Materials System Specification

34-SAMSS-830 20 March 2013

Programmable Logic Controller
Document Responsibility: Instrumentation Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Conflicts and Deviations................................. 2
3 References..................................................... 2
4 Definitions...................................................... 4
5 Electrical Requirements................................. 7
6 Design............................................................ 7
7 Component Selection................................... 12
8 Programming and Configuration.................. 12
9 PLC Cabinet Construction............................ 14
10 Documentation............................................. 16
11 Testing......................................................... 16
12 Other Miscellaneous Requirements............. 17

Previous Issue: 21 June 2009 Next Planned Update: 20 March 2018

Revised paragraphs are indicated in the right margin Page 1 of 17
Primary contact: Al-Hashim, Abdullah Mohammed on +966-3-8801388

Copyright©Saudi Aramco 2013. All rights reserved.

Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
Issue Date: 20 March 2013
Next Planned Update: 20 March 2018 Programmable Logic Controller

1 Scope

This specification together with the purchase order and appropriate specification sheets,
prescribes the minimum requirements for stand-alone programmable logic controllers
(PLC), as well as PLCs integrated within other process control systems, e.g., Distributed
Control Systems (DCS). Emergency Shutdown Systems (ESD) are covered by
34-SAMSS-623 and are excluded from this specification.

This specification shall be used in conjunction with 34-SAMSS-820 “Instrumentation

Control Cabinets - Indoor” for indoor PLC locations or 34-SAMSS-821
“Instrumentation Control Cabinets - Outdoor” for outdoor PLC locations except as may
be superseded within this specification.

Hybrid controllers are considered a special type of PLC. Hybrid controllers may be
used for projects with less than 50 PID loops. P&CSD/PID/IU review and approval is
required when specifying hybrid controllers for hydrocarbon facilities.

2 Conflicts and Deviations

2.1 Any conflicts between this specification and other applicable Saudi Aramco
Materials System Specifications (SAMSSs), Engineering Standards (SAESs),
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer’s Representative through the
Manager, Process & Control Systems Department of Saudi Aramco, Dhahran.

2.2 Direct all requests to deviate from this specification in writing to the Company or
Buyer’s Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Process & Control Systems
Department of Saudi Aramco, Dhahran.

2.3 The designation “Commentary” is used to label a subparagraph that contains

comments that are explanatory or advisory. These comments are not mandatory,
except to the extent that they explain mandatory requirements contained in this
SAMSS.

3 References

Material or equipment supplied to this specification shall comply with the latest edition
of the references listed below, unless otherwise noted.

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory

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Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
Issue Date: 20 March 2013
Next Planned Update: 20 March 2018 Programmable Logic Controller

Saudi Aramco Engineering Requirement

Saudi Aramco Materials System Specifications

34-SAMSS-820 Instrumentation Control Cabinets-Indoors
34-SAMSS-821 Instrumentation Control Cabinets-Outdoors

Saudi Aramco Inspection Requirements Form

175-344000 Programmable Logic Controllers

Saudi Aramco Form and Data Sheet

SA-8020-830-ENG Instrument Specification Sheet (ISS) for
Programmable Controllers

Saudi Aramco Non-material Requirements

NMR-7907 Nonmaterial Requirements for Instrumentation
(General)

3.2 Industry Codes and Standards

Telecommunications Industry Association

ANSI/TIA/EIA-232-F Interface between Data Terminal Equipment and
Data Circuit-Terminating Equipment Employing
Serial Binary Data Interchange
ANSI/TIA/EIA-422-B Electrical Characteristics of Balanced Voltage
Digital Interface Circuits
ANSI/TIA/EIA-485-A Electrical Characteristics of Generators and Receivers
for use in Balanced Digital Multipoint Systems

Institute of Electrical and Electronics Engineers

ANSI/IEEE C37.90.1 Surge Withstand Capability (SWC) Tests for Relays
and Relay Systems

International Electrotechnical Commission

IEC 60255-22-3 Measuring Relays and Protection Equipment - Part
22-3: Electrical Disturbance Tests - Radiated
Electromagnetic Field Immunity-Edition 3.0
IEC 61000-4-3 Electromagnetic Compatibility (EMC) - Part 4-3:
Testing and Measurement Techniques - Radiated,
Radio-Frequency, Electromagnetic Field
Immunity Test-Edition 3.0

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Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
Issue Date: 20 March 2013
Next Planned Update: 20 March 2018 Programmable Logic Controller

National Electrical Manufacturers Association

NEMA IA 2.2 Programmable Controllers-Equipment
(IEC 61131, Part 2) Requirements and Tests
NEMA IA 2.3 Programmable Controllers-Programming
(IEC 61131, Part 3) Languages

National Fire Protection Association

NFPA 70 National Electrical Code (NEC)

Underwriters Laboratories, Inc.

UL 508 Industrial Control Equipment - Part XVII,
Programmable Controllers

4 Definitions

This section contains definitions for acronyms, abbreviations, words, and terms as they
are used in this document.

4.1 Acronyms and Abbreviations

ac Alternating Current
BCD Binary Coded Decimal
CPU Central Processing Unit
dc Direct Current
DCS Distributed Control System
FAT Factory Acceptance Test
ISS Instrument Specification Sheet (SA-8020-830-ENG)
I/O Input/Output
mA Milliampere
NMR Non-Material Requirement
P&ID Piping and Instrumentation Diagram
PCB Printed Circuit Board
PID Proportional Integral Derivative
P.O. Purchase Order
RLL Relay Ladder Logic
RTD Resistance Temperature Detector

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Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
Issue Date: 20 March 2013
Next Planned Update: 20 March 2018 Programmable Logic Controller

SI System International (International System of Units)

UPS Uninterruptible Power Supply
VAC Volts Alternating Current

4.2 Words and Terms

Buyer or Purchaser: The Company actually placing the order for the material,
(e.g., Saudi Aramco, AOC, ASC, or third party contractor).

Buyer’s Representative: The person acting on behalf of the Buyer, who may
be from the Engineering, Inspection, Purchasing, or User Organization.

Cabinet: An enclosure designed either for surface or flush mounting and

provided with a frame, mat, or trim in which a door or doors are attached.

Configuration: The physical installation of hardware modules to satisfy system

requirements, and/or the selection of software options to satisfy system
requirements.

Conformal Coating: An electrical insulating material applied as a coating to

loaded printed circuit boards to produce a thin layer conforming to the surface in
order to provide a protective barrier against deleterious effects from
environmental conditions.

Connected Load: The sum of the continuous ratings of the load-consuming

apparatus connected to the system or any part thereof.

Factory Acceptance Test: The final test at the Vendor’s facility of the integrated
system being purchased. This test is usually witnessed by Saudi Aramco personnel.

Failure: The state of a module that is not capable of performing its specified
function.

Firmware: Hardware used for the nonvolatile storage of instructions or data

that can be read only by the CPU. The stored information is not alterable by any
computer program.

Functional Test: A sequence of tests applied to a unit under test to establish

whether it is functioning correctly.

Functional Block Diagram (FBD): A PLC programming method that consists

of one or more networks of graphically represented functions, function blocks,
data element, labels, and connective elements.

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Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
Issue Date: 20 March 2013
Next Planned Update: 20 March 2018 Programmable Logic Controller

Module: An assembly of interconnected components that constitutes an

identifiable device, instrument, or piece of equipment. A module can be
disconnected, removed as a unit, and replaced with a spare. It has definable
performance characteristics that permit it to be tested as a unit.

Network: An interconnected or interrelated group of relay ladder logic rungs.

Programmable Logic Controller: A digitally operating electronic system,

designed for use in an industrial environment, which uses a programmable
memory for the internal storage of user-oriented instructions for implementing
specific functions such as logic, sequencing, timing, counting and arithmetic, to
control, through digital or analog inputs and outputs, various types of machines
or processes. Both the PLC and its associated peripherals are designed so that
they can be easily integrated into an industrial control system and easily used in
all their intended functions.

Programming Workstation: An integrated collection of hardware and

software tools required for designing, editing, compiling, loading, testing, and
configuration of the PLC system.

Rack: A framework, constructed of rails or steel members, for mounting an

assembly of modules for monitoring, measuring, and controlling remotely
operated systems.

Relay Ladder Logic Diagram (RLL): A PLC programming language where

one or more networks of contacts, coils, graphically represented functions,
function blocks, data elements, and connective elements delimited on the left
and (optionally) on the right by power rails.

Self-Diagnostic: The capability of an electronic device to continuously monitor

its own status and indicate faults that occur within the device.

Sequential Function Chart (SFC): A graphical representation of a sequential

program consisting of interconnected steps, action and directed links in which
the individual steps are processed in a predetermined order.

System: A set of components, comprised of hardware and software elements or

subsystems that interact with each other in a defined manner to effect control of
a process.

Vendor: The other party to the order for the material who may or may not be
the manufacturer of the equipment.

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Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
Issue Date: 20 March 2013
Next Planned Update: 20 March 2018 Programmable Logic Controller

5 Electrical Requirements

Unless otherwise stated on Form ISS SA-8020-830-ENG, PLC system components

shall be listed, labeled, or designed to conform to UL, FM, CSA, or CENELEC
guidelines.

6 Design

The Programmable Logic Controller shall be designed, constructed, and tested in

accordance with this specification and the following standards;
a) NEMA IA 2.2 & 2.3 (IEC 61131, Parts-2&3)
b) UL 508, Part XVII
c) ANSI/IEEE C37.90.1

If so specified in the purchase order or ISS, the Vendor shall develop an application
program(s) which performs the logic sequence and functionality as indicated in the
following Buyer supplied documents:
a) Piping and Instrument Diagram(s)
b) Binary logic diagram(s)
c) Cause & Effect diagram(s)
d) Written description of operational requirements

The PLC shall be self-checking, i.e., have automatic internal checking capability
(so-called ‘self-diagnostics’; see paragraphs 6.1.2 and 6.1.3 for details) to detect a
failure. When a failure occurs, an alarm shall be initiated.

6.1 Processor Unit

The Central Processing Unit (CPU) shall continuously scan the application
program stored in memory, along with the status of all inputs, and execute
specified commands to the appropriate outputs. The CPU shall have 50% spare
internal memory locations, after the application program has been loaded.

6.1.1 CPU Operating Modes

A key-lock mode-select switch on each CPU module shall prevent

memory modification from any outside source. The key-lock switch
shall allow optional operating modes, including PROGRAM, RUN,
LOCK/UNLOCK or other equivalent functions.

In the ‘PROGRAM’ or ‘UNLOCK’ mode it shall be possible to load

programs; create, modify, or delete programs and data files; download to
a memory module and save and restore programs. It shall be possible,

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Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
Issue Date: 20 March 2013
Next Planned Update: 20 March 2018 Programmable Logic Controller

through the use of special commands, to disable selected inputs and

outputs.

In the ‘RUN’ or ‘LOCK’ mode, normal operation shall occur with the
inputs and outputs active; the CPU and the program running. It shall not
be possible to create or delete programs or data files, program on-line,
modify the size of a data file, or change ‘processor’ mode of operation
through an external programming device or communications interface
while in this mode.

The selected CPU operating mode shall be visually indicated on the front
of the CPU module.

6.1.2 CPU Status Indicators

The CPU shall continuously monitor its own status and indicate both
normal operation and error conditions via LED status indicators
(or equal) on each CPU module faceplate. When PLC failure occurs,
the discrete outputs shall either freeze in their present state (‘fail-as-is’)
or turn off, whichever was selected in the ISS or Purchase Order.

Status indication shall be provided for the following conditions

(or their equivalents):
a. FORCE: (Any I/O which is forced on or off)
b. COMM ACTIVE/FAULT: (Communications status)
c. PROG RUN/FAULT: (Faulted condition within the CPU)
d. BATT: (Status of battery backing up RAM)
e. REMOTE I/O ACTIVE/FAULT: (Status of remote I/O, required
only with system using remote I/O)

6.1.3 PLC Module Failure Indication and Action

6.1.3.1 A failure or fault indication on any I/O module shall initiate a

system status alarm.

6.1.3.2 Failed modules within the PLC system shall be automatically

detected, identified and alarmed via output contact(s),
diagnostic status words and LEDs (or equal) without
interruption of normal processing functions. On-line
removal/replacement of any PLC system module shall be
possible without having to reconfigure system software, alter
system wiring or cabling, or re-initialize the PLC system.

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Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
Issue Date: 20 March 2013
Next Planned Update: 20 March 2018 Programmable Logic Controller

6.1.4 Quick-Reference Charts

Unless otherwise specified, laminated plastic quick-reference charts shall

be permanently attached to the inside of the PLCs front door. The charts
shall clarify proper module or PCB placement, and assist in the
interpretation of the status indicators.

6.2 Input/Output Modules

6.2.1 I/O module types, quantities, and respective signal levels shall be as
indicated on attached ISS sheet.

6.2.2 I/O modules shall be capable of being inserted into or removed from
their rack without disturbing external wiring. Field I/O wiring shall be
connected to the I/O rack, via integral screw type terminals.

6.2.3 It shall be possible to mix all types of I/O modules in any given rack,
irrespective of their voltage levels.

6.2.4 All discrete I/O modules shall include local status indicators to monitor
the status of each input and output. All analog modules shall include a
local status indicator to monitor the status of the module.

6.2.5 All discrete I/O circuits shall be isolated from logic or processor
circuitry. Transient voltage isolation for discrete I/O shall be a minimum
of 1000 Volts RMS, common-mode.

6.2.6 All I/O circuits shall be designed so that accidental normal-mode

connection of 1000 VAC/DC to discrete I/O field terminals for an
unlimited time shall not destroy any devices in I/O circuits other than the
circuit to which the voltage was applied.

6.2.7 All input and output points shall be individually fused, or employ
current limiting circuitry, e.g., in the case of module ‘self-powered’ I/O.
Fuses shall be located on an external termination panel, fused terminal
strip, or in a location readily accessible for maintenance. Removal of I/O
modules shall not be necessary to accomplish fuse replacement.
Commentary Note:

Fuse ampacity ratings must be sized for the maximum expected load at
the maximum operating temperature of the system, but not to exceed the
I/O module rating.

6.2.8 Discrete output circuits shall be provided with protection against the
switching of inductive loads (i.e., R-C circuits, solenoid valve coils).

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Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
Issue Date: 20 March 2013
Next Planned Update: 20 March 2018 Programmable Logic Controller

6.2.9 Discrete outputs that drive solid state inputs, i.e., annunciator points,
shall be provided with dry relay contacts. No triac outputs, with
minimum current load resistors, shall be used for this particular type of
service.

6.3 Remote I/O

6.3.1 Remote I/O modules, if so specified on the ISS, shall be capable of being
located at an extended distance from the CPU. Actual cable length
requirements will be specified in the ISS. Communications links shall
comply with Vendor recommended cabling incorporating either twisted
shielded pairs, coaxial, twin axial or optical fiber, with physically-
lockable cable connectors. If remote I/O is selected, Vendor shall
confirm, in writing, that the selected communications cable(s) meet the
communications driver specification.

6.3.2 Communications driver software/firmware shall continuously monitor

and check the status of communication links and associated I/O.
Communication status indication shall be provided on the face plate of
each associated module.

6.3.3 Remote I/O cabinets shall incorporate their own power supply.

6.4 Power Supplies

Incoming power to the PLC system will be from Saudi Aramco supplied
120 VAC UPS power sources, which are over-current protected.

6.4.1 System Power Supplies

The PLC system shall be designed such that all rack power supplies
(e.g., main, expansion rack) are separate and distinct, connected via
cabling or internal bus structure. Each power supply shall be sized to
provide 100% of the ampacity requirements (at rated voltage and
maximum design temperature) for the specified configuration of I/O
cards, CPU, etc., including 25% spare modules, with all modules and
outputs energized and carrying their maximum connected load.
Commentary Note:

The 25% spare module figure includes the 10% “installed spare” modules
referenced in paragraph 9.1a.

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Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
Issue Date: 20 March 2013
Next Planned Update: 20 March 2018 Programmable Logic Controller

6.4.2 Auxiliary Power Supplies

Auxiliary power supplies used to power I/O field points shall be sized for
125% of the ampacity requirements (at rated voltage and maximum design
temperature). Power supply loads shall be calculated with all points
energized, and all outputs carrying their maximum connected load.
Commentary Note:

This includes sizing provisions for an expansion capacity of 25% of the

system modules.

6.4.3 Power Fluctuations

The PLC shall be capable of operating without malfunction when

continuously energized at between 57 and 63 Hertz and 90% to 110% of
rated voltage.

6.4.4 Protection

Each power supply shall have its own internal fuse/circuit breaker
protection on the incoming line side. Fuses or circuit breakers shall be
capable of being replaced or reset, without removal of the power supply
or disconnecting any wiring termination’s. Output protection shall be
provided by current-limiting circuitry.

6.4.5 Power Restoration

The PLC system shall be designed such that, no incorrect commands are
given to the output field devices when power is applied or restored to the
CPU or I/O modules.

6.5 Communications Interface

6.5.1 The controller shall support multiple RS-232, RS-422, or RS-485 ports
(ANSI/TIA-232F, 422B or 485A) for communicating with external
devices such as a DCS operator interface station, auxiliary system,
program development workstation, or printer. Specific porting
requirements and communication protocol will be listed on the ISS.

6.5.2 The system shall also support communications using Modbus TCP/IP
protocol or OPC DA 2.0 or greater.

6.5.3 All communications ports shall be manufacturer’s standard hardware,

and shall permit connection and disconnection without interrupting or
jeopardizing system operation.

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Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
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Next Planned Update: 20 March 2018 Programmable Logic Controller

7 Component Selection

7.1 Printed Circuit Boards (PCB)

7.1.1 All PCB components shall be commercial grade type, designed to

operate continuously. Conformal coating shall be provided when
specified in the ISS.

7.1.2 All edge connectors shall incorporate a keying system to prevent

improper board or module placement if such improper placement would
cause a system failure or damage to any component.

7.1.3 LED’s or visual indicators which are installed on PCBs within modules
must be mechanically protected (i.e., by a transparent cover), and be
labeled externally.

7.2 Identification

Each type of PLC module shall be uniquely identified by a type number, serial
number, and a revision or some other production lot identification code. In
addition, each PLC Module shall clearly indicate the designed field signal range,
type, and service; e.g., 120 VAC Digital Output, etc.

8 Programming and Configuration

a) Program development software tools shall be provided by Vendor, enabling the

applications programmer and user to develop, edit or debug application logic or
programs. Software shall be menu driven and user friendly incorporating
on-screen help functions. Software shall conform to NEMA IA 2.3 (IEC 61131,
Part-3) requirements and shall operate under a standard operating system.

b) The program development workstation software shall be capable of monitoring

the real-time status of data/memory locations while the CPU is scanning the
applications program.

c) The software tools shall be either developed or third-party licensed, by the PLC
Vendor, and shall be the latest revision available at the time of placement of
purchase order.

8.1 Program Development Workstation

8.1.1 The program development workstation, if specified in the P.O. or ISS,

shall, as a minimum, consist of personal computer or compatible laptop.

8.1.2 It shall be possible to connect or disconnect the programming workstation

without the need to de-energize the PLC or the programming device.

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Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
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Next Planned Update: 20 March 2018 Programmable Logic Controller

8.1.3 The programming workstation shall have the capability of backing up the
CPU memory onto its internal hard drive and on a removable storage media.

8.2 On-Line and Off-Line Programming Support

The program development software shall be capable of supporting both on-line

and off-line programming. Off-line program emulation capability shall be
provided if specified on the ISS.

8.3 Programming Functions

The following programming utilities/tools (or equivalent functions) shall be

provided by the Vendor:
a) Entry, display, and editing of program Industry standard Relay Ladder
Logic (RLL), functional blocks or others.
b) Generation, listing, and printout of application programs, memory
contents, configurations, and cross reference tables.
c) On-Line Data Display/Changes.
d) Input/Output Forcing.
e) System Diagnostics/Fault Status.

8.4 Program Development Elements

The following ladder instructions or elements (or their equivalent functional

instructions) shall be provided by the PLC manufacturer:
a) Arithmetic Functions: Add, Subtract, Multiply, Divide, Square Root,
BCD to Integer, Integer to BCD,
b) Logic Functions: And, OR, exclusive OR, NOT, Flip/Flops.
Commentary Note:

The selected programming language shall provide integer math instructions

for above functions. Real or floating point arithmetic and functions should
also be provided to convert analog input to real (floating point) numbers.

c) Shift Register Functions: Bit Shift Left, Bit Shift Right

d) Comparison Elements: Less Than, Greater Than, Less than or Equal,
Greater than or Equal, Equal, Not Equal.
e) Timer & Counter Elements: Countup, Countdown, Time Up, Time Down
(with accumulator, preset and time-base sub-elements) Time base.
01 seconds and 1.0 seconds.

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Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
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Next Planned Update: 20 March 2018 Programmable Logic Controller

f) Relay Contact Elements: N.O., N.C., Transition.

g) Relay Coil Elements: Standard, Latch, Unlatch.
h) Any additional functions specified in the purchase order.

8.5 Application Program Development

The following guidelines shall be followed for application program development:

a) The application program shall be designed in such a manner as to promote
user friendliness (for operations and maintenance personnel). This means
that complex logic functions and instructions which are difficult to explain
or describe, shall be avoided. Ladder logic networks, functional blocks or
sequential steps shall be arranged in such a manner as to group all logic
dealing with a specific piece of equipment or function.
b) All I/O and internal addresses shall have tag names and descriptors
representative of their purpose. Insert comment blocks to explain the
operation and sequence of each network by tag name. Each comment
block shall include a cross reference to the source binary logic diagram
drawing number.
c) Segregate logic for individual pumps, turbines, compressors, and process
interlocks into separate networks. Identical logic structures and elements
(except for tag names and addresses) should be used for identifying logic
of equipment operating in parallel trains, or which are controlled in a
similar manner.
d) Proportional-Integral-Derivative (PID) control loops shall not be
implemented in the PLC. Analog inputs may be used for alarming,
monitoring, sequencing, and interlock applications.
Exception:

PID loops can be implemented in PLCs used as part of packaged air

compressors or custody metering skids control systems.

9 PLC Cabinet Construction

Indoor PLC cabinet construction and wiring shall comply with the requirements of
34-SAMSS-820 “Instrumentation Control Cabinets - Indoor”, for outdoor installations
34-SAMSS-821 “Instrumentation Control Cabinets - Outdoor” should be applied,
except as may be overruled by this specification.

9.1 System Spare Requirements

In addition to the spare requirements of 34-SAMSS-820, each PLC enclosure(s)

shall be provided with the following spare capacity to allow for future system

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Document Responsibility: Instrumentation Standards Committee 34-SAMSS-830
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Next Planned Update: 20 March 2018 Programmable Logic Controller

modifications:
a) 10% installed spare I/O modules, based on I/O points used.
(Minimum one spare module of each different type configured
within the application program).
b) 15% empty rack space.

9.2 Assembly and Mounting

9.2.1 PLC system modules (or cards) shall be mounted so that they are
oriented in the vertical plane. Card/rack installation shall facilitate quick
replacement of failed components. Card mounting and supports shall be
designed in such a manner as to dampen the effects of external vibration
on installed modules and components. Components which are not
mounted on PCBs must be securely fastened to a rack or bus assembly.

9.2.2 If power supply units are mounted in the same enclosure as the processor
unit, they shall never be mounted below the CPU and always in the
upper section of the rack(s) or cabinet.

9.2.3 A 100 ohm Platinum RTD shall be mounted at the inside top of any
cabinet containing a PLC CPU(s). The RTD shall be wired into an analog
input module. This analog input shall initiate a temperature alarm.
The setpoint for the alarm is 50°C. The alarm shall be a dry set of contacts
wired to a terminal strip in the cabinet. The alarm will be connected
(by Buyer) to an annunciator or functional equivalent device in the main
process control room. As an alternative, the alarm may be set to
annunciate at the control room DCS console via a communications link.

9.2.4 If so specified in the purchase order or ISS, a strong pull-out tray shall be
provided for the laptop/notebook programming workstation. The tray
shall be positioned to conveniently view the CPU’s front indication panel.

9.3 Power and Signal Wiring

9.3.1 Discrete input field devices shall be wired so that they switch the hot
side of the line. Discrete outputs shall be switched from the hot side of
the line. Isolated commons shall be used when passing signals between
devices which utilize different grounding systems.

9.3.2 I/O wiring for each process train (including duty/standby equipment)
shall be terminated on separate I/O modules. If racks are required to be
powered down for replacing an I/O module, then each process train shall
be terminated in separate racks. This is to facilitate on-line maintenance
of each train without affecting the operation of the other train(s).

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Next Planned Update: 20 March 2018 Programmable Logic Controller

9.3.3 All installed spare I/O modules are to be wired to spare terminal points.

10 Documentation

Required Vendor’s Documentation: If the Vendor is responsible for the development

of the applications program, then he shall provide the documentation listed in items a, b,
c, d, and e. The Vendor shall always provide the documentation listed in items f, g, and h.
Items a, b, c and d shall be generated by the program development workstation software
tools, and shall be transmitted to Buyer in hard (printout) and soft (diskette) format.
a) Annotated printout of all programs or program files in the ladder logic (or
equivalent) format including all embedded address tag names, address descriptors,
rung comments, and network comments.
b) An index of the system’s data base including tag name(s), descriptors, and initial
values.
c) I/O and internal memory element allocations and cross reference;
d) A complete narrative describing the operation and sequence of each network;
e) A complete marked-up (red-lined) set of Buyer supplied binary logic diagrams;
f) Cabinet/Rack interconnecting wiring diagrams, I/O module layout showing all
equipment with each I/O point labeled showing its associated ‘instrument tag
number’ or labeled as a ‘spare’ point, cabinet fabrication drawings;
g) Manufacturer’s standard Programming, Installation, Maintenance/Troubleshooting
Manuals, and Processor, Power Supply, Communications, I/O module
specification sheets;
h) Factory Acceptance Test (FAT) document detailing the set-up and procedures for
the Functional Test.

11 Testing

11.1 Functional Test

11.1.1 The Vendor is responsible for providing all test equipment required to
perform the tests described in this section. In addition, he shall perform full
functional tests and confirm that any problems have been resolved prior to
inviting Buyer’s representative for the Buyer-witnessed functional test.

11.1.2 The complete system including all modules and interconnecting wiring
shall be subject to both hardware and software functional tests.
These tests shall demonstrate the functionality of each individual
component module within the integrated system, including individual
I/O point tests. Wire tagging and terminations shall be checked and

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“Tug” tested. (A tug test involves physically stressing a wire termination

to determine whether it has been crimped and terminated properly.
The intent is not to break wiring or stress insulation but to test the
integrity of the termination).

11.1.3 All software logic/application programs shall be checked against binary

logic diagrams and dynamically tested and verified for proper sequence
and functionality. The dynamic test will involve physically simulating
all inputs and outputs in their proper operational sequence, unexpected
operational sequence, and on power up to verify that the application
program logic is executed properly.

11.1.4 Any external communications link shall be functionally tested using

reels of cable to simulate the specified communication distance.

11.2 Radiated Electromagnetic Field Disturbance Test

11.2.1 The Vendor shall provide testing to confirm that the equipment will
operate properly when energized and subjected to an electromagnetic
field from a radiating source. In particular hand-held radio transceivers
(walkie-talkies) operating at 5 Watts within the frequency range of
68 MHz to 470 MHz shall not cause any malfunction, data corruption, or
damage to the equipment.

11.2.2 The radiated electromagnetic disturbance test shall be conducted in

accordance with IEC 60255-22-3, Test Method ‘C’, Severity Class -’II’
or IEC 61000-4-3, Level 3 (10 volts/meter).

12 Other Miscellaneous Requirements

12.1 Inspection

Items manufactured to this Specification are subject to the minimum Inspection

Requirements as specified in Saudi Aramco Inspection Requirement Form
175-344000.

12.2 Nonmaterial Requirements

The supplier shall provide nonmaterial items as shown on Form NMR-7907.

Revision Summary
20 March 2013 Revised the “Next Planned Update”. Reaffirmed the contents of the document, and reissued
with editorial changes.

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