Vol IX - PG B210 - IC Works

ENGINEER’S STAMP: CONTRACTOR’S STAMP:
C Issued for Tender Wilken 06.11.2020

Gasic Nyoundou
B Issued for Tender Shahab Nyoundou Wilken 22.07.2020
0 Issued for Tender Shahab Maiwald Wilken 20.04.2020
REV DESCRIPTION PREPARED CHECKED APPROVED DATE
KINGDOM OF SAUDI ARABIA ‫اﻟـﻤﻤـﻠـﻜــﺔ اﻟﻌــﺮﺑـﯿــﺔ اﻟﺴــﻌـﻮدﯾـــﺔ‬

‫اﻟﻤـﺆﺳــﺴــــﺔ اﻟﻌــﺎﻣــﺔ ﻟﺘﺤــﻠـﯿﺔ اﻟـﻤــﯿــﺎه اﻟـﻤــﺎﻟــﺤــﺔ‬
SALINE WATER CONVERSION CORPORATION
CONSTRUCTION OF SALES GAS SUPPLY PIPELINE TO YANBU
PLANT PHASE-3 PROJECT
FICHTNER GMBH & CO. KG
TENDER DOCUMENTS
LOCATION: TITLE:
Western Coast VOLUME IX PART PG-B210
PACKAGE: TECHNICAL SPECIFICATION
INSTRUMENTATION AND CONTROL (I&C)
SCALE: REV:
None Q A 1 0 - H - 0 4 1 0 C
SUBCONTRACTOR:
Sheet 1 of 102
CONSTRUCTION OF SALES GAS SUPPLY PIPELINE TO YANBU PLANT
PHASE-3 PROJECT
Subject: VOLUME IX PART PG-B210 Page 2 of 102

TECHNICAL SPECIFICATION
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Disclaimer
The content of this document is intended for the exclusive use of Fichtner’s client and
other contractually agreed recipients. It may only be made available in whole or in part to
third parties with the client’s consent and on a non-reliance basis. Fichtner is not liable to
third parties for the completeness and accuracy of the information provided therein.
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Table of Contents
1. General 7
1.1 Codes, Permits and Agency Approvals 8
1.2 Service Conditions and Environmental Requirements 9
1.3 Submittals 10
1.4 Tagging 11
1.5 Packing & Storage 11
1.6 Spare parts list 12
1.7 Familiarization and Development 13
1.8 Technical Requirements 13
1.9 Hazardous Areas 14
1.10 Hazard and Operability Study (HAZOP) 15
2. Operation and Control Philosophy 16

2.1 Automation Degree 16
2.2 Availability and Redundancy 17
2.3 Task of the main control loops 18
2.4 General Requirements for Modulating Control, Protection and Interlock
system 19
2.5 Control rooms 19
2.5.1 Technical room 20
2.6 Package’s PLC 21
3. Instrumentation 22
3.1 General 22
3.1.1 Local instruments 23
3.2 Flow instruments 24
3.2.1 Ultrasonic flowmeters 25
3.2.2 Rotameters 25
3.2.3 Flow switches 26
3.3 Pressure Instruments 26
3.3.1 Pressure & differential pressure transmitters 27
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3.3.2 Pressure switches 27

3.3.3 Pressure gauges 28
3.4 Level Instruments 30
3.4.1 Radar level transmitters (microwaves) 30
3.4.2 Hydrostatic level transmitters 31
3.4.3 Ultrasonic level transmitters 31
3.4.4 Level switches 32
3.5 Temperature Instruments 33
3.5.1 Temperature sensors/ transmitters 33
3.5.2 Thermometers 34
3.6 Analytical Instrumentation 35
3.6.1 Wobbe meter 36
3.6.2 Gas chromatograph 36
3.7 Settlement Metering System (check meter) 36
3.8 Vibration Measurement System (VMS) 36
3.9 Automatic Valves 37
3.9.1 On-off valves (Isolation) 38
3.9.2 Control valves 38
3.10 Actuators 40
3.10.1 Electric actuators 42
3.10.2 Pneumatic actuators 43
3.11 Installation Requirements 45
3.11.1 Power supply 45
3.11.2 Grounding and surge suppressors 45
3.11.3 Instrument’s installation 46
3.11.4 Wiring and cabling 49
3.11.5 Instrument air supply system 52
3.11.6 Instrument’s interface 53
4. Control System 54
4.1 Availability and Redundancy 55
4.2 Cyber Security 57
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4.3 Hardware Requirements 58

4.3.1 Process controllers 59
4.3.2 Signal processing 60
4.3.3 Marshalling 63
4.3.4 Data highway communication 63
4.3.5 Power supply 64
4.4 System Software Configuration 64
4.4.1 Software requirements 65
4.5 Operator’s Stations 72
4.5.1 Human machine interface (HMI) 74
4.5.2 Alarm annunciation 80
4.5.3 Large screen projection panels (LSPP) 82
4.6 Engineering Station (EWS): System Diagnostics and Configuration 82
4.7 Plant Management System (PMS) 83
4.8 Asset Management System / Field Device Tools (FDT) 85
5. Communication System 86
5.1 General 86
5.2 Telephone System 86
5.3 Clock System 87
6. Scope of Supply and Service 88

6.1 Field Equipment 88
6.2 Distributed Digital Control System (DCS) 89
6.2.1 Plant management system (PMS) 91
6.2.2 Asset management system/field device tool (FDT) 91
6.2.3 PLC based control systems for package equipment 91
6.2.4 Central control room equipment 91
6.2.5 Technical room (TR) equipment 92
6.3 Data Network 92
6.4 Telephone System 92
6.5 Clock system 93
6.6 Spare Capacity after Completion of Commissioning 93
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6.7 Engineering & Services 93

6.8 Documentation 95
6.8.1 Documents with Bidder’s proposal 95
6.8.2 Submittals after contract award 96
6.9 Erection, Cabling, Wiring, Labelling 100
6.10 Commissioning, Trial Operation, and Acceptance Tests 101
6.11 Documentation 101
6.12 Training 101
6.13 Special tools and Spare Parts 101
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1. General
This Part of the specification covers the general and technical requirements
to be considered in the design and supply of the instrumentation, control,
monitoring and communications systems, for the new GRS system
providing fuel gas to the Yanbu Power & Desalination Plant.
The system shall be furnished as specified, complete with all software,

distributed control system (DCS) hardware, human machine interface (HMI)
hardware, instrumentation and all devices, accessories, appurtenances,
programming, testing, and training services necessary for the proper and
safe operation ensuring utmost availability of the plant.
The control, instrumentation and monitoring equipment to be provided shall

be suitable for faultless and safe control and supervision of the entire GRS
during all the operating conditions.
The Specification stipulates the minimum requirements for the design,

scope of supply of the required equipment and materials, fabrication,
inspection, testing and commissioning of the systems. The Contractor shall
be responsible for the design of all hardware, software, interfaces to other
systems, system testing, documentation, delivery, installation, supervision
and field support for the systems as defined within this Specification.
All instrumentation and control work/equipment not expressly called for in

this specification, but necessary at the discretion of the Engineer, for the
complete and proper installation and operation of the plant equipment and
accessories shall be performed and provided by the Contractor at no
additional cost to SWCC.
Reference within this specification does not automatically indicate that the
particular form of instrumentation or equipment is required on this project
or will be acceptable for particular application. This specification does not
however relieve the Contractor of his responsibility for the basic and
detailed design and execution of the instrumentation, control system, and
communication systems as per scope of supply in relevant chapters of this
specification.
The rules of good engineering practice and the relevant approved standards
and regulations shall be observed.
A consistent control and instrumentation philosophy shall apply throughout

the plant and shall be implemented in terms of a range of equipment
exhibiting a minimum diversity of type and manufacture. The objective
shall be to standardize all measurement, control and surveillance equipment
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throughout the plant in order to rationalize operation, maintenance and

reduce spares holding.
Generally, equipment shall be supplied from one composite range of

measurement and control equipment as marked by a reputable manufacturer
of international standing and shall have a minimum of three years of
operational use on similar projects.
The equipment shall be of modern compact design incorporating the latest

developments in proven technology.
All systems installed in the plant and their components (e.g. DCS racks,
processors, I/O modules, servers, network components, major panel
accessories, field transmitters, analyzers...) shall have CoO (Certificate of
Origin) to maintain high quality of the product.
1.1 Codes, Permits and Agency Approvals

All work performed, and all materials used shall be in accordance with the
applicable SWCC standards and Saudi Electric Codes (SEC), Saudi Aramco
(SA) as well as with applicable local regulations and ordinances. Contractor
shall, as part of their work, arrange for and obtain all necessary permits,
inspections, and approvals by the authorities having local jurisdiction of
such work. This shall include any third-party inspections and testing of
panels and equipment.
The works for instrumentation, communication, control and supervisory

systems will have to be designed, manufactured, installed and tested
according to the relevant codes, standards, rules, and regulations as listed
below, all in latest valid edition.
In case of any inconsistency or conflict exists between the different

specifications, codes, forms or drawings and standards, the more restrictive
shall be applied. The inconsistency shall be brought to the attention of
SWCC for resolution. Information regarding inconsistencies not brought to
SWCC's attention could result in the rejection of the proposal.
IEC 60034 Rotating electrical machines – Part 1 rating and

performance
IEC 60079 Electrical apparatus for explosive gas atmospheres. Part
11: Equipment protection by intrinsic safety “i”
IEC 60255-151 Class-II for over voltage
IEC 60529 Specification for degrees of protection provided by
enclosures.
IEC 60751 Industrial platinum resistance thermometer sensors
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IEC 61131 Programmable controllers.

IEC 61508 Safety integrity level (SIL)
IEC 61511 Functional Safety - Safety instrumented systems for the
process industry sector.
ISO 2954 Mechanical vibration of rotating and reciprocating
machinery.
ISO 5167 Measurement of fluid flow by means of pressure
differential devices inserted in circular cross section
conduits running full:
· Part 1: General principles and requirements,
· Part 2: Orifice plates,
· Part 3: Nozzles and venturi nozzles, and
· Part 4: Venturi tubes.
ISO 20816 Mechanical vibration - Measurement and evaluation of
machine vibration.
ISO 13373 Condition monitoring and diagnostics of machines –
vibration condition monitoring.
API 670 For Mechanical vibration of rotating equipment.
EN 837-1 Bourdon type pressure and vacuum gauges.
EN55011 For noise disturbance.
ANSI B36.10M Welded and seamless wrought steel pipe
BS 1041 Code for temperature measurement.
BS 3693 Recommendations for the design of scales and indexes.
BS 6739 Code of practice for instrumentation in Process Control
Systems: installation, design and practice:
· ISA
· NEMA
· IEEE
· NFPA
· ATEX
· HCIS (High Commission for Industrial Security)
1.2 Service Conditions and Environmental Requirements

The equipment provided shall be suitable for the service conditions
specified in the attached sections.
All equipment shall be designed and selected to operate without degradation

in performance throughout the environmental extremes specified.
Equipment shall be designed to prevent the generation of electromagnetic
and radio frequency interference and shall be in compliance with applicable
SWCC standards.
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All equipment shall be suitable for operation in following ambient

conditions:
· Equipment located in air-conditioned rooms: temperatures from 10-25°C,

10-80% R.H., noncondensing (E.g. Control room, electrical room,
technical rooms…).
Equipment located in non-air-conditioned indoor areas: temperature from
10-50°C,10-100% R.H, noncondensing.
· Equipment located outdoors: temperature from 0°-66°C,10-100% R.H.
Heaters and air conditioning/cooling equipment shall be provided where

essential to maintain equipment within its manufacturer recommended
operating ranges. All equipment and instruments facing sea should have
proper protection against heat, salt and humidity.
1.3 Submittals
Complete specifications, layouts, dimensional, assembly and installation
drawings, wiring and schematic diagrams, as well as details and technical
data covering the equipment, devices and materials used or installed in the
plant, shall be submitted for review by the Employer.
Submittal data shall be grouped and submitted in separate stages. The

submittal for each stage shall be substantially complete. Individual
documents, drawings and data sheets submitted at random intervals will not
be accepted for review.
For following major engineering documents, but not limited to, will be
mandatory to obtain SWCC approval before purchasing or construction:
· Process and Instrumentation Diagrams (PI&D).

· Control System Functional Specification.
· Verbal description and graphical representation of control, interlock and
protection systems.
· Control System Architecture.
· Make and model of DCS & PLC’s manufacturers, as well as field
instrument’s manufacturers with hardware and firmware version
numbers.
· Central Control and Technical rooms arrangement layouts.
· Communication Systems architecture and general layouts (PA system).
· Make and model of communication systems manufacturers (PA system,
Radio).
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A detailed list of any exceptions, functional differences, or discrepancies

between the systems proposed by Contractor and this specification shall be
clearly stated at tendering stage.
1.4 Tagging
All devices shall be provided with permanent identification tags. The tag
numbers shall agree with Contractor’s equipment drawings and shall be the
tag numbers used on the project drawings and device schedules. All field-
mounted transmitters and devices shall have stamped stainless steel
identification tags. Panel, subpanel, and rack-mounted devices shall have
laminated phenolic identification tags securely fastened to the device. Hand-
lettered or tape labels will not be acceptable. All tags shall be in Arabic and
English language.
1.5 Packing & Storage

All electronic equipment and instruments shall be suitably packaged to
facilitate handling and to protect against damage during transit and storage.
All equipment shall be boxed, crated, or otherwise completely enclosed and
protected during shipment, handling, and storage. All equipment shall be
protected from exposure to the elements, shall be kept dry at all times, and
shall not be exposed to adverse ambient conditions.
Painted surfaces shall be protected against impact, abrasion, discoloration,

and other damage. Painted surfaces that are damaged prior to acceptance of
equipment shall be repainted to the satisfaction of Employer. Each shipment
shall include an appropriate shipping list that indicates the contents of the
package, including the specific instrument or equipment tags.
The shipping list shall be accessible without exposing the instruments to the
atmosphere. The shipping list shall also contain any cautionary notes
regarding storage of the instruments, including requirements to protect the
instrument from static discharge, chemicals (solvents, paints, etc.), or
ambient atmospheric conditions.
Individual instruments shall be appropriately tagged or labelled to positively

identify the device. All identification shall be visible without the need to
unpack the instrument from its protective packaging.
Instrument shipment and storage requirements shall be coordinated with

Employer prior to shipment. Contractor shall provide adequate storage and
be ready to accept the shipment before shipping any equipment to the site.
Additional shipping and storage requirements shall be as detailed in the
individual instrument specifications.
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Components which are shipped loose due to transportation limitations shall

be assembled and disassembled by the manufacturer prior to shipment to
assure that all components fit together and are adequately supported.
Upon delivery, all equipment and materials shall immediately be stored and
protected by Contractor in accordance with Product Storage and Handling
Requirements section, and in accordance with manufacturer's written
instructions, until installed in the Work. Equipment shall be protected by
Contractor against damage and exposure from the elements. At no time shall
the equipment be stored on earth or grass surfaces or come into contact with
earth or grass. Contractor shall keep the equipment clean and dry at all
times. Openings shall be plugged or capped (or otherwise sealed by
packaging) during temporary storage.
1.6 Spare parts list

The Successful bidder shall supply the specified spare parts and specials
tools, necessary to ensure the maintenance and repair of any equipment
throughout the guaranteed period. At the end of this period, a complete set
of spare parts shall be handed over to the Owner.
Spare parts list and consumable items shall be, as minimum, as specified
herein, and in any case, shall be enough to assure five years of operation
after guaranteed period:
· Replacement analyzer probes of each type to cover the period.
· Service kits of each type to cover the required period.
· Reagents, Buffers and cleaning agents to cover the required period.
· One Instrument of each type along with mounting accessories.
· One valve actuator of each type along with accessories.
· One Conductivity and pH analyzer assembly.
· Two of each type of DCS processor (CPU’s).
· Two of each type of power supply modules and units used in the project
(DC, AC,).
· Two of each type DCS I/O cards.
· Two of each type DCS network interface cards (including Ethernet).
· Two of each type of Vibration monitoring Systems components,
including sensors and accessories installed in pump’s motors.
· Two of each type of Fire Detection & Alarm System components.
· Two of each type of PLC system components.
Contractor shall guarantee the above listed critical spare parts and any other
recommended and required spare parts for the Plant.
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All commissioning spares parts to be supplied by Contractor. Contractor

may utilize spare parts and supplies during system installation, debugging,
start-up, or training, but shall restore all such materials and supplies to the
specified quantities before final acceptance of the systems.
1.7 Familiarization and Development

Contractor shall conduct familiarization courses for the personnel selected
by Employer in coordination with the overall training requirements.
Training shall be conducted by experienced instructors who are familiar

with the specific system supplied and are fluent in the Arabic language.
In general, Contractor’s standard training courses may be used to reach the

training objectives specified, where standard courses do not reach these
objectives, additional coursework shall be developed.
Additional training time shall be provided if considered necessary to meet

the training objectives.
All costs associated with the familiarization and development program,

excluding travel for Employer’s personnel to attend off-site familiarization
programs shall be the responsibility of Contractor and shall be included in
the contract price.
1.8 Technical Requirements

Technical Requirements defined within this specification shall be binding
for the specified Instrumentation, Control system, Communication and
Clock System within the Scope of the Contract. They do not relieve the
Contractor of any of his responsibilities.
Should it not be possible to comply with specific provisions of these

requirements, or if their observance would result in technical disadvantages,
the Contractor is obliged to point this out at the tendering stage in the form
of a deviation list which will be subject to review and approval of the
Employer/Engineer.
Once a final deviation list is approved at the tendering stage, no other

deviation will be accepted after contract award. The Contractor is obliged to
settle the design in accordance with the Specification, considering the
approved deviations only, in consultation with the Engineer.
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Equipment for the systems shall be planned, manufactured and installed in

accordance with this Specification, relevant laws, regulations, standards,
codes, guidelines and recommendations.
The Contractor will be liable for all defects resulting from non-observance
of these.
1.9 Hazardous Areas

The Contractor shall take full account of any special requirements
concerning the nature, handling and storage of all diesel oils, gases and
chemicals etc. and provide plant, equipment, buildings and other services
accordingly including all facilities to ensure the safety of the operating and
maintenance personnel.
Contractor shall provide a full area classification of the GRS and its
connections to interfaces.
The Contractor shall provide drawings to define all the hazardous zones
taking account of all sources of hazards under normal and abnormal
operating conditions, (regardless of whether or not these areas are
specifically listed in the specification). The zoning philosophy shall be in
accordance with the Institute of Petroleum Code/National Electric Code and
will be subject to the approval of the Engineer.
All equipment necessary for mounting in these areas shall meet the
requirements of IEC 60079, SIL and NFPA codes and standards or an
equivalent National Standard. Where required by the Engineer, certification
shall be provided to confirm the suitability of the equipment and devices.
Electrical equipment shall not be installed in Zone 0 areas without the

approval of the Engineer, though this does not preclude cables passing
through such areas.
Intrinsically safe (preferably) and explosion proof instruments/equipment

shall be utilized in these areas.
All equipment offered for use in these areas shall have the necessary
certification by the appropriate National Certification Bureau and its
proposed application shall fully comply with all conditions of the certificate.
The Contractor shall be responsible for ensuring that all electrical

equipment installed in any hazardous zone is designed and tested to suit the
relevant zone classification.
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1.10 Hazard and Operability Study (HAZOP)

Contractor shall develop a hazard and operability study (HAZOP) which
examines the process and operation of GRS in order to identify and evaluate
problems that may represent risks to personnel or equipment or prevent
efficient operation.
At least following actions shall be carried out:

· Planning of the workshop meeting with the Employer in order to identify
HAZOP strategy, division of the subsystems, choose relevant Piping and
Instrument Diagrams (P&ID), and identifying guide words.
· Accomplishment of the HAZOP review.
· Documentation of observations into information and actions point,
document findings on the P&IDs.
· Draft report for Employer’s review/approval.
· Final HAZOP report.
Study shall be carried out by a suitably experienced multi-disciplinary team,

which shall finally determine the appropriate Independent Protection Layers
(IPLs) to be applied in the project.
Employer shall participate in study’s development.
After HAZOP study completion, P&I diagrams shall be updated

consequently (according HAZOP’s report conclusions) and a final P&ID
revision shall be issued “For Construction”.
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2. Operation and Control Philosophy

The plant will be designed for base load operation.
The plant instrumentation and control equipment shall be selected and

designed to maximize plant performance and availability as well as to
achieve a cost-effective installation.
The essential plant operational management functions of starting up,

shutting down and load demand setting of the GRS shall remain directly
under the operator’s control whilst the on-line regulation of the plant
components shall be fully automated.
Consequently, control protective and supervisory functions required for the

central operation of all the plant facilities shall be implemented in a
uniformed Distributed Control System (DCS), segregated at its automation
level, in such way, that each unit/system shall have its own dedicated DCS
process controller.
Final number of controllers per unit shall be defined by the Contractor and
approved by SWCC.
Each plant system / unit shall be started by initiating a sequential step

program and then shall automatically follow the operating conditions
changes.
The control system shall be designed so, that the plant can be safely
operated with a minimum number of operators.
2.1 Automation Degree

The plant shall be designed with high degree of optimized automation,
safety protection and minimum of operator interface. Normal operation shall
require in general a minimum of attendance by field operators throughout
the plant.
All GRS and auxiliary equipment shall be provided with an automatic start-
up, switch-over and shut-down sequences, always subject to the fulfilment
of safety conditions. Switching over shall be carried out bumpless.
All process units shall be controlled, monitored and operated via the DCS,
from the Control Desk in the Control Room of the GRS. Secondary sub-
systems as compressed air system, etc. shall be also controlled, monitored
and operated locally, via the HMI located or directly attached to local
panels.
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Contractor shall issue a fully detailed Control System Functional

Specification, subject to SWCC’s approval, which shall include, but not
limited to, following major items:
· Control strategies with additional graphical representation,
· Automatic sequences,
· Interlocks and protection with additional graphical representation,
· Graphics displays,
· Trending,
· Alarm managing, and
· Reports.
Any additional graphical representation shall be intelligible to all

engineering disciplines, printout of program configuration code is not
sufficient.
Preliminary Control System Functional Description shall be provided by the

Contractor at tendering stage.
2.2 Availability and Redundancy

The highest demands are placed on the control, instrumentation and
monitoring equipment with regard to availability, plant safety and
reliability. No single point of failure of I&C equipment must endanger the
plant’s production. All vital system functions that can affect part of the plant
operation shall be duplicated with automatic bump less/ smooth switch over
and fault reporting and diagnostic facilities.
At least triple redundant measuring and control loops shall be used for plant
and equipment protection and interlocks. At least dual redundant measuring
and sensing loops shall be applied for modulating control functions. Where
triple redundant measuring loops are applied, the resultant signals may be
commonly used for protection and modulating control. A single fault never
shall cause a trip or loss of performance and shall not cause loss of the
protection system. The redundancy shall be complete including the
processors, interfacing modules, power supply modules, station bus etc.
The data highways system shall be single fault tolerant. One failure in the
data highways shall not reduce the availability of any of the system
components or degrade system performance. Failure recovery shall be
smooth, bump less and automatic. Connection of additional equipment shall
be possible while the system is online without disrupting the running of the
plant. Any data communication failure shall not disrupt process control.
These capabilities shall be proven during the acceptance tests or during trial
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operation. Test schedule shall be forwarded for approval to Owner /

Engineer.
In case of major or catastrophic failure of the DCS, a safe shut-down of the

plant must be guaranteed. To fulfill this requirement the failsafe concept
(normally energized principle) will be used and plant protection equipment
will be fed from DC battery systems and/ or UPS as appropriate.
The redundant I/O or automation processors (CPU) shall be installed in

different rack and shall be supplied by different power supply. The I/O
modules used for control and protection shall be designed in redundant
hardware.
Distributed installation should be taken into consideration when assigning

the hardware to the process plant components. The system shall be
structured to reflect the redundancy provisions of the Plant so that no single
fault within the system will cause an operational disturbance or spurious
operation or make more than one train unavailable. This means among
others that control functions of redundant equipment shall not be installed in
the same hardware module or rack.
The possibilities of the redundant design shall be considered when planning

the system architecture. It is essential that the following parts be in
redundant design, but not limited to:
· Central modules whose failure would result in the loss of extensive or
critical functions,
· The DCS communication system,
· The DCS process control station modules and components,
· Components for operation and monitoring (workstations),
· Power supply, and
· Any other element a failure of which will disable large portion of the
plant or create an unsafe operating condition.
2.3 Task of the main control loops

The description of the following control loops covers the main control
requirements and contains an outline proposal for meeting the requirements.
Alternative designs shall be proposed where cost/benefit or - with respect to

special mechanical equipment - technical improvements can be shown. Such
alternative designs, however, shall meet the minimum functional
requirements of the following descriptions.
The control ranges of the various individual control systems must not limit
the control range of the plant unit as a whole. The control equipment and
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monitoring facilities to be supplied shall ensure continuous operation of the

all systems without manual intervention.
2.4 General Requirements for Modulating Control, Protection and

Interlock system
The I&C systems for the GRS shall be designed in such a way that a single
instrument/component failure does not cause a trip of plant/unit/system. To
achieve this, double redundancy for key equipment shall be considered.
Suitable measuring devices shall be installed on the GRS to give warning of

all abnormal conditions. As well as automatic action to safeguard plant in
abnormal conditions, suitable visual and/or audible warning shall be given
to the operators.
The instruments/devices used for interlocking and protection shall be triple

redundant and different from instruments/devices installed for general
measuring, alarms or control purposes. Each one shall be provided with
individual process connections.
Systems protecting the safety of the plant/equipment by causing tripping

action shall always be arranged on a de-energize to trip basis.
All control and protection signals shall be hard-wired.
The measurements serving for vital control / monitoring shall be provided

with at least two separate transmitters which will be used normally for
averaging. If one transmitter signal is realized to be failed, averaging shall
not be made for the process controller and only the proven signal shall be
considered for process control. Each of the redundant transmitters shall be
connected to a separate module and shall have a separate circuit all through.
2.5 Control rooms

The control system shall be so designed, that full control and supervision of
the GRS shall be possible from the local control Cubicle (LCC) and also the
Central Control Room (CCR) located in the existing Yanbu plant. The LCC
shall be the operational focus for the GRS from where all major system
items shall be capable of being started, on-line regulated and maintained.
The design, engineering and layout of the Local Control Room shall comply
with international ergonomic standards.
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The ESD valve shall be capable of being operated both from the central
control room and locally without using a selector switch.
The Contractor shall design the local control room in order to provide a
productive and safe environment for operators and on the basis of the
human-centered design approach by balancing efficiency and functionality.
Following aspects shall be considered:
· Plant operation tasks and organization for operation (normal situations
and emergencies).
· Design standards for control rooms (ISO 11064 “Ergonomic design of
control centers, industry standards including customer’s standards)
· Study items based on ergonomics (layout, lighting, coloring, sound,
operator console design, large screen, and selection of furniture and
materials).
Engineering Desk/Console shall be located inside LCR but separated from

the operator’s area (Engineering room).
Electrical and technical rooms shall have the same environmental conditions
as the CCR (air conditioned, dust free, vibration free, etc.) as defined in
paragraph 1.2.
Generally, all operation a monitoring shall be centralized. The Local

Control Rooms (LCR) shall be equipped with operator station of the
projects DCS. DCS control stations may be placed locally and connected to
the plant DCS via redundant serial communication interface.
Cables in the control room(s) shall be routed through a raised floor with
min. 800 mm clear height.
2.5.1 Technical room

Technical room (TR) is intended to allocate DCS control cabinets and
communication panels and shall also be provided with controlled
environmental conditions.
All DCS control cabinets and network panels will be installed in the main
technical room, located in the main plant control facilities building, except
those affecting Electrical system which will be located in the electrical
premises.
Auxiliary panels (communication panels, UPS distribution, etc.) will also be

located into the technical room.
Cables shall be routed through a raised floor with min. 800 mm clear height.
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2.6 Package’s PLC

The plant items and equipment shall be controlled, protected and monitored
by DCS process controllers. The use of local PLC's for ancillary plants or
systems shall be limited to secondary systems which do not affect the
availability or the performance of the plant.
PLC systems shall be of uniform type, compatible with the main DCS
system and shall be built single fault tolerant in all aspects. PLC’s shall be
suitably interfaced with the DCS by hardwiring and additionally in a dual
redundant interface configuration based on one standard protocol.
Bidder shall list and justify the intended use of package PLC for the
ancillary areas. The application and the manufacturer/type of this control
systems shall be subject to Employer/ Engineer's approval.
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3. Instrumentation
This section covers the design, furnishing and installation of an
instrumentation system for the GRS of Yanbu plant.
3.1 General
All components of the instrumentation systems shall be as indicated on the
P&ID drawings, once Contractor have fully developed the detail
engineering and have been approved by SWCC/engineers.
The instruments furnished shall be standard products. To the extent

possible, instruments used for similar types of functions and services shall
be of the same brand and model line. Similar components of different
instruments shall be the products of the same manufacturer to facilitate
maintenance and stocking of repair parts. Whenever possible, identical units
shall be furnished.
Measurement and control instrumentation shall have high electromagnetic

and radio frequency interference immunity and shall not be affected by
mobile phone to portable radio transmitters operated in the vicinity of the
equipment. Any limitations shall be stated.
All the equipment shall be suitable for the location in which it is to be

mounted and in particular all outdoor equipment shall be suitable for the
prevailing climatic conditions.
Generally, threshold values shall be derived from analogue input signals

within the DCS. The use of binary sensors (switches) shall be limited to a
minimum and justified by the Bidder. The application and make and type
shall be subject to Employer/ Engineer's approval.
All instruments whether for local indication or remote transmission shall

have an accuracy and repeatability appropriate to their duty. The accuracy
and repeatability of each instrument offered shall be stated and be certified
when supplied, by means of supporting documentation such as calibration
sheets, testing certification and data sheets.
The ranges of all instruments shall be arranged, where practicable, so that

normal working indication is at approximately 60% of full-scale deflection
with the exception of devices based on a square root relationship which
shall normally work at 75%.
Measurement and control instruments shall be matched to the main plant

equipment ratings in all aspects. Instrument ranges, installation codes of
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practice and precautionary measures for safety of the Plant and the operating
and maintaining personnel shall be observed.
Each field mounted instrument or device shall be properly labelled/ tagged
as detailed in the general requirements. All instruments shall be identified
by appropriate tag numbers; permanent non-perishable nameplates attached
to each instrument shall be used for this purpose. Further, every such
instrument or device incorporating an indicator shall also be labelled with its
duty description.
For Instruments mounted in direct sunlight, sunshades must be provided.
Field instruments must be selected according to the operating conditions and

process requirements, especially with regard to the safety and
interchangeability, instruments shall be installed to measure, monitor, or
display the specified process values at the service conditions. The plant will
be fully instrumented to allow a highly automated, secure and efficient
operation with high availability.
All compression fittings of one dimension used without the plant shall be of
one type and fully compatible to each other.
3.1.1 Local instruments

Local indication instruments shall additionally be provided where local
indications are required for local plant commissioning, maintenance and
adjustment. In all cases where monitoring, control or protection is required,
a transmitter and remote monitoring shall be provided.
All locally mounted instruments shall be located in readily viewable and

accessible positions.
The scope of local measuring instrumentation shall generally be as follows:
· Pressure gauges shall be provided on the suction and discharge side of all
pumps, on all pressurized vessels and on all main distribution header
sections.
· Differential pressure gauges shall be provided on all strainers and filters
of all types.
· Temperature indicators shall be provided on the inlet and outlet of all
coolers/heaters, and on all lube oil return lines and all lube oil tanks.
Thermowells shall be installed for all temperature elements in the field.
Removal of temperature element shall not affect the running process.
Thermowell material shall be suitable for the process media. Spare
plugged thermowells shall be provided at each important temperature
measurement point.
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· Level indicators shall be provided on all vessels, typically but not

necessarily limited to storage and buffer tanks of all types, liquid/gas or
air separators, knock-out vessels and header tanks. Graduated level
indications shall be provided on all reagent tanks for prevision reading.
· Flow indicators or tell-tales shall be provided on all cooling water lines
and bearing lubrication lines, for both water and oil lubricated bearings.
Flow graduated indicators shall be provided on all sample lines.
3.2 Flow instruments

Flow measurement shall be provided to measure:
· All raw materials and final product streams associated with the plant.
· Major internal and external services (e.g. Water, Air, Chemicals etc.).
· Equipment’s protection (dry running).
The Contractor shall provide tapping points before each major flow meter to
allow calibration checking by insertion of a reference flow meter. One
suitable insertion flow meter shall be provided.
The accuracy of the measurements shall be appropriate to the duty

concerned and shall be submitted to the Engineer's approval.
As general, following features must be provided for all flow transmitters:

· Signal current: 4-20mA (HART),
· Accuracy: From 0.1% to 2%,
· Linearity: 0.1% of span,
· Stability: + 0.1% of Upper Range Limit,
· Repeatability: 0.1% of span,
· Temperature effect not greater + 0.5% of span per 50°C,
· Hysteresis: Less than 0.2% of output span,
· Dead Band: Not exceeding 0.1% of span.
Flow shall be measured in mass or volume rate, changes in density, pressure

or temperature of measured medium shall be compensated wherever
necessary with separate instruments.
Magnetic and Ultrasonic flowmeters shall be considered as preferred flow

measurement instruments for water applications (especially for sea water
applications). Other measuring flow transmitters may be used under
approval of SWCC’s Engineer (e.g. Coriolis mass flowmeters, insertion
paddle wheel, turbine, vortex, etc.).
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Isolation valves (upstream and downstream), equalizing manifolds, drains,

vents and purge points shall be provided for all types of flowmeter (where
necessary), to enable dismantling and removal of the flowmeter assembly.
All flow meters shall be provided with a local display.
Bodies, primary elements and wetted parts shall be suitable for process fluid
and environmental conditions.
3.2.1 Ultrasonic flowmeters

Ultrasonic flowmeter shall be in-line type, completely welded construction,
wear and maintenance free. Sensor tube shall be full bore, unobstructed,
without pressure loss and without moving parts.
Measuring principle shall be ultrasonic transit time and sensor shall be able
to measure accurate bi-directional flow, with a minimum of two parallel
acoustic (beams). Overall accuracy shall be within ±0.5 % of the range with
a repeatability of ±0.2 %.
Wetted parts shall be suitable for measured product. Enclosure protection

shall be IP65, and coating shall be corrosion resistant in marine atmosphere
(offshore).
Transmitter (signal converter) shall be remotely installed from sensor, wall

or pipe mounted. Power supply shall be 230 VAC, 60 Hz and transmitter
shall be furnished with in-built flow rate and total display. Output signal
shall be 4-20mA DC HART. Screened and armored cable between the
sensor and the transmitter shall be supplied by the manufacturer.
Transmitter shall provide diagnostic functionality, as well as configurable

contacts for alarm transmission.
3.2.2 Rotameters
Rotameters, if applicable, shall be metal type design with conical float.
Float position shall be directly visible through a sealed glass or Plexiglas
viewing window. Flow scale shall be engraved on the viewing window.
For high pressure, high temperature, dangerous or aggressive fluids, or other

demanding flow applications where safety is a concern, rugged metal tube
construction must be considered.
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Flowmeter wetted components shall be compatible with measured process

fluid. For aggressive application Monel must be considered. Flowmeter
process connections shall be flanged.
If required, flowmeters shall be provided with an adjustable magnetic

actuated switch for alarm signaling. Switches shall be rated 5A at 230 volts
AC.
All rotameters shall be installed in vertical pipes.
3.2.3 Flow switches

Flow switches where required (e.g. pumps protection, flow-no flow
detection...), shall be paddle or paddle wheel type. For pipe sizes greater
than or equal to DN50 (2 “), switches shall have a thread connection (NPT)
for direct insertion into the process pipe. For pipes sizes smaller than 2”,
flow switch shall be factory installed in a spool piece, suitable for flange
mounting in the process pipe.
Switch wetted components shall be compatible with the process fluid.

Switches shall contain at least one SPDT or DPDT contact, rated 5A at
230VAC (0.5A at 125VDC) and enclosure shall be a minimum IP56
housing.
Switches shall be factory calibrated (manufacturer’s certificate shall be

included) to actuate at the specified flow rates for the given pipe size. All
flow switches shall be installed in horizontal piping.
3.3 Pressure Instruments

All pressure instruments shall be capable of continuous operation at the
maximum pressure indicated on the chart or scale and shall have suitable
over- range protection for at least 115% of nominal range, without damage
or calibration change.
Pressure instruments installed for measurement of steady pressure shall

operate in a band centered on 60% of its nominal range.
All pressure instruments (gauge, transmitters, switches...) shall be provided

with suitable valve manifold (3 / 5 ways) for purge/venting and isolation
purposes. Valve manifold shall be made of stainless streel (A316) and
compatible with the process fluid.
All pressure transmitters shall be remotely mounted, in pipe-stand or walls.
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Integral local gauge and switch/transmitter units shall not be used. Separate
devices shall be provided for local indication and remote monitoring or
interlocking.
3.3.1 Pressure & differential pressure transmitters

Transmitters shall be an electronic two-wire device, loop powered. Process
fluid shall be isolated from the sensing elements by a metallic diaphragm
(Hastelloy-C, ceramic, or cobalt-chromium-nickel alloy), and the transducer
may use a silicone oil as transmission fluid.
Following materials shall be considered for instruments wetted parts:

· Product water/ general application: SS316, PTFE seals,
· Sea water / Brine: Monel, PTFE seals.
Transmitters shall be enclosed in IP66 housing and shall be suitable for

operation at temperatures from -10° to +82°C, and a relative humidity of 20
to 100 percent.
Transmitters shall have self- diagnostics and electronically adjustable span,

zero, and damping, as well as over range protection according to maximum
line pressure. Accuracy of the transmitter shall be 0.075 percent of span, and
transmitter output shall be 4-20 mA (HART).
Transmitters shall not be damaged by reverse polarity and they shall have
elevated or suppressed zero. Transmitters will have a turndown ratio of
30:1, or more.
Each transmitter shall be provided with valve manifold with test ports on the
instrument side of the valves. Manifold’s material shall be according
instrument’s wetted parts materials.
All transmitters shall be furnished with LCD type digital indicators and shall
be provided with brackets for wall or pipe-stand mounting.
Transmitters shall be factory calibrated to the required range and provided

with the manufacturer's calibration certificate. A standard hand-held
communications/calibration device shall be supplied. One device shall be
furnished for all transmitters provided by a single manufacturer.
3.3.2 Pressure switches

Pressure switches shall be diaphragm actuated type switches. Switches shall
be field adjustable type, with trip point repeatability better than 1 percent of
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actual pressure. Switches shall have over-range protection to maximum

process line pressure. Switches mounted inside panels shall have general
purpose housings. All other switches shall have weatherproof housings.
Switch wetted parts shall be compatible with the process fluid. Where the
process is not defined, all wetted parts shall be Teflon-coated, or Viton and
the connection port shall be stainless steel.
Panel-mounted and surface-mounted switches shall be provided with

½ inch NPT connections.
All pressure switches shall be ranged in mbar/bar and all vacuum switches
in mm of water column. Unless otherwise indicated, switches shall have a
fixed dead band and shall be auto-reset type. As a minimum, switches shall
be DPDT, rated 10 amp [A] at 230 V ac.
Each switch shall be provided with a threaded end, ball-type shutoff valve.
Shutoff valve materials shall be compatible with the process fluid. Where
the process is not specified, valves shall have AISI316 wetted parts and
Teflon seals. Multi-port valves shall have all unused ports plugged. Shutoff
valve construction shall be as detailed in the miscellaneous instruments
section.
The switch shall be provided with a pressure snubber as required. Each

snubber shall be of a size and pressure range compatible with the switch
served.
For applications involving corrosive fluids or chemicals, a diaphragm seal

shall be provided for the respective switch.
Switches shall be installed at the locations indicated on the drawings and as

required, with installation conforming to the installation details. All
switches, snubbers, and diaphragm seals shall be installed in the vertical,
upright position. Thread sealer, suitable for use with the associated process,
shall be used in the assembly of threaded connections. All connections shall
be free from leaks. Lines shall be purged of trapped air at switch locations
prior to installation of the switch or diaphragm sea.
3.3.3 Pressure gauges

Pressure gauges shall be dial type, with stainless steel Bourdon tube (C-
shape for pressures <70bar, others helical). Case made of stainless steel,
with pressure relief on the back of the case, adjustable pointer, cam ring
(bayonet type) made of stainless steel and window made of laminated safety
glass.
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Pressure gauge shall be provided with liquid-filled case for applications

with high dynamic pressure loads or vibrations.
Gauge dial shall be 100mm size, made in white aluminum, black lettering.
Measured units shall be indicated on the dial face. Pointer travel shall be not
less than 200 degrees or more than 270 degrees of arc.
Panel-mounted and surface-mounted gauges shall be provided with 1/4-inch

NPT lower mount connections. Other gauges shall be provided with 1/2-
inch NPT lower mount connections. All process connection shall be made in
stainless steel.
All pressure gauges shall measure in mbar/bar and all vacuum gauges in
mm water column. All gauges shall have a suitable range to give mid-scale
readings under normal conditions. Gauge accuracy class shall be 1.0.
Each gauge shall be provided with a threaded end, ball-type gauge valve.
Gauge valve materials shall be compatible with the measured process and
wetted parts shall be compatible with the process fluid. Where the process is
not defined, gauge valves shall have AISI Type 316 stainless steel wetted
parts and Teflon seals. Multi-port gauge valves shall have all unused ports
plugged.
Where required by the application, the pressure gauge shall be provided

with a pressure snubber. Each snubber shall be of a size and pressure range
compatible with the gauge served.
For applications involving corrosive fluids or chemicals, a diaphragm seal

shall be provided for the respective gauge.
Gauges shall be installed at the locations indicated on the drawings and as

required, with installation conforming to the installation details. All gauges,
snubbers, and diaphragm seals shall be installed in the vertical, upright
position. Thread sealer, suitable for use with the associated process, shall be
used in the assembly of threaded connections. All connections shall be free
from leaks. Lines shall be purged of trapped air at gauge locations prior to
installation of the gauge or diaphragm seal.
Each pressure gauge shall be provided with all required mounting

accessories to securely mount the unit according to the application mounting
requirements.
Unless otherwise indicated, mounting and installation accessories shall be in

stainless steel.
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3.4 Level Instruments

Level measurement shall generally be made by radar transmitters
(microwave), however other technologies such as hydrostatic transmitter
may be considered after approving of SWCC/engineer. Use of any other
technologies shall be previously approved by SWCC/engineer. If level
detection is required, float operated switch or vibrating fork probes shall be
used.
For local indication, gauge glasses or magnetic level indicators may be used.
All level indicators shall be conforming to the rated design criteria for the
vessel and equipped with isolation valves. Connections shall be provided at
the top/side and bottom of the level indicator for draining and venting
purposes.
On all forms of measurement, all parts of the switch, transmitter, etc. in

contact with the process fluid shall be made of material compatible with the
process fluid. Stainless steel shall normally be used on all duties (except sea
water or corrosive fluids).
All types of level device (e.g. indicator, switch, transmitter, etc.) shall be
installed so that removal of the device is possible with the tank or vessel full
and/or with the process in operation, as applicable. This requirement applies
to all types of tanks, both storage tanks and process vessels.
3.4.1 Radar level transmitters (microwaves)

Each radar level transmitter shall be a microprocessor-based electronic unit
consisting in a sensor (antenna), a signal converter/transmitter and the
interconnecting cable.
Instrument shall be suitable for operation over a temperature range of -10°

to +66°C, and a relative humidity of 20 to 100 percent.
The level sensor shall be suitable for flange connection or bracket mounting,
as required, and shall be weatherproof to IP 65.
Sensor shall be compatible with the process media being measured and
insensitive to mounting location and obstructions. For sensors mounted in
direct sunlight, sunshades must be provided.
When not accessible, transmitter shall be remotely installed from the sensor.
Screened and armored cable between the sensor and the transmitter shall be
supplied by the manufacturer. Transmitter shall be housed in an IP65
enclosure suitable for wall or pipe stand mounting.
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Transmitter shall be provided with local display and shall be able of

intelligence signal processing for improved measurement reliability and
Auto False-Echo Suppression. Transmitter’s output shall be 4-20 mA
(HART), loop powered.
The Contractor shall coordinate the sensor mounting requirements and

provide installation drawings, with full dimensions and elevations. Structure
and associated material required for supporting the level sensor / transmitter
shall be in the Contractor’s scope.
3.4.2 Hydrostatic level transmitters

All hydrostatic level transmitters shall be provided with flanged connection,
direct-mount seal with fully welded design. Seal materials shall be suitable
for process fluid and conditions (minimum acceptable quality SS316).
For rest of technical features, please refer to “Pressure & Differential

Pressure Transmitter” in this section.
3.4.3 Ultrasonic level transmitters

Each ultrasonic level transmitter shall be a microprocessor-based electronic
unit consisting of a sensor assembly, a signal converter/transmitter, and an
interconnecting cable.
The sensor shall be encapsulated in a chemical and corrosion-resistant

material such as CPVC or equivalent and shall be suitable for operation over
a temperature range of -10° to +66°C and a relative humidity of 10 to 100
percent.
The sensor shall be compatible with the process media being measured.
Sensors mounted in direct sunlight shall be provided with sunshades.
Supplier shall coordinate the sensor mounting requirements and furnish

drawings complete with dimensions and elevations. The ultrasonic level
transmitter shall have automatic compensation for changes in air
temperature at the sensor location. If separate temperature sensing probes
are provided, they shall be mounted with or adjacent to the ultrasonic
sensor, as recommended by the manufacturer.
The transmitter shall have a four-digit LCD display scaled to read in

engineering units and shall be designed to ignore momentary level spikes,
false targets, or momentary loss-of-echo.
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The transmitter output shall be an isolated 4-20 mA dc signal (HART)

linearly proportional to the measured level range and shall have a minimum
of two relay outputs for indication of high/low level alarms. The contacts
shall be suitable for 0.5A at 230VAC.
Calibration parameters shall be entered through a keypad on the unit and

shall be stored in nonvolatile EEPROM memory. Accuracy of the
transmitted signal shall be ±0.5 percent of the level range.
When not accessible, transmitter shall be remotely installed from the sensor.
Screened and armored cable between the sensor and the transmitter shall be
supplied by the manufacturer.
3.4.4 Level switches

All switches used for tripping purposes shall be in direct contact with the
process, preferably vibrionic type.
Switches used for low level detection in pump chambers might be float type
(Tilting or fixed-mount float type).
3.4.4.1 Fixed-mount float type level switches

Switches shall be floating ball type, consisting in a non-metallic float ball
that contains a sealed switch assembly. The float shall be supported with a
flexible synthetic rubber hinge fastened to an adjustable mounting bracket.
The hinge shall also act as housing for the lead wires from the alarm switch.
The lead wire shall be a waterproof cable of such length that no splice or
junction box is required in the wet well.
Suitable mounting accessories shall be furnished. The switch contacts shall

be SPDT or DPDT rated 5A at 250VAC.
3.4.4.2 Tilting float level switches

Tilting float level switches shall use the tilting movement of the float, whose
specific weight shall be less than that of the process liquid, to actuate the
switches as the level changes. The switch shall be integrally mounted in the
float (free of mercury or lead) and connected to a control box by an
appropriate waterproof electric cable. A movable weight shall be mounted
on the cable to allow adjustment of the set-point.
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Sufficient cable length shall be provided to facilitate termination in a

junction box unless otherwise stated in the project specification. The float
shall be polyethylene, stainless steel or other approved material.
The desired switching action (pump-up or pump-down), level set-points,

cable length and optional features shall be as specified in the project.
Contractor may utilize either a series of floats or a single float to provide the
specified switching action. The "pump-up" type shall close a contact at a
low level and open it at a high level. The "pump-down" type shall provide
the opposite action. The switch shall be rated for 1 A, 230 V 60 Hz.
Adjustable mounting accessories shall be provided for supporting each level

switch.
3.5 Temperature Instruments
3.5.1 Temperature sensors/ transmitters

Temperature sensor shall be a four wire RTD (resistance temperature
detector), hermetically sealed, with platinum resistance element (100
ohm/0ºC), class A in accordance with IEC 60751. The sensing element shall
be duplex, fast response, and shall be enclosed in Monel outer sheath.
The measuring insert shall be made vibration-resistant, spring-loaded and

replaceable.
Connection head shall be threaded to the insert (through neck tube) and
shall be made of appropriated materials for withstanding marine
atmosphere. Protection degree shall be IP66. Process connection for
temperature sensor shall be ½” NPT.
Each temperature sensor shall be provided with a protective thermowell

which materials shall be compatible with the process fluid (minimum
quality A316). The thermowell shall be solid machined with stepped design
(reduced tip). Process connection shall be flanged and reinforced by solid,
welded thermowell sockets. Each thermowell shall come with its individual
wake frequency calculation certificate as per ASME PTC 19.3 TW-2016.
Process insertion length of the thermowell shall be as required by the

application.
Transmitters shall be, in general, head mounted type and shall accept
thermocouple, RTD (3 and 4 wires), ohms or DC millivolts input signals.
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Output signal shall be 4 to 20 mA DC supporting HART protocol. Case

shall be made of polycarbonate and terminal shall be screwed.
Transmitter shall be conforming to the standard DIN form B head mounting

and shall be suitable for operation over a temperature range of -10 to 66°C.
Transmitter accuracy shall better than ±0.5% of span.
Remote transmitters shall be used in case of high-performance requirements

or non-easy access.
For this purpose, transmitters shall provide microprocessor-based sensing

technology and ensure long-term accuracy and high reliability. Enclosure
material shall be low copper cast-aluminum alloy, coated with polyurethane
resin providing IP66 degree of protection. Mounting brackets for two-inch
pipe or flat panel mounting shall be supplied. Transmitter shall be provided
with built- in LCD display and accuracy shall be better than 0.2% of span.
Transmitters shall be factory calibrated to the required range

(manufacturer’s certificate shall be included) and provided with the
manufacturer's standard hand-held communications/calibration device. One
device shall be furnished for all transmitters provided by a single
manufacturer.
3.5.2 Thermometers
Filled system and bimetallic type dial thermometers shall be used as
appropriate for local indications in the field. Dial size shall be 100 mm and
casing of the instrument and associated fittings shall be 316SS.
Thermometers shall be provided with adjustable viewing angle to allow the
dial to be positioned for optimum viewing.
Capillary tubing for all filled system thermometers shall be 316SS (if
required).
Each temperature sensor shall be provided with a flanged thermowell which

materials shall be compatible with the process fluid. Where the process fluid
is not defined, thermowells shall be made of stainless steel, solid-machined.
The thermowell shall be solid machined with stepped design (reduced tip).
Process connection shall be flanged and reinforced by solid, welded
thermowell sockets. Each thermowell shall come with its individual wake
frequency calculation certificate as per ASME PTC 19.3 TW-2016.
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3.6 Analytical Instrumentation

The Contractor shall provide technical data relating to each type of analyzer
being supplied, including but not limited to:
· Specifications of physical and chemical conditioning of sample streams.
· System requirements of accuracy, reliability and servicing frequency.
· Details of analysis instrument.
· Display and output signal level information.
All analyzers shall be single stream, suitable for mounting in ambient plant
conditions, SMART type, and each analyzer shall be provided with
integrated LCD display.
Multiple prefabricated analyzers’ panels shall be preferably used to reduce

site installation work. This prefabrication shall include sample conditioners,
analyzers, air and electrical distribution, cooling water distribution or
coolant circulating system, manual sampling point, all piped and wired on a
common frame.
If required, analyzers shall be provided with an automatic cleaning system

with spray head. Cleaning system shall control the automatic cleaning of the
electrodes, in conjunction with pneumatically operated retractable holders,
without interrupting the process. The system shall provide spray cleaning of
the electrode inside the holder by feeding a cleaning agent, previously
diluted in the injector with water, in the spray nozzle.
The arrangement shall permit testing of the entire assembly before dispatch
to site and shall be arranged for convenient removal from on-line operation
to facilitate routine maintenance and calibration.
The sampling system shall include but not be limited to all probes, valves,
filters, coolers, pressure regulators, flow-meters, piping, fittings and pumps
as necessary, to give the analyzer a representative and suitably conditioned
sample of real process media requirements.
All instruments shall be installed and connected so that in-situ calibration

using portable test equipment is possible, without removal of the instrument
from the process.
The GRS includes a Wobbe meter and a chromatograph, which shall be

provided by the supplier.
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3.6.1 Wobbe meter

The Wobbe meter shall have individual flow computers, energy counters,
Wobbe and other parameter computation and signal transmission/ data link
to the CCB/ Central Control Building.
3.6.2 Gas chromatograph

The gas chromatograph shall be supplied for billing purposes (settlement
meters, Primary Measurement System pursuant to Aramco standard (SABP-
Y-856).
3.7 Settlement Metering System (check meter)

The metering system (check meter) shall be supplied for a Metering
Supervisory Computer (MSC) used in hydrocarbon gas Custody Metering
Systems (check meter) in compliance to SABP-Y856 and the main meters in
SA scope. The metering system includes, but is not limited to, the meter
skid (meters, strainers, flow conditioning sections, valves), GC, sampler,
and metering control system, etc.).
3.8 Vibration Measurement System (VMS)

On-line measurement of vibration shall be made for all large rotating or
reciprocating machinery (MV-motors >= 900 kW and LV-
motors >=200kW), in order to facilitate evaluation as per ISO 20816 for
protection and predictive maintenance.
Suitable indicators shall be provided in DCS for each measurement point

and the measurement shall be suitably alarmed where high vibration levels
may cause possible damage or affect the safety of the plant.
The on-line vibration measurement system (VMS) shall comply with API
Standard 670, ISO 13373 and ISO 2954 standards. For the protection and
predictive maintenance of major rotating machinery a vibration monitoring
system shall be provided in accordance with ISO 13373.
The supplied VMS shall be having the following features:

· Pre-trip and post trip data shall be available for all the channels in the
input module.
· Supplied with full vibration analysis software.
· Graphic mimic/display for the machinery information like vibration trend
and alarms.
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· The scanning and resolution time for all vibration channels shall be less
than 1 millisecond.
· The protection signal (Relay contact) shall be initiated in the input
module of the VMS.
· The protection signals for each machinery shall not be shared with other
input module of any other machinery.
· The VMS racks shall be supplied with redundant power supply.
· Portable vibration measurement shall be provided as a scope of supply
(Minimum two).
All the vibration on-line monitoring shall be equipped with a computerized

machinery monitoring system which can be hooked up with all pumps.
At least, each high-pressure feed pumps shall be provided with following

instruments to be monitored:
· Two (2) temperature sensor (Pt-100) per pump bearing,
· Two (2) temperature sensors (Pt-100) for motor bearings.
· Six (6) temperature sensors (Pt-100) for motor windings.
· Two (2) radial proximity sensor per pump bearing, total four (4) per
pump.
All vibration sensors shall be wired to VMS cabinets through specific

junction boxes and cables.
Temperature sensors shall be wired to MCC’s (for interlock) and DCS

respectively through specific junction boxes and cables.
Vibration alarm and protection signals shall be hardwired directly as a

binary signal to the MCC’s for interlocking purposes. All vibration
indications and alarms shall be connected / integrated with the DCS as
analogue signals, through data bus (Communication Gateway).
VMS system shall be provided with a non-redundant server and an
engineering station for diagnostic and configuration purposes.
3.9 Automatic Valves

Automatic valve’s type shall be selected according process conditions and
required services, i. e. automatic valves shall be operated by the DCS or, if
applicable by packaged equipment controllers. Selection shall be base in
following types described below.
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3.9.1 On-off valves (Isolation)

Mainly, all isolation and on/off services shall be automatic valves. Valve’s
body specification will be according piping specifications, but additionally,
below minimum criteria shall be considered in valve type selection:
· Ball valves: high pressure services, small pipes (sea water, brine,
DN<100..).
Main features: two-way valve, Three pieces, PN100, process connection
BW sch40, Trunnion mounted ball, wetted parts in Super duplex PREN
min >40, body and ball material A890 5A CE3MN, seat/gasket PTFE.
For chemicals (sulfuric acid, HCl,) wetted parts shall be corrosion
resistant.
· Plug valve: high pressure services, large pipes (sea water, brine, treated
water..).
Main features: Design acc. ANSI B16.34, PN100, process connection
BW sch20/40, wetted parts in Super duplex PREN min >40, body and
plug material A890 5A CE3MN, gaskets PTFE.
· Butterfly valves: low pressures services. Main features: fully elastomer
lined body, centered shaft design, metal disc, soft seated, tight shutoff.
Flange connection (Lug type DN-40-125). Body material Ductile Cast
iron (JS 1030).
· Wetted part materials:

· Water: seat in EPDM, Disc and shaft in stainless steel (1.4408),
· Chemicals: body and disc PTFE coated.
All valves external coating shall be suitable for environment class C5M
according ISO 12944-2.
Where alternative specifications are considered more appropriated, then

details and justification shall be submitted to the Engineer for approval.
3.9.2 Control valves

Control valves shall be sized for optimum control. The sizing calculations
shall include CV, noise and cavitation calculations.
Valves bodies shall in all cases match the piping pressure and temperature
rating specifications as a minimum, and the operating point on the valve
characteristic should be within the 60 - 70% operating range.
For normal service duties valve bodies shall be made of same material than
the pipe where installed, end connections flanged (raised face), unless
process conditions requires special material or otherwise specified. Flange
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type connections shall in all cases match the piping specifications, but never
below than ANSI Class 300#.
Control valve trims shall be of stainless-steel ANSI 316 or equivalent as a

minimum, where appropriate according and compatible to the service, fluid
and conditions.
Hardened and/or stellite plug and seat shall be used for the following
applications:
· erosive service;
· wet steam service with pressure drop above 5 bar;
· general service with pressure drops greater than 5 bar.
For the above applications valves up to and including DN25 shall have their
plug and seat made from solid stellite. For larger sizes, the plug and seat
shall be made from stainless steel (A316) and fully metal coated with
Stellite No.6.
Valves shall be provided with Teflon packing and a lubricator assembly. For
services with fluid temperatures above 200C or below 10C an extended
bonnet shall be provided to keep the packing box at proper temperature.
Bellow seals shall be used for services with dangerous or poisonous fluids.
Suitable valve stem material shall be provided on valves used on chlorine
services or other services which become corrosive when in contact with a
moist atmosphere.
For liquids the exit trim velocity shall not exceed 30m/sec.
For flashing service, the exit trim velocity shall not exceed 22.5 m/sec.
For gas and steam the velocity head in line shall be less than 70 psia.
Supplier shall provide sizing/calculations data sheet for all control valves.
The maximum allowable noise level shall be 85 dB A or less.
Following valve type shall be used in the project:

· Globe valve: For normal duty services. On applications with relatively
high pressure drop, balanced seat valves, cage-guided, shall be used.
· Butterfly valves: Where very large sizes are involved (on high flows), or
low pressure drops and low static pressure are a determining factor,
making globe valves unattractive or impossible.
· Angle valves: shall be provided for erosive service (e.g. slurries), on
applications where solid contaminants might settle in the valve body, on
hydrocarbon services with tendency for choking.
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Where alternative specifications are considered more appropriated, then

details and justification shall be submitted to the Engineer for approval.
The installation shall include isolating valves and a bypass valve for each
control valve on all services. Unless otherwise agreed by the Engineer, the
bypass valve providing tight shut-off shall have the same characteristics and
construction as the control main valve.
3.10 Actuators
This section covers furnishing valves and gate actuators as well as the
accessories specified herein. Each actuator shall be designed to open or
close the valve under all operating conditions. Actuators shall be designed
for the maximum differential pressure across the valve and maximum
velocities through the valve.
Valve actuators shall be provided and adjusted by the valve manufacturer.

Actuator mounting arrangements and positions shall facilitate operation and
maintenance and shall be determined by the valve manufacturer unless
indicated otherwise on the drawings or directed by the Employer.
Gate actuators shall be sized to produce the torque or thrust required to

operate the gate when subject to the seating and unseating operating heads.
Both, the design head and the operating head shall be measured from the
surface of the liquid to the center line of the gate.
Actuators shall conform to following requirements:

· Cylinder and vane type actuators shall conform to ANSI/AWWA C541.
· Electric motor actuators shall conform to ANSI/AWWA C542.
· Actuators for butterfly valves shall conform to ANSI/AWWA C504.
· Manual actuators for ball valves shall conform to ANSI/AWWA C507.
· Actuators for open channel slide gates and weir gates shall conform to
ANSI/AWWA C513.
· Actuators for stainless steel slide gates shall conform to ANSI/AWWA
C561.
Actuators for on-off valves and gates shall be electrical motor driven,
however the use of pneumatic actuators on small valves (DN<200) or
special applications may be considered dependent on duty and subject to the
Employer / Engineer approval.
Self-contained sealed hydraulic units may be considered where high thrusts

or high speeds of operation are required but each application shall be to the
approval of the Employer / Engineer.
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Actuators for control valves shall be pneumatical preferably, except for

those applications where valve’s size or process conditions do not
recommend it.
All actuators and related accessories to be installed in hazardous areas shall

satisfy the safety class requirement of those areas.
All actuators shall be possibly removed on-line for servicing
The various types and sizes of actuators shall be standardized and as far as
possible each type shall be from a common manufacturer to facilitate
interchangeability and spares. The actuators shall be from a reputed
manufacturer with a minimum of 3 years of proven service reliability for
typical applications.
The operation of all actuators, control valves and driven units, shall be so
arranged/ designed as to ensure the safety of the "plant" under failure of
control or actuating supplies.
Unless specified otherwise, the failure of a control signal or actuator power

supply shall either:
a) causes the actuator to move to a safe position (predefined position)
b) freezes in its last operating position
The failure response of all actuators in the event of the loss of the prime
mover (air pressure, oil pressure, electrical power) shall be indicated on the
Piping and Instrumentation diagrams (P&I), and valve’s specifications.
All electric actuators shall have a handwheel for direct manual operation.
The diameter of the handwheel and geared effort shall be such that they are
reasonably operable by one man.
All actuators shall include a mechanical device to show fully open/ closed
feedback limit. Additionally, limit switches shall be provided for all
electrical and pneumatic valves and gates.
All Actuators shall be light weight and construction materials shall conform
to the requirements of ANSI/AWWA C504 and C540 and shall be suitable
to the corrosive marine environment found on the Site. Actuator material
selection shall be submitted for review and approval to SWCC/Engineers.
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3.10.1 Electric actuators

Electric actuators shall come with integrated thyristor unit. Electric
actuators shall be operated conventionally, control signals shall be
hardwired, field-bus technology shall not be used.
Electric actuators shall be supply quarter-turn, lineal or multi-turn type

depending on valve type or service.
All electric actuators shall be from a reputable company. Electrical actuators
produced by other manufacturers are not acceptable.
Intelligent electric actuators shall be capable of non-intrusive configuration

without requiring removal of any actuator covers. Configuration of actuator
functions shall be by use of a hand-held Bluetooth-linked device, laptop or
smartphone with compatible software, or by local control switches and 32-
character LCD display mounted on the actuator housing.
Each electric actuator shall be furnished complete with a motor, gearing,

handwheel, configurable output relays, torque sensors, lubricants, wiring,
and terminals. Each actuator shall be constructed as a self-contained unit
with stainless steel housing and shall be integrally assembled on the
applicable valve or gate by the valve or gate manufacturer. Housings shall
have two O-ring seals, one on the controls compartment and one on the
terminal cover.
Actuators shall be designed for their individual duty but at least for duty
type S4 acc. to IEC 60034-1 and to cycle the valve or gate from the fully
open to the fully closed position or the reverse in approximately 60 seconds.
Actuator motors may be mounted horizontally adjacent to or vertically

above the reduction gearing. All gearing shall be oil or grease lubricated.
Actuators for valves or gates listed for modulating service in the valve and
gate schedules (if any), shall be provided with a control module for position
modulating type service. The control module shall be mounted within the
controls compartment.
The control module shall contain adjustments for span, zero, gain, and
deadband.
3.10.1.1 Remote indication and controls

Valve or gate control commands and actuator status indication shall be
exchanged with the DCS by hardwiring. The actuator shall accept remote
controls to open, close, and stop the actuator and shall also accept a position
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setpoint. Hardwired signals to the actuator shall prevent or allow the

actuator to operate (interlocks).
Hardwired signals (permissive, inhibit or emergency stops) shall override

control signals.
At a minimum, the actuator shall transmit the following status information:

· Valve opening, closing, or moving,
· Valve fully opened, fully closed,
· Motor failure,
· Remote mode selected,
· Local mode selected,
· Valve position, and
· Valve torque.
If actuators are not easily accessible, it shall be furnished with a remote-

control station. The control station shall include red and green indicating
lights for valve position status, Local-Off-Remote selector and Open-Close
selector switches.
Power for the remote-control station shall be provided from its respective
actuator unit. The remote-control station shall be rated NEMA 4X.
3.10.2 Pneumatic actuators

Pneumatic actuators for isolating valves shall be modular, scotch yoke
design with double-acting or spring-return configurations, depending on
valve size or service. Actuator shall provide high torques at low pressures.
The actuator body shall be made of rugged, ductile cast iron and shall be
corrosion resistant, IP67. Pneumatic actuators shall be designed for the fail-
safe operation of the process/unit/plant.
All pneumatic control equipment and control drives shall be able to operate
with an air supply pressure between 5 and 7 barg.
All actuators involved in control functions shall be furnished with digital

valve controller (positioner), microprocessor-based current-to-pneumatic
converter. Positioner shall provide 4-20mA signal (HART). The positioner
shall be Smart type, with auto calibration and self-testing. Control signals
shall be transmitted hardwired, fieldbus is not allowed.
Valve controller shall include a LCD display as local user interface, and
provide advanced diagnostic capabilities. Additionally, the controllers shall
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be furnished with integrated limit switches and valve position transmitter (4-
20mA output). The valve controller shall come with NAMUR mounting.
All actuators which are in critical control loops shall be provided with
separate robust precision position measuring transmitters for operation and
monitoring via DCS. Positioner and position transmitters shall be mounted
in such a way that can be easily removed during maintenance tasks.
Positioner and position transmitter feedback shall be securely attached to

valve stem to avoid backlash or motion’s lost, if strong pipe vibrations are
expected.
All positioners shall be provided with pressure gauges (air supply and
control air output) as well as an air filter regulator set.
All pneumatic actuators (isolating or modulating purposes) shall have local

mechanical indicator to display valve’s position.
External limit switches (e.g. for Open/Close) shall also be provided for
isolation valves and gates. Limit switches shall be heavy duty type, with a
cast NEMA Type 4 enclosure, a spring return roller lever, and four isolated
contacts (two normally open and two normally closed) rated for 10A at 120-
480VAC and 5A at 125VDC.
Inductive proximity switches, non-contact detection, are also acceptable. It

shall be installed in a switchbox mounted onto the actuator. Switchbox
enclosure shall be corrosion resistant, made of fiberglass reinforced resin,
IP65.
3.10.2.1 Solenoid valves

All solenoid valves shall be designed for continuous operation, waterproof
type, and shall have a junction box- enclosure, corrosion resistant, IP65.
Coils shall operate either at 24VDC or 230VAC, insulation Class H.
Electrical connections shall be through cable gland, forming part of the
scope of supplies. Each solenoid valve shall be fused individually.
When required, solenoid valves shall be provided with manual operators to
operate the valve manually when electric power is off.
Solenoid valves shall be mounted on a rigid mounting frame or plate

independent from the actuator. It is not permitted to mount the solenoid
valve on the actuator, unless agreed by the Engineer.
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3.11 Installation Requirements
3.11.1 Power supply

The power supply for Instrumentation and control system shall be supplied
from the 230VAC UPS (Uninterrupted power supply) units to be located in
electrical rooms. Power supplies for voltages other than 230VAC shall be an
integral part of the equipment furnished. The Contractor shall provide
necessary redundant power supply units, transformers, etc... to achieve
required voltage level within control panels and ensure continuous supply.
Internal power supplies shall be regulated, current limiting, and self-
protected.
Power distribution for field instruments / equipment shall be from control

panels, separate MCB’s with auxiliary contact for monitoring shall be
provided in the CP (control panel) for power supply distribution to each
instrument. Contractor shall be responsible for distribution of power among
enclosures, consoles, peripherals, and other components of the system from
the power supply receptacles and junction boxes.
The instrumentation and control system power supply shall be 24V DC.
Generally, two wire transmitters shall be used (24VDC loop powered), and
all protection and control circuits shall be suitable for operating on 24V DC.
If external power supplied is required, 230VAC shall be considered. Use of

230VAC transmitters / analyzers shall be minimized.
Equipment not indicated to be powered from an uninterruptible power

source shall be suitable for being supplied from the facility distribution
system and shall be capable of withstanding voltage variations of +/- 10
percent and harmonics up to the limits of IEEE 519 without affecting
operation. Contractor shall provide voltage conditioning or filtering
equipment if necessary, to meet the requirements specified.
All equipment shall meet all surge withstand capability tests as defined in
ANSI C37.90 without damage to the equipment.
3.11.2 Grounding and surge suppressors

In addition to other environmental protection specified herein, the entire
system shall be provided with lightning protection.
The instrumentation grounding system shall be separated from electrical
ground conductors.
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Instrumentation grounding’s bus bars shall be considered in all technical

rooms and shall be connected to the buried electrical grounding network
through insulated Cu earthing conductors.
No electrical bonding between electrical and instrumentation components

shall be considered. Electrical and instrumentation grounding networks shall
be kept independent in all the installation except in the interconnecting point
(underground).
Earth resistance shall be maintained less than 2 ohms. Grounding junction

box with disconnect links shall be provided.
All major components of the system shall have a low resistance ground
connection.
Surge and lightning suppressors shall be non-faulting, non-interrupting, and

shall protect against line-to-line and line-to-ground surges. Devices shall be
solid-state metal oxide varistor (MOV) or silicon junction type, with a
response time of less than 50 nanoseconds.
Surge protective devices shall be applied for the following:
· All power connections to DCSs, instruments and control room
equipment.
· All connections to coaxial-based networked equipment where any part of
the circuit is outside of the building envelope.
· All analogue signal circuits where any part of the circuit is outside of the
building envelope. Circuits shall be protected at both the transmitter and
the control system end of the circuit. Surge protection devices shall not
impede or interfere with the use of smart transmitter
calibration/communication.
· All metallic pair (twisted and untwisted) conductor local area network
and data highway termination points, where any part of the data highway
cable is routed outside of the building envelope.
· All serial, DCS data highways, and remote I/O network termination
points where any part of the circuit is routed outside of the building
envelope.
· All telephone lines at points of connection to the system.
3.11.3 Instrument’s installation

All the associated field instrument transmitters will be installed at a nearby
common location segregated according to the P&ID and/or process within a
weatherproof instrument panel with safe and ease of access for maintenance.
Preferred material for instrument’s panels shall be GRP (glass reinforced
polyester), otherwise panels shall be covered with GRP roof.
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Similarly, all analyzer in a common area shall be installed in a common

location segregated according to the P&ID within a weatherproof analyzer
panel with safe and ease of access. The remote analyzer, and associated
sample conditioning equipment will be pipe-stand, panel or rack-mounted in
close proximity to where the sample is drawn, to minimize the measurement
delay. Technical details of the analyzer used for a particular application will
be provided.
Equipment installed under this section shall be fabricated, assembled,

erected, and placed in proper operating condition in full conformity with the
drawings, specifications, engineering data, instructions, and
recommendations of the equipment manufacturer.
· In general, each transducer shall have its own tapping point and sensor,
in particular all transmitters to be used for protection and control shall
have their own separate tapping points.
· Instruments shall be mounted in a height between 1,20 m and 1,60 m so
that they can be easily read and serviced from ground or platforms and so
that all auxiliary devices can be easily operated.
· All transmitters shall be supported in a vibration free manner,
independently from plant connections, and mounted in the right
elevation. No stress shall be imposed through the process connections.
· All type of instruments (indicator, switches, transmitters, etc.) shall be
installed in principle so that removal of the device is possible without
causing shutdown of the process. Attachment method for isolating
valves, vent/test valves and valve manifolds to measuring devices, shall
be such that it is possible to disconnect the device from the connecting
pipework without having to disconnect or drain the pipework.
· All instruments shall be installed and connected so that on-site
calibration using portable test equipment is possible, without removal of
the instrument from the process line.
· All electronic devices shall be protected against transient voltage levels
or short circuits, as well as against vibration, dust or heat which would
damage the device.
· All instruments and junction boxes shall be mounted in locations, which
allow easy and safe access for maintenance without the use of temporary
ladders, scaffolding or similar means.
· Electronic instruments shall not be located close to hot lines, vessels or
other hot equipment. Black bulb temperatures exceeding 80 degrees
Celsius shall not result in calibration difficulties / control module
malfunction nor rapid deterioration of electronic components. For open
locations appropriate sunshades shall be provided.
· All sensors/transmitters mounted in direct sunlight shall be provided with
sunshades.
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· All instruments used in high-pressure applications (above 32 bar) shall be

provided with a double primary isolating valve at the pressure source.
The connection from instrument primary isolation valve shall generally
be in welded piping with socket weld connections or in tubing with
double ferrule compression fittings. Piping and fittings shall be in
precision 316L SS (1.4571), diameter 1/2" or 12mm OD. Welded piping
shall be used for dangerous fluids or explosive gas measurements.
Tubing and compression fitting shall be used on general services.
Chemical protectors (diaphragm seals) shall be used with the pressure

instruments for the following services:
· Fluids that will clog the pressure element.
· Corrosive fluids requiring special materials available for diaphragms
but not satisfactory for use as pressure measuring element.
· All pressure instrument/gauges on steam/vapors services shall be fitted

with U-type or "Pigtail" type condensing siphon to prevent live steam
entering the pressure measuring element. Condensing pots are to be
provided for instruments where required.
· Where pressure measurements are subject to pulsation, snubbers
(dampers) shall be fitted.
Instrument shutoff valves shall be provided by Contractor for all
instruments. Shutoff valves shall be compatible with the measured
process and shall be selected in accordance with the manufacturer’s
recommendations for the specified process. Unused ports of multi-port
gauge valves shall be plugged.
Installation design and practice of the instrumentation shall follow BS 6739

latest edition. The Contractor shall provide typical hook up drawings for
each type of measurement he proposes to use on the project.
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3.11.4 Wiring and cabling

Instrument cables shall be screened with stranded conductors, cores twisted
together in pairs.
All cables shall be flame retardant, low smoke non- Halogen, fully
compliant with IEC standards.
All multipair-cables shall be furnished with single screen (each pair) and
overall screen.
Screen continuity shall be maintained from the instrument, through the field
junction boxes, to incoming screen bar at the marshalling terminals.
Control cables for sensors and actuators shall always be hardwired, field bus
technology shall not be used. Structured cabling shall be applied.
Between the instrument and the local junction box, the cable maybe
supported in metal open conduit system or cable tray; however, for all skid
mounted packages the instrument cable shall be supported in continuous
metal conduit from the instrument to the local panel or junction box, but not
necessarily connected at the ends.
Manufacturer’s data for all cables, materials and fittings shall be approved
by the Engineer prior to purchase.
All cable support systems including trays, fittings and accessories shall be
detailed on instrument electrical hook-up drawings and shall be subject to
the approval of the Engineer.
Ferrules shall be provided on all power supply wiring within instrument

cubicles, and on all wiring within control panels and desks.
The cable access to junction boxes, cubicles and marshalling racks shall be
from the bottom. Other kind is subject for approval of Employer / Engineer.
Cable color codes shall be provided for all signals instrument cables. All
cables shall be provided with ferrule for cable identification.
3.11.4.1 Cabling
Prior to installation of cable ladders/trays, the routing shown on the
instrument cable and location layouts shall be checked for interference with
piping, structural and electrical components.
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Individual cable runs from junction boxes or racks to instruments shall be

run as directly as possible.
Multipair cables shall run overhead in cable rack/ladder, or in trenches, as

specified on the applicable drawings.
Cabling should be designed and laid in accordance with the guidelines

drawn up by the contractor, which has been laid down in this specification
and in accordance with the applicable regulations.
Field mounted electric instrumentation shall be wired and connected to

identified junction boxes.
Instrument wiring between the marshalling racks in the technical room (TR)
and field junction boxes shall be wired and connected by means of
identified multipair cables.
All electrical signal cables shall be installed and terminated observing the
following details:
· Special signals cables (such as coaxial cables, fiber optic etc.) shall be
installed in accordance with the seller’s instructions.
· All signal cables shall be individually marked on each side with plastic
markers.
· Special attention shall be paid to the interconnection of cable screens in
such a way that the screening is earthed only at the intended location and
that multiple earthing does not occur.
· Cable glands on equipment in the plant shall preferably be in the bottom
and never in the top, to prevent ingress of water. Where cable glands are
installed in the side wall of the equipment, the cables shall enter from
below. Cables coming from above shall first drop to below the elevation
of the gland.
· All external crevices between cables and cable glands in the plant shall
be sealed with a suitable compound.
· All field single cabling shall be coded with the applicable instrument tag
number close to the junction box.
A minimum of 20% spare capacity shall be provided in each signal cables

trunk, terminal strips, signal inputs and outputs (including i/o modules,
processors and relays etc.), instrument power supply MCB's and fuses etc.
control equipment cubicle racks and associated internal wiring to signal i/o
terminals.
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3.11.4.2 Cable Connections/Termination

Cables should be connected up in accordance with the connection lists/
diagrams.
Where the use of cable glands is not possible for practical reasons, other
systems may be used in consultation with Employer / Engineer. It shall be
ensured that at the cable gland, the cable shields shall be insulated from the
instrument.
All cables should be laid with sufficient length in view of the connections to
be made. For terminal boxes, plug connections and the like, at least one (1)
meter of connection length should be allowed for. For marshalling
racks/boxes, switch fields, control boxes, etc., the cables, if the connection
spot is not known, can be connected up to any spot in the box or any
section.
Before making a start with connecting up of cables, a few trial connections

should be made for approval by the Engineer.
Cable conductors which are connected to terminal strips should each be

about 5 cm longer than what is required for the connections. The extra
length should be taken up in a loop just before the terminals.
It is not allowed to connect two (2) or more conductors to one (1) terminal,
unless the terminal is specially equipped for that purpose. For each
deviation, approval from the Employer / Engineer is required.
Wires should be mounted without interruptions. Weld connections and the

like are not allowed. All stranded cable conductors shall be fitted with
crimped taper pins, AMP (or equivalent) and all screens with lugs. Supply
and installation of all AMP wire pins and screen lugs shall be done by the
contractor.
Cable ends should be supported up to at least 20 cm from the cable lead-in

spot.
In principle, all unused conductors shall be connected to spare terminals.

Unused conductors which cannot be connected to spare terminals should be
kept as long as the longest conductor that is connected up. The ends of these
conductors should be insulated. Non connected cables should always be
protected against moisture effects.
For special equipment, the cables should be joined in accordance with the
seller’s instructions.
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3.11.4.3 Cable shielding
· Cables from Field Instrument to Junction Box

Shield at instrument side isolated from transmitter casing and plant earth.
Shield at junction box side to be connected on terminals or via an isolated
instrument earth rail in junction box.
· Cables from Junction box to Control Room Cabinet

Individual shields and overall shield at junction box side to be connected on
terminal or via an isolated instrument earth rail in junction box. Individual
and overall shields at cabinet side (inside control room), to be connected via
isolated instrument earth rail with clean instrument earth.
3.11.4.4 Cable identification

The cable tag shall be used for cable identification. All instrument cables,
conductors and the instrument screen/ earth wires shall be tagged on both
sides in accordance with the instrument connection list. Cable ends shall be
provided with marker strips.
Wire ends shall be identified with closed ring-shaped coding showing the
number of the terminal to which the wire is connected. Color of the ring
coding shall be yellow with black lettering.
For color coding cable conductors/wires refer to IEC 446. For marking of
insulated conductors/wires refer to IEC 391.
All materials, instrumentation, fittings, methods and layout shall be

approved by the Engineer before purchase.
3.11.5 Instrument air supply system

Instrument air shall be connected to the existing plant Instrument air system.
All instruments/valves shall be provided with individual reducing regulators

and air filter sets.
Where a common reducing regulator and filtering assembly is fitted, it shall

be duplicated, and the system provided with block valves to enable one unit
to be on stand-by service. Safety relief and pressure indicator shall be
provided on the reduced air side of the system.
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The air shall be taken from instrument main air ring and instrument tubing
for pneumatic actuators shall be made of stainless steel (SS316L), plastic
coated (PVC or polyethylene). Tube compression fittings shall double
ferrule type, leak-free, stainless steel (316L).
Compressors provided for instrument air supply shall be of the dry cylinder
type, i.e. which use no oil on the parts exposed to the compressed air.
Each compressor unit shall be provided with its own control panel, being
part of main control network.
3.11.6 Instrument’s interface

Contractor will provide field communicators for instruments configuration
and maintenance purposes. Communicator shall deliver full-color graphical
interface, long-lasting Lithium-Ion power module for days of battery life, as
well as universal support for HART and Wireless HART.
Appropriate operation manuals shall be provided and included in the

familiarization requirements.
If any device requires a serial interface, it shall be provided with all

necessary accessories to properly communicate over the serial link. As a
minimum, an appropriate cable shall be provided to allow the transmitter
serial interface connection to a personal computer. Licensed diagnostic
software shall also be provided. If software furnished performs same
functionality as the obtained with the field communicator previously
specified, then the software/serial interface shall not be furnished.
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4. Control System
Control System will be designed as a total solution, providing necessary
control and monitoring means for all main systems of the whole plant.
Plant operation, monitoring and control shall be foreseen from a CCR thru
standard operator’s workstations (OWS), Workstations from proprietary
systems shall not be accepted. Local emergency push buttons shall also be
provided for the major plant equipment.
The system shall be furnished as specified, complete with all software,

distributed control system (DCS) hardware, human machine interface (HMI)
hardware, instrumentation, and all devices, accessories, appurtenances,
programming, testing, and training necessary for proper and safe operation.
Equipment furnished and installed under this section shall be fabricated,

assembled, erected, and placed in proper operating condition in full
conformity with the drawings, specifications, engineering data, instructions,
and recommendations of the equipment manufacturer.
For all control, instrumentation and monitoring systems the latest versions
of proven hardware, firmware and software modules, which are available on
the date of shipping, shall be supplied. This is subject to the approval of the
Engineer. However, prototype equipment will not be accepted, only high-
quality systems from reputable suppliers preferably with established local
back-up for maintenance and after-sales technical and spares supports shall
be offered.
For the system offered, a guarantee shall be given that spare parts will still
be available at least 15 years after commissioning of the plant.
The DCS shall be proven solution for similar type of plants.
The system shall be designed to allow an easy extension in case of

subsequent modifications on the controls and the associated signal
processing equipment for hardware and software.
The distributed control system (DCS) of the whole Plant shall be a

programmable microprocessor based up-to-date modern digital process
control system with self-diagnostic features ensuring the operation for the
remaining lifetime of the Plant.
The DCS system shall achieve the functions of data acquisition, signal
conditioning, closed loop control, open loop control, calculation, alarm
processing and annunciation, sequence of event recording, historical and
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real-time trend recording, graphic display of process and communication

with other devices/systems. All equipment shall be synchronized by a real
time master clock system.
The control system shall be designed such that any of the single failure of a
equipment (module, controller, data highway, etc.) shall not leave the plant
with less than full duty capacity. A cause and effect diagram shall be
produced to demonstrate the robustness of the system.
It shall be possible to display, operate and control any equipment/ system of

the plant from any operator station.
Additionally, DCS shall be able to communicate with the existing plant

control system based on standardized protocol. All supply and service
relating to the interface between the DCS and the control system of the
existing plant shall be considered in Bidder’s scope including the fiber-optic
cables, routing and cableways, particularly for establishing cyber security,
interoperability and modification and coordination of interfaces and the
signal exchange path shall be considered.
4.1 Availability and Redundancy

The highest demands are placed on the control, instrumentation and
monitoring equipment with regard to availability, plant safety and
reliability. No common single point of failure must exist in the systems.
All vital system functions that can affect large part of the plant operation
shall be duplicated with automatic bump less/smooth switch over and fault
reporting and diagnostic facilities. A single fault shall not cause a trip or
loss of performance and shall not cause loss of the protection system.
No single control system fault shall directly cause any of the following
conditions:
· complete loss of one boiler/steam generator unit or more,
· Loss of communication between the HMI in the CCR and the plant
control system such that safe shut down and on-line operation cannot be
maintained from the CCR.
The system redundancy shall be complete, and it is essential that following

parts be in redundant design, but not limited to:
· Data highway,
· Process controllers,
· Interfacing modules,
· Power supply Units, and
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· Any other element a failure of which will disable large portion of the
plant or create an unsafe operating condition.
In case of a hardware failure within the automatic controls, the

corresponding process controller shall be automatically switched over to the
redundant unit and shall not degrade the system performance or cause any
operational disturbance.
The data highway system shall be single fault tolerant; one failure in the
data highways shall not reduce the availability of any of the system
components or degrade system performance. Failure recovery shall be
smooth, bump less and automatic. Connection of additional equipment shall
be possible online without disrupting operation. Any data communication
failure shall not disrupt process control.
The assignment of the various displays on the VDUs shall be flexible and
simple, so that in case of failure of a VDU, any remaining VDU can take
over its function.
The power supply source for all the DCS equipment and Operation Stations
shall be dual-redundant. However, in case of total control system power
interruption the DCS shall set all outputs (analogue or digital) to a
programmed fail-safe position.
A safe shut-down of the plant must be guaranteed in case of major or

catastrophic failure of the DCS. To fulfil this requirement the fail-safe
concept (normally energized principle) will be used and plant protection
equipment will be fed from DC battery systems and/ or UPS as appropriate.
The possibilities of the redundant design should be taken into consideration

when assigning the hardware to the process plant components. The system
shall be structured to reflect the redundancy provisions of the Plant so that
no single fault within the system will cause an operational disturbance or
spurious operation or make a standby plant unavailable.
At least, following recommendations shall be applied:

· The redundant process controllers (CPU) shall be installed in different
racks and shall be powered from different power supply units.
· Power supply units shall be fed from different UPS system.
· Non-redundant modules for protection system signals (2oo3) shall be
installed in three different racks.
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The I/O modules in the DCS process controllers shall be provided redundant
as follows:
· Signals for close-loop control shall be connected to non-redundant
modules.
· Signals for open loop control shall be connected to non-redundant
modules.
· Protection system signals and control monitoring signals shall be
connected to different I/O modules.
· Protection system signals shall be connected to dual redundant modules.
· Protection system signals being part of 2 out of 3 voting shall be
connected to three different modules.
If signals only can be sourced from/to single instrument/devices, so

connection to redundant input/output modules (i.e. protection signals) shall
be provided through field termination assemblies (FTA) with dual redundant
pin-connectors or dual amplifiers.
Special precautions shall be taken to provide maximum reliability for

"Vital" control loops or interlocks whose failure could result in outages, in
major financial losses or threaten human life. These measures shall be
implemented as 2 out of 3 voting.
In addition to the above measures, for areas of the plant in which proper and
reliable functioning of measurements and process control equipment is
essential for the prevention of human injury or death, fail-safe and type-
approved systems shall be employed. All control subsystems shall have a
demonstration or calculation of the MTBF. The Contractor shall provide
MTBF figures related for each subsystem and the overall figure for the
proposed system.
4.2 Cyber Security

The vulnerability of the control system shall be minimized without loss of
functionality and stability.
Following items shall be considered generally:

· Creation of a network topology scheme with special attention to all
interfaces and separation of safety levels.
· Interfaces and security methods for:
· Interfaces to office LAN,
· Interfaces to Package’s PLCs,
· Interfaces to set off working places,
· Remote maintenance.
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· Patches and software updates, including anti-virus scanners, are required

to lessen the possibility of cyber-attacks upon known vulnerabilities and
exploits.
To ensure availability, confidentiality and integrity at least the following

item shall be considered:
· Design of DCS with security measures, segregation and availability to
reflect the plant requirements.
· Measures to protect itself from unauthorized access from external
systems including the corporate office data network.
· Measures that enable secure remote operation according to process
requirements.
· Measures for disaster recovery.
· Safe operation if communication to external systems fails.
· Be documented and maintained in a manner that reflects the requirements
of the connected systems.
The measures shall be based on international standards, particularly ISO

27001, IEC 62443. Bidder shall develop a cyber security concept for the
plant, considering particularly the standards ISO 27001, IEC 62443 and
include all supply and service, support the Employer for implementation and
integration of the RO-project. Bidder shall consider Employer’s Cyber
Security guidelines as far as existing.
Access level authority shall be submitted to the Engineer approval at the

beginning of the design phase.
A close cooperation for developing the final operation and access

philosophy to the plant, as well as to the control & IT systems will be
necessary between client and supplier.
Cybersecurity design shall fulfil at least all requirements stated in “Security

Directives for Industrial facilities” SEC-12 Cybersecurity, version 2.0,
issued by the High Commission for Industrial Security, Ministry of Interior,
Kingdom of Saudi Arabia.
4.3 Hardware Requirements

All systems shall require minimum maintenance and shall have
comprehensive off-line and on-line self- checking and self-diagnostic
capabilities including self-test failure alarms etc. for all control modules and
nodes. Comprehensive status information recording, and reporting shall be
provided for all systems allowing for efficient fault detection and tracing.
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4.3.1 Process controllers

The process controllers shall consist of a redundant microprocessor-based
system or multi-functional computerized controllers with the appropriate
process interfaces. They shall contain all functions, which are necessary to
keep the process running without operator's intervention and independent of
the availability of a workstation or the state of data highway. The cabinets
shall be accommodated in related TRs and electrical rooms.
The main functions of the process controller shall be acquisition of digital

and analogue signals from the process, signal conditioning and processing,
output of digital and analogue signals, closed loop control and open loop
control. All system clocks shall be synchronized. This includes also
synchronizing of external systems (e.g. local PLC’s).
DCS shall use purely DCS controllers. It shall not use controllers which are
also sold as PLC. Hybrid systems are not acceptable.
In order to ensure high availability, the hardware shall be functionally

distributed, i.e. a limited number of inputs and outputs per module and
individual modules for closed loop control, functional group control and
drive control, so that any failure shall have limited effect.
Failures shall be indicated by alarms and LEDs, and logged, including the
hardware address of the failed module. All process and C&I alarms shall be
provided with proper texts to indicate the nature of the fault.
The DCS process controller shall be provided as single fault tolerant and
shall be structured as entirely redundant in all specified aspects, including
the processor modules, power supply modules and communication modules.
The hardware shall be of utmost reliability and shall have modular

construction. Each module shall be of plug-in, on-line replaceable type, with
100% redundancy for failure and automatic transfer to a healthy standby
CPU module. Each CPU module shall contain requisite hardware, firmware
and software to perform modulating, sequential control and alarm functions
in an integrated manner.
Processor shall be provided with self-monitoring diagnostic techniques and

shall contain easily visible LED diagnostic indicators for "run" and "halt"
conditions as well as memory and input/output error conditions. Diagnostic
codes shall also be available through the programming device to facilitate
troubleshooting.
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The processor shall be programmable using DCS software tools, and shall
include, at least, the following capabilities for programming, debugging of
programs and troubleshooting:
· Off-line development of all DCS-related programming, including user
annotation of the program, and creation and printing of application
programs and I/O cross-reference lists.
· On-line programming including IEC-1311 standards program
modification and monitoring of real-time programming execution.
Removal or disruption of any DCS items for on-line programming or
monitoring will not be acceptable.
· On-line status of data and registers. I/O hardware diagnostic and status
information shall be accessible in on-line mode. For DP and HART
instruments, diagnostic programs shall be installed in DCS and activated
for plant time.
· Input/output forcing.
DCS processor shall be able to feature following scanning times:

· Data Acquisition
· Analogue values 200 ms
· Binary values 100 ms
· Time-critical binary values ≤ 10 ms
· Control Loops
· Fast control loops 250 ms
· Slow control loops 500-1000 ms
· Scanning time for processors ≤100 ms
The DCS process controllers shall be loaded maximum to 60% during

normal operation and maximum of 75% during operational disturbances.
The process controllers shall be supplied as fully assembled and functional,

pre-wired, programmed and tested, in lockable steel cabinets, fully
accessible front and rear.
4.3.2 Signal processing

Dedicated hardware modules for input and output signal conditioning shall
be provided. The process I/O shall be able to accept signals from
commercially available signal sources Conversion into engineering units
and linearization of the signals shall be possible. The input modules shall
have wire break detection facilities.
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DCS systems shall support, at least, the following types of input/output

modules:
· 22- 50 VDC digital input and output.
· 4-20 mA dc HART analogue input and output.
· High speed pulse accumulator input.
· Platinum RTD analogue input.
The system I/O shall be designed to meet the following general

requirements:
· The DCS I/O shall be of intelligent microprocessor based I/Os with real
time tagging / stamping.
· The I/Os shall have a self-diagnostic system.
· Any input shall withstand a steady signal of 24 V- or 10-times normal
input, whichever is the greater. Overload of any channel shall not affect
any other.
· The process I/O operation shall not be affected or damaged by ground
faults of field equipment (surge protected).
· The process I/O operation shall not be damaged by a short circuit in the
field wiring.
· All field signals (analogue and digital) shall be hardwired to the process
interface (I/O).
· A selection of scanning rates shall be applied, which shall in all cases be
adequately high to ensure safe and efficient control of the plant.
· It shall be possible to remove all I/O modules without disconnection of
plant cables.
· High insensibility against noises and other disturbance signals (e.g.
walkie-talkies). The requirements of EN 55011have to be fulfilled, at
least.
· High insensibility against over-voltage (IEC 60 255-151 class II).
· 20% spares channel shall be available in each I/O module.
· I/O’s modules shall be individually isolated for each channel and hot
swappable.
· The outputs of analogue and binary output cards shall be short circuit
proof.
A mechanical method of preventing incorrect positioning of I/O type

modules in the rack shall be provided.
All input/output modules shall be furnished with easily removable plug-in

or hinged field wiring terminals to allow removal of modules without
disconnecting individual wires.
Wire break and short-circuit supervision shall be provided in the I/O level
for all incoming remote field signals, the faulty signal shall be alarmed.
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4.3.2.1 Analogue I/O

The following minimum requirements shall be considered for the analogue
I/O modules:
· For the analogue inputs the system software shall check for signal
integrity and if the input signal exceeds ±5% of the specified range of the
zero and full signal range the measurement shall be declared invalid.
· Analogue input modules which provide also the power supply for the
field transmitters will be preferred.
· The analogue output modules shall provide 4 - 20 mA DC, capable of
driving up to 600 Ohms total loop resistance. 24 V DC loop power to be
provided by the DCS.
· Each analogue output shall be short circuit proof.
· Linearity shall be within 0.2% of all inputs.
· For analogue 4 - 20 mA inputs, the input resistance shall not exceed 250
Ohm.
· Analogue inputs shall contain over range protection circuits to protect the
equipment from ground faults or high voltage either in common or
normal mode. Ground fault detection alarm shall be provided.
· Analogue signals shall be measured at a rate of 2 scans per second or
higher and shall be programmable per channel.
· Input modules for pulse inputs should be available.
· All AI/ AO modules shall be with HART pass-through function. External
HART multiplexers shall not be used, except in case of SWCC
engineer’s approval.
4.3.2.2 Binary I/O

The following minimum requirements shall be considered for the binary I/O
modules:
· Binary signals shall be measured at a rate of two scans per second
(normal) up to 20 scans per second for fast events.
· A resolution of 1ms for all input digital signals with time stamping at the
input module as an inherent characteristic feature of the DCS.
· The binary input modules shall be provided for 24 V DC.
· Sense voltage to field contacts and input for proximity switches shall be
provided by the DCS.
· Inputs shall be individually isolated.
· The binary input modules shall be able to supervise the circuit integrity
and they shall ensure that the current through the closed contacts of
binary transmitters shall be at least 3 mA.
· The digital output modules shall provide dry contacts rated at 2 amperes,
24 V DC and shall be selectable as normally open or normally closed.
· Wire break detection.
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4.3.3 Marshalling
All DCS input/output signals shall be connected to galvanically isolated
Field Termination Assemblies (FTA). Direct connection of field wiring to
the I/O module terminals is not acceptable.
Terminal connectors on the FTA shall provide the connection points for the
process control wiring. Fuses, relays, and resistors shall protect the FTA
circuitry. The assembly shall also provide surge and ESD protection for the
field wiring terminals. FTA terminal connectors shall be screw-type.
The FTA shall communicate with the associated IO module through pin
connectors (single or redundant). The FTA’s shall be installed at the rear or
front of the dual-access DCS’s cabinets.
Interposing relays shall be provided in the FTA’s for all digital output
signals coming out form DCS cabinets.
Interposing relay shall also be provided in case digital input requires AC

voltage. Final digital input signal to the DCS input modules shall always be
22–50 DCV.
All FTA’s shall be fed from dual redundant power supply units.
4.3.4 Data highway communication

The distributed controller modules shall communicate with the operator
stations and with each other through a data highway. The data highway shall
have ring topology and it shall be a highly reliable and high speed bi-
directional single fault tolerant system of fiber optic, capable of data
transmission over a distance of a minimum of 1000 m without any repeater.
However, extension of the data highway shall be possible.
The communication system shall have all necessary fault diagnostics. The
data transmission shall be continuously supervised. Any errors should be
alarmed and recorded in the CCR.
The data highway shall be single fault tolerant. Under no circumstances

shall one single failure lead to an outage of the complete data system.
The speed of the data highway shall not be less than 1Gbit/s. The data
highway shall connect all the systems to perform real time information
exchange between the various DCS components.
Loading of the data highway should not exceed 60% with full load
operation.
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The data protocol used shall safeguard against erroneous data transmission
and allow for error detection, recovery and initiate switch-over to the
redundant data highway.
4.3.5 Power supply

All DCS/PLC electronic cubicles shall have double infeed and dual
redundant power supply units each with power failure alarm. The equipment
shall be properly fused.
All operator stations, panels, local operator stations, engineering stations,

DCS cabinets, etc. shall be supplied from a redundant UPS system,
230VAC, with a static automatic changeover switch. The power supply
shall be designed with no more than 70% load in each unit when operation
individually.
4.4 System Software Configuration

System software programming for the process equipment shall be provided
by the Contractor. Configuration services shall consist on the creation of the
system database, report formats, operator interface graphic and tabular
display screen formats, password and security implementation, and
programming of control units to provide a fully functioning system. The
Contractor shall fully configure the system using data provided herein or
supplied by the Employer after award of the contract. The Contractor shall
furnish all configuration tasks required. The Contractor shall obtain all
required programming licenses for development and programming efforts.
All database addresses, IP addresses, standard protocoll addresses, and

similar device configuration information shall be fully coordinated to ensure
compliance with project standards and to eliminate possible conflicts.
The system shall have the ability to calculate required data from membrane
supplier, simulation for Operation training and functional test for any
control loop.
Tuning of software programs shall be accomplished in such a manner that

the program operates at its highest performance level. These programs
include, but are not limited to Microsoft SQL Server, all logic programming
and others.
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4.4.1 Software requirements

The system software shall contain functional software modules that will
perform the basic control, monitoring and calculations. Function blocks in
the form of standard software modules shall be available. These modules
shall be stored in a non-volatile memory (Firmware).
The function blocks will be linked to build the required control functions.
Control blocks should have individual control database. Implementation of
the control functions shall be easily possible using readily understandable
configuration procedures. All configuration modifications shall be
implemented on-line.
The library of software modules shall contain all the functions required for:
· Closed loop control, such as PID, analogue and step output, multivariable
control, bias, cascade control, adaptive gain, etc.
· Standard software modules for motor/actuator control logic shall be
available, covering the functions described under 'Drive control' in clause
‘Open loop control’.
· Standard software modules for sequence control, such as sequence
header and step modules.
· Standard software module for the selection of the operating and stand-by
units and automatic change-over from a faulty unit to the selected
standby unit.
· Calculating functions such as generator capability curves, operating
characteristics, etc.
· Calculating required data from membrane supplier (Membrane
Performance Normalization).
The configuration control software shall include provisions for setting each
loop's scan rate. The configuration software should also be able to be
implemented by means of fill in the blank templates or other user-friendly
approaches that allow the user to easily create and modify control strategies
by lining the predefined algorithms.
The DCS system shall have provision to develop sequences and shall be
capable of being programmed directly from logic flow charts using an
operator-oriented language.
The system shall be furnished complete with working programs. All
software design, development, debugging, reprogramming tasks and final
configuration backups which are required to achieve operation in
accordance with this specification shall be provided and shall be
Contractor’s responsibility.
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4.4.1.1 Closed loop controls
4.4.1.1.1 General equipment design guidelines

The control valves and actuators shall comply with the general technical
requirements of this specification. The analogue position feedback signal
shall be used for control of the valve position.
For each final control element (FCE), it is preferred that automatic single-
channel closed-loop control shall be provided to ensure that a failure in one
loop will have only limited effect on the plant. This does not apply if the
control loop hardware is in a fully redundant arrangement.
The closed-loop controls shall permit control actions from the open-loop
control functions or systems, such as automatic MANUAL/AUTO
switchover and controlled OPEN/CLOSED actions of the control valve and
shall issue corresponding check-back signals to the open-loop control.
Control loop gain shall be automatically adjusted through parameter control
when the number of effective Final Control Elements (FCE) changes, e.g.
with one or two pumps under closed-loop operation.
The high/low limit should be indicated on the controller’s faceplate.
In the event of transmitter failure or a fault in the measuring transducer, the

design shall permit the following options:
· Switch-over to a second transmitter or MAX selection with double
measurement of the same variable,
· Control with a default value,
· Switch-over to manual operation.
Faults in the power supply shall not result in any unwanted or dangerous
switching actions.
Besides the modulating control function PID, the controllers shall contain
facilities for bumbles transfer, anti-reset windup, auto/manual switching,
parameter scheduling, cascading, feed forward control, signal exchange with
open loop controls, etc. Advanced control algorithms shall be provided
wherever they would result in advantages of process control. Due to a better
control quality self-adjustment of control parameters, use of state controllers
also with observer, adaptive controllers or multiple input multiple output
controllers shall be available.
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4.4.1.1.2 Cascade control

The tracking of cascade loops has to be automatic so that the manual
balance less and bump less operation can be achieved at any time without
having to specially configure the signal tracking.
When a controller in a cascade hierarchy is turned off (cascade open) or to

manual mode, the upper level controllers shall sense the mode change of the
controller. The output signal of the upper level controller shall then track the
set point of the controller at the next lower level automatically.
When a controller output reaches a maximum or minimum limit the primary

(master) controller shall sense the condition (set point limits) of the
secondary (slave) controller and shall stop the adjustment of the set point of
the secondary controllers.
4.4.1.1.3 Feed forward control

In case of disturbances, feed forward control shall take place in order to
minimize the disturbance effect. For this, suitable control, instrumentation
and monitoring functions have to be provided, taking also into consideration
the status and availability of components.
If useful, also automatic load shedding shall be initiated by the control
system.
The system shall allow implementation of feed forward control applications

and ratio control applications. Standard algorithms like lead/lag logic, ratio
control and free programming capability shall be provided. Moreover,
facilities to activate and deactivate feed forward and ratio controls have to
be provided.
4.4.1.2 Open loop controls
4.4.1.2.1 General
Open loop control shall be hierarchically organized and shall contain
individual drive controls and sequential controls. Protection and safety
interlocks of the drives shall be provided by the open loop control system.
As far as possible the design shall be so decentralized that a disturbance in

the control system shall not affect more than one sequence (e.g. one main
pump). In the case of a higher degree of centralization a redundant
configuration is mandatory so that the controller shall automatically switch
to a back-up controller in case of failure.
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To allow for the process redundancies 'Functional distribution' shall be

provided i.e. the grouping of the functional subgroups controlled by one
common redundant microprocessor shall be done in such a way that the loss
of the controller shall not cause any dangerous operational conditions or
plant shutdown. For example, if the control of pump 1 is disturbed, the
control of pump 2 has to be still available.
4.4.1.2.2 Sequential drive group and functional group control

Sequential Group controls are to be provided for start-up, operation and
shutdown of associated functional units and drive groups, i.e. it shall be
possible to start or stop main aggregates with all associated equipment by
issuing one command.
To indicate the sequence progress special sequence displays shall be

provided. Via these displays the sequential steps within the individual
sequential programs and 'missing criteria' (error condition) shall be
displayed on the VDU. Sequences including time related events shall
include a time-out alarm indication.
Group controls shall be capable of being switched 'on' and 'off' and shall
have defined commands for 'automatic' and 'manual'.
Any faults in the control system, which could cause the control sequence to
stop, have to be confined to one control sequence. Any faults in the control
system or in the plant equipment shall lead to an automatic changeover from
a faulty unit to an appropriate standby unit.
If a sequence control is stopped for any reason it should be possible to:

· Resume automatically on any step-in function of the prevailing plant
conditions.
· Resume manually on any step-in function of the prevailing plant
conditions.
For this reason, jump conditions shall be foreseen. Before entering in the
step, the sequence logic shall check the status of the jump condition. If the
jump conditions are fulfilled the respective step commands will not be
executed and the control sequence will be continued with the next step of
the sequence. Jump conditions shall not violate any protections or process
safety.
In case if the sequence control stopped and the plant went for a safe
shutdown the cause of the failure shall be indicated in the DCS.
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At least functional groups should be considered for all main pumps. All
necessary function group controls shall be provided, which are necessary for
the intended automatic start of the Plant.
4.4.1.2.3 Drive control

Every remote operated drive or breaker shall be controlled by means of a
drive control module as the standard interface between the DCS and the
switchgear. Drive control in the I/O level of the DCS shall be utilized for
drive control equipment such as motors, pumps, motorized valves, solenoid
valves and actuators etc.
To this module all orders i.e. from the operator station via the keyboard,
step signals of the control sequences, interlocks or protection as well as all
check-back signals of the drive or switchgear shall be connected. After the
processing of these signals the control module shall issue the order to the
switchgear via coupling relays. Drive control in the I/O level of the DCS
shall be utilized for the motorized control actuators and the protection. The
functions of the drive control shall be integrated in a dedicated multichannel
hardware module.
The Contractor shall describe in his offer the hardware and software
modules he intends to use for the drive control. Drive control modules shall
meet the following minimum requirements:
· Inputs for hardwired manual, automatic and interlock signals. Protection

signals shall have priority over other commands. If activated they shall
block the ON/OFF commands up to acknowledgment. There shall be a
visual display of this blocking action and it shall be capable of
acknowledgment. In cases where it is necessary, for safety reasons, to
provide a local emergency stop push-button, the operation of this
pushbutton shall have the same effect as the operation of other protection
devices.
· Dedicated outputs for ON and for OFF commands.
· In the event of on/off command arising simultaneously or commands
repeating alternately, provisions must be made to lock out these
commands.
· Stop command of the actuator upon triggering of the stroke or torque
limit switch.
· Signaling of drive position and operation status (e.g. local operation).
· Selection of local or remote operation mode • monitoring of any changes
in status not brought about by the drive control module.
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· Selective fault annunciation for drive connected faults such as differential

signals, i.e. the position of the drive is in opposition to a given command,
or trip by fault in the switchgear.
· Processing time from incoming signals to outgoing commands shall be
less than 20 ms, in order to stop torque seated motor valves.
· Maximum of four drives control shall be implemented in each I/O
module.
In the event of any tripping or failure, a group signal must be passed via the
annunciation equipment and the fault status must be displayed individually
for each drive in the appropriate operation display on the operator station.
The local controls shall act only if selected by a local/remote key on the
local control point. The local/remote signal shall be sent to the drive control
where the selection of the control mode shall be processed. If local
operation is selected, it shall be displayed on the VDU in the CCR and no
operation from other place shall be possible. The command from the
emergency stop push-button of the local control point shall be transmitted
directly to the switchgear.
For unidirectional motor drives (pumps, fans) the issued command shall be
an impulse (e.g. reset by switchgear feedback signal) which shall be
memorized in the switchgear by latching, so that the interposing relays shall
not be permanently energized.
The control command shall be reset by stroke end or by torque switches for
reversing drives (actuators for valves, dampers). Drives/actuators with
intermediate positions shall be designed either with a stop command or for
inching operation.
Solenoid valves that do not exceed the drive control module power limit
may be energized directly from the drive control module.
Individual controls of reversing drives shall be so designed that upon
withdrawing of the control cable plug connector the drive actuator will stop
and it will not be possible to set it in motion.
The control commands from the drive control module to the switchgear
shall be transmitted to the switchgear through two interposing relays at 24 V
DC, one for the ON and one for the OFF command. The coils of the
interposing relays shall be connected with freewheeling diodes.
4.4.1.2.4 Protection and safety interlocks

To protect individual units or parts of the plant, interlocks are to be formed
in accordance with process criteria, which can be either active or passive
depending on their functions.
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Active interlocks shall automatically disconnect units or parts of the plant

before they reach a critical operating condition or shall start certain units
(e.g. stand-by) in order to avoid a critical operating condition. In addition,
such dangerous conditions must be immediately indicated to the operating
personnel by means of an alarm.
Passive interlocks are intended to prevent operational errors or wrong
commands from being carried out in the event of selective faults in the
automatic control.
Active and passive interlocks must not be capable of being switched off
operationally from the control room. All protections have to work fully
automatically and independent of the operator and always have to be
effective for all procedures (manual, partial automatic, fully automatic).
All protections and interlock signals shall be implemented in hard-wired.
After a stop or close action by protection, the restart of the equipment shall
be possible only after the fault is rectified and the protection signal is reset.
Simple cancellation of protection signal by start command shall not be

possible. The protection action and the operator reset shall be recorded by
the DCS with real time stamping.
An evaluation to determine the appropriate Independent Protection Layers

(IPL) to control hazards is necessary. IEC 61508, IEC 61511 shall be
followed to determine, design, and build IPL´s and especially the Safety
Instrumented Systems.
Every safety related loop has to be verified according to the standard IEC
61508, IEC 61511 that the requested and necessary Safety Integrity Level
(SIL) is fulfilled for the individual loop. The Contractor has to assess all
safety related loops to ensure compliance with the related requirements and
has to submit the report of these studies to the client.
4.4.1.2.5 Interlocks for alarm annunciation

Some alarm annunciation is of interest to the operating personnel only if the
corresponding part of the assembly or units are in the start-up, operating or
shut-down condition. These linked annunciations are usually made up of
signals showing conditions and process monitoring criteria. The alarms shall
be inactive when the relevant unit or equipment is supposed to be out of
operation.
Different tones of alarm annunciation shall be implemented in the operator

control desks for different units.
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4.4.1.3 Simulation and test

Test software for on-line and off-line test shall be provided with the system
and shall conform to the same standards as system software supplied with
the system. The software shall ensure that there is no risk of corruption of
operational data in this mode of operation.
The software shall include a DCS simulation and training tools which allow
operators to train on a computer in an environment identical to the control
room.
4.5 Operator’s Stations

The operator interface should be provided by operator stations, which
permit the operator to control and monitor the plant. In addition to the
standard displays provided by the system, it shall be possible to display the
process with corresponding graphic displays, control loop displays,
electrical single line schematics, group displays, on-line and historical trend
curves, alarm lists, all with dynamically updated process parameters on the
VDU's.
Through the operating consoles it shall be possible to start or stop the plant's
equipment, control the various valves, pumps, solenoids etc., change modes
and setpoints of controllers. All necessary information concerning process
behavior, control instrument and controller integrity for modulating control,
sequential control and alarm function should be immediately available to the
operator at the operator station.
All analogue signals from field equipment shall be shown on the VDUs, in
the dynamic graphic displays or/and other displays. It shall be possible to
provide a historical and real-time trend display for analogue and status
signals.
For high availability of the plant redundant connection to data highway shall
be provided in all operator stations. The number of operator’s stations shall
assure that in case one operator station fails, the normal operation of the
plant would still be possible using the remaining operator stations.
Operator’s station shall have direct connection to process controllers for

data, alarms and events, for other functions it is acceptable the use of
application servers.
At any operator station the operator shall be able to choose any kind of
display and execute control on any of the VDUs from any of the keyboards.
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The shift supervisor, Engineers and Plant Manager shall have access to all
systems of the Plant for monitoring. It is not foreseen that they will operate
the Plant.
Main memory shall be protected against loss or corruption in case of power

failure. Automatic reload and restart shall be provided not requiring
operator’s intervention. Contractor shall state in his proposal the size of the
memories, both used and installed.
The system shall be provided with the main and bulk memories of adequate
size including 40% spare capacity, i.e. 40% of the installed memory shall be
free for future extended functions after commissioning. If during execution
of this project, memory sizes prove inadequate, Contractor shall increase
memory at no cost.
Bulk memory shall be provided with redundant hard disk drives (RAID 10).
CD/DVD may be used only to load and to extract or store programs or data.
All CPU computers shall be industrial workstation, rack mount type (19”)
and shall be installed in appropriated network rack panel provided with a
KVM switch for keyboard/mouse extension. KVM switch shall allow to
control, switch and manage any PC’s (CPU’s computers) from any
keyboard, monitor and mouse.
VDU's shall be:

· TFT-type,
· High resolution 1920 x 1200 as a minimum,
· Size minimum 24 inches,
· Compliance with newest TCO standards,
· CE mark according EU-Directive 2004/108/EC,
· lowest pixel fault class (according ISO 9241 part 302 and 305),
· LCD lifetime > 40,000h,
· Tilt-and-swivel base with height-adjust,
· High and fine drawing resolution for CAD applications,
· Typical brightness 300 cd/m2,
· Typical contrast 900:1,
· Typical viewing angle horizontal/vertical 178 degrees,
· Radiation immunity and suppression equivalent to CE certification,
· According RFI to EC directive,
· Video input, and
· Plug and play.
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The intensity of the display shall be adjustable by the operator so that

characters and symbols shall be clearly legible from a distance of 1.5 meters
under high ambient lighting conditions.
The keyboard should have standard operator control keys. All keyboards
used for control of the process should be identical, clearly labelled, and it
shall be provided with a mouse.
To perform the described functions no operator programming should be

required. All features should be available through use of the functional
standardized faceplates. Pressing of “illegal push-buttons” during any
operation should be ignored and the error condition should be indicated on
the display.
All data entry and operator commands should be subject to two steps of
operating action so as not to cause any inadvertent actions. Regularly used
keys shall be of extra rugged design.
Keyboard operation must be conceived in such a manner that the selection

of the different displays and access to the process variables, motors and
actuators shall be possible with only a few strokes. In critical situations the
switch from a general display to a display suitable for direct control must be
possible directly without the need to select additional intermediate displays.
In addition to the capability of invoking control actions from dedicated

displays, the system shall also provide the facility of invoking such actions
via graphic displays.
4.5.1 Human machine interface (HMI)

The HMI of the DCS shall include a hierarchic visualization concept tuned
to the requirements of plant operation. Through it the operator
communication and monitoring shall be performed.
For this purpose, graphic elements (plant displays, curves, loop displays,
alarm displays, operating windows etc.) arranged in a hierarchic order shall
display easily, quickly and transparently the status of the plant, of the
control equipment and of the control loops.
The highest demand in the designing of the HMI shall be placed on user
friendly displays. For the control room operator displays for monitoring,
information and control functions shall be provided. The displays shall
present process sequences and statuses in a functionally related manner.
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4.5.1.1 HMI update

The system shall be capable of scanning all inputs in such a manner that all
displayed data shall be updated within maximum 1 sec. When a piece of
equipment is not in service the associated analogue and digital inputs shall
not be eliminated from the scan cycle. The system shall however be capable
of inhibiting any nuisance alarms during the period when the equipment is
out of service.
4.5.1.2 Overview display

An overview display should enable the operator to determine the overall
operation of a large segment of the plant. It shall indicate the alarm status of
all loops. The operator should be able to call up directly any overview
display.
4.5.1.3 Process graphic display

Dynamic interactive graphics of different sections of plant should be able to
be displayed on the operator stations. Graphic displays should be
configurable only through engineering environment (i.e. from a console by a
protected access via password, access card) and use symbols from a library
of standard/ user defined graphic symbols. Different plant sections should
be displayed on different pages.
Graphic displays should be of the interactive type with the possibility of

integrating process parameters ('live' points) through which it should be
possible to control the process. This includes control actions, such as
Manual/Auto, On/Off, Open/Close, set point generation, start of functional
groups, etc.
The operation status of individual drives, progress and status of functional

group controls shall be displayed on the graphic pages. Different colors
should be used to identify different status and events.
All process lines in graphic displays shall be colored according to its

process medium.
Face plate and trending information should be accessible from the graphic
displays directly through free format windowing facilities. All control
parameters should be displayed on their respective graphic pages. It should
be possible to view the process variable and alarm points, and to view and
change set point values, manipulated variables, and controller mode, etc.
from the graphic display.
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4.5.1.4 Operator input windows

For operator actions operator input windows shall be provided. It shall be
possible to select operator input windows from any of the displays and to
open various operator control windows simultaneously on the screen.
When particular operator input has been accepted by the DCS, this
condition shall be indicated to the operator by a change of color, short
blinking, short audible tone etc.
Process control operations shall be performed in two steps:

· Entering/setting of value,
· Confirmation / execution of the entry.
In all cases the current and the entered data shall be shown separately.
Standard displays shall be used for adjustment of drives and open/closed
loop controls, e.g. for selection of remote manual operation. All relevant
values of the open loop or the closed loop controller (actual value,
manipulated variable, etc.) shall be displayed. All operator inputs shall be
transferred to the automation system only after the ´Execute´ key has been
pressed.
4.5.1.5 Group display

A group display shall include the status of a smaller number (6 to 8) of
control loops, including:
· Bar charts with process variable, setpoint and controller output;
· Numerical values of process variable and setpoint, in engineering units,
numerical value of output in percentage,
· Status indication of binary inputs and outputs,
· Status indication of functional group controls,
· Control mode of each control loop, and
· Alarm condition in each loop.
The grouping of the control loops shall be done based on the system or
equipment mode of operation and is subject to Engineer's approval.
4.5.1.6 Loop Display

The loop display shall contain all detail information of the individual control
or measurement loops, including:
· Configuration of the loop,
· Control signals,
· Control parameters,
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· Status of drive control and functional group control containing trip

signals, interlocks, criteria, actual step of sequence and commands,
· Transmitter range,
· Alarm set values, and
· Output limits.
The detailed information shall be card coded or access code word protected
from unauthorized alteration.
4.5.1.7 Alarm summary display & printout

All activated alarms shall be listed in chronological order. Alarms not yet
acknowledged shall be distinguishable by red and flashing annunciation.
The VDU shall display the message of occurrence and of disappearance.
All new alarm messages shall be displayed on the next available line and
shall flash until acknowledged from the keyboard. Every new alarm shall
activate a bell for 2 seconds to call the attention of the operator. If more
alarms are detected than are to be shown on the VDU, more recent ones
shall be displayed, and the earlier messages shall be shifted to the alarm
backlog memory. In this case a special message on the screen will indicate
presence of messages in the backlog memory. Recall of backlog messages
on the VDU display shall be provided.
The alarm condition of each point should be displayed on the group display
by color change and blinking. Alarms acknowledge should be possible only
from the relevant (assigned) operator station. For all alarms a direct access
to the dedicated graphic display shall be provided.
On request the system shall list all the alarms implemented in the system,
grouped by equipment or function (i.e. common equipment, electrical etc.),
showing the alarm status of each alarm.
It shall be possible to transfer each VDU from one operator station by the
keyboard in alarm mode or monitoring mode. However, while in the latter
mode, occurrence of any new alarm shall activate the bell and the new alarm
shall be shown on the existing display.
Alarm acknowledgement and first failure resetting shall always be from
VDU’s. Local alarms acknowledge from any equipment or a panel is not
acceptable.
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4.5.1.8 Trend display

The system should be capable of displaying both real time and historical
trends as follows:
· Real time trend. The real-time trend should be for a minimum of 8 hours
at a sampling rate of 10 seconds.
· Historical trend. The historical trend should be for a minimum period of
96 hours. Historical data should be stored on a non-volatile memory
device such as hard disk. It should be able to be archived for recall.
· Long-term data archive. For the long-term data storage and retrieval
CD/DVD or tapes should be used. Data compression techniques shall be
provided to optimize storage capacity. Selection criteria for analysis of
analogue variables, alarms and events shall be available (period of time,
tag name, etc.). The long-term data shall be backup and stored for 1,000
days.
The available storage should be sufficient for all analogue points for a
period of 1 month at a sampling rate of 1 second or better. Varying the
sampling rate or producing averages such as 1 minute, 2 minutes etc. should
make it possible to store more points or for longer periods.
Real time and historical trends should be possible on any parameter or

variable like measured variable, set point, output, calculated value, etc. The
trend display should be single line type and bar graph type. It should also
display information like loop tag, engineering units, span, current value,
alarm status, etc. of the trended variable. It should be possible to display by
scrolling or expanding the time base all of the trend data available on the
system. Selection of the tag and sampling time for real time and historical
trending should be possible from operator keyboard.
It should be possible to sample and store data of instantaneous and average

value at the intervals mentioned below:
· at intervals of 1 second or higher for the real-time trends;
· at 10 seconds, 1 minute and 10 minutes interval for historical trends.
The system should also have a multi-trend feature from which it should be
able to display the set point, measured variable and output of any
combination of variables on the same trend variable.
4.5.1.9 Characteristic Curves

Multi-variable displays shall be provided to show the relationship between
individual process variables (e.g. pressure, flow rate). Actual values and
design operating points shall be displayed to determine whether a
component is operating correctly or is likely to exceed one of its limits.
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4.5.1.10 Logging
The system should be able to assemble data and print various kinds of
standard reports.
The system should provide the following basic types of reports as a
minimum:
· Event lists,
· Incident (trip) review log,
· Operator action reports,
· Custom reports with fixed and variable formats.
The above reports should use real time data, historical data, or calculated
data generated, by any node in the system or any connected device to the
system such as PLCs or plant management system. All points in the system
should be available for reporting.
A report generation function should be available at the engineering
workstation for free-format reports generation of text and data.
The report types should be:

· On demand,
· At a predefined time (hourly, shift, daily, etc.),
· Event triggered.
These reports should be archived for further recall. Schedule assignment for
reports shall be flexible. Demand for immediate output of a report must not
affect any scheduled reports that have been set up previously.
The types or classes of data used by the report generator shall include:
· Analogue variables and associated parameters,
· Operator entered values,
· Status of multi state variables,
· Alarm and event messages,
· Calculated variables,
· Historical data values and status, and
· Other retrievable tagged items.
The report generator shall also be able to incorporate text supplied for report
titles, explanations, messages, etc. Data validity indicators have to be
propagated throughout report production to provide information on the
reliability of requested values.
Math functions to provide more complex reports (more than list of totals
and averages) shall be a standard tool of the report package. The software
package shall be easy to use and not require programming skills.
Following reports shall be provided:
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· Daily Operating Report: A daily report, listing the major plant variables
(up to 100 variables) shall be provided. The report shall include hourly
values and minimum/maximum/average values where appropriate. A
minimum of 10 separate daily reports shall be provided.
· Monthly Operating Report: A monthly operating report, which averages
the values from the above daily reports, shall be provided. The report
shall include monthly minimum / maximum / average values where
appropriate.
Specific SWCC operational reports shall be provided by the Contractor

using DCS functionality.
Report formats shall be developed and programmed by the Contractor using

tag names defined in the database creation. All reports will be provided with
a header on each page indicating the information included on each column.
Each page shall also be numbered and shall indicate the name and date of
the printed report.
4.5.2 Alarm annunciation

Abnormal operating conditions and events in the plant have to be
announced. For optimum identification of the cause of faults all alarms shall
be displayed on VDU and printed out in their true sequence of appearance.
Corresponding graphic or loop displays shall be immediately accessible by
selection of individual alarm messages.
Under operation control, it should be possible to enable/disable the printing

of all or selected alarms. The design shall be as follows:
· Detection of fault and status annunciation in correct time sequence;
· Changes in annunciation are to be shown with annunciation tag number,
alpha-numeric signal code, clear text and with date and time of day;
· System shall be able of self-checking for system faults and creating
special control system alarms.
Sources of alarms are:

· Status inputs,
· Analogue or derived variables,
· Instrument alarms within the DCS (for example open circuit detection on
analogue inputs, bad process measurement, etc.),
· Discrepancy alarms (i.e. both limit switches open etc.),
· System fault alarms,
· Data communication alarms i.e. errors data,
· Alarms transmitted via serial links from external systems such, if not
realized in DCS, etc.,
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· I&C alarms, and

· Process alarms.
Alarms should be presented on the alarm display, the first being the newest
non-acknowledged alarm. It shall be possible to implement the first out
alarm in graphical display for the unit/major equipment. Different selection
criteria should be available at least:
· Acknowledged/unacknowledged alarms;
· Priorities or states,
· Period of time,
· Systems or groups, and
· Sources of alarms.
The display should list for each alarm:

· The time of alarm followed by DAY/MONTH/YEAR,
· The alarm point tag,
· The alarm point description,
· The violation type such as, high, low, deviation, rate of change, "bad"
process value,
· Priority should be indicated by color,
· The alarm condition of each point should be clearly shown in group
graphics and individual point displays. Alarms should be displayed as
they happen on the correct screen in the allocated area. It should be easy
to determine from these displays if the alarm has been acknowledged (for
example, blinking indication for not acknowledgment alarms).
· Related messages and information like orders, instructions, cause-effect,
countermeasures, etc., shall be shown on the VDU on demand for each
alarm.
Regardless of its source, a configurable priority should be able to be

allocated to an alarm. For example, priorities could include:
· Shut-down safety alarms or fire alarms,
· Vital alarms (abnormal process conditions which the operator may be
able to correct) before protection is activated,
· Alarms which do not require the operator to be alerted, but which are to
be recorded,
· System alarms.
Process alarms and 'return to normal' messages should be shown with a time
stamp as and when they occur. Alarm printing shall be on request of the
operator. The alarm archiving shall be done continually.
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4.5.3 Large screen projection panels (LSPP)

For the Station overview modular large LCD-IPS displays shall be provided,
each in front of the different Control Desks.
The LCD-IPS displays shall be industrial standard. The minimum size of

each display shall be 85” with ultra-high definition (3840 x 2160).
The display shall be aesthetically integrated in a panel and into the CCR
environment in a manner that maximizes operator ergonomics. The system
shall be capable of displaying any graphic screen available in the DCS and
special graphic displays created for the large screen projection system. The
system shall be supplied with dedicated keyboards and mouse.
It shall be possible to use the system as one screen or as multi-screen

system. The offer shall contain:
· A detailed description of the displays including type, resolution, optimum
viewing distances, brightness and all required hardware and software.
· A detailed description of the DCS interface for the system.
· Number of plant overview displays for the system included in the offer.
4.6 Engineering Station (EWS): System Diagnostics and

Configuration
The engineering stations shall be accommodated in the engineering desk,
within the CCR. The engineering console shall be equipped with VDU,
engineering and functional keyboard and mouse used for tests, configuration
and tuning purposes.
The engineer's console shall allow system configuration, writing and

executing of user written macros, graphics development, report generation,
logging specification, system self-documentation functions, system
monitoring functions (which show the result of self-diagnostic tests), system
database load/save etc. In addition, it should be possible to tune controllers,
change limit set-points, view all loop variables, configure control systems,
add and delete alarms. The engineer’s console shall be capable for signal
simulation and signal dynamization.
Back-up facilities (e.g. RAID 1 – Mirroring) shall be provided to prevent

loss of data and software.
For the generation of process graphic displays, a standard library of symbols

shall be used. A graphics package should be available on the system. This
should be able to create user defined symbols and store them in user defined
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libraries. In addition, standard industrial ISA symbols such as heat

exchangers, pumps, compressors and tanks should be provided.
Configuration of the control function should be possible by simply selecting

a programmed algorithm and entering the required attribute information
such as input and output location and tuning constants. Control loop and
sequential logic should be built by linking the desired control function as
they appear on control and sequential diagram. Modification should be
easily made by revising the attribute information and inserting and deleting
the control function.
Operation of the engineering console by unauthorized personnel shall be

prevented by the use of access cards or passwords.
The system shall monitor itself continuously for failures by means of self-
diagnostics. Diagnostic routines shall be applied for each control module.
Detailed diagnostic messages shall be displayed on the engineering
console’s VDU and printer, and group alarms shall be given at the process
operator's desk. The diagnostic display shall clearly identify in graphical
manner the faulty component, the nature of the fault and the component
location (at least panel number, rack number and slot number).
Diagnostic displays should be available to assist fault location. It is expected

that most faults will be quickly repaired by simple replacement of a card or
module. The diagnostic display should clearly identify the faulty
component, the nature of the fault and the component location.
If the required diagnostic functions/displays are not available in the
engineering station than separate diagnostic hardware/software within the
DCS shall be offered.
Remote accessibility shall be possible via DSL to allow the specialist for
example to troubleshoot all the DCS components for routine maintenance or
system repair or configuration.
4.7 Plant Management System (PMS)

A Plant Management System (PMS) shall be provided by Contractor and
shall be passive in nature. (The PMS can be of PI system or equivalent.)
The following functions shall be implemented in the PMS:
· Optimal load distribution.
· A visual display of the measured plant efficiency deviation from the
reference plant efficiency.
· Alarm warning (when the operational configuration of the plant has to be
changed to maintain adequate control margins).
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· An off-line function permitting to explore the influence on plant output,

efficiency and control margins of different plant operating
configurations.
· Mass and energy balances for the entire GRS.
· Printing of monthly and daily management reports including all
important parameters of the plant.
To achieve the above control functions the following supporting functions

are anticipated:
· On-line performance calculations.
· Reference efficiency characteristics to be provided for GRS.
· On-line efficiency assessment of GRS.
· Performance optimization of the major equipment.
· Data representation in a graphical form.
· Entry facility for the expected daily water load demand.
· Entry facility for the plant outage log.
· Entry facility for unit prices in local currency.
· Full on-line status monitoring.
· Calculation functions, statistical evaluation and integration of user
programs (to be executed automatically or manually).
· Trend log.
· Incident (trip) review log.
· I&C log.
· Process parameter reports/logs.
· Event information log.
· Data export to standard office software.
· System software data base shall be open architect for flexible interfaces
· Support decision taking processes by extending data access to all relevant
information.
The Vibration Monitoring System (VMS) and other external controllers

(packages) shall be interfaced with PMS.
PMS server shall provide all data information through the office LAN to
following PC clients:
· Shift supervisor office,
· Engineers office, and
· Plant manager office.
PMS server shall provide protected remote access functionality from web
browser.
Configuration and diagnosis of the system shall be possible from the
centralized PC to be located in the Engineering desk of the CCR.
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4.8 Asset Management System / Field Device Tools (FDT)

An Asset Management System shall be provided for remote diagnostics and
calibration. The system shall be able to read all information from HART
transmitters, analyzers and actuators independent of their manufacturer. I. e.
all equipment in the loop shall be able to pass the HART communication.
Configuration shall be possible from the centralized operator station (to be

located in the Engineering desk of the CCR) through the data highway of
the Plant DCS.
Data exchange with portable handheld devices shall also be possible.
The system shall provide maintenance information and alarms for the O&M
crew to perform predictive maintenance activities.
Asset management system should have the following features:

· FDT allows intelligent device-specific applications data (status,
diagnostics, etc.) accessible to the system and enables applications such
as preventive and predictive maintenance and optimization.
· Field data that are available in intelligent field devices can be transferred
directly to the FDT.
· Diagnostic function self-tests, calibration functions, update options for
parameters, or estimated remaining useful lifetime shall be realized in the
FDT.
· Detect deviations in device functions at an early stage.
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5. Communication System
5.1 General
This section of the specification covers all relevant services for the proper
installation of all these communication systems:
· Complete data network fully compliant to Volume IX, Part-B218 Data
network,
· Telephone System (extension of existing one),
· Portable radio system,
· Clock system.
The specified systems will be state of the art and proven for the specified
application. Wherever applicable, the systems shall meet the approval
standards of the local regulatory authorities for the specified application.
Refer to the Appendices for Kingdom of Saudi Arabia, Security directives

for industrial facilities for details. The Contractor shall comply with these
directives for designing the communication systems.
The Contractor shall be responsible for all engineering, design,

documentation, materials, supplies, delivery and installation of fixing
material, through completion of the work specified.
The following Technical Requirements are binding for the specified

equipment. This information shall be used for the comprehensive
understanding and as bases for planning of the location of the different
communication components and their installation.
Equipment and the installation of these systems shall be planned and

installed in accordance with this Specification, relevant laws, regulations,
standards, codes, guidelines and recommendations. The Contractor will be
liable for all defects resulting from non-observance of these.
The requirements of the “Security Directives of HCIS (High Commission

for Industrial Security)” have to be considered.
All final communications systems layout and architectures shall be

submitted and approved by Employer.
5.2 Telephone System

Contractor shall supply some telephone sets (local, CCR, electrical rooms,
etc..) to be integrated in the existing telephone system.
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5.3 Clock System

The Station’s Clock System shall be state-of-the-art and as a minimum
include a redundant real time master clock, number of slave clocks,
independent power supply equipment, interfaces for synchronizing the
Plant’s control systems.
The master clock shall provide for highly reliable, accurate and stable real-
time information. It shall be provided with necessary interface for
synchronizing form standard GPS time signal.
The DCS shall have a redundant real time master clock which will be
synchronized by standard GPS time signal.
The real time clock is used for time synchronization for all the DCS and
PLCs components, etc. In case of GPS failed, one of the master clocks shall
lead for the synchronization of all the plant DCS components and other
systems.
The master clock in turn shall provide necessary safe synchronizing signals
to the following:
· The slave clocks (wall mounted, double face, etc.),
· Specified DCS,
· Maintenance/data management system,
· All supplied PLCs,
· All other systems, which requires time synchronizing
.
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6. Scope of Supply and Service

This section sets out the scope for the control, instrumentation, monitoring
and communication equipment for the installations covered by this
Specification as well as supplies and services, but without excluding other
necessary components and services not mentioned.
This includes all control, instrumentation and monitoring equipment within

the CCR, LCR and TR and associated field mounted equipment at each site,
which fulfils the control, instrumentation and monitoring tasks as specified
in the various parts and sections. Sufficient instrumentation to the
satisfaction of the Engineer shall be provided to meet appropriately the
operational and safety requirements of the plant.
The Contractor shall be responsible for all engineering, design,

manufacture, programming, configuration, documentation, materials,
supplies, factory and field testing, delivery, installation, start-up, tuning and
initial operation through completion of the work specified.
6.1 Field Equipment

Sufficient instrumentation and field equipment/devices shall be provided
and shall meet appropriately the requirements of reliable and safe operation
of the entire GRS.
· All measuring instruments and signal conditioning equipment (e.g.

sensors, transmitters, switches, analyzers, flowmeters, etc.) installed in
the field as well as in the CCR, LCRs and TRs of the entire plant.
· All local instrumentation necessary for general start-up preparation,
shutdown, local plant supervision and maintenance.
· All automatic valves, including actuators and accessories, necessary for
plant operation.
· Any other field equipment as required for the specified mode of
operation and for a safe and satisfactory operation and supervision of the
plant.
· All field junction boxes, cabling and wiring of the entire units/equipment
of the Plant.
· All cable trays, conduit, cable glands, tubing and any auxiliary material
required for the proper installation of all instruments and equipment of
the entire plant.
· Two (2) portable programmers (handheld computers) of each type (or
with the related software) for programming and calibration of HART
transmitters and positioners.
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6.2 Distributed Digital Control System (DCS)

All main systems shall be controlled by DCS. The typical overall DCS
architecture is shown in attached drawing. The plant’s main control system
shall be a distributed digital control system (DCS) in accordance with the
technical requirements specified under this specification.
The DCS shall cater for the following main functions:

· Signal acquisition, conditioning and processing,
· Closed-loop control,
· Open-loop control and interlocks,
· Plant and Unit Coordinator,
· Function group controls, sub-group controls and drive controls,
· Plant and equipment protection,
· Alarm and status annunciation,
· Data communication,
· Data displaying and information presentation to the operating staff,
· Data storage for periodic or post-trip analysis of the plant or equipment
analysis in form of curves, tables and lists (redundant historian server),
· Supervision and plant performance calculation, and
· System engineering and diagnostic.
The DCS shall include as a minimum, but not limited to the following
systems/equipment:
· Redundant Single fault tolerant fiber optical plant bus/highway (Ethernet
TCP/IP in accordance with IEEE 802.3, at least 1 Gbitps), ring topology.
· Redundant Processing Units and Server Units shall be provided to
connect the Plant Bus/highway bus to the Operation Stations.
· Operator stations and large screen monitor in CCR, which are specified
somewhere else in the specification.
· Local operator stations, which are specified somewhere else in the
specification.
· Engineering stations, which are specified somewhere else in the
specification.
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· Server for data acquisition (Plant Management System, PMS).

· Redundant optical switches to connect the DCS process control stations
to the plant highway bus redundantly and for bus-to-bus connection.
· PC stations for maintenance (Asset Management system) and supervision
(PMS), which are specified somewhere else in the specification.
DCS process control stations shall be designed to maximize the

plant/unit/systems availability. Non-availability of any DCS process control
station shall affect a minimum process function.
All DCS process control stations shall be redundant and segregated
according to their function, which shall be provided at least as follows:
· GRS shall be provided with its own DCS process control stations for
control and protection. In order to maximize the availability and the
reliability of the plant/ units/process, the total number of process control
stations will be defined at beginning of the engineering phase based on
the final plant configuration.
· Redundant interface modules and serial data links to the Package’s PLC
control panels, which are specified elsewhere and subject to the
Employer/ Engineer’s approval.
Each unit/system shall be provided with separate dedicated marshalling

cabinets, which shall be supplied from the supplier of the DCS cabinets and
shall have the same material, color and size.
A reliable modern connection technology shall be used inside the

marshalling cabinets. Cross-wiring, field and DCS cabling and connection
work inside the marshalling cabinets is within the scope of Contractor. Each
marshalling cabinet shall have front and rear access and shall be provided
with 20% spare capacity in the terminal blocks, to be counted after
completion of commissioning. The number of marshalling cabinets to be
provided for each unit/system shall be decided taking into consideration the
quantity and size of cables in-and-out. It shall be ensured that in no way the
marshalling cabinets are over-crowded with cables in the entrance opening
and/or inside the cabinet.
· Redundant interface modules.

· Human-Machine Interface as specified elsewhere in this Specification.
· Signals transfer to the Employer’s plant DCS, to be clarified during detail
design as specified elsewhere in this Specification.
· Any other equipment/service not specified above but deemed to be
necessary shall also be provided within the scope of work of Contractor.
Connection, coordination and operation of the entire DCS as one unified

system for the entire plant is within the scope Contractor, including all
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required interconnection among different equipment / systems (redundant

DCS Process Controllers, the redundant Optical Switches Modules (OSM),
package’s PLC’s, plant/highway bus, OWS, EWS…).
The whole design, engineering, manufacturing, programming,

configuration, implementation, factory and field testing, materials, supplies,
delivery, installation, commissioning, start-up, tuning, operation, tests on
completion and documentation of the Instrumentation and Control
equipment of the GRS shall be within the scope of the work of Contractor.
6.2.1 Plant management system (PMS)

A Plant Management System (PMS) as highest level in the control hierarchy
shall be provided by the Contractor. A general structure is given in
Chapter 4.7.
The necessary data exchange between Package’s PLC’s and PMS shall be
part of the scope Contractor.
6.2.2 Asset management system/field device tool (FDT)

Contractor will provide a centralized asset management system (AMS) for
instruments, transmitters and actuators configuration, diagnosis and
management. General features and requirements are provided in
Chapter 4.8.
6.2.3 PLC based control systems for package equipment

Contractor will provide all PLC’s based control systems for package
equipment, if approved by the client, including two programming devices
for each type of PLC together with all required software licenses.
6.2.4 Central control room equipment

Normal operation of the plant shall be performed from plant DCS operator
desks in the CCR.
Each Operator or Engineering Workstation shall consist in two TFT LCD

color monitor 24”, a dedicated CPU, graphic display controller, keyboard
and mouse. Additionally, every desk shall be furnished with following
equipment:
· One (1) hardcopy laser printer A4 (color and black/white),
· One (1) hardcopy laser printer A3 (color and black/white),
· Hard-wired emergency shut-down pushbuttons,
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· One (1) control desk, and

· Operator’s chairs.
All control desks shall be supplied with audible/ visual equipment for the
DCS alarms and annunciations which shall be of different tones for different
systems.
Additional Engineering stations have to be provided during commissioning

and tuning period in sufficient number that parallel commissioning works
can be carried out independent for the different systems and process areas.
Portable stations (e.g. Laptop) for diagnostic and programming functions

shall be included in the scope with the relevant functions for diagnostic and
programming features for programmable components e.g. transmitters and
actuators.
Bidder to include all chairs and furniture to arrange equipment,

documentation, spare material etc.
6.2.5 Technical room (TR) equipment

The TRs shall mainly accommodate the DCS control panels, as well as
network and auxiliary panels.
Network panel shall contain, apart from all required switches, all CPU
computers for the industrial workstation, rack mount type (19”) and shall be
provided with a KVM switch for keyboard/mouse extension.
6.3 Data Network

Complete data network fully compliant to the Plant and shall be provided by
the Contractor.
6.4 Telephone System

Extension of existing telephone system including, but not limited to the
following:
· Minimum one indoor telephone sets (operator desks in the LCR, each
electric and electronic equipment rooms, offices...).
· Minimum one outdoor telephone sets (At least one set for each major
process area).
· Necessary cables, junction boxes, etc.
· Interface with existing telephone.
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6.5 Clock system

The complete system, as specified including, but not limited to the
following:
· One (1) number of master clock complete,
· At least ten (2) numbers of slave clocks,
· Minimum of two (2) wall clocks for CCR,
· One (1) set of uninterruptable power supply unit including charger and
battery,
· Serial interfaces for synchronizing all control systems of the Plant (DCS,
PLCs etc.), and
· GPS (Global Positioning System) interface for synchronizing the Clock
System.
Final number of clocks shall be defined during the engineering phase.
6.6 Spare Capacity after Completion of Commissioning

At least 20% free channels of each I/O-module shall be available after final
commissioning for future modifications.
At least 20% free space shall be available in all cabinets, junction boxes and
marshalling racks after final commissioning for future ad-on items. This free
space shall be distributed inside the cabinets in such a way that additional
terminals, equipment or modules may be added to any group of controls. At
least 20% spare cores shall be provided in each control and monitoring
cable. All spare cores shall be terminated.
Each module shall be sized such that no more than 60% of its installed
capacity is utilized during normal operation and shall not exceed 80% even
under extreme load condition.
6.7 Engineering & Services

The Contractor shall provide all services required for a safe, reliable,
efficient and trouble free of specifies instrumentation, Control,
Communication and Clock equipment, complete in every respect, without
excluding other necessary services not mentioned below.
These services shall include but not be limited to:

· Basic Engineering,
· Hazop Study,
· Detailed Engineering,
· Design of all equipment to be supplied,
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· Examining of interface documentation,

· Coordination and interfacing with external or separate systems like (the
following is a minimum list of systems to be controlled and monitored by
the DCS) but not limited to:
· Local PLC’s from package units,
· Vibration monitoring system (VMS),
· Plant Management System (PMS),
· Asset Management system / Field device tool,
· Documentation of all equipment to be supplied,
· Programming of all digital equipment,
· Testing in the Contractors/Vendors workshop and on site (FAT and
SAT),
· Packing, transportation to site, unloading and proper storing,
· On time delivery of all documents needed for proper assembly,
· Handling from site storage to the point of final installation,
· Erection of all parts to be supplied,
· Commissioning of all equipment,
· Trial operation, and
· Acceptance tests.
The Contractor is responsible for the overall DCS layout and design of the
entire plant, as well as for the coordination of the interfaces and overall
design of all package control equipment or other control equipment supplied
by other sub-contractors and for making sure that the design of this
equipment and the submitted documentation is in line with the General
Project Requirements and Technical Specification.
As far as the final execution of the work is concerned all design data,
interlocking conditions, control loops and logic diagrams supplied by the
various sub-contractors shall be checked, verified and closely coordinated
with the other sub-contractors of the corresponding equipment. For this
purpose, close collaboration with all sub-contractors supplying control
equipment shall be arranged.
All engineering to be provided, required and additionally requested by the

Owner / Engineer shall be elaborated in English language.
All-important design documents shall be submitted for approval to the

Engineer. The Contractor shall submit a detailed time schedule for the
drawing approval procedure at the beginning of the design phase.
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6.8 Documentation
Bidder to prepare and provide all information and documents necessary for
review and assessment by the Owner / Engineer. Bidder shall use overviews
and zoom into details, represent structures, split, concentrate and use further
methods to simplify comprehension of each equipment, function system and
the plant at large.
6.8.1 Documents with Bidder’s proposal

All documents and information required for evaluation of Bidder’s proposal
shall be submitted, these shall include but not be limited to:
· All datasheets enclosed in the Bidding documents filled out by Bidder.

· With their Proposal Bidder shall provide a timeline of their scope of
supply and service, stating milestones and listing of necessary
engineering deliverables to be submitted by the Owner / Engineer
including due dates and their quality requirements (uncertainty) aligned
to the time schedule of this project. The listing shall include designation
and content of the documents.
· As minimum following milestones shall be mentioned (sequence may
vary):
a) All concepts, studies and basic engineering available
b) Start of manufacturing when 90% input for HW engineering will be
available
c) 90% input available for ready to manufacture DCS network
d) 80% input available for 1. System meeting
e) Hardware FAT, Network Health test, etc.
f) Design freeze for DCS task description, start of DCS programming
g) Software FAT, System health test
h) Ready for erection
i) DCS power on
j) End of loop check
k) Start of hot commissioning
l) Start of test run
· The Bidder shall provide a listing of all DCS hardware and software to be
scheduled, indicating make and type.
· The Bidder shall provide a detailed DCS architecture drawing of the
proposed system. The drawing shall include interconnection of all DCS
components and interfaces with equipment provided by others. All
Process Control Units (PCU) shall be identified with their functional
distribution. Bidder shall state in their bid which of auxiliary and
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ancillary systems shall be integrated in DCS and which shall be

controlled by PLC with signal exchange to DCS.
· The Bidder shall provide a detailed migration plan for software updates
(operating system, application software, virtualization software, etc.) for
the next fifteen (15) years with details of costs implied.
· The Bidder shall identify the functional distribution of control between
the proposed control processors. The plant systems intended for each
control processor shall be identified as well as the maximum quantity of
I/O’s to be handled by each control processor.
· The Bidder shall provide a conceptual layout drawing of the proposed
control console based on referenced projects.
· Bidder shall include the proposal of the CCR layout.
· The Bidder shall describe the proposed operator display system including
examples, preferably color screenshots, of each type of display (alarm,
trend, control station, process graphic, etc.) available with the Bidder's
DCS.
· The Bidder shall describe all the features of the proposed alarm summary
displays. The description shall detail the proposed use of element
highlighting before and after alarm acknowledgement to show the
various states of the alarm. The capabilities of the alarm system to group,
prioritize, and filter alarm messages shall be fully described. Return to
normal messages and effects of alarm acknowledgement shall also be
described.
· The Bidder shall describe the "self-documenting" features and limitations
of the proposed system.
· The Bidder shall describe how the database is maintained and extracted
from the DCS to third party applications (e.g. Microsoft Access).
· The Bidder shall provide typical logic drawings as generated by the DCS.
· The Bidder shall state any network cable length limitations and detailed
specifications of cables and connectors required in the system.
· The Bidder shall state any specific storage, handling and environmental
requirements for the equipment offered.
· The Bidder shall identify the number, roles and responsibilities of field
service personnel required to operate the plant in all transient and steady-
state conditions.
References of the offered DCS for similar plants, implemented by the

Bidder, shall be given.
6.8.2 Submittals after contract award

Owner / Engineer. The Bidder shall submit a detailed Master Document List
(MDL), including description of the content of the documents and real
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examples filled with data, and associated time schedule for the drawing
approval procedure at the beginning of the design phase. Owner / Engineer
reserve themselves the right to require further documents to be integrated in
the MDL and require additional details to be included in each document.
Out of the finally agreed MDL the Engineer will select the important
documents and the interval for submission.
For each equipment, Bidder shall indicate the Stock Keeping Unit (SKU)
identifier of the equipment manufacturer and a SKU identifier to be agreed
with the Owner. The SKU system for the Owner shall be set up by the
Bidder acc. to Owner’s requirements.
Bidder to provide all information on paper and digitally necessary to fully

understand the plant as a whole and all parts of it, to efficiently (in terms of
economic and environmental) and safely operate the plant, to optimally
maintain the plant as a whole and all parts of it without deterioration.
All concepts required for standardization and unified operation and

maintenance of the plant, including but not limited to:
· Safety concept,
· Operation concept,
· Automation concept,
· Optimization concept,
· HMI concept,
· Alarm concentration concept,
· Signal-exchange typical,
· Maintenance concept,
· Hook-up drawings,
· MCC-typical,
· Interface typical,
· Etc.
Drawings, diagrams, lists etc. including, but not limited to:

· Control system architecture drawings.
· General and internal arrangement drawings for panels, cabinets, boxes
etc., installation drawings, wiring diagrams, cable list, data sheets as
output of the engineering tool.
· Detailed arrangement drawings containing complete dimensions for each
discrete (stand-alone) component or piece of equipment showing all
physical details of the component or piece of equipment, including
terminal locations, anchor bolt locations, shipping splits, leveling
devices, and locations of penetrations for external wiring.
· Equipment data sheets, including Stock Keeping Unit (SKU) identifiers
· Vessel protection sheets.
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· Setpoint sheets (flow, temperature, pressure, differential pressure, etc.).

· Self-documenting functional and control logic drawings for the
configured control system.
· For meetings and reviews with non-I&C system experts: cause and effect
matrix diagrams, modulating control diagrams, logic diagrams without
DCS specific symbols in such manner, that process engineers are able to
comprehend, including corresponding verbal description referring to the
equipment by using tags according to the project’s coding system and
unified terms for denomination of the equipment.
· Representation of all I&C equipment in the 3-D model, particularly final
control elements, sensors and cableways in the field.
· One comprehensive field cable list as output of the engineering tool.
· Power and grounding drawings including power requirements.
· HVAC loads.
· Circuit diagrams.
· Loop diagrams.
· Graphics and Displays:
· Color graphics and displays programmed for the Bidder's operator
DCS.
· Graphic device symbol / shape library, including all static and
dynamic shapes to be used throughout the whole project.
· Control faceplates for all operator-controlled devices and sequences.
· Lists (all lists must be submitted in an acceptable agreed electronic
format):
· I/O database, including termination data, node and I/O card, and other
pertinent data in Bidder's standard database structure.
· Instrument list including Stock Keeping Unit (SKU) identifier.
· Instrument data sheets including Stock Keeping Unit (SKU) identifier
· Signal - exchange lists (DCS / PLC, PLC / PLC) including origin and
target.
· List of Final Control Elements (FCE) including Stock Keeping Unit

(SKU) identifier.
· Alarm database including all points that generate alarms including
internal, system-generated alarm points. The alarm tag name, alarm state,
alarm message, alarm group and alarm priority shall be included for each
alarm point.
· Database of all points to be recorded by the DCS historian, including all
tags needed by PADO and office-LAN. This shall include internal,
system-generated points as well as all I/O points. The tag name,
description, analog point range, engineering units, and deviation limit for
data storage compression shall be included for each archived point.
· Hardware bill of materials including Stock Keeping Unit (SKU)
identifiers shall be structured and provided.
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· List of software packages and all licenses shall be provided, indicating

version identifier, release date, Stock Keeping Unit (SKU) identifiers:
· Required database structure and format with an explanation of all
fields.
· Software tools applying GRAFCET acc. to IEC 60848. Sufficient
licenses of the fully featured editing software shall be provided to the
Owner / Engineer.
· And any other applicable drawings, necessary for review and
assessment by the Owner / Engineer.
Test procedures and reports, including, but not limited to:

· Intended calibration procedures for all instruments for approval by the
Employer / Engineer
· System Test Plan, including Bidder's system checkout and testing as
well as the Factory Acceptance Test.
· Loop-check procedure, including organization chart etc.
· Site Operational Test procedure(s); test to be performed after initial
energizing of supplied equipment.
· Report about the acceptance test of control loops
Operation and Maintenance Manuals, including, but not limited to:

· All native hardware specific to this system.
· All native software specific to this system
· All third-party hardware and software specification sheets and
instructions.
· Operation manual.
· Safeguarding manual.
All certificates, approvals, reports, calculations, including, but not limited

to:
· Certificates of qualification,
· SIL certificates,
· Intrinsic safety certificates,
· Calibration certificates, protocols,
· Etc.
Complete, up to date, as shipped and as-built documentation, including all

drawings, lists, databases, displays, etc. to be provided by Bidder.
Any other documents / information / data upon request of Owner / Engineer

shall be provided by the Bidder.
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6.9 Erection, Cabling, Wiring, Labelling

The scope of this Contract covers complete supply, erection, cabling and
wiring of all control, instrumentation and monitoring equipment and valves.
The Contractor shall be, in all cases, fully responsible for the correct
installation and erection with regard to the measuring and control functions
of all the supplied equipment.
The Contractor shall make all necessary provisions for the site testing and
commissioning of the control and instrumentation systems which include
but shall not be limited to the following:
· Test calibration of all instruments prior to installation. The
instrumentation used for calibration or check of operational
instrumentation shall carry a valid test certificate from an approved
authority and not from the contractor.
· Functional test of instruments once installed.
· Loop testing of all measurement and control loops.
· Site demonstration test required confirming that all control and
supervisory function conform to their respective functional specification.
All tests performed on site, including the results and deficiencies, shall be
recorded and the test protocols shall be submitted to the Engineer for
approval.
All cabling for the field equipment shall be supplied, laid, labelled and
terminated. For the supplied field cabling all necessary cable routes,
supporting tray work and intermediate marshalling shall be provided.
A common system of earthing for cable armouring, cable screens, signal

cabinet earthing shall be agreed with Engineer.
All field equipment including local instruments, transducers, valves,
actuators, sensors, junction boxes, cabinets shall have nameplates with the
instrument tag number and descriptor. All equipment in CCR and TR,
control module, power supply, circuit breakers, fuses and control systems
shall have name plates. The nameplates shall be fixed to the mounting plate,
the mounting brackets or junction box.
Loosely attached nameplates by wires are not acceptable. Label material and
writing shall be selected to withstand the environmental conditions where
they are mounted. The label size and fixing place shall be selected to allow
easy reading.
Inside the control cabinets, all control equipment shall be labelled.
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6.10 Commissioning, Trial Operation, and Acceptance Tests

The Contractor shall be entirely responsible for the commissioning of the
instrumentation and DCS in conjunction with the Communication and Clock
system of the entire Plant. Commissioning shall be carried out in accordance
with the commissioning procedures prepared by the Contractor and
approved by the Engineer. The scope includes:
· Adjustment of control parameters, alarm limits and other adjustable
parameters.
· Optimization of closed loop control systems.
· Modification or correction of control functions during optimization, if
necessary, VDU displays, logs, etc.
· Optimization of alarm annunciation and SER functions and the
associated printing functions.
· Trial operation.
· Performance of acceptance tests.
· Correction of any latent errors found within the DCS
general requirements regarding inspection and testing are included in
Volume VI.
6.11 Documentation
All documents and information requiring checking and approval by the
Engineer in accordance with Part 1.3 of this specification shall be submitted.
Engineer as per approved procedure.
6.12 Training
The Tenderer shall include in his offer the provision for training for all I&C
systems and equipment to the client's management, operation and
maintenance staff in accordance with the requirements specified under
Volume VI.
The training shall cover the main control systems like all DCS hardware and
software components, different PLC systems, field instruments
(transmitters, analyzers…), vibration monitoring system, as well as all
communication systems.
6.13 Special tools and Spare Parts

All necessary spare parts (for five years operation), wear and tear parts,
maintenance equipment and special tools shall be part of the scope of
supply. The Tenderer should consider at least 10% of all different, installed
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I&C components (CPUs, I/O –Modules, fuses, transmitters, operator

stations, etc.) or at least one individual piece of equipment as required spare
parts in the scope. All these parts shall be priced individually.
The Tenderer shall include a list with individual prices of all spare parts he
recommends should be held by the employer to enable the plant to be
operated efficiently considering maintenance and repair.
Any parts ordered must be strictly interchangeable and suitable for use in
place of the corresponding parts supplied with the contract works. Each
spare part item shall be marked with the equipment name and designation
number corresponding to the appropriate section of the operation and
maintenance manuals.
All special tools such as PLC programming tools, instrument calibration

tools, smart transmitters/ positioner communication tools, hand-held
calibration tools and electronic workshop tools shall be part of the scope of
supply.
4871A95/S133Doc-801060045-7064

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ENGINEER’S STAMP: CONTRACTOR’S STAMP:

C Issued for Tender Wilken 06.11.2020

KINGDOM OF SAUDI ARABIA ‫اﻟـﻤﻤـﻠـﻜــﺔ اﻟﻌــﺮﺑـﯿــﺔ اﻟﺴــﻌـﻮدﯾـــﺔ‬

FICHTNER GMBH & CO. KG

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Subject: VOLUME IX PART PG-B210 Page 3 of 102

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2. Operation and Control Philosophy 16

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3.3.2 Pressure switches 27

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4.3 Hardware Requirements 58

6. Scope of Supply and Service 88

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6.7 Engineering & Services 93

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The system shall be furnished as specified, complete with all software,

The control, instrumentation and monitoring equipment to be provided shall

The Specification stipulates the minimum requirements for the design,

All instrumentation and control work/equipment not expressly called for in

A consistent control and instrumentation philosophy shall apply throughout

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throughout the plant in order to rationalize operation, maintenance and

Generally, equipment shall be supplied from one composite range of

The equipment shall be of modern compact design incorporating the latest

1.1 Codes, Permits and Agency Approvals

The works for instrumentation, communication, control and supervisory

In case of any inconsistency or conflict exists between the different

IEC 60034 Rotating electrical machines – Part 1 rating and

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IEC 61131 Programmable controllers.

1.2 Service Conditions and Environmental Requirements

All equipment shall be designed and selected to operate without degradation

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All equipment shall be suitable for operation in following ambient

· Equipment located in air-conditioned rooms: temperatures from 10-25°C,

Heaters and air conditioning/cooling equipment shall be provided where

Submittal data shall be grouped and submitted in separate stages. The

· Process and Instrumentation Diagrams (PI&D).

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A detailed list of any exceptions, functional differences, or discrepancies

1.5 Packing & Storage

Painted surfaces shall be protected against impact, abrasion, discoloration,

Individual instruments shall be appropriately tagged or labelled to positively

Instrument shipment and storage requirements shall be coordinated with

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Components which are shipped loose due to transportation limitations shall

1.6 Spare parts list

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All commissioning spares parts to be supplied by Contractor. Contractor

1.7 Familiarization and Development