MQ SP I 7012 2 PDF

Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification: MQ-SP-I-7012-2
Project Name: Date: 14 Jan 2011

Contract Number: Page: 1 of 42
Revision: 1
SPECIFICATION - PROCESS CONTROLS - PROGRAMMABLE LOGIC CONTROLLER (PLC)
This specification has been revised as indicated below and described in the revision record on the following
page. Please destroy all previous revisions.
Revision Date Originator's Reviewed/Checked By Pages

No. Name & Initials Name & Initials
A 8/24/2010 Cory A. Haynes Vincent E. Mezzano 42
0 11/04/2010 Cory A. Haynes Anna M. Pham 42
1 1/14/2011 Cory A. Haynes Anna M. Pham 42
APPROVALS SIGNATURES DATE
Lead Engineer Thomas B. Robinson

Project Manager: Russell Shulz
Client Approval:
ISSUED FOR : Construction X Other Approved

Revision: 1
Record of Revisions
Revision Date Description
No.
A 8/24/2010 Issued for Approval, Table of Contents Only
0 11/04/2010 Issued for Review/Approval
1 1/14/2011 Issued Approved

Revision: 1
TABLE OF CONTENTS
Section
1.0 SCOPE ........................................................................................................................................................6

1.1 Purpose.........................................................................................................................................6
1.2 Objectives.....................................................................................................................................6
1.3 Scope of Supply and Responsibility ..........................................................................................6
2.0 REFERENCES ..........................................................................................................................................7
2.1 Codes and Standards ..................................................................................................................7
2.2 Project Specifications and Drawings ........................................................................................8
2.3 Conflicts .......................................................................................................................................9
3.0 DEFINITIONS AND ABREVIATIONS.................................................................................................9
3.1 Definitions ....................................................................................................................................9
3.2 Abbreviations ..............................................................................................................................9
4.0 ENVIRONMENTAL CONDITIONS ...................................................................................................10
4.1 Design Temperature .................................................................................................................10
4.2 Design Sound Pressure Levels (Noise)....................................................................................10
5.0 GENERAL REQUIREMENTS .............................................................................................................11
5.1 System.........................................................................................................................................11
5.2 Design .........................................................................................................................................11
5.3 Modification Capability ...........................................................................................................11
5.4 Failure Mode .............................................................................................................................11
5.5 Communications .......................................................................................................................11
5.6 System Capacity ........................................................................................................................12
5.7 Port Connections.......................................................................................................................12
5.8 Protection...................................................................................................................................12
5.9 Assembly ....................................................................................................................................12
5.10 Training and Application Support .........................................................................................12
5.11 Submittals ..................................................................................................................................12
5.12 Quality Assurance.....................................................................................................................13
5.13 Product Delivery and Handling ..............................................................................................13
6.0 HARDWARE ...........................................................................................................................................14
Revision: 1
6.1 General .......................................................................................................................................14

6.2 Transmitter Interface ...............................................................................................................15
6.3 Modules ......................................................................................................................................15
6.4 Processors ..................................................................................................................................15
6.5 I/O General ................................................................................................................................16
6.6 Input Modules ...........................................................................................................................17
6.7 Output Modules ........................................................................................................................18
6.8 Remote I/O.................................................................................................................................19
6.9 Cabinets......................................................................................................................................19
6.10 Redundancy ...............................................................................................................................20
6.11 Power Supply.............................................................................................................................21
6.12 Grounding System ....................................................................................................................21
6.13 Radio Frequency Interference (RFI/EMI).............................................................................21
6.14 System hardware testing shall cover the following areas: ...................................................22
7.0 SOFTWARE ............................................................................................................................................22
7.1 Control Strategy Integrity .......................................................................................................22
7.2 Controllers .................................................................................................................................23
7.3 Sequential Control ....................................................................................................................24
7.4 Ladder Logic Control...............................................................................................................25
7.5 Control Processor Software.....................................................................................................26
7.6 Special Requirements ...............................................................................................................27
7.7 Programmable Devices.............................................................................................................28
7.8 Bypass Switches.........................................................................................................................28
8.0 DIAGNOSTICS .......................................................................................................................................28
8.1 General .......................................................................................................................................28
9.0 HUMAN-MACHINE INTERFACE .....................................................................................................29
9.1 General .......................................................................................................................................29
9.2 PLC Configuration ...................................................................................................................31
9.3 Load Media................................................................................................................................31
9.4 Database .....................................................................................................................................32
9.5 Configuration Recovery ...........................................................................................................32
9.6 Utilities .......................................................................................................................................32
9.7 System Documentation Tool ....................................................................................................33
9.8 Trending.....................................................................................................................................33
Revision: 1
9.9 Reports and Logs ......................................................................................................................34

9.10 Documentation ..........................................................................................................................34
9.11 Self-Testing ................................................................................................................................34
9.12 Start-Up Tests............................................................................................................................34
9.13 Quality Logic Tests ...................................................................................................................34
9.14 On-Process Tests .......................................................................................................................35
9.15 Off-Process Tests.......................................................................................................................35
10.0 DCS/PLC COMMUNICATION............................................................................................................35
10.1 General .......................................................................................................................................35
11.0 INSPECTIONS AND TEST...................................................................................................................36
11.1 Factory Acceptance Test (FAT) ..............................................................................................36
11.2 Site Acceptance Test (SAT) .....................................................................................................36
11.3 Sustained Performance Test (SPT).........................................................................................37
12.0 MAINTENANCE MATERIALS...........................................................................................................37
12.1 Recommended Service and Spare Parts List.........................................................................37
12.2 Maintenance Training ..............................................................................................................37
12.3 Maintenance Service.................................................................................................................37
13.0 DRAWINGS, DOCUMENTATION AND DATA REQUIREMENTS ............................................38
13.1 Design Drawings........................................................................................................................38
13.2 Design Interface ........................................................................................................................38
13.3 Supplier Documents..................................................................................................................38
13.4 System Logs ...............................................................................................................................40
13.5 Requirements with Proposal....................................................................................................40
13.6 After Kick Off Meeting ............................................................................................................42
13.7 As Built.......................................................................................................................................42
13.8 Electronic Documentation .......................................................................................................42
Revision: 1
1.0 SCOPE
1.1 Purpose
A. This specification defines the minimum requirements of Programmable Logic

Controllers (PLC’s) for the Power and Water Utility Company for Jubail and Yanbu
(MARAFIQ) projects located at the existing COMPANY complexes at Jubail
Industrial City and Yanbu Industrial City, in the Kingdom of Saudi Arabia Scope of
Specification
B. This document covers the PLC hardware, software and functional requirements for
projects.
1.2 Objectives
A. Control and operations of Packaged Mechanical Equipment shall, as far as is

practical, be automated, thereby minimizing Operator Manual Control to give
operation consistency and maximizing plant availability. A PLC based control
system control and monitor the packaged equipment and be able to provide
continuous production of products and services.
B. The intent is that a standardized approach be used by the PLC suppliers, COMPANY
and CONTRACTOR in regards to new PLC hardware and software as defined in this
specification.
1.3 Scope of Supply and Responsibility
A. The PLC SUPPLIER shall accept total responsibility for the overall system as
specified. This includes, but not limited to; system design, site survey, procurement,
management, progress reporting, fabrication, assembly, configuration, programming,
graphics and reports/logs building, documentation, integration, factory testing,
packing, shipping, receiving, warehousing, installation at site, interfacing, site
testing, commissioning and any other requirements defined in this specification, the
material requisition or contract documents for a fully functional, operable, reliable
and maintainable system.
B. The PLC SUPPLIER shall provide the correct and timely submittal of all required
engineering data and documentation as required by the material requisition or
contract document.
C. CONTRACTOR shall provide the correct and timely submittal of all required
engineering data and requests for information for use by PLC SUPPLIER to perform
the work.
D. In the event of conflict within this specification, the PLC SUPPLIER shall request a
written clarification. All exceptions to the specification must be in writing, and shall
reference the section/paragraph.
Revision: 1
E. The PLC SUPPLIER shall provide comprehensive detailed functional design

specifications describing all aspects in the PLC SUPPLIER scope of supply.
F. Refer to the roles and responsibility matrix for details of compliance required by the
PLC SUPPLIER, CONTRACTOR and other parties.
G. All 3rd party hardware components / equipment (i.e. OTS computer / server
equipment, Ethernet switches, etc.) to be provided by PLC SUPPLIER as integral
components of the SYSTEM shall be approved by COMPANY prior to purchase.
2.0 REFERENCES
2.1 Codes and Standards
A. The PLC shall be designed in accordance with the following codes, standards, and
regulations. Except as modified by the requirements specified herein or the details of
the drawings, work included in this specification shall conform to the applicable
provisions of these publications. Revisions (or editions) of codes, standards and
specifications in effect at the inception of the project shall apply for the duration of
the work.
B. International Electrotechnical Commission (IEC)
 IEC 73 : Specification for color of indicator lights, push-buttons, annunciators

and digital readouts
 IEC 79 : Electrical equipment for use in hazardous locations
 IEC 529 : Degrees of Protection of Enclosures
 IEC 617 : Graphic Symbols for Electronic Diagrams
 IEC 60364-4-41 : Low Voltage Electrical Installations
 IEC 61508 : Programmable Electronic Safety Systems
 IEC 61131-3 : Programmable Controllers - Part 3: Programming Languages
C. International Society of Automation (ISA)
 ISA 5.1 : Instrumentation, Symbols and Identification.
 ISA 5.2 : Binary Logic Diagrams for Process Operations.
 ISA 5.3 : Graphic Symbols for Distributed Control/Shared Display

Instrumentation, Logic and Computer Symbols
Revision: 1
 ISA-18.2 : Management of Alarm Systems for the Process Industries
 ISA MC96.1 : Temperature Measurement Thermocouples
D. International Organization for Standardization (ISO)
 IS0 9000 : Quality Systems
E. U.S. Military Specification and Standards (MIL: HDBK 217E)
 MIL-V-173 - Varnish, Moisture, and Fungus-Resistant for the Treatment of

Communications, Electronic, and Associated Electrical
F. National Electrical Manufacturers Association (NEMA)
 NEMA ICS-6 - Enclosures for Industrial Controls and Systems
G. National Fire Protection Association (NFPA)
 NFPA 70 - National Electrical Code
 NFPA 496 - Purged Enclosures for Electrical Equipment Quality Assurance Test
2.2 Project Specifications and Drawings
A. All equipment and accessories covered by this specification shall comply with all
Project Specifications and Drawings listed herein.
B. MARAFIQ Standards and Specifications
Specification No. Title

MQ-SP-I-7010 Safety Instrumented Systems (SIS)
MQ-SP-I-7012-1 Process Controls - DCS
MQ-SP-I-7016 Control Panels
MQ-SP-I-7017 Fire and Gas Detection System
MQ-SP-I-7022 Instrumentation for Packaged Equipment
MQ-SP-T-7811 Fiber Optic Cable
MQ-SP-E-6001 Electrical Design
MQ-SP-E-6009 Uninterruptible Power Supplies
MQ-SP-E-6018 Low Voltage Power and Control Cable
Revision: 1
2.3 Conflicts
A. In the event of conflict within this specification, the PLC Supplier shall request a
written clarification. All exceptions to the specification and conflicts with the
existing system installation must be in writing, and shall reference the
section/paragraph.
3.0 DEFINITIONS AND ABREVIATIONS
3.1 Definitions
A. Terms used in this document are defined as follows:
PLC SUPPLIER Supplier of PLC equipment purchased by CONTRACTOR.

Power and Water Utility Company for Jubail and Yanbu (MARAFIQ)
COMPANY
or designated representative.
Other Engineering, Procurement and Construction contractor
CONTRACTOR responsible for one or more of the plants / facilities associated with the
MARAFIQ projects.
SYSTEM Refers to the PLC as specified in this document.
3.2 Abbreviations
HMI Human Machine Interface
Integrated Control System is the collective name assigned to the core

control system components. This includes the following;
ICS
 Distributed Control System (DCS)
 Safety Instrumented System (SIS)
 Fire & Gas System (FGS)
LED Light Emitting Diode
LCD Liquid Crystal Display
MTTFd Mean Time to Failure to a Dangerous Mode
PEC Programmable Electronic Controller
PFD Probability of Failure on Demand
PLC Programmable Logic Controller
PSU Power Supply Unit

Revision: 1
SAT Site Acceptance Test
SER Sequence of Event Recording
TÜV Technischer Überwachungs-Verein
UPS Uninterruptible Power Supply
4.0 ENVIRONMENTAL CONDITIONS
4.1 Design Temperature
A. PLC’s shall normally be installed and operated in an air conditioned environment

which will be maintained at the following conditions:
 21 ºC ± 3 ºC and 50% ± 10% Relative Humidity
B. PLC Supplier standard equipment shall be fully operational so as to perform per

specifications at any air temperature range from 5 to 40 ºC in all the Control Rooms,
Operator Shelters and Field Auxiliary Rooms, and a relative humidity range of 40 to
60 percent non-condensing. The PLC shall have no failures when operated at 50 ºC
room temperature and relative humidity of 95% for a 4 hour period (in case of air-
condition loss). PLC Supplier shall specify any environment limitations to the
Company.
C. PLC Supplier equipment installed in local control panels / field control cabins shall
meet the design temperature at the following conditions:
 9.0 to 50.0 ºC and 22 to 95 % Relative Humidity
D. PLC Supplier shall include a “High temperature” option for equipment to meet this
requirement.
E. For components exposed to the sun the surface design temperature shall be 85 ºC.
4.2 Design Sound Pressure Levels (Noise)
A. The maximum acceptable sound pressure level for each piece of equipment installed
in the Control Rooms shall be 60 dBA measured at a distance of 1 meter lateral from
the source and 1.5 meter vertical from floor with a sound level meter using the “A-
weighted” sound level scale. Sound level measurement shall be based on tests carried
out per IEC standards.
Revision: 1
5.0 GENERAL REQUIREMENTS
5.1 System
A. The PLC system shall consist of I/O boards and termination panels, which gather
various inputs from various equipment and a central processor cabinet (or, rack)
mounted system, consisting of one or more microprocessors which give output based
on a logic program.
5.2 Design
A. The design shall be modular, with the latest field proven hardware and software,
process input/output devices, microprocessors, signal conditioning equipment and
engineering/ maintenance facilities in order to perform on-line reconfiguration and to
test all system components with on-line diagnostics. The system software and
hardware shall be updateable with new equipment.
5.3 Modification Capability
A. The PLC shall allow the inclusion and/or removal of additional control unit devices
or printed circuit boards without causing process upset and/or equipment shutdown.
The control loops, sequences, etc., shall be easily modifiable. These capabilities
shall be achievable with the PLC on-line.
5.4 Failure Mode
A. Any system failure shall be to a fail-safe state. This includes all module removal and
cable faults.
5.5 Communications
A. Communications between the PLC and other equipment shall be via digital
communication. The communications system shall have automatic self-checking
facilities, and “hand shaking diagnostics”, and include a fully redundant second link
that is automatically switched into service on failure of the primary operating link.
Once the second link is operational, it becomes the primary link. Switching back to
the new secondary link (if available) shall be automatic upon failure of the primary.
The PLC communication shall support RS 232 and RS 422/485 with adjustable baud
rates up to 144 kbaud. Any server must be able to exchange data via windows
interface and OPC standard protocol. Any non-OPC applications (serial
communications links) require approval by MARAFIQ.
Revision: 1
5.6 System Capacity
A. The system as commissioned shall provide room for system expansion and
optimization. No more than 50% of the available system memory shall be used. I/O
racks shall be sized for 30% unassigned card slots. I/O terminal strips shall be sized
to provide 30% unused terminals, including fused terminals. At least 20% spare I/O
by I/O type shall be supplied fully installed and wired.
5.7 Port Connections
A. The PLC shall have at least two port connections to link with stand-alone controllers,
supervisory and optimization computers and interface with protocols like Ethernet
TCP/IP, MODBUS, Allen Bradley DH, Allen Bradley DH+, etc. This shall include
the simultaneous transmission and reception of information from this equipment.
5.8 Protection
A. The system shall be protected against errors and hardware damage resulting from
electrical transients on power or signal wiring generated by switching large electrical
loads, by power line faults, lightning strikes and lightning induced surges on power
or signal cables.
B. All components of the PLC shall also be immune to electromagnetic radiation and
radio frequency interference such as generated by hand held radios.
5.9 Assembly
A. The system shall be factory assembled and wired, complete with all necessary
devices, the latter consisting of placing the equipment in position, connection of
power supply, terminals installed input/output wiring and communication cables.
5.10 Training and Application Support
A. Seller shall quote separately a recommended training plan for MARAFIQ. personnel.
The plan shall consist of formal comprehensive training programs with “hands-on”
experience in operation, hardware, configuration, applications and maintenance of
the PLC. Training courses in Seller’s training facility shall be in English.
B. A syllabus and tentative course schedule of training provided at the main training
facilities shall be provided by Seller with the quotation.
5.11 Submittals
A. Seller shall submit drawings and data listed in the attachments to the procurement
documents. For each drawing submittal, Seller shall furnish the specified number of
prints and reproducible drawings. Document submittals shall consist of the specified
number of hard copies and text files on machine-readable format.
Revision: 1
B. PLC software documentation shall be developed on an approved, commercially

available, personal computer based development system. Software submittals shall
consist of 2 hard copies of fully commented source code. Three sets of all source
code and executable code shall be supplied in machine-readable format. Ladder logic
diagrams and written interlock design documents shall be provided for Owner’s
approval. Annotated logic is required. Application Configuration will be supplied
by the Owner/Contractor. The PLC supplier will supply program logic and
documentation required for proper configuration. This documentation shall be
written so that it is understandable by non-technical operating personnel and shall
include the following:
 Hardware configuration Instructions
 I/O configuration Instructions
 Alias dictionary
 Program logic
 Seller shall retain a record copy of all as commissioned software media for a
period of ten years.
5.12 Quality Assurance
A. Seller shall prepare and submit to Owner a Quality Assurance Program Plan. This
plan shall be submitted within 30 days after notice to proceed. Approval of the
Quality Assurance Program Plan shall not relieve Seller of the responsibility to
deliver a system or equipment that meets the contractual requirements.
B. Seller shall provide QA (Quality Assurance) policy with respect to item quality. The
minimum acceptable policy shall state that Seller's executive management is
committed to assuring that the items offered for acceptance shall conform to the
contractual requirements and that such conformance shall be verifiable by
documented inspection and test results.
5.13 Product Delivery and Handling
A. Electrical equipment shall be designed to withstand storage and transportation

temperatures within the range of 40 to 95 degrees F and up to 100 degree F for short
periods not exceeding 24 hours. Suitable means shall be provided to prevent damage
from excessive moisture, vibration, stress and mechanical shock during shipment.
Shock indicators and tip-n-tells shall be included on crates.
Revision: 1
B. The front of each panel shall be covered with plastic that can remain in place during
installation. Crating, skids and any additional bracing required shall be provided to
protect against damage to structure, finish and components during transit and
handling. Seller shall remove and properly pack all plug-in instruments and devices
that cannot be properly secured for transit and handling to prevent damage. Vendor
shall provide documentation listing shipped loose items to the engineering contractor
and the material manager receiving the shipment.
6.0 HARDWARE
6.1 General
A. As a minimum, the PLC shall be capable of operating from 9 to 50 degrees C and

from 5 to 100% relative humidity without condensing moisture.
B. The process input/output equipment shall be designed to ensure data acquisition,

regulatory control and sequential control functions are performed in integrated
manner utilizing common equipment such that a process signal is terminated no more
than one time regardless of its numerous uses within the PLC.
C. Redundant separate processors are required for process network communications,

communication with process I/O modules and for control processing. In addition,
each process I/O module shall have its own microprocessor and shall perform
functions such as alarming, signal characterization, engineering unit conversion and
output read back checking.
D. Control processing shall occur at a guaranteed interval and shall be de-coupled from
fetching of process I/O data and peer-to-peer communications.
E. Each controller shall be configurable to allow an optimum mix of point types for a
particular application. This mix not only applies to I/O signal processing, but to the
controller’s configuration of regulatory control, regulatory PV, logic, digital
composite and process module points. Memory management within the controller
shall be automatic. If memory is required, the controller shall allocate and manage it.
F. Process input/output cabinets shall accept dual 120 VAC, 60 Hz, Single phase UPS
input power sources. DC power supplies within the cabinets shall be redundant such
that a faulty power supply unit is replaceable on-line. DC power supplies shall have
an LED indicator and an alarm contact for each of the following conditions:
 Loss of DC power
 Ground fault
Revision: 1
6.2 Transmitter Interface
A. Smart transmitters, HART protocol, will normally be used for analog inputs. The 4-
20 mA component of the signal will be used as the input to the PLC. The digital
HART component of the signal will be separated at the remote termination panel,
which facilitates remote calibration and maintenance activities.
6.3 Modules
A. The system shall provide continuous monitoring of analog and digital (contact)
inputs signals at a fast scan and processing speeds. The following common functions
shall be performed:
 Signal isolation
 Signal conditioning
 Surge protection
6.4 Processors
A. Each processor module shall consist of a microprocessor, memory, math co-

processor and necessary communication processors. The processor shall be
mechanically and electrically isolated.
B. All software shall be retained during power outage or internal failure through the use
of battery back up RAM or EEPROM. Wherever batteries are used, lithium batteries
shall be utilized and the processor programmed for low battery alarming. Battery
backed up RAM shall be capable of retaining the application program in memory for
a minimum of six months after power loss. The memory shall be sufficient for the
initial configuration plus 100% excess for future expansion.
C. A real time clock with a 10 ms resolution shall be available for time dependent
functions such as rate calculations.
D. The PLC system clock shall be synchronized with the master clock in the
communications network so that communications arrive and depart at precise times
and information is neither lost nor jumbled.
E. The PLC system clock shall watch redundant components in the system so that upon
failure there is a bump-less transfer to the backup device.
F. The PLC shall be capable of scanning and updating the I/O and executing user
defined logic at a rate less than 20 ms.
Revision: 1
6.5 I/O General
A. Each module type shall have unique mechanical and electronic keying. Keying shall
prevent physical insertion and on-line activation of a module in a wrong location.
The module type identifier shall be automatically recognized by the operating system
and fault diagnostics. Input/Output shall also have individual load/fuse status
indication.
B. I/O module shall be constructed such that it can be removed or inserted without
disturbing any external wiring. Field wiring shall be directly connected to I/O
modules or to external terminal panels.
C. I/O modules shall be capable of being located anywhere in the chassis without regard
to the type and voltage levels.
D. All I/O modules shall include local status indication to show the status of each input
and output, communication faults and any module fault. Outputs shall have
load/status indication.
E. In a fault tolerant configuration with redundant I/O, removal of a single module shall
have no impact on the process.
F. Isolation up to 2500 V shall be provided on all I/O modules.
G. Provide a low pass filter for all digital inputs to reduce the effects of noise and
contact bounce.
H. Means shall be provided to detect a failed transmitter signal versus an over-range

signal. The application software shall alarm all failed transmitter signals. The criteria
are:
Open < 3.8 ma
Under range 3.8-4.0 ma
Over range 20-21 ma
Short >21 ma
I. Inputs and Outputs shall be modular with a minimum of 16 circuits per module. I/O
modules shall have status LEDs for each circuit # I/O shall be the same for the
selected I/O type.
Revision: 1
J. All inputs and outputs shall meet the following minimal requirements on conversion
accuracy:
 Analog to Digital Conversion
 Digital to Analog Conversion
 Resolution 14 bits
 Resolution 12 bits
 Linearity + 1 bit (LSB)
 Linearity + 1 bit (LSB)
 Repeatability + ½ bit (LSB)
 Repeatability + ½ bit (LSB)
 Accuracy + 0.1% full scale
 Accuracy + 0.25% full scale
6.6 Input Modules
A. The system shall accept the following field or PLC powered input signals directly
from the field:
B. Digital: Dry contact rated for 24 VDC, motor Control outputs shall use an
interposing relay mounted in a separate cabinet.
C. Digital input signals shall be conditioned by a low pass filter up to 15 ms. Each
individual input signal path on the input module shall be automatically tested for
proper operation at least every ten minutes.
D. Analog: 4 – 20 mA, 1 – 5 VDC or 0 – 100 mVDC signals from 2 wire transmitters.

The modules shall also perform:
 Automatic self-calibration
 Normal mode rejection ratio of 15 dB or better at 60 Hz
 Common mode rejection ratio of 80 dB or better from 0 to 100 kHz
 Sampling rate 1 – 5 milliseconds maximum per channel

Revision: 1
E. ANSI standard type thermocouples, J, K, and T
F. RTD inputs shall have 12 bit minimum analog to digital conversion, and shall receive
inputs from 3 wire RTD’s 100 ohm Platinum.
G. Pulse inputs at rates up to 20 kHz. Inputs shall be filtered, converted to engineering

units and the data validity checked. These inputs shall be optically isolated and
current limited to protect against inadvertent damage. They shall be configurable as
status, latched inputs or accumulator inputs.
6.7 Output Modules
A. Output modules shall fail to the safe state upon microprocessor failure. Digital
outputs shall be current rated for an inductive load with a minimum of 1 A per point
at 60 degrees C. Modules shall be rated for full load at maximum specific
conditions. Digital output modules shall operate properly with a +/- 10% voltage
variation.
B. The module shall detect and alarm open or shorted field circuits as well as power
monitoring. If any energize to trip signals are specified, load monitoring shall be
required
C. The system shall provide output signals to transducers, solenoid valves, alarm
annunciators and DCS interface I/O shall have the following:
Analog: 4 – 20 mA signals output characteristics
 Direct or reverse operation
 D/A per output
 Power regulator per output
 Software calibration
 Loopback output
 5 segment output characterization
 Default options upon failure:
 Hold last value, or
 Go to zero
Each digital (contact) output shall have the following characteristics:

Revision: 1
 Mechanical relay dry contact rated for 24 VDC, 2 A. Motor control shall
also have an interposing relay mounted in a separate cabinet
 Individual fuse with blown fuse indication
 Individual contact suppression
 Configurable as: Momentary (10 ms – 1 min) Latched Pulse-width

modulated (1 s – 120 s on time)
 Individually definable default state
 Output readback verification
6.8 Remote I/O
A. The use of remote I/O can reduce both cable volumes at the processor location and
the average length of connecting cable per I/O point. The degree to which these
benefits can be realized depends on the physical arrangement of equipment on the
Project. Use of remote I/O motor control centers or control building shall be limited
to those locations where advantages can be gained from using remote I/O.
B. Communications with remote I/O shall be by means of coaxial or fiber optic cable,
and must occur at a speed high enough to adequately support system operations.
C. Requirements for Remote I/O shall be specified where required . All Remote I/O
modules shall be provided with redundant communication links and communication
interface modules.
D. All communication links shall comply with Seller recommendation. Seller shall
recommend cable and connector type and model and installation techniques to be
followed. The communication links shall be provided with proper diagnostics to
monitor the health of communication. Status lights shall indicate the status of the link
module. Single failure shall not cause loss of Remote I/O communication. But all
failures shall be capable of being logged for future analysis.
 Remote I/O chassis shall be provided with their own redundant power supplies.
6.9 Cabinets
A. All PLC’s shall be located inside air conditioned enclosures/buildings, and shall meet
NFPA 70 standard and MQ-SP-E-6001 “Electrical Design” to comply with the
electrical area classification and any specified corrosive atmospheres (marine,
ammonia, chlorine, hydrogen sulfide, etc.) complete with inert gas purge where
applies. Purging shall meet NFPA 496 if applicable.
Revision: 1
B. Cabinets shall be freestanding, completely assembled, wired and designed to operate

between 9 – 50 degrees C and 5 – 100% non-condensing ambient conditions.
Cabinets shall be fully enclosed with doors in front and rear as required. They must
have four lifting lugs. The cabinet interior finish shall be white and fitted with a
fluorescent light inside. Cabinets in buildings shall have redundant cooling fans.
Adequate ventilation shall be provided to keep the temperatures within design
specifications and an over temperature alarm shall trip when the temperature is
greater than the vendor recommended maximum temperature. All cabinets shall be
standard Rittal cabinets or equal; they must be consistent in design and color as
cabinets housing the DCS.
C. The equipment, electronic circuitry and wiring shall be arranged to facilitate good
access and perform maintenance safely. Segregation shall be in accordance with
specification MQ-SP-I-7016 “Control Panels”. Engraved nameplates shall be
provided for each cabinet, peripherals and subsystems such as controllers,
multiplexers, communication devices, etc. Contractor shall approve legends.
D. Termination assemblies shall be mounted in marshalling panels. All interconnecting

cables shall be tagged at both ends using shrink sleeve type markers or equivalent.
Refer to MQ-SP-I-7016 “Control Panels” for proper wire tagging.
E. Terminal blocks for input and output signals shall be non-hygroscopic. Terminals
shall be tinned and clearly identified. All instrument wiring shall be in accordance
with applicable MARAFIQ project specifications.
F. All conductors shall be so terminated to prevent fraying of strands and to permit easy
disconnection. Terminal blocks shall be wired and mounted so the internal and
external wiring does not cross over the terminals. Not more than two conductors
shall be terminated at each terminal connection.
G. Analog wiring shall be shielded cable of twisted pairs with 600V insulation. All
wiring shall be stranded copper except for thermocouple where it should match the
T/C type.
H. Prior to assembly Seller shall make the cabinets available for Contractor's inspection.
No assembly is to commence until any shop defects are remedied to Contractor's
satisfaction.
6.10 Redundancy
A. Equipment to be backed up includes:
 Back up of power supply cards to CPU’s and I/O cards (1:1 back up)
 Back up of internal bus between CPU and Input/Output (1:1 back up)
Revision: 1
6.11 Power Supply
A. All equipment shall comply with the latest IEC, IEEE, EIA, NEMA, ISA, NEC, UL,
FM, and CSA standards and codes.
B. The equipment shall operate on 24 VDC or 120 VAC, 60 Hz. Each power user
(consoles, controllers, I/O devices, etc.) shall have a separate circuit breaker with its
own fuse.
C. The PLC shall include a redundant power supply with a 120 VAC (+/- 10%), 60 Hz,
single phase input. Surge protection and isolation from the AC line must be
provided. If the input voltage level deviates from the safe operating range, the power
supply shall activate alarm. The PLC shall supply 24 VDC power to electronic
transmitters or other external devices requiring electrical power. Each process I/O
device shall be provided with self-regulatory capability to assure proper power levels.
Internal dc power supplies shall be capable of tolerating a supply voltage variation of
10 percent, frequency variation of plus or minus 2.5 Hz, interruption time of 10 ms
and 5 percent rms harmonic content without adverse effect on the system operation.
D. The power supplies shall be sized to manage the I/O load requirements, plus 30%
additional load capacity.
E. Independent redundant power supplies shall be used for controllers, process I/O
subsystems and communication devices (including interfaces), such that any
individual power supply unit failure does not have any effect on the operation of the
installed PLC equipment.
6.12 Grounding System
A. The safety grounding system for metallic enclosures and the isolated electronic
circuits ground shall be separate and designed for connection to the main grounding
system of the plant. The grounding system shall have a maximum resistance of 1
ohm. Grounding shall be performed following the guidelines of MQ-SP-E-6001
“Electrical Design”.
6.13 Radio Frequency Interference (RFI/EMI)
A. The noise level for all equipment shall be limited to 60 dBA.
B. Noise measurements shall be based on tests carried out per applicable ANSI
standards.
C. Operators shall be assumed to use hand held radios with wattage rating of 5 watts.
The PLC System shall be designed to operate such that there shall be no degradation
of performance when these radios are used within 3 meters from equipment.
Revision: 1
D. Equipment shall have RFI protection against hardware damage and system error.
Error caused by RFI shall not exceed 0.1% of span for exposure to field strength of
10 volts/meter over the frequency range of 10 – 1000 MHz.
E. Minimum clearances and shielding shall be maintained between data communication

link and power cabling, transformers, motors, etc. The design shall maintain
minimum separation distance between process interface equipment, process,
controllers, remote multiplexers and electrical substation equipment to protect the
PLC from power system noise.
F. The plant radio transmitter/receiver station shall be installed in a separate cabinet,

remote from the PLC equipment.
6.14 System hardware testing shall cover the following areas:
 Continuity check of cross-board and interconnecting cables
 AC and DC power checks
 Proper operation of back up devices
 Diagnostic checks of all devices
 Proper operation of communication network
 I/O continuity checks of marshalling to I/O module interconnections
 Isolation of instrument and equipment ground busses
7.0 SOFTWARE
7.1 Control Strategy Integrity
A. The security of the PLC shall be ensured by providing internal security and failure
protection circuitry. The PLC shall include extensive internal self-checks and status
indicators so that no external diagnostics are required to determine operational status.
The system shall function with minimum maintenance and be designed so that
servicing can be performed with process units on-line with no control degradation.
B. All controllers shall be configured with logic blocks, which can perform interlocking,
counting and sequencing functions. These functions shall be configured by means of
logic function as given below. These functions shall be software linkable with other
logic functions and to inputs and outputs.
C. Function Blocks, Ladder logic or Boolean logic as allowed in IEC-61131-3, is an

acceptable form of configuration.
Revision: 1
D. All analog comparison functions shall be supported with adjustable dead-bands.
E. It shall be possible to define a tag item with multiple inputs and outputs. An operator
shall then use this tag to start, stop and receive feedback (Run, Stop) from the field
(e.g. Start / Stop of an MOV or a Motor).
F. All process alarms and system faults shall be time and date stamped and recorded in
memory for 30 days. If specified, the system shall be able to log discrete and analog
inputs that are configured as alarms or shutdowns. The first out alarm and all
subsequent alarms shall be time tagged in the order they occur with a minimum
resolution of 100 ms. The Seller shall provide a utility to support logging, buffering,
reporting and printing.
7.2 Controllers
A. The control device shall be microprocessor based with dual processor architecture
providing continuous control for analog loops, sequencing and logical operations for
discrete signals.
B. The algorithms shall be contained in functional control built-in blocks, which shall be
configurable and connectable to implement the desired control strategies.
C. All cascaded or interconnected loops shall reside in the same controller. No

interwiring between controllers is allowed.
D. Redundancy (only for PLCs with more than one microprocessor)
E. The control system architecture shall provide continuous uninterrupted control in the
event of any single failure in the controller. The fault detection and exclusion of the
faulty processor shall be automatic and provide for continuation of full automatic and
bumpless control without operator intervention. The controller shall be able to
switch back to the primary controller automatically without a restart (if the primary is
available).
F. The back up scheme shall ensure that only error free memory transfer are made to the
back up controller and that they accurately reflect the state of the failed controller
prior to occurrence of the failure. The back up scheme shall cover both configurable
and programmable control functions without the need of using special configuration
or programming steps.
Revision: 1
7.3 Sequential Control
A. Controllers shall have the capacity to perform Sequence / Batch control. In this mode
Controllers shall perform a number of sequential steps to control the process. These
shall be a combination of discrete control logic and continuous PID controllers.
Programming steps shall involve adjusting set points, ranges, modes etc. based on the
step number. Programming shall also provide outputs to control devices; motor
controls based on inputs (Discrete and Analog) from the field and the program step.
Program shall be able to store multiple recipes. Selection of a recipe by the operator
shall set up the controller with the appropriate set points and sequence operation for
that process.
B. Systems shall allow debugging programs by stepping through programs one step at a
time and displaying output values. It shall have the ability to modify program logic
while other sequences are active.
C. Batch program shall support all the functions mentioned before for continuous
control and any special functions required to execute batch programs effectively.
D. Sequential control points shall be configurable via Flat Panel Display (FPD)
templates to execute the required sequential control functions through a versatile mix
of algorithms available for use in logic points. The logic points shall have the
following capability:
 Up to twelve input connections
 Up to twelve output connections
 Up to sixteen logic blocks
E. Each logic block shall have access to and be capable of executing the following
algorithms:
 Logic (AND, OR, NOT, NAND, NOR, XOR)
 Compare Real (EQUAL, NOT EQUAL, GREATHER THAN, GREATHER

THAN OR EQUAL TO, LESS THAN, LESS THAN OR EQUAL TO)
 Delay, on Delay, off Delay
 Pulse (Fixed, Max Time, Min Time)
 Watchdog Timer
 Flip-Flop
 Check for Bad Input

Revision: 1
 Switch
 Change of State
 Flags
F. Logic points shall have the capability to link parameters without output destinations.
The sequential control functions shall also accommodate two types of interlocks,
permissive and overrides. The permissive shall provide an “allow” function to the
operator or program to command a specific output state. The override shall “force” a
specific output state without operator or program intervention.
7.4 Ladder Logic Control
A. The Contractor is responsible for Ladder Logic programming. The software structure
of the PLC shall permit its ladder logic to be partitioned onto logical frames that can
be enabled or disabled for purposes of equipment or software maintenance or tests. It
shall be possible to prioritize the execution of frames, and to require individual
frames to be executed more than once per logic scan cycle.
 The types of operations allowed in ladder diagrams shall include:
 Derived points, i.e., software generated inputs
 Contacts that may represent either digital or analog values
 Ability to treat analog values as digital through the use of dead bands
 AND/OR logic functions
 Change an up down level status transitional digital value
 Arithmetic functions (add, subtract, multiply and divide)
 Time delay relays i.e., timers that become true when expired
 Up and Down counters
 Go to function (to bypass portions of ladder diagrams)
 Logic control using familiar ladder logic
 Off-line or on-line ladder development and emulation
 On-line viewing of ladder diagram and the ability to perform dynamic de-
bugging
Revision: 1
 Ability to manually set sensor variables for ladder diagram checkout
 Ability to provide hard copy documentation of all ladder diagrams
 Ability to suppress the operation of a ladder diagram if any process variable

within the ladder diagram is tagged or placed off-line
7.5 Control Processor Software
A. Analog Control Function - The following control modes shall be available for control
loops:
 Manual and Auto.
 Control loops shall be able to perform mode switching based on external or

internal logic function.
 Switching between different modes of the controller shall be bump-less.
 Controllers shall have the ability to limit output, set-point and perform integral
tracking. It shall be possible to clamp set points and set rate of change on set
points. This shall be available on a tag by tag basis.
 It shall be possible to reverse the output of output module on a per point basis.
Provide ability to perform output characterization in the output module before
sending the signal to the field devices.
 Provide Anti Reset windup feature for all control loops.
 Tuning parameters shall be available to designated personnel only. The

availability shall be controlled by means of key-lock in the operator station or
password protected.
 The following initial tuning parameters shall be configured and fine-tuned

during startup.
INTEGRAL DERIVATIVE
APPLICATION GAIN MINS MINS
Flow 0.7 0.2 0
Pressure and DP 1.0 0.2 0
(Liquids)
Pressure and DP 1.0 5.0 0
(Vapor)
Level 1.5 15 0
Temperature 1.0 10 0
Revision: 1
B. The following computational functions shall be made available as standard

configurable Algorithms:
 Summer (Add and Subtract)
 Multiply - Divide
 Lead - Lag
 Rate Limit
 Accumulator
 High-Low Select
 Median Select
 Totalizer with Reset
 Signal Selector Switch
 Absolute Value
C. It shall be possible to soft wire all computational Algorithms between themselves and
with control Algorithms. The proper output limiting and bump-less transfer feature
shall apply.
D. Configuration of Controller and Sequences
 The configuration of the PLC with the required functions shall be done using an
interactive technique.
 All configurations shall be kept in memory or in suitable magnetic or optical

storage in the event of power failure. It shall be possible to load a previously
configured control or sequence scheme over the communication link from a host
computer. It shall have facilities to update or modify loop configuration in
complex control algorithms without disturbing the normal operation of other
loops in the controller. The network configuration shall be modifiable with the
entire system on-line to add a node or add new software to an existing node.
7.6 Special Requirements
A. Where quick closing or quick opening process valves are specified, the PLC shall
track and store the last stroking time of the valve. This shall be accomplished by
tracking the time from when the open limit switch deactivates to when the close limit
switch activates (or vice versa as the case may be with a quick opening valve).
Revision: 1
7.7 Programmable Devices
A. The system shall have capabilities for free programmable computing devices,
working on engineering language, (e.g., C, Basic) or high-level manufacturer
languages, shall be available on the PLC. The human-machine interface shall create,
develop and edit the program. A full-featured IEC-61131-3 programming software
system shall be supplied with each PLC system.
7.8 Bypass Switches
A. All software input bypasses shall be key locked or password protected from the
Operator interface screen and shall only permit access through password activation of
the bypass screen. Software bypass switches shall be programmed to allow on-line
maintenance/calibration of sensors and end devices and to test functionality of logic
without affecting the output. Only one input/sensor shall be able to be bypassed at a
time and operation of an input shall actuate audible and visual alarms. The visual
alarm shall be non-cancelable until the override is removed. The operation of input
bypass switches shall be alarmed and logged by the Sequence of Event (SOE).
8.0 DIAGNOSTICS
8.1 General
A. The PLC shall include automatic on-line diagnostic facilities to test all hardware and
software system components such that all permanent and transient faults are
identified, alarmed and reported. All testing described shall be performed
automatically on-line and without disturbing the process or reducing the reliability of
the PLC system. The diagnostics described above shall be built into the operating
system of the PLC hardware. Diagnostics shall be capable of identifying, locating
and reporting the following faults as a minimum:
 Scan failure of main or I/O processors
 Memory faults, both PROM and SRAM
 Microprocessor faults
 Communications faults
 I/O interface or addressing faults
 Application program and hardware layout consistency
 I/O module faults
 Voted signal discrepancy on inputs and outputs

Revision: 1
 Voted discrepancy on calculated values within application program
 Load power or fuse faults on field circuits
 Power supply faults including battery back up monitoring and output voltage
verification
 Over temperature conditions
B. I/O module diagnostics shall be able to detect and alarm I/O point faults of the
following types (Where required or specified).
 “Stuck-on” - short circuited failure of a discrete input or output
 “Stuck-off” - open circuit failure of a discrete output
C. Status indicators shall be provided to indicate normal operation or fault conditions on

each replaceable module. In addition, each fault shall initiate an internal fault flag
and hard alarm contact for communication to the control room. Fault information
shall be available and displayed for the maintenance staff in a manner that enables
fault diagnosis to a module level.
D. The system shall continuously monitor the status of all system devices, components
and communications (both main and back up) for failure. Upon failure it shall
initiate an alarm at the operator station to allow the operator to easily identify the
failed device. A watchdog timer shall be provided with an external time delay relay
constantly being reset by the PLC. Contacts from the time delay relay shall be sent to
the PCS and/or a hardwired annunciator. This shall insure that the program in the
PLC is working properly.
E. The system shall continuously monitor for errors in digital data transmission between
any two-system devices. The system shall log and notify the operator when an error
is detected. A serial interface bit handshake (Heartbeat) shall be programmed in the
PLC to receive one bit into a write register and to move that bit over into a read
register. The PCS shall initiate the bit handshake and perform the alarming of the
serial connection.
9.0 HUMAN-MACHINE INTERFACE
9.1 General
A. The PLC shall be designed ergonomically to enable the operator to supervise all
system operations and make the decisions to ensure safe operating conditions.
Revision: 1
B. It shall contain auxiliaries such as man-machine terminal interface or portable

programmer for on-line system test, maintenance and modification facilities. The
station shall normally be on view-only mode, but it shall be capable of performing
control and operational tasks, as required by normal plant operation via special
keylock or password function.
C. The programming terminal shall be a personal computer with Windows 7 capability

and a hardware interface module to permit program downloading to, and program
uploading from the PLC CPU. The terminal shall provide a means to monitor
program execution and overall system status. Terminal interactions, such as I/O
forcing, data manipulation, and system initiation shall be supported. The terminal
shall be furnished with the necessary software for on-line and off-line program
development and off-line program documentation for each PLC processor (system)
supplied. The PLC shall have ethernet capability where a remote programming
terminal can access the PLC system over an ethernet link.
D. Off-line programming shall provide run emulation software for testing and trouble
shooting of the application program.
E. Programming utilities shall provide for on-line management of all I/O for purposes of
calibration, reconfiguration, input/output forcing, system diagnostics, data display
and checking memory content.
F. A portable PC shall be included if specified for initial programming and making

program changes and shall include a built-in data storage unit for program saving,
loading and verifying, and interfaces for an external Flat Panel Display (FPD).
G. The program development software shall be capable of operating in ‘on-line’ mode,

‘off-line’ mode and ‘monitor’ mode:
H. In ‘on-line’ mode, operator shall be able to make any program change while the CPU
is running.
I. In ‘off-line’ mode, programmer shall be able to create an application program

without connecting the program development terminal to the programmable
controller CPU.
J. The program created in off-line mode shall be able to be saved on the storage unit
and loaded back in program development PC memory if required.
K. In ‘monitor’ mode, the programmer shall be able to read from, but not write to, the
programmable controller main memory.
L. Mode of operation shall be selected by operating a multi-position key switch.

Revision: 1
M. Programming capabilities shall include the entering of non-closing logic circuits,

non-allowable addresses or missing addresses. Program changes shall be allowed
element by element such as adding, deleting, or reversing (NO to NC) contacts
without replacing an entire rung. Program changes shall also be allowed to delete or
insert entire rungs inside the program. A search feature shall allow operator to call up
any contact or coil in the program by reference. The search function shall be
provided by a special push button on the keyboard.
N. An override feature shall allow operator to override input and outputs. The override
function shall be provided by a special push button on the keyboard.
O. The data storage shall be sufficient to hold the entire application data. The following
functions shall be provided:
 Each element shall be entered through the keyboard by depressing the selected
element key and the proper numeric keys for addresses and values.
 As each element is entered, it shall be added to the visual display on the FPD.
 Editing and ‘on-line program change’ capability shall allow any rung to be
corrected without having to totally re-enter.
P. New elements may be inserted or deleted in a rung, and rungs may be added or
removed any place within the ladder diagram. This capability may be performed at
any time in the program mode.
Q. All elements of a rung shown on the FPD shall be intensified when ‘true’ to allow
viewing of the rung and observing the condition that exist on both input and output
devices.
R. The PC shall have the capability to monitor or program all programmable controllers
in the system one at a time, by means of selection.
S. The displays and auxiliaries shall form part of the PLC system itself
9.2 PLC Configuration
A. The system configuration shall be done by fill in the blank type fields.
9.3 Load Media
A. Each disc system shall store the entire PLC configuration through optical discs,
cartridges or similar devices. Additional disc drivers shall be provided as required
for historical trend recording or other functions.
B. Disk systems shall be fast loading tape cartridges or optical disks, high density, high-
speed device, not required for use during normal operation.
Revision: 1
C. Once the initial system software is loaded into the system, it shall not be necessary to
use cartridge disks to restore a failed node. A copy of the node files shall be loadable
from on-line bulk memory.
9.4 Database
A. The human-machine interface shall be able to remove or add new data points, modify
existing data points and install the points in any applicable node without removing
that node from service or affecting any existing points in the system. The system
shall determine and advise if a proposed new point ID is already in use in the system.
B. The system shall load or install multiple data points from the load media to any
applicable node on-line without affecting that node. A database editor shall be
provided. The editor shall have the following features:
 It shall be possible to modify or generate database using the editor.
 It shall be user friendly and intuitive and employ fill-in the blank type screens.
 The system shall provide a step by step guide for completing the information
required to complete the database.
 It shall be possible at the beginning of a project to build the database in a

personal computer using a commercially available database such as Access and
later download it to the system using a converter.
9.5 Configuration Recovery
A. The system shall permit to recover the configuration of a node, its database and store
it in mass storage or the removable media (optical disc or cartridge) for later
reloading.
9.6 Utilities
A. The system shall include the utilities, files and management tools necessary to format
the load media, copy floppies (or cartridges), copy files from one source to another,
delete files, list the directories of files and view or print the data within a file. The
system shall also include text edit features similar to a word processor.
B. The following programming functions shall be available to the user:
 Programming Language as per IEC IEC-61131-3
 Sequence of Events configuration
 Event Log printing

Revision: 1
 Fault History
 Hardware configuration table
 System Diagnostics status
 Program documentation and cross-referencing printout
 Configurable multi level Password to control user access
 The PLC system shall be able to print the ladder logic diagrams, database
configuration tables, graphic displays, and user defined reports and logs.
9.7 System Documentation Tool
A. The system documentation tools shall effectively manage changes in the PLC
environment. This function can query the entire operating database for entities and
selected parameter values on-line. These queries shall be saved and the result output
to the screen, a file on a bulk storage device or to a printer.
B. A data file utility shall be provided that can create, display and manipulate files
consisting of named fields of data. The following functions shall be provided:
 Set up tabular text files composed of records of named fields.
 Create and update documentation files. These files include fields that can be
updated on command by the system and can contain location information,
parameter values and programs using specific tag name.
 Sort and filter files by field.
 Output results to a file or printer.
9.8 Trending
A. System shall be capable of displaying real time and historical trends. Trend shall
display tag number, engineering units, span, and alarm status. The Operator station
shall be capable of displaying trends. Trends shall be available in full and half-size
screen size.
B. Each trend shall consist of the trend graph and the trend parameters.
C. Control points shall be controllable from the trend display. At least four variables
shall be trendable on the same plot. Each variable shall be represented by a different
color. It shall be possible to display multiple trends on the same screen.
Revision: 1
D. Trends shall be scrollable and display value and time at a selected point. Trends shall
have an adjustable time base and measurement span. Time periods between 5
minutes and 4 days shall be available.
E. It shall be possible to pre-configure trend groups.
F. It shall be possible to display trends as part of an active graphic display.
G. Real time trends shall be updated every 4 seconds with live process data.
9.9 Reports and Logs
A. The report function shall allow the user to define fixed or free format logs, define
periodic execution and to select the output device. The fixed format logs shall report
current and historical data and display the information on the operator station. The
report generator shall have the ability to specify report generation on demand or on a
time schedule basis. It shall be possible to define the output device (Printer, or FPD
storage media).
9.10 Documentation
A. The system shall be complete with all documentation necessary to configure, install,
startup, operate and maintain the system. All maintenance documentation shall be
oriented to facilitate expedient repair with minimum downtime.
9.11 Self-Testing
A. Each PLC system shall contain test levels to ensure that the module is performing
correctly prior to being placed in operation and to monitor its performance while in
operation.
9.12 Start-Up Tests
A. These tests shall reside in ROM and shall be automatically executed following power
on or restarting of the module. They shall verify the correct operation of the basic
logic on each PCB in the module. Failures shall be indicated by means of LEDs on
each PCB and on the display.
9.13 Quality Logic Tests
A. These tests shall be automatically loaded and executed after the Start-Up test. These
tests shall verify the correct operation of the module hardware and qualify it for
loading its on-process software. Failure shall be indicated on the display.
Revision: 1
9.14 On-Process Tests
A. These tests shall be part of the on-process software of each module and shall be
executed periodically whether a module is primary or back up. A recoverable error
shall be error message report for analysis by maintenance personnel. A non-
recoverable error shall cause the module to be shutdown, recorded in the system error
message and indicated to the operator. A printed error history shall be available to be
returned to factory with the failed PCB/module.
9.15 Off-Process Tests
A. Maintenance personnel shall load these tests when automatic tests cannot resolve a
problem. These tests shall have the following functions:
 Display the system error event record
 Display the hardware and software revision status of all modules on the network
 Display a snapshot of the system status, including all nodes, modules, boxes, etc.
 Display the contents of memory of any node, module, box, etc.
 Link the system to Seller’s technical assistance center.
10.0 DCS/PLC COMMUNICATION
10.1 General
A. Plant Operations requires a single operator window for DCS and PLC controllers. As
such, the DCS shall provide capability to interface with PLC for complete
information exchange, including setting of parameters and monitoring of the process
controlled by the PLC. This interface is considered very critical and hence a
redundant interface shall be provided.
B. In view of the criticality of maintaining a continuous view of the plant, a prevailing

requirement of the operator interface is the availability of information to multiple
operator screens within an operational area.
C. Supplier shall also propose a method of maintaining complete PLC engineering

functions. This could be through a separate PC based workstation or via the DCS
Engineering workstation.
Revision: 1
11.0 INSPECTIONS AND TEST
11.1 Factory Acceptance Test (FAT)
A. The Factory Acceptance Test (FAT) shall be designed to demonstrate the complete
integration and function of the PLC according to the requirements of the
specifications. All PLC systems shall be subjected to a factory acceptance test at the
vendor’s facility. MARAFIQ or its affiliate Engineers will witness the test. Prior to
FAT, the vendors shall have completed their own check for hardware and software
functionality and integrity. Seller shall submit FAT procedures and schedules twelve
(12) weeks prior to the FAT for review and approval. Seller shall provide all
necessary test and simulation equipment. Contractor shall reserve the right to
witness all testing.
B. Test records and results shall be kept and subject to review by Contractor at any time.
In any event, these records shall be submitted to Owner eight (8) weeks after FAT.
C. Terminal, wiring and equipment labeling shall be verified to match with wiring
diagrams and drawings. Prior to the FAT, the system shall be fully operable and
fully tested by Seller.
D. Seller shall demonstrate the operation of diagnostic and maintenance functions

provided with the system. Errors shall be simulated to demonstrate the capability of
the system to detect and report errors.
E. Seller shall correct all discrepancies found during the FAT. Contractor may require
the suspension of the FAT until any such discrepancy has been corrected. After the
discrepancy has been corrected, Seller shall repeat the procedure or perform any
other testing required to verify correct operation of the system and that the
discrepancy has been corrected.
F. Any suspension or retesting that may be imposed due to discrepancies shall not
constitute a change. Seller shall document all discrepancies and verification of
correct operation. Unless otherwise agreed, all discrepancies shall be corrected prior
to shipment of the system. Seller shall update all affected documentation to reflect
the system at the completion of FAT.
G. The FAT shall also include a test of the communication between the PCS and the
PLC as well as the complete functionality of the PCS HMI. This test shall be
conducted at the PCS integrator’s facility.
11.2 Site Acceptance Test (SAT)
A. The Site Acceptance Test (SAT) procedure and schedule shall be derived from the
FAT procedure. The SAT procedure shall be prepared by Seller and presented
twelve (12) weeks prior to the SAT. The SAT shall also verify any interfaces that
could not be verified during the FAT. Seller shall propose in the quotation the
representation planned for the SAT.
Revision: 1
11.3 Sustained Performance Test (SPT)
A. The objective of the SPT is to determine the long term stability and availability of the
PLC under normal operating conditions. It will also verify the ability of the PLC to
report any and all malfunctions in an easy to understand manner and Seller's ability to
diagnose and fix any problem in a timely manner. The test commences when the
PLC assumes a portion as specified by Contractor. Contractor will conduct the SPT
over a sustained period of 30 consecutive days (or longer under agreed conditions).
The criteria for success will include at least 99.9% availability (in the standard
statistical sense) and not more than one hardware and/or software failure during the
30-day period.
B. A failure is defined as any occurrence preventing full utilization of the PLC.

Availability will not be affected, and the SPT will be temporarily suspended in case
of any failure caused by Owner supplied equipment or services.
12.0 MAINTENANCE MATERIALS
12.1 Recommended Service and Spare Parts List
A. Seller shall provide with the quotation a recommended list of one (1) year start-up
spares and two (2) years operating spares. The spare parts list shall:
 Identify the part number and description of the item. Associated major
equipment part is recommended for.
 Source of the part including third party suppliers and availability in Indonesia
 Price of part
 Lead time for part
B. Spare parts shall be guaranteed available for the period specified. Any spare parts
used by Seller during the warranty period shall be replenished at Seller's expense.
12.2 Maintenance Training
A. Seller shall provide recommended maintenance training quotation.
B. This requirement shall be quoted only for large and/or complex PLC systems that are
tightly integrated with the PCS or PLCs that perform specialized control.
12.3 Maintenance Service
A. Seller shall provide a recommended long-term maintenance/service agreement

quotation for on-site maintenance service.
Revision: 1
B. Any maintenance/service proposal shall identify the qualifications of servicemen,

types of services provided, limitations and restrictions with regards to the work
performed, requirements for special tools, parts, any other special requirements, etc.
13.0 DRAWINGS, DOCUMENTATION AND DATA REQUIREMENTS
Documentation of the complete system shall be provided in accordance with, but not limited to, the
general requirements in this specification and as listed in the material requisition document.
13.1 Design Drawings
A. Prior to start of hardware fitting out the PLC Supplier shall submit relevant drawings
for review and approval in accordance with the Drawing and Data Commitment
Form.
B. After completion of FAT the PLC Supplier shall issue a complete set of updated
drawings reflecting any modifications made during the FAT.
C. Final as built documents shall be submitted by PLC Supplier after incorporating field
modifications up to Contractor turnover of the SYSTEM.
13.2 Design Interface
A. The PLC Supplier shall develop / define the system configuration with input from
Contractor. Configuration definition shall be provided to Contractor / Company for
review and comment.
B. Contractor shall supply via electronic means to PCL Supplier information to

configure the I/O databases. The minimum information to be provided by Contractor
will include tag names, service descriptions, I/O type, engineering units, scale ranges,
alarm settings and trip points, IS loop and special power requirements. As necessary
the Contractor shall provide to the PLC Supplier P & IDs, cabling interconnection
drawings, logic diagrams or cause & effect charts, and control building layouts
showing equipment positions and cable routing, etc.
C. PLC Supplier shall supply electronic files of the configured databases for importing
by Contractor into the instrument index database.
13.3 Supplier Documents
A. The PLC Supplier shall furnish all drawings, documents, data and software required
to accurately define the design of the PLC.
B. As a minimum the following shall be provided:
 Supplier document index

Revision: 1
 Spare part requirements
 Catalog data
 Quality plan
 Manufacturing plan / schedule
 Inspection and testing plan
 Test data / records
 List of materials
 Overall system block diagram
 Interface block diagram
 Dimensional outline drawings
 Location / equipment layouts
 Physical wiring diagrams
 List of cables
 Power and earthing distribution diagrams / schedules
 Heat dissipation and power consumption
 Certificates of compliance
 Mean Time between undisclosed failure & disclosed failures data
 Installation, operation and maintenance manuals
 System loading calculations
 System availability calculations
 Functional design specifications
 Engineering manual containing all application configuration and operating data
 FAT documentation (procedure / test records)

Revision: 1
 SAT documentation (procedure / test records)
 Standard software manuals (original CD’s of system software and licenses)
 Electronic back-up of system configuration and application programming
13.4 System Logs
A. A system log (punch list) shall be maintained once system integration starts and
through FAT. The log shall indicate all problems noted by date, type of problem and
action taken to correct the problem. The system shall not be released for shipment
prior to the clearing of all log items.
B. A system log (punch list) shall be maintained once system integration starts at site to
mechanical completion. The log shall indicate all problems noted by date, type of
problem and action taken to correct the problem. The system shall not be accepted by
Company prior to the clearing of all log items.
13.5 Requirements with Proposal
A. PLC Supplier shall include the following in his technical proposal:
 Project execution plan for manufacturing, testing, site survey and installation
(tie-in to existing system both hardware and software):
 Organization chart
 Preliminary Schedule - preliminary project schedule for the proposed system

identifying major milestones including equipment design, manufacture, testing
and delivery. The schedule should include all PLC Supplier, Contractor and
Company activities critical to the proper management of the work. The schedule
should also identify dates for information to be supplied by Contractor
 Communications
 Location of project execution
 Reporting
B. A list of conflicts / exceptions / deviations referenced to the relevant paragraphs of

this specification and all referenced specifications, codes and standards which are
part of this specification, if applicable.
C. List of concerns and / or optional proposals.
D. Itemized list of equipment separated by unit or area.

Revision: 1
E. Technical literature and product specifications on the equipment such as network

switches, servers, workstations, printers, logic solvers (including available standard
algorithms, libraries and templates), I/O cards, archive devices, communications
subsystem, etc. included in the proposal.
F. System block/architecture diagram including interfaces to equipment not supplied by

PLC Supplier.
G. Commitment to supply drawings and data required by Contractor, complete with

dates for submittal.
H. FDS Contents page/format.
I. Preliminary equipment layout drawings with dimensions.
J. Proposed termination cabinet design and layout.
K. General grounding and power requirements.
L. Standard software capability.
M. Details and costs of software options that may be applicable to this project.
N. Details and costs of software licensing requirements.
O. List of standard pre-configured serial link software packages which are available to
interface with the DCS.
P. Price list of commissioning and start-up spares and also a spares list for two years
continuous operation.
Q. Price list of consumables such as disks, printer paper and accessories, tapes, etc.
required for 12 months operation.
R. The procedure and length of time required for repair and/or replacement of parts.
S. Power requirements of all the users and also the heat dissipation of consoles and
equipment cabinets.
T. Suppliers quality control procedures for inspection and testing of all parts, assemblies
and complete system, including procedures for thermal cycling, inspection and
testing of the parts, circuit boards, assemblies of the entire system.
U. Reliability and Availability calculations. Field experience data is preferred.
V. Details of diagnostics and fault reporting including any covert faults which are not
expected to be revealed by the automatic test facility and diagnostics.
Revision: 1
W. Details of suitable training courses, their duration's, schedule and associated costs for
the following levels of personnel: engineer; maintenance technician, operator.
Availability for On-site training After Order
X. Complete cabling, wiring and schematic drawings.
Y. System Operating, Maintenance and Engineering manual.
Z. Power and grounding plan.
13.6 After Kick Off Meeting
A. Specifications for all interfaces and programs. Fabrication drawings showing

dimensional detail for cabinets and consoles.
B. Drawing showing equipment location, terminal panel location, power entry point,
and breaker location.
C. A system startup procedure describing the sequence of events for powering and
commissioning the system. Provide a boot up procedure for fast system recovery in
case of system lockup or loss of power.
13.7 As Built
A. After Commissioning the Unit, Contractor shall provide marked-up database,

cabling, wiring and schematic drawings for Seller to update as final “As Built”.
13.8 Electronic Documentation
A. All hardware and software manuals
B. Two copies of the database in electronic form

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Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Master Specification: MQ-SP-I-7012-2

Project Name: Date: 14 Jan 2011

SPECIFICATION - PROCESS CONTROLS - PROGRAMMABLE LOGIC CONTROLLER (PLC)

Revision Date Originator's Reviewed/Checked By Pages

APPROVALS SIGNATURES DATE

Lead Engineer Thomas B. Robinson

ISSUED FOR : Construction X Other Approved

SPECIFICATION - PROCESS CONTROLS - PROGRAMMABLE LOGIC CONTROLLER (PLC)

A 8/24/2010 Issued for Approval, Table of Contents Only

0 11/04/2010 Issued for Review/Approval

1 1/14/2011 Issued Approved

SPECIFICATION - PROCESS CONTROLS - PROGRAMMABLE LOGIC CONTROLLER (PLC)

1.0 SCOPE ........................................................................................................................................................6

SPECIFICATION - PROCESS CONTROLS - PROGRAMMABLE LOGIC CONTROLLER (PLC)

6.1 General .......................................................................................................................................14

SPECIFICATION - PROCESS CONTROLS - PROGRAMMABLE LOGIC CONTROLLER (PLC)

9.9 Reports and Logs ......................................................................................................................34

SPECIFICATION - PROCESS CONTROLS - PROGRAMMABLE LOGIC CONTROLLER (PLC)

A. This specification defines the minimum requirements of Programmable Logic

A. Control and operations of Packaged Mechanical Equipment shall, as far as is

1.3 Scope of Supply and Responsibility

SPECIFICATION - PROCESS CONTROLS - PROGRAMMABLE LOGIC CONTROLLER (PLC)

E. The PLC SUPPLIER shall provide comprehensive detailed functional design

2.1 Codes and Standards

B. International Electrotechnical Commission (IEC)

 IEC 73 : Specification for color of indicator lights, push-buttons, annunciators

 IEC 79 : Electrical equipment for use in hazardous locations

 IEC 529 : Degrees of Protection of Enclosures

 IEC 617 : Graphic Symbols for Electronic Diagrams

 IEC 60364-4-41 : Low Voltage Electrical Installations

 IEC 61508 : Programmable Electronic Safety Systems

 IEC 61131-3 : Programmable Controllers - Part 3: Programming Languages

C. International Society of Automation (ISA)

 ISA 5.1 : Instrumentation, Symbols and Identification.

 ISA 5.2 : Binary Logic Diagrams for Process Operations.

 ISA 5.3 : Graphic Symbols for Distributed Control/Shared Display

SPECIFICATION - PROCESS CONTROLS - PROGRAMMABLE LOGIC CONTROLLER (PLC)

 ISA-18.2 : Management of Alarm Systems for the Process Industries

 ISA MC96.1 : Temperature Measurement Thermocouples

D. International Organization for Standardization (ISO)

 IS0 9000 : Quality Systems

E. U.S. Military Specification and Standards (MIL: HDBK 217E)

 MIL-V-173 - Varnish, Moisture, and Fungus-Resistant for the Treatment of

F. National Electrical Manufacturers Association (NEMA)

 NEMA ICS-6 - Enclosures for Industrial Controls and Systems

G. National Fire Protection Association (NFPA)

 NFPA 70 - National Electrical Code

2.2 Project Specifications and Drawings

B. MARAFIQ Standards and Specifications

Specification No. Title

SPECIFICATION - PROCESS CONTROLS - PROGRAMMABLE LOGIC CONTROLLER (PLC)

3.0 DEFINITIONS AND ABREVIATIONS

A. Terms used in this document are defined as follows:

PLC SUPPLIER Supplier of PLC equipment purchased by CONTRACTOR.

HMI Human Machine Interface

Integrated Control System is the collective name assigned to the core

LCD Liquid Crystal Display

MTTFd Mean Time to Failure to a Dangerous Mode

PEC Programmable Electronic Controller