Basic Process Control Systems Requirements PDF
Basic Process Control Systems Requirements PDF
I3510E-BASE
PAGE 1 OF 32
This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
TABLE OF CONTENTS
Section
1.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
2.
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
3.
3.1
3.2
3.3
4.
4.1
4.2
4.3
4.4
4.5
4.6
5.
5.1
5.2
6.
7.
7.1
7.2
8.
9.
Title
Page No.
GENERAL ............................................................................................................................2
Scope...................................................................................................................................2
KBR Documents, Codes, and Industry Standards ....................................................................2
Definitions of Terms ..............................................................................................................3
Supplier General Response ...................................................................................................4
Project Management .............................................................................................................6
Testing and Inspection...........................................................................................................6
Shipping ...............................................................................................................................8
Installation, Initial System Check, and Site Acceptance Test (SAT) ...........................................8
Field Loop Test .....................................................................................................................9
Training ................................................................................................................................9
GENERAL SYSTEM REQUIREMENTS .................................................................................9
System Scope.......................................................................................................................9
System Layout .................................................................................................................... 10
Process Inputs/Outputs Assembly ........................................................................................ 10
Controller Features.............................................................................................................. 13
Control Algorithms............................................................................................................... 15
Process Logic/Sequence Control.......................................................................................... 15
Operation Station Features .................................................................................................. 16
Operator Console Printers ................................................................................................... 17
Operator Keyboard .............................................................................................................. 17
System Diagnostics............................................................................................................. 17
Historical Data and Trends ................................................................................................... 18
Reports .............................................................................................................................. 19
SYSTEM DESIGN REQUIREMENTS ................................................................................... 19
System Wiring Requirements ............................................................................................... 19
Communication Bus ............................................................................................................ 20
Electrical Power .................................................................................................................. 21
SYSTEM CONFIGURATION AND DISPLAYS ...................................................................... 22
Configuration ..................................................................................................................... 22
On-line Modification............................................................................................................. 22
System Backup Alarm ......................................................................................................... 23
System Failures .................................................................................................................. 23
Loop Tags .......................................................................................................................... 23
Mass Storage...................................................................................................................... 23
ELECTRICAL AREA CLASSIFICATION AND NOISE .......................................................... 23
Radio Frequency Interference (RFI) ..................................................................................... 23
Electrical Area Classification ................................................................................................ 23
SYSTEM DOCUMENTATION AND DRAWINGS .................................................................. 23
SPARE CAPACITY, EXPANDABILITY, MAINTENANCE, AND SPARE PARTS.................... 23
Spare Capacity/Expandability............................................................................................... 23
Maintenance/Spare Parts .................................................................................................... 24
EQUIPMENT IDENTIFICATION........................................................................................... 24
CABINETS ......................................................................................................................... 24
APPENDIX A: SYSTEM BLOCK DIAGRAM ........................................................................ 25
APPENDIX B: I/O SUMMARY TABLE................................................................................. 26
APPENDIX C: ROLES AND RESPONSIBILITIES MATRIX .................................................. 27
APPENDIX D: WORKSHEET - CONTROL CENTER NAME / NUMBER (2 Pages) ........... 28-29
APPENDIX E: WORKSHEET - I/O CLUSTER NAME / NUMBER (3 Pages) ..................... 30-32
TECHNICAL SPECIFICATION
I3510E-BASE
PAGE 2 OF 32
This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
1. GENERAL
1.1 Scope
1.1.1 This specification defines the minimum design and performance requirements of a microprocessor
based Basic Process Control System (BPCS) and the system components, functions and services within the
scope of the BPCS Supplier. KBR will be referred to as the Purchaser. (Items and paragraphs that are
underlined in this specification must be revised with project specific data before using this
specification in a Project.)
1.1.2 The BPCS shall enable plant operators to perform all the conventional actions required for safe plant
monitoring, operation control and reporting. The BPCS shall monitor all process variables, display their
values on Operator Stations, and allow operator control of designated process variables. The system shall
also generate alarms to warn the operator of any system or process variable values which are out of limits;
the alarms shall be reported as timed messages on the screen displays and on the console printers, and
stored in the history devices for future evaluation or printing. The system shall store process information in
electronic format for future access and review through the Operator Stations, Plant Information Network
(PIN), and personal computers. The BPCS shall also be able to communicate and configure Foundation
Fieldbus (FF) certified instrument devices via H1 protocol. Additionally, system shall be capable of
displaying Foundation Fieldbus (FF) instruments' health or diagnostic variables and displayed them in a clear
manner so the Operator or Maintenance technician can take action faster.
1.1.3 The BPCS Supplier shall provide all necessary hardware and software to meet the technical and
functional requirements of this specification. The BPCS supplier scope shall include the following:
a.
A state of the art, microprocessor based, fully integrated and assembled, completely functional and
tested system; complete with process interface and control devices, operator interface with printers,
serial interfaces to foreign devices, BPCS equipment cabinets, system wiring marshalling cabinets, all
pre-fabricated system cabling and connectors, system software for configuration and programming.
b.
Project management services, including system engineering, project scheduling, testing and
procurement, as required to implement the system.
c.
Configuration Services, if any specified in the Roles and Responsibilities Matrix, Appendix C.
d.
The Supplier shall follow all purchasing requirements in the Purchaser Standard I2-3PS, Purchasing
Requirements for Instrument Control Centers".
e.
Software enhanc ement packages if any, shall be included as options. Any software license restrictions
shall be clearly stated by the BPCS supplier.
f.
System Documentation as specified in Supplier Data Requirements for BPCS (SDR), attached to the
Engineering requisition.
1.1.4 All special features or improvements over the standard specification are shown in the Basic Process
Control System Data Sheets, which shall be adhered to by the BPCS Supplier.
1.2 KBR Documents, Codes, and Industry Standards
1.2.1 The following documents are referenced herein and form part of the Order. Additional KBR
documents, when applicable, will be listed on the Requisition. The issue of KBR documents shall be as
specified in the Requisition. Current editions of the industry standards including all mandatory addenda in
effect at the time of the Order shall apply unless otherwise indicated.
TECHNICAL SPECIFICATION
I3510E-BASE
PAGE 3 OF 32
This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
KBR DOCUMENTS
I2-3PS,
Purchasing Requirements for Instrument Control Centers
SDR-2I-I351-XXXX, "Supplier Data Requirements for BPCS"
DEUTCHES INSTITUT FOR NORMUNG (DIN)
DIN 43760,
"Measurement and Control; Electrical Temperature Sensors; References-Tables For
Nickel Resistors for Resistance Thermometers"
FIELDBUS FOUNDATION (FF)
FF 569, "Host Interoperability Support Test"
INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)
IEEE 518,
"IEEE Guide for the Installation of Equipment to Minimize Electrical Noise Inputs to
Controllers from External Sources"
IEEE 802.3
Local and Metropolitan Area Networks: Specific Requirements
Part 3, CSMA/CD, Access Method and Physical Layer
INSTRUMENTATION, SYSTEMS, AND AUTOMATION SOCIETY (ISA)
ISA 5.1,
Instrumentation Symbols, and Identification
ISA 5.3,
Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and
Computer Systems
ISA 5.5,
Graphic Symbols for Process Displays
ISA 12.00.01,
Electrical Apparatus for Use in Class I, Zones 0, 1, & 2 Hazardous (Classified)) Locations
ISA 12.01.01,
Definitions and Information Pertaining to Electrical Instruments in Hazardous (Classified)
Locations
ISA 12.12.01,
"Nonincendive Electrical Equipment for Use in Class I and II, Division 2 and Class III,
Divisions 1 and 2 Hazardous (Classified) Locations"
ISA 50.00.1,
"Compatibility of Analog Signals for Electronic Industrial Process Instruments"
INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)
IEC 61158, "Digital Data Communication for Measurement and Control - Fieldbus for Use in Industrial
Control Systems" Parts 1 thru 8.
PROCESS INDUSTRY PRACTICES (PIP)
1.2.2 Appendices
Appendix A: Initial Network Diagram
Appendix B: I/O Summary Table
Appendix C: Roles and Responsibilities Matrix
Appendix D: Worksheet - Control Center Name / Number
Appendix E: Worksheet - I/O Cluster Name / Number
1.3 Definitions of Terms
1.3.1 Basic Process Control System (BPCS): the entire control system described in this specification. It
shall include, as a minimum, control modules with their associated input/output modules, operator stations,
third party device interface modules, protective enclosures and cabinets to house these modules, power
supplies, internal power distribution wiring, internal communications wiring, marshalling cabinets and buses.
TECHNICAL SPECIFICATION
I3510E-BASE
PAGE 4 OF 32
This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
1.3.2 Operator Station: The basic unit of the operator interface to the BPCS via which operator can view the
process information and can give operator commands to process and/or peripherals. As a minimum, it shall
include a flat panel monitor and associated pointing devices such as touch screen, keyboard and mouse or
track ball.
1.3.3 Operator Console: consists of two or more operator stations assigned to a process unit and may
house additional accessories such as pushbuttons, lamps, telephones etc.
1.3.4 Input/output (I/O) Modules: BPCS components directly connected to the process instrumentation that
perform the process interface and multiplexing functions of the control system, and their protective
enclosures (cabinets or racks).
1.3.5 Communication Buses: The communication cables and interface devices used for data exchange and
data integrity protection, between the operator consoles, the control modules, the foreign device interfaces
and the I/O modules.
1.3.6 Plant Information Network: Information network not directly related with process control and isolated
with a firewall from the BPCS.
1.3.7 Programmable Electronic System (PES): Configurable or programmable devices to perform logic.
Field devices are not included in PES.
1.3.8 Foundation Fieldbus (FF): Fieldbus is an all digital, two-way multi-drop communications link among
TM
intelligent smart field devices and automation systems. FOUNDATION Fieldbus is the local area network
(LAN) for instruments used in process automation with built-in capability to distribute the control applications
across the network, including placing the control in the field device.
1.3.9 OLE for Process Control (OPC): OLE for process control, a new industry standard, defines a standard
interface to access data from a variety of process control devices. The applications must implement one
OPC compliant driver to access data from any OPC compliant server.
1.3.10 PROFIBUS: PROFIBUS is an open, digital communication system with a wide range of applications,
particularly in the fields of factory and process automation. PROFIBUS is suitable for both fast, time-critical
applications and complex communication tasks. There are three types of networks/sub-protocols defined by
PROFIBUS: DP, PA and PROFINET.
1.4 Supplier General Response
1.4.1 The BPCS Supplier shall respond to each paragraph of this specification. The replies for each
paragraph shall be:
a.
b.
c.
In Compliance.
Not in Compliance: BPCS Supplier shall state the specific reason for the deviation.
Enhancement; BPCS Supplier shall explain the enhancement and how it will benefit this project.
All Not in Compliance and Enhancement replies shall be substantiated with published specifications or
firm guaranteed commitments. Deviations included in any other part of the Suppliers proposal will not be
accepted by the Purchaser. The Purchaser does not take the responsibility to discover missing Not in
Compliance items. Supplier must comply with all applicable requisition documents except for those
deviations and alternatives accepted by the Purchaser as stated in the Purchase Order.
TECHNICAL SPECIFICATION
I3510E-BASE
PAGE 5 OF 32
This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
1.4.2 Any omission of details in this specification shall not relieve the BPCS Supplier of the obligation to
furnish a functional system, which operates in a manner satisfactory to the Purchaser. All conflicts between
the specifications, standards and purchase order shall be referred to the Purchaser for clarification before
proceeding with manufacture of the affected items.
1.4.3 Where this specification requests technical data, the BPCS Supplier shall respond by providing a
special document or, when necessary, by attaching relevant technical data. When documents are attached,
page number and paragraph number must reference the data in the response. The BPCS Supplier shall
provide a reply for both equipment and services specified here.
1.4.4 System costs such as hardware, cabinet integration, engineering services, factory acceptance and site
Acceptance tests, shall be broken out and defined separately. The Supplier shall provide unit pricing for all
equipment, software, and services in the proposal so that items, may be added or deleted on a reasonable
basis. A total price to meet the job requirements and a price to add/subtract components, on an individual
basis and with appropriate qualifiers, shall be supplied in the quote. For example, the price to add a new I/O
card should include not only the cost of the new board, but any labor and related services required to order,
install, wire and document the new addition. BPCS Supplier shall precisely describe the point licensing
philosophy and costs for the proposed BPCS. Details shall include point type and limits per controller and/or
system; license upgrades procedures. In the case of sources of large amounts of data such as third party
equipment integration via OPC or Modbus, BPCS Supplier shall describe how the licensed points are
utilized.
1.4.5 The Supplier shall provide sufficient support documentation with the quotation, including technical data
on all quoted hardware and software, to help the Purchaser perform a complete technical evaluation. The
Supplier shall also provide a simple block diagram showing all major components, interconnections and
communication interfaces.
1.4.6 The Supplier shall provide the following additional information with the quotation:
a.
Dimensional sketches of the proposed layout, including access space for cabinet door openings, chassis
slides, and inspection covers
b.
HVAC load, power and grounding requirements, and weight for all major pieces of hardware
c.
d.
e.
Complete listing of all software and Licenses quoted for system configuration and operations - include
the number of copies supplied and unit cost. Supplier shall also furnish a complete, descriptive listing of
all other available software tools, packages and programming aids.
1.4.7 The Supplier may propose alternate system features other than those specified in this document.
Supplier shall clearly identify those features in the alternate quotation that do not comply with this
specification. Supporting documents and explanations shall be included in the quotation to indicate how and
why the proposed alternative is technically (in compliance) equivalent or superior (enhancement) to the
specified system.
1.4.8 The BPCS Supplier shall provide a summary project milestone schedule, based on the site need date.
The schedule shall identify major milestones in engineering, design, parts procurement, manufacture, factory
testing, and shipment. All milestones at which information is required from the Purchaser shall be shown.
Activities that require the presence of the Purchaser such as FAT, system crating, system unloading shall
also be identified by the Project team. Preliminary design freeze dates and information required at those
TECHNICAL SPECIFICATION
I3510E-BASE
PAGE 6 OF 32
This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
dates shall be shown. Any deviation from the agreed upon schedule must have the Purchasers approval.
This schedule shall be reviewed and agreed upon during the pre-award meeting. All clarifications regarding
the scope of work and other requirements shall be completed during the pre-award meetings.
1.5 Project Management
1.5.1 The BPCS Supplier shall assign a Project Manager, who will be the main source of official contacts for
the Purchaser. A project organization chart, identifying project personnel, their responsibilities shall be
provided at the pre-award meeting. The BPCS supplier shall also indicate their proposed manpower loading
for the project. Purchaser requires continuity on all key personnel assigned to the Project.
1.5.2 The BPCS Supplier shall also designate a Project Engineer, who will be assigned to assist during the
engineering effort. However, all correspondence shall be through the BPCS Supplier Project Manager. The
project engineer shall serve as the technical contact and provide assistance to the KBR project team on
system engineering/configuration issues
1.5.3
Purchaser requires continuity on all key personnel assigned to the Project so any changes must be
previously approved by Purchaser.
1.5.4 Milestone schedule dates shall be established showing all the target dates for transmission of project
documents so that the delivery of equipment will not be delayed. Any deviation from the agreed schedule
will require the Purchasers approval
1.5.5 BPCS Supplier shall issue monthly written job progress reports to Purchasers Purchasing
Department. Progress report shall have the following items as a minimum:
a.
b.
c.
d.
e.
f.
The entire system shall be given a complete shop and functional test prior to the Factory Acceptance
Test (FAT). The BPCS Supplier shall perform this test. Written reports with test results shall be
provided to the Purchaser, at least 10 (ten) working days prior to the FAT. This shop test shall include
hardware checks, system power checks, and system diagnostic tests as well as the redundancy of
power supplies and controllers. All deficiencies shall be corrected prior to start of FAT. The Purchaser
reserves the option to perform any spot tests on the completed shop test.
b.
All electronic components and circuit boards shall be tested and burned-in before installation into
electronic assemblies.
TECHNICAL SPECIFICATION
I3510E-BASE
PAGE 7 OF 32
This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
Major components of the BPCS shall be tested at the BPCS Supplier shops before final system test.
After system hardware assembly BPCS Supplier shall perform their standard hardware diagnostic and
system tests. Test results shall be available to Purchasers inspectors. The BPCS supplier shall notify
Purchaser in writing once the system has been completely assembled and is ready for inspection and
testing.
b.
Purchaser will assign engineers to witness the shop tests and any subsequent corrections and
debugging of hardware and diagnostics problems, until the tests are completed satisfactorily. The Shop
tests shall successfully be completed prior to start of the FAT.
FAT shall be performed as per Appendix C, Roles and Responsibilities Matrix", Item 2.14. Tests shall
consist of loop-by-loop functional tests of all inputs and outputs, alarms, and control functions, to confirm
proper operation and display (Project specific). The Project configuration database shall be used for
testing. Supplier shall provide written test procedures to the Purchaser according to the Roles and
Responsibilities matrix prior to FAT. FAT procedure shall be approved by the Purchaser. Tests shall be
performed for all the inputs and outputs using signal simulators provided by the BPCS Supplier
(Minimum one set per checkout team) (Project specific). In the case of FF cards and devices, the
BPCS Supplier shall propose a method or product to simulate FF devices to test the configuration during
the FAT. Such software/product should be reviewed / approved by the Owner and if accounted for in
the main BPCS Purchase Order if it has commercial implications (Project specific). During FAT an
integrated test of all systems including the BPCS, the Programmable Electronic System (PES), and any
other third party system shall be performed to ensure proper functionality.
b.
BPCS Supplier shall furnish qualified technical personnel to assist Purchaser perform tests and debug
the system during the scheduled acceptance test period. The Supplier shall provide the detail of support
in the quote (number of individuals, duration of support, and qualifications of support individuals).
Technical support may include but is not limited to configuration, graphics, network, wiring support
(Project specific).
c.
Office Space and office equipment (desk, chairs, phones, PCs phone connections, office supplies) shall
be provided by the Supplier at the FAT location. A floor plan of FAT location shall be provided three
weeks prior to FAT to ensure the logistics, spaciousness and workability of FAT activities.
d.
A complete set of System documentation shall be made available by the BPCS supplier at the FAT
locations for use during the FAT.
e.
A set of engineering documents such as P&IDs, Control Narratives, Alarm Summary, Cause and Effect
Tables, etc., shall be used to validate the system configuration (database and graphics). Configuration
Acceptance Test (CAT) procedures shall be provided by the party that performed the configuration as
per Appendix C, Roles and Responsibilities Matrix", Item 2.14.
f.
Once the system has been accepted, the responsible engineer (according to the matrix) shall prepare
electronic copies of the configuration data on duplicate magnetic or optical media to be shipped
separately. The electronic files will be used to configure the system after installation and power-up, at
site.
TECHNICAL SPECIFICATION
I3510E-BASE
PAGE 8 OF 32
This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
g.
FAT will be performed at the BPCS Supplier shops, unless a different agreement is reached during the
pre-award meeting. Both cost and milestone schedule in the BPCS Supplier quotation shall be based
on an XX week period for the FAT activity. The Supplier quotation shall also include the additional cost,
on a weekly basis, including weekend and after-hours support, if a longer period is required to complete
the FAT (Project specific).
h.
A punch list shall be maintained for all deficiencies found during the test. The responsible engineer shall
correct the deficiencies and demonstrate the corrective action prior to shipment of the system.
1.7 Shipping
1.7.1 All interconnecting cables shall be labeled at both ends, specifying cabinet, terminal panel and plug-in
connectors to which each cable end is to be reconnected. After satisfactory completion of FAT, BPCS
Supplier shall disconnect all the equipment and prepare the system for shipment.
1.7.2 Cabinets shall be shipped intact. Circuit board cards are not to be removed for shipping, as long as
the integrity of the electronic equipment is not compromised. BPCS Supplier shall protect and crate all
cabinets properly to avoid damage during shipment and storage. BPCS supplier shall provide accelerometer
indication on all BPCS cabinets.
1.7.3 Domestic shipment shall be by air ride van as minimum protection.
1.7.4 For overseas shipment, the BPCS Supplier shall contact Purchaser for special export licensing
requirements. The responsible party for exporting equipment shall determine if export license is required
according to the U.S. Department of Commerce Export Regulations.
1.7.5 BPCS Supplier shall ship touchup paint with the system.
1.7.6 BPCS Supplier shall immediately advise the Purchaser of any delays during shipment or damage
during shipment.
1.8 Installation, Initial System Check and Site Acceptance Test (SAT)
1.8.1 BPCS Supplier shall assign qualified personnel to:
a.
Inspect, supervise, assist and approve site installation of BPCS building equipment, including computer
floor and air conditioning.
b.
Supervise uncrating of BPCS equipment and check for any physical damage to the hardware.
c.
d.
e.
Install diagnostic software and perform hardware test, power checks, and system diagnostics to verify
successful installation.
1.8.2 Purchaser will provide labor for uncrating, installation of equipment, connection for power and
grounding, connection of field wiring to predefined terminal cabinets, and also connection of BPCS Supplier
interconnecting cables. BPCS Supplier may install interconnecting cabling if this is required by Supplier
warranty (Project specific).
TECHNICAL SPECIFICATION
I3510E-BASE
PAGE 9 OF 32
This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
1.8.3 The Supplier shall perform SAT. The Supplier shall provide a detailed test procedure for the SAT
(Project specific).
1.8.4 The SAT shall include loading the configuration on the system to assure the BPCS system including all
third party communications is functional.
1.8.5 BPCS supplier proposal shall state the amount of time and cost allowed for the installation support at
the site and shall also provide a rate sheet for other field and engineering support activities, by job positions.
1.9 Field Loop Test
1.9.1 The field loop test shall be performed for all input and output signals from the field instruments to the
BPCS. Refer to Roles and Responsibilities Matrix (Appendix C) for field support responsibilities.
1.9.2 The Purchaser may request technical assistance from the BPCS Supplier in conducting the field tests;
therefore, BPCS Supplier proposal shall state the cost and amount of time allowed to support the field tests
as an option and shall include a rate sheet for field and factory support activities, by job positions.
1.9.3 BPCS Supplier shall provide information on the service network that covers the site location and shall
confirm the availability of 24-hour on-call service and provide details on the spare-part program.
1.10 Training
1.10.1 For the following training, Supplier shall furnish dates, location of schools, descriptions of course,
duration and cost for the associated BPCS equipment. If "group training" conducted at the Purchasers
facility will be more cost effective, this should be quoted as an option. Training to accomplish the following
shall be included and shall be listed as a separate cost item.
a.
b.
c.
Training of operators and foremen in all aspects of system operation (non-process related). System
training will be preferably conducted at the job site.
TECHNICAL SPECIFICATION
I3510E-BASE
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
2.1.3 The BPCS Supplier shall provide detailed technical data, with information on actual applications,
documenting the capabilities of the quoted BPCS to maintain bi-directional communications with Object Link
Embedded (OLE) for Process Control (OPC) compliant foreign devices based on the standards of the OPC
Foundation.
2.1.4 The system shall be capable of multiformat displays such as custom process graphics, overview,
group and face plate detail, trends, process status indicating all the loop parameters such as process
variable, set point, output, tuning constants, alarms, name tag and service description.
2.1.5 The system shall provide user-configurable alarm functions to alert the operator of abnormal or
dangerous conditions. The following listed features shall be available (as a minimum):
a.
b.
c.
d.
Configurable alarms from analog inputs: Low and High, Low-Low, and High-High
Deviation from set point
Controller output - Low and High
Alarms from discrete inputs
Common means of alarm acknowledgment and horn silencing from the operator station keyboards shall be
provided. BPCS Supplier shall state maximum counts of alarms that can be stored and displayed in real
time from the alarm summary.
2.1.6 BPCS Supplier shall support all system hardware and firmware with spare parts and service for a
period of at least ten (10) years after the withdrawal of the product from the market. BPCS Supplier shall
provide upgrades and revisions of the software for a period of X years from the shipment date at no
additional cost (Project specific).
2.1.7 All software licenses shall be registered to the Plant Owner.
2.1.8 BPCS shall provide the highest possible level of security of operations. The failure of a single BPCS
component shall not affect the performance of the BPCS or the security of operations. If there is a high
probability that the failure of a BPCS component will cause loss of control of more than one critical process
variable, then that electronic component should have the capability to add a redundant backup. Specific
redundancy requirements will be indicated in the initial network diagram and I/O summary table.
2.2 System Layout
BPCS Supplier shall provide dimensioned sketches of the floor area requirements of the quoted equipment
as indicated within this specification. The sketches shall show the layout of the equipment to be supplied,
identified by name.
2.3 Process Inputs/Outputs Assembly
2.3.1 BPCS I/O processor modules shall be provided in quantities to match the input and output counts
listed in the BPCS Data Sheets (Appendices B, D, and E) and an additional 10% margin for fully wired
spares. BPCS supplier shall install the I/O processor modules, termination panels, cabling, terminals and
accessories inside the BPCS controller cabinets. The controller cabinets shall provide both additional
terminals for I/O wires and cabinet space to allow for future installation of an additional 10% I/O count, above
the 10% margin for spares, when the system is turned over to the Plant owner at the end of Site Acceptance
Tests.
TECHNICAL SPECIFICATION
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
2.3.2 BPCS I/O modules shall provide 24 volts DC power to all field devices from dedicated power supplies
installed in the controller cabinets. Power supplies shall be sized to handle the maximum controller I/O
loading capacity, at the maximum power rating of the I/O modules. Power supply to each I/O channel shall
be provided through either individually fused terminals or disconnect switches and current limiting circuitry in
the marshalling panels (Project specific). FF devices/H1 segment will require separate power supplies and
power conditioners.
2.3.3 BPCS Supplier shall design the BPCS process signal power distribution system. Protective and
interrupting devices shall be properly coordinated to avoid single cause multiple failures. A single electrical
failure shall not cause power interruption to multiple I/O modules.
2.3.4 BPCS I/O data monitoring functions shall be programmed from the BPCS Supplier standard set of predefined, configurable data collection algorithms. I/O processing algorithms will include the following, as a
minimum:
a.
b.
Input signal characterization like square root, ISA Thermocouples and 100 ohm platinum RTD's, signal
filtering, signal totalization.
c.
Input signal monitoring to generate invalid or out-of-range value status alarms. I/O processors shall be
configurable, to allow or inhibit propagation of invalid or out-of-range values.
d.
Analog input and output signals will be monitored to generate out-of limit alarms when selected signal
parameters exceed configurable limits. As a minimum, alarms shall be activated when the signal levels
exceed high or low (HI or LO) warning, and high or low emergency (HI-HI or LO-LO), and rate of change
limits. Individual prioritization of alarms shall be possible. The capability to enable and disable alarm
functions shall be provided on an individual basis.
e.
Discrete input and output signals will be monitored and if required generate alarms. As a minimum,
alarms will be activated based on signal status, change of state, un-commanded change and status
disagree with command.
2.3.5 BPCS supplier shall provide one-to-one redundancy of selected BPCS analog input and output
modules (See Appendix B, "I/O Summary Table"), with single field devices to improve the operability, safety
and maintainability of continuous control loops and custody transfer variables. A pair of terminals shall be
provided for termination of each field instrument wiring signal. Transfer of I/O module shall be automatic with
fault indication on the operators console.
2.3.6 The BPCS supplier shall provide inputs and outputs suitable for nonincendive circuits as specified on
the I/O Summary Table, per ISA S12.12.01 (Project specific).
2.3.7 Input/output Capabilities
Analog signals provided for the BPCS shall be compatible for use in electronic process systems as per
ISA 50.00.1.
a.
TECHNICAL SPECIFICATION
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
b.
c.
d.
e.
The system shall be capable of delivering isolated and non-isolated 4-20 mA output signal driving
up to 600 ohms.
2.
Discrete Input
1.
System Powered Digital Input - The signal is a dry contact or an open collector transistor powered
by the BPCS.
2.
3.
The I/O modules shall accommodate both normally open and normally closed contacts and shall
include isolation and filtering functions to insure that chatter or bounce, typical of contact
closures, do not cause erroneous information.
4.
BPCS monitoring of discrete inputs shall be based, as a minimum, on detection of change of state
or current status.
5.
BPCS shall have the capability to handle and monitor Sequence of Events (SOE) with a minimum
resolution of 1 millisecond. Digital inputs that require SOE capability shall be indicated in the I/O
Summary Table.
Discrete Output
1.
DC Discrete Output - This signal is an isolated relay or solid state output. Both momentary and
sustained actions, normally open and normally closed shall be available. The outputs should be
capable of driving loads as specified on the I/O Summary Table, Appendix B.
2.
Isolated AC Discrete Output - This signal is an isolated relay or a triac output. The outputs should
be capable of driving loads as specified on the I/O Summary Table, Appendix B.
3.
Non-Isolated AC Discrete Output - This signal is a dry contact or triac output with power supplied
from the BPCS.
4.
Each discrete output channel shall be individually provided with contact surge protection/arc
suppression devices and fused disconnects at the output module.
RTD Input
o
Three wire, 100 ohm, platinum RTD, 100 ohms at 32 F, per DIN Standard 43760.
f.
Thermocouple Input
1.
Input cards shall be able to accept any industry standard thermocouples. Thermocouple burnout
indication shall be selectable, either downscale or upscale. Inputs shall include automatic cold
reference junction compensation.
2.
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
g.
h.
i.
2.
3.
4.
5.
Supplier is to state the limits associated with FF devices and configuration such as maximum
number of devices per H1 segment; maximum number of VCRs, maximum number of Function
Blocks and number of macrocycles.
Frequency Input
1.
Pulse train interpreted as either a scaled quantity per pulse for totalization or as an instantaneous
process value proportional to pulse frequency.
2.
The system should be able to supply 24-volt DC power for the field pulse device or accept fieldgenerated pulses.
3.
Pulse Input cards shall be capable of receiving frequency-input signals from turbine meters and
PD (positive displacement) meters
4.
The system shall be capable of accepting sine or square wave pulse signals.
j.
Interface to other control systems and serial devices. Interface protocols and electrical interface
(i.e., RS485, Ethernet 10BaseT UTP) shall be determined on a case by case basis. See Appendix
B, I/O Summary Table for definition.
2.
The BPCS gateway shall be capable of performing self-diagnostics of the communication links with
the external systems.
3.
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
2.4.2 Each BPCS process control sub system shall include power supplies, controller modules,
communication modules, I/O processor modules, termination panels, cabling, terminals and accessories all
mounted inside cabinets provided by the BPCS supplier. BPCS supplier shall also provide power supply
modules dedicated to the field devices (Project specific).
2.4.3 The controller cabinets will be installed inside the rack room in a control building, remote rack rooms or
in remote cabinets located throughout the process areas and will interface directly with the process field
sensors and final control elements via hardwired signals or communication networks.
2.4.4 The quantity, performance and type of controllers required shall be determined by the BPCS supplier,
based on the following sizing criteria:
a.
Process control functions shall be performed by the minimum possible number and type of devices and
shall satisfy the redundancy and security requirements of this specification.
b.
The controller shall support selectable algorithm execution rates of at least four times a second.
c.
The controllers provided shall be capable of handling a minimum count of I/O processor devices, power
supplies, terminations, wiring, etc., equivalent to 110% (Project specific) of the process I/O counts
listed in this specification.
d.
The controllers shall be capable of handling a minimum count of control loops, calculations, logic and
sequence functions equal to 110% (Project specific) of the corresponding counts listed in this
specification.
e.
It will be assumed that the execution rate for 80% of the control functions will be set at once per second
while the execution rate for 20% of the control functions will be set at four times per second. It will also
be assumed that the execution rate for all calculations, sequences and logic functions will be set at once
per second.
f.
BPCS controller shall provide 30% spare additional processing and memory capacity, to accommodate
for future high level application programming and configuration. Supplier to provide memory size quoted
that is dedicated to these applications.
g.
Controller redundancy is required. The switch over on failure of main controller shall be bumpless.
2.4.5 Controller fault handling and recovery procedures shall be fully programmable functionality, on a loop
by loop basis, shall include:
a.
Controller shall monitor all I/O signals and shall generate invalid or out-of-range value status alarms for
inputs and calculated variables.
b.
Controllers shall be configurable, to either allow or inhibit propagation of invalid or out-of-range values
through continuous or logic control loops.
c.
Controller shall be configurable to continue operating with the last valid data upon failure of
communications with either the operator interfaces or any other communication subsystems or switch
over to manual mode upon detection of bad process value.
d.
Signal to field devices from analog and discrete output modules shall be configurable to either hold last
good value or change to a selectable value, upon either failure of field device or controller module or
loss of communication between the output processor and the controller module.
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
Multiple proportional-integral-derivative (3-mode PID) control functions, in both simple loop and complex
loop arrangements, like cascade and ratio control, split range, feed compensation, and feed forward.
b.
c.
Calculation functions, either simple mathematical functions, or advanced calculations like signal
linearization, mass flow compensation, signal averaging, polynomials, ramp generation, lead-lag
compensation, totalization, etc.
d.
2.5.3 The control algorithms shall include additional selectable features like bumpless automatic mode
transfer, anti-reset wind-up protection, process variable tracking when in manual mode, controller
initialization when not in cascade mode, etc.
2.5.4 The BPCS shall provide discrete control algorithms for implementation of logic interlock, sequencing
and batch controls. Logic controls shall be implemented using functional block programming and shall
provide the following capabilities, either individually or in combination:
a.
Timer functions, like time delays (on delay, off delay and one shot), pulse counters, latches, etc.
b.
Logic function blocks with logic gates like or, and, not, flip-flop, etc.
c.
d.
2.5.5 Batch control algorithms shall provide flexible control of recipe execution and shall be capable of
handling batch recipes with several different product grades, phases and steps. Operator shall be able to
follow the execution of a recipe and also issue commands to skip and repeat steps; stop, hold, restart, and
abort recipes; and enter data for use by the recipe (Project specific).
2.6 Process Logic/Sequence Control
2.6.1 If BPCS Supplier quotes a separate logic/sequence controller then it shall be able to communicate with
the Basic Process Control System and preferably be an integral part of the BPCS.
2.6.2 Programming of the logic/sequence controller shall be functional block programming or equivalent.
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
Dual Screen, High-resolution flat panel color monitors, 21-inch diagonal, with touch screen, and high
performance CPU running at the highest speed available at the time of the purchase order, and a
minimum memory of 512 MB RAM.
b.
Operator Keyboards: One keyboard per Station is required for normal operation. The keyboard shall
allow access to both displays in dual tier consoles. Membrane or QWERTY keyboards to be Project
Specific.
c.
d.
Removable bulk storage drives, like CD-R/W, tape drive or cartridge. Details on storage mediums shall
be included in the quote.
2.7.2 Process control operations such as set point adjustment, manual controller output, alarm limit setting,
etc., shall be performed through the operator consoles. BPCS Supplier shall provide either a console
keylock switch or a password protection (access level) procedure to prevent unauthorized changes to system
parameters and settings, such as controller tuning and alarm limits.
2.7.3 Update period for all active data in pre-formatted displays shall not exceed two seconds.
2.7.4 Call-up time for all custom graphic displays of average complexity, including all updated fields, shall
not exceed 4 seconds after an operator request. The update period for real time data in custom graphic
displays shall be not greater than two seconds for both alphanumerical data and dynamic display symbols
like shape changes, color changes, etc.
2.7.5 BPCS Supplier shall provide each Operator Station with enough space for installation, by others, of the
auxiliary control equipment: display based man-machine interface devices for selected packaged equipment,
CCTV controls and plant communication sets. Counts of additional console mounted devices are estimates
and will be confirmed before the hardware freeze dates. (See Worksheet (Appendix D) and Network
Diagram (Appendix A) (Project specific).
2.7.6 BPCS Supplier shall provide each Operator Station with (when specified) the following auxiliary control
equipment completely installed and wired to a terminal strip in the back of the station furniture: hardwired
hand operated Emergency Shutdown (ESD) switches, Closed Caption Television (CCTV) displays, plant
communication equipment, and paperless three inputs recorders.
2.7.7 Operator station redundancy shall be achieved by providing two or more identical operator stations for
each Operator Console. Loss of one operator Station and associated components shall only reduce the
number of windows to the process and shall not affect operation or performance of the other operator
station(s).
2.7.8 Mounting of operator console equipment shall be based on BPCS Supplier's standard design,
arranged in accordance with the Purchaser layout described in the BPCS Data Sheet.
2.7.9 Console furniture shall be BPCS Supplier standard design and color. The console adjustable writing
surface shall have a minimum depth of 12 inches (305 mm). The writing surface shall be continuous
between console units in the same operating station. Console construction shall include proper
reinforcement to provide adequate rigidity for an industrial environment.
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
2.7.10 Maintenance access to the electronics shall be from both sides of the console.
2.7.11 BPCS Supplier shall provide dedicated engineering stations to allow on-line modifications to BPCS
configuration and displays. The engineering station shall include: one high-resolution display color monitor,
21 inch diagonal; one Engineer Keyboard; screen pointing devices like mouse or track-ball; removable bulk
storage drives, like CD-R/W, tape drives, etc. (See Subparagraph 2.7.1.d). See Worksheet (Appendix D) for
details (Project specific).
2.8 Operator Console Printers
2.8.1 BPCS Supplier shall supply (as specified in Worksheet, Appendix D) each operator console with
LaserJet printers: black and white printers for process and system alarms, logs and reports; and one (1)
color printer for display printing. (Project specific).
2.8.2 Alarm and report printers shall be laser using plain bond paper. The alarm printer shall be
automatically activated by any alarm condition. The printout of alarm messages shall also be available upon
operator demand (Project specific).
2.8.3 Alarm messages on both the operator console screens and on the printer shall include the following
items for each message, as a minimum:
a.
b.
c.
d.
e.
f.
Tag name
Description
Alarm Type and priority
Date (day/month) and time (hour/minute/second) stamp
Time alarm is acknowledged
Time when alarm returns to normal
The FF devices shall be capable of performing continuous diagnostic, including self-test functions to
provide specific diagnostic information to the Host.
b.
All Foundation Fieldbus instruments shall support methods to allow automation of on-line procedures,
such as calibration from the host.
2.10.3 All devices shall as a minimum satisfy the requirements of the fieldbus certification laboratory. In the
case of Foundation Fieldbus, the FF "check mark" logo and listing on the Approved devices list maintained
on its website www.fieldbus.org verifies interoperability of devices.
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
2.10.4 BPCS Supplier shall describe, and quote as options in the proposal, all additional special diagnostic
tools or aids that can be used with the BPCS, such as remote diagnostics to factory, recommended field test
equipment, etc.
2.11 Historical Data and Trends
2.11.1 The Supplier shall provide a configurable real time and historical data collection package to support
trending, logging and reporting. The package shall include:
a.
b.
Storing the value of any analog entity or calculated value in history files
c.
Recording the change of state of any discrete point in one of the event histories
d.
Short term Historical Data collection with transfer of data to removable media for long term historical
data storage and/or archiving.
2.11.2 BPCS Supplier shall provide a configurable trend package to satisfy the following real time and
historical trending requirements:
a.
b.
The system shall support on-line trends for at least one minute snapshot and average values for seven
(7) days (Project specific).
c.
BPCS Supplier shall indicate in the quotation the maximum number of analog points that can be trended
in the proposed system.
2.11.3 Both real time trends and historical trends shall be provided. All operator stations shall be capable of
displaying real time and historical trends. Each trend display shall consist of the plotted trend graph(s) and a
table showing trend parameters. It shall be possible to incorporate trends in graphic displays.
2.11.4 Each event history file entry shall contain the time and date of occurrence, the tag ID, the tag
description and value/state and the type of event. The BPCS Supplier quotation shall indicate the maximum
number of events that can be historically archived in the electronic mass storage media.
2.11.5 The following events as a minimum shall automatically be stored in history files for later reporting and
analysis.
a.
Process Events
1.
2.
3.
b.
Operator Events
1.
2.
3.
4.
TECHNICAL SPECIFICATION
I3510E-BASE
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
c.
Engineer Events
1.
2.
3.
4.
d.
System Events
1.
2.
3.
4.
5.
6.
2.11.6 Adequate storage shall be provided for on-line access to the last seven days of data without manual
selection of removable media from off-line files.
2.10.7 BPCS Supplier shall provide enough memory to store/retrieve data for past 6 months for a minimum
of 4000 points and at sample rate of 1 minute with data compaction algorithm (Project specific).
2.12 Reports
The BPCS Supplier shall provide a report generation functionality to access all information available on the
communication networks (control and alarm data, equipment failure data, configuration, etc.). The reports
can then be executed on demand or automatically (based on an event or on time) and produce the report
output to the communications network for access by all system components or users (i.e., operator
consoles, engineering stations, printers, PCs, host computers, etc.). Supplier to provide copies of the
standard reports from the system.
3. SYSTEM DESIGN REQUIREMENTS
3.1 System Wiring Requirements
3.1.1 All BPCS network interconnecting wiring and cable to be installed inside system cabinets shall be
provided by the BPCS Supplier.
3.1.2 BPCS Supplier shall provide complete wiring and termination information for all BPCS interconnecting
cables (installed or shipped loose) either in the form of wiring schematics or wiring schedules, to Purchasers
instrument design and electrical groups, in accordance with the Supplier Data Requirements.
3.1.3 All wiring shall be color coded according to project and local wiring requirements. Wiring size to be
16 AWG consistent with the terminal block size. Wiring insulation shall be 16 AWG, 600 V THWN as
minimum.
3.1.4 Terminal blocks shall be non-hygroscopic type and provided by the BPCS Supplier. Terminals shall
be tinned and shall be clearly identified. The size of the terminal block shall be consistent with 16 AWG
(1.5 mm) twisted pairs or triads of stranded copper wire. Captive screw terminal strips are preferred. All
terminals shall be numbered and the wiring identified with the loop tag number (Project specific). Terminal
strips will be segregated in accordance with the type and level of the signal in the connected wires. All spare
I/O points shall be wired as indicated in Paragraph 2.3.1.
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
3.1.5 All AC power wiring shall be routed for maximum personnel safety and reduction of electrical
interference. AC and DC wiring segregation inside BPCS cabinets shall be accomplished by wireways or
loomed cable bundles segregated by a minimum of 12 inches (305 mm). Where intersections of AC and DC
wiring are unavoidable, care shall be exercised to make the intersections at right angles, with maximum
possible separation. Power wiring (120 V AC or less) to be 14 AWG, 600 V THWN as minimum, however,
cable size shall always be calculated by BPCS Supplier.
3.1.6 Wires in the same cabinet wireways or support shall be of the same type of signal (AC vs . DC).
3.1.7 Cable entries into the BPCS cabinets for power, grounding and interconnections between cabinets
shall be from either top or bottom to be defined by Purchaser before the hardware freeze date. Cable
entries into the BPCS cabinets for wiring to field devices shall be from either top or bottom, to be defined by
Purchaser before the hardware freeze dates.
3.1.8 Wiring shall be arranged in such a way that it will not interfere with maintenance operations, i.e., card
removal or insertion, etc.
3.1.9 BPCS supplier shall provide marshalling cabinets for terminating field wiring. The BPCS Supplier is
responsible for all interconnection cable assemblies between the marshalling and controller cabinets and for
all scramble wiring between BPCS termination assemblies and field termination blocks within the marshalling
cabinet. Purchaser will be responsible for all field wiring to the BPCS marshalling cabinets. Purchaser must
indicate if surge suppressors are required for lightning protection. (Project specific).
3.1.10 The BPCS Supplier shall provide interconnection wiring information as per SDR Requirements. The
wiring information shall be provided with sufficient details to permit the preparation of the cable block wiring
diagram, and shall include wiring size and quantities between interconnection panels or equipments. The
detailed wiring information showing exact terminal numbers can be submitted later with other engineering
information.
3.2 Communication Bus
3.2.1 Communication buses shall have redundant cables, routed in separate paths to avoid a single incident
causing simultaneous failure of both buses. Separation of paths shall extend all the way to the bus interface
and control devices on the I/O racks, operator/engineering interfaces, and any other type of unit connected to
the communication buses.
3.2.2 BPCS Supplier shall provide dual BPCS internal communication buses for the Human Machine
Interface (HMI), controllers and I/O buses and historian. The bus shall be equipped with independent
transmitter and receiver for each cable. The operator station shall provide system status displays to monitor
the operation of all communication buses and shall generate system alarm messages to report any bus
failures. Redundant cables of each communication bus shall alternate at regular intervals, as recommended
by the BPCS Supplier. When one cable fails, the other one shall take over automatically, without any
operator intervention. A single failure of either of the bus cables shall not result in any system degradation.
Any variables normally updated over the communication bus shall retain their last value before failure.
3.2.3 The BPCS shall be capable of interfacing with other commercially available process computers,
personal computers and microprocessor based process control equipment with serial communication
interfaces using OLE for Process Control (OPC), TCP/IP or Modbus.
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
a.
The BPCS Supplier shall provide the BPCS interface link devi ce, including any modems or protocol
converters as required. For non-critical monitoring of analog and discrete points, simplex OPC
Client/Server arrangements connected to plant information network may be used. For critical control
functions, redundant OPC Client-Server designs connected to a dedicated redundant network shall be
used (Project specific).
b.
The BPCS supplier is responsible for approving the communication between all third party devices.
c.
The Purchaser will provide all communication wires between the interfaces, following the specifications
provided by the Suppliers and the applicable industry standards.
3.2.4 BPCS Supplier shall provide an interface to the Plant Information Network (PIN) if required. The
BPCS Supplier shall provide necessary hardware and software to allow remote file transfer and accessibility
to process data and schematics through an Ethernet (in accordance with IEEE 802.3) network and firewall;
the network hardware will be provided by others (Project specific).
3.2.5 Interconnecting cables for BPCS communication buses between control rooms and I/O Buildings (fiber
optic or coaxial) shall be furnished and installed by the Purchaser, based on specifications provided by
BPCS Supplier.
3.2.6 Failure of both cables of the communication buses shall not disable the functionality of the BPCS
control modules. After recovering from a communication failure, the BPCS shall automatically generate
operator station displays to prompt the operator.
3.2.7 BPCS Supplier shall describe the method used for communication bus error detection and correction
to confirm the validity of the communications.
3.2.8 BPCS Supplier shall state transmission speed of the bus in bits/second and transactions/second, and
state if communication is based on polling, interrupts, or other method. If it is based upon polling, BPCS
Supplier shall state frequency of polling.
3.3 Electrical Power
3.3.1 The BPCS Supplier shall provide all the required BPCS internal DC power distribution, power
conditioning, power supplies, bus bars, power wiring, etc., as part of the scope of supply. System power
shall be provided with transient suppressors and shall be capable of handling voltage surges in the
AC power supply of _______ (Project specific).
3.3.2 BPCS Supplier shall provide redundant DC power supplies for all power requirements of controllers,
communication processors, two-wire analog inputs and outputs, digital inputs and digital outputs. Each
power supply of the redundant pair shall be rated to supply full load plus 30% reserve capacity.
3.3.3 For discrete outputs, a separate power system may be required. The BPCS Supplier shall coordinate
with Purchaser to determine the power system and wiring requirements before the hardware freeze date
(Project specific).
3.3.4 BPCS supplier shall provide redundant power supplies capable of handling isolated dual AC feeds.
Primary power to the power supplies will be provided by a UPS (minimum 30 minutes at full load) (Project
specific), provided by Purchaser. BPCS Supplier shall specify BPCS AC power requirements, including
power supply wave shape, distortion limits, in order for Purchaser to specify UPS. BPCS Supplier shall
indicate if battery backup is available for their power supplies. BPCS supplier shall provide status indication
lights to confirm the status of the backup batteries. BPCS Supplier shall indicate how long the battery will
support the system controller.
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
3.3.5 Redundant power supplies shall be sized and wired by the BPCS Supplier, such that failure of one
power supply will not affect the operation of the system. The power supply units shall have fuse protections
and diagnostic indicators that are easily observable by the user showing as a minimum: loss of power, loss
of redundancy and power supply failure.
3.3.6 The failure of any power supply shall cause a BPCS alarm message on the BPCS status displays and
report printer. Each power supply shall be provided with a failure warning relay and a set of relay contacts
that will be connected to a BPCS digital input to activate the alarms. In addition, power to each termination
board shall be fused or otherwise protected, to prevent a fault in one board from affecting other boards.
3.3.7 Configuration data and operating parameters shall be stored in non-volatile memory, battery powered
RAM, or equivalent memory capable of retaining data during short duration (not less than 72 hours) power
outages. BPCS Supplier shall provide data showing battery de-rating after one and fi ve year operation. The
backup battery shall be replaceable while the BPCS is in operation, without affecting the normal BPCS
functions.
3.3.8 The BPCS Supplier's proposal shall provide detailed BPCS grounding requirements and installation
details and will indicate if the system ground must be separate from the process computer ground and data
communication bus ground.
4. SYSTEM CONFIGURATION AND DISPLAYS
4.1 Configuration (Project specific, see Appendix C, "Roles & Responsibilities Matrix")
4.1.1 Purchaser shall perform programming, configuration and custom display building of the BPCS. BPCS
Supplier shall quote, as an option, software packages and/or associated equipment required to perform
BPCS configuration using a network of PCs in the Purchaser offices. BPCS Supplier shall also provide
detailed configuration and custom display building documentation (forms, dictionary of parameters, etc.) and
technical support from suppliers technical specialist during the configuration activities. Supplier shall
indicate in the proposal the type and duration of support to be provided.
4.1.2 Display graphics shall conform to ISA 5.3 and ISA 5.5, unless otherwise directed by the Purchaser.
Display graphics will be configured based on P&ID's that follow ISA 5.1 symbology or similar.
4.1.3 Graphics software shall provide the means to list all the entity tags referenced in a display.
4.1.4 If process technology is to be exported by the BPCS Supplier, documents supplied by KBR containing
that technology are to carry a Technology Export Recipient Notification. The Export Control Classification
Number (ECCN) for this technology is _______________(Later). It is the responsibility of the BPCS Supplier
to adhere to all Export Compliance Regulations associated with this ECCN Number.
(Note: For KBR Engineers, the Export Compliance Administrator, Office of the Chief Engineer can help in
obtaining the correct Export Control Classification Number. The Supplier Export Compliance Officer shall
also offer assistance, if necessary.)
4.2 On-line Modification
On line modification of, or creation of new, control/monitoring loops and preformatted or custom BPCS
displays shall not affect the operation and performance of the BPCS.
TECHNICAL SPECIFICATION
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
TECHNICAL SPECIFICATION
I3510E-BASE
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
TECHNICAL SPECIFICATION
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
(Project specific)
TECHNICAL SPECIFICATION
I3510E-BASE
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
(Project specific)
TECHNICAL SPECIFICATION
I3510E-BASE
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
(Project specific)
TECHNICAL SPECIFICATION
I3510E-BASE
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This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
APPENDIX D (Page 1 of 2)
WORKSHEET - CONTROL CENTER NAME / NUMBER
Location
Ambient Temperature Range
Humidity Range
Electrical Area Classification
Supply Voltage
Electrical Power Feed
(Single/Dual)
UPS furnished by:
Unusual Service Conditions
Name/Number of I/O Clusters
associated with control center
Operator Console
Number of stations (Qty.)
Screens per station
Screen size/type
Printer required?
(Yes/No)
Software
Other requirements
V AC
Hz
Other:
Printer Type
Engineering Console
(not including operator stations with engineering capacity)
Number of stations (Qty.)
(station = network node)
Screens per station
Screen size/type
Operator functionality required? (Yes/No)
Number of dedicated printers/Type
Min. Software Included
On-Line/Off-Line Configuration Software? (Yes/No)
Other requirements
Fault tolerant / Raid / etc.
Network printers
Number of color laser printer?
Number of black & white laser printer?
Other requirements
Server
Type
Redundancy?
Other requirements
TECHNICAL SPECIFICATION
I3510E-BASE
PAGE 29 OF 32
This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
APPENDIX D (Page 2 of 2)
WORKSHEET - CONTROL CENTER NAME / NUMBER
Server
Type
Number of attributes
Add-ons
Other requirements
Server
Type
Capacity(Tags)/Collection
frequency
Other requirements
Server
Type
Number of OPC devices
Redundancy?
Port traffic:
Total number of AI
Total number of AO
Total number of DI
Total number of DI (SOE)
Total number of DO
Total Number of Serial I/O's
Software
Other requirements
Event Historian
For Alarm
TECHNICAL SPECIFICATION
I3510E-BASE
PAGE 30 OF 32
This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
APPENDIX E (Page 1 of 3)
WORKSHEET - I/O CLUS TER NAME / NUMBER
Location
Distance to control room
Overall Enclosure
Ambient Temperature Range
Humidity Range
Electrical Area Classification
Supply Voltage
Electrical Power Feed
(Single/Dual)
UPS furnished by:
Unusual Service Conditions
V AC
Hz
Other:
TECHNICAL SPECIFICATION
I3510E-BASE
PAGE 31 OF 32
This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
APPENDIX E (Page 2 of 3)
WORKSHEET - I/O CLUSTER NAME / NUMBER
Integrated System and Marshalling Cabinets allowed? (Yes/No)
Cable Entry?
Maintenance Access? ( Front / Rear / Both)
Cross wiring requirements (single or dual terminals)
Signal segregation requirements
Other requirements
Hardwired I/O
Type
Control /
indication
System
Powered
AI
AO
DI
DI (SOE)
DO
RTD
T/C
Pulse
Other
Nonincendive I/O required?
Intrinsically Safe Barriers
Required?
Foundation Fieldbus
Number of ports
Redundant H1 Port?
Redundant Power Modules?
Intrinsically Barriers required?
For all segments:
Total number of AI blocks
Total number of AO blocks
Total number of DI blocks
Total number of DO blocks
Total number of PID blocks
Redundant
Hart
Contact
Type
Contact
Volts/Rating
Comments
Comments
TECHNICAL SPECIFICATION
I3510E-BASE
PAGE 32 OF 32
This BASE specification must be revised by the project team to meet project specific requirements . Refer to Appendices A, B, C, D
and E for additional clarification of project requirements.
APPENDIX E (Page 3 of 3)
WORKSHEET - I/O CLUSTER NAME / NUMBER
ProfiBus DP
Number of Ports
Redundant Port?
For Indication
Comments
For control
For Indication
Comments
Total number of AI
Total number of AO
Total number of DI
Total number of DO
AS-i
Number of ports
Port traffic:
Total number of devices
Third Party Interface
Type
For control
For Indication
Single Mode
Multimode
TOTAL NUMBER OF AI
Total number of AO
Total number of DI
Total number of DO
Total number of PID blocks
Fiber Optic Cable Converters
Type
.................................Size
Comments