Basic Process Control Systems Requirements.pdf

8/19/2019 Basic Process Control Systems Requirements.pdf

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TECHNICAL SPECIFICATION

BASIC PROCESS CONTROL SYSTEMSREQUIREMENTS I3510E-BASE

DATE: 01 MAY 2005 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 32This BASE specification must be revised by the project team to meet project specific requirements. Refer to Appendices A, B, C, D

and E for additional clarification of project requirements.

TABLE OF CONTENTS

Section Title Page No. 1. GENERAL ............................................................................................................................21.1 Scope...................................................................................................................................2

1.2 KBR Documents, Codes, and Industry Standards ................................................ ....................21.3 Definitions of Terms ..................................................... ........................................................ .31.4 Supplier General Response................................................... ................................................4

1.5 Project Management .................................................... ........................................................ .61.6 Testing and Inspection............................... ........................................................ ....................61.7 Shipping ................................................... ........................................................ ....................8

1.8 Installation, Initial System Check, and Site Acceptance Test (SAT)..... ...... ..... ...... ..... ..... ...... .....81.9 Field Loop Test.............. ....................................................... ................................................91.10 Training .................................................... ........................................................ ....................9

2. GENERAL SYSTEM REQUIREMENTS .................................................................................9 2.1 System Scope..................................................... ....................................................... ...........92.2 System Layout .................................................... ....................................................... .........10

2.3 Process Inputs/Outputs Assembly .................................................... .................................... 102.4 Controller Features....................................................... ....................................................... 132.5 Control Algorithms............................ ........................................................ ........................... 15

2.6 Process Logic/Sequence Control............................................ .............................................. 152.7 Operation Station Features .................................................... .............................................. 162.8 Operator Console Printers ..................................................... .............................................. 17

2.9 Operator Keyboard......... ....................................................... .............................................. 172.10 System Diagnostics........ ....................................................... .............................................. 172.11 Historical Data and Trends....... ........................................................ .................................... 18

2.12 Reports .................................................... ........................................................ ..................19

3. SYSTEM DESIGN REQUIREMENTS ...................................................................................193.1 System Wiring Requirements ................................................. .............................................. 193.2 Communication Bus ..................................................... ....................................................... 20

3.3 Electrical Power... ........................................................ ....................................................... 214. SYSTEM CONFIGURATION AND DISPLAYS ......................................................................224.1 Configuration ..................................................... ....................................................... .........22

4.2 On-line Modification........................................................................................... ..................224.3 System Backup Alarm .................................................. ....................................................... 234.4 System Failures .................................................. ....................................................... .........23

4.5 Loop Tags ................................................ ........................................................ ..................234.6 Mass Storage...................................................... ....................................................... .........235. ELECTRICAL AREA CLASSIFICATION AND NOISE ..........................................................23

5.1 Radio Frequency Interference (RFI) ................................................. .................................... 23

5.2 Electrical Area Classification .................................................. .............................................. 236. SYSTEM DOCUMENTATION AND DRAWINGS ..................................................................23

7. SPARE CAPACITY, EXPANDABILITY, MAINTENANCE, AND SPARE PARTS....................23 7.1 Spare Capacity/Expandability............................................................................. ..................237.2 Maintenance/Spare Parts ...................................................... .............................................. 24

8. EQUIPMENT IDENTIFICATION...........................................................................................249. 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


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1. GENERAL

1.1 Scope

1.1.1 This specification defines the minimum design and performance requirements of a microprocessorbased Basic Process Control System (BPCS) and the system components, functions and services within the

scope of the BPCS Supplier. KBR will be referred to as the Purchaser. (Items and paragraphs that areunderlined in this specification must be revised with project specific data before using thisspecification in a Project.)

1.1.2 The BPCS shall enable plant operators to perform all the conventional actions required for safe plantmonitoring, operation control and reporting. The BPCS shall monitor all process variables, display their

values on Operator Stations, and allow operator control of designated process variables. The system shallalso generate alarms to warn the operator of any system or process variable values which are out of limits;the alarms shall be reported as timed messages on the screen displays and on the console printers, and

stored in the history devices for future evaluation or printing. The system shall store process information inelectronic 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 ofdisplaying Foundation Fieldbus (FF) instruments' health or diagnostic variables and displayed them in a clearmanner 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 andfunctional 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 andtested system; complete with process interface and control devices, operator interface with printers,

serial interfaces to foreign devices, BPCS equipment cabinets, system wiring marshalling cabinets, allpre-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 Responsibilit ies Matrix, Appendix C.

d. The Supplier shall follow all purchasing requirements in the Purchaser Standard I2-3PS, “PurchasingRequirements for Instrument Control Centers".

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

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

1.1.4 All special features or improvements over the standard specification are shown in the Basic ProcessControl 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 KBRdocuments, when applicable, will be listed on the Requisition. The issue of KBR documents shall be asspecified in the Requisition. Current editions of the industry standards including all mandatory addenda in

effect at the time of the Order shall apply unless otherwise indicated.


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KBR DOCUMENTSI2-3PS, “Purchasing Requirements for Instrument Control Centers”

SDR-2I-I351-XXXX, "Supplier Data Requirements for BPCS"

DEUTCHES INSTITUT FOR NORMUNG (DIN)

DIN 43760, "Measurement and Control; Electrical Temperature Sensors; References-Tables ForNickel Resistors for Resistance Thermometers"

FIELDBUS FOUNDATION (FF)FF 569, "Host Interoperability Support Test"

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)IEEE 518, "IEEE Guide for the Installation of Equipment to Minimize Electrical Noise Inputs to

Controllers from External Sources"

IEEE 802.3 “Local and Metropolitan Area Networks: Specific Requirements”Part 3, “CSMA/CD, Access Method and Physical Layer”

INSTRUMENTATION, SYSTEMS, AND AUTOMATION SOCIETY (ISA)ISA 5.1, “Instrumentation Symbols, and Identification”ISA 5.3, “Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and

Computer Systems”ISA 5.5, “Graphic Symbols for Process Displays”ISA 12.00.01, “Electrical Apparatus for Use in Class I, Zones 0, 1, & 2 Hazardous (Classified)) Locations”ISA 12.01.01, “Definitions and Information Pertaining to Electrical Instruments in Hazardous (Classified)

Locations”ISA 12.12.01, "Nonincendive Electrical Equipment for Use in Class I and II, Division 2 and Class III,

Divisions 1 and 2 Hazardous (Classified) Locations"ISA 50.00.1, "Compatibility of Analog Signals for Electronic Industrial Process Instruments"

INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)

IEC 61158, "Digital Data Communication for Measurement and Control - Fieldbus for Use in IndustrialControl Systems" Parts 1 thru 8.

PROCESS INDUSTRY PRACTICES (PIP)

1.2.2 Appendices

Appendix A: Init ial 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. Itshall 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 theprocess information and can give operator commands to process and/or peripherals. As a minimum, it shallinclude a flat panel monitor and associated pointing devices such as touch screen, keyboard and mouse or

track ball.

1.3.3 Operator Console: consists of two or more operator stations assigned to a process unit and may

house additional accessories such as pushbuttons, lamps, telephones etc.

1.3.4 Input/output (I/O) Modules: BPCS components directly connected to the process instrumentation that

perform the process interface and multiplexing functions of the control system, and their protectiveenclosures (cabinets or racks).

1.3.5 Communication Buses: The communication cables and interface devices used for data exchange anddata integrity protection, between the operator consoles, the control modules, the foreign device interfacesand the I/O modules.

1.3.6 Plant Information Network: Information network not directly related with process control and isolatedwith a firewall from the BPCS.

1.3.7 Programmable Electronic System (PES): Configurable or programmable devices to perform logic.Field devices are not included in PES.

1.3.8 Foundation Fieldbus (FF): Fieldbus is an all digital, two-way multi-drop communications link amongintelligent smart field devices and automation systems. FOUNDATION

TM 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 standardinterface to access data from a variety of process control devices. The applications must implement oneOPC compliant driver to access data from any OPC compliant server.

1.3.10 PROFIBUS: PROFIBUS is an open, digital communication system with a wide range of applications,particularly in the fields of factory and process automation. PROFIBUS is suitable for both fast, time-criticalapplications and complex communication tasks. There are three types of networks/sub-protocols defined by

PROFIBUS: DP, PA and PROFINET.

1.4 Supplier General Response

1.4.1 The BPCS Supplier shall respond to each paragraph of this specification. The replies for eachparagraph shall be:

a. In Compliance.b. Not in Compliance: BPCS Supplier shall state the specific reason for the deviation.

c. 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 Supplier’s proposal will not beaccepted by the Purchaser. The Purchaser does not take the responsibility to discover missing “Not inCompliance” 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 tofurnish a functional system, which operates in a manner satisfactory to the Purchaser. All conflicts betweenthe specifications, standards and purchase order shall be referred to the Purchaser for clarification before

proceeding with manufacture of the affected items.

1.4.3 Where this specification requests technical data, the BPCS Supplier shall respond by providing a

special document or, when necessary, by attaching relevant technical data. When documents are attached,page number and paragraph number must reference the data in the response. The BPCS Supplier shallprovide a reply for both equipment and services specified here.

1.4.4 System costs such as hardware, cabinet integration, engineering services, factory acceptance and site Acceptance tests, shall be broken out and defined separately. The Supplier shall provide unit pricing for all

equipment, software, and services in the proposal so that items, may be added or deleted on a reasonablebasis. A total price to meet the job requirements and a price to add/subtract components, on an individualbasis 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 licensingphilosophy 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 partyequipment integration via OPC or Modbus, BPCS Supplier shall describe how the licensed points areutilized.

1.4.5 The Supplier shall provide sufficient support documentation with the quotation, including technical dataon all quoted hardware and software, to help the Purchaser perform a complete technical evaluation. TheSupplier shall also provide a simple block diagram showing all major components, interconnections and

communication interfaces.

1.4.6 The Supplier shall provide the following additional information with the quotation:

a. Dimensional sketches of the proposed layout, including access space for cabinet door openings, chassisslides, 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 - includethe number of copies supplied and unit cost. Supplier shall also furnish a complete, descriptive listing of

all other available software tools, packages and programming aids.

1.4.7 The Supplier may propose alternate system features other than those specified in this document.

Supplier shall clearly identify those features in the alternate quotation that do not comply with thisspecification. Supporting documents and explanations shall be included in the quotation to indicate how andwhy the proposed alternative is technically (in compliance) equivalent or superior (enhancement) to the

specified system.

1.4.8 The BPCS Supplier shall provide a summary project milestone schedule, based on the site need date.

The schedule shall identify major milestones in engineering, design, parts procurement, manufacture, factorytesting, 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


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dates shall be shown. Any deviation from the agreed upon schedule must have the Purchaser’s approval.This schedule shall be reviewed and agreed upon during the pre-award meeting. All clarifications regardingthe scope of work and other requirements shall be completed during the pre-award meetings.

1.5 Project Management

1.5.1 The BPCS Supplier shall assign a Project Manager, who will be the main source of official contacts forthe Purchaser. A project organization chart, identifying project personnel, their responsibilities shall beprovided at the pre-award meeting. The BPCS supplier shall also indicate their proposed manpower loading

for the project. Purchaser requires continuity on all key personnel assigned to the Project.

1.5.2 The BPCS Supplier shall also designate a Project Engineer, who will be assigned to assist during the

engineering effort. However, all correspondence shall be through the BPCS Supplier Project Manager. Theproject engineer shall serve as the technical contact and provide assistance to the KBR project team onsystem engineering/configuration issues

1.5.3Purchaser requires continuity on all key personnel assigned to the Project so any changes must be

previously approved by Purchaser.

1.5.4 Milestone schedule dates shall be established showing all the target dates for transmission of project

documents so that the delivery of equipment will not be delayed. Any deviation from the agreed schedulewill 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 following 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 AcceptanceTest (FAT). The BPCS Supplier shall perform this test. Written reports with test results shall beprovided 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 ofpower supplies and controllers . All deficiencies shall be corrected prior to start of FAT. The Purchaserreserves 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 intoelectronic 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 andsystem tests. Test results shall be available to Purchaser’s inspectors . The BPCS supplier shall notifyPurchaser 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 Shoptests 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 Responsibili ties Matrix", Item 2.14. Tests shall

consist of loop-by-loop functional tests of all inputs and outputs, alarms, and control functions, to confirmproper operation and display (Project specific). The Project configuration database shall be used fortesting. 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 beperformed 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 duringthe FAT. Such software/product should be reviewed / approved by the Owner and if accounted for inthe main BPCS Purchase Order if it has commercial implications (Project specific). During FAT anintegrated 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 debugthe system during the scheduled acceptance test period. The Supplier shall provide the detail of supportin the quote (number of individuals, duration of support, and qualifications of support individuals).Technical support may include but is not limited to configuration, graphics, network, wiring support

(Project specific).

c. Office Space and office equipment (desk, chairs, phones, 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 threeweeks 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 FATlocations for use during the FAT.

e. A set of engineering documents such as P&ID’s, Control Narratives, Alarm Summary, Cause and EffectTables, 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 shippedseparately. The electronic files will be used to configure the system after installation and power-up, atsite.


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g. FAT will be performed at the BPCS Supplier shops, unless a different agreement is reached during thepre-award meeting. Both cost and milestone schedule in the BPCS Supplier quotation shall be basedon 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 completethe FAT (Project specific).

h. A punch list shall be maintained for all deficiencies found during the test. The responsible engineer shallcorrect the deficiencies and demonstrate the corrective action prior to shipment of the system.

1.7 Shipping

1.7.1 All interconnecting cables shall be labeled at both ends, specifying cabinet, terminal panel and plug-in

connectors to which each cable end is to be reconnected. After satisfactory completion of FAT, BPCSSupplier shall disconnect all the equipment and prepare the system for shipment.

1.7.2 Cabinets shall be shipped intact. Circuit board cards are not to be removed for shipping, as long asthe integrity of the electronic equipment is not compromised. BPCS Supplier shall protect and crate allcabinets properly to avoid damage during shipment and storage. BPCS supplier shall provide accelerometer

indication on all BPCS cabinets.

1.7.3 Domestic shipment shall be by air ride van as minimum protection.

1.7.4 For overseas shipment, the BPCS Supplier shall contact Purchaser for special export licensingrequirements. The responsible party for exporting equipment shall determine if export license is requiredaccording to the U.S. Department of Commerce Export Regulations.

1.7.5 BPCS Supplier shall ship touchup paint with the system.

1.7.6 BPCS Supplier shall immediately advise the Purchaser of any delays during shipment or damageduring shipment.

1.8 Installation, Initial System Check and Site Acceptance Test (SAT)

1.8.1 BPCS Supplier shall assign qualified personnel to:

a. Inspect, supervise, assist and approve site installation of BPCS building equipment, including computerfloor 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 diagnostic software and perform hardware test, power checks, and system diagnostics to verifysuccessful installation.

1.8.2 Purchaser will provide labor for uncrating, installation of equipment, connection for power andgrounding, connection of field wiring to predefined terminal cabinets, and also connection of BPCS Supplier

interconnecting cables. BPCS Supplier may install interconnecting cabling if this is required by Supplierwarranty (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 allthird party communications is functional.

1.8.5 BPCS supplier proposal shall state the amount of time and cost allowed for the installation support atthe site and shall also provide a rate sheet for other field and engineering support activities, by job positions.

1.9 Field Loop Test

1.9.1 The field loop test shall be performed for all input and output signals from the field instruments to the

BPCS. Refer to Roles and Responsibilities Matrix (Appendix C) for field support responsibilities.

1.9.2 The Purchaser may request technical assistance from the BPCS Supplier in conducting the field tests;

therefore, BPCS Supplier proposal shall state the cost and amount of time allowed to support the field testsas 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 shallconfirm 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 followingshall 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 facility.

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

2. GENERAL SYSTEM REQUIREMENTS

2.1 System Scope

2.1.1 The system shall be microprocessor-based, assembled using supplier or third party standard

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 Foundation Fieldbus and HART protocol devices.. Foundation Fieldbusimplementation 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 dataacquisition, 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 technical data, with information on actual applications,documenting the capabilities of the quoted BPCS to maintain bi-directional communications with Object LinkEmbedded (OLE) for Process Control (OPC) compliant foreign devices based on the standards of the OPC

Foundation.

2.1.4 The system shall be capable of multiformat displays such as custom process graphics, overview,

group and face plate detail, trends, process status indicating all the loop parameters such as processvariable, set point, output, tuning constants, alarms, name tag and service description.

2.1.5 The system shall provide user-configurable alarm functions to alert the operator of abnormal ordangerous conditions. The following listed features shall be available (as a minimum):

a. Configurable alarms from analog inputs: Low and High, Low-Low, and High-Highb. Deviation from set pointc. Controller output - Low and High

d. 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 realtime from the alarm summary.

2.1.6 BPCS Supplier shall support all system hardware and firmware with spare parts and service for aperiod of at least ten (10) years after the withdrawal of the product from the market. BPCS Supplier shallprovide upgrades and revisions of the software for a period of X years from the shipment date at noadditional 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 BPCScomponent shall not affect the performance of the BPCS or the security of operations . If there is a highprobability that the failure of a BPCS component will cause loss of control of more than one critical process

variable, then that electronic component should have the capability to add a redundant backup. Specificredundancy requirements will be indicated in the initial network diagram and I/O summary table.

2.2 System Layout

BPCS Supplier shall provide dimensioned sketches of the floor area requirements of the quoted equipment

as indicated within this specification. The sketches shall show the layout of the equipment to be supplied,identified by name.

2.3 Process Inputs/Outputs Assembly

2.3.1 BPCS I/O processor modules shall be provided in quantities to match the input and output counts

listed in the BPCS Data Sheets (Appendices B, D, and E) and an additional 10% margin for fully wiredspares. BPCS supplier shall install the I/O processor modules, termination panels, cabling, terminals andaccessories 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, abovethe 10% margin for spares, when the system is turned over to the Plant owner at the end of Site AcceptanceTests.


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2.3.2 BPCS I/O modules shall provide 24 volts DC power to all field devices from dedicated power suppliesinstalled in the controller cabinets. Power supplies shall be sized to handle the maximum controller I/Oloading 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 inthe marshalling panels (Project specific). FF devices/H1 segment will require separate power supplies andpower conditioners.

2.3.3 BPCS Supplier shall design the BPCS process signal power distribution system. Protective andinterrupting devices shall be properly coordinated to avoid single cause multiple failures. A single electrical

failure shall not cause power interruption to multiple I/O modules.

2.3.4 BPCS I/O data monitoring functions shall be programmed from the BPCS Supplier standard set of pre-

defined, configurable data collection algorithms. I/O processing algorithms will include the following, as aminimum:

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 signalparameters 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 changelimits. 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, safetyand maintainability of continuous control loops and custody transfer variables . A pair of terminals shall beprovided for termination of each field instrument wiring signal. Transfer of I/O module shall be automatic with

fault indication 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 perISA 50.00.1.

a. Current Analog Input

The system shall be capable of handling grounded and ungrounded 4-20 mA signal from either a twowire 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. 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.

c. Discrete Input

1. System Powered Digital Input - The signal is a dry contact or an open collector transistor poweredby 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 contactclosures, 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 minimumresolution of 1 millisecond. Digital inputs that require SOE capability shall be indicated in the I/OSummary Table.

d. Discrete Output

1. DC Discrete Output - This signal is an isolated relay or solid state output. Both momentary andsustained actions, normally open and normally closed shall be available. The outputs should becapable 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 shouldbe 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 suppliedfrom the BPCS.

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

e. RTD Input

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

f. Thermocouple Input

1. Input cards shall be able to accept any industry standard thermocouples. Thermocouple burnoutindication shall be selectable, either downscale or upscale. Inputs shall include automatic coldreference junction compensation.

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


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g. 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 maximumnumber of devices per H1 segment; maximum number of VCR’s, maximum number of Function

Blocks and number of macrocycles.

h. Frequency Input

1. Pulse train interpreted as either a scaled quantity per pulse for totalization or as an instantaneousprocess value proportional to pulse frequency.

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

3. Pulse Input cards shall be capable of receiving frequency-input signals from turbine meters andPD (positive displacement) meters

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

i. 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 AppendixB, I/O Summary Table for definition.

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

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

2.4 Controller Features

2.4.1 BPCS control units shall be microprocessor based, independent distributed digital controllers. Each

process controller sub-system shall be capable of true stand-alone operation. Controllers shall provide themain physical and electrical interface to the process for data acquisition, continuous process control, logicand sequential control and high level application programming languages.


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2.4.2 Each BPCS process control sub system shall include power supplies, controller modules,communication modules, I/O processor modules, termination panels, cabling, terminals and accessories allmounted inside cabinets provided by the BPCS supplier. BPCS supplier shall also provide power supply

modules dedicated to the field devices (Project specific).

2.4.3 The controller cabinets will be installed inside the rack room in a control building, remote rack rooms or

in remote cabinets located throughout the process areas and will interface directly with the process fieldsensors and final control elements via hardwired signals or communication networks.

2.4.4 The quantity, performance and type of controllers required shall be determined by the BPCS supplier,based on the following sizing criteria:

a. Process control functions shall be performed by the minimum possible number and type of devices andshall 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 countslisted in this specification.

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

e. It will be assumed that the execution rate for 80% of the control functions will be set at once per secondwhile 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 onceper 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 quotedthat is dedicated to these applications.

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

2.4.5 Controller fault handling and recovery procedures shall be fully programmable functionality, on a loop

by loop basis, shall include:

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

inputs and calculated variables.

b. Controllers shall be configurable, to either allow or inhibit propagation of invalid or out-of-range values

through continuous or logic control loops.

c. Controller shall be configurable to continue operating with the last valid data upon failure of

communications with either the operator interfaces or any other communication subsystems or switchover 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 lastgood value or change to a selectable value, upon either failure of field device or controller module orloss of communication between the output processor and the controller module.


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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 ofanalog and discrete process variables.

2.5.2 The set of process control algorithms shall include, as a minimum, the following:

a. Multiple proportional-integral-derivative (3-mode PID) control functions, in both simple loop and complex

loop arrangements, like cascade and ratio control, split range, feed compensation, and feed forward.

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

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

compensation, totalization, etc.

d. High level programming language.

2.5.3 The control algorithms shall include additional selectable features like bumpless automatic modetransfer, 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, sequencingand batch controls. Logic controls shall be implemented using functional block programming and shall

provide the following capabilities, either individually or in combination:

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

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

c. 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 ofhandling 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, andabort recipes; and enter data for use by the recipe (Project specific).

2.6 Process Logic/Sequence Control

2.6.1 If BPCS Supplier quotes a separate logic/sequence controller then it shall be able to communicate with

the Basic Process Control System and preferably be an integral part of the BPCS.

2.6.2 Programming of the logic/sequence controller shall be functional block programming or equivalent.


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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 highperformance CPU running at the highest speed available at the time of the purchase order, and a

minimum memory of 512 MB RAM.

b. Operator Keyboards: One keyboard per Station is required for normal operation. The keyboard shall

allow access to both displays in dual tier consoles. Membrane or QWERTY keyboards to be ProjectSpecific.

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.

2.7.2 Process control operations such as set point adjustment, manual controller output, alarm limit setting,

etc., shall be performed through the operator consoles. BPCS Supplier shall provide either a consolekeylock switch or a password protection (access level) procedure to prevent unauthorized changes to systemparameters and settings, such as controller tuning and alarm limits.

2.7.3 Update period for all active data in pre-formatted displays shall not exceed two seconds.

2.7.4 Call-up time for all custom graphic displays of average complexity, including all updated fields, shall

not exceed 4 seconds after an operator request. The update period for real time data in custom graphicdisplays 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 theauxiliary control equipment: display based man-machine interface devices for selected packaged equipment,

CCTV controls and plant communication sets. Counts of additional console mounted devices are estimatesand will be confirmed before the hardware freeze dates. (See Worksheet (Appendix D) and NetworkDiagram (Appendix A) (Project specific).

2.7.6 BPCS Supplier shall provide each Operator Station with (when specified) the following auxiliary controlequipment 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, plantcommunication equipment, and paperless three inputs recorders.

2.7.7 Operator station redundancy shall be achieved by providing two or more identical operator stations foreach Operator Console. Loss of one operator Station and associated components shall only reduce thenumber of windows to the process and shall not affect operation or performance of the other operator

station(s).

2.7.8 Mounting of operator console equipment shall be based on BPCS Supplier's standard design,

arranged in accordance with the Purchaser layout described in the BPCS Data Sheet.

2.7.9 Console furniture shall be BPCS Supplier standard design and color. The console adjustable writing

surface shall have a minimum depth of 12 inches (305 mm). The writing surface shall be continuousbetween console units in the same operating station. Console construction shall include properreinforcement to provide adequate rigidity for an industrial environment.


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2.7.10 Maintenance access to the electronics shall be from both sides of the console.

2.7.11 BPCS Supplier shall provide dedicated engineering stations to allow on-line modifications to BPCS

configuration and displays. The engineering station shall include: one high-resolution display color monitor,21 inch diagonal; one Engineer Keyboard; screen pointing devices like mouse or track-ball; removable bulkstorage drives, like CD-R/W, tape drives, etc. (See Subparagraph 2.7.1.d). See Worksheet (Appendix D) for

details (Project specific).

2.8 Operator Console Printers

2.8.1 BPCS Supplier shall supply (as specified in Worksheet, Appendix D) each operator console withLaserJet 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 uponoperator demand (Project specific).

2.8.3 Alarm messages on both the operator console screens and on the printer shall include the followingitems for each message, as a minimum:

a. Tag nameb. Descriptionc. Alarm Type and priorityd. Date (day/month) and time (hour/minute/second) stamp

e. Time alarm is acknowledgedf. 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 locatedin an unobtrusive location.

2.10 System Diagnostics

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 failuresbetween 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 performing continuous diagnostic, including self-test functions to

provide specific diagnostic information to the Host.

b. All Foundation Fieldbus instruments shall support methods to allow automation of on-line procedures,

such as calibration from the host.

2.10.3 All devices shall as a minimum satisfy the requirements of the fieldbus certification laboratory. In the

case of Foundation Fieldbus, the FF "check mark" logo and listing on the Approved devices list maintainedon its website www.fieldbus.org verifies interoperability of devices.


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2.10.4 BPCS Supplier shall describe, and quote as options in the proposal, all additional special diagnostictools or aids that can be used with the BPCS, such as remote diagnostics to factory, recommended field testequipment, etc.

2.11 Historical Data and Trends

2.11.1 The Supplier shall provide a configurable real time and historical data collection package to supporttrending, logging and reporting. The 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 historicaldata storage and/or archiving.

2.11.2 BPCS Supplier shall provide a configurable trend package to satisfy the following real time andhistorical 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 average values for seven(7) days (Project specific).

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

in the proposed system.

2.11.3 Both real time trends and historical trends shall be provided. All operator stations shall be capable ofdisplaying real time and historical trends. Each trend display shall consist of the plotted trend graph(s) and a

table showing trend parameters. It shall be possible to incorporate trends in graphic displays.

2.11.4 Each event history file entry shall contain the time and date of occurrence, the tag ID, the tag

description and value/state and the type of event. The BPCS Supplier quotation shall indicate the maximumnumber 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 andanalysis.

a. Process Events

1. Discrete inputs changing state

2. Analog inputs going into or out of alarm3. Equipment changing state (running/stopped, open/closed)

b. Operator Events

1. Opening/closing isolation valves

2. Starting/stopping of pumps and motors3. Changes to set points.4. Changing control blocks between automatic and manual


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c. Engineer Events

1. Placing stations and devices on-line or off-line

2. Changes to alarm set points3. Inhibiting/enabling alarms4. Changes to tag parameters on line.

d. System Events

1. Failed process Input/Output modules2. Communication errors3. Program error messages

4. Switchover between primary and backup5. Failed controller modules6. Other function module failures

2.11.6 Adequate storage shall be provided for on-line access to the last seven days of data without manualselection 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 minimumof 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 reportscan 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., operatorconsoles, engineering stations, printers, PC’s, host computers, etc.). Supplier to provide copies of thestandard reports from the system.

3. SYSTEM DESIGN REQUIREMENTS

3.1 System Wiring Requirements

3.1.1 All BPCS network interconnecting wiring and cable to be installed inside system cabinets shall beprovided by the BPCS Supplier.

3.1.2 BPCS Supplier shall provide complete wiring and termination information for all BPCS interconnectingcables (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 asminimum.

3.1.4 Terminal blocks shall be non-hygroscopic type and provided by the BPCS Supplier. Terminals shallbe tinned and shall be clearly identified. The size of the terminal block shall be consistent with 16 AWG(1.5 mm) twisted pairs or triads of stranded copper wire. Captive screw terminal strips are preferred. All

terminals shall be numbered and the wiring identified with the loop tag number (Project specific). Terminalstrips will be segregated in accordance with the type and level of the signal in the connected wires. All spareI/O points shall be wired as indicated in Paragraph 2.3.1.


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3.1.5 All AC power wiring shall be routed for maximum personnel safety and reduction of electricalinterference. AC and DC wiring segregation inside BPCS cabinets shall be accomplished by wireways orloomed 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 maximumpossible separation. Power wiring (120 V AC or less) to be 14 AWG, 600 V THWN as minimum, however,cable size shall always be calculated by BPCS Supplier.

3.1.6 Wires in the same cabinet wireways or support shall be of the same type of signal (AC vs. DC).

3.1.7 Cable entries into the BPCS cabinets for power, grounding and interconnections between cabinetsshall be from either top or bottom to be defined by Purchaser before the hardware freeze date. Cableentries 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 forall scramble wiring between BPCS termination assemblies and field termination blocks within the marshallingcabinet. 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. Thewiring information shall be provided with sufficient details to permit the preparation of the cable block wiring

diagram, and shall include wiring size and quantities between interconnection panels or equipments. Thedetailed wiring information showing exact terminal numbers can be submitted later with other engineering

information.

3.2 Communication Bus

3.2.1 Communication buses shall have redundant cables, routed in separate paths to avoid a single incidentcausing simultaneous failure of both buses. Separation of paths shall extend all the way to the bus interfaceand 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 independenttransmitter and receiver for each cable. The operator station shall provide system status displays to monitorthe 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 recommendedby the BPCS Supplier. When one cable fails, the other one shall take over automatically, without anyoperator 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 communicationinterfaces using OLE for Process Control (OPC), TCP/IP or Modbus.


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a. The BPCS Supplier shall provide the BPCS interface link devi ce, including any modems or protocolconverters as required. For non-critical monitoring of analog and discrete points, simplex OPCClient/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 beused (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 accessibilityto process data and schematics through an Ethernet (in accordance with IEEE 802.3) network and firewall;the network hardware will be provided by others (Project specific).

3.2.5 Interconnecting cables for BPCS communication buses between control rooms and I/O Buildings (fiberoptic 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 generateoperator 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, andstate if communication is based on polling, interrupts, or other method. If it is based upon polling, BPCSSupplier shall state frequency of polling.

3.3 Electrical Power

3.3.1 The BPCS Supplier shall provide all the required BPCS internal DC power distribution, power

conditioning, power supplies, bus bars, power wiring, etc., as part of the scope of supply. System powershall be provided with transient suppressors and shall be capable of handling voltage surges in the AC power supply of _______ (Project specific).

3.3.2 BPCS Supplier shall provide redundant DC power supplies for all power requirements of controllers,communication processors, two-wire analog inputs and outputs, digital inputs and digital outputs. Each

power supply of the redundant pair shall be rated to supply full load plus 30% reserve capacity.

3.3.3 For discrete outputs, a separate power system may be required. The BPCS Supplier shall coordinate

with Purchaser to determine the power system and wiring requirements before the hardware freeze date(Project specific).

3.3.4 BPCS supplier shall provide redundant power supplies capable of handling isolated dual AC feeds.Primary power to the power supplies will be provided by a UPS (minimum 30 minutes at full load) (Projectspecific), provided by Purchaser. BPCS Supplier shall specify BPCS AC power requirements, including

power supply wave shape, distortion limits, in order for Purchaser to specify UPS. BPCS Supplier shallindicate if battery backup is available for their power supplies. BPCS supplier shall provide status indicationlights to confirm the status of the backup batteries. BPCS Supplier shall indicate how long the battery will

support the system controller.


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3.3.5 Redundant power supplies shall be sized and wired by the BPCS Supplier, such that failure of onepower 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, lossof redundancy and power supply failure.

3.3.6 The failure of any power supply shall cause a BPCS alarm message on the BPCS status displays andreport printer. Each power supply shall be provided with a failure warning relay and a set of relay contactsthat 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-volati le memory, battery powered

RAM, or equivalent memory capable of retaining data during short duration (not less than 72 hours) poweroutages. BPCS Supplier shall provide data showing battery de-rating after one and five year operation. Thebackup 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 datacommunication bus ground.

4. SYSTEM CONFIGURATION AND DISPLAYS

4.1 Configuration (Project specific, see Appendix C, "Roles & Responsibilities Matrix")

4.1.1 Purchaser shall perform programming, configuration and custom display building of the BPCS. BPCSSupplier 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 providedetailed configuration and custom display building documentation (forms, dictionary of parameters, etc.) andtechnical support from supplier’s technical specialist during the configuration activities. Supplier shallindicate in the proposal the type and duration of support to be provided.

4.1.2 Display graphics shall conform to ISA 5.3 and ISA 5.5, unless otherwise directed by the Purchaser.Display graphics will be configured based on P&ID's that follow ISA 5.1 symbology or similar.

4.1.3 Graphics software shall provide the means to list all the entity tags referenced in a display.

4.1.4 If process technology is to be exported by the BPCS Supplier, documents supplied by KBR containingthat technology are to carry a Technology Export Recipient Notification. The Export Control ClassificationNumber (ECCN) for this technology is _______________(Later). It is the responsibility of the BPCS Supplier

to adhere to all Export Compliance Regulations associated with this ECCN Number.

(Note: For KBR Engineers, the Export Compliance Administrator, Office of the Chief Engineer can help in

obtaining the correct Export Control Classification Number. The Supplier Export Compliance Officer shallalso 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.


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4.3 System Backup Alarm

The activation of any backup unit to maintain the system operating integrity shall automatically generate

diagnostic and warning alarm messages to be shown on both the operator station alarm displays and the logand 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 stationalarm displays and the log and report printer(s).

4.5 Loop Tags

BPCS shall be designed to accept at least 12 alphanumeric characters for loop nametags.

4.6 Mass Storage

All system configuration files (loops and displays) shall be stored on high integrity hard drives within thesystem 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 (RFI)

The entire BPCS shall be protected against radio frequency and electromagnetic interference when exposedto 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 closedBPCS cabinet doors. BPCS equipment shall conform to IEEE 518.

5.2 Electrical Area Classification

The BPCS equipment supplied shall conform to the electrical classification and environmental conditionsrequired 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 requirementsspecified in the Supplier Data Requirements List (SDRL) attached with the requisition.

7. SPARE CAPACITY, EXPANDABILITY, MAINTENANCE, AND SPARE PARTS

7.1 Spare Capacity/Expandability

7.1.1 Supplier shall state the installed physical point capacity and shall enumerate the number of installedspare inputs/outputs by type, based on area quantities provided.

7.1.2 Supplier shall state the amount of spare space available in the proposed input/output racks and shallstate 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.


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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 ofbid by Supplier. The recommendation shall state the dollar value of a spare part inventory for theinstrumentation system.

7.2.2 Supplier shall state the approximate turnaround replacement time on defective parts.

8. EQUIPMENT IDENTIFICATION

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 requiring identification for proper assembly atthe jobsite shall be so identified.

9. CABINETS

9.1 Supplier shall provide the standard cabinets for controller, I/O module and other accessories. Cabinet

requirements, such as size, color, front/rear access, cable entry top/bottom tagging of cabinets, are stated inworksheet, Appendix D (Project specific).

9.2 BPCS Supplier shall provide cooling fans with filters, as required, for heat dissipation from operatorstations 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 theoperator 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.


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APPENDIX A: INITIAL NETWORK DIAGRAM

(Project specific)


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APPENDIX B: I/O SUMMARY TABLE

(Project specific)


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APPENDIX C: ROLES AND RESPONSIBILITIES MATRIX

(Project specific)


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APPENDIX D (Page 1 of 2)WORKSHEET - CONTROL CENTER NAME / NUMBER

Location

Ambient Temperature Range

Humidity Range

Electrical Area Classification

Supply Voltage V AC Hz Other:

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.) (station = network node)

Screens per station

Screen size/type

Printer required? (Yes/No) Printer Type

Software

Other requirements

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 OPC Alarm & Events

Redundancy? All / None / As specified

Other requirements


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DATE: 01 MAY 2005