ADNOC SPECIFICATIONS … 15

OTHER REFERENCES … 16

DOCUMENT PRECEDENCE … 16

SPECIFICATION DEVIATION / CONCESSION CONTROL … 16

PROCESS SAFETY REQUIREMENTS … 17

DESIGN CONSIDERATIONS / MINIMUM DESIGN REQUIREMENTS … 17

OPERATION & DESIGN LIFE… 17

ENVIRONMENTAL REQUIREMENTS … 17

ELECTRIC UTILITY DATA … 18

SEISMIC REQUIREMENTS … 18

HAZARDOUS AREA PROTECTION … 18

INGRESS PROTECTION … 19

ENGINEERING UNITS … 19

SECTION B – TECHNICAL REQUIREMENTS … 20

TECHNICAL REQUIREMENTS … 20

GENERAL DESIGN … 20

PROVEN TECHNOLOGY… 21

STANDARDISATION … 22

ELECTROMAGNETIC COMPATIBILITY … 22

REDUNDANCY REQUIREMENTS … 22

SYSTEM RESPONSE TIME … 23

I/O ALLOCATION RULES … 23

ARCHITECTURE… 24

SYSTEM HARDWARE … 27

SYSTEM SOFTWARE … 36

SYSTEM FAULT ALARMS … 38

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RELIABILITY … 39

FUNCTIONAL SPECIFICATION (FS) AND FUNCTIONAL DESIGN SPECIFICATION

(FDS) … 39

ADDITIONAL SPECIFIC REQUIREMENTS … 42

SECTION C – OTHER REQUIREMENTS … 43

DETAILS OF SCOPE SUPPLY … 43

QUALITY CONTROL AND ASSURANCE … 44

SUB-CONTRACTORS, SUB-SUPPLERS … 45

CERTIFICATION … 45

INSPECTION AND TESTING REQUIREMENTS … 46

GENERAL … 46

SHOP INSPECTION … 47

PRE-FACTORY ACCEPTANCE TEST … 47

FACTORY ACCEPTANCE TEST … 47

INTEGRATED FACTORY ACCEPTANCE TEST … 48

SITE INSTALLATION TEST… 48

SITE ACCEPTANCE TEST … 49

CERTIFICATES OF ACCEPTANCE … 50

SERVICES BY THE SUPPLIER … 50

SPARE PARTS, CONSUMABLES AND SPECIAL TOOLS … 50

SPARE PARTS … 50

SPARES… 50

CONSUMABLES … 51

SPECIAL TOOLS … 51

PAINTING, PRESERVATION AND SHIPMENT… 51

PACKING AND SHIPPING … 51

PRESERVATION AND STORAGE … 51

INSTALLTION, COMMISSIONING AND MAINTENANCE SUPPORT … 52

INSTALLATION … 52

LIFE CYCLE / LONG TERM SUPPORT … 52

MAINTENANCE… 53

TRAINING … 53

GENERAL … 53

TRAINING COURSE DOCUMENTATION … 53

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MAINTENANCE TRAINING COURSE… 53

SYSTEM ENGINEERING COURSE … 53

DOCUMENTATION / MANUFACTURER DATA RECORDS … 54

GUARANTEES AND WARRANTY … 56

PROJECT ADMINISTRATION … 56

PROJECT PERSONNEL … 56

PROJECT SCHEDULE … 57

PROGRESS REPORTING … 57

COORDINATION MEETINGS … 57

SECTION D – STANDARD DRAWINGS & DATASHEETS … 58

DATASHEET TEMPLATES … 58

STANDARD DRAWINGS… 58

SECTION E - APPENDICES … 59

PLC SPECIFICATIONS TABLE … 59

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LIST OF TABLES

TABLE 1.1 LIST OF ABBREVIATIONS … 9 TABLE 22.1 PLC SPECIFICATIONS TABLE … 59

LIST OF FIGURES

NO TABLE OF FIGURES ENTRIES FOUND.

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GENERAL

Introduction

This specification defines the minimum requirements for the Programmable Logic Controller (PLC) system.

Purpose

The purpose of this specification is to define the minimum mandatory requirements for execution, functional and technical requirements for design & engineering, materials, fabrication, assembly, configuration, inspection & testing, packing, installation, and commissioning of the PLC system across the ADNOC Business Units.

Unless otherwise stated in this specification, the supplied equipment shall comply fully with the requirements of relevant AGES, ADNOC Group standards / guidelines, industry, national and international standards.

COMPANY’s intent is to implement the package equipment control and safety functions within the Integrated Control Safety System (ICSS) provided for the facility for efficient & optimized implementation of monitoring, control and safety functions together with the required computation, communications to achieve a ‘single window’ concept from a Central Control Room (CCR). Hence, PLC shall be used only where SUPPLIER of packages or Process Licensors specifically do not accept equipment control / protection on plant wide ICSS (i.e., Process Control System (PCS) and Emergency Shutdown (ESD) system). PLCs that are intended for equipment protection, equipment shutdown, equipment isolation and/or implement functions related to safety/risk reduction shall conform to AGES-SP-04-004 Emergency Shutdown (SIS) System Specification.

The technical requirements described in this specification apply for all PLC systems in process and non-process control applications. Specific COMPANY approval and TUV/NFPA certification is required if a package SUPPLIER proposes the use of a PLC for safety (or) fire and gas applications.

The non-process control PLC applications include such as those used in Analyser Shelter, Integrated Protection and Control System (IPCS), Building Management Systems, Load Dispatch / Control Systems, Diesel Generator, HVAC PLC, etc. PLCs shall record sequence of events (SOE) related to the associated equipment/ package/ process monitored/ controlled (inclusive of safety functions as applicable) and PLCs shall communicate the SOE records/ reports to the facility PCS/ ICSS and also connected to the printer to print the SOE report.

It is preferred to select only one (1) MANUFACTURER for a project ease off the integration of PLC network, including spare parts, training, life cycle cost, however a maximum of only two (2) MANUFACTURERs of PLC shall be considered for the project. The selected types shall be approved by COMPANY. CONTRACTOR shall ensure standardisation of PLC types.

The SUPPLIER shall be responsible for all PLC hardware, software, configuration, OT/Cyber security requirements, Licenses if any, and interfaces with Process Control System (PCS), Emergency Shutdown System, and Integrated Control and Safety System (ICSS), testing, documentation, delivery, installation supervision, and field support as defined within this specification. The SUPPLIER shall supply the latest version of proven hardware and software.

The requirements detailed within this specification shall apply to both offshore and onshore installations, unless specifically stated to apply for either one or the other, i.e., requirement starting with “for installations offshore” applies only to equipment to be located on an offshore installation.

This specification provides the structure to support standardisation and its associated savings in lifecycle costs, including total cost of ownership, and maintenance requirements.

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Definitions and Abbreviations

1.3.1

Definitions

The following defined terms are used throughout this specification:

‘[PSR]’ indicates a mandatory Process Safety Requirement

“COMPANY” means ADNOC, ADNOC Group or an ADNOC Group Company, and includes any agent or consultant authorized to act for, and on behalf of the COMPANY.

“CONTRACTOR” means the parties that carry out all or part of the design, engineering, procurement, construction, commissioning, or management for ADNOC projects. CONTRACTOR includes its approved MANUFACTURER(s), SUPPLIER(s), SUB-SUPPLIER(s), and SUB-CONTRACTOR(s).

‘may’ means a permitted option

‘shall’ indicates mandatory requirements

‘should’ means a recommendation

“SUPPLIER” means the party entering into a Contract with CONTRACTOR to provide the materials, equipment, supporting technical documents and/or drawings, guarantees, warranties and/or agreed services in accordance with the requirements of the purchase order and relevant specification(s). The term SUPPLIER includes any legally appointed successors and/or nominated representatives of the SUPPLIER.

“CONCESSION REQUEST” - A deviation requested by the CONTRACTOR or SUPPLIER, usually after receiving the contract package or purchase order. Often, it refers to an authorization to use, repair, recondition, reclaim, or release materials, components or equipment already in progress or completely manufactured but which does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is subject to COMPANY approval.

1.3.2

Abbreviations

The abbreviations used throughout this specification are shown in Table 1.1

Table 1.1 List of Abbreviations

Abbreviations

Alternating Current

Abu Dhabi National Oil Company

ADNOC

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AGES

ANSI

ATS

BMS

BSI

CCB

CCR

CMOS

CoC

COTS

CPU

ECAS

EMC

EMI

ESD

EWS

FAT

FDS

HART

HMI

HSE

HSSD

I.S.

I/O

IAMS

Abbreviations

ADNOC Group Engineering Standards

Analogue Input

American National Standards Institute

Analogue Output

Automatic Transfer Switch

Burner Management System

British Standards Institute

Central Control Building

Central Control Room

Complementary metal–oxide–semiconductor

Certificate of Conformity

Commercial-Off-The-Shelf

Central Processing Unit

Direct Current

Digital Input

Digital Output

Emirates Conformity Assessment System

Electromagnetic Compatibility

Electromagnetic Interference

European Norms

Emergency Shutdown

Engineering Workstation

Factory Acceptance Test

Functional Design Specification

Fibre Optic

Functional Specification

General Arrangement

Gigabyte

Highway Addressable Remote Transducer

Human Machine Interface

Health, Safety & Environment

High Sensitivity Smoke Detection

Intrinsic Safety

Input / Output

Instrument Asset Management System

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ICSS

IEC

IEEE

IES

IFAT

IPCS

ISA

ISO

ITP

ITR

LED

LER

MCB

MDR

MIL

MTBF

MTTF

MTTR

OPC

PAC

PCS

PLC

Abbreviations

Integrated Control and Safety System

International Electrotechnical Commission

Institute of Electrical and Electronics Engineers

Instrument Equipment Shelter

Integrated Factory Acceptance Test

Ingress Protection (rating)

Integrated Protection and Control System

International Society for Automation

International Organisation for Standards

Inspection and Test Plan

Instrument Technical Room

Light Emitting Diode

Local Equipment Room

Miniature Circuit Breaker

Manufacturing Data Record

Military

Mean Time Between Failure

Mean Time to Failure

Mean Time to Restore

Open Platform Communication or Object Linking and Embedding for Process Control

Operational Technology

Provisional Acceptance Certificate

Personal Computer

Process Control System

Programmable Logic Controller

Pre-FAT

Pre-Factory Acceptance Test

PSU

RAM

RFI

SAT

SIF

SIL

Power Supply Unit

Quality Assurance

Quality Control

Random Access Memory

Radio Frequency Interference

Site Acceptance Test

Safety Instrumented Function

Safety Integrity Level

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SIT

SOE

SPI

SSD

TCP/IP

UPS

USB

Abbreviations

Site Installation Test

Sequence of Events

Smart Plant Instrumentation

Solid State Drive

Transfer Control Protocol / Internet Protocol

Uninterrupted Power Supply

Universal Serial Bus

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SECTION A – GENERAL

REFERENCE DOCUMENTS

International Codes and Standards

The following Codes and Standards shall form a part of this specification. When an edition date is not indicated for a Code or Standard, the latest edition in force at the time of the contract award shall apply.

AMERICAN PETROLEUM INSTITUTE (API)

API RP 552

API RP 554

Transmission Systems

Process Control Systems – Functions and Functional Specification Development

BRITISH STANDARDS INSTITUTE (BSI)

BS 7671

BS 6739

Requirements for Electrical Installations

Code of practice for instrumentation in process control systems: installation design and practice

EUROPEAN STANDARDS

EN 50156

EN 50178

EN 50600

Electrical Equipment for Furnaces and Ancillary Equipment

Electronic equipment for use in power installations

Information technology - Data Centre Facilities and Infrastructures

INTERNATIONAL ELECTRO-TECHNICAL COMMISSION (IEC)

IEC 60073

IEC 60079

IEC-60331

IEC-60332

IEC 60529

IEC 60617

IEC 60664

IEC 61000

IEC 61010

IEC 61131

IEC 61326

Basic and Safety Principles for Man-Machine Interface, Marking and Identification-Coding Principles for Indicators and Actuators

Explosive Atmospheres - All Parts

Tests for Electrical Cables Under Fire Conditions – Circuit Integrity

Tests on Electric and Fibre Optic Cables under Fire Conditions – All parts

Degrees of Protection provided by Enclosures (IP Code)

Graphical Symbols for Diagrams

Insulation coordination for equipment within low-voltage supply systems

Electromagnetic Compatibility (EMC)

Safety requirements for electrical equipment for measurement, control, and laboratory use

Programmable Controllers

Electrical equipment for measurement, control, and laboratory use – EMC requirements

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IEC 61499-1

IEC 61499-2

IEC 61508

IEC 61511

IEC 61643-21

IEC 61804

IEC 62381

IEC 62402

IEC 62443

IEC 62603

Function Blocks – Part 1: Architecture

Function Blocks – Part 2: Software Tool Requirements

Functional Safety of Electrical / Electronic / Programmable Electronic Safety - Related Systems - All Parts

Functional Safety - Safety Instrumented Systems for the Process Industry Sector – All Parts

Low Voltage Surge Protective Devices - Part 21: Surge Protective Devices Connected to Telecommunications and Signalling Networks - Performance Requirements and Testing Methods

Function Blocks for Process Control

Automation systems in the process industry – FAT, SAT and SIT.

Obsolescence Management

Security for industrial automation and control systems - Part 4-1: Secure product development lifecycle requirements

Industrial process control systems – Guideline for evaluating Process Control Systems

IEC 62682

Management of Alarms Systems for the Process Industries

IEC PAS 63131

System Control Diagram

INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS (IEEE)

IEEE 81

IEEE 802.1

IEEE 802.3

IEEE 802.11

IEEE 802.15.4

IEEE C37.90.1

Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System

Local and Metropolitan Area Networks – Part 1: Higher Layer LAN Protocols

Local and Metropolitan Area Networks – Part 3: Ethernet

Information Technology - Telecommunications and Information Exchange between Systems - Local and Metropolitan Area Networks - Specific Requirements - Part 11: Wireless LAN Medium Access Control (MAC) and Physical Layer (PHY) Specifications

Low-Rate Wireless Networks

Standard for Surge Withstand Capability (SWC) Tests for Relays and Relay Systems Associated with Electric Power Apparatus

INTERNATIONAL ASSOCIATION OF OIL&GAS PRODUCERS

IOGP REP 551

Obsolescence and life cycle management for automation systems – Recommended Practice

INTERNATIONAL SOCIETY OF AUTOMATION (ISA)

ANSI/ISA-5.1

Instrument Symbols and Identification

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ISA 5.2

ISA 5.3

ISA 5.5

ISA 18.1

ISA RP 60.3

ISA 71.04

Binary Logic Diagrams for Process Operation

Graphic Symbols for Distributed Control/Shared Display Information, Logic and Computer Systems

Graphic Symbols for Process Displays

Annunciator Sequences and Specifications

Human Engineering for Control Centers

Environmental Conditions for Process Measurement and Control Systems: Air-borne Contaminants

INTERNATIONAL ORGANIZATION FOR STANDARDISATION (ISO)

ISO 9001

ISO 9004

Quality Management Systems - Requirements

Quality Management – Quality of an organization – Guidance to Achieve Sustained Success

ISO 19011

Guidelines for Auditing Management Systems

NAMUR Recommendations / Worksheets (NENA)

NA 102

NA 163

NA 169

NE 022

NE 043

NE 121

NE 142

NE 165

Alarm Management

Security Risk Assessment of SIS

Automation Security Management in the Process Industry

Manufacturer Documentation for Process Control Systems

Standardisation of the Signal Level for the Failure Information of Digital Transmitters

Quality Assurance of Control Systems

Functional Safety of Electrotechnical Elements

BPCS Protection Layers

NATIONAL FIRE PROTECTION AGENCY (NFPA)

NFPA 70

National Electric Code

ADNOC Specifications

AGES-PH-04-001

Automation and Instrumentation Design Philosophy

AGES-SP-04-001

Process Control System Specification

AGES-SP-04-003

Fire &Gas System Specification

AGES-SP-04-004

Emergency Shutdown (SIS) System Specification

AGES-SP-04-006

Instrument & Control Cable Specification

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AGES-SP-04-007

Instrumentation for Packaged Equipment Specification

AGES-SP-04-013

OT / Cyber Security Standards

AGES-SP-07-011

Preservation and Export Packing Specification

AGES-SP-13-001

Criticality Rating Specification

Other References

Not applicable

DOCUMENT PRECEDENCE

The specifications and codes referred to in this specification shall, unless stated otherwise, be the latest approved issue at the time of contract award.

It shall be the CONTRACTOR’s responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.

The CONTRACTOR shall notify the COMPANY of any apparent conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein.

Resolution and/or interpretation precedence shall be obtained from the COMPANY in writing before proceeding with the design/manufacture.

In case of conflict, the order of document precedence shall be:

UAE Statutory requirements

ADNOC HSE Standards

Equipment datasheets and drawings

Project Specifications and standard drawings

Company Specifications

National / International Codes and Standards

SPECIFICATION DEVIATION / CONCESSION CONTROL

Deviations from this specification are only acceptable where the SUPPLIER has listed in his quotation the requirements he cannot, or does not wish to comply with, and the COMPANY / CONTRACTOR has accepted in writing the deviations before the order is placed.

In the absence of a list of deviations, it will be assumed that the SUPPLIER complies fully with this specification.

Any technical deviations to the Purchase Order and its attachments including, but not limited to, the Data Sheets and Specifications shall be sought by the SUPPLIER only through Concession Request Format. Concession requests require CONTRACTOR’s and COMPANY’s review / approval, prior to the proposed technical changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.

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PROCESS SAFETY REQUIREMENTS

Sr. No. Description

PLC used for process safety applications shall meet the highest Safety Integrity Level (SIL) specified for the Safety Instrumented Functions (SIFs) in the Safety Requirement Specifications.

Process Safety PLC I/O modules and its associated Components, field instruments that form part of SIFs shall be minimum SIL-2 certified by the qualified & accredited certifying agency meeting IEC 61508.

Documentation required by IEC 61508/ IEC 61511 shall be provided by SUPPLIER/ CONTRACTOR inclusive of Safety Manuals, Certificates, Test Reports, Reliability Data, etc. for PLC used in Process Safety applications.

DESIGN CONSIDERATIONS / MINIMUM DESIGN REQUIREMENTS

Operation & Design Life

The PLC system shall be designed for a minimum life of fifteen (15) years.

Environmental Requirements

Unless otherwise specified, PLC system cabinets shall be installed within a climate-controlled area.

The indoor installed cabinets shall be suitable for an air-conditioned environment to ISA S71.04, G3 classification.

The selected electrical and electronics items shall be suitable for environment classification ISA S71.04, G3 and cards/ circuit boards/ PCBs shall be provided with suitable conformal coating accordingly for protection against environment corrosion.

Normal indoor operating conditions will be 22°C ± 2°C and 50% Relative Humidity.

PLC equipment shall continue to operate in HVAC upset conditions during which the temperature in the indoor location of the installation can fall to 0ºC or rise to 60ºC, and the humidity can vary between 5% and 95% non- condensing.

PLC cabinets may be located in outdoor areas including sulphur environment subject to COMPANY approval. Sunshades / cabinets shall be supplied to protect the instruments, accessories.

Normal outdoor operating conditions are as follows:

Temperature:

Maximum Temperature in shade:

54° C

Maximum solar metal Temperature in the sun: 87° C

Minimum ambient Temperature:

5° C

Relative Humidity:

Maximum (at 43° C):

Average (at 28° C):

Design:

95 %

60 %

100 %

Rainfall is infrequent but may occur with winds up to 44 m/sec. Sandstorms are frequent and dust adheres to all exposed surfaces. Heavy salty dews are frequent.

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The PLC system shall generally comply to the storage environment STH5 and the transportation environment of TTH4 as recommended for PLCs in IEC 61131-2.

Electric Utility Data

Two separate power feeders from dual redundant UPS and one feeder from Utility power supply shall be made available for use by the SUPPLIER for powering PLC system cabinets.

The Electrical power supply details are as follows:

Nominal voltage – 110VAC to 240V AC; however, existing facilities shall follow as per facility standard.

Single Phase, 50 Hz, earthed

Steady state Voltage variation ± 10% nominal voltage

Steady state Frequency variation ± 5 %

Seismic Requirements

The system shall be designed to operate in the presence of a sinusoidal vibration of 2g at 10 - 500 Hz and withstand a shock of 15g for 11 milliseconds.

Hazardous Area Protection

Unless otherwise specified, PLC system and marshalling cabinets shall be installed in non-classified electrical area.

If equipment is in hazardous area, when approved by COMPANY for specific reasons, the Hazardous area classification and method of protection shall comply with IEC 60079. The field equipment / field cabinet or panels shall be in Zone 2 area with Ex’e’ or Ex’n’ protection.

PLC Equipment located in certified Hazardous Area enclosures shall comply with the maximum ambient conditions for continuous operation and shall be provided with adequate redundant climate control arrangement to maintain cabinet temperature at 22°C. Sunshade or shelter for equipment / cabinet / panel in field shall be provided to avoid direct sunlight.

Instrumentation located in hazardous areas shall be certified to IEC Ex or equivalent standards by a certifying body acceptable to COMPANY. Hazardous area PLC installation shall have higher temp and humidity withstand capability. The IEC Ex directive requires that a register is held of all IEC Ex certified equipment installed on the facilities and that the equipment is certified to the IEC Ex 02 scheme in conformance to IEC 60079. Additional ATEX marking shall be applicable for equipment conforming to IEC as per European Union Directive, whereas equipment conforming to North American Practices / NEMA shall carry Ex apparatus marking.

All equipment within the scope of supply shall be suitable for the area classification in which they are to be installed. The PLC equipment supplied shall be located in non-hazardous areas, however interconnecting system cabling may, in certain cases, pass through hazardous areas, and should be adequately designed and protected for this duty.

Field equipment connected to the PLC system will typically be located in hazardous areas and shall be certified as per IEC 60079 or other relevant international standard.

All field instruments connected to PLC system supplied shall be suitable for use in Zone 1, IIB, T3 hazardous area as a minimum.

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For instrumentation installed in hazardous area, Ex ia or ib (Intrinsically Safe) design is the preferred method for hazardous area protection. The use of flameproof or increased safety instruments shall be avoided except for solenoid valve which should be certified Ex db (Flame Proof) or Ex mb eb (combined encapsulation and increased safety), operating on 24VDC with maximum power consumption, of 12W. Ex ia or ib solenoid valves shall not be permitted. Use of Ex ia or ib (Intrinsically Safe) solenoid valves is subject to COMPANY approval.

Only active or galvanic barriers shall be provided for Intrinsic Safety (I.S.) requirements, unless otherwise specified in project documents.

Local Control Panels (LCPs) shall be flameproof Ex db as per IEC 60079-1, or Increased Safety Ex eb as per IEC 60079-7, for installation within a Zone 1 or Zone 2 hazardous area. Non-incendive Ex n as per IEC 60079-15 shall not be permitted for installation within a hazardous area.

In addition, for the UAE, Ex certified equipment also requires an Emirates Conformity Assessment System (ECAS) Ex Certificate of Conformity (CoC) issued by notified body. Requirement of the ECAS Ex programme utilises IEC standards, and qualification of conformity is met by meeting the requirements of the IEC Ex scheme in full, including mandatory factory site Quality Assessment Reports (QARs).

For further requirements on hazardous area protection for field equipment, refer to AGES-PH-04-001 Automation & Instrumentation Design.

Ingress Protection

The degree of Ingress Protection (IP) for equipment enclosure shall comply with IEC 60529 and equipment data sheets. The equipment minimum IP rating shall be as follows:

IP 42 for Indoor climate-controlled environments

IP 65 for Outdoor onshore field environments

IP 66 for Outdoor offshore field environments

Engineering Units

Reference shall be made to Project Engineering Design basis for Units of Measure. For brownfield projects, units shall be followed as per existing plant’s design basis.

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SECTION B – TECHNICAL REQUIREMENTS

TECHNICAL REQUIREMENTS

General Design

The SUPPLIER shall provide PLC system based on the package equipment SUPPLIER’s I/O list and functional design specification. The selection of PLC system shall be subject to COMPANY approval. The package equipment supplied with PLC system shall be classified as Package Equipment Type C in accordance with Instrument Equipment Package types defined in AGES-SP-04-007, Instrumentation for Package Equipment specification.

The PLC system SUPPLIER shall have a proven track record over a minimum three (3) years in providing design, engineering, supply and commissioning services for large scale Oil, Gas, Petrochemical, and related process facilities.

The PLC system shall be engineered considering the full life cycle from design, installation, commissioning, validation, start-up, operations, and maintenance through to decommissioning.

As a general minimum requirement, PLC systems shall comply to the following standards and the SUPPLIER shall provide the related testing & certification details to COMPANY for review:

IEC 61131-2 for basic design of PLC covering requirements for type tests, service conditions, function tests, etc

IEC 61131-3 for programming languages for PLCs

IEC 61010 for requirements related to considerations of equipment safety aspects in instrumentation for measurement and control

IEC 61326 for EMC requirements in instrumentation for measurement and control

IEC 61508 for functional safety requirements (as applicable)

Further, PLC systems shall be scalable and expandable without the need the need to re-engineer the entire architecture and/ or without replacement of hardware or software (refer IEC 62603).

The Programmable Logic Controller or Processor shall be a ‘state of the art’ microprocessor with a 256 Kilobytes words memory minimum, and in the event of disruption of program execution or scan, loss of logic power, loss of communication between controller and essential devices, or memory error, shall have the ability to either perform an orderly shutdown and alarm, or freeze the output, or both as per the configuration and design philosophy.

The PLC shall be highly modular in design and shall use a 32-bit microprocessor as a minimum; with a 10 msec resolution or better shall be available for time dependent functions such as rate calculations.

The system shall be composed of dual redundant processors and they shall perform all the data handling and computing functions required to:

Acquire data and send commands to field instruments and/or other requirements

Handle operator communications.

Perform the computations required by the control strategies.

All programming and monitoring equipment shall be capable of being connected or disconnected with the programmable controller in operation without losing or interrupting the program.

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Automatic restart of PLC system after power restoration shall be provided.

Provision shall be made for the CPU (Central Processing Unit) to check all logic words for parity when read from memory. A parity error shall cause the respective CPU an immediate shutdown with alarm and visual indication. The CPU shall have the capability of servicing the input/output at any point in the user program as many times as desired during a scan.

A key locking arrangement at the CPU shall prevent memory modification unless a key operator has intentionally enabled such a change.

Main memory shall be retentive memory (core or CMOS with battery backup). CMOS memory with battery backup shall be capable of retaining all memory for a minimum of six (6) months off the shelf. A battery alarm shall be generated to replace the batteries ahead of time before complete loss of energy.

The backup battery shall be capable of being replaced online without interruption of memory integrity with AC power off.

The SUPPLIER shall establish a method of sizing memory required to fully implement the functions described in this Specification with 40% spare memory.

The programmable logic controller shall have the capability to perform the following functions:

Data display in engineering units, scaling and conversion

Data printing

Alarming and Sequence of Event (SOE) generation

First out alarm facility shall be available, and the alarm shall be communicated to PCS/ICSS

Sequential process control

Logic control

PID control

Numerical calculation

Diagnostic monitoring

Report generation

Peripheral interfacing

Data processor interfacing

Time synchronisation with ICSS

Programmable functions as per IEC 61131-1 Table 1

Continuous control functions, Auxiliary Control functions, Logic functions, and HMI Displays as per API RP 554-1 Tables 2,3,4,5 respectively.

SOE logger with separate desktop computer

Proven Technology

The proposed PLC system inclusive of all components, hardware & software shall be field proven and shall have references of successful operation in petroleum & natural gas industry for the minimum period of three (3) years in similar applications, operating and environment conditions.

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Only System Hardware and Software that is field proven shall be included in the SUPPLIER’s scope of supply. Prototypes shall not be proposed.

Standardisation

The system shall be based on ‘Commercial-off the shelf (COTS)’ standard products of a field proven design. It shall have a high degree of availability, reliability, and tolerance to faults.

The system shall be designed in a modular fashion. The number of different parts shall be minimized and standardized to reduce spare parts holding. Standardization will also minimize the maintenance and Operator training requirements.

Standardization shall apply to all software and hardware items inclusive of system / sub-system modules, field instrumentation, workstations, firmware / operating system, application programs, networking items, and related accessories.

Electromagnetic Compatibility

The PLC systems shall be designed to prevent the emission of, and susceptibility to, Radio Frequency Interference (RFI) and Electromagnetic Interface (EMI) and shall comply with the requirements of IEC 61000 Electromagnetic Compatibility (EMC), IEC 61326-1, IEC 61131-2, and CE certified. The applicable requirement for EMC (emission restriction and immunity) as described in IEC 61326-1 Table 2, clause 7 and IEC 61131-2 clause 7, Tables 36 to 46 meeting performance criteria A.

The application of RFI / EMI protection components or configurations such as filtering, screening, minimal physical discontinuities, and bonding shall be employed. This includes unit construction and packaging design to ensure easy serviceability and the integrity of RFI / EMI features will not be degraded during normal maintenance conditions. RFI protection against hardware damage and system errors shall be provided for the equipment being furnished.

SUPPLIER’s equipment shall be tested, for RFI and susceptibility using, SUPPLIER supplied, handheld radios. The radios shall have a nominal transmitted power of 5 Watts.

SUPPLIER shall state any frequencies in the VHF and UHF bands for which they cannot comply.

PLC systems shall also be supplied with provisions for protection from electrical transients on power or signal wiring. These transients include those generated by switching large electrical loads, by power line faults, and due to lighting strikes, which induce surges on power or signal cables. The IEEE C37.90.1 shall apply to all system power inputs and signal inputs from field devices. The SUPPLIER shall detail in the proposal the method proposed to provide this protection.

Redundancy Requirements

The general project philosophy for redundancy shall also be followed, i.e., if systems/machineries are in duty/standby arrangements, they shall have segregated processors, I/O systems, and cabinets/rack, allowing each system to have individual turnaround and spares shall also be distributed accordingly. If major equipment has any parallel equipment, it shall be assigned to different I/O rack of the same controller and spares shall also be distributed accordingly.

Duty and standby protection of critical equipment shall be configured in different processors and cabinets/rack to ensure segregation of hardware and software design. Each rack shall be powered from independent power supplies, even if the racks are located in the same cabinet.

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The system design shall be such that there shall not be any common cause of failure considering all panel components and panel cabling & wiring.

The system shall be designed for maximum reliability, safety, and integrity while maintaining an availability which shall be 99.99% or better, where availability is defined as:

Availability % = (MTTF / (MTTF + MTTR)) x 100

In order to achieve the availability, each PLC system shall be supplied with the following components redundant as a minimum:

CPU Modules

Power Supply Modules

Communication Interface Modules

I/O modules for loops which provide a critical' control function, where a critical’ Function is defined as a function that, if lost due to a fault, would adversely affect asset safety or cause a significant loss of production.

Redundancy for implementing safety functions shall be as per the SIL level and the corresponding Hardware Fault Tolerance (HFT) requirements. Minimum HFT requirement shall be as per IEC 61511-1 Table 6.

Automatic and bumpless switch over to hot stand-by CPU shall be provided in case of failure of primary PLC and switchover shall be flawless without impacting the logic execution and updating all I/Os. Failed module shall be serviceable without affecting the active one. Down time is required to be minimal. The SUPPLIER shall provide reliability/ failure rate data from each component of the offered PLC system together with reliability modelling for the offered system availability prediction. The time to repair/ restoration shall be agreed with COMPANY.

System Response Time

System overall response time (defined as the time elapsed between a change in state of an output based on state of corresponding input) and scan time of the PLC system (defined as the processing inputs, execution of the PLC program and processing of all outputs) shall not exceed 300 ms.

However, sufficient scan surplus time shall be maintained in order to execute programs smoothly and in no cases, PLC shall not be overloaded or paused due to overload or higher execution time. Scan surplus time shall consider future minor changes / modifications as well.

The above specifications are for PLCs used for general use. For specific applications (e.g., surge control, fuel gas control etc.) the SUPPLIER shall provide a PLC with system response time adequate to the application.

I/O Allocation Rules

SUPPLIER shall comply with project I/O allocation rules without any exception at any stage of the project.

I/Os allocation and related segregation shall take into consideration service of the signals, associated criticality of the functions being performed (i.e., monitoring/ low level alarm/ high level alarm/ control, safety, level of shutdown, etc).

Spares shall be distributed across the I/O and other modules considering segregation and service.

The following allocation rules shall be strictly applied regardless of the number of channels per card (i.e., 8, 16 or 32). The underlying philosophy is to avoid accidentally losing duty and standby equipment when a single card becomes faulty. Following this principle, the auxiliaries of major equipment such as pumps, motors, air fin coolers,

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and heaters of duty equipment can be in one card to facilitate maintenance on the card / module or equipment without any upset for standby equipment.

I/O allocation for duty/standby and parallel equipment shall follow requirements specified in section 7.5.

In utility units, all equipment or packaged units are critical to utility production. When two equipment produce the same utility (steam generation, instrument air, nitrogen…) they shall be in different PLC controllers and cabinets. Other utility units shall be spread to optimize system resource utilization.

In PLC, where process gas detectors are interfaced, they shall be on separate cards subject to COMPANY approval. Project shall decide the use of this specification for application.

In general, analogue, and digital signals shall be segregated in separate marshalling cabinets as per I/O segregation philosophy and to avoid possibility of signal interference. However, for implementation scope involving small I/O quantities and for non-critical applications, analogue and digital signals may be combined in the same marshalling cabinet with I/O level segregation, subject to specific COMPANY Approval & appropriate segregation within the marshalling cabinet. Marshalling cabinets shall be segregated for I.S. and non I.S. signals. Criticality definition shall be as per AGES-SP-13-001, Criticality Rating specification.

Architecture

SUPPLIER shall develop and provide a detailed network architecture showing the interconnection of controller(s), I/O bus, network interfaces, interfaces to other systems, engineering workstation, and network devices.

The PLC system shall include control processors, power supplies, I/O modules, Field Termination Assembly (FTA) to interface field instrumentation signals from the package equipment, and communication modules to interface with the PCS/ICSS with necessary segregation firewall.

The PLC shall utilise dedicated redundant communication modules to interface with PCS at the controller level via redundant Modbus over Ethernet Interface for transfer all package equipment signals and status data from PLC to PCS. The changeover of link from primary to backup link shall be bumpless and there shall not be any disturbance in transfer of information to the PCS. All communication interfaces to PCS shall be through firewalls supplied as part of ICSS. PLC SUPPLIER shall verify the compatibility of firewall and configuration provided by the ICSS SUPPLIER.

All measured values, associated pre-alarms, alarms, set points, reset, and all chassis/module/channel fault alarms including diagnostic status of controller, power, I/O, communication modules, servers, workstations, switches etc. shall be transmitted to the PCS.

Maintenance Override activation signals for field signals where applicable shall be configured in the PCS HMI and sent as soft signals through Modbus TPC/IP communication link to the PLC for maintenance purposes without causing equipment shutdown.

Operator workstations for PCS shall be the Human Machine Interface (HMI), which will be provided with custom graphic page displays including PLC diagnostics displays in PCS, HART data in the IAMS for the package equipment to display field instrumentation and monitoring parameters.

Panel mounted PLC HMI can be provided for local operation, start-up, system parameter settings etc. in addition to centralised CCR PCS HMI.

The PLC and ICSS SUPPLIER shall be responsible to ensure that the operator data display on Central Control Room PCS workstation screens of PLC value / state changes occur within three (3) seconds.

All set point changes in PLC shall be dynamically updated and displayed in the PCS. All signals shall have individual alarm with description of status and location. Common alarm is not acceptable in all interface signals.

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HART data communication link from PLC shall be interfaced to the IAMS (supplied as part of ICSS).

All data exchange tags for each interface shall be finalised by CONTRACTOR and SUPPLIER and submitted for review and approval by COMPANY. SUPPLIER shall fully define data exchange capabilities as to types, formats, time resolution, storage capability, etc. as well as data exchange formats supported.

The PLC shall have hardwired interface to the PCS for critical control signals and cabinet alarms, and to the ESD system for shutdown related signals. All package equipment’s shutdown / trip related signals shall be hardwired from PLC directly to the plant’s ESD system/Safeguard system/protection system, including other parameters that may also affect tripping of the package equipment. The alarms shall be transmitted through the PCS communication data link for operator notification.

The PLC system shall have its own independent network to connect its controller(s) and Engineering Workstation (EWS).

The PLC system and marshalling cabinets shall be located in Instrument Equipment Shelter (IES) or Instrument Technical Room (ITR), or Local Equipment Room (LER), Satellite Instrument Shelter (SIS), or in a Room / Building closest to the package equipment within the plant.

Based on project decision, where there are multiple PLCs of the same MANUFACTURER is provided within a facility, the requirement for a centralised desktop PC based EWS at the central location/CCB shall be finalised in consultation with the COMPANY.

The requirements for local desktop/portable EWS and the quantity required at the IES/ITR/LER/SIS shall be finalised in consultation with the COMPANY.

Portable laptop-based EWS provided for ad-hoc use shall have spare port available for connection in the PLC network switch.

The EWS shall meet the minimum requirements specified in section 7.9.14.

All network extensions outside the buildings shall utilise redundant Fibre optic cables which will be supplied and installed under the scope of CONTRACTOR.

The preference is to interface the PLC system with ICSS in accordance with requirements specified in sec 16.2 of AGES-PH-04-001, Automation and Instrumentation Design Philosophy.

The PLC network shall be interfaced with the ICSS Network either locally or at a central location/CCB through firewall for the provision of the following services. The PLC SUPPLIER shall provide the required system hardware/software that meets compatibility with the ICSS and work with the CONTRACTOR/ICSS SUPPLIER to achieve the following interfaces.

7.8.1

Time Synchronisation

Time synchronisation of PLC system shall be implemented using time source reference received from ICSS through ICSS network interface. Refer to AGES-SP-04-001 Process Control System for further details.

Where PLC is not interfaced with ICSS network, or where time source is not available, hardwired time synchronisation signal, i.e., pulse signal at 12’o clock midnight, shall be provided from the PCS.

7.8.2

Alarm and Event Data Exchange

Alarm and Event associated time stamped data exchange to ICSS shall be implemented through the ICSS network interface where applicable using OPC protocol. PLC system shall be supplied with OPC data exchange server for providing this data exchange to ICSS.

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Where PLC is not interfaced with ICSS network, dedicated Alarm & Event data collection server and viewing capabilities shall be provided.

7.8.3

Backup and Restore

The PLC system shall interface with the ICSS network so that all workstations (and servers as applicable) shall be centrally backed up using the ICSS supplied backup and restore application. Where not interfaced, dedicated backup and restore application shall be provided.

7.8.4

Anti-virus and Patch Management

The PLC system shall interface with the ICSS network so that all workstations (and servers as applicable) shall be get anti-virus and operating system patch updates from the ICSS supplied patch management system. Where not interfaced, anti-virus and patch updates shall be manually deployed.

7.8.5

Active Directory / Network Management

The PLC network shall interface with the ICSS network so that it can be monitored by the ICSS Network Management System for providing network monitoring and management functions.

All workstation computers (and servers as applicable), and network devices shall have user-based access control provided from ICSS supplied Active Directory / Domain Controller.

Where not interfaced, dedicated networking management and user management applications / functions shall be provided.

7.8.6

Cyber Security

The PLC system architecture design shall be designed in compliance with AGES-SP-04-013 OT/ Cyber Security Standards.

The offered PLC System shall be cyber security certified by a qualified & accredited certification body as per IEC 62443-4-2 and other related standards. All the relevant certification documents shall be provided reflecting the level of cyber security certification.

The network shall be divided into zones with separate levels of security. All communication between the ICSS / PCS and PLC system shall be via Firewalls.

SUPPLIER shall provide details of their proposed interfacing strategy and procedures, and alternatives available that give due cognizance to COMPANY’s system security requirements.

All automation installations shall comply with COMPANY’s OT Security policies and procedures.

The system functionality shall provide for user configurable access security control via software password recognition to limit the access rights of personnel to the PLC functionality. SUPPLIER shall describe the mechanisms available to achieve this, the logging facilities for access requests and how the access rights can be modified as necessary to suit commissioning and operational purposes.

A cyber security risk assessment as per IEC 62443-3-2 and NAMUR NA 102 shall be performed by COMPANY/CONTRACTOR. SUPPLIER shall provide all required support for this assessment.

The cyber security risk assessment shall be performed as follows and shall be an iterative and continuous process:

Define the risk analysis methodology (for example architecture based)

Identify major items (organization, systems, subsystems, networks)

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Identification, evaluation of the threat scenarios with their impact and likelihood

Reduce the risks by designing adequate countermeasures

Summarize the results in a Risk Register.

The cyber security risk assessment findings and recommendations, mitigation plan as well as reporting & recovery measures relating to PLC design and configuration shall be implemented by SUPPLIER.

The OT cyber security risk assessment shall clearly specify all the required zones & conduits together with network safety barriers (firewalls, etc). The risk assessment shall establish required Security Levels (SLs). The specific foundational requirements (FR) and system requirements (SR) shall be established considering SL required as per IEC 62443-3-3. The cyber security certification of the offered PLC shall establish compliance to the required SLs for each FR and SR.

ICSS SUPPLIER shall provide the necessary firewalls to interface with PCS/ICSS.

Where portable computers / laptops are provided, they shall comply AGES-SP-04-013 OT/Cyber Security standard and it shall be hardened for all external access and all storage devices, i.e., USB, Optical Drives, etc shall be blocked.

SUPPLIER shall provide in-built Intrusion Prevention and Intrusion Detection functionalities (White-listing, User configurable ports, User authentication etc.)

System Hardware

7.9.1

System Design

The PLC shall be used as a main input/output and control device for monitoring and basic logic control and will be a standalone component.

The PLC shall be capable of being configured as fully redundant with dual redundant processor modules, redundant power supplies, redundant communication modules and redundant I/O modules. Power supply and processor modules shall reside in separate rack. Sharing of the rack is allowed if there is no common mode of failure and COMPANY approval shall be obtained.

PLCs shall be dedicated for Control, Monitoring and Protection / safety applications. Control, monitoring (PLC) and shutdown / protection (safety PLC) functions shall be segregated. All protection / safety function shall be independent from control functions. Programmable Logic Controllers (PLC) used for Protection / safety functions shall conform to AGES-SP-04-004, Emergency Shutdown (SIS) System Specification.

Programmable Logic Controllers (PLC) used for non-ESD / non-BMS (Burner Management System) / non-safety functions shall conform to this specification.

7.9.2

System Interfaces

The PLC modules shall be capable of being inserted or removed online while in operation without switching off the chassis / rack power OR causing adverse effect.

I/O configuration data shall be automatically downloaded to the replaced spare module without any disturbances.

Interface to plant signals will normally be via PLC I/O modules with field terminals mounted within adjacent field termination cabinets. All plant signals shall be intrinsically safe with barriers mounted in the marshalling cabinet. Refer to section 7.9.9 for details.

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Field cables shall be terminated at the Marshalling Cabinets using COMPANY approved terminal blocks. The PLC SUPPLIER shall provide sufficient terminals for all I/O including cable/pair screens and 20% installed spares equally distributed including field terminations, isolators etc.

All analogue and digital signal terminals shall be provided with disconnect facility for maintenance/testing. All multi- strand wiring shall be crimped.

The system shall be capable of accepting signals from external powered or loop-powered SMART transmitters. All analogue 4 to 20mA I/O shall be fully compatible with the HART standard frequency shift keying signal superimposed at a low level on the 4 to 20mA analogue measurement signal.

The PLC SUPPLIER shall provide all hardware necessary to support the bi-directional communication between SMART field devices (transmitters / positioners) and the Instrument Asset Management System (IAMS) supplied as part of ICSS using superimposed HART communication signals. HART pass-through analogue I/O modules shall be supplied. The use of external HART multiplexers shall be subject to COMPANY approval.

The PLC shall include redundant Modbus TCP/IP communication modules with Ethernet ports for providing communication interface to the PCS. The PLC system provide HART data interface to the IAMS (supplied as part of ICSS). The PLC system shall have an independent network to link engineering station, and interface to ICSS network for provision of shared network services. Refer to section 7.8 for details.

7.9.3

Analog Inputs

Each Analog Input (AI) card / module shall have a minimum of eight (8) and a maximum of sixteen (16) Inputs.

4-20mA analogue inputs shall be capable of interfacing with either 2 or 4 wire transmitters.

AI module shall be NE43 compliant.

HART pass-through AI modules shall be supplied.

The analogue inputs shall support the use of a field calibrator for maintenance without affecting system operation. The 4-20mA analogue input processors shall be calibrated to 1 to 5V, an internally installed 250-ohm precision resistor shall be used to generate the respective voltage input. All inputs shall be differential types capable of operating under a common mode voltage range of -15V to +15V peak.

4-20mA inputs shall be capable of being configurable on an individual channel basis to provide energizing power for a 2-wire transmitter, or to receive a powered signal from an external device. Externally powered signals will be galvanically isolated within the external device.

The 2-wire transmitter option shall be capable of providing 24V DC energizing voltage to ensure operation with most transmitters plus an additional loop resistance of 600 ohms.

The circuit for the transmitter power supply shall be protected by a current limiting resistor, such that the effect of a short circuit in one current is limited to less than 30mA. Power supply fusing shall be provided on an individual I/O basis.

Input resolution shall be 16bits minimum. Calibration accuracy shall be better than +/- 0.15% of range.

Common mode rejection ratio shall not be less than 70dB; channel to channel crosstalk rejection shall not be less than 60dB.

Inputs shall be capable of withstanding over-voltage of +/-30 Volts with respect to common, with no damage.

The input scan rate shall be four samples per second per channel. All channels shall be scanned within a 250ms window.

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Each input processor shall be provided with a reference calibration input channel, used internally to monitor the performance of the A/D converter. An alarm shall be generated on detection of error and change-over to the redundant module.

7.9.4

Analog Outputs

Each Analog Output (AO) card / module shall have a minimum of four (4) and a maximum of sixteen (16) Outputs.

Analog outputs shall be 4-20mA current sources capable of driving into a 600-ohm load.

Each output shall have individual current limiting such that the effect of a short-circuit to earth in an output does not affect the operation of any other, and that the fault current is limited to less than 30mA. Power Supply fusing shall be provided on individual I/O basis.

AO module shall be NE43 compliant.

HART pass-through AO modules shall be supplied.

Each I/O processor module shall have multiple internal power supply paths to ensure that output power is not lost due to a single fault.

Output resolution shall be 15 bits across range.

Calibration accuracy shall be better than +/- 0.15% of range.

For certain applications where an isolated analogue value is to be transmitted to foreign device, 12-bit resolution and +/-0.1% full scale accuracy will be required.

7.9.5

Digital Inputs

Each Digital Input (DI) card / module shall have a minimum of eight (8) and a maximum of thirty-two (32) Inputs.

Digital inputs will be derived from volt free contacts from external equipment or from NAMUR proximity switches. Contact wetting voltage shall be 24V DC supplied internally. Sender current shall not exceed 20mA. Fusing shall be provided on individual I/O basis.

Each input shall be galvanically isolated from the system and other inputs to 1000V DC and shall be capable of withstanding input voltages of 110V AC on a continuous basis without causing damage.

Input filter delay shall not exceed 1ms. Field resistance for guaranteed ON conditions shall be 100 ohms maximum, and 200 ohms minimum for OFF condition.

Line monitoring feature shall be provided as specified in project specifications.

7.9.6

Digital Outputs

Each Digital Output (DO) card / module shall have a minimum of eight (8) and a maximum of sixteen (16) Outputs.

Digital outputs will be required, providing volt-free contacts, capable of withstanding 24V DC minimum. For brownfield modifications in plants having 110VDC SOVs shall have DO with volt-free contacts, capable of withstanding 110VDC minimum.

Volt-free contacts shall be fully isolated, software selectable SPST/NO or SPST/NC, and shall be rated for 2A at 30V DC. Fusing shall be provided on individual I/O basis.

Replaceable load fusing shall be provided on an individual channel basis.

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For digital output to solenoid valve an independent 24V DC ± 10% shall be derived from external power supply (see 7.9.11) to drive relays to ensure isolation between PLC and the field.

Line monitoring feature shall be provided as specified in project specifications.

7.9.7

Communication Modules

Communication modules for PCS/ICSS interface or other third-party system interface shall be based on the project specific requirements and system documentation such as architecture.

7.9.8

Diagnostics

The PLC shall provide complete power supply and system fault diagnostics including CPU, I/O card/modules, communication modules, Power modules, I/O bus, input bad quality etc.

CPU diagnostics shall include memory error and forced input-output bit status and write protect. CPU diagnostics shall have a capacity to be able to store and trace back of any faults up to minimum 72 hours.

I/O modules shall come equipped with integral light emitting diode (LED) indicators displaying signal status.

The system shall have full extensive diagnostic capability for all modules, I/O channels, power supply, communication module, system cables and field cable failures. Fault status shall be capable of transmission across the Modbus over Ethernet communication link interface. As a minimum the system faults listed in section 7.11 shall be made available for display on the PCS HMI diagnostic displays for PLC system.

7.9.9

Signal Isolation and Safety

Hardwired analogue signals, where required, and serial communications outputs shall be fully isolated from the system power supply to prevent power supply interactions between transmitting and receiving systems.

Input and Output modules shall have opto-isolators to protect the I/O modules when no barriers or isolators are not present in the loop. DIN Rail Mounted surge protectors shall be provided as specified in project deliverables.

Intrinsic Safety (I.S.) barriers or certified galvanic isolation shall be provided between all field signals and I/O channels for all instrumentation located within hazardous areas where the instruments are not Ex’d’ rated.

I.S. barriers / isolators are not required for signals hardwired to PCS / ESD system within the building /room. I.S and non-I.S. cables/ circuits shall be segregated.

I.S. barriers / isolators used shall be single channel only. Zener barriers shall not be used without prior COMPANY approval. All barriers should be active type and installed on Field Termination Assembly (FTA). Alarm terminals of Power Supply Unit (PSU) of active barrier system shall be hardwired to cabinet alarm terminal block in cabinet.

Redundant PSU units for I.S. barrier rail shall be provided and powered from redundant power feed source.

SIL certified barriers shall be provided on safety instrumented function loops that are SIL rated.

Instrument tag number shall be included on labels provided for I.S. barriers.

7.9.10 Cabinets

All electronic equipment may be housed in SUPPLIER’s standard cabinets but are subject to CONTRACTOR and COMPANY approval on size and finish. Cabinet shall be standard enclosures from COMPANY approved SUPPLIERs. Marshalling cabinets shall be supplied using the same type of cabinet as the PLC system cabinets.

SUPPLIER shall standardise cabinet designs per cabinet type, i.e., System cabinet, Marshalling cabinet, Network cabinet, Workstation / Server cabinet etc.

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Cabinet internal arrangement of PLC system / I/O racks and other components shall be such that sufficient clearance to provide access for maintenance while system is under operation must be available complying with the spareage requirements provided in this specification.

Combining of System Cabinet and Marshalling Cabinet under the same cabinet is not acceptable without prior approval from COMPANY.

Two (2) types of cabinet shall be provided:

System cabinets including PLC racks comprising CPUs, I/O cards / modules, communication modules, power supplies, switches, etc.

Marshalling cabinets equipped to receive all package signals from and to the field, the electrical room, or other technical rooms or to receive signals from other systems such as PCS, ESD, etc.

Each package shall have dedicated PLC cabinets.

PLC system and marshalling cabinets shall be rigid and self-supporting. Cabinets shall be constructed of sheet steel with a rigid internal steel frame. Cabinets shall be braced for shock and vibration normally encountered during transport and construction.

The cabinet’s structure thickness shall be minimum 1.5mm for cabinet steel plate sides, roof, and bottom, and minimum 2mm for doors and plinths. The dimensions of the cabinets shall be 2000mm (H) (excluding plinth) x 800mm(W) x 800mm (D) (front and rear access). The cabinets shall have front and rear access to enable maintenance / construction activities. In case only front access is feasible due to site condition the system rack shall be mounted on an internal frame to allow access to the rear side of system rack. If cabinets are permanently bolted to form sections, the length of these sections shall not exceed 2400 mm.

All cabinets shall have the same exterior and interior finish and colour. Cabinet colour shall be RAL7035. Plinth colour shall be RAL7022.

The cabinet Internal layout shall be designed to provide safe and unimpeded access to all electronic modules, power distribution, fuses, terminals and cables termination areas, cables and wiring routings and replacement of defective parts with the minimum amount of dismantling or removal of associated equipment.

All cabinets shall be bottom entry unless with approval from COMPANY. Cables shall be supported by Unistrut cable clamps for indoor installed cabinets. For outdoor cabinets, cable entry shall be through cable glands.

IP42 shall be minimum standard for all indoor cabinets.

Cabinets shall have UPS powered redundant ventilation fans for heat removal. The cooling fan noise shall be less than 55dbA.

Cabinets shall be equipped with ventilation louvers with dust filters units. Inlet louvers shall be installed at the bottom of cabinet doors. Filter screens shall be readily accessible and easily removable.

Cabinet and inside equipment support shall be designed to dampen effects of external vibration.

Eyebolts shall be mounted on each cabinet to facilitate handling during unloading and permit transportation of the enclosure by crane.

All unused I/O module slots shall be fitted with removable cover plates.

Cabinet shall have lockable hinged doors. Hinges shall be the lift off type for example doors shall be easily removable from cabinet.

All door locks shall be provided with the same lock and key combination. Keys shall be removable with the doors either locked or unlocked.

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Internal lighting lamp at the top of the cabinet shall be controlled by a door switch or movement detector and incorporating a manual on/off/auto switch.

All components shall be safe to personal and environment that shall comply with listed international electrical safety standards. All terminals containing voltages more than 50V shall be shrouded with clear insulation sheet and labelled as hazardous.

Each Cabinet and all its major components shall be clearly labelled and identified with a Tag Number.

Cabinet nameplates shall be by engraving on three-layer plastic. Material layers shall be white-black-white and attached with stainless steel screws. Nameplate engraving shall be subject to COMPANY review and approval.

When available space inside the technical room is limited or when package equipment I/O quantity is low enough, combined marshalling/system cabinets may be considered. However, physical segregation between marshalling and systems sections, and easy access to any equipment/device/terminal requirements shall be fulfilled. Such arrangement shall be submitted to COMPANY for approval, as a cost saving.

Side mounting of components shall not be permitted, unless approved by COMPANY.

All cabinets shall have drawing/document folders located on front and rear doors.

All components shall be safe to personal and environment and shall comply with electrical safety standards.

Prefabricated system cables shall be provided to connect the system cabinets to the marshalling cabinets. All cabling, sockets, plugs and terminating blocks shall be arranged and positioned to facilitate easy access for testing, inspection, and maintenance.

Terminals shall be Blue for Intrinsically Safe and grey for all others.

Cabinet alarms shall be provided for individual fan failure, high temperature, rack fault, and power supply units failure hardwired to the PCS for annunciation.

In each system and marshalling cabinet, drawings specific to that cabinet such as layout, wiring diagrams, termination schedules, power supply schemes and loop wiring shall be provided.

Provision for High Sensitivity Smoke Detection (HSSD) supplied by others shall be considered in the cabinet design. Based on the type of system (i.e., aspirated or point type), cabinet entry holes, washers etc. to meet IP requirements shall be provided.

Each item of PLC system and its accessories shall have nameplate attached firmly to it showing the following information (as applicable):

Manufacturer’s model number and serial number

Manufacturer’s name and trademark

Tag Number (at a visible space)

Type of area classification/protection

Identification of each electronic module

Input/Output signal specification

Power requirement

Identification of each system / I/O rack

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7.9.11 Power Supplies

All cabinets supplied for PLC, i.e., system, marshalling and workstation (or Server) cabinets shall be designed to accept dual redundant UPS power supply feeds and single utility feed.

Two (2) nos. of 240 VAC (or 110 VAC or as per facility) 50 Hz power supply feeders shall be provided from UPS- A and UPS-B, respectively. Power supplies shall convert 240 VAC (or 110VAC) 50 Hz supplied power into voltage levels required by the PLC system / I/O racks, I.S. Barrier, etc. 240VAC redundant power supplies shall not be paralleled at any point unless converted to DC feeding common distribution DC bus. Redundant power supplies shall be provided with diode O-ring circuits to prevent back current.

Power Supply Modules / Power Supplies shall be supplied to accept universal input voltage, i.e., 85- 240VAC.

For each incoming power feed, a double pole isolation switch shall be provided. Each power supply located inside PLC cabinets shall be capable of supplying 100% system power if other fails. All power supplies, without considering redundancy shall include a spare capacity of 25% of the maximum load considering all spare I/O slots were filled. Power supplies shall be replaceable on-line without disrupting the process and without affecting functioning of PLC System. Distribution of all power levels to all system rack and modules shall also be completely redundant as a minimum. This is to be inclusive of all voltage levels required for logic processors, all chassis requirements, I/O modules, and communication modules.

Miniature circuit breakers (MCB) and fuses shall be employed to provide electrical protection and isolation for all powered components. The distribution circuit shall ensure that at no point of single MCB failure will result in other consequences or cascade effect. MCB fault contacts shall be wired in series to generate a common fault alarm. Selection of fuses and MCB ratings shall be carefully coordinated with upstream fuses / MCBs including UPS distribution, considering power up inrush currents.

Each PLC system chassis / rack shall be supplied with dual PSUs in redundant configuration, each accepting single UPS feed. Similarly, Dual PSUs shall be supplied for I.S. Barrier power supplies. A failure or removal of single PSU in a redundant configuration shall not impact function or cause a machine trip. Faulty PSUs must be removable without powering down the system.

Each power supply shall be provided with primary and secondary overload protection. The secondary overload shall be self-resetting or have a time delay to prevent a momentary fault from tripping the system. Over-voltage protection shall be provided for protection of the connected loads.

Each power supply shall be provided with a pilot light and with a fault detector. Failure of any power supply must be signalled via a dry normally closed contact (opens on power supply failure) which shall be wired to a discrete input point for alarm indication on the PCS.

For single feed loads, an Automatic source Transfer Switch (ATS) shall be provided and switching time shall be mentioned for components that cannot accept dual power feeds (e.g., workstation etc.). The transfer time of ATS shall be fast enough and shall not cause any operational interruption in the powered component during changeover.

Power supply spare requirements shall be in accordance with Spareage requirements specified in this specification.

Additionally, separate 24 VDC redundant power supply for powering field instruments shall be provided.

The SUPPLIER shall be responsible for designing the 24 VDC power distribution with circuit protection for all system I/O. All 24V DC –ve terminals shall be connected to Instrument earth (floating earth is not allowed).

The SUPPLIER shall wire cabinet lighting and utility outlets to a separate breaker which will be fed from a single phase 240V AC 50 Hz utility non-UPS supply.

SUPPLIER shall provide the power consumption including inrush currents and crest factors for each cabinet to size incoming power feeders.

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7.9.12 Wiring and Cabling

Instrumentation cabling requirements in general shall comply requirements specified in AGES-SP-04-006, Instrument & Control cable specification.

Prefabricated system cables shall be provided to connect the system cabinets to the marshalling cabinets, if remote I/O is not used. All cabling, sockets, plugs and terminating blocks shall be arranged and positioned to facilitate easy access for testing, inspection, and maintenance.

Unless otherwise specified in the requisition, or approved by COMPANY, the colour coding of wires within PLC cabinets shall be as follows:

Power 24V DC positive / negative - RED / BLACK

Power 240V AC phase / neutral - BROWN / LIGHT BLUE

Input and output signals - BLACK/WHITE or BLACK/ BLUE (to indicate intrinsically Safe signals)

Signal Earth - GREEN

Intrinsically Safe Earth - GREEN/BLUE

Safety Earth – GREEN/YELLOW

All interconnecting cables shall be tagged at both ends with cable number and cabinet number. Wiring core shall be tagged at both ends (where applicable) with tag number using shrink sleeve type markers or equivalent. All interconnecting wiring shall be labelled easily readable (they should not be upside down) and shall have cross- reference ferrule (source/destination).

Shielded signals cables shall be utilised to provide protection against Electromagnetic Interference (EMI) and Radio Frequency Interference (RFI).

Internal wiring shall be laid in PVC close slotted ducting (raceway) with a covering lid colour coded blue for Intrinsically Safe and Grey for non-Intrinsically Safe wiring. Ducting (raceways) shall have at least 40% spare capacity after commissioning.

Internal cabinet wiring, cables and wire ways shall be minimum flame retardant in accordance with IEC 60332.

All internal and external wiring shall be connected to terminals. Splices are not permitted in wiring. Terminal blocks shall be Push-in Spring type (cage clamp type) and non-hygroscopic type. Terminals shall be tinned and clearly identified. The size of the terminal blocks shall be consistent with the wire size. Terminal colour for Non-IS wiring shall be Grey and Intrinsic Safe wiring shall be Blue. Terminals utilized for voltages higher than 48 volts shall be protected against accidental contact with removable cover plates which carry high voltage warning labels. Terminal blocks shall be labelled and numbered.

All interconnecting wiring within cabinets and between PLC cabinets shall be the responsibility of the SUPPLIER. All cabling between field devices and PLC marshalling cabinet shall be under the responsibility of CONTRACTOR, including cabinet alarm wiring from PLC cabinet to PCS marshalling cabinets.

All communication network cables within building for distances up to 100m shall be copper cables based on Ethernet specification. For distances exceeding 100m, Fibre optic cable interface shall be provided. Fibre optic patch cords required for PLC within a building shall be supplied by the SUPPLIER.

Fibre optic cables shared with ICSS shall be used to connect PLC network outside buildings.

All hardwired signal cabling from field to cabinet and inter-cabinet signal wiring shall be supplied and installed by CONTRACTOR.

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7.9.13 Earthing

There shall be three separate isolated Earthing Systems within the PLC cabinets as follows:

Safety Earth: Each cabinet shall have a M10 brass earth stud, complete with nuts and washers for dedicated safety earthing. All metal racks, internal panels, cable tray, doors and detachable panels shall be earth bonded together to this safety earth with a flexible copper braid strap of at least 10mm2 to ensure effective earthing.

Instrument Earth: Each system and marshalling cabinet shall be provided with one 5mm x 15mm copper galvanically isolated instrument earth busbar across the full width of, and insulated from, the panel for earthing System electronics and electrostatic screens of field cables. In general, field instrument shields shall be grounded to instrument earth within the Marshalling Cabinet.

Intrinsically Safety Earth – IS Earth: Marshalling cabinets with non-isolating IS barrier (for example Zenner barrier) circuits shall be supplied with an additional isolated IS earth busbar clearly labelled.

These will be connected at one point only and as near as possible to the earth electrodes as directed by the CONTRACTOR.

7.9.14 Workstations & Servers

All workstations (i.e., EWS), servers as applicable shall kept inside a locked environments as per AGES-SP-04- 013 OT/Cyber security requirements specification.

Portable EWS is not preferred, where required shall be as per COMPANY approval in compliance with AGES-SP- 04-13, OT/Cyber Security specification. The portable PC Laptop / Notebook based EWS shall include application software for the program development, system configuration, maintenance, troubleshooting, diagnostic and backup purposes.

The portable EWS for the project shall be ordered after plant start-up to ensure latest hardware is bought. This shall not be used for plant use during start-up and shall be handed over as brand new to COMPANY.

SUPPLIER should utilise the COMPANY assigned assets to the maximum extent instead of using their own portable PC / Laptops / Notebooks, and software for project start-up purposes.

As a minimum, EWS shall be PC Laptop / Notebook with 15” TFT display, 512GB SSD hard disk, and 16GB RAM. However, final specifications shall be subject to COMPANY approval six (6) months before FAT date.

Desktop EWS where required / specified for project to provide permanent / centralised engineering facility shall be rack mount version for installation within cabinet, and supplied with minimum 24” colour LED display, 16GB RAM, Keyboard, mouse and storage capacity of 512GB.

EWS shall be configured to use shared ICSS printers in the room.

The EWS shall be supplied with a PC based program development application. The program development application shall be capable of operating in “on-line” mode, “off-line” mode, and “monitor” mode:

In “on-line” mode, the engineer / technician shall be able to make any program changes while the CPU is running.

In “monitor” mode, the program development workstation shall be able to read from, but not write to the programmable controller main memory.

In “off-line” mode, programmer shall be able to create an application program without connecting the program development terminal to the programmable controller CPU. The program created in off-line mode shall be able to be saved on the storage and loaded back in the development workstation if required.

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The mode of operation of the program development application shall be selected by operating a multi-position key switch.

PLC systems that are provided with servers for alarm and event data exchange with ICSS shall utilise virtual server platform provided for the ICSS where available or possible. Servers shall be rack mount type for installation in cabinet, with 512GB storage using RAID-5 hard disk configuration as a minimum.

All specifications for workstations, servers and portable computers shall be finalised with COMPANY approval six (6) months prior to FAT.

7.9.15 PLC HMI Display

The use of a dedicated PLC Human Machine Interface (HMI) display shall be minimised unless essential from an operation point of view e.g., local start-up/shutdown purposes, periodic monitoring and control, maintenance/diagnostics purposes or mandatory for packaged equipment subject to COMPANY approval. HMI display shall be used for operator interface only and no control and safety function shall be performed.

PLC HMI display may be mounted either in system cabinets within buildings or depending upon the application, they may be installed at field in Local Control Panel (LCP) subject to COMPANY approval. For requirements on LCP, refer to AGES-SP-04-007, Instrumentation for Packaged Equipment specification.

The Human Machine Interface (HMI) display shall be touchscreen display with keys, configured with interactive displays to assist operation and maintenance functions. The location, screen size, buttons, displays, configuration etc., shall be based on project/application requirements subject to COMPANY approval.

The HMI display shall be supplied from the PLC manufacturer’s standard product line compatible with the offered PLC. HMI display for LCP use shall be an extended display with interface ports hardened to meet cyber security requirements.

The HMI display shall be rated for environmental design considerations / minimum design requirements specified in section 6.

7.9.16 Network Device Requirements

All network switches shall be managed switches provided from COMPANY approved SUPPLIER. Layer 2 Ethernet 100Base-T switches with Gigabit Ethernet 1000Base FX-SX Backbone fibre optic uplink interfaces shall be supplied as a minimum.

Network switches for PCS interface links shall meet compliance to requirements specified by ICSS SUPPLIER.

Network Monitoring solution will be provided by ICSS SUPPLIER for ICSS which shall provide network monitoring and management functions for PLC Network. PLC SUPPLIER shall be responsible for compatibility to network monitoring solution provided by the ICSS SUPPLIER.

All network equipment shall be mounted in PLC system cabinets with adequate space for routing of patch cords and network cables.

System Software

The programming software shall be IEC 61131 compliant. The system software design considerations shall comply with API 554-2 clause 7.0.

All application software (online/offline programming system software) and operating system software shall be the latest version / edition approved and tested by the SUPPLIER at the time of project’s Provisional Acceptance Certification (PAC) time.

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Program changes shall be allowed element by element such as adding, deleting, or reversing (NO to NC) contacts without replacing the entire rung. Program changes shall also be allowed to delete or insert entire rungs inside the program. Dynamic power flow logic display shall be provided for sequence and cause & effect diagrams. A search feature shall allow user to call up any function code, logic gate, contact or coil. The search function shall be provided by a special push button on the keyboard. An override feature shall allow user to override input and outputs on or off from the program interface entry system. The override function shall be password protected. Software maintenance override switches shall be configured in the PCS.

Data storage capability shall be sufficient to store all the application data.

The following program features shall be provided:

Multiple program partitions shall include but not limited to the following:

System inputs

ii. System outputs

iii. Cause and effects

iv. Matrix alarms

v. External System interface routine

vi. Trip signals

vii. Start-up sequence

viii. SOE and First out detection capability

ix. Any other different sequence.

All programming language ladder diagrams, functional logic diagram using gates and flow charts shall have a search facility with tag and comments, in addition to the search facility by contact, registers and coil addresses. The system shall be capable of on-line logic modification.

It shall also be possible to call up a display by page number and rung number.

When searching by tag or by tag comments, the program shall have the feature to display all the locations where these tags or tag comments are being used (including the tags in the register).

There shall not be any users’ blocks in the program.

Each logic element shall be entered by selection of an appropriate menu icon using a mouse or trackball or by depressing the element key and the proper numeric keys for addresses and values. As each element is entered, it shall be added to the visual display on the screen. New elements may be inserted or deleted in a rung, and rungs may be added or removed any place within the ladder diagram.

The software shall support a Tag (alias) based program.

Editing and “online program change” capability shall allow any rung to be corrected without having to totally re-enter the logic. This operation may be performed in the Program mode or the Run/Program mode.

The program shall support offline simulation of the element logic states. All elements of a rung shown on the display shall be intensified when “true” to allow viewing of the rung and observing the condition that exists on both input and output devices.

The program shall support function block or ladder logic programming modes and shall provide configurable function blocks.

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The program panel shall have the capability to monitor/program all logic controllers in the plant, one at a time, by means of selection.

Program documentation software shall include, but not limited to:

ii.

Hard copy printing of program and comments

Full program annotation

iii. Cross-reference tables’ generation and printing.

Each software module shall have a complete annotation, with author name, revision level and any software code change that took place since its creation. SUPPLIER shall identify in Functional Design Specification (FDS) a complete structure of his software modules, and the overall software tree structure showing modules interaction. SUPPLIER shall state the programming method used, and the operating system required for the programming system with the quotation. Additionally, the SUPPLIER shall provide the programming/monitoring software resides, and the various licensing agreements for single and multiple users of the software.

7.10.1 Software and Licensing

All workstations and servers shall include perpetual/one time software licenses for application software, configuration software, and operating systems and other software as applicable to make it a fully functional system. Licenses to cover the I/Os for the full capacity of the PLC shall be supplied by the CONTRACTOR.

All software licenses shall be multi-user, supplied with five (5) concurrent users, with multi-level password for monitoring, access, editing, etc.

The EWS shall include required operating system original license, engineering or configuration license and any other material with license to make it a fully functional system.

Software Licensing shall be on COMPANY name.

The operating system shall be based on Microsoft Windows latest edition approved for PLC by SUPPLIER. For servers latest Windows Server edition shall be used while for client workstations Windows Client edition shall be used.

EWS shall be provided with licensed Microsoft Office application.

All Servers and Workstations shall be provided with licensed Anti-virus software as per the requirements defined under AGES-SP-04-013 OT/ Cyber security standard.

System Fault Alarms

As a minimum, the following system fault alarms shall be provided for the following:

Field circuit failures

Signal transmission faults (communication fault)

Power Supply failures

Card/module failures

I/O channel fault

Communication interface failure/fault

Network device failure/fault

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HMI/EWS failure/fault

All faults shall be reported to the PCS through communication interface for display on operator workstations and shall also be made available on PLC EWS.

LED indications for faults in power supply modules, communication modules, per channel in I/O modules, and other modules, network devices etc. shall be provided for visual identification.

Reliability

The SUPPLIER shall supply a list of all single points of failure which will affect other systems receiving outputs generated by the PLC system.

Any component of the system which cannot be replaced while the system is running shall be explicitly identified. For system components that can be replaced while the system is running, necessary steps to bring the components to fully functional shall be described in the maintenance manuals furnished.

In all redundant systems, single point failure shall not lead to failure of functionality and the design shall allow on- line replacement of faulty component without interruption to the operation of system. Also, alarm shall be configured in plant PCS / ICSS on failure of any component within PLC.

Functional Specification (FS) and Functional Design Specification (FDS)

The Functional Specification shall be prepared by CONTRACTOR in consultation with COMPANY and shall form the basis for the SUPPLIER proposals and for the SUPPLIER to develop the PLC system design in detail. The FS shall be written specifically for each project.

The FS shall include the following:

This specification

Number and spacing of IES/ITR/LER/SIS.

Number and type of interface I/O definitions (Analog, Digital, hardwired / ‘Soft’ serial, IS, Non-IS) and

allocation to PCS and IES/ITR/LER/SIS.

Number of Supervisory Control functions (Controllers, sequences, interlocks, batches, etc.) and allocation to package.

I/O Criticality ratings (as applicable)

Requirements for ‘island’ operation.

Identification of Security Levels for each zone of the system

I/O counts for each package and segregation details.

Interfaces to other systems.

Interfaces to other networks.

Historization requirements.

Number and location of Engineering Workstation.

Estimated number of Package Equipment Graphics.

Number and type of additional Workstations (for example maintenance) required.

P&IDs (to support segregation assessment).

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Based on the FS and additional supporting documentation, SUPPLIER shall develop the detailed design of the PLC system and document it in the FDS.

The supporting information supplied to SUPPLIER to develop the FDS shall include:

Control Narratives.

Logic Descriptions.

Sequence Narratives.

Updated P&IDS.

Operating Philosophies.

Interface details for other systems.

Interface details for field instruments.

The FDS shall detail the project specific architecture, system layout, hardware, software, and graphics structure. The FDS shall be project specific and shall only contain references to project specific requirements and proposed solutions to meet COMPANY requirements. It shall be written in conjunction with COMPANY/CONTRACTOR by SUPPLIER, based on the Functional Specification, provided in the requisition, and the additional supporting documents.

The system design and build will not be approved until the FDS is approved by COMPANY. At any point in review cycle if it is observed that the systems do not meet the criteria, then that shall be highlighted to COMPANY in formal submission and shall be closed with a Contractual procedure.

The FDS shall provide a detailed inventory and description of the equipment, functional definition, and equipment data, including, as a minimum:

System Overview

Overall System Architecture

System Software

i. Operating System Software

ii. Application Software

iii. Software Module Specification (with detailed description for all modules)

iv. Software Module Tree Structure

v. Network Software

vi. Third-party applications

vii. Configuration Management

System Interfaces

System Communication and Protocols

Power Supplies

Earthing

Wiring and Cabling

Revision and Change control procedures

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Number and nature of communication networks:

ii.

Identification of networks

Identification of network criticality & redundancy

iii. Communication link capacities

iv. Communication link loadings for all operational cases

Identification of security zones

vi.

Identification of conduits

vii. Definition of security measures between zones

viii. Definition of data flows to achieve FS requirements.

ix. Communication details of all network elements

a. Controllers

b. Gateways

c. Servers

d. Switches

e. Firewalls

f. Engineering stations

x. Network architecture

xi. Details of Historization

xii. Number and type of I/O chassis

xiii. Allocation of PLCs to IES/ITR/LER/SIS and units

xiv. Allocation of I/O to PLCs

xv. Number of PLC cabinets

xvi. Allocation of I/O to cabinets

xvii. General Arrangement (GA) of cabinets including, rack distribution and mounting, power distribution, terminations, trunking, cooling fans, temperature monitoring, cable entry arrangement and dimensional drawings.

xviii. Preliminary configuration database

xix. Function block definitions (voting logic, etc.)

xx. Detailed descriptions of agreed graphics elements/standards

xxi. Engineering station details including GA and dimensional drawings.

xxii. Access control

xxiii. Communication data map for ICSS data exchange

xxiv. Calculations for power loading, CPU loading, and Network Loading (to be referenced in the FDS if

provided as a separate documents)

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ADDITIONAL SPECIFIC REQUIREMENTS

Not applicable

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SECTION C – OTHER REQUIREMENTS

DETAILS OF SCOPE SUPPLY

Detailed engineering and design of the PLC in accordance with all specifications, standards, datasheets, and other statements of requirement included with or referenced in the requisition.

SUPPLIER shall complete and provide the details of specification items listed in Table APPENDIX A1 along with quotation for COMPANY review.

The SUPPLIER shall have single point responsibility for all aspects of the works, inclusive of all components sub- contracted or purchased from other parties. These shall include, but not be limited to:

Total system engineering definition of the PLC system in the form of a Functional Design Specification (FDS) based upon the Functional Specification (FS), datasheets and COMPANY specifications provided by CONTRACTOR. FDSs shall be written by the SUPPLIER and approved by COMPANY during the Design Phase to detail the SUPPLIER scope of work.

The agreed FDS

System Architecture

Design and supply of the PLC, including the interface design.

Design and supply of the PLC System Cabinets

Design and supply of the PLC Marshalling Cabinets

Design and supply of the PLC Workstation / Server Cabinets (as applicable)

Design of the PLC Network and supply of all communication equipment

All System Interconnecting Cables, network cables for interfaces, including FO patch cords between cabinets and FO patch panel within buildings.

Supply of operating system software and firmware.

Supply of system configuration and application software including design and configuration of database,

graphics, and reports.

Supply of specialist integration services for interfacing with the PCS / ICSS

Supply of System test procedures (i.e., FAT, IFAT, SIT and SAT procedures), all necessary test equipment, and personnel for all tests. Perform tests for witness by the CONTRACTOR’s representative and COMPANY.

ICSS interface and configuration for data exchange to PCS controller, ICSS Network alarm / event data exchange, time synchronisation, patch and anti-virus, backup and restore, network management, and Cyber security compliance.

Design and Supply of application servers / engineering workstations

Documentation and certification in accordance with the material requisition, this specification and the standards referenced herein.

Special tools required for installation, operation, and maintenance of the equipment.

Painting, Preservation and Packing.

Insurance spares.

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Spares (commissioning and two (2) year).

Cyber Security design review and solution for compliance

Supply of portable engineering workstations laptop / notebook, with necessary special cables

Certified calculations shall form part of the scope of supply including, but not limited to: Sizing Calculations;

Power Calculations; Heat loading calculations, etc.

Design and supply of power distribution system within the PLC system cabinets

Commissioning; start-up and long-term support.

In addition to the above requirements, design, fabrication, configuration, testing and installation shall also be compliant with cyber-security requirements.

SUPPLIER shall include all hardware, system and application software, configuration, cabinets, termination facilities, workstations, peripherals, systems cables, documentation, and other equipment required for a fully functional, operable, reliable, and maintainable system.

All conditioning modules, i.e., galvanic isolators, communication modules, power supplies and other rack electronic components necessary to convert the signals into electronically processable formats shall be included in the scope of the supply.

Any bought-out items like system cable connectors, backplanes, accessories etc used in marshalling cabinet shall be identified early during the bidding stage for COMPANY review and approval.

SUPPLIER shall accept total responsibility for the overall system as specified. This includes system design, procurement, fabrication, assembly, configuration, FAT, packing and shipment. SUPPLIER shall provide site supervision and assistance for unpacking, installation, perform tests, FAT, Integrated-FAT, SAT, pre- commissioning, and commissioning.

All field instruments on package equipment shall be under the scope of package equipment SUPPLIER.

All field cabling from field instruments shall be supplied and installed by CONTRACTOR.

All fibre optic cabling outside buildings shall be supplied and installed by CONTRACTOR.

All power supply, earthing and inter-cabinet signal wiring (i.e., alarm, trip etc.,) shall be supplied and installed by CONTRACTOR.

QUALITY CONTROL AND ASSURANCE

SUPPLIER’s quality management systems shall comply with all the requirements of ISO 9001 - Quality Management Systems – Requirements and ISO 9004 - Quality Management — Quality of an Organization — Guidance to Achieve Sustained Success. The quality system shall provide for the planned and systematic control of all quality-related activities performed during design.

The quality management system shall be implemented in accordance with the CONTRACTORs Quality Manual and the Project Quality Plan, which shall both together with all related / referenced procedures, be submitted to COMPANY for review, comment, and approval.

CONTRACTOR shall have in effect at all times, a QA/QC program, which clearly establishes the authority and responsibility of those responsible for the quality management system. Persons performing quality functions shall have sufficient and well-defined authority to enforce quality requirements that initiate, identify, recommend, and provide solutions to quality problems and verify the effectiveness of the corrective action.

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The CONTRACTOR shall identify in purchase documents to its SUB-CONTRACTORs all applicable QA/QC requirements imposed by the COMPANY and shall ensure compliance. On request, CONTRACTOR shall provide objective evidence of its QA/QC surveillance of its SUB-CONTRACTORs activities. If selected SUB- CONTRACTORs have ISO 9001 certification, as required for contracted scope, then copies of these certifications are to be provided for COMPANY review. The COMPANY may elect to waive their audits in favour of ISO 9001 registrar audits. Any contracted services without ISO 9001 certification will be subject to COMPANY audit requirements.

A representative / service engineer from SUPPLIER shall be available at site during site installation, SIT, Commissioning & SAT phases, in order to ensure QA/QC of the installation.

COMPANY reserves the right to inspect materials and workmanship standards at all stages of manufacture and to witness any or all tests. CONTRACTOR, thirty (30) days after award but prior to the pre-inspection meeting, shall provide COMPANY with a copy of its manufacturing Inspection and Test Plan (ITP) for review and inclusion of any mandatory COMPANY / CONTRACTOR witness or hold points.

Equipment shall only be purchased from SUPPLIERs approved by COMPANY Category Management. This approval indicates that the SUPPLIER has an approved Quality management system and a proven track record in supply of this equipment type.

SUPPLIER shall comply to Criticality Rating for Equipment outlined in respective ADNOC Group Company’s Quality System Specifications for requirements of production checks, shop inspection, testing and material certification.

The SUPPLIER shall provide equipment inspection and test reports as per approved ITP by CONTRACTOR.

SUPPLIER shall submit a quality plan for approval by COMPANY.

SUB-CONTRACTORS, SUB-SUPPLERS

All subcontracted services and hardware shall be approved in writing by COMPANY. The term services include all System hardware design, fabrication, assembly, configuration, programming, and testing.

SUPPLIER shall assume responsibility and overall guarantee for all supply and services provided by SUB- CONTRACTOR/SUB-SUPPLIER.

The SUPPLIER shall transmit all relevant Purchase Order documents including specifications to his SUB- CONTRACTORS.

It is the SUPPLIER’s responsibility to enforce all Purchase Order and Specification requirements on his SUB- CONTRACTORS.

The SUPPLIER shall submit all relevant SUB-CONTRACTOR drawings and engineering data to the CONTRACTOR.

SUPPLIER shall obtain necessary warranties from SUB-CONTRACTORS/ SUB-SUPPLIERS.

CERTIFICATION

All certifications including system equipment, test equipment calibration sheets, shall be submitted for verification to COMPANY.

The certifications shall typically include, but not limited to, the following:

Ex Certification

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ECAS Certificate for all electronics equipment / Instrument.

SIL Certification (where applicable)

Cyber Security Certification

Certification and compliance to IEC 61010 (Basic safety design standard for any instrumentation, IEC 61326 (EMC requirements for instrumentation & controls)

INSPECTION AND TESTING REQUIREMENTS

General

SUPPLIER shall be responsible for inspection and quality assurance of the materials and standard of workmanship.

Inspection and Testing shall be carried out by the SUPPLIER and witnessed by the CONTRACTOR and COMPANY representatives at various stages and locations as follows:

Shop Inspections - conducted at the system assembly/SUPPLIER location

Pre-Factory Acceptance (Pre-FAT) - conducted at the system assembly/SUPPLIER location

Factory Acceptance Test (FAT) - conducted at the SUPPLIER location as a standalone System

Integrated Factory Acceptance Test (IFAT) – conducted following FAT, either at the ICSS SUPPLIER location or using portable PCS at SUPPLIER location.

Site Installation Test (SIT) - conducted at the job site once system is installed and powered up

Site Acceptance Test (SAT) - conducted at the job site as a system operating test after commissioning

SUPPLIER shall provide all test procedures to CONTRACTOR and COMPANY for review and approval at least two (2) months prior to the proposed test schedule. Each formal acceptance test must be signed by the SUPPLIER, CONTRACTOR and COMPANY representative at the successful completion of the test(s).

Inspection and Testing requirements for FAT, IFAT, SIT and SAT shall be developed based on requirements specified in API 554-3 clause no.7, IEC 62603-1 clause no. 4.11, and IEC 62381.

The test procedure shall include the following sections as a minimum:

Objective

Reference documentation

Procedure steps

Criteria (acceptable results), and

Results check sheet / comments / test record sign-off sheet

Day-wise schedule including list of tests to be completed during each day.

The acceptance test report shall include design information that was used to configure the system and records of any exceptions (variations) that may be discovered during testing.

CONTRACTOR shall be responsible to organise/supply supervision, specialist personnel and materials to support inspection and shop/site testing, including multi-meters, signal generators and any other equipment (PC, printer etc.) necessary for simulation and testing.

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Shop Inspection

CONTRACTOR’S representative shall periodically visit the SUPPLIER’s shop facilities and inspect system progress from a hardware and software perspective.

Pre-Factory Acceptance Test

SUPPLIER shall detail all physical tests and inspections which will be performed in the Pre-FAT procedure. As a minimum, Pre-FAT shall cover 100% hardware and software of the PLC together with all interfaces. Heat soak test for minimum duration of forty-eight (48) hours shall be included as part of Pre-FAT. These tests shall include complete physical inspection of all cabinets, system components, wiring, labelling, etc. Additionally, the procedure shall list all internal SUPPLIER test/inspection records which can be provided to the CONTRACTOR during the Pre-FAT. As a minimum, project related QA inspections covering bought out components and internal inspections of assemblies are to be included.

The system equipment shall be inspected by CONTRACTOR representative at the Pre-FAT for satisfactory quality and workmanship. In addition, COMPANY or CONTRACTOR shall have the right to inspect the work in progress at any stage.

The SUPPLIER is responsible to maintain a punch list during the Pre-FAT. The Pre-FAT punch list shall list the problems discovered, include the date discovered, the name of the person reporting the problem, the date corrected, the name of the person who performed the correction, the date retested and accepted, and the name of the individual accepting the retest. This entire Pre-FAT punch list shall be included in System Log report and maintained as part of the System log. Unless otherwise agreed by COMPANY, all items on the Pre-FAT punch list shall be cleared before the commencement of FAT.

The entire Pre-FAT procedure must have been successfully exercised on the system by the SUPPLIER prior to the FAT.

Pre-FAT results/documents shall be submitted to COMPANY personnel prior to commencement of the FAT as one of the reference documents.

Factory Acceptance Test

The FAT shall include the complete testing and acceptance of both hardware and software.

The SUPPLIER shall be required to submit FAT procedures for COMPANY approval through CONTACTOR prior to FAT. These shall cover, but not be limited to:

Complete hardware testing including system hardware visual and mechanical inspection, 100% simulation of all input and output channels, testing of all system redundancy (CPU’s, power supplies, I/O buses, I/O comm modules, highway communication modules, etc.), peripheral connection and functionality, observation of fault reporting via hardware indicators and data transfers, and hot swap component replacement.

Complete simulation of all functional groups. This testing is to be inclusive of I/O simulation through the marshalling cabinets and system cables to ensure healthy HW and SW configuration for all I/O. Functional test shall be performed through software simulation for all tested I/O. This includes graphic display / HMI check, network function / loading check, time synchronisation check, historian data, alarm, and event data check, etc. Additionally, full redundancy testing of the communications interface shall be performed.

As the functions are checked, proper recording of alarm and event data shall be verified. Additionally, the

sorting and reporting capabilities shall be demonstrated and certified correct.

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Each type of test report template shall be included in the FAT procedure; containing these minimum sections e.g., Details of the test, Expected Results, Acceptance Criteria, Signatures (SUPPLIER, CONTRACTOR, COMPANY).

During FAT, the system shall be made available to CONTRACTOR and COMPANY for sufficient periods to verify satisfactory performance.

COMPANY and CONTRACTOR’S representative shall witness the entire FAT. The FAT procedure/checklist shall be signed off by the SUPPLIER, CONTRACTOR and COMPANY representative at the successful conclusion of testing. A copy of the signed off FAT procedures/checklist and related printouts shall be furnished to CONTRACTOR and COMPANY representative. Each punch point shall be categorised to define criticality and time frame for completion. This is applicable to all tests & punch lists.

All field inputs and outputs must be simulated during the FAT. The purpose of this simulation is to provide a facsimile of the production process, with all points of an individual loop or interconnected loops hooked up for test simultaneously.

All system programs must be complete and resident in the system prior to the start of FAT. All program listings must be free of pencilled (patched) corrections. The system software loaded must be the final version encompassing all required changes incorporated after SUPPLIER’s internal testing. Any changes which were made as a result of internal testing shall be documented as part of the System log.

The SUPPLIER is responsible to maintain a punch list during the FAT. The FAT punch list shall list the problems discovered, include the date discovered, the name of the person reporting the problem, the date corrected, the name of the person who performed the correction, the date retested and accepted, and the name of the individual accepting the retest. This entire FAT punch list shall be included in the System Log report and maintained as part of the System testing log. All Punch List items shall be cleared prior to equipment shipment to the site.

Diagnostic programs which are tested during FAT shall be shipped to IFAT with system.

Completed test records shall be provided as part of FAT report to COMPANY/CONTRACTOR representatives. A complete set of documentation used and red lined during FAT shall be scanned and copied to a CD/DVD for each attendee to take away as a record of the test.

Integrated Factory Acceptance Test

Following FAT, IFAT shall follow and include testing of communication interfaces between PLC System and PCS / ICSS. Data transfer between them shall be checked. Package Equipment graphics implemented in PCS OWS shall be 100% tested.

All required system hardware, configuration laptop with required software, interface cables, etc. shall be shipped to PCS / ICSS SUPPLIER premises for conducting the IFAT.

IFAT testing procedure shall be furnished by SUPPLIER for CONTRACTOR and COMPANY approval.

Site Installation Test

After the System has been installed on site and site QA as well as SUPPLIER inspection of the mechanical and electrical installation has been successfully completed, a Site Installation Test (SIT) will be conducted by the SUPPLIER when directed by the CONTRACTOR / COMPANY.

SIT shall include as a minimum:

An audit and inspection of equipment as installed. A deficiency report shall be written, and appropriate action taken to rectify any problems.

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All alarm status, analogue and pulse inputs, and controlled end devices shall be disconnected by means of isolating terminals.

Each system shall be powered up and system and application software will be loaded. System diagnostics

shall be run and checked to ensure the system is error free.

Communications shall be established between all components of the system.

Redundancy testing of processor, power supply systems, I/O buses and communication modules shall be performed.

At least one point from every input/output module shall be verified by signal simulation/monitoring from the

associated marshalling cabinet.

All hardwired relay contact output signals shall be tested by simulation along with PCS/ESD/ICSS interface.

A random sampling of data transfers between the System and PCS/ICSS systems shall be performed to ensure proper operation of the data links.

Random sampling of alarm and event data shall be conducted.

Full details of all tests to be performed shall be defined in the SIT procedure.

The SUPPLIER is responsible to maintain a punch list during the SIT. The SIT punch list shall list the problems discovered, include the date discovered, the name of the person reporting the problem, the date corrected, the name of the person who performed the correction, the date retested and accepted, and the name of the individual accepting the retest. This entire SIT punch list shall be included in System Log report and maintained as part of the System test log.

COMPANY and CONTRACTOR representative shall witness the entire SIT. The SIT procedure shall be signed off by the SUPPLIER, CONTRACTOR and COMPANY representative at the successful conclusion of testing. A copy of the signed off SIT procedures and related printouts shall be furnished to CONTRACTOR and COMPANY representative.

Upon completion of the SIT, the system shall remain powered on and loop checks shall be conducted as loops are made ready. System status shall continue to be monitored and all detected faults and/or changes/modifications to system hardware and software shall be recorded in the System test log. During commissioning, loop checking shall include the whole loop, from the control room to the field device.

Site Acceptance Test

After the system has been commissioned and put in service the SAT period commences. The purpose of the SAT is to verify that all hardware and software is correctly installed and functioning according to the specifications in the real environment and verify integrated performance of the PLC and ICSS system.

The SAT shall also be done to a previously approved procedure prepared by the SUPPLIER and approved by the CONTRACTOR and COMPANY. This procedure will detail the monitoring functions to be performed, the methods to be employed, and clearly stipulate the conditions which must be met for acceptance.

This test shall include monitoring the system data transfer and update times. Alarm and event data capture and time synchronization between the PLC System and ICSS shall be verified. Transmission and display of correct alarm notifications shall be observed. System diagnostics shall be routinely checked. The SAT procedure shall fully detail all acceptance test criteria. Duration of SAT shall not be less than seventy-two (72) hours.

The SUPPLIER is responsible to maintain a punch list during the SAT. The SAT punch list shall list the problems discovered, include the date discovered, the name of the person reporting the problem, the date corrected, the name of the person who performed the correction, the date retested and accepted, and the name of the individual

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accepting the retest. This entire SAT punch list shall be included in System Log report and maintained as part of the System test log.

The SAT procedure shall be signed off by the SUPPLIER, CONTRACTOR and COMPANY representative at the successful conclusion of testing. A copy of the signed off SAT procedures and related printouts shall be furnished to CONTRACTOR and COMPANY representative.

Successful completion and approval of the SAT will constitute system acceptance by the CONTRACTOR and COMPANY.

Certificates of Acceptance

At the satisfactory conclusion of the FAT, IFAT, SIT, and SAT a Certificate of Acceptance shall be provided by the SUPPLIER for signature by the CONTRACTOR and COMPANY.

Following documents as minimum shall be attached to Certificate of Acceptance dossier:

Signed and Approved FAT, IFAT, SIT and SAT test reports.

Electric Equipment Test Certificates

Approved As-Built Drawings

Services by the SUPPLIER

The SUPPLIER shall supply necessary manpower and specialist personnel and all necessary tools and equipment to support testing at SUPPLIER’s shop, PCS/ICSS SUPPLIER works and at site as defined in above sections.

SPARE PARTS, CONSUMABLES AND SPECIAL TOOLS

Spare Parts

SUPPLIER shall include the provision of all commissioning spares in the bid. The SUPPLIER shall also include list of spares required for two (2) years operation, FAT Spares and insurance spares along with price schedule for each item along with the bid.

SUPPLIER shall complete Spare Parts Interchangeability Record (SPIR) Form in COMPANYS approved formats. Parts data shall be supplemented with appropriate drawings / bulletins identifying each part in their respective position.

Spare for Servers (like hard disk drives, power supply module, etc.) and for networks (like media converter, network switches, small form-factor pluggable (SFP) ports, network cables, FO patch cords) shall be considered.

The SUPPLIER shall propose the minimum required number of different card types.

Spares

The System shall be delivered with installed spares of 20% for each type of input and output fully wired to terminal blocks including isolators, licensed and ready for use.

Processors, memory, software, communications and software shall be adequately sized to allow for the specified inputs and/or outputs (including all spares detailed above) and associated controllers, algorithms, system functions and applications (logic and / or sequences) without any upgrade being required, accordingly processor loading, network bandwidth usage and memory utilisation (including consideration of 20% increase of future I/Os, memory, software, communications) shall at no time exceed 60% after SAT.

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Specified spare capacity should include only cabinet space and power supply capacity unless specific pre- investment is approved.

The SUPPLIER shall propose the minimum required number of different card types.

Minimum 30% spare space shall be provided for future use is system and marshalling cabinets.

Consumables

SUPPLIER shall ship, with the hardware, a six-month supply of consumables.

Special Tools

SUPPLIER shall include all special tools, test, and calibration equipment necessary for site installation, pre- commissioning, commissioning and SAT. Standard test equipment such as multi-meters are not required. Full listing of required test equipment and calibration tools shall be provided by SUPPLIER for review by CONTRACTOR and COMPANY. All specialised test hardware / tools shall be included in the scope of supply.

PAINTING, PRESERVATION AND SHIPMENT

Packing and Shipping

Preparation for shipment shall be in accordance with purchase order Preservation and Export Packing requirements. 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 will be subject to inspection and rejection by COMPANY’s/CONTRACTOR’s inspectors. All costs occasioned by such rejection shall be to the account of the SUPPLIER. Equipment shall be packed, securely anchored, and skid mounted when required. Bracing, supports, and rigging connections shall be provided to prevent damage during transit, lifting, or unloading. 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 CONTRACTOR’s order 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.

All kinds of regulatory / non-regulatory approvals and procedures required for shipping shall be in the scope of CONTRACTOR / SUPPLIER.

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 eighteen (18) months. Equipment shall be protected to safeguard against all adverse environments, such as humidity, moisture, rain, dust, dirt, sand, mud, salt air, salt spray, and seawater. All equipment and material shall be preserved, and export packed in accordance with project specifications.

The SUPPLIER shall provide preservation plan to protect and ensure the integrity of the System equipment during the period that starts when the System equipment is prepared for the first shipment from the point of origin and ends at the completion of project commissioning and start-up. The plan shall identify protective measures to be implemented during each phase of the project, inclusive of maximum ambient conditions. The completion plan shall be submitted to COMPANY for review and comment no later than ninety (90) days prior to the first shipment of System equipment from the factory.

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INSTALLTION, COMMISSIONING AND MAINTENANCE SUPPORT

Installation

SUPPLIER shall provide supervision assistance for Installation and Commissioning of System at site.

Installation will be carried out by the CONTRACTOR with supervision assistance from the SUPPLIER. The SUPPLIER shall notify the CONTRACTOR of any special tools required for installation and supply these, if necessary, to the CONTRACTOR.

The SUPPLIER shall include the provision for all commissioning spares in its bid.

SUPPLIER shall be required to support COMPANY / CONTRACTOR by preparing detailed the System Commissioning procedures, together with detailed plans covering all site-based activities necessary to fully commission the System.

The SUPPLIER shall identify any special requirements or recommendations for SUPPLIER support during commissioning and start-up of the equipment supplied.

Life Cycle / Long Term Support

SUPPLIER must provide assurances that system equipment will not be obsolete in the next fifteen (15) years. In the belief that portions of the system will eventually be withdrawn from sale, a firm commitment by the SUPPLIER that for his standard products there will be either repair capability or equivalent parts and/or products available for a minimum of fifteen (15) years from the withdrawal date is required. SUPPLIER shall submit Life-cycle status of each of the supplied products individually to ensure availability of spare / service / support in the declared lifetime.

Refer to IOGP Report 551, Obsolescence and life cycle management for automation systems recommended practice for the definitions of the terms below.

The entire system shall be in ‘Active life’ for a minimum period of minimum fifteen (15) Years. SUPPLIERs shall provide life cycle commitment including:

Start of Active life

End of active life

Start of limited support

End of limited support

Start of Obsolescence

Active life: Denotes the system is active and available for sale for new projects and revamp projects, full support from R&D, continuous support in terms of upgrade, patch update, bug fixing etc.

Limited Support: Product has limited support with local maintenance and engineering support; bug fixing, continue to supply of spares (refurbished or new parts)

Obsolete: Out of sale and support is discontinued

Between active to support phase, SUPPLIER shall provide a minimum support period of seven (7) years for company to plan for a smooth upgrade or replacement. Life cycle notice of product Obsolescence shall be provided to COMPANY at least six (6) years in advance for smooth upgrade using Turnaround window.

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Maintenance

During warranty period, SUPPLIER shall provide service personnel for periodic fault finding, repair and replacement of all faulty hardware, firmware, and software.

During bidding stage, SUPPLIER proposal shall include the details and costs of all standard maintenance services available after SAT. 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. SUPPLIER shall provide local maintenance support facility and team availability.

TRAINING

General

The following training courses are proposed for the selective attendance of suitable personnel such as Engineers, Supervisors and Technicians. SUPPLIER shall provide customised training schedule for COMPANY personnel both on site and at the SUPPLIER facility for COMPANY approval. The purpose of these training courses will range from gaining an appreciation of the System, its software and associated hardware, to acquiring an in-depth knowledge for administration and system configuration and software development purposes:

System Architecture (all)

System Hardware Maintenance including Troubleshooting and Repair (Engineers, Technicians)

Systems Software and Maintenance (System Administrator)

System Administration (System Administrator)

Network /Cyber Security (System Administrators, Supervisors)

Application Programming (Engineers, Supervisors)

Advance Programming Techniques (Engineers, Supervisors)

Above training shall be included nominally for five (5) Engineers / Supervisors and Three (3) Technicians.

Training Course Documentation

For each trainee who will attend a training course, a copy of the complete training course, notes, and drawings shall be provided to COMPANY eight (8) 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.

In addition, two (2) copies of the training course documentation shall be available on site prior to the installation and pre-commissioning for reference purposes.

Maintenance Training Course

The purpose of the course is to train Engineers/ Supervisors/ Technicians for first line fault diagnosis, and repair by replacement.

System Engineering Course

The purpose of this course is to enable COMPANY Engineers/Supervisors to be able to modify system I/O and system application software including interfaces to the System. The course shall include:

System Hardware.

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System operating software.

Review of project specific typical application software modules, data formats, data table allocations.

DOCUMENTATION / MANUFACTURER DATA RECORDS

SUPPLIER shall submit the type and quantity of drawings for COMPANY/CONTRACTOR authorization or information as per SUPPLIER Document Register and Schedule (SDRS) provided in Purchase Order.

The SUPPLIER shall provide all standard and project-specific documentation and software required for system definition, installation, initialisation, operation, maintenance, troubleshooting and training. This information shall provide complete documentation for the System in sufficient scope and detail to permit programming and maintenance of the equipment.

Mutual Agreement on document list and documents issue dates shall be an integral part of Purchase Order.

Comments made by CONTRACTOR on drawing submittal shall not relieve SUPPLIER of any responsibility in meeting the requirements of this specification. 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.

All drawings, documents, information, correspondence, test reports, operating and maintenance instructions and like items shall be in the English language and metric Units.

All documents and drawings issued by the SUPPLIER shall be produced in an electronic format compatible with Microsoft Office computer software. Documentation shall also be provided in Native format, in order to allow company to update during operational upgrade and future projects. SUPPLIER shall provide final documentation on optical disks with search and retrieval capabilities.

All system drawings shall be prepared and submitted in accordance with recognized standards. Every effort shall be made to minimize the total number of drawings prepared by use of common drawings, where practicable without loss of clarity.

Before Site Acceptance Test, SUPPLIER shall issue As-Built drawings incorporating all changes that have taken place during installation, testing and commissioning at site. Each drawing shall be clearly marked ‘As-Built’ and dated.

The below list of documents required is intended to define the minimum technical documents to be provided by the SUPPLIER. This list is not exhaustive and additional documentation necessary for the work execution be provided by SUPPLIER. System documentation to be supplied by SUPPLIER shall include, but not be limited to:

System Architecture Diagrams

System Block Diagrams and interface schematic

Functional Design Specifications for Hardware and Software, Cabinets, Networking, Interfaces, Cyber

Security etc

System Configuration Specifications including Logic and Application Program Design

Reliability/Availability Calculations and Reports

Loading Calculations (CPU, memory, networks, power supplies, spares)

Cabinet General Arrangement drawings

Cabinet internal wiring diagrams

Inter-panel Cable Connection Schedule

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Interconnection Wiring Diagrams

Input/Output Assignment List

Configuration database

Functional Logic diagrams

Loop Diagrams (in COMPANY standard software Smart Plant Instrument (SPI))

Communication / Modbus mapping tag list with details

HMI Graphics (if applicable)

Software / Program backups

Software licenses

Power supply, distribution, and earthing drawings.

Power and Heat Loading calculations

Electrical Load Schedule

I.S. certification dossier (if applicable).

SIL Certificates for SIL rated components (as applicable)

Bill of Materials

Comprehensive data sheets for all major items, including completed data sheets included in the

enquiry/purchase order.

ITP

QA/QC Procedures

Internal Testing and Pre-FAT Report

FAT Procedure & Report

SAT Procedure& Report

SIT Report

List of all spare parts, tools, test equipment and installation materials.

Spare Part Interchangeability List

Packing, Marking and Shipping Procedure

Preservation and Site Storage Procedure

Complete catalogue sheets of all furnished items.

System Hardware Manuals

Programming Manual

Application software manuals.

System Security Manual

Functional Safety Manual

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Operation and Maintenance Manuals

Installation and Configuration Manuals

Quality Manuals

Third Party Manuals

Training Manuals

Manufacturing Data Records (MDR) Book

All drawings, lists, datasheets etc. shall be submitted in native format. All system tags, loop drawings, wiring drawings, schedules etc. shall be developed using SPI application.

GUARANTEES AND WARRANTY

SUPPLIER shall provide warranty support for a period of two (2) years, commencing on the date of the system PAC following the site acceptance test. Warranty shall apply to defective material workmanship and facility design, and/or facility software. Warranty work shall be done at COMPANY local facilities. The cost of diagnostics and/or correction of any warranty items shall be borne by the SUPPLIER.

The SUPPLIER will not be required to provide resident maintenance personnel during the warranty period but shall have competent technical personnel available from the local facility within twenty-four (24) hours, if so, required by COMPANY.

SUPPLIER shall guarantee availability of spare parts for the System for a minimum period of fifteen (15) years from the date of acceptance of the System.

SUPPLIER shall guarantee that the software to be supplied shall be free from errors, for example software/firmware failure to perform function(s) as specified in this specification or COMPANY documentation.

PROJECT ADMINISTRATION

Project Personnel

The SUPPLIER shall insure that sufficient qualified personnel are at all times allocated to the project. The SUPPLIER shall utilize a project team structure to achieve continuity and accuracy of implementation. The SUPPLIER shall submit for CONTRACTOR’S approval the resumes of all personnel engaged in the project.

It is anticipated that the project team shall comprise at least the following disciplines:

Project Manager (Commercial/Technical) (shall be nominated representative of the SUPPLIER with responsibility and authority to fully implement the project with technical correctness, on schedule and within the budget).

Senior System Designer (Technical).

Hardware Design (Technical Hardware).

Software Designer (Technical Software).

Test Technician (Technical Testing).

Site Engineer (Installation/Commissioning).

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Project Schedule

The SUPPLIER shall include with his quotation, a detailed Project Schedule showing the SUPPLIER’S best estimate of the achievable major schedule milestones.

The Project schedule shall be used as the main progress control document during the implementation of the project. The Project Schedule shall clearly show any ‘float’ or ‘slack’ time available together with any freeze dates required by the SUPPLIER and major milestones for equipment design, manufacture, and delivery. The schedule shall clearly indicate required dates for each of CONTRACTOR supplied design data.

The SUPPLIER may include in the proposal any additional material which clarifies the procedure for implementing the Project Schedule.

Progress Reporting

The Project Schedule shall be used as the basis for monthly progress reporting, schedule controlling and schedule forecasting. At regular intervals, the SUPPLIER shall revise the Project Schedule to include the effect of changes and to reflect actual Project Progress.

Coordination Meetings

Coordination meetings shall be held as required between COMPANY, CONTRACTORS and SUPPLIER.

The agenda for each coordination meeting will be prepared by the SUPPLIER prior to each meeting. Detailed meeting minutes will be taken by the SUPPLIER and submitted for COMPANY and CONTRACTORS for approval. An ‘action item’ log shall be prepared and continuously updated by the SUPPLIER.

Coordination meetings, to be held either in Abu Dhabi or home office, will be a part of the purchase order scope.

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SECTION D – STANDARD DRAWINGS & DATASHEETS

DATASHEET TEMPLATES

Not Applicable

STANDARD DRAWINGS

Not Applicable

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SECTION E - APPENDICES

PLC SPECIFICATIONS TABLE

Table 22.1 PLC Specifications Table

Note: This table shall be completed by SUPPLIER and submitted with quotation.

DESCRIPTION

SPEC. REQUIREMENTS

ACTION

REFERENCE BID PAGE

PLC SUPPLIER

1.0 General

1.1 System History

Manufacturer/Brand

To be defined by SUPPLIER

Indicate

Hardware Model

Software Release

1st Year of Hardware Industrial Operation

1st Year of Software Industrial Operation

To be defined by SUPPLIER

Indicate

To be defined by SUPPLIER

Indicate

To be defined by SUPPLIER

Indicate

To be defined by SUPPLIER

Indicate

System Expected operation life

15 years minimum

Long Term spare parts availability

15 years minimum

Reference List in U.A.E.

Reference List Worldwide

Conformation with ISO 9000 or Equivalent

1.2 Maximum Capacity

Required

Yes/No

Inc./Not inc.

Maximum number of tags per system

To be defined by SUPPLIER

Indicate

Maximum number of connected I/O by system

To be defined by SUPPLIER

Indicate by type

1.3 Diagnostics and Failover

Diagnostic Scheme

On-line Hardware Diagnostics

Self-test/Others

Required

Indicate

Off-line Hardware Diagnostics

To be defined by SUPPLIER

Indicate

On-line Software Diagnostics

Required

Indicate

Off-line Software Diagnostics

To be defined by SUPPLIER

Indicate

On-line Repair or Module Replacement

Required

Indicate

Behaviour on Power supply failure

To be defined by SUPPLIER

Indicate

1.4 Power Requirements

Voltage

240V AC

Allowable (+/-) voltage Variation

(+/-) 10% VAC

Indicate

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DESCRIPTION

SPEC. REQUIREMENTS

ACTION

REFERENCE BID PAGE

PLC SUPPLIER

Phase

Frequency

Single

50 Hz

Indicate

Allowable (+/-) Frequency Variation

To be defined by SUPPLIER

Indicate

Noise

Isolation

Redundancy

EMI/RFI Immunity

1.5 Air & Service Conditioning:

Temperature Limits

Max temp. rate of change in IES / LER / ITR / SIS / Control Room

Max temp. rate of change in technical room

To be defined by SUPPLIER

Indicate

To be defined by SUPPLIER

Indicate

Required

IEC 61000

refer to sec 6.2

Max. 10% per hour

Describe

Indicate

Max. 10% per hour

Indicate

Humidity

refer to sec 6.2

Indicate

Air Borne Contaminants

To be defined by SUPPLIER

Indicate

1.6 Grounding:

Specification

To be defined by SUPPLIER

Indicate

Ground Loop Avoidance

To be defined by SUPPLIER

Indicate

1.7

Local Support for:

2 to 4 hours service Response

To be defined by SUPPLIER

Describe

Spare parts stocking

To be defined by SUPPLIER

Describe

System Engineering support

To be defined by SUPPLIER

Describe

Training

1.8 Others

To be defined by SUPPLIER

Describe

Total system Reliability

Better than 99.99%

Indicate (Provide) calculation details

Memory/Program Scan Rate

Block/msec.

Response Time

Total figure needed to respond to external action in a fully loaded system

Interface to PCS system

To be defined by SUPPLIER

Indicate/List

Interface to Smart devices

To be defined by SUPPLIER

Indicate/List

1.9 Applications Software:

Real time data bases

Industrial Applications

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DESCRIPTION

SPEC. REQUIREMENTS

ACTION

REFERENCE BID PAGE

PLC SUPPLIER

Graphics Packages

1.10 Spares:

Spare Capacity

Spare I/O

Min. 40% in all CPU’s & Memories

Min. 20% Equally distributed in each rack & card

Indicate

Spare space in each Cabinets

Min. 30%

Indicate

Other Spares

2.0 CABINETS:

Size (W, D, H,) mm

Colour

Protection

Front & Rear Access

Door

Cable Entry

Power Supply

3.0 HARDWARE SPECIFICATIONS

3.1 General:

CPU

To be defined by SUPPLIER

Indicate

800W x 800D x 2000H

Cabinet- RAL 7035, Plinth- RAL7022

IP 42

Required

Single

Bottom

UPS, Required Dual

Non-UPS

Indicate

Yes/No

Indicate

Dual

Single

Type

Indicate

Total I/O per CPU/system

To be defined by SUPPLIER

Indicate

I/O Scan Rate/system

To be defined by SUPPLIER

Indicate

Memory Back-up Battery

Workstation Programmer/Programming Device

3.2 Digital Input

Max. No. of Digital Input points / Module

Max. DI/Input Card

DI status indicator

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Yes/No

Battery replacement possible

Yes/No

Failure or low battery voltage will be monitored by the sys.

Battery Min. life expectancy two years

Yes/No

Portable Personal Computer

Indicate

Panel Mounted HMI

Indicate

To be defined by SUPPLIER

Indicate

32 / card Max.

Power, Logic

Indicate

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DESCRIPTION

SPEC. REQUIREMENTS

ACTION

REFERENCE BID PAGE

PLC SUPPLIER

DI Isolation

Digital Input devices

Standard Rating for digital Input Interfaces

3.3 Digital Output

Ex. 1500 Volts Optical

Indicate

Ex. (selector switch, P.B., Field switch, Proximity saw, Relay contact, etc.)

Ex. (24,48,120,230) V ac/dc, TTL Level, non-Voltage, Isolated, etc.)

No. of Digital Output Points/Module

Max. 16 Points/module

DO status indicator

DO Protection

Discrete Output devices

Standard Rating for discrete Output Interfaces

Power, Logic, Individual blown fuse

Fuse, Suppression on contact output

Ex. (control Relays, Solenoid, Motor starter, Valves, etc.)

Ex. ((12-48,120, 230) V ac/dc, contact (Relay), TTL Level, Isolated, etc.)

Interposing Relay requirement

To be defined by SUPPLIER

Yes/No

3.4 Analog Input

No. of AI Input Points/Module

Max. 16 Inputs/module

Indicate

Resolution (No. of Bits)

To be defined by SUPPLIER

Indicate

Type

Ratings

Built in Transducer

Supply of Power

HART Pass-Through I/O card

3.5 Analog Output

Current, Voltage

Indicate

4-20 mA, 0-5V, 0-10V, etc.

Indicate

Ex. Thermocouples input

Internal

AI Modules

No. of AO Points/Module

Max. 16 AO/module

Type

Ratings

Max. AO/Channel

HART Pass-Through I/O card

3.6 Field Termination Assembly (FTA)

Current, Voltage

4-20 mA, etc.

Ex. 16 Outputs

AO Modules

List

Indicate

HART Pass-Through

AI and AO modules

Indicate

3.7 Special I/O

High speed Pulse Counter

Local & Remote, 50 KHz

Indicate

AGES-SP-04-018

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DESCRIPTION

SPEC. REQUIREMENTS

ACTION

REFERENCE BID PAGE

PLC SUPPLIER

4.0 SOFTWARE SPECIFICATIONS

Operating System Type

Standard/Proprietary

Programming Languages

Logic ladders

Indicate

Functional block/High Level Language

Math Capabilities

To be defined by SUPPLIER

Indicate

Addition, Subtraction, Multiplication, Division, Square root, floating point, etc.

Indicate

PID Modules

Required

Indicate

5.0 NETWORKING & COMMUNICATION SPECIFICATIONS:

Data Highway Specification:

To be defined by SUPPLIER

Indicate

Name Type/Model

To be defined by SUPPLIER

Indicate

Communication Media

Coaxial/fibre optic/UTP/STP

Indicate

Access Method

Speed (Max.)

Cables supplied

Maximum length

Protocol

Rolling, Collision Detection, Token Passing, etc.

Indicate

To be defined by SUPPLIER

Indicate

To be defined by SUPPLIER

Indicate

To be defined by SUPPLIER

Indicate

To be defined by SUPPLIER

Indicate

Max. Number of nodes per network

To be defined by SUPPLIER

Indicate

Redundancy

Peer-to-Peer Communication

Required

Yes / No

Indicate

AGES-SP-04-018

Rev. No: 1 Page 63 of 63

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Project: Q-32859 - NMDC - Ruwais Folder: RFQ Files

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