LNG Terminal - Draft PCS [PDF]

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LNG RECEIVING TERMINAL AND REGASIFICATION FACILITY

INTEGRATED PROCESS CONTROL ANDSYSTEM SAFETY SYSTEM (ICSS) GENERAL SPECIFICATIONS

REVISION INDEX Rev

Description

No 00

Original Document

Prepared Checked Approved By By By IT

EG

Date

Dec 20, 2017

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL

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The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL

TABLE OF CONTENTS 1. INTRODUCTION.................................................................................................................................... 4 1.1Purpose.......................................................................................................................................... 4 1.2Project Overview............................................................................................................................. 4 1.3Terms and Definitions..................................................................................................................... 6 1.4CODES, STANDARDS, AND REFERENCES................................................................................7 2. ICSPCS OVERVIEW.............................................................................................................................. 8 3. SPECIFICATIONS OF BPCS............................................................................................................... 10 3.1BPCS Controllers:......................................................................................................................... 11 3.2BPCS Input / Output Sub-System.................................................................................................12 3.3Advanced Process Control (APC) Capabilities:............................................................................14 3.4BPCS Communication System:.................................................................................................... 15 4. SUPERVISORY LAYER - VISUALIZATION AND OPERATOR INTERFACE......................................16 4.1HMI/DATA servers:........................................................................................................................ 16 4.2Visualization/ HMI Application:...................................................................................................... 17 4.3Historical Data Capabilities:.......................................................................................................... 18 4.4Asset Management Capabilities:.................................................................................................. 18 5. SAFETY INSTRUMENTED SYSTEM (SIS)......................................................................................... 18 5.1SIS LOgic Solver.......................................................................................................................... 19 5.1.1 Safety Logic Solver Certification Requirements:...........................................................19 5.1.2 Required Features of SIS Logic Solver:........................................................................20 5.2TIME SYNCHRONIZATION AND SOE......................................................................................... 21 6. TERMINAL AUTOMATION SYSTEM................................................................................................... 22 7. INTERFACE WITH INTELLIGENT MOTOR CONTROL CENTRE AND POWER SYSTEMS.............23 1. INTRODUCTION.................................................................................................................................... 4 1.1Purpose.......................................................................................................................................... 4 1.2Project Overview............................................................................................................................. 4 1.3Terms and Definitions..................................................................................................................... 6 1.4CODES, STANDARDS, AND REFERENCES................................................................................7 2. ICSS OVERVIEW................................................................................................................................... 8 3. SPECIFICATIONS OF BPCS................................................................................................................. 9 3.1BPCS Controllers:......................................................................................................................... 10 3.2BPCS Input / Output Sub-System................................................................................................. 11 3.3Advanced Process Control (APC) Capabilities:............................................................................13 3.4BPCS Communication System:.................................................................................................... 14 4. SUPERVISORY LAYER - VISUALIZATION AND OPERATOR INTERFACE......................................15 4.1HMI/DATA servers:........................................................................................................................ 15 4.2Visualization/ HMI Application:...................................................................................................... 16 4.3Historical Data Capabilities:.......................................................................................................... 17 The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL 4.4Asset Management Capabilities:.................................................................................................. 17 5. SAFETY INSTRUMENTED SYSTEM (SIS)......................................................................................... 17 5.1SIS LOgic Solver.......................................................................................................................... 18 5.1.1 Safety Logic Solver Certification Requirements:...........................................................18 5.1.2 Required Features of SIS Logic Solver:........................................................................19 5.2TIME SYNCHRONIZATION AND SOE......................................................................................... 20 6. TERMINAL AUTOMATION SYSTEM................................................................................................... 21 7. INTERFACE WITH INTELLIGENT MOTOR CONTROL CENTRE.......................................................22

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL

1. INTRODUCTION 1.1 PURPOSE The purpose of this document is to define the Design Basis and establish the general specifications for the design, fabrication, and testing of the IntegratedProcess Control and Safety System (ICSS)System for the HaiLinh Limited Company’s LNG Receiving and Re-gasification Plant at PCai Mep Tank Farm Area, Vung Tau province, Vietnam. This specification is not intended to specify the complete details of design and construction and should be used in conjunction with the Control System Architecture Block Diagram. In general any necessary but not covered in this specifications should be taken care by the PCS vendor. Integrated Control and Safety System (ICSSProcess Controls )System that will be comprised of a basic process control system (BPCS),hardware and software Safety Instrumented System (SIS), and a Fire and Gas System (FGS), and other miscellaneous systems that interact with the above mentioned systems. It is the responsibility of the ICSS Supplier to supply a full and complete working system compliant with this specification. However, Compliance with the requirements of this document does not relieve SUPPLIER from any obligation to supply equipment that is safe to operate and maintain. 1.2 PROJECT OVERVIEW HaiLinh Limited Company (HL Ltd) is planning to build the LNG receiving terminal and re-gassing project, located in vacant land of CaiMep Oil product tank farm who is the Owner. LNG terminal project proposed to send out with capacity of 2.0 million metric tons LNG per year, to be able supplying natural gas for customers in CaiMep Industrial Zone and power/ fertilizer plants in near industrial zones via low pressure gas pipeline and high pressure gas pipeline. Besides, the project also is designed to supply LNG for ISO tank/ LNG tank truck at the terminal and compressed natural gas (CNG) via CNG trailers at the terminal, the capacity for each kind of users as follows: -

HP gas pipeline: 1.3 Million Metric Tons Per Year LNG truck loading: 0.6 Million Metric Tons Per Year CNG & LP gas: 0.1 Million Metric Tons per Year

Main components of the project, consists of: LNG storage tank - Number of LNG tanks in terminal: 03 LNG tanks; - Storage capacity: 220,000m3 LNG stored; - Tank type: Full containment with double LT steel walls; - Outer tank roof type: Dome roof (LT steel) with support structure; - Inner roof: Suspended deck 87,500m3 LNG tank dimension: 02 tanks - Inner tank diameter: 61.13m; - Inner tank height (T/T): 33.00m; - Outer tank diameter: 63.67m; - Outer tank height (T/T): 35.80m (incl. of shell compression ring) - 45,000m3 LNG tank dimension: 01 tanks - Inner tank diameter: 45.84m; - Inner tank height (T/T): 30.00m; - Outer tank diameter: 48.32m; The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL - Outer tank height (T/T):32.25m (incl. of shell compression ring);

Primary pump (In tank removable submerged motor pump): - LNG truck loading: 02 pumps per tank; - LNG ship loading pump: 01 pump per tank (for 87,500m3 tanks); - LNG pump for HP pipeline: 02 pumps per tank High pressure pump (Mounted vessel submerged motor pump): - - CNG loading pump: 02 pumps; - - LNG pump for HP pipeline: 04 pumps (03 [2+1] pumps for holding mode + 01 [1+0] pump for unloading mode) LNG Vaporizers: - For CNG loading: 04 Ambient Air Vaporizers W/ fan; - For HP pipeline: 02 Open Rack Vaporizers BOG compressors - 033 BOG compressors for BOG recovering via re-condenser (02 working + 01 standby); - 01 BOG compressor for BOG recovering into CNG system during unloading mode Gas metering system: - One (01) gas metering system for HP gas pipeline, design capacity of 6,25 MMSCMD. Utility systems - Firefighting system; - Fire & Gas system; - Emergency shutdown system; - Control system; - Power supply system; - Lighting system; - Lightning system; - Grounding system; - Piping system; - Instrument air system; - Plant air system; - Nitrogen system; - Infrastructure items. Unloading system The LNG terminal shall be designed to receive LNG cargo transfer from LNG carrier at maximum unloading rate of 12,000m3/h to inside terminal’s facilities within 10 - 18 hours period, the system consists of: - 03 unloading arm 16”; - 01 vapor return arm 16”; - 01 vapor return knock out drum; - 01 jetty control system

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL 1.3 TERMS AND DEFINITIONS AI

Analog Input

AIO

Analog Input and Output

AO

Analog Output

BPCS

Basic Process Control System

CCR

Central Control Room

DCS

Distributed Control System

DI

Discrete/Digital Input

DIO

Digital Input and Output

DO

Discrete/Digital Output

ESD

Emergency Shutdown System

EWS

Emergency Work Station

FGS

Fire and Gas System

FAT

Factory Acceptance Test

FF

Foundation Fieldbus

GPS

Global Positioning System

HART

Highway Addressable Remote Transducer Also, protocol to communicate with such devices

HMI

Human Machine Interface

ICSS

Integrated Control and Safety System

IO

Input/ Output

OPC

OLE for Process Control

OWS

Operator Workstation

PCS

Process Control System

PFD

Probability of Failure on Demand

MTA

Marshaling Termination Assembly

QA

Quality Assurance

RTD

Resistance Temperature Detector

SAT

Site Acceptance Test

SOE

Sequence of Events

SIL

Safety Integrity Level

SIS

Safety Instrumentation System

TMR

Triple-Modular Redundant

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL 1.4 CODES, STANDARDS, AND REFERENCES The codes, standards, and specifications of the following organizations shall be interpreted as the minimum requirements applicable to this specification. All codes, standards, and specifications referenced here are meant to be the latest edition and include latest addenda.

International Electrotechnical Commission (IEC) – – – – – – – –

IEC 60751 (1983-01) Industrial platinum resistance thermometer sensors IEC 61000-4-2 (2001-04) Electromagnetic compatibility (EMC)- Part 4-2: Testing and measurement techniques - Electrostatic discharge immunity test. IEC 61000-4-3 (2002-03) Electromagnetic compatibility (EMC) - Part 4-3 IEC 61000-4-4 (1995-01) Electromagnetic compatibility (EMC) - Part 4: Testing and measurement techniques - Electrical fast transient/burst immunity test. IEC 61158 (2000-08) Fieldbus standard for use in industrial control systems - Part 2: Physical Layer specification and service definition. IEC 61131-3 (1993-03) Programmable controllers - Part 3: Programming languages IEC 61508: Functional Safety of electrical/electronic/programmable electronic safety- related systems IEC 61511: Functional Safety, Safety Instrumented Systems for the process industry sector

National Fire Protection Association (NFPA) – NFPA 70 Underwriters Laboratories – UL 508 ISO – ISO-9001 CENELEC / ATEX ISA/ANSI S88.01 – Batch Control Part 1: Models and Terminology • DIN 40 050 / IEC 529 / VDE 0470/ EN 60529 Defines Degrees of Protection • EEMUA Publication 191 – Alarm Systems: A guide to Design, Management and Procurement

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL

2. ICSPCS OVERVIEW The LNG Terminal and the re-gasification facility will be designed with an overall facility Integrated Process Control System.and Safety System (ICSS) approach. The individual systems to be integrated will include the BPCS, the SIS, the FGS, and the packaged equipment control systems. The BPCS will be responsible for the process control functions and monitoring of the facility, including regulatory control, process-related interlocks, Human Machine Interface (HMI) and process-related reporting functions. The BPCS shall provide the sole means of process control and supervision of the Terminal from the Main Control Room. Plant BPCS design will be based on conventional hardwired I/O with HART capability and should have the capability to communicate with the packaged equipment control systems over Modbus Serial, Modbus TCP/IP, and EtherNet/IP. SIS will be responsible for the safety related functions of the facility, including all end devices for process safetyrelated interlocks and safety-related reporting functions, Operator initiated emergency shutdowns and all interlocks. The SIS Logic Solver shall have the capability of implementing Safety Instrumented Functions of up to Safety Integrity Level (SIL) 3. The SIS will be safety Logic solver based system comprising a different hardware technology than BPCS but should ideally be from the same manufacturer as BPCS. The specification of the SIS system is to be referred to the Document number –xxxxxxx. The FGS will be responsible for the detection of fire or the presence of hydrocarbon vapors outside of pressure containment. Primary elements (sensors/detectors) include fire, smoke, thermal, and combustible gas detectors. FGS will have alarm devices, interfaces to SIS and HMI consoles, and fire & gas related alarm/report functions. FGS should be based on the same hardware platform as SIS. The specification of the SIS FGS system is to be referred to the Document number –xxxxxxx. Packaged equipment control systems will be responsible for the control, operation, and machine monitoring of the associated mechanical equipment, like BOG Compressors, Vaporizer Systems, Custody Transfer Metering, Tank Gauging and Loading/unloading systems. These equipment will each have a dedicated control system with regulatory control from the BPCS. The ICSS PCS should have the capability to connect process, discrete, power, information, and safety control into one plant-wide infrastructure. Even though the ICSS will be fully integrated, Tthe essential functions of the three (3) main subsystems are mutually independent whereby single failure of one subsystem cannot affect the other subsystems. The following Systems will be controlled by the individual packaged system PLC controllers:  BOG Compressor Controls  Vaporizer System  Marine Mooring Systems  LNG Tank Gauging System  Flue Gas Heaters  Unloading Arms Packaged System  Custody Transfer/Metering System

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL

3. SPECIFICATIONS OF BPCS The Basic Process Control System (BPCS) shall use open, industry-standard networking technologies like EtherNet/IP to support and enable integration to plant systems, optimization, information, and business processes. The BPCS shall be an open architecture client/server based system. It shall be an integrated, modular, and scalable architecture of robust control hardware and software, with the ability to share data between applications. A major consideration of the BPCS shall be its modular, field expandable design allowing the system to be tailored to the Terminal process control application needs. The capability shall exist to allow for expansion of the system by the addition of hardware and/or software. The system should have ability to view remotely via Web and therefore Cybersecurity for data at rest and motion should be considered in the design. The BPCS shall use 4-20 mA and HART protocol as the platform to interface with field devices. The BPCS Control Systems Equipment will reside in the Main Control Room. All the components of the BPCS shall be located in controlled environmental room. Remote I/Os in the field are envisioned for this project but and they may be used after approval by the Owner.

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL

3.1

BPCS CONTROLLERS:

The Controller (control Processors) sub-system shall consist of microprocessor based multi-loop controllers, which will receive data from the process through the I/O sub-system, execute control functions and send output signals to the process via the I/O sub-system. The CPU shall be a self-contained unit, and will provide control program execution and support remote or local programming. This device will also supply I/O scanning and inter-controller and peripheral communication functions. The points in the regulatory control must be able to access values from and send values to other regulatory control points and data acquisition points To ensure control strategy integrity, a reliable means of controller redundancy shall be provided. Any activecontroller failure shall cause the failed controller to switch over to the redundant controller without upsetting the process or causing interruption or loss of control, within minimum possible time. During a switchover, a Scan time delay of no more than 10ms should be ensured while the Primary and Secondary controller should always remain fully synched. The BPCS Controller shall use multiple independent, asynchronous scans. These concurrent scans shall be designated for processing of input and output information, program logic, and background processing of other controller functions. Input and output devices located in the same backplane (local I/O) as the CPU will produce at the rate of the configured RPI (Requested Packet Interval), and for discrete input modules enabled for Change Of State (COS), at the time any point changes state. BPCS controller should have the capability to do regulatory controls as well as to meet the demands of highspeed applications that require scan rates of 10-20 milliseconds. All BPCS Control Processors Shall be Redundant and “hot swap” type. All system modules including the controller may be removed from the chassis or inserted in to the chassis while power is being supplied to the chassis without faulting the controller or damaging the modules. This is known as Removal and Insertion Under Power (RIUP). Alternately a software configurable option shall exist to fault the controller if required. In a single chassis system all system and signal power to the controller and support modules shall be distributed on a single backplane. No interconnecting wiring between these modules via plug-terminated jumpers shall be acceptable. BPCS Controller shall have the ability to be updated electronically to interface with new modules. Modules should be pluggable into a chassis and keyed to allow installation in only one direction. The design must prohibit upside down insertion of the modules as well as safeguard against the insertion of a module into the wrong slot or chassis via an electronic method for identifying a module. Electronic keying performs an electronic check to insure that the physical module is consistent with what was configured. The Controller modes should be able to change from the hardware keyswitch located on the Processor module itself. The CPU operating system firmware shall be contained in non-volatile memory. An option shall be possible to store both the user program and system firmware in a removable non-volatile memory for backup/restore purposes.

Load criteria of Control Processors: The system shall be designed such that, the loading criteria of Control Processors shall not exceed 50% including spare capacity. The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL 3.2

BPCS INPUT / OUTPUT SUB-SYSTEM

The input / output sub-system shall consist of I/O modules located inside the BPCS system cabinets, located in the Main Control Room. The possibility of installing remote I/O cabinets in the plant shall be reviewed during the detailed engineering stage. The input / output sub-system shall be microprocessor based and shall consist of different modules for different types of input and output signals like analog, discrete, etc. Any I/O module shall be capable of being replaced while the system is energized without causing any effects on other modules in the system. The I/O modules shall be capable of accepting the following types of inputs and outputs: - Analog inputs (4-20mA DC) (HART) - Thermocouple inputs - RTD inputs - Pulse input (frequency input, 24 VDC) - Digital inputs (dry contacts) - Digital outputs (dry contacts) - Digital outputs (wet contacts/relays) - 24 VDC input Proximity Switches

Analog Input Modules: The Analog Input module should be 08 or 16 channels and should have following features: 

     

Choice of three data formats - Analog only - Analog and HART PV - Analog and HART by channel 0…20 mA or 4…20 mA input ranges Module filter Real-time sampling Under-range and over-range detection Wire-off detection Highway addressable remote transducer (HART) communication

Apart from standard Modules, the BPCS system should also have the cards with 08 or 16 isolated, individually configurable input channels with a separate HART modem on each channel. Channel-to-channel, channel-to-backplane, and channel-to-frame ground galvanic isolation at a continuous level of 250V AC rms.

Analog Output Modules: The Analog Output module should be 04 or 08 channels and should have following features: 

     

Choice of three data formats - Analog only - Analog and HART PV - Analog and HART by channel 15-bit or 16-bit resolution Ramping and rate limiting Hold for initialization Open wire detection Clamping and limited Clamp and limit alarms

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL  Data echo Apart from the standard modules, the BPCS shallould have the option of AO cards with individually controllable output channels with an individual HART modem per channel.

Digital Input Modules: BPCS input modules should use either 8-, 16-, or 32-point densities for greater flexibility in the application. The Digital input modules will convert the AC or DC On/Off signals from field devices to appropriate logic level for use within the processor. Typical input devices should include the following: -

• Proximity switches • Limit switches • Selector switches • Float switches • Push button switches The available input modules shouldall provide isolated or non-isolated wiring options offering point to point isolation, channel to-channel isolation and no isolation options. The available I/O modules shouldall also have diagnostic features option. The BPCS should offer Time Stamping options. Dedicated Time stamp resolutions of up to 10 msec (through separate SOE modules) should be available. All BPCS inputs are should be updated asynchronously in relation to the controller’s task execution. In other words, an input may be updated in the controller at any time during the controller’s execution of the tasks it is configured to run.

Digital Output Modules: The BPCS DO Modules should have following features as minimum:    

Configurable Point-level Output States Output Data Echo Isolated and Non isolated Varieties of Output Modules Multiple Output Point Densities

Apart from these, there should be options available for followings:  Electronic Fusing  Field Power Loss Detection  Diagnostic Latch of Information  Time-scheduled Output Control

RTD Modules: The RTD input must be capable of measuring and linearizing the following type of 3 and 4 wire RTD’s  Type: PT100  Digital Accuracy: + 0.28ºC, (0.5ºF)  Resolution: Minimum 12 bits

IO Summary: IOCOUNT

DI

DO

AI

AO

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL

TOTAL

247

105

50

22

Spares: 20% spares should be considered for future expansion. Expansion space of 20% should be considered. Some Critical Digital and analog outputs shall be considered for redundancy. Note: The number of IS and non-IS will be decided during the detail engineering of the project. 3.3

ADVANCED PROCESS CONTROL (APC) CAPABILITIES:

The BPCS must have be capable of executing Advance Process Control Logic, Functions, and Commands directly at the controller level rather than in process control server application. The Controller level Model Predictive Control should have the capability to support up to five MPC applications, each with:  Up to 10 controlled variables (targeted and/or constrained measurements).  Up to 10 manipulated variables (PID instruction outputs or slave targets adjusted by MPC).  Up to 10 disturbance variables (inputs that would shift some controlled variables without proactive 

adjustments on available manipulated variables). A predictive horizon of up to 200 controller execution steps.

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL 3.4

BPCS COMMUNICATION SYSTEM:

The BPCS communication system shall consist of following networks.   

Dedicated Control Network: (Controller to I/O Chassis/Rack Communication) Dedicated Network for Package Interface Communication Dedicated Network for HMI Communication.

Control Network: The control network shall be dedicated to the BPCS. The control network shall be high performance, EtherNet/IP based, single-fault-tolerant ring network type with the following characteristics:  Media redundancy  Fast-network fault detection and reconfiguration  Resiliency of a single-fault-tolerant network  Easy implementation without more hardware requirements One Control network should be able to support up to 50 nodes, and 100 megabits/seconds speed. The network should allow to build fast recovering and fault tolerant network topologies that do not influence the controlling applications. (Recovery Time up to max of 3 milliseconds). The control Network in structure and components (Switches/media converters wherever applicable), should be deducted and not shared for any other communication purposes.

Package Interface Network: The Package Interface Network should ensure seamless integration from 3 rd Party Package systems into the plant-wide / site-wide ICSS PCS and make these packages “Plug and Play” with lowest cost of integration, visualization and control of Package data (wherever required) from the ICSS PCS.. The Package Network should support both the EtherNet/IP and Modbus TCP/IP interfaces. It should support redundancy. A dedicated switch should be included for Modbus TCP/IP network interface with the package suppliers, while the EtherNet/IP network can be integrated with the HMI layer-2 switches. The Modbus TCP/IP should have option for local and remote configuration and diagnostics through the module's Ethernet port, CIPconnect technology for bridging though BPCS EtherNet/IP network, and an on-board web server for access to module documentation and sample program files. Configurable floating point data movement should be possible, including support for Enron or Daniel floating point formats. Error codes, counters, and module status should be available from module memory through the Server, through the Client, or through the ladder logic and controller tags.

HMI Network: The HMI network should include a high availability architecture with fully redundant Layer-2 and layer 3 network switches for communication with fault Tolerant Servers for Visualization, Historization and Asset Management. The architecture should offer industrial grade network rationalizing common IT infrastructure. It should ensure redundancy of the network with no single point of failure, fault tolerance of all network component, high availability and increased reliability offering benefits of a centralized infrastructure management and scalable management of engineers, supervisors and operators. The Terminal HMI Network will utilize Redundant Star network, where every Layer 2 access switch has dual connections to a Layer 3 distribution switch. Devices, such as servers and workstations, are connected via a Dual connection by using NIC teaming. The system should support high availability by offering redundancy options at each level of the architecture in a modular and selectable way.

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL A large screen wallmounted display of minimum 56” LED monitor should be able to connect to the control system for operator viewing.

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL

4. SUPERVISORY LAYER - VISUALIZATION AND OPERATOR INTERFACE The ICSS PCS HMI must provide the main control room operators with a “single window” interface to all control and safety systems of the process facilities. The supervisory layer of the ICSS PCS will include client/server architecture with fully redundant Data/HMI servers:  Process Automation System Server (HMI, Data Server, Alarm Server, System Directory)  Real Time Historian Server  Asset Management and Disaster Recovery Server  Engineering Work Stations (01 for BPCS, 01 for SIS and FGS)  Operator Workstations (04)  Remote View only station via the Internet The HMI should follow modern visualization concept having Intuitive displays, objects and faceplates with integrated diagnostics to help streamline navigations and provide flexibility for operators to build and configure procedures. The system shall be capable of managing system security, including user and groups on a single unified administrative server. The system shall be based on hardware and software whose compatibility is managed by the manufacturer, and has public web sites to confirm compatibility of hardware & software revisions. 4.1

HMI/DATA SERVERS:

The Process Automation System Server (PASS) will host essential software components to run the Visualization /Supervisory layer. The essential software components will include the data server, HMI server, and alarm server. The total number of server machines required will be determined by the supplier depending on the system size, but as minimum one set of redundant HMI/Data Servers must be provided. Specification of the server should be adequate to avoid memory/network loading. The server must meet the recommended system requirements of the HMI applications, but as min should comply to below: Server Specifications: (Min)

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL 4.2

VISUALIZATION/ HMI APPLICATION: 

   



 

Display requirements shall include general overview, LNG Tank Monitoring, groups, point (individual loop), trend (single and multi-loop), alarm, process graphics, equipment status (Packaged PLC functions, (BOG Compressors, and diagnostics. The HMI application licenses should be based on unlimited tags and HMI screens. The application should support a very Scalable Architecture from standalone HMI stations to multiclient/multi-server system. The HMI architecture should support maximum system availability with built-in software redundancy for automatic failure detection and switchover without losing client connectivity. The application should have the capability to support Multiple users to simultaneously manage the application from anywhere on the network and easily make online changes to a running system without taking down the HMI application The application should give operators access to view and interact with alarm conditions throughout the integrated architecture with easy-to-use graphical alarm objects, System-wide diagnostics report, and route and store information about events that happened in a system and provide a system wide diagnostic solution for determining root cause of an issue. The application should support Virtualization and should have been tested and vendor statement issued on VMWare compatibility. The application should have the capability to support Mobile users and one or more View only station via Internet..

Modular Object Library  



 



The manufacturer shall provide a process library for both function blocks and their corresponding display elements Operator faceplates, compliant to ISA standards. The system shall include modular, configurable process objects developed by the manufacturer (controller functions and HMI templates) for operator control, maintenance & engineering functions. All process objects must have manufacturer supplied documentation and supported by the manufacturer’s standard technical support service. The system shall include configurable process objects developed by the manufacturer (controller functions and HMI templates) for standard procedural control, such as sequence control. All process objects must have manufacturer supplied documentation and supported by the manufacturer’s standard technical support service The system shall have pre-engineered device objects from the manufacturer displaying Ethernet network switch status and diagnostics. The system shall have pre-engineered device objects from the manufacturer displaying system controller status, HMI server status, Variable Frequency Drives control and status, soft starter control and status, and electronic overload control and status. The system shall have pre-engineered device objects from the manufacturer for integrated motor control with the capability to display motor control inhibits, faults, status information and preventative maintenance diagnostic information. Integrated motor control profiles must be available as a standard feature in the controller development environment.

Alarming Capabilities:       

The PAS shall allow users to set up a complete alarm system. The alarm system shall have the ability to monitor any analog or digital tag for alarms. The alarm system database must allow up to 10,000 analog or digital alarm tags per PAS server. The alarm system shall provide a means of displaying up to 2,000 tags that are in alarm per PAS server. This alarm summary display shall be fully configurable. In the alarm summary display, a user can acknowledge an alarm. The alarm will then appear as acknowledged to all OWSs in the application. Custom alarm summary objects shall be able to be embedded on any display The alarm system shall allow online export of an alarm log file to ODBC format databases. The alarm system shall allow the operator to write a custom message to the alarm history.

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL  Alarms can either be polled or sent by exception from the controller.  The alarming will support ISA 18.2 alarm management state model. 4.3

HISTORICAL DATA CAPABILITIES:    

4.4

The system shall be capable of adding a historical data collection, based upon industry leading OSIpi database, and be a capable of browsing for system tags with a wizard, including filter of tags. Data collection nodes will feed the PI historian and be redundant. The system shall be capable of embedding historian trends and analytic tools into the HMI. The system shall be capable of exporting historical process data to Excel for Ad Hoc reporting with the use of Excel Add Ins. ASSET MANAGEMENT CAPABILITIES:

The system shall be capable of source revision control. The system shall be capable of providing revision control, with security profiles to limit access to electronic assets and feature access within development environments.

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Check-out: Writes the selected file or folder to a local working folder with read-write access and locks the selection to prevent multiple-user editing. Check-In: Reads the local working folder and updates the source control repository, creating new versions as needed. Get: Writes the selected file or folder to the local working folder with read-only access. Note: A Get can retrieve the latest or any historical version that is in the archive. Undo Check Out: Returns the selection to an unchecked out state and unlocks the selections. The system shall be capable of system record audit trail.

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Data value changes (timers, tags, instructors, etc.) Create, delete or changing of rungs Create, delete or changing of tags User log-in/out The system shall be capable of system event tracking through system logs.

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Audits - Any changes on records such as:

o 

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Logging of events based on time and function.

Reporting - Reporting of events or audits with scheduler: Weekly program file parameter report from applicable controllers Daily operator inputs from terminals Change history report for any electronic file Disaster Recovery Provides control system backup that is integrated with source control to provide reliable and easy access to the latest control system configuration files. Calibration Management Manages calibration records and files associated with the field instruments Process Device Configuration Ability to configure field instrumentation from the engineering work station.

5. SAFETY INSTRUMENTED SYSTEM (SIS) The SIS system will include the logic solvers and I/O equipment necessary for implementation of the safety functions associated with the LNG terminal and associated facility. The SIS implementation includes configuration, provision of outputs for alarm, sequence of events, and status, as well as provision of outputs to field equipment that prevents hazards. The specification is not intended for identification of hazards or for the specific application of the SIS. The specific interlock/shutdown strategies, software implementation, and process hazard analysis methods which provide the necessary Safety Integrity Level (SIL) for each safety function will be reflected in the project P&ID’s, cause and effect diagrams, Safety Requirement Specifications (SRS) and other project specific documentation, delivered by The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL the buyer. The specification for Fire and Gas system(FGS) is similar to ESD system except programmed for energize on fail. Persons involved, departments, or organizations responsible for the specification, design, and implementation of SIS shall be competent to perform the activities for which they are accountable. Persons involved in the design, configuration, integration, testing, installation, and training of the Safety Instrumented System Logic Solvers and associated equipment shall be TUV Functional Safety Engineer certified. 5.1

SIS LOGIC SOLVER

The Logic Solver shall provide a safeguarding system for the plant and be configurable to monitor and automatically operate up to and including SIL 3 functions. The SIS Logic Solver hardware should be diverse, based on different hardware platform than the BPCS but ideally from the same manufacturer, and supported in integrated ICSS architecture. The SIS Logic Solver must offer flexibility of the design to meet different SIL levels (SIL-1, SIL-2 and up to SIL-3) in a modular way so that the system can be assembled to the scale and configuration that are applicable to initial requirements (SIL 1 and SIL 2) and can be easily changed to meet higher levels, when required. All of the configurations should readily achievable by combining modules and assemblies without using special cables or interface units. System architectures should be user configurable and can be changed without major system modifications. Processor and I/O redundancy of the SIS logic solver should be configurable to be Fault Tolerant, or Fail Safe. There is no change to the complexity of operations or programming that the controller can handle if redundancy is added. The Safety Logic Solvers should have below features as minimum: 

The SIS platform should provide a set of components that can be configured to meet a range of safety and fault tolerance user requirements within a single system such as - fault tolerant topologies 1oo1, 1oo2D and 2oo3.



The SIS Logic Solver should be IEC 61508 certified, reviewed and approved for safety systems up to SIL 3 by TÜV. The processor modules should be designed to meet the requirements for SIL 2 in a simplex configuration and SIL 3 in a dual or triplicated configuration. Individual input modules should be designed to meet the requirements for SIL 3 in simplex, dual or triple configurations.

     

Individual output modules have been designed to meet the requirements for SIL 3 in a simplex or dual configurations. The SIS Logic Solver should support SIL-3 rated communication (to be used between SIS or FGS Logic Solvers) Support SIL 2 architectures for fail-safe low demand applications. All SIL 2 architectures can be used for energize or de-energize to trip applications.



Should support SIL 3 de-energize to trip applications and SIL 3 energize to action applications (with Dual Modules)

5.1.1 Safety Logic Solver Certification Requirements: The SIS Logic Solver should carry below certifications as minimum:  IEC 61508, Part 1‐7:1998‐2000  EN 50156‐1:2004  EN 50178:1997 The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING        

5.1.2      

 

TERMINAL IEC 61511‐1:2004 NFPA 72:2007 EN 61131‐2:2007 NFPA 85:2015 EN 61326‐3‐1:2008 NFPA 86:2015 EN 61000‐6‐2:2005 EN 61000‐6‐4:2007 Required Features of SIS Logic Solver: Safety Integrity Level: SIL-2, SIL-3 (Energize to Trip and De-energize to Trip Applications) Safety level Degradation: 1oo1D, 1oo2D, 2oo3D Processor Modules supported: Three I/O Modules supported per System: Min 40 Sequence of Event Resolution: 10 msec Supported I/Os: Discrete Input: Dry Contact, 24 VDC. Discrete Output: 24 VDC Analog Input: 4–20 mA with HART Analog Output: 4–20 mA with HART Discrete Outputs must have line monitoring capabilities option. Should support On-line updates I/O Configuration Changes Should support "hot swap" capability for business critical data channels.

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL 5.2

TIME SYNCHRONIZATION AND SOE

The ICSS PCS should be designed with dedicated hardware/setup to support Time Synchronization across the network (BPCS as SIS/FGS systems), with BPCS being the Master. Time source for the BPCS should be a GPS clock. (part of the scope). The Time clock between the BPCS Racks should implemented using IEEE 1588-2008 Precision Time Protocol standard. (Like CIP Synch). The Time synchronization of the SIS with the BPCS should be over SNTP and synchronized within 100 msec. The SIS should support SOE up to 10 msec resolution or better.

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL

6. TERMINAL AUTOMATION SYSTEM The Intelligent Terminal Automation System (TAS) should provide monitoring, control and management of the entire product handling process from receiving to storage to distribution. With data integration as the system’s core, TAS combines automatic control and business management functions. It should an integrated, modular, open and scalable solution that helps ensure the safe and stable operation & optimal terminal management. The TAS software should not reside in Computer/Server but rather integrated as part of the process automation hardware. A typical terminal should be able to provide the following facility – for offloading and loading ships – Tank – for offloading and loading Truck – Tank – storing products – for offloading and loading road and rail tankers – for direct feeding or receiving and distributing via pipelines Nearly all operations to be transaction based. Every transaction should be recorded and used for commercial purpose. Terminal Automation software platform should include customer account, product list, inventory, Truck Loading order creation and processing, bay queue, sales order and reporting depending on the application and should be flexible ,easily manageable and maintainable by the customer. Obsolescence of the Computer should not affect the TAS software to larger extent. Below features are necessary but not limited to the project requirement.           

Easy maintenance Modular TAS module/library– Standard library is available. Scalable/expandable – For future terminal expansion e.g adding loading bay Less or no mapping or coordination between software platform TAS are accessible from any client windows / laptop via Internet Explorer TAS Module (standard library) is available, thus will mitigate a risk during upgrade process. Diagnostics and Analytics of all Information Information & reconciliation of transactions across multi terminals available in single system. Integrated Terminal Management system at MES layer Web Interface Client Modular and customizable based on requirements  Modules in Terminal Management System  Customer management  Inventory management  Product management  Truck management  Vessel management  Order and contract management  Reporting  ERP Interface  Forecasting

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

ICSS PCS SPECIFICATIONS FOR LNG RECEIVING TERMINAL Other Features expected in the software are: 

Connect to Data Sources  Seamlessly integrate to field devices  Connect to 3rd Party Sources via OPC / OPC-HAD using Ethernet/IP



Connect to the Data Sources  Premier integration with Rockwell Automation devices and data sources  Connect to 3rd Party Historians  Connect to 3rd Party Data Sources via OPC-DA / OPC-HAD using Ethernet /IP  Connect to databases

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Build a Logical Model  Combines multiple data sources into a logical unit  References data directly from its source

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Visualize & Analyze Data  Creating reporting content to meet customer needs  Leverage a variety of reporting options including Excel, Advanced Trending tools  View information in your favorite web browser including mobile device support

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Data stays with the source  Reduced loading on network – only accessed when needed  No replication of data necessary

7. INTERFACE WITH INTELLIGENT MOTOR CONTROL CENTRE AND POWER SYSTEMS Integrated Control and Safety System (ICSS)The Control system should be able to integrate with MCC on a common platform without using any gateways or proprietary protocol. The low voltage MCC should be configurable and ability to view them as note on the network. The diagnostics and troubleshooting information should be available to the operator. The MCC should be type tested for IEC60439/61439 standards. The variable speed drives shall be part of the MCC and should be able to interface with PCS on the process network and ability to perform remote operations, maintenance for troubleshooting remotely. The forms of separation shall be 2b,3a,3b & 4b as required at various location of the plant. The technology shall be proven with a minimum of 10 years. interface with MCC and other power equipment using open protocol without need of any interface convertors.

The information contained in this document consists of technical, commercial and/or financial information which is confidential and proprietary to Rockwell Automation, Inc. This information is furnished in confidence and with the understanding that it may not be disclosed to third parties or reproduced or used, in whole or in part, for any purpose other than evaluation of this document. The recipient agrees to return the document to Rockwell Automation upon request. Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved