Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Maintenance Training System (MTS) Document No.: 192-YER-PE-I35-0013 Revision No.: FF Issue Date: 24 April 2008

TABLE OF CONTENTS 1.0 2.0 3.0 3.1 3.2 3.3 3.4 3.5 4.0 4.1 4.2 5.0 5.1 5.2 6.0 6.1 6.2 7.0 7.1 7.2 7.3 8.0 8.1 PURPOSE................................................................................................................... 4 SCOPE........................................................................................................................ 4 REFERENCE DOCUMENTS & STANDARDS ........................................................... 4 Conflicting Requirements ............................................................................................ 4 YERP Reference Documents...................................................................................... 4 SAUDI ARAMCO Specifications and Standards ......................................................... 4 Project Specific Specifications .................................................................................... 5 Project Specific Documents and Drawings ................................................................. 5 DEFINITIONS & ABBREVIATIONS ............................................................................ 5 Definitions.................................................................................................................... 5 Abbreviations............................................................................................................... 6 MTS SYSTEM DETAILS ............................................................................................. 7 General........................................................................................................................ 7 Deliverables................................................................................................................. 8 HARDWARE REQUIREMENTS ................................................................................. 9 General........................................................................................................................ 9 Engineering and Operator Workstations ..................................................................... 9 SOFTWARE REQUIREMENTS ................................................................................ 10 General...................................................................................................................... 10 Engineering Software Function ................................................................................. 10 Maintenance Software Function................................................................................ 10 MTS SECURITY ACCESS LEVELS AND CONTROL .............................................. 10 General...................................................................................................................... 10
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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Maintenance Training System (MTS) Document No.: 192-YER-PE-I35-0013 Revision No.: FF Issue Date: 24 April 2008

9.0 9.1 10.0 10.1

FIELD INSTRUMENTS ............................................................................................. 10 General...................................................................................................................... 10 CABINET REQUIREMENTS..................................................................................... 11 General...................................................................................................................... 11

APPENDIX A: INSTRUMENTS TO BE INCLUDED WITH THE MTS ........................................ 12 APPENDIX B: MTS CABINETS AND FURNITURE ................................................................... 13

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Maintenance Training System (MTS) Document No.: 192-YER-PE-I35-0013 Revision No.: FF Issue Date: 24 April 2008

1.0

PURPOSE The purpose of this Project Specification Document is to describe the minimum requirements for the design, materials, manufacture, supply and testing of Maintenance Training System (MTS) to be installed, as part of the Process Automation System (PAS) for the Yanbu Export Refinery Project (YERP), Saudi Arabia. The MTS will be used to train, certify, and re-certify YERP maintenance personnel for the Yanbu Export Refinery Facilities.

2.0

SCOPE The scope of the Main Automation Contractor shall include the design, supply and testing of the Maintenance Training System. The detailed scope of the MTS is provided in the subsequent sections of the document.

3.0 3.1

REFERENCE DOCUMENTS & STANDARDS Conflicting Requirements Any conflict between this document and any other project specification, or Saudi Aramco standards/specifications, shall be brought to the attention of the YERP PMT for resolution.

3.2

YERP Reference Documents The design, materials and construction of the equipment described herein shall comply with references listed below which are considered part of this specification.

3.3

SAUDI ARAMCO Specifications and Standards YERP-23-SAMSS-010 YERP-34-SAMSS-623 YERP-34-SAMSS-625 YERP-23-SAMSS-820 YERP-SAES-J-904 YERP-SAES-Z-001 YERP-SAES-Z-020 Distributed Control Systems Programmable Controller Based ESD Systems Machinery Protection Systems Instrument Control cabinets- Indoor Foundation Fieldbus Systems Process Control Systems Design and Installation of Fiber Optic Cable Systems for Process Control Networks
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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Maintenance Training System (MTS) Document No.: 192-YER-PE-I35-0013 Revision No.: FF Issue Date: 24 April 2008

3.4

Project Specific Specifications 192-YER-PE-I35-0001 192-YER-PE-I35-0002 192-YER-PE-I35-0003 192-YER-PE-I35-0004 192-YER-PE-I35-0005 192-YER-PE-I35-0006 192-YER-PE-I35-0009 192-YER-PE-I35-0011 192-YER-PE-I35-0015 192-YER-PE-I35-0018 Main Automation Contractor (MAC) Scope Definition Project Specification For Process Automation System Project Specification For Main Automation Contractor Supplier Services Project Specification For Emergency Shutdown System Project Specification For Vibration Monitoring System Project Specification For Compressor Control System Project Specification For Asset Management System Project Specification For Foundation Fieldbus Project Specification For Wireless Infrastructure & Applications PAS Console Requirements

3.5

Project Specific Documents and Drawings 192-YER-PE-I35-0023 Process Automation System Architecture Drawing

4.0 4.1

DEFINITIONS & ABBREVIATIONS Definitions Company Project Management Team (PMT): The Company Project Management Team (PMT) is the group responsible for the management of the entire project and is dedicated to the overall success, development and execution of the work and to ensure alignment across the numerous project interfaces. The PMT consists of Aramco Services Company and ConocoPhillips team members, partner(s), agency personnel, and contractors. These project management resources will form a cohesive, seamless team responsible for the project execution. Saudi Aramco (SA): Saudi Aramco as used in this procedure shall mean Saudi Arabian Oil Company and its affiliated companies, including, but not limited to Aramco Services Company.
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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Maintenance Training System (MTS) Document No.: 192-YER-PE-I35-0013 Revision No.: FF Issue Date: 24 April 2008

ConocoPhillips (COP): ConocoPhillips as used in this procedure shall mean ConocoPhillips Company and its affiliated companies, including but not limited to ConocoPhillips Yanbu Ltd. Yanbu Export Refinery Project (YERP): The Yanbu Export Refinery Project (YERP) as used in this procedure, shall also mean the Yanbu Export Refinery Company and its affiliated companies. It is also named as the COMPANY. Contractor or Contractors: Any Design, Construction or Service Contractor(s); Manufacturer(s); Vendor(s); Government Agencies; and other similar organization(s) having a contractual relationship or a prospective contractual relationship with the Company. When used in this or referenced documents the following words are used in the manner described below: Shall and must are used in the imperative sense. Will is used in the preferred sense. May is used in a permissive sense to state authority or Permission to do the act prescribed or provide the function being defined in the prescribed manner, and the words no person may. Or a person may not. mean that no person is required, authorized, permitted to do the act prescribed, and the words a may not . mean that the item being described is not required, authorized, or permitted in the prescribed manner. Includes means includes but not limited to.

4.2

Abbreviations ADS ALMS AMS APC BMS CCB CCS CMS COP CCTV Program Development Station (for CCS) Alarm Management System Asset Management System Advanced Process Control Burner Management System Central Control Building Compressor Control System Condition Monitoring System ConocoPhillips Closed Circuit Television
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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Maintenance Training System (MTS) Document No.: 192-YER-PE-I35-0013 Revision No.: FF Issue Date: 24 April 2008

DAHS DCS EPC ESD EWS FAT FGS KVM LAN MAC MTS OMS OTS PAS PIB PIN PLC PMT SA UPS VMS YERP

Data Acquisition and Historization system Distributed Control System Engineering, Procurement, Construction Emergency Shutdown System Engineering Work Station Factory Acceptance Test Fire and Gas System Keyboard, Video and Mouse Local Area Network Main Automation Contractor Maintenance Training System Oil Movement & Storage Operator Training Simulator Process Automation System Process Interface Building Plant Information Network Programmable Logic Controller Project Management Team Saudi Aramco Uninterruptible Power Supply Vibration Monitoring System Yanbu Export Refinery Project

5.0
5.1

MTS SYSTEM DETAILS

General The Main Automation Contractor (MAC) shall be responsible for the procurement, design, configuration, and engineering of the MTS hardware, software and applicable software defined in this document.
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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Maintenance Training System (MTS) Document No.: 192-YER-PE-I35-0013 Revision No.: FF Issue Date: 24 April 2008

MAC shall provide one (1) MTS as part of the PAS. MTS shall be a stand alone system and shall not be connected to the Plant Control Network or PIN. The scope of supply shall consist of, but not limited to, the following, mounted and wired to form one integrated system, including all data exchange servers and interfaces as provided for in the PAS: One DCS system One ESD system including FGS One AMS system One VMS/CMS system One CCS system PLCs (furnished by others)

The above systems shall contain the same components used for the actual PAS as defined in the project specification for the PAS and in line with the design requirements implemented for the PAS. This includes one of each type of the following: Redundant power supplies Redundant controllers I/O racks I/O cards terminal assemblies, communication interface

The MTS shall include field instruments (one of each type in the PAS), as identified in Appendix A. The EPC CONTRACTOR shall supply these instruments to MAC for mounting and integration with the MTS. MTS does not include any Advanced Process Control, Operator Training Simulator, Master Clock, OMS, ALMS, Anti Virus System, Network Monitoring, Backup Recovery, CCTV, ICS Anywhere/Wireless, Domain Controller/Profile Server or Data Acquisition and Historization System (DAHS) components. 5.2 Deliverables The MAC shall be responsible for providing cabinets and furniture for the DCS, ESD and integration hardware for the CCS and VMS equipments and mounting stands (or cabinet) for field instruments (supplied by EPC CONTRACTOR).

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Maintenance Training System (MTS) Document No.: 192-YER-PE-I35-0013 Revision No.: FF Issue Date: 24 April 2008

Associated software and services as defined in this document shall also be provided. The MAC shall be responsible for the system integration and FAT for the MTS as a stand alone system. The I/O chassis, power supplies, wiring and terminal blocks will be pre-wired and installed in an easy to access, caster mounted cabinet. The Appendix B contains a list of all the cabinets and furniture that shall be provided by MAC.

6.0
6.1

HARDWARE REQUIREMENTS
General The MTS hardware shall duplicate the standards and features of the actual plant PAS hardware. All MTS hardware shall reflect the PAS hardware in type and module number. APC, OTS, and DAHS are not required.

6.2

Engineering and Operator Workstations Operator consoles shall be provided per the PAS Console Requirements document 192-YER-PE-I35-0018. Operator consoles shall include one common ESD panel. Operator Workstations shall be provided equivalent to that provided in the CCB and shall include hardware and licensed software to support engineering and diagnostic functionality for the DCS, ESD, FGS, and AMS. For VMS and CCS, the Local Workstations shall be provided equivalent to that provided in the PIBs (within PC cabinets) and shall include hardware and licensed software to support engineering and diagnostic functionality. The Operating Systems shall match the plant PAS. At least one CD/DVD-writer shall be provided for the Operator Workstations. One high speed laser printer shall be provided for the MTS console. It shall be used for alarm and report printing. Any MTS operator work station shall be able to access the printer. Monitors/Keyboards shall be the same as that used in the PAS.

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Maintenance Training System (MTS) Document No.: 192-YER-PE-I35-0013 Revision No.: FF Issue Date: 24 April 2008

7.0
7.1

SOFTWARE REQUIREMENTS
General All software and licenses required for MTS operation, configuration, maintenance and graphic display, etc. shall be provided. All functions and features supported by the plant PAS shall be supported by the MTS. MTS software shall be the same version as that used in the plant PAS.

7.2

Engineering Software Function The Engineering software shall provide access to the development aids to allow an engineer to perform full functions of engineering work including configuration, create process database and develop graphics, etc.

7.3

Maintenance Software Function On-line and off-line diagnostic and maintenance software provided with the plant PAS shall also be provided for all DCS, ESD, VMS, CCS and AMS components supplied with the MTS.

8.0 8.1

MTS SECURITY ACCESS LEVELS AND CONTROL General Restriction to the various access levels shall be controlled the same way as the plant PAS.

9.0
9.1

FIELD INSTRUMENTS General Appendix A lists, but is not limited to, the field instruments which shall be integrated into the MTS. These instruments shall be supplied by the EPC CONTRACTOR, and shall be integrated into the MTS by the MAC.

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Maintenance Training System (MTS) Document No.: 192-YER-PE-I35-0013 Revision No.: FF Issue Date: 24 April 2008

10.0
10.1

CABINET REQUIREMENTS General Requirements for MTS systems cabinets, marshalling cabinets, wiring & cabling, smoke detection, cabinet cooling, electrical power system, grounding etc. are specified in the Specification for Process Automation System 192-YER-PE-I350002. MAC shall provide all required inter-cabinet and intra-cabinet wiring for the MTS. The MTS shall be included in the overall testing plan for the PAS.

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Maintenance Training System (MTS) Document No.: 192-YER-PE-I35-0013 Revision No.: FF Issue Date: 24 April 2008

APPENDIX A: INSTRUMENTS TO BE INCLUDED WITH THE MTS One (1) of each of the following list of instruments will be supplied to the MAC by the EPC CONTRACTOR for the purpose of integrating them into the MTS. These instruments shall be installed on mounting stands or one (1) Cabinet (supplied by MAC). 2 Control Valve With Foundation Fieldbus Positioner Temperature Indicating Transmitter- Foundation Fieldbus type Pressure Indicating Transmitter- Foundation Fieldbus type Flow Indicating Transmitter- Foundation Fieldbus type Motor Operated Valve-2" (Foundation Field bus type Actuator) 1 ZV -Safety Isolation Valve configured as a smart ZV TE -Temp. Sensor RTD & T/C Vibration Transmitter Lamp Hand Switch For Local Remote Push Buttons Vibration Shaft With Probes (Thrust(X-Y) Bearing + Axial (A&B) Displacement)

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Maintenance Training System (MTS) Document No.: 192-YER-PE-I35-0013 Revision No.: FF Issue Date: 24 April 2008

APPENDIX B: MTS CABINETS AND FURNITURE DCS System: DCS System cabinet consisting of one (1) each of the Controller Unit and IO Chassis unit and IO Modules. This cabinet shall also contain the Network Switches. DCS Marshalling Cabinet-1: The front side of the cabinet shall be similar to the Foundation Fieldbus (FF) Marshalling cabinet. The rear side shall be similar to the Analog I/O Marshalling cabinet. DCS Marshalling Cabinet-2: The front side of the cabinet shall be similar to the Digital Input (DI) Marshalling cabinet. The rear side shall be similar to the Digital Output (DO) Marshalling cabinet. PC Cabinet: This cabinet shall be used to locate the PCs and KVM extension units for the DCS Operator station / Engineering Station, ESD/FGS Engineering Station and AMS Engineering Station. Power Distribution Cabinet: The front side of the cabinet shall be similar to the 120 VAC power distribution cabinets. The rear side of the cabinet shall be similar to the 24 VDC Power supply cabinet.

ESD/FGS System: ESD/FGS System Cabinet consisting of one (1) Controller Unit and IO Modules. ESD/FGS Marshalling Cabinet: The front side of the cabinet shall be similar to the Analog I/O Marshalling cabinet. The rear side shall be similar to the Digital Input / Output (DI/DO) cabinet.

AMS System: The AMS System shall comprise of the AMS Engineering station and other necessary software that are required to communicate with the Field devices (provided by EPC Contractors). The AMS Engineering station shall be located in the PC Cabinet as mentioned under the DCS Equipment list.

VMS/CMS System: VMS Cabinet consisting of one (1) of the Monitoring System rack and interface Modules. This cabinet shall also house the necessary interface boards. CMS Server Cabinet: The CMS server (Engineering station and LCD Monitor) and the necessary Network equipment shall be located in this cabinet.

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 192B.1 SPECIFICATIONS - Project Specification For Maintenance Training System (MTS) Document No.: 192-YER-PE-I35-0013 Revision No.: FF Issue Date: 24 April 2008

CCS System: CCS Cabinet consisting of one (1) CCS System and necessary interface equipments. CCS Server Cabinet: The Program Development Workstation (ADS and LCD monitor) and the necessary Network equipment shall be located in this cabinet.

Operator Consoles (Furniture): Operator Console-1 shall be a Type-B console. This console shall consist of one (1) DCS Operator Station/Engineering Station with 2 nos. of 20 inch LCD screens, one (1) no. of communications panel and one (1) printer. Operator Console-2 shall be similar to a Type-B console. This console shall consist of one (1) Engineering Station (for ESD/FGS) with 2 nos., of 20 inch LCD screens, one (1) ESD panel containing Switches/Lamps and one (1) printer. Additionally, space shall be available on the console to locate one (1) AMS Engineering Station with one (1) no. of 20 inch LCD screen.

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