28037.eng - Sta.std - Instrumentation & Automation
28037.eng - Sta.std - Instrumentation & Automation
28037.eng - Sta.std - Instrumentation & Automation
28037.ENG.STA.STD
Rev.01 - November 2015
GENERAL NOTE This Re-coding does not affect the document content.
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REVISION TRACKING
INDEX
1. GENERAL ............................................................................................................. 7
1. GENERAL
1.1 SCOPE
This specification outlines the minimum requirements to be followed for the design,
engineering, construction, testing and installation of the instrumentation and automation
systems included in a Package supply.
This document is applicable for both onshore and offshore facilities.
In case of conflict between what is described in this specification and other COMPANY standards
on the subject, this specification shall have the priority.
Good practice rules shall be always applied, particularly with respect to safety and accident
prevention.
Any other additional information not covered by this specification shall be part of the project
documentation and and in the applicable codes, normative references.
Technical Data Sheet (TDS), Inspection Data Sheet (IDS) and Document Data Sheet (DDS) will
be developed at project based on available COMPANY standards.
The technical requirements of this Functional Specification are based upon considerations of
performances and functionality, therefore the instructions contained in this document are not
meant to be discriminatory.
Any alternative suggestion will be considered, provided that the compliance with what required
in this document is satisfied both from functional and performance points of view.
For the purpose of this specification, the following definitions shall be applied:
Here below are listed the common used acronyms. Maybe other technical definitions,
terminology references, symbols and abbreviations shall be mentioned where necessary in this
specification.
2. REFERENCE CODES
All instrumentation design, procurement and works shall be fully in accordance with all
applicable regulations, codes and standards.
The requirements of Laws, Rules, and technical codes, issued by the local Authorities of the
country on which the plants shall be installed, shall be always respected.
The equipment shall be designed, manufactured and tested in accordance with the latest
revision of all relevant national/international Codes and Standards that will be defined and
listed in the project documents.
Some specific standards mentioned in this document are listed here below, where other
applicable standards shall be defined in the project documents:
Directive 94/9/EC Equipment and protective systems intended for use in potentially
explosive atmospheres (ATEX)
IEC 61511 Functional Safety - Safety Instrumented System for the Process
Industry Sector
PACKAGE SUPPLIER/CONTRACTOR shall verify the validity and relevance of each rule, as a
minimum checking the latest edition available and also the issuance of new pertinent
regulations.
The selection or priority criteria in the application of the normative references (European,
national, international, national or issued by recognized Organisations) shall be defined in the
project specifications.
Where conflicts exist between these documents and other drawings, standards, codes and
specifications, the most stringent shall be applied, and COMPANY decision shall be final.
Here below there is an identification table with a short description of the four typologies of the
Instrumentation COMPANY standards.
The COMPANY standards to be used shall be listed during the project execution.
2.3 RESPONSIBILITY
PACKAGE SUPPLIER/CONTRACTOR is responsible for the compliance with the requirements set
in this specification and with applicable laws and regulations.
Compliance with this specification shall not relieve PACKAGE SUPPLIER of the responsibility to
supply, test and inspect systems and equipment of correct design, materials, and performance
suitable to satisfy the required service conditions and regulations.
Proposals of alternative solutions with respect to technical requirements of this specification
will be taken into consideration if they are adequately supported with documentation proving
that their functional characteristics and performance levels are not lower than the ones herein
required.
3. BASIC REQUIREMENTS
The complete engineering and detailed design for the instrumentation, control and safety
systems supply within the Package shall fully comply with this document and the following
COMPANY Standards:
20047.VAR.STA.SDS
20048.VAR.STA.SDS
The PACKAGE SUPPLIER shall be fully responsible for the correct and safe operation of their
equipment.
The instrumentation control of a package unit will be defined according to the relevant P&ID.
Instruments used for safety function loops shall be dedicated to this service and have dedicated
tapping and impulse lines. Transmitters measuring the same range (control and safety) shall
always be compared against each other with discrepancies flagged by and alarm on the
operator workstation.
All the instruments provided shall be pre-calibrated, installed, supported, labelled and
connected to process piping inside the system. All instrument piping/tubing shall be properly
supported and identified, and the pipe routing shall be laid in such a way as to suffer the
minimum of disturbance when any plant item is removed for maintenance.
Where piping is subjected to vibration, individual pipe shall not touch each other or any metal
part, other than the pipe support and clips. In case of pneumatic instruments, these
instruments shall be suitable to work with instrument air.
All the cables installed shall be terminated at both ends; any spare cores shall be terminated
to spare terminals. Instrumentation signal cables shall comply with COMPANY Standard
06798.MAT.STA.FUN. All instrument cables shall be adequately supported and identified.
Where instruments, pipes and cables are in such a position as to possibly sustain accidental
damage during operation or during maintenance, suitable protective shields shall be provided.
The PACKAGE SUPPLIER shall provide the software library for the HART protocol and
maintenance PC and a hand held field communicator in order to allow the remote calibration,
maintenance, diagnostic, etc.
All correction or modification requested by the COMPANY/CONTRACTOR and agreed by the
PACKAGE SUPPLIER will be under PACKAGE SUPPLIER’s responsibility to ensure that the
request is operable and safe, regarding the process and safety.
The PACKAGE SUPPLIER shall provide to CONTRACTOR/COMPANY all documents as requested
in this document (including the DDS) for review and approval according to the interface
matrix . Partcular attention shall be paid to the functional specifications of the equipment, to
all P&IDs, to the definition and the quality of selected instrumentation equipment.
When CONTRACTOR/COMPANY specifies typical schemes in the Invitation to Tender (ITT)
documents, it is the PACKAGE SUPPLIER’s responsibility to examine them and condense or
modify them to ensure that the PACKAGE SUPPLIER proposes a safe and operable unit.
CONTRACTOR will provide the selected suppliers from the “Recommended Vendor List”, starting
from the COMPANY vendor list when it is present inside the ITT, within a specific time period
after order of the Package.
instruments type and model used for the project will be confirmed by PACKAGE
SUPPLIER/CONTRACTOR at a determined date, defined during detail engineering.
To achieve standardisation with the plant instrumentation, the following points should be
imposed to PACKAGE SUPPLIER such as:
Choice of manufacturer for instruments, control equipment and installation accessories
limited to the “Vendor List” as defined above.
The measurement units shall be in compliance with the International System (SI) and
COMPANY standard 20183.COO.GEN.FUN.
The graphic symbols, codes and identification tags used for the instrumentation and automation
in the P&IDs and other design documents shall be in accordance with ISO 3511 and/or
ANSI/ISA-S5.1, as defined in the Project Specification.
In general, instrument symbols and tagging must comply with ANSI/ISA-S5.1 and COMPANY
standard 20198.COO.GEN.SDS. The tag numbering system must be reviewed and approved by
the COMPANY for each project.
Field mounted instruments and junction boxes, panels, cabinets, etc. shall be identified by the
manufacturer using non-removable AISI 316 SS name plates, engraved as per project
specification.
In order to assist the standardization and spares management, all materials / equipment and
installation methods shall be specified to meet the requirements for the worst general
classification identified for the zone where such materials / equipment are placed. For instance,
whenever Zones 1 and 2 are present, all equipments, materials and installation works shall be
suitable for the classified area Zone1).
Special attention has to be paid to any eventual specific areas of increased hazard.
All electrical/electronic field instruments shall be suitable for installation in the defined
hazardous area and certified in accordance with the normative references indicated in the
project specification (ATEX Directive 94/9/EC).
Hazardous area protection preferred method is Ex-ia both for process and utilities areas.
For special cases, as lack of availability, high absorbed power, space problem, some specific
performances, or impossibility in obtaining the certification, Ex-d explosion-proof type
instrumentation is acceptable.
The Ex-e execution is acceptable for no-sparking equipment connections (i.e. junction boxes).
The certifications shall be provided for the equipment by the appropriate authority in the
manufacturer country.
Protection methods Ex-p (pressurisation) or Ex-s (special execution) shall be avoided and are
subject to written COMPANY approval.
OUTDOOR INDOOR
IP65
Field Instruments
IP54
Pneumatic Instruments
IP65
Junction Boxes
IP65
Local Control Panel
n. a. IP40
Cabinets
IP65 IP40
Consoles, HMI
The design life of Package equipment for each project shall be agreed with COMPANY case by
case.
4. PACKAGES TYPE
4.1.1 General
This Package type is very simple and is restricted to units with few instruments installed,
supported and tagged, including some instruments supplied separately.
This Package is fully controlled by the plant PCS/SIS.
The Package is equipped with its instruments without junction boxes, cable trays and cables;
except special interconnecting cables between primary element (e.g. temperature element)
and related transducer if remotely field mounted (e.g. temperature transmitter).
The CONTRACTOR shall design, engineer, supply and install cabling from instruments to
junction boxes, as well as junction boxes, cable trays, cable ducts, cable tray covers and
multicables cabling from junction boxes to PCS/SIS.
Loose instruments can be also considered as package P1 type if purchased to a common
vendor. In this case it is considered the supply activity only.
CONTRACTOR is responsible for further integration of the P1 type Package into the facility and
its functionality.
The purpose of this Interface Matrix is to provide an overview of the responsibility activities to
be executed and the possible interfaces (COMPANY, CONTRACTOR, PCS/SIS SUPPLIER) that
the P1 type PACKAGE SUPPLIER shall meet during the project phases: design, supply,
installation, testing, commissioning & start-up.
The codes used in the Interface Matrix have the following meaning:
D = DOCUMENT DEVELOPED BY X = ACTION BY
A = DOCUMENT REVISED/APPROVED BY Y = SUPERVISION BY
R = DOCUMENT REVISED BY
Testing,
Design Supply Installation Commiss.
& Start-up
Item
CONTRACTO
CONTRACTO
CONTRACTO
CONTRACTO
COMPANY
COMPANY
COMPANY
COMPANY
PACKAGE
PACKAGE
PACKAGE
PACKAGE
Task Description
PCS/SIS
PCS/SIS
PCS/SIS
PCS/SIS
Instruments within the Package
a) Instrumentation (i.e.: shutdown/blowdown valves,
control valves, safety valves, pressure/flow/temperature/
D A A X X X Y Y
1 level instruments, analyzers, any probes, etc.) inside the
Package
b) Instrument accessories (tubing and fittings, labels on
supports, cable glands, conduit, clips, cable tray with A D X X X Y Y
covers – fittings – supports, etc.) inside the Package.
Instrumentation cables
2
a) Special cables (if any). D A X X X Y Y
Plant PCS/SIS
3 a) Hardware (based on CONTRACTOR documents) A A D X Y X Y Y Y X
b) Application software (programming, configuration). A A D X Y Y X Y Y X
4.2.1 General
The Package is equipped with its instruments, cables and cable trays. This Package is fully
controlled by the plant PCS/SIS. Instruments are wired and connected up to junction boxes,
located at skid edge of the Package. All cables shall run on cable trays.
Junction boxes shall be grouped per signal type. Signals segregation shall be according with
COMPANY Standard 20048.VAR.STA.SDS. Junction boxes shall be accessible from the ground
level and their arrangement shall allow easy access for installation and wiring of multicables.
The multicables between the junction boxes and the marshalling cabinet shall be specified,
provided and installed by the CONTRACTOR.
This Package type is foreseen for Packages with many instruments but which control and safety
logic is simple and does not exist as standard supply by the SUPPLIER or for Packages
considered as integral part of the facility’s process functions.
The SUPPLIER shall provide the CONTRACTOR with a detailed functional definition and design
documents to be forwarded to the PCS/SIS SUPPLIER.
The purpose of this Interface Matrix is to provide an overview of the responsibility activities to
be executed and the possible interfaces (COMPANY, CONTRACTOR, PCS/SIS SUPPLIER) that
the P2 type PACKAGE SUPPLIER can meet during the project phases: design, supply,
installation, testing, commissioning & start-up.
The codes used in the Interface Matrix have the following meaning:
D = DOCUMENT DEVELOPED BY X = ACTION BY
A = DOCUMENT REVISED/APPROVED BY Y = SUPERVISION BY
R = DOCUMENT REVISED BY
Testing,
Design Supply Installation Commiss.
& Start-up
Item
CONTRACT
CONTRACT
CONTRACT
CONTRACT
COMPANY
COMPANY
COMPANY
COMPANY
PACKAGE
PACKAGE
PACKAGE
PACKAGE
Task Description
PCS/SIS
PCS/SIS
PCS/SIS
PCS/SIS
Instruments within the Package
a) Instrumentation (i.e.: shutdown/blowdown valves,
control valves, safety valves, pressure/flow/temperature/
D A A X X X Y Y
1 level instruments, analyzers, any probes, etc.) inside the
Package
b) Instrument accessories (tubing and fittings, labels on
supports, cable glands, conduit, clips, cable tray with D A X X X Y Y
covers – fittings – supports, etc.) inside the Package.
F&G detectors/devices
Testing,
Design Supply Installation Commiss.
& Start-up
Item
CONTRACT
CONTRACT
CONTRACT
CONTRACT
COMPANY
COMPANY
COMPANY
COMPANY
PACKAGE
PACKAGE
PACKAGE
PACKAGE
Task Description
PCS/SIS
PCS/SIS
PCS/SIS
PCS/SIS
Interface and Interconnecting (only documentation)
10 a) Input hardware data (I/O quantities, power supply
D A A
consumption, etc.) to PCS/SIS SUPPLIER.
4.3.1 General
This Package shall be similar to that of P2 Type Package with the following
exceptions/additions:
Package is delivered with its own autonomous control and safety cabinets, generally PLC based,
and shall include all relevant control equipment as well as safety equipment if applicable.
This Package will be controlled by this dedicated system having individual computation and
disply capability (e.g. Programmable Logic Controllers [PLC]) and shall be monitored through
PCS/SIS.
UCP housing the PLC or other special electronics shall be part of PACKAGE SUPPLIER’s scope
of supply.
The Package may include its local control panel, which shall be designed to be located on skid,
mainly for local control during operation / maintenance / testing mode and diagnostics.
The PACKAGE SUPPLIER shall design all the cable requirements (multicables, multipair, multi
triad, etc.) between the Package junction boxes and the UCP. CONTRACTOR shall calculate the
length from package skid edge to the final connection point. Supply and installation of this
cable will be carried out by CONTRACTOR.
Whenever control and shutdown functions are present inside the Package unit, the safety
section of logic solver shall be independent from the control one according to according to IEC
61508/61511.
The logic solver for safety purpose shall be SIL 3 rated according to IEC 61508/61511.
For any other additional requirements relative to P3 Type Package not covered by this
document, refer to COMPANY Standards:
20150.PKG.STA.FUN
20456.PKG.STA.FUN
The purpose of this Interface Matrix is to provide an overview of the responsibility activities to
be executed and the possible interfaces (COMPANY, CONTRACTOR, PCS/SIS SUPPLIER) that
the P3 type PACKAGE SUPPLIER can meet during the project phases: design, supply,
installation, testing, commissioning & start-up.
The codes used in the Interface Matrix have the following meaning:
Testing,
Design Supply Installation Commiss.
& Start-up
Item
CONTRACT
CONTRACT
CONTRACT
CONTRACT
COMPANY
COMPANY
COMPANY
COMPANY
PACKAGE
PACKAGE
PACKAGE
PACKAGE
Task Description
PCS/SIS
PCS/SIS
PCS/SIS
PCS/SIS
Instruments within the Package
a) Instrumentation (i.e.: shutdown/blowdown valves,
control valves, safety valves, pressure/flow/temperature/
D A A X X X Y Y
level instruments, analyzers, any probes, etc.) inside the
1 Package
b) Instrument accessories (tubing and fittings, labels on
supports, cable glands, conduit, clips, cable tray with D A X X X Y Y
covers – fittings – supports, etc.) inside the Package.
F&G detectors/devices
Testing,
Design Supply Installation Commiss.
& Start-up
Item
CONTRACT
CONTRACT
CONTRACT
CONTRACT
COMPANY
COMPANY
COMPANY
COMPANY
PACKAGE
PACKAGE
PACKAGE
PACKAGE
Task Description
PCS/SIS
PCS/SIS
PCS/SIS
PCS/SIS
UCP (PLC and other automation equipment)
a) Hardware. D A A X X X Y Y
9
b) Application software (programming, configuration). D A A X X X Y Y
c) Configuration tools. D A A X X X Y Y
Plant PCS/SIS
10 a) Hardware (based on CONTRACTOR documents) A A D X Y X Y Y Y X
b) Application software (programming, configuration). A A D X Y Y X Y Y X
Interface and Interconnecting (only documentation)
a) Input hardware data (layouts cabinets, I/O quantities,
D A A
power supply consumption, etc.) to PCS/SIS SUPPLIER.
b) Input software data (I/O’s List of serial link UCP-
D A A
PCS/SIS) to PCS/SIS SUPPLIER.
11 c) Interconnecting wiring diagram between UCP and plant
D A A
PCS/SIS.
d) Input software data (graphic pages, etc.) to PCS/SIS
A D
SUPPLIER.
e) Interconnecting wiring diagram between UCP and
D A A
electrical MCC interface panel.
Testing activities
a) Procedure and Test for the HW & SW between PCS/SIS
and UCP during the FAT of plant PCS/SIS.
R A A D Y Y Y X
b) Procedure and Test for the serial link UCP-PCS/SIS
12 during the FAT of plant PCS/SIS.
R A A D Y Y Y X
c) Procedure and Test for the HW & SW between PCS/SIS
and UCP during the SAT of plant PCS/SIS.
R A A D Y Y X Y
D) Procedure and Test for the serial link UCP-PCS/SIS
during the SAT of plant PCS/SIS.
R A A D Y Y X Y
According to project requirements, the UCP which is interfaced with the plant PCS/SIS can be
installed either in Instrument Equipment room (ref.to figure 1), or in the skid at field (ref.to
figure 2).
Figure 1 - P3 Type Package with Control & Safety UCP inside the Instrument Equipment room
Figure 2 - P3 Type Package with Control & Safety UCP inside the Package Skid
The UCP is equipped with its own autonomous control (and safety, if required) functions, it is
PLC based with the latest release of hardware and software industrial type and each UCP shall
be equipped with at least the following main equipments:
Human Machine Interface (HMI).
Control machine/Package system (PLC with CPUs, I/O cards, communication cards,
power supply modules, etc.).
ESD/F&G system (if required).
Marshalling cabinets.
Local control panel (to be installed closed to the skid or directly on the skid).
In order to allow a proper and safe data exchange among the involved systems, provided by
the PACKAGE SUPPLIER, and to/from the plant PCS, the PLC shall provide a redundant
communication connection with high performances in terms of standard interface,
communication protocol, speed data exchange, reliability, availability, diagnostic, etc. avoiding
any bottle neck.
Interface signals to/from PCS and PLC shall be achieved by a dedicated dual redundant data
link, whereas some critical commands/information signals are present, they shall be connected
also hardwired.
In case of complete communication loss or major failure, communication shall automatically
restart after repair. At common restart, all commands issued by plant’s control system to the
UCP are set in accordance with PLC internal values (UCP is the logic master for all information
concerning the Package).
The failure of the link shall not affect the operation of the Package.
To ensure the detection of the communication failure, a watchdog function shall be available
and exchanged between the plant’s control system and UCP through the digital data link.
Whenever requested, the UCP can be located in a dedicated shelter (joined with other
electric/electronic cabinets related to the same machine) that will be installed closed to the
skid.
Provide all actions (i.e. alarm arisen handling, activate the firefighting system, close fire
dampers [if any]), apply voting logics, etc.) necessary to take the Package’s plant back
to safe condition (i.e. by means of blowdown) when dangerous conditions are detected
upon process upset and/or upon the monitoring of the relevant risk areas for any fire,
gas (toxic or flammable) emergency situation.
To Alert personnel in the plant Control Room (via UCP/PLC) of any fault detected by
self-test facilities.
The F&G systems shall follow the NFPA 72 standard or the EN 54 standard according to project
requirements. All F&G detection equipment (including push buttons) and final elements (e.g.
relays, solenoid valves, etc.) connected to the main F&G system shall be minimum SIL 2
certified by an approved third party. The SIL of the Loops shall be in line with the project
Functional Safety requirements and compliant with requirements of IEC 61508 and IEC 61511.
PACKAGE SUPPLIER shall develop a detailed Cause and Effect Matrix showing all critical inputs
and outputs of the ESD and F&G system and their specific functions, in the context of the
protective philosophy adopted for the whole supply.
F&G monitoring modules shall be suitable for the field sensors which can be wired with two or
three wires; however the PACKAGE SUPPLIER will provide the proper signal
conditioning/detectors feeding where necessary.
4.3.5.5 Functions of Burner Management System (BMS) for “P3” Type Package
A Burner Management System (BMS) is required to provide the start-up, shut down and flame
safeguarding safety functions. There are two possible routes available to implement the BMS.
• Use a UCP (Unit Control Panel), splitted into UCP_C and UCP_S for control and safety
functions, based on a PLC technology suitable for this purpose.
• Use a SIS (Safety Instrumented System) node that is part of the plant ICSS.
In either case the SUPPLIER shall be responsible for the proper design of the system and for
ensuring its performance and safety. The detailed requirements and scope of supply of
hardware and software will be defined in the project documentation considering the applicable
standards and specifications.
Where specified in the project specifications and data sheet the Supplier shall provide a Burner
Management System (BMS) implemented in a UCP (Unit Control Panel), splitted into a UCP_C
for control and a UCP_S for safety functions, based on PLC technology suitable for the purpose.
Signals between plant Safety Systems (SIS) and UCP Packages shall be hardwired for
commands and interlocks. Signals between plant control system (PCS) and Package UCP will
be exchanged via redundant serial link or hardwired for critical commands/signals/interlocks.
Whenever control and shutdown functions are present inside the package unit, all the safety
sections of the logic solver shall be independent from those dedicated to control. This safety
section shall be SIL 3 rated.
The Supplier is any case responsible for the compliance with any applicable regulations
regarding burner management systems in the place of installation of the heater, including
providing any and all equipment required by any regulation within the Supplier’s battery limits
and providing any certification, including third party, required to install and operate the system.
The BMS, either the BMS panel or the SIS node, shall be implemented in a failsafe SIS certified
as at least SIL 3 capable, according to IEC 61508/61511. In addition functional certification
including the following standards related to burner management systems is required, to provide
confirmation that the SIS is suitable for the BMS application:
• NFPA 85
• EN 50156-1
• EN 298
Any alarm status shall be voltage free and SPDT contact type.
If required by the project, a printer Ink jet or laser type shall be provided and located inside
the UCP cabinet itself.
PCS serial link) to update the time/hour/minutes. The resolution shall not be less than 10ms.
As well as the internal clock shall have a resolution not less than 10ms.
The POS key switches shall be momentary type and spring return; while the MOS key switches
shall be have two stable positions (“Normal” and “Bypass”) with key extractable only in
“normal” position.
For all the time the POS is active the PLC system will light the relevant LED on the Panel for
operator feedback.
In case one input is healthy the request of its bypass eventually requested by the operator
shall be disregarded by the PLC system.
Activation/deactivations of any POS or MOS shall be logged.
About the I/O signals, the PLC design shall take in account the following:
Separate output modules for multiple devices (i.e.: solenoid valves.).
Separate input modules for multiple instruments (i.e. 2 or more independent process
sensors, with 2oo2 or 2oo3 voting logic).
About the F&G I/O signals, in case the F&G will be integrated within the safety system, the
PLC design shall take in account the following:
Separate input and output modules for the F&G detectors/devices from the ESD section.
Separate input modules for multiple instruments (i.e. 2 or more independent sensors
with any voting logic).
4.3.8.19 Relays
The relays (if any) shall be plug in type with hermetically sealed contacts providing the following
characteristics:
Coil voltage: 17÷28 Vdc.
Contact ratting: 1A/24 Vdc.
Contacts arrangement: NO/NC according the functional requirement.
LED of signalling YES.
4.3.8.20 Spares
Spare for UCP shall be based on the following requirements as minimum:
10% spare space available on cable ways.
10% spare terminals inside junction boxes, panels and cabinets (per type of I/O).
10% installed spare for PLC Input/Output (per type of I/O).
30% PLC’s CPU spare capacity.
10% spare conductors per multicables.
Cable ducts inside cabinets shall not be filled more than 70%.
Programming language shall be based on, Boolean, Ladder, Logic-block, or Grafcet language.
The programming language shall be able to support textual descriptions, in order to permit the
CONTRACTOR to define clearly all functions (I/O, internal variable, etc.).
5. DOCUMENT REQUIREMENTS
5.1 GENERAL
At least, and unless different agreement (where PACKAGE SUPPLIER standard can be accepted
if match with project requirements), the CONTRACTOR/PACKAGE SUPPLIER’s document
content shall meet (where applicable), but not necessarily be limited to, the following
requirements:
Arrangement sketches to show all materials involved starting from the local sensing instrument
to the final control device. The relevant support location shall be clearly identified from a
suitable tag reference.
Arrangement sketches and diagrams showing all fittings & wiring required for the pneumatic
and electrical connections of instruments (including F&G detectors/devices), equipment and
panels/junction boxes.
Arrangement drawings of all the terminals inside the junction boxes, cabinets, panels and the
system/equipment involved. These documents will show cable entries, cable cores, terminal
marks, sizes and spacing.
Cable and tubing ways drawings will be developed to cover all the electrical, pneumatic and
hydraulic connections.
This drawing(s) shall also show the location of all instruments requiring
electrical/pneumatic/hydraulic connections, and location of the involved equipment.
A schematic diagram showing the wiring among any component and equipment involved.
A summary of all cables used (including cables, supplied by others, within the limits of the
equipment) to show cable tag, typology, quantity and size of cores, insulation and armouring
and sheath/insulation colouring.
The Instrument List shall be provided for all instruments giving tag number, service and
relevant references.
This document shall be organized by functional units and by instrument typology (pressures,
flows, levels, temperatures, analysers, valves, F&G detectors/devices, etc.).
The Instrument List shall be developed according to the COMPANY Standard
12157.DOC.STA.PRG, MOD.STA.ELN.100.
Inputs/Outputs list shall be provided for all Input/Output signals to/from field electric/electronic
instruments (including F&G detectors/devices) and to/from involved systems (any serial link or
peer to peer connections).
This document will show at least the instrument tag, service description, signal type, alarm
thresholds, range and the setpoint, and all references as requested by COMPANY standard.
This document shall be organized by functional units, by System (Package PLC, Machinery PLC,
etc.) and by instrument typology (pressure, flow, level, temperature, analysers, valves, F&G
detectors/devices, etc.).
The Inputs/Outputs list shall be developed according to the COMPANY Standard
12158.DOC.STA.PRG, MOD.STA.ELN.101.
5.11 DATABASE
The Database configuration will include the loading of all information about instruments,
equipments, systems involved and documents references to be recorded using standard
software (i.e. Excel, Access) on standard support such as CD/DVD disc.
In order to have a complete view of the instrument loop from the field up to the instrument
equipment room and control room, the involved systems (PCS, SIS, or PLC, or SCADA/RTU,
etc.), with relevant marshalling panel if any, will be shown on the same page.
The CONTRACTOR/PACKAGE SUPPLIER shall start to develop this kind of document and shall
complete it with all references (any tag, terminal strip numbering, I/O channel references, etc.)
when these data will be available from the ICSS supplier, from the Package Control/Safety
systems (UCP), and any eventual other SUB-CONTRACTOR(s).
A schematic diagram showing the control and safety sequences logics to handle each
component/equipment (valve, motor, panel, etc.) and any other instrument/device linked to
the Unit Control Panel (UCP).
Any logic shall be developed highlighting all involved hardware and software tag references
with relevant logic status.
The symbols to be used shall be according to ISA standard.
This document shall be organized by functional units, by System (PCS, SIS, etc.) and by site
(if any).
The CONTRACTOR/PACKAGE SUPPLIER shall develop this kind of document with all references
(any tag, function description, etc) in order to allow the Unit Control Panel (UCP) SUB-
CONTRACTOR to implement the relevant software within its equipment.
A detailed Cause and Effect Matrix showing all critical inputs and outputs of the ESD and F&G
system and their specific functions, in the context of the protective philosophy adopted for
the whole supply.
The PACKAGE SUPPLIER shall produce a Functional Design Specification, based also on the
project requirements defining criteria and rules that will be applied to the UCP.
The contents of this document shall reflect what COMPANY has purchased; then the
capability/performances of each equipment/component has to be tailored for the purpose of
this document.
The Functional Design Specification shall provide, as a minimum, the following:
Overview description of the overall system, including detailed block diagram, with a
description of the communications and interaction scheme.
Operational details of the provided systems which have an effect on plant operations,
such as power failure response, communication failure response and automatic
shutdown and start-up of the system (where relevant).
Description of the interface of the involved systems with any equipment via serial link.
References documents of the project.
General description of the overall system (including cabinets, wiring rules and cable
specifications, equipment layouts, etc.).
Overall architecture (when more machines are purchased) and UCP architecture
showing all involved equipments/components.
Details of UCP’s Control system section including all hardware components.
The PACKAGE SUPPLIER shall supply documentation for all software provided with its systems.
The documentation shall include, but not be limited to, the followings:
An inventory of all software and software documentation to be provided.
Functional descriptions of the involved sequence.
Detailed operating instructions.
Database descriptions.
Program logic description.
Memory requirements for logic and data.
Execution timing information.
PACKAGE SUPPLIER shall provide for each type of equipment a complete set of acceptance
tests certificates composed by test procedure books and relevant tests data sheets.
The sets shall be issued for the Factory Acceptance Test (FAT), the site tests as well as for the
commissioning. The documentation shall be submitted for approval before any test start.
The above mentioned documentation shall be a reference for the subsequent maintenance
operations.
The test procedures shall include as a minimum:
Specification parameters.
Test instrument(s) to be used.
Results to be expected.
Reference to the test data sheets.
PACKAGE SUPPLIER shall provide the final technical documentation either in the native
electronic format (i.e.: autocad, word, excel, etc.) and paper standard sizes according to
project requirements.
The design and tests documentation shall be part of the final documentation.
The final documentation shall be subdivided into three (3) groups:
1. Design and Certifications Manual, including:
Package Design documentation.
Certificates of equipment and components
Certificates relating to tests.
2. Installation and Construction Manual, including:
Description of the installation procedures.
3. Operating and Maintenance Manual, including:
Description of start-up modalities.
Description of utilisation modalities.
Description of each equipment/system used.
Instructions and procedures for the periodic and corrective maintenance to take out and
replace all components and accessories included in the spare parts list.
Instructions of estimative maintenance, with the schedule of inspection programs.
Electric and topographic diagrams of the units.
List of components and consumables, with all necessary data for spare parts
procurement (name and material codes).
6. INSPECTION REQUIREMENTS
6.1 GENERAL
No equipment or materials shall be delivered until all applicable tests have been completed and
all defects rectified and re-tested successfully.
COMPANY reserves the right to witness testing or to request additional testing according to its
requirements. Such witnessing shall include all components and equipment included inside the
supply.
The PACKAGE SUPPLIER shall notify CONTRACTOR / COMPANY of the detailed requirement for
the Inspection and Test Plan (ITP).
PACKAGE SUPPLIER shall be responsible for the inspection and quality assurance / quality
control of materials and equipment and for the standard of the workmanship.
A quality dossier shall be submitted complete with certificates and test results.
In addition the quality dossier shall include database access schemes required for interfaces.
PACKAGE SUPPLIER shall allow COMPANY or their representatives to review system and
documentation at any stage of design and assembly.
All formal testing will be conducted in accordance with approved test procedures.
PACKAGE SUPPLIER shall attach a detailed description, under procedure form, of all tests to
carry out on the supply in subject during the bidding phase.
Each procedure shall be referred to a single test and shall contain at least the following items:
Scope of the test.
Execution method (procedure).
Equipment and devices used.
Criteria and limits of acceptance. The acceptance limits must be according to the
specification including the international standards.
Part of the system, or unit, to which the procedure is applicable.
PACKAGE SUPPLIER shall submit the procedures for approval at least six weeks prior to
commencement of testing.
Test procedure shall define the surveillance level for each test (100%, 1 lot, spot check, etc.)
based on the criticality of the equipment to be tested.
The result of each test can be satisfactory, not conform or pending.
In case of not conformity points, recovery actions shall be identified by the PACKAGE SUPPLIER
to solve the problems.
In case of pending points, action shall be identified by the PACKAGE SUPPLIER or by the
CONTRACTOR to clarify the matter.
PACKAGE SUPPLIER shall provide skilled manpower, all standard and special tools, test and
calibration equipment necessary for FAT, site installation, SAT, and commissioning in order to
maintain the system and equipment to its maximum reliability.
PACKAGE SUPPLIER shall conduct a test on the supplied equipment at its factory during which
CONTRACTOR/COMPANY and/or their representatives shall inspect and witness the test before
all the equipment is approved for shipment.
The FAT will be carried out on the Package completely assembled and integrated.
PACKAGE SUPPLIER shall provide temporary cables to connect the various sections of the
systems, devices and simulation software necessary to test the system as if it were installed
on site.
PACKAGE SUPPLIER shall confirm the readiness of the FAT to COMPANY at least 2 weeks in
advance after ensuring that the system is fully functionally configured and tested.
PACKAGE SUPPLIER shall ensure adequate time, space, facilities, and test equipment,
engineering and support personnel to enable satisfactory testing.
One set of all approved drawings, documents, configuration printouts of latest revision and test
reports of various system and I/O cards and peripherals used to configure each UCP shall be
made available during the test.
PACKAGE SUPPLIER shall furnish complete internal QA/QC checklist and documents before FAT
to ensure internal checks of the following tests are done by PACKAGE SUPPLIER before client
FAT.
PACKAGE SUPPLIER shall perform the following tests during the FAT as a minimum:
Visual/dimensional Check.
Power up and initialization.
Power failure and recoveries.
Redundancy test for backup controllers, power supply, communication systems, I/O
cards and operator consoles.
Integrated test of all involved system.
Synchronisation test of all involved systems via GPS.
The test required inside the IDS and ITP.
Total system reboot.
Hardware/software inventory.
Diagnostic test.
RFI protection.
Functional loop checking (100% signals).
Custom application programs and sequences test.
Logic test.
Graphics & Alarm list Check.
Interface test.
Any other test(s) as per project requirements.
Attendance test c/o plant PCS premises for the communication test. This test has the
purpose to verify that the link PCS-PLC will work properly in terms of read/write and time
synchronization. Since is unknown when and where this test will be performed, this test has to
be quoted at unit rate.
SAT procedure (derived from the FAT procedure) shall be submitted by the PACKAGE SUPPLIER
for COMPANY/CONTRACTOR approval.
All the equipment shall be checked on site to verify the System integrity after shipment and
installation.
The checks shall include as a minimum:
Visual and mechanical check.
Power/Earthing connections check:
After System installation and wiring is completed, PACKAGE SUPPLIER’s supervisor(s)
shall check that power supply and earthing connections are executed in a proper way,
according to the SUPPLIER's recommendations, before powering the System. The UPS
effects on the System shall also be checked.
Equipment functionality check:
The purpose is to check that all the equipment such I/O cards, controller modules,
VDU's, printers, hardwired instrumentation, etc. are working properly.
The correct changeover of redundant devices shall also be checked.
PACKAGE SUPPLIER shall provide suitable personnel to conduct this test when requested by
COMPANY during the construction phase.
7. SPARE PARTS
At least, and unless different project requirements, the supply shall include:
The spare parts for Commissioning and Start-up.
The spare parts list for two years of continuous operation.
PACKAGE SUPPLIER shall submit a list of these spare parts with the bid.
PACKAGE SUPPLIER shall guarantee to support all spare parts supplied as minimum for the
project duration life following the written announcement of product withdrawal.
These spare parts shall be utilised for Erection, Pre-Commissioning, Commissioning and Start-
up. They are included in the scope of supply.
All spare parts used during the warranty period shall be replenished at PACKAGE SUPPLIER’s
expense.
PACKAGE SUPPLIER shall provide the typology and quantities of consumables spare parts based
on his experience.
PACKAGE SUPPLIER shall supply the typology and quantities of spare parts for Commissioning
and Start-up based on his experience.
The spare parts list for two years of continuous operation shall include the quantities
(reccomended by PACKAGE SUPPLIER) and shall be estimated by PACKAGE SUPPLIER based
on his experience. This supply shall be foreseen and quoted in the bid as optional.