Automation & Control Requirements For Package With PLC (Coc)

Identification Code
AUTOMATION & CONTROL REQUIREMENTS FOR 4128-JK-SE-0000132C

PACKAGE WITH PLC (COC)
Sheet 1 / 12 Issue 01
Plant Employer Ref. Plant Location
Urea Fertilizer Project
GEMLIK GÜBRE, Gemlik, Turkey
(UREA 1640 MTPD and UAN 500 MTPD)
AUTOMATION & CONTROL REQUIREMENTS FOR

PACKAGE WITH PLC (COC)
03
02
01 ISSUE FOR DESIGN P. GOPAL G. PREMOD G. PREMOD 10-Sep-2020

Issue Reason for Issue - Description Prepared Checked Approved Date
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PACKAGE WITH PLC (COC) Sheet 2 / 12 Issue 01
INDEX
1 INTRODUCTION .................................................................................................. 3
1.1 DEFINITIONS ................................................................................................ 3
1.2 ABBREVIATIONS ......................................................................................... 4
1.3 REFERENCE DOCUMENTS ......................................................................... 5
2 ENGINEERING ..................................................................................................... 6
2.1 LIST OF DOCUMENTS REQUIRED FOR THE PACKAGE CONTROL
SYSTEMS ENGINEERING ...................................................................................... 6
2.2 SOFTWARE REQUIREMENTS FOR DOCUMENTATION ........................... 7
2.3 ENGINEERING SERVICES........................................................................... 7
2.4 SCOPE OF SUPPLY ..................................................................................... 8
2.5 AUTOMATION & CONTROL – BATTERY LIMITS..................................... 12
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1 INTRODUCTION
This specification defines the general requirements about the automation and control (limit of
supply, standard execution, materials) to be foreseen for the CO2 Compressor (20-K-102)
package.
1.1 DEFINITIONS
In this and in all the other applicable documents, the following terms will be used to identify
the different parties involved:
Vendor: Selected provider for PLC, other equipments and services

defined in this document. This term includes such descriptions
as "Supplier", "Seller", and “Manufacturer".
End User: Gemlik Gubre (Employer)

This term includes such descriptions as "Owner", and “Client".
Contractor: TECNIMONT S.p.A. (TCM)

Party which carries out the activities of issuing the Material
Requisition, design, engineering, procurement, commissioning
of the project. From now on it will also be indicated as
"Contractor”.
OEM Original Equipment Manufacturer

Selected provider for the Package to which the PLC is
associated
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1.2 ABBREVIATIONS
Acronym Description
AC Alternate Current
AI Analog Input signal
AO Analog Output signal
CPU Central Processing Unit
DC Direct Current
DCS Distributed Control System
DI Digital Input signal
DO Digital Output signal
EMC Electro Magnetic Compatibility
ESD Emergency Shutdown System
EMI Electromagnetic Interference
FAT Factory Acceptance Test
FBD Functional Block Diagram
HART Highway Addressable Remote Transducer Protocol
HAZOP Hazard and Operability Analysis
HMI Human Machine Interface
HW Hardware
IAMS Instrument Asset Management System (HART)
IFAT Integrated Factory Acceptance Test
I/O Input / Output
IOM Installation, Operating and Maintenance Manual
IS Intrinsically Safe
LED Light Emitting Diode
MCC Motor Control Centre
MDR Manufacturing Data Report
MOS Maintenance Override Switch
MPS Machinery Protection System
NIS Not Intrinsically Safe
OPC Open Connectivity standard (OLE for Process control)
PLC Programmable Logic Controller
RFI Radio Frequency Interference
SAT Site Acceptance Testing
SIF Safety Instrumented Function
SIL Safety Integrity Level
SIS Safety Instrumented System
SOE Sequence Of Events
SW Software
UPS Uninterruptible Power Supply
VDU Visual Display Unit (LED / TFT Monitor)
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1.3 REFERENCE DOCUMENTS
The following project specifications form a part of this specification & shall be applied:
Document Number Document Title

4128-JK-GS-00000001 Basic Plant Control and Safety Philosophy
4128-JK-SZ-00000001 Safety Requirements Specification (SRS)
4128-JK-DQ-00000001 Control System General Architecture
4128-JK-SE-00000001 Serial Interface Implementation Guidelines
4128-JK-SE-00000004 Human Machine Interface Guidelines
4128-JK-SE-00000130 PLC Technical Specification
4128-JK-SE-00000131 Acceptance Test Procedure for PLC
CONTRACTOR will advise VENDOR of any changes to Reference Documents after the
Package Purchase Order issuing. VENDOR shall comply with CONTRACTOR instruction to
fully comply with any changes on Referenced Documents. VENDOR shall advise of conflict (if
any) among Reference Documents or other technical specification listed in the Package
Material Requisition and therefore CONTRACTOR will determine which shall govern and
inform timely VENDOR.
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2 ENGINEERING
2.1 LIST OF DOCUMENTS REQUIRED FOR THE PACKAGE CONTROL

SYSTEMS ENGINEERING
The following information is required from VENDOR as basic engineering input.
VENDOR shall ensure their availability according to the time schedule and format to
be agreed with CONTRACTOR.
- P&ID;
- Electrical single line diagram;
- Complete heat dissipated and electrical load lists for all Control equipments in
VENDOR scope;
- Detailed List of HW signals between PLC and plant DCS/SIS;
- Detailed List of SW signals between PLC and plant DCS (Memory Map according to
CONTRACTOR standard format applied for the Project including the Serial
Interfaces implementation guidelines);
- I/O List for each equipment in VENDOR scope to be managed by PLC;
- Alarm/Trip and Set-point list for each equipment in VENDOR scope to be managed
by PLC;
- Detailed interlocks/complex loops/sequences descriptions (according to
CONTRACTOR standard format applied for the Project) for each equipment in
VENDOR scope to be managed by PLC;
- Logic diagrams (according to CONTRACTOR standard format applied for the
Project) for all the closed control loops, interlocks and sequences to be implemented
in PLC to manage each equipment in VENDOR scope;
- Operator HMI mimic displays realized for PLC to manage any equipment in
VENDOR scope; Similar graphics shall be prepared in DCS by Contractor’s selected
DCS vendor. These shall be supplied in advance to match DCS engineering
development stage.
- Functional and constructive drawings for Control equipments;
- Power distribution drawings for Control equipments;
- Control equipments Installation Manual in English and Turkish languages;
- Control equipments Operator Manual in English and Turkish languages;
- Control equipments Maintenance Manual in English and Turkish languages.
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2.2 SOFTWARE REQUIREMENTS FOR DOCUMENTATION

The following list specifies the tools to be used; the electronic format and the main
requirements for the documentation to be provided by VENDOR:
Document type Electronic format Software tool

Drawings Autodesk file AutoCAD Autodesk, rel. LT 2019
WP documents Microsoft file Word (Office 365)
Spreadsheets Microsoft file Excel (Office 365)
Databases Microsoft file Access (Office 365)
Memory Map Microsoft file Excel (Office 365)
Images *.pdf file Acrobat / Equivalent
2.3 ENGINEERING SERVICES

Besides of the documents listed in paragraph 2.1, Vendor shall provide the following
services:
 VENDOR shall attend HAZOP (Hazard and Operability) and SIL (Safety Integrity Level)
review meetings at the CONTRACTOR office. VENDOR of the equipment shall have
overall responsibility for the proper design and safety of the equipment supplied. Any
item and certificate required as result of the HAZOP/SIL studies shall be fully
implemented by the VENDOR without cost impact for CONTRACTOR or delaying on
material delivery according to the delivery term defined in the Purchase Order.
 VENDOR shall provide SIL certificates, SIL certification reports and Safety Manuals for
any item involved in a SIF SIL classified belonging to the package in VENDOR scope.
 VENDOR shall allow CONTRACTOR and OWNER witnessing the PLC HW and SW
FAT (Factory Acceptance Test) at VENDOR or PLC sub-vendor premises. VENDOR
shall organize the testing activities and make available all the assistance and
equipment necessary so that the testing activity proceeds as quickly as possible.
Location, staff and equipment to perform the test are completely at VENDOR charge.
The FAT will concern all the equipments in VENDOR scope (installed in their final
configuration) and will be carried on the HW and application SW in the scope of supply,
as well as on the integration of the PLC with other subsystem supplied by different
VENDOR Suppliers’. The testing procedure shall also foresee a complete integrated
test of the DCS interface and master clock synchronization to be carried on preferably
at DCS vendor premises or alternatively at VENDOR or PLC sub-vendor premises
(System Integration Test). Main aim of the system Integration test is to check the
communication (complete configured memory map) between PLC and plant DCS.
CONTRACTOR may ask to postpone the starting date of FAT if any material omissions
or relevant errors in the documentation are met.
Prior to the FAT all the necessary equipment shall be fully assembled, wired and
connected in order to test all the functionality of the supply.
All the anomalies, defections or changes detected during the PLC FAT shall be
reported and corrected by VENDOR before the end of testing or, at least with the
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CONTRACTOR approval, before shipment. CONTRACTOR reserves the right to re-test

and approve all punch list items before the PLC system may be released for shipping.
If during the test activity problems occur so that it will be difficult to continue, in the
opinion of the CONTRACTOR personnel, the testing will be interrupted until VENDOR
remedies to these problems.
In the event testing is interrupted for repairs or modification of the PLC System, the
CONTRACTOR may require testing to be restarted from the beginning.
 VENDOR shall allow CONTRACTOR and OWNER witnessing the PLC HW and SW
SAT (Site acceptance test) at site.
Testing at site shall include all system hardware, communications, back-up and
redundancy operations, 100% of I/O points (including spares) during loop check
execution, local panel (if any), and any other foreign device communications interface.
Testing shall also include complete integrated testing of the DCS interface and all other
system interfaces including master clock synchronization and PLC system/cabinet
diagnostic.
VENDOR shall provide all necessary test equipment and software including any special
software or hardware required for a complete functional test of the system.
In the event testing is interrupted for repairs or modification of the PLC, the
CONTRACTOR may require testing be restarted completely.
 VENDOR shall quote on daily rate basis the assistance at Site for the following
activities in VENDOR Scope of Supply (to be carried on after PLC SAT completion):
 Training for operation and maintenance personnel belonging to OWNER
organization;
 Loop & Interlock checking for the PLC in VENDOR scope of supply (testing shall
include functional tests of all logic block diagrams, including all associated interfaces
with the operator console and graphic displays; all testing is to be carried out to show
that the system operates correctly and in compliance with the provided logic
drawings, cause and effect matrix, ladder logic, block diagrams);
 Start up and tuning for the PLC in VENDOR scope of supply.
 VENDOR shall issue, after the completion of plant start up, the AS BUILT version of all
automation documents on the basis of the red marked up MASTER copies.
2.4 SCOPE OF SUPPLY

The following shall be supplied as part of the CO2 compressor (20-K-102) MR requirements:
1) UCP PLC system, complying with “Type 2 Package Equipment - Complex Process
Package” requirements mentioned in ‘PLC Technical Specification document no. 4128-
JK-SE-00000130’.
2) UCP PLC system shall be supplied with the following
a. Proven, standard fault tolerant, fail-safe, dual redundant logic processors
(CPU) including redundant I/O bus extenders and accessories
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b. redundant I/O modules for all types of I/Os (AI/AO/DI/DO) signals of SIL and
non-SIL certified hardware
c. redundant communication modules, dedicated for DCS communication
(Modbus TCP/IP with auto-changeover)
d. redundant communication with vendor supplied Operator and Engineering
stations.
e. redundant network switches
f. redundant power supplies
3) Engineering and Operator stations shall be supplied with the following
a. One (1 no.) Operator station HMI PC of latest configuration with 24” monitor
(Full HD), suitable for 24 x 7 service. This PC shall be loaded with the latest
version of Windows operating system, software for all the operator functions
required for the control of the supplied package Machinery and any other sub-
systems in the UCP supply. This PC shall be in the Operator room of the
central control building and primarily used for Operational purposes. The HMI
software used shall have the functionality of facilitating all required operations
of the machine consisting of graphic displays, First-out alarm, other alarm
messages, operator action journal, SOE / time stamping of trips, real time and
historical trend viewing and export of trend data in Excel format. This PC could
also be loaded with engineering software, in case of failure of Engineering PC
with license interchange.
b. One (1 no.) Engineering / Operator Station HMI PC of latest configuration with
24” monitor (Full HD), suitable for 24 x 7 service. This PC shall be loaded with
the latest version of Windows operating system, all engineering & configuration
software for all the sub-systems in the UCP supply. This PC shall be in the
engineering room of the central control building and primarily used for
Engineering / configuration purposes. This PC shall also be loaded with
Operator functionality (same as above (a)) capable of performing all the
functions of Operator Station.
c. To meet the above requirements, it is recommended to have similar hardware
configuration for both the stations.
d. USB speakers shall be provided for the Operator station HMI PC for
generation of audible alarm for Operator action.
e. Accessories for PCs like keyboard, mouse, power cables, monitor stands, etc.
f. UPS power supplies for Operator and engineering stations shall be powered
from the UCP cabinet itself.
4) Machine Protection System shall be supplied with the following
a. Bently Nevada 3500 Machine Protection System (MPS) rack(s) shall be
supplied in compliance with latest revision of API 670. All the monitoring
parameters shall be transferred to the PLC via redundant serial links. Trip
commands shall be hardwired from MPS racks to PLC.
b. Bently rack configuration software shall be supplied and loaded in the
engineering station.
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c. External isolating barriers shall be used in case of probes located in

Hazardous area in the field.
5) HART Interface shall be supplied with the following
a. Smart instruments and valve positioners with HART protocol shall be
connected to the PLC; PLC I/O cards shall not introduce interferences nor
degradation to the superimposed HART signal. HART patch panels along with
mux-slaves shall be supplied and installed in the PLC cabinets by package
vendor.
b. It shall be possible to read/access HART protocol data from SMART
instruments for testing and calibration from the Contractor supplied Instrument
Asset Management System. Required DD, DTM driver files shall be shared by
respective instrument supplier through machinery OEM to Contractor.
6) MCC/VFD Interface shall be supplied with the following
a. For each of the electrical drive (pump, fan, heater etc.,) vendor shall consider 3
Digital inputs (Run, Local/Remote & Available) and 2 Digital Outputs (Start,
Stop) hardwired signals exchanged with MCC / VFD panels to PLC, via
interposing relay panels supplied by Contractor. Digital inputs to PLC shall be
pot-free contacts via IRP, interrogated by PLC. Digital outputs from PLC shall
be via 24 V DC relays in IRP cabinets, supplied by Contractor. Vendor shall
provide 24 V DC, powered digital output contacts from PLC to drive the relays
purchased by Contactor.
b. In case of VFDs, one analog input (actual speed reference) and one analog
output (speed setpoint) shall be considered to PLC, via interposing relay
panels supplied by Contractor. Galvanic isolators shall be supplied by vendor
within UCP for any such analog signals.
c. Start/Stop commands shall be pulse shaped (latching mechanism will be
implemented in the MCC); Stop commands will be maintained (“0” logic) till an
interlock cause is active requiring motor to be kept stopped by PLC logic. If no
interlock cause is active, Stop commands must be “ON” (contact close => 24V
DC to interposing relays). Start commands are to be implemented as normally
“off” (contact open). Start command shall be a ON pulse of 3~5 secs.
d. LOC(state-0)/REM(state-1) information shall be used (where required) only as
a condition to remote Start, not as a cause of tripping. This information will be
transferred hardwired from local control station on field via MCC interposing to
PLC.
e. ‘Available(state-1)’ input shall be used only for indication & alarm, i.e. not to be
used in Stop/Trip interlock within PLC.
7) Miscellaneous requirements as follows
a. The UCP panels shall be of Rittal TS-8 or equivalent with Comfort key lock
arrangement. Double bit locks are not acceptable. All panels shall have the
same keys for opening. Panels should have transparent doors for MPS and
PLC processor, IO racks sections.
b. Local panel with PBs, lamps and hooter as per vendor standard
requirement, to be installed near the machine skid.
c. All Fibre Optic interface components (F.O converter, F.O Patch cords, F.O
Patch panel etc,) required for connectivity between PLC and local panel HMI
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(19” size, only if recommended by OEM) installed near the machine shall be
included in the scope of supply. Single mode F.O cable with SC connector
shall be considered as project standard.
d. UCP panel shall be mounted in the rack room of the CCR building. Vendor
shall supply CAT-5E (minimum) Ethernet cable with RJ-45 connectors
between UCP network switches and the Operator station (located in Operator
Console bay) and Engineering Station (located in Engineering room). Vendor
to consider 100m cable length for each leg of communication cable link.
e. Software licenses are preferred over hardware license (e.g. USB dongle) for
the project. Wherever hardware license(s) are mandatory to be used, they
shall be securely located inside the CPU compartment of the PCs using
suitable USB ports/extenders. In case of Tower PCs, the CPU case shall be
supplied with lock and key arrangement. No hardware license dongle shall be
located outside the CPU casing in any case. In case such hardware dongles
are to be dispatched separately, they shall be handled in person by the
vendor’s field service engineer visit during SAT at site, to avoid loss / theft of
such critical items.
f. DCS to PLC Serial communication shall be through a single dedicated
redundant Modbus/TCP-IP channel. All the subsystems (like BN3500) of the
UCP shall transfer the data to PLC and PLC shall consolidate all the
subsystems data and provide as a single source of data link to DCS. DCS shall
be the Master of such communication link.
g. If permitted by machinery OEM, MOS key switches shall be supplied within the
UCP panels with key lock arrangement for safety.
h. If required by machinery OEM, Printer for alarm, trend, graphic printing from
Operator / Engineering station shall be supplied.
i. Vendor shall share their Operator HMI graphic pages as design inputs to the
Contractor selected DCS vendor for duplication of similar graphics in DCS for
monitoring purpose.
j. Vendor control engineering scope in compliance with serial communication
guidelines, HMI development guidelines, Basic Plant Control Philosophy,
Safety Requirement Specification, etc as per the reference documents issued
for the project.
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2.5 AUTOMATION & CONTROL – BATTERY LIMITS

Automation & Control Requirements For Package With PLC (Coc)

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AUTOMATION & CONTROL REQUIREMENTS FOR 4128-JK-SE-0000132C