KUWAIT OIL COMPANY (K.S.C.)

STANDARDS PUBLICATION

KOC STANDARD

FOR

INSTRUMENTATION AND CONTROL SYSTEM DESIGN

I DOC. NO. KOC-1-001

STANDARDS DlViSlON

ISSLllNG AUTHORITY:

STANDARDS DIVISION

KOC STANDARD

FOR

INSTRUMENTATION AND CONTROL SYSTEM DESIGN

TABLE OF CONTENTS

PAGE NO.

FOREWORD 5

1 .O SCOPE 6

3 .O TERMINOLOGY 6

1 4.0 REFERENCE CODES & STANDARDS 9 9 5.0 ENVIRONMENTAL CONDITIONS HEALTH SAFETY AND ENVIRONMENT 11

1 7.0 SERVICE CONDITIONS 7.1 Control Room Conditions 7.2 Area Classification 7.3 Corrosive Services

I 8 .O BASIC ENGINEERING INFORMATION 1 3 8.1 Units and Scales 8.2 Instrument Identification

I 9.0 DESIGN REQUIREMENTS 1 4

9.1 General 9.2 Control System 9.3 DCS 9.4 SCADA System 9.5 Shutdown and Logic System 9.6 Fire and Gas System 9.7 Packaged Equipment 9.8 Field Equipment 9.9 lnstrument Cables 9.10 Instrument / Electrical Interface 9.1 1 Control Building 9.1 2 Utilities 9.13 HVAC System for Contrd/Auxiliary Rooms 9.14 Earthing and Bonding

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PY $ 1 '

9.1 5 Electromagnetic Compatibility and Radio krequency Interference (RFI)

9.16 Equipment in Hazardous Area 9.17 Hazardous Area Certification

11.0 QUALITY ASSURANCE

12.0 DOCUMENTATION

12.1 Scope of Documentation 12.2 Document Categories 12.3 Document Details

13.0 SPARE PARTS AND MAINTENANCE REQUIRE~~ENTS

13.1 General 13.2 Construction Spares 13.3 Commissioning Spares 13.4 Operating Spares 13.5 Insurance Spares

ACKNOWLEDGEMENT

DOC. NO. KOC-1-001 REV. 1

FOREWORD

This document "KOC Standard for Instrumentation and Control System Design" (KOC- 1-001) is intended to provide an overview of the system requirements and design basis for instrumentation and control system to be installed at KOC facilities in Kuwait.

This Standard has been approved by the Standards Technical Committee (STC) and Standards Division for use throughout the corporate Engineering and operational functions of Kuwait Oil Company (K.S.C). This Standard has been issued by the Standards Division in order to achieve the following objectives:

. .

To provide the basic data and design basis for instrumentation and control system, for project development and equipment selection.

b) To provide technical guidance on instrumentation and control system strategy, and establish the base document for developing detailed design and projectlmaterial specifications with a view to achieve uniformity, quality, reliability and efficiency in an economical manner.

c To maintain the KOC requirements of safety and protection to plant, personnel and environment established. by KOC's Fire Regulations and HSE policies.

Feed back as well as any comments or suggestions derived from the application of this Standard at any stage of design, construction or operation are invited and should be directed to:

t Supdt. Standards Division (Chairman, Standards Technical Committee) Engineering Group, K.0.C P.O.Box-9758, Ahmadi- 61 008 State of Kuwait. Task Force responsible for the Standard

The preparation of this Standard was entrusted by Standards Technical Committee to the Task Force (TF-IIO1) comprising of the following members: -

Dr. Mohammad llyas (Standards Div.) : Team Leader Tel No.61406 Mr. A.Unnikrishnan . (Standards Div.) : Author I Member Tel No.61633 Mr. Abdulla Al-Qabandi (Maint.Dept.S&E) : Member Tel No.22005 Mr. K.Janardhanan (Gen.Proj. Div.) : Member Tel No.61289 Mr. Godfrey Saldanha (Maint. Dept.S&E) : Member Tel No.20122

1 .O SCOPE

1 .1 This Standard describes basic data and desidn requirements, for selection and installation of lnstrumentation and ~ h n t r o l Systems at the KOC facilities within Kuwait.

1.2 This . Standard also provides the and documentation requirements for lnstrumentation and

1.3 The provisions of this Standard shall applh to all areas of major and ancillary plant, proprietary equipment and "packaged units" unless otherwise agreed by KOC.

2.0 APPLICATION

2.1 The design, performance, inspection and and Control Systems shall comply with all the requirements specified in this Standard and the reference standards / herein.

2.2 Any exceptions or deviations from this standard, along with their merits and I justifications, shall be brought to the attention of KOC's Controlling I Department for their review, consideration and amendment by Standards Division (if required).

2.3 Compliance with this KOC Standard does not bf itself confer immunity from legal or statutory obligations.

3 .O TERMINOLOGY

3.1 Definitions

I For the purposes of this Standard , the followin& definitions apply. 1 3.1 .1 Compatible Equipment

I Equipment that interfaces with other equipdent as manufactured without I requiring any field modification, for providing thei intended functionality . 1 3.1.2 Configurable System 1 I

3.1.3 Electromagnetic Compatibility

The capacity of the system to allow the user to 6 elect from pre- programmed

The ability of equipment to function satisfactorily in its electromagnetic environment without introducing intolerable distJrbances to that environment

functions (Modular software units), those which a control strategy or other complex functions, language.

I

or to other equipment. m

are necessary to accomplish without the use of computer

1 3.1.4 Galvanic lsolation I The transfer of electrical power or signal from one circuit to another by means that do not include direct electrical connection.

( 3.1 -5 Protocol Data packaging and transmitting / receiving guidelines to which the digital link must ad here.

3.1 .6 Sulphide Stress Cracking

Brittle failure by cracking under the combined action of tensile stress and corrosion in the presence of water and H,S.

3.2 Abbreviations

DCS Distributed Control System -. I DP Differential Pressure

. I DPDT Double Pole Double Throw (Switch) E/P Voltage to Pneumatic

I EM1 Electromagnetic Interference I ESD Emergency Shutdown

F&G Fire and Gas

HART Highway Addressable Remote Transducers

H2S Hydrogen Sulphide

I

HSE Health, Safety and Environment

HAZOP Hazard and Operability I

HVAC Heating, Ventilating and Air Conditioning

I I/E Current to Voltage I

I/P Current t o Pneumatic

IS Intrinsically Safe

KOC Kuwait Oil Company (K.S.C.) I I MI Mineral Insulated

MIS Management Information System

MMMS ater rials and Maintenance h/lanage'ment System

MOS Maintenance Override Switch

MOV Motor-Operated Valve

MTU Master Terminal Unit

OPC OLE (Object' Linking and ) for Process Control

OSI Open System Interconnection

?&ID Piping and Instrumentation Diagran

PLC Programmable Logic Controller

POS Process Override Switch

PPM Parts Per Million

PVC Polyvinylchloride . I

RFI Radio Frequency Interference I I RT D Resistance Temperature Detector

RTU Remote Terminal Units

SCADA Supervisory Control and Data ~cqu fs i t i on I SSCS Sequencing and Shutdown Logic stem TIC Thermocouple

UPS Uninterruptable Power Supply 1 I VDU Visual Display Unit

Very High Frequency

Cross-linked Polyethylene

REFERENCE CODES AND STANDARDS

In the event of conflict between this Standard and the latest edition of standards1 codes referred herein, or other purchase or contractual requirements, the most stringent requirement shall apply.

List of Standards and Codes

lnstrumentation and control system shall conform in design, manufacture, performance and testing, except where otherwise specified, with the current issue and amendments of the applicable codes, standards and 01 5 series of KOC specifications, of which the following are cited in this Standard:

4.2.1 National Standards f

API RP 554 Process Instrumentation and Control

BS 4937 Part 3 0 International Thermocouple Reference Tables- Extension and Compensating Cables. Tolerances and ldentification System

BSEN 60529 Degrees of Protection Provided by Enclosures ( IP Code )

ISA S5.1 Instrumentation Symbols and Identification

NACE MR 01 75 Sulfide Stress Cracking Resistant Metallic Material for Oilfield Equipment

NFPA 72 National Fire Alarm Code

NFPA 90A Standard for the Installation of Air Conditioning and Ventilating Systems

4.2.2 KOC Standards

KOC-E-004 KOC Recommended Practice for Selection, Part-1 Installation and Maintenance of Electrical

Equipment in Hazardous Areas: General Requirements

4

Flameproof ~nc losu/e "d"

Intrinsic Safety "i"

Increased Safety "e I KOC-E-008 KOC ~ecommendeb Practice for the Design.

Selection and ~ n s t a ~ ~ d t i o n of Electric Cables. Cable Systems and Wiring

KOC Standard for hinterruptable Power Supply Systems

KOC-E-013 I KOC Standard for Motor Operated Valve Actuators

KOC Practice for Electronic

KOC-G-002 KOC Standard for H zardous Area Classification

KOC Standard fdr Packing. Marking and Documentation

KOC-G-007 KOC Standard f o r ~ a k i c Design Data I

KOC Standard for Spare Parts and Maintenance Data

I KOC Recommended Practice for shutdown System Panels

KOC Recommendedl Practice for Fire & Gas System Panels

KOC-1-011 KOC Standard for lndtrument Cables I KOC Recommended Requirements

Practice for Loss Prevention

KOC Standard for Equipment

Fire and Gas Detection

KOC-ME-018 KOC Standard for Reciprocating Compressor and Dryer for Plant and lnstrument Air Service (Factory Assembled Package Unit) KOC Standard for Painting and Coating of Metal surface-New Construction

General Specification for Air Conditioning Installation

4.2.3 01 5 Series of KOC Specification

All equipment and accessories covered by this Standard shall also comply wi th the following 01 5 Series of KOC Specification:

01 5-JH-1903 General Instruments

01 5-JH-1904 Distributed Control Systems (DCS)

I 01 5-JH-1908 Instrument Installation 01 5-JH-1909 Instrumentation for Packaged Equipment

01 5-JH-1911 Standard Auxiliary Control Room Cabinets

5.0 ENVIRONMENTAL CONDITIONS

5.1 The environmental conditions in Kuwait are severe and shall be considered carefully before selection of equipment. The equipment for outdoor installation shall be suitable for continuous operation at a desert location under high ambient temperature and humidity. The atmosphere

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shall be considered to be dusty and corrosive and may contain traces of hydrogen sulphide.

5.2 Refer t o "KOC Standard for Basic Design Data" (KOC-G-007) which provides the detailed design information regarding the environmental, site and utility supply conditions prevailing throughout the KOC Facilities.

6 .O HEALTH SAFETY AND ENVIRONMENT

All relevant safety requirements of KOC's Fire and Safety Regulations and KOC's HSE policies shall be adhered to while performing the design of lnstrumentation and Control System to be installed in KOC Facilities.

SERVICE CONDITIONS

Control Room Conditions

commissioning.

the humidity is up to 90% (non-condensing).

Area Classification

7.3 Corrosive Services

7.3.1 General

The project specification shall state whether t e equipment to be installed in a corrosive servicelarea, in which case, the 1 quipment supplied shall be suitable for operation in such services/areas wikhout any adverse effect.

7.3.2 Sulphide Stress Cracking Considerations

a) When it is specified that the presence of hydrogen sulphide (H,S) in the process fluid is exceeding the limits specified as critical within the code NACE MR0175,the contractbr shall supply equipment using materials, manufacturing methods and testing as per NACE MR0175 specification.

b) The requirements stated in clause 7.3.2 (a) above shall apply to all components that can come into contacl with the process fluid and its vapour, including remote mounted instruments and impulse lines.

L . L I -- 3 e

c) When any part of the plant falls within the requirement for materials to be specified and fabricated in accordance with the NACE MR0175, it is deemed that the H,S content in the general atmosphere over the whole plant is above allowable limits. In such cases, all the materials used throughout the fac~lity shall be in accordance with NACE MR0175.

BASIC ENGINEERING INFORMATION

Units and Scales

8.1 .I Calculations shall be made using metric units. The result shall be written in metric with the imperial conversion written in brackets alongside.

8.1.2 Data sheets and specifications shall be written in metric units with the imperial conversion shown in brackets.

8.1.3 Drawings shall be in metric units.

8.1.4 Field instruments shall be calibrated in metric units. Scales shall be dual ranged (metric and imperial) with the metric range given prominence.

8.1.5 Update points on Distributed Control System (DCS) graphics shall be in metric units. However the daily schedule reports shall be provided with dual units metric and imperial.

8.1.6 The units to be followed for various applications are shown in Appendix-1 of this Standard.

8.2 Instrument Identification

8.2.1 Tag Number System

a) Instruments shall be allocated an alphanumeric tag number uniquely identifying the instrument to the Facility equipmentlgroup and the instrument loop. The form of the tag number shall be as follows:

XXXX - YYY - ZZZ- A

Where,

XXXX = Numeric sequence identifying the Fac~lity Process equipmentlgroup.

YYY = Alpha sequence loop identification conforming to ISA S5.1

. I*.

ZZZ = Numeric instrument tag humber sequence. The tag number starts from 001 for each type of loop eg. flow, pressure, level etc. i

A = Suffix if applicable.

b) The numbering systems for the eq)Jipmentlgroups shall be in accordance with the numbering vessels, rotating machines and other equipment WID. Where the instrument is associated with an group but not mounted on an item of equipment, the first digits shall be the group designation and the remaining digits

C) Typical tag numbering system used fdr instrument identification is given below:-

ii. Pressure gauge mounted on a biping system to a separator group, the tag number is of the fdrm: 1000-PI-002.

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i. I Pressure gauge mounted on separator equipment number

8.2.2 Equipment and Site Number

XXXX-C-1011, the tag number is of the form: 101 1 -PI-001.

9 .O DESIGN REQUIREMENTS

After finalising the P&IDs and instrument lihts for the complete Facility, I KOC shall allocate for each instrument an Equipment Identification

9.1 General

Number (EIN) , and designate a Site Number be fitted with stainless steel tag plates bearing

9.1 -1 This Standard covers the instrumentation a n d control individual equipment requirements, respective subject

(SN). Each Instrument shall the allocated numbers.

9.1.2 The detailed engineering shall be carried out ih accordance with this KOC Standard to ensure that the specified requi 1 ements for instrumentation and control are provided on the finished plant.

a) Provide monitoring and control of the ~ b c i l i t ~ to meet the specified requirements for safety, product quality! throughput, efficiency and

9.1.3 The instrumentation and control system shall following areas. Any specific requirements

be designed to address the applicable to a particular

project shall be identified in the project specification: - I

b) Enable safe and convenient plant start up, uninterrupted operation and controlled shut down.

C) Provide automatic protective action where deviation of plant variables could result in a hazard to personnel or equipment.

d) Means of recording plant variables for fault diagnosis and for the prevention of unscheduled shutdown. This shall include real time information on sequence of events and plant trips.

e) Information to enable early detection of any degradation of plant or equipment due to fouling, wear or other malfunction.

f ) Means of processing and recording key information for plant operation and for plant efficiency monitoring.

g) Environmental and health monitoring systems to meet the environmental legislative requirements, which includes measurements, information processing, recording and automatic controls for any emissions to atmosphere/discharges of liquid effluents and gases.

Control System

9.2.1 Centralized Control - -

a) The Facility control and monitoring functions shall be performed using state-of-the-art DCS / SCADA as applicable, located in the control room to achieve all the functions specified.

b) All controllers, indicators, recorders shall be located in the control room except for those loops/packaged equipment, where the process philosophy demands a local controller.

C) Specialized equipment having individual computation and display capability such as packaged equipment shall be interfaced with the Facility DCS, SCADA, ESD system, F&G system, SSLS, MIS, and Long-Term Storage and Reporting Computer system as required for data transfer, alarm, trend, system reporting etc.

d) The DCS/SCADA shall be equipped with necessary hardware and software to communicate and control the "smart" field devices for all functions such as calibration, re-ranging etc.

C-.

I e) DCSISCADA shall have provision for data transfer between one I Facility to another through KOCts optical fiber networklradio link or by any other means as specified.

f 1 All control systems shall support OPC doftware.

9.2.2 Signal Types

a) The Facility shall use electronic kignal transmission unless otherwise specified.

b) The following signal levels are preferred: I. Electronic analogue signals shall be 4-20 mA, DC.

superimposed with digital signal based on HART protocol. I I ii. Digital signals shall be based on 2 4 V DC. I

iii. Signal to solenoid valves shall be 11 0 V AC.

iv. Signal to and from electrical sybtems such as motor control

C) Serial transmission among DCS, SCADA. PLC, F&G system for data transmission. status information and oderator commands t o remote intelligent devices shall be fully using industrial standard protocols. Serial signal devices shall be used only with prior approv'al from KOC.

centers, starters etc. shall be Interposing relays, if required, shall end.

v. Pneumatic signals shall be 0.2 t o

d l Serial transmission shall not form pah of basic level of automatic I control or of any automatic shutdown initiation or actuation.

by potential free contacts. be provided at the source

1 bar gauge (3 to 15 psig).

e) All field instruments shall be powe?ed from the control room interface cabinets and shall be i d trinsically safe (IS) 2-wire type with signals of 4-20 mA at 2 4 V DC supply. Power supply to Individual loop shall be galvanically is01 1 ted. The use of other types of power and signal wiring methods such be restricted to applications where it is

f ) All field signals shall be directly intekaced with DCS I SCADA. I Converters to interface such signals are permissible only where no

as 3 wire and 4 wire shall inevitable.

alternative is possible and KOC prior approval shall be taken for such applications. The location of converters shall be agreed upon I with KOC depending upon the type of application.

g) Vendor's proprietary signals and protocols shall not be used. Any such requirements if unavoidable, specific approval shall be obtained from KOC.

9.2.3 Final Control Element

a) Final control element shall be pneumatic unless otherwise specified. Control output signals shall be converted to 0.2-1.0 barg (3-15 psig) air signals by the use of I/P converters .

b) Direct-mounted E/P positioners or "smart" positioners shall be considered with prior approval from KOC.

DCS

9.3.1 The monitoring and control of process shall be carried out by a stand- alone DCS using state-of-the-art technology.'

9'.3.2 The system shall provide intelligent monitoring and control of all Facility functions, which includes but not limited to the following:

a) Regulatory control. I b) Discrete control.

C) ~ d v a n c e d control capability (as required).

d) Alarm management and event recording.

e) Graphical and schematic displays.

f) Trending of real time and historical data.

I ' . g) Communication with other devices and subsystems. I h) Data acquisition.

i) Report generation.

j 1 Data historisation.

9.3.3 The system shall provide user-friendly operator work stations for monitoring and control of the Facility.

1 9.3.4 The system shall have storage, collation and reporting of all necessary data for trending, shift/ period logging and condition monitoring.

DOC. NO. KOC-1-001 1 Page 18 of 48 1 I REV. 1 - 1

DCS shall provide a full as SCADA, ESD. SSLS, packaged F&G system, MIS, long term storage and give a complete monitoring

For details on DCS refer to 01 5 Series ot KOC Specification entitled "Distributed Control System" (01 5-JH-1904).

SCADA System

Control and data acquisition for applications s ch as well head monitoring shall be achieved usiqg a SCADA system. /I The SCADA system shall include Remote terminal Units (RTU), Master Terminal Units (MTU), transmission system (communication system) and all other peripheral equipment conforming to international standards.

I The RTU shall be directly interfaced with field devices and suitable for the ambient conditions specified.

RTU shall be located in non-hazardous locadion for ease of maintenance I unless otherwise specified. MTU shall be ' located a t the Facility with

associated peripherals.

Unless otherwise specified, the RTU shall located at a minimum distance of 70m. from the well heads to well workover operation without dismantling the RTU.

The data at the RTU shall be scanned by aster Terminal Unit through communication link at predetermined intervels and 1 or on demand as specified.

Process alarms and diagnostic alarms shall de communicated to MTU in exception report mode.

Solar powered RTU's utilising radio cornmunidation shall be considered in applications where power source is not available, approval from KOC.

Transfer of data and control signals between RTU'S and MTU shall be via

but it shall require prior

KOC's existing VHF radio trunking system, other means as applicable.

optical fiber network or by

DOC. NO. KOC-1-001

9.4.1 0 Data transmission protocols for communication between RTU&MTU shall conform with IS0 recommended OSI format and shall be compatible with KOC1s existing communication system. Full error detection 1 correction and encryption techniques shall be employed to ensure data reliability and security.

9.4.1 1 A radio signal propagation study at all, RTU sites and KOC repeater stations shall be carried out before designing the SCADA radio system to ensure a path reliability of 99.9% for each radio link. Prior approval shall be taken from KOC Telecommunication department before selecting the SCADA communication system1 protocol.

9.4.12 In the event of SCADA system being installed in a facility provided with DCSI MIS, the SCADA shall be interfaced with the DCSIMIS.

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9.5 Shutdown and Logic System

9.5.1 Types of Systems

The logic functions of the Facility shall be handled by independent SSLS and ESD systems dedicated to the following:

a) Control and sequencing logic.

b) Safety shutdown and venting service.

9.5.2 Shutdown Levels and Systems

a) The safety requirements of the Facility shall be arrived at on the basis of Process Hazard Analysis, HAZOP' studies, and a matrix produced with various levels of shutdown and venting.

b) The Emergency Shutdown System (ESD) is divided into 4 levels and shall be referred to on the P&ID and all other relevant documents as follows:

Level 1 : Plant Shutdown with Depressurisation.

Level 2: Plant Shutdown without Depressurisation.

Level 3: Production Train Shutdown.

Level 4: Local Process Element and related Shutdown.

DOC. NO. KOC-1-001 I Page 20 of 48 I REV. 1 C) Levels of shutdown 1-4 shall be acco)nplished by a high- integrity

ESD system having dedicated inputs and outputs controlling a set of ESD valves, depressurising and veni valves and interfacing with other systems to trip motors and electrical supplies to various systems as required.

d) The type of system shall be selected according to the number of Inputs and Outputs (110) involved, the level of reliability required, the economics of the various option1 and the complexity of the logic arrangements required. For details on various systems, refer to "KOC Recommended Practice for Shutdown System Panels" (KOC-1-004).

I 9.5.3 Sequencing and Shutdown Logic Requirements

a) The logic functions for control and sequencing (auto start of standby equipment, organized normal shutdown etc.) shall be indicated in graphical form on the P&ID I nd be fully developed in all respects including the operating descrip ions and functional logic.

b l These logic requirements including for lpackaged equipment (when a dedicated control system is not shall be incorporated in a common system designated and Shutdown Logic System (SSLS) or in with Clause 9.5.4 (a-iv).

C) Where a separate SSLS is specified, it s!hall be a PLC-based system I capable of controlling the startup and normal shutdown sequences of running and standby plant,.checkin$ the inhibits, providing the alarm logic and time stamping functidns and interfacing with the DCS to enable full display of all function4 and events.

d l The SSLS shall incorporate logic for kirst-up alarm of shutdown sequences. The outputs shall be relayed to the DCS for display and print functions.

e) A dedicated printer shall be provided for ISSLS and ESD Systems. f) 'There shall be no however,

repeats of selected sequencing and trip shall be conveyed to field panels to enable safe specific equipment in the field.

g) For details on SSLS, refer to "KOC hecommended Practicefor Shutdown System Panels" (KOC-1-004).

9.5.4 Location of Logic

a) The various safety and control logic functions with their location shall be depicted on the P&ID/ Cause & effect1 Logic diagram. The functions shall be allocated to various systems according to the following list of priorities:

All safety functions shall be accomplished in the ESD system without reliance on any other system.

Monitoring and regulatory control functions shall be accomplished in DCSISCADA.

iii. All manipulations requiring input to the ESD system for organized normal shutdown resulting in the closing of an ESD valve shall be conducted in the SSLS.

iv. Logic sequencing may be accomplished in the DCS or in the SSLS or combinations of these, selected on the basis of economics of the system with prior permission from KOC. However when SSLS functions are combined in DCS, care shall be taken to see that the functionality, safety, performance, and efficiency of DCSISSLS are not impaired.

b) The location of the functions shall be shown on the P&ID in accordance with the following legend:

I. - -Y DCS logic accessible to the operator. The tag identifier XXX shall be FY (for f low loop), PY (for pressure loop) etc.,

and the tag number shall be that of the instrument loop.

II. - -Y - - DCS logic not accessible to the operator. XXX

iii. USL Unit shutdown( ESD) logic visible to the operator XXX (Each related logic group shall be numbered).

iv . - USL- Unit shutdown( ESD) logic not visible to the operator. XXX

v. UCL Unit control logic (SSLS) visible to the operator XXX ( Each related logic group shall be numbered 1.

vi. -UCL- Unit control logic (SSLS) not visible to the operator. XXX

9 .

9.5.5 Process / Maintenance Override Switches

a) POS / MOS shall be hard-wired key sditches or software switches as specified in the contract docuhent to suit the project requirements.

c) For details regarding POS / MOS ,re/fer to "KOC Recommended Practice for Shutdown system Panels " (KOC-1-004).

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b) Where software switches are provided, protected.

9.6 Fire and Gas System

the same shall be password

9.6.1 The Fire and Gas (F&G) system shall be sdand-alone, with a dedicated display, and power supply system, compakible with the control and shutdown systems.

9.6.3 F&G systems supplied integrally with packag&d equipment shall interface wi th the Facility F&G system to present a single-operator interface.

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9.6.2 The F&G system shall be interfaced with interface wi th ESD system shall be hard wired.

DCS & ESD system. The

9.6.5 A microprocessor-based F&G control panel shall monitor the status of each detector and provide an audio/visual alarm output to the DCS. the F&G mimic and other alarm devices. The hystem shall include bypass

I facilities for testing and be provided with complete diagnostic facilities.

9.6.4 The F&G system shall provide zoned and kpecific point detection of I escaping flammable and toxic gases, fire or overheating, in the field,

control room. electrical room and other de?ignated areas. The system

9.6.6 The F&G control panel shall be with plug-in cdrds to accept various types I of detectors, which includes flammable 1 toxic gas, smoke, fire, flame etc.

shall be supplemented by manual call points in

9.6.7 A hard-wired mosaic-type mimic panel shall be mounted in the control room for visual indication, and there shall b e a data link or hard-wired update connection to the DCS, which shal(beconfigured to alarm the operator and enable immediate page-up of the

all the areas as specified.

9.6.8 The mimic and the DCS graphics shall represbnt a schematic plan of the facility showing the position and status of eabh detector relative to main equipment, main access ways and fire hydrante.

9.6.9 The F&G system shall have a dedicated logic system to take pre- programmed executive actions, when an emergency is detected. The operator shall also be equipped with a hard-wired interface to the protective system enabling manual initiation of all functions in case of failure of the automatic system.

9.6.10 The Facility F&G system shall have provision for auto dialing to the Fire Station and operation of foam & water deluge system in the event of F&G detection system actuation.

9.6.1 1 The system shall be supplied in accordance with the latest edition of the national Fire Alarm Code NFPA 72 and "KOC Recommended Practice for Loss Prevention Requirements" (KOC- L- 005).

9.6.1 2 For details on F&G system panels refer to "KOC Recommended Practice for Fire and Gas System Panels" KOC-1-005 and for details on fire and gas detection equipment refer to "KOC Standard For Fire and Gas Detection Equipment" (KOC-L-006).

Packaged Equipment

9.7.1 General

a) The instrumentation and control system components associated with packaged equipment shall be as far as possible from KOC approved manufacturers. The make, type and ranges shall be common and/or compatible across the complete Facility.

b) Package units which interface with the instrumentation and control system of main plant or other packaged unit, the compatibility between various equipment supplied shall be ensured to cover safety, and maintenance aspects.

c) Instruments to which process impulse lines are directly connected shall be installed in a separate panel, and shall not form a part of electrical / electronic control panels.

d) For details on instrumentation on packaged equipment refer to 01 5 Series of KOC Specification "Instrumentation for Packaged Equipment" ( 01 5-JH-1909).

e) Packaged equipment shall be provided with field instruments cabled and wired to package-mounted junction boxes, in accordance with 01 5 Series of KOC Specification entitled "Instrument Installation" (01 5-JH-1908).

r(l

9.7.2 Integration with DCS

a. All controllers, data recording and dther functions in packaged equipment shall be integrated into the main DCS. 'The only exception to this shall be where t b e equipment guarantee or performance would be affected by ady possible inadequacy in the DCS to provide special or high-speed ontrol e.g., surge control of compressors, engine management sy k tems, burner management systems etc. Such exception would reAuire KOC approval.

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C) For all controls incorporated in the DCS, including repeats from packaged. control provide details of the ranges, alarm points, data necessary for the DCS strategies shall be provided in the form diagrams.

b) In such exceptional cases as stated

9.7.3 Location of Logic

above, the packaged control

a) No logic shall be mounted in field panelk unless otherwise approved by KOC. Packaged equipment which fbr essential reasons requires start and stop sequencing by a field oberator, together with visual display of alarms etc. for the safe economical control of the equipment, shall have local lamp stations in the field, together with any of DCS alarmitrip displays. In such shall be powered from the control room.

b) All equipment shall be designed to dnable stop from the DCS, unless otherwise specified.

system shall be provided in racks/panels of the same type and I colour as the main control room equipment, and fully compatible

C) Fire pump control logic shall be field mo nted in a panel adjacent to I the pumps to maintain the necessary stand-alone integrity. I

with the selected DCS protocol for shali be presented to the DCS in such a there is no difference between the the normal instrumentation.

d) Where logic is installed in field pane s, the system used shall be I suitable for the exposed environmental conditions and direct sun temperature rise.

data exchange. Information way that in operator's view

packaged control system and

e) An emergency stop pushbutton (stayput, lockable type) shall be provided in the vicinity of the packaged equipment, and shall be hardwired to the ESD system.

f) For packaged equipment, shutdown logic shall be integrated in the main ESD and SSLS, wherever possible.

g) The packaged equipment manufacturer shall provide all necessary logic sequences for start, stop, normal running and emergency shutdown in the form of comprehensive block logic diagrams for programming into the SSLS I ESD and shall verify the logic functional test related to the equipment.

Where the equipment guarantee and performance would be affected, or the sequences are of such complexity that programming, testing and integration of packaged equipment with SSLSIESD would present .difficulties, pre-assembled, fully tested panels incorporating the logic shall be provided for mounting in the auxiliary room, subject to KOC approval. In such cases, all necessary data for the DCSISSLS shall be supplied through hard wired or serial communication links.

i) 'The emergency shutdown signal shall be hard wired and not form any part of a serial communications link. The supplied system shall have controlled and emergency shutdown on receipt of signals from the DCSISSLSIESD.

9.8 Field Equipment

6 9.8.1 General a) Instruments located in the process area shall be moisture and dust

proof, suitable for the area classification and meet the specified Iqgress Protection (IP) in accordance with BSEN 60529.

b) Field-mounted instruments shall be suitable for the maximum ambient temperature and all electronic instruments shall be provided with sunshades to protect them from direct solar radiation.

c) Instruments, junction boxes and local panels for outdoor use shall have an ingress protection rating of not less than IP65 unless otherwise specified. Sealed protective enclosures shall be provided to minimize the number of exposed moving parts such as limit switches.

d) Package units shall follow the same cbncepts for field instruments as used on the main plant.

9.8.2 Transmitters

a) All transmitters shall be "smart" type based on HART protocol using analogue signals superimposed with digital signals. Where "smart" transmitters are particular application, or the response time is not meet specific applications such as compressor conventional electronic transmitters shall be used from KOC.

b) The "smart" transmitter shall be combatible with the Facility DCS and shall be programmable for fail-safe hperation.

I l

a) Where a . pre-alarm action as a result of a change in a process variable is required, the method empoyed shall be by use of an I analogue field transmitter and a switohing action in the DCS. The I transmitter shall normally be the same one as used for the analogue control function.

(

I b) Switching action for inputs to the shutdown system shall be field process switches for pressure and level applications. For flow and temperature service, a dedicated field trlansrnitter interfacing with a

unless otherwise specified. I dedicated trip amplifier in the auxilia y room shall be provided

9.8.3 Switched Inputs I I

9.8.4 Switches

C) Separate instruments and process tadpings shall be used from control functions where a shutdown ihput is required. This input

a) Field process switches shall h a d hermetically sealed or environmentally protected cases and go~b-p~ated contacts. I

shall not be used for any function other transmitted inputs, if within the rangeab~lity

b) For ease of maintenance and to reducd inventory, all field process switches shall be DPDT type with milnimum rating of 1 10 V AC,

than shutdown service. For of the transmitter, both

Hi-Hi and Lo-Lo trips may be derived same twin-point trip amplifier.

from the same loop and the

9.8.5 Field Redundancy

Voting systems shall be installed in the following circumstances:

For increased availability where a single instrument failure can cause a shutdown of the complete Facility or portion of a plant which is critical.

ii. For increased integrity where a single instrument failure to the "safe" condition can cause a catastrophic failure of a system.

iii. For increased integrity where instruments for detection of a vital shutdown may need to be overridden for maintenance.

iv. Where an instrument is vulnerable or has an unavoidable short life element.

v. Where a failure of a single device in a unit can disrupt the down stream process.

vi. Where a breakdown of an instrument shall result in personnel safety and environmental damage.

9.8.6 The instruments/systems selected for equipment redundancy shall be depicted on the P&ID. Where voting systems are used, each instrument shall have a separate process tapping, the field cabling shall run by separate routes, and the interface systems shall be installed on separately fused circuits and shall not use the same multipoint interface or I/O card.

9.8.7 For details on other field instruments, refer to 01 5 Series of KOC Specification General Instruments (01 5-,IH-1903).

.9.9 Instrument Cables

9.9.1 General

a) Cable with stranded copper conductor shall be normally used unless otherwise specified.

b) Underground cables shall be XLPE / PVC insulated, lead sheathed, single galvanised steel wire armoured and PVC over sheathed.

C) All instrumentation cables shall have outer sheaths formed from flame retardant PVC, except for emergency shut down (ESD) and fire and gas (F&G) system, which shall be fire resistant in accordance with KOC Recommended Practice for " Design, Selection and Installation of Electric Cables, Cable Systems and Wiring" (KOC-E-008).

d) The outer sheath of fire and gas syste+ cables shall be distinctively coloured "Red" for easy identification if specifically called for in the project specification.

el Mineral Insulated (MI1 copper sheathled cables shal,l be used for above ground runs in safe or hazardous areas where mechanical strength, heat resistance and appearanke are important.

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g) Multipair cables shall be used to mAke connection between field junction box and marshaling panels.

f ) Field instruments shall be connected digital) field junction box using single

h) The multipair cable shall be of minimuh 10 pairs and there shall be I at least 50% spare capacity provided in each multipair cable.

to segregated (analog from pair cables.

j The junction boxes shall be sized big enough for ease of I maintenance and equipped with sufficient terminals for the termination of all cores of multicore dab~es. An additional 25% of terminals shall be provided in excess bf the actual requirement for future use.

k) The individual conductors, individual and common screens, conducting sheaths and armouring shall be electrically continuous throughout the cable run.

1) Individual instruments shall be cabled b 1 ck to group junction boxes. Cable laying shall comply with the jelevant clauses of the KOC Recommended Practice for "Design, Selection and Installation of Electric Cables, Cable Systems and wirihg" (KOC-E-008).

i) The outgoing multi pair cable from a shall have at least 25% additional field cabling pairs to that junction box.

I m) Correct cable separation shall be maintained in accordance with the

01 5 Series of KOC Specification entidled "Instrument Installation" (01 5-JH-1908).

junction box/control cubicle capacity over the total installed

n) For details on various types of cab~ds refer to KOC Standard for "Instrument Cables" (KOC-1-01 1).

9.9.2 Segregation of Signal Cables

a) Within a multi-core cable the condudtors carrying signals of .the same category only shall be contained. 1

b) Intrinsically safe signals may be transmitted in multicore cables, These cables, however shall contain no other type of circuits and shall be distinctively coloured in "Blue".

c) Multi-core cables of intrinsically safe circuits shall not be connected t o non 'IS' circuits. The multi-core cables, junction boxes, etc. must be dedicated to intrinsically safe circuits of the same level of

d) High integrity signals such as data transmission signals or shutdown signals should be contained in separate cables and routed separately from other signals.

9.9.3 Low Level Signal (below 5 v DC) Cables Individually screened pairs of conductors in multicore cables shall be used for low level signals from individual sensors.

9.9.4 High Level Analogue Signal (4-20mA,5-50 v DC) Cables

a) Individual circuit cables shall consist of twisted pair with tape screen.

b) Multicore cables for analogue transmission shall be with individual pair screened and overall screened.

c) The conductor size shall be adequate for maximum permitted loop resistance for the transmitters specified.

9.9.5 Digital Transmission Cables

a) Screening for cables carrying digital data transmission signals shall be as per vendor's requirement and approved by KOC.

b) Cables for switched signals from the plant shall be screened overall. A common switch signal return conductor is not permitted.

9.9.6 Shutdown Circuit Cables

a) Initiating signals for shutdown circuits may be transmitted in multicore cables. These cables shall contain no other type of circuit cables and shall be distinctively coloured.

b) Special consideration shall be given to limit voltage drop in the cable.

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9.9.7 Thermocouple Cables

a) Cables for TIC application shall hav+ single strand conductors, colour coded in accordance with BS 4937 Part 30.

I b) Thermocouple conductors shall be in ividually screened pairs. In

multicore cables , the screens shall be i 1 sulated from each other. 9.9.8 Resistance Thermometer Cables

9.10 Instrument 1 Electrical Interface

Individual resistance thermometer circuits core cables, screened overall. In multicircuit insulated f rom each other.

1 9.1 0.1 Motor Start

shall be installed using 3 or 4 cables, the screens shall be

a) The mode of motor start (Remote or ~ b c a l ) shall be decided based on the type of equipment, operational a nd safety requirements and shall be indicated on the P&ID.

b) Where field control only is called fol1 on the P&IDs, starting I stopping shall be by direct signals t o the! electrical system from field mounted startlstop stations. In such1 cases, there shall be an additional remote stop installed in the DGS.

c) The remote start for motors shall be avoided in cases where the physical presence of the operator to c h . I ck various preconditions t o

e) Where a DCS start is installed, there s also be a field startlstop station wi th a locallofflremote selector provided wi th status indication in the DCS.

ensure safe start of the equipment approval shall be taken for motors t o be facility.

d) Wherever a motor remote stop or start this shall be from the control room, screen. In such cases, startlstop sha the motor starter via SSLS.

f ) All motors shall have a dedicated stop (stay-put, lockable type) pushbutton in the connected to the electrical system with a repeat SSLS, unless otherwise specified.

is mandatory. KOC prior provided wi th remote start

is called for on the P&IDs, by the operator at the DCS I be initiated by the DCS to

DOC. NO. KOC-I401

9.10.2 lnterface Signals l a) Startlstop from the DCS shall pass through ESD or SSLS for

incorporating necessary interlocks. The interface with MCC shall be via a relay cabinet. For DCS start, a start relay shall be pulsed on for 500 msec. The Stop relay shall be maintained "on" for run.

b) The permissivelshutdown signals from SSLSI ESD shall overrule the start signal from any locations to motors.

c) The DCS signals shall not overrule electrical interlocks or test arrangements. However, the emergency stop signal shall overrule all other signals.

d) Start I Stop of all motors, including remote-controlled MOVs , shall be repeated to the event logging systems.

e) The following indications regarding the status of the motors shall be provided in the DCS graphics.

I. Available.

ii. . Tripped. .. .

111. Running.

iv. Stopped.

1 . . . 9.10.3 Interface Relay Cabinet ' Details of the interface relay cabinets are specified in 01 5 Series of KOC Specification entitled "Standard Auxiliary Control Room Cabinets" (01 5-JH-19 1 1 ). All instrumentlelectrical startlstop signals shall . pass through interposing. relays to preclude the chance of mismatched voltage connections between the systems.

9.10.4 MOVs . .-

a) Operation of MOVs shall be controlled by pushbuttons and contactors provided integral with the actuator. This shall apply .for valves whether provided for remote control duty, or for local manual shutoff duty .

b) All remote controlled MOVs shall be provided with remote valve position indicators (continuous or intermittent) as specified in P&IDl data sheet.

C) All remote controlled MOVs shall bd fitted with lo.cal/off/remote selector switches connected to thd logic and integral control system. Additional contacts on these switch positions shall be cabled into the instrument system to eAable status indication on the DCS screen.

d) For details on MOV actuators, refer to KOC Standard for " Motor Operated Valve Actuators" (KOC-E-013/.

I Control Building

9.1 1.2 The size and type of construction of the coAtro~ building shall be project specific in accordance with the relevant proje d t drawings.

9.1 1 .I The control of the process plant shall be coordinated from a centrally located control building. 'The control buil I ing shall accommodate the

9.1 1.3 The control building shall be positioned in location, and shall employ air locks and positive pressure ensure that the ingress of w.ind- blown gases, dust and Gas detection at the air inlet to the HVAC system shall belincluded in the general F&G detection system. Fire-detection elements s!hall be strategically placed within the building to give early warning of halardous incidents.

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necessary process control equipment and continuous operation of the plant.

personnel to provide safe,

I 9.1 1.4 All furnishings required for the mounting or landing of equipment shall be provided, and shall be of the same type And be compatible with the rooms, surroundings, equipment and displays. tables, report trays and other necessary ancillary to produce a fully operable system.

9.1 1.5 The cable entry to the instrumentation system be arranged via ho-llow floor of the building,

9.1 1.6 Sufficient space between panels shall be access. Where panels have doors, there shall them when they are open.

Operator's chairs, working items shall be provided

in the control building shall through sealed transits.

provided for maintenance be adequate access past

Sufficient space shall be allowed for marshaling of the incoming cables and for maintenance access. The floor /shall be constructed with removable mosaic panels to enable the efficient placement and cable access for equipment in the room.

9.1 1.7 While designing the space requirement for instrumentation, provision shall be made for 50% spare area in each room for future expansion. In respect of the allocation made for instrumentation, the control building shall be divided as follows:

a) Control room, with sufficient space for operator area, colour VDUs and keyboards, the trend and event printers and recorders, F&G and fire pumps panels, F&G mimic, and the Facility ESD panel. Provision shall be made to mount the gate security VDU and gate control panel, the package unit 'operator interface (where required), condition monitoring VDUs and telephones.

b) Auxiliary room for installation of racks for the processor, I/O, marshaling racks, interface racks, shutdown system PLC, and any other equipment required for the correct functioning and display of the Facility instrumentation. All cabinets and racks shall be of the same type, size, colour and in conformance with 01 5 Series of KOC Specification entitled "Standard Auxiliary Control Room Cabinets" (01 5-JH-1911). The cabinets shall where necessary incorporate twin redundant cooling fans and temperature alarm switches.

d) Engineering station area, which contains restricted access programming terminals for the DCS, SCADA, ESD, F&G systems etc. shall be an enclosed area (glassed) with access only to authorised personnel. Engineer station shall be provided with dedicated printer. Space shall be allocated for the portable computer/printer set used for fault diagnosis of. DCS, SCADA, ESD,

I C) Space for MMMS.

F&G system etc.

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e) A separate operator training room shall be provided, with a fully, functional simulated operator station including a dummy ESD operator' facia, a dedicated printer and a simulation computer provided' with training software.

f) A room for UPS, DC power supply units etc. for the distribution of power supplies at various voltage levels.

9.1 2.1 Instrument Power Supply

1' . a) The instrument power supplies, distribution and installation shall 1 conform to KOC Recommended Practice for " Electronic Equipment Power Supplies" (KOC-E-015).

b) The type of system and voltage requirements for various instrumentation systems shall be as s ated below unless otherwise specified:

I

ii.. Field-mounted solenoids shall Se powered by 110 V AC supply from a dedicated UPS system provided with redundant twin feeders. For details regarding UPS system refer to KOC Standard for "~hinterruptabie Power Supply Systems" (KOC-E-011).

I. Instruments shall be powered by supply system.

iii. The fire and gas 24 V DC supply system with battery bac having sufficient battery capacity for 24 hours of operation, followed by operation of the alarm system minutes. For details of F&G power supply unit refer Recommended Practice for "Fire & Gas System

a redundant 24 V DC power

In case of any special applicatiohs, where power supply requirements are different from specified in clause 9.1 2.1 (b), prior approval shall be taken from KOC.

C) Power supply units shall be sized fbr supplying 120% of the I maximum design load to cater for any anticipated future expansion

requirements.

'h d) Power supply units shall be rated to tak, into account of switching surges and the effects of harmonics and transient loads.

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e) Separate feeders shall be provided equipment is duplicated to increase availability.

f) Spare circuits ' shall be provided througl out the distribution system to permit utilization of spare capacity. i

g) A separate switched and fused sub each functional loop. Redundant switched and fused.

circuit shall be provided for equipment shall be separately

h) All circuits and sub circuits shall be cleafly identified and labeled. i ) Protective devices shall be time and

discrimination. current graded to maintain

Where dual power supplies are installed to increase availability, indication shall be provided to show failure of a single supply. In such cases it shall be possible to replace a single failed supply without reducing the availability of the equipment.

k) The power supply unit shall contain necessary isolation and auto switching and other measures to maintain the system integrity, when a fault develops at one feeder.

Sufficient information shall be provided either remotely or local to the power supply equipment to enable rapid identification of fault conditions or confirmation of healthy status.

m) Each cabinet shall be locally alarmed, when a single feeder is lost, with a common alarm to the DCS.

9.12.2 lnstrument Air

a) The quality of air supply to lnstr~~mentation and control equipment is of utmost importance since the contaminants such as water, oil or particulate matter can damage components, result in blockage of protective filters or orifices, and lead to equipment malfunction.

b) The compressed air supply to lnstrument and control system shall be dry, clean, oil free and shall comply with the following:

I. The dew point of the air anywhere in the system (measured at the distribution pressure and at the maximum air throughput) shall be atleast 10' C below the minimum specified ambient temperature.

ii. The air shall not contain dust particles larger than 3 microns.

iii. The oil content of instrument air at the normal temperature/pressure operating conditions shall not exceed 1 ppm by mass/mass.

The above permissible level of contamination in the instrument air supply system shall be further reduced to meet the specific requirements of any measurement, control and protective instrumentation equipment used in the system.

C) The lnstrument air shall be free from corrosive contaminants and hazardous gases (flammable or toxic), which may be drawn into the compressor air intake. If the possibility of contamination exists, the air should be taken from a remote or elevated clean location or should be suitably processed to avoid the contamination.

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e) The system shall be designed in such a way that each compressor can be isolated for maintenance while I h e other one is operating.

I

d l The instrument air supply shall be package units, which shall maintain

f l The output capacity of a compressor1 shall be atleast 150% of the total instrument air requirement fo 1 the entire plant including installed spareage. An additional 20%lcapacity shall be provided in excess of above requirements for future use unless otherwise specified. For details on the instrum k nt air package units, refer to KOC Standard for "Reciprocating ~ d m ~ r e s s o r and Dryer for Plant and lnstrument Air Service" (KOC-ME-018).

g) The supply pressure in the instrument a ir header shall be suitable to meet the requirements of the contrd~ system, or at least 2 bar

I above the maximum operating required by any item of instrumentation equipment. In any the normal design pressure of the instrument air system shall less than the following:

taken from the instrument air uninterrupted supply of air.

i. Normal minimum at the furthest /saint of the air header: 6.0 barg.

This shall be achieved using dual compressors, standby compressor I driven by a different source (e.g. diesel engine), or a combination

of both as specified.

h) The air supply to field mounted insdruments and valve actuators shall be through individual isolating and regulator sets with pressure gauges.

ii. Normal design at the start of the

i Panels requiring instrument air shall be provided with instrument air header, fed from 2 sets of isolating valves, filters, pressure

I reducing valves and pressure gauges installed in parallel and arranged to permit on line maintenance.

air header: ' 8.5 barg.

j 1 Instrument air dryers, filters and coaledcers shall be protected from I the effect of surge in the air supply system (e.g. on start-up of a stand-by compressor following a suddej high demand).

I k) A local control panel shall be provided adjacent to the compressor

with all necessary control' and alarm i nnunciation required for the safe operation of the system. This &hall include any abnormal deviation of key parameters within purification and distribution system .

the air supply generation,

I) The following indications regarding the status of the instrument air compressor shall be provided in the DCS graphics in the control room as a minimum for each compressor units:

iii. Fault.

iv. Tripped.

9.1 2.3. Cooling Water

No continuous cooling water supply is available at the Facility, which shall be considered while designing instrumentation and control system.

9.13 HVAC System for Control/Auxiliary Rooms

9.13.1 The control room and auxiliary rooms shall be provided with HVAC system. The load factors for system design shall include the heat load of the operating control equipment, average number of occupants etc.

9.13.2 Consideration should be given to potential problems caused by HVAC system failure. Redundant systems or alternate arrangement as approved by KOC shall be provided to prevent serious overheating of equipment.

9.1 3.3 HVAC system shall be equipped with air filters capable of removing in excess of 90% of particulates with a maximum particulate size of 0.01 micron permitted.

9.1 3.4 In areas prone to hydrogen sulphide, sulphur dioxide etc. the HVAC system shall be provided with acid gas removal system to reduce the level of such gases as specified in API RP 554.

9.13.5 The HVAC control system shall be provided with all important status indications at the DCS.

9.1 3.6 Conditioned air shall enter each zone via overhead ducts. The ducts shall incorporate fire shutoff louvers, which shall prevent the f low of air to the whole system or to specific rooms in the event of a fire. The actuation system shall be pneumatic in fail-safe mode direct from the F&G system logic, and by manual intervention.

9.1 3.7 The HVAC system shall be supplied in accordance with the NFPA 90A: "Standard for the Installation of Air Conditioning and Ventilation Systems" and KOC Standard 381103 "General Specification for Air Conditioning Installations".

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9.14 Earthing and Bonding

9.14.1 Earthing and bonding shall be provided to the instrumentation and control equipment to ensure:

a) protection of personnel and plant;

b) maintenance of signal integrity;

c) provision of signal reference point whete necessary.

9.14.2 All equipment for electronic signal transmiss~on, including enclosures and cable armouring, lead sheathing and screening, shall be properly earthed

I for personnel safety and for obtaining the maximum possible rejection of electrical interference.

9.14.3 The earthing systems shall be segregated between cable screen earthing (noise reducing requirement) and cable Armour I instrument casing earthing (electrical safety requirements).

9.15 Electromagnetic Compatibility and Radio ~ r e ~ h e n c ~ Interference (RFI) I

9.14.4 For details on types of earthing systems to 015 Series of KOC Specification entitled (01 5-JH-1908).

9.15.1 All equipment supplied shall be designed and manufactured such that under normal operating conditions, the 1 ssociated system shall be unaffected by electromagnetic disturbances likely to be encountered and shall not radiate RFI which shall affect t h normal operation of. other electronic devices.

b

and earthing materials, refer "Instrument Installation"

9.16 Equipment in Hazardous Area

9.1 5.2 The equipment shall be electromagnetically supply and all other items of the system.

9.1 6.1 When designing instrumentation and contrd~ systems to be installed in hazardous areas, i t is essential that thk following are taken into consideration:

compatible with the power

a) The zone classification of plant area.

b) The apparatus enclosure group. C) The apparatus temperature classification.

9.1 6.2 The control room interface devices shall be galvanically or optically isolated. The instrument and circuits in hazardous zones shall be of IS type. Where the circuit loading is such that IS equipment is not suitable, Ex 'd', or Ex 'e' equipment certified for the particular area classification shall be used with prior approval from KOC. Air-purged equipment and Zener barrier shall only be used with the prior approval of KOC and only when no other alternative is possible.

9.16.3 All materials and Installation methods shall meet the requirements of defined hazard classification. However, to assist in standardisation and spares holding, equipment shall be specified to meet the requirement for the worst general classification identified for a zone.

9.1 7 Hazardous Area Certification

9.17.1 All equipment to be installed in a hazardous area shall conform to the relevant parts of KOC Recommended Practice for Selection, lnstallation and Maintenance of Electrical Equipment in Hazardous Areas (KOC-E-

9.17.2 The equipment to be installed in a hazardous area shall be certified for use in those areas by a testing authority of an international recognition. The list of testing and certifying agencies acceptable to KOC are given in KOC-E-004 Part-2.

9.1 7.3 The copies of relevant certification documents shall be submitted for KOC review and approval.

10.0 PERFORMANCE REQUIREMENTS

10.1 The design, fabrication, assembly, erection and testing of all instrumentation and control system shall be well coordinated so that the complete instrument system operate and control all the process plant installed on the facility, inclusive of all data acquisition, operator aids and safety features.

10.2 All items included in the supply shall be designed, manufactured, inspected and tested under the control of a documented Quality Assurance system, the general requirements are given in clause 11.0 of this Standard.

10.3 All equipment shall be subjected to routine tests at the manufacturer's works as per relevant project specification, and standards . Any additional testing, if required, shall also be carried out as and where specified.

10.4 No equipment shall be delivered until all applicable tests have been successfully completed.

E.,

I 10.5 The documentary evidence of the test report and certification shall be submitted to KOC for acceptance1 approval.

QUALITY ASSURANCE

It shall be ensured that are operating a quality system preferably of standards to satisfy the requirements of this The manufacturer shall demonstrate compliance by providing the accredited certificate or the manufacturer's, quality of the manufacturer's quality system is normally procedure, and is therefore not detailed in the core text of this ktandard .

12.0 DOCUMENTATION

I 12.1.1 The instrumentation work shall be doqumented to cover detailed engineering, procurement, supply, installation and testing of all instruments and control systems included in tAe project.

12.1 Scope of Documentation

12.1.2 Packing, Marking and Shipping Documentadion shall comply with " KOC Standard for Packing, Marking and Documentdtion" (KOC-G-004).

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s

I 1 2.1 -3 . All correspondence, drawings, instructions, data sheets, design I calculations, or any other written information phall be in English language:.

In case of dual languages, one language shall be English. I

12.1.4 All dimensions, unit of measurement, etc. shall be in SI units unless otherwise specified.

12.1.5 The supply of Instrumentation and ~ o n t r b ~ system shall include all documents necessary to confirm:

a) that the design, equipment and installetion is of a sufficiently high I standard to meet the service conditions; I b) that the electrical and other safety anid inspection standards have

been fully complied with;

d) that sufficient information is availabl4 for the safe and effective maintenance of the Facility, including full spares information, details rsgatding replacement and lubrication1 1 caiibrarion periods and all

C) that sufficient information is supplied efficient starting, running and stopping equipment and services;

for the safe, effective and of the Facility and all its

12.1.6 A document describing the Instrumentation, control and monitoring philosophy for the project shall be submitted for KOC's approval. The document shall, as a minimum requirement, include the following information:-

a) The control strategy for the plant, including the degree of information gathering and automatic operation necessary to meet the manpower requirements and operating efficiency targets specified by KOC.

b) The location of operator and supervisor control stations and the facilities thereon, including the methods of providing, displaying and accessing plant measurements and controls, alarm handling, and routine and on-demand reports.

C) The physical distribution of main control equipment hardware and the method of data transmission between areas. This shall identify the interfaces between major system packages (e.g. distributed control system, emergency shutdown system, fire and gas system panels, programmable logic controllers, SCADA system, communications systems]. Interfaces with such equipment supplied as part of sub-contracted plant packages shall also be included.

d) Levels of protection to be incorporated into the fire and gas panellemergency shutdown systems.

e) The interconnection of instrumentation forming part of a safety system (e.g. fire and gas monitoring) with the main plant instrumentation, control and display system.

f) The interface with any external equipment (long distance radio or telecommunications system, data processing computers, MIS etc.).

g) The design basis adopted to meet hazardous area classification.

h) Where applicable, the provision of uninterruptable power supplies and the distribution to equipment.

Instrument numbering system.

12.2 Document Categories

12.2.1 The following categories of documents shall be included in the scope of deliverables:

a) Design definition for approval. b) Design verification for approval. C) Equipment definition for approval.

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d) Operating and maintenance data for a1 e) Final for construction. f) As built. g) Testing and commissioning reports. h) ~ a n u f a c t u r i n ~ records.

proval.

12.2.2. Where a document is supplied by KOC ds part of contractltender or a commercial package. the Contractor shall /egard the supplied document as the minimum requirement, to be repla ed by the Contractor's fully developed document.

i,

12.2.3 The documents , shall be presented for KOC review in the correct sequence, e.g., review of design verification or equipment definition drawings is not possible before design definihon documents are approved.

I 12.3 Document Details

12.3.1 The design definition documents shall includd the following:

Complete document index. Hazardous area classification drawing. Plot plan showing the location of all m jor items of instrumentation. P&ID. Process data for instrumentation.

1 Shutdown cause and effect diagrams for ESD,SSLS,F&G systems. Block shutdown logic.

Flow chart and ladder diagram. b DCSI SCADAI ESDI SSLSI F&G hierarc y (architecture).

Configuration block diagrams. Block cable diagram. Control room and auxiliary room layout. Fire and gas block diagram. Specimen (frame) loop diagrams and di ital input diagrams.

junction boxes and terminals. k

Loop and system wiring diagrams iden'tifying all equipment, cables,

Complete earthing arrangement block diagram.

12.3.2 The design verification calculations shall inclulde the following: l Control valves sizing and noise level. Pressure relief valves. Valve actuators. MOV motors. Orifice plates. Restriction orifice. Venturi or similar DP device. Thermowell vibration and stress. Level skexhes.

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11 DOC. NO. KOC-1-001 '1 Page 43 of 48 I REV. 1 11

I 1 IS calculations (loop verification). k) Power requirements at all levels. I) Instrument air consumption.

12.3.3 The equipment definition documents (General) shall include the following:

Material Requisitions for inquiry; lnstrument schedule. lnstrument data sheets. Multicore cable and gland schedule. Equipment schedule. Junction box schedule. Junction box diagrams. lnstrument area layout. Main tray and junction box layout. Layout of local panels. Equipment label schedules.

12.3.4 Equipment Definition Documents for DCS, SCADA, Packaged equipment, Marshaling Cabinets and Other Control Room Items shall include the following:

I10 listing. Standard cabinet arrangement. Marshaling cabinet internal and external layout. I10 cabinet internal and external layout. . Power distribution cabinet internal and external layout. Desk arrangements. Lists of chairs, trays and other minor control room items to render the system complete and operable (where applicable). Control room cable routing. Detailed control room layout. Details of F&G system , HVAC etc.

12.3.5 Approved Manufacturer's Drawings and Data shall include the following:

a) lnstrument outline and dimensional drawings. b) Connection details (process, air and electrical) C) Terminal arrangements. d) Field panel detail drawings. e) Operating and maintenance manuals, material test certificates,

NACE certification (If specified), hazardous area certification, calibration certificate etc.

12.3.6 DCSl SCADAI ESDl SSLSl F&GI Packaged equipment and other items, Approved Manufacturer's Drawings and Data shall include the following:

a) Outline drawings of all equipment. **

12.3.7 Installation Details shall include the following

b) Fully specific system architecture description, model numbers etc.

Air distribution system layout. Loop diagrams with overall index. Digital connection diagrams with overa Marshaling cabinet connection diagram Interconnection diagrams. Loop wiring diagram. Bench calibration reports. Instrument mounting/support details. Cable trenchnray details. Junction box location and terminal deti Power distribution diagram. Packaged unit interface diagrams. Proc'ess hook-ups and MTO. Pneumatic hook-ups and MTO. ~anufacturer 's installation drawings.

block diagram giving full

index.

Is.

C) Complete set of colour printed graph;c layouts showing all update points, page change patches etc. I d) Flow chart, ladder diagram and cross-reference list.

el Complete annotated set of programme nd parameter printouts. f) Detailed operating and programming m 1 nuals. g) Detailed installation and maintenance manuals, sufficiently

annotated and explained to be job speqific.

12.3.8 Shop and Field Testing t o Mechanical ~ o m ~ l e f i o n

a) Test and inspection plan. b) Test procedures and completed checkli C) Instrument calibration sheets. d) Test equipment calibration certificates. e) Loop check sheets.

ts.

12.3.9 Plant Records I a) Material certificates and NACE certifibation (as applicable) for all

instruments and final control element. b) Manufacturing Data Dossiers and Co, b struction Test Records. For

details refer to 01 5 Series of KOC Specification "General Instruments"(Ol5-JH-1903) and "lnstrbment lnstallation" (01 5-JH- 1 908). t C) Hazardous area certificates and I S loop , erification. Installation, operation and maintenalnce manuals including full Vendor input. Recommended spares list.

--- -.-

12.3.1 0 Operation and Maintenance Manuals

Operation and maintenance manuals shall be provided for all plant and equipment, including that supplied by vendors and sub-contractors. The manuals shall include a reference to the equipment tag number. The manuals shall depict the as built details of various equipment including the

a) Schedule of all instruments calibrated ranges, alarm, trip and control settings.

b) Instructions for software modifications (including system configuration) and maintenance. This shall include clear methodology for essential operations carried out with the system on-line, such as start-up of new plant connected to the system, re- calibration, hardware modifications and software modifications.

C) Power supply line diagrams showing sources of power supply and circuit protection, including individual ratings and discrimination between levels of protection.

13.0 SPARE PARTS AND MAINTENANCE REQUIREMENTS

13.1 General

This section covers the description of various categories of spare parts to be supplied. The actual scope and number of spares required shall be as per details covered in respective project specifications. For details on spare parts and maintenance data, refer to the "KOC Standard for Spare Parts and Maintenance Data " (KOC-G-009).

13.2 Construction Spares

The scope of supply shall include construction spares sufficient for the equipment to be in fully installed and operable condition. It shall be ensured that all necessary construction spares are included in the base supply quantities to account for underestimates and losses and breakage during construction.

13.3 Commissioning Spares

Commissioning spares shall include the following:

a. Those items which may normally require replacement during commissioning (such as gaskets and seals after equipment first-run checks).

a -C 3

b. Commonly used parts such as fuses, I mps, fittings, terminals etc. which might reasonably be expected require replacement during fault-finding and rectification.

c. ltems that are susceptible to ak occasional failure from construction damage or manufacturi g error such as, solenoid coils, airsets etc. t

13.4 Operating Spares

a. Those items having an expected lifd of two years or less, or required to be replaced during normal maintenance of an item / system. I

b. A percentage of large quantity items where a failure of one or more items could result from use for two yeais or less.

I

The following operating spares required for included in the scope of supply:

c. ltems where a movement towardA the failure mode is not recognizable under normal maintenan e reviews, requiring instant replacement to maintain the plant running condition, e.g., pressure gauges.

two years operation shall be

d. Consumables such as sample gases, chbrt paper etc.

13.5 Insurance Spares

Insurance spares are those items with an extended expected life, but the I delivery time of which could cause serious plant shutdown delays if a I failure occurred, e.g., controller card, control valve. I

DOC. NO. KOC-1-001 1 Page 47 of 4 8 1 REV. 1

14.0 APPENDIX- I

UNITS TO BE USED

(MSCFD or SCFM)

Temperature Deg. C Deg C , Deg C Deg C Deg C (Deg F) (Deg F)

Pressure bar a bar a (psi a) bar g or bar g or bar g or mm WG mm WG mm WG (psi g or ins WG)

Differential bar d bar d (psi d) bar d or mm bar d or mm bar d or mm WG d pressure WG d WG d (psi d or Ins WG d)

. .

Viscosity cP . CP Length mm mm (ins) Heat duty MM MM kcal/hr

.kcaVhr (MMBtuJhr) Power kW kW (hP) Density . . kg/m3 kg/m3 (lblft7-

ACKNOWLEDGEMENT 1 I I This Standard has been approved by the Standards Technical Committee ( STC ) consisting of the following :-

I I Mr. Ali l-I. Baba Mr. Jassem Al- Quraini Mr. Mohd. Emam Mr. S. Kumar Dr. Mohammad llyas Mr. Khalid S. AI-Ali Mr. Henry S. Hill

( Standards Div.) ( Design Div. ) ( Insp.& Corr. Div.) ( Standards Div.) ( Standards Div.) ( Gen.Proj. Div.) ( Maint. Plng. Div.)

Chairman Member Deputy Chairman Secretary1 Member Member Member

1 Member The draft of this Standard has been circulated to the User Departments for their review and responses were received from the following :

ENGINEERING GROUP PROD.& EXPORT OPNS. GROUP I

Gen. Supdt. Engg. Services Gen. Supdt. Proi. Mgmt ( N&W )

dt. Prod. Services dt. Prod. Opns.( N&W

Gen. Supdt. Proj. Mgmt ( S&E ) Gen. ~ u b d t . Mar.& Export Opn.

MAJOR PROJECTS GROUP L o s s P L v E r u l o N GROUP

Gen. Supdt. Engg. Projects ( N&E ) Gen. Supdt. Insp.& Corrosion Gen. ~ u b d t . Fire & HSE

MAINTENANCE GROUP INDUST~IAL SERVICES GROUP I I

Gen. Supdt. Maint. Services I Gen. Su,pdt. Ahmadi Services Gen. Supdt. Maint. (N&W) Gen. ~ u b d t . Transport & Plant

This KOC Standard for "Instrumentation and Control syst&m Design" (KOC-1-001) has been prepared by the Task Force (TF-1/01) comprising of i/he following members: -

I

DRILLING OPNS. GROUP DIVIDE d , ZONE GROUP

Dr. Mohammad llyas ' Mr. A.Unnikrishnan Mr. Abdulla Al-Qabandi Mr. K.Janardhanan Mr. Godfrey Saldanha

Gen. Supdt. Drill. Engg. & Supp. Services Supdt.

(Standards Div.) : Team deader Tel No.61406 (Standards Div.) : Author / Member Tel No.61633 (Maint.Dept.S&E) : Memb d r Tel No.22005 I (Gen.Proj. Div.) : Member Tel No.61289 (Maint.Dept.S&E) Tel No.20122

Proj. Engg. & Facilities Div.