23-SAMSS-010

Sec 8.1.5
A. General Input and Outputs Testing
A1
23-SAMSS-010
Sec 8.1.6
The following configurable fail-safe options shall be available for each
output module: a) Drive to zero output (4 mA for a 4-20 mA analog
output, de-energized for a digital output). b) Maintain last good output
value for an analog or hold for a digital output.
A2
The fail-safe actions listed above shall be taken upon processor halt or
communication break between the controller and the I/O module, if so
configured.
A3
The system shall be capable of supporting Fieldbus Foundation H1
based field instrument devices.
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
PROJ ECT TITLE WBS / BI / J O NUMBER CONTRACTOR / SUBCONTRACTOR
Electronic Control Systems -DCS / ESD Systems-Functional
Testing
SATR-J-6801 1-Oct-05 INST
SYSTEM ID.
LAYOUT DRAWING NUMBER
PLANT NO. EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE
SCHEDULED INSPECTION DATE & TIME
SAUDI ARAMCO INSPECTION LEVEL
TRAVEL TIME QUANTITY INSP.
WORK PERMIT REQUIRED?
ACTUAL INSPECTION DATE & TIME
SAUDI ARAMCO USE ONLY
MH's SPENT
SAUDI ARAMCO ACTIVITY NUMBER
RE-TEST DATE
ITEM
No.
TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A
EC / PMCC / MCC NO. REV. NO. PURCHASE ORDER NUMBER
CONTRACTOR INSPECTION LEVEL
SAUDI ARAMCO TIP NUMBER
A5
Saudi Aramco Inspection Requirements Form 175-230100 lists all
system components that are subject to verification by buyer's
representative.
Standard hardware shall be inspected and standard diagnostic facilities
shall be used to test individual system components.
23-SAMSS-010
Sec 20.1
23-SAMSS-010
Sec 8.1.7
A10
Calibration of the A/D converters shall be automatically checked by the
system on a periodic basis. An indication of calibration error shall be
provided by the system.
23-SAMSS-010
Sec 8.2.5
A7
A4
The system shall be capable of supporting the following analog process
input signals: a) 4-20 mA dc. b) 0-10 Vdc. c) 1-5 Vdc. d) Type E, J , and
K thermocouples.
23-SAMSS-010
Sec 8.2.1
A11
The noise level that is generated by the input circuitry shall be less than
the minimum resolution of the measurement.
23-SAMSS-010
Sec 8.2.6
A12
Analog input modules shall be able to power 4-20 mA field
instrumentation loops with a loop resistance of 600 ohms.
23-SAMSS-010
Sec 8.2.7
23-SAMSS-010
Sec 8.2.1
23-SAMSS-010
Sec 8.2.4
A9
A8
The system shall provide automatic detection of thermocouple open-
circuit conditions. Open-circuit detection circuitry shall not affect the
accuracy of a temperature measurement by more than 0.25 C.
23-SAMSS-010
Sec 8.2.3
Analog input modules shall provide the repeatability and accuracy shown
below: a) Repeatability : +0.05% of full range b) Accuracy : +0.5% of full
range
The system shall be capable of supporting the following analog process
input signals: a) 4-20 mA dc. b) 0-10 Vdc. c) 1-5 Vdc. d) Type E, J , and
K thermocouples) Platinum resistance temperature detector (RTD), per
ASTM E1137 or IEC 751. f) Pulse inputs.
A6
Saudi Aramco Inspection Requirements Form 175-230100 lists all
system components that are subject to verification by buyer's
representative.:
(a) Integrated Systems: Integrated systems that are staged at a
vendor's facilities shall be tested according to Factory Acceptance Test
(FAT) procedures produced for each DCS project.
(b) FAT criteria shall be developed by the vendor and approved by Saudi
Aramco.
23-SAMSS-010
Sec 20.2
Page 1 of 6
C1
Fault Handling : Invalid value status shall be generated for inputs and
calculated variables.
23 SAMSS-010
Sec. 9.1
B17
Manual inputs may be of the following types: a) Analog values b) Digital
values c) Text values (including date/time values) Commentary Note:
Tags receiving analog and digital manual inputs shall
23 SAMSS-010
Sec. 8.6.2
B16
Manual Input : The system shall be capable of accepting manual entry
inputs into a tag type configured for such manual entry.
23 SAMSS-010
Sec. 8.6.1
B15
Output modules shall be provided with individually fused outputs or
current limiters.
23 SAMSS-010
Sec. 8.5.5
B13
Relay or solid state output contacts that are free of voltage and ground
should be available.
23 SAMSS-010
Sec. 8.5.3
B12
The following solid state or relay board output ratings shall be available:
a) 24 VDC, 80 mA, non-inductive load
b) 48 VDC, 80 mA, non-inductive load
c) 120 VAC
23 SAMSS-010
Sec. 8.5.2
23 SAMSS-010
Sec. 8.5.1
B10
Output modules shall be provided with individually fused outputs or
current limiters.
23 SAMSS-010
Sec. 8.4.4
Analog Output : The system shall support 4-20 mA outputs.
23 SAMSS-010
Sec. 8.4.1
B6
Analog Output 8.4.1 The system shall support 4-20 mA outputs. 8.4.2
The analog outputs shall be capable of driving resistive loads of 600
ohms impedance. 8.4.3 Analog output modules shall provide the
repeatability and accuracy shown below: a) Repeatability : +0 1%of full
23 SAMSS-010
Sec. 8.3.1
23 SAMSS-010
Sec. 8.3.5
B14 The duration of the single pulse outputs shall be individually configurable.
23 SAMSS-010
Sec. 8.5.4
B11
Digital Output: The system shall be capable of supporting the following:
a) On/off
b) Single pulse, (configurable width).
c) Latching and non-latching (momentary) contact outputs
B8
The analog outputs shall be capable of driving resistive loads of 600
ohms impedance.
23 SAMSS-010
Sec. 8.4.2
B5
System interfaces shall include circuitry to filter out contact "chatter" /
"bounce".
B3
Twenty-four volt dc inputs shall be able to use either internal or external
power supplies. The other voltages may be provided by external power
supplies.
23 SAMSS-010
Sec. 8.3.3
The system shall be capable of supporting the following digital input
types, time stamped to 1 second or better resolution: a) 24 Vdc b) 48
Vdc c) 120 Vac d) 125 Vdc
23 SAMSS-010
Sec. 8.3.1
B2
The system shall be capable of detecting digital input transitions with
duration of 50 millisecond.
23 SAMSS-010
Sec. 8.3.2
B1
B4
B9
Analog output modules shall provide the repeatability and accuracy
shown below: a) Repeatability : +0.1% of full scale b) Accuracy : +1.0%
of full scale
23 SAMSS-010
Sec. 8.4.3
B7
C. Control and Data Handling Testing
N/A RE-TEST DATE TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE
CONTRACTOR / SUBCONTRACTOR
Electronic Control Systems -DCS / ESD Systems-Functional
Testing
SATR-J-6801 1-Oct-05 INST
PROJ ECT TITLE WBS / BI / J O NUMBER
PASS FAIL
ITEM
No.
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
Relay or solid-state input from field powered contacts shall be available.
23 SAMSS-010
Sec. 8.3.4
A13
Pulse input modules shall be capable of measuring pulse frequency.
Input pulses will be characterized as follows: a) Square wave, sine wave,
or dry contact b) 0 to 10 kHz c) 5 to 10 Volt peak to peak d) 2-wire (self-
powered or dry contact) or 3-wire (DCS powered at 24 Vdc)
23-SAMSS-010
Sec 8.2.8
B. Digital Input , Analog and Digital Output Tests
Page 2 of 6
N/A RE-TEST DATE TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE
CONTRACTOR / SUBCONTRACTOR
Electronic Control Systems -DCS / ESD Systems-Functional
Testing
SATR-J-6801 1-Oct-05 INST
PROJ ECT TITLE WBS / BI / J O NUMBER
PASS FAIL
ITEM
No.
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
C16
Mode switching shall include the following: a) Auto/computer/manual
switching b) Local/remote set point switching.
23 SAMSS-010
Sec. 9.2.9
C15
Control blocks shall be able to perform automatic mode switching based
on external or internal logic inputs.
23 SAMSS-010
Sec. 9.2.8
C14
Information shall be transferred between cascaded loops that are in the
same controller module within second.
23 SAMSS-010
Sec. 9.2.7
C13
Information shall be transferred between cascaded loops that are in
separate controller modules within 2 seconds.
23 SAMSS-010
Sec. 9.2.6
C12 All cascaded loops shall support bump less transfer.
23 SAMSS-010
Sec. 9.2.5
C11
All control blocks that can accept a setpoint shall be capable of being
switched between local setpoint (operator entered) and remote setpoint.
23 SAMSS-010
Sec. 9.2.4
C10
For cascade control, it shall be possible to configure remote set points
from other regulatory controllers or from other DCS modules.
23 SAMSS-010
Sec. 9.2.3
C3 Invalid value status shall be propagated through control schemes.
23 SAMSS-010
Sec. 9.1.3
C2
A value shall be declared invalid if any of the following conditions are
true:
a) if a value is out of range.
b) if a value can not be measured or calculated.
c) if a value is declared invalid by an application program.
d) if a value is declared invalid by the source instrument.
23 SAMSS-010
Sec. 9.1.2
C19
Variables that are being initialized shall be subject to the following: a)
The system shall suppress nuisance alarms created by the initialization
of the algorithm. b) Calculations involving time-based data shall be reset.
23-SAMSS-010,
Sec. 9.3.3
C4
It shall be possible to inhibit the detection and propagation of an invalid
value status. This selection shall be available on a per tag basis.
23 SAMSS-010
Sec. 9.1.4
C18
Initialization: Initialization shall occur when any of the following
conditions exist: a) The control block is turned from off to on, b) The
control block mode is changed from manual to automatic, from manual
to cascade or from automatic to cascade, c) The control block output is
cascaded to a control block, which is being initialized.
23-SAMSS-010,
Sec. 9.3.2
C20
Set point shall be initialized when the block is turned from off to on. It
shall be possible to configure its initial value.
23-SAMSS-010,
Sec. 9.3.4
C5
It shall be possible for an invalid value status to be used as a logical
input to initiate control algorithm changes.
23 SAMSS-010
Sec. 9.1.5
C6
When a control algorithm's input is declared invalid, it shall be possible
to configure the output to fail as follows, on a per point basis: a) hold last
good value, b) zero output signal, c) full-scale output.
23 SAMSS-010
Sec. 9.1.6
C7
In the event of communications subsystem failure, regulatory control
algorithms shall continue operating with the last valid information.
23 SAMSS-010
Sec. 9.1.7
C8
Control Modes: It shall be possible to put any individual control loop in a
manual mode; and it shall be possible for an operator to manipulate the
output of a control loop in the manual mode.
23 SAMSS-010
Sec. 9.2.1
C9
In manual mode, an output signal from a field output module must
change within one second from the last operator action that is required to
command the change.
23 SAMSS-010
Sec. 9.2.2
C17
The system shall continuously monitor and test all backup equipment to
determine whether the backup equipment is capable of assuming
control.
23-SAMSS-010,
Sec. 17.5
Page 3 of 6
N/A RE-TEST DATE TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE
CONTRACTOR / SUBCONTRACTOR
Electronic Control Systems -DCS / ESD Systems-Functional
Testing
SATR-J-6801 1-Oct-05 INST
PROJ ECT TITLE WBS / BI / J O NUMBER
PASS FAIL
ITEM
No.
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
C25
C23
Sequential/Batch Control : a) It shall provide the necessary facilities for
real time control of sequential processes. b) It shall have access to
process control and other database information. c) It shall be possible to
modify the program logic while other sequences are active.
23-SAMSS-010,
Sec. 9.6
When either set point tracking or output tracking is active, this state shall
be clearly visible to the operator in a standard faceplate display, and
available as a parameter which can be accessed for either a graphic
display or an application program.
23-SAMSS-010,
Sec. 9.3.7
C24
Standard software algorithms shall be available to perform regulatory
control functions. These process control functions shall be performed by
predefined algorithms with configurable parameters.
23-SAMSS-010,
Sec. 9.5
C22
In a cascade loop an output tracking option shall be available. When
configured for output tracking the primary controller output tracks the
secondary controller set point when the secondary controller is in either
manual, automatic, or is itself output tracking.
23-SAMSS-010,
Sec. 9.3.6
C34
Communication System Status: Displays Standard displays shall show
as minimum as the operational status of the communication system. The
communication parameters of each module connected to the
communication system (on-line, off-line, failed, primary failed, backup
failed) shall be shown.
23-SAMSS-010,
Sec. 12.3
C33
Faceplates : Faceplates shall show dynamic process and status
information about a single control loop and shall permit an operator to
change control parameter values or mode for the loop.
23-SAMSS-010,
Sec. 12.2
C32
All displays and graphics that show real time data shall meet the
following requirements: a) They shall be automatically updated when the
display or graphic is on a screen. b) Updates shall not require operator
initiation.
23-SAMSS-010,
Sec. 12.1
C31
The requirements for restricting the access to process control system
functions are detailed below and they have to be ensured. Five levels are
required - Level 0 View Only and Levels 1 to 4. It shall be possible to
configure these levels with selectable privileges. Each higher level shall
include all the lower level privileges.
a) Level 0 (View Only)
b) Level 1 (Process Operator)
c) Level 2 (Process Operations Supervisor)
d) Level 3 (Engineer)
e) Level 4 (System Administrator)
23-SAMSS-010,
Sec. 10.5
C30
Data Base, Reporting and Modification Utilities: Global Search Utility
Utilities shall be provided for global searching of all on-line data bases.
These utilities shall be under system access control.
23-SAMSS-010,
Sec. 10.4
23-SAMSS-010,
Sec. 9.3.5
C21
The control blocks shall offer the option of either initializing the set point
to the input value or of maintaining the last valid set point upon algorithm
initialization.
C29
Each analog input, output, and control block shall be assigned an
engineering unit designation. It shall be possible to automatically display
this designation with the value when the input, output, or algorithm is
accessed.
23-SAMSS-010,
Sec. 10.3
C28
Tag Parameters : All tags shall be defined with at least the following
parameters: a) Tag ID b) Tag descriptor c) Tag type d) Alarm
requirements
23-SAMSS-010,
Sec. 10.2
C27
Configuration : It shall be possible to use multiple engineering
workstations for configuration, database generation and editing.
Configuration displays shall be provided to aid in configuration.
23-SAMSS-010,
Sec. 10
C26
Supervisory Control: The vendor shall be able to supply standard
supervisory control functions fully integrated with the regulatory control
functions.
23-SAMSS-010,
Sec. 9.7
Page 4 of 6
N/A RE-TEST DATE TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE
CONTRACTOR / SUBCONTRACTOR
Electronic Control Systems -DCS / ESD Systems-Functional
Testing
SATR-J-6801 1-Oct-05 INST
PROJ ECT TITLE WBS / BI / J O NUMBER
PASS FAIL
ITEM
No.
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
C42
A single failure anywhere in the system shall not result in loss of an
operator's ability to view or manipulate the process from his workstation
except with respect to the I/O associated with a single process
input/output card.
23-SAMSS-010,
Sec. 17.2
C41
A single failure anywhere in the system shall not result in the loss of
regulatory control to more control loops than those associated with a
single process input/output card.
23-SAMSS-010,
Sec. 17.1
C40
It shall be possible to use any variable in the system or the history files in
a report. It shall be possible for all reports to be displayed on a
workstation screen as well as printed on a report printer.
23-SAMSS-010,
Sec. 10.2
C39
It shall be possible to initiate historical trend displays for any process tag
or calculated variable that has been stored in either the on-line history or
off-line history media, including both analog and digital types.
23-SAMSS-010,
Sec. 15
C38
There shall be a configurable, real time and historical data collection
package to support trending, logging, and reporting. The requirements
for historical data characterization, collection, storage and use to be
ensured.
23-SAMSS-010,
Sec. 14
C37
Alarms and Message Handling: Process and designated system
alarms shall be annunciated, displayed and stored in history files. Normal
plant operator actions, events and normal system actions and events
shall not be alarmed, however, they shall be stored in history files if
designated. Messages shall be categorized as: a) Process alarms b)
System alarms c) Operator actions d) Engineer actions 13.1.1.2 Alarms
and messages shall be
23-SAMSS-010,
Sec. 10.2
C36
All displays and graphics including fully active dynamic elements for up
to one hundred (100) fields, displaying their current values, shall be
completed within four (4) seconds of the graphic display being requested.
23-SAMSS-010,
Sec. 12.6
C35
Generation and Modification: A utility shall be provided that is able to
generate and modify user-defined color graphics and that is able to
implement all the features of the following paragraphs, using an
interactive conversational or CAD-like procedure.
23-SAMSS-010,
Sec. 12.4
1. Attachment-1 Air -borne dust concentration and contaminant levels 34-SAMSS-821 Sec 4.3
ATTACHMENTS:
2. Schedule Q -- Quality Requirements (Pro Forma Contract), November 2003
REFERENCE DOCUMENTS:
REMARKS:
5. 23-SAMSS-010 Distributed Control Systems, 31 October, 1999.
6. 34-SAMSS-820- Instrument Control Cabinets - Indoor 29, May 2002
7. SAES-Z-001 Process Control Systems, 28 J anuary, 2004
4. 34-SAMSS-821- Instrument Control Cabinets - Outdoor 29, May 2002
2. Attachment 2 --Segregation of parallel wiring internal to cabinets
3. 34-SAMSS-830. Programmable Logic Controller, 29 J anuary,2003
1. Schedule G -- Material, Tools and Equipment (Pro Forma MP-IK-LS Contract), J uly 1993
Page 5 of 6
N/A RE-TEST DATE TEST PROCEDURE ACCEPTANCE CRITERIA REFERENCE
CONTRACTOR / SUBCONTRACTOR
Electronic Control Systems -DCS / ESD Systems-Functional
Testing
SATR-J-6801 1-Oct-05 INST
PROJ ECT TITLE WBS / BI / J O NUMBER
PASS FAIL
ITEM
No.
SAUDI ARAMCO ID/PID - 3/01/05 - REV 0 (Standards Cutoff - August 2004)
SAUDI ARAMCO TEST REPORT
SATR NUMBER DATE APPROVED QR NUMBER
Work Verified
Construction Representative* PMT Representative
Name, Initials and Date:
Work is Complete and Ready for Inspection:
Name, Initials and Date:
T&I Witnessed QC Record Reviewed
4. Labeled - Equipment or materials to which has been attached a label, symbol, or other identifying mark of an approved qualified organization
or services, that maintains periodic inspection of production of listed equipment or materials or periodic evaluation of services, and whose listing
3. Listed - Equipment and materials included in a list published by an approved qualified organization concerned with evaluation of products
that the equipment, material, or services either meets appropriate designated standards or has been tested and found suitable for a specified
NOTES:
2. Identified - Recognizable as suitable for the specific application by a qualified testing laboratory (i.e., listing and/or labeling).
Contractor / Third-Party Saudi Aramco
indicates compliance with appropriate standards or performance in a specified manner.
with product evaluation, that maintains periodic inspection of production of labeled equipment or materials, and by whose labeling the
*Person Responsible for Completion of Quality Work / Test Y =YES N =NO F =FAILED
1. Approved - Acceptable to the authority having jurisdiction (i.e., Saudi Aramco ID).
QC Inspector
Work Verified
Name, Initials and Date:
Performed Inspection Work / Rework May Proceed
PID Representative
Work Verified QC Record Reviewed T&I Witnessed
Name, Sign and Date:
Quality Record Approved:
Name, Organization,
Initials and Date:
Proponent and Others QC Supervisor
T&I Witnessed QC Record Reviewed
Name, Initials and Date:
Page 6 of 6