Iooc Idhc BDP Ins SPC 015 016 DCS R2

BAHREGAN
CRUDE OIL STORAGE TANKS DEVELOPMENT
(PIPING, MANIFOLD, CONTROL SYSTEM & FIRE FIGHTING)
Contract No. :94-111

Title: Functional Design Specification for DCS/ESD/FGS Hardware Rev. 2
Page
Document No:. IOOC-IDHC-BDP-INS-SPC-015-016
Section Page 1 of 29

Integrated Control and Safety System

(ICSS)
Functional Design Specification for DCS/ESD/FGS Hardware
01 26-Apr-2016 Issued For Approval M.B. R.A. R.A.

00 10-Nov-2015 Issued For Approval M.B. R.A. R.A.
Prepared Checked Approved Reviewed Approved
Rev. Date Description
Vendor’s/ Supplier’s Name EPC EPC
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BAHREGAN CRUDE OIL STORAGE TANKS DEVELOPMENT

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SECTION 1
FUNCTIONAL DESIGN SPECIFICATION

DCS HARDWARE AND SOFTWARE
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SECTION 1
Table of Contents
1- GENERAL ................................................................................................... 3
2- OPERATING AND CONTROL PHILOSOPHY.................................................. 6
3 - HARDWARE ............................................................................................. 25
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1. INTRODUCTION
1.1 GENERAL
The purpose of this document is to describe the functionality and design of Distributed
Control System (DCS) for the Project of BAHREGAN CRUDE OIL STORAGE TANKS
DEVELOPMENT project. This document describes how the system meets the project
requirements. The scope of the project includes: Design, engineering, procurement,
assembly, wiring and testing.
1.2 REFERENCES
1.1. References
Following documents are use as basis for calculation of required Hardware items in this project:
Table 1 ‐ References Document
Item Document Title. Document No
1 Overall Control & Safety System Block Diagram IOOC‐LPGC‐BPD‐ INS‐DIA‐061

2 Material Requisition for control System ‐
3 Specification for Control System ‐
4 DCS & ESD Signal List ‐
1.3 PROJECT OVERVIEW
SCOPE
The scope of supply of the Distributed Control System (DCS) shall include the provision of
design, engineering, supply, assembly, testing, packaging and documentation of the DCS
and all associated hardware and software.
The preliminary DCS topology is shown in the “Overall System Block Diagram”.
The CENTUM VP Distributed Control System is Yokogawa's latest state of art Integrated
Distributed Control System.
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CENTUM VP System is an integrated control system used to manage and control the operation
of plants in wide variety of process industries. CENTUM VP is a key part of Yokogawa's
Enterprise Technology Solutions and features,
● Open environment for optimizing the whole enterprise,
● optimal operation environment, hardware upgradeable to the latest technology,
● Flexible, durable system that can be optimized for plant operation
● Minimize total cost of ownership
● Powerful engineering functions.
The Human Interface Station (HIS) or the operator station of CENTUM VP is based on general purpose
PCs running on standard Microsoft's Windows XP operating system.
CENTUM VP uses proven high reliability “pair and spare” dual redundant controllers. One can
select the control station hardware and software based on the size and requirements of the process.
The standard control stations handle a large amount of I/O which can be distributed throughout the
plant. It can handle high speed communications as well.
Up to 256 control stations can be connected in an overall system configuration making it ideal for
medium and large process plant control.
1.5 SYSTEM OVERVIEW
The Integrated Control / Safety System (ICSS) consists of control systems and safety
systems.
1.5.1 Control Systems
The development of the BAHREGAN CRUDE OIL STORAGE TANKS is
based upon the following main process units:
- Control of new tanks T-A1, T-A2, T-A3 & T-A4 (new system)
- Communication with STARDOM (existing system) for control of existing tanks.
The normal control & monitoring system is the Process Control System (PCS) that will
allow operational monitoring and control from the CCR. The control and monitoring
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functions will be implemented via a Distributed Control System (DCS) linked to other
subsystems such as:
 ESD system (Vnet/IP)
 EWS ,OWS (via Vnet/IP)
 Printer (via TCP/IP)
 Package panels/ stations such as TGS control panel (via Modbus)
 Field instruments (via hardwiring)
 MCCs and related power distribution status with IRP (via hardwiring)
 Communication with existing system STARDOM (via Modbus)
1.4 GLOSSARY
The following terms and abbreviations/definitions will be used in this document.
CCR Central Control Room

DCS Distributed Control System
EDP Emergency Depressurization
ESD Emergency Shutdown
ESDV Emergency Shutdown Valve
EWS Engineering Workstation
FGS Fire and Gas System
FAT Factory Acceptance Test
FCS CENTUM VP Field Control Station
HVAC Heating, Ventilation and Air Conditioning
IE Electronic ground (Instrument Earth)
I/O Input/Output
IPCS Integrated Plant Control System
IPE Primary earth ground; Instrument Protective Earth
ISO International Standardization Organization
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LER Local Equipment Room
LAN Local Area Network
LED Light Emitting Diode
LNG Liquid Natural Gas
MC Marshalling cabinet
Matrix Panel of lamps and switches for interfacing to logic systems
MCB Miniature Circuit Breaker
MCC Motor Control Center
MIH Maintenance Inhibit
MTBF Mean Time Between Failures
NGL Natural Gas Liquids
OCS Operator Control Station
OCD Operator Control Desk
PCS Process Control System
PDCS Power Distribution Control System
PLC Programmable Logic Controller
SDV Shutdown Valve
SIL Safety Integrity Level
SOE Sequence Of Events
SIH Start-up Inhibit
SS Electrical Sub Station
UCP Unit Control Panel
UPS Uninterruptible Power Supply
USS Ultimate Safety System
Vnet/IP CENTUM VP Process Network
2 . OPERATING AND CONTROL PHILOSOPHY

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2.1 GENERAL
The received crude oil from offshore oil fields, Bahregansar & Hendijan, is stored in
Bahregan existing storage tanks and then is exported.
In Development of Bahregan Storage Capacity Project, It is purposed that crude oil from
onshore oil field, Azadegan, will be transferred to four new floating roof storage tanks and
eight existing storage tanks of Bahregan field and then exported to the oil tankers.
The scope of this project is to transfer the incoming crude oil from pipeline to 30" main
header and distribution between 30" first, 48" second and 48" third manifolds. The incoming
crude oil will be loaded to new constructed storage tanks. In order to integrate the new and
old manifolds, there are also some interconnection between Bahregan manifolds and
Azadegan manifolds.
Contract scope for Bahregan Crude Oil Storage Tanks that will be performed by IDEH
consist of:
- Tanks control room (CCR):

1- One central control panel (Yokogawa) and 3 marshaling panel for control of new
tanks (T-A1, T-A2, T-A3 & T-A4) and communication with existing system (STARDOM) for
control of existing system.
2- Tank gauging system (TGS) for new tanks (T-A1, T-A2, T-A3 & T-A4)
3- One ESD Console
4- Two operator station (HIS) for DCS & ESD
5- One engineering station for DCS & ESD & TGS
6- Two operator station for TGS
7- Two Printers for DCS and ESD system And Two Printers for TGS. 02
- Fire fighting control room:

1- One engineering station for F&G (Laptop)
2- One F&G main panel (SCAME)
3- One Consul for operator station
4- One printer
CCR includes related DCS & ESD cabinets and other necessary component such as TGS
panel and operator station. DCS &ESD system located in CCR shall perform all control/ logic
functions related to new and existing tanks independently. Furthermore it shall make data
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acquisition from existing system (STARDOM) via making the following interfacings with
pertinent LAN via integrated communication modules.
SYSTEM OPERATION
In HMI will be designed matrix for choice a transfer operation as follows:
START OF TRANSFER:
1- Section of related Button to desired transfer for example: Tank A to Tank B

2- All Buttons for inhibited transfer will be deactivated
3- Source and destination of desired transfer will be shown in screen page
4- Source volume and destination capacity will be shown and operator can set the Set
Point
5- Quantity of set point will be checked with source volume and destination capacity as
below:
- in normal condition volume status will be set as ready
-in abnormal condition volume status will be set as not available
6- when operator select the Start push Button , all valves which must be close , will be
closed and all related valves of desired transfer will be opened.
7- If in desired transfer exist any pump, operator must start the pump. In HIS ,there is a
page for pumps that operator can select DUTY or STANDBY for pumps basis on
pumps performance duration.
STOP OF TRANSFER:
Transfer will be stop when one of the below condition occurs:
1- operator select the stop push Button

2- ESD condition occurs
02
3- Transfer cycle has been finished.
4- One of the ready conditions has been vanished.
If one of the above condition occurred first related pump will be stop ,Then all of the related valves
and manifolds will be reset and all of the deactivated push Button will be activated.
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2.2 COMMUNICATION WITH EXISTING SYSTEM
Communication with existing system (STARDOM) will be performed by Modbus RS 485

serial link for below items:
1-. The new Yokogawa system will be performed data acquisition from existing system and
processes data for transmission of command to existing system.
2- The new tanks will be controlled directly by new Yokogawa System.
3- safety of existing tanks will be performed by new Yokogawa system and existing system
(STARDOM)
4- Existing operation system will be uninstalled and all operation for new and existing
tanks will be done by new operation system.
5- Communication between existing TGS and STARDOM will be remained.
2.3 NETWORK ORGANIZATION
On this project, there are 1 domains as below.(Refer to “System Architecture General

Layout”)
All Vnet/IP Equipment are connected by Layer 2 Switch inside a domain and the domains
are interconnected using Layer 3 switch. All general purpose Ethernet devices are connected
using Layer 2 Ethernet switches with 1GBPS.
The network architecture is organized in STAR topology from CCR.
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2.3.1 Equipment located in the Central Control Room
System Description ID
02
DCS System Cabinet DCS-PNL-01
DCS marshaling Cabinet DCS-MAR-01
DCS marshaling Cabinet DCS-MAR-02
DCS
& DCS marshaling Cabinet DCS-MAR-03
ESD Engineering Station DCS-EWS-01
DCS Operation Station DCS-OWS-01
DCS Operation Station DCS-OWS-02
SIS System Cabinet ESD-PNL-01
Black-white Laser printer DCS-PRT-01
Color Laser printer DCS-PRT-02
TGS Cabinet TGS-PNL-01
Operation and Engineering
TGS-EOWS-01
Station
TGS Operation and Engineering
TGS-EOWS-02
Station
Laser Printer GEN-PRN-01
Laser Printer GEN-PRN-02
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2.3.2 I/O
DCS MODULE
MODBUS
AI 4- AO 4-
Signal Type DI DO RS485- AMOUNT 02
20mA 20mA
RTU
Actual I/Os 7 1 215 88 0 311
I/O (Incl. 20%

9 1 258 106 0 374
Spare)
I/O Module AAI143 AAI543 ADV151 ADV551 ALR121 -
Channel 16 16 32 32 - -
Qty. 1 1 8 5 2 17
I/O Module(With
2 2 8 6 2 20
Red.)
Provided IO s 32 32 256 128 - 448
Terminal Board
Yokogawa Yokogawa Yokogawa Yokogawa - -
Type
Qty. 1 1 8 5 - 15
Signal Cable KS1 KS1 SAKB331 SAKB331 - -
Qty. 2 2 8 6 - 18
NODE 2 FCU 1 COVER 4
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2.4 SOFTWARE PACKAGES(Key codes)

Operator and engineering stations will have different software packages loaded onto them
depending on their function. Key code licenses will decide what kind of function each station can
have.
DCS Software Pacakge
S/N. Description Card No. Qty
1 Project ID Basic Software License LHMPJT1‐V51
1
2 Software disk package LHSKM50‐V11
1
3 Electronic version manual LHS5495‐V11
1
4 Standard monitoring & operation software package LHM1101‐V11/N0003
2
5 OPC software package LHS2411‐V11
1
6 Standard configuration software package LHM5100‐V11
1
7 Standard P&ID configuration software package LHS5150‐V11
1
8 Control status display software package LHM4410‐V11
2
9 Logic status display software package LHM4420‐V11
2
10 Trend recording software package LHS6510‐V11
1
11 Report software package LHS6530‐V11
1
12 Dual Monitor Package LHS4600‐V11
2
13 Node Expansion Package LHS1750‐V11
1
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2.5 SYSTEM MANAGMENT

2.5.1 Proposed System Overview
The Integrated control system uses Yokogawa's CENTUM VP with Vnet/IP network which include:
● HMI (HIS) stations ,
● Engineering Work station (EWS)
● Field Control Station (FCS)
● Vnet/IP network
● Layer 2 switches
2.5.2 HIS
HIS is an Operator Console which is a PC running on Win7 OS & CENTUM VP software. HIS is a
node on 2 different networks, V-net IP LAN through VI702 Card & HMI Database LAN (E1)
through Ethernet Card. They act as an interface station for Operator.
V-Net I/P network connect FCS & HIS to gather and display data from the FCS. It can also convey
commands issued by the operator from HIS through FCS to field.
Operator keyboards supplied with the HIS will serve to provide “One-touch” operations to the
operator utilities. In BAHREGAN CRUDE OIL STORAGE TANKS DEVELOPMENT Project trends shall be
available on the basis of OCD grouping.
Trend segregation and grouping shall be performed during detail engineering. Apart from operator
keyboard a mouse will be provided for each station.
Input device for HIS are mouse and key board. HIS uses static IP address system. Dip switch
setting in the VI702 card will determine the Domain number and station name.
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2.5.3 Engineering Station
Master Engineering station located in Central Control Room (CCR ),is running on Windows 7 having
CENTUM VP engineering software. All application software generation
activities related to DCS software are carried out on this station & then loaded to the other HIS /
FCS over their respective networks. Engineering station sits in 2 different networks V-net IP LAN
through VI702 card and HMI/Engineering Database LAN through Ethernet Card. The additional
LAN will make HMI equalization faster. Database Engineering changes can be carried out in both
“online / offline “modes. However once the plant is commissioned changes shall be restricted to
online mode.
2.5.4 FCS
The Field Control Station (FCS) controls the plant process through the control functions and
algorithms configured in the FCS. The FCS consists of CPU, power supply units and
communication bus interface cards in it as dual redundant configuration.
Each FCS is a node on the control data Highway called V-net I/P, with a dedicated unique
address. One control network can have a maximum of 16 domains (Domain is a combination of
operation stations and the control stations)
FCS supports two different kinds of I/O node units, Local node and remote node.
The local node unit is connected directly to the FCS through ESB Bus; the maximum length of the
ESB Bus is 2M hence local node has to be mounted on the FCS cabinet.
The remote node units are connected to FCS through interface card on a local node. Remote
node can be mounted in a cabinet or enclosure near to the plant equipment. The connection
between remote and the local node can be through Optical link. A simplest configuration is
illustrated in Figure -1
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Figure-1
2.5.5 Network
Vnet/IP is a control network with high reliability and quick response and achieves steady response
with little delay even under heavy load. Using general- purpose network equipment conforming to
IEEE802.3 and UDP/IP standards, it realizes open-based communications. This is a control bus
conforming to the IEEE802.3
Standard Line speed is 1Gbps. A Vnet/IP bus has a dual redundant configuration. On its bus 2,
control communications and open-based communications with various Ethernet standard
protocols are provided. At the Open Communication side, data access through an Exaopc OPC
interface and TCP/IP protocol- based communications can be carried out. For equipment for
network connections, including repeaters, cables, layer 2 switches, layer 3 switches, and the like
commercially available general- purpose products are used. For the IP address, IPv4 for Class C
private space addressing is applied. (IPv4 for Class B private space addressing is also applied.)
Back bone of CENTUM VP Vnet/IP system is the 1000 Mbps (1Gpbs) redundant Network. The
proposed network and system architectures are illustrated in system architecture drawing IOOC-
02
IDEH-BPD-INS-BDM-014-00.The Architecture is based on Yokogawa VNET/IP dual redundant Bus
system. In the event of a Bus failure a single Bus can support both control and open
communications. Level 2 Managed Switches (L2MS) are used for communicating to Yokogawa
based equipment.
All other connections inside CCR and Fire Fighting Room shall be through CAT6 Ethernet cable.
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Figure-4
● Number of Vnet/IP stations connected: Max 64 Stations (This includes all HIS, FCS,
Station, SENG, SCS and PRM).
● Number Maximum of 7 Level of Layer-2 can be connected to CENTUM VP Vnet/IP

network
● Maximum distance between layer 2 switch and station is only 90m
● Maximum distance between two layer-2 switch is 5Km when optical fiber cable is used
without repeater. (Only single mode Fiber optic cable is supported for CENTUM VP
system)
● Other general purpose Ethernet communication device such as PC, Printer including
CENTUM VP component are connected on a separate network (E1).The speed of this
network is 1Gbps.
● Refer BOM for the make and model for the switch.

2.5.6 Vnet/IP Network
The CENTUM VP system consists of the HIS (Human Interface Station) for the operation and
monitoring functions, the FCS (Field Control Station) that carries out the control functions, and the
control bus Vnet/IP)that connects these stations.
Vnet/IP is an Ethernet based 1Gbps network. Although Ethernet is a collision detection network,
a Vnet token passing application layer overlays this. To the HIS, it connects to the network as if it
is standard Vnet.
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Token Passing and Collision Detection:
A token passing network works on the concept of a token that is passed from station to station on
the network. When a device has the token it is the master of the network and initiates all
read/write communications. When it has finished it passes the token to the next station. If a
station holds the token for too long it is forcibly moved to the next station so that all stations get a
chance to communicate within a given period of time. As such, a token passing network is
deterministic, that is, it is possible to predict its performance when fully loaded, and as such is
ideal from real-time control networks. Vnet is a token passing network.
Ethernet is based on collision detection. Every station can communicate on the network at any
time and therefore it is possible for stations to attempt communication simultaneously. If this
happens then a collision occurs and the network shuts down. The two stations that caused the
collision start random timers and the first to time out has control of the network. Once completed,
the network is open again for all devices to attempt communication. This type of network
nondeterministic and works very inefficiently at loads above 10%. The efficiency can be significantly
improved by using switches (which cut down the number of collisions) and having very fast
datatransfer (eg, 1Gbps).
Vnet/IP uses Ethernet to take advantage of the latest Ethernet technologies, and the availability of
a wide range of commercially available hardware. However, to get around the problem of the
nondeterministic nature of Ethernet, a Vnet token passing technology is used.

Application layer is imposed over the top of Ethernet so that a token is still passed from station to
station to avoid collisions.
2.6 THE SYSTEM ADMINISTRATION

2.6.1 Engineering Work Station(EWS)
Engineering Work station is mainly used for to configure all the HIS, Control, and Logic for the
projects. All the source database is residing on the engineering station. Access ability on
engineering station is limited with Engineers only. In this project there are one numbers (one ENG
Station in CCR) for BAHREGAN CRUDE OIL STORAGE TANKS DEVELOPMENT.
The function of engineering station is described below:
Engineering
SL_NO Remarks
Station Description
● Engineering Station located in CCR
1 Engineering station
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● All engineering Function can be done from here along
with other engineering station
● Master Data base will be on this engineering station
● All the operator station functionality (Operation and
monitoring) also available on this engineering station
● Graphics Source file Master is available on this Engineering
station.
● All HIS Database equalize is from Engineering

station
● User Adequate security permission to log on engineering
environment
Eng Functions for Field control Station
● Tag list building
● Adding Nodes and I/O Cards to the configuration
● Input / Output Card database building
● Communication database building Such as Modbus mapping list
● Configuration of control loops and Logics scheme
● Download the Application Image to FCS
● Tag and Data base equalization to all HIS.
● Off line downloading the Image to FCS on demand.
Eng functions for HIS
● Configuring Graphics Functions
● Configuring all other HIS like control group, trend group, overview panel etc.

System Administration Function
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● Adding / Deleting a new station / node to the configuration
.
● User security control (adding / deleting user and privilege setting for each use)

● Adding common items like eng unit, Alarm color etc.
2.6.2 Reference Database
In CENTUM VP system the database in the engineering station is referred to as the reference
database. The Human interface stations (HIS) on the Control network (V-Net I/P) shall refer
to one database. The reference database host name is specified while the operation and
monitoring function is installed in the HIS. However this definition can be changed for the HIS
setup in the Equalize tab. The following figure shows the equalize tab in the HIS setup.
In BAHREGAN CRUDE OIL STORAGE TANKS DEVELOPMENT PROJECT, all the HIS shall refer to
Engineering station as the reference database.
3 HARDWARE
3.1 HARDWARE OVERVIEW
3.1.1 Field Control Station (FCS)
Duplexed Field Control Station, type AFV30D (Vnet/IP), in cabinet with its own nodes and
I/O’s cards. FCS including CPU, Power, Vnet/IP Bus and ESB Bus are fully redundant.
There are 2 feeders for power. A battery unit provides 72 hours backup for memory data.
The FCS is connected to the Vnet/IP and provides an interface between the field
equipment and the CENTUM-VP Vnet/IP system. Continuous and sequential control
functions are performed by the FCS.
FCS consists of FCU (Field Control Unit) and Nodes through redundant ESB bus. Each
node is able to hold up to eight (8) different I/O modules both in redundant and single
configurations. The FCU is able to hold up to six (6) different I/O modules. The Processor of
FCU is 133MHz and 32Mbyte memory.
3.1.2 Vnet/IP interface card / VI702
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After installing the Vnet/IP interface card into the PCI slot of the workstation, it can be
connected to the Vnet/IP network.
Communication Speed: 1000Mbps Full Duplex
Cable: CAT6 (Enhanced Category 6 cable), UTP
Transmission: 1000Base-T compliance
Connector: RJ45 Connector
Max. Distance: 100m (Distance between VI702 and Layer 2 Switch using copper
media)
3.1.3 Vnet/IP
This is a control bus confirming to the IEEE802.3 standard. Line speed is 1Gbps and a real-
time process control network used to connect system components. The Vnet/IP supports two
types of communications: control-bus communications and open communications. It has a
dual redundant configuration. On its bus 1 side, control bus communications are carried out
and on its bus 2 side, open communications are carried out. If a control communications
error occurs at the bus-1 side, control bus communication will be carried out via bus-2.
3.1.4 Input / Output Card
The following types of I/O cards are being used in the project:
Models Description
Analog /I/O Module
AAI143 Analog Input Module (4-20mA, 16-Channel, Isolated)
AAI543 Analog Onput Module (4 to 20 mA, 16-Channel, Isolated)
Digital /I/O Module
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ADV151 Digital Input Module (32-Channel, 24 V DC, 4.1 mA)
ADV551 Digital Output Module (32-Channel, 24 V DC, 100 mA)
Communication Module
ALR121 Serial Communication Module
3.1.5 Signal Route configuration
For details of Loop wiring for different signal type refer to typical loop wiring document
3.1.6 Layer 2 Switch
This is a device to connect equipment’s that belong to the same Vnet/IP domain. The
layer 2 switch, unlike a HUB, incorporates bridge functions to send data to the
destination terminal equipment only; it can, therefore reduce traffic within its domain.
Specification
Auto detecting of speed, configuration Auto negotiating on 10/100/1000 ports Auto

selecting half/full duplex transmission Dynamic trunk configuration across all switch ports
Auto adjustment transmission for cable type (crossover or straight-through) IEEE 802.3z
compliant 1000Base-SX,- LX,-LH,-ZX and –T physical interface
1.5 RU standalone, managed switch
3.1.7 Operator Control Station in CCR:
Dual 22" LCD Monitor, (Without Touch Screen)
Processor: Xeon(R) E5-2603 1.8GHz 10M,
Hard Disk :500G,
Memory : 4G,
48x DVD writer,
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Graphics card resolution: 512MB AMD FirePro 2270
Operating System: Win 7 (OS To Be Supplied by Client)
3.1.8 Engineering Work Station (EWS) for DCS & ESD at CCR:
Single 22" LCD Monitor, (Without Touch Screen)
Processor: 3.2 GHz ,
Memory: 2 GB,
Hard Disk: 500GB, 02
48x DVD writer,
Graphics card resolution: 256MB
Operating System: Win 7 02
3.1.9 Cables
3.1.9.1 Cable identification
All system cables have identification at each end of the cable. The identification shows
the location where the connector should be plugged in.
3.1.9.2 Vnet/IP cable
Commercially available “Unshielded twisted pair (UTP) at enhanced category 6” cables can
be used.
The standard cable specification by connection
Connection Maximu
Cable Spe
m
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Standard ed Distance
Between Station
1000Base-T
(Note1) & Layer 2 1Gbps 100m
(IEEE802.3ab)
Switch
Between Layer 2 1000Base-T

1Gbps 100m
Switches (IEEE802.3ab)
Between Layer 2 1000Base-T

1Gbps 100m
Switch and router (IEEE802.3ab)
Note 1: Station means PCS main equipments which connected to Vnet/IP such as FCS,
EWS and HIS etc, but except switch
3.1.9.3 ER bus /Remote I/O Cable
Commercially available enhanced category 5 cable will be used Refer to Cable List.
3.1.9.4 I/O’s Cable
KS1-xx: Connection between Analogue I/O module and A1BA4D/EQUIVALENT terminal

board. xx means cable length.
AKB331-xx: Connection for between Digital I/O module (ADV151,ADV551) and A1BD5D/
EQUIVALENT terminal board. xx means Cable length. Serial Link cable details are
provided in 3.1.17.8
3.1.9.5 Power Cable
Power Cables run between Power Distribution Board (PDB) located in each panel. There
are 3 types of power are supplied via PDB. Redundant 230VAC 50Hz unearthed, single
48VDC unearthed which are from the Uninterruptible Power Supply and redundant 24VDC
unearthed which converted from redundant 230VAC UPS. Supply and installation of Power
cables from PDB to main feeder is not in the scope of IDEH.
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3.1.9.6 Ground Cable
Ground Cables run to Power Distribution Board (PDB)
from all panels’ bus bar individually within the CCR and Fire Fighting Control Room indoor.
And the Earth Section on PDB is connected to the master ground pole within the CCR. The
type of cable is FR-PVC Insulated Grounding (TFR-GV). Supply and installation of Grounding
cables from individual equipments to the ground bars in CCR and Fire Fighting Control
Room is not in the scope of IDEH.
Constructor: Annealed Copper Wire, 35mm2 Insulation: FR-PVC
Color of the insulation: Green/Yellow for IPE, Green for IE Sheath: PVC
3.1.9.7 Serial Links Cable
Four-wire and two-wire types are used for the connection of Model ALR121 with external
equipment. Each type has 1 to 1 and 1 to n connections.
2 wires type connection is preferably used
3.1.10 Terminal boards
The main functionality is to change connections from connectors into terminals. Boards
are mounted in Marshalling cabinet.
Type of the terminal board is as below:
A1BA4D (Yokogawa) /EQUIVALENT: Terminal Board for Analog Input/Output

Module.(Single/Redundant)
A1BD5D (Yokogawa) /EQUIVALENT: Terminal Board for Digital Input/Output Module

(Single/Redundant)
3.1.11 Field Interface
For the field cable connection, the front side of marshalling panel is prepared. On front side,
there are terminal blocks, vertical IE shield bus rail and cable ducts for this connection.
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3.1.12 System Interface
On the front side of marshalling panel,there are terminal boards .This terminal board is
connected to I/O module in FCS with dedicated system cable and also connected to
terminal block on the other side with internal wiring.
3.1.13 Cross Wiring
I/O point order in terminal board which connected I/O modules is according to the process
unit, function, voltage etc. And I/O point order in terminal blocks is according to the field
connection like junction box connection order. Therefore, the internal wiring between terminal
board and terminal block are cross wired. Cross ferruling philosophy will be adopted in all the
wiring with in the cabinets. The individual ferrules will show both the source and the
destination of the wires.
3.1.14 MCC Interface
The dedicated digital module for MCC is connected to the terminal board with on board relays. The
relays send the voltage free contact output to connect or cut off the 230VAC flowing circuit related to
MCC when operated. I/O modules, terminal boards and relays for MCC are segregated from SOV output
components within the cabinet.
3.2 Redundancy
This section is for information and is applied to only specified IO in client IO list for
redundancy requirement
3.2.1 FCS
In each FCS the following parts are redundant:
Processor Cards: The FCS contains two processor cards.
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Power supply cards: The power supplies in the FCS and NIU are redundant.
Internal ESB Bus: The FCS has two redundant ESB Bus control cards.
Vnet/IP Interface cards: The FCS has two redundant Vnet/IP Bus control cards.
3.2.2 Vnet/IP
Vnet/IP is a network that confirms to the IEEE802.3 and TCP/IP communication standards.
It supports a transmission speed of 1Gbps. It has two independent communication paths,
control communication and open communication. Control communication is for transferring
control data and Open communication is conducted by using the various standard protocols
of Ethernet.
Vnet/IP is designed as a redundant network. In Vnet/IP, a redundant bus is configured with

independent subnets of bus1 and bus 2. If both buses are normal, bus 1 is used for control
communication and bus 2 is used for open communication. If a communication error occurs
in bus1 for some reason, control communication is performed using bus2. In this case,
because open communication is also performed using bus2, control communication and
open
communication coexist. Therefore, to secure the band for control communication, the band
for open communication will be restricted.
3.2.3 I/O Module Redundancy
Following cases are considered redundant module consideration.
All MODBUS connections are considered as redundant and will be connected using CAT6 cables
with RJ45 connectors which will get connected in the ALE111 cards
RS 485 Redundant Serial Communication links also will be used by using ALR121
module, if 3 rd party side could not support the Modbus on Ethernet
All other I/Os are considered as simple as defined in client specification.
Page 29 of 29

Iooc Idhc BDP Ins SPC 015 016 DCS R2

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BAHREGAN

Integrated Control and Safety System

01 26-Apr-2016 Issued For Approval M.B. R.A. R.A.

FUNCTIONAL DESIGN SPECIFICATION

2- OPERATING AND CONTROL PHILOSOPHY.................................................. 6

1 Overall Control & Safety System Block Diagram IOOC‐LPGC‐BPD‐ INS‐DIA‐061

1.3 PROJECT OVERVIEW

● Open environment for optimizing the whole enterprise,

● optimal operation environment, hardware upgradeable to the latest technology,

● Flexible, durable system that can be optimized for plant operation

● Minimize total cost of ownership

● Powerful engineering functions.

1.5 SYSTEM OVERVIEW

1.5.1 Control Systems

The development of the BAHREGAN CRUDE OIL STORAGE TANKS is

based upon the following main process units:

- Communication with STARDOM (existing system) for control of existing tanks.

 ESD system (Vnet/IP)

 EWS ,OWS (via Vnet/IP)

 Printer (via TCP/IP)

 Package panels/ stations such as TGS control panel (via Modbus)

 Field instruments (via hardwiring)

 Communication with existing system STARDOM (via Modbus)

The following terms and abbreviations/definitions will be used in this document.

CCR Central Control Room

2 . OPERATING AND CONTROL PHILOSOPHY

- Tanks control room (CCR):

- Fire fighting control room:

In HMI will be designed matrix for choice a transfer operation as follows:

1- Section of related Button to desired transfer for example: Tank A to Tank B

Transfer will be stop when one of the below condition occurs:

1- operator select the stop push Button

Communication with existing system (STARDOM) will be performed by Modbus RS 485

2- The new tanks will be controlled directly by new Yokogawa System.

2.3 NETWORK ORGANIZATION

On this project, there are 1 domains as below.(Refer to “System Architecture General

The network architecture is organized in STAR topology from CCR.

2.3.1 Equipment located in the Central Control Room

I/O (Incl. 20%

I/O Module AAI143 AAI543 ADV151 ADV551 ALR121 -

Provided IO s 32 32 256 128 - 448

Signal Cable KS1 KS1 SAKB331 SAKB331 - -

NODE 2 FCU 1 COVER 4

2.4 SOFTWARE PACKAGES(Key codes)

DCS Software Pacakge

S/N. Description Card No. Qty

2.5 SYSTEM MANAGMENT

● HMI (HIS) stations ,

● Engineering Work station (EWS)

● Field Control Station (FCS)

2.5.3 Engineering Station

● Number Maximum of 7 Level of Layer-2 can be connected to CENTUM VP Vnet/IP

● Maximum distance between layer 2 switch and station is only 90m

2.6 THE SYSTEM ADMINISTRATION

● All HIS Database equalize is from Engineering

Eng Functions for Field control Station

● Tag list building

● Adding Nodes and I/O Cards to the configuration

● Input / Output Card database building

● Communication database building Such as Modbus mapping list

● Configuration of control loops and Logics scheme

● Download the Application Image to FCS

● Tag and Data base equalization to all HIS.