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SPECIFICATION
FOR
DISTRIBUTED CONTROL SYSTEM

CONTRACT NO. : GTC-001/NODCO

CONSORTIUM JOB NO. : LGEN : 7J48

LURGI : 69660

PROJECT NAME : NODCO REFINERTY EXPANSION PROJECT

CLIENT : NATIONAL OIL DISTRIBUTION COMPANY

SITE : MESAIEED, STATE OF QATAR

3 25/11/1999 REVISED AS PER

COMPANY’S COMMENTS
2 20/10/1999 REVISED AS PER J.T.Jeong J.K.Kim SMB/SCK N.J.Lee
COMPANY’S COMMENTS
1 26/05/1999 REVISED AS PER J.T.Jeong J.K.Kim SMB/SCK N.J.Lee
COMPANY’S COMMENTS
0 08/01/1999 FOR COMPANY’S REVIEW J.T.Jeong J.K.Kim SMB/SCK N.J.Lee
B 16/11/1998 FOR REVIEW J.T.Jeong J.K.Kim SMB/SCK N.J.Lee
A 28/10/1998 FOR QUOTATION J.T.Jeong J.K.Kim SMB/SCK N.J.Lee
REV. DATE DESCRIPTION PRPD CHKD APPD QA CLIENT
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TABLE OF CONTENTS

1. INTRODUCTION

1.1 General
1.2 Order of Precedence
1.3 Definitions
1.4 Responsibility
1.5 System Overview

2. PROCESS DESCRIPTION
2.1 Introduction
2.2 Scope
2.3 Process Description

3. PUBLICATIONS, CODES AND STANDARDS

4. ELECTRICAL AND EARTHING DESCRIPTION

4.1 Power Supplies Available
4.2 Earthing
4.3 Other Requirements
4.4 Heat load
4.5 Load Schematic

5. ENVIRONMENT
5.1 Introduction
5.2 Temperature and Humidity
5.3 Pressure
5.4 Pollutants
5.5 Vibration / Acceleration
5.6 Sound Pressure Level
5.7 Hazardous Area Classification
5.8 Materials

6. QUALITY ASSURANCE
6.1 Project Requirements
6.2 VENDOR

7. DIRSTRIBUTED AND INTEGRATED CONTROL SYSTEM (DCS)

7.1 General Requirements
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7.1.1 Compliance List

7.1.2 Documentation with Quotation
7.1.3 Operating Conditions

7.2 Scope of Supply

7.2.1 Proposals
7.2.2 System Installation and Mounting
7.2.3 Fans
7.2.4 AC Power Supply

7.3 Architecture
7.3.1 System General
7.3.2 Hardware General
7.3.3 Overall Configuration
7.3.4 Communication and Loading Requirements
7.3.5 System Configuration
7.3.6 Sizing and Capacity
7.3.7 Database Configuration

7.4 Human Machine Interface (HMI)

7.4.1 General
7.4.2 Point Identification
7.4.3 Operator Stations
7.4.4 Keyboards
7.4.5 Video Displays
7.4.6 Standard Operation Displays
7.4.7 Printers and Peripherals

7.5 Process Interface

7.5.1 General
7.5.2 Hardware and Architecture
7.5.3 Continuous Control
7.5.4 Discrete Point Control
7.5.5 Calculation Functions
7.5.6 Faceplates
7.5.7 Processing Period
7.5.8 Control and Input / Output Sizing
7.5.9 Process Interface Requirements
7.5.10 Analogue I/O Isolation
7.5.11 Digital I/O Isolation
7.5.12 I/O Quality
7.5.13 24-volt Power Supplies
7.5.14 Transmitter Power Supply
7.5.15 Back-up Batteries

7.6 Alarm Function

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7.6.1 General
7.6.2 Alarms
7.6.3 Process Alarm Types
7.6.4 Process Alarm Management
7.6.5 Alarm Priorities

7.7 Historical function

7.7.1 Trending Function
7.7.2 Historical Events
7.7.3 Acquisition Rate
7.7.4 Historical Data Distribution
7.7.5 On-Demand Reporting

7.8 Engineering Functions (Database Configuration)

7.8.1 Engineering Environment
7.8.2 Engineering Security
7.8.3 Standard Engineering Tools
7.8.4 Concurrent Engineering
7.8.5 Workstations
7.8.6 Application Program Debugging
7.8.7 Application Program Documentation

7.9 Other Software Capability

7.9.1 High Level Language

7.10 System Integrity

7.10.1 Redundancy
7.10.2 System Access
7.10.3 Availability

7.11 Openness and Connectivity

7.11.1 Connectivity with Upper Level Computers and Networks
7.11.2 Interface Requirements
7.11.3 File Transfer Function
7.11.4 DDE Function
7.11.5 Interface with real-time Data Acquisition Package
7.11.6 Interface with Optimization Package
7.11.7 Interface with Lower Sub-systems
7.11.8 System Interface with Tank Gauging, Metering Packages, etc.
7.11.9 Blending
7.11.10 Oil Movement and Overall Tank Farm Management System

7.12 Maintenance
7.12.1 General
7.12.2 Card Failure Indication
7.12.3 Cards Access
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7.12.4 Diagnostics
7.12.5 System Back-up
7.12.6 Special Tools

7.13 Acceptance Test

7.13.1 Works Check-out
7.13.2 Refinery Check-out

7.14 Services
7.14.1 General
7.14.2 Basic Project Services
7.14.3 Other Project Services
7.14.4 Support Services
7.14.5 Maintenance and Service Contract

7.15 The Content of Bidder’s Proposal

7.15.1 Executive Volume
7.15.2 Technical Volume

7.16 Table of Compliance

7.16.1 Table of Compliance - Example
7.16.2 Table of Compliance Form

7.17 Appendix List

Appendix A Overall Control System Block Diagram
Appendix B Units of Measurement
Appendix C Training
Appendix D Central Control Building, Plan, Section and Elevations
Appendix E DCS Console Layout in Central Control Room
Appendix F DCS Overall Integrated Communications Network
Appendix G I/O Schedule (Summary)
Appendix H System Interface, Associated Units and Power Consumer list for
PDB
Appendix I P&ID Unit 21 Blending Units
Appendix J Instrument and Electrical Interface Earthing Philosophy
Appendix K Special Requirement for Year 2000 Compliance
Appendix L Offsite Automation and Management System
Appendix M Not used
Appendix N Specification for Inspection, Testing and Precommissioning of
Instrument Equipment Items
Appendix O Consumables and Spare Parts
Appendix P Marshalling Cabinet
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1. INTRODUCTION

This specification along with the attachments covers the minimum requirements for the design,
documentation, material, manufacture, configuration, inspection, works test, identification,
shipment and site testing of a Distributed Control System (DCS) for NODCO Refinery Expansion
Project to be installed on NODCO Refinery Facilities at Mesaieed, Qatar, Berth No. 6(Jetty) at
Mesaieed and Doha Distribution Center, Doha, Qatar.

The information in this document is strictly confidential and bidders are required not to divulge the
contents to any third party.

Layout and size of the system shall be based on Appendix G & H.

Errors or discrepancies found in this specification and other associated documents shall be brought
to PURCHASER’s attention for resolution.

Any deviation from the design standards and requirements laid out in this specification will be
considered, but will not be acceptable unless agreed in writing by the PURCHASER.

The VENDOR shall supply all components and accessories for proper operation of the complete
system in compliance with site and operating conditions, and performance as detailed in this
document, attached data sheets and drawings.

Prototype or unproven equipment not having a well established operating record will not be
considered. Only standard designs which are in regular current production and have been in use in
petrochemical and oil and gas installations for longer than 3 years shall be considered.

The design life shall be 20 years for major items of equipment whose removal and
replacement would necessitate a total shutdown of production and significant installation
activities. All equipment shall be supported for this period.

The VENDOR shall, with his submission, identify the companies product support policy for
the equipment offered.

1.1 General

This specification defines the minimum requirements for the DCS for the said project.
This work forms a part of the NODCO Expansion Project.

The VENDOR is required to demonstrate his experience of work in the Gulf area and shall
provide the following information about his Gulf area representative:

y Name and address.

y Telephone number.
y Fax number.
y Contact name.
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y Response time for emergency call-out.

y Response time for normal call-out.
y Repair turnaround time.
y Training packages available with details.
y Location of training (VENDOR works or Gulf area).

The VENDOR shall note that, generally, intrinsically safe equipment shall be used
throughout the project with the exception of solenoid valves. For Doha Distribution Center
and Berth No. 6 (Jetty) see the relevant “Scope of Work” documents for Doha depot and Jetty.

Training for the DCS shall be included in the VENDOR’s scope of work and the details of
shall be referred to Appendix C of this specification. The VENDOR shall state the exact
details of the training packages based on the requirements and the location for the training;
i.e. VENDOR works or Gulf area.

1.2 Order of Precedence

In the event of conflict of requirements within the requisition documents, the order of
precedence shall be:

y Statutory Requirements.
y This Specification.
y Referenced Project specifications.
y Referenced codes and Standards.

It is the responsibility of the VENDOR to contact PURCHASER for a resolution of any

conflict and secure a written clarification via PURCHASER’s concession procedure prior to
starting work.

1.3 Definitions

Unless otherwise qualified the following terms shall apply:

PURCHASER LG Engineering Co., Ltd., Seoul, Korea(LGEN)

COMPANY National Oil Distribution Company(NODCO)
VENDOR The Company selected by the PURCHASER to undertake the
work associated with the DCS and associated services.
Work Work shall mean all work to be performed by the VENDOR
as described in this scope of work.
FEED Front End Engineering Design.
DCS Distributed Control system.
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ESD / PSD Emergency / Process Shutdown.

HVAC Heating, Ventilating and Air Conditioning.
CCR Central Control Room.
SER Satellite Equipment Room.
PLC Programmable Logic Controller.
APC Advance Process Control.
POIS Plant Operation Information System.
FAT Factory Acceptance Test.
SAT Site Acceptance Test.
SIT System Integration Test.

1.4 Responsibility

The VENDOR shall define and offer all equipment required to ensure satisfactory operation
under the conditions stated in this document and be in accordance with the applicable codes
and standards.

Offer fully comprehensive documentation to ensure satisfactory operation, maintenance and

trouble-shooting for the DCS.

1.5 System Overview

The NODCO Expansion project includes the upgrade and integration of Mesaieed Refinery
facilities and two remote facilities i.e. the Doha Distribution Center (Doha Depot) and Berth
No. 6 (Jetty). Each shall be a node off the main Mesaieed refinery DCS system. The links
between the two sites and Mesaieed refinery shall be via radio links which shall be supplied
by the DCS VENDOR. Doha Depot is 45km from the refinery and Jetty is 6km from
refinery.

Doha shall be Node 7 and Berth no.6 shall be Node 6 as per “DCS Overall Integrated
Communications Network” DWG. No. 7J48N-00-15-41-001.
The drawings 7J48N-34-15-41-001 & 7J48N-39-15-41-001 indicate the DCS systems at
Doha and Jetty.

At Doha depot, information from an existing “Spektra-Trek” road tanker loading system will
be read into the DCS system via and available RS 232 or RS 485 port. DCS VENDOR,
shall include all hardware necessary for conversion from RS 232 or 485 to Modbus RTU
protocol. An estimate of the amount of data taken via this data link is 100 Analogue values,
50 digital values. A certain amount of tanker driver information may also be gathered e.g.
date and time a particular driver collected a certain load and properties of the load e.g.
quantity of product, type of product etc.
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Doha Distribution depot will also have a Depot Information System (DIS) which will collect
all necessary data from the DCS highway via a gateway. The loading from the DIS is at
present unknown but shall be developed during detailed design.

The Jetty will be fitted with a multi product metering panel. This panel will receive flow
metering inputs from two positive displacement meters which will also provide temperature
compensation. The field sensors will feed into two flow computers fitted within the metering
panel. DCS VENDOR shall assume normal highway data loading for this type of panel.

Appendix A attached shows the overall process as a block diagram for the Mesaieed refinery.

2. PROCESS DESCRIPTION

2.1 Introduction

The current NODCO refinery facilities at Mesaieed comprise a medium size hydroskimming
refinery supplying petroleum products for the home market and selling surplus stocks for
export. The smaller Refinery 1 was installed in the 1970s for essentially home consumption
and Refinery 2 was added in the 1980s. Total capacity of Refinery 1 and 2 is circa. 60,000
BPD based on Dukham crude. An isomerization unit has been added more recently. The
existing facilities permit the upgrading of SR naphtha to gasoline via hydrotreating,
reforming and isomerization and the desulphurization of kerosene and diesel via
hydrotreating. Current operations, however, do not permit upgrading of residue. As residue
represents a significant proportion of the refinery’s product slate its economics are restrained.

The Refinery Expansion Project seeks to alter this picture by adding residue catalytic
cracking to upgrade the value of products made and reduce the net production of fuel oils. In
addition the refinery is to be expanded in capacity to handle more Dukham crude, which will
be essentially achieved by revamping/upgrading the Refinery 2 units; and also to accept a
condensate stream from Ras Laffan which will be handled by adding new facilities.

Associated with the proposed Residue Catalytic Cracker are also a number of support units
whose function is to sweeten / hydrofinish its products or make use of the olefinic content to
increase gasoline blending stocks.

The whole upgrade, therefore, consists of revamping/re-utilizing existing units and also
adding new ones. Some of the revamped units are licensed processes as are some of the new.
The key new unit is the Residue Catalytic Cracker. This is a licensed unit and a number of
other process units are dependent on it for their feedstock.
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2.2 Scope

2.2.1 The process scope covers all the work on the:

y Revamp Units – Units 01, 02, 03, 06, 11, 12, 13, 14, 15, 16, 17, 18 and 19
y FCC Units – Units 41, 42, 43, 44, 45, 46, 47, 48 and 49.
y Condensate Units – Units 61, 62, 63, 64, 65
y Tankage
y Blending
y Import / Export Control

2.2.2 A brief unit description follows.

2.3 Process Description

2.3.1 No. 2 Crude Distillation & SWS – Unit 11

This unit is an existing unit that was built in the middle 1980s. The current intention
is to debottleneck and revamp the unit from the original 50,000 BPD to 70,000 BPD.

Dukham 3 and 4 crude is defined as the feedstock and two blends of these crude set
the design basis. Three explicit cases are given:

y 80/20 Dukham 4/3 blend maximum naphtha summer.

y 80/20 Dukham 4/3 blend maximum naphtha winter.
y 50/50 Dukham 4/3 blend maximum RFCC feed summer.

In parallel, the current capability of the heat train will be reviewed and compared
with potential requirements of the revamp. A flexible approach is therefore needed
that balances the possibly conflicting requirements of the tower and the heat train.

The existing heat train appears to be relatively simplistic and greater heat recovery is
likely to be realizable. This may require rearrangement of the configuration such as
interleaving hot, important streams like residues, back against crude earlier in the
heat train. This would permit running residue down cooler and allow greater heat
recovery.

Any development of the current heat train needs to be reviewed with due
consideration of:

y good heat recovery achieved economically

y retaining good unit flexibility and operation
y achieving acceptable desalting conditions
y not excessively wasteful in pumping energy
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Unit 11 also includes an existing Sour Water Stripper. This unit is dependent on
others for its final definition of feedstock.

2.3.2 No. 2 Naphtha Hydrotreater – Unit 12

This is a UOP unit built as part of Refinery 2 during the 1980s and hydrotreats
naphtha to remove sulphur from light and heavy naphtha’s which are first
debutanized to remove LPGs and lighter, and split to provide a light and heavy
naphtha. The heavy naphtha is provided as feed to the CCR.

2.3.3 No. 2 Continuous Catalytic Reformer Unit – Unit 13

This is an existing unit built as part of the Refinery 2 expansion in the mid-1980s.
The unit is a UOP licensed CCR type reformer and requires revamping for the
current expansion. It takes heavy naphtha feed from Unit 12.

The revamp will be based on UOP studies on major equipment done in 1992 and
requires the FEED Contractor to work closely with UOP to design the unit.

2.3.4 No. 2 Kerosene Hydrotreater– Unit 14

This unit originally provided as a UOP licensed unit in the mid-1980s and requires
revamping to meet the new throughput and performance.

2.3.5 No. 2 GO Hydrotreater – Unit 15

This unit was originally installed as part of the Refinery 2 expansion in the mid-
1980s and now needs revamping for the current expansion. The new requirement is
to expand the unit’s overall LGO handling capacity and, in addition, take some LGO
from the new residue catalytic cracker. Two possible configurations are suggested.
The first takes 1,150 BPD LGO and requires a separate main LGO treater, but limits
the required capacity of Unit 15. The second takes 4,750 BPD of LGO and
eliminates the separate LGO treater.

The selection of a best new alternative and configuration will be developed by

making best, economic and practical use of existing facilities and by limiting the
need for new items as practical.

2.3.6 No. 2 Amine Treatment Facilities – Unit 16

This is an existing unit which is part of Refinery 2 and uses MEA as treating agent.
The unit comprises LPG liquid treating and fuel gas treating as is fairly common in
refinery applications.

The continued use of MEA as a treating solvent will be reviewed for this particular
unit, as an upgrade / debottlenecking is contemplated. In addition, amine treating
separately associated with the catalytic cracker may justify other than MEA use.
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The current treating solution is 20 wt% MEA. Currently treating is largely for H2S
removal as the streams involved are associated predominantly with Hydrotreating.
Two absorbers, one liquid-liquid and the other vapor-liquid are in use.

A significant capacity increase in treating suggests a second train is needed.

However, consideration will be given to changing the treating solvent to see whether
existing towers could cope or whether any other compromise is feasible. Review of
the hydrotreaters may require addition of separate amine contractors in their
hydrogen recycle loops, if not already present. These, if needed, may need
integration into this unit. Alternatively, if the fuel gases needing treating have
significantly different pressure, they may feasibly be kept separate and more
effectively treated that way. If the new amine systems needed for other refinery
activities can be combined or located nearby each other, a more economic overall
strategy may be feasible.

2.3.7 No. 2 LPG Recovery Facilities – Unit 17

This unit is existing and was built as part of Refinery 2. Significant upgrade in
capacity is required. The existing unit appears to consist only of a C3/C4 splitter and
is simply a depropanizer with propane and lighter being sent to fuel. The tower may
be too small for the new duty and hence a new tower to replace it or a new parallel
item may be necessary.

As an alternative, the addition of a vaporizer, may be viable. This implies keeping

within the current gas plant capability, but boil off more C4’s effectively to fuel in
front of the C3/C4 splitter.

While this may accommodate the C3/C4 splitter, it will make more fuel gas and create
a still greater load on the amine unit. In addition C4 overall recovery is likely to
suffer.

If separate propane recovery has any relative value to the refinery, over its value as
fuel, the addition of a de-ethanizer may feasibly help to unload the C3/C4 splitter.
This would also reduce the load on the amine unit. The effect would be to retain C4
recovery and introduce C3 recovery. The latter may need treating before sale.

2.3.8 No. 2 Penex/Molex – Units 18/19

This unit is a licensed UOP unit attached to Refinery 2 and completed in the last few
years. This unit needs revamping as part of the current expansion.

The revamp will be based upon UOP studies on major equipment done in 1992.

2.3.9 Fluid Catalytic Cracking – Unit 41

This unit will be a new licensed UOP unit. It represents the most significant part of
the refinery upgrade as it is the means to upgrade the low value residue currently
going to fuel oil. The feedstock comes from the Refinery 1 and 2 crude units and the
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proposed new condensate unit.

2.3.10 Light FCC Gasoline Merox – Unit 42

This unit is to be a new licensed UOP unit that supports the RFCC itself taking sour
gas streams from the RFCC and treating them for H2S removal.

If layout permits there may be merit combining the regeneration facilities in unit 49
and in general for amine throughout the refinery as long as enough flexibility is
retained to provide sufficient operating integrity to cover loss of individual
equipment items.

This particular unit is intended to be dedicated to RFCC feedstock and those from the
Catalytic Polymerization unit only, but other treating applications could be included
and would be likely to mean that respective absorber towers are located within their
respective units and lean/rich amine brought to/from a common regeneration facility.

2.3.11 FCC C3/C4 Merox – Unit 43

This is a new unit to be associated with the RFCC and will a licensed UOP process.
The feedstock for the unit will be dependent on the RFCC unit licensor.

2.3.12 Catalytic Polymerization and Hydrogeneration Unit – Unit 44

This is a new unit whose function is dependent on the RFCC.

As the feedstock to this unit is dependent on the RFCC, the design of this unit is
dependent on the development of the RFCC.

2.3.13 Heavy FCC Gasoline Hydrofinisher – Unit 45

This will be a new licensed Mobil unit whose function is to desulphurize heavy
RFCC gasoline and will be a proprietary unit.

The unit is dependent on the RFCC for its feedstock.

2.3.14 Light Cycle Oil Hydrotreating Unit – Unit 46

This unit is a new unit and dependent on the RFCC for feed. The unit could be a
stand-alone unit as indicated or its function combined into the revamp of No.2 Gas
Oil Hydrotreater. Both alternatives will be considered.

2.3.15 Sulphur Recovery and Sulphur Handling – Unit 47

This will be a new licensed Pritchards unit comprising more than one train and
provided as a license unit.

The unit will accept feeds from several sour gas sources, notably the amine treating
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units 16, 42 and 49 and the sour water strippers 11 and 48. As sour water stripper gas
will contain ammonia from Hydrotreating operations and possibly other
contaminants, proper destruction of these components is essential in the sulphur plant.
It is therefore important to select proven sulphur plant technology to do this.

2.3.16 Sour Water Stripper – Unit 48

This will be a new unit to accept sour waters from a number of sources. The
objective is to remove contaminants such as H2S/CO2/Phenols/Cyanides, etc. from
the water so that the stripped water can be re-used effectively. Depending on the
sources of water it may contain entrained/dissolved oil which needs removal. This
may be separable in a simple feed surge drum, but in some difficult circumstances
may also need longer settling times. In addition, the need for residence time to
permit source units to continue operation when the sour water stripper is down may
also influence the need for significant storage.

2.3.17 Amine Treatment Facilities – Unit 49

This is to be a new unit. The purpose is to collect rich amine from a number of
absorbers in other units and return the rich solution to this unit for regeneration.

Absorbers in hydrotreater recycle loops are best kept as part of those units for
operational reasons. Absorbers on product or fuel gas streams are best located in
their own units or in combined form in a separate amine unit, including the
regenerator.

The objective is to provide a unit that will meet its treating objectives for liquid and
gas treating and provide suitable feed to the sulphur plant in an economical way.
Lean amine loading and regeneration efficiently could be mutually conflicting and
are only indirectly relevant to the unit’s purpose.

2.3.18 Condensate Distillation Unit – Unit 61

This will be a new unit and will take stabilized condensate from North Dome field as
feedstock.

The unit itself will be similar to a crude unit, except that heavy ends will be present
in much smaller amounts and that would impact on the heat exchange philosophy, etc.

Three design cases are assumed for the intended design.

Separate kero and LGO draws are implied, yet the distillate hydrotreater may either
combine these and separate after or run separately in blocked operation. In the event
that separation of kero/gas oil is preferred after the hydrotreater, the question could
arise as to whether the same product draws should be adopted for this unit or whether,
in that case, this unit should be designed solely on its own merits with or without
separate draws.
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The fractionation section in the hydrotreater may, however still be accessible to the
combined distillate even if the main hydrotreater is down.

2.3.19 Naphtha Hydrotreater Unit – Unit 62

This will be a new unit supplied as a licensed UOP package. The feed comes from
the condensate distillation unit which is desulphurized in this unit. The unit
separates LPG and light gases in its debutanizer, then splits naphtha into light and
heavy naphtha. Light naphtha is directed to blending or Penex and heavy naphtha to
the new CCR unit.

There may be merit in providing crossovers from Refinery 2 to achieve better

flexibility.

2.3.20 Continuous Catalytic Reformer – Unit 63

This unit is a new licensed UOP unit taking heavy naphtha from Unit 62.

In practice, some crossover with refinery 2 may be prudent for flexibility.

In the case of reformers and hydrotreaters, overall hydrogen balance will be

undertaken to ensure best use is made of this resource. However, the use of CCR
units should readily ensure adequate hydrogen is available for Hydrotreating duties.

2.3.21 Middle Distillate Oil Hydrotreater – Unit 64

This unit will be a new open art unit and is intended to treat the distillates from the
condensate distillation unit. The unit design considers two basic options:

y treat kero / gas oil together then separate

y treat separately in blocked operation

Nominally this may have impact on the distillation unit design depending on
blending philosophy, etc. This is covered in unit 61.

Crossovers should be considered from Refinery 1 and 2 to aid greater flexibility.

2.3.22 Pyrolysis Gasoline Hydrotreater

The possible availability of a pyrolysis gasoline stream for an adjacent ethylene unit
in the nearby facility will require Hydrotreating of this stream in the refinery, if
brought in for processing.

2.3.23 Metering (see Section 7.11.8)

Measurement accuracy is essential in the sale, purchase and handling of petroleum

products. It avoids disputes between buyer and seller and provides a reliable means
of control over losses. Accurate measurement involves the use of standardized
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equipment and procedures.

Metering will be the primary means of accounting for quantity of product

imported/exported, hence the need for great accuracy to a known reference standard.

A secondary means of accounting for quantity of product exported will be the tank
gauging system, which can be used as a comparative measurement or used in the
emergency case during the failure of the metering system.

Measurement from the metering system and the tank gauging system will be fed to
the plant operation information system (POIS) via the proposed DCS for use by the
process/management staff of the Refinery.

The new metering systems to be installed at Doha Depot and Jetty shall provide
metering data to the DCS resident on that site.

2.3.24 Blending (see Section 7.11.9)

2.3.25 Offsite Automation and Management System (see Appendix L)

3. PUBLICATIONS, CODES AND STANDARDS

The following codes, standards and specifications shall be considered as a part of this scope of
work. All documents shall be the latest issues available.

In case of conflict between the codes and standards listed, or between codes/standards and this
scope of work, the VENDOR shall notify the PURCHASER, who will determine which
documents shall take precedence.

BS 1259 Intrinsically safe electrical apparatus and circuits for use in explosive
atmospheres.
BS 5501 Part 7 Intrinsic safety ‘i’.
BS 5515 Documentation of Computer Based Systems
BS 5750 Quality Systems (All Parts)
BS 5887 Code of Practice for Testing of Computer Based Systems
BS 4058 Data Processing Flow Chart Symbols, Rules and Conventions
BS 6238 Code of Practice for Performance Monitoring of Computer-based Systems
BS 6488 Code of Practice for Configuration Management of Computer-based Systems.
EN 50020 Electrical apparatus for potentially explosive atmospheres.
SFA 3012 BASEEFA standards – intrinsic safety.
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Electronic Industries Association / CCITT Recommendations

It should be noted, that since the interfaces/protocols are yet to fully be defined, some of the
documents listed in this section may not apply. Conversely, other more appropriate ones may
be added at a later date.

V 22 1200 bps Full-Duplex 2-wire Modem Standardized for Use in the

General Switched Telephone Network.
V22 bis 2400 bps Full-Duplex 2-wire Modem Standardized for Use in the
General Switched Telephone Network.
RS 449 General Purpose 37-position and 9-position Interface for DTE and DCE
Employing Serial Binary Data Interchange.
V 24/RS 232D Interface between Data Terminal Equipment Employing Serial Binary
Data.
V 27 4800 bps Modem for Leased Circuits
V 27 bis 4800/2400 bps Modem with adaptive Equalizer Standardized for Use on
Leased Circuits.
V 27 ter 4800/2400 bps Modem Standardized for Use in the General Switched
Telephone Network.
V 28 Electrical characteristics for Unbalanced Double Current Interchange
Circuits.

V 35 Data Transmission at 48 Kilobits per Second Using 60~108kHz Group

Band Circuits.
V 54 Loop Test Devices for Modems.
IEC 529 Specification for Degree of protection provided by enclosure.
ISA S5.1 Instrumentation symbols and identification.
ISA S5.2 Graphic symbols for logic diagrams
ISA S5.3 Graphic symbols for distributed control / shared display instrumentation, logic
and computer system.
ISA S5.4 Instrument loop diagrams.
ISA S5.5 Graphic symbols for process displays.
ISA RP18.1 Alarm and sequence.
IEEE 802.2 Logical Link Control (LLC) employed in conjunction with the media access
standard defined under IEEE 802.3/4/5/6.
IEEE 802.3 Carrier Sense Multiple Access and Collision.
IEEE 802.4 Token Passing Access Method
IEEE 802.5 Token Ring Access Method.
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Project References Document

7J48N-00-15-41-001 DCS Overall Integrated Communication Network

7J48N-00-15-41-002 Overall Control System Block Diagram
7J48N-34-15-41-001 Control System Block Diagram for Doha Depot
7J48N-39-15-41-001 Control System Block Diagram for Berth No.6 (Jetty)
7J48N-00-15-41-201 DCS Console Layout in Central Control Room
7J48N-00-15-41-301 Instrument & Electrical Interface Earthing Philosophy
7J48N-00-15-41-302 Instrument & Electrical Interface Earthing Philosophy for Computer
& Telemetry Equipment
180126/00/15/15/26 Scope of Work – Doha Depot Instrument Upgrade
180126/00/15/15/27 Scope of Work – Berth No.6 (Jetty) Instrument Upgrade
180126/00/20/41/02 Marshalling Cabinet Layout (Design Basis)
180126/00/20/41/03 Marshalling Cabinet Layout (Design Basis)
3 7J48N-00-15-17-021 Specification for Instrument Cable
3 7J48N-00-15-17-013 Engineering Specification – Inspection, Testing and Precommissioning
of Instrument Equipment

4. ELECTRICAL AND EARTHING DESCRIPTION

4.1 Power Supplies Available

The following supplies are available to the DCS system.

110V AC Supply (Main Control Building and SER)

The specification of this supply is:

110V AC±2% (±5% on bypass)

50 Hz ±1%
THD ±5%

Transient Voltage Disturbance

y 1st cycle 30% steady state peak

y 2nd cycle 15% steady state peak
y Recovery to steady state complete within 4 cycles.

4.2 Earthing

Earthing shall be in accordance with the VENDOR’s recommendations and Instrument and
Electrical Interface Earthing Philosophy (7J48N-00-15-17-301 and 302). Any conflicts
between the VENDOR specification and standards referred in this document shall be
highlighted by the VENDOR and resolved during the detail design stage.
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The VENDOR shall review the above Project Earthing Philosophy drawings and shall make
recommendations to eliminate any interference resulting from incorrect earthing. Any
specific earthing requirements such as earthing for high frequency interference shall be
clearly stated in the quotation.

Similarly the VENDOR shall advise if isolation or protection is required to eliminate the
effects of lightning, raised earth potential due to earth faults and switching transients.

4.3 Other Requirements

The DCS equipment shall exhibit a high degree of immunity to radio frequency interference
in the 27 MHz to 500 MHz band with a field strength of 10V/M independent of cabinet doors
being open or closed and shall comply with EEC EMC Directive Ref. 89-336 EC, RFI
susceptibility. The VENDOR shall clarify and define installation procedures required to
comply with the RFI immunity requirements. Typically the equipment must continue to
operate without fault when a hand held communicator is keyed at approximately ½m
distance from the equipment with the doors closed.

The VENDOR shall ensure that the DCS equipment is immune to electromagnetic
interference in accordance with the requirements of IEC 801, Part 3. The most likely source
of electromagnetic interference will be switch gear, power cabling, electric motors. The
VENDOR shall clarify and define installation procedures required to comply with the EMI
immunity requirements.

4.4 Heat Load

The VENDOR is to provide detailed heat dissipation figures so that the air conditioning
equipment can be sized.

4.5 Load Schematic

The VENDOR shall provide detailed schematics showing the complete power supply
distribution system within the DCS cabinets, together with the capacity of power source
required.

5. ENVIRONMENT

5.1 Introduction

The following sub-sections define the environment in which all control systems associated
with this project will operate in normal conditions. This information should be forwarded to
all sub-system VENDORs, any recommendation forwarded by the VENDOR for hardware
should take account of these conditions.

5.2 Temperature and Humidity

Storage
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All control system equipment associated with this product must be suitable for storing under
cover at the following conditions:

Temperature : -4°C to +50°C

Humidity : 95% (non-condensing)

Operating

The Central Control Room, Satellite Equipment Room and the Operator Monitoring Station
will be supplied with HVAC systems which will maintain the following conditions:

Temperature : 18°C to 24°C

Max. Rate of Change : 8°C/Hr
Relative Humidity : 40~50%

5.3 Pressure

The plant is 2 meters above sea level. The respective control rooms will be pressurized at
approx. 6mm Wg above atmospheric.

5.4 Pollutants

The VENDOR is to state the upper limits for any equipment proposed to the following
pollutants:

H2S (ppb) : Present only in abnormal conditions

SO2 (ppb) : Present only in abnormal conditions
Dust (mg/m3 or microns) : Continuously present

5.5 Vibration/Acceleration

The supplied equipment must be suitable for continuous operation under sinusoidally varying
accelerations of magnitude 2G and frequencies anywhere in the range 10 to 500Hz.

5.6 Sound Pressure Level

Equipment supplied must not produce a sound pressure level exceeding 55dBA measured at
1 meter from the equipment cabinet. This includes DCS system sub-assemblies, power
supplies, printers, etc. Noise data for electrical / electronic cabinets must include any integral
ventilation equipment supplied with the cabinets.
3
y Dust (mg/m or microns) continuously present

5.7 Hazardous Area Classification

The CCR Equipment Room, SERs and Doha and Jetty control buildings will be classified as
non-hazardous areas under normal operating conditions.
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Most field instruments connected to the system will be in accordance with BS 4683, BS 5345
and BS 5501 and BASEEEFA or PTB to CENELEC standard certified intrinsically safe for
use in Zone 1 Hazardous area, Gas Group IIC, Temperature T4 (135℃) and will be
weatherproof to IP65 as a minimum. VENDOR shall provide suitable Intrinsic Safety
Barriers for Zone I, Group II C applications. Some field instruments are non-IS type, such as
Exd.
Electrical equipment for use in other gas group and/or requiring another temperature class, if
any, will be identified by the PURCHASER during detail design stage.

The certifying authority for electrical instruments in a hazardous area shall be BASEEFA.

Where BASEEFA certified equipment is not available, certification to CENELEC standards

will be considered. Each case shall be submitted to the PURCHASER for written approval.
Generally the following certifying and testing authorities are accepted:

Certifying and Testing Authorities

For CENELEC or BS:

+Belgium INIEX
+Denmark DEMKO
+France LCIE or CERCHAR
+Germany PTB or BVS
+Great Britain BASEEFA or HSE
+Italy CESI

For NEC:

+US Factory Mutual (FM) or Underwriter Laboratory (UL).

Generally, intrinsically safe equipment shall be considered as the project standard to the
following:
Ex(ia) to BS 5501 Parts 7 and 9 or BS 1259
SFA 3012

(Solenoid valves excluded)

IS Barriers shall be of the galvanically isolated type.

5.8 Materials

All materials and components shall be new and of the highest quality. Should any material or
component prove unsatisfactory during fabrication it shall be rejected, notwithstanding any
previous certification, satisfactory examination or tests.

6. QUALITY ASSURANCE
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6.1 Project Requirements

The VENDOR shall comply with the requirements of:

BS-5750/ISO 9000 Quality Systems or operate an equivalent quality procedure.

6.2 VENDOR

The VENDOR shall provide a copy of his Quality Manual with the bid.

Following contract award the VENDOR shall submit a Quality Plan for the approval. This
plan should include Subcontractor/VENDOR tasks with witness/Hold points identified.

The person responsible for the Quality Assurance aspects of the project must be from the
executive management but independent from the rest of the project team.

The VENDOR shall provide a list of the documents that he requires from the PURCHASER
and from the sub-system VENDORs in order to fulfil his quality assurance obligations.

7. DISTRIBUTED AND INTEGRATED CONTROL SYSTEM

7.1 General Requirements

This specification enumerates design features, construction features, materials of

construction and performance for a system based on true Distributed Control System (DCS).

7.1.1 Compliance List

The intent of this specification is to define the explicit and desirable requirements of
a microprocessor based Distributed Control System (DCS). The system proposed
against this specification shall conform to the requirements described herein and the
bidders shall highlight the system features which fall in the ‘desirable’ category as
well for proper evaluation. Exceptions and/or deviations are to be clarified in detail.
The bidders shall attach a compliance list (see Section 7.16), which indicates one of
the following for each item listed in this Document in a spreadsheet format attached
to this document.

Fully Complied : the bidders fully understand the requirements and comply 100%
with it. Items underlined are considered of high importance and the bidders must
fully comply with them.

Partially Complied : compliance with most of the requirements with minor

deviations which must be indicated in detail.

Deviations : any item that cannot be met shall be described including any
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alternatives that have been proposed to give functions near to the requested
requirements.

Notes : for items where no requirement is given to the bidders, and no comments are
required.

7.1.2 Documentation with Quotation

The VENDOR shall produce a detailed quotation listing item name, model and part
numbers which shall be supported by specification sheets.

The VENDOR shall produce an integrated system architecture sketch showing major
components.

The VENDOR shall provide estimates of all power consumption, heat dissipation
and power distribution plan with capacity information of fusing or circuit breakers.

The VENDOR shall provide an optimum project schedule (see Appendix C) and
clearly define the key milestones on the schedule.

The VENDOR shall propose project organization chart, and describe the function of
each member of the chart.
The VENDOR shall submit catalogues and brochures that provide detailed technical
specifications of the proposed equipment.

The VENDOR shall provide maximum overall dimension of all desks, cabinets,
peripheral devices and furniture indicating all clearance required for access.

7.1.3 Operating Conditions (See Section 5 for additional information)

The system will be installed in air-conditioned environment, however, as a minimum

the following operating conditions shall not degrade the continuous operation of the
system:

Minimum / maximum temperature 5 to 40°C

Minimum / maximum humidity 20 to 90% non-condensing

7.2 Scope of Supply

The VENDOR shall accept full responsibility for all hardware, software and integration of
the system components.

7.2.1 Proposals

The system shall include as minimum the following main components:

Refinery
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y 24 operating stations, configured in redundant form, with equal access capabilities

to any point in the system. Additionally include 7 VDUs (display unit only) at 7
outstations as indicated in Appendix F.
y Dual redundant bulk memory devices (including hard disk controllers and all
associated electronics).
y 5 engineering workstations, with laser printer.
y 1 video display unit in the Fire Station approximately 800m to 1000m away from
CCR. It shall be identical to the fire and gas workstation in CCR.
y 8 serial printers, 6 laser printers.
y 4 Color Laser Jet Printers (Typical HP Color Laser Jet suitable for A3 size
printing), 2 color copiers and 1 scanner.
y Dual redundant real-time LAN.
y Dual redundant control modules as per required system capacity including spare.
y 5 blank operator consoles and 7 blank cabinets for the free issued equipment or
instruments to be supplied by others, however shall be installed by DCS
VENDOR.
All works and materials necessary for the installation of the said equipment and
instruments shall be included in DCS VENDOR’s scope of supply.

Doha Depot

y 4 operating stations, configured in redundant form, with equal access capabilities

to any point in the system.
y Dual redundant bulk memory devices (including hard disk controllers and all
associated electronics).
y Dual redundant real-time LAN.
y Dual redundant control modules as per required system capacity including spare.
y 2 serial printers.
y 1 Engineering workstation with laser printer.

Jetty

y 3 operating stations, configured in redundant form, with equal access capabilities

to any point in the system.
y Dual redundant bulk memory devices (including hard disk controllers and all
associated electronics).
y Dual redundant real-time LAN.
y Dual redundant control modules as per required system capacity including spare.
y 2 serial printers.
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y 1 Engineering workstation with laser printer.

General (All Sites)

y All necessary hardware such as cards, buffer relays, signal conditioning hardware,
mounting accessories, marshalling cabinets, I/S barriers, etc.
y All communication cables such as FIBRE OPTIC cable, SERIAL data
communication cables, COAXIAL cables, etc.
The length of each cables required shall be taken off by VENDOR based on
“Overall Plot Plan”, Drawing No. 7J48N-00-13-22-001 attached hereto.
y Necessary software package for complete system generation, including all control
3 functions, operation functions, graphics reporting, etc. To support all the
functions included in this document.
y All PCs, Printers, and Copiers shall be the latest versions available at the time of
installation.
y Engineering, design and system programming shall be included in the VENDOR
scope of supply and include:

3 - Customized process graphic pages total – 500 pages or more as required.

- Group displays - Quantity of pages shall be determined by total quantity of all
tags in the system and assuming 8 tags per page.
- Complete configuration of all control functions.

7.2.2 System Installation and Mounting

Operator interface:
Operator stations shall be of Console type, ergonomically designed for easy use and
access by plant operators.

Process interface:
VENDOR standard cabinets shall be used for all controllers, nests, I/O cards, I/O
boards and other process interface devices.

7.2.3 Fans

All DCS equipment including operator station, printers, control modules and all
related nests for interfacing with field wiring shall be supplied with fans to circulate
air and reduce the accumulation of dust on the electronic boards and heat dissipated
by the electronic boards. Fan failure alarms, such as controller, I/O and marshalling
cabinets with fans, shall be annunciated on DCS consoles.

7.2.4 AC Power Supply

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Central Control Buildings and SERs

Two diversely routed UPS backed 110vAC supplies will be provided by

PURCHASER to Power Distribution Panel(PDP) to be supplied by VENDOR in the
Central Control Buildings and SERs.
Each DCS module shall be individually fed by separate power cable from the PDP.
The PDP shall cover all items in his scope of supply and all UPS consumers like
field instruments, local control panels, any other auxiliary control equipment in
control room to be supplied by others, etc for the associated plant.

Details shall be referred to Appendix H - System Interface, Associated Units and

Power Consumer list for PDB
The VENDOR shall provide termination facilities, protection, isolation (double pole)
and internal cabinet power supplies for conversion to DCS system operating voltage;
i.e. 24vDC along with distribution such that loss of any one external feed shall not
affect system operation. The maximum fuse rating of each single incoming supply
will be 20A with the VENDOR to seek PURCHASER approval for incomers
requiring capacity in excess of this figure.

Power distribution from the central point, marshalling/auxiliary cabinet, to other

cabinets shall be arranged such that the power feeding each cabinet may be isolated
enabling maintenance work on individual cabinets to be carried out. Fusing to each
individual cabinet shall be provided as well as for main incomers to system as a
whole.

UPS Detail

The supply shall be available for two hours following failure/isolation of the main
power supply and emergency generator.

The DCS hardware shall be housed in a cabinet adjacent to the auxiliary cabinet and
24vDC power shall be taken from the auxiliary cabinet.

All power supplies to the DCS system and all subsequent distribution within the
system (by VENDOR) shall be fully floating and isolated from ground.

The VENDOR is to confirm the power requirements(W) for in-the (with duration)
and normal operation for each equipment component.

The VENDOR shall co-ordinate with the PURCHASER to ensure that discrimination
can be achieved with the supply. The VENDOR shall provide time/current co-
ordination curves showing that faults on the downstream circuits will not affect
upstream protective devices.

Power Loss

The equipment shall be so designed that no damage shall be caused by a burn-out or

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loss of power.

7.3 Architecture

The system shall provide the capability to perform operation, monitoring and control of the
plant from a Central Control Room (CCR). It shall be microprocessor and computer based
system with components physically and functionally distributed at various plant locations.

7.3.1 System General

The DCS described in this specification shall by manufactured using the state-of-the-
art microprocessor’s equipment suiting the needs of process control application. All
the plant operation will be done through operator work stations housing CRT screens,
keyboards and pointing devices.

The DCS system shall include completed, tested and operational programs that are
fully documented and described clearly.

7.3.2 Hardware General

The VENDOR proposal shall include all hardware required to interface the process
with the DCS. The process interface shall be supplied with the necessary termination,
safety features, interconnecting cables, signal conditioning units and input/output
modules (I/O cards).

All field connections are via marshalling cabinets as shown in Appendix P.

Marshalling cabinets and connection cables (cord sets) between the marshalling
cabinets and the Field Control Station are part of the DCS scope of supply, including
any I/S barriers as required.

Each I/O module shall consist of electronics such as processor and memory which
are housed in a nest, sufficient to perform I/O manipulation and control function
listed in this specification. Each I/O module shall have redundant power supply.

Most inputs shall be intrinsically safe. Some inputs are Exd (non-IS). IS barriers shall
be the galvanically isolated type, single channel and associated circuits shall be left
floating or earthed at any one point. Status LED’s facilities shall be provided and all
module shall have single power supply and redundancy power. Inputs from other
systems and CCR shall be non-IS however. These will be detailed during the
detailed engineering phase. Field transmitters shall be of the “smart” type, used in
digital mode however.

Cabinets shall be designed as cabinets with base framework and plinth or with legs
and shall have a minimum of four bolt down points. On all panels lifting eyes are
required on top, each one strong enough to support the fully equipped panel during
handling, shipping or placing operations.
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Consideration shall be given to safety barrier location, the preferred arrangement

shall be to locate them within dedicated marshalling cabinet/auxiliary cabinet(s).

Bottom entry signal/control action cabling is the preferred arrangement for all DCS
cabinets with top entry for power cables. Final entry location shall be specified
during detailed design by PURCHASER.

A minimum of 20% spare space shall be provided in each cabinet to allow for
undefined future expansion. A predetermined percentage of the spare space shall be
racked out and fitted with cards. 20% installed spare shall be fully populated with
hardware, wired and configured as a hot spare.

The VENDOR shall install all instruments, display units, switches, electrical terminal
boards, wiring system supports and auxiliary fittings, suitably mounted and
supported, ensuring good accessibility of all items.

Instruments on the panel front which require adjustment or which have dials that
must be easily inspected, shall be fitted between a height of 1m and 2m with no part
lower or higher.

The panels may have top or bottom entry. The VENDOR shall group the connection
to the panel, into electric power, electric control wiring and intrinsically safe
connections.

Cabinets shall be constructed from a suitably stiffened mild steel framework with
following thickness:

Doors 1mm
Remainder 3mm
Load bearing sections of cabinet framework 3mm

Design and quality shall be such that it can withstand normal handling during
transport and permit lifting by removable lifting lugs (eye bolts).

Cabinets shall be supplied mounted on a 100mm steel channel plinth.

Overall dimensions of the cabinet including plinth shall be as follows:

Width of the cabinet To suit application

Height of the cabinet 2100mm
Depth of the cabinet To suit application

Single doors shall be no wider then 800mm, multiple doors shall be no wider than
600mm. The latter shall have divider pairs. 3 point latches of heavy duty design
shall be used. Hinges shall be lift-off types. Lift-off panels with latches all round
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will be required where space is limited.

The entire panel shall be provided with anti-vibration mountings at all attachment
points to floor or wall.

Convenient access to all auxiliaries, such as terminal points, relays, modules, etc.,
mounted in cabinets and enclosures shall be maintained. Access to all equipment
within a cabinet or rack shall not be via adjacent units.

All cabinets and enclosures must be designed to provide adequate heat dissipation. If
forced ventilation is required, back-up fans and air filters must be provided by the
VENDOR. Intake must be through the lower section and exhaust through the upper
section. Fan failure detection shall be provided and annunciated on the DCS console.

Engraved nameplates shall be provided for the identification of each cabinet at the
front and the rear.

A nameplate schedule shall be provided by VENDOR for approval by PURCHASER

prior to manufacture.

Finishing;

Panels and cabinets shall be painted in accordance with VENDOR’s standard

painting system.

Cabinets exterior shall be painted Rittal beige (RAL 7032). PURCHASER shall
verify during detailed design. Interior shall be semi-gloss white and base (plinth)
shall be black.

Electrical Standards;

Electrical fittings, components and wiring shall comply with the requirements of the
approving authority. To meet the above, the design and installation shall also
conform to the requirements of the latest edition of the following standards and
codes:

y IEE Regulations
y British Standards

For the Mesaieed Refinery the cabinet internal layout shall reflect the modular nature
of the facility. The individual process unit shall each have dedicated rack(s).
Rack(s) associated with a particular process unit shall be fused by one common fuse
covering the hardware associated with the particular process unit. Each rack forming
a part of the process unit concerned shall be further sub-fused. The fusing shall be
designed such that individual process units may easily be isolated for maintenance
purposes, even though the remainder of the system is live. Where a particular
process unit is too small to justify a dedicated rack it may be combined with another
process unit of similar size. This, however, must be brought to the attention of the
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PURCHASER/COMPANY for approval. Where possible the two process units shall
be electrically isolated within the same rack.

Internal Wiring;

y All wiring shall be neat and tidy, run in plastic channel/trunking.

y All wiring shall be numbered and labeled. Standard wire numbers shall be used
throughout the cabinet and shall be subject to PURCHASER approval.
Numbering shall be in an alpha-numerical sequence.
y Trunking shall be sized so that the total cross-sectional area of the wire and
insulation to the available terminal space shall not exceed sixty percent (60%) of
the cross-sectional area of the wireway. This shall also apply to trunking which
houses field cable to terminal blocks.
y Wiring shall conform to requirement of BS 6883, with maximum HCL emission
of 17% and low smoke during fire.
y Panel wiring 0.75mm2 minimum section shall be used for loads below 6A,
1.5mm2 up to 10A, 2.5mm2 above 10A. (Maximum loading shall be as specified
under statutory regulations.) All wire shall be insulated to 250V specifications.
y All wiring between system cabinets and peripherals shall be with system cables.
3 System cabling shall include for 20% spare capacity post commissioning.
y Multiway plugs and sockets shall be used to terminate the cables and shall be
complete with screw locking to prevent accidental disconnection.
y The printed circuit boards used in the system must have the following minimum
characteristics – restraint by a locking bar or other suitable means to positively
ensure that normal plant vibration bill not cause the boards to become loose.
y To be provided with full length card guides in their respective card cages to
space and restrain the boards properly.
y All cards shall be polarized to prevent insertion in an incorrect location.
y All I/O cards, control & communication cards shall be capable of being inserted
or removed with power applied.
y Contact surfaces on printed circuit boards and their respective receptacles shall
be gold plated.

Each termination shall hold only one wire. Correct ferrules or jumper straps
especially designed for the block must be used if more than one wire requires
connection to a common point. Bomb tail connections shall never be used. Wires
shall be made off with a crimped pin, connection spade or eye as required.

AC voltage trunking, cabling and terminations shall be clearly identified as such with
appropriate labels.
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VENDOR’s standard internal wiring conductor identification method shall be

submitted for PURCHASER’s approval.

Plastic warning shields shall be placed over Printed Circuit Board (PCB) card edges
on outputs. High level voltage signals (>24v) wiring shall be segregated from low
level voltage signals.

The VENDOR shall supply all sundries and install and wire all electric,
instrumentation and accessories. The instrument panel shall be complete and ready
for site connections to power inputs, ground and in/out going field connections.

All instruments incorporating switch contacts, all manual switches, automatic

switches and fuses shall be sealed for full protection against corrosion.

The VENDOR shall install means of isolating power supplies to instruments where
such provision has not been made in the instrument design. Non-operating
instrument or equipment switches shall be placed within the panel enclosure.

Identification sleeves shall be fitted to each end of wiring runs, and shall be inscribed
with instrument tag number and terminal number.

No splices or connectors will be permitted in a cable or wire run. All terminations

shall be crimped pin type. Any other type must be approved by the PURCHASER.

A copper grounding bar 25mm x 6mm shall be provided for the AC systems, made
continuous when all panel parts are in place. A similar separate grounding bar
arrangement is required for DC and for signal circuits; this bar shall be electrically
isolated from panel metalwork. End connectors for on-site ground connection to be
provided by VENDOR, dimensioned to take 35mm2 bare stranded copper cable
through a solderless connection.

All instrumentation specified to be grounded in the hook-up drawings shall be

connected to the grounding bar by direct wiring from the instrument terminal.

Intrinsically safe circuits (wiring, terminals, zener barriers (if any), grounding and
power supply units) shall be grounded together on a separate insulated earth bar.

Power supplies to panels will be 110V AC, 50 Hz. The VENDOR shall provide shut
off switches for each panel section with a miniature circuit breaker for each
instrument.

Multi-cable wiring between panels and cabinets shall conform to BS 5308 Part 1
Type 1 and flame retardant to IEC 332 Part 3 or equal, and internal wiring of panels
and cabinets shall be VENDOR’s standard compatible with system characteristics.

The design shall ensure, for all terminations, that:

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y There is sufficient spacing between trunking and determinations so that any core
can be installed and removed without undue effort and that the core ferruling is
clearly identifiable.
y Ferruling is the correct way up to cores entering from the right or left.
y Field cables arriving at the equipment cubicles are terminated a cleanly as
possible; i.e. successive terminals for cores where possible.
y Analogue and digital loops are segregated and identified.
y Each terminal at the equipment rack end shall have label identification of the tag
number.

Field Cable;

PURCHASER will provide information during Detail Design identifying signal

allocation, etc.

Cable Entry

All equipment shall be mounted on elevated floors. Field cable entry shall be from
bottom of the panels with inter-system cables provided to/from top of the panels.
Cables shall be glanded onto a gland plate to prevent the escape of any extinguishant
from under the floor void

Marshalling Cabinet Design;

The Marshalling Cabinet Design shall contain a number of pairs of rows of terminals.
Signals from the hazardous area shall be terminated at the row of field terminals.
The system cable from the DCS system will be terminated at the second row of
terminals. Marshalling shall be achieved between the two rows of terminals. The
layout of the marshalling cabinets shall be in accordance with drawing
180126/00/20/41/02 and 03 (or PURCHASER approved equivalent).

All incoming and outgoing signal wires / cables shall be terminated on rail mounted
Klippon SAKT (disconnect type) terminals. 20% spare capacity shall be provided.

These will enable loops to be tested without removing incoming or outgoing cables.
Terminals for field cable inputs, shall be labeled with the instrument tag number
input.

Cable gland plates and clamps shall be supplied for the support of field and
interconnecting cables. 50% spare spaces are required for all entries. Similar spare
capacity shall be provided in the cable trunking.

All field connecting terminals shall be suitable for up to 2.5mm2 copper cables.

Identification of Control Panels

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The identification of panels shall be as follows;

1st Following
2nd letter
letter number
P D Distributed controls system (DCS) 01 to n
E Emergency/process shutdown system (ESD/PSD)

K Fire/gas detection system

Example:

For DCS operator console, PD.01 to n.

Identification of Marshalling and System Cabinets

1st 2nd 3rd Following

letter letter(only for Marshalling cabinets) letter number
A E ESD/PSD D Distributed controls system (DCS) 01 to 49 for control
room (CCR)
F 110VAC supply E Emergency/process shutdown
system (ESD/PSD)
G Electricity/instrumentation int. K Fire/gas detection system 51 to 99 for field
cabinet
K Fire/gas detection U Composite
M Measurement/analogue control (4- Y Aux. cabinets
20mA)
Z Solenoid valves
T Digital 24VDC
Y Miscellaneous

Note: For system cabinets only the 1st and 3rd letters shall be used.

7.3.3 Overall Configuration

The system architecture shall provide the necessary hardware and software to satisfy
the needs of the following four major functions:
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Human Machine Interface (HMI) : operator stations for the HMI shall be CRT
based single window platform capable of displaying DCS information and other sub-
systems connected to the DCS.

Process Interface : interface to the process shall be through distributed

microprocessor based controllers (control modules). Each controller shall be a stand-
alone unit capable of performing full data acquisition and control of the process via
I/O interface hardware.

Engineering Workstation (EWS) : the EWS shall be a high performance

workstation capable of engineering and configuring any DCS device linked on the
network.

Communication Network : a high speed network connecting all the above systems
to perform real-time information transfer between the various DCS components.

Interface with Sub-systems : third party dedicated sub-systems and computers shall
be linked to the DCS via gateways, routers and interface ports.

Peripherals and Servers : the system shall include all necessary modules for bulk
memory and removable storage media as well as printers and copiers where
necessary.

Radio Link : two of the outstations (remote facilities) are located as follows:

y Doha Depot some 45 kilometers away.

y Jetty some 6 kilometers away.

These shall be linked via a radio system. The VENDOR shall include this in the
proposal. Brief requirement is as follows:

Radio link shall be able to operate at two different frequencies as a minimum if one
frequency system fails. The system shall be dual redundant. The authorized
frequencies will be decided during the order placement stage. The VENDOR shall
include details of similar system installed. The system shall have its own battery
back-up power supplies as standard (1-hour back-up to be confirmed at order
placement stage).

7.3.4 Communication and Loading Requirements

Modules of the DCS shall be linked via real-time dual redundant communication
system (real-time LAN), which must be based on industrial grade digital
communication link, utilizing a co-axial cable providing a high speed data transfer
between all modules connected to the communication network. The line access
control shall be deterministic and utilize decentralized protocol.
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The real-time communication network is considered the backbone of the system and
only extremely high reliability and quality network architecture shall be used.

Capacity : the real-time LAN shall be capable of accommodating a large number of

devices and be able to provide extended communication up to 3 kilometers minimum.

Speed : communication speed shall be at least 10M bits per second.

Signal modulation shall be utilized on the co-axial communication cable, with

transformer isolated couplers on each node on the communication network.

All nodes on the communication network shall read/write data to each other at a
speed of at least 200 times per second.

Each node on the network shall be notified of the status of all nodes for any trouble
or failure.

Process data accessed by the HMI displays shall be continuous and in real-time.

Both communication lines in a dual redundant network shall be continuously

diagnosed and checked for errors at least 200 times per second.

Network load shall not exceed 50%. This load shall be calculated base on the
following system usage:

y No alarm status.
y While standard operation displays shown on the operator workstations or during
calling up those displays.
y Simultaneous calling of historical events or trend displays.
y APC and POIS usage.

Communication protocol shall be of deterministic type to enable proper estimation of

the network load.

The VENDOR shall state the maximum CPU (Control Processor) loading and how
this was arrived at. This shall include for spare capacity as well.

The network shall have the added facility to interface with extended nodes via radio
links as follows:

y A node approximately 6 kilometers to Berth No.6 (Jetty)

y A node approximately 45 kilometers to 50 kilometers at Doha Deport.

The radio links, interfaces and any repeaters required are also part of the VENDOR’s
responsibility.
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Devices or bridges shall be available from the VENDOR to isolate two real-time
LANs from each other to reduce network load and allow certain data transfer
between nodes of both networks. The devices shall be of high throughput and allow
process data transfer rate of more than 1,000 data per second.

The network shall have the capability to cover wide areas (WAN) with the use of
commercially available telephone lines and other high speed WAN networks such as
FDDI (Fiber Distributed Data Interface).

Nodes and Hang-on Devices : as a minimum the number of nodes that the system
can support on the real-time LAN shall be 32 nodes without requiring an additional
network. A dual redundant module shall be considered as one node on the network.

The failure of any hang-on device / node shall not affect the highway communication
or the performance of other hang-on devices.

Adding or removing nodes shall not cause disturbance or shutdown whatsoever.

7.3.5 System Configuration

The VENDOR shall provide with the proposal a detailed configuration diagram with
associated outline diagrams of the recommended system depicting all
interconnections.

7.3.6 Sizing and Capacity

System shall be sized according to the given basic I/O list. See Appendix G – I/O
Schedule.

The following table shows the required installed spares and expansion capability of
proposed system:

Item Additional Installed spare Additional Spare Capacity

I/O power 20% 20%
I/O cards 20%, but not less than one 20%
card of each type
I/O rack, nests 20% 20%
Nodes of communication As required 30% space to install any node
network
Sub-system communication 2 ports 4 ports
ports

7.3.7 Database Configuration

The DCS shall utilize distributed real-time database (non-centralized).

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Process I/O referencing is done by the term “tag number” identification. Any control
algorithm or computation can be performed using tags. The definition of the tag
shall be applicable to continuous control, calculation blocks, and to discrete points
such as digital input, digital output, timers, counters, etc.

The system database shall have the capability to be configured in accordance with
the actual plant hierarchical organization. As a minimum the system shall support
five levels of hierarchy. Operator stations shall be grouped to support certain groups
in the plant organization. Typical top-down plant hierarchy will have the following
architecture:

REFINERY : at the tope of the organization

OUTSTATION OR AREA : refinery may be sectioned into several OUTSTATIONS
OR AREAS.
UNIT : each OUTSTATION OR AREA may be sectioned into one or more UNITS.
TRAIN : a UNIT may be sectioned into one or more TRAINS.
EQUIPMENT : a TRAIN may be sectioned into one or more EQUIPMENT.

The system shall provide a method to let an operator set a pseudo measurement for
the other control schemes, when the field devices are out of service for repair or are
being calibrated.

7.4 Human Machine Interface (HMI)

7.4.1 General

Operator interface shall be provided by operator stations and peripherals, which shall
permit the operator to control and monitor the plant.

7.4.2 Point Identification

Each point shall be designated by an identification tag number of minimum 16

characters. There shall be no restriction to the use of letters or numbers in any of the
16 positions.

The system shall allow same tag number exist in the database for different plants
controlled by the same system.

Point identification shall support identification by the plant name as well. At least
eight digits shall be available to support plant names.

Each tag shall have a short description (service name) of a minimum of 24 characters.
There shall be no restriction to the use of letters or numbers.

Each tag shall have engineering units which shall have a minimum of six characters.
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There shall be a minimum of 100 preconfigured internationally used engineering

units. Empty space shall be available for the user defined units.

Some of discrete points such as digital input/output, logic point and so forth which
are not monitored or controlled by operators must have assignable tag identification
as well.

7.4.3 Operator Stations

There shall be operator stations in the Control Room, each with global access
capability to any point in the plant. The operators shall use those stations for all
process sections monitoring and control.

The operator stations shall be able to supervise the data of regulatory control,
sequence functions, batch control and Advanced Process control (APC)

Each operator station shall include:

One CRT screen and one dedicated operator keyboard and as shown in the system
configuration attached to this document.

Every operator station must have the same capabilities and database. Every operator
station shall have its own processor (CPU). Hence, if one fails, another station shall
take over the function of the failed one and the operation shall be maintained without
any disturbance.

No more than two operator stations are allowed to share one processor and other
electronics. In such case dual redundant processor and electronics must be used.

Each station must be able to display all assigned tags in the plant as well as all the
tags to be assigned after future expansion. One station shall be able to handle at least
50,000 tag numbers.

7.4.4 Keyboards

Operator Keyboards

The keyboard shall be flat membrane type, dust and spill proof. Each keyboard entry
shall be registered with an audio beep. The operator keyboard shall have the
dedicated keys to perform the functions listed below as a minimum:

y Auto / manual / cascade keys

y Set point or output ramp up / down (two speeds) and changing digital status keys.
y Alarm acknowledgement key and alarm silencing key.
y Dedicated display keys for – graphics, group display, detailed display, overview,
trends, alarm overview, messages, HELP key.
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y Dedicated keys for – engineering, system diagnostics and historical files access.
y Screen hard copy print.
y Tag number and data entry keys (alphanumeric keys).
y System status access key.
y System menu access key.

In addition to the above dedicated keys, an extra 80 assignable keys as minimum

shall be available. Each key shall be provided with lamp or LED to indicate an alarm
situation which requires the operator to push that key to access the relevant page to
the alarm. The operator shall have access to assign displays to those keys.

Engineering Keyboards

Engineering Keyboards, where provided, shall be standard QWERTY type having

108 keys.

7.4.5 Video Displays

Each Video Display Unit (VDU or CRT) shall have a minimum resolution of 1280 x
1024 pixels.

CRT size shall be 21” minimum.

Refresh time of real-time data on a standard operation display shall be one second.

Call up time to bring full display with all information of a standard operation display
shall take no more than one second.

7.4.6 Standard Operation Displays

The operator station shall be able to perform the functions of the following listed
displays as a minimum in the system.

Overview Display

The following shall be standard of this display:

y An overview display shall enable the operator to determine the overall operation
of a large segment of the plant.
y The alarm condition of the pre-assigned points and groups shall be displayed in
the overview display with color change and blinking.
y The number of points which can be displayed in one screen (i.e. one page) shall
be more than 200 when configured.
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y The operator must be able to call up directly any group display or other
predetermined displays covered by overview screen.
y Each operator station shall have capacity to display minimum 1500 points in
overview display pages. Those displays can have different assignments among
different operator stations.

Group Display

The following shall be standard of this display:

y A group display shall show a limited number of tags; i.e. analogue / digital inputs
/ outputs, controllers, trend graph, etc.
y Each tag shall be displayed as a faceplate with graphical as well as numerical
presentation of variables like the measured process variable, set point and
controller output. Faceplate shall have scale in engineering unit and appropriate
divisions. High/Low limits of output and alarm limits for process variables shall
be also displayed.
y For discrete elements such as timers, switches, digital I/O, etc., a faceplate shall
be available as standard for each type.
y Each faceplate shall be accompanied with numeric and text description of – tag
number, tag service comment, alarm status, controller mode, engineering units,
and digital values for process variable, set point and output are also to be
displayed.
y The alarm condition of each point shall be displayed in the group display with
color change and blinking. Alarm acknowledge shall be possible.
y The number of points displayed in one screen shall be eight (maximum).
y It shall be possible to call up any individual point display swiftly with one
operator action from tags shown on the group display.
y Any tag may be displayed in several pages of the group displays according to the
operator or system engineer assignment.
y On operator station shall be able to display at least 5000 points in group displays.

Individual Point Display

The following shall be standard of this display:

y An individual display for all tags configured in the system shall be available and
show all relevant information. This information shall include tuning and
operational parameters, along with the faceplate and information as in the group
display.
y The operator shall be able to change parameters from this display, with the
security clearance.
y The alarm condition of the point shall be displayed in the display with color
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change and blinking. Alarm acknowledgement shall be possible.

y The individual point display shall include a small size of real-time trend display to
facilitate easy tuning of control loops.
y The small trend display shall have a rotary buffer of 240 samples, with data
sampling period of 1 to 10 seconds.

Graphic Trend Display

The following shall be standard of this display:

y Graphical trend display shall present data in the form of a strip chart.
y A minimum of three and a maximum of eight variables are to be displayed in one
screen, and are to be identifiable by different colors.
y Trend display shall allow for marking pens on the display to enable black and
white hard copy of the display.
y Following two types of trends shall be available in the system:

- Rotary buffer trend – this is continuous trend with new data overlapping old
data when the buffer is full.
- Scheduled trend – with starting time and end time of the trend recording. Such
trends shall start / stop on operator demand or triggered by sequence program.
y Operator shall have the ability to input a background trend pattern form reference
on schedule trends, as well as the ability to compare two trends gathered at
different time for the same point.
y Trend display shall support:

- scale magnification by up to 10 times

- time axis variation
- biasing
- switching any pen on / off.

y It shall be possible for the operator to use a hair cursor to read the old value
exactly in the trend screen (with indication of a value, date and time). Screen
scrolling function shall be available to verify the old data.
y Trends shall be snapshots of process data. Accuracy of trended process value
shall be exactly the same as the actual process value being measured at the time of
the snapshot.
y Side information on the trend display shall show the following information for
each trend channel:
- Tag number and service comment.
- Process value.
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- Scale of trended value.

y Operator shall be able to select any point on the trend display to be individually
displayed in detail.
y The trend display will have the capability to call up the faceplate for any point
being trended and manipulate the faceplate from the operator keyboard while
trend group is displayed.

Custom Graphic Display

The following shall be standard of this display:

y A custom graphic display shall have the ability to present process and control
schematics, alphanumeric text, real-time data and faceplates together in one page.
y More than 200 live data shall be displayed on a graphic page, updated
continuously within one second.
y The proposed system shall have a capacity for building and showing at least 600
graphic pages accessible by any operator station. The call up time for any of
those graphics shall be within one second.
y The layout of each screen can be designed by the engineering using user-friendly
interactive software. A library of ISA symbols shall be available to reduce the
time for graphic generation.
y A capability to show process data dynamically in any of the following graphical
forms:
- Bar graph of any width and height.
- Radar chart.
- x-y graph.
- Polyline graph.
- Variable area circles.
y The operator shall be able to operate the control strategies; i.e. change set points,
control modes, outputs and so forth, from graphic displays.
y The operator shall be able to call up any operation displays from graphic display.
y Text for graphics shall have size as small as 12 x 24 dots.
y The color scheme for various process lines, utility lines, valves and equipment
color modifiers, etc. shall be defined at detail design stage.

Alarm Display

y Alarm display shall show all existing process alarms with blinking and color
modification. Each alarm shall have time stamp of month, day, hour, minute and
second. Each alarm shall consist of time stamp, point identification (tag number),
point description and the kind of alarm. Current value of the process variables
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(input) in alarm shall be displayed.

y It shall be possible to call up the group display, in which the alarm point is
included, directly from alarm display. Alarm acknowledgement shall be possible.
y It shall indicate 15 to 25 alarms in one page. One operator console shall have the
ability to preserve a minimum of 100 occurring alarms in this display. The
display will allow the operator to change to related operation display when
pointing to any alarm.
y This display shall not include system self-diagnostic alarms. Self-diagnostic
alarms shall be displayed in a different dedicated display.

Operation Instruction Display

y Operation instruction display shall send messages / instructions to the operator

regarding the plant operation.
y It shall display a minimum 10 messages per screen page, preserve a minimum of
20 occurring messages.
y Above messages are sent from the request of the sequencing control function.
y The operator shall be able to know the occurrence of those messages by sound.
y One message shall consist of a minimum of 50 characters.
y Messages acknowledge shall be possible.
y The operator shall be able to call up another predetermined display corresponding
to each message directly from operation instruction display by a key stroke.

Other Display

y The screen shall have dedicated area which is independent from the main display
and it enables the operator to make data entry by using alphanumerical keys. Any
point in the console shall be able to be called by specifying the point identification
and the data entry will become possible. This function shall be available
regardless of the current operation display on the screen.
y Other displays shall also be provided for displaying historical events and self-
diagnostics with menus for data retrieving and filtering.

Windowing

The operating system of the operator station shall be field proven with at lest five
years of life. The operating system will be open, supporting migration to multi-
hardware platforms, and can display multi-window to the operator.

y The system shall have the capability to shrink standard operation displays to be
shown in full as a small window.
y Windowed operation displays shall have the same capabilities performed by the
standard full page display, including pointing to assigned targets.
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y Operator will be free to move windows any where on the display, overlap
windows and bring them forward/backward.
y Multi-media functions shall be supported by the system. Any industrial close
circuit camera interface and software to display and control the camera shall be
available as an off the shelf package. This function is not included in the scope of
supply, but should be available as an option. Price for this should be shown under
options available.
y The operator station shall have the capability to act as x-terminal to display
images from other multi-user computers connected to the operator stations via
information LAN.

7.4.7 Printers and Peripheral

Serial Printer Specifications

The printer shall have at least following specifications to secure quick and clear
print-outs:

Average speed 128 characters/sec. to 400 cps selectable

Print quality Letter quality/draft – selectable
Character/line 136 to 180 to 240 selectable
Paper width 4 to 16 inches (A4 to spreadsheet)
Paper feed Automatic and manual, for paper with hole or without hole
(friction feed)
Memory Maximum available
Provided cable 50m interface cable (maximum)

Color Copier Specifications

Display lock-up time Less than one second

Printing speed 1 page in less than 2 min.
Resolution 300 dots/inch
Copy area Larger than 200mm x 240mm
Paper feed Automatic
Memory Maximum available

Laser Printer Specification

The system shall support connection to laser printers for report printing and
documentation of system engineering database. Include for 6 laser printers.

Specification – HP LaserJet 5 Si/mx or equal:

Printing speed 24 ppm
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Resolution 600 x 600 dpi

Interface Parallel
Memory 12MB
Paper handling A3 / A4(1100 sheet input)
Paper feed Automatic

Operators shall be able to share any printer or color copier within the same control
room, via networked printer server functions without the need to install hardware
selector switches for the printers. All interface cables to have 50m length.

7.5 Process Interface

7.5.1 General

This section defines functional requirements of control capability such as algorithms,

loading requirements and guidelines on architecture. The VENDOR shall quote the
system that best fits the specifications.

In the front level, considerable control capability shall be made available for
regulatory control through preprogrammed algorithms and easy fill in the blank type
entry forms which is understandable by instrument engineers without the ability of
programming experience.

Typical control module capacity shall allow for implementing average of the
following function simultaneously within one second:

y PID control – 15 blocks.

y Analogue input monitoring blocks – 200 blocks
y Calculation blocks – 100 blocks
y Sequence control functions – 2000 conditions and 2000 actions.

Processing time should be consistent with table in clause 7.5.7.

Function associated with controllers (signal selectors, summers, calculation blocks,
etc.) shall have the same execution rate as the fastest controller.

7.5.2 Hardware and Architecture

Control modules shall incorporate latest 32 bit microprocessor technology preferably

with high computing power such as Pentium or RISC technology.

Control modules shall be supplied with high speed main memory of not less than
8MB to satisfy the high capacity requirements.

Interfaced with field I/O shall allow for remote location of I/O cards from the main
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control module.

Remotely located I/O cards in the same room with control modules, shall be
interfaced via copper cables. Fiber optic cables shall be considered when I/O cards
are mounted in other buildings far from the control module. See below.

The system shall allow installing the I/O cards at a distance from the control modules
not less than 1500 to 3000 meters without using any intermediate repeaters. Cables
shall be copper in this case. VENDOR shall state whether fiber optic cables are
required or not.

Communication between the I/O cards and the control module shall be via well
secured communication link with high capacity of data transfer and speed not less
than 375 Kbaud

I/O cards used for control loops shall scan the input signals at 100msec rate or better,
without affecting the signal quality or resolution. VENDOR shall specify the I/O
card scan rate.

I/O cards for digital signals shall scan the field devices at 50msec rate or better.
VENDOR shall specify the I/O card scan rate.

I/O cards used for accessing bulk I/Os for monitoring purposes may have slower scan
rates.

All control modules and I/O cards shall be housed in suitable cabinets with front and
rear access. Cabinet environment shall be maintained with the following:

y Dual redundant fans to provide good air circulation inside the cabinet.
y Fans shall automatically increase the speed of rotation when cabinet internal
temperature is higher than normal or when one of the fans fails.
y Temperature conditions inside the cabinet shall be continuously checked by a
built-in temperature sensor.
y Cabinet fans and temperature status shall be checked continuously by the system
self-diagnostics and shown on the operator’s system maintenance panel.

7.5.3 Continuous Control

Regulatory control functions shall be represented by software block objects. As a

minimum the following type of blocks shall be available:

y Standard regulatory control functions:

- Process value monitoring

- PID control – dead band, On/Off, time proportioning
- Ratio setting
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- Automatic signal selectors

- Program set function (generate function of time)
- Computing functions – mass flow computation (temperature pressure
compensation), lead/lag, first order, rate limit, dead-time, moving/cumulative
average, line segment function for non-linear signal, square root extraction,
mathematics functions, exponential function, logarithmic function, SIN/COS
function, signal selection, etc.

y Batch loader block shall be available. The function of this block is used for jobs
such as charging reactors from storage tanks. The block shall be supplied with
totalizer function and shall be able to compare the totalizer with the batch settings
so that output is controlled automatically to obtain the desired batch. The block
shall include alarming for start of loading, end of loading and pre-end of loading.
Other functions shall include emergency halt, auto restart and manual operation.
y The functions mentioned above shall be standard and do not require customization
of sequencing functions to achieve those functions, the VENDOR shall give
details of availability and functions of batch loader instrument.
y Data acquisition blocks (data buffers) to read and write data from different
analogue instruments. Data of this block shall be accessed from the graphic
displays when assigned. Operator shall be able to enter data into those blocks
from standard operation displays.
y The tags in the regulatory control shall be able to access values from and send
values to other points in the regulatory controls within the same controller module
or other modules on the network.

All regulatory control and batch related blocks shall be provided with built-in:

y alarm detection capabilities, for detecting four levels of high/low alarms,

deviation alarms from set points, process value rate of change alarm (velocity)
y process value conditioning – square rooting, filter, pulse input conversion input
totalizer

Without custom configuration the PID control algorithm will have integral wind-up
protection and bumpless initialization. Transitions between any levels of a cascade
hierarchy shall be bumpless.

Without custom configuration the basic PID control algorithm shall be based on
velocity calculation type and the tracking of cascades loops shall be made
automatically so that the bumpless operation can be achieved at any instant of time
without preparing the configuration for signal tracking. When a controller in the
cascade hierarchy is turned to cascade open or to manual mode, the upper level
controller (primary controllers) shall sense the mode change of the controller and the
output signals of the upper level controllers shall track the set point of each controller
at the next lower level automatically.
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All analogue outputs shall be capable of providing:

y output limiter based on velocity or H/L settings

y setting of preset outputs – scale High, Low and preset value, this setting shall be
accessed by sequence functions
y tight shut shall be possible by having output value range exceed –25% ~ +25%
settings if required.

Dedicated software blocks shall be available for control of electrical motors,

actuators and pumps. The block shall be used to perform CRT based operation to
start-up or shutdown motors, giving the operator one faceplate to interface to the
motor. The block shall have the capability to:

y receive inputs from thermal trips, analogue inputs representing motor load or
temperature, feed back from limit switches
y output shall be pulsive or status type digital output supporting 1, 2 or 3 contacts
y manual mode shall allow the operator to manipulate the output to the electrical
device by allowing it to operate or stop for seconds (inching)
y faceplate shall show switches to start / stop the motor, bar graph indication of
motor load or temperature, motor status and alarm indication
y perform answer back check and generate an alarm when this is due to invalid
answer back signals
y interact with sequencing function to perform motor interlocking.

7.5.4 Discrete Point Control

Discrete tag number control functions are required at the regulatory level for
handling discrete points such as digital input, digital output, timer, logic gate, etc.
The system offered shall be able to perform, as a minimum, the following functions
in the regulatory control level:

y Boolean logic based on discrete variables, control modes (CAS / AUTO / MAN)
and alarm status of continuous control points with a digital output to another
continuous or discrete algorithm or to the field.
y There shall be free transfer of data between continuous control function and logic
or discrete control function, by calling regulatory controllers by tag name and data
type of that tag.
y The following discrete control functions shall be possible:

- Mode change of continuous control points (CAS / AUTO / MAN).

- Logic function using the loop status or alarm status of continuous control
points.
- Control of on-scan and off-scan of continuous control tags.
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- Parameter change of continuous control points by the calculation block which

can be triggered by the logic function. (PID parameters, alarm setting, set
point, output, bias / ratio, lead time, lag time, dead time, etc.)
- Trigger logic function based on comparison results of two parameters in
continuous control tags.
- Sequence functions shall have the ability to trigger calculation functions
similar to that of continuous control instruments.
- The system engineering environment shall give options to the user to configure
sequence functions using decision tables, CAD based logic diagrams and high
level programming language.

y Flags shall be available to be used as triggered by sequence functions or

manipulated by the operator manually.
y Switch blocks shall be available with the capability to support the control and
operation of on/off valves and other devices. Such switches shall be supplied with
various options of faceplates showing device state and feedback from limit
switches connected to the field devices. The switch shall initiate alarm to the
operator when feedback time out is detected. Time out shall have a range of 0 to
1000 seconds with 1 second resolution, without configuring external timers to
support this function.

7.5.5 Calculation Functions

Calculations shall be provided in the form of blocks, supporting regulatory and

sequence control functions as well as providing general purpose calculation functions.
Following are the minimum requirements of the calculation functions:

y Data shall be floating point type, expressed in engineering units, and integer data,
with the ability to handle data of 64 bit numerical figures.
y Allow for logical and Boolean operations.
y Support string data handling.
y Preconfiguration functions shall be available as stand-alone blocks. At least the
following blocks shall be available:
- Square root block.
- Exponential block.
- Lead, lag, lead / lag, dead time and delay blocks.
- Integration and derivative blocks.
- Moving average block.
- Steam, gas and liquid compensations with built-in ASTM correction data.
- Mathematical functions.
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- Configurable line segment pattern to relate input to output. Pattern block shall
be of static type (fixed at engineering stage) and dynamic type (vary according
to other inputs).

y A general purpose calculation block shall support linking to at least five inputs
and three outputs to other regulatory control blocks or field devices, and allow for
implementing several program steps to achieve complex calculations combined
with logical decisions within the same block.

7.5.6 Faceplates

Each function blocks whether regulatory control, sequencing of calculation type have
as a standard its own preconfigured faceplate. Additionally the system shall allow to
combine several blocks or parameters to configure a user selectable faceplate that
will give the operator one interface to a process unit such as reactor, heat exchanger,
distillation unit, heaters, compressors, etc.

7.5.7 Processing Period

The controller shall have the capability to process the I/O point in accordance to the
following scan rates:

Processing
Control Function Assumption
Time
PID blocks Flow/Liquid press & Diff. press control 250 msec
PID blocks Gas press/Temp/All other control 500 msec
PID blocks Level control 1000 msec
All open loop Ai Ai not considered for PID loops 1000 msec
All open loop temperature inputs T/C, RTD signals not considered for 2000 msec
PID
60% of digital I/O Without sequence or interlocks 1000 msec
40% of digital I/O For complex sequencing and 1000 msec
interlocking; each Di + Do requires 5
Boolean logic
Sub-system I/O Memory mapping of Ai/o and Di/o of 1000 msec
third party systems

The system shall have a standard feature to give the user the freedom to select some
control or sequencing functions to be executed at rates as fast as 10 times per second
(fast execution).
This requirement is in addition to other provisions for spare capacity in the control
systems.

7.5.8 Control and Input/Output Sizing

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In sizing the system, the VENDOR shall consider the expansion capability of process
and the system loading described in accordance with the response times described
elsewhere in this document. The DCS provides all I/O and regulatory controls as
specified.

Following minimum functions shall be required for each PID algorithm tag in the
regulatory control. The VENDOR shall consider the necessary number of points
based on this criteria and shall size the proposed system:

y Analogue input.
y Standard software input processing shall be available to provide square root and
adjustable line segment, digital filter with time constant and alarm checks shall be
provided.
y Input data compensation (dead time compensation, pressure / temperature
compensation, etc.)
y Alarm checks.
y PID calculation with wind-up protection.
y CAS / AUTO / MAN switching (with bumpless transfer).
y Feed forward function.
y Output limit (H, L).
y Analogue output.

Also the following are the minimum functions required for each monitoring point in
the regulatory control (including temperature monitoring):

y Input data conversion such as square root, line segment.

y Digital filter for analogue inputs.
y Alarm checks.

7.5.9 Process Interface Requirements

Field I/O Types

The control module and input module shall be able to handle a wide variety of
signals including analogue and digital. The following inputs / outputs shall be
covered:

Analogue inputs : signal type is 4-20mA DC, suitable for 4-wire transmitters (power
supply for transmitters is external), and 2-wire transmitter (24VDC power supply for
the transmitter shall be supplied from the DCS), short circuit protection by current
limiting or replaceable fuse shall be provided for each channel.

Analogue inputs (T/C) : thermocouples type K, T, J, R, E, S, B. Range and type shall

be user selectable at site by software tools without need for any recalibration or
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mechanical adjustments.

Analogue inputs (RTD) : platinum RTDs 100 ohm standard DIN 43760. Range and
type shall be user selectable at site by software tools without need for any
recalibration or mechanical adjustments.

Analogue inputs : 1-5VDC.

Pulse inputs : 0-6000Hz with 24VDC or 12VDC power supply to the transmitter
from the DCS. Range and type shall be user selectable at site by software tools
without need for any recalibration or mechanical adjustments.

Digital inputs / outputs : with buffer relays or potential free contacts.

Analogue outputs : 4-20mA able to drive load resistance of 750 ohms.

Analogue outputs : 1-5VDC.

Analogue input from intelligent (smart) transmitters : transmitters shall be 2-wire

type, with hybrid signal of 4-20mA and digital signal. The system input card shall
separate the two signals and transfer digital information to the system engineering
worksation for transmitter setting, maintenance and diagnostics. Communication
with intelligent transmitters shall be bi-directional allowing read/write procedures.
The VENDOR shall state any limitations on the protocol.

7.5.10 Analogue I/O Isolation

All analogue inputs / outputs to / from DCS (including temperature signals) used for
close loop control shall be provided with isolator type Intrinsic Safety barriers except
for non-IS loop. Each isolator type barrier shall provide 3-port isolation between
input, output and power supply circuits, thus eliminating the need for high integrity
earth and giving floating voltage signal that can be earthed at any point.

Each barrier shall be replaceable on-line without disconnecting the wiring between
the DCS and field instrument, and without affecting other signals in the system.

For the non-IS loops, separate isolators are not required if the isolation is available in
the field termination assembly.

7.5.11 Digital I/O Isolation

Digital inputs shall be of dry contact type connected directly to transistor type
detection circuit or through buffer relay (see I/O list).

Interposing (buffer) relays shall be provided for digital inputs and outputs, unless
otherwise stated in the I/O list. The interposing relays shall be replaceable type on
individual channel bases. Changing of a relay will not require replacing more than
the faulty relay, other relays or signals shall not be effected.
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Contact output rating 1.5 amp at 240Vac, or 0.5 amp at 24VDC resistive load.

Contact inputs shall detect dry contact field switch status changes with sensing
voltage supplied from the system side.

Power supply to a group of buffer relays (32 maximum) shall be protected by

replaceable fuse.

Each buffer relay shall be provided with indicating lamp or LED to show the signal
status.

Digital input cards shall have software configurable filter to eliminate contact
chattering.

7.5.12 I/O Quality

Analogue input cards (voltage / current) accuracy shall be at least ±0.001% of full
scale.

Analogue output cards (voltage / current) accuracy shall be at least ±0.003% of full
scale.

T/C and mV input cards accuracy shall be at least ±50 microV (special applications
±10 microV).

7.5.13 24-volt Power Supplies

All 24 VDC power supplies in the control modules shall be redundant. Both power
supplies shall be operating continuously and in parallel. It shall be possible to
remove one power supply for maintenance without affecting the overall load
requirements of the system.

7.5.14 Transmitter Power Supply

There shall be provision to power all field transmitters from the 24-volt system
power supply units. Internal power supplies shall be fused for short circuit
protection. Outputs shall be electronic current limiting for each channel.

7.5.15 Back-up Batteries

The contents of the memories of the control modules shall be backed up by

rechargeable batteries for three days minimum. Low battery alarm and charger
malfunction shall be annunciated on the DCS console.

Operator stations shall be loaded from a bulk memory automatically when power is
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recovered.

DCS modules and stations with operating system that require proper shutdown
procedure before shutting off the power supply shall automatically be provided with
intelligent type UPS and shall perform automatic shutdown procedure when mains
power supply fails for any reason.

7.6 Alarm Function

7.6.1 General

This section describes alarm handling and alarm reporting requirements and other
packaged software function within the system. The data may be from various
sources which include, but are not limited to, the following devices:

y From the control and monitoring tags.

y From sequence functions and elements tags.
y From operator input devices, keyboards, etc.
y Third party systems.

7.6.2 Alarms

Alarm monitoring shall be performed for system failures and process alarms. All
alarms generated shall be displayed in operator CRT with color change or reverse
video.

The system must alert the operator for process alarms with an audio and a visual
signal, regardless of the current display on the screen. Dedicated area for alarm
indication shall be required for all displays.

The operator should be able to call up the proper display with a single keystroke.

Process alarm condition of each point shall be clearly shown in alarm, group and
individual point displays. Also, it shall be easily determined if the alarm has been
acknowledged from these displays (for example, blinking indication for not
acknowledged alarms).

7.6.3 Process Alarm Types

This following process alarm types shall be available within the system:

y Absolute high-high, high, low, low-low and deviation from set point alarms for
each tag.
y Process value rate of change alarms for each point.
y Input and output signal open alarms for each point due to short circuit or open
circuit signals.
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y All RTD signals shall be provided with open detection which shall be a standard
feature and does not require application programming.

7.6.4 Process Alarm Management

Operator stations shall be grouped per plant area, such that each operator will receive
only the alarms assigned to that Operator’s group. Fire and Gas alarms shall be
brought up on a separate dedicated display unit.

Color coding of the alarm indication on the tag faceplate shall be configurable for
each type of alarm, to enable the operators recognize certain alarm status at one
glance.

Alarm priority shall be assignable based on individual tag such that different tags
will have different alarm priority settings for the similar alarm types (e.g. Hi alarm in
one tag can be of high priority while with other tags could be of less importance).

The system shall have standard feature to allow for alarm suppression from sequence
functions or by operator demand.

A small window showing chronological list of at least the past three alarms shall
appear automatically on the screen every time an alarm condition occurs. This
widow shall not take more than quarter of the screen size.

It shall be possible to group more than 16 tags together to manage their alarms as one
tag, such that alarm silencing, prioritization and other alarm management functions
be performed on the group as one tag.

7.6.5 Alarm Priorities

Minimum four (4) levels of alarm priorities shall be provided. Each priority shall be
assigned to each tag based on necessity of alarm indication on CRT, alarm printing,
audible alarm and acknowledge action, etc.

The VENDOR should state whether the system can be configured to bring up FIRST
UP ALARMS.

7.7 Historical Function

7.7.1 Trending Function

Trend Types

Trends are divided into two types, real-time trends and historical trends.

Real-time trend data shall be recorded at 1 second resolution, and shall be available
for at least two hours period.
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Historical trend data shall be recorded at configurable periods of time (1 min. to 10

min.). The system shall have the capacity to store 1 min. scanned trends for periods
not less than 120 hours, and 10 min. scanned data for 50 days.

y Any trend point assigned by an operator shall be available for monitoring by other
operators in the same control room.
y Saved trend data shall be of the same accuracy engineering unit, scale and range
of the actual process value (e.g. process value of 450.01°C at time of scanning,
shall be recorded as 450.01°C, keeping the measuring accuracy, range and other
information handled by the control module).

Trend Capacity

The system shall be designed such that every analogue input including temperature
signals is trended with snapshots of 1 min. rate for total of 96 hours (4 days).

7.7.2 Historical Events

Historical event recording shall be a standard feature of the proposed system. The
following paragraphs list the type of events that must be logged by the system and
other related global systems (database):

Process Events

This shall include at least the following events:

y Tags going into alarms, showing tag number and associated comment, status,
process value which triggered the alarm.
y Tags recovering from alarms.
y Messages initiated by control algorithms.
y Annunciators generated by sequence control algorithms.

Actions carried out by Authorized Personnel

Related to control functions, such as:

y Modifying controller parameters.

y Modifying controller settings – PID parameters, alarm settings, etc.
y Modifying controller mode (A / M / C) and scan on / off.
y Alarm masking.

System Events

y System alarms and component failures.

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y Off-line and on-line loading.

y Start / stop of system modules.
y Sequence of events.

Database for events shall be as much as possible distributed in separate hardware

platforms to serve operators of different plant areas.

For each group of operator stations handling specific area of the plant, the capacity of
event recording shall be not less than1000 events for each of the three categories
mentioned above.

All events shall be time stamped with date and time with 1 second resolution.

7.7.3 Acquisition Rate

Event database shall be able to gather up to 100 events per minute as minimum.

7.7.4 Historical Data Distribution

To enhance the plant safety and segregation among plant units, historical and trend
database shall be stored in distributed archiving hardware. Separate redundant
hardware shall be proposed for each group of operator stations.

7.7.5 On-Demand Reporting

The system shall have standards function to allow the operator access to the global
real-time database and historical files to search for data based on the following
criteria:

y Search for tags under certain alarm or status condition.

y Check digital I/O status at I/O card level.
y Check for specified events that occurred at specified period from the historical
files.
y Check for messages history by defining text of the message.
y Check for current alarms at certain plant section.
y Search function shall allow quick filtering by defining several conditions such as
plant section + tag number + alarm type.

7.8 Engineering Functions (Database Configuration)

The following paragraphs defines the necessary engineering environment and tools to assure
simplified engineering, reduced time, and improves the engineering quality by reducing
errors and repetitive work. It is important to note that the following paragraphs describe
function that MUST be standard in the engineering environment and tools, without having
the user learn any operating system commands or generate any script file.
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7.8.1 Engineering Environment

A program shall be supplied to fully engineer and configure the system to achieve as
a minimum all the requirements mentioned in this DCS specification.

The program shall allow for full configuration of the system as a whole and for
individual components such as operation stations, control modules and other related
peripherals.

Engineering environment shall run in window based operating system, allowing

multiple pages displays simultaneously. The operating system shall be open type and
not a proprietary of the VENDOR.

Dialogue windows, fill in the form, icons and CAD environment shall be used for
engineering.

Mouse or trackball shall be used as the main device for the engineering with the
keyboard being used for text entry.

Engineering environment shall be based on Object Oriented Technology built and

compiled from a C/C++ programming language to allow future migration to other
platforms and provide hardware independent environment.

Human error shall be minimized with the use of confirmation dialogue windows
before executing commands that may affect the system database.

The system shall allow for the configuration program to be complied in sections
without the need to perform compilation on all the system configuration database.
This will allow for partial modifications without having to execute full compilation
every time.

Compilation shall prompt a window informing the user to the compilation status and
results. Compilation results including errors or unsuccessful execution shall be
clearly listed with a warning sign displayed to the user.

Standard Operation Displays

Except for the graphic displays, all other standard operation displays shall be
available as standard and the engineering shall only require filling in the tag numbers
that will appear on those displays (all graphic symbols and data shown on such
displays shall be standard and default values).

Full requirements of those displays are explained in detail in other sections. The
engineering program shall allow for all those requirements to be achieved easily.

Graphic Displays
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Utility shall be provided to draw lines in different thickness, types and colors. Draw
shapes, symbols and characters in different shapes and colors. Assign switches to
move to other displays and assign area for showing faceplates of any tag in the
system.

Full requirements of those displays are explained in detail in other sections. The
engineering program shall allow for all those requirements to be achieved easily.

Window Configuration

Engineering environment shall include utilities to generate window type displays

used for operation and displayed on the operator stations.

7.8.2 Engineering Security

The system shall check for user name and password to allow accessing to the
engineering environment.

The system shall have multi-level user name and password according to plant name,
plant units, as well as by the type of engineering that can be performed on the
configuration.

On-line maintenance (loading and configuration modification) shall prompt dialogue

windows to confirm the operation prior to allowing the on-line maintenance.

7.8.3 Standard Engineering Tools

Search tools shall be available in the engineering environment to search the

configuration database for user defined items such as tag numbers, panel names and
area names. Duplicated names shall be checked.

A file management utility shall be available to give the user access to configuration
related files only without being involved in operating system commands. The utility
shall allow the user to file save, move, back-up, restore, remove, copy to user
specified directories and drives.

Time stamp shall be attached to all configuration files stored in back-up removable
media. The user shall be able to access time stamp data from the file management
utility displays.

Database revision management utility shall be provided to inform the user of the
history of modification executed on the engineering database, including facility for a
print-out of only the modifications carried out on demand.

7.8.4 Concurrent Engineering

The system shall support work group engineering by allowing engineering

environment run on commercially available personal computers, RISC processing
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workstations, and operator stations all connected through Ethernet-LAN network.

Work group stations shall be networked in a client / server architecture, allowing all
engineering terminals share same database for:

y system generation
y graphics generation
y system maintenance

Client/server architecture shall have files centralized in a file server computer with
engineering and generation application programs distributed among PC / WS clients
on the network.

Files related to one plant shall be grouped inside the file server as one project. The
file server shall have the capability to handle more than one project (group of files).

X-terminals connected to a powerful workstation will be allowed to achieve

concurrent engineering. As a rule no more than two X-terminals shall be connected
to a workstation.

The system shall not allow more than one engineering master database which will be
the only database used for downloading configuration files into the various DCS
stations and modules. Other users working on the same project shall have “work
files” to work on, and those files shall be merged to the master file after checking and
compilation.

The system shall allow off-line PC/WS not connected to the workgroup to generate
and build system configuration and merge those work files into the master database.

7.8.5 Workstations

Engineering workstation EWS shall be a multi-platform type, supporting engineering

from high performance workstations, X-terminals, personal computers as well as
engineering from the operator stations. As a minimum the mentioned platforms shall
be able to perform standard system generation including control functions, operation
displays and graphics. VENDOR shall list any limitations implied with the use of
any of the listed platforms.

VENDOR shall include two (2) console based engineering workstations for system
engineering and generation work. As minimum the workstation shall have the
following specifications:

Process High performance RISC type

Main memory 80MB min.
Hard disk 2 GB min.
Resolution 1280 x 1024 dots
CRT size 21” min.
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VENDOR shall separately offer additional software for engineering and generation
using three (3) sets of commercially available personal PC. PC specifications shall
be clearly listed by the VENDOR. VDU size for these PC’s shall be 21”.

VENDOR shall separately offer additional software for engineering and generation
using two of the operator stations for engineering back-up.

7.8.6 Application Program Debugging

This tool must be included in the proposal.

An off the shelf tool shall be offered by the VENDOR for testing and debugging
application programs for the DCS.

The tool will be used for testing the master files of application program before being
downloaded to the control module or operator stations.

The tool should perform the functions mentioned in the following paragraphs:

y Debugging tools shall have all the operator station standard operation displays,
including, but not limited to, graphic displays, detail panels, group displays and
tag faceplates. Standard application programs of the operator stations shall be
downloaded directly into the engineering workstation without the need to generate
separate displays for the program debugging.
y Two modes shall be available for debugging the program, an on-line mode and
off-line mode.
y On-line mode shall allow the engineer to test and debug application programs by
running them on actual control module hardware, and test the application from the
engineering workstation.
y On-line mode shall allow debugging of any group of algorithms (analogue control,
monitoring, sequencing and calculations) without affecting other control functions
connected to the process I/O directly.
y On-line testing shall allow the engineer to disconnect the software link of control
functions from actual I/O cards and replace the process signals with signal
generators, or connect control function outputs to inputs.
y Off-line mode shall allow the engineer build, test and debug the application
program from a stand-alone workstation not connected to real-time LAN or
control modules of the DCS.
y The off-line mode shall include an emulation software to emulate the control
module functions. This software shall allow standard application programs
generated for the control module be downloaded into the stand-alone engineering
workstation and emulate their functions without the need to generate nay
programs to simulate each control functions.
y Debugging program shall include the following functions as minimum :
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- Ability to perform debugging on entire control module (off-line and on-line).

- Ability to perform debugging on applications covering smaller parts of the
program such as plant units.
- Software blocks shall be available in the debugging tool to simulate various
process I/O signals such as digital and analogue I/Os, timers.
- Analogue signal generators shall include:
. mathematics functions
. signal ramp up or down
. waveform generator
. pulse
. dead time lag
. first order lag
- A display shall be available as a window allowing the engineer modify the
status and value of function generators (analogue and digital values).
- Sequence and interlock application programs shall be tested stepwise. The
engineer shall have the freedom to test:
. one single sequence step at a time.
. a specified number of sequencing steps at a time
. continuous execution with configurable scan periods (ability for slow
motion execution)
- Ability to connect control functions to signal generator software blocks, by
virtual wiring procedures.

7.8.7 Application Program Documentation

A documentation software package must be added to the proposal to allow for

documentation of the application program which is built using the standard builder
functions of the system. The documentation shall include every detail configured in
the engineering environment including, but not limited to, the following:

y System configuration with control modules and operator station configurations,

gateways, etc.
y Operator station assignments including trends, overviews, grouping, function keys,
window assignments.
y Regulatory control functions (including instrument details and parameters,
instruments connections).
y Sequence control functions (including sequence programs, D I/O and flags,
messages, elements, timers, counters settings, etc.).
y Computational functions.
y Graphic displays and related graphic attributes.
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y Configuration of user defined reports and report scheduling

y The documentation function shall provide easy to understand documentation in
the form of table of contents, chapters and sections.
y User shall have the choice to specify print-out of any of the following:

- Full print-out of all system configuration database.

- Print-out of revised items only.
- Print-out differences between old and modified configuration files.
- Select items to be printed, such as hardware configuration only, or graphics, or
by plant unit and section, etc.

7.9 Other Software Capability

7.9.1 High Level Language

The function is required.

A high level language such as BASIC, C or FORTRAN shall be available in the

operator station level for further data processing such as calculations, message
handling, report generator, etc. as user task. This function should provide high speed
real-time executable programs with library of functions capable of reading/writing
data to the control modules, accessing alarm and event messages, accessing printers
and graphic screens of the operator station.

It should provide high speed, real-time executable codes through compiler, and
support multi-tasking as well.

As a minimum the system shall be able to handle four programs of different

applications running in parallel (four tasks).

The process data should be freely accessible by specifying tag number and data type
when required in those programs.

7.10 System Integrity

7.10.1 Redundancy

Key components of the DCS system shall be fully redundant so that neither a
hardware nor a software failure will result in the loss of the features supplied by the
components.

In general the system shall be designed such that the loss or failure of any module or
card will not cause more than the loss of one operator station or any control loop.
Further 1 : 1 redundancy shall be provided for the following system components:

y Operator station (see Section 7.4.3).

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y Hard disks carrying real-time database, images of displays, historical events,

redundancy shall include disk drives, and disk path to the real-time LAN.
y Real-time communication network and related communication hardware, circuits,
couplers, etc.
y Control module processor (whether used for close loop control or monitoring
open loops).
y Input/output cards associated with control loops and selected recorded points.
y Control module DC power supply cards.
y Control module internal communication circuit including, but not limited to,
communication between control module and I/O cards.
y DC power supply for all field instruments.
y DC power supply for all I/O cards.
y DC power supply for all buffer relays used for digital I/Os.
y Multiplexer type I/O cards not to be used for control loops.

Redundant components shall perform calculations in parallel and synchronized

manner, so that switching from main component to back-up, cause no interruption to
analogue or digital output signal and without any data loss.

The built-in diagnostics shall include a mechanism to validate the calculation results
of redundant components. Validation shall incorporate a function to check for any
difference in the calculation results of the redundant components. If such error
occurs, the built-in diagnostic function shall determine which calculation was invalid
and select the component output with the correct calculation.

Transfer between any redundant components shall be instantaneous and better than
50 msec. VENDOR should state the actual figure.

Operator stations and control module processors shall utilize Error Correction Code
(ECC) on the main memory to reduce errors that may be caused by main memory
(RAM).

Real-time network shall utilize CRC and frame length check as minimum precaution
for securing real-time data transfer.

The system shall guarantee on-line replacement of any failed redundant module on-
line without complete system shutdown. I/O cards and other components of the
control module shall be replaced on-line without shutting down the control module
and without the need to remove any field signal cable.

Transfer between redundant real-time networks shall be less than 5 msec and with no
data loss at all during the transfer.

Redundant power supply units shall be protected from affectiog each other from
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internal or external short circuits.

Redundant power supplies shall be designed with no more than 80% load on each
unit when operating individually.

Control modules shall detect AC failure / recovery and perform immediate AC fail /
recover processing and set the control algorithm status to certain defined conditions.

Analogue output cards shall have the capability to act immediately upon losing
communication with control module or control module failure by driving the output
to a predefined level.

7.10.2 System Access

During the development of the functional design specification by PURCHASER the

access levels will be decided in conjunction with COMPANY. Apart from the “View
Only” level where no data entry or process changes are made, but only monitoring
facility is available, operation shall be subject to security levels with access by key
and/or password. The following access levels are the minimum requirements for
plant operation:

Level 0

This level shall require no key or password to access this level. Tags assigned to this
level shall give complete access to the operator to perform the following:

y Change of control set point and output.

y Change control mode (C/ A/ M).
y Alarm acknowledgement.
y Change of tuning parameters and alarm settings.

Level 1

This level shall require a key or password for the operator to access tags configured
with Level 1. Without the key or password the operator will be limited to access the
following functions:

y Change set point and output.

y Change controller mode.
y Alarm acknowledgement.

Level 2

This level shall require a key or password for the operator to access tags configured
with Level 2. Without the key or password the operator will be limited to access the
following functions:
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y Monitor the faceplate, but no access allowed at all.

Level 3

This level shall require a key or password for the operator to access tags configured
with Level 3. Without the key or password faceplates of tags assigned to this level
will not be shown to the operator.

7.10.3 Availability

The VENDOR shall state the availability figure for the system offered. The
availability figure shall be calculated for an MTTR (Mean Time to Repair) value of 8
hours.

⎡ MTBF ⎤
Availability = ⎢ ⎥ x 100
⎣ MTBF + MTTR ⎦

Where MTBF = Mean Time Between Failures in hours.

7.11 Openness and Connectivity

7.11.1 Connectivity with Upper Level Computers and Networks

Openness is defined here by the ability of the system to easily be integrated with
upper level computers on the information LAN with minimum development of
application programs to interface with the DCS.

The control system shall have the capability to interface with upper level computers
and network using the method described herewith.

Data transferred from DCS to a database on the plant information network will be
used for plant analysis and reporting to maintenance personnel, process, management
or others.

7.11.2 Interface Requirements

The DCS shall be connected with upper computers and networks using tried and
tested protocol. (VENDOR to state the type. Typical = Ethernet with TCP/IP
protocol [Transmission Control Protocol/Internet Protocol].)

Storage module for historical data shall be interfaced with information LAN directly
so that historical data and files can be transferred to the upper computer database
without loading the real-time network of the DCS.

The storage modules shall have a high security operating system to prevent
unauthorized user from accessing the system database.
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Real-time network shall be interfaced to information LAN through Router type

module having no intermediate buffer to store information or tag data. The module
shall have high throughput to transfer any data between the control module and upper
level computers without any limitation to quantity of tags that can be accessed.

The Router module shall have sufficient security measures to prevent unauthorized
user from accessing the system database. As a minimum the following limitations
shall be configurable:

y Limit the access to certain IP (Internet Protocol) addresses on the Information

LAN.
y Limit the access to computers directly connected to the Information LAN (other
LANs connected through Routers and bridges will not have access right).

7.11.3 File Transfer Function

Trend Files : it shall be possible to transfer any trend data (real-time or historical) in
TEXT format to any personal computer connected to the upper network with a FTP
procedure (File Transfer Protocol).

Alarm Files : it shall be possible to transfer alarm data to any personal computer
connected to the upper network with FTP procedure.

Event Files : it shall be possible to transfer historical event data to any personal
computer connected to the upper network with a FTP procedure.

Report Files : it shall be possible to transfer schedule process logs (shift, daily,
monthly reports).

FTP transferred files shall be immediately read by spreadsheet packages running on

the PC such as MS Excel or Lotus 123. The file transfer and reading by the
spreadsheet shall not require any development of interface package. VENDOR shall
clarify how to implement this function in the proposed system.

7.11.4 DDE(Dynamic Data Exchange) Function

The DCS shall provide DDE server function for assigned PC. It shall provide real-
time data on continuous basis or on request. PCs on the network shall be using
packages that support DDE such as MS Access database package or MS Excel and
other off the shelf packages.

7.11.5 Interface with Real-Time Data Acquisition Package

It is the intention of the project to implement a third party data acquisition package
that will collect data from various systems in the plant including process data,
products inventory, laboratory information – part of Management Information
System packages.
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The DCS VENDOR shall include in their proposal necessary hardware and software
to enable real-time data transfer to the data acquisition system. The data transfer
shall include analogue and discrete process values, alarms and messages.

Alarms and messages shall be accompanied with DCS time stamp with 1 second
resolution when transferred to upper level computers.

One of the following packages shall be implemented for the data acquisition,
VENDOR shall clarify their experience and connectivity with those packages:

y PHD (Honeywell Hi-Spec Solutions)

y PI Systems (by Oil System Inc.)
y InfoPlus (by Setpoint – part of Aspen Technology Inc.)
y Marex
y SAP (CAP Gemini)
y Others (VENDOR to specify).

7.11.6 Interface with Optimization Package

It is the intention of the project to implement a third party optimization package that
will perform unit or plant optimization and other advance control or operation
functions.

The DCS VENDOR shall include in his proposal necessary hardware and software to
enable real-time data to the data optimization. The data transfer shall include
read/write tag data such as process values, setpoints, manipulated values, alarm
settings and tag status.

VENDOR shall clarify his experience and connectivity with the following
optimization packages. It is envisaged that anyone of them will be selected for
optimization.

y RMPCT (Honeywell Hi-Spec Solutions)

y DMC Controller (by DMCC)
y SMCA (by Setpoint – part of Aspen Technology Inc.)
y IDCOM, SMOC, CONNOISSEUR
y Others (VENDOR to specify).

7.11.7 Interface with Lower Sub-systems

Dedicated control and monitoring systems for special tasks such as emergency
shutdown systems, PLCs, tank gauging, etc., shall be interfaced to the DCS, and will
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be controlled and monitored by the operators.

Sub-systems shall be interfaced via serial link RS-232 / 422 / 485. The VENDOR
shall have interface ports for all those serial links.

VENDOR shall state any limitations on the type protocol if any.

It is preferable that interfacing with sub-systems be via the control module of the
DCS.

If, however, gateways are offered to link the sub-systems to real-time LAN then
those gateways shall have the same redundancy features of the control modules, and
shall have built-in monitoring and sequence control functions.

The DCS shall perform memory mapping of the sub-system and achieve seamless
integration between the DCS database and sub-system.

The DCS shall interface with a dedicated first-up alarm annunciator system. The
data along with appropriate time stamp will be transferred via serial link as per
details above. High speed dedicated printer shall be accessed via DCS for immediate
printing and all such alarms shall be stored in the database for historical reporting.

7.11.8 System Interfaces with Tank Gauging, Metering Packages, etc.

Facilities shall be included to interface the DCS with other electronic systems. Brief
details of the systems are given below, but VENDOR shall obtain further information
where necessary from the original manufacturer. VENDOR shall include for all
special software and for system development where applicable including liaison with
manufacturer. System interfacing shall be considered solely the responsibility of
DCS VENDOR. Further information will be made available by the PURCHASER
following order placement.

APC and POIS

VENDOR shall include the interface with the APC and POIS presented by the
PURCHASER.

Tank Level Gauging

3 Radar type tank level measurements are being used for existing and new tanks.
These are intelligent transmitters, protocol used will depending on the final selection
made.
Vendor shall make following provisions.

y Serial Interface Provision and cabling work to personnel computer based Tank
Gauging System, IBM compatible.
y Power supplies to the system
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Lock-Hopper Control System

Lock-Hopper Control system (Texas Instruments – Series 500) – VENDOR shall

include for interfacing with the above system including graphic display pages. All
graphic panel functions shall be performed via the DCS (display and keyboard).

Compressor Instrumentation and Anti-surge System

VENDOR shall include for interfacing with the above system, including graphic
display pages. All graphic panel functions shall be performed via the DCS (display
and keyboard).

Metering Packages

Fifteen metering stations are proposed. A compact portable meter prover is being
proposed for meter proving. Metering and proving operations for the stations will be
supervised and controlled by dedicated computers located in metering panels housed
in Satellite Equipment Room or Central Control Room. One or more interfaces shall
be furnished to permit information interchange between the DCS and the metering
panels. Information may include:

To Metering Panel – required batch size, batch number, loading constrains, oil
analysis and others.

To DCS – actual batch size, batch records, stream flow rates, total flow rates,
compensated flow rates, meter factors, proving records and others.

Data shall be transferred via an RS 232C / 485 /422 link.

For metering at Doha Depot and Jetty see 2.3.23.

Mainframe Computer (Part of Management Information System)

A mainframe computer will be located in the administration area of the Refinery.

This will interchange information via an interface unit with the DCS computer
located in the Central Control Building. Information may include:

From Mainframe Computer : general constraints, objectives and targets for plant
operation, blending requirements, blending recipe, laboratory analyses, etc.

To Mainframe Computer : Transmission of all data contained in DCS computer,

reports, etc.

Other Systems

It shall be necessary to interface the DCS with other electronic systems which may
include chromatograph controllers, programmable logic controllers (PLCs)., turbo-
generator controls and machinery monitoring system, etc. VENDOR shall include
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full details in the bid of all system interfaces presently in service or under
development.

7.11.9 Blending

It is proposed to control three blending systems by the DCS – one system for
gasoline blending, one for gas oil blending and one for fuel oil blending. These will
consist of the following:

Gasoline Blending

Up to 11 streams will be controlled by each system, plus additives. Turbine meters

with pulse transmitters will be used to measure stream flows. Stream flow rates will
be regulated by control valves. Additive rates will be proportional to total blend flow
rate and will be regulated by stroke or speed control of positive displacement pumps.
On-line analyzers will be employed to measure blend octane number (RON), vapour
pressure (RVP), ASTM distillation and Benzene. See figure 1 attached.

Gas Oil Blending

Up to three streams will be controlled by each system. Turbine or positive

displacement meters will be used to measure stream flows, and flow rates will be
regulated by control valves. On-line analyzers will be employed to measure blend
cloud point, pour point, cetane value, distillation, specific gravity and sulfur. See
Figure 2 attached.

Fuel Oil Blending

Up to four streams will be controlled, using positive displacement meters to measure

flow and control valves to regulate flow rate. On-line analyzers will be employed to
measure blend specific gravity and % sulfur. See Figure 3 attached.

Note:- The VENDOR shall include relevant software for any Sensor Validation and Data
Reconciliation techniques (Computer Integrated Manufacturing – CIM) as an
“option” for Analyzer down-time or for Analyzer data reconciliation. The VENDOR
shall include a list of such applications implemented in any Petrochemical
environment.
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Figure 1 – Gasoline Blending Schematic

NOTE 1. ANALYZERS TO MEASURE ;

RESEARCH OCTANE NUMBER (RON)

DISTILLATION
BENZENE
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Figure 2 – Gas Oil Blending Schematic

NOTE 1. ANALYZERS TO MEASURE ;

. CETANE INDEX (CALCULATED)
. SPECIFIC GRAVITY
. DISTILLATION
. POUR POINT
. CLOUD POINT
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Figure 3 – Fuel Oil Blending Schematic

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Blend Modes

Only Non-interactive In-line Bending (NIB) is considered for this project, but in
exceptional circumstances where it is not possible to carry out NIB, controlled rate
blending shall be the mode of operation. This mode of operation shall be used only
in emergency cases.

In general the operation shall be as follows:

A proprietary blend and blend property control software is downloaded from the
Plant Operations Information System computer (POIS) into the DCS. Once the
blend recipe has been downloaded the blending process can be initiated when
required. Blending and blend property control software shall be part of the DCS
VENDOR deliverables.

The blend control software shall provide automatic start-up, operation and shutdown
of pumps, controllers and associated equipment. This includes ramp-up and ramp-
down at the start and end of the batch, and continual equipment and valve status
checking throughout the blend.

At the end of the blend, the blend data can be archived for used on the Plant
Operations Information System (POIS).

Blend Control Software

y Blend Ratio Control

The flow of each component stream is measured by means of a flow meter and
regulated by a control valve. Compensation is provided where temperatures may
vary between stream. The set points for each stream are generated by the control
software based on the required stream percentage. Any deviations between the
measured flowrate and the required flowrate are stored in the control system
memory, which automatically adjusts the stream flow controller set point to
compensate. This is a continuous process with the component flowrates being
totalized and compensated to achieve the required total blend composition.

If modification to the blend flowrate during a blend is desired, this can be

implemented without affecting the individual component percentages.

If there is a starvation in one of the components streams, the control valve will
open to compensate. However, if it reaches a point where available flow cannot
meet the demand, a pacing signal is sent to the Master Controller which
automatically reduces the total blend flowrate to a level at which the accurate
control of the lagging component can be maintained. This would produce a
system alarm. If the lagging component flowrate drops to a level at which control
of the blend cannot be maintained, the system will automatically shutdown. The
amount of the lagging component which is missing from the blend will be stored
in the controller memory, and will be compensated on restart of the blender.
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y Blend Property Control

For this mode blend quality will be measured by the on-line analyzers and
analytical data will be passed to the DCS computer. The computer will retain the
latest compositional data for each blend stream, constraints such as permitted
maximum or minimum flow for any stream, and possibly product values. Blend
measured quality will be compared with required quality, and flow rates for each
stream will be adjusted in accordance with the blend property control software
program.

If found necessary blending could be started at low flow in the controlled rate
mode, and the system should be switched to NIB (Non-Interactive Blending) as
analyzer results stabilize. In the event of computer failure or the failure of one or
more analyzers, blending should automatically revert to the controlled rate mode.
In both controlled rate or non-interactive modes the DCS computer will check
valve positions, running of pumps, pressurization of headers, availability of blend
products, etc. prior to blend start-up. The DCS computer will also check total
batch passed using the blended product tank inventory management computer
(Transfer Volume), and will also calculate compensated flows for all streams, if
required.

VENDOR shall include full details of the equipment proposed for blending and
examples of current applications. For the NIB mode a standard proven program
shall be offered, if available. PURCHASER shall make available more precise
requirements for NIB (in-line blending) during detail design stage.

For details of streams and instrumentation see P&ID attached – (Appendix I).

7.11.10 Oil Movement and Overall Tank Farm Management System

The VENDOR shall include for an overall tank farm management system to include
for tank level gauging from PURCHASER’s level gauges (it is envisaged that these
will be of the radar type gauges compensated for average temperature measurement
using nine spot measurements). Tank gauging shall include for inventory control,
custody transfer, product movements and loss control and reconciliation. VENDOR
shall also include for an oil movement management system for a total of
approximately 90 tanks of varying capacities (interfacing with three interface units –
each interface unit able to communicate with a maximum of 32 tanks). See
Appendix L “Offsite Automation and Management System – General Requirements”.
The interface requirement may vary after finalization of Tank Farm Management
System. The VENDOR shall consider the compliance to these changes, if necessary.

7.12 Maintenance

7.12.1 General

The system shall be designed so that any failure can be eliminated as quickly as
possible. The repair policy shall be based on replacing printed circuit boards (cards)
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or sub-systems (CRT, hard disk, keyboard).

7.12.2 Card Failure Indication

Each individual card and power pack shall be fitted with an LED or lamp to denote
failure on the card or power pack. The hardware shall be modular in construction
and cards replacements and adjustments can be on-line. Wherever redundancy is
specified, it shall be possible to replace the failed part on-line without affecting the
system performance.

7.12.3 Cards Access

Access to cards and printed circuit boards of operator station, control modules and
other main components of the system shall be easily replaceable from the rear or
front of the main body by pulling out the failed card and replacing it with healthy
card, without the need to dismantling or opening the body enclosure.

7.12.4 Diagnostics

The system shall include comprehensive on-line diagnostics.

System alarms initiated by the self-diagnostics functions of the system must alert the
operator at the operator station at once. System alarms directed to the EWS only will
not be permitted as it is assumed that EWS will not be attended continuously.
Diagnostic displays must be accessed be the operator as well.

The on-line diagnostic programs, as a minimum, shall consist of a peripheral exercise

program and a malfunction check program, that will alert the operator upon the
detection of a fault. This shall be a unique and separate system from plant alarms.
The self-diagnostics shall detect a fault or malfunction in, but not be limited to, the
following:

y Data highways and communications lines.

y Power supplies.
y All cards (analogue and digital I/Os, controllers, processors, etc.).
y CRTs and keyboards.
y Printers.
y Alarms are to be monitored in operator station.

7.12.5 System Back-up

The entire control software shall be backed up; this includes VENDOR software,
control database, user-built programs, source code, data files, schematics and so forth.

Back-up must be possible on commercially available media. To recover from an

outage, any component of the system must be able to be reloaded from bulk memory
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(hard disks).

All the system related software including building, application programs, standard
and optional packages that are included in the scope of supply shall be delivered with
the system on magnetic media.

7.12.6 Special Tools

Maintenance Tools

The VENDOR shall supply special tools required to maintain the system to the board
replacement level.

Back-up Unit

A back-up unit for 16 analogue outputs to control valve shall be offered, the unit
shall be portable with battery back-up, and capable of plugging in directly on the
output card to provide 4-20mA output signal.

7.13 Acceptance Test

Appendix N (Document No. 7J48N-00-15-17-013) – Inspection, Testing and

Precommissioning of Instrument Equipment Items, complements the following and shall be
used in combination. Any conflict between the two shall be referred to the PURCHASER.

7.13.1 Works Check-out

General

System check-out will be concerned with the final examination and testing of
equipment prior to dispatch. Preliminary examinations; e.g. to view panels or
cabinets during or on completion of fabrication, will be performed as necessary and
recorded separately. Devices using customized programs; e.g. computer or systems
interfaces, will be the subject of extensive preliminary examination and testing, and
VENDOR shall propose test procedures for such equipment and demonstrate that
QA/QC procedures have been applied to the development of any software or
correction of the software. PURCHASER reserves the right to extensively check any
part of the system, or any system block, prior to final check-out.

VENDOR shall not offer the system for check-out until he has carried out his own
shop tests to the latest approved drawings and specifications and has ensured that the
equipment functions satisfactorily and is complete in all respects. A report shall be
available as evidence of this work and shall be submitted to the PURCHASER before
the system check-out commences.

During system check-out VENDOR shall demonstrate that the equipment fully meets
all requisition requirements following the guidelines in this section. PURCHASER
shall be present throughout the demonstration. Any deviations from this
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specification are subject o PURCHASER’s agreement. Such deviations shall be

recorded.

The works check-out shall demonstrate to the satisfaction of the PURCHASER that
the system performs all functions as described in its functional design specification.

The PURCHASER shall supervise all testing designated by the VENDOR as

acceptance testing. The PURCHASER shall have the option to run these tests if the
PURCHASER deems it necessary.

The VENDOR shall provide written notification to the PURCHASER of the

acceptance test procedures 30 days prior to the acceptance test period. The
PURCHASER shall review and, if necessary, modify these procedures.

All system hardware and software used for acceptance testing shall be complete as
specified and shall be the actual equipment to be shipped to the job site except for
those items that may be dropped shipped (such as third party computers or color
3 copiers).

VENDOR shall perform a complete system functional test before advising the
PURCHASER that the system is available for a witnessed factory test. All input
points, output points, alarm points, digital and regulatory control loops shall be tested
by VENDOR using actual system configuration prior to witnessed factory test.

If problems or malfunctions develop in any part of the system during the acceptance
test period, it shall be at the sole discretion of the PURCHASER to determine if
corrections shall be made at the VENDOR’s facility during check-out or job site at
no cost, to the PURCHASER.

It shall be the responsibility of the VENDOR to provide a suitable site for acceptance
testing. Also, the VENDOR shall provide any necessary test equipment and
simulation facilities required for demonstration not less than 25% of the input/output
signals, equipment interface, etc., at any one time. However, all equipment shall be
checked during the course of the test. Witnessed test shall consist of a functional
check of each input point, output point, alarm point, digital and regulatory control
loop for proper functions and proper display on the CRT(VDU). Tests should be
performed using simulated inputs. The site and facilities to be used for acceptance
testing shall be approved by acceptance test schedule.

The VENDOR shall provide any necessary personnel to:

y Review acceptance test criteria.

y Schedule and arrange test facilities.
y Demonstrate the system according to acceptance test criteria.
y Analyze and interpret test results for PURCHASER personnel.
y Provide assistance in case of system malfunctions during the acceptance test
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period.

The acceptance test shall be divided into two major areas:

y A hardware test using the VENDOR’s standard diagnostic tests as a basis. An

integrated test developed by the VENDOR, agreed to by the PURCHASER,
intending to exercise the system using simulated plant inputs and outputs.
y A 72 hour test shall be run at the completion of the integrated test. Equipment
will run without failure, or else this test will be repeated.

Details of the hardware and integrated test criteria shall be supplied by VENDOR,
agreed to by the PURCHASER after the configuration has been established.

For the demonstration, VENDOR shall make available:

y Two complete sets of the latest approved drawings, approved functional design
specifications and data sheets for the system(s). These will include loop diagrams,
loop schedules, control circuit diagrams and junction box termination schedules.
y All necessary personnel to perform the tests together with suitable tools and test
equipment.
y Adequate sources of power at all required voltage levels.

Faults discovered during system check-out shall be rectified as work proceeds and all
previously tested circuits affected by the repair work shall be retested. VENDOR
shall mark up and retain one set of drawings and data sheets for the subsequent
production of “as-built” information.

The system shall be tested as a fully assembled programmed package complete with
all cord sets and interconnections. Where a circuit is incomplete for any reason or
where temporary wiring is installed then PURCHASER’s agreement must be
obtained and details shall be recorded. Check out shall include proving of system
interfaces for which PURCHASER will provide equipment wherever feasible. When
the interface cannot be fully proven during the works check-out then suitable tests
shall be performed during the refinery check-out –see paragraph 7.13.2.

VENDOR shall also indicate where major system blocks will be built and shop tested
prior to final check-out.

Visual Examination and Preliminary Testing

The system assembly shall be visually examined to ensure that construction is in

accordance with the specifications, data sheets and approved drawings. Examination
shall include, but need not be restricted to, the following:

y Use of instrumentation and components previously approved by PURCHASER.

y Standard of finish of components and assemblies including structures and paint
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work.
y Overall dimensions, fixing points and lifting points as per approved drawings.
y Frameworks sufficiently rigid to support equipment without distortion.
y Individual devices accessible for adjustment and/or maintenance without removal
of trunking, wiring, supports and other instruments.
y Heat generating equipment suitably located with provision for cooling, if
necessary.
y Tags, nameplates, scales, charts, dials and warning labels provided as per
approved schedule.
y Terminals and wiring segregated and protected to meet hazardous are and
electrical safety requirements.
y Wiring and trunking sized, colured and identified in accordance with codes and
specifications.
y Adequate space allocated for future additions and changes, as specified in the
technical documentation.

Earthing, both the instrument and electrical purposes, shall accord with VENDOR’s
agreed standard, if any, and with PURCHASER’s Earthing Philosophy Diagram. See
Appendix J.

Fuse holders shall be identified with the fuse rating and service, and fuses and
isolating switches shall be examined to ensure they are connected to the correct
circuits. Circuits shall be checked for correct polarity, and the following shall be
established:

y That the protective device associated with the faulty instrument or circuit is the
only protective device to operate.
y That there is sufficient power available to cause the protective device to operate
without dropping the voltage to other instruments or circuits to an unacceptable
level and thus affecting their normal operation.

Configuration of all parts of the system shall be checked against the agreed
configuration data sheets.

The system shall be checked for invulnerability to radio frequency interference.

Such test shall be conducted using a portable 1W radio transmitter operating at
frequencies – typically HF (27 MHz), UHF and VHF. The range of frequencies will
be specified prior to order placement. With all cabinet doors closed equipment shall
be unaffected when the transmitter is keyed at a proximity not closer than 1 meter.
Also repeat the test as per paragraph 4.3 of this document.

The total electrical load (VA) and power factor shall be measured for the complete
system and for discrete parts of the system. All values shall be recorded.
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Tests of Elevated Temperature

VENDOR to submit the certificate of elevated temperature test result.

This certificate shall list the serial numbers of all project components and batch
number.

Test procedure to be developed during detailed design and approved by the

PURCHASER.
The temperature shall be cycled for a minimum of 10 complete cycles between a
minimum and a maximum temperature of 40 to 60°C for a minimum period of 48
continuous hours. During the courses of the tests, a test routine shall be used to vary
a representative number of digital and analogue inputs on a scheduled basis with all
outputs monitored. During the test period a continuous recording of temperature and
humidity will be maintained. This shall form part of the test report.

Simulated Functional Tests

During the functional tests all equipment shall be powered up and shall remain
powered throughout the test period. Test equipment shall be connected at field
terminals only and not at any intermediate point, with the objective of testing the
complete system, or system loop, as it will be installed.

Circuits shall generally be tested one at a time. However, where cascade or

interrelated loops are involved then these shall be tested as one complete system.
Functional tests shall include multi-loop devices such as computers or system
interfaces, and also ancillary devices such as printers, copiers and recorders. Data
transfers shall be fully exercised to/form the DCS.

For circuits with milli-amp inputs and outputs, resistors shall be introduced at the
field terminals to simulate field devices, and the resistance varied up to the maximum
rating in accordance with VENDOR’s standard specification. Thermocouple or RTD
circuits shall be tested using a potentiometer or decade resistance box.

Where circuits are multiplexed no more than four circuits need be functionally tested
per multiplexer block, but all circuits shall be checked for continuity and correct
wiring.

Indicator and recorder circuits shall be checked by varying the input and ensuring
that the correct receiving device operates and that no interaction occurs with other
circuits. Checking of control circuits shall ensure that:

y the control action is correct

y the auto / manual changeover operates correctly
y cascade systems and more complex systems operate correctly
y range of adjustment of proportional / integral / derivative action meets requisition
requirements and that all such actions are operative
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y all other control or signal conditioning algorithms; e.g. for square root extraction,
are effective, whether multiplexed or individual devices.

It should be noted that all tests are to establish system or component function and not
calibration, which will be performed during site loop tests. However, VENDOR
must be able to furnish works test certificates for all system components, and sample
tests may be performed during system check-out at PURCHASER’s discretion.

Alarms operated by switch contacts shall be tested by opening the circuit at the
connection terminals where the switch is field mounted, or at the system connection
point where the alarm is generated by a separate system in the outstation. The test
shall ensure that:

y the correct alarm operates, plus audible and visual warnings

y there is no interaction with any other circuit
y alarm priority is correct
y alarm printers function satisfactorily.

Where alarms are derived from an analogue signal the alarm operation shall be
verified by varying the signal input, and not by adjusting alarm switch, where
provided, or alarm setting (software).

VENDOR shall make available all necessary test equipment to check interlock and
sequential control circuits. This shall include switches and lamps to simulate inputs
and outputs and any necessary timers.

The system shall be checked against approved final drawings and system function
against PURCHASER’s design specification and any associated documents.

7.13.2 Refinery Check-out

Following satisfactory completion of works check-out, the PURCHASER will

provide authorization to ship all equipment to the Refinery for installation by the
PURCHASER. VENDOR shall be present during the installation phase and the DCS
shall not be considered fully proven until the refinery check-out has been completed.
VENDOR shall be involved in the following activities as a minimum:

y Supervision of packing, transport and unloading at site, inspection of site storage

facilities and inspection of equipment during storage period.
y Inspection of outstations and control rooms to ensure areas are fit to receive
equipment.
y Supervision of uncrating or equipment plus installation in final position.
y Inspection of any section of the DCS and associated cabling, earthing, etc., prior
to power up.
y Proving of any system interface not fully proved during works check-out.
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y Proving of all components of communications system including final assessment

of highway loading.

Additionally VENDOR’s involvement may be required during loop testing. The

extent of such work shall be agreed later.

VENDOR shall specify in the bid the full extent of their intended involvement, and
shall indicate the number and source of suitable personnel, and the costs of such
work.

VENDOR shall additionally specify rates and availability of a service engineer for
the period following Refinery start-up.

7.14 Services

7.14.1 General

The VENDOR services shall include all engineering and project management effort
3 to be incurred in fulfilling the requirements of this specification.

The contract shall include a complete list of items the VENDOR requires from the
PURCHASER in order to perform services proposed.

7.14.2 Basic Project Services

Project Management

Project Management services shall be provided for the duration of the project.

The Project Manager shall provide one point of contact on all matters affecting the
project between PURCHASER and VENDOR. The Project Manager will be
responsible for ensuring all aspects of the PURCHASER’s requirements are met
including, but not restricted to:

y System performance
y Timely execution
y Documentation

The Project Management shall perform the following duties to assure PURCHASER
of timely progress:

y Planning and Scheduling

y Monitoring and Reporting
y Technical and Contractual Liaison
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y Attendance at Meetings
y Application of Licenses

The VENDOR shall provide PURCHASER with the names and qualifications of
prospective project managers for this project. PURCHASER expects the
VENDOR’s Project Manager to have the authority to make all commercial decisions.

The Project Manager shall co-ordinate technical support required for specific
questions related to formatting of displays and configuration of control logic.

With acceptance of purchase order, the Project Manager shall provide a schedule of
fabrication, system initiation, debugging, testing, issue and approval of
documentation, etc. This schedule must contain all the milestones from contract
award to successful completion of the project. It should be updated and maintained
as the project proceeds. Bidders should include sample schedules with the proposal.

Also, the Project Manager shall provide an organization chart of the team set up to
execute this project.

Project Documentation

The VENDOR shall provide ten (10) copies and 3 CD ROM Disks or as specified
elsewhere in the Contract requirements of all standard documentation including, but
not limited to, the ensuing required documentation list. This documentation shall be
transmitted to the PURCHASER’s program development. The VENDOR must
advise the PURCHASER of changes and modifications to the documentation and be
kept “current” at least until the date of system acceptance at the job site. Accurate
and complete “standard” documentation is a criteria for final system acceptance.

Drawings relating to PURCHASER’s electrical design work and equipment layout

shall be available ten (10) weeks after receipt of order or as specified elsewhere.

Required documentation list:

y Schematics layouts of all printed circuit boards power supplies A/D and D/A
boards and all other components.
y Module interconnection drawing showing interconnecting cables and termination
points of cables at modules or racks.
y Input and output termination point drawings for interface to PURCHASER’s
process equipment.
y System drawings showing system layout and physical configuration.
y All system manuals including technical, operating diagnostic and programming /
database configuration manuals for all system hardware and software.

Engineering Package
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VENDOR will be furnished with an engineering package which will contain all the
necessary information required to allow the VENDOR to engineer, load I/O and
configure the system. It will be the VENDOR’s responsibility to convert this
information into an appropriate form suitable to be utilized in conjunction with
furnished system. The engineering package will consist of the following.

Loop Listings : This document is a listing of all system I/O loop tags with
engineering information required to load loops into I/O devices and configure
database. Include in this document is the loop tag, loop type, service descriptor,
range, alarm setpoint, etc.

Loop Sketches : Contained in this document is sketches of all unique loop types.
Sketches are in P&ID form with each sketch provided with a loop type reference
number that is indexed in the loop listing.

Graphic Display Sketches : This document provides sketches of process graphic

displays. Sketches are computer drawn with graphic colors indicated by line textures
indexed to a legend.

Display Group Listing : Provided in this document is a listing, by tag, of system

display groups. Each display groups furnished with a service descriptor.

Custom Management Reports : Contained in this document is custom reports to be

programmed into the system by the VENDOR. Document specifies report formats,
data to be incorporated into reports, time intervals that reports are to be printed. etc.

Boolean Logic Drawings or Cause and Effect Chart : Functional requirements for the
interlock system will be reflected in this document.

While it is assumed that PURCHASER’s system engineering information will be

transferred to the VENDOR as described, VENDOR may offer as alternates, other
plans for the transferral of this information.

7.14.3 Other Project Services

Staging

VENDOR shall provide firm cost per week for staging the system specified in this
specification at the VENDOR’s facilities. Staging might be required for
precommissioning work after the system has been accepted and prior to shipment to
site.

Shipment

The VENDOR shall provide firm cost information regarding the shipment of the
specified system to site.

The PURCHASER will formally authorize shipment based on completed factory

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acceptance testing or at end of the staging period.

The VENDOR will be responsible for the following:

y Crating and loading the system.

y Insurance.
y Filing claims with shipper for any damages incurred during shipment.
y Shipment to job site.

Compete shipping instructions will be furnished by PURCHASER at a later date.

Delivery

The system delivery shall be made in accordance with the agreed project schedule.
VENDOR shall price storage in the event of construction delays.

7.14.4 Support Services

Training

The VENDOR shall arrange for a PURCHASER’s and COMPANY’s technical team
to participate and learn all phases of design, software preparation and configuration,
Hardware installation and testing, FAT, SAT etc. as per relevant document (See
appendix C).

The duration period of the team should be mutually agreed upon starting from
approximately three months after the receipt of the order. Training will be required
for operators and maintenance personnel as well.

Installation

The proposal shall detail installation services available with any special requirement
and degree of responsibility on the part of the PURCHASER.

These services shall include:

y Installation supervision.
y Power check-out.
y Environmental check-out.
y Interconnection and power up of all components
y Connection of the system to all instrument wires, communication links, etc.

Commissioning and Start-up assistance.

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The VENDOR shall provide a priced proposal per Diem rate commissioning and
start-up assistance.

y “Providing” of all communication links.

y Continuity check.
y Loop ring out.
y Valve stroking
y Input calibration.
y Installation check-out.

The VENDOR’s proposal shall provide information on:

y Start-up services and degree of involvement.

y Split of responsibility.
y Site resident specialist.

7.14.5 Maintenance and Service Contract

Single maintenance and service contract is preferred. A local service division with
permanently resident hardware and systems engineers is required. The bidder shall
provide the follow-up.

Type of service and maintenance contracts and costs for variations in response to
time, parts stocking, etc.

Any special maintenance requirements from PURCHASER and COMPANY.

Within 3 year operation, for PURCHASER’s approval, VENDOR shall be required

to furnish approved spare parts and will be directly reimbursed for the materials cost
of the parts.

List of special maintenance tools and prices.

The bidder’s proposal should include a recommended service and maintenance

program and estimated cost and COMPANY’s manpower requirements.

Warranty

The VENDOR guarantees to the PURCHASER all material and equipment furnished
against defects of design, materials and workmanship for a period of one year from
the date of satisfactory completion of the acceptance test, which includes refinery
check-out and when all the papers have been signed off, and shall correct at
VENDOR’s expense, and if fails to do so on reasonable notice, shall indemnify
PURCHASER for correcting any such defects as may develop within this period.
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The VENDOR shall also include for an extended warranty for a period of one year
form the final commissioning date of the whole refinery if this date is alter than the
refinery check-out.

Spare Parts (see Appendix O for details)

A list of recommended spare parts required to operate and maintain furnished

equipment and shall be supplied with pricing.

7.15 The Content of Bidder Proposal

Bidders are instructed to submit proposals according to the format described in this section.
Bidder’s proposal should be organized into separately bound volumes as follows:

7.15.1 Executive Volume

This volume shall service as a handbook containing all the pertinent information in a
concise and direct form legible to technical, purchasing and managerial personnel. It
will also serve as the document for pricing and terms and conditions.

Proposal Summary

This volume shall contain a proposal summary briefly describing in one or two pages
the control system offered.

Pricing Summary

Pricing shall be divided into two main sections – the first covering the cost of control
system and essential engineering service for VENDOR project execution; and the
second covering the project services that might be consummated after the system is
accepted.

In the first section, the bidder shall quote prices in an itemized format. Each item
shall be further divided into individually priced entities. Unit prices shall be
extended to future additions. Essential services shall include other services deemed
necessary by the bidder for project execution.

In the second section, the bidder shall quote prices in itemized format as described in

Section 7.14.3 for other project services.

Section 7.14.4 for support services and
Section 7.14.5 for maintenance and service contract.

Compliance Summary

This summary shall list the content of this design study and requirements on the left
hand side and the bidder’s degree of compliance on the right hand side. The bidders
shall respond with “Yes” for compliance, “No” for no compliance. For sections that
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the bidder has acceptance alternatives, or clarification shall be provided. See Section
7.16.

Bidder Terms and Conditions

The bidder shall include all the relevant terms and conditions complying with the
commercial terms attached to this DCS specification.

7.15.2 Technical Volume

General Approach

The bidder will be responsible for configuring a system to meet the functional
requirements and intent of this specification and for clearly noting any exceptions or
alternate techniques used to achieve a given performance feature. The bidders
should also explain what their interpretations of each functional requirements is.

Bidders are encouraged to be factual and concise. Drawings should be supplied

where appropriate. If desired, the Bidder’s Technical volume can refer to explicit
page references for descriptions of hardware and software.

Bidders are to use their standard catalogued products wherever possible. It is

expected that there will be hardware specifications of the manufacturer not in
compliance with the functional requirement and hardware requirements described in
this specification. The bidder should specifically note these exceptions or any
interpretations that might be considered and exception.

The PURCHASER is not responsible for reviewing the standard documentation

in manuals to determine what exception may exist.

If particular functional requirements cannot be met using the bidder’s standard

hardware the bidder shall clearly state what alternative proposal is being offered or
shall state this as an exception in the Exception Report (or Compliance Summary
Report).

Functional design requirements will be detailed by the PURCHASER and VENDOR

in consultation with COMPANY.

7.16 Table of Compliance

7.16.1 Table of Compliance - Example

FULLY PARTIALLY
PARA DEVIATION NOTED COMMENTS
COMPLIED COMPLIED
1.0 *
1.1 1 *
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7.16.2 Table of compliance form

FULLY PARTIALLY
PARA DEVIATION NOTED COMMENTS
COMPLIED COMPLIED
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7.17 Appendix List - Reference the latest revision of the project drawings listed in the
following appendices.

Appendix A Overall Control System Block Diagram(7J48N-00-15-41-002)

Appendix B Units of Measurement
Appendix C Training
Appendix D Central Control Building, Plan, Section and Elevations(To be later)
Appendix E DCS Console Layout in Central Control Room
(7J48N-00-15-41-201)
Appendix F DCS Overall Integrated Communication Network
(7J48N-00-15-41-001)
Appendix G I/O Schedule
Appendix H System Interface, Associated Units and Power Consumer List for
PDB
Appendix I P&ID Unit 21 Blending Units(To be later)
Appendix J Instrument and Electrical Interface Earthling Philosophy
(7J48N-00-15-51-301 and 7J48N-00-15-51-302)
Appendix K Special Requirement for Year 2000 Compliance
Appendix L Offsite Automation and Management System – General
Requirements
Appendix M Not used

Appendix N Inspection, Testing and Precommissioning of Instrument

Equipment Items (7J48N-00-15-17-013)
Appendix O Consumables and Spare Parts
Appendix P Marshalling Cabinet (180126/00/20/41/02 & 180126/00/20/41/03)
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APPENDIX A

OVERALL CONTROL SYSTEM BLOCK DIAGRAM

(7J48N-00-15-41-002)
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APPENDIX B

UNITS OF MEASUREMENT

The following basic units shall be used:

Mass kg, mg
Length / Elevation mm
Density (Liquid) kg/m3
(Vapour) kg/m3
Area m2
Volume m3
Time hr
Mass Flow kg/hr, bpsd, mtpy
Velocity m/s
Volume Flow (liquids) Sm3/hr (at 15°C standard conditions)
m3/hr (at flowing conditions)
(gases) Nm3/hr (at 0°C and 1.0133 bar abs)
m3/hr (at flow conditions)
Force kN or N
Pressure bar g or bar abs
Pressure (vacuum) mm Hg / mm Wg
Viscosity cP or cSt
Temperature °C
Heat Quantity kcal
Heat Flow Rate kcal/h
Thermal Conductivity kcal/mh °C
Coefficient of Heat Transfer kcal/m2h °C
Specific Heat Capacity kcal/kg °C
Enthalpy kcal/kg
Fouling m2 °C h/kcal
Corrosion Allowance mm
Line Size (pipe diameter) ins.
Surface Tension dynes/cm
Heat Flux kcal/m2
Corrosion Thickness mpy (mils per year)
Power kW
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APPENDIX C

TRAINING

As a part of the work, Vendor shall provide technical training for COMPANY personnel or
personnel appointed by COMPANY. Vendor shall submit a training program with his quotation.

General;

Vendor shall provide personnel facilities and resources necessary for sufficient and adequate
“high level” training of COMPANY operation and maintenance personnel in order to ensure that
they are qualified for operation and maintenance of the work.

Vendor shall provide professional, dedicated trainers who have experience in start-up,
commissioning and operation relevant to the work.
The CVs of the proposed lecturers shall be submitted to Purchaser and COMPANY for approval
at least six months before any training commences. The COMPANY reserves the right to reject
personnel that they consider unsuitable, in which case vendor shall submit suitable alternatives for
APPROVAL, well in time and not jeopardizing the overall training program.

Vendor shall provide all training in English language and the level shall be adapted to general
level of education of COMPANY staff.

In the event that vendor considers that a trainee is not suitable for the training and probable
operating post, then vendor shall report the situation to the COMPANY for comment and
resolution.

Vendor shall keep a log of all the trainees to record their progress, attendance and general
ability(competence assurance).

Course of Training

Vendor shall provide training as follows, but not be limited to:

• Classroom Training
• Site Training during construction and pre-commissioning phases.
• Training during commissioning and start-up stages.
• Training during on the job involvement.

Classroom training shall include but not be limited to technical lectures, guidance through and
explanation of manuals, exercises, and visits and demonstration on the FACILITIES or respective
control room / computer system.

1. Classroom Training

The classroom training shall include the following training programs as a minimum.
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• DCS system configuration and programming

Upon placement of order for the system, the vendor shall arrange for initial training on the
respective systems for COMPANY staff within the first month of order placement.

The training shall be structured such that the assigned COMPANY staff can:

- Have an understanding of the technology

- Apply the technology within the constraints imposed by the WORK
- Configure / program the system for the detail design phase of the project
- Undertake system management / maintenance of the computer environment
- Duration to be discussed with COMPANY (minimum 3 weeks)

2. Site Training

During the construction and pre-commissioning phases, vendor shall provide practical
instruction to COMPANY’s staff on the assembly, checking, testing, and preparation for start-
up and first-line maintenance of all systems supplied. On the job training will take place during
the commissioning phase of the WORK.

3. Training during Commissioning.

During the period of commissioning, VENDOR shall provide training and guidance to
COMPANY’s operators in the practical operation of the facilities by dedicated trainers /
lecturers during handover and start-up of the FACILITIES.
For the service vendor shall dispatch his specialist or representative experienced in the
operation of similar equipment and the inter-relationship of the overall control scheme.
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APPENDIX D

CENTRAL CONTROL BUILDING, PLAN, SECTION AND ELEVATIONS

(TO BE PROVIDED LATER)

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APPENDIX E

DCS CONSOLE LAYOUT IN CENTRAL CONTROL ROOM

(7J48N-00-15-41-201)
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APPENDIX F

DCS OVERALL INTEGRATED COMMUNICATIONS NETWORK

(7J48N-00-15-41-001)
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APPENDIX G I/O SCHEDULE

Satellite SYSTEM DCS Console

Equipment I/O CAI AI LAI AO DI DO Aux.
Inst.
Room UNIT IS Exd IS Exd IS IS Exd IS Exd Exd HA PB
No. 1 22/24 8 26 7 41 3 2 19 25 57 4 30 25

47/48/49 105 4 374 4 3 95 4 239 4 16

No. 2 11/12/14 62 69 59 76 147 67 70 9 157 12 30 25

No. 3 13/15/16/17/18/19 66 118 86 140 209 62 117 18 167 7 40 35

No. 4 41/42/43/44/45/46 369 6 557 6 6 325 6 87 6 6 60 35

No. 5 61/62/63/64/65 273 6 426 6 6 260 6 259 6 8 60 35

No. 6 21/27/28/31/32/33/37/38 50 20 167 29 22 52 18 527 92 409 48 22

CCR 51/52/53/54 27 24 97 13 4 23 23 30 69 110 40 35

01/02/03/06 98 4 70 13 4 92 4 15 81 4

Jetty 28/29/30/38/39 5 5 20 5 5 5 5 191 5 52 30 25

Doha 33/34 2 2 2 10 2 2 2 2 114 34 30 20

Total 1065 284 1865 343 411 985 274 1402 758 662 368 257

1. Abbreviation AI : Analog Input DO : Digital Output

I.S : Intrinsically Safe AO : Analog Output CAI : Analog Input for Control PB : Push Button & Other Switches
Exd : Flamefroof DI : Digital Input LAI : Low Energy (T/C, Etc) AI HA : Hard Annunciat
Note 1: The I/O quantity in each SER will be subdivided (later) to each process unit basis so that the individual process unit shall have dedicated rack(s).
Sharing the same rack for small process units shall be discussed case by case and is subject to COMPANY acceptance.
2 : The I/O quantity indicated are preliminary and as likely to undergo changes during further detail engineering.
3
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APPENDIX H

SYSTEM INTERFACE & ASSOCIATED UNITS

1. Associated Process Units, SER No., and Assigned Operator Station(O.S NO)

SER NO. Unit No. Unit Name O.S NO.

CCR 01 No.1 Crude 1

CCR 02 No.1 Naphtha Hydrotreater Unit 1
CCR 03 No.1 Platforming 1
CCR 06 Desalter 1
2 10 Interconnecting Line between process unit 1
2 11 No.2 Distillation Unit 1
2 12 No.2 Naphtha Hydrotreater 1
3 13 No.2 Continuous Catalytic Reformer 2
2 14 No.2 Kerosene Hydrotreater 1
3 15 No.2 GO Hydrotreater 2
3 16 No.2 Amine treatment Facilities 2
3 17 No.2 LPG Recovery Facilities 2
3 18 No.2 Penex Unit 2
3 19 No.2 Molex Unit 2
6 21 Tanks 4
1 22 Cooing Tower and Flare Facilities 4
1 24 Effluent Water treatment 4
6 27 Export / Import System at Refinery 4
6 28 Transfer line between refinery and Berth No.6 4
6 31 Slops Dispos., F/F, Water & Drain System for Ex./Import 4
6 32 Export Facilities to Doha Depot at Refinery 4
6 33 Multi Products Transfer Line from Refinery to Doha Depot 4
6 34 Residue Transfer Line between Refinery and Doha Depot 4
6 37 Residue Tanks and Pumps at refinery 4
6 38 Residue Transfer Line between Refinery and Berth No.6 4
4 41 Fluid Catalytic Cracking 5
4 42 Light FCC Gasoline merox 5
4 43 FCC C3 / C4 Merox 5
4 44 Catalytic Polymerization and Hydrogeneration 5
4 45 Heavy FCC Gasoline Hydrofinisher 5
4 46 LCO Hydrotreater 5
1 47 / 47A Sulphur Recovery and Sulphur Handling 3,5
1 48 Sour Water stripper 3,5
1 49 Amine Treatment 3,5
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APPENDIX H
1 – continued

SER NO. Unit No. Unit Name O.S NO.

CCR 51 Boiler, Refinery Water, Steam Cond. & W/T, Power 4

CCR 52 Plant and Instrument Air and N2 4
CCR 53 Fuel Oil 4
CCR 54 Fire Fighting Unit 4
5 61 Condensate Distillation 3
5 62 Naphtha Hydrotreater 3
5 63 Continuous Catalytic Reformer 3
5 64 Middle Distillate Hydrotreater 3
5 65 Cap Condensate Splitter 3
Doha 33 Multi Products Transfer Line from Refinery to Doha Depot 7
Doha 34 Facilities at Doha Depot 7
Jetty 28 Transfer line between refinery and Berth No.6 6
Jetty 29 Loading & Unloading facilities & Drain System at Berth No.6 6
Jetty 30 Fire Fighting System at Berth No.6 6
Jetty 38 Residue Transfer Line between Refinery and Berth No.6 6
Jetty 39 Residue Loading Facilities at Berth No.6 6
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APPENDIX H

2. Serial Interface Schedule in CCR, SERs, Doha Depot and Berth No.6(Jetty)

(Note: The detail of serial interface with package control system will be developed during detail design
stage)
SER SYSTEM OR EQUIPMENT Q’t Interface PLC protocol Comm. Bau Locati
NO y Method Type Card d on
Model Model Rate Of
PKG
System
1 1 Vibration Monitoring 1 NOTE 2 Bently- SER1
3 System Nevada
2 UPS 1 SI *Note1 SER1
3 Intelligent MCC 1 EPLCG® ?? PLC S/S 4002
4 Battery Charger 1 SI ?? PLC S/S 4002
5 Other Aux.(Spare) 1 SI

2 1 Vibration Monitoring 1 NOTE 2 Bently- SER2

3
System Nevada
2 WWT System (24 Unit) 1 SI A-B Local
3
PLC
3 EDR Package (24 Unit) 1 SI A-B Local
3
PLC
4 UPS 1 SI *Note1 SER2
5 Other Aux. 1 SI

3 1 Rotary Valve Panel 1 SI TI LOCAL

(Lock Hopper PLC) Series
500
PLC
2 Vibration Monitoring 1 NOTE 2 Bently- SER3
3 System Nevada
3 UPS 1 SI *Note1 SER3
4 Other Aux. 1 SI

4 1 Anti-Surge System 1 EPLCG® CCC SER4

2 Lock Hopper PLC (Unit 41) 1 SI ?? PLC SER4
3 Vibration Monitoring 1 NOTE 2 Bently- SER4
3 System Nevada
4 UPS 1 SI *Note1 SER4
5 Intelligent MCC 2 EPLCG® ?? PLC S/S 4000
& 4001
6 Battery Charger 2 SI ?? PLC S/S 4000
& 4001
7 Other Aux. 1 SI
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SER SYSTEM OR EQUIPMENT Q’t Interface PLC protocol Comm. Bau Locati
NO y Method Type Card d on
Model Model Rate Of
PKG
System
5 1 Air Drier Package(6347L) 1 SI ?? PLC LOCAL
2 Catalyst Regeneration 1 EPLCG® A-B SER5
System PLC
3 - - - - -
3
4 Vibration Monitoring 1 NOTE 2 Bently- SER5
3 System Nevada
5 UPS 1 SI Note1 SER5
6 Intelligent MCC 1 EPLCG® ?? PLC S/S 6000
7 Battery Charger 1 SI ?? PLC S/S 6000
8 Other Aux. 1 SI

6 1 Sphere Launcher (2801-1L) 1 SI A-B LOCAL

3
PLC
2 UPS 1 SI *Note1 SER6
3 Intelligent MCC 1 EPLCG(R) ?? PLC S/S6001
& 6002
4 Battery Charger 1 SI ?? PLC S/S6001
& 6002
5 Other Aux. 2 SI

CCR- 1 Metering System 1 SI PC CCR

1
2 Vibration Monitoring 1 SI Bently- CCR
3
System Data Manager or Nevada
Ethernet PC
3 Tank Gauging System 1 SI SAAB CCR
PC
4 UPS 1 SI *Note1 CCR
5 Intelligent MCC 1 EPLCG(R) ?? PLC S/S CCR
6 Battery Charger 1 SI ?? PLC S/S CCR
7 Other Aux. 1 SI

CCR- 1 MP Steam Boiler (5107u) 1 EPLCG(R) A-B Local

2 PLC
2 Power Generation Package 1 SI PLC Local
3
(5105u)
3 Nitrogen Package (5204l) 1 EPLCG(R) A-B
PLC
4 Air Compressor Package 3 SI Elliot Local
(5205l) PLC
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SER SYSTEM OR EQUIPMENT Q’t Interface PLC protocol Comm. Bau Locati
NO y Method Type Card d on
Model Model Rate Of
PKG
System
5 Air Dryer Package (5206l) 2 SI A-B
PLC
6 Water Dealkaliser Package 1 SI A-B Local CR
3
(5106u) & MP/LP PLC
Dealkaliser Package (5108u)
7 Intelligent MCC 1 EPLCG(R) ?? PLC S/S5000
8 Battery Charger 1 SI ?? PLC S/S5000
9 Other Aux. 1 SI

DOH 1 Sphere Receiver (3302L) 1 SI A-B Local

A PLC
2 Truck Loading System 1 SI Spectra Dist.
Office
-Tek
3 Metering System 1 SI A-B Doha CR
PLC
4 Tank Gauging System 1 SI SAAB Doha CR
PC
5 Other Aux. 1 SI

BERT 1 Metering System 1 SI A-B Jetty

H PLC CR
NO.6
2 Sphere Receiver (2802L) 1 SI A-B Local
PLC
3 Sphere Receiver (2804L) 1 SI A-B Local
PLC
4 Sphere Receiver (2812-L) 1 SI A-B Local
PLC
5 Other Aux. 1 SI

* Note 1: Vendor standard Intelligent Microprocessor, MOD BUS, RS 232 or 485.

2: Dual data link shall be provided as per the FEED specification for Vibration and
3 Temperature Monitoring System to interface the system to DCS.
3: ??PLC to be finalized later.
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4. Power Consumer List in CCR, SERs, Doha Depot and Berth No.6(Jetty)
(Power : 110V AC, 50Hz, UPS)
SER NO SYSTEM OR EQUIPMENT Q’TY CONSUMPTION PER
UNIT
1 1 Claus Air Blower (4701JA) 1 1.0 KVA
2 Claus Air Blower (4701J) 1 1.0 KVA
3 Thermal Reactor (4701D) 1 1.0 KVA
4 Thermal Oxidizer(4701B) 1 1.0 KVA
5 Claus Air Blower (47801J) 1 1.0 KVA
6 Thermal Reactor (47A01D) 1 1.0 KVA
7 Thermal Oxidizer(47A01B) 1 1.0 KVA
8 47-AE-001 (H2S Gas Analyzer) 1 500VA
9 47-AE-002 (H2S Gas Analyzer) 1 500VA
10 47-AE-003 (SO2 Analyzer) 1 500VA
11 47-AE 004 (Oxygen Analyzer) 1 500VA
12 Flare System (22 Unit) 2 500VA
13 Cooling Water System (2202U) 1 1.0 KVA
14 WWT System (24 Unit) 1 1.0KVA
15 RO Package (24 Unit) 1 1.0KVA
16 PH Analyzer 5 300VA
17 Conductivity Analyzer 4 300VA
18 Corrosion Analyzer 1 300VA
20 Other Aux. 10 2.0KVA
2 1 Overhead Gas Compressor(1109J/JA) 2 2.0KVA
2 Two Stage Desalter Unit(1103L) 1 2.0KVA
3 Recycle & Make-up Gas Comp. 2 1.5KVA
(1401J / JA)
4 Other Aux. 4 2.0KVA
5 Vibration Monitoring System 1 1.0KVA
6 Tank Gauging System 1 1.0KVA
3 1 Recycle Gas Compressor(1305J/JA) 2 2.0KVA
2 Net Gas Compressor(1307J/JA/JB) 3 2.0KVA
3 Recycle Gas Compressor(1501J1/JA1) 2 2.0KVA
4 Make-Up Gas Compressor(1501J2/JA2) 2 2.0KVA
5 Sour Gas Compressor (1502J/JA) 2 2.0KVA
6 Rotary Valve Panel(Lock Hopper PLC) 1 2.0KVA
7 Monirex Control Panel 1 2.0KVA
8 Anti-Surge System 1 1.0KVA
9 Other Aux. 4 2.0KVA
10 Vibration Monitoring System 1 1.0KVA
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SER NO SYSTEM OR EQUIPMENT Q’TY CONSUMPTION PER

UNIT
4 1 Main Air Blower (4101J) 1 1.5KVA
2 Wet Gas Compressor (4143J) 1 1.5KVA
3 Make-Up Recycle Gas Compressor 1 1.5KVA
(4502J)
4 Make-Up Recycle Gas Compressor 1 1.5KVA
(4502JA)
5 Make-Up Gas Compressor(4601J1) 1 1.5KVA
6 Recycle Gas Compressor(4601J2) 1 2.0KVA
7 Make-Up Gas Compressor(46014JA1) 1 1.5KVA
8 Recycle Gas Compressor(4601JA2) 1 2.0KVA
9 Sour Gas Compressor (4602J) 1 2.0KVA
10 Sour Gas Compressor (4602JA) 1 2.0KVA
11 41-AE-001( Oxygen Analyzer) 1 700VA
12 41-AE-201 (Distillation ) 1 1.0KVA
13 41-AE-551 (Distillation ) 1 1.0KVA
14 41-AE-501 (Chromatograph) 1 10KVA
15 45-AE-001 (Hydrogen Analyzer) 1 1.0KVA
16 45-AE-002 (Oxygen Analyzer) 1 700VA
17 45-AE-003 (Combustibles) 1 700VA
18 Anti-Surge System 1 1.0KVA
19 Other Aux. 6 2.0KVA
20 Vibration Monitoring System 1 1.5KVA
21 Lock Hopper PLC(Unit 41) 1 1.0KVA
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SER NO SYSTEM OR EQUIPMENT Q’TY CONSUMPTION PER

UNIT
5 1 Recycle Comp(6215j & 6215ja) 2 2.0KVA
2 Recycle Compressor (6305j) 1 2.0KVA
3 Net Gas Compressor (6307ja) 1 2.0KVA
4 Net Gas Compressor (6307j) 1 2.0KVA
5 Air Drier Package(6347l) 1 1.5KVA
6 Regeneration Heater L/P(6332b) 1 1.0KVA
7 Air Heater Insulator L/P(6333b) 1 1.0KVA
8 Recycle Gas Compressor (6412j) 1 2.0KVA
9 Make-up Gas Compressor (6411j) 1 2.0KVA
10 Recycle Gas Compressor (6412ja) 1 2.0KVA
11 Make-up Gas Compressor (6411ja) 1 2.0KVA
12 Catalyst Regeneration System 1 2.0KVA
13 61-AE-001 (PH/ORP)Analyzer) 1 1.5KVA
14 61-AE-002 (Color Analyzer) 1 1.0KVA
15 62-AE-004 (Oxygen Analyzer) 1 700VA
16 62-AE-005 (Oxygen Analyzer) 1 700VA
17 62-AE-006 (Oxygen Analyzer) 1 700VA
18 62-AE-002 (Portable Oxygen) 1 700VA
19 63-AE-002 (Moisture Analyzer) 1 1.5KVA
20 63-AE-003 (Hydrogen Analyzer) 1 1.0KVA
21 63-AE-004 (Octane / RVP Monitor) 1 2.0KVA
22 63-AE-005 (Oxygen Analyzer) 1 700VA
23 63-AE-006 (Oxygen Analyzer) 1 700VA
24 63-AE-007 (Oxygen Analyzer) 1 700VA
25 63-AE-008 (Oxygen Analyzer) 1 700VA
26 63-AE-002 (Portable Oxygen) 1 700VA
27 63-AE-004(R)( PH Analyzer) 1 700VA
28 63-AE-001(R) (Oxygen Analyzer) 1 700VA
29 Anti-Surge System 1 1.0KVA
30 Other Aux. 10 2.0KVA
31 Vibration Monitoring System 1 1.0KVA
6 1 Sulfur Analyzer 21 2 2.0KVA
2 RVP Analyzer-21 3 2.0KVA
3 NIR Analyzer-21 3 2.0KVA
4 Density Analyzer 6 1.0KVA
5 Sphere Launcher/Receiver (2801L) 1 1.0KVA
6 Sphere Launcher (2801-1L) 1 1.0KVA
7 Sphere Receiver (2803L) 1 700VA
8 Sphere Launcher (3301L) 1 700VA
9 Tank Gauging System 1 1.0KVA
10 Other Aux. 5 2.0KVA
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SER NO SYSTEM OR EQUIPMENT Q’TY CONSUMPTION PER

UNIT
CCR-1 1 Crude Tower Gas Compressor(#301) 1 1.5KVA
2 Platforming Recycle Comp.(#304A/B) 2 1.5KVA
3 Fee Gas Compressor(#302) 1 1.5KVA
4 Crude Oil Desalter Package(1108A/B) 2 2.0KVA
5 Metering System 1 1.5KVA
6 Vibration Monitoring System 2 1.0KVA
7 Other Aux. 5 2.0KVA
CCR-2 1 MP Steam Boiler (5107u) 1 3.0KVA
2 Power Generation Package (5105u) 1 3.0KVA
3 Nitrogen Package (5204l) 1 1.5KVA
4 Air Compressor Package (5205l) 1 1.5KVA
5 Air Dryer Package (5206l) 1 1.5KVA
6 Tank Gauging System 1 1.5KVA
7 Water Dealkaliser Package (5106u) 1 1.5KVA
8 MP/LP Dealkaliser Package (5108u) 1 1.5KVA
9 BFW Treatment Package (5105l) 1 1.5KVA
10 Raw Water System 1 1.5KVA
11 Oil In Water Analyzer-51 Unit 3 1.5KVA
12 Moisture Analyzer-51 Unit 1 2.0KVA
13 Other Aux. 10 2.0KVA
DOHA\ 1 Sphere Receiver (3302L) 1 700VA
2 Leak Trap (3424L) 1 700VA
3 ASA Package (3411L) 1 1.0KVA
4 Traffic Management System 1 700VA
5 VRU Panel 1 1.0KVA
6 Density Analyzer 2 1.0KVA
6 Other Aux. 3 2.0KVA
BERTH 1 Sphere Launcher/Receiver (2802L) 1 700VA
NO.6 2 Sphere Launcher (2804L) 1 700VA
3 Sphere Launcher (2802-1L) 1 700VA
4 Density Analyzer 4 1.0KVA
5 Other Aux. 3 2.0KVA

General Notes on Power Distribution;

1. The power consumption denotes “Power Consumption per equipment or system”.
Total feeds shall be referred to the Q’ty of equipment or systems shown on the table.
2. The table only shows additional power consumers supplied by others and therefore vendor
shall provide all feeds required for equipment or systems to be supplied by vendor such as POIS,
DCS, ESD, F&G, all peripheral devises, etc.
3 3. Actual power consumption may vary as per vendor’s final information.
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APPENDIX I

PIPING AND INSTRUMENTATION DIAGRAM UNIT 21 BLENDING UNITS

(7J48N-21-00-30-033)
(TO BE INFORMED SEPARATELY)
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APPENDIX J

INSTRUMENT AND ELECTRICAL INTERFACE EARTHING PHILOSOPHY

(7J48N-00-15-51-301 AND 7J48N-00-15-51-302)
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APPENDIX K

SPECIAL REQUIREMENT FOR YEAR 2000 COMPLIANCE

To implement the Project, a high level of computer based technology will be employed. All
hardware, software and middleware considered for the Project shall be Millenium (Year 2000)
compliant, irrespective of system considered, i.e. application servers, file servers, PC’s,
Distributed Control System (DCS), PLC’s, small closed loop controllers, etc..

The Millenium crisis is not an information technology issue. It will effect the whole Project and
should be treated with a degree of importance on the Project. Due diligence should be paid
throughout.

The Vendor shall submit Year 2000 Compliance and associated Quality Plan with the Proposal,
which shall address the following issue as a minimum.
i The corporate statements to handle the Year 2000 issue.
i The current status of company progress to date.
i The resources allocate to manage this issue.
i Company sponsor to monitor the issue and report corporate status independent of any one
project
i Procedure to handle partners and subcontractors.
i Protection of the supply chain, i.e. VENDORs, consultants, subcontractors, service companies,
etc..

1. The VENDOR shall warrant and guarantee that all equipment, including software, that is provided
and/or used by the VENDOR will neither fail nor produce incorrect results due to the impact of
the changing century and the calculations based on those dates. Both business application
programs and operating systems utilities must perform arithmetic operation, comparison and
sorting of date fields to yield correct results when working with years either inside or outside the
range 1900 – 1999, including the correct calculation of leap years.

2. PURCHASER shall have the right to audit the VENDOR against BSI Code of Practice PD2000-2
for Managing Year 2000 Conformity (Refer to http://www.bsi.org.uk/disc/products/pd2000-
2.html) and in the event of non-compliance instruct VENDOR to take whatever action
PURCHASER deems necessary in the best interest of the PURCHASER.

3. In addition to, and without limiting in any respect any other warranties, indemnities in the
AGREEMENT(Contract or Purchase Order), The VENDOR shall warrant, that the following shall
be Year 2000 compliant:

3.1 all computer application and system software and all instrumentation and control systems
which include imbedded processing(hereinafter “software/systems”) supplied or licensed to
or developed for PURCHASER upgrades or modifications to software/systems previously
supplied or licensed to or developed for PURCHASER, and
3.2 all computer hardware with embedded processing, and any upgrades or modifications thereto,
supplied to PURCHASER under or pursuant to this AGREEMENT(Contract or Purchase
Order), and
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APPENDIX K - CONTINUED

3.3 all other equipment, machinery or materials of whatever nature supplied, provided to made
available to PURCHASER under or pursuant to this AGREEMENT(Contract or Purchase
Order) which include software/systems or computer hardware with embedded processing,
and
3.4 all software/systems and computer hardware with embedded processing and all equipment,
manufacturing processes, machinery or materials which include or involved the use of such
software/systems or hardware, utilized by VENDOR directly or indirectly in or in connection
with the performance of the WORK, services or supply of goods or the performance by
VENDOR of any of it obligations under this AGREEMENT(Contract or Purchase Order).

4. For the purpose of this Article, Year 2000 Compliant means that, in relation to software/systems,
it or they will:
a) completely and accurately address, present, produce, store and calculate data for dates before,
during and after the year 2000, and
b) provide that all date-related functionality’s and data fields include the indication of century
and millennium either explicitly or be unambiguous algorithms or interfacing rules, and
c) correctly perform calculations which involve a four digit field, and
d) not produce abnormally ending or incorrect results involving dates before, during or after the
year 2000 as used in any forward or regression date-based functions, and
e) recognize the year 2000 as a leap year, and

5. This warranty shall survive the expiry or termination of the AGREEMENT (Contract or Purchase
Order) and expiry of any warranty or guarantee period contained herein or elsewhere in the
AGREEMENT (Contract or Purchase Order).

6. Without prejudice to VENDOR obligations hereunder and to any other inspection or audit rights
of the PURCHASER hereunder, PURCHASER may carry out such audit or inspection as it
considers appropriate to establish compliance by VENDOR and its Sub-VENDORS with this
Article. The VENDOR shall co-operate fully with all reasonable requests made by PURCHASER
for this purpose.

7. The VENDOR shall include a provision in the same terms as this Article (specification)
appropriately adapted, in any SUBCONTRACT entered into by it in connection with the subject
matter of the AGREEMENT (Contract or Purchase Order).

8. In the event of any breach of the warranties contained in Article 3, The VENDOR shall promptly
take all actions required to remedy such breach at no cost to PURCHASER.”
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APPENDIX L

OFFSITES AUTOMATION AND MANAGEMENT SYSTEM - GENERAL REQUIREMENTS

PRODUCT MOVEMENT

Produce movements consist of transferring products from one point to another point within the refinery
offsites area.

The product movements foreseen for the refinery are of the following “elementary” categories:

y Product blending
y Product transfer
- Storage tank to process unit (unit feed)
- Process unit to storage tank (unit rundown)
- Storage tank to storage tank (Specific cases only)
- Product shipment:
. Storage tank in line towards rail car and truck loading
. Storage tank to pipeline
- Product receipt:
. Pipeline to storage tank (crude oil)
. Line coming from rail car and truck unloading to storage tank
y Storage tank drainage (only manual and local)
y Flushing (only manual and local)
y Washing (only manual and local)

The above categories of movements are so called “elementary” as to perform the movement of a
product from a source to a destination, several of the above movements categories may be carried out
(for instance, tank to tank transfer with prior line flushing).

PRODUCT MOVEMENT CATEGORIES

a. Blending

Two different blending movements shall be performed by the system.

The first type of blending (this is the preferred type) shall be in-line blending. In this case, the
components shall be mixed in blend headers and flow together in the destination tank. In-line
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analysis shall be performed to control in real time the quality of the finished product.

The second type of movement shall be batch blending. It shall only be used for final finished
product quality adjustment by successively filling through the blend header the destination tank
with the different required components while mixing.

Type Blend
Source tank
Swing optional
Sharing optional
Destination tank
Swing no
Sharing optional
Mvt with pump required for each component
Mvt by gravity no
Flow rate controlled by “Blending In-line Control” function for each line /
component (based on calculated blending total flow rate)
Volume component meters totalization
Mode batch
Normal stop conditions blended volume

b. Rail and Truck Loading and Unloading

Source or destination shall be the rail and truck loading or unloading lines.

Type Rail and Truck Unloading

Source unloading line
Swing not applicable
Sharing not applicable
Destination tank
Swing optional
Sharing optional
Mvt with pump required
Mvt by gravity no
Flow rate controlled by source
Volume flow metering
Mode non-continuous
Normal stop conditions manual

Type Rail and Truck Unloading

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Source tank
Swing optional
Sharing optional
Destination loading line
Swing not applicable
Sharing not applicable
Mvt with pump required
Mvt by gravity no
Flow rate controlled by destination
Volume flow metering
Mode non-continuous
Normal stop conditions manual

c. Pipeline Receipt and Shipment

Source or destination shall be the pipelines battery limits.

Type Pipeline Receipt

Source pipeline
Swing not applicable
Sharing not applicable
Destination tank
Swing optional
Sharing optional
Mvt with pump required
Mvt by gravity no
Flow rate controlled by source
Volume flow metering
Mode non-continuous
Normal stop conditions manual

Type Blend
Source tank
Swing optional
Sharing optional
Destination pipeline
Swing not applicable
Sharing not applicable
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Mvt with pump required

Mvt by gravity no
Flow rate controlled by destination
Volume flow metering
Mode non-continuous
Normal stop conditions manual

d. Unit Feed

This movement shall be executed during two different phases of the lifetime of the refinery.
Generally, during the units normal operation, unit feed movement shall ensure the suitable feeding
of the units. Uncommonly, during the start-up of an unit, a specific unit feed movement shall be
activated to fill up the various pipes and intermediate tanks inside the unit (hold up).

Type Unit Feed

Source tank
Swing optional
Sharing optional
Destination process unit
Swing not applicable
Sharing not applicable
Mvt with pump required
Mvt by gravity no
Flow rate controlled by destination
Volume flow metering
Mode non-continuous
Normal stop conditions manual

This movement covers only the transfer of unit rundown streams to intermediate storage tanks and
does not include the transfer from a process unit to another.

Type Unit Rundown

Source process unit
Swing not applicable
Sharing not applicable
Destination tank
Swing optional
Sharing optional
Mvt with pump optional
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Mvt by gravity no
Flow rate controlled by source
Volume flow metering
Mode continuous
Normal stop conditions manual

f. Tank to Tank Transfer

Type Blend
Source tank
Swing no
Sharing no
Destination tank
Swing no
Sharing no
Mvt with pump optional
Mvt by gravity optional
Flow rate not controlled
Volume source and / or destination volume variation
Mode non-continuous
Normal stop conditions transferred volume or level
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Product Movement Functions Versus Levels of Automation

The following table summarizes which functions of the Product Movement Management System will
be available depending on the level of automation of product movement.

Product Movement
Full Automation Manual Operation
Management Functions
Movement orders management Yes Yes
Movement case definition Yes No
Movement case setting Yes No
Movement validation Yes No
Movement start-up Initiated by operator. Initiated by operator.
Full automatic execution. Manual execution.
Movement monitoring Yes No (except data reconciliation)
Normal movement close-out Fully automatic execution. No
Operator movement close-out Initiated by operator. Initiated by operator.
Full automatic execution. Manual execution.
Movement close-out on incident Fully automatic operator. Initiated by operator.
Fully automatic execution. Manual execution.
Movement data reconciliation Yes Yes

PRODUCT MOVMENT ORDERS MANAGEMENT

Product Movement Orders Handling

The system shall provide facilities to the offsites operator in the Main Control Room (offsites console),
so that he can make the best use of the information contained in the movement orders during his
current activity. The facilities shall mainly consist in an enhanced operator-system interface working
on the offsites database and enabling interactive chaining of displays.

Movement orders data are stored in the offsites database where they have been entered either manually
by the Planning / Scheduling Department or automatically by transfer from a dedicated scheduling
application from the MIS (Management Information System).

This function shall allow the operator to perform, as a minimum, the following:

y to work on the movement orders list

y to view, at any time, movement orders data
y to create or cancel movement orders
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y to change the movement order execution chronology

y to initiate a movement

Confirmation and warning messages shall be displayed whenever the action requested by the operator
from the system is not compatible with the current operations.

Treatment movement order shall be maintained in the offsites database and shall be accessible to the
operator for information.

Movement Orders List

Following data shall be displayed for each movement order:

y movement order identification and associated labeling

y movement category
y movement order sate (scheduled, pending, underway, treated)
y product name and code
y scheduled date and time of movement start-up
y scheduled date and time of movement completion

Transfer Orders Data Detailed View

Following data shall be displayed for each transfer order:

y origin and destination points of the transfer

y volume of product to be moved

Blending Orders Data Detailed View

Following data shall be displayed for each blending order:

y origin and destination tanks

y volume of finished product to be manufactured
y initial blend recipe (component percentage)
y mini / maxi allowable percentages for each component
y initial heel volume in the finished product tank
y qualities of components used to elaborate the initial blend recipe
y quality specifications targets

Creating “Operator” Product Movement Orders

This function shall enable creating new movement orders at the initiative of the operator. This facility
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can be used, for instance, when system fault occurs and communication with the Planning / Scheduling
Department is not available.

All necessary checks shall be performed by the system (in particular, the movement order
identification numbers).

Product Movement Order Canceling

Canceling a movement order leads to the automatic generation by the system, of a report to be stored
in the offsites database and further in the refinery database.

The system shall prevent from canceling a movement order under execution.

A cancelled movement cannot be initiated.

Change of Product Movement Order Execution Schedule

The possibility of changing the movement order execution chronology shall be given to the operator
for providing more flexibility of offsites operation.

This facility can be used, for instance, when some equipment availability problems occur and provided
that it has no impact on the overall schedule of operation.

Product Movement Initiation

Product movement initiation by the operator will consist of:

y selecting a movement order

y activating the movement setting sub-function
y making all required selections and / or modifications of related movement case
y asking the system to validate the movement

The different steps of a movement initiation and validation are schematically represented on the next
sheet.
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Product Movement Initiation and Validation Steps

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Example of Off-site Process

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List of Oil Movement Oprerations(1 of 2)

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List of Oil Movement Operations(2 of 2)

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APPENDIX M

Not used
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APPENDIX N

SPECIFICATION FOR INSPECTION, TESTING AND COMMISSIONING OF

INSTRUMENT EQUIPMENT ITEMS (7J48N-00-15-51-013)
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APPENDIX O

CONSUMABLES AND SPARE PARTS

CONSUMABLES

The Vendor shall provide consumables for the guarantee period, as:

y Printer paper
y Printer ink ribbon
y Discs
y Floppy
y Fuses, etc.

The quantities must be estimated by the Vendor, based upon their experience and by taking into
account two periods:

y Precommissioning and commissioning period where consumption of consumables is greater.

y Normal use of the system.

SPARE PARTS

The Vendor can propose different type of spare part contracts. It is up to the Vendor to make the best
contract taking into account the amount of spares needed on site, the type of these spares and the stock
of parts that they store in their premises locally.

START-UP SPARES

The Vendor shall start-up spares normally required for the installation, testing, commissioning and
start-up period.

The start-up spare parts shall be delivered on site with the first system delivery.

OPERATIONAL SPARE PARTS

The Vendor shall supply spares normally required for the first year of warranty period. The spare
stock must be based on a separate recommended spare parts list (with itemized prices) in accordance
with proposed maintenance contract, including the possible remote diagnosis and trouble shooting, and
sufficient for one year of continuous operation of the system.

This spare part list has to be provided by the Vendor and it shall detail:
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y Identifying model and / or figure number of the piece of equipment for which the spare part is
being supplied.
y Spare part number and identifying name.
y Drawing or sketch number which reference the spare parts.
y Source of the part; when an art is not manufactured by the Vendor, the original Vendor’s
identification must be given.
3 y Recommended quantities of spare parts.

The Vendor shall explain their spare parts repair program and the spare parts deposit nearest to site as
well as which of the recommended spare parts are currently stocked at this depot.

The spare parts list shall be prepared on the basis of the reliability of the supplied equipment; i.e. the
expected MTBF and MTTR of each component of the system considered in their operative conditions
and related to the quantities installed in the plant.

The spare parts recommendation shall include all tools, auto test facilities or equipment necessary for
preventive maintenance and / or trouble shooting. The Vendor shall guarantee the availability of all
spare parts and replacement parts required by any equipment item supplied for a minimum 20 years
operational period (from the date of start-up and plant running normally)

INSURANCE SPARES

In addition to above vendor shall provide following insurance spares;

ITEM PARTS Q’TY

Touchsreen VDU(Visual Display Unit) 1
OPERATOR STATION Card Assembly 1
Keyboard 1
Power Supply Unit 1
Communication Interface Module 1
Controller Module Assembly 1
CONTROLLER & I/O Power Supply Unit 1
Analog Input Module 2
Analog Input Module(Smart Type) 2
Analog Output Module 2
Pulse Input Module 1
Digital Input Module 2
Digital Output Module 2
Field Termination Unit – Analog Input 1
Field Termination Unit – Analog Input(Smart) 1
Field Termination Unit –Analog Output 1
Field Termination Unit –Digital Input 1
Field Termination Unit –Digital Output 1
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APPENDIX P

MARSHALLING CABINET

Refer to Drawings:-

180126/00/20/41/02 Marshalling Cabinet layout (Design Basis)

180126/00/20/41/03 Marshalling Cabinet layout (Design Basis)