General Spec PAC

8/6/2019 General Spec PAC

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Engineering Department PT Petrokimia Gresik

Job/Project Title :RETROFIT SYSTEM CONTROL CCR PABRIK III

WITH PLC SYSTEM

Client :

DEPARTEMEN JASTEKON

Location :

PABRIK III

3 Issued For Construction 29 April 2011

2 Issued For Construction 10 Maret 2011 RWY SOL AF

1 Issued For Construction 1 Maret 2011 RWY SOL AF

0 Issued For Approval 1 Februari 2011 RWY SOL AF

REV. DESCRIPTION DATE PREPARED CHECKED APPROVED

PT. PetrokimiaGresik

GENERAL SPECIFICATION

FOR

PROGRAMMABLE AUTOMATION

CONTROLLER

Project / Job No:

32-RKAP-2011Revision

3Document No:34-JI-01-04-2000-10

Sheet No : 38 Sheets (w/ Cover)


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General Spec PAC/82944 K Bytes

LIST OF REVISION

General Revision

Revision No. Revision Date Remarks

0 1 Februari 2011 Issued For Approval

1 1 Maret 2011 Issued For Construction

2 10 Maret 2011 Issued For Construction

3 29 April 2011 Issued For Construction

Detail Revision

Revision No. Page/sheet Revision Date Remarks

13, 5, 13, 14, 22

and 23 of 271 Maret 2011

Sesuai Risalah Rapat Aproval no:

014/01.02/32/RR/2011 tgl 21

Februari 2011

2 3, 13, 31 and 32

of 37

14 Maret 2011 Sesuai surat Kakomp Pabrik III

no. 26/PR.00.01/47/MI/2011

tanggal 14 Maret 2011

3 3, 13, 32 and 37 29 April 2011 Sesuai Risalah Rapat Aproval no:

019/04/TK.00.04/38/RR/2011 tgl

19 April 2011.


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CONTENTS

PARAGRAPH PAGE

1 GENERAL 3

2 CODE AND INDUSTRY STANDARD 4

3 DESIGN AND MATERIALS 4

4 MMI (MAN MACHINE INTERFACE) 17

5 TEST AND INSPECTIONS 34

6 PAC & MMI TRAINING 357 COMMISSIONING SPARE PARTS 36

8 SYSTEM CONFIGURATION 36


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1 . GENERAL1.1 This specification covers the common and fundamental technical minimum

requirements for the supply, design, programming, configuration, materials

fabrication, and testing of the Programmable Automation Controller (PAC) for

the RETROFIT SYSTEM CONTROL CCR PABRIK III DENGAN PLC SYSTEM

project.

1.2 The Contractor must provide a complete and operable control, interlock andshutdown system in accordance with this specification including all accessories

for erection, commissioning, maintenance and spare parts.

1.3 The PAC including all hardware and softwares to meet the requirements detailedin this specification and/or specified in the instrument data sheet is the

Contractor responsibility.

1.4 Programmable Automation Controller (PAC) must be applied to control, interlock,shutdown system and start/stop sequence of the PA and CR plant.

1.5 The CPU (Central Processing Unit), Communication Module and Power SupplyModule must be Redundant System. The I/O module for loop control and critical

equipment must be redundant. The critical equipment shall be decided on I/O list

document.

1.6 The PAC vendor must design, configure, program, install, start up assistant andsupervise the PAC and MMI for control dan interlock plant operation. The

memory capacities, software licenses, CPU scanning time, CPU load and others for

these requirements shall be PACs vendor responsibility.

1.7 The total amount I/Os must be subject to these approved P&ID, control loop,interlock system, sequence and monitoring.

1.8 The PAC Vendor must configure the PAC System. Instrument engineer, processengineer and maintenance must be involved in the configuration work.

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2. CODE AND INDUSTRY STANDARD2.1 The document listed below is referenced herein and form part of the order.

Applicable issues of Codes and Industry Standards are indicated below:

a. National Electrical Manufacturer Association ( NEMA )b. NEMA ICS 6-83 : Enclosure for Industrial Control and Systemc. NFPA 70-87 : National Electrical Coded. IEC 61131-1/2 : Programmable Controllers General Information,

Equipment Requirements and Tests.

e. IEC 61508 : Functional safety of electrical / electronic /programmable electronic safety-related systems.

f. ISA S 5.1 : Instrumentation Symbols and Identificationg. ISA S 5.2 : Binary Logic Diagrams for Process Operationh. ISA S 5.5 : Graphic Symbols for Process Displayi. ISA S 71.04 : Suitability of Electronic Equipment in Corrosive Gas

Environment

j. ISA S 72.1 : LAN Industrial Data Highwayk. National Electrical Code (NEC)l. Instrument Society of America (ISA)m. American National Standards Institute (ANSI)n. Industrial Electronic Control (IEC)

3. DESIGN AND MATERIALS3.1 General

3.1.1 Dual modular fully redundancy Programmable Automation Controllersmust be applied for particular control system and supervision tasks.

The Controller must be capable of executing the following command

functions:


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a. Latches h. Sequencing

b. Logic functions . Limit value functionsc. Timer functions k. Arithmetic functions

d. Counter functions l. Proposal, Integral &

e. Comparison functions Derivative.

f. Totaliser m. Advanced Proportional,

Integral & Derivative

3.1.2 The system must be designed for fail safe operation and maximumreliability, flexibility and serviceability. All the module of the PAC

must be able to be replaced online without shutdown and

disturb performance of the system. All modules must be possible to

be replaced without interfering with the external wiring.

3.1.3 The PAC must have the features below but not limitted to:a. Bumpless-balanceless transfer (Controller must not be Hot Standby

System)

b. Anti reset windupc. Auto manual switchingd. Cascading with process variable trackinge. Initialisation are contained in standard algorithms

3.1.4 The PAC must be multiple input and output arrangement, immunity toelectrical noise and resistance to vibration and impact.

3.1.5 The CPU, Communication modules and I/O must be able to be removaland insertion under power.

3.1.6 PAC Central Processing Unit (CPU) and I/O must be suitable formounting in non hazardous control room environment. Ambient

temperature range is 25 to 45 C at 60 to 95 % relative humidity.

The PAC modules must be corrosive coated and if required for

outdoor usage must be covered with dust proof enclosure.

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3.1.7 Power Supplies must be self cooled and be provided with indication ofproper operation of the system. The PAC inside temperature must be

indicated and alarmed on MMI.

3.1.8 Power is available at 110 VAC, 50 HZ from UPS, unless otherwisespecified in the Individual Specification for Programmable

Automation Controller.

3.1.9 The PAC must have screw terminations for the wiring connections.Terminal must be marked for polarity, test connection, etc., and must

be protected against accidental contact. The controller must be

located in the control cabinets and to be mounted in

manufacture's standard size racks with modular expansion

capabilities. The control cabinet must house the power supply unit,

CPU, interfaces and I/O modules. The cooling fans must be provided

in the system cabinets.

3.1.10 Design and materials not specified must be in accordance withmanufacturers standard suitable for the operating and design

conditions specified on the Instrument data Sheet.

3.2 Central Processing Unit (Redundant)3.2.1 The Redundant CPU modules must be of the plug-in type. The

processor must be mechanically and electrically isolated. Each module

must provide protection against overload current and line voltage

spikes.

3.2.2 The CPU must retain memory in the event of power failure or internalmalfunction.

3.2.3 The RAM must have their own battery backup with lithium batterieswith the backup time must not less than 30 days.


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3.2.4 The PAC Systems CPU memory must be provided with minimum 64 MBand PAC System User Flash Memories must have minimum 64 MB, or

higher for future requirements.

3.2.5 Permanent self-monitoring functions must be included in case offailure of CPU, memory module, I/O module and etc.

3.2.6 In case of power supply interruption, automatic restart of the CPUmust be provided without operator interference.

3.2.7 The system must include diagnostic capability for identifying thefailure down to the card level, communication bus, module level and

monitoring workstation.

3.2.8 The controller must perform the error checks such as bus structure,memory and power supply modules.

3.2.9 Sufficient logic inside the I/O module must be provided to diagnosethe component or communication failure and also able to shutdown

the I/O module independently.

3.2.10 The PAC must be capable of executing the user logic minimum in 10times per second.

3.2.11 The CPU load conditions must be as follows:a. Peak load condition : less than 50% of available capacityb. Normal load conditions : less than 40% of available capacity

3.2.12 The processing time of particular controller must be dedicated to therequirement of controlled technological process and maximum

processing time including input operation, logic or function processing

and output operation must not be exceed the following limits:

a. Closed loop control : 250 msecb.

Open loop control : 150 msec


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3.2.13 Full system synchronization. Link module synchronizes CPU (Primary &Secondary) at beginning and end of each logic scan execution to keep

all variable data in the same-providing rapid and bumpless switchover.

3.2.14 PAC systems high-speed memory sharing enables multiple device totransfer up to 20 times faster than Ethernet (2.12 Gbit/s). The use

of fiber optic connections allows to easily operate in high-noise areas

and cover large distances in real time; a manual toggle switch enables

to easily change control between primary and secondary units.

3.3 I/O Module Requirements3.3.1 In general, inputs and outputs of particular technological process

system must be grouped. The I/O modules must be plug-in type with

easy module removal without disturbing field wiring.

3.3.2 The I/O module must be configured, replaced or added in online(without shutdown the system) or disturb the current system

3.3.3 The failure of one particular I/O module must be kept isolated tothat technological process system and must not cause any

disturbances to the other systems.

3.3.4 The spare inputs and outputs must be provided minimum 20% of I/Otype installed or at least 1 (one) of each kind of types.

3.3.5

All individual I/O channel must be electrically isolated from the mainframe CPU and the internally used circuits.

3.3.6 The I/O Module must be provided with protection against overloadcurrent and line voltage spikes.

3.3.7 The I/O type, operating voltage and quantity must be specified onthe Instrument data Sheet.

3.3.8

All individual I/O channel and CPU must be grounded external to PAC.


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3.3.9 Total amount of the I/O point capacity must be subject to theapproved P&ID, interlock system, tripping system and its equipment

protection system.

3.3.10 The minimum noise rejection capability for the digital inputs must beas follows:

3.3.10.1 120 dB from DC to 50 Hz and 1000 ohms unbalance forCommon Mode.

3.3.10.2 60 dB at 50 Hz for Normal Mode.3.3.11 The equipment must be immune to electro-magnetic and radio

frequency interference from devices operating 1.2m away and at

frequencies up to 470 MHz and with power outputs up to 5 watts.

3.3.12 Redundant I/O LAN must be provided to connect each I/Obackplane. Each I/O backplane must be completed with redundant

power supply, redundant communication module and redundant hubswitch LAN.

3.3.13 The following I/O modules must be provided but not be limited to:3.3.13.1 Analog input module

3.3.13.1.1 The standard analog input signal must be 4-20 mADC corresponding to the range of 0-100%.

3.3.13.1.2 The system must be capable of accepting 100 ohmPlatinum RTDs, Type E (chromel-Constantan) and

type K (chrome-Alumel) thermocouples, contact

closure and pulse input.

3.3.13.1.3 The analog input signal must be monitored on thelife-zero, which means that alarm must occur if


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the input signal is less than 3.9 mA or more than

21 mA.

3.3.13.1.4 The particular analog input must be isolated fromthe others and from ground in order to avoid

erroneous signals caused by ground loops.

3.3.13.1.5 The resolution of analog to digital (A/D)conversion must be minimum 12 bits.

3.3.13.1.6

Each of analog input module must be automaticallycalibrated using multiple reference voltage.

3.3.13.1.7 Input signal from the field must be 4 to 20 mA DCat nominal 24 VDC power and fully isolated as

defined in ISA S 50.1. Controller must be capable

of driving output above 20 mA and below 4 mA.

3.3.13.1.8 Line Fault Detection, each channel can beconfigured to sense both open and short circuit

conditions on inputs. On detection, the actions are

those for the high/low alarms.

3.3.13.2 Digital input module3.3.13.2.1 In general, 24 Vdc must be used for digital input

signal voltage. The input module must be noise-

proof and the external signal voltage must beinsulated from the internally used voltages.

3.3.13.2.2 The input modules must also be provided with overvoltage protection.

3.3.13.2.3 The input status must be indicated with LED onthe front face of modules.


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3.3.13.2.4 The input voltage range corresponding to binary 0signal must be 0 Vdc.

3.3.13.2.5 The input voltage range corresponding to binary 1signal must be 24 Vdc.

3.3.13.2.6 Each channel must have line fault detection, thisshall cause a flag to be set to indicate a short or

open circuit fault.

3.3.13.3

Digital output module3.3.13.3.1 In general, 24 Vdc must be used for digital output

signal voltage. The output modules must be short-

circuit protection and the external signal voltage

must be insulated from the internally used

voltage.

3.3.13.3.2 The output modules must also be provided withover voltage protection for induced surge voltage

caused by the switching of inductive loads.

3.3.13.3.3 The rated output current must not less than 24Vdc and output status must be indicated with LED

on the front face of modules.

3.3.13.3.4 Each channel must have line fault detection. Thisshall cause a flag to be set to indicate a short oropen circuit fault even when channel output is in

OFF state.

3.3.13.4 Analog output module3.3.13.4.1 The standard analog output signal must be

4-20 mA DC corresponding to the range of 0-

100%. The particular analog output shall be


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isolated from the others and from grounding

order to avoid erroneous signals coursed by

ground loops.

3.3.13.4.2 The resolution of digital to analog (D/A)conversion shall be minimum 12 bits.

3.3.13.4.3 I/O module must be fully isolated as defined inISA S 50.1.

3.3.13.4.4

Line Fault Detection, each channel can beconfigured to sense both open and short circuit

conditions on inputs. On detection, the actions are

those for the high/low alarms.

3.4 Diagnostic3.4.1 The PAC shall employ continuous diagnostics in order to verify the

system status and to revert to back-up systems without delay.

Diagnostics shall be capable of identifying a degradation or failure in the

following items as a minimum:

a. Rack backplane data busb. Rack power supply modules and power railsc. Battery failure or low voltage (as applicable)d. Processor hardware (including memory cards, EEPROM, etc.)e. Communications module hardwaref. I/O card (module) failureg. I/O point (channel) failureh. Incorrect card type inserted (I/O card)i. Program haltj. Control network failure (inter rack communications)k. Data Highway failure including switches


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3.4.2 All monitored faults shall be reported to the HMI wherever possibleassuming that a means of communication remains viable, as a minimum,

a common failure alarm shall be generated at the HMI regardless of

the nature of the fault or component.

3.4.3 The system shall be configured such that a total failure of thesystem shall automatically initiate a Process Shutdown (PSD) via the

ESD System.

3.5 Overall System3.5.1 The PAC must have minimum listed as below:

3.5.1.1 Redundant CPU (Central Processing Unit)3.5.1.2 Redundant Backplane Mounting (For Redundant Module)3.5.1.3 Redundant Power Supply Module electrically isolated.3.5.1.4 Redundant Regulated Power Supply for PAC3.5.1.5 Redundant Network Module3.5.1.6 Redundant Communication Bus (Remote I/O)3.5.1.7 Buffer Relays operated at 24 Vdc for all Contact Inputs and

Outputs.

3.5.1.8 Fuse block for all Analog Signal Input and Outputs.3.5.1.9 Analog Input Module3.5.1.10 Analog Output Module3.5.1.11 Digital Input Module3.5.1.12 Digital Output Module3.5.1.13 Redundant I/O Module for loop and critical process and

equipment

3.5.1.143.6 Software Requirements

2

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3.6.1 The PAC must provide configuration software which allows processcontrol strategy development for Function Block Diagrams (FBD),

Instruction List (IL), System Function Calls (SFC), Structure Text

(ST) and Ladder Diagram (LD) complying. The development, testing

and documentation software must be complied with IEC61131.

3.6.2 The system must be capable of adapting to program changes withoutaffecting the hardware. Programs must be protected from accidental

changes by use of passwords or keylock switches.

3.6.3 The Logic Programming and I/O Configuration printout capabilitymust be provided, unless otherwise specified.

3.6.4 Software must be provided to record the user logic programming onDVD or CD.

3.6.5 Software Revision3.6.5.1 All software must be the latest version. Prior the shipping, if

the manufacturer has released a new version/revision, the

software provided must be replaced with the new one.

3.6.6 Advanced PID3.6.6.1 PAC software must have PID controller function types as

below but not limited to:

3.6.6.1.1

P control, I control, PI control, PD control and PIDcontrol algorithm.

3.6.6.1.2 ON-Off Control Action, Linier Output Control,Closed Loop Valve Control, Open Loop Valve

Control, PID with Feed Forward, etc.


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3.6.6.2 PLC software must accommodate all continuous processcontrol, monitoring, recording, alarm, report, interlock,

sequence, shutdown system and etc.

3.6.6.3 Auto tuning PID facility must be included and be standardPAC software itself. Auto tuning facility must not be as

added software/program (from other brand software). It

must be proprietary by PAC system.

3.6.6.4

Auto tuning PID must have some essential qualities:3.6.6.4.1 The auto-tuning PID is easy to use. The

parameters that the user must entered are self-

explanatory.

3.6.6.4.2 The auto-tuning sequence is not too long and doesnot disturb too much the production. During this

time, the process must remain in closed-loop

control.

3.6.6.4.1 The auto-tuning PID is able to deal with differenttypes of dynamics: processes with and without a

delay, processes with zeros (minimal and non-

minimal phase), integrating processes, etc.

3.6.6.4.2 The performances of the loop are improved by theuse of the auto-tuning. The loop must also berobust to process behavior changes.

3.7 Communication Interface3.7.1 The following interfaces must be provided but not be limited to:

3.7.1.1 Data gateway interface3.7.1.1.1 In case of particular controller is part of the

plant control system, the complete duplicated

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data gateway interface must be provided for

signal exchange with the communication speeds of

10/100 Mbps/sec.

3.7.1.1.2 RS 232 / RS 485 interface must be provided foroff-line configuration, reprogram and

troubleshooting of the PAC.

3.7.1.1.3 The standard RS 232 / RS 485 interface modulemust generally be provided including all necessaryhardware and software with D type connector.

3.7.1.1.4 The Local Area Network (LAN) must be a highspeed, bi serial communication bus.

3.7.2 A Network Communication Module must be available to transfer data,which is capable of peer-to-peer communication with system PACs

and external hosts over IEEE 802.3 networks as well as supporting

TCP-IP/UDP-IP protocol.

3.8 System security3.8.1 A method of securing access to the operating and system engineering

functions of the plant systems / sub-systems must be provided. The

objective of this method must be to safeguard plant operation,

prevent unauthorized and unqualified personnel from accessing the

plant systems / sub-systems.

3.8.2 Operator access must be through the use of user ID and password.3.8.3 Operator access through key from the Operator Keyboard must also

be provided.

3.8.4 Key access must have privilege to the user login through User ID andpassword.


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3.8.5 Two access levels must be provided with the key. Each level musthave distinct key.

3.9 Power Supply3.9.1 Available Electric Power Supply from source must be nominal 110 VAC

50 Hz from UPS.

3.9.2 Connection from the MCB panel the instruments must be made withno. 14 AWG stranded Copper, or bigger size as required.

3.9.3 Each instrument must have individual disconnect switch. Thecontractor must prepare Power Distribution Panel and be placed in

CCR.

3.10 Logic Programming3.10.1 Vendor must provide all necessary hardware, cables, and software

necessary for the maintenance to implement the user logic

programming.

3.10.2 Programming Software must be furnished on Floppy Disks andCompact Disk.

4. MMI (MAN MACHINE INTERFACE)4.1 Display/Graphic System Requirements

4.1.1 GeneralThe HMI shall be configured to provide many types of displays and

schematics for the process, shutdown, start-up, control, indicator, etc,

dependent on which display is selected.

4.1.2 Operating DisplaysThe system shall make available to the operator at least two (2)

categories of displays - process displays and system displays. Process


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displays shall be those displays used to monitor and control the process.

System displays shall be those displays used to view system status and

assignments, and make limited changes to the system, such as starting or

stopping a node or process connected box. All displays shall be available

for display on any HMI.

4.1.3 Process Displays4.1.3.1 Group Displays - shall be a single page display showing the

values and status of the primary operating parameters in

both numeric and graphic (bar) form for up to eight (8)

display points.

4.1.3.2 Any data point shall be capable of being assigned to one ormore groups. A minimum of 400 usable groups shall be

available per operator console.

4.1.3.3 The operator shall be able to make process changes to any ofthe points assigned to this display (e.g., setpoint, mode,

output, etc.) based on their configured scope of

responsibility. Additional group displays shall be accessible

by depressing forward and backward display keys.

4.1.3.4 Point Detail Display - A unique, operator viewable, detaildisplay shall exist for every point in the system,

automatically built as a byproduct of point building. This

display shall consist of one or more pages, and shall

characterize every parameter and attribute of the data

point. The individual data point shall be capable of being

manipulated from this display. The detail display shall include

an automatic link to a dynamically updating graphical view of

the control configuration for the point.


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4.1.3.5 Trend Displays - shall supply a graphical presentation ofhistorical process data, for up to 32 point parameters

simultaneously on an x-y axis. Additionally, the following

trend functions/types shall be available:

4.1.3.5.1 X-Y plot any two analog point/parametersconfigurable.

4.1.3.5.2 Numeric history shall be optionally viewed withthe real-time trend.

4.1.3.5.3 Trend with Events event data shall be availableon the real-time trend to allow for analysis of

process events.

4.1.3.5.4 A legend shall be available to provide detail on aconfigured point parameter. The legend shall be

able to be hidden to provide maximum screen real

estate for the trend.

4.1.3.5.5 Auto scaling feature for a selected pointparameter or for all point parameters configured

for a trend.

4.1.3.5.6 Standard and user-configurable time ranges.4.1.3.5.7 Seamless review of historical data (even when

pulled from archived data) on the same trend usedfor real-time data.

4.1.3.6 The following history sample intervals shall be user-selectable for all trend types:

4.1.3.6.1 1 second, 30 second, 1 minute, 1 hour, 8 hour and24 hour snapshots

4.1.3.6.2 6 minute, 1 hour, 8 hour and 24 hour averages


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4.1.3.7 The range for each trended parameter, normally the Y-axis(but also the X-axis for X-Y plots), shall be operator-

selectable. The value shall be displayed as a percent of range

(0-100%) or as fixed engineering unit values, either unipolar

or bipolar. Each trend trace shall have a user-selectable

color.

4.1.3.8 Trends shall support hairlining to accurately determine thevalue of a particular trace at a specific point in time.

4.1.3.9 It shall be possible to scroll the Y (usually time) axis forwardand backward. It shall also be possible to scroll the X (usually

parameter value) axis up and down.

4.1.3.10 Trends shall support rubber-band zooming and simple zooming(clicking on a button to zoom in and out in steps) with the

ability to return to normal size by selecting a screen target.

4.1.3.11 The operator shall be able to configure trends on line andsave them by name, so that they may be attached to a trend

menu or recalled by name.

4.1.3.12 It shall be possible to call up a Group Trend display directlyfrom a Group display, automatically trending each point in the

group with the point PVs automatically selected as the

trended parameter. It shall be possible to revert back to theoriginal Group display with a single screen target action or

menu selection.

4.1.3.13 It shall be possible to add, delete or modifypoint/parameters, trace colors, displayed value range, time

range, with an immediate update and redrawing of the trend

by the HMI.


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4.1.3.14 User changes to any trend require a specific action to savethe changes.

4.1.3.15 Hourly Averages - shall display the last 10 hourly averagesfor the points of the selected group display in tabular form,

including the corresponding clock times. The points shall be

easily identified by both point ID and descriptor.

4.1.3.16 Help Displays - shall be displays that provide detailedoperational information to the operator about a particularfunction. These displays shall be context sensitive, and be

preconfigured for standard engineering functions; or defined

by owner and built for custom or configurable displays (e.g.

custom schematics). Vendor shall state the number of help

displays available. The user shall have the capability of

defining a specific "help" display to be called whenever any

custom graphic is on the HMI and the help key is pressed.

4.1.3.17 Schematics shall be provided detailing a particular area ofthe process or overviews of the generating unit and all its

subsystems.

4.1.3.18 Values shown on schematics shall normally be updated on afour (4) second interval to optimize the ergonomic interface

to the operator (e.g. minimize eye strain and fatigue).However, it shall be possible to modify the update rate of

each object on the schematic from 1 second to every 24

hours.

4.1.3.19 Schematic displays shall be built as HTML pages that arebased on the Web-standard Document Object Model (DOM),

suitable for calling up in the meeting room Dept.Pemeliharaan


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III or Internet Explorer Web browser on any network-

connected PC that has the proper network security access to

view process data.

4.1.3.20 Schematic displays shall support the following displayobjects:

4.1.3.20.1 Text, lines and solids - geometric and free-form4.1.3.20.2 Live parameter values -- numeric, status and

enumerated (or text)4.1.3.20.3 Bitmap objects created in the display builder or

imported

4.1.3.20.4 Static shapes pre-built and saved in a shapelibrary

4.1.3.20.5 Dynamic shapes which can change theirproperties (color, line parameters, etc.), move

around on the screen or rotate in place by the

execution of a display script

4.1.3.20.6 Fill levels configurable for a rectangle or free-form object, driven by an analog parameter such

as a tank level

4.1.3.20.7 ActiveX documents and ActiveX controls.4.1.3.20.8 Standard Alarm and Event tables

4.1.3.21 Any display object shall have the ability to be a screentarget, selectable by the operator to call up point-specific or

associated displays, or to execute a programmed script.

4.1.3.22 Schematics shall support VBScript or JScript to allow forevent-based, user-defined functionality at runtime.

4.2 System Displays


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4.2.1 System Status Display - shall show the status of every hardwarecomponent in the system. From this display, targets shall be invoked

to access additional displays showing individual modules or nodes.

From these displays, nodes and modules shall be capable of being

started, stopped, switched (for those nodes with primary and backup)

or checked for status and operability. Detailed maintenance

information and history shall also be available from this status

display.4.2.2 Channel (Process Network) Status Display - shall show the status of

any and all data highways, process networks and system interfaces, as

well as all devices attached to these networks, such as process

controllers.

4.2.3 Console (Station) Status Display - shall show the status of eachoperator and engineering station

4.2.4 Printer Status - shall show the status of all system printers.4.2.5 Workstation Status - shall show the status of all process

workstations, including the status of all server redundancy and

distribution.

4.2.6 The operator shall be able to launch any station display in the system(in his/her area of responsibility) from any of the HMIs in the

console using one of the system displays or a desktop icon.

4.2.7 It shall be possible to automatically launch system modules with asingle keystroke.

4.3 PAC & MMI Configuration4.3.1 The Main contractor must configure the PAC system.

4.3.1.1 Configuration must be based user friendly type.


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4.3.1.2 The system must enable for On-line Configuration.4.3.1.3 The control system must have ability to alter or configure

loops without affecting other loops on automatic control.

Likewise, the modification or creation of graphic display must

not affect loops on automatic.

4.3.1.4 System must be provided to accept eight alpha numericcharacters as tag numbers.

4.3.1.5

After performance Test all system configuration must beback up on CD or DVD Compact Disc as the latest backup

included MMI program.

4.3.2 Alarm Management4.3.2.1 Alarm Logic

4.3.2.1.1 When a point goes into alarm, it shall cause adedicated on-screen indicator and a dedicated

alarm summary keyboard pushbutton to enter a

flashing mode. When the operator acknowledges

the alarm, the indicator and pushbutton shall

cease flashing. The system shall support the

capability to configure whether the operator shall,

by acknowledging the alarm(s) from any of the

operator keyboards in an operator console, cause

the alarm(s) to cease flashing on one or all HMIs.

4.3.2.1.2 When the alarm summary display is invoked, themost recent alarms shall appear on the screen.

Alarms shall remain on the alarm summary display

until they are both acknowledged and cleared (e.g.

return to normal). Pressing the acknowledge alarm


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key or an alarm acknowledge target shall only

acknowledge the alarms that can be seen on the

display page. The operator shall have to scroll

down to see and acknowledge.

4.3.2.1.3 It shall be possible to perform alarm managementfunctions from within a custom graphic.

4.3.2.1.4 The system shall time stamp for each alarm thetime of occurrence, time of acknowledgment, andtime of return-to-normal. The time stamp shall

have a resolution of one second for all alarms

except sequence of events alarms, which shall

have a resolution of one millisecond.

4.3.2.1.5 All analog inputs shall have an assignable alarmdeadband value. Before an input is defined as

returned to normal, the input must have returned

into the normal operating range by the deadband

value. The deadband value shall be selectable as

either a percentage of span or engineering units.

4.3.2.2 Alarm Priority4.3.2.2.1 The system shall be capable of at least three (3)

levels of process alarm priority. Any points highand low alarm limits shall be capable of being

assigned a different priority during database

configuration. These priorities shall distinguish

between low, high and emergency alarms.

4.3.2.2.2 The system shall provide a separate relay contactfor each of the three alarm levels. These


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contacts may be used to drive external audible

devices. It shall be possible to momentarily

suppress the audible annunciation of a HMI.

4.3.2.2.3 The system shall support at least four (4) lowerlevels of priority that shall be assigned to any

point during database configuration. These

additional priorities shall allow for control over

alarm logging and/or printing, but are not audiblynor visually annunciated on the HMI.

4.3.2.2.4 The system responses to each priority of alarmshall be specified.

4.3.2.3 Alarm Suppression4.3.2.3.1 Under predefined conditions, the user shall have

the option to suppress alarming from selected

points. This shall prevent alarms from being

reported when alarming would be obvious (such as

preventing a low pressure alarm when the

associated pump is off). This "intelligent"

alarming shall be configurable and modifiable by

an engineer without the need for programming

knowledge. The system responses to a point inthis alarm state are:

4.3.2.3.2 Additionally, when the operator desires totemporarily change the alarm enable status to

prevent nuisance alarms, the system shall be

Display Print Journal

No No Yes


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capable on a per point basis to enable or disable

alarms. These changes shall be made from the

point detail and alarm summary displays. This

action shall override the response as defined by

the alarm priority and alarm configuration. All

operator actions that change a points alarm

status shall be recorded in the operator process

change journal.4.3.2.4 Alarm Summary Display

4.3.2.4.1 As a minimum, the following alarm informationshall be displayed:

4.3.2.4.2 The alarm summary display shall contain a readilyvisible means of distinguishing acknowledged from

unacknowledged alarms (e.g. blinking field). If an

alarm returns to normal prior to being

acknowledged, it shall remain on the screen with a

unique identifying characteristic (e.g. reverse

field). Upon being acknowledged, the alarm shall

be removed from the screen.

4.3.2.4.3 The number of alarms displayable on one pageshall only be limited by the display resolution and

Analog Alarms Digital Alarms

Time Time

Point ID Point ID

Process Area Process Area

Alarm Type Alarm Type

Alarm Priority Alarm Priority

Point Description Point Description

Alarm Limit Current Value

Current Value

Engineering Units


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the size of the display window. Only the total

number of concurrent alarms configured for the

system shall limit the number of alarms and alarm

summary pages. Each alarm summary page shall

have a prominently displayed page number. The

total number of active alarms for each priority

shall be displayed in a taskbar by process area and

on the page being viewed.4.3.2.4.4 The alarm summary display shall support the

ability to sort alarms based upon any alarm

information available, in ascending or descending

order. (For example: sort all alarms by

alphanumeric description, in descending order.)

4.3.2.4.5 It shall be possible to pause the alarm summarydisplay, allowing the operator adequate time to

respond to alarm information.

4.3.2.4.6 The system shall allow the engineer to configurethe colors assigned to each of the three (3) alarm

priorities (emergency, high, low) when they are

displayed on the system alarm summary.

4.3.2.4.7 It shall be possible to customize the alarmsummary display columns, choosing which

information to display. It shall also be possible to

adjust the width of the display columns using drag

and drop techniques. The operator shall be able

to save any customized view of the Alarm

Summary for easy call up at a later time.


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4.3.2.5 Event Summary lists events that occur in the system,including:

4.3.2.5.1 Alarms4.3.2.5.2 Alarm Acknowledgements4.3.2.5.3 Return to Normal4.3.2.5.4 Operator Control Actions4.3.2.5.5 Operator Login & Security Level Changes4.3.2.5.6

On-line Database Modifications

4.3.2.5.7 Communications Alarms4.3.2.5.8 System Restart Massages4.3.2.5.9 etc

4.3.3 Popup FaceplatesIntegrated popup faceplate windows support is standard in the EWS and

OWS. Faceplates are launched with a single click from process graphic

display. No engineering is required. All standard point types are delivered

complete with faceplates, and if required, the user can build their own

custom popup faceplates. The faceplates provide advanced features

including:

4.3.3.1 Up to 32 popup faceplates of tag number can be opened atonce.

4.3.3.2 The 32 faceplates of tag number can be opened at 4windowing. Each windowing consist of 8 tag numbers of

faceplates.

4.3.3.3 Faceplates operate in round-robin scheme, unless a specificfaceplate is push-pinned.

4.3.3.4 Push pinning preserves the faceplate from closure when newdisplay pages are called. As a result, the operator can call a


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trend display, view an alarm display and then return to

process display while maintaining process control from the

faceplates.

4.3.4 Trending4.3.4.1 The standard trend must include single bar graphs, dual bar

graphs, triple bar graphs, multi-plot trends, multi-range

trends, X-Y scatter plots, Numeric tables, and Group trends.

4.3.4.2 Functions providing data analysis must include Combinationreal-time/historical trending, trend zooming, panning and

scrolling, hairline readout, declutter, Configurable trend

density, simple recall of archived history, trend protection

and smart clipboard for copy/paste of data.

4.3.5 Group DisplaysThe Standard Group Displays are provided to allow configuration of panelboard-like displays. By grouping related points into a Group Display,

operators can more easily interpret process activity. Each group contains

up to eight points, and each point has its own faceplate that displays the

values of the major parameters.

4.3.6 ReportingReports must be generated periodically, or on an event-driven or demand

basis and may be configured on line. Report output must be directed to

screen, printer, file, or directly to another computer for analysis or

viewing electronically.

4.3.7 Alarms and indicators must be grouped operationally and must bevisible to the operator to allow access to operational devices.


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4.3.8 All emergency alarm indicators, push buttons and selector switchesmust be visible to the operator and labeled clearly. They must be

protected to avoid inadvertent actuation.

4.3.9 All control functions must be grouped for accessibility and inproximity to their associated alarm and indication devices.

Where video display units (VDUs) are used, data must be displayed on

monitor screens in a logical, operational grouping to minimize the number

of keystroke operations needed to respond to system upsets. Alarm

functions must be prioritized to appear on the monitor screen upon being

sensed, regardless of any information already displayed.

4.4 Central Control Room & Marshalling Room4.4.1 The equipment of control system must be supplied and located on the

CCR and Marshalling Room consist of:

4.4.1.1 SA, SU Plant and Boiler B-6203 Operator Workstation with dual monitor - unit Engineering Workstation - unit Workstation Console - unit Alarm Printer (dot matrix, or equal ) - unit Report Printer A3 (DeskJet Color or equal) - unit Printer Console - unit Marshalling Cabinet (double access/door) - unit Marshalling Cabinet (single access/door) - unit Power Distribution Panel - unit Junction Box - unit

4.4.1.2 PA Plant Operator Workstation with dual monitor 1 unit

2


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Engineering Workstation 1 unit Workstation Console 2 unit Alarm Printer (dot matrix, or equal ) 1 unit Report Printer A3 (DeskJet Color or equal) 1 unit Printer Console 2 unit Marshalling Cabinet (double access/door) 2 unit Marshalling Cabinet (single access/door) 4 unit Power Distribution Panel 2 unit Junction Box 4 unit

4.4.1.3 Cement Retarder Operator Workstation with dual monitor 1 unit Engineering Workstation 1 unit Workstation Console 2 unit Alarm Printer (dot matrix, or equal ) 1 unit Report Printer A3 (DeskJet Color or equal) 1 unit Printer Console 2 unit Marshalling Cabinet (double access/door) 1 unit Marshalling Cabinet (single access/door) 4 unit Power Distribution Panel 2 unit Junction Box 4 unit

4.4.1.4 Purification Plant Operator Workstation with dual monitor 1 unit Operator Workstation with single monitor 1 unit Workstation Console 2 unit Alarm Printer (dot matrix, or equal ) 1 unit Report Printer A3 (DeskJet Color or equal) 1 unit

1

2

1

2

1

2

3


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Printer Console 2 unit Marshalling Cabinet (single access/door) 4 unit Power Distribution Panel 2 unit Junction Box 4 unit

4.4.2 The size of marshalling cabinet is 2200 (H) X 800 (W) X 880 (D) andhave double and single access windows.

4.4.3 Control Room layout as shown in CCR Layout no: 34-I-32-04-2000-01.

4.5 Specifications4.5.1 The Industrial PC must be prepared with the following minimum

specification:

4.5.1.1 Rugged enclosure designs with high electromagneticcompatibility (EMC) and degrees of protection up to IP 55 /

NEMA 4.

4.5.1.2 The processor must be at least Dual Quad CoreIntel Xeon Processor X5677, 3.46 GHz 12M L3, 6.4 GT/s.

4.5.1.3 Windows operating system must be Genuine Windows 7Ultimate, 32 bit with the latest SP or the latest technology.

4.5.1.4 The dual hard drives must be installed with each capacity600 GB SAS 3.0 Gb/s, 3.5 inch, 15 K RPM.

4.5.1.5 Random Access Memory (RAM) shall be DDR3, 1333 MHz,ECC (4 DIMM), capacity 2 x 4 GB system memories.

4.5.1.6 Communication network from/to PAC must be redundant.4.5.1.7 Expandability with cards must be 1 x PCI and 1 x PCI

Expressx4. T


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4.5.1.8 The graphic card must have minimum 1 GB NVDIA Quadro,with dual monitor, 2 DP and 1 DVI.

4.5.1.9 As Optical drive must be provided DVD +/-R/RW.4.5.1.10 Optical Mouse and Keyboard must be provided with USB

connection.

4.5.1.11 Engineering tool for develop program and reinstallation mustbe provided.

4.6

Engineering and Maintenance Tool

4.6.1 The 1 (one) licenses for each plant (hart key/dongle (if any) andSerial Number) for engineer and maintenance to configure program,

process parameters, system data, download, upload and etc to the

MMI and PAC must be provided.

4.6.2 Maintenance tool must be engineering specification. They must haveserial port RS-232C and parallel port LPT.

4.6.3 Communication Cable and connector must be included.5. TEST AND INSPECTIONS

5.1 General5.1.1 The entire instrumentation must be tested and/or calibrated prior to

the installation.

5.1.2 All electronic components and circuit board must be tested andburned-in before installation into electronic assemblies.

5.2 Shop Test5.2.1 The PAC vendor must perform a complete system functional test

before advising the purchaser that the system is available for

witnessed testing.

1


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7. COMMISSIONING SPARE PARTS7.1 PAC (Programmable Automation Controller)

7.1.1 The contractor must provide commissioning spare part for each plantas follows:

1 (one) module for each I/O PAC module type. 20 % (twenty percent) of installed Buffer Relays. Ink for each printer and color. Paper (A4 dan A3 Size).

8. SYSTEM CONFIGURATION PA PLANT


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9. SYSTEM CONFIGURATION CR PLANT

3

Purifikasi Plant is

outside of battery

limit project

General Spec PAC

Documents

Transcript of General Spec PAC