kwait security computer12

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KUWAIT OIL COMPANY K.S.C. )

Engineering Group

Specification Number

0 75-ZH-7002

Reporting Computer

Condition Monitoring Telecommunica ion

and Security System

Rev

5 AUG 9

7 MAR 93

Date

ISSUED AS KOC ENG GROUP SPEC

ISSUED FOR INVITATION TO BID

Revision BY Chkd Section PE Client



0 STANDARD SPECIFICATIONS 3

0 SERVICE C ONDITIONS 5

Sheet

20f 35

0 BASIC DESIGN REQUIREMENTS 5

1 Reporting Computer 5

2 Detailed Technical Requirements 9

3 Signal Analysis and Frequency 114 Historical Requirements 12

5 Archive Requirements 13

6 Reports 14

7 Facility Process Condition Monitoring 16

Date

5 8 94

0 CRITICAL EQUIPMENT CONDITION MONITORING 21

1 Scope of the Condition Monitoring System CMS) 21

2 Machinery To Be Monitored 21

3 Major Design Criteria 22

4 Functional Description 22

5 ManIMachine Interface 23

6 Vibration Analysis 23

7 Thermodynamic Analysis 24

8 Diagnostics 26

9 Hardware Requirements 27

Rev

1E n d n g m p

Spa catrion

0 COMMUNICATIONS 28

1 General 28

2 Voice Services 28

3 Data Services 29

4 Facility Security System 305 Interconnection Media and Interfacing 31

6 Control Room Operating Facilities 32

7 Power Supplies 32


01 5 ZH 1002

0 PERFORMANCE REQUIREMENTS 32

1 Shop Inspection and Testing 32

2 Quality Assurance and Quality Control QA and QC) 32

3 Shop Testing Component Level) 33

4 Factory Acceptance Test FAT) 33

0 PACKING MARKING AND DOCUM ENTATION 35

0 SPARE PARTS AND MAINTENA NCE REQUIREMENT 35



1.0 SCOPE

OEngineering mup

S p ~ c a ~ f f

1 1 This specification covers the design, manufacture, inspection, testing andsupply of the following systems for installation at the facility in Kuwait:

1 I Reporting computer.


15 ZH 1002

1 1 2 Process condition monitoring.

I 3 Condition monitoring of rotating machines.

Rev

1

I .4 Facility internal communication.

1 2 The above specified systems shall fully comply with all relevant contractualrequirements specified in the Scope of Work and Technical Specification ofthe Contract.

Date

5 8 94

2.0 STANDARD SPECIFICATIONS

Sheet

3 of 5

2 1 The systems shall conform in design, materials and performance, exceptwhere otherwise specified, wi th the current issue and amendments of thefollowing prevailing on the effective date of the Contract:

2 1 1 lnternational Standards

API 67 Vibration Axial Position and Bearing TemperatureMonitoring Systems

API 75 Management of Process Hazards

Standards traceable as appropriate) to the following:

IS0 International Organization of Standardization

CClTT International Telegraph and Telephone ConsultativeCommittee

CClR International Radio Consultative Committee

IEEE Institute of Electrical and Electronic Engineers

ANSI American National Standards Inst itute

2 1 2 Engineering Group Specifications

All equipment and accessories covered by this specification shallcomply with all relevant Engineering Group specifications of whichthe following are specifically referred in this specification:



Basic Design Criteria

International Codes and Standards

Shell and Tube Exchangers

lnstrument Engineering Basic Data

lnstrument Design

General Instruments

Distributed Control System

lnstrument Installation

Instrumentation for Packaged Equipment

Mechanical Completion of lnstrument Systems

Standard Auxiliary Control Room Cabinets

lnstrument Cables

Gas Turbine Driver

Reciprocating Compressor

Gas Engine Drivers

Spare Parts and Maintenance Requirements

Electrical Design Installation and Testing

Packing Marking and Documentation

Shop and Field Painting

2 2 Compliance with this specification shall not relieve the Contractor of itsresponsibility to supply equipment suited to meet the specified service

conditions and applicable regulations.

2 3 Where conflicts exist between this specification and other Drawingsstandards codes and specifications the most stringent shall be applied.

ate

5 8 94

Rev

1OnglneerfngGmup

SpeMcat On

Sheet

4 f 35

Specification N umber

01 ~ ZH IOO~



3.0 SERVICE CONDITIONS

3.1 The equipment shall be suitable for continuous operation at a desert locationunder high ambient temperatures and humidity. The atmosphere at theFacility is generally dusty and corrosive and may contain traces of hydrogensulphide.

Sheet

5 of 35

3.2 The Systems shall in all respects be suitable for continuous operation in theservice conditions stated in the Engineering Group Specification entitledBasic Design Criteria (Number 015-AH-1 001 .

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4.0BASIC DESIGN REQUIREMENTS

Rev

1


0 5-ZH-1002

The reporting computer shall be a microprocessor-based system.The system shall be compatible wi th the Facility Distributed ControlSystem (DCS) (see Figure 1).

Date

5 8 94

The reporting computer shall have the capacity to process the dataretrieved from the DCS, display the information on a dedicatedconsole and provide interface to telephone line and an interface to

a future fibreoptic link.

When selecting the size of the reporting computer, ease ofexpansion shall be taken into account. The unit shall preferablysupport the following software standards:

a. UNIX.

b. Windows.

c. OSFIMotif manlmachine interface.

d. TCPIIP networking communication.

e. SQL database interface.

Notes

1. UNIX is a registered trademark of the American Telephone andTelegraph (AT&T) multi-user, multi-session computer operatingsystem.

2. X-windows is an internationally agreed to standard for multi-session presentation on a single screen.




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Spedficatrion o ~ - Z H - I O O ~

3 Motif is the name of the open software foundation OSF)

graphical user interface GUI).

4 TCPIIP Transmission Control Protocolllnternet Protocol) is a defacto standard networking protocol suite.



Specification Numbernginewing Group

Rev Date Sheet

S c a i b n 01 ~ ZH IOO~ 1 5 8 94 7 of 35

FIGUREREPORTING COMPUTER CON DITION MON ITORING DCS INTERF CES



5. SQL (Structured Query Language) is a high-level programmingfacility.

E n g M n g Group

S p w i f W b n

6. The software standards above specify an open computer system.

The Supervisory Control and Data Acquisit ion (SCADA) system maybe provided in future as a possible communication system betweenthe Facilities and a future control centre by others.


015 ZH 1002

The Facility s DCS shall have the provision for futurecommunication. Accordingly, the Facility s Contractor shallidentify the necessary SCADA data that need to be handled by a

future SCADA system.

The LSTK Contractor shall identify optional equipment requirementfor the SCADA communication during design. The optionssuggested shall not have any cost impact to the Project.

Rev

The reporting computer unit shall have the following functions:

a. Reporting.

ate

5 8 94

b. Overall Facility performance.

Sheet

8 o f 35

c. Process condition monitoring and central managementmonitoring.

d. Data protection (data access control).

e. Ease of software expansion.

f. User-friendly operator interface.

g. Modem interface.

h. Capability to interface future fibreoptic link.

The condition monitoring system for rotating machines is describedin Section 5.0.

The communication and security services required by the Facility arespecified in Section 6.0.



Company operator. Any information requested from the systemwhich has been lost to the archiving facility shall result in the

system advising the staff as to its location the archive package tobe retrieved).

OngineeringGroup

Specificalrion

4 2 6 The reporting system shall display an open-systems architecture, inline with the recommendations and standards of CClTT and ISO,which shall enable ease of interfacing for a remote SCADA systemwith a future fibreoptic wide area network WAN).

4 2 7 The following is an overview of the requirements for performanceand process condition monitoring. This shall provide predictive

information to minimize downtime and enable management toevaluate production efficiency. This list shall be the basis ofperformance monitoring data for the Facility:


01 5 ZH 1002

a. Manifold Status: Pressures.

b. Wellhead Flowlines: P r e s s u r e s l t e r n p e r a t u r e sdownstream of RCVs).

Rev

1

c. Production Separators: Flows.Pressureslternperatures.

d. Test Separator: Flowlduration.Test tank.Pressures/temperatures/levels

Gasloil ratio and waterloil ratio.

Date

5 8 94

e. Desalter Trains:

Sheet

10 of 35

f. Gas Compression:

g. Tankage:

h. Production Export):

Flows crudelwater: templpressure).Washwater.Transformers VoltIAmp).

Salt-in-Crude and BS W.

Stages.Flows1Temperatures1PressuresHigh Pressure HP), MediumPressure MP) and Low Pressure

LP).Turbine performance.

Levels/flows/stock change.

Flows/pressures/temperatures.

Crude oil production.Condensate.



i Burn Pit andFlare System losses): Flows, flame detection.

n g l w n g GmupS p ~ ~ n

j. Fuel Gas System: Energy consumption.

k. Electrical Systems: Diesel and turbine generators.Productionlconsumption.Imported power.


0 15 ZH 1002

I Water Treatment: Analyzer oil in water.

m. Gas and Condensate: Flows.

Temperatures.Water Content.

Rev

1

4.2.8 For these systems, algorithms and rule-based interpretations of thedata gathered by the system shall be devised in order to identifyevents which shall ultimately lead to failure.

4.2.9 Condition-monitoring schemes of a stringent nature are required forcritical items of equipment see Section 5.0).

ate

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4.2.10 The reporting system is needed to verify the day-to-day operation

and to indicate process adjustments for improved Facility operation.Deterioration in performance shall be trended to enable correctiveaction to be taken or maintenance operations planned.

Sheet

11 of 35

4 3 Sianal Analvsis and Freauencv

The reporting system shall allow for trending o f up to 16 signalseither direct or derived) and provide the Facility where appropriate)

to extrapolate the trend to predict when an operator definablethreshold would be crossed. This shall allow time for corrective

action or preventative maintenance to be instigated.

The frequency of measurement shall reflect the forecast reliability ofeach item of equipment and the parameter monitored. This mayvary from 1 second to 1 hour, providing for daily, weekly andmonthly analysis. The Contractor shall state proposed scan time foreach monitor point for the Company approval.

The analysis of the signals within the system software shall includepredefined and re-configurable) algorithms and also permitinterpretations to be built up with operational experience.

Facilities shall be provided for manual input of data to allowinformation obtained from laboratory measurements or operatormeasurement to be incorporated into the database for trending andreporting. Overwrit ing of monitored values shall be permitted only



if the instrument is off-scan and derived values only with correctauthorization. All manual entry changes shall be logged as events.

At least two levels of access control shall be provided so that onlyauthorized Company personnel perform out changes to the system(data or configuration).

EngineeringGroupi; gecrirmtion

4 4 Historical Reauirements

4 4 1 Historical records shall be maintained automatically once configuredto enable display of trends.


01~ Z H I O O ~

4.4.2 The following treatment shall be applied to all information categoriesshown below and required for the history files. The data samplerates specified are typical for the purpose of report generation butmay be changed by specific reference within Section 4.7.

a. Flows and Pressures

Rev

1

Values shall be stored as 5-minute samples over the previous60 minutes.

At each hour, the average of the previous 1 2 samples shall bestored as an hourly average.

ate

5 8 94

For each variable designated for the historical file, a daily setof 24 hourly averages shall be stored, and such daily recordsshall be retained for ten days.

Sheet

120f 35

Total flows for the day, of designated variables, shall bemaintained in on-line storage (history files). This informationis required for monthly reports.

The above is to enable the operator to examine hourly values

over the past 240 hours for all designated variables, and at anytime t o examine the previous hour s readings with provision totrend hourly and 5-minute readings.

b. Temperatures and Levels

1 . Values shall be stored at 10-minute intervals over theprevious 60 minutes.

2. At each hour, an hourly average shall be computed.

3 For each temperature variable a daily set of 24 hourly averagerecords shall be held over 10 days.



c. Analysers

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Spe catbn

1. Sample rate may be greater than minutes, set by theanalyzer type. The Contractor shall advise the Company forclarification acceptance; otherwise, the values shall be storedat 5-minute intervals.

2 Designated analyzer data shall be averaged at each hour.


5 ZH 1002

3 Averaged analyzer data shall be maintained as a daily set of24 readings for the previous 10 days.

d. Run Times

Rev

1

For each designated rotating machine, a cumulative run (on) timeis calculated on a monthly basis by monitoring at 6-minuteintervals, either a digital onloff status or an analogueperformance parameter, and integrating for total runtime. Screenor print resolution shall be to one hour (rounding down if lessthan 0.5 and up if greater than or equal to 0.5). Twelve monthlyreadings shall be held to cover the previous year.

e. Alarm and Event Files

Date

5 8 94

These files shall be held for the previous 1 0 days.

Sheet

1 3 0 f 5

4 5 Archive Reauirements

The archiving system shall be non-volatile electronic media andprovide automatic transfers of information from the history recordsfor long term archiving. Operator prompts and menu-drivenguidance shall be provided to ensure successful data transfers andinformation retrieval. The objective is to be able to review past

events and plant behavior as viewed by the operator.

In the event of a system trip, the previous hour s sample data for

the associated variables shall be archived for later analyses of thetrip.

Flows and Pressures

On a regular basis, the daily values shall be transferred automaticallyto the archiving system. Playback via the reporting system shallpermit both tabular or trending access to the data, including theability to print out records.



Temperatures, Levels

Temperature values shall be stored in a similar manner to flows,pressures.

Runtimes

Monthly figures shall be stored. Runtime data shall be stored toenable generation of productivity and maintenance reports.

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SpaMeatbn

t shall be possible to produce reports at regular intervals of timeoperator definable). Access to this Facility and activation of report

generation shall be available to authorized Company personnel usinga security entry mechanism Company-configurable to three levels,and the system shall be capable of allowing the generation either toscreen or to the local printer. t is expected that future managementreports shall be electronically transferred via a Company wide AreaNetwork WAN). However, such E-mail transfers shall requirecorrect authorization to initiate.

The report generator package shall be suitable for use by operations

personnel, giving menu-driven guidance and prompting for necessaryinput report name, etc.) and provide the following capabilities:


0 15 ZH 1002

a. Facilities

The report package shall provide authorized personnel with thefollowing:

ev

1

1 Word processing ability, for the generation of memos or

report text entry.

2 Spreadsheet access, for special one-off reports which shall bepopulated by plant data either directly or indirectly via astandard report.

ate

5 8 94

3 Graphics, for the creation of graphically presented data suchas histograms, pie charts, etc.

Sheet

1 4 0 f 3 5

b. Formats

The package shall allow the creation of reports, and it shall be

possible to define standard graphics, tables, etc.), text headings,areas for free-form text, position and identification of plant data,histograms, pie charts, etc.



c. Data Population)

Englneeting Group

SpMfii abbn

1. All data shall be available for reports and shall automaticallypopulate a selected pre-defined report at generation run time.

2. Manually entered data overwritten value of an off-scan input)or off-scan data due to fault condition) shall be recognizedand marked at report generation time.


015-ZH-1002

3. The report, once generated, shall be stored as a named filefor review VDU), printing and subsequent archiving backup).

d. Report Content

Rev

1

Although the system shall be capable of allowing for thecreation of one-off reports and providing the operator withsufficient guidance to facili tate this, a number of reports shallbe predefined. These reports shall be prepared by theContractor and approved by the Company and shall bescheduled for generation at specified times but shall oftenrequire text input to clarify changes of operational status orprovide technicallmanagement information with regard to

plant performance data.

2. To allow for this text input, the system shall promptoperators andlor engineers for this requirement and shallmonitor for a conclusion to the generation of the report. Thesystem shall time-out to be defined on the Facility specificdata sheet) and automatically run print) the report if notmanually requested. Text input can, of course, be made atany time prior to the scheduled report runtime.

ate

5-8-94

3. The content and presentation of predefined reports shall beapproved by the Company and shall be configured to provide:

Sheet

15 0f 35

a. On a weekly basis, and related to items defined on theFacility specific data sheet, information for maintenancepersonnel advising on equipment status, run times,system failure, predictive life timelcycle of consumablesfiltersldryers) and warning trends of major equipment

failure.

b. On a daily and monthly basis, production performanceinformation providing manifold status and a flowbreakdown of raw fluid throughput, final crude oilproduction, gas production, export from Facility andvariation in dry crude tank stock) production losses and

energy consumed by the Facility. The monthly report



shall be a consolidation of the daily reports but shallprovide graphic representation to indicate daily

fluctuations in oillgas, production and energy consumed.

En neering Gmuppecifmtrion

c. Breakdown of production losses against objectives givingreasons for loss, action taken and possible futureprevention action for engineering and managementpersonnel. (in the future, this report may be availableover a Company WAN).

d. Test separation results for well under test.


015 ZH 1002

4.7 Facilitv Process Condition Monitorinq

The following describes the information required for performance monitoring.Although some data shall be specific for this requirement, much of it shallalso be required for real-time plant supervision and control.

Rev

1

4.7.1 Manifold Status

a. A provision shall be supplied to allow manual input for thedefinition of which wells are flowing to each production headerand which well is flowing to the test header. The entry

mechanism shall be user friendly suitable for Company operatorsand provide transparent (to the operator) confirmation withrespect to possible interconnections. Refer to inlet manifoldP IDs.

Date

5 8 94

b. Reconfiguration of possible interconnections, at a later date, shallbe easy to perform by authorized Company personnel. Thisinformation shall be subsequently used by the report facility.

Sheet

1 6 f 35

c. Each wellhead flowline, down stream of RCVs, within the

incoming manifold shall be monitored for pressure andtemperature.

d. t is possible that some incoming flowlines, current or future,carry the fluid combination of two or more wells. Provision shallbe made to highlight such flowlines (multi-well) and define thestatus of associated junction site (manual input).

4.7.2 Production Separators

Each separator with in a train shall be monitored for the f lows of gas,

oil and water as appropriate inclusive of temperatures and pressures.The gasloil and waterloil ratios shall be calculated and comparedagainst predicted results for the well(s)/separator combination.Deviation from this is an indication of a change of incoming fluid




n . . Ah3 LH I U U L

composition or of problems wi th the separator train. Refer to P IDs(production separators).

Rev

1

4 7 3 Test Separator

a. Results from each test shall be aligned with a specific well. Thisshall be achieved by manual input for wel l under test. This shallalso qualify correct preparation of any junction sites associatedwith the active test flowline of the Facility.

Date

5 8 94

b. All flows of produced water, gas (corrected for temperature andpressure) and oil shall be accumulated and used with

measurements of total fluid and oil-water interface levels (testtank) to enable accurate calculation of the gasloil and waterloilratios. This information shall be available for reports and shall bearchived. Units shall be barrels of oil and standard cubic feet ofgas.

Sheet

17 f 35

4 7 4 Desalter Trains

a. Temperature differentials shall be monitored on all heatexchangers to provide a performance indication. Units shall beOF and OC

b. Incoming wet crude to the desalter train(s) shall be heated by anindirect gas fired-heater. Gas mass flow rate shall be monitoredfor each heater and the energy input calculated using the calorificvalue of the feed gas (manual input). An energy balance shallthen be obtained by comparison against the output heat energyobtained from the mass flow of wet crude, specific heat (manualinput) and temperature differential.

c. A trend of the energy balance ratio shall be maintained.

Extrapolation of this trend shall be used to predict potentialsystem failure. (Thresholds t o be operator definable.)

d. At the first stage of separation within the desalter train, the fluidflows through an electro-static field to coalesce small waterdroplets into larger globules which assists separation. Thetransformer power shall be monitored to alert maintenancepersonnel in the event of failure.

e. Flows, pressure and temperature of input fluid and final dry crudeto storage shall be measured, but quality o f the dry crude must

be ensured. This shall be achieved by monitoring on-lineanalysers for salt in crude and bulk sediment and water BS W)on the final oil outlet.



f. General indication of desalter performance shall be assessedusing the above information and from monitoring the oillwater

interface level of the train separator vessels and the differentialpressure across mixing values.

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g. If the oil outlet quality is low, the crude oil shall be diverted tothe wet crude storage tank. Any flow to the wet crude tankshall be reported together wi th the duration of flow. This willprovide a generic indication of system malfunction, and t isexpected that other performance indicators shall pinpoint theproblem area.

Tankage


01 5 Z H 1002

Tank level shall be monitored, and changes shall be used toconfirm/support integrated oil flows both into and out of the tanksto and beyond the battery limits. Discrepancies here are used as aself test o f the monitoring system. Tank vapour flows t o the gascompressors or from the LP header shall be monitored. Tank levelshall be in feetlinches and tank stock in barrels translated from levelmeasurement with the use of the tank strapping table.

Production

Rev

1

a. Differential pressure shall be used to evaluate the condition ofthe strainers. Feed flows to each booster pump shall bemonitored to indicate the problem line in the event of productionfall-off. Vibration monitoring of the driverlpump systems isessential see Section 7.0 .

b. Flow, pressure and temperature of the oil and gas transfer linesout of the Facility shall be monitored.

ate

5 8 94

Burn Pit and Flare System

Sheet

1 8 o f 35

a. Apart from purge gas to the flares, any product diverted to aflare constitutes system error or plant upset and financial loss.Gas from separators, tanks, export gas and fuel gas shall bemeasured. Based on these measurements, the flare gas flowshall be determined for Facility upset situations. Flare line flowsshall be measured for normal production gas flows to flare.

b. Pilot burners for the burn pit and flare systems shall be monitoredby two thermocouple devices per pilot. Each flare shall beprovided wi th three pilots, and each burn pit shall use two pilots.

c. The status of the pilots shall be reported by exception. In thecase of temporary or permanent failure of any pilot, the report



shall time and date stamps each and provide outage period sincethe last report.

4.7.8 Utilities

All electric motor drivers referred to in this section are accounted forin Section 7.0.

a. Electrical Systems Generation/Consumption)

The Facility shall be provided with the capability to providestandby power (for crude oil export booster and main pumps,desalter trains and utilities) in case of power failure from thecountry's distribution system, (Ministry of Electricity andWater (MEW)) in the form of a gas-turbine or diesel-drivengenerator. There wil l be also a diesel-driven emergencygenerator of low power. (Refer to the Engineering GroupSpecification entitled Electrical Design, Installation andTesting, Number 015-PH-1901). These units will be thesubject of a defined test procedure to ensure availability.Each test shall be recorded to provide total run time, numberof startlstops and provide an audit trail to confirm correctprocedure. During operational periods of the standby

generator, this equipment shall be included within the crit icalequipment condition monitoring.

All electrical power brought into the Facility from theCountry's power distribution system shall be recorded foraccountancy purposes and production cost analysis.

Electrical power generated within the Facility shall bemonitored for energy balance (i.e., energy of fuel used by thedriver against electrical power consumed from the

generatork)

There are a number of electrical drivers for pumpingrequirements throughout the Facility. Many, but not all, shallbe monitored (status) to derive total run times and counts ofthe startlstop cycles. The most significant of these itemsbeing the booster and product pumps for the dry crude outputfrom the Facility (see Section 7.0).

b. Firewater System

This will comprise two main pumps (diesel driven) and twoelectrically driven jockey pumps. The system shall have its ow ntest procedure and shall alarm if not adhered to. Monitoring ofthis alarm is sufficient for report purposes.



c. Instrument Air

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Spedficblan

The two compressors (electric drivers) shall be monitored forflow and pressure. Dryers and filters shall be monitored bymoisture level and differential pressure respectively. Usefulremaining life of the desiccant will be by extrapolation ofmoisture level at the end of a dryer s duty cycle, and theremaining life of filters by extrapolation of differential pressure.Both reference levels (extrapolation target) shall be definable bythe Company Operator.

d. Lube Oil System


015-ZH-1002

Flows and pressures from the electrically driven pumps shall bemonitored. This information has particular significance to thecondition monitoring of the compressor and driver.

4 7 9 Facility Efficiency

Rev

1

a. The fundamental objective of the Facility is to produce crude oil.Associated gas shall not be lost to the flare. The Company shalldefine production objectives wi th respect to crude oil which shallbe used to evaluate the effectiveness of the Facility in terms of

actual production against objective and actual against Facilitycapacity. Alarm levels shall be definable by the operators.

b. All energy consumed within the Facility shall be measured toprovide accountancy of production:

ate

5-8-94

1 Kwh consumed from MEW

Sheet

20 of 35

2 Kwh produced by standby generator.

3Kwh produced by emergency generator.

4 Total fuellgas flows, temperature, pressure and calorific value(manual input) to:

a. Driver (compressors).

b. Driver (standby generator).

c. Heaters (desalter).

5 Diesel consumption.

c. A ratio of total energy consumed per tonne of crude oil producedshall be used as a performance indicator of the Facility in a

steady state condition. Variation of I- 15 of this figure shall



alarm for investigation. Variation for alarm and steady statereference shall be operator definable.

Onginewing Gmup

Specificatbn

4 7 10 Water Treatment

Separated water from within the Facility, fol lowing any oil recoveryprocess, is collected at the wastewater sump. The pollution levelshall be monitored via an oil in water analyzer prior to disposal.The level of oil in water shall be trended to the Project (byextrapolation) unacceptable, defined by operator levels, thusproviding time for corrective action.

5 0 CRITICAL EQUIPMENT CONDITION MONITORING


01 5 ZH 1002

This section covers the specific requirements of Company for condition monitoringwhere required of the rotating machinery installed in the Facilities (see Figure 1 .

ate

5 8 94

Rev

5 1 S c o ~ e f the Condition Monitorina Svstem E MS1

Sheet

21 o 35

This system shall perform on-line condition monitoring on the gasturbines, compressors, pumps and electrical drives. t shall consistof one CMS if required located at each of the Facilities and handhelddevices for off-line monitoring of pumps.

The CMS shall have the capability to perform diagnostics andefficiency (performance) calculations.

The diagnostic package shall have the capability to interpret themachine conditions and present on the operator console the resultas a diagnostic message showing the cause of the alarm. Inaddition, compressor and gas turbine efficiency deterioration shallbe monitored.

The CMS, as part of the overall control system, shall make use ofother systems as front-end data acquisition units such as, but notlimited to, Turbine Control Panel (TCP), Vibration and TemperatureMonitoring System (VMS and TMS) and Surge Control System(SCS). The CMS shall function only as a data acquisition andanalysis system. The CMS shall not control or affect any processcontrol or protection system to which it is connected.

The system shall gather static and dynamic data under steady stateand transient conditions, as well as process variable data in order tofully document machinery behavior under all operating conditions.

The CMS system shall be capable of utilizing the Company'sequipment identifiers for accessing the information and shallinterface with the existing CMMS.



5 2 Machinerv To e Monitored

Rotating machinery which requires particular focus, if part of the Facility sequipment, are:

5.2.1 Gas turbines.

5.2.2 Compressors.

5.2.3 Generators.

5.2.4 Pumps.

5.2.5 Coolertheat exchange.

5.2.6 Electrical drives.

5.2.7 Airblowers.

5.2.8 Gas engine.

5 3 Major Design Criteria

The CMS shall be designed to include the following features:

5.3.1 High reliabil ity and availability.

5.3.2 Easy to operate.

5.3.3 Modularity.

5.3.4 Easy to expand.

5 4Functional Desc ri~ tion

The system shall include real-time, on-line data acquisition.

5.4.1 Input Data (Direct)

The following types of data shall be acquired by the CMS:

a. Static data from vibration input signals.

b. Dynamic data from vibration input signals.

c. Current values from analog input signals (via DCS and TCP).

d. Gas composition (manual entry).



Specification Number Rev Da te SheetngineeringGroup

S P ~ ~ W I 015 ZH 1002 5 8 94 3 of 35

5.4.2 Interfaces with Other Systems

The CMS system shall handle real-time data from the specifiedinstrument systems through industry standard networks/protocols.

a. Distributed Control System (DCS).

b. Vibration Monitoring System (VMS).

c. Temperature Monitoring System (TMS).

d. Turbine Control Panel (TCP).

e. Surge Control Panel (SC) via TCP or DCS.

Data links from these systems shall use industry standard

transfer link and protocols.

5.5 ManIMachine Interface

The user interface shall be user friendly. This shall be achieved by the

inclusion of dynamic soft keys, full-screen menus, windows, plain language

messages and help functions, etc.

5.6 Vibration Analvsis

5.6.1 General

a. Calculations

The system shall perform all necessary calculations for

meaningful presentation of data.

b. Presentation of Data

1. The displays shall be based on vibration data from machine

steady state and transient behavior.

2. Steady state dynamic data shall be presented in Spectrum,

Orbit, Timebase, Waterfall and Acceptance region.

3. Transient dynamic data shall be presented in Cascade, Polar

and Bode formats.

5.6.2 Parameters for Analysis

The following parameters shall be available for vibration analysis:

a. Measured values.



b. DC gap voltage.

c. First X amplitude and phase.

d. Frequency components.

e. Damping coefficient.

5.6.3 Vibration Analysis Displays

The system shall have the capability to generate and transmit thefollowing displays:

a. Spectrum.

b. OrbitITimebase.

b. Timebase.

d. Cascade.

e. Polar.

f. Bode.

g. Waterfall.

h. Order tracking.

i Acceptance region.

5.7 Thermodvnamic Analvsis

5.7.1 General

The thermodynamic analysis shall produce relevant performance

data efficiency etc) for each machine train. These shall be availablein summary charts local and remote future).

5.7.2 Flexibility

a. It shall be possible to correct the performance data for bothambient conditions and operating point.

b. All calculated performance parameters, both actual andcorrected, shall be retained for trending purposes.

c. Company personnel shall be able to modify or replace the values

of any constants e.g., gas properties tables).

E@n ng mup

S p ~ ~ n

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5 8 94

Sheet

2 4 of 35


0 15 ZH 1002

Rev



5.7.3 Condition Parameters

OEn,n ng mup

Spei mtion

The fol lowing parameters shall be considered; however theContractor may propose to the Company for approval alternative oradditional performance parameters:

a. Gas Turbine


015 ZH 1002

1. Air inlet filter pressure loss.

2. Air flow.

3.

Compressor pressure ratio.

4. Compressor isentropiclpolytrophic efficiency.

5. Gas generator turbine isentropic efficiency.

6. Power turbine isentropic efficiency.

7. Gas generator power absorbed.

8. Power turbine power output.

9. Fuel gas flow.

10. Turbine overall efficiency.

Rev

1

b. Process Compressor

1. Suction pressure/temperature/f low

2. Discharge pressureltemperature.

3. Pressure ratio.

4. Polytrophic head efficiency.

ate

5 8 94

5. Isentropic head efficiency.

Sheet

25 o 35

6. Gas horsepower.

7. Recycle valve position.

8. Gas properties.

c. Air Fin CoolerIHeat Exchanger

1 Coolerlheat exchanger efficiency.



2 Temperature riselfall.

wlneering roup

S ~ ~ n

3 Pressure drops.

d. Pumps


0 5 ZH 1002

Only critical pumps and those over 50 kW to be monitored on-line:

1. Suction pressureltemperature.

Rev

2. Flow.

3 Discharge pressure.

ate

5 8 94

4 Hydraulic horsepower.

Sheet

26 of 35

5. Pump Efficiency.

e. Generator

Output kW shall be measured; however the followingparameters can be considered:

1. Voltage per phase.

2 Current.

3 Load Reactive.

4 Excitor Voltage.

5. Frequency.

6 Winding temperatures.

5 8 Diaanostics

The CMS shall contain diagnostic capability to bring attention t o conditionswhich require further analysis by an engineer.

5.8.1 Alarm Occurrence

On the occurrence of a specified alarm condition the system shall

present an alarm message on the operator console.

5.8.2 Diagnostic Message



Specification NumberE n g i n g Group

015-ZH-l OC--- ..

SpeiMmanI

a. On detection of alarm condition and acknowledgement of thealarm by the Company operator, the system will automatically

bring up a diagnostic message on the screen.

b. The diagnostic message shall relate to the cause of the alarm.The Contractor to submit the software package to Company forapproval.

5.8.3 Conditions for Alarm

a. Rate of change of trend.

b. Vibration spectrum.

Alarm message shall be generated if a vibration spectrum orcomponent exceeds a pre-set window level.

5 9 ardware Reauirements

The system shall include the fol lowing equipment:

5.9.1 Main Microcomputer

a. The main microcomputer shall be either a powerful PC orworkstation. The following hardware platforms are preferred:

1. PC: International Business Machines IBM)Personal Computer PC) Compatible.

2. Workstation: HP VAX or similar.

3. User Interface:

a. Colour monitor.

b. Keyboard.

c. Disc station.

d. Communication lnterface via Local Area Network LAN).

e. Printerlplotter.

f. Event logger.

b. The CMS console shall be located in the main control room.

1. lnterface wi th Other Systems



a. Turbine Control Panel (TCP).

Eng/ ng Group

pedfkwbn

b. DCS.

c. Vibration Monitoring System (VMS).


01 5 ZH 1002

5.9.2 Vibration Monitoring System (VMS)

See Chapter 2 and API 670.

Rev

5.9.3 Sensors

See Chapter 2 and API 670.

Date

5 8 94

6 0 COMMUNICATIONS

Sheet

28 of 35

6 1 General

6.1.1 The communications services required by the Facility shall includevoice, data communication and video connections.

6.1.2 The services detailed shall be both autonomous local services, andat the same time extension facilities of corporate systems, allowing

interconnection or interoperability between local and centrally basedsystems.

6.1.3 The communications media over which the external communicationssignal are transmitted and received is fibreoptic cable. The text thatfollows identifies some centralized interlocation services that falloutside the scope of this specification. These details of servicesprovided by others (identified herein as such) are given forinformation purposes only to aid Facility system design.

6.1 .4 All equipment, materials and services external to the Facilitycommunication are outside the scope of this specification and theContractor s scope of supply.

6 2 Voice Services

These shall provide local telephony at the Facility (and shall be capable ofproviding national and international calling options available via the Companycentral Private Automatic Branch Exchanger (PABX)), mobile radio paging, andlocal public address announcement and alarm tone broadcasting (if required).

6.2.1 Telephony

a. Local calling shall be provided by a small standalone, or PC-basedPABX. No operator shall be needed for calls between Facility

local handsets.



b. All outside calls to and from authorized handsets shall be routedvia the Company central PABX system.

c. Handsets for interior use shall be desktop type, either analogueor digital as appropriate to the system being proposed, wi th dualtone multi-frequency (DTMF) signalling having at least the currentstandard of in-built features and facilities.

d. The local exchange shall similarly feature a full range of facilitiesfor call diversion, transfer, pick-up, automatic answering (voicemail) and recorded announcement.

e. Fax and telex interfaces and messaging services shall be includedwithin the general system definition.

f. The system shall be sized to provide:

1 Thirteen interior (safe-area) handsets.

2 Four voice circuit interconnections (64Kbls).

The system shall support up to eight simultaneous calls wi th fall-back facilities to nominated extensions working from the central

PABX in case of local PABX failure.

g. The switch (PABX) and main distribution frame (MDF) shall belocated in the control building communications room with localintermediate distribution frames (IDFs) provided within all otherbuildings and externally (in Ex d enclosures) where circuitbranching and splitting is necessary.

6 3 ata Services

These shall primarily provide a means of exchanging data between localFacilities and the Company central control complex in the Ahmadi area.Secondary functionali ty is also required to provide access from the Facility tocorporate management information systems. All access to these services wil lbe via the Company fibreoptic digital network provided by others.

6 3 1 Supervisory and Management System Data Exchange

a. Data may be received from adjacent associated Facilities whichmay themselves require status or control data in return.

b. Any polling of other sites and data receipt; the polling responseto others; all data processing, local display and compilation ofdata files for transmission shall be the responsibility of thesystems defined earlier in this specification, and elsewhere in the



Engineering Group Specification enti tled Distributed ControlSystem (Number 015-JH-1904).

OEng/n ng GroupS p e M h t b n

c. The transparent interconnection of individual systems over

dedicated fibreoptic (or other) bandwidth provided by others fallsoutside the scope of this specification.

6.3.2 Security Data Exchange


01~ z H ~ o o ~

The Facility security system (described in Section 6.4 below) shalldigitally intercommunicate wi th monitoring facilities at the corporateoperational and security control centres. Links from all security

subsystems (data and video) shall be presented for interconnectionto the external circuits at the Facility MDF.

6.3.3 Other Data Services

Rev

1

a. The direct use of Company interactive data services such as, butnot limited to, E-mail, inventory stock checking and spare partsrequisitioning etc. from the Facility shall be required. These shallbe carried over broutered LAN-type multiple access bandwidth,or for more specialist systems over dedicated TDM bandwidthlinked by the fibreoptic network provided by others.

b. Terminals for accessing these systems shall be assumed to beIBM PC-compatible personal computers. System hardware andsoftware configurations (including all necessary networkinterfacing) shall be current at the time of supply. All suchterminals shall to be provided by others.

Date

5 8 94

c. A minimal LAN shall be provided within the Facility controlbuilding serving all offices, laboratories, workshops, equipmentand control rooms. This shall be either Ethernet or token-ring

type wi th bridge presentation at the MDF for interconnection tothe main bearer services provided by others.

Sheet

30 of 35

6 4 Facilitv Securitv Svstem

The Facility security system shall comprise:

6.4.1 A closed-circuit TV surveillance system (CCTV) used to provide agate entry system (GES).

a. Closed-Circuit Television (CCTV)

1. A colour camera shall be positioned by the Facility main gate,with appropriate lighting to permit 24-hourlday operation.



2. Control facilities shall be provided from the operations controlroom.

OEngi1 081JngGmupSpMcatrion

3. A video output shall be available, for the connection via thedata network to the Company corporate security controlcentre in the Ahmadi area.

b. Gate Entry Security (GES)


01 5 zH 1002

1 Access shall be manually controlled from the gatehouse or viathe CCTV system in the control room.

2Vehicular access shall be controlled by duty staff in thecontrol room on direct requests made by visitors.

ev

1

6 5 Interconnection Media and Interfacing

Sheet

5 8 94ate 3 l n 3 5

The supply of the interconnection media and its interfacing falls outside thescope of supply for this specification.

6.5.1 Media

a. Inside and local to the Facility, direct metallic-core cable may beused for Site interconnection. However, where obstacles orexcessive distance make it necessary, radio intercommunicationshall be provided. All other services wil l be connected via theCompany fibreoptic network provided by others.

b. For any system provided as part of this scope of work, theContractor shall be responsible for all link calculations used in thedetermination of signal transmission levels, antennae installationheights and spacings etc. Company geographical andtopographical detail shall be made available to the Contractor by

the Company.

6.5.2 External Link Interfacing (By Others)

a. Internode links wil l be CClTT recommendation G703 (GeneralAspects of Interfaces) compliant.

b. Patch panels shall be provided by others to enable circuittermination and service bandwidth allocation as necessary.

6.5.3 External Link Service Channel (By Others)

a. A dedicated Engineer's Order Wire and supervisory systemchannel shall be provided over all internode links.



b. Termination, test and m onitoring equipment shall be provided byothers at each node t o perm it netw ork management b y specialist

telecommunications technicians.

Engln 81Jng Gmup

SpeMcatrlon

External Link Equipment Configuration (By Others)

Ma in equipment shall be provided in ho t-standby dual configurationt o ensure con tinuity o f service d uring single failure circumstances.Alarm outputs to the network supervisory system shall alertmaintenance staff of the remedial actions required.


1 ~ ZH IOO~

Equipment Accom modation and Antenna Location

A t the Facil ity, equipment accom modation and antenna masts andmo untings shall be provided by others. The Con tractor shall detailminimum condit ions and space necessary for equ ipment operationand housing.

Rev

1

6.6 Control Room O ~ e ra t i n a acil it ies

6.6.1 The control room shall be provided w ith the fol low ingcomm unications and security systems operating facil i ties:

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5 8 94

a. Four desktop telephone handsets.

Sheet

32 of 35

b. T w o ceil ing-mounted CCTV monitor.

c. One f lush-mounted CCTV control unit.

6.6.2 For details of control room layout, refer to the Engineering GroupSpecif ication entitled Distributed Control Systems (Number 0 15-JH- 1904).

6.7 Power Sum l ies

All comm unications and security system s shall be pow ered from UPS 110

VAC or 24-DC sources supplied by others. Refer to the Engineering GroupSpec ification entitled Electrical Design, Installation and Testing (Numb er0 15-PH-1901).

7.0 PERFORMANCE REQUIREMENTS

7.1 S h o ~n s~ e c t i o n n d Te st in g

The C ontractor shall be responsible for all inspec tion and tes ting o f materialsand equipm ent prior t o delivery. N o equipment or m aterials shall be deliveredun til all applicable tests have been com pleted and all defects rectifie d and re-tested successfully. Documentary evidence shall be available for Company

revie w if requested.



7 2 Qualitv Assurance and Qualitv Control (QA and QC]

Ongindhg Group

Spe miion

All items are to be designed, manufactured, inspected and testedunder the control of a documented QAIQC system. Generalrequirements are given elsewhere in the Contract.

Special reference to inspectionltest actions within the detailedsections of this specification are additional to and shall not replaceor reduce the general QAIQC requirements stated above.


01 5 ZH 1002

The Approved Manufacturer s is specific data and model numbersshown on Project data sheets in no way relieves the Contractor of

the responsibility of providing equipment to satisfy the serviceconditions stated on the specifications and data sheets. t is theContractor s responsibility to not ify the Company o f anydisagreement with model numbers, materials or designs specified.

The Company shall be permitted to witness the ApprovedManufacturer s QAIQC systems operating on all instruments duringdesign, fabrication, assembly and testing.

Rev

1

The Contractor shall submit for Company approval minimuminspection requirements summaries for each item.

S h o ~estina (Com~onent evel)

ate

5 8 94

The Company reserves the right to witness testing or to requestadditional testing according to their requirements. The detailedrequirement shall be noted by the Company on the Contractor ssubmitted Quality (Test and Inspection) Plan.

Sheet

3 3 of 35

The Test and lnspection Plan shall detail the methods used toidentify and eradicate infant mortality, heat soak failures, faulty

component failures and shall clarify whether the tests are at item orassembly level. The schedule shall include system cables, pre-wiredassemblies and cabinet wiring, and shall as a minimum include a 2hour elevated temperature test of the completed sub-assembly.

The certificate of Works test and inspection shall not be acceptedunti l all items on the Test and lnspection Schedule are completedand signed off by the Contractor s QAIQC personnel and theCompany has witnessed tests according to its requirements.

7 4 Factorv Acce~tance est (FAT)

7 4 1 The FAT shall be performed at the Contractor s Facility where thesystem is engineered and assembled. The FAT shall not beperformed until the certificate of Works Test and inspection has

been issued.



7.4.2 The FAT shall be conducted in three stages:

a. Preliminary Functional Test

Owndng mup

SpecHalion

The preliminary full functional test conducted by the ApprovedManufacturer without the presence of the Company. Allequipment and logic shall be tested by the ApprovedManufacturer before taking the equipment forward to the nextstage of the FAT.


01 5 ZH 1002

ev

b. Heat Soak Test

Prior to the commencement of the functional testing of theCMS system, the CMS shall be subjected to a heat soak test.This test shall be conducted for a period of not less than 48

hours at an average temperature of not less than 50°C.During the test period, all the equipment shall be powered onand in the normal operational condition. All inputs andoutputs shall be driven at their maximum voltagelcurrent. Allevents/component failures shall be recorded for Companyreview. All failed components shall be replaced and notrepaired.

ate

5 8 94

2 At the Company s discretion, this test may have to berepeated if modifications are made as a result of acceptancetesting.

Sheet

34 of 35

c. Witnessed Full Functional Test

1 All 110 signals shall be simulated, and all screen functionsshall be checked for the respective display and controlfacilities. Alarm function, trending, logging and reportgeneration, system peripherals, etc., shall all be checked.

2 Redundancy (if any) and fail-over systems and systemdiagnostics shall also be checked against the requirements ofthe system functional specification.

d. Systems Communication Test

The reporting and condition monitoring computers shall betransported to the DCS Approved Manufacturer s Works andconnected to the DCS using the system bus. Full two-waycommunication and integration shall be confirmed.

e. Radio Frequency Immunity Test



1. The CMS system shall be unaffected by radio frequencyinterference and shall be tested in accordance with the

performance requirements herein described.

ongineering roup

pecirjcatrion

2 The system shall be checked for vulnerability to radiofrequency interference by running a range of functional testswhile a portable 1 W radio transmitter is operated with in thevicinity o f the cabinet. The transmitter shall be operated atthe commonly frequencies for the local Facility area. Therange of frequencies shall be agreed to with the Companyprior to the test.

3 With all cabinet doors closed, equipment shall be unaffectedwhen the transmitter is keyed at a proximity not closer than1 m. Analogue signals for alarm inputs shall be powered andtheir inputs set close to their alarm setting.


o ZH 1002

f. Site Acceptance Test

Final system acceptance will be fol lowing satisfactory installationand site acceptance as a commissioned system. Site acceptancetesting is described in the Engineering Group Specificationentitled Mechanical Completion of Instrument Systems

(Number 015-JH-1910).

Rev

1

8.0 PACKING MARKING AND DOCUM ENTATIONN

For all relevant requirements, refer to the Engineering Group Specification entitledPacking, Marking and Documentation (Number 015-UH-1001).

Date

5 8 94

9.0 SPARE PARTS AND MAINTEN ANC E REQUIREMENTS

Sheet

35 of 35

For all relevant requirements, refer to the Engineering Group Specification entitled

Spare Parts and Maintenance Requirements (Number 015-KH-1902).

kwait security computer12

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