1.

1 SCOPE
1.2 Introduction

Shell Pakistan Limited (SPL) intends to install motor operated valves in receipt lines
from other refineries and jetty. These MOVs will be linked with tank Overfill
Protection system and the Terminal ESD system.

This Specification, together with all reference documentation, defines the minimum
technical requirements for the design, fabrication, testing and documentation of PLC
based System to achieve the project requirement.

1.3 Definitions

Owner : Shell Pakistan Limited (SPL)

Engineer/Consultant : Petrochemical Engineering Consultants (PEC)
Contractor
: The Company named as such in the deed.
Sub-Contractor /
: The Manufacturer / Supplier engaged
by Contractor
Vendor shall/
: A Mandatory Requirement
must Should
: A non-mandatory requirement, advisory
or Recommendation

1.4 Scope of Supply

The PLC vendor shall include the following in the scope:
1. PLC complete
with CPUs, Power Supply Modules, I/O Modules, and
Communication Modules.
2. All necessary engineering and operating software with licenses.
3. PLC cabinet suitable for indoor installation.
4. All interconnecting cables (system, network, and
other cables within the PLC
cabinet).
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 5. System engineering services.
6. All necessary terminal blocks, DIN rails etc.
7. Pre-Bid site visit to fully understand the extent of works required.
8. Submission of design documents for approval.
9. Liaison
with Overfill Protection System vendor (E&H), if needed. The current
overfill protection system is E&H make, with FTL670 modules installed.
10. No as-built of the overfill protection system are available. But since, the system
is simple and the interlocking work is minimal, the vendor shall study the system
during the pre-bid visit.
11. Assistance during pre-commissioning and commissioning.
12. Engineering Workstation (Laptop).

This Specification shall not relieve the Vendor of any responsibility to provide
equipment and services that are suitable for the intended duty.

1.5 Compliance & Order of Precedence

Any conflicts or discrepancies found in any design documentation shall be referred in
writing to
the Owner for clarification. No deviations shall be made from design
documentation without prior approval in writing by the Owner.
Where conflicts or
discrepancies occur, the order of precedence shall generally
be:
Local Statutory requirements.
Th Purchase Order and its attachments.
International code and standard requirements.

Every deviation from design documentation must be brought to the attention of the
Owner, whose written approval must be obtained before any work can commence. If
no exceptions are stated, or the Owner's approval of a deviation is not given, then
full compliance will be assumed and required.
2.0 GENERAL REQ IREMENTS

2.1 Codes and Standards

A listing of applicable Codes and Standards is shown below.

- BS767 Requirements for Electrical Installations

- IEEE 472 Guide for Surge Withstand Capability
- ISA RP55.1 Tests.
- ISA S5.1 Hardware Testing of Digital Process
- ISA S5.2 Computers. Instrument Symbols and
- ISA S5.3 Identification.
Binary Logic Diagrams for Process
Operations. Graphic Symbols for Distributed
- SAMAPMC-33.1 Control/Shared Display Instrumentation, Logic
and Computer Systems.
- BS7671 Electromagnetic Susceptibility of Process
- IEC 61508/6113 Control Instrumentation.
- BS EN 60801 Requirements for Electrical Installations
Functional Safety – Safety related Systems
Electromagnetic Compatibility for Industrial
Process Equipment management and control

2.2 Units of Measurement

The PLC BASED CO TROL SYSTEM shall support any unit of measure system.
The Vendor shall refer to the project specific PLC BASED CONTROL SYSTEM data
sheet for project requirements. In the absence of project specific information, the
units of measurement to be used shall be based on the International System of Units
(SI Units).
2.3 Power Supply Available
One source of UPS supply 230 VAC, 3-wire shall be provided for the PLC. All AC/
DC power
requirement of the various cards, modules, interrogation supply,
components & sub systems under the package shall be in supplier’s scope.

3.1 SERVICE CONDITIONS

3.2 Environmental
Equipment and materials shall be suitable for service under a temperature controlled
indoor environment.
4.1 DESIGN REQUIREMENTS
The PLC
shall be industrially certified. The programmable logic controllers (PLC)
shall be of rugged and modular construction, plug in type. PLC shall be suitable for
installation
in a safe area. It shall have field expandable design so as to
accommodate incremental increase in memory and I/Os as required.

4.2 Main Equipment

Programmable logical controllers complete with Rack, Digital Input/output cards,

Analog cards, pulse counter cards, communication interface cards, with necessary
inter connection cable / connectors, Generation of all power supplies including field
interrogation power supply, housed and wired in required number of control panels.
Ethernet cards for connectivity to higher end system to be included as option.
The PLC shall have controllers configured in the Dual redundant mode and shall
have Bumpless transfer from working to standby and also dual redundancy in I/O
communication and Ethernet communication.
The entire PLC and other cards provided shall be of the same type and from the
same family.

At present no serial communications with any client system is envisaged. But the
PLC shall have provision of adding serial and Ethernet communication modules in
future.

4.2.1 Configuration of PLC

PLC shall be with redundant CPU and power supply modules. I/O cards as required
based on the system I/O count.

The CPUs shall not be loaded more than 50% after full system configuration and
programming.
 Software shall shall comply with IEC 61131-3– 1 set.

4.3 Field Signal I/O

4.2.1 Conventional I/O

All I/O cards shall include current limiting devices to prevent damage upon short-
circuiting of I/O field circuit conductors. All I/O cards shall also provide transient
suppression in accordance with the IEEE 472 standard and undergo surges
withstand capability testing.
All I/O points shall be earthed at the negative terminal at the I/O card. All individual
and overall screens
shall be earthed at the marshalling cabinet. These earth
connections shall be to the clean instrument earth
All other points in the circuits
bar. shall be isolated from earth.
All I/O cards shall latch or maintain digital inputs or events where analogue inputs
move through an alarm point in their latest driven state until scanned or read into
the system.
The I/O cards, as offered, shall be capable of being removed and inserted into the
I/O card cage or slot under power without affecting any other I/O cards in the
system.
The I/O card cages shall utilize a modular rack mount construction and shall be
mounted in the system cabinets.
All field I/
terminations shall be in the marshalling cabinet (incorporating optical
isolators and fuses where applicable). Segregation of 24V DC and 240V AC
voltages shall be provided.
The system shall be capable of employing configurable DI filters and timers as well
as configurable AI filters and signal characterization.
To compensate for possible hardware failure on testing, a manual override function
shall be available to allow forcing of the measurement associated with any DI or AI
or to mask changes to any DO or AO. These functions shall be controlled by
software, not hardware and shall be subject to key switch security access and shall
be fully logged by the system.
4.2.2 Analogue I/O
All analogue I/O points shall be individually isolated and individually fused on the
high (supply) side through the use of fused terminals. The fuse rating for all
analogue I/O shall be 250mA.
All analogue I/O cards shall have an individual power regulator to provide isolated
power for AO and isolated transmitter power for AI (where the AI is system
powered). Any AI exceeding the high or low range of the analogue to digital
conversion shall generate a fault indication and alarm on the control system
The system shall be able to support "Smart" (simultaneous analogue and digital)
communications on all analogue I/O points as standard.

Specifications on analogue I/O shall be as follows:

Analogue Inputs
4 to 20mA DC with a maximum input resistance of 250 ohms.
The CONTROL SYSTEM shall be capable of employing programmable input
filters and signal characterization (where necessary).
All events where AI points move through an alarm point shall be latched until
scanned or read into the CONTROL SYSTEM.
All AI points shall be automatically monitored for short-circuit (above a threshold
over 20mA) and
open-circuit (below a threshold under 4mA) faults. The
thresholds shall be fully programmable.
All AI
points shall be individually isolated and individually fused on the high
(supply) side.
The fuse rating shall be 250mA. All AI points shall have an individual power
regulator to provide field transmitter power.
A single analogue-to-digital converter (ADC) may be used for multiple AI points.
The ADC shall have a resolution of 16 bits and
a minimum common mode
rejection at 50 Hz of 98 dB.
 Analogue Outputs
4 to 20mA DC capable of driving up to 600 ohms total loop resistance. 24V DC
loop power shall be supplied by the CONTROL SYSTEM.
All AO points shall be automatically monitored for short-circuit (above a threshold
over 20mA) and
open-circuit (below a threshold under 4mA) faults. The
thresholds shall be fully programmable.
All AO
points shall be individually isolated and individually fused on the high
(supply) side.
The fuse rating shall be 250mA. All AO points shall have an individual power
regulator to provide field transmitter power.
A single digital-to-analogue converter (DAC) may be used for multiple AO points.
The DAC shall have a resolution of 12 bits.

4.2.3 Digital I/O

The digital I/O cards shall have any mix of digital inputs and digital outputs.
All digital I/O points shall be individually isolated. Those in 230V AC service shall
utilise solid-state optical isolators. All digital I/O points shall be individually fused.
Fuses shall be able to be replaced without removing the I/O card. The fuse rating for
all 24VDC digital I/O shall be 1A. The fuse rating for all 230V AC digital I/O shall be
3A.
All digital I/O shall be time stamped by the I/O block and have a resolution of less
than 100 milliseconds.
All digital I/O cards shall provide loop status LED indication.
All interposing relays shall be provided by Control System Vendor.

Specifications on digital I/O shall be as follows:

Digital Inputs
24V DC or 230V AC as input "1" (logical "true") and open circuit as input "0"
(logical "false"). For 24V DC inputs, the sense voltage to field contacts shall be

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 supplied from the CONTROL SYSTEM via individually fused circuits.

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 Field devices with normally-closed in the normal process condition (fail-safe)
voltage free contacts. Multiple field devices may be connected in series by the
Owner as a single DI point. These shall be powered at 24V DC by the PLC via
individually fused circuits at 0.5A (maximum). These will be used for the majority
of DI points.
Field devices with normally-open (non fail-safe) voltage-free contacts. Multiple
field devices may be connected in parallel by the Owner as a single DI point.
These shall be powered at 24V DC by the PLC via individually fused circuits at
0.5A (maximum). An end-of-line device shall be provided by the CONTROL
SYSTEM Vendor suitable for its input card to be installed in parallel with the field
devices. Three circuit conditions shall be monitored; normal loop resistance
(normal condition), high loop resistance (fault condition or open-circuit) and low
loop resistance (alarm condition or short-circuit).

Digital Outputs
Dry contacts rated at 4A (24V DC) or 2A (hold-in)/8A (inrush) (230V AC). These
shall be selectable as normally open or normally closed, momentary or
maintained. The voltage to outputs shall be supplied by the CONTROL
SYSTEM (including individual fuse protection) for 24V DC outputs.
Normally energized (fail-safe) 24V DC outputs. These shall be powered by the
CONTROL SYSTEM via individually fused circuits at 2A (maximum). These will
be used to drive solenoid valves and relay coils. Surge suppression will be
provided when driving such inductive loads. Surge suppression devices will be
supplied and installed by the supplier of the field device.
Normally de-energised (non fail-safe) 24V DC outputs. These shall be powered at
24V DC by the
CONTROL SYSTEM via individually fused circuits at 2A
(maximum). An end-of-line device shall be provided by the CONTROL SYSTEM
Vendor suitable for its input card to be installed in parallel with the field device.
Three circuit conditions shall be monitored; normal loop resistance (normal

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 condition), high loop resistance (open-circuit) and low loop
resistance (short-

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 circuit). These will be used to drive status lights, alarm horns, and to trip shunt-
trip coils on circuit breakers.

4.4 Operator Interfaces & Engineering Workstation

4.4.1 Operator and Engineering HMIs
The Engineering Workstation shall be a Laptop of latest technology loaded with
all necessary engineering software.
For Operator HMI, indicating lamps and push buttons shall be employed and shall
be installed on the PLC cabinet. Vendor shall propose the
cabinet layout for
review and approval.
The PLC cabinet shall be suitable for installation in safe area.
The PLC cabinet shall be suitable for free standing.
Preferable dimensions of the PLC cabinet shall be 600 x 600 mm (width x
depth). Height shall be such that the location of indication lamps and push
buttons are ergonomically accessible and ensuring ease of operation.

Construction Features
Totally enclosed, sheet steel clad, dust & ver in proof and floor mounting
type with IP 41 degree of enclosure. Panels with at least 30 % free space
shall be supplied for PLC and remote I/O panels.
All plug in modules to be mounted in suitable racks.
An extractor / handle to pull module out of rack.
Provision to guard against incorrect insertion and test points to check
necessary signal.
Exte der module for testing of plug in modules shall be provided.
Panel front, rear and side door shall be using 1.6 mm thick sheet steel and
load bearing members with 2 mm thick sheet steel.
Paint shade outside and inside – RAL 7035.
Tinned copper earth bus size – 30 x 6 mm

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 SPECIFICATION FOR
PROGRAMMABLE LOGIC
CONTROLLER
SHELL PAKISTAN LIM TED

Two Earthing studs shall be provided externally at side of the panel.

Front door shall be hinged type with concealed hinges.
Cable entry shall be from bottom
Panel shall be free standing type. Each panel shall have 4 Nos removable
lifting hooks at top.
Cable termination shall be done with pin/U type lugs.
Gland plate 3 mm HRSS shall be provided.
All door and cover plates for cutouts shall be provided with suitable
Neoprene/ rubber gaskets to give the required degree of protection.
Foundation frame shall be made using MS channels size 75 x 40 x 6 m
thick painted black.
Panel internal wiring shall run through PVC channels with covers.
Door shall be provided with locking arrangements.
15 mm anti-vibration pad shall be provided.
Panel to panel
jointed sides will be with cork sheet beading between
frames.
Tolerance shall be +5 mm of panel dimension
Heat load data for each panel shall provided
All cubicles, racks and modules to be provided with readily visible
identification labels.
Copper bus shall be provided for grounding purposes.
All cables shall enter from bottom of panels and removable gland plates will
be provided with each cubicle.
Following shall be provided in each vertical panel –
o 5A, 240V, AC Socket outlet with MCB.
o Screw type incandescent lamps for cubicle illumination rated for
240V 50 Hz AC switched on by door switches.
o Cooling fans of adequate rating for the ventilation of cubicles.

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 o All panels shall be provided with Colored “Shell Pakistan Limited”
Logo made of SS.
o 20% spare terminals shall be provided in each panel
Metallic parts of all components shall be effectively earthed using green
coloured insulated copper wire or other approved means. Electrical
continuity of the whole enclosure / frame work shall be maintained even
after painting. All hinged
doors shall be earthed through flexible earthing
braids of copper.
Electrical & Electronic earthing shall be separate and marked in panels and
diagrams.

4.6 Internal Wiring

Shall be with 1100 V grade multi stranded copper wires with PVC
insulation. Segregation of wiring shall be done for different voltage levels.
Cross ferruling system shall be followed for internal wiring. Ferrules shall be
interlocked type.

4.7 Terminal Blocks

Shall be suitable for accommodating 2 Nos conductors of 2.5 and 1.5 sq
mm copper controls.
All TBs shall have fuse TBs with fuse failure LED indication.
Separate sets of terminal blocks for inputs and outputs. Digital inputs &
outputs shall have fuses where there is a possibility of short circuit e.g.,
lamp drives for desks, contactor output etc.,
20% additional interposing relays (for 20% potential free DOs) shall be
provided which shall be pre-wired to the TB. All spare contacts of the relays
shall be pre- wired up to the TB.
Terminal blocks shall be properly arranged to facilitate easy termination of
cables. They shall have
minimum clearance of 300 mm. to cable gland
 SPECIFICATION FOR
PROGRAMMABLE LOGIC
CONTROLLER
SHELL PAKISTAN LIM TED

plates and of 150 mm. to adjacent terminal rows, panel sides & other
equipment.

4.8 Wiring Diagrams

In control schemes wiring diagrams, all the wires shall be designated with
clearly defined external TB number, internal TB number card slots racks
and ferrule Nos.

5.1 INSPECTION & TESTING

Test & inspection shall be as per PL/ customer approved procedure.

Supplier shall produce during inspection:

Raw material inspection certificate.
In House test reports (Type test certificate shall be produced for exactly the
same rating/specifications)
Statutory certificates as required.

All Inspection & Testing shall be carried out based on the following documents:-
Relevant Standards
Specifications
Approved Drawings.
Data sheets.
Approved supplier QAP
Supplier
shall furnish all type and routine test certificates along with the
inspection call. Manufacturer’s test certificates shall incorporate Model No,
Sr. No etc.
Supplier shall submit Total BOM along with Inspection call.
Inspection call shall be given
reports. at least 3 weeks in advance with all test

Supplier shall carryout/demonstrates various routine tests and any other

test specified by Customer at supplier’s works at no extra cost.

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 Test inspection procedure specified hereunder is subject to change during
detailed engineering and is only for reference.
Equipment’s Model version should be the latest available in the market.
All reports / certificates shall bear company seal and signature of supplier /
manufacturer.

Testing shall be carried out strictly as per Quality Assurance Plan, which is
approved by Customer. Basic tests are as below:
ROUTINE
TEST
Sr. NO TEST DESCRIPTION TEST INSPECTION METHOD
(See
Notes
Visual inspection &
1 As per GA drawing BC
dimensional Check.

IR measurement with suitable megger

before and after HV test.
Insulation resistance test
2 High voltage shall be applied for 1 BC
& HV test
minute at 1.0 KV with all
electronic cards pulled out.
Temperature test (aging)
3 for CPU and other A
modules
Mechanical vibration test
4 for CPU and other A
modules
As per detailed control scheme and as
Functional test for
5 per manufacturer’s practice/ approved BC
modules and CPU&
FAT
HMI
Noise immunity test for
6 A
CPU and other modules
As per detailed control scheme and as
7 Integrated functional test per manufacturer’s practice/approved BC
FAT

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 Notes:
A -Manufacturer’s Test certificate to be furnished
B -Test to be conducted in presence of SPL’s representative & report to be
submitted
C -Test to be conducted in the presence of customer / consultant or his
authorized representative

5.2 Factory Acceptance Testing (FAT)

The supplier will be responsible for setting up the PLC, loading the software
and ensuring the proper
functioning of the PLC system and necessary
communications.
Documentation as indicated in the respective section
Inspection & testing at factory
Supplier shall quote for any additional hardware /software such as
communication
software, cable, connectors etc required for successful
operation of the system as per Configuration Diagram enclosed and it shall
be clearly indicated in un-priced BOM. The supplier shall also include any
cable, connector, card etc.(on PLC-HMI side) for communication to third
party devices as mentioned in the scope.
The supplier shall furnish all clarifications and
extend all co-operations in
preparing the application software.

6.0 DOCUMENTATION
The following documents shall be submitted by the supplier for approval:

Sr. no Title No: of copies

1 Overall system configuration diagram 2 sets

2 Datasheet which includes technical leaflets of modules 2 sets

 Catalogues + hardware and software manuals for PLC
3 2 sets+ 2 CDs
system in CD

OGA ,BOM , Power Distribution SLD for Panel ,QAP,

4 2 sets
Foundation plan

5 UPS power requirement for PLC 2 sets

6 Earthing requirements for PLC panel 2 sets

7 PLC I/O address to be added based on I/O list 2 sets

8 PLC Wiring Diagram with ferruling principle 2 sets

PLC Nest Loading /Module Loading Diagram / IO diagram

9 2 sets
& Terminal Plan in approved format
Software / design philosophy / connection details for third
10 2 sets
party interface
11 Project specific FAT procedures 2 sets
1 Original
12 Internal Test Certificates
+ 2 copies

O&M manual –All final approved documents and hardcopy 2 sets + 2 sets of
13
of manuals CDs +RFT

Please note that initially one set of documents to be provided for SPL
approval and then after SPL’s approval only the documents shall be
multiplied.
Resubmission of any document incorporating comments shall be made
within 3 days and the number of copies shall be as above.
All documents to be submitted in SPL approved template, a soft copy of
which shall be provided.
If any additional document is required during detailed engineering it shall be
included.
All drawings provided by the contractor shall be on standard size A4/A3
sheets, in the form of black or blue lines on a white background.
Approval of drawings shall not relieve the supplier of his responsibility in
terms of the contract

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 Final payment is subjected to furnishing the complete documentation in
required volumes in required number of sets.

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