Basic Process Control Systems Requirements.pdf

TECHNICAL SPECIFICATION BASIC PROCESS CONTROL SYSTEMS REQUIREMENTS

DATE: 01 MAY 2005

ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC.

I3510E-BASE PAGE 1 OF 32

This BASE specification must be revised by the project team to meet projectspecific requirements. Refer to Appendices A, B, C, D and E for additional clarification of project requirements.

TABLE OF CONTENTS Section 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 3. 3.1 3.2 3.3 4. 4.1 4.2 4.3 4.4 4.5 4.6 5. 5.1 5.2 6. 7. 7.1 7.2

Title Page No. GENERAL ............................................................................................................................2 Scope...................................................................................................................................2 KBR Documents, Codes, and Industry Standards ................................................ ....................2 Definitions of Terms ..................................................... ........................................................ .3 Supplier General Response ................................................... ................................................4 Project Management .................................................... ........................................................ .6 Testing and Inspection............................... ........................................................ ....................6 Shipping ................................................... ........................................................ ....................8 Installation, Initial System Check, and Site Acceptance Test (SAT) ..... ...... ..... ...... ..... ..... ...... ..... 8 Field Loop Test.............. ....................................................... ................................................9 Training .................................................... ........................................................ ....................9 GENERAL SYSTEM REQUIREMENTS .................................................................................9 System Scope..................................................... ....................................................... ...........9 System Layout .................................................... ....................................................... ......... 10 Process Inputs/Outputs Assembl y .................................................... .................................... 10 Controller Features....................................................... ....................................................... 13 Control Algorithms............................ ........................................................ ........................... 15 Process Logic/Sequence Control............................................ .............................................. 15 Operation Station Features .................................................... .............................................. 16 Operator Console Printers ..................................................... .............................................. 17 Operator Keyboard......... ....................................................... .............................................. 17 System Diagnostics........ ....................................................... .............................................. 17 Historical Data and Trends....... ........................................................ .................................... 18 Reports .................................................... ........................................................ .................. 19 SYSTEM DESIGN REQUIREMENTS ...................................................................................19 System Wiring Requirements ................................................. .............................................. 19 Communication Bus ..................................................... ....................................................... 20 Electrical Power... ........................................................ ....................................................... 21 SYSTEM CONFIGURATION AND DISPLAYS ......................................................................22 Configuration ..................................................... ....................................................... ......... 22 On-line Modific ation........................................................................................... .................. 22 System Backup Alarm .................................................. ....................................................... 23 System Failures .................................................. ....................................................... ......... 23 Loop Tags ................................................ ........................................................ .................. 23 Mass Storage...................................................... ....................................................... ......... 23 ELECTRICAL AREA CLASSIFICATI ON AND NOISE ..........................................................23 Radio Frequency Interference (RFI) ................................................. .................................... 23 Electrical Area Classification .................................................. .............................................. 23 SYSTEM DOCUMENTATION AND DRAWINGS ..................................................................23 SPARE CAPACITY, EXPANDABILITY, MAINTENANCE, AND SPARE PARTS ....................23 Spare Capacity/Expandability............................................................................. .................. 23 Maintenance/Spare Parts ...................................................... .............................................. 24

8. 9.

EQUIPMENT IDENTIFICATION ...........................................................................................24 CABINETS .........................................................................................................................24 APPENDIX A: SYSTEM BLOCK DIAGRAM ........................................................................25 APPENDIX B: I/O SUMMARY TABLE .................................................................................26 APPENDIX C: ROLES AND RESPONSIBILITIES MATRIX ..................................................27 APPENDIX D: WORKSHEET - CONTROL CENTER NAME / NUMBER (2 Pages) ........... 28-29 APPENDIX E: WORKSHEET - I/O CLUSTER NAME / NUMBER (3 Pages) ..................... 30-32


DATE: 01 MAY 2005




1. GENERAL 1.1 Scope 1.1.1 This specification defines the minimum desi gn and performance requirement s of a microprocessor based Basic Process Control System (BPCS) and the system components, functions and services within the scope of thein BPCS Supplier. KBRmust will be as the Purchaser. and paragraphs underlined this specification bereferred revisedtowith project specific(Items data before using thisthat are specification in a Project.) 1.1.2 The BPCS shall enable plant operators to perform all the conventional actions required for safe plant monitoring, operation control and reporting. The BPCS shall monitor all process variables, display their values on Operator Statio ns, and allow operator control of designate d process variables. The system shall also generate alarms to warn the operator of any system or process variable values which are out of limits; the alarms shall be reported as timed messages on the screen displays and on the console printers, and stored in the history devices for future evaluation or printing. The system shall store proc ess information in electronic format for future access and review through the Operator Stations, Plant Information Network (PIN), and personal computers . The BPCS shall also be able to communicate and configure Foundation Fieldbus (FF) certified instrument devices via H1 protocol. Additionally, system shall be capable of displaying Foundation Fieldbus (FF) instruments' health or diagnostic variables and displayed them in a clear manner so the Operator or Maintenance technician can take action faster. 1.1.3 The BPCS Supplier shall provide all necessary hardware and software to meet the technical and functional requirements of this specification. The BPCS supplier scope shall include the following: a.

A state of the art, microprocessor based, fully integrated and assembled, completely functional and tested system; complete with process interface and control devices, operator interface with printers, serial interfaces to foreign devices, BPCS equipment cabinets, system wiring marshalling cabinets, all pre-fabricated system cabling and connectors, system software for configuration and programming.

b.

Project management services, including system engineering, project scheduling, testing and procurement, as required to implement the system.

c.

Configuration Services, if any specified in the Roles and Responsibilities Matrix, Appendix C.

d.

The Supplier shall follow all purchasing requirement s in the Purchaser Standa rd I2-3PS, “Purchasing Requirements for Instrument Control Centers".

e.

Software enhanc ement packages if any, shall be included as options. Any software license restrictions shall be clearly stated by the BPCS supplier.

f.

System Documentation as specified in “Supplier Data Requirements for BPCS” (SDR), attached to the Engineering requisition.

1.1.4 All special features or improvemen ts over the standard specification are shown in the Basic Process Control System Data Sheets, which shall be adhered to by the

BPCS Supplier.

1.2 KBR Documents, Codes, and Industry Standards 1.2.1 The following documents are referenced herein and form part of the Order. Additional KBR documents, when applicable, will be listed on the Requisition. The issue of KBR documents shall be as specified in the Requisi tion. Current editions of the industry standa rds including all manda tory addenda in effect at the time of the Order shall apply unless otherwise indicated.


DATE: 01 MAY 2005




KBR DOCUMENTS I2-3PS, SDR-2I-I351- XXXX,

“Purchasing Requirements for Instrument Control Centers” "Supplier Data Requirements for BPCS"

DEUTCHES INSTITUT FOR NORMUNG (DIN) DIN 43760,

"Measurement and Electrical Temperature Sensors; References-Tables For Nickel Resistors forControl; Resistance Thermometers"

FIELDBUS FOUNDATION (FF) FF 569, "Host Interoperability Support Test" INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE) IEEE 518, "IEEE Guide for the Installation of Equipment to Minimize Electrical Noise Inputs to Controllers from External Sources" IEEE 802.3 “Local and Metropolitan Area Networks: Specifi c Requirements” Part 3, “CSMA/CD, Access Method and Physical Layer” INSTRUMENTATION, SYSTEMS, AND AUTOMATION SOCIETY (ISA) ISA 5.1, “Instrumentati on Symbols, and Identification” ISA 5.3, “Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and Computer Systems” ISA 5.5, “Graphic Symbols for Process Displays” ISA 12.00.01, “Electrical Apparatus for Use in Class I, Zones 0, 1, & 2 Hazardous (Classified)) Locations” ISA 12.01.01, “Definitions and Information Pertaining to Electrical Instruments in Hazardous (Classified) Locations” ISA 12.12.01, "Nonincendive Electrical Equipment for Use in Class I and II, Division 2 and Class III, Divisions 1 and 2 Hazardous (Classified) Locations" ISA 50.00.1, "Compatibilit y of Analog Signals for Electronic Industrial Process Instruments" INTERNATIONA L ELECTROTECHNI CAL COMMISSION (IEC) IEC 61158, "Digital Data Communication for Measurement and Control - Fieldbus for Use in Industrial Control Systems" Parts 1 thru 8. PROCESS INDUSTRY PRACTICES (PIP) 1.2.2 Appendices Appendix A: Initial Network Diagram Appendix B: I/O Summary Table Appendix C: Roles and Responsibilities Matrix Appendix D: Worksheet - Control Center Name / Number Appendix E: Worksheet - I/O Cluster Name / Number 1.3 Definitions of Terms 1.3.1 Basic Process Control System (BPCS): the entire control system described in this specification. It shall include, as a minimum, control modules with their associated input/output modules, operator stations, third party device interface modules, protective enclosures and cabinets to house these modules, power supplies, internal power distribution wiring, internal communications wiring, marshalling cabinets and buses.


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1.3.2 Operator Station: The basic unit of the operator interface to the BPCS via which operator can view the process informa tion and can give operator command s to process and/or peripheral s. As a minimum, it shall include a flat panel monitor and associated pointing devices such as touch screen, keyboard and mouse or track ball. 1.3.3 Operator Console: cons ists of two or more operator stations assigned to a process unit and may house additional accessories such as pushbuttons, lamps, telephones etc. 1.3.4 Input/output (I/O) Modules: BPCS components directly connect ed to the process instrumentation that perform the process interface and multiplexing functions of the control system, and their protective enclosures (cabinets or racks). 1.3.5 Communication Buses: The communication cables and interface devices used for data exchange and data integrity protection, between the operator consoles, the control modules, the foreign device interfaces and the I/O modules. 1.3.6 Plant Information Network: Information network not directly related with process control and isolated with a firewall from the BPCS. 1.3.7 Programmable Electronic Syst em (PES): Configurable or programmable de vices to perform logic. Field devices are not included in PES. 1.3.8 Foundation Fieldbus (FF): Fieldbus is an all digita l, two-way multi-drop commu nications link among TM intelligent smart field devices and automation systems. FOUNDATION Fieldbus is the local area network (LAN) for instruments used in process automation with built-in capability to distribute the control applications across the network, including placing the control in the field device. 1.3.9 OLE for Process Control (OPC): OLE for process control, a new industry standard, defines a standard interface to access data from a variety of process control devices. The applications must implement one OPC compliant driver to access data from any OPC compliant server. 1.3.10 PROFIBUS: PROFIBUS is an op en, digital comm unication syst em with a wide range o f applications, particularly in the fields of factory and process automation. PROFIBUS is suitable for both fast, time-critical applications and complex communication tasks. There are three types of netw orks/sub-protoco ls defined by PROFIBUS: DP, PA and PROFINET. 1.4 Supplier General Response 1.4.1 The BPCS Supplier shall respond to each paragraph of this specification. The replies for each paragraph shall be: a. b. c.

In Compliance. Not in Compliance: BPCS Supplier shall state the specific reason for the deviation. Enhancement; BPCS Supplier shall explain the enhancement and how it will benefit this project.

All “Not in Compliance” and “Enhancement” replies shall be substantiated with published specifications or firm guaranteed commitments. Deviations included in any other part of the Suppli er’s proposal will no t be accepted by the Purchaser. The Purchaser does not take the responsibility to discover missing “Not in Compliance” items. Supplier must comply with all applicable requisition documents except for those deviations and alternatives accepted by the Purchaser as stated in the Purchase Order.


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1.4.2 Any omission of details in this specification shall not relieve the BPCS Supplier of the obligation to furnish a functional system, which operates in a manner satisfactory to the Purchaser. All conflicts between the specifications, standards and purchase order shall be referred to the Purchaser for clarification before proceeding with manufacture of the affected items. 1.4.3 Where this specification requests technical data, the BPCS Supplier shall respond by providing a special document when neces sary, by attaching data. When are attached, page number and or, paragraph number must referencerelevant the datatechn in theical response . Thedocuments BPCS Supplier shall provide a reply for both equipment and services specified here. 1.4.4 System costs such as hardware, cabinet integration, engineering services, factory accept ance and site Acceptance tests, shall be broken out and defined separately. The Supplier shall provide unit pricing for all equipment, software, and services in the proposal so that items, may be added or deleted on a reasonable basis. A total price to meet the job requirements and a price to add/subtract components, on an individual basis and with appropriate qualifiers, shall be supplied in the quote. For example, the price to add a new I/O card should include not only the cost of the new board, but any labor and related services required to order, install, wire and document the new addition. BPCS Supplier shall precisely describe the point licensing philosophy and costs for the proposed BPCS. Details shall include point type and limits per controller and/or system; license upgrades procedures . In the case of sources of large amounts of data such as third party equipment integration via OPC or Modbus, BPCS Supplier shall describe how the licensed points are utilized. 1.4.5 The Supplier shall provide sufficient support documentation with the quotation, including technical data on all quoted hardware and software, to help the Purchaser perform a complete technical evaluation. The Supplier shall also provide a simple block diagram showing all major components, interconnect ions and communication interfaces. 1.4.6 The Supplier shall provide the following additional information with the quotation: a.

Dimensional sketches of the proposed layout, including access space for cabinet door openings, chassis slides, and inspection covers

b.

HVAC load, power and grounding requirements, and weight for all major pieces of hardware

c.

Equipment installation and site planning instructions

d.

General equipment specifications

e.

Complete listing of all software and Licenses quoted for system configuration and operations - include the number of copies supplied and unit cost. Supplier shall also furnish a complete, descriptive listing of all other available software tools, packages and programming aids.

1.4.7 The Supplier may propose alternate system features other than those specifi ed in this document. Supplier shall clearly identify those features in the alternate quotation that do not comply with this specification. Supporting documents and explanations shall be included in the quotation to indicate how and why the proposed alternati ve is technically (in compliance) equivalen t or superior (enhancement ) to the specified system. 1.4.8 The BPCS Supplier shall provide a summary project milestone schedule, based on the site need date. The schedule shall identify major milestones in engineering, design, parts procurement, manufacture, factory testing, and shipment. All milestones at which information is required from the Purchaser shall be shown . Activities that require the presence of the Purchaser such as FAT, system crating, system unloading shall also be identified by the Project team. Preliminary design freeze dates and information required at those


DATE: 01 MAY 2005




dates shall be shown. Any deviation from the agreed upon schedule must have the Purchaser’s appro val. This schedule shall be reviewe d and agreed upon during the pre-award meeting. All clarifications regarding the scope of work and other requirement s shall be completed during the pre -award meetings. 1.5 Project Management 1.5.1 The BPCSA Supplier shall assign chart, a Project Manager, who personnel, will be the main source of official contacts for the Purchaser. project organization identifying project their responsibilities shall be provided at the pre-award meeting. The BPCS supplier shall also indicate their proposed manpower loading for the project. Purchaser requires continuity on all key personnel assigned to the Project. 1.5.2 The BPCS Supplier shall also designate a Project Engineer, who will be assigned to assist during the engineering effort. However, all correspondence shall be through the BPCS Suppli er Project Manager. The project engineer shall serve as the technical contact and provide assistance to the KBR project team on system engineering/configu ration issues 1.5.3 Purchaser requires continuit y on all key personnel assigned to the Project so any changes must be previously approved by Purchaser. 1.5.4 Milestone schedul e dates shall be established showing all the target dates for transmissio n of project documents so that the delivery of equipment will not be delayed. Any deviation from the agreed schedule will require the Purchaser’s approval 1.5.5 BPCS Supplier shall issue monthly written job progress reports to Purchaser’s Purchasing Department. Progress report shall have the fol lowing items as a minimum: a.

Project schedule updates.

b.

Indication of job progress to date and forecast to completion.

c.

Highlights of open commercial and technical issues .

d.

Resolution of open issues .

e.

Status of open change order requests.

f.

Financial and invoicing status.

1.6 Testing and Inspection 1.6.1 General a.

The entire system shall be given a complete shop and functional test prior to the Factory Acceptance Test (FAT). The BPCS Supplier shall perform this test. Written reports with test results shall be provided to the Purchaser, at least 10 (ten) working days prior to the FAT. This shop test shall include hardware checks, system power checks, and system diagnostic tests as well as the redundancy of power supplies and controllers . All deficiencies shall be corrected prior to start of FAT. The Purchaser reserves the option to perform any “spot” tests on the completed shop test.

b.

All electronic components and circuit boards shall be tested and burned-in before installation into electronic assemblies.


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1.6.2 Shop Test a.

Major components of the BPCS shall be tested at the BPCS Supplier shops before final system test. After system hardware assembly BPCS Supplier shall perform their standard hardware diagnostic and system tests. Test results shall be available to Purchaser’s inspectors . The BPCS supplier shall notify Purchaser in writing once the system has been completely assembled and is ready for inspection and testing.

b.

Purchaser will assign engineers to witness the shop tests and any subsequent corrections and debugging of hardware and diagnostics problems, until the tests are completed satisfactorily. The Shop tests shall successfully be completed prior to start of the FAT.

1.6.3 Factory Acceptance Test (FAT) a.

FAT shall be performed as per Appendix C, “Roles and Responsibilities Matrix", Item 2.14. Tests shall consist of loop-by-loop functional tests of all inputs and outputs, alarms, and control functions, to confirm proper operation and display ( Project specific ). The Project configuration database shall be used for testing. Supplier shall provide written test procedures to the Purchaser according to the Roles and Responsibilities matrix prior to FAT. FAT procedure shall be approved by the Purchaser. Tests shall be performed for all the inputs and outputs using signal simulators provided by the BPCS Supplier (Minimum one set per checkout team) ( Project specific ). In the case of FF cards and devices, the BPCS Supplier shall propose a method or product to simulate FF devices to test the configuration during the FAT. Such software/product should be reviewed / approved by the Owner and if accounted for in the main BPCS Purchase Order if it has commercial implications ( Project specific ). During FAT an integrated test of all systems including the BPCS, the Programmable Electronic System (PES), and any other third party system shall be performed to ensure proper functionality.

b.

BPCS Supplier shall furnish qualified technical personnel to assist Purchaser perform tests and debug the system during the scheduled accep tance test period. The Supplier shall provide the detail of support in the quote (number of individuals, duration of support, and qualifications of support individuals) . Technical supp ort may include but is not limited to configuration, graphics, networ k, wiring support (Project specific ).

c.

Office Space and office equipment (desk, chairs, phones, PC’s phone connections, office supplies) shall be provided by the Supplier at the FAT location. A floor plan of FAT location shall be provided three weeks prior to FAT to ensure the logistics, spaciousness and workability of FAT activities.

d.

A complete set of System documentation shall be made available by the BPCS supplier at the FAT locations for use during the FAT.

e.

A set of engineering documents such as P&ID’s, Control Narratives, Alarm Summary, Cause and Effect Tables, etc., shall be used to validate the system configuration (database and graphics). Configuration Acceptance Test (CAT) proced ures shall be provided by the party that performed the configuration as per Appendix C, “Roles and Responsibilities Matrix", Item 2.14.

f.

Once the system has been accepted, the responsible engineer (according to the matrix) shall prepare electronic copies of the configuration data on duplicate magnetic or optical media to be shipped separately. The electronic files will be used to configure the system after installation and power-up, at site.


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g.

FAT will be performed at the BPCS Supplier shops, unless a different agreement is reached during the pre-award meeting. Both cost and milestone schedu le in the BPCS Supplier quotation shal l be based on an XX week period for the FAT activity. The Supplier quotation shall also include the additional cost, on a weekly basis, including weekend and after-hours support, if a longer period is required to complete the FAT (Project specific).

h.

A punchthe listdeficiencies shall be maintained for all deficiencies found during thetotest. The responsible engineer shall correct and demonstrate the corrective action prior shipment of the system.

1.7 Shipping 1.7.1 All interconnecting cables shall be labeled at both ends, specifying cabinet, terminal panel and plug-in connectors to which each cable end is to be reconnected. After satisfactory completion of FAT, BPCS Supplier shall disconne ct all the equipment and prepare the system for shipment. 1.7.2 Cabinets shall be shipped intact. Circuit board cards are not to be removed for shipping, as long as the integrity of the electronic equipment is not compromised. BPCS Supplier shall protect and crate all cabinets properly to avoid damage during shipment and storage . BPCS supplier sh all provide acce lerometer indication on all BPCS cabinets. 1.7.3 Domestic shipment shall be by air ride van as minimum protection. 1.7.4 For overseas shipment, the BPCS Supplier shall contact Purchaser for special export licensing requirements. The responsible party for exporting equipment shall determ ine if export license is required according to the U.S. Department of Commerce Expor t Regulations. 1.7.5 BPCS Supplier shall ship touchup paint with the system. 1.7.6 BPCS Supplier shall immedia tely advise the Purchaser of any delays during shipme nt or damage during shipment. 1.8 Installation, In itial System Check and S ite Acceptance Test (S AT) 1.8.1 BPCS Supplier shall assign qualified personnel to: a.

Inspect, supervise, assist and approve site installation of BPCS building equipment, including computer floor and air conditioning.

b.

Supervise uncrating of BPCS equipment and check for any physical damage to the hardware.

c.

Check installation of BPCS networks and grounding.

d.

Provide technical support during initial BPCS power-up.

e.

Install diagnosti c software and perform hardware test, power checks, and system diagnostics to verify successful installation.

1.8.2 Purchaser will provide labor for uncrating, installation of equipment, connection for power and grounding, connection of field wiring to predefined terminal cabinets, and also connection of BPCS Supplier interconnecting cables. BPCS Supplier may install interconn ecting cabling if this is required by Supplier warranty ( Project specific).


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1.8.3 The Supplier shall perform SAT. The Supplier shall provide a detailed test procedure for the SAT (Project specific). 1.8.4 The SAT shall include loading the configuration on the system to assure the BPCS system including all third party communications is functional. 1.8.5 supplier of time cost allowed for activities, the installation at the siteBPCS and shall alsoproposal provide ashall rate state sheetthe foramount other field and and engineering support by jobsupport positions. 1.9 Field Loop Test 1.9.1 The field loop test shall be performed for all input and output signals from the field instruments to the BPCS. Refer to Roles and Responsibiliti es Matrix (Appendix C) for field support responsib ilities. 1.9.2 The Purchaser may request techn ical assistance from the BPCS Supplie r in conducting the field tests; therefore, BPCS Supplier proposal shall state the cost and amount of time allowed to support the field tests as an option and shall include a rate sheet for field and factory support activities, by job positions. 1.9.3 BPCS Supplier shall provide information on the service network that covers the site location and shall confirm the availability of 24-hour on-call service and provide details on the spare -part program. 1.10 Training 1.10.1 For the following training, Supplier shall furnish dates, location of schools, descriptions of course, duration and cost for the associated BPCS equipment. If "group training" conducted at the Purchaser’s facility will be more cost effective, this should be quoted as an option. Training to accomplish the following shall be included and shall be listed as a separate cost item. a.

Training of engineers in all aspects of system configuration at Supplier's training facility.

b.

Training of technicians in all aspects of system maintenance at Supplier's facilit y.

c.

Training of operators and foremen in all aspects of system operation (non-process related). System training will be preferably conducted at the job site.

2. GENERAL S YSTEM REQUIR EMENTS 2.1 System Scope 2.1.1 The system shall be microprocessor- based, assembled using supplier or third party standar d hardware, software and firmware, which can be configured to meet the specified requirements. All hardware, software and firmware supplied with the system shall have been field proven prior to placement of Order, with successful operation in similar system applications for six (6) or more months. The system shall be capable of communicating with Foundati on Fieldbus and HART protocol devices.. Foundation Field bus implementation guidelines are available in an Addendum to this specification (Project Specific). 2.1.2 The system shall be capable of performing all control functions, such as analog and discrete data acquisition, basic process and advanced regulatory control, logic, sequence and batch control (if required), first out alarming, etc., and all other operator and process interface tasks conventionally associated with main control room panels.


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2.1.3 The BPCS Supplier shall provide detailed techn ical data, with info rmation on actual applications, documenting the capabilities of the quoted BPCS to maintain bi-directional communications with Object Link Embedded (OLE) for Process Control (OPC) compliant foreign devices based on the standards of the OPC Foundation. 2.1.4 The system shall be capable of multiformat displays such as custom process graph ics, overview, group and plate detail,tuning trends, process alar status theservice loop parameters variable, setface point, output, constants, ms,indicating name tagalland description.such as process 2.1.5 The system shall provide user-configurable alarm functions to alert the operator of abnormal or dangerous conditions. The following listed features shall be available (as a minimum): a. b. c. d.

Configurable alarms from analog inputs: Low and High, Low-Low, and High -High Deviation from set point Controller output - Low and High Alarms from discrete inputs

Common means of alarm acknowledgment and horn silencing from the operator station keyboards shall be provided. BPCS Supplier shall state maximum counts of alarms that can be stored and displayed in real time from the alarm summary. 2.1.6 BPCS Supplier shall support all system hardware and firmware with spare parts and service for a period of at least ten (10) years after the withdrawal of the product from the market. BPCS Supplier shall provide upgrades and revisions of the software for a period of X years from the shipment date at no additional cost ( Project specific). 2.1.7 All software licenses shall be registered to the Plant Owner. 2.1.8 BPCS shall provide the highest possible level of security of operations . The failure of a single BPCS component shall not affect the performance of the BPCS or the security of operations . If there is a high probability that the failure of a BPCS component will cause loss of control of more than one critical process variable, then that electro nic component should have the capabil ity to add a redundant backup. Specific redundancy requ irements will be indicated in the initial network diagram and I/O summary table. 2.2 System Layout BPCS Supplier shall provide dimensioned sketches of the floor area requirements of the quoted equipment as indicated within this specification. The sketches shall show the layout of the equipment to be supplied, identified by name. 2.3 Process Inputs/Outpu ts Assembly 2.3.1 BPCS I/O processor modules shall be provided in quantities to match the input and output counts listed in the BPCS Data Sheets (Appendices B, D, and E) and an additional 10% margin for fully wired spares. BPCS supplier shall install the I/O processor modules, termination panels, cabling, terminals and accessories inside the BPCS controller cabinets. The controller cabinets shall provide both additional terminals for I/O wires and cabinet space to allow for future installation of an additional 10% I/O count, above the 10% margin for spares, when the system is turned over to the Plant owner at the end of Site Acceptance Tests.


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2.3.2 BPCS I/O modules shall provide 24 volts DC power to all field devices from dedicated power supplies installed in the controller cabinets. Power supplies shall be sized to handle the maximum controller I/O loading capacity, at the maximum power rating of the I/O modules. Power supply to each I/O channel shall be provided through either individually fused terminals or disconnect switches and current limiting circuitry in the marshalling panels (Project specific ). FF devices/H1 segment will require separate power supplies and power conditioners. 2.3.3 BPCS Supplier sha ll design the BPCS p rocess signal powe r distribution sys tem. Protective and interrupting devices shall be properly coordina ted to avoid single cause multiple failure s. A single electric al failure shall not cause power interruption to multiple I/O modules. 2.3.4 BPCS I/O data monitoring functions shall be programmed from the BPCS Supplier standard set of predefined, configu rable data collection algorit hms. I/O processing alg orithms will includ e the following, as a minimum: a.

Input signal linearization.

b.

Input signal characterization like square root, ISA Thermocouples and 100 ohm platinum RTD's, signal filtering, signal totalization.

c.

Input signal monitoring to generate invalid or out -of-range value status alarms. I/O processors shall be configurable, to allow or inhibit propagation of invalid or out-of-range values.

d.

Analog input and output signals will be monitored to generate out-of limit alarms when selected signal parameters exceed configurable limits. As a minimum, alarms shall be activated when the signal levels exceed high or low (HI or LO) warning, and high or low emergency (HI-HI or LO-LO), and rate of change limits. Individual prioritization of alarms shall be possible. The capability to enable and disable alarm functions shall be provided on an individual basis.

e.

Discrete input and output signals will be monitored and if required generate alarms. As a minimum, alarms will be activated based on signal status, change of state, un-commanded change and status disagree with command.

2.3.5 BPCS supplier shall provide one-to-one redundancy of selected BPCS analog input and output modules (See Appendix B, "I/O Summary Table"), with single field devices to improve the operability, safety and maintainability of continuous control loops and custody transfer variables . A pair of terminals shall be provided for termination of each field instrument wiring signal. Transfer of I/O module shall be automatic with fault indicati on on the operator’s console. 2.3.6 The BPCS supplier shall provide inputs and outputs suitable for nonincendive circuits as specified on the I/O Summary Table, per ISA S12.12.01 (Project specific ). 2.3.7 Input/output Capabilities Analog signals provided for the BPCS shall be compatible for use in electronic process systems as per ISA 50.00.1. a.

Current Analog Input The system shall be capable of handling grounded and ungrounded 4-20 mA signal from either a two wire or a four wire transmitter. If two wire, the system shall supply the 24 volt DC transmitter power, BPCS Supplier shall furnish all input range and current limiting resistors.


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b.

c.

d.

e.

Current Analog Output 1.

The system shall be capable of delivering isolated and non -isolated 4-20 mA output signal driving up to 600 ohms.

2.

I/O module output circuits shall be current limited.

Discrete Input 1.

System Powered Digital Input - The signal is a dry contact or an open collector transistor powered by the BPCS.

2.

Wetted Discrete Input - This is an externally powered voltage signal.

3.

The I/O modules shall accommodate both normally open and normally closed contacts and shall include isolation and filtering functions to insure that “chatter” or “bounce”, typical of contact closures, do not cause erroneous information.

4.

BPCS monitoring of discrete inputs shall be based, as a minimum, on detection of “change of state” or “current status”.

5.

BPCS shall have the capability to handle and monitor Sequence of Events (SOE) with a minimum resolution of 1 millisecond. Digital inputs that require SOE capability shall be indicated in the I/O Summary Table.

Discrete Output 1.

DC Discrete Output - This signal is an isolated relay or solid state output. Both momentary and sustained actions, normally open and normally closed shall be available . The outputs should be capable of driving loads as specified on the I/O Summary Table, Appendix B.

2.

Isolated AC Discrete Output - This signal is an isolated relay or a triac output. The outputs should be capable of driving loads as specified on the I/O Summary Table, Appendix B.

3.

Non-Isolated AC Discrete Output - This signal is a dry contact or triac output with power supplied from the BPCS.

4.

Each discrete output channel shall be individually provided with contact surge protection/arc suppression devices and fused disconnects at the output module.

RTD Input o

Three wire, 100 ohm, platinum RTD, 100 ohms at 32 F, per DIN Standard 43760. f.

Thermocouple Input 1.

Input cards shall be able to accept any industry standard thermocouples. Thermocouple burnout indication shall be selectable, either downscale or upscale. Inputs shall include automatic cold reference junction compensation.

2.

I/O modules shall provide automatic detection of thermocouple open-circuit conditions.


DATE: 01 MAY 2005




g.

h.

i.

Foundation Fieldbus H1 Interface Card 1.

Card shall reside in BPCS Controller chassis.

2.

Redundancy is required. Automatic failover switching shall be transparent to the system.

3.

Card can perform as the backup Link Active Scheduler (LAS)

4.

Each card shall have a minimum of 2 H1 ports or channels

5.

Supplier is to state the limits associated with FF devices and configuration such as maximum number of devices per H1 segment; maximum number of VCR’s, maximum number of Function Blocks and number of macrocycles.

Frequency Input 1.

Pulse train interpreted as either a scaled quantity per pulse for totalization or as an instantaneous process value proporti onal to pulse frequency.

2.

The system should be able to supply 24-volt DC power for the field pulse device or accept fieldgenerated pulses.

3.

Pulse Input cards shall be capable of receiving frequency-input signals from turbine meters and PD (positive displacement) meters

4.

The system shall be capable of accepting sine or square wave pulse signals.

Smart Device Interface Direct interface to “Smart/Intelligent” devices using industry standard protocols (Field Bus Foundation, ProfiBus, Hart, Device Net, Ethernet, etc.) shall be made available per the attached I/O Summary Table.

j.

External system gateways 1.

Interface to other control systems and serial devices . Interface protocols and electrical interface (i.e., RS485, Ethernet 10BaseT UTP) shall be determined on a case by case basis. See Appendix B, I/O Summary Table for definition.

2.

The BPCS gateway shall be capable of performing self-diagnostics of the communication links with the external systems.

3.

Maximum acceptable time lag across the gateway shall be 1 second.

2.4 Controller Features 2.4.1 BPCS control un its shall be mic roprocessor based, independ ent distribute d digital contr ollers. Each process controller sub-system shall be capable of true stand -alone operati on. Controllers shall provide the main physical and electrical interface to the process for data acquisition, continuous process control, logic and sequential control and high level application programming languages .


DATE: 01 MAY 2005




2.4.2 Each BPCS process control sub system shall include power supplies, control ler modules, communication modules, I/O processor modules, termination panels, cabling, terminals and accessories all mounted inside cabinets provided by the BPCS supplier. BPCS supplier shall also provide power supply modules dedicated to the field devices ( Project specific ). 2.4.3 The controller cabinets will be installed inside the rack room in a control building, remote rack rooms or in remoteand cabinets located throughout the process areas will interface directly with the process field sensors final control elements via hardwired signals orand communication networks. 2.4.4 The quantity, performanc e and type of controllers required shall be determined by the BPCS supplier, based on the following sizing criteria: a.

Process control functions shall be performed by the minimum possible number and type of devices and shall satisfy the redundancy and security requirements of this specification.

b.

The controller shall support selectable algorithm execution rates of at least four times a second.

c.

The controllers provided shall be capable of handling a minimum count of I/O processor devices, power supplies, terminations , wiring, etc., equivalent to 110% ( Project specific ) of the process I/O counts listed in this specification.

d.

The controllers shall be capable of handling a minimum count of control loops, calculations, logic and sequence functions equal to 110% (Project specific ) of the corresponding counts listed in this specification.

e.

It will be assumed that the execution rate for 80% of the control functions will be set at once per second while the execution rate for 20% of the control functions will be set at four times per second. It will also be assumed that the execution rate for all calculations, sequences and logic functions will be set at once per second.

f.

BPCS controller shall provide 30% spare additional processing and memory capacity, to accommodate for future high level application programming and configuration. Supplier to provide memory size quoted that is dedicated to these applications.

g.

Controller redundancy is required. The switch over on failure of main controller shall be bumpless.

2.4.5 Controller fault handling and recover y procedures shall be fully programmable func tionality, on a loop by loop basis, shall include: a.

Controller shall monitor all I/O signals and shall generate invalid or out-of-range value status alarms for inputs and calculated variables.

b.

Controllers shall be configurable, to either allow or inhibit propagation of invalid or out-of-range values through continuous or logic control loops.

c.

Controller shall be configurable to continue operating with the last valid data upon failure of communication s with either the operator interfaces or any other communication subsystems or switch over to manual mode upon detection of bad process value.

d.

Signal to field devices from analog and discrete output modules shall be configurable to either hold last good value or change to a selectable value, upon either failure of field device or controller module or loss of communication between the output processor and the controller module.


DATE: 01 MAY 2005




2.5 Control Algorithms 2.5.1 All basic process controls shall be programmed from the BPCS Supplier standard set of pre-defined, configurable control algorithms. All algorithms shall have capabilities to read and/or write parameters of analog and discrete process variables. 2.5.2 The set of process control algorithms shall include, as a minimum, the following: a.

Multiple proportional-integral-deriv ative (3-mode PID) control functions, in both simple loop and complex loop arrangements , like cascade and ratio control, split range, feed compensatio n, and feed forward.

b.

Parameter selection functions (high, low, middle of three, etc.)

c.

Calculation functions, either simple mathematical functions, or advanced calculations like signal linearization , mass flow compensation, signal averaging, polynomials, ramp generation, lead -lag compensation, totalization, etc .

d.

High level programming language.

2.5.3 The control algorithms shal l include additional selectab le features like bumpless automat ic mode transfer, anti-reset wind-up protection, process variable tracking when in manual mode, controller initialization when not in cascade mode, etc. 2.5.4 The BPCS shall provide discrete control algorithms for implementation of logic interlock, sequencing and batch contro ls. Logic controls shall be implemented using funct ional block programming and shall provide the following capabilities, either individually or in combination: a.

Timer functions, like time delays (on delay, off delay and one shot), pulse counters, latches, etc.

b.

Logic function blocks with logic gates like or, and, not, flip -flop, etc.

c.

Relational expressions like equal, less than, greater than, etc.

d.

High level structured sequence or batch programs.

2.5.5 Batch control algorithms shall provide flexible control of recipe execution and shall be capable of handling batch recipes with several different product grades, phases and steps. Operator shall be able to follow the execution of a recipe and also issue commands to skip and repeat steps; stop, hold, restart, and abort recipes; and enter data for use by the recipe (Project specific ). 2.6 Process Logi c/Sequence C ontrol 2.6.1 If BPCS Supplier quotes a separate logic/sequence controller then it shall be able to communicate with the Basic Process Control System and preferably be an integral part of the BPCS. 2.6.2 Programming of the logic/sequence contro ller shall be functional block programming or equivalent.


DATE: 01 MAY 2005




2.7 Operator Station Features 2.7.1 Each Operator Station shall consist of at least the following items: a.

Dual Screen, High-resolution flat panel color monitors, 21-inch diagonal, with touch screen, and high performance CPU running at the highest speed available at the time of the purchase order, and a

b.

Operator Keyboards: One keyboard per Station is required for normal operation. The keyboard shall allow access to both displa ys in dual tier cons oles. Membrane or QWERTY keyboa rds to be Project Specific.

c.

Screen pointing devices like mouse or track-ball.

d.

Removable bulk storage drives, like CD-R/W, tape drive or cartridge. Details on storage mediums shall be included in the quote.

minimum memory of 512 MB RAM.

2.7.2 Process control operations such as set point adjustmen t, manual controller output, alarm limit setting, etc., shall be performed through the operator consoles. BPCS Supplier shall provide either a console keylock switch or a password protection (access level) procedure to prevent unauthorized changes to system parameters and settings, such as controller tuning and alarm limits. 2.7.3 Update period for all active data in pre-for matted displays shall not exceed two seconds. 2.7.4 Call-up time for all custom graphic displays of average complexity, including all updated fields, shall not exceed 4 seconds after an operator request. The update period for real time data in custom graphic displays shall be not greater than two seconds for both alphanumerical data and dynamic display symbols like shape changes, color changes, etc. 2.7.5 BPCS Supplier shall provide each Operator Station with enough space for installation, by others, of the auxiliary control equipm ent: display based man-machine interface devices for selected packaged equipment, CCTV controls and plant communication sets. Counts of additiona l console mounted device s are estimates and will be confirmed before the hardware freeze dates. (See Worksheet (Appendix D) and Network Diagram (Appendix A) ( Project specific ). 2.7.6 BPCS Supplier shall provide each Operator Station with (when specified) the following auxiliary control equipment completely installed and wired to a terminal strip in the back of the station furniture: hardwired hand operated Emergency Shutdown (ESD) switches, Closed Caption Television (CCTV) displays, plant communication equipment, and paperless three inputs recorders. 2.7.7 Operator station redundancy shall be achieved by providing two or more identical operator stations for each Operator Console. Loss of one operator Station and associated components shall only reduce the number of windows to the process and shall not affect operation or performance of the other operator station(s). 2.7.8 Mounting of operator con sole equipment shall be based on BPCS Sup plier's standard desig n, arranged in accordance with the Purchaser layout described in the BPCS Data Sheet. 2.7.9 Console furniture shall be BPCS Supplier standard design and color. The console adjustable writing surface shall have a minimum depth of 12 inches (305 mm). The writing surface shall be continuous between console unit s in the same operating station. Console constructi on shall include pro per reinforcement to provide adequate rigidity for an industrial environment.


DATE: 01 MAY 2005




2.7.10 Maintenance access to the electronics shall be from both sides of the console. 2.7.11 BPCS Supplier shall provide dedicat ed engineering stations to allow on-line modifications to BPCS configuration and displays. The engineering station shall include: one high-resolution display color monitor, 21 inch diagonal; one Engineer Keyboard; screen pointing devices like mouse or track-ball; removable bulk storage drives, like CD-R/W, tape drives, etc. (See Subparagraph 2.7.1.d). See Worksheet (Appendix D) for details (Project specific ). 2.8 Operator Console Printers 2.8.1 BPCS Supplier shall supply (as specified in Worksheet, Appendix D) each operator cons ole with LaserJet printers: black and white printers for process and system alarms, logs and reports; and one (1) color printer for display printing. (Project specific ). 2.8.2 Alarm and report printers shall be laser using plain bond paper. The alarm printer shall be automatically activated by any alarm condition. The printout of alarm messages shall also be available upon operator demand ( Project specific ). 2.8.3 Alarm messages on both the operato r console screens and on the printer shall includ e the following items for each message, as a minimum: a. b. c. d. e. f.

Tag name Description Alarm Type and priority Date (day/month) and time (hour/minute/s econd) stamp Time alarm is acknowledged Time when alarm returns to normal

2.9 Operator Keyboard The operator keyboards shall be considered an integral part of the operator console. If a separate keyboard is required for configuration and programming, then the configuration keyboard shall be removable or located in an unobtrusive location. 2.10 S ystem Diagn ostic s 2.10.1 The control system shall automatically perform continuous self-diagnostic functions, at least once every five seconds. The self-diagnostic functions shall detect and isolate both communications failure s between components and failures at the board level in all system components, and alert the operator. 2.10.2 Interoperability a.

The FF devices shall be capable of perfor ming continuous diagnostic, inc luding self-test functions to provide specific diagnostic information to the Host.

b.

All Foundation Fieldbus instruments shall support methods to allow automation of on-line procedur es, such as calibration from the host.

2.10.3 All devices shall as a minimum satisfy the requirements of the fieldbus certification laboratory. In the case of Foundation Fieldbus, the FF "check mark" logo and listing on the Approved devices list maintained on its website www.fieldbus.org verifies interoperability of devices.


DATE: 01 MAY 2005




2.10.4 BPCS Supplier shall describe, and quote as options in the proposal, all additional special diagnostic tools or aids that can be used with the BPCS, such as remote diagnostics to factory, recommended field test equipment, etc. 2.11 Historical Data and Trends 2.11.1 The Supplier provideThe a configurable real time and historical data collection package to support trending, logging andshall reporting. package shall include: a.

Simultaneous trending of multiple tagged entities

b.

Storing the value of any analog entity or calculated value in history files

c.

Recording the change of state of any discrete point in one of the event histories

d.

Short term Historical Data collection with transfer of data to removable media for long term historical data storage and/or archiving.

2.11.2 BPCS Supplier shall provide a configurab le trend package to satisfy the foll owing real time and historical trending requirements: a.

Any analog variable can be configured for trending.

b.

The system shall support on-line trends for at least one minute snapshot and ave rage values for seven (7) days (Project specific ).

c.

BPCS Supplier shall indicate in the quotation the maximum number of analog points that can be trended in the proposed system.

2.11.3 Both real time trends and historical trends shall be provided. All operator stations shall be capable of displaying real time and historical trends. Each trend display shall consist of the plotted trend graph(s) and a table showing trend parameter s. It shall be possible to incorporate trends in graphic displa ys. 2.11.4 Each event history file entry shall contain the time and date of occurrence, the tag ID, the tag description and value/state and the type of event. The BPCS Supplier quotation shall indicate the maximum number of events that can be historically archived in the electronic mass storage media. 2.11.5 The following events as a minimum shall automatically be stored in history files for later reporting and analysis. a.

Process Events 1. 2. 3.

b.

Discrete inputs changing state Analog inputs going into or out of alarm Equipment changing state (running/stopped, open/closed)

Operator Events 1. 2. 3. 4.

Opening/closing isolation valves Starting/stopping of pumps and motors Changes to set points. Changing control blocks between automatic and manual


DATE: 01 MAY 2005




c.

Engineer Events 1. 2. 3. 4.

d.

Placing stations and devices on-line or off-line Changes to alarm set points Inhibiting/enabl ing alarms Changes to tag parameters on line.

System Events 1. 2. 3. 4. 5. 6.

Failed process Input/Output modules Communication errors Program error messages Switchover between primary and backup Failed controller modules Other function module failures

2.11.6 Adequate storage shall be provided for on-line access to the last seven days of data without manual selection of removable media from off-line files. 2.10.7 BPCS Supplier shall provide enough memory to store/retrieve data for past 6 months for a minimum of 4000 points and at sample rate of 1 minute with data compaction algorithm (Project specific ). 2.12 Reports The BPCS Supplier shall provide a report generation functionality to access all information available on the communication networks (control and alarm data, equipment failure data, configuration, etc.). The reports can then be executed on demand or automatically (based on an event or on time) and produce the report output to the communications network for access by all system components or user’s (i.e., operator consoles, engineerin g stations, printers, PC’s, host computers, etc.). Supplier to provide copies of the standard reports from the system. 3. SYSTEM DESIGN REQUIREMENTS 3.1 System Wiring Requireme nts 3.1.1 All BPCS network interconnecting wiring and cable to be installed inside system cabinets shall be provided by the BPCS Supplier. 3.1.2 BPCS Supplier shall provide complete wiring and termination information for all BPCS interconnecting cables (installed or shipped loose) either in the form of wiring schematics or wiring schedules, to Purchaser’s instrument design and electrical groups, in accordance with the Supplier Data Requirements. 3.1.3 All wiring shall be color coded according to project and local wiring requirements. Wiring size to be 16 AWG consistent with the terminal block size. Wiring insulation shall be 16 AWG, 600 V THWN as minimum. 3.1.4 Terminal blocks shall be non-hygroscopic type and provided by the BPCS Supplier. Terminals shall be tinned and shall be clearly identified. The size of the terminal block shall be consistent with 16 AWG (1.5 mm) twisted pairs or triads of stranded copper wire. Captive screw termina l strips are preferred . All terminals shall be numbered and the wiring identified with the loop tag number (Project specific ). Terminal strips will be segregated in accordance with the type and level of the signal in the connected wires. All spare I/O points shall be wired as indicated in Paragraph 2.3.1.


DATE: 01 MAY 2005




3.1.5 All AC power wiring shall be routed for maximum personnel safety and reduction of electrical interference. AC and DC wiring segregation inside BPCS cabinets shall be accomp lished by wireways or loomed cable bundles segregated by a minimum of 12 inches (305 mm). Where intersections of AC and DC wiring are unavoidable, care shall be exercised to make the intersections at right angles, with maximum possible separation. Power wiring (120 V AC or less) to be 14 AWG, 600 V THWN as minimum, however, cable size shall always be calculated by BPCS Supplier. 3.1.6 Wires in the same cabinet wireways or support shall be of the same type of signal (AC vs. DC). 3.1.7 Cable entries into the BPCS cabi nets for power, grounding and inte rconnections betwee n cabinets shall be from either top or bottom to be defined by Purchaser before the hardware freeze date. Cable entries into the BPCS cabinets for wiring to field devices shall be from either top or bottom, to be defined by Purchaser before the hardware freeze dates. 3.1.8 Wiring shall be arranged in such a way that it will not interfere with maintenance operations, i.e., card removal or insertion, etc. 3.1.9 BPCS supplier shall provide marshalling cabinets for terminating field wiring. The BPCS Supplier is responsible for all interconnection cable assemblies between the marshalling and controller cabinets and for all scramble wiring between BPCS termination assemblies and field termination blocks within the marshalling cabinet. Purchaser will be responsible for all field wiring to the BPCS marshalling cabinets. Purchaser must indicate if surge suppressors are required for lightning protection. (Project specific ). 3.1.10 The BPCS Supplier shall provide interconnection wiring information as per SDR Requirements. The wiring information shall be provided with sufficient details to permit the preparation of the cable block wiring diagram, and shall include wiring size and quantities between interco nnection panels or equipments. The detailed wiring information showing exact terminal numbers can be submitted later with other engineering information. 3.2 Communication Bus 3.2.1 Communication buses shall have redundant cables, routed in separat e paths to avoid a single incident causing simultaneous failure of both buses. Separation of paths shall extend all the way to the bus interface and control devices on the I/O racks, operator/engineering interfaces, and any other type of unit connected to the communication buses. 3.2.2 BPCS Supplier shall provide dual BPCS internal communication buses for the Human Machine Interface (HMI), controllers and I/O buses and historian. The bus shall be equipped with independent transmitter and receiver for each cable. The operator station shall provide system status displays to monitor the operation of all communication buses and shall generate system alarm messages to report any bus failures. Redundant cables of each communication bus shall alternate at regular intervals, as recommended by the BPCS Supplier. When one cable fails, the other one shall take over automatically, without any operator intervention. A single failure of either of the bus cables shall not result in any system degradation. Any variables normally updated over the communication bus shall retain their last value before failure. 3.2.3 The BPCS shall be capable of interfacing with other commercially available process computers, personal computers and microprocessor based process control equipment with serial communication interfaces using OLE for Process Control (OPC), TCP/IP or Modbus.


DATE: 01 MAY 2005




a.

The BPCS Supplier shall provide the BPCS interface link devi ce, including any modems or protocol converters as required . For non-critical monit oring of analog and discrete points, simplex OPC Client/Server arrangements connected to plant information network may be used. For critical control functions, redundant OPC Client-Server designs connected to a dedicated redundant network shall be used (Project specific ).

b.

The BPCS supplier is responsible for approving the communication between all third party devices.

c.

The Purchaser will provide all communication wires between the interfaces, following the specifications provided by the Suppliers and the applicable industry standards.

3.2.4 BPCS Supplier shall provide an interface to the Plant Information Network (PIN) if required. The BPCS Supplier shall provide necessary hardware and software to allow remote file transfer and accessibility to process data and schematics through an Ethernet (in accordance with IEEE 802.3) network and firewall; the network hardware will be provided by others (Project specific ). 3.2.5 Interconnecti ng cables for BPCS communication buses betw een control rooms and I/O Buildings (fiber optic or coaxial) shall be furnished and installed by the Purchaser, based on specifications provided by BPCS Supplier. 3.2.6 Failure of both cables of the communication buses shall not disable the functionality of the BPCS control modules. After recovering from a communication failure, the BPCS shall automatically generate operator station displays to prompt the operator. 3.2.7 BPCS Supplier shall describe the method used for communication bus error detection and correction to confirm the validity of the communications. 3.2.8 BPCS Supplier shall state transmission speed of the bus in bits/second and transactions/second, and state if communication is based on polling, interrupts, or other method. If it is based upon polling, BPCS Supplier shall state frequency of polling. 3.3 Electrical Power 3.3.1 The BPCS Supplier shall provide all the requir ed BPCS internal DC power distribut ion, power conditioning, power supplies, bus bars, power wiring, etc., as part of the scope of supply. System power shall be provided with transient suppressors and shall be capable of handling voltage surges in the AC power supply of _______ (Project specific ). 3.3.2 BPCS Supplier shall provide redundant DC power supplies for all power requirements of controllers, communication proce ssors, two-wire analog inputs and outputs, digital input s and digital outputs. Each power supply of the redundant pair shall be rated to supply full load plus 30% reserve capacity. 3.3.3 For discrete outputs, a separate power system may be required. The BPCS Supplier shall coordinate with Purchaser to determine the power system and wiring requirements before the hardware freeze date (Project specific). 3.3.4 BPCS supplier shall provide redundant power supplies capable of handling isolated dual AC feeds. Primary power to the power supplies will be provided by a UPS (minimum 30 minutes at full load) (Project specific ), provided by Purchaser. BPCS Supplier shall speci fy BPCS AC power requirements , including power supply wave shape, distortion limits, in order for Purchaser to specify UPS. BPCS Supplier shall indicate if battery backup is available for their power supplies . BPCS supplier shall provide status indication lights to confirm the status of the backup batteries . BPCS Supplier shall indicate how long the battery will support the system controller.


DATE: 01 MAY 2005




3.3.5 Redundant power supplies shall be sized and wired by the BPCS Supplier, such that failure of one power supply will not affect the operation of the system. The power supply units shall have fuse protections and diagnostic indicators that are easily observable by the user showing as a minimum: loss of power, loss of redundancy and power supply failure. 3.3.6 failure of any power supply cause a with BPCS on the BPCS displays and report The printer. Each power supply shallshall be provided a alarm failure message warning relay and a setstatus of relay contacts that will be connected to a BPCS digital input to activate the alarms. In addition, power to each termination board shall be fused or otherwise protected, to prevent a fault in one board from affecting other boards. 3.3.7 Configuration data and operating parameters shall be stored in non -volatile memory, battery powered RAM, or equivalent memory capable of retaining data during short duration (not less than 72 hours) power outages. BPCS Supplier shall provide data showing battery de-rating after one and fi ve year operation. The backup battery shall be replaceable while the BPCS is in operation, without affecting the normal BPCS functions. 3.3.8 The BPCS Supplier's proposal shall provide detailed BPCS grounding requirements and installation details and will indicate if the system ground must be separate from the process computer ground and data communication bus ground. 4. SYSTEM CONFIGURATION AND DISPLAYS 4.1 Configuration (Project specific , see Appendix C, "Roles & Responsibilities Matrix") 4.1.1 Purchaser shal l perform progr amming, config uration and cus tom display buil ding of the BPCS. BPCS Supplier shall quote, as an option, software packages and/or associated equipment required to perform BPCS configuration using a network of PC’s in the Purchaser offices . BPCS Supplier shall also provide detailed configuration and custom display building documentation (forms, dictionary of parameters, etc.) and technical support from supplier’s technical specialist during the configuration activities . Supplier shall indicate in the proposal the type and duration of support to be provided. 4.1.2 Display graphics shall conform to ISA 5.3 and ISA 5.5, unless otherwise directed by the Purchaser. Display graphic s will be configured based on P&ID's that follo w ISA 5.1 symbology or similar. 4.1.3 Graphics software shall provide the means to list all the entity tags referenced in a display. 4.1.4 If process technology is to be exported by the BPCS Supplier, documents supplied by KBR containing that technology are to carry a Technology Export Recipient Notification. The Export Control Classification Number (ECCN) for this technology is _______________(Later). It is the responsibility of the BPCS Supplier to adhere to all Export Compliance Regulations associated with this ECCN Number. (Note: For KBR Engineers, the Export Comp liance Administra tor, Office of the Chief Engineer can help in obtaining the correct Export Control Classification Number. The Supplier Export Compliance Officer shall also offer assistance, if necessary.) 4.2 On-line Modification On line modification of, or creation of new, control/monitoring loops and preformatted or custom BPCS displays shall not affect the operation and performance of the BPCS.


DATE: 01 MAY 2005




4.3 System Backup Alarm The activation of any backup unit to maintain the system operating integrity shall automatically generat e diagnostic and warning alarm messages to be shown on both the operator station alarm displays and the log and report printer(s). 4.4 System Failures The control system shall be designed in such a way that a failure of any component shall not cause a total failure of the entire system. All failures shall generate warning alarm messages on both the operator station alarm displays and the log and report printer(s). 4.5 Loop Tags BPCS shall be designed to accept at least 12 alphanumeric character s for loop nametags. 4.6 Mass Storage All system configuration files (loops and displays) shall be stored on high integrity hard drives within the system and can be backed up using removable mass storage devices like CD’s or tape disks. 5. ELECTRICAL AREA CLASSIFICATION AND NOISE 5.1 Radio Frequency Interference (RF I) The entire BPCS shall be protected against radio frequency and electromagnetic interference when exposed to field strength of 15 volts/meter or less over a frequency range of 27 MHz through 1 GHz. BPCS Supplier shall state the extent of RFI and electro magnetic interference protection provided with both open and closed BPCS cabinet doors. BPCS equipment shall confo rm to IEEE 518. 5.2 Electrical Area Classificatio n The BPCS equipment supplied shall conform to the electrical classification and environmental condition s required for the area in which they are installed and shall conform to ISA 12.00.01, and ISA 12.01.01. 6. SYSTEM DOCUMENTATION AND DRAWINGS All documentation required to complete the BPCS system shall be in accordance with the requirements specified in the Supplier Data Requirements List (SDRL) attached with the requisition. 7. SPARE CAPACITY, EX PANDABILITY, MAIN TENANCE, AND SPARE PAR TS 7.1 Spare Capacity/Expandability 7.1.1 Supplier shall state the installed physical point capacity and shall enumerate the number of installed spare inputs/outputs by type, based on area quantities provide d. 7.1.2 Supplier shall state the amount of spare space available in the proposed input/output racks and shall state the number of inputs and outputs that could be added in this space. 7.1.3 Supplier shall state the ultimate capacity of the proposed system for inputs/outputs.


DATE: 01 MAY 2005




7.2 Maintenance/Spare Parts 7.2.1 Supplier shall state recommended spare parts requirements for startup and operation (two years) that Purchaser should maintain on hand. This recommendation, along with pricing, shall be submitted at time of bid by Supplier. The recommendation shall state the dollar value of a spare part inventory for the instrumentation system. 7.2.2 Supplier shall state the approximate turnaround replacement time on defective parts. 8. EQUIPMENT IDENTIFICATIO N Each component shall be identified by Purchaser’s tag number inscribed on a nameplate for cabinets and consoles or a metal tag for hardware items. Each component req uiring identifi cation for proper assembly at the jobsite shall be so identified. 9. CABINETS 9.1 Supplier shall pro vide the standard ca binets for control ler, I/O module and othe r accessories. Cabinet requirements, such as size, color, front/rear access, cable entry top/bottom tagging of cabinets, are stated in worksheet, Appendix D ( Project specific ). 9.2 BPCS Supplier shall provide cooling fans with filters, as required, for heat dissipation from operator stations and equipment cabinets. For operator stations the heat shall be directed away from the operator (i.e., to the rear of the console, not the front). A BPCS fan failure alarm shall be provided to alert the operator of a malfunction. Cooling fan noise shall be 65 dBA or less when measured at 0.9 meters from the source with all cabinet doors closed.


DATE: 01 MAY 2005




APPENDIX A: INITIAL NETWORK DIAGRAM

(Project specific )


DATE: 01 MAY 2005




APPENDIX B: I/O SUMMARY TABLE

(Project specific )


DATE: 01 MAY 2005




APPENDIX C: ROLES AND RESPONSIBILITIES MATRIX

(Project specific )


DATE: 01 MAY 2005




APPENDIX D (Page 1 of 2) WORKSHEET - CONTROL CENTER NAME / NUMBE R Location Ambient Temperature Range Humidity Range Electrical Area Classification Supply Voltage Electrical Power Feed (Single/Dual) UPS furnished by: Unusual Service Conditions Name/Number of I/O Clusters associated with control center Operator Console Number of stations (Qty.) Screens per station Screen size/type Printer required? (Yes/No) Software Other requirements

V AC

Hz

Other:

(station = network node)

Printer Type

Engineering Console (not including operator stations with engineering capacity) Number of stations (Qty.) (station = network node) Screens per station Screen size/type Operator functionality required? (Yes/No) Number of dedicated printers/Type Min. Software Included On-Line/Off-Line Configuration Software? (Yes/No) Other requirements Fault tolerant / Raid / etc. Network printers Number of color laser printer? Number of black & white laser printer? Other requirements Server Type Redundancy? Other requirements

OPC Alarm & Events All / None / As specified


DATE: 01 MAY 2005




APPENDIX D (Page 2 of 2) WORKSHEET - CONTROL CENTER NAM E / NUMBER Server Type Number of attributes Add-ons Other requirements Server Type Capacity(Tags)/Collection frequency Other requirements Server Type Number of OPC devices Redundancy? Port traffic: Total number of AI Total number of AO Total number of DI

(Process Book, Excel, etc) Fault tolerant / Raid / etc.

Event Historian

Fault tolerant / Raid / etc.

OPC Data Access All / None / As specified For control For Indication

Total Total number number of of DI DO(SOE) Total Number of Serial I/O's Software Other requirements

OPC Mirror, etc. Fault tolerant / Raid / etc.

For Alarm


DATE: 01 MAY 2005




APPENDIX E (Page 1 of 3) WORKSHEET - I/O CLUS TER NAME / NUMBER Location Distance to control room Overall Enclosure Ambient Temperature Range Humidity Range Electrical Area Classification Supply Voltage Electrical Power Feed (Single/Dual) UPS furnished by: Unusual Service Conditions

None / Field Rack / Skidded Field Rack / Building

V AC

Hz

Other:

Operator consoles required at this location? (Yes/No) Number of stations (Qty.) (station = one network node) Screens per station Screen size/type Engineering functionality required? (Yes/No) Printer required? (Yes/No) Software Other requirements Engr. Consoles required at this location? (Yes/No) (Do not include above consoles) Number of stations (Qty.) (station = one network node) Screens per station Screen size/type Operator functionality required? (Yes/No) Number of dedicated printers/Type Min. Software Included Other requirements Controller Redundancy Control Logic Complexity Marshalling Cabinet

All / None / As specified Simple PID / PID with Minor Logic / Advanced Controls and Complex Logic By BPCS Vendor By Others


DATE: 01 MAY 2005




APPENDIX E (Page 2 of 3) WORKSHEET - I/O CLUSTER NAME / NUM BER Integrated Syste m and Marshalling Cabinets allowed? (Yes/No) Cable Entry? Maintenance Access? ( Front / Rear / Both) Cross wiring requirements (single or dual terminals) Signal segregation requirements Other requirements

Hardwired I/O Type

Control / indication

System Powered

AI AO DI DI (SOE) DO RTD T/C Pulse Other Nonincendive I/O required? Intrinsically Safe Barriers Required? Foundation Fieldbus Number of ports Redun dant H1 Port? Redundant Power Modules? Intrinsically Barriers required? For all segments: Total number of AI blocks Total number of AO blocks Total number of DI blocks Total number of DO blocks Total number of PID blocks

Redundant

Hart

Contact Type

Contact Volts/Rating

Comments

All / None / As specified All / None / As specified

All / None / As specified All / None / As specified All / None / As specified For control For Indication

Comments


DATE: 01 MAY 2005




APPENDIX E (Page 3 of 3) WORKSHEET - I/O CLUSTER NAME / NUM BER ProfiBus DP Number of Ports Redundant Port?

All / None / As Specified

Redundant Power Modules?

All / None / As Specified

Intrinsically Safe Barriers Required? Port traffic:

All / None / As Specified For control

For Indication

Comments

For control

For Indication

Comments

Total number of AI Total number of AO Total number of DI Total number of DO AS-i Number of ports Port traffic: Total number of devices Third Party Interface

(copy and paste section as required)

Type

(ModBus / DeviceNet / Foundation Fieldbus – HSE / etc.)

Redundant Port? (Yes/No) Port traffic:

For control

For Indication

Single Mode

Multimode

TOTAL NUMBER OFAI Total number of AO Total number of DI

Total number of DO Total number of PID blocks Fiber Optic Cable Converters Type .................................Size

Comments

Basic Process Control Systems Requirements.pdf

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