Saep 1650

Engineering Procedure
SAEP-1650 Main Automation Contractor 26 November 2012 Document Responsibility: Process Control Standards Committee
Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 Scope............................................................ 3 Applicable Documents................................... 3 Definitions...................................................... 3 Instructions.................................................... 4 Responsibilities........................................... 12
Appendix A......................................................... 14 Appendix B......................................................... 16 Appendix C........................................................ 18 Appendix D........................................................ 20 Appendix E......................................................... 21
Previous Issue: 11 July 2012 Next Planned Update: 11 July 2017 Revised paragraphs are indicated in the right margin Primary contact: Damluji, Ahmed Sabah on 966-3-880-1836
CopyrightSaudi Aramco 2012. All rights reserved.
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Document Responsibility: Process Control Standards Committee Issue Date: 26 November 2012 Next Planned Update: 11 July 2017
SAEP-1650 Main Automation Contractor
Scope This Saudi Aramco Engineering Procedure (SAEP) defines the methodology and responsibilities for the execution of Process Automation System (PAS) projects utilizing the Main Automation Contractor (MAC) concept. This procedure is applicable to all Saudi Aramco capital projects, Maintain Potential and Master Appropriations projects which include Process Automation Systems.
Applicable Documents The requirements contained in the following documents apply to the extent specified in this procedure: Saudi Aramco Engineering Procedures SAEP-12 SAEP-14 SAEP-15 SAEP-16 SAEP-302 SAEP-1610 SAEP-1622 SAEP-1624 Project Execution Plan Project Proposals Preparation of Restricted Vendor Lists for Process Automation Project Execution Guide for Process Automation Systems Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement Preparation of Functional Specification Document Preparation of Technical Bid Evaluation Plan Document for Process Automation Systems Preparation of System Design Document
Definitions 3.1 Acronyms COTS DBSP DCS DSS ESD Commercial Off the Shelf Equipment Design Basis Scoping Paper Distributed Control System Decision Support System Emergency Shut Down System
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FAT HMI LSTK MCC MTS OTS PA PCS PLC PP RTU RVL SAT SCADA TMS TPV TVO VMS 3.2 Terms
Factory Acceptance Test Human Machine Interface Lump Sum Turn Key Mechanical Completion Certificate Maintenance Training System Operator Training Simulator Process Automation Process Control System Programmable Logic Controller Project Proposal Remote Terminal Unit Restricted Vendors List Site Acceptance Test Supervisory Control and Data Acquisition Terminal Management System Third Party Vendors Total Value of Ownership Vibration Monitoring System
Commercial Off The Shelf: All personal computers, monitors, printers, peripherals, Ethernet switches and other commercial off-the-shelf (COTS) equipment provided by the vendor as part of its approved PA system. Main Automation Contractor: A highly qualified, large projects experienced, and well-resourced control systems contractor assigned to engineer, supply/procure and manage Process Automation Solutions and associated instrumentation for all project process areas and facilities. Process Automation System: A network of computer-based or microprocessorbased electronic equipment whose primary purpose is process automation. The functions may include process measurement, control, safety, data acquisition, advanced control and optimization, historical archiving, and decision support. Examples of PA solutions are either standalone or integrated systems such as DCS, SCADA, TMS, DSS, ESD, and PLC-based systems. PA solutions may include software applications and tools to meet functional requirements.
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Project Types: Expansion: a) b) Units: Adding process unit(s) within an existing operating facility Equipment: Adding additional process equipment within an existing operating facility
Grass Root: A totally new operating facility Modernization: Replacing an existing PA system and field instruments with a new system of a different technology. (e.g., pneumatic to DCS or conventional to fieldbus) Total Replacement: Replacing an existing PA system with a totally new system from the same vendor or others. Upgrade: Upgrading an existing PA system to a newer system by the same vendor. 4 Instructions 4.1 Applicability 4.1.1 MAC shall apply to all Saudi Aramco capital projects, Maintain Potential and Master Appropriations projects involving Process Automation Systems. For all project types, MAC should be pre-selected by SAPMT with the MAC scope clearly defined and rolled directly under the LSTK contractor(s).
Commentary Note: SAPMT may elect to contract directly with a MAC for project types limited to PA equipment expansion, upgrade, total replacement and modernization if it has been determined that an LSTK contractor is not deemed necessary.
4.1.2
4.1.3
In Projects with multiple LSTK contractors, the MAC scope shall be shared by all LSTK contractors. Each LSTK scope shall cover the PA scope specific to its area. One LSTK contractor shall have the overall responsibility for PA system integration. MAC shall be the single point responsible body for the overall PA system scope including integration, rationalization and standardization.
4.1.4
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4.2
MAC Execution Methodology PA project execution shall follow current Saudi Aramco procedures SAEP-12, SAEP-14, and SAEP-16. Once a project DBSP is approved, SAPMT shall detail the PA section of the DBSP in order to generate a MAC bid package as outlined in Section 4.4 of this procedure. SAPMT shall assign a lead process automation engineer during DBSP development to commence executing MAC bid package development. The MAC bid package should be developed by SAPMT with the assistance of a specialized PA Design contractor during the time after the approval of DBSP and prior to PP award.
4.3
MAC Selection MAC selection process shall be based on Saudi Aramco competitive bidding practices using currently approved RVLs. MAC bids evaluation and selection should be based on SAEP-1622.
4.4
MAC Bid Package The MAC bid package shall include the following as a minimum: 1. 2. Functional Specification Document (FSD) based on SAEP-1610 and Appendix A of this procedure. MAC scope document. This shall include the following: a) b) c) d) 3. 4. 5. PA equipment listed in Appendix B. PA engineering services listed in Appendix C. Construction services specified in Appendix D. Operation services specified in Appendix E.
Job Specification Document Instructions to Bidders Purchase Order Terms & Conditions
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4.5
MAC Scope 4.5.1 Project Proposal Selected MAC should be contracted by SAPMT on a time unit rate basis to provide PA specific technical support during Project Proposal development. The documents that the MAC develops during the Project Proposal will constitute the MAC/LSTK scope for the process automation part of the project. MAC shall be responsible for the following Project Proposal documents and services as a minimum: 1. 2. 3. Develop the PA System Design Document (SDD). Refer to SAEP-1624. Identify Applicable Saudi Aramco Mandatory documents, i.e., Standards, SAMSS, etc. Develop and finalize PA philosophy, operational requirements and standardization of control schemes for multiple process equipment of the same type.
NOTE: Dedicate sufficient time with designated plant personnel, MAC rd and 3 party vendors' personnel to ensure PA project scope is well understood by all parties and completely finalized during the project proposal stage.
4. 5.
Finalize risk areas and segregation requirements. Conduct technology analysis and finalize decisions required to identify latest offerings and value added technologies and applications that would result in business benefits to the Company. Develop standardization guidelines for all PA systems, i.e., redundancy, performance, reliability, power, grounding, etc. Review and verify P&IDs process control representation Update Functional Specification Document (FSD) Update Job Specification Document for LSTK bid package Update quantities and types of Input/output points and instruments.
6. 7. 8. 9. 10.
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11.
Update MAC scope Boundaries in terms of: a) b) c) d) Equipment Engineering Services Construction Services Operation Services
12. 13.
Develop matrix of roles and responsibilities between MAC, LSTK contractors and Saudi Aramco. Develop a procedure to standardize data format and types to be exchanged between MAC, third party equipment suppliers, major packaged equipment vendors, and LSTK contractors based on INtools (or equivalent) software package. Develop communication procedures between MAC, third party equipment suppliers, LSTK contractors and Saudi Aramco. Develop time schedule in terms of duration (number of weeks) for data exchange and execution of scope activities between MAC, third party equipment suppliers, major packaged equipment vendors, and LSTK contractor(s). Establish project management and execution plan identifying locations, organization structure and manpower requirements for all projects phases. Update change orders control document. Update terms and conditions document. Update man-hours for engineering services. Update man-hours for construction services. Update operational services requirements/cost. Update MAC proposal package for LSTK competitive bidding.
14. 15.
16.
17. 18. 19. 20. 21. 22. 4.5.2
MAC/LSTK Scope Validation Within the two week grace period of LSTK contract(s) award, each LSTK should verify the Process Automation scope under its responsibility. Identified changes and clarifications shall be discussed and resolved by SAPMT, MAC, and LSTK contractor(s). Based on the validation process, changes affecting MAC and LSTK scopes shall be adjusted accordingly.
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4.5.3
Detail Design 4.5.3.1 General Requirements Upon commencement of LSTK scope of work, MAC shall be part of the LSTK(s) team to provide scope of supply, including engineering and construction services specified in Sections 4.4 and 4.5 above. Upon commencing of project detailed design phase, the following activities shall be initiated: 1. SAPMT shall form a MAC Steering Committee comprising of project senior management personnel from SAPMT, Proponent organizations, LSTK contractors, MAC and major 3rd party vendors. The purpose of this committee is to maintain close communication throughout project design and execution in order to maintain progress, resolve issues and avoid risks. MAC shall establish formal communication links with 3rd party subsystem vendors to ensure that numerous system interfaces are correctly implemented. LSTK contractor(s) shall establish formal coordination between the MAC and major packaged equipment vendors to ensure that supplied instruments and control systems are compatible with the MAC system for overall PA solution and integration. This is essential in cases where major packaged equipment is purchased independently by LSTK contractor(s). Major package equipment vendors shall follow interface requirements provided to them by the MAC. MAC shall establish proper documentation management control for all equipment under his scope of responsibility, including 3rd party equipment to ensure completeness, latest revision level, and formal turnover to Saudi Aramco. LSTK contractor(s) shall be responsible for all measurement instruments, analyzer and control valves design and engineering. MAC shall be responsible for procuring measurement instruments and analyzers. Control valves positioners shall be selected by MAC and the complete control valves assembly including
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2.
3.
4.
5.
positioners shall be procured by LSTK from the original control valve manufacturers. 6. MAC shall be required to have competent and certified engineers for 3rd party (auxiliary) systems under his supply at all phases of the project execution. Otherwise, MAC shall acquire this service from the respective TPV of each PA system. MAC compliance with this requirement shall be based on submittal of proper documentation including resumes and certifications. MAC shall formally commit to after sales support of third party system vendors through their local agents / representatives regardless of location of purchase. This shall be documented in the purchase agreement between MAC and third party vendors. MAC shall develop a plan outlining responsibilities of third party vendors' local offices for after sales support.
7.
4.5.3.2
Equipment 4.5.3.2.1 MAC responsibility is to provide PA equipment per project scope and Saudi Aramco RVLs. 4.5.3.2.2 MAC is required to ensure that all supplied equipment including 3rd party systems have the latest approved hardware revision level at the time of the hardware freeze date as defined in the contract purchase order or the Preliminary Design Review (PDR); whichever is later. Such revisions shall include newly introduced technologies and major product line releases. 4.5.3.2.3 MAC shall ensure that all supplied equipment including 3rd party systems have the latest approved software revision levels upon project completion (MCC).
4.5.3.3
Engineering Services 4.5.3.3.1 MAC responsibility is to provide engineering services per project scope and applicable Saudi Aramco standards. 4.5.3.3.2 Selected MAC should be on board with the LSTK early on to provide engineering services required to
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complete detailed design phase per the approved project schedule. 4.5.4 Construction Services MAC responsibility is to provide construction services per project scope and applicable Saudi Aramco standards. 4.6 TimeLine The following milestones structure shall be followed in support of MAC executed projects: 4.6.1 4.6.2 DBSP: DBSP is developed per current procedures and will serve as the base line for starting MAC execution process. MAC Bid Package: Upon approval of DBSP, SAPMT should immediately commence preparation of the MAC bid package. The MAC bid package should be developed with the assistance of a specialized PA Design contractor. The MAC Bid Package should be completed six weeks after DBSP approval and no later than two weeks after the start of the Project Proposal. The MAC Bid Package shall be reviewed following company procedures. 4.6.3 MAC Bid Slate Approval: MAC bid slate and execution plan shall be developed and submitted for approval in parallel with the development of the MAC bid package. MAC Selection: The MAC bidding, evaluation, and selection should be completed within eight weeks from the issuance of the MAC bid package. MAC Approval: MAC approval should be accomplished within 2-3 weeks from MAC selection. Project Proposal: MAC should be onboard with the PP design contractor to develop the PP package no later than twelve weeks from the start of PP. MAC Scope Adjustment: MAC should adjust any scope changes during PP development and prior to issuance of LSTK bid package per the approved project schedule.
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4.6.4
4.6.5 4.6.6 4.6.7
4.6.8 4.6.9
LSTK Selection: MAC should be part of the project team supporting job explanation, clarifications, and evaluation during LSTK selection. MAC/LSTK Scope Validation: Selected LSTK contractor(s) should verify the Process Automation scope under its responsibility with MAC within a grace period of two weeks from LSTK(s) selection. Identified changes and clarifications shall be discussed and resolved by SAPMT, MAC, and LSTK contractor(s). Based on the validation process, changes affecting MAC and LSTK scopes shall be adjusted accordingly.
4.6.10 Detailed Design: MAC is part of the LSTK(s) team to provide engineering services per the approved project schedule. 4.6.11 Construction: MAC is part of the LSTK(s) team to provide construction services per the approved project schedule. MAC Project Timeline
DBSP Completed
Design Prep./ Basic design
PP
Completed Project Proposal phase
Implementation Phase
Strategy
MAC BP Prep.
MAC Bidding
MAC Sel.
Design of PAS
LSTK BP
Work Together
Bid Package Finalized MAC Bid Package PEFSs rev A Units etc.
Quotation Project LS cost Unit rates etc.
Selection Award for Work on PP Phase
LSTK award PP includes: System sizing and architecture Implementation plan & execution Duration (Weeks) Functional Design specs Project standards Site planning data New Quotation (< Ceiling) (Ceiling = Old Quote +/- Units * Unit rates + contingencies)
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Responsibilities 5.1 Saudi Aramco Project Management a) b) c) d) e) f) 5.2 Develop MAC bid package Complete MAC selection process Develop PA project proposal package Form and manage the MAC Steering Committee Execute project per SAEP-16 Provide P&CSD with feedback on MAC execution to enhance this procedure
P&CSD a) b) c) d) Review/Comment on MAC Bid package Participate in MAC Bids Review and selection process Review/comment on MAC Scope Package Support project per SAEP-16
5.3
FPD a) b) c) d) Review/Comment on MAC Bid package Participate in MAC Bids Review and selection process Review/comment on MAC Scope Package Support project per SAEP-16
5.4
Purchasing a) b) c) d) Review MAC Bid Slate Review Purchase Order Terms and Conditions Participate in MAC Bids Review and selection process Support project per SAEP-16
5.5
Saudi Aramco Operating Organization a) Review/Comment on MAC Bid package

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b) c) d) e) f)
Participate in MAC Bids Review and selection process Review/comment on MAC Scope Package Assign permanent control system engineer(s) as part of the MAC Steering Committee Participate in finalizing PA philosophy, operational requirements and risk areas Segregation Support project per SAEP-16
11 July 2012 26 November 2012
Revision Summary Revised the Next Planned Update. Reaffirmed the content of the document, and reissued with editorial changes and to replace primary contact person. Editorial revision to correct definition of OTS as Operator Training Simulator.
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Appendix A Functional Specification Document The Functional Specification Document (FSD) should be developed per SAEP-1610 and should include the following as a minimum: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Plant Overview PA scope boundaries Operating Philosophy Segregation requirements if applicable System Layout Architecture Network and Communication Technology Platform Best solution Auxiliary Systems (as applicable): a) b) c) d) e) 12. 13. ESD VMS CC/TC Tank Gauging etc.
Auxiliary Systems interfaces Applications (as applicable): a) b) c) d) MIS AMO APC LDS
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e) f) 14.
ASM Etc.
Quantities and types of: a) b) c) d) e) Instruments Input/output points Reports Graphics etc.
15. 16. 17. 18.
Lengths of cables Applicable Standards Inspection Requirements Non Material requirements (NMR)
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Appendix B MAC Scope Boundaries (Equipment) Following process automation equipment shall be selected to be included in the MAC scope. Selection of this equipment shall be adjusted to meet the specific requirements of a project. 1. 2. 3. 4. 5. 6. 7. Distributed Control System Emergency Shutdown System SCADA System Computing Platforms Network and Communication COTS such as HMIs, printers, etc. Field instruments and Transmitters a) b) c) 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Conventional Smart Fieldbus
Fire and Gas Systems Analyzer Systems PLC Systems Machinery Monitoring Systems Tank Gauging Compressor Control Systems Turbine Control Systems Cabinets Startup Spares Application Packages (As applicable): a) Asset Management
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b) c)
Information Systems Simulation Systems i. ii. Operator Training Simulator Maintenance Training System
d) e) f)
Advance Control Alarm Management Environmental Control
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Appendix C MAC Scope Boundaries (Engineering Services) Following engineering services shall be selected to be included in the MAC scope. Selection of these services shall be adjusted to meet the specific requirements of a project. 1. 2. 3. 4. 5. Review and verify P&IDs process control representation Review Foundation Fieldbus segments design Review and verify all PA drawings produced by LSTK contractors Develop all PA documentation requirements per SAEP-16 Project Guidelines Development for: a) b) c) d) e) f) 6. 7. 8. 9. 10. 11. 12. 13. Graphics Alarms Reports Configuration Logic Development Tagging
Packaged Equipment Review Control Room Arrangement assistance PA Material Take Off PA Equipment Design Third Party Systems Integration Value Engineering Assessment Subcontractors Management Configuration for: a) b) Network Graphics
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c) d) e) f) g) h) 14. 15. 16. 17. 18. 19.
Points Logic Third Party Systems Reports Databases Etc.
Analyzer Systems PLC Design & Programming Plant Network and Communication Commissioning Spare Parts Planning, Purchase and Management FAT and Integration Testing PA Installation Plans
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Appendix D MAC Scope Boundaries (Construction Services) Following construction services shall be selected to be included in the MAC scope. Selection of these services shall be adjusted to meet the specific requirements of a project.
Commentary Notes: Construction services outside the boundary of this appendix and not directly related to Process Automation Systems (i.e., building construction, etc.) should be obtained via applicable company contracting procedures. Construction Services" that fall outside the guidelines contained in Supply Chain Management Manual Procedures CU02.02 Requesting Services ("Requesting Installation Services with Material") and CU02.03 Requesting Services ("Requesting Incidental Service Visits to Saudi Arabia") shall be obtained via applicable company contracting procedures
1. 2. 3. 4. 5.
Field Fiber Optic cables Installation Supervision. Control Room and Interface Building PA Equipment Installation Supervision. Hot cutover Planning and Assistance. System Grounding Installation Supervision. Plant Network Equipment Installation Supervision: a) b) c) Data Servers. Switches, Routers. Protocols, IP Addressing, Subnet Mask, etc. Videos.
6. 7. 8. 9.
Site Acceptance Testing. Pre-commissioning Assistance. Integrated Process Control Commissioning. Start-up Assistance.
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Appendix E MAC Scope Boundaries (Operation Services) MAC should submit unit rates and prices for operational services as a separate line item in the bid package. These services will not be part of the project scope and will be executed directly with the operating organization. 1. 2. 3. 4. Training Maintenance Operational Spares After sale support for MAC and 3rd party equipment
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Engineering Procedure

Saudi Aramco DeskTop Standards

SAEP-1650 Main Automation Contractor

SAEP-1650 Main Automation Contractor

SAEP-1650 Main Automation Contractor

SAEP-1650 Main Automation Contractor

SAEP-1650 Main Automation Contractor

SAEP-1650 Main Automation Contractor

17. 18. 19. 20. 21. 22. 4.5.2

SAEP-1650 Main Automation Contractor

SAEP-1650 Main Automation Contractor

SAEP-1650 Main Automation Contractor

4.6.5 4.6.6 4.6.7

SAEP-1650 Main Automation Contractor

Quotation Project LS cost Unit rates etc.

Selection Award for Work on PP Phase

SAEP-1650 Main Automation Contractor

Saudi Aramco Operating Organization a) Review/Comment on MAC Bid package

SAEP-1650 Main Automation Contractor

11 July 2012 26 November 2012

SAEP-1650 Main Automation Contractor

SAEP-1650 Main Automation Contractor

15. 16. 17. 18.

SAEP-1650 Main Automation Contractor

SAEP-1650 Main Automation Contractor

Advance Control Alarm Management Environmental Control

SAEP-1650 Main Automation Contractor

SAEP-1650 Main Automation Contractor

c) d) e) f) g) h) 14. 15. 16. 17. 18. 19.

Points Logic Third Party Systems Reports Databases Etc.

SAEP-1650 Main Automation Contractor

SAEP-1650 Main Automation Contractor

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