LNG Terminal - Draft PCS

LNG RECEIVING TERMINAL AND REGASIFICATION FACILITY
INTEGRATED PROCESS CONTROL ANDSYSTEM

SAFETY SYSTEM (ICSS) GENERAL
SPECIFICATIONS
REVISION INDEX
Rev Description Prepared Checked Approved Date

No By By By
00 Original Document IT EG 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
DISCLAIMER
Because of the variety of uses for this information, the user of and those responsible for applying this information
must satisfy themselves as to the acceptability of each application and use of the program. In no event will
Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use of
or application of this information. The illustrations, charts, and examples shown in this document are intended
solely to illustrate the principles of Programmable Automation Controllers (PAC) and some of the methods used to
apply them. Particularly because of the many requirements associated with any particular installation, Rockwell
Automation, Inc. cannot assume responsibility or liability for actual use based upon the illustrative uses and
applications.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment,
or software described in this text.
request.

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
request.

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
request.

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;
request.

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
request.

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
request.

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
request.

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 safety-
related 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
request.

TERMINAL
request.

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.
request.

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 active-
controller 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 high-
speed 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.
request.

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
request.

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
request.

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.
request.

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.
request.

TERMINAL
A large screen wallmounted display of minimum 56” LED monitor should be able to connect to the control system
for operator viewing.
request.

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)
request.

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 multi-
client/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.
request.

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:

 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.
4.4 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.
 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.
Audits - Any changes on records such as:
- 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.
o 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
request.

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
request.

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
5.1.2 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.
request.

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.
request.

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
request.

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
 Build a Logical Model

 Combines multiple data sources into a logical unit
 References data directly from its source
 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
 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.
request.

LNG Terminal - Draft PCS

Uploaded by

Copyright:

Available Formats

LNG Terminal - Draft PCS

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

LNG Terminal - Draft PCS

Uploaded by

Copyright:

Available Formats

What is the purpose of the document?

What is the purpose of the document?

What are the main components of the BPCS discussed in the document?

What are the main components of the BPCS discussed in the document?

LNG RECEIVING TERMINAL AND REGASIFICATION FACILITY

INTEGRATED PROCESS CONTROL ANDSYSTEM

Rev Description Prepared Checked Approved Date

00 Original Document IT EG Dec 20, 2017

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

4. SUPERVISORY LAYER - VISUALIZATION AND OPERATOR INTERFACE......................................16

5. SAFETY INSTRUMENTED SYSTEM (SIS)......................................................................................... 18

6. TERMINAL AUTOMATION SYSTEM................................................................................................... 22

7. INTERFACE WITH INTELLIGENT MOTOR CONTROL CENTRE AND POWER SYSTEMS.............23

4. SUPERVISORY LAYER - VISUALIZATION AND OPERATOR INTERFACE......................................15

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

5. SAFETY INSTRUMENTED SYSTEM (SIS)......................................................................................... 17

6. TERMINAL AUTOMATION SYSTEM................................................................................................... 21

7. INTERFACE WITH INTELLIGENT MOTOR CONTROL CENTRE.......................................................22

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

1.2 PROJECT OVERVIEW

- HP gas pipeline: 1.3 Million Metric Tons Per Year

Main components of the project, consists of:

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

Primary pump (In tank removable submerged motor pump):

High pressure pump (Mounted vessel submerged motor pump):

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

1.3 TERMS AND DEFINITIONS

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

1.4 CODES, STANDARDS, AND REFERENCES

International Electrotechnical Commission (IEC)

National Fire Protection Association (NFPA)

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

3.1 BPCS CONTROLLERS:

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

3.2 BPCS INPUT / OUTPUT SUB-SYSTEM

Analog Input Modules:

 Choice of three data formats

Analog Output Modules:

 Choice of three data formats

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

Digital Input Modules:

Digital Output Modules:

The BPCS DO Modules should have following features as minimum:

 Configurable Point-level Output States

Apart from these, there should be options available for followings:

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

3.3 ADVANCED PROCESS CONTROL (APC) CAPABILITIES:

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

3.4 BPCS COMMUNICATION SYSTEM:

 Dedicated Control Network: (Controller to I/O Chassis/Rack Communication)

Package Interface Network:

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

Copyright © 2017 Rockwell Automation, Inc., All Rights Reserved

4. SUPERVISORY LAYER - VISUALIZATION AND OPERATOR INTERFACE

4.1 HMI/DATA SERVERS: