Turbine - Turbine Control Systems

8/8/2019 Turbine - Turbine Control Systems

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G

XXXXXXXXXX

SPECIFICATION FOR

TURBINE CONTROL SYSTEMS

Rev Date Prepd by Checked BY Appd by Reason for Issue

XXXXX

XXXXX

XXXXX


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TABLE OF CONTENTS

1.0 GENERAL ................................................................................................................................................. 3

PROJECT OVERVIEW ..................................................................................................................... 3SCOPE ............................................................................................................................................... 4DEFINITIONS AND ABBREVIATIONS ......................................................................................... 4

CODES AND STANDARDS, REFERENCE DOCUMENTS ............................................................ 5

CODES AND STANDARDS ............................................................................................................... 5ENGINEERING PRACTICES ............................................................................................................. 5REFERENCE DOCUMENTATION ....................................................................................................5ORDER OF PRECEDENCE ................................................................................................................ 5COMPLIANCE .....................................................................................................................................5ENVIRONMENTAL CONDITION .............................................................................................. 6

UNITS OF MEASUREMENT ............................................................................................................ 7

EXISTING SYSTEM DETAILS ...................................................................................................................... 8

ASAB ................................................................................................................................................ 8BAB ................................................................................................................................................... 9

3.0 TECHNICAL REQUIREMENTS .............................................................................................................. 10

GAS TURBINE CONTROL SYSTEM ............................................................................................. 10FUEL GAS VALVES ....................................................................................................................... 16VIBRATION MONITORING .......................................................................................................... 16FIRE AND GAS DETECTION SYSTEM ........................................................................................ 16TURBINE EMERGENCY SHUTDOWN ......................................................................................... 16INTERFACE TO THE PROCESS COMPRESSOR ANTISURGE CONTROL SYSTEM ................17HARDWARE CONFIGURATION .................................................................................................. 17CLASSIFIED AREAS ...................................................................................................................... 19OPERATOR INTERFACE REQUIREMENTS ................................................................................ 19

4.0 SPECIFIC REQUIREMENT ..................................................................................................................... 19

TAGGING ....................................................................................................................................... 20

5.0 IMPLEMENTATION ................................................................................................................................ 20

5.1 TECHNICAL REQUIREMENT ................................................................................................. 215.2 SCOPE OF WORK ..................................................................................................................... 215.3 TESTING & INSPECTION ........................................................................................................ 21SITE SERVICES ............................................................................................................................. 23

SITE INSTALLATION AND COMMISSIONING ..........................................................................23COMMISSIONING ENGINEER ....................................................................................................... 23COMMISSIONING .............................................................................................................................24SPECIAL TOOLS, SPARE PARTS ...................................................................................................24SPECIAL TOOLS ...............................................................................................................................25

DOCUMENTATION ....................................................................................................................... 25

6.0 TRAINING ............................................................................................................................................... 25

ATTACHMENT 1 : Serial I/O count preliminary

SUMMARY OF REVISION HISTORY

Rev. No. DateSection or Pages,

RevisedDescription of Change


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A 20.09.03 - Original Issue

B 08.11.03 All Sections Reissue for Comments

0 08.12.03 - Final Issue

1.0 GENERAL

PROJECT OVERVIEW

XXXXX Gas Industries Ltd (XXXXX) has NGL extraction facilities at Asab & Bab,located at 190 KM south & 150 KM south west of XXXXX city respectively. Thefacilities consist of the following plants which are:

Gas Gathering (Booster area).Gas compression


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Gas Treating (Bab only)Propane Refrigeration and ExtractionUtilities, relief and blowdown.Power GenerationAcid gas recovery (Bab only)Lean gas station

The facility has been operational since 1981. The process control system is pneumaticand safeguarding logic is by means of relays based system. Separate fire & gas panels areprovided for the fire & gas detection & protection of the plant and main equipment.These systems are very old and have become obsolete.

The Company, XXXXX, will replace and upgrade the existing control system by newintegrated control system (ICS) comprising of the following main components.

Distributed Control system (DCS) Instrumented Protective System (IPS) Fire & Gas system (FGS)

Associated with the above, interfaces to subsystems or the subsystems will also beupgraded.

SCOPE

This specification covers the minimum requirements for the design, manufacture,inspection and testing of the upgraded Turbine control systems and the interface for newICS.

DEFINITIONS AND ABBREVIATIONS

The following definitions are used in this specification:

VENDOR The Supplier with whom the purchase order will be placed forthe supply of the specified equipment.

OWNER XXXXX

CONTRACTOR The EPC Contractor

ICS VENDOR The supplier of the main ICS components comprising of DCS,IPS & FGS.

The following abbreviations are used in this specification:

DEP : Design and Engineering Practice from Shell International OilProduct B.V.ICS : Integrated Control SystemDCS : Distributed Control SystemMCR : Main Control RoomAR : Auxiliary RoomGTCS : Gas Turbine Control SystemMPU : Main Processor Unit


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CODES AND STANDARDS, REFERENCE DOCUMENTS

CODES AND STANDARDS

The following codes and standards shall be applied. Any deviations or conflicts shall bereported in writing and shall require prior approval by the Company.

IEC : International Electro Technical CommissionIEC 79 : Electrical Apparatus for Explosive Gas AtmospheresIEC 529 : Degree of Protection of EnclosureIEC 331 : Fire Resisting Characteristics of Electrical Cables

NEMA : National Electrical Manufacturers Association

ICS 1-1978 : General standards for industrial control systemICS 6-1978 : Enclosures for Industrial Control and SystemsICS 2-230 : Electromagnetic Interference

CENELEC standardsEN 50018 : Electrical Apparatus for Potentially Explosive AtmospheresAPI : American Petroleum InstituteAPI 670 : Machinery Protection SystemANSI : B 1.20.1

Vendors shall indicate in their proposal the codes and standards, which have beenapplied in the manufacture of the material required under this specification

ENGINEERING PRACTICES

The following Shell DEPs of latest issues shall be applied.

DEP 32.37.20.31-Gen System Cabling

REFERENCE DOCUMENTATION

The following documents are applicable for reference:

P5223-30-A-0004P5223-30-B-0004

I/O list for AsabI/O list for Bab

Note :Bulk I/O count attached is preliminary and for reference only. EPC contractorto finalize the actual I/O requirement for system upgrade requirement.

ORDER OF PRECEDENCE

In the case of conflict, the following order of precedence shall apply,1. Contract Specifications2. SHELL Design and Engineering Practice (DEP)3. International Codes and Standards

COMPLIANCE

The VENDOR shall notify the CONTRACTOR or OWNER of any apparent conflictbetween this specification, equipment or software functional detailed


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specifications/drawings, the Codes and Standards and any other specifications notedherein. The VENDOR is to prepare a tabulated list of discrepancies between any of thesedocuments for review with CONTRACTOR. Resolution and/or interpretation precedenceshall be obtained from the CONTRACTOR or OWNER in writing before proceedingwith the design/manufacture.

In case of conflict or ambiguous possible interpretation of documents, the vendor shallnotify Contractor and seek clarification during the tender period.

The Vendor may propose alternative improved performance features as long as thesystem is made up of field proven hardware and software modules.

The Vendor shall ensure that the design complies with the requirements of thisspecifications and its referenced standards and work practices.

Vendor shall submit with his quotation a completed Table of compliance. Vendor shallconfirm compliance to the specifications and the referred standards by section by sectionAn example of the table of Compliance is given below:

TABLE OF COMPLIANCE

Date :Project :Vendor :

ParagraphNumber

Enhancement Conforms Alternative Exception Noted ClarificationNote

2.0

2.1

2.1.1

2.1.2

2.1.3

2.1.3.1

Definitions of the column headings are as follows

Enhancement: Feature fully complies with the specifications and offers morefunctionality. Vendor to give full description.

Conforms: Feature fully complies with the specification.Alternative: Feature does not meet the specification, however the functionalrequirements can be met in different way. Vendor to give full description.

Exception: Vendor cannot meet the specification.

Noted: The relevant paragraph in the specification contains information only. Bychecking this paragraph as noted, Vendor confirms that the information is understoodand that the supply will be in compliance with this information.

Clarification Note: To be detailed by Vendor item wise.

ENVIRONMENTAL CONDITION


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EXISTING SYSTEM DETAILS

The details of the existing Turbine control panels various locations of the plant areelaborated in the following sections. The turbine control panels are used for themonitoring, control & safeguarding of the power turbines, generator or compressor unitsand their associated auxiliaries.

ASAB

2.1.1 MCR

The details of the existing Turbine control system in the MCR are given below.

Sl.No.

Panel Description System Description

1 22-K-101(LP Compressor)

One Netcon 5000 F/T system along with Woodwardspeed controller, HMI interface equipment includingCompac PC monitor, HP LaserJet Printer and a

separate event printer. Also Bently Nevada VibrationMonitoring system along with Vibrometer system &F&G linked with Netcon system.

2 24-K-401(Propane)

General Electric (GE Mark II) control panel, used formonitoring and control associated with Feed gascompressor. Also Bently Nevada for Vibration andtemperature monitoring along with F&G linked to thissystem.Total there are three panels: Turbine GE MK2 control panel Compressor control panel (including BN

monitors) HOW-R3 F&G panel

3 24-K-101(HP gas)

General Electric (GE Mark II) control panel used formonitoring and control associated with feed gascompressor. Also Bently Nevada for Vibration andtemperature Monitoring along with F&G linked to thissystem.Total there are three panels: Turbine GE MK2 control panel

Compressor control panel (including BNmonitors) HOW-R3 F&G panel

Note : Control systems for 24-K-401, 24-K-101 are being upgraded and relocated to SS4 and SS 5 respectively (under a separate project).

2.1.2 SUBSTATION-1

The details of the existing Turbine control system in the Substation-1 are as follows:


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Sl.No Panel Description System Description

1 Power generator controlpanels 3 No.One for each 26-V-101,26-V-102, 26-V-103

One GE Speedtronic control (GE Mark II) control panelused for monitoring and control each power generator.Vibration monitoring along with F&G is also linked to thissystem.

Note : Control system for 26-V-101, 26-V-102 & 26-V-103 are being upgraded (undera separate project).

2.1.3 LEAN GAS STATION

The details of the existing Turbine control system in the Lean gas station are as follows:


1 Compressor control panelfor Lean gas train A

One Netcon 5000 F/T system complete with a HMIunit, printer and a separate event printer. VibrationMonitoring from Bently Nevada along with Vibrometersystem, with Netcon system. F& G has its own panel

and monitor however linked to Netcon & HMI for alarmand trip only

2 Compressor control panelfor Lean gas train S

One Netcon 5000 F/T system complete with a HMIunit, printer and a separate event printer. VibrationMonitoring from Bently Nevada along with Vibrometersystem, linked with Netcon system. F& G has its ownpanel and monitor however linked to Netcon & HMI foralarm and trip only.

BAB

2.2.1 MCR

The details of the existing Turbine control system in the MCR are given below.


1 14- K-101 HPCompressor

One Netcon 5000 F/T system complete with a HMI unitand a printer. Vibration monitoring along with vibrometer

system and F&G is also linked with Netcon system.

2.2.2 SUBSTATION-1

The details of the existing Turbine control system in the Substation-1 are as follows:


1 Power generator controlpanels 3 No.One for each 16-V-101,

One GE Speedtronic control (GE Mark II) control panelused for monitoring and control each power generator.Vibration monitoring along with F&G is also linked to this


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16-V-102, 16-V-103 system.

Note : Control system for 16-V-101, 16-V-102 & 16-V-103 are being upgraded (undera separate project).

2.2.3 LEAN GAS STATION

The details of the existing Turbine control system in the Lean gas station are as follows:


1 Compressor control panelfor Lean gas train A

One Netcon 5000 F/T system complete with a HMIunit, printer and a separate event printer. VibrationMonitoring from Bently Nevada along with Vibrometersystem, Vibration Monitoring system linked with Netconsystem. F& G has its own panel and monitor howeverlinked to Netcon & HMI for alarm and trip only

2 Compressor control panelfor Lean gas train S

One Netcon 5000 F/T system complete with a HMIunit, printer and a separate event printer. VibrationMonitoring from Bently Nevada along with Vibrometer

system, Vibration Monitoring system linked with Netconsystem. F& G has its own panel and monitor howeverlinked to Netcon & HMI for alarm and trip only

3.0 TECHNICAL REQUIREMENTS

Since the plant controls is being upgraded to a new ICS system, it is necessary tointegrate monitoring of machine parameters in ICS, which require communicationbetween machine control and ICS. Presently the Netcon 5000 F/T control systems havebecome obsolete and many of the cards are not supported by M/s Woodward. Similarlythe GE Mark II systems also have become outdated. In view of this it is necessary toupgrade the systems and establish communication to ICS.

GAS TURBINE CONTROL SYSTEM

3.1.1 GAS TURBINE SYSTEM DESIGN REQUIREMENTS

The new Control and Protection system will be used to provide all control andprotection functions currently performed by the existing system, with the addition of thenew features that will improve the reliability, availability and maintainability (greaterthan 99,99%) of the Gas Turbine.

3.1.2 SYSTEM HARDWARE

The new system shall be a fully programmable gas turbine controller with its ownpower supply, processor, communications, and I/O for turbine control and protection.Critical functions, such as emergency overspeed, exhaust over-temperature protection;ESD and backup synchronous check protection shall be provided by an independentprotection system as per API 670.

3.1.2.1THE MAIN PROCESSOR UNIT (MPU) shall have the following requirements:

a) All Algorithms and Human Machine Interface (HMI) tasks shall be executed by theMPU

b) Real time clock with a 1m seconds resolution shall be available for time dependent


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functions such as rate calculations as well as time stamp process variables, alarmsand events generated by the controller.

c) The microprocessor shall be capable of scanning and updating the I/O andexecuting user-defined logic a minimum of 40 times per second.

d) Communication facility with DCS via Modbus RTU protocol or OPC

3.1.2.2 I/O INTERFACE

Input ModulesThe GT Control System must have input modules capable of accepting input signalsdirectly from all the following categories as required:

a) Field switches-volt-free contacts and solid statedevices with 1msec time stamp for sequence of events monitoring.

b) Analog 4-20ma, 0-5VDC or 0-10VDC signalsfrom 2 or 4 wire transmitters.c) Low-level analog signals from J, K, T, or Ethermocouples.d) Pulse Inputs (for rate measurement)e) RTD inputs.f) Vibration inputs for the casing vibration probes.

Digital input signals shall be conditioned by a low pass filter, typically up to 15 ms, toreduce the effects of noise and bounce. A minimum of 1000 VDC opto-isolation shallbe provided between each input signal and microprocessor. Each individual input signalpath on the input module shall be automatically tested for proper operation at leastevery 10 minutes. Analog and pulse input signals shall have a minimum of 150VDCinput over range protection

Digital inputs shall not be fused

Input modules shall have test circuitry to detect stuck-on and stuck-off conditions to

ensure safe operation.

Output ModulesThe Gas turbine control system must have output modules capable of driving outputsignals for all the following categories:

a) Analogue signals 4-20mA (500 ohms max.) or 0-200 mA (50 ohms max.)b) Solenoid valves, relays, motors and LVDT valve position feedback (24 VDC,

125VDC, 240 VAC)c) Alarm annunciators and DCS interface I/O

Output modules shall fail to open state upon microprocessor failure.

Digital outputs shall be current rated for an inductive load with a minimum of 1 ampper point at 60 degrees Celsius.

Each individual output point shall be automatically tested for proper operation at leastevery 10 minutes.

Digital output modules shall operate properly with a +/- 10% signal voltage, provide aminimum of 1000 VDC opto-isolation between each output signal and microprocessorand accept surge current on each point of 12A per cycle for AC voltage and 2.5A persecond for DC voltage.


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Digital output modules, which support line fault monitoring, shall also be available.The modules shall be capable of detecting and alarming open or shorted field circuits aswell as power monitoring. Line monitoring shall be required if any energize to tripsignals are specified.

Each digital output shall be individually fused with blown fuse indication and knifedisconnect terminals for complete isolation capability.

Analog I/OThe Gas turbine control system shall be capable of accepting both high level and lowlevel analog signals directly through an input module without the use of externalmonitor switches.

Thermocouple inputs shall have built in automatic cold junction compensation andlinearization. A single module shall accommodate type J, K, T and E thermocouples.

Analogue outputs shall be capable to be configured to provide a 4-20 mA signalsthrough 500 ohms load or 200 mA through 50 ohms load. Each output shall beautomatically calibrated. Analog inputs shall be automatic calibrated.

Analog I/O shall have 12 bit minimum analog to digital or digital to analog conversion.Accuracy shall be at least +/- 0.25% of full scale over the entire operating range.

The vendor shall provide any dropping resistors necessary for analog modules operatingwith 4 to 20 mA DC

3.1.2.3 AUTOMATIC TESTING AND DIAGNOSTICS

The system shall incorporate self-diagnostics such that permanent and transient faultsare identified, alarmed and reported. The reporting shall be up to and including theindividual channels in modules and the system shall have the first-out alarm facility.

The diagnostics shall be capable of identifying locating and reporting the followingfaults as a minimum:

Scan failure of main or I/O processors.Memory faults.Communication faults.I/O Interface or addressing faults.Application program and layout consistency.I/O module faults.Load power or fuse faults on field circuits.Power supply faults.Over temperature conditions.

I/O forcing status.System cabinet high temperature.

Minimum test period for all logic circuits shall be once every 10 minutes. Faultinformation shall be available and displayed for maintenance staff in a manner thatenables fault diagnosis to at least the module level.

All testing described shall be performed automatically on-line and without disturbingthe process or reducing the reliability of the GTCS. The diagnostics described aboveshall be built into the operating system of the GTCS hardware and not located in the


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application program.

3.1.2.4 INTERNAL SEQUENCE OF EVENTS RECORDERfor logging of (but not limitedto):

a) System alarmsb) Diagnostic alarmsc) System events (turbine operation monitoring).d) Turbine trips (including a real first out alarm facility of signal condition that

caused a turbine trip, and freeze frame feature for key parameters just before andafter the trip). 5 minutes pre trip and 2 minutes post trip data shall be available.

3.1.2.5 ALARM LOG

1) The alarm logging shall be available to the operator on the Operator Interfacedisplay and on the printer.

2) The alarm management screens shall list the alarms in the chronological order oftheir time tags.

3) The alarm line must show (color highlighting) whether the alarm has beenacknowledged or not and whether the alarm is still active.

4) When the alarm condition clears the alarm can be reset. If reset is selected and thealarm has not cleared, the alarm shall not clear and the original time shall beretained.

5) An audible alarm shall be initiated when a new alarm occurs, and will bemaintained until the operator manually silences the alarm.

6) A status field on the alarm display showing the current status on the origin of eachalarm regardless of whether the alarm has been acknowledged shall be made

available.

7) Facility to change or add alarm messages in the alarm status field shall beprovided.

8) Lock out feature to enable the operator to lock out the logging of a nuisance alarmsuch as contact inputs continuously changing state must be provided.

9) The locked out alarm shall be highlighted on the alarm display to providecontinuous record that it locked out.

10) Separate queues shall be maintained for the turbine system alarms and internal

control equipment diagnostics.

11) All contact inputs to the new control system will be included in the events log andwill be logged on the printer with individual time tags. Facility to add or deleteindividual contact inputs from the event log shall be provided.

12) Separate queue for trip contacts shall be provided, and any logic forcing of thesecontacts, shall be highlighted on the alarm display by continuous flashing.

3.1.2.6 TRENDING


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Signal trending facilities shall include:

a) Real time trendingb) Short term trending

c) Long term trending (Historian), to be quoted as an option

High resolution trends (1sec) shall be provided

For Real time trending purposes the Operator Interface Station shall have the facility todisplay up to six points (user defined) of data simultaneously.

3.1.2.7 COMMUNICATIONS

DCS InterfaceThe new control system shall be capable of interfacing to a DCS via RTU Modbusprotocol or OPC (preferred). The vendor shall provide details of successful interfaces toDCS systems, stating client and location of the project. The vendor shall supply in theproposal a list of services and hardware necessary to provide a complete working DCSinterface. All data must be upgraded in the ICS every one second or faster.

The information to be transferred to and from the DCS via this data link shall include,but not limited to the following:

a) All operational and control signal.b) System diagnostic, alarms and status.c) Field I/O statusd) Shutdown signals and first out indicatione) DCS generated signalsf) System maintenance override status conditionsg) GT accessories status

3.1.2.8 APPLICATION SOFTWARE

The application software shall be specifically designed for the turbines listed in thespecification.

The vendor shall be fully responsible for all the programming and configuration of theproposed system and will fully describe his proposed system, including in detail the failsafe operation of the control system, referring to resets, condition of valves, lube oil,fuel supply system etc. in the proposal.

Software shall be protected from unauthorized changes by the use of both passwords

and key lock switches. Vendor shall state with proposal methods available in his systemfor such protection.

3.1.2.9 HUMAN MACHINE INTERFACE

A separate operator interface shall be provided as a back up for any failure of the paneloperator interfaces. This operator interface shall have all the functionalities of any of thelocal operator interfaces, which can be selected and identified through software buttonslocated in the corner of each screen. The location of this equipment shall be locatedinside the same building as the GTCS panels (exact location yet to be decided but no


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more than 30 meters from the referred panels)

Note: The operator interfaces hardware requirements are described under 3.9.

Control1) Unit control display (Operational command screen)2) Start up sequence display3) Turbine wash display4) Unit test display5) GCV and IGV calibration and stroke check.6) Mechanical and Over speed tests

Data1) Exhaust temperatures and spread display.2) Lube oil temperatures and pressures display.3) Lube oil and hydraulic oil system display4) Wheel space temperatures display.5) Vibration monitoring display (generator, gas turbine).6) Timers and event counters display.7) Fuel system display.8) Start check display9) Bearing temperature displays10) Air temperatures display (Accessory compartment, turbine compartment, compressordischarge)11) Flame monitoring display.12) Ventilation system overview display

Administrative1) Annunciation of Trips display2) Annunciation of alarms and fault conditions display3) Ladder logic display4) Logic forcing display

5) Diagnostic alarms display

Trending1) Standard and user defined trend displays

Note: All screens must have a window preferably at the bottom of the screen to displaythe most recent alarm and trip events. The size of the window shall be enough todisplay at least five alarms. From the same window alarms can be scrolled through thecomplete list of alarms. The listed alarms shall be displayed with its date, time, alarmidentification, device, acknowledge state and message. Software buttons shall beavailable on the top of this alarm screen to acknowledge, silence, lock, unlock, seecomments and set up the alarms.

Display print out samples (from the above list) shall be submitted along with quotationsfor evaluation and complete set of print out displays shall be submitted by thesuccessful bidder before FAT for review and comments.

3.1.2.10TURBINE CONTROL SYSTEM ACCESSORIES HARDWARE

The vendor shall have the capability of furnishing any control system accessorieshardware, which may be required to complement the Gas Turbine Control System. Thevendor shall fully describe his proposed accessory system in the proposal with the block


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diagram to explain functionality. The installation of these accessories shall be theresponsibility of the contractor.

3.1.2.11SPARE CAPACITY/EXPANDABILITY

At least 15% wired spares and 20% spare capacity shall be made available within eachsystem. The spares shall be distributed all over each system. This includes marshallingcabinets, terminations, I/O, etc. Processor utilization shall be no more than 70%.

FUEL GAS VALVES

Vendor shall quote for the upgrading / replacement (if required) of the control valve,servo hydraulic to suit the new control systemrequirements.Any new servos shall be compatible with existing valve actuator assembly.Redundancy should apply for the actuators commands and valve position feedback.

3.2.1 FUEL GAS MEASUREMENT

The turbines fuel gas flow is measured through an orifice plate, and the measurementloop includes the differential pressure, pressure and temperature transmitters. Using theexisting mentioned signals (4 to 20 mA), the vendor shall be responsible to interface andprovide the necessary computation and display graphics to ensure that the corrected flowrate and totalized flow, pressure and temperature will be displayed in the new controlsystem.

VIBRATION MONITORING

The vendor shall quote for the required hardware and software interface to the vibrationsystem (Bently Nevada 3500 & vibrometer) to provide monitoring, alarm and trip.

Bently Nevada system shall be installed on separate cabinet. Vibrometer may also bereplaced and interfaced with new Bently Neveda System

FIRE AND GAS DETECTION SYSTEM

The Gas turbine / Compressor unit is protected by a dedicated fire and gas detectionsystem, located in the main control room.

Vendor shall interface/connect the Fire & Gas panel signals to the new control system.The interface/connection to the new control system will be limited to the alarm and tripsignals, which will be available at the Fire & Gas panel as voltage free contacts.

TURBINE EMERGENCY SHUTDOWN

Dedicated ESD push buttons (red color) shall be provided with spring loadedtransparent covers, clearly marked as Turbine ESD in the following places:

a) In the new control system panels.b) In the Main Control Room (location to be advised)c) In the turbine area (two numbers) one on each side of theturbine (location to be advised).

The ESD push buttons will be hardwired to the new control system panel throughindividual input channels.


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INTERFACE TO THE PROCESS COMPRESSOR ANTISURGE CONTROLSYSTEM

A unit and run trip contact (free of voltage), shall be provided from the control systemfor interface with the latest C.C.C. anti-surge control system.

HARDWARE CONFIGURATION

3.8.1 LOCATION / SUPPORT

a) The room where the new control equipment is to be installed is air-conditioned andthe temperature is maintained between 20C and 25C, with approximately 60%RH. However the system shall be designed to meet a satisfactory performancewithout any kind of disturbance or malfunction up to temperatures of 50C, and RHof 95% approximately. Which may occur as a result of air-condition malfunction.

The supplier equipment cabinets shall be installed as given below:

22-K-101 - in auxiliary room (Asab)Lean Gas Train A&S - in Lean Gas station CR (Asab)14-K-101 - in auxiliary room (Bab)Lean Gas Train A&S - in Lean Gas station CR (Bab)

b) Suitable support framework shall be provided by the supplier to support allequipment cabinets. Blank floor plates shall be fitted to open areas.

3.8.2 MECHANICAL DESIGN

a) Construction and finish for the cabinets and consoles shall be to industry acceptedstandards so that durable, high quality cabinets that facilitate operation and

maintenance are provided. Cabinets shall be fitted with removable eyebolts.

b) Cable entry to cabinets, console and racks shall be from below.

c) Ventilation is not required through the bottom of the enclosure, consequently allholes remaining after the entry of the cables shall be sealed against entry of dust.The dust seal shall be easily removed to enable entry of future cables. Suppliershall identify his means of achieving this requirement.

d) Equipment cabinets shall have front access. Each door shall include a locking latchwith integral locks and common keys.

e) Louvers, filters and exhaust fans shall be provided as required to maintainElectronic Instrumentation within manufacturers/suppliers specified operatingrange.

f) Cabinet interior lighting shall be provided.

3.8.3 ELECTRICAL DESIGN

a) Supplier shall employ industry-accepted practices in cabinet and wiring design.


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b) All equipment installed inside the cabinet shall be easily accessible and secured inposition to prevent any possibility of a loose contact.

c) The power supply available for the panel will be 240v AC 10%, 50Hz 4%single phase and neutral.

d) Nevertheless supplier shall provide in the quotation the power supply requirementsof the proposed system, (HMI, printers, control panel, ignition transformers, etc.).Main power ELCB shall be provided by vendor.

e) All terminals shall be clearly identified.

f) All field I/O shall be terminated at knife edge terminals (widemuller or Klipon).

g) Care shall be taken to minimize interference between signals and power supplywiring. Separate trunking shall be used with appropriate space between.

h) Field power supply shall be floating and monitored for low voltage and earth fault

i) Joints in internal wiring are prohibited. All jumpering shall be done at terminalstrip, using proprietary cross-links.

j) A minimum of 20 % installed spare terminals shall be provided.

3.8.4 EARTHING

a) An A.C. safety earth bar, bonded to framework, shall be provided in each

equipment cabinet. It shall be used to provide earthing for power supply modules,metal equipment enclosures and doors.

b) An instrument earth bar, mounted on insulators shall be provided in the equipmentcabinet. It will be used to provide 0V reference (where required) and grounding ofsignal cable screens.

c) Provision shall be made for terminating earth continuity cabinet links (by supplier)and main earthing conductors.

d) Supplier shall specify his system grounding requirements.

Note : Control system to include earthing detection

3.8.5 RFI / EMI Immunity

a) Radio Frequency InterferenceStandard U.H.F and V.H.F personal radio equipment will be operated at down toone-meter distance of system equipment. Provision shall be made to render thecontrol system immune to interference from such radio operation with cabinetdoors open.


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Field devices shall also be immune to R.F.I. (i.e. valve servos, LVDTs, etc.). Thesuppliers equipment shall not cause R.F.I. to the radios.

b) Electromagnetic EmissionsCare shall be taken to ensure that signal lines susceptible to interference are notaffected by power wiring.

CLASSIFIED AREAS

All equipment under the scope of this specification shall be supplied and installed inaccordance with the defined standards (see section 11.0) for the following HazardousArea classification:

a) Within turbine enclosures:Hazardous area: Zone 1; Gas group: IIA; Temperature class: T3

b) Outside turbine enclosures:Hazardous area: Zone 2; Gas group: IIA; Temperature class: T3

c) Within substations and the main control room: Safe

OPERATOR INTERFACE REQUIREMENTS

As a minimum, the operator interface stations shall include the following:

a) Industrial Colour LCD monitor 21 high resolution and shall be easily readableunder normal fluorescent conditions.

Note: For the panel monitors vendor shall propose alternatives for flat screens, whichhe may find more suitable for the application.

b) Industrial grade PC Pentium 4, 1GHZ, 30 GB Hard disk, 1 GB RAM

c) Back up devices such as CDRW and DAT tape drive.

d) Wireless keyboard and mouse, shall be mounted in drawable type in the panel.

Note: The available power supply for the operator interface units and printers is 240v,50 Hz.

4.0 SPECIFIC REQUIREMENT

As mentioned in section 2.0 panels for turbine control systems of GE Mark II are

being upgraded to new control system under different project scope of work whichinclude HP and propane along with turbine control of power generators at ASAB andBAB.

Hence scope of this specification is to upgrade stand alone Woodward Netcon controlsystem only for compressors mentioned as below:

Asab22-K-101 (LP)29-K-501 A (Lean Gas Train A)29-K-501 S (Lean Gas Train S)


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Note:Each package consists of : Starter Rolls Royce gas generator Gas turbine Compressor Oil system

Existing control system for each package includes: WW Netcon F/T BN vibration system Vibrometer F&G system

Bab14-K-101 (HP)401-ME-104 (Lean Gas Train A)401-ME-105 (Lean Gas Train S)

Note:Each package consists of : Starter Rolls Royce gas generator for HP and Solar for Lean Gas train A & S Gas turbine Compressor Oil system

Existing control system for each package includes: WW Netcon F/T BN vibration system Vibrometer F&G system

In each of the stand-alone WOODWARD Netcon control system shutdown signals fromthe existing Vibration monitoring system (BN 3300 series & Vibrometer) and Fire &

Gas system (HOW panel) are hardwired. These signals will be now re-routed from thenew Vibration monitoring system and Fire & Gas system (PLC based), to the upgradedsystem but the functions will remain unchanged.

For the monitoring of the analogue, alarms, faults and status signals, a communicationlink must be established between the upgraded system and the ICS as mentioned earlier.

The following shall be done for Netcon System.

Upgrade the existing system to the new system. Add communication links as indicated earlier in the sub sections for each system to

new ICS.

TAGGING

Data issued from the Turbine Control Systems will be tagged in accordance with thegeneral tagging convention defined in the Project. Tag numbers will be made availableduring Detailed Engineering.

5.0 IMPLEMENTATION


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5.1 TECHNICAL REQUIREMENT

Provide total turbine control. Provide Turbine protection system. Shall be expandable to meet future needs. Communication with ICS. Hot replacement of modules should be possible.

All different type of I/O interface modules.

5.2 SCOPE OF WORK

VENDOR shall be responsible for:

Supply of new upgraded Turbine Control system. Site survey to establish the current functionality and system spec for upgrade and

interface to the new ICS. Establishing the serial link or OPC communication at the new system end and

required configuration. Verification of hardware with those existing at site which includes provision of

appropriate devices fully compatible and the same revision as that of the hardwareexisting at site. Ensuring proper data exchange between ICS and the Turbine control systems. Modification & loading of program in the new system including consideration of

tag number changes, Control Commands from ICS, monitoring signals to ICS andother changes.

Connect Power Supply alarms to ICS

Necessary OPC/MODBUS software licences shall be provided for each communicationlink.

Vendor shall note that all the necessary software modifications & changes should bedone at their works and shall not leave any work to be done at site.

The following are out of the scope of supply of the VENDOR. This is the scope ofsupply of the ICS VENDOR.

Communication modules at ICS end Cables and connectors, to ensure the communication between ICS and sub-system. Configuration for the ICS side.

However the Turbine system supplier shall be responsible providing full support to theICS supplier for the development & testing of the interface. Such support to includeengineering services, hardware for development and testing at an early stage of projectimplementation.

5.3 TESTING & INSPECTION

5.3.1 GENERAL

The interface shall be fully tested at the ICS vendors premises to ensure that therequirements of the specification are met. The vendor will provide necessary interfacedevices (model control system) in line with the new system to be installed at site forinterface testing at ICS Vendors facility with the turbine control system program.

5.3.2 ACCEPTANCE TESTS


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a) Vendor shall be responsible for performing all tests, and shall supply all necessarytest and simulation hardware and software.

b) Equipment shall comply with any Health and Safety type regulations in force inXXXXX.

c) Before the start of formal acceptance tests, supplier shall perform such tests asnecessary to ensure that the system is in fit condition to commence acceptancetesting. Such tests shall include the component testing and burn-in tests. 100%internal tests shall be performed by vendor.

5.3.3 FACTORY ACCEPTANCE TEST (FAT)

a) The FAT shall include the testing and acceptance of both hardware and softwaresystems. The supplier shall generate the FAT procedures used for these testsincluding the pass / fail criteria used and submit them for Cascos approval atleast one month in advance.

Note: All software must be completed prior to the start of the FAT.

The test plan shall include the following:

1) Hardware physical inspection for completeness; safety; finish; correct labeling;conformity with arrangement and lay out drawings.

2) Electrical testing to confirm correct system operation under marginal power supplysituations.

3) Demonstration of correct operation of all inputs and outputs.

4) Demonstrations of correct control algorithms and communications.

5) Demonstration of all configured graphic displays.

b) XXXXX personnel will witness the entire tests at the vendors premises. Prior toproceeding with test, the supplier must submit his system log, pre-test records anddemonstrate any certified test equipment. The FAT procedure will be signed off bysupplier and XXXXX personnel at the successful conclusion of testing, and willformally accept satisfactory completion of FAT, when all test certificates have beensigned.

c) All hardware diagnostic programs shall be run at the start of the FAT.

d) The supplier shall allocate adequate time, space, facilities, test equipment,engineering, and support personnel to permit testing to the satisfaction of XXXXX.If the system is not ready for testing upon arrival of XXXXX team, the supplierwill be liable for costs for any extra time required to complete the testing.

e) All components of the system, including cables supplied as part of the system, shallbe connected in operating configuration.

5.3.4 SITE INSPECTION TEST


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a) Site inspection tests shall be carried out to verify that the system did not sufferdamage during shipment to the site.

b) The contractor shall include for travel to site to carry out the unpacking andinstallation of the equipment and site inspection tests.

The interface shall be fully tested at the ICS VENDORs premises to ensure that therequirements of the specification are met. The VENDOR will provide necessaryinterface devices in line with the new system to be installed at site for interface testing atICS VENDORs facility with the modified Turbine Control system program.

All tests, both hardware and software, shall be documented, with specimens of testsheets and certificates submitted to the CONTRACTOR and OWNER for priorapproval.

SITE SERVICES

SITE INSTALLATION AND COMMISSIONING

Vendor will be responsible for the site installation(supervision) and commissioning ofall equipment in his supply.

In particular, this shall include:

a) Locating and fixing new panels and equipment (supervision only).

b) Interconnecting cables between suppliers equipment.

c) Connecting power supplies.

d) Cross-wiring to the existing panels.

e) Pre-commissioning, including verification of correct cabling.

f) Full commissioning of the system to XXXXX`s satisfaction.

In order to carry out this project in a professional and safe manner, the vendor shallsupply the services of a dedicated team, who will be fully acquainted and familiar withthis project and its requirements, and shall comply with all safety rules and regulationsprevalent in XXXXX sites.

Vendor is requested to estimate and indicate in his proposal the number ofengineers/technicians required and their categories.

The vendor shall be responsible to provide all working tools, equipment and instrumentsnecessary for job execution, (unpacking of new panels, installation and connection ofnew system and consoles, cable laying, installation of new instruments and devices,testing and measurement instruments and equipment. etc.).

The supplier shall indicate in his offer all the required lifting equipment necessary forthe job execution.

COMMISSIONING ENGINEER


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a) The vendor shall supply the services of a system start-up commissioning engineerwith very good experience in the installation and commissioning of similar systemsand fully acquainted with the requirements of this particular project.

b) The vendor-commissioning engineer shall be responsible for on-site pre-start-upchecks and a full system and peripherals functional test in order to satisfy anominated XXXXX engineer of the correct system operation prior to on-linecommissioning.

c) The vendor-commissioning engineer shall provide an approved pre-test andcommissioning check list detailing the above procedure.The compliance to this shall be witnessed and accepted by a nominated XXXXXengineer.

d) To satisfactory, complete the on-site testing. The commissioning engineer shall bein possession of all necessary manufacturers documentation and standard testequipment.

e) The vendor-commissioning engineer shall be fully responsible for taking all theprecautions for safe commissioning and start-up of the gas turbine.

f) Commissioning shall be regarded as complete if the system can successfully satisfyat least the following operations:

1) Full start-up from cold conditions.2) Normal stop.3) Full start-up from hot conditions.4) Emergency stop.5) Another hot start-up.6) Redundancy function checks for all devices.(where applicable).7) Trip by simulating a process trip condition.8) Another cold start-up (e.g. 2 hours after the trip).

9) Continuous operation of the machine for 48 hours under the control of the newcontrol system, subjected to speed and load changes as per processrequirements.

10) Overspeed and synchrocheck protection tests.

The VENDOR shall provide qualified personnel to connect the communication modulesinside the existing Turbine Control systems equipment, software changes and to verifythe cabling prior to power-up.

COMMISSIONING

VENDORs qualified personnel shall carry out implementation of corrected program inthe new system, which will include requirements called for in this specification.

VENDORs personnel will co-ordinate with ICS Vendor personnel and establish link.

Test the interface requirements like executing control commands from ICS to Turbinecontrol system.

SPECIAL TOOLS, SPARE PARTS


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Any special tool needed for the commissioning and/or for the troubleshooting of thecommunication links must be supplied.

SPECIAL TOOLS

The VENDOR shall supply all software programs (including licenses) as well as anyspecial tools, programming tools and calibration equipment deemed necessary for thecorrect installation and testing of the control system equipment for use either in theworkshop, or on site.

DOCUMENTATION

In addition to the information required in this specification, the VENDOR shall furnishthe information indicated in the material requisition documents.

VENDOR shall provide documentation: In English Complete, accurate and internally consistent. Clearly indexed. Easily updated. Mounting instructions clearly detailed.

The VENDORs documents shall include: The standard documentation on the interface modules. The as-built documentation for the hardware, the software and the specific

configuration for each communication link. The connection drawings on both ends of the communication links. Listing with Tag No., Valve and description. Complete software documentation (hard and electronic copies). Operator Manual. Configuration Manual. Installation Manual. Maintenance and troubleshooting manual. Logic diagram for the interlocks and sequences control logic. Loop drawings. Cable core assignments. Overall system shielding and grounding schems indicating all components and

ground paths.

6.0 TRAINING

Vendor shall provide site training by competent engineers from suppliers HeadQuarters. Training by commissioning engineers is not acceptable. Training shall be

specific to supplied system for the project. The trainers shall have total familiarity withboth project hardware and software and shall be able to answer queries during training.The proposed Trainers CV and course material shall be submitted for companyapproval 8 weeks before start of training. Supplier shall arrange required trainingequipment (demo kits, simulator, etc.). Since training will be required for operating andmaintenance personnel, vendor shall specify different type of training sessions for eachsystem, which will include: system familiarization, operation, troubleshooting andmaintenance.


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The training shall be planned to be conducted immediately after the commissioning ofthe first system.


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ATTACHMENT # 1

Bulk I/O COUNT

Documents

Turbine - Turbine Control Systems