BK4A-001-TS-IA2-SP-01_B_Specification for Safety Integrated System SIS _FGS-SDS_ Markup

OWNER: VIETSOVPETRO

CONTRACTOR: PETROVIETNAM ENGINEEING

CONSULTANCY CORPORATION

PROJECT NAME :MODIFICATION AT WHITE TIGER FIELD TO RECEIVE GAS FROM THIEN UNG, DAI HUNG FIELDS

SUB-PROJECT NAME : BK4A PLATFORM

DOCUMENT TITLE : SPECIFICATION FOR SAFETY INTEGRATED SYSTEM SIS (FGS/SDS)

DOCUMENT No. : BK4A-001-TS-IA2-SP-01

B Re-Issued for Review

22/02/2014 CAT LVD NNT

A Issued for Review 07/01/2014 CAT LVD NNT

REV. DESCRIPTION DATE PREPARED CHECKED APPROVED CHECKED APPROVED

PVE VSP

MODIFICATION AT WHITE TIGER

FIELD TO RECEIVE GAS FROM THIEN UNG, DAI HUNG FIELDS

BK4A PLATFORM

SPECIFICATION FOR SAFETY INTEGRATED SYSTEM SIS (FGS/SDS)

Doc. No BK4A-001-TS-IA2-SP-01

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TABLE OF CONTENTS 1.0 INTRODUCTION 4 2.0 SCOPE 4 3.0 CODES AND STANDARDS 4 4.0 DEFINITIONS & ABBREVIATIONS 6 5.0 ENVIRONMENTAL CONDITIONS 7 6.0 AREA CLASSIFICATION 8 7.0 UTILITIES SUPPLIES 8 7.1 INSTRUMENT AIR 8

7.2 ELECTRICAL SUPPLIES 8

8.0 DIMENSION, WEIGHT, HEAT DISSIPATION AND POWER CONSUMPTION 9 9.0 GENERAL REQUIREMENTS 9 9.1 DESIGN LIFE 9

9.2 OVERALL CONCEPT 9

10.0 SCOPE OF SUPPLY 10 10.1 GENERAL 10

10.2 VENDOR'S RESPONSIBILITIES 11

10.3 VENDORS SCOPE OF WORK 14

11.0 FUNCTION DESCRIPTION FOR SIS 16 11.1 GENERAL 16

11.2 SIS PHILOSOPHY 19

11.3 SYSTEM HARDWARE AND SOFTWARE REQUIREMENTS 21

11.4 INPUT/OUTPUT MODULES 25

11.5 SYSTEM TESTING AND DIAGNOSTICS 29

11.6 OPERATOR INTERFACE 30

11.7 ENGINEERING & MAINTENANCE WORKSTATION (EWS) 30

11.8 COMMUNICATION TO PCS 31

11.9 INTERFACE WITH OTHER SYSTEMS 32

11.10 SEQUENCE OF EVENT RECORDING (SER) 32

11.11 PUSHBUTTONS/SWITCHES/LAMPS 33

11.12 OVERRIDE SWITCHES 33

12.0 GENERAL SIS SYSTEM REQUIREMENTS 33



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12.1 SYSTEM CABLES & CABLE ACCESSORIES 34

12.2 SYSTEM AND MARSHALLING CABINETS 34

12.3 SYSTEM RELIABILITY AND AVAILABILITY 39

12.4 INSTALLED SPARES 39

12.5 EARTHING 40

12.6 SYSTEM INTEGRATION 40

13.0 INSPECTION AND TESTING REQUIREMENTS 41 13.1 SCOPE 41

13.2 INSPECTION 42

13.3 TESTING FACILITIES 43

13.4 PREPARATION FOR TESTS 43

13.5 FACTORY ACCEPTANCE TEST (FAT) 44

13.6 SYSTEM TEST 51

13.7 SITE ACCEPTANCE TEST (SAT) 52

13.8 DOCUMENTATION FOR INSPECTION & TESTING 53

13.9 SPARE PARTS AND SPECIAL TOOLS 54

14.0 VENDOR ASSISTANCE AND SERVICES 55 14.1 PRE-COMMISSIONING AND COMMISSIONING 55

14.2 ONSHORE & OFFSHORE SUPPORTS 55

14.3 TRAINING 55

15.0 DOCUMENTATION REQUIREMENTS 56 15.1 GENERAL 56

15.2 SPECIFIC REQUIREMENTS 57

16.0 PACKING AND SHIPPING 58 17.0 PERFORMANCE GUARANTEE 59 18.0 QUALITY ASSURANCE 60 19.0 HEALTH, SAFETY AND ENVIRONMENTAL REGULATIONS 61



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1.0 INTRODUCTION

The BK-4A riser platform is located in the White Tiger Oil Field, approximately 145km South-East of Vung Tau City of Vietnam. The BK-4A riser platform is connected to the existing BK4 platform via linking bridge.

The BK-4A riser platform consists of topside and jacket. It is able to receive gas - condensate at low pressure condition from the Thien Ung Platform (BK-TNG) via NCS-2 pipeline (phase 1) and transport to BK-4 riser platform via linking bridge. One Pig receiver 26" is installed on the topside of BK-4A platform to receive pig launched from BK-TNG platform via the NCS-2 pipeline (Phase 1).

2.0 SCOPE

This specification covers the minimum requirements for the design, manufacture, painting, inspection and testing, delivery and installation supervision of the SS (Safety Integrated System) for BK-4A platform.

3.0 CODES AND STANDARDS

In general, the SIS shall be designed as per the following standards, codes and practices (latest revisions), in the order of preference: Vietnam Government Statutory Regulations International Standards

INTERNATIONAL CODES & STANDARDS

Reference Title API RP-14C API RP-14FZ

Recommended Practices for Analysis, Design, Installation and Testing of Basic Surface Safety Systems on Offshore Production Platforms. Design and Installation of Electrical Systems for Fixed and Floating Offshore Petroleum Facilities for Unclassified and Class 1, Zone 0, Zone 1 & Zone 2 Locations.

BS 1259 Specification for Intrinsically Safe Electrical

Apparatus and Circuits.



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BS 5308-1 Instrumentation Cables - Specification for

polyethylene insulated cables

BS 5345 Selection, Installation and Maintenance of Electrical Apparatus for use in Potentially Explosive Atmospheres (Part 1, 2, 3, 4, 6 and 8).

BS 5501 IEC 60079 IEC 60331 IEC 60332 IEC 60381 IEC 60508 IEC 60529 IEC 60801 IEC 61000 IEC 61131-2 IEC 61131-3 IEC 61499 IEC 61508 IEC 61511

Electrical Equipment for Potentially Explosive Atmospheres (Part 1,5,6,7,9) Electrical Apparatus for explosive gas atmospheres. Fire resisting characteristics of electric cables. Tests on electric cables under Fire Conditions. Analogue Signals for Process Control Systems. Functional Safety of Electrical /Electronic / Programmable Electronic Safety related Systems. Degrees of Protection provided by Enclosures (IP Code). Electromagnetic Compatibility for Industrial Process Measurement and Control Equipment (Parts 2, 3 & 4) Electromagnetic Compatibility (EMC) Programmable Controllers - Part 2: Equipment Requirements and Tests. Programmable Controllers - Part 3: Programming Languages. Functional Blocks Functional Safety of Electrical / Electronic / Programmable Electronic Safety-Related Systems Functional Safety Safety Instrumented Systems for the Process Industry Sector.

IEC 61892 Mobile and Fixed Offshore Units Electrical



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Installations IEEE Protocol Standards NFPA 70 - 2011 Edition National Electrical Code NFPA 72 - 2013 Edition National Fire Alarm and Signaling Code

4.0 DEFINITIONS & ABBREVIATIONS

The following terminology and abbreviations are used throughout this document:

1oo2D API BS

One out of two Devices with Diagnostic (Voting Technique) American Petroleum Institute British Standards

BDV CCTV CIST CPU DEG DIN EMI

Blowdown Valve Closed Circuit Television Composite Instrument System Test Central Processing Unit Diesel Engine Generator German Industrial Standards Electromagnetic Interference

ESD ESDV

Emergency shutdown Emergency shutdown with Ventilation

EExd Flame-proof Safety EExe EExi EWS

Increased Safety Intrinsic Safety Engineering Workstation

FAT FGS GEG GPA GPS

Factory Acceptance Test Fire and Gas System Gas Engine Generator General Platform Alarm Global Positioning System

HMI HPU

Human Machine Interface Hydraulic Power Unit

IEC IER I/O IPF IS ISO

International Electro-technical Commission Instrument Equipment Room Input and Output Instrumented Protective Function Intrinsically safe International Standards Organization

MC MOS MOS-ENA MOS-IND

Marshalling Cabinet Maintenance Override Switch Maintenance Override Switch Enable Maintenance Override Switch Individual



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NIS Non Intrinsically Safe OPC OPS OWS

OLE for Process Control (open connectivity via open standard) Operator Pushbutton Station Operator Workstation

PLC PCS PSD

Programmable Logic Control Process Control System Process Shutdown

RAM RFI SAT

Random Access Memory Radio Frequency Interference Site Acceptance Test

SSIV Subsea Isolation Valve SDV SDS SER SIL

Shutdown Valve Shutdown System Sequence of Event Recorder Safety Integrity Level

SIS SOS SOS-ENA SOS-IND

Safety Instrumented System Start-up Override Switch Start-up Override Switch Enable Start-up Override Switch Individual

TV UPS USD VDU VFC

Technischer Uberwachungs Verein Uninterrupted Power Supply Unit Shutdown Visual Display Unit Voltage Free Contact

5.0 ENVIRONMENTAL CONDITIONS

All SIS equipment shall be suitable for operation on offshore platforms. They shall be suitable for continuous and short time duty, in the environmental conditions prevailing at site, without temperature rise of any part of the Instrument & Control equipment exceeding the maximum permissible temperature rise values stipulated in the relevant IEC standards listed herein. The design environmental and climatic data are summarized below: Atmosphere Humid and salt laden.

Temperature Maximum ambient temperature 36C

Average ambient temperature 25C

Minimum ambient temperature 14C

Humidity Minimum, 65% Average, 85% Maximum, 94%



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Indoor Temperature

(IER)

Maximum, 27C

Minimum, 18C

6.0 AREA CLASSIFICATION

All field electronic instruments & electrical accessories used shall be ATEX certified for use in Hazardous area: Zone 1, Gas Group IIA, T3 Area. All electrical components and equipment enclosure shall be in accordance with IEC 60529 and as follows: Minimum IP 56 for outdoor installations. Minimum IP 44 for installations inside enclosed rooms. Hazardous area certification shall be in accordance with ATEX, by approved bodies such as CENELEC, BASEEFA, etc.

7.0 UTILITIES SUPPLIES

7.1 INSTRUMENT AIR

Pneumatics supply to Actuated Valves shall be instrument air supplied from the Platform Instrument Air System.

Each instrument air supply shall be fitted with an isolation valve in the supply line.

The instrument gas supply pressure is as follows: Minimum : 4.2 barg Normal : 5 ~ 6.5 barg Maximum : 8 barg

Each instrument/ valve requiring instrument air supply shall be provided with individual filter regulator and isolation valve.

7.2 ELECTRICAL SUPPLIES

The COMPANY/PURCHASER will make available the following electrical power supplies:



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- 220V AC (+/- 10%), 1 Phase, 50 Hz (+/- 5%) UPS and normal

- 380V AC (+/- 10%), 3 Phase + N, 50 Hz (+/- 5%).

- 24V DC (+/- 10%) from PLC cabinets for instruments, max output 2A.

The AC-UPS will be supply by VENDOR and will be sized to supply enough power for PCS at least 30minutes of operating time and SIS at least 90 minutes of operating time upon all working conditions.

8.0 DIMENSION, WEIGHT, HEAT DISSIPATION AND POWER CONSUMPTION

The VENDOR shall ensure that an accurate estimate of equipment dimension, weight, power consumption and heat dissipation information, required and spare space for BK-4A platform and expansion space for BK-4 platform installed in the future are submitted in the VENDORs bid documents. Any variations to the calculated figures made during the course of detail design shall be made known to the COMPANY/PURCHASER as soon as they have been identified.

9.0 GENERAL REQUIREMENTS

9.1 DESIGN LIFE

The design life for the project shall be minimum 25 years.

9.2 OVERALL CONCEPT

Following are the major instrument systems provided for BK-4A system: An electronic microprocessor based PCS system, which carries out the functions of

Platform Process Control and Monitoring of BK-4A.

An Safety Integrated System (SIS) - electronic microprocessor based safety PLC SIL 3 SIS system conform to IEC 61508, which covers Safety shutdown as well as platform Fire & Gas detection for BK-4A. The SIS will be an unique and totally integrated system which has Safety Shutdown (SDS) and Fire Gas (FGS) functions.

PCS and SIS will communicate through one common Industry Redundant Network as

in Doc. No BK4A-001-TS-IA2-DW-01 Control Archiecture Block Diagram. PCS and SIS will synchronize time between 2 system through this Industry Redundant Network.

For PCS system: CPU shall be Redundancy, Communication Card shall be

Redundancy, non-critcal I/O signals will be installed in non-redundancy I/O cards, critical I/O signals will be installed in redundancy I/O cards. (refer to Doc. No. BK4A-001-TS-IA2-LST-03 IO List for PCS for non-critical and critical I/O signals)

Mr HaRectangle

Mr HaCallouta vo spec cho PCS



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For SIS system: CPU will be certificated SIL 3 or AK6, all CPU, Communication Cards and I/O card shall be redundancy (fully redundancy)

All transmitters, F&G equipments conneted to SIS System of BK-4A platform shall be

certificated to SIL 2

PCS and SIS shall be operated through 2 common PCS/SIS Operation Workstations (PCS/SIS OWS) and share the same Engineering Workstation (PCS/SIS EWS) as in Doc. No BK4A-001-TS-IA2-DW-01 Control Architecture Block Diagram.

2 black-white printers (one Report printer, one Alarm printer) will be installed to service

for PCS/SIS operating works. PCS system and SIS system of BK-4A platform will be installed and located in BK4s

control room. Due to limit space on BK-4s control room, cables from field instruments for SIS and

PCS will be consider to go directly to system cabinets, not through marshalling cabinet (marshalling cabinet will be omitted for this project).

Required Space for installing PCS and SIS for BK-4A platform, and enough reversed

capacity and space for expansion for BK-4 platform (PCS and SIS) in the future. Shutdown and Blowdown philosophy for this project shall follow offshore standard

DNV-OS-A101 Safety principles and arrangements.

10.0 SCOPE OF WORK

10.1 GENERAL

This Specification defines the minimum requirements for the engineering, manufacturing and delivery including but not necessarily limited to the design, manufacture, material procurement, fabrication, documentation, inspection, testing, training, installation and commissioning of the Safety Integrated System (SIS) in accordance with this Specification. The manufacture, supply, testing and installation of the SIS system will consist of the following: - All equipment required for BK-4A standalone operations.

All materials and equipment supplied for BK-4A shall meet the design and environmental conditions as stated in this Specification (section 5.0) and shall be new, sound, free of defects and of the quality as specified herein.



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The SIS shall be supplied as a completely pre-wired and tested system. VENDOR shall note that all accessories should be supplied as a completely assembled unit to meet the operation requirements. VENDOR is expected to make optimum use of his standard range of equipment to meet the functional requirements as stated in this Specification. To the extent possible and practical, the system supplied shall be based on VENDOR's standard hardware and software, avoiding any special or customised design for this particular installation. In case where special design cannot be avoided, the description shall positively state so in VENDOR's proposal, otherwise it is taken that VENDOR's standard design is provided. VENDOR shall supply only equipment which is field proven. No prototype of any kind is permitted. VENDOR shall have experience supplying 3 or more systems each of which with at least 5 years of continuous operation in offshore environment. These systems shall be of similar configuration to the proposed system. Any omissions from the Specification shall not relieve VENDOR of his responsibility to provide a system complete with the intent of this Specification. Where cost effective alternatives are offered, they shall be fully described and must be accompanied by all pertinent engineering information to facilitate evaluation of alternative. It is VENDORs responsibility to inform the COMPANY/PURCHASER of any deviations from or exceptions to this Specification and the listed Codes and Standards. VENDOR shall furnish deviations/exceptions (if any) in the typical format enclosed. Non-listing of deviations/exceptions during bid stage by VENDOR will construed as being in full compliance with this Specification, codes and standards listed.

10.2 VENDOR'S RESPONSIBILITIES

10.2.1 Single Point Responsibility

VENDOR shall assume single point responsibility for all aspects of the work. This shall include timely completion, liaison with the COMPANY/PURCHASER, liaison with any vendor/sub-vendor of specialised items, co-ordination of the work, performance guarantee and provision of a warranty for the system. Where parts of the system are subcontracted and purchased by VENDOR, these become part of VENDOR's package and it is VENDOR's responsibility to ensure that the complete package complies with all the relevant specifications.

10.2.2 Quality / Performance

VENDOR shall provide quality guarantees/warranties for the systems. VENDOR shall be responsible to provide all necessary hardware/software based on documents/ drawings given



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by the COMPANY/PURCHASER. VENDOR to note that COMPANY/ PURCHASER supplied documents/drawings are not 100% correct or complete and need further work as necessary. It shall be the responsibility of VENDOR to inform COMPANY/PURCHASER of any errors, ambiguities, inconsistencies or discrepancies which may be found to exist in any documents, specification or drawings given by the COMPANY/PURCHASER.

10.2.3 Engineering

After award of order and prior to commencing detail manufacture, VENDOR shall produce a Functional Design Specification (FDS) for the systems for approval by COMPANY/PURCHASER. The FDS shall provide all information necessary to define the systems in detailed e.g. the equipment to be supplied, the levels of redundancy, the layout of systems, systems network diagram, cabinet layouts, power arrangements, processor loading calculations, communications calculations, graphic displays, etc. The FDS shall be issued for COMPANY/PURCHASER review within six (6) weeks after firm order. The FDS shall be updated from time to time as the project progress and shall be submitted to COMPANY/PURCHASER for approval according to agreed project milestones. VENDOR shall seek COMPANY/PURCHASER's approval to any required changes. VENDOR shall prepare the engineering level definition i.e. Functional Logic Diagram (FLD) shall be in accordance to IEC 61131/or ISA standard format reflecting all the required logics for his system design based on P&IDs and Cause and Effect Matrices provided by COMPANY/PURCHASER. VENDOR shall liaise with COMPANY/PURCHASER for final requirements. VENDOR shall include adequate and easy to understand, annotations to the FLDs to facilitate maintenance of the logic. Annotation provided shall be to COMPANY/PURCHASERs satisfaction Special purpose logic design tools that convert Cause and Effect Matrices to FLD and SFC (sequential flow charts) automatically shall be available for use in the engineering software. VENDOR's responsibility shall include checking proper receipt of all documents and checking the drawings provided by the COMPANY/PURCHASER and advise the COMPANY/PURCHASER of any omission or incorrect design, so that the complete system supplied will function reliably and provide trouble free service throughout its life. COMPANY/PURCHASER shall be providing field cable termination drawings after award. VENDOR shall review the termination and provide additional information as required for correctness and completeness of the termination drawings. VENDOR shall ensure that arrangement and labeling of the terminal blocks in accordance with the termination drawings. VENDOR shall supply terminal blocks to terminate all field cables as shown in the termination drawings VENDOR shall submit the relevant detailed fabrication drawings and wiring diagrams for approval by the COMPANY/PURCHASER before proceeding with the fabrication work.



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This Specification does not attempt to detail all VENDOR supplied hardware, software or items of equipment that will be needed for the systems to perform all the functions specified herein. The responsibility for ensuring that the systems will be fully operational within the intent of this Specification rests solely with VENDOR.

10.2.4 Project Management and Services

VENDOR shall be responsible to set up a proper project organisation consisting of project manager, system engineers, technicians and services to ensure smooth operation of the project after award. VENDOR shall also be responsible to set-up project procedures in accordance to ISO9001/2. VENDOR shall submit project organisation chart for approval during bid proposal. Change in any personnel after award shall be subjected to COMPANY/ PURCHASER approval. VENDOR shall submit in his bid resume of all personnel (project manager, system engineers, test engineer, training instructor, etc.) in bid proposal for COMPANY/ PURCHASER reviews. VENDOR shall submit in his bid proposal the manpower workload and facilities capacity to meet the project schedule. A monthly work progress report shall be submitted to the COMPANY/PURCHASER indicating the percentage of work completed, portion of work currently in progress and highlighting any constraints that may exist.

10.2.5 Successful Interface with Other Systems

This refers to instance where the SIS system is required to interface to other third party systems at VENDOR works, at third party vendor factory, at fabrication yard or at offshore. The interfaces shall be tested and verified at the first possible opportunity. VENDOR shall be responsible for liaising with various third party system vendors (PCS, F&G devices etc.) and provide all necessary information to enable them to configure their system for successful implementation of the data exchange and monitoring and control of these third party systems. VENDOR to arrange and perform the integrated test at VENDORs facility to ensure for successful interfaces. In the event where VENDOR shall ship the SIS portable test kit to the other vendors factory to perform the test to verify that the system can satisfactorily interface with the SIS, the costs arising from this test, including any modification, packing, unpacking, mobilisation and demobilisation of personnel, etc. shall be borne by VENDOR. VENDOR to provide quote for interface test to each third party package. VENDORs scope shall include technical clarifications with the third party vendors, either by fax, telephone, email, travelling, etc. as appropriate. VENDOR shall provide timely information



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or request required information so as to prevent delays to delivery of the packages and the SIS system.

10.3 VENDORS SCOPE OF SUPPLY

VENDOR's scope shall include but not limited to the following: i) Design, engineering, perform system configuration, manufacture, fabricate, assemble, test,

supply and deliver the complete system, including all required ancillary equipment and cabinets as defined in this Specification and as necessary for the satisfactory operation of the SIL 3 SIS system. This shall also includes responsibility for the selection of components required to perform the functions described, configuration of I/Os, configuration of communications, configuration of application logic, trip setting, timers, graphic, etc.

ii) List of major equipment for SIS system shall not be interpreted as limit of VENDORs scope

of supply.

(a) One (1) lot standalone SIL 3 SIS / IEC 61508 system and system cabinets c/w all necessary hardware and software, processor modules, I/O modules, communication modules, power supply modules, I.S. isolators (if required), terminal assemblies, cables, cable ducts, earth bars, lighting etc. to be installed in Control Room of BK-4 platform with control capacity is design for expansion for BK-4 platform control system in the future.

(b) One set of Lamp test buttons, Acknowledge pushbuttons, Reset buttons, and Fire Gas

light alarms, Buzzer, EDS button installed on the SIS system cabinet door at BK-4s control room

(c) One (1) set of PCS/SIS Engineering & Maintenace Workstations (PCS/SIS EWS) (to be

share used for programming with PCS) fully assembled c/w all required softwares for SIS system engineering and maintenance including SER software. VENDOR shall also provide process control network port for EWS connection. Life time licence validity for the software and latest version.

(d) Two (2) PCS/SIS Operator Workstation (PCS/SIS OWS) including all required hardwares and softwares for the operation and monitoring of SIS. The PCS/SIS OWS will be use in share for PCS and SIS operating works.

(e) One (1) lot of Dual redundant Industrial network equipments, network cables, glands and all accessories.

(f) One (1) lot of cables (system cables, etc.) c/w connectors, glands and accessories.



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(g) One (1) lot of dual redundant serial link interface units for interface with PCS systems, including serial link cables, interconnecting cables, connectors, glands, etc. VENDOR to provide unit price for the serial link cables.

(h) Two (2) set of laser Black-white printer with Ethernet interface port (one as Report Printer, one as Alarm Printer)

(i) All other equipment to complete the scope

iii) All engineering and wiring of the system cabinets, network systems, system cables and

accessories required. Vendor will base on the supplied I/O list and available space of BK4s control room to finalized the dimension and number of system cabinets to be supplied suitable for the project (with counting of the reserved capacity for future PCS, SIS I/O extension for BK-4 platform). System cabinets shall be supplied complete with terminals installed.

iv) Supply of complete system software, application programs, software lifetime licences and

documentation. Antivirus software with genuine license shall be supplied by VENDOR.

vi) Supply of end-of-line devices required for field circuit monitoring. vii) Supply of spare parts for start-up and commissioning including complete set of special

tools required for testing and maintenance purposes. Supply of spare parts list for two years operation.

viii) Supply of all drawings and documentation as well as that required for installation, pre-

commissioning, operations and maintenance functions. VENDORs documentation shall include but not limited to all inter-cabinet wiring diagrams, FLDs, loop drawings, etc. Documents and drawings submitted in the VDRL proposed by Vendor.

ix) Provision of training of systems software and hardware for COMPANY's engineering,

operations and maintenance personnel. x) Engineering and collaboration with third party system suppliers for total system integration

to the systems. xi) Involvement with and provision for factory inspections and tests witnessed by the

COMPANY/PURCHASER. This shall include the preparation of all required test procedures, test facilities and performance of the Factory Acceptance Test (FAT) and Integrated Test at VENDOR's or third party system manufacturing facility.

xii) Preparation, preservation and packing of the supplied equipment to the fabrication yard. xiii) Provision of installation, testing, pre-commissioning and commissioning support at the

fabrication yard leading to a Site Acceptance Test (SAT) for the systems.



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xiv) Provision of commissioning support at offshore for commissioning of the fully integrated system, including interfaces to/from other systems

xv) Involvement with and provision for Composite Instrument System Test (CIST) with PCS

package at PCS premises and the test procedures for the systems. xvi) Supply of consumable for system testing and commissioning at VENDORs facilities,

onshore fabrication yard and offshore. xvii)Provision for technical support personnel to be stationed after commissioning.

11.0 FUNCTION DESCRIPTION FOR SIS

11.1 GENERAL

11.1.1 Choice of Technology

The SIS shall be a standalone fault tolerant SIL 3 PLC based system with minimum 1oo2D architecture. The PLC shall be TV AK6 approved and shall conform to the requirements of SIL 3 to IEC 61508. The TV certification shall include input and output modules, central processors, I/O bus., etc. VENDOR supplied equipment shall have EMI/RFI suppression and shall meet all electromagnetic compatibility requirements of IEC 61000-6-4.

11.1.2 Main Functional Role

The SIS consist of an Integrated combined system of SDS and FGS function which shall provide all Shutdown and Fire Gas functions necessary to monitor the selected process and utility parameters and safeguard the platform from abnormal situations. a) SDS functions

The following SDS functions shall be supported as minimum: Monitoring of process and plant operational limit conditions as per Process Cause & Effect

Matrices Executive control (manual and automatic) Sequence Event Recording (SER) Reporting and operator communication via the PCS/SIS OWS Initiation of ESD-2 and PSD (Refer to Doc BK4A-001-TS-TX1-SH-01 Process shutdown

Hierarchy Diagram for more details of Scope of Work of SIS system for this BK4A project) . Initiation of sounders and beacons alarms.



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The safety functions shall be design to be fail-safe such that: System faults shall not in themselves causes an unwanted action and such faults shall be

revealed occurrence Unrevealed faults (faults detected when system is called upon to operate) which will

prevent an executive action from taking place in the event of a genuine trip input shall be minimized as much as possible

No single fault shall prevent the system from working as normal (i.e. no common mode failures)

b) FGS functions The following FGS functions shall be supported as minimum:

Fire detection Gas detection Status indications and alarm (via PCS/SIS OWS) Maintenance Override Switch (MOS) Implementation of maintenance override switch (MOS). For voting configuration, negative

MOS shall be implemented as per the company's requirement. Implementation of open-circuit and short-circuit protection logic. Loop monitoring / supervised I/O Logic implementation of manual/auto/off of final element Initiation of sounders and beacons alarms.

All Fire & Gas input and output circuits shall be normally open or de-energized (unless otherwise specified) to avoid spurious executive actions. All normally open or de-energized circuits shall be monitored by the SIS for open and short-circuits. All self-check result and faults shall be made available at the PCS/SIS EWS workstation, PCS/SIS OWS. The SIS shall be design and configure as follows: Utilize dedicated and independent I/O modules and I/O rack for SIS functions. I/O modules

shall not be shared with PDS Utilize dedicated and independent terminals, wiring and connectors (i.e. allow easy

identification, modification, replacement and operation)

11.1.3 Operation Interface Concept

The SIS will be interfaced to PCS/SIS OWS, which will act as the main operator interface for the SIS system. All shutdown and common system alarms, analogue detector values, override/status indications, etc. from the SIS will be displayed/ annunciated on the PCS/SIS OWS. Fire Gas status overviews, zones, detectors layout, etc. shall also be displayed on the PCS/SIS OWS.



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All alarm, tripping, indication, status signal will be send to PCS/SIS OWS for operating works.

11.1.4 Maintainability

The SIS shall have comprehensive self-test and diagnostics facilities. All faults shall be identified, alarmed and reported. The diagnostics shall clearly identify the faulty module. The results of diagnostics shall be made available to the PCS/SIS EWS and communicated to the PCS/SIS OWS. The SIS shall also permit remote system monitoring and diagnostics via the communication link. VENDOR shall elaborate in his proposal how this is achieved. The SIS shall require minimal or no manual intervention. The automatic reconfiguration upon replacement of card shall be a standard feature. Hot replacement of module shall be possible without any special tools. Inadvertent installation of module in wrong slot shall be impossible. The SIS shall have the capability of on-line software download from the EWS without shutdown of the process. Live download shall require hardwire key-switch and security password to avoid unauthorised access. VENDOR to indicate in his proposal any limitation of on-line software download.

11.1.5 Off-The-Shelf Components

None of the modules shall be custom built. All modules used shall be VENDOR standard off-the-shelf items. VENDOR shall design the system in such a way as to minimise the number of different types of modules.

11.1.6 High Reliability, Availability and Fault Tolerant

The SIS shall be of high reliability and maximum availability. The overall SIS availability shall be better than 99.999%. The SIS shall be robust to suit the environment and application. The SIS shall have redundancy such that a single failure shall not cause system malfunction and shutdown. It shall be possible to replace any faulty module on-line without interrupting the normal operation of the system. Redundancy The SIS shall employ redundancy techniques for the following items: Power Supply modules (minimum dual redundant) Central Processor Unit modules (minimum dual redundant) I/O Modules (dual redundant) Power supply units (dual redundant)



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Communication Modules (dual redundant) Redundant modules shall be powered up in standby mode. Empty hot standby modules are NOT ACCEPTABLE. System shall be configured such that any loss in redundancy due to I/O or CPU module failure shall not reduce the SIL rating of the system. The system shall be allowed to continue for 'unlimited' time without any restricted from TUV.

11.1.7 NE Failsafe Circuits, Supervised NDE Circuits

Type of input and output circuits, either Normally Energised (NE-failsafe) i.e. de-energised to trip or Normally De-energised (NDE- Non - failsafe) supervised, shall be as per the I/O List.

11.1.8 Modular, Scalable and Flexible

The SIS shall be of modular design for easy maintenance and future expansion and modification. Reserved space and capacity for future expansion for BK-4 platform control system (PCS and SIS) will be supplied and given out by SIS Vendor.

11.1.9 Autonomy

Each node of the SIS shall be self-contained such that it will continue to perform its prime function during malfunction elsewhere and or unavailability of communication to other nodes or other systems

11.2 SIS PHILOSOPHY

The SIS at BK-4A shall be functionally independent to manage the overall safety (Process Safeguarding and Fire & Gas) of the platform. This is achieved by automatic generation of output commands to shutdown devices in the field and alerting the operation personnel when potentially hazardous process conditions are detected by field initiators. The SIS shall be designed to continuously monitor potential operation hazards and provide means to manually and automatically initiate shutdown of equipment, isolation of process and utility systems, including emergency depressurization of process facilities, where appropriate, in a safe and controlled manner. The causes and executive actions taken by the SIS in response to any abnormal process conditions shall be in accordance with the Process Shutdown and Fire & Gas Cause and Effect Matrices.



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The SIS shall alert operations personnel of a shutdown condition by annunciation at operator workstation. First-up alarm feature shall be incorporated into the alarm annunciation in the workstation. A Sequential Event Recording (SER) system is to be integrated into the SIS of BK-4A system. Time - stamping of shutdown events shall be done at the SIS at BK-4A itself.

Shutdown and Blowdown philosophy for this project shall follow offshore standard DNV-OS-A101 Safety principles and arrangements. There shall be two (2) stages of shutdown in the BK-4A Platform facilities shutdown hierarchy representing a staged response to increasing levels of Hazard (details of shutdown inititators and actions will be available in the form of C&E charts).

The following are the two stages of shutdown, in ascending oder of priority:

(Also reder to the Process Shutdown Hierarchy Diagram, Dwg No. BK4A-001-TS-TX1-SH-01)

PSD Level Process Shutdown

ESD-2 Level Emergency Process Shutdown and De-pressurization

All shutdown shall be designed to operate automatically when the process operating condition or equipment is outside normal control or operating limits and that a potentially hazardous situation is likely to occur before an operator could intervene. Pre-alarms shall be initiated and annunciated via PCS prior to automatic initiated shutdown. Dedicated manual shutdown facilities shall be provided dependent on shutdown level both locally and remote in the existing CCR on BK-4 Platform.

PSD LEVEL:

A Process Shutdown (PSD) shall be initiated by:

- PSD push button from BK-4 Central Control Room

- Import Pipeline PZALL and PZAHH

Actions taken on a Process Shutdown shall include:

- Initiated PSD activated alarm on PCS/SIS OWS;

- Initiated PSD mode on SDS system: Trip process SDV.

PSD signal will be sent from SDS to FGS system to initiated alarm on Sounder (for PSD tone).

ESD-2 LEVEL:

An Emergency Process Shutdown and De-pressurization (ESD-2 Level) shall be initiated by:

- ESD push button from BK-4 Central Control Room / at linking bridge



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- Confirmed Fire or Gas via flame/gas detectors in process area on BK-4A Platform.

- An emergency shutdown on BK-4 Platform

Actions taken on an Emergency Shutdown and De-pressurization shall include:

- Initiated ESD activated alarm on PCS/SIS OWS;

- Initiated ESD mode on SDS system: trip all SDVs and open all Blowdown Valves;

- Open all Deluge Valves and start Fire Pumps in case of comfirmed fire

ESD signal will be sent from SDS to FGS system to initiated alarm on Sounder (for ESD tone), on Red Strobe Light, on Yellow Strobe Light.

(TO BE UPDATED from Process Shutdown, Blowdown Philoslosphy)

The SIS must be designed to minimise latent faults (unrevealed failure), which lie dormant and render the system inoperable when invoked. Shutdown commands generated by the SIS in response to the process safeguarding logic will close these valves. The SIS shall override the PCS commands. VENDOR shall submit detailed sequential flow charts and logic diagrams for COMPANY/PURCHASER review 6 weeks after award. Shutdown Signals SDS shall be designed for fail-safe operation except for lamp/sounder/beacon outputs. A 1 logic signal is considered to be normal state and a 0 logic signal the abnormal (trip or failure) state. Inputs, which are normally opened under healthy condition, shall have line monitoring for detection of open and short circuit per input channel. Outputs, which are energised to trip, shall have line monitoring and earth fault detection for each output channel. Output signals shall be configured to a 0 (de-energised) state on power failure or on component failure. Any initiator failure, e.g. analogue input open circuit, short circuit or out of range shall be configured as a trip or a vote in the logic. Fire Gas Signals FGS shall be designed based on energise to trip (non-failsafe) principles and shall have line monitoring. Field devices such as transmitters, etc. shall be EExia, EExd type ATEX certified and operate at 24 V DC nominal power supply. Transmitters instead of switches will be used for shutdown initiation wherever possible as they have proven to be more reliable. Trip or safeguarding devices will be separated from those used for measurement and control, with particular attention paid to separate process tapping and junction boxes.

11.3 SYSTEM HARDWARE AND SOFTWARE REQUIREMENTS

11.3.1 General

The SIS SIL 3 system shall provide the following minimum features:



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- Fault tolerant power supply modules.

- Fault tolerant central processor / logic solver.

- Fault tolerant input modules for all critical input signals.

- Fault tolerant output modules for all critical output signals.

- Fault tolerant communication interface to PCS.

- Automatic self-testing and diagnostic facilities.

- Maintenance, operational overrides and resets.

- On-line replacement of any faulty module.

- System circuitry shall have a high immunity to radio frequency interference (RFI) and electromagnetic interference (EMI).

- The system circuitry shall be modular and expandable to accept future additional hardware in addition to the known spare capacity required by this Specification.

- On-line software download.

- SIS shall be OPC compliant.

- Software calculations.

11.3.2 Central Processor Unit (CPU)

The CPU's shall be installed in the main chassis. PLC System shall be fault-tolerant and certified by TV AK6 and meets IEC 61508 SIL 3 requirement. In case of one CPU failure the system shall still maintain SIL3 at all time and an alarm shall be indicated in PCS. Upon replacement, the system shall utilise scan free time to automatically reconfigure the new CPU card. Automatic reconfiguring shall also occur when diagnostic routines detect disagreement between the CPUs. The CPU's shall contain extensive diagnostics routines and execute diagnostic software, which shall be capable of locating and reporting the following faults as a minimum:

i) Watchdog Timer

ii) Scan failure of main or I/O processors.



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iii) Memory faults in PROM or RAM.

iv) Memory backup battery faults.

v) Microprocessor faults.

vi) I/O interface or addressing faults.

vii) I/O module faults.

viii) Voted signal discrepancies on inputs and outputs.

ix) Load power/fuse faults on field circuits.

x) Power supplies faults.

11.3.3 Response Time

i) The response time of the SIS from input change (trip request) to output response (trip

action) shall be 300 msec or faster. VENDOR shall submit the calculated effective response time for the complete system including spare and estimated future I/O capacity fully occupied in the bid.

ii) The response time for alarm annunciation and display at OWS shall not exceed 1 second

from initiation of event to display at OWS. iii) The scan cycle time of inputs shall be 300 msec or faster. iv) The response time for screen update at EWS shall not exceed 0.5 second.

11.3.4 System Synchronisation

Synchronisation between PCS and SIS shall be done by the Industry Redundant Netowrk.

11.3.5 Memory and System backup

The SIS shall be designed to have zero database administration requirements. The entire software including database, controller settings, software, source code, schematics, etc. shall be automatically backed up in the system hard disk or DVD at regular intervals. It shall also be possible to have a back up on demand. All failed devices of the system shall be capable of being reloaded from the back ups. The controller memory (RAM) shall have a battery back up of 1 year to save the controller configuration in case of power failure. Use of flash RAM is preferred. VENDOR shall provide a list of all batteries used within the SIS during bid proposal, indicating battery type, rating, shelf life, location within the SIS and renewal frequencies. Detailed testing



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and renewal procedure shall also be provided. VENDOR shall advise how the status of batteries is indicated. Immediately after SAT, VENDOR shall replace all batteries within the system. Spare capacity for CPU memory shall be minimum 40%. No degradation of the system performance including response times shall take place at 60% loading. It shall be possible to monitor system loading via system status / diagnostic displays. Battery back up for volatile memory shall be minimum 1 year.

11.3.6 Software Requirements

Software development tools to be provided shall include the following as a minimum:

- Hardware configuration editor

- Communication configuration editor

- Logic configurator and compiler.

- Automatic conversion of cause & effect matrix to FLD and SFC

- Diagnostic of system faults

- Event logger

- Off-line simulation

Implementation of Shutdown and Fire&Gas related logics shall be performed separately within SIS system program. The voting method of 1oo2D shall be implemented for confirmed fire and gas detection. This strategy requires 2 detectors for confirmed fire or gas as with 2ooN, except that under detector fault conditions, e.g. if a detector has failed, the logic shall revert to 1ooN (i.e. the logic considers failed detectors as alarms, which is the equivalent of voting high on detector fault).

All required software development tools shall be supplied as master copy in DVD-ROM (2 sets) and fully set up on the EWS Workstation. Use of "dongle" for software licence is not acceptable. VENDOR shall allow for minimum 5 installations of the software on different PC for each DVD-ROM. If there are limitations with regard to the number of installations, un-install utilities shall be provided. Setting of trip alarm levels for analog inputs, setting of timers shall be done by software configuration via the EWS. Mnemonic and high level language type programming shall not be used.



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The application software may initially be stored in RAM memory for system testing, commissioning and plant start-up and shall thereafter be stored in non-volatile RAM. VENDOR shall indicate in his proposal whether de-compile software is supplied with the system. Both the operating system compile software and (if applicable) the de-compile software shall be TV approved. SIS software package shall be version control and version comparator capable of comparing two application software versions and to indicate where the variations have taken place. The SIS shall have anti-virus protection and access security facilities to ensure the integrity of the software.

11.4 INPUT/OUTPUT MODULES

11.4.1 General

Unless otherwise specified in I/O List, the I/O modules for SIS shall have redundancy for all inputs and outputs. Each type of I/O module shall be provided with hot spare modules. All inputs and outputs shall be electrically isolated for protection against power supply, field surges and short circuits. Short circuiting of individual inputs and outputs shall not affect other inputs and outputs. If fuses are used for protection, preferred location of fuses is at the I/O module. Each module shall be mechanically keyed to prevent improper installation. Field input/output line monitoring by the I/O module shall include wiring from module to the field devices. Line monitoring shall not be dependent on barrier line monitoring circuits. All relays shall be heavy duty, hermetically sealed, plug in type with 24 VDC coils and fitted with indicated LED. Relay contact outputs shall be rated at a minimum of 24 VDC, 5 A. VENDOR shall include slots for future I/O cards, terminals to accommodate future I/O expansion/modifications (as Referred in Section 9.2 Overall Concept). The actual I/O requirements are detailed in the I/O List. Selection of correct I/O modules for the I/O type indicated in the I/O list is VENDOR responsibility. Different types of I/Os shall not be on the same I/O module. The organisation of the inputs and outputs shall be arranged in a fashion to facilitate efficient maintenance. e.g.:



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Where a single input is required to be used in more than one logic function, design shall be

such as to enable maintenance to be carried out on any of the logic without affecting the other logic using the same input. This will avoid shutting down other sections of the plant where routine maintenance is required or a fault occurs in one particular section of the plant.

Where the logic generates the same outputs to more than one process equipment. E.g.

duty pump A and standby pump B, each output shall be generated from separate output cards

In general, one I/O module shall not contain the I/O of more than one process unit that are dependent from each other. VENDOR shall be responsible for the correct quantity, arrangement and assignment of the I/Os and I/O modules. Each of the voted signals shall be allocated to separate modules. Furthermore, where redundant devices are installed, the I/O associated with each piece of device shall be on different module. The SIS shall be capable of supporting the input/output functionality without requiring custom-built modules. VENDOR shall supply end-of-line devices that are necessary to be installed at the field instrument to enable input/output line monitoring. Fuse replacement shall be possible without shutdown of system.

11.4.2 Analog Inputs

Analog inputs shall be utilised for the safety shutdown process loops. Each channel shall as a minimum, provide:

- 4-20 mA, non-earthed, passive and active, 24 VDC, 2-wire

- 4-20 mA, isolated power, 24V DC, 4-wire

- 3 or 4 wire platinum resistance temperature detector (RTD)

- Pulse/frequency

- Type K, J, T and B thermocouples

- Multiple alarm levels to be configured including alarm limits below 4mA and signal overrange.

- 0 - 100% signal indication, via the OWS.

- Channel and module fault indication.

- Range of transmitter shall be configurable per input channel.



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- Open and short circuit and out-of-range fault indication.

Each input shall be provided with digital filtering with adjustable time constants.

11.4.3 Digital Inputs

These input modules shall monitor field input contacts from switches, pushbuttons, panel interfaces, etc. Each channel and module shall as a minimum, provide:

- Monitoring of potential free contacts / wetted contacts.

- Open and/or short circuit fault indication.


11.4.4 24 VDC Powered Outputs

The 24 VDC powered output modules shall provide power to the field devices. These outputs shall not be switched by relay contacts. Only solid-state switching shall be used. These outputs shall generally be used for normally energised, de-energise to trip, executive action devices, typically solenoid valves, interposing relays, etc. with coil voltage of 24 VDC and power consumption of 3 to 12 watts maximum. Powered outputs used for powering lamps shall have suitable lamp test circuits implemented. All powered output shall be individually fused. Each channel and module shall as a minimum, provide:

- Power to the field device

- Indication when output is energised

- Open and/or short circuit fault indication

- Channel and module fault indication

It should be noted that solenoid valves are certified EExd for Zone 1 Gas Group IIA Temperature Class T3.

11.4.5 Digital Outputs



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These outputs shall generally provide volt free contact outputs to other systems. Each channel and module shall as a minimum, provide:

- Indication when output is energised.


11.4.6 Fire & Gas Detectors Analogue Inputs

Analogue inputs module shall be suitable for the fire and gas detector loops. The analogue inputs module shall provide all required power supply to interface with the fire and gas detectors. VENDOR shall also required to provide external power supply to power up the detectors where required external power supply e.g. 3-wire or 4-wire type detectors. Each channel shall as a minimum, provide:

- At least four alarm levels to be configured including alarm limits below 4 mA and signal overrange.

- 0 - 100% signal indication, via the OWS.

- Detector fault, dirty optics indications, etc.



It should be noted that gas detectors have, in addition to 4-20mA measurement output representing gas concentration, the current output below 4mA shall be set for status information such as beam blocked, dirty optics, detector fault, etc. These status outputs which are below 4mA shall not raise system hardware fault alarm. Similar type provision shall be available for flame detector where applicable.

11.4.7 Supervised Digital Inputs

These input modules shall monitor field detector circuits or loops. Each channel and module shall as a minimum, provide:

- Indication when the detector circuit or loop goes into alarm.





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11.4.8 Supervised 24 VDC Powered Outputs

These outputs shall generally be used for normally de-energised, energise to trip, executive action devices, typically for electrical power isolation, solenoid valves, alarm sounders and beacons. Powered outputs to solenoid valves shall be rated at between 3 to 12 W. Powered output to beacon or sounder, if required, shall be minimum 25 W. All powered outputs shall be individually fused. Powered outputs used for powering lamps shall have suitable lamp test circuits implemented. Each channel and module shall as a minimum, provide:

- Indication when output is energised

- Open and/or short circuit fault indication

- Channel and module fault indication

11.4.9 Supervised Digital Outputs

These outputs shall generally provide normally de-energised volt free contact outputs that energise an alarm to other systems. Each channel and module shall as a minimum, provide:

- Indication when output energised.

- Relay fault indication.


11.5 SYSTEM TESTING AND DIAGNOSTICS

The SIS shall incorporate extensive self-diagnostics, fault monitoring and fault diagnostics via continuous and periodic testing procedures automatically and upon operator initiation. The self diagnostics shall be such that all transient and permanent faults are identified, alarmed and reported. Self testing shall be performed to ensure that the modules are capable of performing correctly prior to being put into operation and to monitor the performance during operation. Tests shall be performed on all modules whether primary or backup. The following types of testing and fault monitoring shall be provided as a minimum:



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- I/O Module fault monitoring.

- I/O circuit operation verification/line monitoring.

- Logic system self tests.

- Power supply distribution monitoring.

- Data storage availability and integrity tests.

- Communication interface checks.

The system configuration and design shall be modular in construction utilising plug-in modules. I/O modules shall be redundant and the removal of one such module shall not affect the overall system operation or associated circuits i.e. redundancy shall not be on the same card. Module replacement will be possible with the associated rack powered up and system operational. Testing and fault monitoring shall not in any way affect the normal operations of the protective systems. Automatic testing shall not disable the correct executive actions from taking place in the event of a genuine hazard conditions. A malfunction in the testing and monitoring facilities shall not degrade the operation of the system. All detected faults shall be indicated on the OWS. Detailed fault diagnostics and system self test reports shall be available to the operator via the EWS.

11.6 OPERATOR INTERFACE

The PCS/SIS OWS is the primary operations window for the SIS. The SIS shall utilise the PCS/IS OWS for alarm, display and operator interface purposes. The PCS and SIS shall share the same have separated OWS.

11.7 OPERATOR / ENGINEERING & MAINTENANCE WORKSTATION (EWS)

The OWS/ EWS shall be use for following functions:

- HMI displaying.

- System configuration.

- SIS and Safety Control Network Systems performance monitoring.

- System maintenance.

- Display graphic builder.

- Application and logic builder.

- File management.

- Download a modified configuration into the SIS.



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- On-line and off-line system test, diagnostic and systems performance reports.

- Printing of software, I/O listing, I/O cross-reference list, etc.

- Online system documentation (self documentation) as per VDRL.

- Off-line simulation.

- SER data retrieval.

The OWS/EWS shall be in accordance but not limited to the following:

1. Intel Xeon Quard Core 3.06 processor GHz or better.

2. 8 GB DDRAM, 1066MHz, 1M Cache

3. 1 TB of HDD (7200 RPM)

4. 22" wide screen LCD monitor

5. Graphics Accelerator Card with a minimum of 1GB of Video RAM

6. QWERTY Keyboard

7. Mouse/Trackball

8. 16X max DVD +RW drives

9. 10/100 BaseT Network adapter cards and other accessories

10. Microsoft Windows Server 2008 Enterprise

For item 1 to 3 and 9 VENDOR to size the system to support the various required functions. The system shall also come with other peripherals, deemed appropriate to support OWS/EWS intended function.

VENDOR shall supply, install and configure any software that the OWS/EWS needs as to perform its intended functions.

The OWS/EWS shall be supplied with the operating system software in English Language. Antivirus software with genuine license shall also be supplied by VENDOR.

VENDOR shall also supply the interconnecting cables between OWS/EWS network cables and power unit / cable for use on 230VAC 50Hz.

VENDOR shall check with the third party package vendor, supply, install and configure any additional software that the OWS/EWS needs as to perform its intended functions.

11.8 COMMUNICATION TO PCS

The SIS communication protocol for the link to PCS shall be TUV certified through Industry Redundant Network. RS485/Modbus.



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VENDOR shall furnish the services and hardware necessary to provide a completely working SIS to PCS interface. VENDOR shall work out the message contents and other details such as hardware and software requirements and shall provide all pertinent information of the network structure such as system addressing structure of various data to be transmitted to the PCS, gateway information, etc. to ensure a completely working SIS to PCS interface. The inter-system communications is the responsibility of the VENDOR. An alarm shall be sent to PCS for total SIS failure. SIS will send ESD, APS-Abandon Platform Singals to PCS through hardwire link.

11.9 INTERFACE WITH THIRD PARTY SYSTEMS

VENDOR shall be responsible to supply all required interface units, hardware and software as well as co-coordinating with the various system vendors to ensure successful communication interfaces

The SIS shall interface to the following third party package equipment:

- Hydraulic Power Unit (HPU)

Loss of data communication link shall initiate alarm at OWS. Data not being updated due to communications failure is to be flagged on all OWS displays.

11.10 SEQUENCE OF EVENT RECORDING (SER)

The Sequence of Events generated in the SIS shall be time stamped and stored in a buffer in the SIS and the buffer memory shall maintain a minimum of 1000 time stamped events. Upon overflow the oldest event shall be overwritten by a new event. These records shall be time stamped to 1 millisecond resolution or better. It shall also be possible to retrieve the time stamped events in the buffer using SER data retrieval software installed in the portable EWS. VENDOR shall supply SER hardware and software to retrieve the time stamped events logged in the buffer. The SER software shall be Windows based. The event data can be used for preventive maintenance and to help identify the causes of system shutdowns. The sequence of events database shall be readily and easily accessible by operator and engineers using a set of software tools to quickly and effectively view, analyse and prepare report on the plant. The sequence of event software tools shall have following functions:

- Incident replay

- Identify cause of a process upset

- Report generation



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The sequence of events database shall be capable of collecting and storing up to 100,000 events, each with time and date stamp

11.11 PUSHBUTTONS//LAMPS/BUZZERS

The manual control buttons and light alarms, buzzer available on SIS cabinet shall be of the following types:

- Fire, Gas light alarms: working in flashing mode (warning) and steady (warning and execute ESD mode) including One 20% Gas Alarm, one 50% Gas Alarm, 1 Fire Alarm, 1 Fire Confirmed, 1 ESD alarm, 1 Common Alarm.

- One Buzzer: with 2 tone Common Alarm and ESD alarm.

- One Reset button: Use to reset all audible visual alarm to normal mode.

- One Acknowledge button, one Local ESD button

- One Lamp test button

11.12 OVERRIDE SWITCHES

11.12.1 Maintenance Override Switch (MOS)

MOS will be provided to service for Maintenance works and will be set by software (soft-switch).

11.12.2 Start-Up Override Switch (SOS)

SOS will be provided to service for Start up the system and will be set by software (soft-switch). After one period time, the system has started up successfully, SOS will be reset by software.

12.0 GENERAL SIS SYSTEM REQUIREMENTS

12.1 INDUSTRY REDUNDANT NETWORK

Transfer of data between PCS and the Safety Systems shall be achieved via dual Industry Redundant Network (refer to Drawing No. BK4A-001-TS-IA2-DW-01 Control Architecture Block Diagram for more details). The Industry Redundant Network shall support TCP/IP, ETHERNET protocolor VENDORs standard protocols. The Industry Redundant Network shall be used suitable for SIS safety system, and PCS system specified in the project. VENDOR shall furnish the services and hardware necessary to provide a completely working PCS and SIS interface. VENDOR shall work out the message contents and other details such as hardware and software requirements and shall provide all pertinent information of the TCP/IP, ETHERNET protocol structure.



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12.2 SYSTEM CABLES & CABLE ACCESSORIES

12.2.1 System Cables

All SIS system cables 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. Segregation of any terminals, earthing and screening connections to be carried out in accordance with IEC 60079 or EN 50020.

All internal wiring cables for SIS cabinet system shall be via system cables which shall be provided by VENDOR. All SIS System cables shall be low smoke zero halogen and flame retardant in accordance with IEC 60332 and fire resistant in accordance witch IEC 60331. System cable connectors shall have gold plated contacts/pins. All multiconductor system cables required for the internal wiring for the SIS system cabinet must be pre-fabricated with plug-in receptacles at each end and supplied by VENDOR. System cables shall be adequately sized for minimum voltage drops Field instrument cable for SIS system will be specified in Doc No BK4A-001-TS-IA2-SP-02.

12.2.2 Cable Accessories.

All system cables enter and exit the cabinet are through gland plate. All VENDOR's inter-cabinet system cables for SIS system shall be provided with cable glands. The gland shall be SS316. The cable gland shall be EEx'de' certified with IP65 protection. The VENDOR will supply all the other required accessories for the wiring of the system cable for the SIS system cabinet.

12.3 SYSTEM AND MARSHALLING CABINETS

12.3.1 General

VENDOR shall estimate the required size and the number of SIS cabinets based on the I/O List (with reserved capacity and space for expansion for BK-4 PCS and SIS system in the future). VENDOR shall also reflect in his bid the proposed cabinet list. System cabinets shall be provided for housing the I.S. isolators and for termination of incoming field cables. SIS system cabinets shall be complete with but not limited to the following:



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i) The I/O modules, processors, communication cards, power supply units, hubs, network switches etc.

ii) Pre-wired system cable sockets and power supplies.

iii) Analogue and digital, I.S. and Non-I.S. termination rails.

iv) Galvanic Isolators as required.

v) Pre-wiring from the field interface terminals to suitable plug/sockets for connection to the system cables.

vi) Knife edge disconnect-type terminal blocks for analogue and digital input signal field cables.

vii) Fused terminal blocks for digital output signal field cables.

viii) The terminals for the screen of each analogue cable pair.

ix) Fuses and MCB's.

x) Cable clamps for field cable support.

All relay contacts and connectors shall be gold plated. All hardwares shall be of flame retardant materials. Interposing relays, when required shall have minimum of four (4) contacts, two NO and two NC. All relays shall be 24 VDC, 5A output contact rating. The interposing relays, if any, shall be mounted in the system cabinets. Fuses with built-in fault LED shall be used.

12.3.2 Construction

The cabinets shall be free standing with front and rear access doors and selected from a cabinet Vendor's standard range (RITTAL or equal). Dimension of Cabinet will be optimized, advised and given out by Vendor to be suitable for installing in limited space of BK-4s control room. VENDOR shall submit the model of the cabinet to the COMPANY/PURCHASER for approval. SIS system cabinets will be installed in Instrument Equipment Room (safe area). The cabinets shall have a degree of protection of IP44 to IEC 60529 as a minimum. The size and quantity of cabinets shall not exceed the allocated space in IER. Layout drawings of the cabinets shall be submitted for COMPANY/PURCHASER's approval prior to starting of fabrication work. The cabinet shall be completely assembled, wired and tested. Attention shall be given to any special arrangements, which shall facilitate easy maintenance.



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The cabinets shall be free from visible defects. No clamp marks, scratches, gouges, sharp edges and uneven surfaces shall be permitted. Where necessary, additional stiffeners or equipment support shall be added to the cabinet bracing structure to prevent distortion under imposed loading. All cabinet doors shall have lift-off hinges and be lockable with identical keys. The opening angle of the doors shall be at least 135. The cabinets shall be fitted with removable eye bolts (with a 2.5 safety factor) for lifting purposes. All cables shall enter and exit the cabinet from top through the cabinet gland plate. Suitably sized gland plates shall be provided for all cabinet cable entries. Sufficient free space shall be available for properly accommodating and termination of all cables, plus 20% spare. Cable clamps shall also be provided to support cables rigidly. VENDOR shall check correct quantity and sizes. All metallic equipment within the cabinets shall be connected to a single common cabinet safety protection earth point. Each cabinet shall be provided with two M10 earthing boss for connection to the plant safety earthing system. VENDOR shall provide drawing pockets inside each cabinet. VENDOR shall provide one document pocket suitable for A4 size documents inside each cabinet. Redundant fans shall be provided to cool the system cabinets. The incoming air shall be filtered The cabinet fan failures, cabinet temperature high alarms and cabinet incoming power supply failure alarms shall be provided and wired to SIS systems respectively. These alarms shall be derived from volt-free contacts inside the cabinet which shall be monitored by the input cards and the alarms shall be available in OWS. Dust filters where provided shall be of the replaceable or cleanable type, and this action shall be possible without disturbing the functions of the cabinet.

12.3.3 Equipment Installation

The SIS system shall be modular in construction with the cabinets incorporating a Vendor standard rack system. If consistent with enhancement of accessibility to cabinet interior and rear of rack-mounted equipment for purpose of installation, inspection and maintenance, the racking system may be



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mounted on a swing frame. However, the application of the swing-out frames requires the written approval from the COMPANY/PURCHASER. Heavy items such as power transformers shall not be rack mounted but installed securely within the main body of the cabinet on specially designed supporting structures. VENDOR shall provide sufficient clearance between components to permit maintenance whilst in operation.

12.3.4 Electrical Requirements

VENDOR shall pre-wire and connect I/O modules (including spare modules) to connector sockets via proper terminals in the cabinet. VENDOR shall also be responsible to provide the matching connector plugs and corresponding system cables for connection to the system cabinets. VENDOR shall provide appropriately sized terminals for termination of field cables. All field cables shall be terminated in the system cabinets. Power supply wires shall be stranded. The conductors shall be sized to be of such cross sectional area so as to safely withstand the greatest magnitude of fault current that can exist within the circuitry of the conductors. Internal wiring shall be of insulated stranded copper wire (230 V grade) terminated with pin crimps appropriate to the application and applied with the correct tools. Cores shall be continuous without splice. Multiconnections shall be arranged at terminal blocks and not by means of core junctions. Conductor sizes shall be as follows:

i) 1.5 mm for all general wiring including low power mA signals, discrete inputs.

ii) 2.5 mm for solenoid circuits.

For power supply distribution (for system internal used) appropriate cable size shall be provided depending upon the power required. All cabinet internal wiring cables and system cables shall have flame retardant outer sheath with oxygen index of not less than 30 and be type tested for reduced flame propagation in accordance with IEC 60332. VENDOR shall follow PURCHASERs field wiring diagrams for termination of field cables in the system cabinets.



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Each multicore shall be terminated on a block of terminal strip in a continuous manner inside one cabinet only. Splitting of a multicore cable termination into separate cabinets is not acceptable. Wiring from field terminals to Galvanic Isolators/I.S. barriers (Zener barrier is not acceptable) shall be segregated from other Non-I.S. circuits (minimum separation 50 mm). I.S. panel wiring, trunking and terminal blocks shall be blue colour. VENDOR shall separate the different voltages terminal blocks and the I.S. terminal blocks. Input and Output signal termination shall also be segregated. All spare inputs and outputs shall be completely prewired to terminal blocks. 20% spare terminals shall be provided for all terminal strips for future expansion. VENDOR shall provide suitable trunkings for all wiring. Separate trunking for system cables shall be provided such that segregation of different voltages can be achieved. All AC voltages shall be clearly labelled, segregated and protected from signal cables. Utilisation of the cable trunking shall not exceed 50%. Wires shall be marked at both ends using heat shrinkable, water and scratch resistant, no smear permanent image type lettering. Wire tags shall be shown in the wiring diagrams. Wire tag schedule shall also be provided by VENDOR. VENDOR shall provide sufficient internal cabinet 230 VAC 50Hz fluorescent lighting with automatic door switch. 24 VDC redundant power supplies with circuit breakers shall be provided where required, e.g. for IS isolators etc. Contacts from circuit breakers shall be wired to a common alarm to annunciate circuit breaker trip. The contacts shall be monitored by the input card and the alarm shall be available in OWS. Removal of an I.S. isolator for replacement or checking shall not affect power supply to other I.S. isolators. Main power interruptions of up to 100ms shall not affect operation. Daisy chaining of power supplies and two or more signal wires on same one terminal block is not acceptable. Instead, combing bars shall be used. Power distribution within SIS system cabinet shall be equipped with sufficient breakers, fuses, isolators and other protective devices such that the possibility of a fault affecting a significant amount of equipment avoided and each component is protected from undesirable power surges. The VENDOR shall ensure that each circuit and sub-circuit shall be individually protected and capable of being isolated for maintenance or replacement. Each cabinet shall be provided with 15A convenient socket outlet.



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12.3.5 Labelling

Terminals carrying voltages higher than 48 volts shall be protected against accidental contact by having removable cover plates, and shall be labelled to indicate high voltage. Red warning labels shall be provided to warn personnel of the presence of 230 VAC supply. Sockets, terminals and main wiring shall be clearly identified in accordance with the system documentation. Earthing for screens, AC and DC systems shall be segregated and identified. Each cabinet and all system components, card files and individual card locations shall be clearly labelled and identified with a tag number. Nameplates shall be in the English language. In addition, all equipment shall be durably identified with the VENDOR type and serial number and with the COMPANY's order number to facilitate future reference. Cabinets shall be identified with tag numbers and descriptions. Segregated sections within a cabinet, that are provided for intrinsically safe signals (Ex(i)a or Ex(i)b) shall be labelled as such. Cables and ducting for intrinsically safe signals shall be in blue colour.

12.4 SYSTEM RELIABILITY AND AVAILABILITY

The availability of SIS shall be 99.999% It shall be possible to replace defective cards while the system is on line. VENDOR shall advise in his quotation of any cards that require all or part of the system to be powered down. Where fault-tolerant/redundant modules are provided, it shall be possible to replace the faulty module on-line without interrupting the process. VENDOR is required to substantiate the systems, including all the associated components in the scope of supply, comply with the reliability and availability criteria stated by VENDOR.

12.5 INSTALLED SPARES

The SIS for BK-4A platform (including with reserved capacity and space for expansion for BK-4 in the future) shall have minimum 20% spare prewired and tested, up to field I/O incoming cable termination blocks in the system cabinet. In