Programmable Electronic System (PES) Requirements PDF

TECHNICAL SPECIFICATION
DATE: 03 APR 2003
PROGRAMMABLE ELECTRONIC SYSTEM (PES)

REQUIREMENTS
I3520E
ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC.
PAGE 1 OF 16
TABLE OF CONTENTS
Section
1.
1.1
1.2
2.
2.1
2.2
2.3
2.4
2.5
2.6
3.
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
4.
4.1
4.2
4.3
4.4
4.5
5.
6.
6.1
6.2
6.3
6.4
7.
7.1
7.2
7.3
8.
8.1
8.2
8.3
8.4
8.5
9.
Title
Page No.
GENERAL ......................................................................................................................................2
Scope..............................................................................................................................................2
Codes and Industry Standards .......................................................................................................2
GENERAL ......................................................................................................................................2
Scope of Supply..............................................................................................................................2
Supplier General Response............................................................................................................3
Project Management.......................................................................................................................4
Testing and Inspection....................................................................................................................4
Shipping ..........................................................................................................................................6
Installation.......................................................................................................................................6
GENERAL SYSTEM REQUIREMENTS ........................................................................................6
Reliability.........................................................................................................................................6
Environment....................................................................................................................................6
Power Requirements ......................................................................................................................7
Input/Output ....................................................................................................................................7
On-line Testing Switches and Shutdown Switches ........................................................................7
BPCS Interface ...............................................................................................................................8
System Self Testing........................................................................................................................8
Sequence of Events (SOE).............................................................................................................9
Cabinets, Power Supplies, and Wiring ...........................................................................................9
Grounding .....................................................................................................................................11
Interposing Relay Cabinets...........................................................................................................11
MICROPROCESSOR BASED SYSTEM .....................................................................................11
Microprocessors ...........................................................................................................................11
Digital I/O Modules .......................................................................................................................12
Analog I/O Modules ......................................................................................................................13
Human-Machine Interface (HMI) ..................................................................................................13
System Software...........................................................................................................................13
TRAINING.....................................................................................................................................14
LONG TERM SUPPORT..............................................................................................................14
Obsolescence ...............................................................................................................................14
Maintenance .................................................................................................................................14
Spare Parts ...................................................................................................................................14
Warranty .......................................................................................................................................14
DOCUMENTATION......................................................................................................................14
Hardware Documentation .............................................................................................................14
Software Documentation ..............................................................................................................14
Supplier Data Requirements.........................................................................................................15
MISCELLANEOUS.......................................................................................................................15
Operational Consumable ..............................................................................................................15
Quality Assurance.........................................................................................................................15
Site Acceptance Test (SAT) .........................................................................................................15
Miscellaneous Notes.....................................................................................................................15
Fiber Optic Cables and Splice Cabinets.......................................................................................16
SPARE CAPACITY ......................................................................................................................16
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REQUIREMENTS
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1. GENERAL
1.1 Scope
This specification covers all control room equipment and other requirements for a complete Programmable
Electronic System (PES) intended for application in a Safety Instrumented System (SIS). This specification
covers centralized system design and permits remote/distributed I/O as an option. The PES will be totally
separate and independent from the Basic Process Control Systems (BPCS). This specification covers minimum
PES requirements. Project specific PES requirements, with details of number of PES, input/output for each
PES, applicable Codes/Standards, etc., will be specified in the PES inquiry/purchase order attachment.
1.2 Codes and Industry Standards
The following documents are referenced herein and form part of the Order. KBR documents, when applicable,
will be listed on the Requisition. Current editions of the industry standards including all mandatory addenda in
effect at the time of the Order shall apply unless otherwise indicated.
INSTRUMENTATION, SYSTEMS AND AUTOMATION SOCIETY (ISA)
ISA 84.01,
"Application of Safety Instrumented Systems for the Process Industries"
INTERNATIONAL STANDARDS ORGANIZATION (ISO)
ISO 9001,
"Quality Management Systems - Requirements"
INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)
IEC 61000-4,
"Electromagnetic Compatibility (EMC) - Part 4-1: Testing and Measurement Techniques"
IEC 61131-3,
"Programmable Controllers -Part 3, Programming Languages
IEC 61508 (1-7), Functional Safety of Electrical/Electronic/Programmable Electronic-Safety Related Systems
TECHNISHER BERWACHUNGS-VEREIN (TV) - TECHNICAL SUPERVISORY ASSOCIATION
DIN V VDE 19250,
Fundamental Safety Aspects to be considered for Measurement and Control
Protective Equipment
DIN V VDE 0801,
Principles for Computers in Safety Related Systems
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 496,
"Purged and Pressurized Enclosures for Electrical Equipment"
MILITARY TEST REPORT
MIL HDBK 217, "Reliability Prediction of Electronic Equipment" (Military Handbook, 217)
2. GENERAL
2.1 Scope of Supply
2.1.1 The Supplier shall provide all PES hardware, firmware, software, system cabinets, Field Termination
Assemblies (FTA) suitable for DIN rail mounting, test/monitor switches, sequence of events (SOE) function,
cabinet wiring, internal power distribution, parts and materials for a fully functional PES, as itemized in this
specification. The interconnecting cables between all PES control building components furnished by the
Supplier shall be supplied as part of the systems, unless noted otherwise.
2.1.2 The Purchaser/Client shall perform all required configuration of the PES for both process application and
gateway interfaces.
2.1.3 The PES equipment shall be supplied in strict accordance with this specification and all attachments. In
case of any conflict between the requirements of this specification and Supplier standards, Supplier shall refer to
Purchaser for clarification before proceeding with the manufacturing of the affected item.
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REQUIREMENTS
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2.1.4 Supplier shall provide special tools and devices necessary for lifting, erection, testing, and maintenance of
the equipment and materials of Supplier. The price for these items shall be indicated separately and included in
the total lump sum price.
2.1.5 The Supplier accepts system responsibility for all supplied hardware, operating firmware software, testing,
training, supervision, spares, delivery and site support for the construction, staging, installation and
commissioning phases of this project through final acceptance. The Supplier shall be responsible for specifying,
purchasing and integrating all material required to complete the requirements of the specification, including any
third party items not provided by the Purchaser.
2.1.6 The Supplier shall confirm formally that the offered system is field-proven for more than twelve months.
The Supplier shall identify new releases as applicable.
2.1.7 The Supplier shall provide hardware that will meet all identified site conditions.
2.2 Supplier General Response
2.2.1 The Supplier shall respond to each paragraph of this specification. There are three options for each
paragraph:
a.
In Compliance.
b.
Not in Compliance: Supplier shall state the specific reason for the deviations.
c.
Enhancement: Supplier shall explain the enhancement and how it will benefit the project.
Any paragraphs that are "Not in Compliance" or are "Enhancements" shall be substantiated with published
specifications or firm guaranteed commitments. Deviations included in any other part of the Supplier's proposal
will not be accepted by the Purchaser. The Purchaser does not take the responsibility to discover missing "Not
in Compliance" items. If the Supplier is awarded the order, Supplier must comply, without any cost or schedule
impact, with all applicable requisition documents except for items of deviations and alternatives accepted by the
Purchaser as stated in the Purchase Order.
2.2.2 The Supplier may propose alternate system features other than those specified if the Supplier considers
that the use of an alternative would improve performance or reduce costs. Any alternative proposed is still
required to meet the Purchase Order requirements. Itemized pricing shall be provided for all alternatives.
2.2.3 The Supplier shall provide unit pricing for all equipment, software, and services in the proposal so that
items, may be added or deleted on a reasonable basis. System costs such as hardware, cabinet integration,
engineering services, programming, Factory Acceptance Test (FAT) and Site Acceptance Test (SAT) shall be
broken out and defined separately. Prices for individual modules/cards and sub-assemblies shall be provided.
A total price to meet the job requirements and a price to add/subtract I/O on a module by module basis shall
also be provided. Appropriate qualifiers shall be supplied in the quote.
2.2.4 The Supplier shall provide sufficient support documentation with the quotation for the Purchaser to be
able to perform a complete technical evaluation. This includes technical data on all hardware and software
proposed.
2.2.5 The Supplier shall provide with the quotation a simple block diagram showing all major components,
interconnections and communication interfaces.
2.2.6 The Supplier shall provide dimensional sketches, proposed layout, and power and heat load for each
PES, power and grounding requirements and weight of each PES/piece of equipment with the quotation.
Access space for door openings and chassis slides, shall be included on the sketches.
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DATE: 03 APR 2003
2.2.7 The Supplier shall provide a reference list with the quotation. Details including the number of systems
and process application shall be included on the list.
2.2.8 System hardware and software shall be certified (general certification and not Project specific) by TV
and must be certified to fulfill the requirements of ISA-S84.01 for SIL 3 applications. Copies of TV
certifications, TV report detailing all the exceptions/deviations/comments, on the system shall be provided with
the quote. Where "TV-approved" or "TV-certified" is specified in this specification, this shall be in accordance
with DIN V VDE 0801 and DIN V 19250. The PES must be certified to fulfill the requirements of "Class 6" (AK6).
2.2.9 The PES hardware and system software shall be certified by TV. All input and output cards shall be
TV-approved. All conditions regarding application of the PES listed in the TV approval report and in the PES
safety manual shall be met. TV certification shall include the serial communication with the BPCS, Sequence
of Event Recorder (SER) and maintenance and engineering network, and PES to PES communication. The
PES shall be unresponsive to faults in the BPCS, SER and maintenance and engineering workstation. The
design of the PES must be compliant with IEC 61508, Parts 1-7.
2.2.10 The Supplier shall provide a summary project milestone schedule. The Supplier may be asked to
arrange schedule or part shipment to meet KBR Project schedule or site need. The schedule shall identify
major milestones in engineering, hardware freeze, software freeze, parts procurement, manufacture, factory
testing, and shipment. All points at which information is required from the Purchaser shall be shown. Activities
that require the presence of the Purchaser shall be identified. Preliminary freeze dates and information required
at those dates shall be shown. Any deviation from the agreed upon schedule must have the Purchaser's
approval. This schedule shall be reviewed and agreed upon during the precommitment meeting.
2.3 Project Management
2.3.1 The Supplier shall assign a qualified person as the project manager who will be the sole source of contact
for the Purchaser. A local Supplier engineer shall also be assigned to assist during the engineering effort. The
Supplier shall submit, with their quotation, resumes of personnel for these key roles. These individuals shall be
approved by the Purchaser and shall not be released from the project, unless approved in advance by the
Purchaser.
2.3.2 A precommitment meeting shall be conducted prior to contract award. This meeting shall include the
Supplier's project manager and project engineer. The Supplier shall assign the same project engineer
throughout the project. It is the responsibility of the Supplier to have completely reviewed all specifications and
attachments prior to this meeting.
2.3.3 The Supplier shall report job progress in writing to the Purchaser monthly, unless agreed to differently in
the precommitment meeting. The Supplier shall bring typical reporting documents from another project similar
to this one for review by the Purchaser.
2.4 Testing and Inspection
2.4.1 The entire system shall be given a complete shop and functional acceptance test prior to the Factory
Acceptance Test (FAT). This test shall be performed by the Supplier. A written notification that the Supplier has
completed the test and the system is ready for FAT shall be provided to the Purchaser, at least 5 working days
prior to the FAT. This shop test shall include hardware checks per hardware list, system power checks, and
system and diagnostic test. The Purchaser reserves the option to perform any "spot" tests or 100% check on
the completed shop test. The Purchaser shall provide a record of punch list items and their completion. The
Supplier shall provide hardware test procedures, for acceptance, for the PES FAT at least four weeks prior to
the FAT.
2.4.2 All PES active modules (processor and I/O) shall undergo a powered heat soak test of at least 48 hours to
remove infant mortality. These test reports shall be provided.
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2.4.3 Factory Acceptance Test

a.
Hardware Factory Acceptance Test.

The Hardware Factory Acceptance Test shall be performed/witnessed by the Purchaser/Supplier/Owner
(who has developed the system application software configuration) and consist of a loop-by-loop test of
each input, output, alarm, and control/trip function for proper operation and display. The job data base shall
be used for the testing. Test shall be performed using simulator boxes. The required simulators shall be
provided by the Supplier. The Supplier shall also provide output simulator boxes or devices (if part of the
order) to verify proper output functionality. Supplier shall provide required number of simulators to
functionally test the most complex loop at one time. The Supplier shall provide record to show that all
simulators are calibrated per Nationally Recognized Testing Laboratory (NRTL) requirements. Temporary
wire tags will be available to use during simulation. If jumpers and cables are used just for testing or
simulation, these must be of different colors, and ensure that these temporary wires are removed after the
test. The Supplier shall also provide interface maintenance PC for the duration of the test. The Supplier
shall provide all drawings, documents, and manuals of PES for FAT.
b.
Software Factory Acceptance Test.

The Purchaser and Owner will witness the test if the system application software is developed by the
Supplier. The Purchaser shall assign engineers to witness/perform the above tests. These engineers shall
also witness the subsequent debugging of hardware and firmware/software problems until the test is
completed satisfactorily. The Supplier shall maintain record of test data, hardware/firmware/software
problems, their solutions, and issue to KBR. The Supplier shall provide clerical support, desks, telephones,
and a fax. Long Distance service shall be included in Supplier's quotation.
c.
The Supplier shall provide qualified technicians on an on call basis, to assist in performing tests and
debugging the system during the scheduled software acceptance tests if the system application software is
not developed by the Supplier. Checkout teams will be assigned consisting of teams of two/three
Purchaser engineers and one Supplier technician. The Supplier shall keep all simulators used for the
duration of the hardware test connected for software FAT test. Technicians shall be assigned by the
Supplier, as soon as possible, on call basis, to provide full support during the software FAT.
d.
The FAT will be held at the Suppliers' facility or the Purchasers approved Suppliers System Integrator
facility.
e.
Once the system has been accepted, records of the configuration and programming data shall be
transferred to a ZIP disk, or equivalent by Purchaser/Owner/Supplier, who has developed the application
software. Three copies are required. All copies shall be shipped separately. This medium will be used to
reload the system after installation.
2.4.4 The PES/BPCS interface shall also be tested as part of the PES FAT. BPCS interface hardware shall be
supplied and supported by others. This interface test will consist of connecting a BPCS simulator and confirm
communication, diagnostics alarms and data transfer. Full testing of the PES/BPCS interface will occur at the
FAT for the BPCS or at site.
2.4.5 The Supplier shall provide QA/QC procedure index of the manuals for manufacturing and testing with the
proposal. Purchaser has the right to request a chapter or the complete set of QA/QC procedures.
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2.5 Shipping
2.5.1 After satisfactory completion of the FAT, the Supplier shall disconnect all equipment and prepare the
system for shipment. All interconnecting cables shall be clearly labeled at both ends. The Supplier shall pack
cabinets so as to avoid damage during shipment and in storage. The Supplier shall state his recommendation
on whether to ship any supplied panel intact or to remove the modules/cards and ship them separately. The
Supplier shall also specify shipping and storage requirements.
2.5.2 The Supplier shall arrange for shipment of the system to the site in accordance with the instructions given
in the Purchase Order. Domestic shipment shall be by dedicated air ride van. The Supplier will be provided
with special instructions for overseas shipment. Approximate packed crate weights and dimensions are to be
stated for planning purpose. The Supplier shall provide actual details for shipment. The Supplier shall confirm
with the Purchaser before deleting the application software program on the System Processors.
2.6 Installation
The Supplier shall assign qualified personnel to approve the system installation and supervise grounding, the
initial system power-up activities at the Site Acceptance Test (SAT). This individual shall have prior in-plant
experience with the PES suppliers equipment. The Supplier shall state in their proposal the estimated amount
of time and cost included for this and shall include a rate sheet for field support by job positions.
3. GENERAL SYSTEM REQUIREMENTS
3.1 Reliability
3.1.1 The system design shall be such that the failure mode is to fail-safe as defined by the system logic
(typically de-energize to trip). This includes card removal and cable faults.
3.1.2 The system shall be designed for maximum safety and reliability. The availability of the PES system
(excluding field devices) shall be 99.97% or better in both the fail-safe and fail-danger modes, where availability
is defined as:
For fail-danger (covert) mode:
Availability =
MeanTimeBe tweenFailure (MTBF )

MTBF + MeanDownTime
Mean Down Time = 1/2 Test Interval + Mean Time to Repair

3.1.3 Availability figures must be provided by the Supplier as part of his quotation, with method of calculations
and all assumptions clearly stated. This statement must include information on the basis of statistics such as
MTBF (e.g., field returns, testing, etc.). Data for failure rates shall be derived from MIL HDBK 217, wherever
possible. If MIL HDBK 217 is not used, Supplier shall state basis of data submitted.
3.2 Environment
3.2.1 All equipment will be located in a control room environment, with exception of distributed/remote I/O. If
distributed/remote I/O has been specified, the hardware shall meet the field electrical area classification and all
identified environmental conditions. If the hardware cannot meet the criteria, then the Supplier shall provide the
equipment in suitable enclosures and comply with NFPA 496. The field enclosures shall include all required
purging, heating and/or cooling devices and sun shield as required for site.
3.2.2 Radio-Frequency and Electro-Magnetic Interference Immunity:
The PES hardware shall be immune to radio-frequency and electro-magnetic interference as follows, and
comply with IEC 61000-4.
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DATE: 03 APR 2003

a.
Field strength of 10 volts/meter or less over a frequency range 50 Hz to 1000 Hz (with doors open)
minimum.
b.
If the equipment ratings are different than subparagraph 3.2.2.a, the Supplier shall provide EMI and RFI
immunity test figures for all equipment to be supplied with the cabinet doors both opened and closed.
3.3 Power Requirements

3.3.1 The Purchaser will provide dual power feeds (120 V AC 10%, 60 Hz 3%, single phase), for the system.
The Supplier shall state the power requirements for each item of equipment (e.g., cabinet) and total power
requirement for each system, including transient requirements in their quotation.
3.3.2 The Supplier shall provide drawings and/or written instructions on primary power and grounding systems
with quotation.
3.3.3 The Supplier will assist Purchaser regarding power and grounding requirements for proper design.
3.4 Input/Output
3.4.1 Signals fall into the following categories:
a.
b.
c.
d.
e.
f.
g.
h.
i.
Field switches - voltage free contacts.

Analog 4 - 20 mA from 2 wire field transmitters.
Analog thermocouple signals (Type J, K, E, R, S, or T).
Analog RTD signals (100 ohm resistance, PT, 2, 3, or 4 wire).
Proximity inputs (Namur, fail-safe proximity switches (ferrometal/non-ferrometal sensing)).
Digital output (24 volts DC, powered by PES).
Dry Relay Contact Outputs (contact rating of 2.0 amps @ 5-125 V DC and 155 V AC).
Analog Output (4-20 mA).
Pulse input (max frequency will be specified).
The PES must be able to accept/provide all of these types of signals.

3.4.2 Both field devices and internal system power for digital and analog I/O shall be provided by the PES. The
system shall be capable of accepting signals from self-powered transmitters. Both field devices and internal
system power supplies shall be redundant.
3.4.3 I/O assignments will be by the Purchaser.
3.5 On-line Testing Switches and Shutdown Switches
3.5.1 Switches designated as On-line Test Switches located on the PES cabinet or main control room console
shall be input to the logic system in the same manner as any other shutdown input. These switches will be
included in the I/O list. The Supplier shall provide key locked testing switches mounted on the door of one of the
I/O cabinets and pre-wired to assigned I/O points.
3.5.2 Switches designated as Shutdown Switches located on the PES cabinet or main control room console
shall be input to logic system in the same manner as any other shutdown input. These switches will be included
in the I/O list. The Supplier shall provide the shutdown switches, with protective cover to avoid inadvertent
operation, mounted on the door of one of the I/O cabinets and pre-wired to assigned I/O points.
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DATE: 03 APR 2003
3.5.3 If specified, the supplier shall provide a master shutdown or manual Watchdog/ESD switch with protective
cover mounted on the PES cabinet door or main control room consoles. The master shutdown switch will be
wired to an interposing relay in the cabinet. The relay contacts shall be wired to the power termination of the
digital output (DO) termination panel. This manual trip circuit wiring must be implemented to avoid nuisance trip
conditions. The independent switch contacts, maintained open to trip, shall also be input to trip system, and
include a reset function. The master shutdown or manual Watchdog/ESD switch is independent of logic solver.
3.6 BPCS Interface
3.6.1 As a minimum, the PES will be capable of interfacing to the BPCS via the industry standard Modbus
protocol.
3.6.2 The information to be transferred to the BPCS shall include, but not be limited to the following:
a.
b.
c.
d.
e.
System alarms and status as defined under Paragraphs 3.8.2 and 4.1.6.
Field I/O status/Trip Condition.
PES alarm annunciation.
Deviation alarms for multiple inputs.
Input bypass active alarms with repeat.
3.6.3 The system shall be capable of transferring every field input and output of the PES to the BPCS. Actual
signals transferred will be determined later. Supplier to state the transfer rate of data from the PES to the BPCS
based on I/O. A specific tag/address list for all transferred data will be developed for the project.
3.6.4 The system and discrepancy alarms defined under Paragraphs 3.8.2 and 4.1.6 shall be transferred to the
BPCS in such a way as to determine from the BPCS the type of fault and the PES location where the fault
exists.
3.6.5 The minimum speed of transmission shall be such that any change in I/O which is to update on the BPCS
CRT shall not exceed 1 second from time of the event to the time that the change is made available for transfer
to the BPCS.
3.6.6 The Supplier shall be responsible for defining the requirements for all interface hardware and software to
enable a proper functioning interface with the BPCS. (It is recognized that the PES is a slave system and must
be polled from the master device, e.g., the BPCS. The programming of the BPCS for this operation is not within
the scope of the PES Supplier.) This communication from the BPCS to the PES will, in general, be "read only".
The Supplier shall provide with quotation a priced list of services, hardware and software necessary to provide a
complete working PES/BPCS interface. Redundant PES/BPCS interface shall be provided. These two
interface cables shall be routed on opposite sides of cable trays.
3.6.7 PES clock shall be synchronized with BPCS master clock. BPCS will provide a hard wired digital output
to PES once a day at set time to synchronize PES clock with BPCS clock. Any other method to synchronize the
clocks is acceptable if it does not introduce any time error.
3.6.8 A BPCS/PES interface trouble alarm for each BPCS interface port shall be available in the BPCS.
3.6.9 The Supplier shall provide technical and experience details list of the PES's Object Linking and
Embedding for Process Control (OPC) compliance and its compatibility for connecting to the Project BPCS.
3.7 System Self Testing
3.7.1 The system shall have full, automatic testing to ensure that fail-to-danger faults are detected promptly.
Minimum test period shall be once every process safety time or 1 (one) second, whichever is faster. Fault
information shall be available and logged for the maintenance staff in a manner that enables fault diagnosis to a
module/card level.
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3.7.2 All diagnostics shall be performed automatically on-line and without disturbing the process or reducing the
availability/reliability of the PES.
3.8 Sequence of Events (SOE)
3.8.1 Time stamping of all data shall occur at every Processor scan.
3.8.2 Time stamp information (status and time stamp) shall be transmitted to the BPCS or PC via the interface
link.
3.8.3 If the Supplier's system cannot support Paragraphs 3.8.1 and 3.8.2, one common SOE software package
shall be included in the PES in order to give first-out indication of events. This package shall have a time stamp
resolution equal to or less than 10 millisecond and shall identify the first-out event. The SOE shall be stored in a
PES buffer to transmit to the BPCS or PC in the correct order of occurrence. Supplier to state the maximum
buffer size for storage and how information is removed if the buffer size is exceeded. An alarm shall be
generated on pending SOE memory allocation overrun.
3.8.4 The system shall support an optional dedicated PC for logging events as they happen, in the order in
which they happen.
3.9 Cabinets, Power Supplies, and Wiring
3.9.1 The Supplier shall mount all equipment in standard cabinets suitable for a general purpose area
classification, with minimum IP 52 (NEMA 12). All cabinets shall be supplied with fans for proper
cooling/ventilation. Alarms shall be provided for cabinet high temperature. All cabinet doors shall have labels,
fixed by adhesive, in English, front and rear door, outside each cabinet. Permanent engraved sticker labels
shall be mounted inside the cabinet (front and rear) housing (not on the doors). All PES cabinets shall have
front and rear access, bottom cable entry, and enough space for allowing field cables and FTA cables bending.
The Supplier shall arrange wiring inside PES cabinets to facilitate easy start-up and maintenance of system.
Site environmental and physical data will be given if any PES component is mounted in uncontrolled condition.
3.9.2 Field Termination Assemblies (FTA) shall be supplied by the Supplier in accordance with the system I/O
requirements. The Supplier to offer cabinet mounted with FTAs and marshalling terminals with fused
disconnects for all input/output points, power supply distribution.
3.9.3 All interconnecting wiring from FTAs marshalling cabinets, within PES cabinets and between PES
cabinets shall be the responsibility of the Supplier. All wiring except power wiring between cabinets shall utilize
Supplier standard length multicore cables with Elco type plug connectors. These standard lengths shall be
shown on the system architecture drawing included in the proposal. The Supplier shall provide required
prefabricated multicore cables with connectors to connect FTAs to I/O cards in the PES cabinet. FTA boards
mounted in the marshalling cabinet by means of extended FTA cables between PES and Marshalling shall show
the total length of each cable quoted.
3.9.4 Each indoor enclosure shall be free standing with removable hinged access doors with louvers including
filters front and back. Paint color details are to be given by Supplier. Each enclosure shall be supplied with a
fluorescent overhead light (with motion sensor) and one (1) utility 120 VAC power receptacle with switch and
fuse, meeting the local standard requirement. The doors shall be lockable with a common key. Each indoor
enclosure shall be supplied with full width removable top and bottom entry plates. Top cable entry is not
allowed for outdoor enclosures.
3.9.5 All system power supplies shall be provided by the Supplier. These power supplies shall be of redundant
design and self-cooled. Alarms shall be generated upon a single power supply failure. Each power supply must
be rated for equivalent to prescribed spare requirements with a minimum of 30% spare capacity. Replacement
of a failed power supply shall be on-line, with no interruption to the processing function.
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3.9.6 All I/O shall be powered by two independent, sealed 24 VDC power supplies, operating in a redundant
mode. These power supplies shall be removable for repair "on-line" without interruption to the operation of the
PES. Power distribution wiring to the terminal strips shall not have a single point of failure, i.e., the circuit shall
be looped, so that any point in the chain will not result in loss of power to downstream modules. The voltage
from the power supplies shall have variations of no more than 10%. The PES shall accept two separate input
120 VAC feeders.
3.9.7 All interconnecting cables shall be supported and tagged at both ends with cable/plug numbers and
cabinet numbers, accepted by the Purchaser. Wiring shall be tagged at both ends (where applicable) with tag
numbers using shrink sleeve type markers.
3.9.8 Terminal blocks shall be non-hygroscopic type. Terminals shall be tinned and shall be clearly identified.
The size of the terminal blocks shall be consistent with the wire size specified in Paragraphs 3.9.9, 3.9.10, and
3.9.14. Captive screw terminal strips are preferred. All terminals shall be tagged with numbers and marked for
polarity. Output terminals powered by the PES shall be fused on the hot side to avoid affecting more than one
circuit in the event of a short circuit unless the modules provided are short circuit proof or with current limiting
feature. Terminals shall be protected against accidental contact. For input or output signals, commoning of
negative terminals shall not be done.
3.9.9 Wire sizes for terminal to ELCO type connector wiring and multiconductor wires shall be 18 AWG
(1 mm2), 16 AWG (1.5 mm2), or 14 AWG (2.5 mm2) as required.
3.9.10 Analog wiring shall be shielded twisted pairs or shielded triads, 18 AWG (1 mm2). Terminals/Ground bar
shall be provided for analog input shields in each cabinet.
3.9.11 All wire shall be stranded copper except for thermocouple. The thermocouple wire shall match the
thermocouple type.
3.9.12 Two main feeder system power disconnect breakers shall be provided at the point of power supply entry.
Also each individual cabinet (system and marshalling) shall have dedicated power disconnect breakers. These
breakers shall isolate power to the specific cabinet. If any power disconnect switch is provided on outside of the
cabinet, it shall be physically protected from accidental disconnecting by a screwed-on cover.
3.9.13 All outputs shall be individually fused and have blown fuse indicators. Fuses shall be as per project
requirements. Specify the details if outputs are short circuit proof or with current limiting feature. All input shall
have individual current limiting resistors or fuses with blown fuse indication. All signals will have knife switch
disconnects, with fuses, for individual isolation, provided by the Supplier.
3.9.14 Wire and cables provided by the Supplier shall be segregated by voltage and color coded meeting the
applicable US/International Standard, and tagged.
a.
b.
c.
d.
e.
120 VAC power hot; 120 V AC neutral.

5 V DC.
24 V DC.
Switched/Analog/Potential Free/Marshalling.
Protective Earth.
3.9.15 Power wiring shall be single conductor copper THW stranded, 14-AWG (2.5 mm2) minimum, with 600 V
insulation. Control wiring shall be single conductor copper THW stranded, 16-AWG (1.5 mm2), minimum, with
300 V insulation. Analog signal wire shall be two conductor 18 AWG (1 mm2), stranded, and twisted pairs, with
overall cable shield, PVC jacketed overall and 300 V insulation. Special shielded or co-axial cable shall be used
when required by the instrumentation manufacturer.
3.9.16 All 2 wire transmitters shall be loop powered from the PES.
DATE: 03 APR 2003

REQUIREMENTS
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3.10 Grounding
3.10.1 Each enclosure shall include a 1-1/4 in. x 18 in. x 1/4 in. (32 mm x 460 mm x 6 mm) copper ground bus
bar with two (2) bolts, sized for a 4 AWG (25 mm2) ground wire, for connections to the external plant grounding
system.
3.10.2 All racks, power supplies, doors, rails, shield terminals, termination panels, etc., must be individually and
securely tied directly to the ground bar using, insulated wire meeting the applicable standard.
3.10.3 Each termination cabinet shall have an instrument ground bus of each cabinet width for collecting field
cable shields. A lug shall be provided on each bar for a 4 AWG (25 mm2) ground wire.
3.10.4 No daisy chain connections are permitted.
3.10.5 The Supplier shall comply with all relevant national and local electrical codes for grounding of this
system.
3.11 Interposing Relay Cabinets
3.11.1 The Supplier will be responsible for providing relay cabinets with hermetically sealed interposing relays
and power supplies mounted and wired. Relays with coil operating on DC voltage shall be with diode across
each coil.
3.11.2 The number of cabinets, relays, and relay wiring shall be in accordance with details provided in the
inquiry.
3.11.3 The spare capacity specified in Section 9 is also applicable to the relay cabinets.
4. MICROPROCESSOR BASED SYSTEM
4.1 Microprocessors
4.1.1 Each system shall contain triple modular redundant (TMR) or 2004 (D) (QMR) microprocessors and a
system that is certified to a minimum of TV DIN V VDE 19250 AK 6. Each microprocessor shall consist of
CPU, memory, communication processor, and communication bus.
4.1.2 Each CPU shall retain its memory in the event of a power failure or internal malfunction for a minimum of
six month. If battery backed-up RAM is used, rated back-up period shall be stated.
4.1.3 Each CPU shall be provided with sufficient memory for the initial configuration plus 50% additional for
future expansion. This additional memory shall be based on a scan time of 100 msec (ms) or the actual
configured system scan time. The calculation (including all assumptions) shall be submitted to the Purchaser.
The additional memory shall be available after the FAT.
4.1.4 The CPU shall be provided with protection against overload current and line voltage spikes.
4.1.5 Redundancy techniques shall be incorporated in order to ensure that failure of any single module/channel
supplied with the system shall not cause a shutdown action. During such a failure, the system shall remain
on-line and shall maintain the safety protection. Replacement of the failed module shall be on-line while the
system is active.
4.1.6 The system shall incorporate comprehensive field-proven self-diagnostics such that faults are identified,
alarmed, and reported. Diagnostics shall be capable of identifying, locating and reporting the following faults as
a minimum:
DATE: 03 APR 2003

a.
b.
c.
d.
e.
f.
g.
h.
i.

REQUIREMENTS
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Scan failure.
Power failure.
Memory faults, both PROM and RAM.
Communications faults with time out alarms for each foreign device. The alarm shall be programmed in
each foreign device by others.
I/O faults.
I/O module faults.
I/O voting signal discrepancy.
High Temperature in the PES hardware.
Battery Low (Only local in the cabinet).
4.1.7 Digital Input module diagnostics shall be able to detect and alarm hardware point faults of the following
types:
"Stuck-on"
"Stuck-off"
4.1.8 Fault repair consists of on-line replacement of faulty modules (any and all types). With no wiring changes
required to perform on-line repair. This replacement shall be transparent to the control program and have no
affect on the system functionality.
4.1.9 Status indicators (LEDs) on individual modules/cards or system diagnostic module shall be provided to
indicate normal operation on digital I/O modules or fault condition by means diagnostic message, for faults listed
in Paragraph 4.1.6. At a minimum, the same alarm condition will be provided to the BPCS via the interface
connection.
4.1.10 A real time clock with a one (1) msec (ms) or better resolution shall be provided for time tagging events,
rate calculations and other time dependent functions.
4.1.11 The system shall be capable of scanning and updating the I/O and executing user-defined logic and
diagnostics in less than 100 msec (ms). It is recognized that scan time is variable, and depending upon system
size and programming complexity, may exceed 100 msec (ms). The Supplier shall state an approximated scan
time for the system proposed.
4.1.12 The controller shall be capable of executing the following command functions:
a.
b.
c.
d.
e.
f.
g.
h.
i.
Boolean logic.
Time delays.
Counters.
Latches.
Arithmetic functions.
Sequencing.
Sequence of events recording (Time stamping of all events shall occur in the Processor).
Scaling of analog signals (including linerization for differential pressure signals).
Capability of adding description on the code.
4.1.13 The system shall permit expansion of I/O data files, and modules, without stopping the program, up to
the memory allocation limits defined in Paragraph 4.1.3.
4.2 Digital I/O Modules
4.2.1 I/O modules shall not have address links or switches mounted on them. Each I/O module shall assume
the address of the slot into which it is plugged. Each type of I/O module shall be keyed in its chassis slot to
prevent insertion of incorrect modules.
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DATE: 03 APR 2003
4.2.2 Input signals shall be conditioned by a low-pass filter, typically less than 15 msec (ms), to reduce the
effects of noise and bounce. Input status for each point shall be indicated on the front of the input module.
Opto-isolation shall be provided between each input signal and main microprocessor. Each input signal path on
the input module shall be automatically tested (See Paragraph 4.1.6 for types of tests to be performed).
4.2.3 Output modules shall have circuits to ensure the field device achieves its commanded state. Diagnostics
will detect module/circuit failures and the system shall automatically alert the user that there is a problem. The
Supplier shall provide output load requirements for using supervised digital output modules. The Supplier shall
state in his proposal the current ratings of the output devices, if different from Paragraph 3.4.1.
4.3 Analog I/O Modules
4.3.1 Analog inputs will be brought directly to the Supplier AI input cards. AI input modules shall maintain a
lifetime accuracy of 0.25% full scale reading (FSR) utilizing either automatic calibration techniques or high
accuracy components. Supplier to specify accuracy for RTD/Thermocouple input modules.
4.3.2 The Supplier shall provide any dropping resistors necessary for analog modules operating with 4 to
20 mA DC. Line monitored switches, if required, shall have end of line devices installed (by others) and the
signal shall be read by the PES as an AI or Digital input line monitored signal. Supplier shall provide fault and
diagnostic routines.
4.4 Human-Machine Interface (HMI)
In general, the PES will communicate with the BPCS (Redundant PES-HMI link), and the BPCS consoles will
provide the operator interface. A laptop PC (by Supplier) shall be provided for PES configuration. Program
maintenance and engineering functions shall be available via the laptop PC.
4.5 System Software
4.5.1 Configuration of the PES shall be performed by the Purchaser/Client.
4.5.2 Each PES system shall be configured using ladder logic, or binary function block or logic diagrams.
4.5.3 The PES must provide a secure method of storing the application program in the memory of the PES unit,
such as battery backed-up RAM or non-volatile memory. The Supplier shall state which method is used and
battery life.
4.5.4 Programs in the PES controller shall be protected from unauthorized changes by the use of keylock
switches, password, or both. The Supplier shall state in the proposal additional methods available in the system
for protection. Additionally, the development/maintenance software on the PC shall be password protected (at
least 3 levels) in accordance with application program.
4.5.5 Software and hardware shall be provided to record the user-defined logic programming on ZIP disk or
CD-ROM. The Supplier shall state which methods are used for their system.
4.5.6 The Supplier shall provide (in the quote) all necessary hardware (laptop PC and laser printer) and
software to allow the Purchaser to enter, add, delete or modify logic networks. The system software should be
"Windows" based, multi-user, with "on-line" and "off-line" configuration modes. It should be self-documenting
and transparent to a running processor. This self-documentation is a requirement. The printout shall use
Purchaser's tag names to identify all inputs and outputs, and shall contain a remarks column for Purchaser's
use. The format shall be either function block logic diagrams or as specified by the Purchaser, meeting
IEC 61131. The Supplier shall state distinctly if any restriction or limit of nature/number of characters is imposed
in naming of tags by the Supplier.
REQUIREMENTS
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DATE: 03 APR 2003

5. TRAINING
The Supplier shall confirm capability for training of operating, engineering, and maintenance personnel. This
shall include the recommended courses and duration, optimum number of trainees with brief course outlines.
The option of training at jobsite should be included. A schedule sheet (including class fees and locations) shall
be included in the proposal for all classes.
6. LONG TERM SUPPORT
6.1 Obsolescence
The Supplier must provide reasonable assurances that system equipment will not be obsolete in the next ten
years. In the event that portions of the system will eventually be withdrawn from sale, a firm commitment by the
Supplier that standard products will have repair capability or that equivalent parts and/or products will be
available for a minimum of ten years from the withdrawal date is required.
6.2 Maintenance
6.2.1 The Supplier shall provide a list of all special tools and test equipment, including pricing, required to install,
operate, or maintain the PES.
6.2.2 The Supplier shall fully describe and quote as an option any off-line diagnostic tools that are available for
use with the system.
6.3 Spare Parts
The Supplier shall state his recommended spare parts requirement for both start-up and two years operation
with pricing. Two years spares shall include card of each type, one power supply, and 100% fuses. These
spare parts shall include an allowance for normal maintenance. The spare parts list must be itemized by part
number and price. This shall be included in the quote.
6.4 Warranty
The Supplier shall state in the quotation the standard warranty for hardware and software. As a minimum,
12 months from start-up or 18 months from shipment is required.
7. DOCUMENTATION
7.1 Hardware Documentation
PES documentation to be supplied by the Supplier shall include, but not be limited to index of all documents,
connection drawings or wire lists, detailed descriptions of physical equipment, equipment dimensions, power
and cooling requirements, grounding, and site preparation. Documentation formats shall be approved at the
precommitment meeting. All documents/drawings shall be in metric or imperial size, as required for the Project.
7.2 Software Documentation
If the Supplier is responsible for the programming, then the Supplier shall provide samples of standard forms or
formats to document logic implementation. This documentation must include Purchaser's tag numbers, I/O
assignments and interconnecting logic, and comments throughout the program that describe the functions being
performed in enough detail to help maintain the software provided.
REQUIREMENTS
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DATE: 03 APR 2003
7.3 Supplier Data Requirements

Refer to Supplier Data Requirement (SDR) documents provided in the requisition for other documentation
requirements. The Suppliers drawings and documents shall have applicable SDR reference number on their
drawings and documents.
8. MISCELLANEOUS
8.1 Operational Consumable
Supplier shall inform Purchaser of the specification and quantities of operational consumables such as
computer papers, recording charts, light bulbs, all sizes of fuses, etc. If the consumables are Supplier's
exclusive products, Supplier shall provide a price list in the quotation.
8.2 Quality Assurance
Supplier should have a Quality Assurance System based on ISO 9001 International Standard or equivalent
standards. The Supplier shall submit his Quality Certificate with the proposal. The Supplier is fully responsible
for the quality assurance of their subsupplier's and/or subcontractor's activities.
8.3 Site Acceptance Test (SAT)
The Supplier shall provide any specialized equipment/tools required for testing. The Supplier shall provide
services related to SAT and acceptance of the equipment that shall include, but is not limited to, the following:
a.
b.
c.
d.
e.
f.
g.
h.
i.
Verify proper system cabling and grounding per drawings and documents.
System power up.
Perform diagnostics on all system components.
Install system software.
Verify overall integrity of the system software.
Verify PES-BPCS Redundant interface.
Verify proper system operation.
Verify proper operation of back-up systems.
Submit a detailed report, including punch list items with the details of their completion, on the system.
8.4 Miscellaneous Notes

8.4.1 The level of noise produced by any item (fan, etc.) in the proposed system shall not exceed 65 dBA
measured at 3 foot radius from the system cabinets with all devices/equipment powered and cabinet doors
closed. The Supplier shall include soundproofing as required to meet (or exceed) this requirement, and shall
specify the resultant noise level.
8.4.2 The Supplier shall provide sufficient wiring and termination information to Purchaser's instrument design
and electrical groups during the design phase of the system. The information transfer dates will be shown on
the schedule. Supplier shall perform a breaker/fuse coordination within their system. Specific information will
be required from the Supplier on breakers/fuses in order to perform an overall breaker/fuse coordination study.
The specific information will be provided at the precommitment meeting and agreed upon dates for information
delivery will be shown on the schedule.
DATE: 03 APR 2003

REQUIREMENTS
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PAGE 16 OF 16
8.5 Fiber Optic Cables and Splice Cabinets

Fiber optic cable (by others) communication systems shall be of a homogenous design with respect to all
applications. Optical fiber size shall be the same for all systems. Optical fibers shall be continuous throughout
the cable without production splices. Supplier shall provide recommended fiber optic cable specification.
Additionally, if the Supplier has a fiber optic installer experienced with their system installation, their names are
to be provided.
9. SPARE CAPACITY
At least 20% fully wired spare capacity shall be available within the system when the system is accepted by the
Owner at site. This includes FTAs, terminations, monitor switches, I/O points, user program memory, etc. For
I/O points, the 20% spare is on a point type basis. All spare points are to be wired to FTAs.

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DATE: 03 APR 2003