VECO Doc. No.

20298-01-EJ12-003
Project Title

MEHAR GAS DEVELOPMENT PROJECT

Area Location Discipline Document No Rev. Page
12 MEGP I 1023 0 2 of 41
TABLE OF CONTENTS

1.0 INTRODUCTION.............................................................................................................4
1.1 General ...........................................................................................................................4
1.2 Scope ..............................................................................................................................4
1.3 Definitions .......................................................................................................................5
1.4 Abbreviations...................................................................................................................5
1.5 Environmental Conditions................................................................................................6
1.6 Device Protection ............................................................................................................7
1.7 Units of Measurement .....................................................................................................7
2.0 CODES AND STANDARDS............................................................................................8
3.0 VENDOR’S RESPONSIBILITY .....................................................................................11
3.1 Scope of Supply & Services ..........................................................................................11
3.2 Conflicts, Discrepancies and Deviations ........................................................................13
4.0 MEHAR APPLICATION ................................................................................................13
5.0 DESIGN REQUIREMENTS ...........................................................................................13
5.1 General .........................................................................................................................13
5.2 Functional Requirements...............................................................................................15
5.3 Logic Controllers ...........................................................................................................16
5.4 Inputs and Outputs ........................................................................................................17
5.5 Operator Interface .........................................................................................................19
5.6 Hardwired Matrix(Mimic)................................................................................................20
5.7 FGS Interfaces ..............................................................................................................23
5.8 PMCS / FGS Engineering HMI ......................................................................................23
5.9 Critical Controls Panel ...................................................................................................23
5.10 Expandability .................................................................................................................24
5.11 Reliability.......................................................................................................................24
5.12 Diagnostics and Maintenance........................................................................................25
5.13 Electrical Requirements.................................................................................................26
5.14 FGS System Enclosures ...............................................................................................30
6.0 SYSTEMS ENGINEERING ...........................................................................................32
6.1 Consultation Service......................................................................................................32
6.2 Programming Services ..................................................................................................32
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Area Location Discipline Document No Rev. Page
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6.3 System Initialization.......................................................................................................32
7.0 SPARE PARTS.............................................................................................................33
7.1 Start-up and Commissioning Spare Parts......................................................................33
7.2 Operational Spare Parts ................................................................................................33
8.0 INSPECTION AND TESTING .......................................................................................33
8.1 General .........................................................................................................................33
8.2 Pre-Factory Acceptance Test ........................................................................................35
8.3 Factory Acceptance Test ...............................................................................................36
8.4 IFAT Test ......................................................................................................................36
8.5 Site Acceptance Test.....................................................................................................37
8.6 Availability Test .............................................................................................................38
8.7 Shop Inspection.............................................................................................................38
8.8 Certificates of Acceptance .............................................................................................38
9.0 DOCUMENTATION.......................................................................................................38
9.1 General .........................................................................................................................38
9.2 Functional Specification.................................................................................................39
9.3 Drawings .......................................................................................................................39
9.4 Design Interfaces ..........................................................................................................39
9.5 Operation and Maintenance Manuals ............................................................................40
9.6 System Log ...................................................................................................................40
10.0 TRAINING .....................................................................................................................41
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1.0 INTRODUCTION

1.1 General

PETRONAS CARIGALI (Pakistan) Ltd. (PCPL) is undertaking the development of

Mehar Gas Field in Mehar Block (Block 2767-1) located in Sindh and Balochistan
Provinces of Pakistan.

PCPL intends to develop the Mehar Field by installing a Gathering System, Gas
Processing Facility (GPF) and Product Storage & Loading Facilities. The field facilities
will be developed in two phases, Phase-I and Phase-2. Phase-1 development will cater
to 55 MMSCFD of gas productions and Phase-2 will cater to 80 MMSCFD of gas
productions. The expected condensate production rate is 6600 BPD for Phase-I and
7000 BPD for Phase-2. From GPF, treated sales gas will be exported through a new
pipeline to existing SSGCL/SNGPL gas pipeline. Stabilized condensate and produced
LPG will be exported by road tankers.

Mehar Block is located in the Kirthar Fold belt area, in the Middle Indus Basin. Mehar
field is located about 190 km west of Sukkur and 400 km north of Karachi in Sindh
province. The environment is arid and the terrain is mountainous. Mazarani gas field,
operated by PPL is situated about 25 km to the north, while Zamzama gas field
operated by BHP is situated about 70 km to the north of Mehar Field.

Mehar field consists of Pab and Ranikot formations. The wells will be connected to the
new GPF through a Gathering System. There will be a total of 8 wells (4 in Pab & 4 in
Ranikot) in Phase-1 and 3 additional wells (2 in Pab & 1 in Ranikot), totaling 11, in
Phase-2 of the Mehar field development.

1.2 Scope

This Specification, together with all reference documentation, defines the minimum
technical requirements for the design, fabrication, configuration, testing, documentation
and preparation for shipment of a microprocessor based Fire and Gas System (FGS)
for Mehar Gas Development Project.

The FGS shall be a single integrated hardware platform used for Fire and Gas
monitoring functions for all plant facilities.The FGS for well head shall be covered
under the Well head Control System (RTU).

The VENDOR shall supply fully intelligent system cabinet that exceeds the requested
functions or performance provided the system is made up of field-proven hardware and
software modules. The VENDOR shall clearly identify any design which is
nonstandard or does not have a history of at least six field-installed systems which
have been in similar service for two years or longer.
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1.3 Definitions

Petronas Carigali Pakistan Limited (PCPL) or

COMPANY
any Third Party assigned by the COMPANY
Party which carries all or part of the design,
ENGINEER engineering of the PROJECT. VECO
Engineering, Abu Dhabi is the ENGINEER.
Party which carries out all or part of the design,
engineering, procurement, construction,
commissioning or management, of the
EPCC CONTRACTOR
PROJECT. EPCC CONTRACTOR includes his
approved MANUFACTURERS, SUPPLIERS,
VENDORS and SUBCONTRACTORS.
PROJECT MEHAR GAS DEVELOPMENT PROJECT

1.4 Abbreviations

FAT Factory Acceptance Test

IFAT Integrated Factory Acceptance Test

SAT Site Acceptance Test

FGS Fire & Gas System

GPF Gas Processing Facility

GUI Graphical User Interface

HART Highway Addressable Remote Transducer

ICS Integral Control System

IER Instrument Equipment Room

I/O Input Output

LAN Local Area Network

LED Light Emitting Diode

MCC Motor Control Centre

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MOS Master Override Switch

MTU Master Terminal Unit

PLC Programmable Logic Controller

PMCS Process Monitoring and Control System

PSD Process Shutdown

RTU Remote Terminal Unit

SAT Site Acceptance Test

SDS Shutdown System

SLD Single Line Diagram

SIS Safety Instrumented System

UHF Ultrahigh Frequency

USD Unit Shutdown

DC Direct Current

SSV Safety Surface Valve

SCSSV Surface Controlled Subsurface Safety Valve

TMR Triple Modular Redundant

SIL Safety Integrated Level

DI Digital Input

DO Digital Output

AO Analog Output

AI Analog Input

CCR Central Control Room

1.5 Environmental Conditions

Wellhead facilities, Gathering stations and GPF area has been tentatively selected at a
location about 190 km west of Sukkur and 300 km north of Karachi in Sindh Province.
The environment is arid the terrain is mountain.
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The Environmental conditions are:

Maximum Ambient Temperature : 55ºC

Minimum Ambient Temperature : 0.5ºC

Wet bulb temperature (design) : 30ºC

Relative humidity (max / nor /min) : 90 / 65 / 20 %

Direction of prevailing wind : From south to north

Wind Velocity (max / normal) : Hold / 2.9 knots

Elevation above mean sea level (GPF) : 54m (Site-IV) / 56m (Site-l)

Average barometric pressure : 1001.2 mbara (29.56 inches of

Mercury)

Ice / Snow : None

Seismic zone : Zone 2B, upper moderate with

ground acceleration of 0.2 (Hold)

Annual rainfall min. : 63.3 mm (year 2006)

Annual rainfall max : 139.9 mm (year 2005)

1.6 Device Protection

All instruments shall be certified as EEx‘i’ IIA/IIB per ATEX Directive. Suitable isolators
shall be provided in control room. EEx‘d’ protection shall be used for solenoid valves &
where not available.

Detector & device enclosures, in field, shall be dust proof, weather proof to IP 65, as a
minimum. All external surfaces shall be suitably painted for corrosion protection.

Instruments shall be selected based on Area classification drawings by Electrical.

1.7 Units of Measurement

The FGS shall support any unit of measure where appropriate, however, the units of
measurement to be used on this project shall be:

Liquid Density API and kg/m3

m3 / hr, MMSCFD (gas), BPD (condensate), BWPD

Flow Rate
(Water)
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Area Location Discipline Document No Rev. Page
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Power, Duty kW

Heat Transfer Coefficient: W / m2 K

Thermal Conductivity W / m.K

Heat Capacity kJ/ Kg °C

Viscosity cP

Kinematic Viscosity centistokes (cSt)

Area m2

Length Metre (m), Km, mm

Pressure Bar (g), Bar (a), Psi (g)

Temperature °C

Volume m3

Pipe Diameter Inch, mm

Stress Mpa, Kg/cm2, Psi

Weight Kg

2.0 CODES AND STANDARDS

Codes, specifications and standards referred to within this specification, form a part of
the requirements of this specification in a manner and to the extent specified within
those codes and standards.

Unless otherwise specified, the latest edition or revision to these codes specifications,
and standards in force at the time of Request for Quotation (RFQ) and/or Purchase
Order (PO) shall apply.

No deviations from the Codes and Standards listed in this document will be allowed
unless such deviations are clearly identified in the bids, with the reasoning. In addition,
they must be approved in writing by COMPANY.

API/RP 502 Signal Transmitters and Air Supplies

Manual on Installation of Refinery Instruments

API/RP 550
and Control Systems
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API/RP 2001 Fire Protection in Refineries

Wiring Regulation Requirements for Electrical

BS 7671
Installations

BS EN 54 Fire Detection and Fire Alarm Systems

DIN V 19250 Microcomputers in Safety Techniques

NFPA 72 National Fire Alarm Code

NFPA 101 Life Saving Code

Guide to Fire Hazard Properties of Flammable

NFPA 325
Liquids, Gases and Volatile solids

Standard for Purged and Pressurized

NFPA 496
Enclosures for Electrical Equipment

Interface Between Data Terminal Equipment

EIA 232 (DTE) and Data Communication Equipment
(DCE). Employing serial binary data Interchange

Balanced Serial Data Communications

EIA 422
Interchange

Limits of Electromagnetic Interference for

IEC/CISPR11
Electrical Appliances and Equipment

Electrical Apparatus for Potentially Explosive

IEC 50014
Atmosphere-General Requirement

Electrical Apparatus for Potentially Explosive

IEC 50019
Atmosphere-Increased Safety EExe

Electrical Apparatus for Explosive Gas

IEC 60079
Atmospheres

IEC 60364 Electrical Installation of Buildings

IEC 60446 Basic Safety principle for Man Machine Interface

Classification of Degrees of Protection Provided

IEC 60529
by Enclosures (IP Code)

IEC 61000 Electrical Installation Guide

IEC 61131 Programmable Controller

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IEC 61508 Functional Safety: Safety Related Systems

Functional Safety Instrumented Systems for

IEC 61511
Process Industry sector

IEEE 472 Guide for Surge withstand Capability Tests

ISA RP 12.1 Electrical Instruments in Hazardous Atmosphere.

ISA RP 18.1 Alarm Annunciation

ISA RP 55.1 Hardware Testing of Digital Process Computers

ISA S5.1 Instrument Symbols and Identification

ISA S5.2 Binary Logic Diagrams for Process Operations

Graphic Symbols for Distributed Control / Shared

ISA S5.3 Display Instrumentation, Logic and Computer
System

ISA S5.4 Instrument Loop Diagrams

ISA S5.5 Graphic Symbols for Process Display

Application of Safety Instrumented Systems for

ISA-S84.01
the Process Industries

Federal “Occupational Safety and Health

OSHA
Standards”
SAMA PMC-33.1 Electromagnetic Susceptibility of Process
Control Instrumentation

PTS 00.00.05.05 Index To PTS Publications and Standard

Specifications

PTS 32.80.10.10 Classification and Implementation of

Instrumented Protective Functions

PTS 32.30.20.11 Fire,Gas and Smoke Detection System

PTS 32.80.10.30 Instrumented Protective Systems

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3.0 VENDOR’S RESPONSIBILITY

The VENDOR shall have responsibility for complete engineering approach to the FGS
design, fabrication, engineering, staging, testing, documentation, shipment and
commissioning.

FGS programming shall be conducted as a joint exercise between the VENDOR and
the COMPANY. The VENDOR shall supply engineering documentation, which shall
include appropriate FGS input to the COMPANY'S CAD generated instrument loop
diagrams.

The COMPANY’S approval of the manufacture and model number of equipment and
approval of the VENDOR'S drawings/documents does not in any way affect the
VENDOR'S full responsibility to supply strictly in accordance with project specifications,
codes and standards.

This Specification shall not relieve the VENDOR of any responsibility to provide
equipment and services that are suitable for the intended duty.

The EPCC is responsible for the integration of the well head facilities fire and gas
detectors to the FGS supplied by the VENDOR for the GPF. The VENDOR shall
provide all the necessary equipment and manpower for the same. It is the overall
responsibility of the PMCS vendor to integrate the communication/data exchange from
the FGS to the Well head facilities.

3.1 Scope of Supply & Services

The Vendor shall supply, but is not limited to, the following:

• Project management & reporting

• Fully intelligent system cabinet with a dedicated workstation in PMCS console;

display matrix incorporated into the system cabinet for the areas it covers;

• Providing diagnostic facilities for the system

• A site wide FGS communications network connecting the fire and gas alarm
system in the buildings and the detection and alarm facilities on the plant.

• Open book pricing valid for 12 months for additions or deletions of hardware;

• All necessary interconnecting cables, with plug-in connections at each end,

between system cabinets. Connectors (only) shall be provided for all peripheral
equipment;

• LAN / Ethernet connectors and LAN / Ethernet cables for FGS PLC
communication to the control system network, splitters, taps, etc. as required
by the system and the application.
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• All communication interfaces and associated software as called for by this
Specification and the Purchase Order including a system integration
specification for each interface;

• Nameplates for equipment cabinets, individual devices, terminal strips for

groups of input/output terminals, individual tagging of signal pairs and
terminals and tag destinations of plug-to-plug cables;

• The FGS programming activity shall be executed in the VENDOR'S premises

using the VENDOR'S configuration tools and assisted as necessary by the
COMPANY;

• All operating and application software as called for by this Specification and
the Purchase Order. This shall be the latest revision of all proprietary software
and all software revisions and manual upgrades, which may be released
during the first year after Purchase Order award;

• All necessary fire alarm signals will be repeated on PMCS by peer to peer
connection, and will be displayed on control room PMCS consoles. All fire
alarm systems in buildings will have local panels with display matrix.

• All FGS testing services including the pre-FAT, FAT and IFAT (with SIS &
PMCS) test. All tests shall be conducted in the VENDOR'S premises using the
VENDOR’S utilities and test equipment;

• A complete staging test shall be conducted at the PMCS VENDOR’S premises

in order to verify the correct operation of all interfaces between the FGS, SIS
and PMCS;

• Complete documentation as called for by this Specification and the Purchase

Order up to and including "As-Builts";

• Spare parts for commissioning and two years operation;

• Packing of the FGS in readiness for shipment in accordance with VENDOR

standards unless otherwise specified in Purchase order. CONTRACTOR shall
provide delivery at site of full turnkey solution;

• Site services such as installation supervision, Loop checking commissioning

assistance, the SAT, etc. and other activities as deemed necessary by the
COMPANY and/or the VENDOR/CONTRACTOR;

• Training for company design engineers, programmers, operators and

technicians;

• Commitment to support the hardware supplied with diagnostics, testing and

replacements for 25 years (i.e. the life of the project).
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3.2 Conflicts, Discrepancies and Deviations

Any conflicts or discrepancies found in the COMPANY design documentation shall be

referred in writing to the COMPANY for clarification. No deviations shall be made from
design documentation without prior approval in writing by the COMPANY. Where
conflicts or discrepancies occur, the order of precedence shall generally be:

• Government and Statutory regulation;

• FGS I/O List;
• System Block Diagrams;
• This specification;
• Project Specifications;
• Company Standards (PTS);
• International Codes and Standards.

Every deviation from design documentation must be brought to the attention of the
COMPANY, whose written approval must be obtained before any work can commence.
If no exceptions are stated, or the COMPANY'S approval of a deviation is not given,
then full compliance will be assumed and required.

4.0 MEHAR APPLICATION

The Plant is geographically segregated into various process areas and buildings. The
main FGS system shall monitor and send command signal (pump start, deluge valve
open, etc) at following areas but not limited to:

• Wellhead surface facilities;

• Gathering stations;

• Gas Processing Facility.

5.0 DESIGN REQUIREMENTS

5.1 General

The basis of design for the F&G detection and alarm system for this project is to:

• Detect a fire or gas as early as possible;

• Provide plant wide visual and audible alarms to alert the operators;

• Initiate appropriate shutdown signals to the SIS on confirmed fire;

• Initiate fire protection system;

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• Initiate of alarms at the PMCS (via peer to peer connection) and display the
geographically area on the dedicated HMI;

The FGS comprises (but not limited to) of the following:

• Detectors and warning devices;

• Interface to plant protection facilities;

• Alarm Systems;

• Marshalling Panels;

• An operator interface via the PMCS console;

The Fire and Gas Detection System (FGS) shall be designed as stand-alone and
redundant system. Peer to Peer communication for information purpose shall be
provided for the interface between FGS and PMCS.

The system shall be able to transmit and receive signals to/from other systems as
PMCS and SIS.

Addressable fire alarm system shall be installed for all buildings (i.e. accommodation,
administration, workshops, etc.) in the GPF facilities. Each building will have a fire
alarm control panel. These fire alarm control panel shall be hardwired to the FGS for
common alarm. Details of fire detection information shall be available in the building
fire alarm panel by LEDs on the panel door.

The main function of the FGS system will be to monitor the plant (process and non-
process areas) and advice the plant personnel, by audible and visual means, in the
event of fire or gas leak.

The system will also be designed for high integrity, reliability and availability in order to
minimize the spurious trips.

At the wellheads, there will be no separate FGS system. All F&G detectors will be
connected to the wellhead RTU. Fire and gas alarms will be transmitted to the GPF
control room via the RTU. Wellhead shutdown due to flame detection shall be by
voting.

For the power supply of the system, a feeder from 240 VAC, 50 Hz, UPS to be
provided in the control room. Dual feed shall be provided from different UPS electrical
distribution boards.

The overall availability of the FGS (Logic Solver central parts, I/O cards and
communication cards) shall be based on SIL 2 TUV certified programmable logic
controller technology and comply with the requirements of BS EN-54 standard. The
overall availability of the FGS shall be greater than 99.99%.The scanning time for all
loops shall be less than 300 msec.
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The proposed system shall use VENDOR standard field proven product lines. No
product development shall be undertaken during the length of the contract.

The projected life of the installation is twenty-five years. The FGS must be capable of
sustaining an equivalent operational life; the same shall be achieved by the VENDOR
guaranteeing product development and supply of hardware/software for five years
followed by upgradeable development and support for a further twenty years.

The FGS shall be chosen for its simplicity, its use of established proven components,
and its use of techniques that minimize the need for maintenance and its overall design
such that the integrity of the installation is enhanced.

Only new equipment shall be supplied. No second hand or obsolete equipment shall
be supplied. All hardware items shall be standard modules from existing product
ranges. No prototype equipment shall be utilized.

The FGS shall incorporate precious metal plating of component lead wiring,
connectors, etc. Construction shall not use techniques which are prone to damage by
corrosive atmospheric pollutants or vibration (e.g. wire wrapping).

5.2 Functional Requirements

5.2.1 Alarm Zone

When an initiating device such as flame detectors, manual call points, FGS detectors
and signals of the pressure switches are actuated, its individual “alarm zone” indicating
light on the FGS panel matrix, located at ICCS control room, shall become illuminated
and simultaneously the PAGA speakers installed in the associated area shall be
sounded in addition to the buzzer (sounder) of the panel itself. The name of “alarm
zone” shall be clearly indicated on the FGS system panel.

There project plant areas are segregated into 13 alarm zones as indicated in the Fire
and Gas detectors location layout (12-MEGP-F-5000) and the individual well head
facilities(9 nos.). However the actual number of zones may increase at EPCC stage.

5.2.2 Time Delay

The time delay between the activation of an initiating device and the automatic
activation of local safety function shall not exceed 500 ms.

5.2.3 Alarm Acknowledgement

The buzzer shall be silenced by actuating the switch on the FGS system panel.
However the zone indication on the FGS panel matrix and the beacon in the individual
zones shall remain illuminated until the actuated device has been restored to its normal
“stand-by” condition. A means for acknowledging the notification appliance shall be
permitted only where it is key locked, located within a locked enclosure, or arranged to
provide equivalent protection against unauthorized use.
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5.2.4 Fire Alarm Supervised Circuit

Any “trouble” condition which occurs in the supervised circuits of the fire alarm initiating
devices shall cause, on the FGS panel, the white trouble light of the associated alarm
zone to illuminate and sound the buzzer (sounder). The beacons and sounders at the
various zones shall not be affected by the trouble condition. The buzzer shall be
silenced by actuating the switch on the panel; however the trouble light shall remain
illuminated until the source of the trouble condition is corrected. Audible trouble signals
shall be distinctive from alarm signals. A means for silencing the notification appliance
shall be permitted only where it is key locked, located within a locked enclosure, or
arranged to provide equivalent protection against unauthorized use.

5.2.5 Fire Pump Manual Operation

It shall be possible for the operator to start the fire pumps manually after the fire and/or
gas alarm has been received.

5.2.6 Manual Call Points

The Manual Call Points / sounders in the same zone or area are connected in series
and one end will be connected to Main FGS System Panel.

5.3 Logic Controllers

5.3.1 Hardware

The FGS shall incorporate a SIL 2 TÜV certified construction and comply with the
requirements of BS EN-54 standard. The various racks are to be located within the
FGS cabinets. Card addresses shall be software selectable (i.e. any card in any slot).

A figure of less than 200 milliseconds between an input state change and a
corresponding output state change shall be achievable by the offered system.

5.3.2 Software and Programming

The FGS shall, as a minimum, perform the logic as shown on the FGS C&E tables (12-
MEGP-F-4002).

All logic programs shall reside in password protected battery backed memory in order
to maintain logic security. Interrogation from the engineering HMI shall be available,
but shall have 4 levels of passwords plus key switch security.

The FGS shall be simple and flexible with regards to programming of logic
connections. The FGS shall only be able to be programmed off-line from a Laptop/PC
having a Microsoft Windows operating system. The FGS programming software
package shall conform to IEC 61131: 1-3 and shall also provide the facility for
automatically documenting and annotating logic program. The logic program shall be
liberally commented throughout, to assist with fault-finding and maintenance. The Logic
shall also be TÜV certified.
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Facilities shall be provided for majority voting techniques to be applied to multiple input,
logic or output paths, with discrepancy and trip actuation indication alarms as
appropriate.

This shall include standard system modules, an extensive library of standard proven
function blocks and application specific function blocks.

A change control procedure that leaves an audit trail of approved logic programming
modifications shall be implemented. This shall include paper records and identification
of version within application code.

5.4 Inputs and Outputs

5.4.1 General

The I/O cards shall utilize modular mount construction.

All digital I/O cards shall provide LED indication of the status of each I/O point,
independent of any bypass, override or latch function. All I/O cards shall provide LED
identification of card status (faulty, healthy, etc).

All I/O circuits shall include a current limiting transformer to prevent damage upon
short-circuiting of I/O field circuit conductors. All I/O circuits shall provide transient
suppression in accordance with IEEE 472 and undergo surge withstand capability
testing. Lightning suppression devices are required. As a standard, all I/O circuits shall
be individually isolated, utilizing integral solid-state optical or transformer isolators. In
addition, all 240V AC I/O circuits shall incorporate external interposing relays. Each
I/O circuit shall be individually fused with automatic blown fuse monitoring. This shall
be in the form of resetable electronic fuses.

For all I/O circuits, the negative terminal at the I/O card in the system cabinet shall be
at the clean instrument earth level. All other points in the circuits shall be isolated from
earth.

I/O Point shall be individually isolated. Failure of one point shall not freeze the whole
card.

All I/O shall be time stamped by the controllers and have a resolution of at least 100
milliseconds.

All inputs shall be self resetting, however, alarms will latch. This alarm latching will be
performed by the PMCS. Interlocking shall be configured such that outputs cannot be
reset prior to the associated inputs becoming clear.

5.4.2 Digital Inputs

There shall be three types of DI point which may be used on this project:

• Field devices with normally-closed in the normal condition (fail-safe) voltage-free

contacts. Multiple field devices may be connected in series by the COMPANY as
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a single DI point. These shall be powered at 24V DC by the FGS via individually
fused circuits at 0.5A (maximum). These will be used for the majority of DI
points;

• Field devices with normally-open (non fail-safe) voltage-free contacts. Multiple

field devices may be connected in parallel by the COMPANY as a single DI point.
These shall be powered at 24V DC by the FGS via individually fused circuits at
0.5A (maximum). An end-of-line device shall be provided by the FGS VENDOR
suitable for its input card to be installed in parallel with the field devices. Three
circuit conditions shall be monitored; normal loop resistance (normal condition),
high loop resistance (fault condition or open-circuit) and low loop resistance
(alarm condition or short-circuit). These will be used for multiple detection
devices in a single zone for the F&G system;

• A clock synchronization signal from the PMCS to the FGS. This shall be powered
and fused at 24 VDC 1A by the PMCS.

Note: Time synchronization may be achieved by network time protocols (NTP) or

equivalent.

The field devices shall be coupled to the signal conditioning circuits of the logic system.
Signal conditioning shall include galvanic isolation, non-integrating input filters and time
delays to isolate field equipment from system logic and to prevent operation of the
system by any mechanical vibration.

All DI points shall be latched in their latest driven state until scanned or read into the
FGS.

The maintenance override and start-up bypass functions shall be implemented as a

system of key switch controlled soft-buttons available from a faceplate within the FGS
operator interface. The FGS shall maintain a log of these overrides and bypasses.
Override and bypass status indication and common alarming shall be provided.

5.4.3 Digital Outputs

There shall be two types of DO point:

• Normally energized (fail-safe) 24V DC outputs. These shall be powered by the

FGS via individually fused circuits at 2A (maximum). These will be used to drive
solenoid valves and relay coils. Surge suppression will be provided when driving
such inductive loads. Surge suppression devices will be supplied and installed
by the supplier of the field device;

• Normally de-energized (non fail-safe) 24V DC outputs. These shall be powered

at 24V DC by the FGS via individually fused circuits at 2A (maximum). An end-
of-line device shall be provided by the FGS VENDOR suitable for its input card to
be installed in parallel with the field device. Three circuit conditions shall be
monitored; normal loop resistance (normal condition), high loop resistance (open-
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circuit) and low loop resistance (short-circuit). These will be used to drive status
lights, alarm horns, and to trip shunt-trip coils on circuit breakers.

Each DO circuit shall incorporate an output driver to activate the field device and
a logic protection device to guard against field generated interference.

Output defeats shall not be incorporated into the FGS. The design of multiple
path logic systems shall allow testing of the FGS electronics without the use of
output defeats.

5.4.4 Analogue Inputs

AI points shall be 0 to 20mA DC with a maximum input resistance of 250 ohms they
shall be direct acting (increasing signal causing increasing output). There shall be the
following types of AI point:

• Two-wire or three-wire field devices. The 24V DC loop power shall be supplied
by the FGS and the current shall be sourced by the FGS. These will generally
be used where a single field transmitter will be signal conditioned within the FGS
to generate both high-high and low-low trip points;

All events where AI points move through an alarm point shall be latched until scanned
or read into the FGS.

All AI points shall be automatically monitored for short-circuit (above a threshold over
20mA) and open-circuit (below a threshold under 4mA) faults. The thresholds shall be
fully programmable.

All AI points shall be individually isolated and individually fused on the high (supply)
side. The fuse rating shall be 250mA. All AI points shall have an individual power
regulator to provide field transmitter power.

Maintenance override and start-up bypass functions shall be provided for selected AI
points. These points are shown on the FGS I/O schedule. Maintenance override and
start-up bypass functions shall be implemented after signal conditioning and alarm
generation has occurred.

5.5 Operator Interface

A dedicated workstation shall be provided for the FGS which is to be installed at the
ICCS control room as indicated in the ICCS control room equipment layout (12-MEGP-
I-5000). The workstation will be connected to Ethernet TCP/IP communication network.

The following functions, described elsewhere in this Specification, shall be available

from the operator interface:

• Status of all FGS I/O, including, as applicable, field status, maintenance override
status, start-up bypass status, latch status, logic status, etc.;
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• FGS faults and status, including discrepancy alarms on multiple path logic
systems, power supply faults, etc.;

• Soft-button FGS functions, including output latch resets, maintenance overrides,

start-up bypasses, manual test initiation, automatic test enable/temporary
disable, acknowledge test failure, etc. These shall be subject to standard PMCS
keyswitch security;

• FGS operator interface panel integral to the PMCS operator HMI on which a
number of manually operated devices shall be installed. These are the covered
FGS zone pushbuttons.

The PMCS will co-ordinate alarm handling of pre-alarms generated by the FGS and
process shutdown alarms transferred from the FGS. These will be interleaved on
common alarm lists in the PMCS. In order to synchronize alarm time stamping, the
PMCS shall periodically reset the FGS clock via peer to peer connection from the
PMCS to the FGS (eg. at 1 am every morning, as determined by the PMCS master
clock). Note: this may be achieved by use of network time protocols NTP or equivalent.
Alarm points shall be transferred from the FGS to the PMCS via a peer to peer
connection. If the PMCS can manipulate externally time-stamped alarm points, the
PMCS shall receive time-stamping information with the relevant alarm points (e.g.
tenths of a second after 1 am). Alternatively, the PMCS may time-stamp the
occurrence of alarm points when they enter the PMCS. If this second option is taken
up, the PMCS will also include the facility to upload at any time a full sequence of
events alarm list, complete with time-stamping information, from the FGS. Details of
alarm co-ordination shall be resolved at the time of functional design specification
development.

The operator interface shall be designed so that faults on any part of the operator
interface or failure of the communication link between the FGS and the PMCS shall not
degrade the stand-alone functionality or the reliability of the shutdown actions of the
FGS.

The operator interface shall be designed so that “no information” is synonymous with a
healthy system. That is, with the process conditions normal, no bypass(s) or
override(s) operated, all outputs in the healthy, reset position and no faults on the
system, and then all associated alarms will be off.

A system integration specification for the interface between the FGS and the PMCS
shall be produced by the FGS VENDOR for implementation at the PMCS end of the
interface by the PMCS VENDOR and at the FGS end of the interface by the FGS
VENDOR.

5.6 Hardwired Matrix(Mimic)

The hardwired mimics shall contain simplified geographical lay-outs of the plant area
which is to be monitored, showing all traffic access gateways, roads and major plant
equipment for each process unit. The lay-out shall be in accordance with the plot plans.
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The indications on the mimic panel shall be driven via hard-wired signals from the FGS
PLC.

The mimic panel shall be ergonomically integrated with the FGS panel. The mimic
panel shall incorporate separate confirmed (voted) fire, flammable gas and toxic gas
alarms as well as system fault alarms.

The FGS PLC shall group together all types of FGS inputs for a single zone, unit or
equipment item(s). If any zone is in the confirmed alarm state, a zone or unit alarm
LED on the mimic panel shall operate. Separate 'zoned' indications shall be provided
for fire, flammable gas, toxic gas and system alarms.

Detector types shall be identified by means of coloured LEDs. The colour code shall be
as follows:

• toxic gas : yellow,

• flammable gas : blue

• fire : red,

• system fault : white,

• fire-water pump running lights : green,

• other alarms : red.

Flammable gas visual alarms should distinguish between low alarm and high alarm
values by assigning one LED for low alarm and one LED for high alarm.

The LEDs shall be mounted so that they protrude at least 3 mm above the surface of
the panel to enable an alarm to be recognized from various angles.

The following plant common alarms shall be grouped in the top left-hand corner to
facilitate quick appraisal by operating personnel. Each alarm shall be presented by
means of a coloured lamp and the corresponding text as appropriate.

• fire,

• flammable gas,

• toxic gas,

• fire-water pump auto-start stand-by indication,

• system fault,

• utility fault,
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• UPS fault.

The normal situation shall be indicated by extinguished LEDs and lamps on the mimic.
In the event of an alarm, the relevant LEDs and lamps shall start flashing. After
acknowledgement the flashing shall stop and change to a steady light, but it shall be
reactivated on the recurrence of any alarm condition. Return to the normal situation,
after acknowledgement, shall extinguish the LEDs and lamps.

The audible alarm shall be annunciated in the control room by means of a buzzer
mounted at the rear of the mimic having an intermittent tone at 2000 Hz, which shall
stop when the operator acknowledges the alarm by means of a button on the mimic.

An all-clear signal shall not be provided in the control room.

A wind speed and direction indicator shall be mounted in the top right-hand corner.
Plant North shall be indicated on the mimic by an arrow.

The mimic panel shall have a scratch-proof, non-reflective plastic surface. A 'mosaic',
e.g., multi-tile, lay-out shall be provided to facilitate future modification of the panel.

The layout and design shall be provided by Contractor.

The following controls, mounted in the bottom section of the mimic panel, shall be
available to the operator:

• Lamp Test: a non-latching push button to test all indication lights on the mimic.

• Acknowledge: A push button to change all alarm lights (except for the plant
beacons) from flashing into steady and to silence the audible alarm in the control
room.

• NOTE: Pressing this acknowledge button will not acknowledge the DCS alarm.
The operator has to acknowledge the DCS alarm separately.

• Reset: A push button to reset all visual and audible alarms, provided that all
initiators have returned to normal.

• All-Clear: A push button to initiate an all-clear signal in the buildings and in the
plant.

• Fire Alarm: A push button to manually initiate a fire alarm with effects similar to
the activation of a break glass push button.

• Toxic Gas Alarm: A push button to manually initiate a toxic gas alarm in the
relevant unit.

• Flammable Gas Alarm: A push button to manually initiate a flammable gas alarm
in the relevant unit.
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5.7 FGS Interfaces

Interfaces to PMCS shall be peer to peer communications. The FGS shall also be
capable to provide Ethernet/IP (Ethernet Industrial Protocol) capable of handling large
amounts of data at speeds of 100 Mbps or better; at GPF it shall be connected directly
to PMCS data highway.

All communication interfaces, connectors and associated software shall be supplied by

the VENDOR. The VENDOR shall provide pin termination diagrams for connectors.
Communication cables will be supplied by the COMPANY.

The VENDOR shall be responsible for the programming, testing and performance of
the interfaces. The COMPANY will provide technical assistance and input where
applicable.

5.8 PMCS / FGS Engineering HMI

The VENDOR shall supply all hardware, interfaces and engineering software in order
to provide FGS engineering functionality on the PMCS engineering HMI (supplied by
others). However, it is preferable to have the CONTRACTOR/VENDOR to supply both
PMCS and FGS/SIS system (same manufacturer).

The FGS engineering HMI shall give full engineering capabilities plus operator
functions for maintenance purposes and back-up operation. The FGS Engineering HMI
shall be capable of operation on-line (for system diagnostics and operator interface) or
off-line (for programming and documentation).

All on-line operations from the FGS engineering HMI shall be subject to password
security.

5.9 Critical Controls Panel

For manual CCR shutdown purposes, and to provide back-up indication of FGS status,
a hardwired FGS emergency panel will be provided with the FGS for installation within
the operator console in the CCR. The operator console will be supplied within the
PMCS scope.

The Critical Controls Panel shall include as a minimum the following F&G functions:

• Fire and Gas detection alarm status (grouped by fire zone);

• Manual fire pumps start;

• Fire pumps not-in-auto status;

• Fire pumps running status;

• Manual deluge initiation by deluge zone;

• Manual fire protection / suppression system initiation and monitoring, per system;
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• Fire water pressure indicator/controller;

• Fire alarm pushbutton;

• Fire alarm reset;

• Safety Shower / Eyewash activated.

The design emphasis shall be to provide a simple facility, easily operated under
emergency conditions. The FGS emergency panel shall include pushbuttons for fire
protection actions, which will be defined in the cause and effect charts. The emergency
panel shall also include sufficient status lamps such that the operator can determine
critical FGS status across the whole MGDP installation in the event of failure of the
process control system or operator workstations.

The PMCS VENDOR has the responsibility for the construction of the operator
console. The FGS VENDOR has the responsibility of the critical controls panel and
shall coordinate all integration and design issues with the PMCS VENDOR to ensure
the critical controls panel is integrated within the operator console design.

5.10 Expandability

The capacity of the FGS is defined by the FGS I/O schedule. In order to allow for
expansion, a minimum of 20% installed backplane spare capacity shall be provided, in
addition to 20% installed I/O capacity.

The FGS shall be designed such that input/output and logic module expansion by
modular addition is possible without impacting the current system operation.
Expansion shall be able to be implemented with the FGS fully powered and
operational. Expansion shall be achieved by straight addition, not modification, of
hardware and with a minimum of software and programming changes.

5.11 Reliability

5.11.1 Failure Recovery

The FGS shall tolerate a power interruption time of 1 second without disrupting its
operation.

Loss of power to the FGS, (beyond the power ride-out period) shall, upon subsequent
restoration of power, result in automatic reboot of the system to full operation within
five minutes. However, the system logic shall revert to its fail safe state after automatic
reboot.

5.11.2 Availability and Redundancy

The VENDOR shall state the availability of the proposed FGS as a whole. This should
exceed 99.99%, with no degradation mode, based upon a modular change-out
maintenance philosophy utilizing held spares. It is crucial that failure of one point shall
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not freeze the whole card and shall not result in the loss of availability of the entire
FGS.

Availability, A%, is calculated as

A% = (MTBF-MTTR) / MTBF * 100

MTBF = Mean Time between Failure (single component)

MTTR = Mean Time to Repair (assume one hour based on time to diagnose the fault
and make an on-line card replacement)

MTBF and MTTR data shall be based upon field installed equipment data and not
theoretical data.

5.12 Diagnostics and Maintenance

The FGS shall be designed so as to require minimum maintenance and minimum

routine calibration. All I/O points shall incorporate extensive fault monitoring facilities
as standard. This shall include open circuits, short circuits, and over loads.
Diagnostics shall be provided to the individual circuit level.

Comprehensive FGS status information and control of the diagnostic routines shall be
available at the FGS engineering HMI which shall include, as a minimum, the following
functions:

• Fault and status indication, including discrepancy alarms on multiple path logic
systems;

• Soft-button functions, including manual test initiation, automatic test

enable/temporary disable, acknowledge test failure, etc. These shall be subject
to password or keylock type security.

To minimize downtime and assist maintenance personnel, stand-alone diagnostic

software, running on Microsoft Windows GUI, shall be provided with the FGS to
monitor system operation and the status of all hardware throughout the FGS and LAN.

In case of a hardware fault occurring, the diagnostic software shall display on the
PMCS / FGS engineering HMI and PMCS operator HMI time stamped address location
information and provide a graphical presentation of the faulty card location together
with descriptive fault repair instructions.

All FGS shutdown paths shall be tested from input to output automatically with a new
test being initiated at least every thirty minutes. The diagnostic routines shall involve
the generation and monitoring of test pulses which are fast enough to not affect
electro-mechanical output devices. If a test shows that the expected change at the
output is not in accordance with the known C&E relationship (held in a diagnostic map)
then an alarm shall be generated. This testing shall be overridden by an input
changing into the shutdown state. The automatic test system shall have a watch-dog
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to monitor its own operation. If this fails, an alarm shall be generated. Tests shall be
able to be manually initiated at any time.

The design of the FGS shall be on a modular basis to simplify fault finding, with
maintenance being by replacement of complete cards so as to minimize down-time.

All controller, communication, non-volatile memory, and I/O circuit cards shall have
multiple red and green LED indicators to facilitate the identification and repair of failed
cards.

The FGS shall provide the capability to replace a failed part with a spare, on-line and
under power without affecting the existing FGS operation.

The FGS shall be designed to provide maximum ease of equipment servicing. All
necessary hardware, software, drawings and test equipment required to execute fault
identification shall be provided by the VENDOR.

5.13 Electrical Requirements

5.13.1 Codes and Standards

The electrical portion of the FGS, including all wiring, shall be in accordance British
Standard Wiring Rules. The VENDOR shall bring to the attention of the COMPANY all
deviations from this standard for clarification and final ruling.

Exposure of personnel to voltages greater than 24V (AC or DC) shall be prevented.
This shall be accomplished by complying with the requirements of BS 7671, in
particular, by ensuring adequate safety earthing, by segregation of different voltage
levels and by covering and labeling of equipment at voltages greater than 24V DC.

5.13.2 EMI & Radio Frequency Interference (RFI)

The FGS, as offered, shall be supplied with provisions for protecting against system
errors and hardware damage resulting from electrical transients on power or signal
wiring. These transients include those generated by switching large electrical loads, by
power line faults and due to lightning strikes which induce surges on power or signal
cables. The IEEE Standard 472 shall apply to all FGS power inputs and signal inputs
from field devices.

The most common sources of electromagnetic radiation are portable VHF hand-held
radio transceivers with 5 watts of power and portable UHF hand-held radio transceivers
with 4 watts of power. Other sources are fixed radio stations, vehicle radio
transmitters, commutator type electrical devices and spurious sources such as from
welders and contactors. The FGS shall be immune from these EMI/RFI interferences
in accordance with SAMA PMC 33.1. Particular attention shall be given to the
immunity of the FGS to RFI from hand-held radios potentially transmitting at a distance
of one meter from the cabinets whilst the cabinet doors are open.

Errors caused by RFI shall not exceed 0.1% of span for exposure to field strength of 10
volts/meter over the frequency range of 10 to l000MHz. A certified test report shall be
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required in the proposal to verify this performance. The VENDOR'S equipment shall
meet all applicable RFI emissions standards. The VENDOR’S equipment shall not
cause RFI interference to the COMPANY'S hand held radios. The VENDOR shall
provide a hand held radio (preferably Motorola Saber I Handie Talkie or equivalent of
5W RF output and VHF 450 - 520 MHz frequency band) to be used for the factory
acceptance test (FAT) of RFI susceptibility.

5.13.3 Power Requirements

AC Voltage and Frequency Tolerances

The FGS equipment shall be designed to operate on 240V AC 50Hz power. FGS
equipment shall be powered from two separate UPS feeders. UPS shall be supplied by
others in accordance with the power requirements as determined by the FGS
VENDOR and the COMPANY. The vendor shall design and install power buses in such
a manner as to accept individual UPS feeders and distribute individual branch feeder to
FGS chassis and redundant field I/O power supply loads. Voltage will be ±2% with a
maximum transient voltage depression of 20% and frequency regulation will be ±1%.
This is the only power that will be provided to the FGS equipment.

Power Supply Systems

The VENDOR shall provide power supply systems for the FGS equipment mounted in
the system cabinets and all field devices associated with the FGS. At least 30% spare
capacity shall be provided.

Power supply sizing should assume the following power loading for field devices;

• Interposing relays: 1 Watt;

• Gas detectors: 5 Watts;

• Flame detectors: 5.5 Watts;

• Alarm horns and alarm beacons: 10 Watts.

The power loading for all other field devices (i.e. system powered DI and AI) shall be
based upon the FGS VENDOR’S standard power loading figures.

Parallel redundant power supplies with automatic change-over to protect against power
supply failure shall be provided for FGS equipment mounted in the system cabinets.
Each power supply shall be capable of supplying power to the entire FGS. Both power
supplies must be on line at all times, each supplying power to the load. Failed power
supplies shall be removable without disconnecting power from any part of the FGS or
affecting operation.

Each power supply shall be provided with primary and secondary overload protection.

Each power supply shall be provided with a pilot light and with a fault detector. Failure
of any power supply, including incoming power feeders, fuses and circuit breakers,
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shall be alarmed by the FGS through the use of a common FGS unit alarm digital input.

Output current on power supplies shall be locally indicated in order to confirm that
supply capacity exceeds current usage.

5.13.4 Earthing and Shielding

BS7671 Electrical Installations shall govern the earthing requirements of any

equipment supplied and must be adhered to in all respects.

All metal enclosures supplied shall have a minimum of one 6mm x 20mm copper safety
earth bus bar across the full width of the panel. All metal racks, internal panels and
fabrications, cable tray, doors and detachable panels shall be earth bonded together to
this safety earth with a flexible copper braid strap of at least 2.5mm2 to ensure
effective earthing. The safety earth will also be used to connect the earth core from the
multi-core plus earth field control cables being used for solenoid valves.

Each system cabinet and marshalling cabinet shall be provided with one 6mm x 20mm
copper galvanically isolated instrument earth bus bar across the full width of, and
insulated from the panel. The instrument earth shall be used for earthing system
electronics, the negative terminals of DC power supplies and field circuits, and the
electrostatic screens from multi-pair field instrument cables.

All system and marshalling cabinet earth bars shall be clearly labeled.

5.13.5 Wiring and Connections

All wiring shall comply with the requirements of BS7671 Electrical Installations and
shall be carried out using not less than 1mm² flexible stranded, annealed copper
conductors and PVC insulation. Insulation resistance shall be 500 Volts.

The VENDOR shall connect to one side only of the incoming and outgoing terminal
blocks. A terminal shall be allowed for each incoming and outgoing wire. No more
than one wire is to be connected to each side of any one terminal. Where more than
one wire is to be connected on one side for looping purposes, a preformed link or comb
between adjacent terminals shall be provided.

All wiring shall be fitted with PVC insulated crimp pins or lugs. These shall be wire pins
for 1mm2 conductors and lugs for 24V DC power distribution conductors. Separate
pins or lugs, as applicable, shall be used for each conductor. The size of pin or lug
shall be suited to the size of conductor to be terminated and crimped with the pin or lug
manufacturer's approved crimp tool. A method of stripping insulation which does not
damage the wire shall be employed.

Wires shall not be jointed or teed between terminal points.

An allowance shall be made on the length of wire at each terminal to permit cutting and
remaking of the wire termination at least once without interference with the main run of
the wire and loom.
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Terminal blocks shall be Klippon type SAKR polyamide type test/disconnect knife
terminals (or COMPANY approved equivalent) of a size suitable for the particular size
wiring being used. Terminal mounting shall be Klippon terminal rail type TS32 (or
COMPANY approved equivalent). Each terminal shall be clearly tagged with terminal
number. Terminals shall be arranged in groups as per their service. All spare cable
cores shall be terminated into terminal blocks and connected to the instrument earth.

Terminal strips shall be designed so each incoming and outgoing cable can be
terminated such that all cores of the cable fan out in a logical sequence onto a single
uninterrupted section of the terminal strip. The terminal strips shall be fixed such that
terminal screw slots are accessible from outside the compartment to facilitate ease of
wire termination.

All terminated wiring shall have individual alpha-numerical identification in the form of
Grafoplast (or COMPANY approved equivalent) push-on sleeves.

No equipment or terminal block/rail in the system cabinets shall be mounted less than
400mm above the floor. No equipment or terminal block/rail in the marshalling
cabinets shall be mounted less than 200mm above the floor.

A minimum of 50mm shall be allowed between each terminal row and any plastic
slotted trunking to permit sufficient clearance to facilitate fanning of conductors whilst
providing easy access for terminations and identification markers. Terminals shall be
mounted on rails that are attached to a back pan/support and not directly to the surface
of the enclosure.

Removable engraved cover plates of transparent insulating material shall be provided

over all terminals carrying greater than 24V (AC or DC). Terminals carrying mains
supply voltages (240V AC) shall be covered identified with a lightning symbol and the
voltage level clearly identified on a label.

Wiring of voltages greater than 24V (AC or DC) shall be separated from instrument
signal wiring.

All wiring shall run such that it is accessible, neat and tidy. All wiring shall be run in
trunking and loomed with cable ties. Trunking shall be installed in accordance with the
approved layout drawings and shall allow for 30% spare capacity.

Where cabling or looming is required to bridge to a hinged panel the installation

arrangement shall be so that the opening of the hinged panel will cause the wiring loom
to twist longitudinally and not bend or rub on a panel edge or face. At no point shall
any undue stress be placed upon the wires. The loom shall be protected with PVC
spiral wound wrap or flexible conduit or equivalent.

Wiring colour coding shall be in accordance with BS7671 Electrical Installations.

The VENDOR shall propose its own wiring colour code for all other wiring provided that
it complies with BS7671 Electrical Installations and the termination diagrams.
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5.13.6 Circuit Protection and Fusing

The FGS power supply shall have conditioning/filtering and voltage regulation for
immunity against switching surges, as required.

Each field circuit shall be individually fused and a FGS alarm shall be generated in the
case of fuse failure. These shall be in the form of reset table electronic fuses or
indicating cartridge style.

All items shall be selected, sized, constructed and specified with a power rating of
sufficient magnitude to withstand short circuit conditions associated with the
application.

5.14 FGS System Enclosures

5.14.1 General

The VENDOR shall supply FGS system cabinets and marshalling cabinets.

Cabinets shall be the VENDOR’S or third party standard modular construction. Choice
of cabinet type (if there is more than one VENDOR standard) shall be such as to limit
weight and dimensional size consistent with good operational and maintenance
practices. An overall maximum height limit of 2200mm (including the plinth) applies.

All cabinets shall be sized to allow for the installation of all equipment as identified in
the Purchase Order, plus 20% spare. In particular the FGS system cabinets in the
PMCS / FGS equipment room shall have reserve space for at least two additional I/O
racks.

Any deviations from these requirements shall be brought to the COMPANY'S attention
for approval.

5.14.2 F&G Matrix

Fire and Gas Matrix shall be provided for F&G System and shall be integral part of the
F&G system cabinet.

The F&G matrix shall be composed of but not limited to;

• Light Indicators (zone based status of F&G detectors and associated equipment
installed through out the facility)

• Pushbuttons/ Selector Switch, etc.

• Heat and Smoke Detectors alarm reset switch

• Annunciator panel

• Alarm Accept/Reset Facility

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The matrix panel shall be driven by the F&G system.

5.14.3 Structural

The FGS system and marshalling cabinets will be located at ICCS Control room (GPF)
and shall be ingress protected to IP54 as defined in IEC 60529.

The FGS system and marshalling cabinets shall have sufficient structural members
and panels shall be stiffened as necessary to prevent deformation/distortion due to
equipment weight and/or from dynamic loads experienced during transportation.
(Shipping dynamic loads/vibration defined as 0.5g vertical, 0.5g longitudinal, 0.25g
lateral).

All FGS cabinets shall be designed to provide adequate heat dissipation this is to avoid
any damage to the FGS PLC cards due to high temperature which may arise during an
air conditioning failure. Where forced ventilation is required, fans and air filters that are
easily accessible for maintenance shall be provided by the VENDOR. Where forced
ventilation is required, the VENDOR shall include a fan failure alarm built into each
cabinet. This shall be alarmed by the FGS through the use of common FGS unit alarm
digital input.

5.14.4 Access Doors

Access to the FGS system and marshalling cabinets shall be from vertically hinged
doors. Hinged doors shall be mounted on lift-off type hinges and shall be capable of
being swung through an angle of not less than 100o from the closed position. The lift-
off hinges shall have unequal length pins to enable the door to be refitted with ease.

Doors shall be secured in position by a lockable three point locking mechanism and
locks shall have identical keys.

Drawing holders (A3 size) with paper access slots shall be provided on the inside of all
doors.

5.14.5 Panel Lifting

Suitable removable lifting lugs (pad eyes, complete with bolt hole plug) shall be
provided at the top of all FGS system and marshalling cabinets to enable them to be
lifted as complete sub units. It is the VENDOR’S responsibility to ensure that the panel
construction takes account of the loads and stresses imposed by such lifts.

Four lift points shall be provided.

5.14.6 Threaded Fasteners

The threads of all nuts, bolts, screws and studs of 5mm diameter and above on
cabinets supplied in accordance with this Specification shall comply with British
Standards. Where possible, all nuts shall be of the captive type in order to prevent loss
upon dismantling and to aid reassembly.
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5.14.7 Painting and Coating

The VENDOR’S standard shop paint finish for equipment will be acceptable if good
industry practices are followed in surface preparation and cleaning.

Damage to paintwork of material transported, handled or assembled by the VENDOR,

or incurred during such transport, handling or assembly on behalf of the VENDOR,
shall be made good at the VENDOR’S expense. This shall be achieved by thoroughly
cleaning the damaged portion and applying the full number of coats of matching paint
that has been applied before the damage was caused.

The VENDOR shall supply one liter of each paint type used in surface preparation and
painting for use by the COMPANY for site touch-up work.

6.0 SYSTEMS ENGINEERING

6.1 Consultation Service

The VENDOR shall include the provision of the services of a system/applications

engineer who shall be responsible for providing technical guidance and direction during
the execution of the project. This engineer shall also be available to assist in
addressing any questions regarding performance specifications, programming,
installation and field wiring of the FGS.

6.2 Programming Services

The VENDOR shall include the provision of programming services. The programming
activity shall be executed in the VENDOR’S premises using the VENDOR’S
programming tools and assisted as necessary by the COMPANY.

Programming shall be performed on a lump-sum basis to the scope of work as

identified on the I/O schedule and C&E tables at the time of Purchase Order award.
The VENDOR shall allow for up to 10% additions and/or changes to the FGS system
program. Additional work beyond this scope, including additions and/or changes, shall
be performed at rates per the Purchase Order.

Development of the graphics shall be the responsibility of the PMCS VENDOR.

However the FGS VENDOR shall provide the necessary input and assistance as
required.

At the completion of the staging test, the VENDOR shall update the final approved
FGS program. This program shall be generated from the operating software and shall
be free from software patches. The final approved program shall be delivered on a
fully tested and verified system program tape or disk. These shall be supplied complete
in a compartmented storage case with suitable labeling. The VENDOR shall also
retain a copy of this program revision.

6.3 System Initialization

The VENDOR shall include the provision of the services of a qualified field service
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representative to assist with the installation of circuit cards, peripheral devices and
software in addition to the initialization of FGS power. This service shall also include a
functional test and verification of the FGS power distribution and earthing.

7.0 SPARE PARTS

7.1 Start-up and Commissioning Spare Parts

The Vendor shall supply spare parts for start up and commissioning. These will be
required in order to avoid using any of the operational spare parts. The Vendor must
take into consideration the remoteness of Site when deciding which spares and what
quantities are offered.

Spare parts will generally be held by the COMPANY on the shelf at the Mehar Gas
Development Facilities, not as hot running spares. All spare parts shall be clearly
marked and identified by the VENDOR using a concise tag or serial and type number.
Spare parts shall be adequately protected and packaged by the VENDOR to prevent
deterioration of components and contact surfaces during prolonged storage in the
environmental conditions as defined in the Specification for Site Data and Utilities.

7.2 Operational Spare Parts

The Vendor shall submit a spare parts quotation for two years’ continuous operation.
The Vendor must take into consideration the remoteness of Site when deciding which
spares and what quantities are offered.

8.0 INSPECTION AND TESTING

8.1 General

The FGS shall be subject to rigorous QA and testing programs at all stages of
manufacture. Quality assurance and testing shall be designed to simulate as closely
as possible local conditions. The testing programs shall be based on ISA RP55.1 and
outline methods, procedures and simulation facilities proposed.

All equipment will be subject to inspection by the COMPANY'S appointed Inspector as

itemized in the Purchase Order. The VENDOR shall afford full facilities to the
Inspector during the course of manufacture and shall arrange access to any Sub-
VENDOR'S works where necessary. Details of this requirement will be resolved in pre-
inspection meetings.

The VENDOR shall ensure that adequate notice (a minimum of fifteen working days, in
writing) is given to the COMPANY and the Inspector to enable them to arrange their
visits to suit the manufacturing program in accordance with the conditions of the
requisition documents.

The acceptance of the work by the Inspector and/or his release of the equipment for
shipment shall in no way release or relieve the VENDOR from any responsibility for
carrying out all of the provisions of this Specification and/or relevant documentation,
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nor does the COMPANY by such approval and/or release, assume any responsibility
whatever for such provisions.

All test and inspection data shall be legible including the name and signature of the
VENDOR and, where applicable, the Inspector.

All defects in materials detected as a result of testing shall be repaired or replaced by

the VENDOR at no cost to the COMPANY. If the correction of any error or defect
involves serious alterations requiring replacement of parts, the approval of the
COMPANY shall be obtained before proceeding with such corrections. Also, if the
correction of the error requires witnessing by the Inspector or a change in certificates
issued by the Inspector the correction shall be properly corrected and signed by the
Inspector.

If any part of the equipment is damaged after tests have been completed, retesting of
the affected parts is mandatory. The method of repair shall be in accordance with the
VENDOR’S standard procedures.

All formal testing will be conducted in accordance with a written test procedure. The
VENDOR’S standard test procedures will be forwarded to the COMPANY at least two
months prior to the factory acceptance test for approval. Each formal acceptance test
must be signed by the VENDOR’S and the COMPANY'S representatives at the
successful completion of the test.

The VENDOR shall supply supervision, specialist personnel and all necessary
materials to support the inspection and testing. This shall include all the equipment
and signal generation gear adequate to simulate all inputs simultaneously on a loop
containing multiple inputs.

Testing shall be carried out by the VENDOR and may or may not be witnessed by the
COMPANY or the COMPANY'S representative (the Inspector) at various stages as the
FGS equipment is manufactured and assembled. Locations are detailed below:

Pre-Factory Acceptance Test Conducted at the original point of manufacture of

the FGS.

Factory Acceptance Test Conducted at the original point of manufacture of

the FGS.

Integrator FAT Conducted at the IFAT facility nominated by the

VENDOR and approved by the COMPANY.

Site Acceptance Test Conducted at the Mehar Gas Development Facility.

Availability Test Conducted at the Mehar Gas Development Facility.

All power supplies shall be checked for correct voltage and frequency and all cables
shall be checked for insulation resistance (Megger checked at 500V AC) before any
testing is initiated. Test equipment shall be connected to field connection terminals
only.
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8.2 Pre-Factory Acceptance Test

The QA and testing program for printed circuit boards (PCBs) and electronic
components should include as a minimum:

• Physical inspection after initial assembly;

• Initial functional test under power (100% of all PCBs);

• Burn-in cycle (powered environmental cycling to protect against failure due to

infant mortality);

• Heat-soak tests:

The system shall be operated by the Manufacturer in its final on-site

configuration for a minimum period of 200 h (burn-in period). A minimum of 10 %
of digital inputs, 10 % of digital outputs and all analogue inputs and outputs shall
be simulated for this period, with simulation equipment provided by the
Manufacturer.

All deliverable equipment used in the system shall be subjected to an elevated

temperature of 45 °C (typical) for 100 h during the demonstration period. The
system environment shall be cycled between 45 °C and the site ambient
temperature at 12-h intervals, until the 100-h elevated temperature period is
completed.

During the heat-soak test, the system equipment shall be fully energised. Fully-
loaded operating conditions shall be simulated at 24-h intervals by demanding
reports, selecting displays, exercising calculations and sending and requesting
data over communication channels.

If a component failure occurs, all tests shall be repeated after the replacement of
the faulty component, unless otherwise agreed by the COMPANY. This ensures
that all essential components are subjected to the specified minimum testing;

• Unit assembly and coating (inspection);

• Final test and inspection (signed off by test engineer).

The QA and testing program for modules and sub-assemblies shall include as a
minimum:

• Physical inspection after assembly;

• Test under power.

These tests may be witnessed by COMPANY and certification along with a detailed
report on the tests shall be provided. On completion of testing the serial numbers of all
equipment shall be recorded for checking on arrival at Site. The results of the pre-FAT
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shall form part of the Manufacturers Data Report.

8.3 Factory Acceptance Test

The FAT shall be conducted in accordance with the VENDOR'S standard QA

procedures. The VENDOR shall supply a 5 Watt hand-held UHF radio for use in the
vicinity of the FGS to demonstrate that RFI does not affect the system. No other
nonstandard tests are required.

The VENDOR shall be responsible for generating the FAT procedures. The pass/fail
criteria shall be 100% correct performance otherwise the faulty item shall be rectified or
replaced at the VENDOR'S cost.

The FAT shall include the testing and acceptance of both hardware and proprietary
system software. All proprietary system software shall be complete and resident in the
FGS prior to the start of FAT. All documentation and listings must be free of markups.

All hardware diagnostic programs shall be run at the start of FAT. These shall be the
diagnostic programs which have been used for processing the system in the
VENDOR’S factory.

During the FAT, the FGS shall be made available to the Inspector for sufficient periods
to verify satisfactory performance. The Inspector will reserve the right to witness the
entire FAT as a nonparticipating observer. The FAT procedure will be signed off by the
VENDOR and the Inspector and a copy of the signed off FAT procedures and related
printouts shall be furnished to the Inspector at the successful conclusion of the FAT.
However, the FAT is not an inspection and test hold point.

The final FAT shall be done together/integrate the PMCS and FGS/SIS system to
perform as a complete single operating system.

8.4 IFAT Test

The IFAT test will be carried out after the entire FGS equipment has been shipped to
the nominated staging test site. The staging test of the FGS will be conducted in
conjunction with the staging tests of other equipment with which it must interface in
order to verify the correct operation of all interfaces.

The VENDOR shall be responsible for generating the staging test procedures that shall
include pass/fail criteria.

All system HMIs shall be hooked up to the data highway and the whole of the final
configuration data base shall be loaded, tested and signed off by the Inspector.
System diagnostics shall be exercised, and failure modes shall be demonstrated.

All equipment shall be energized and remain energized for the duration of this test.
This includes any externally powered equipment. Dummy loads shall be fitted in all
loops where this is necessary for observing the correct functioning of a loop. These
dummy loads shall remain fitted to all circuits except the circuit under test. To allow for
cable resistance, the circuits under test shall include resistance to the maximum value
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permissible by the VENDOR’S specification. Outputs shall be connected to a device
as similar as possible to the final field element (e.g. relay coil, I/P converter, etc.). The
VENDOR shall provide test sets for checking sequential control circuits. These shall
simulate all interlocks and time delays in the system.

All loops in the system shall be tested by applying a simulated signal (or signals in the
case of complex loops) at the terminal strip in the marshalling cabinet and observing
the effect on the screen, including alarms. Alarms shall not be simply tested by
adjusting the alarm setting. Outputs should also be manipulated and the result
measured again from the marshalling cabinet. All equipment associated with a loop
shall be tested as a system. Circuits shall generally be tested one at a time. However,
where cascade or similar controls are involved, these shall be tested as one complete
system. These tests are not required for calibration purposes.

8.5 Site Acceptance Test

Prior to the commencement of the SAT, the following activities will have been
performed by the COMPANY with optional technical assistance provided by the
VENDOR:

• An audit and inspection of equipment received;

• A deficiency report written and appropriate action taken to rectify any problems;

• The FGS powered up and functionally tested with the appropriate test equipment.

The process controllers, operator HMIs and peripherals powered up and tested with
diagnostic routines.

Communications established among all components of the system and tested using
the appropriate test equipment.

• All alarm status, analog and pulse inputs, control outputs of each processor
module checked with simulated input and output loads;

• Each analog device calibrated, the system function verified, followed by the
interrogation of each analog point and the operation of each final control
element.

The VENDOR shall make available, as an option on day-rates, the services of

personnel to assist in the performance of the SAT. The VENDOR shall supply all
standard and special tools, test and calibration equipment necessary for the SAT.

The SAT procedure will be derived from the FAT and the staging test. The FAT
procedure shall be modified to take account of the field environment.

The SAT will be performed as a joint effort between the VENDOR and the COMPANY.
The SAT will demonstrate the functionality of all hardware, field inputs/outputs and
configuration. The SAT will be witnessed and signed off by the VENDOR, the
COMPANY and possibly third party and statutory representatives.
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8.6 Availability Test

After the completion of the SAT, each system will be subject to an availability test for a
continuous sixty day period. The availability test will be conducted by the COMPANY
and will consist of monitoring the system availability during the sixty-day period.

The FGS provided by the VENDOR shall have an overall availability of 99.99%.

If the system does not meet the 99.99% availability requirement during the availability
test conducted by the COMPANY, the VENDOR shall be responsible for repairing or
upgrading the FGS (at the VENDOR’S expense) in order to meet the requirement. The
COMPANY will then repeat the availability test and the sixty-day period will begin again
following the repairs and upgrades.

The availability test will be conducted concurrently with normal plant operations.

8.7 Shop Inspection

The Inspector will periodically visit the VENDOR shop facilities and inspect system
progress from a hardware and software perspective in accordance with Inspection and
Test Plan.

8.8 Certificates of Acceptance

At the satisfactory conclusion of the FAT the staging test and the SAT, an appropriate
certificate of acceptance shall be provided by the VENDOR.

Attached to these certificates shall be all test records and other pertinent
documentation. These shall form part of the Manufacturer's Data Report (MDR).

The COMPANY will review and approve these certificates.

Final acceptance of the FGS shall be on satisfactory completion of the warranty period.

9.0 DOCUMENTATION

9.1 General

The VENDOR shall provide hard copies of drawings and other appropriate documents
developed on his system, with the data stored on either floppy disks or tapes, in a
format compatible with AutoCAD, for future use and modification by the COMPANY as
required.

All documents shall be in the English language, with the data stored on CDs, in format
compatible with Microsoft Word.

VENDOR shall also comply with the requirements of documentation specified in PCPL
procedure CSP-03.
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9.2 Functional Specification

The VENDOR shall produce a Functional Specification for approval by the COMPANY.
This Functional Specification shall detail all hardware and miscellaneous materials to
be supplied against the specification, full details of the exact functionality, performance
and self-checking which will be available from the FGS and full definition of the
interface to all peripheral equipment. The emphasis of the functional specification shall
be on the functionality of the FGS.

9.3 Drawings

All FGS drawings shall be prepared and submitted in accordance with recognized
standards. Wherever practicable, every effort shall be made to minimize the total
number of drawings prepared by use of common drawings wherever practicable
without loss of clarity.

Prior to start of manufacture, the VENDOR shall submit all drawings for the
COMPANY’S approval.

‘As-built’ revisions shall be prepared and final issue. Any information or data revised
during staging tests or SAT shall be provided before the commencement of the
availability test. Each drawing shall be clearly marked ‘As-built’ and dated.

9.4 Design Interfaces

The VENDOR shall make allowances for 3 issues of COMPANY’S documents

nominally at 75% (Review), 90% (Approved for design) and 100% (Approved for
construction) at completion of detailed design.

The COMPANY will provide the VENDOR with the following information:

• FGS I/O schedule including, but not limited to, the following information for each
loop:

- Tag number;

- Service description;

- I/O type;

- I/O range;

- I/O units;

- Alarm settings and alarm messages;

- Control algorithms and initial tuning parameters;

• Piping and instrumentation diagrams (P&IDs);

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• Single Line Diagrams (SLDs);

• Cause and Effect Diagrams (C&E);

• The COMPANY'S requirements for graphic displays, report format details, tabular
displays, etc.;

• Earthing, power supply and other interface details.

The VENDOR shall supply complete FGS data for inclusion in the COMPANY's
instrument loop diagrams. This data shall include, but not be limited to, the following:

• FGS cabinet termination details;

• Block interconnections and system cables between components of the FGS;

• Hardware addresses including cabinet, rack, card slot and point in the
VENDOR’S standard notation;

• Clear, concise and understandable (by an operator/maintenance technician)

configuration software listings including graphic display building software.

9.5 Operation and Maintenance Manuals

Operations and maintenance manuals shall be provided and shall include, but not be
limited to, the following documents:

• A complete set of the VENDOR’S standard manuals for site preparation and
installation, operation, configuration, maintenance and troubleshooting as
applicable to the FGS hardware and software supplied;

• Drawings and data sufficiently detailed to permit diagnostics.

The VENDOR shall follow its standard practice provided this meets the intent of the
above requirements.

9.6 System Log

A system log shall be maintained by the COMPANY and the VENDOR from the time
the staging tests start, through the SAT and on through the warranty period.

The system log shall note all software, hardware and configuration changes and log
the following:

• Date of occurrence of a problem;

• Who reported the problem;

• Summary of a problem;
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• Problem report number;

• Action taken to correct the problem;

• Confirmation that the correction has been tested and accepted.

This system log shall be kept in chronological order.

10.0 TRAINING

VENDOR / CONTRACTOR shall provide COMPANY personnel with training at

VENDOR premises and at Site. The VENDOR / CONTRACTOR shall provide the
training schedule and program to the COMPANY.

The scope shall include 05 (five) days training for the COMPANY personnel or as per
the terms and conditions in the Purchase Order. Training shall cover the following
areas as a minimum:

• Operation;

• Maintenance / Troubleshooting.