Control Philosoph1

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1/10

PREPARED

BYNA

PTT PUBLIC COMPANY LIMITED

CHECKED

BY ONSHORE COMPRESSOR STATION 4

PROJECT

APPROVED

BY

CERTIFIED

(PTT)NA

REV.

NO.

DATE REVISED

BY

APPROVED

BY

DESCRIPTION

D1 14-Feb-08 NA ISSUED FOR ITB

D2 11-Jun-08 NA REVISION ISSUED FOR ITB

PHILOSOPHY FOR

CONTROL SYSTEMS

PHC-0804.02-60.01 REV.D2

TOTAL 10 PAGES

AREA CODE OF SITE LOCATION

GENERAL AREA: 010

.

PTT PLC. CONTRACT NO.PTT PLC. PROJECT NO.

0804.02


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PHILOSOPHY FOR

CONTROL SYSTEMSPTT PUBLIC COMPANY LIMITED

PHILOSOPHYPHC-0804.02-60.01

PAGE 2 OF 10

REV: D2

CONTENTS

SECTION

1.0 OVERVIEW .............................................................................................. 3

2.0 DCS........................................................................................................ 3

3.0 SAFETY INSTRUMENTED SYSTEM ............................................................. 4

4.0 UNIT CONTROL PANELS FOR MOTOR DRIVEN COMPRESSOR PACKAGE........ 5

5.0 MASTER PERFORMANCE, ANTI SURGE AND LOAD SHARING CONTROLLERS. 6

6.0 FIRE AND GAS CONTROLLERS................................................................... 7

7.0 MACHINE MONITORING SYSTEM............................................................... 7


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REV: D21.0 Overview

This document describes the design philosophy for the development of the

specification, detail design and system implementation for the control systems.

The control systems in this document will be limited to the systems which are

related to THE ONSHORE COMPRESSOR STATION 4 (OCS# 4). The

control systems for the OCS# 4 shall include at least DCS, Safety

Instrumented System, Unit Control Panel for compressor package, Master

performance/Anti surge/load sharing controller and Fire&Gas and Machine

Monitoring System.

2.0 DCSThe DCS system shall consist of a network of Field Control Stations (FCS) to

provide the core plant control and monitoring functions and the Human

Machine Interface (HMI) workstations for operators to operate the facilities.

The DCS shall be designed to execute all process controls which are not

related to safety functions.

PTT operators shall be able to initiate the command to start/stop the

compressor trains, switch over the trains of equipment, change the set points

for any process control and perform any other control functions via the DCS

HMI workstations. The DCS shall also acquire the information from all utilities

and equipment packages, such as motor driven compressor packages,

electrical, instrument air, fire fighting, and machine management system etc.,

in the facilities for monitoring and control. The control signals from DCS to

other package equipments (and vice versa) shall be hard wired while the soft

link shall be used for monitoring only.

The DCS displays and console shall be ergonomically designed to allow PTT

operator to fast access the desired information and to operate the facility

without fatigue. The position of key switch, push button, alarm indication and

communication systems in the DCS console shall also be orderly located for

easy access.

The DCS shall utilize a fully redundant Bus system, CPU, power supply,process and communication to the external system controllers with automatic

bumpless switchover between the hot and standby controllers.

The DCS FCS shall comprise of redundant CPUs, power supplies, Field control

units (FCU) and communication controllers.

All DCS Field Control Units (FCU) shall be foundation field bus for field

transmitters and final elements directly connected to DCS.

The arrangement for the Field Control Stations (FCS) shall prevent the

common cause of inoperability for the equipment trains when the FCS/ itspart fail or are under maintenance. All field process devices of different

compressor trains shall not be connected to the same FCS and the same

principal shall be applied to the inlet scrubber trains and communication

between DCS and the compressor control systems.


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REV: D2All sequential process control, related to the operation of the compressor train

and station, outside the motor driven compressor packages shall be performedby the DCS system. The DCS shall execute the program based on the input

command from the related compressor unit control panel for the required

actions from the field devices.

The DCS system shall be designed to allow the data exchange with the

existing PTT DCS, LNG terminal DCS and the existing PTT SCADA system.

The Sequence Of Event (SOE) in the DCS shall be provided to handle all of

the events related to filed devices connected to the DCS, SIS, other

equipment package control and utility systems.

The DCS shall be equipped with the Plant Information System (PIMS) to

manage all related facility historical operating data for reporting and

process/operation analysis. In addition the Plant Resource Management (PRM)

shall be provided to collect data from all field devices for maintenance

planning and other related activities. These two systems shall be equipped

with the DCS package.

The DCS shall function as a systems master clock for the all equipment

package control systems. DCS shall receive the clock data from GPS and then

synchronize with other systems once per day.

The programming for the logic control in the DCS shall utilize function block.

3.0 Safety Instrumented SystemThe Safety Instrument System (SIS) refers to the field input devices, logic

solver and final element as defined by IEC 61511. It is imperative that the

Safety Life Cycle (SLC) documents as required by IEC 61511 shall be

implemented beginning from SLC analysis up to operation phases. All required

functions and configuration related to the SIS shall be thoroughly defined in

the Safety Requirement Specification (SRS) before the system implementation.

In addition the SIL calculation and SIS equipment selection shall be based onMTTR of 8 hours and 1 year testing interval.

The SIS shall execute only functions related to the safety for the facility

operations such as over pressure protection, process shutdown, and emergency

shutdown with/without blowdown etc. For the shutdown of the motor driven

compressor packages due to process condition, the SIS shall send the hard wire

signal to the required unit control panels (UCP) to execute theirs own shutdown

logic. In the case that the trip of compressor come from its internal causes, the

SIS shall receive the hard wire signal from UCPs to execute related process

shutdown. The status of the final elements, if not required for the safety

functions, shall be sent to the DCS only.

All of the equipments used in the SIS shall be certified by TUV for the safety

application. For logic solver, it shall be certified for SIL 3 application.


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REV: D2All of the field input devices connected to the logic solver shall be 2oo3 voting

configuration. All field input to the SIS logic solver shall be 4-20 mA HARTtransmitter. The DCS shall perform the transmitter integrity check function by

comparing the value of three transmitters in the same loop and shall initiate

alarm when the difference is higher than the preset value. The DCS shall also

set the pre-trip alarm to alert the operators before the process condition reach

the trip set point by using the values from the SIS transmitters.

The SIS logic solver shall be based on 1oo2D configuration. It shall comprise of

the network of Safety Control Stations (SCS). Each SCS shall comprise of

redundant CPUs, power supplies, Safety Control Units (SCU) and

communication controllers.

The arrangement for the Safety Control Stations (SCS) shall prevent the

common cause of inoperability for the equipment trains when the SCS/ its parts

fail or are under maintenance. All field process devices of different compressor

trains shall not be connected to the same SCS and the same principal shall be

applied to the inlet scrubber trains.

The Sequence Of Event (SOE) shall be fully integrated with that of DCS in order

to allow the efficient analysis of the shutdown with related process information.

The design of the SIS shall allow the on line testing for the system from the

field inputs up to the final elements with less human intervention.

4.0 Unit Control Panels for Motor Driven Compressor PackageThe compressor station control system shall comprise of the Unit Control

Panels (UCP), anti surge and load sharing controllers.

Each motor driven compressor shall be provided with its dedicated PLC based

Unit Control Panel. This PLC shall be redundant in all aspects such as CPUs,

power supplies, I/O cards etc.

The UCP shall perform all required functions for the operation of compressorsuch as speed control, start/normal stop and emergency shut down. The UCP

shall receive hard wire signals from the DCS for start/normal stop and the SIS

for emergency shutdown due to process condition. When the compressor

package trips by its own condition, the UCP shall send the hard wire signal to

the SIS to execute the process shutdown functions outside the compressor

package. The UCP shall also send the operating data to the DCS for monitoring

via soft link.

The UCP shall send hard wire command to the related switch gears/MCCs for

the operation of lube oil pumps, lube oil coolers, and any other auxiliary devices

in both normal and emergency case. For the emergency case, the UCP shallsend command to the emergency shut down relays in the related

switchgears/MCCs.


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REV: D2The field transmitters connected to these systems shall be 4-20 mA HART and

the information for each transmitter shall be sent to the PRM.The UCP shall have its dedicated vibration monitoring systems. All data from

these systems shall be transferred to the Machine Monitoring System Server.

The HMIs shall be provided locally at the UCP and remotely at the DCS

consoles. These two HMI shall have similarly functionalities. The remote and

local HMI shall be equipped with the database server to store all historical

operating parameter for the compressor packages.

5.0 Master Performance, Anti surge and Load Sharing Controllers

The master performance, anti surge and load sharing controllers shall beseparate system from the PLC used for the UCP of the compressor train. These

controllers shall be the dedicated systems to serve the desired purposes and

mounted into the unit control panels

The master performance controller shall receive the hard wire process set point

from the DCS, and input from the load sharing/ anti surge controllers, process

the inputs and send the command to the related controllers.

The anti surge and load sharing controllers shall receive the speed , process

data and other required compressor status from the UCP of operated

compressors to perform the anti surge and load sharing functions. The antisurge controller shall also be able to receive the hard wire command from the

DCS for manual operations of the anti surge control valve with anti surge

override function.

The anti surge and load sharing controllers shall be equipped with the fall back

strategy to manage the failure of their input signals in order to minimize the

unnecessary shutdown from this cause.

As same as the UCP, these controllers shall send all operating data to the DCS

for monitoring via soft link in order to allow the DCS HMI workstation to show

the same information and displays as those on the local monitors for thecompressor station control system.

The master performance, anti surge and load sharing controllers shall be fully

redundant in all aspects of the system with bumpless transfer between the hot

and standby units.

The field transmitters connected to these systems will be 4-20 mA HART and

the information for each transmitter shall be sent to the PRM.

The remote HMI workstation for these controllers shall be provided in the DCS

console. This remote HMI workstation shall display all related process data,alarm and event log and healthy of the systems. The remote HMI workstation

shall also be equipped with the engineering and maintenance software for these

controllers.


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REV: D26.0 Fire and Gas Controllers

The fire and gas controllers shall be separated from each other and mounted in

the separate control panel.

The fire controller panels shall include the master fire controller panel and

dedicated fire controller panel for each building. The fire controller panel for

each building shall receive the signal from the detectors, perform voting

function and actuated the fire suppression system. The master fire controller

panel shall handle the detectors and manual call points in the field. The master

fire control panel shall also acquire the information from the fire controller panel

in each building. All information related to the system shall be displayed at the

local and remote HMI workstation.

The gas controller panel shall include at least controllers, local and remote HMI

workstations, and push button for the required functions. The gas controller

panel shall handle the gas detectors and the fire suppression systems in the

field/process areas.

The gas control panel shall be equipped with the dedicated push buttons for

each fire suppression systems, such as fire monitors and deluges, in the field.

The operator shall be able to initiate the action of these devices via these push

buttons. In addition, the reset and horn interrupt push buttons shall also be

mounted on this panel

The fire and gas systems shall utilize the common remote HMI installed in the

DCS control. The remote and local HMIs shall contain the graphical displays for

all areas. The graphical displays design shall be in hierarchy from the overview

to the detail graphical displays. The graphical display shall clearly show the

location of the detectors and fire suppression system. The detectors and fire

suppression systems shall be flashed out on the related displays when the

abnormal situation is detected or the fire suppression systems are actuated.

The local HMI workstations at the master fire and gas controller panels shall be

equipped with the engineering and maintenance software for each system.

7.0 Machine Monitoring System

The Machine Monitoring System shall include server, vibration controllers and

detectors/sensors. The server shall acquire the data from vibration controllers

included those provided by package vendors and store for further vibration

analysis. The server shall be equipped with the software to allow PTT

maintenance personnel to analyze these vibration data in all aspects.

The vibration controllers shall receive the data from vibration detectors/ sensors

and transfer them to the DCS for monitoring via soft link. In case that the

controller detects the vibration of connected equipments, it shall send the hardwire signal to SIS to shutdown the related process units.

All alarm from the vibration controllers shall also be transferred to the DCS.


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REV: D2For the purposes of machine condition monitoring, machines are classified into

four categories as shown in the following table and the system shall designedand provided accordingly.

TYPE OF MACHINE ONLINE OFFLINE

CONTINOUS NON

CONTINOUS

WITH

PROTECTION

(Portable)

CRITICAL MACHINE YES YES

Compressors

Generators

ELECTRIC MOTORS WITH

JOURNAL BEARINGS

GEARBOXES

VOITH VARECON COUPLINGS

Machines With Journal Bearings

ESSENTIAL MACHINE1 YES YES YES

Fans

Fan Motor

ESSENTIAL MACHINE2 YES NO YES

OTHER PROCESS MACHINES

UTILITY MACHINES >= to15KW

SUBSYSTEMS OF CRITICAL

MACHINERY

NON ESSENTIAL MACHINE NO NO NO YES

UTILITY MACHINES < 15KW

Table 2. Types of Machines


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REV: D2Transducer arrangements per type of machine are indicated in the following table

TYPE OF MACHINE TRANSDUCER ARRANGEMENT

CRITICAL MACHINES

All Proximity probes 2-X, 2-Y, for each radial bearing, 2-Z for

each thrust bearing and key phasor. Three accelerometer

measuring point per casing.

ESSENTIAL MACHINE 1

Air coolers 1 accelerometer for the fan bearing, 1 accelerometer for

the motor casing

ESSENTIAL MACHINE 2 Accelerometers, 1-X for the motor casing, 1-X for the

pump casing. Where the machine is a "between bearings"

design an additional probe shall be provided on the driven

machine.

NON ESSENTIAL MACHINES No permanent probes.

Table 3. Transducer arrangements

Critical Machines

The contractor shall provide the Bentley Nevada 3500 rack system segregated

on a machine by machine basis, to interface to field transducer. The Bently

Nevada system shall interface to the machinery control system (local PLC, DCS

or SIS) to provide the required indication, alarm and trip functions. If theBentley Nevada system is connected directly to a local machinery control PLC

then all vibration and monitoring signals shall be repeated to the DCS for

indication.

The Bently Nevada 3500 system shall be interfaced via Bently Nevada TDXnet

modules to form the machine monitoring network.

The TDXnet modules shall be linked to the DCS via dual redundant serial cable

to give the necessary indication.

Each of the TDXnet modules shall be networked using a 10 Base T hub/switch

connection.


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REV: D2 Essential Machines category 1

These machines shall be monitored continuously by accelerometers connected

to a Bently-Nevada 3500 system. The 3500 system shall send trip signals to

the SIS system for machinery protection purposes and to the System 1 server

for machinery analysis. Transducers shall be installed to monitor the fan bearing

housing and the motor casing vibration. Additional data may be collected using

a Bently-Nevada Snapshot portable data collection and analysis unit.

Essential Machines category 2

Each machine in this category shall be fitted with permanent vibration

transducers to monitor pump and motor casing vibration. These transducers

shall be connected to the SPA cards on the System 1 server in a multi-drop

configuration. Additional data may be collected using a Bently-Nevada

Snapshot portable data collection and analysis unit.

Non Essential Machines

Vibration measurements shall be taken by a Bently-Nevada Snapshot portable

data collection and analysis unit. This data shall be downloaded to the System

1 server for machinery analysis purposes.

The machinery monitoring network shall be connected to the ESP DCS ethernet

network via a network switch to allow data to be transferred between the twosystems.

The contractor shall provide a Bently-Nevada System 1 data acquisition and

management system located at instrument rack room to provide full analysis of

all machinery data. This system shall be provided with the following modules:

Data Acquisition, Display and Configuration, Database (SQL Server) DDE

Exporter/Importer, OLE Automation Exporter.

Documents

Control Philosoph1